Pultrusion Products
We offer a wide range of pultrusion products for the Pultrusion process. Pultrusion is a continuous, automated closed-moulding process that is cost effective for high volume production of constant cross section parts. The basic process usually involves pulling of continuous fibers through a bath of resin, blended with a catalyst and then into pre-forming fixtures where the section is partially pre-shaped & excess resin is removed. It is then passed through a heated die, which determines the sectional geometry and finish of the final product. Due to uniformity of cross-section, resin dispersion, fiber distribution & alignment, excellent composite structural materials can be fabricated by pultrusion. The profiles produced with this process can compete with traditional metal profiles made of steel & aluminium for strength & weight. By using various additives, liquid resin systems can be made suitable to provide specific performance. Alumina trihydrate is filler that is used for its ability to suppress flame and smoke generation. Special purpose additives include ultraviolet radiation screens for improved weatherability, antimony oxide for flame retardance, pigments for coloration, and low-profile agents for surface smoothness and crack suppression characteristics. Products
Round rods, rectangles, squares, ‘i’ sections, ‘t’ sections, angles, channels, dog bone profiles, dove tail sticks and spacers, corner profiles, hallow sections, etc. |
Pultrusion Product Range
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Pultrusion is the most cost-effective method for the production of fibre-reinforced composite structural profiles. It brings high performance composites down to commercial products such as light-weight corrosion free structures, electrical non-conductive systems, off-shore platforms and many other innovative new products. Our pultrusion products range include round rods, rectangles, squares, ‘I’ sections, ‘T’ sections, angles, channels, dog bone profiles, dove tail sticks and spacers, corner profiles, hallow sections, etc.
Applications:
1. In transformer industries as spacers, runners, coil winders, wedges, dove tail sticks and spacers, threaded rods, etc.
2. In switchgear industries as operating rods, links, etc.
3. In chemical industries as handrails,ladders walkways, floor gratings, supports, cable trays, pipe supports/ racks etc.
4. In construction industries as load bearing members, supports, etc
5. Construction of cooling towers
6. Mobile towers & structures
7. Tank/reactor stiffeners, girders, agitator/ motor mounting on reactors
8. Landscape decorative items like bench strips, light poles
Physical Properties - Thermal conductivity of composites is affected by both matrix and fibre characteristics. Generally, the glass & organic fibre reinforced composites are excellent insulators for thermal and electrical environments. The use of conductive carbon fibres, however, results in composites that exhibit thermal and electrical conductivity to some extent; this reduces their effectiveness as insulators but creates opportunities because of their static charge and heat dissipation characteristics. Specific gravity is a key consideration when strength-to-weight ratios are important as in aircraft and aerospace applications. Carbon and aramid-reinforced composites excel because of their low specific gravities and high strength & stiffness characteristics. The impact resistance of organic fibre reinforced composite is quite high, making them suitable for energy absorption applications. Fibre glass-reinforced composites are relatively poor in impact performance compared to organic fibres, but are superior to carbon-reinforced composites. Composites using carbon fibre rely on the toughness of the resin matrix for impact properties.
Chemical & Corrosion resistance characteristics of pultruded composites are attributed to the properties of resin used. Chemical & corrosion attack can occur at the product surface or at the end. The presence of a resin rich barrier layer on the surface provides greater degree of corrosion resistance. To achieve a resin-rich surface, a synthetic veil or mat, typically of polyester fibre, is used on the surface of the products when pultruded. The layer can range from 0.15 to 1.00 mm thick, depending on the thickness of the material used. The end cut of the profile is particularly vulnerable to corrosion because fibres are exposed to the environment. Therefore, it is a common practice is to dip-coat the end cuts of pultruded profile to seal them from corrosive attack. If this is not done, the corrosion resistance of the fibre itself becomes an important consideration because the resin does not effectively protect the fibre from attack along the fibre-resin interface at open ends.
