As technology evolves, many industries require parts with properties that traditional materials can't match (e.g., steel, aluminum, wood). Many verticals need options that are both durable and lightweight to meet fast-evolving and unique requirements.
Pultruded fiberglass has been used for many years in various industries. Today, it's an indispensable part of the global manufacturing economy and the material of choice for verticals such as construction and utility.
In this article, we'll look at the unique properties, the wide range of applications, and the many advantages of pultruded fiberglass rods:
Pultruded fiberglass rods are made of a composite material that consists of resin and fiberglass. They have unique characteristics that make them suitable for a wide range of applications across industries such as manufacturing, construction, utilities, motor vehicles, telecommunications, and more.
The pultrusion process allows the rods to be formed into almost any shape and customized to meet the needs of different applications. Some common shapes include solid rods, tubes, bar stock, oval solids, channels, half rounds, and tees.
The characteristics of pultruded fiberglass rods are determined by the composite matrices, which are achieved by varying the resin system and glass content properties. Conductor rods are produced by co-pultruding the fiberglass-reinforced resin with copper wires.
As such, fiberglass rods can be manufactured to meet a wide range of requirements for specific designs and applications. They can be machined, butted, slotted, chamfered, rounded, and pointed easily with simple tools.
In addition, the composition of these rods can be varied to provide extra-high strength, withstand different temperature ranges, or offer flame-retardant, track-resistant, and corrosion-resistant properties.
This manufacturing process converts reinforcing fibers and liquid resin into a fiber-reinforced plastic using a pulling method rather than the pushing method used in an extrusion process.
The first step in the pultrusion process is to saturate the fibers by pulling them through a resin-impregnating bath containing epoxy, polyurethane, polyester, and/or vinyl ester.
Often, fillers and additives such as colorants, fire inhibitors, and UV retardants are blended into the bath to enhance the finished product.
Next, the saturated fibers enter a “pre-former” tool that squeezes out excess resin and shapes the fiber reinforcements. The composite is then pulled through a heated steel die, which cures the thermosetting resin to create a solidified polymer of the intended shape and size.
Lastly, the hardened polymer is pulled toward a cutting blade to be cut to the desired length. Urethane pull blocks are used to prevent the finished product from cracks, distortion, and deformation during this process.
Compared to extrusion, pultruded materials exhibit higher tensile strength due to the continuous length of reinforcing fibers, making them lightweight yet strong.
Thanks to their flexibility in shape, size, and properties, pultruded fiberglass rods have a wide range of applications across the electrical, utility, consumer, sporting goods, construction, infrastructure, and telecommunications industries.
For example, it's used by:
In addition, pultruded fiberglass rods are used in many other verticals and applied to the manufacturing of plant stakes, transformer spacers, isolation rods, cable support rods, corrosion-resistant equipment, food-processing machines, tent and flag poles, window shades, retaining wall pins, advertising panels, antennas, and more.
Thanks to the resin's flexibility, pultruded fiberglass rods are easy to work with. Their non-reactive nature also makes them longer-lasting and safer than many other materials:
For example, steel rebar used in infrastructure, such as bridges, is prone to corrosion and accounts for significant maintenance costs over a structure's lifespan. In fact, over 54,000 of the 615,000 bridges in the US are considered structurally deficient.
On the other hand, fiberglass rebar can maintain its micro-structural integrity and mechanical properties for over 15 years with very little maintenance. This results in a significant reduction in lifecycle costs while enhancing the durability and long-term performance of a structure.
Also, pultruded fiberglass rods can be fabricated with simple tools without the need for welders. They're inexpensive and easy to transport, enabling designers, builders, and manufacturers to respond nimbly to fast-changing market demands.
Pultruded fiberglass rods are also easy to install and don't require costly special equipment, making it an ideal material for specific parts that need to be strong and lightweight in verticals such as motor vehicles, railway, and aerospace.
Last but not least, the long service life and simple maintenance requirements of pultruded fiberglass rods translate into low energy consumption through a product's lifecycle -- helping meet sustainability goals that are of high priority in many industries.
The use of pultruded fiberglass rods allows for rapid, cost-effective, and high-volume manufacturing of structural components that are strong, durable, and lightweight while keeping maintenance costs low.
Not to mention, the virtually infinite customization options mean the materials are highly adaptable and can be used to meet the fast-evolving needs of many industries and technologies without a high added cost.