Composite products are used in the industrial field to combine the advantages of two materials or to counter their disadvantages! Typically these are two physically different elements that cannot bond naturally, but can be joined together by proper processing. The result is a material that is often made to withstand tough conditions with optimum functionality.
Glass fibre reinforced plastic or GRP is a case in point. It is made by combining thermosetting plastics with chopped glass fibres. Other reinforcing agents are used to strengthen the bond. The resultant structure has the advantages of both elements. One of the most common GRP products is the GRP pipe.
GRP pipe is used in a wide range of industries because of its unique properties. Some of these are:
— Water distribution
— Wastewater management
— Wind turbines
— Chemical industry
Composition: As mentioned above, the composition of GRP is thermosetting plastics, glass fibres and reinforcing agents. Thermosetting plastics are polymeric resin that has been cured by chemical additives or heat. The two types in such plastics are polyester and epoxy resin. Polyester, such as vinyl ester, has excellent corrosion resistant and are used to transport highly corrosive elements such as acids and sewage. Epoxy resins are usually used to make pipes of small diameter.
The strength of the pipes depends largely on the reinforcing material. Even the arrangement of the material can make a difference. This arrangement can include continuous roving, surface veil and reinforcing mat.
Continuous Roving has bundles of untwisted strands, while reinforcing mat has chopped strands. Surface Veil has lightweight layers. Reinforcing mat provides a wide-area reinforcement to pipes. Surface Veil, on the other hand, displays excellent resistance to environmental factors.
Apart from these GRP pipes can also have additional elements like organic peroxides, silica sand, catalysts and accelerators.
Strength: GRP combines the strengths of both plastic and glass fibre. The thermosetting plastic can withstand compressive loading, but are weaker in tensile strength. The glass fibre has the exact fit with excellent ability to withstand tension, but weak in bearing compression. The resultant composite material is able to withstand tension and compression. This gives the pipes excellent strength.
Advantages of using GRP:
Corrosion resistance: GRP pipes are highly resistant to most corrosive elements. This mean that it can last intact in most environmental conditions. More importantly, it can be used to carry aggressive materials like chemicals. It is used in wastewater management because of its ability to resist highly corrosive elements in sewage.
Low weight: These pipes find many handy applications because of their lightweight. They can used where pipes have to be mounted or where the weight is a major factor. The lightweight means that they can easily carried in difficult terrains.
Lack of any porosity: The GRP is built in such a way that it is almost leak-proof. The presence of glass wire in a thermosetting plastic makes it the one of most non-porous materials around. It means that there are almost no chances of any leakage of toxic elects like certain chemicals. This also makes it a popular component of water distraction systems worldwide.
Smooth inner surface: The GRP pipes have no rough edges or texture. This makes them ideal for carrying liquid components such as water. The smooth surface also reduces the chances of deposits along the rough edges, keeping its inside clean. This can be a major concern in transport of materials like water.
High load capacity: As explained above, GRP products are very strong and can withstand almost all kinds of pressure. That means that even narrow pipes have excellent load capacity. Not only do they have the strength required to carry any kind of material, they are not easily breakable.
Economic: The GRP pipe is highly economic in the long run. Even where its initial costs are higher than some materials, its long-lasting quality means that it will last you a lifetime. There are other additional cost saving. For instance, the lightweight material has low installation costs since it can be installed easily. Its other physical properties ensure that it is a low maintenance material.
Like many composite materials, GRP combines the strength of plastic and glass fibres. With its ability to withstand tension and compression as well as its high resistance to corrosive materials, it is highly suitable for carrying a number of disruptive materials.
If you have ever purchased pipes, you would not be unaware of FRP. And, once you know about FRP, you would be aware of the benefits that it lends to the pipes manufactured by it. FRP is a composite that is perfect for liquids because it is resistant to rust and does not get affected by weather.
FRP also has antimicrobial properties which means that microorganism growth in such pipes is nil. With somany great properties, FRP pipes are popular choice. Besides these features, FRP pipes are also lightweight which makes them easy to be transported and installed. All the properties of FRP pipes also diminish the frequent maintenance requirement.
But,have you ever wondered how the FRP pipes are manufactured. The strength that they have comes from the manufacturing process that is dictated by quality acquired through state of art machines and technical expertise. This blog will provide information on the process involved in manufacturing FRP pipes.
The Popular Manufacturing Method
FRP pipes are popularly manufactured using a method known as helical winding. This method is named after the helical imprint which the pipes carry. This method uses a machine that moulds the pipe using steel or wooden cases; these cases are known as mandrels.
