FRP Manufacturing

Manufacturing FRP for Infrastructure, Equipment and Buildings

Traditional construction materials are susceptible to weather and normal wear over time. Concrete, wood, or steel can deteriorate, impacting the integrity of the structure. While these materials may initially meet the municipal, commercial, or industrial stakeholders' performance and investment objectives, they can end up costing more over the long term due to repair and replacement. A cost-effective alternative is FRP, a lightweight, high strength, highly durable material used for buildings, equipment, infrastructure and many other products.

What to Look For in an FRP Manufacturer

FRP is a material widely used in industries that often must adhere to stringent standards and requirements. To ensure your FRP manufacturer can provide a quality product that meets each application and industry's specifications, look for the following:

• Experience. Your manufacturer should have demonstrable and verifiable experience manufacturing FRP solutions for the target application. Depending upon the project, the manufacturer may have to meet a minimum level of experience with various applications.
• Standards & certifications. An experienced FRP manufacturer will have extensive knowledge of regulatory requirements and can demonstrate compliance with these codes. Look for certifications that ensure a high standard of quality management to ensure they will meet your project's specifications.
• On-site availability. Though many FRP products can be delivered ready-to-use remanufactured, there are some products like equipment and infrastructure often other related needs that require specific expertise that most general contractors don't have. You'll want to ensure that your manufacturer can provide services on-site, such as installation guidance, product maintenance, modifications, or required inspections.

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How FRP Is Made

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There are several manufacturing methods for producing FRP, and the chosen technique depends on factors such as order volume, aesthetic requirements, size, and desired function. Common manufacturing methods include:

Pultrusion

Pultrusion is a technique that uses a series of rollers to pull strands or mats of fiber into a resin bath to infuse them with polymer. The fiberglass strands are passed through a heated die which, cures the resin around the fibers to produce an FRP profile with a consistent cross-section shape ready for cutting into any length. This energy-efficient process is eco-friendly, affordable, and produces minimal waste. It is the desired method for continuous manufacturing and rapid production.

Vacuum Infusion

Vacuum infusion is often the most cost-effective option for creating large parts including boat hulls, wind turbine blades and bridges. During the process, dry fiber materials are placed into a shaped mold and covered with a sealing plastic. Once the reinforcement materials are under complete vacuum conditions, precisely positioned tubes introduce liquid polymer resin into the mold. Though more time-consuming than other methods, vacuum infusion is a more customizable process that creates a maximum fiber-to-resin ratio. and produce large, high-strength FRP panels.

Filament Winding

Filament winding is an automated process that applies resin-saturated, continuous strands of fiber reinforcements over a rotating cylindrical mold. This process creates parts that can handle high operating pressures.

Hand Layup

One of the original manufacturing methods for creating FRP is hand layup. This low-cost method is primarily reserved for low-production runs, samples, or prototypes. A skilled technician puts the reinforcing fiber into an open mold before manually applying the resin and using a roller to wet out the fibers with the resin. The material then cures naturally in the open air instead of with heat or vacuum. This process easily incorporates gel coats for cosmetic surfaces.

CCG is the Largest Manufacturer of Structural FRP in the U.S.

FRP is a resilient, lightweight and corrosion-resistant alternative for construction projects. CCG is a leader in manufacturing FRP composite products. We can manufacture and fabricate innovative FRP projects to meet your specifications and requirements. To learn more about the benefits, products and applications of FRP, download our FRP Products & Capabilities Brochure today.