Fiberglass Fiber-Reinforced Polymer (FRP) composites are used across industries. Because FRP profiles are versatile and flexible, it’s hard to find an industry that can’t benefit from the use of fiberglass.
Fiberglass Defined
Fiberglass is glass that can be made into very fine fibers and combined with different resins to give it specific properties such as fire retardation, corrosion resistance, high thermal endurance, and dimensional stability. Fiberglass is widely used because of its flexibility and versatility.
According to Science Direct, “FRP composites are lightweight, high-strength, corrosion-resistant materials. In fabric form, they offer unprecedented flexibility since fibers can be oriented to provide strength in any given direction.”
So, what are the factors driving the demand for fiberglass applications?
The four key properties that make fiberglass increasingly popular are:
Corrosion Resistance
In industrial applications, demand for fiberglass profiles is high due to their corrosion resistance. It is one of the few materials that can withstand harsh, corrosive workplace environments.
When constructing structures in outdoor environments or in areas that experience high moisture, corrosion is a major concern. In such environments, traditional materials such as wood will absorb large amounts of moisture and warp, whereas metal will corrode. This can lead to many problems, including safety hazards, costly repairs, and increased accident risk.
Although substances such as oil, acids, and chemicals can be corrosive, water is a major source of corrosion. This is because water is a common substance used in many industrial applications ─ to clean, to cool, or as a result of the environment the facility or structure resides in. While necessary, water can be damaging.
Structures such as wood or metal catwalks, decking, handrails, and stairs can be damaged to the point where the damage becomes detrimental to safety. The deterioration of structures or support can result in accidents that cause serious injury or even death to workers.
Wood
Comparatively speaking, wood is one of the least expensive structural materials in industrial applications but is also the most vulnerable to damage. Fire, extreme temperatures, and hard impacts can readily destroy wood structures. Over time, water can cause significant damage to wood because it is highly absorbent.
In environments such as oil rigs, water parks, marinas, and outdoor support structures and installations, wood is constantly exposed to moisture and water. Even with treated and sealed wood, water can penetrate the wood and cause serious rot or warping.
Water-damaged wood can warp, lose its strength, rot, and fall apart, or it can come loose from fasteners.
Steel
Even steel has its vulnerabilities and weaknesses. For one, metal is very heavy. This weight makes it more expensive to transport structural steel to a job site. In many cases, reinforced concrete is also required to support the loads imposed by steel structures, such as catwalks.
Safety is also a major issue with steel. Aside from being a conductive material posing an electrical shock risk, it is also susceptible to corrosion. Steel can withstand up to thousands of pounds of pressure, yet it can snap due to rust.
Since water is corrosive to the iron in steel, it breaks down the material and causes a chemical reaction that results in rust. For example, when parts of a steel bar rust, that part becomes very weak and brittle. On structures used for walking or support, such as platforms, rust can pose a safety hazard.
Low Absorption Rate
FRP composites are deemed waterproof as they have a low absorption rate. Manufactured out of resin and glass fibers, there is no iron or any metal in its makeup. This means there is zero chance for rust to develop ─ and no safety risks because of it. In fact, FRP composites are excellent for use in wet conditions to the extent that it is used extensively in many “wet” industries such as:
Wastewater Treatment Plants
For metal structures, wastewater treatment plants are one of the most corrosive environments for metal structures. An average plant will have tank platforms, catwalks, stairs, handrails, ladders, and so much more. Maintenance of metal structures in these plants will require inspection, repair, Occupational Safety and Health Administration (OSHA) documentation, and replacement, all of which can consume substantial man-hours.
With the use of FRPs to replace metal structures, the chance of corrosion goes to virtually zero. Therefore, it is economically advantageous to use FRPs in such situations.
Structures for Oil Rigs
Traditionally, offshore oil rigs have been constructed from metal. This means that salty seawater increases the corrosivity of water. On top of that, the platforms, stairs, and rails also come in constant contact with seawater.
In addition, wellhead platforms, rig ladders, and stairs corrode and can become slippery and dangerous. This is expected given the environments where these structures are built.
Using FRPs to construct such structures can be more economical while providing a significant safety benefit. Since FRP grating can be textured with non-slip coatings and doesn’t corrode, it eliminates the threat of slip and fall mishaps because of corrosion, and when oil products coat the surfaces of the rig.
FRPs are relatively easy to install and much lighter. Therefore, outfitting offshore oil rigs is much easier logistically. Structures can be constructed and installed on-site with regular tools, and no heavy equipment is required.
The product is easier to handle, transport, and install. This is especially important because such rigs are often installed in remote locations.
Attractions and Theme Parks
FRP profiles make good economic sense in Theme- and Water- Parks, with thousands of visitors walking on stairs and decking, sitting on picnic tables, and crossing bridges. With metal structures, the constant exposure to water can lead to rapid corrosion and a shortened service life. With wooden stairs or platforms, there may be rot, including dry rot, during the offseason.
In general, the good thing is that newly constructed attractions and parks ─ from stairs, handrails, pedestrian bridges, and especially their rides and water attractions ─ do not use those old school materials anymore. Existing parks are also shifting away from metal and wood materials due to safety and cost concerns.
The Takeaway
FRPs offer a huge long-term financial advantage due to their durability. The return on investment for FRP will be substantially higher than for steel or wood. But, it’s not just about saving on the cost of materials ─ the savings come from mitigating the risk of injury due to structural failures.
As a company, Tencom has produced high-quality pultruded fiberglass products for over 22 years. If you have a design concept or product in mind and would like to learn more about FRPs, we'd love to talk to you. To learn more, contact us to see how we can assist.