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Salient Features of Pultruded FRP Profiles
The Pultruded FRP profiles provided by us are widely acknowledged for their high strength, dimensional accuracy, corrosion resistance, light and better durability. Owing to these features, these profiles find extensive applications in structural process equipment, automotive components, chemical plant, switch gear components, pharmaceutical & food industries and others. Some of the detailed features of Pultruded FRP profiles are given in the following table :
| Features | Description | Benefits | Applications | | Strong | Unit strength in tension & compression is approx. 20 x that of steel when these properties are combined on the basis of unit density | Optional strength as desired. Exceptionally high impact strength reduces damage potential | Structural process equipment support. Tank supports. Cooling tower ancillaries. Flooring supports. Trusses & joints. | | Light Weight | Density of pultruded components is about 20% of steel and 60% of aluminium | Higher performance at less weight. Lower shipping, handling & installation costs. Less operational energy demand. | Automotive leaf springs & bumpers. Prefabricated walkways & platforms. Bus components. | | Corrosion Resistant | Unaffected by exposure to a great variety of corrosive environment & chemicals. | Minimum maintenance costs. Long term safety. Longer life. | Chemical plant hand railings, gratings, walkways & bridges. Cable trays. Pipe supports. | | Electrical Insulation | Provides strength & rigidity with dielectric properties. | Lesser no. of components. Non-magnetic & safe. Predictable insulation values for wide range of frequencies. | Ladders, Cable trays. Switch gear components. Mounting braces and backboards. | | Thermal Insulation | Pultruded components have a low thermal conductivity, 1/250 of aluminium & 1/60 of steel. | Reduces installation thickness. Eliminates condensation problems. Reduces energy operation requirements. | Bulk head frames. Walk in refrigerator door jams. Window frames. Insulated roll up panel doors. | | Consolidation | Many individual components can be combined into a large profile. | Reduced assembly cost. Reduced inventory. Fewer parts improve reliability. | Window latch supports. Roll up door | | Dimensional Stability | Pultruded components are highly resistant to warping stretch/swelling over a wide range of temperature & stresses. | No permanent deformation under high stress. Close tolerances. | Spring bumpers. Crossing gate arms. Scrubber components. | | Safety | The pultruded components are very strong & safe to work with. They are microbes and insect proof. | Many gratings suffer from the problem of microbes etc. due to wet or unhygienic working conditions. | This property makes them ideal choice for pharmaceutical & food industries. |
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Mechanical Properties of Pultruded Profiles
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A broad spectrum of mechanical properties is provided by the selection of reinforcement types, style, form & proportion in combination with different matrix. The directionality of strength in a pultruded composite can be greatly influenced by substituting longitudinal reinforcement by random mat or directional fabrics. The absolute value of the specific property desired would depend on the fibre type chosen: glass, carbon, aramid, organic or natural fibres. Table 1 indicates the effect on select mechanical properties in the axial direction for various continuous fibres.
Table 1 : Effect of Fibre Type on Select Mechanical Properties of Pultruded Profiles
| Fibre type | Specific Gravity | Tensile Strength (M Pa) | Tensile Strength (G Pa) | Compressive Strength (M Pa) | Thermal Conductivity (W/m ok) | | Glass(E-glass unidirectional rovings) | 2.0 | 690 | 40 | 410 | 0.30 | | Carbon(AS graphite fibres) | 1.65 | 1000-1500 | 100-140 | 620-970 | 0.85 - 1.40 | | Aramid(Kevlar-49 fibres) | 1.28 | 1400 | 80 | 280 | 0.15 |
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Comparison of Pultruded Profile with Other Material
Pultrusion is said to be the most cost-effective method for the production of fibre-reinforced composite structural profiles. Thereby, it has advantage over various other materials such stainless steel, mild steel, wood etc. Some of the properties at which these profiles are compared with other materials are : | Mechanical Properties | Pultruded FRP | Rigid PVC | Mild Steel | Stainless Steel | Wood | | Tensile Strength
(N/mm2) | 382 | 44 | 340 | 340 | 80 | | Flexural Strength
(N/mm2) | 468.3 | 70 | 380 | 380 | 12 | | Flexural Modulus
(N/mm2) | 22489 | 2400 | 196000 | 196000 | 700 | | Izod Impact(Kg.m/cm) | 2.15 | 0.09 | 1.5 | 0.53 | - |
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