Mandrels are like standard equipment that are prepared with a sheet wrapped on that which makes it easy to release the FRP pipe once it is ready and also so that the inside of the pipe is smooth. After preparing the mandrel, resin application begins. Depending on the type of pipe, two or multiple layers might be applied.
The resin application is followed by machine work in which the helical winding machine winds the patterns and pipes to the required thickness. This takes place at a temperature which ranges from 50 to 75 degrees. Now, because the winding happens at hot temperature, the pipes are required to be left untouched for a couple of hours before being ready for the next step.
The winding stage is where the dimension and thickness of the pipe is also established. Helical winding process is also popular because of pipes of different sizes can be manufactured using the same machine at the same time. After winding, a hydraulic machine is used to separate the mandrel and the FRP pipe.
A final layer of resin is applied on the pipe to give it a nice finishing and also offer ultra violet stabilization. The ends of the pipe are also cut to make the ends smooth and make the pipe of the perfect dimension required. The pipes are then gathered and packed according to the requirements of different client.
When we are busy using pipes, we rarely give thought to the process and effort that has gone in to make the common pipe. Hopefully, the information provided in this blog provided insights on the manufacturing process of FRP pipes. Watch out this space for more information on the other methods of manufacturing perfect pipes.
If you want to store drinking water, you should opt for brass vessel instead of FRP storage tanks because there are several benefits to it. Drinking water from a copper vessel can reap several health benefits. It is one of such home remedies to drink water from brass or copper vessel that most of the old people follow. Ayurveda says that the water stored in a copper vessel has the ability to balance all three doshas in human body, i.e. Vata, Kapha, and Pitta. Copper vessel positively charges the water and this stored water is known as ‘tamara jal’ that you can consume after 8 hours of storing water.
Here are some health benefits of storing and drinking water from copper/brass vessel:
• Boost performance of digestive system
Acidity or gas problem and constipation are very common problems. Copper has certain properties that stimulate peristalsis and kill harmful bacteria and reduce inflammation inside the stomach. Drinking water that is stored in copper vessel is a great remedy for indigestion, ulcers, and infections.
• Reduce your weight
If you are on a diet and eating rich fibrous food, you cannot guarantee that your will shed some pounds. But if you try and drink water stored in a copper vessel, you will see the results. Copper helps in breaking down the fat and eliminate it more efficiently.
• Heal wounds faster
Since copper holds anti-bacterial, anti-viral, and anti-inflammatory properties, it helps in healing wounds faster. It also strengthens your immunity and helps body to produce new cells. It doesn’t only work on outer wounds, but make you stronger from inside out.
• Slows down ageing
If the fine lines on your face are giving you stress, copper can be your natural remedy. As it has strong anti-oxidant and cell forming properties, copper fights off free radicals and gives you smooth younger looking skin.
• Fights cancer
Copper holds strong antioxidant properties that helps in getting rid from free radicals and negate their ill impacts. It fights cancer and gives you healthy living.
• Stimulates your brain
Our brain works by transmitting orders from one neuron to another via synapses. These neurons are coated with myelin sheath that acts like a sort of conductive agent that helps in impulses flow. Copper stimulates your brain and makes it more active.
So, instead of using Frp storage tanks for storing water, you can use brass tanks and vessels and avail these health benefits.
Thermoplastics are specialized materials that can be re-heated and molded in several shapes. GRP pipe manufacturers use them to fabricate piping systems and other GRP profiles for industries. In this post, they will explain different thermoplastics and their advantages, disadvantages, and uses.
These plastics share common property, they soften when heated and are generally used in schools to vacuum form shapes.
1.Acrylic: It is the most commonly used plastic in a workshop of the school. It is available usually in the form of sheets in different colors. It can be transparent, translucent, or opaque. Acrylic is resistant to many acids and weather conditions.
Advantages of using acrylic:
=> It is fairly cheap
=> Hard to touch
=> Good electrical insulator
=> It can be polished and machined with an ease
Disadvantage of using acrylic:
=> It gets scratches easily
=> It is brittle
Use of acrylic:
=> It is used for making sign boards
=> You can use them for making covers of storage boxes
=> Aircraft canopies and windows
=> wash basins and baths
=> Covers for car lights
2.Polyethene: Polyethene can be molded into any possible form and the credit goes to its excellent molding features. Manufacturers prepare large sheets and use polyethene for the production of a variety of products due to its dual densities- high density and low density.
Advantages of polyethene:
=> Low density polyethene is tough, durable, lightweight, great chemical resistance, fairly soft, flexible, good electrical insulator
=>High density polyethene is hard, stiff, and able to be sterilized.
