Introduction To FRP Materials

Program:
Course Code: CES351
Course Name: ACM

Report (1)

Ain Shams University

Faculty of Engineering
Spring Semester – 2022
SPRING SEMESTER - YEAR 2019/2020
 Student Personal Information for Work

Student Name: kareem Magdy Moheb Elfadaly

Student Code:1803916

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Student Name: Kareem Magdy Moheb Elfadaly

2
Introduction
Fiberglass Reinforced Plastics, or FRP, is a great material for building chemical
storage tanks, pipe systems, apparatus, and other forms of industrial process
equipment. When it comes to chemical and corrosion resistance, FRP material
qualities outperform many traditional materials such as steel. Well-engineered FRP
equipment guarantees little maintenance and a lengthy product life cycle.

What is FRP
FRP material is made up of thermosetting polymers and fibreglass. The primary
component of FRP products is the combination of resin and glass fibres. The resin
provides the product with environmental and chemical resistance and serves as the
binder for the glass fibre in the structural laminate. A resin type is chosen based on
the chemical and environmental variables (provided by the customer or user).
Plasticon Composites typically manufactures a FRP product with three laminates:
Chemical and temperature resistant corrosion barriers
Temperature resistance of structural laminate
Topcoat: weather and temperature resistance
Because each form of laminate serves a distinct purpose, a different type of resin
might be used to create a product for each laminate. Plasticon Composites
generally works with three types of resin (polyester, vinyl ester or epoxy). On this
website, you may learn more about resins and the fabrication of FRP.
Furthermore, we have numerous varieties of glass to choose from, again dependent
on the application and procedures for which the final product will be utilised
(different types of veils). Choosing the correct manufacturer is critical when it
comes to assembling these elements and picking the proper resins, optimum
winding processes, and glass fiber components to ensure the quality and
advantages of the materials.
Characteristics of FRP
FRP is well-known for its mechanical strength and is a preferred choice for
corrosion resistance. FRP is also lightweight, has great temperature resistance,
provides thermal insulation, and can be moulded into various designs. FRP
products are simple to repair and need little upkeep.
Because of the method Plasticon Composites manufactures FRP goods, FRP
products are noted for their smooth interior surface and seamless forms, resulting
in optimal product flow.
A brief history on the use of FRP:
Plasticon Composites began employing FRP in 1950 due of its great mechanical
strength. During the building of a chemical storage tank, a FRP laminate was put
on top of a PVC liner; this is known as a 'Dual Laminate' structure.
polymers:
What exactly are polymers?
A polymer is a big molecule or macromolecule that is composed of numerous
components. Polymer is a Greek word that means'many components.' Polymers
may be found all over the place. From the strand of human DNA, which is a
naturally occurring biopolymer, to polypropylene, which is utilised as a plastic all
over the world.
Polymers can be found naturally in plants and animals (natural polymers) or they
can be man-made (synthetic polymers). Polymers offer a variety of unique physical
and chemical qualities that allow them to be used in everyday life.
Polymers are always formed by the polymerization process, in which their basic
constituents, known as monomers, react together to produce polymer chains, i.e. 3-
dimensional networks that form the polymer links.
The sort of polymerization process employed is determined by the functional
groups connected to the reactants. Almost all macromolecules in biology are either
entirely polymeric or composed of long polymeric chains.

Polymer classification:
Because of their complicated structures, diverse behaviours, and wide range of
uses, polymers cannot be categorised into a single category. As a result, we may
categorise polymers based on the following factors.
Polymer Classification Based on Availability Source:
This topic is divided into three subcategories: natural, synthetic, and semi-synthetic
polymers.
Natural Polymers:
Polymers that arise naturally and are present in plants and animals are known as
natural polymers. Proteins, starch, cellulose, and rubber are a few examples. In
addition, we have biopolymers, which are biodegradable polymers.

Semi-synthetic polymers:
are produced from naturally existing polymers and then chemically modified. For
instance, cellulose nitrate and cellulose acetate.

Synthetic polymers:
are polymers that are created by humans. The most prevalent and commonly used
synthetic polymer is plastic. It is utilized in a variety of industries and dairy
products. For example, nylon-6, polyethers, and so forth.

Polymer classification based on the structure of the monomer chain:

This category is divided into the following subcategories:

Polymers with Linear Chains

This category includes the structure of polymers with long and straight chains.
PVC, or poly-vinyl chloride, is a kind of linear polymer that is commonly used to
make pipes and electric wires.