Disadvantages of polyethene:
=> It is hazardous for environment, animals, water ways
=> Some polyethene are not recyclable
Uses of polyethene:
=> Polyethene is generally used for packaging.
=>Some equipments like plastic bottles, household equipments, and tubing are prepared from polyethene thermoplastic
3.PVC: PVC is a tough composite material that can be either availed as hard material or a flexible form. PVC can be bonded or welded with an adhesive.
Advantages of using PVC:
=> It is stiff
=> It is hard
=> It is tough
=> It gas chemical resistance property
=> It is lightweight
Disadvantages of using PVC:
=> Poor weather ability
=> Prone to scratches
Uses of PVC:
=> Manufacturers use PVC to fabricate pipes, bottles, guttering, and window frames.
You can avail PVC pipes and similar products from GRP pipes manufacturers India. Make request here in comments and talk to professionals.
Fiberglass composites are most common and readily available materials. It is used by manufacturers to make FRP products in India. FRP is strong enough to manufacture some applications. Manufacturers make use of resins to define certain properties of FRP products like corrosion resistance, flame resistance, maximum operating temperature, weather resistance, chemical resistance, etc.
The strength of FRP materials, including fiberglass is usually determined by the orientation, quantity, type, and location of the reinforcing fibers. The resins used by manufacturers bind the reinforcing fibers and offers rigidity. Fiberglass provides similar strength and weighs less than steel and metals.
Fiberglass composites have a polyester fabric surface layer and a resin layer that provides protection against water intrusion, corrosion, and UV rays effect. FRP bridges are made of closed-section shapes. These shapes offer better torsional and buckling characteristics. Sometimes, open sections are used for bridges, but manufacturers recommend using closed sections whenever possible.
Manufacturers use two main processes – pultrusion and extrusion. They use pultrusion process for producing FRP composite products. They manufacture continuous length of FRP structural shapes like rods, channels, beams, plates, and cross sections.
The raw materials used by engineers for manufacturing FRP profiles are a liquid resin mixture and flexible textile reinforcing fibers.
Advantages of FRP materials
There are lots of advantages of FRP materials. The list goes as under:
• Light weight
• High strength
• Corrosion resistance
• Easy to install
• Easy to transport
FRP can be formed in any shape and manufacturers can add any colorants to make the product colorful. The use of composites is environmental friendly because constructors will not cut large trees near bridge sites. Composites are cheaper than metals and never corrode.
Disadvantages of FRP materials
You may have read many benefits and advantages of using FRP materials. But here we will discuss about the limitations.
• Manufacturing unit needs different saw blades and drill bits for FRP materials. Those which work for wood or steel never work with FRP.
• Bridge designs handled by the deflection amount instead of required strength to sustain the bridge structure.
• Lack of design standards and codes
• Lack of performance history
FRP products India manufacturers and suppliers are sourcing FRP scrap for recycling purposes. FRP scrap is great for production of FRP profiles. It is cost saving and helps achieving stronger and robust products. If you want more info on FRP materials, you can talk to the suppliers any time.
FRP materials are flexible ones and can be used by FRP tanks manufacturers to intend robust silos and storage tanks for industrial client. Each material carries its unique properties and in this post, we will discuss about resins that manufacturers use for producing FRP tanks and products and making them robust and non corrosive.
Isophthalic Polyester Resin
Isphthalic polyester resin belongs to a broad class of resins formulated from isphthalic acid, maleic anhydride and glycols. The certain resin specification is picked by manufacturing unit engineers to impart desired properties and corrosion resistance. These Isophthalic polyester resin is used for moderate corrosion resistance applications that would be used at temperature range around 180 degrees Fahrenheit.
Properties of Isophthalic polyester resin-
Weak bases resistant
Hydrocarbons resistant like oil and gasoline
Vinyl Ester resin
Vinyl ester resin are polyester resins, however they are usually categorized in separate list from polyesters as they have enhanced mechanical properties and corrosion resistance. Vinyl esters provide enhanced strength and better impact and thermal shock resistance as compared to polyester resins. These resins offer superb resistance to alkalis, acids, hypochlorites, and other solvents.
Bisphenol A Fumarate polyester resin
This resin is prepared from a process in which experts perform reaction between bisphenol A and propylene oxide and fumaric acid. By this reacting phase, resin achieves a resistance against alkali environments. This type of resin is usally used for applications involving hot caustic solutions. It is ideal for service with acids, salt solutions and selected organic solvents to a temperature range of about 250 degrees Fahrenheit.
Chlorendic polyester resin
It is unsaturated, halogenated polyester resin used for making equipments that is operating at elevated temperatures or in extremely oxidizing environments like hot, wet chlorine. These resins are usually suited for making chimney liners, chrome plating tanks, flue gas duct, pickling tanks, and chlorine headers.
These are earliest commercialized thermoset resins that was first appeared in the late 1800. There are two types of phenolic resins- resole and novolac. Resoles are base-catalyzed thermosetting resins that have self-crosslinking design. Novolacs are catalyzed with acids and require a hexamine crosslinker to transform into thermosetting. These resins provide high temperature resistance, chlorinated solvents resistance, salt water resistance, and excellent smoke/fire properties.
There are a lot more resins used by FRP tanks manufacturers India to construct distinct range of products for industrial customers.
FRP or fiberglass reinforced plastics are the composites used by manufacturers to fabricate tanks, gratings, profiles, sections, and other products. FRP tanks manufacturers India take fiberglass reinforced plastic as useful material because of several properties. In this post, you will read about these features.
• Infinite potential
You can get almost anything made of FRP material. With all the awesome features listed in this article, you will be able to imagine how manufacturers work with their zeal and creativity to fabricate durable structures and profiles.
• Low weight
Even the cheapest FRP material is less dense and lighter than the steel and aluminium.
• Mechanical strength
Fiberglass is so stiff and strong for its weight. It performs better than other materials like wood, steel or metals.
• High impact strength
As compared to most metals, fiberglass doesn’t deform even when it is ruptured.
FRP products such as tanks and gratings have a hard finish. The gelcoat used by manufacturers on the surface of the FRP product protects the color and product from distinct weather conditions.
Fiberglass can be molded to almost any shape and design. Manufacturers can create or imitate most shapes with an ease. Molds used for FRP products fabrication are cheap to buy when compared with metal or plastic materials.
• Corrosion resistance
Unlike metals, FRP materials are corrosion resistant. You can say about FRP products that they are long-lasting.
• Weather resistant
Fiberglass reinforced products are weatherproof. No matter if you install your FRP tanks at the location where temperature is always high or always low, it will not deform or wear. Even acids and chemicals have zero impact on FRP products.
• Electrically insulating
People working in the power industry, FRP materials are the safest for working as they don’t conduct electricity.
• Thermally insulating
FRP material is long lasting and maintains its temperature. This is why it lowers the heat and cooling costs. You can touch the surface of FRP tank because it is neither cold nor hot.
• Low maintenance
Once you install FRP tank at the site, you don’t need to look after it every day. FRP products are maintenance free.
• Durable custom colors
You can avail colorful products in shiny or matte finish from FRP tanks manufacturers India. Normally, these products can last for up to 20 years or even more.
GRP piping systems are tested first before manufacturers send them to the suppliers and vendors. GRP pipes manufacturers India make exotic piping solutions for global customers. They make these products available across the world at reasonable rates. In this article, manufacturers would like to share some of the benefits offered by their products at one time.
• Long lasting
FRP generally has minimum life cycle of 50 years. The smooth surface is maintained throughout the life ofthe pipe.
• Cost effective
FRP pipes have 10 to 15% cheaper price than steel pipes and 20-30% than cement concrete pipes.
GRP and FRP pipes weight is 75% lighter than the steel pipes and 90% lighter than the concrete pipes. GRPpipes are lighter and so it is easier to handle and install them at low transportation cost.
You hardly need any tool for installation and porting these pipes.
• Installation benefits
Since GRP pipes are easy to install, manufacturers can make them up to 12m long to speed up installation,which also eliminates up to 75% of the joints. GRP pipes are easy to handle and move and so you don’t need a bunch of people in the team.
• Dimension stability
GRP piping system can sustain tolerances required of the most demanding piping and structural applications.
• Strength to weight ratio
The GRP pipe has superb strength to weight properties. GRP composites surpass iron, HDPE, PVC and mild steel when the ratio of weight’s strength per unit is considered.
• Very low friction factor
GRP pipes have low friction and its hydraulic characteristics lead to significant saving in pumping costs.
• Low maintenance
There is no such maintenance cost involved for GRP pipes because these are corrosion resistant.
When there is no corrosion, there is no need of replacement.
GRP pipes are OD compatible with CI, DI, and pre-stressed cement pipe. Apart from DI, CI fittings, GRP flanges can be used to link pipe directly to these materials.
• Fire Resistance
GRP products are available in versatile designs and can be made fire retardant with right selection of the resin.
GRP pipes manufacturers India are making distinct ranges of GRP pipes for industrial clients. These pipescan be customized as per the requirement of the customer. If you need assistance regarding GRP pipes or to know how to order it, contact manufacturers today.