Polymers with Branched Chains

When a polymer's linear chains produce branches, the polymer is classified as
branched chain polymer. Low-density polythene, for example.
Polymers that are cross-linked
They are made up of monomers with bifunctional and trifunctional functions. In
compared to other linear polymers, they have a stronger covalent bond. Bakelite
and melamine are two examples of this type of material.
Further Polymer Classification Methods:
Polymerization-Based Classification:
Addition Polymerization: Polyethene, Teflon, and polyvinyl chloride are a few
examples (PVC)
Condensation Polymerization: include Nylon-6, 6, perylene, and polyesters.
Monomer-Based Classification:
Homomer: A single kind of monomer unit is found in this type. Polyethene, for
example.
Co-polymer or heteropolymer: It is made up of many types of monomer units. For
instance, nylon -6, 6
Molecular Forces-Based Classification:
Elastomers are rubber-like substances with weak contact forces. Take, for example,
Rubber.
Fibers: Significant, tough, high tensile strength, and strong interaction forces are
present. For instance, nylon -6, 6.
Thermoplastics: These have intermediate attraction forces. Polyvinyl chloride, for
example.
Thermosetting polymers: These polymers significantly increase the mechanical
characteristics of the material. It has improved chemical and heat resistance.
Polymer Varieties:
Polymers are classified according on the sort of backbone chain they have:
Organic polymers have a carbon skeleton.
Inorganic polymers have a skeleton made up of elements other than carbon.

Some Polymers and the Monomers that Make Them:

Polypropene, often known as polypropylene, is a polymer composed of the
monomer propene.
Polystyrene is an aromatic polymer that is inherently transparent and is composed
of the monomer styrene.
Polyvinyl chloride (PVC) is a polymer composed of the monomer vinyl chloride.
The urea-formaldehyde resin is a non-transparent material made by heating
formaldehyde and urea together.
Glyptic is a polymer composed of the monomers ethylene glycol and phthalic acid.
Bakelite, also known as polyoxybenzylmethylenglycolanhydride, is a material
composed of the monomers phenol and aldehyde.
Fibers:
The qualities of composite materials are typically influenced by the fibre used.
Carbon, glass, and aramid are the three most common forms of fibres used in
construction. The reinforcing fibre is frequently used to name the composite, for
example, CFRP for Carbon Fibre Reinforced Polymer. The most fundamental
differences between fibre types are stiffness and tensile strain.

Matrices:
The qualities of composite materials are typically influenced by the fibre used.
Carbon, glass, and aramid are the three most common forms of fibres used in
construction. The reinforcing fibre is frequently used to name the composite, for
example, CFRP for Carbon Fibre Reinforced Polymer. The most fundamental
differences between fibre types are stiffness and tensile strain.
Types Of Fiber Reinforced Polymer {FRP}:

1. Glass Fiber Reinforced Polymer (GFRP):

Glass fibers are created by combining silica sand, limestone, folic acid, and other
minor elements. At around 1260°C, the mixture is heated until it melts.
After that, the molten glass is allowed to flow through fine holes in a platinum
plate. The strands of glass are cooled, collected, and twisted. Drawn fibres are used
to improve directional strength. The fibres are then braided into different shapes
for usage in composites.
Due to their strong electrical insulating qualities, low sensitivity to moisture, and
good mechanical capabilities, glass generated fibres are regarded the major
reinforcement for polymer matrix composites based on an aluminium lime
borosilicate composition.
Glass is an excellent impact resistant fibre in general, however it is heavier than
carbon or aramid. In certain forms, glass fibres offer exceptional properties that are
comparable to or better than steel.
2. Carbon Fiber Reinforced Polymer (CFRP):

Carbon fibers have a high modulus of elasticity, ranging from 200 to 800 GPa. The
final elongation ranges from 0.3 to 2.5 percent, with lower elongation
corresponding to higher stiffness and vice versa.
Carbon fibers are resistant to various chemical solutions and do not absorb water.
They are extremely fatigue resistant, do not corrode, and exhibit no creep or
relaxation.

3. Aramid Fiber Reinforced Polymer (AFRP):

Aromatic polyamide is abbreviated as aramid. Kevlar is a well-known trademark
for aramid fibres, although other brands exist as well, including Twaron, Technora,
and SVM.
The moduli of the fibres range from 70 to 200 GPa, with a final elongation of 1.5
to 5% depending on the quality. Aramid has a high fracture energy and is hence
utilised to make helmets and bullet-proof clothing.
Because they are susceptible to high temperatures, moisture, and UV light, they are
not commonly employed in civil engineering applications. Finally, Aramid fibres
have relaxation and stress corrosion issues.
Applications of FRP:
1-Carbon FRPs are utilised in prestressed concrete for situations requiring strong
corrosion resistance and electromagnetic transparency.
2-CFRP composites are used for undersea pipes and offshore platform structural
elements. Furthermore, FRP reduces the risk of fire.
3-Carbon fibre reinforced polymers are utilised to make underwater pipelines at
vast depths since they have substantially higher buoyancy (due to their low
density) than steel.
4-The stairways and walkways are likewise composed of composite materials to
save weight and withstand corrosion.
5-It is employed in hybrid constructions with great performance.

6-Internal reinforcement for concrete structures is provided by FRP bars.

7-FRP bars, sheets, and strips are used to reinforce diverse constructions
made of concrete, masonry, wood, and even steel.
8-FRPs are used in earthquake retrofitting.
9-Fibre reinforced polymers are used to build unique constructions that need
electrical neutrality.
10-Aramid fiber reinforced polymer (AFRP) composites' excellent energy
absorption makes them appropriate for reinforcing engineering structures
subjected to dynamic and impact loads.

FRP Processing methods:

IMPORTANT METHODS:
Hand Lay-up
Spray up method

Filament winding
Match die molding
Pultrusion
Resin transfer molding
Reaction injection molding

1-Hand Lay-up
Hand Lay-Up is ideal for low-volume product production. This approach is
applicable to both the corrosion barrier and the structural part.
• If the composite is to be attached directly to another structure, a mould must be
utilized for hand lay-up pieces. The mould might be as basic as a flat sheet or as
complex as an unlimited number of curves and edges.
• For some forms, moulds must be linked in pieces so that parts may be removed
after hardening.
Reinforcement fibers can be cut and laid in the mold. It is up to the designer to
organize the type, amount and direction of the fibers being used. Resin must then
be catalyzed and added to the fibers. A brush or roller can be used to impregnate
the fibers with the resin. -The lay-up technician is responsible for controlling the
amount of resin and the quality of saturation

Hand lay-up: (1) mold is treated with mold release agent; (2) thin gel coat (resin) is
applied, to the outside surface of molding; (3) when gel coat has partially set,
layers of resin and fiber are applied, the fiber is in the form of mat or cloth; each
layer is rolled to impregnate the fiber with resin and remove air; (4) part is cured;
(5) fully hardened part is removed from mold

Materials Used for Hand Layup:

Resins: Any, e.g. epoxy, polyester, vinyl ester, phenolic.
Fibers: Any, although heavy aramid fabrics can be hard to wet-out by hand
Advantages:
Advantages:
i) Widely used for many years.
ii) Simple principles to teach.
iii) Low-cost tooling, if room-temperature cure resins are used. REINFORCE
PLASTICS
iv) Wide choice of suppliers and material types.
v) Higher fibre contents, and longer fibers
Disadvantages:
i) Resin mixing, laminate resin contents, and laminate quality are very Dependent
On The Skills of laminators. Low resin content laminates cannot usually be
achieved without the incorporation of excessive quantities of voids.
ii) Health and safety considerations of resins. The lower molecular weights of hand
lay-up resins generally means that they have the potential to be more harmful than
higher molecular weight products. The lower viscosity of the resins also means that
they have an increased tendency to penetrate clothing
iii) Resins need to be low in viscosity to be workable by hand. This generally
compromises their mechanical/thermal properties due to the need for high diluents
levels
Generally large in size but low in production quantity - not economical for high
production.

Applications:
- Boat hulls –
-Swimming pools
- Large container tanks
-Movie and stage props
- Other formed sheets
The largest molding ever made was ship hulls for the British Royal Navy: 85 m
(280 ft) long

2)Spray Up Method:
Fibre is chopped in a hand-held gun and fed into a spray of catalysed resin directed
at the mould. The deposited materials are left to cure under standard atmospheric
conditions

Materials Options:
pune institute of com Resins: Primarily polyester. Fibres: Glass roving only

Advantages:
-Continuous process
- Any materials can be used as mold.
-Error can be corrected by re-spraying.

Disadvantages:
-Slow. inconsistency.
-No control of fiber orientation.
-Only one side finished.
-Environmental unfriendly

3)Pultrusion:
Fibres are pulled from a creel through a resin bath and then on through a heated
die.
The die completes the impregnation of the fibre, controls the resin content and
cures the material into its final shape as it passes through the die.
This cured profile is then automatically cut to length.
Fabrics may also be introduced into the die to provide fibre direction other than at
0°.
Pultrusion is a continuous process, producing a profile of constant cross-section, a
variant known as 'pulforming' allows for some variation to be introduced into the
cross section

Main Advantages :
1) This can be a very fast, and therefore economic, way of impregnating and
curing materials.
2) Resin content can be accurately controlled.
3) Fiber cost is minimized since the majority is taken from a creel. REINFORC
PLASTIC
4) Structural properties of laminates can be very good since the profiles have
very straight fibers and high fiber volume fractions can be obtained
5) Resin impregnation area can be enclosed thus limiting volatile emissions

Main Disadvantages:
i) Limited to constant or near constant cross-section components
ii) ii) Heated die costs can be high.

Typical Applications: REINFORCED PLASTICS Beams and girders used in

roof structures, bridges, ladders, frameworks
4)FILAMENT WINDING:

This process is primarily used for hollow, generally circular or oval

sectioned components, such as pipes and tanks. Fiber tows are passed
through a resin bath before being wound onto a mandrel in a variety of
orientations, controlled by the fiber feeding mechanism, and rate of
rotation of the mandrel

Main Advantages:
i) This can be a very fast and therefore economic method of laying
material down.
ii) Resin content can be controlled by metering the resin onto each
fiber tow through nips or dies.
iii) Fiber cost is minimized since there is no secondary process to
convert fiber into fabric prior to use.
iv) Structural properties of laminates can be very good since straight
fibers can be laid in a complex pattern to match the applied loads

Main Disadvantages:
i) The process is limited to convex shaped components.
ii) Fiber cannot easily be laid exactly along the length of a
component.
iii) Mandrel costs for large components can be high.
iv) The external surface of the component is unmolded, and therefore
cosmetically unattractive.
v) Low viscosity resins usually need to be used with their attendant
lower mechanical and health and safety properties
5)Resin transfer molding:

Resin transfer molding is a closed molding process

In this technique, as the name indicates, resin is transferred over the
already placed reinforcement
Reinforcement in terms of either woven mat or strand mat form is placed
on the surface of lower half mold
A release gel is applied on the mold surface for easy removal of the
composite.
• The mold is properly closed and clamped. The clamping can be done
either perimeter clamping or press clamping mechanism
 The resin is pumped into the mold through ports and air is displaced
through other vents
After curing, the mold is opened, and composite product is taken out

Advantages:
1) Composite part produced with this method has good surface finish on
both side surface of the product.
2) Any combination of reinforced materials (including 3D) in any
orientation can be achieved.
3) Fast cycle time can be achieved through temperature control tooling
device.
4) Process can be manual control, semi-automated or highly automated.
5) Composite part thickness is uniform which is determined by the mold
cavity.
6) The process does not require high injection pressure

Disadvantages:
1) Mold cavity limits the size of the composite.
2) High tooling cost.
3) There is limitation on reinforcing materials due to the flow and resin
saturation of fibers.
6) Reaction injection molding:
Reaction injection molding (RIM) is similar to injection molding except
thermosetting polymers are used, which requires a curing reaction to occur
within the mold
First, the two parts of the polymer are mixed together.
The mixture is then injected into the mold under high pressure using an impinging
mixer.
The mixture is allowed to sit in the mole long enough for it to expand and cure.
If reinforcing agents are added to the mixture, then the process is known as
reinforced reaction injection molding (RRIM).
Common reinforcing agents include glass fibers and mica. This process is usually
used to produce rigid foam automotive panels.

Advantages and disadvantages:

1. Reaction injection molding can produce strong, flexible,
lightweight parts which can easily be painted.
2. It also has the advantage of quick cycle times compared to typical
vacuum cast materials.
3. The bi-component mixture injected into the mold has a much lower
viscosity than molten thermoplastic polymers, therefore large,
lightweight, and thin-walled items can be successfully RIM
processed.
 4. This thinner mixture also requires less clamping forces, which
leads to smaller equipment and ultimately lower capital
expenditures.
5. Another advantage of RIM processed foam is that a high density
skin is formed with a low-density core.
The disadvantages are slow cycle times, compared to injection moulding, and
expensive raw materials

Structural Application of FRP:

1. Strengthening of RC beams with carbon fiber reinforced polymer
(CFRP) laminates

In parallel with developing of this new anchorage system application of different

NDT techniques for assessing the condition of the attachment of laminates to the
concrete surface and appearance of trapped air in the adhesive in particular have
been investigated (Donchev et al., 2010). Most reliable results have been received
via the usage of infrared thermography (IRT)
Additional extensive research was conducted about the behaviour of CFRP
strengthened systems at high temperatures with the expectation to clarify their
behaviour and to limit the level of conservativity for assumptions connected with
their residual capacity after heating and cooling. The residual deformations and the
ultimate capacity of small scale CFRP strengthened RC
beams after heating up to300◦C were investigated in Petkova & Donchev (2011) .
The pull-out tests after heating and cooling were showing reduction of the
anchoring capacity of the laminates down to 30% at 300C in comparison with the
initial values.
The estimation of residual capacity of CFRP strengthening of RC elements is
possible to be conducted on basis of visual inspection with consideration of
recorded changes in the colour of the adhesive from light grey to black and shape
and volume changes in the laminates. Applicability of other NDT approaches,
mainly IRT and ultrasonic testing of the CFRP laminates, is under consideration.

2. Internal FRP reinforcement:

The behaviour and the anchorage of internal glass FRP (GFRP) and basalt FRP
(BFRP) bar reinforcement at normal and elevated temperatures were investigated.
The initial steps in this direction in Kingston University were conducted since
2007 both as theoretical modelling (Kadhim et al., 2008) and as experimental
investigations. Theoretical model was developed on the basis of existing US
standards for steel with consideration of possible Eurocode2 application. The
experimental research included analysis of higher deformability, crack appearance
and development and ultimate capacity of GFRP reinforced large scale beams.
Increased deformations of GFRP and BFRP reinforced beams in comparison with
steel reinforcement was reason for further redirecting of the focus of our research
to reduce the deformability. The latest progress in this direction is mainly in aspect
of application of BFRP internal reinforcement for prestressed RC elements,
reflected in the works of Pearson and Donchev (2013) and Pearson et al. (2013)
(Fig 4). The NDT techniques for assessing the condition of such elements and
possible structural health monitoring applications are under consideration.
3. Strengthening of masonry walls for out-of plane loading
Extensive research was conducted during recent years in the area of
strengthening of unreinforced masonry with FRP materials. The work
started with small scale experiments and the results from initial testing of
FRP strengthened small masonry panels were analysed and used as
verification for the theoretical modelling developed by Arash Sayari
(Sayari et al, 2010). Further development of this direction resulted in
large scale testing of FRP strengthened masonry walls, which results and
analysis were presented in Sayari et al (2011), Sayari and Donchev
(2012) and others. The application of uniformly distributed out-of-plane
loading allowed estimating that the strengthening with cross-positioned
CFRP laminates is most effective in aspect of decreasing deformability
and increasing the ultimate capacity of the walls

4. Steel and Hybrid (steel/FRP) shear walls.

Significant part of FRP-related structural research in Kingston University is
connected with innovative shear wall systems. The investigations in this area
started with research and experimental programme aiming to investigate the effect
of openings in steel plate shear walls, which was initiated by Ahmad Maleki
(Maleki et al., 2010). It was further developed via adding layers of GFRP fabric to
the steel infill plate, which resulted in the development of innovative Hybrid shear
walls (Maleki et al., 2011 and 2012). The latest research in this area is
investigating the effects of adding of CFRP layers as well as the behaviour of shear
walls with steel frame and pure FRP infill plates (Petkune et al., 2012)
The existing results are indicating significant benefits from the application of
hybrid shear walls in comparison with steel ones. Within the frame of this project
further research abour application of IRT for assessing the level of delamination of
FRP layers at different stage of loading is investigated. Obtained results prove that
the IRT allow precise estimation of the positioning and extent of the delaminated
zones reflected in (Petkune et al., 2013)
Conclusion:
The overview of the research on FRP applications indicate that it is fast developing
and extremely interesting area from Structural Engineering point of view.
However, possible methods for NDT evaluation of the properties of such structural
elements are limited and not sufficiently developed. The wider application of FRP
materials in Structural Engineering will increase the importance of this area and
will stimulate further developments.

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polymer/1583/
https://www.slideshare.net/jeffjose09/fibre-reinforced-
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20%28FRP%29%20composite%20is%20defined%20as,mat
erial%2C%20which%20forms%20a%20continuous%20net
work%20around%20them