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Basic Sub Sub-sub Typical Examples

Category Category Category

Polymers, Plastics and POLYMERS

[Long-Chain
Thermoplastics Nylon, Vinyl, Teflon,
(Flexible and Acrylics,
Composites for Engineers Molecules or
Macro-
PLASTICS
[Natural or
Tough)

molecules Synthetic
Formed by Resins or
Linking and their
Inderdeep Singh Cross- Compounds] Thermosetting Plastics, Epoxies,
linking of (Strong and Bakelite, Phenolics,
Indian Institute of Technology Different Brittle) Polyester, Urea,
Roorkee Monomers]

• Use of plastics has increased at much faster Plastic types: Thermosets

rate than metals in last 60 yrs
• Applications range from toys, bottles to air craft
General properties: more durable, harder, tough,
components
light.
• Why so ?
Typical uses: automobile parts, construction
– Large no. of processes available for variety of
materials.
shapes
– Most of them produce “near net” shape Unsaturated Polyesters: boat hulls, furniture,
(no further processing is needed) electrical fittings
– Low melting point of plastics results in less Epoxies and Resins: coating of electrical circuits,
energy requirement for processing and ease composites (fiberglass in helicopter blades, boats, …)
of handling

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Plastic types: Thermoplastics Common Manufacturing Processes

for Plastics are:
General properties: low melting point, softer, flexible.
Typical uses: bottles, food wrappers, toys, … – Extrusion
•Polyethylene: packaging, electrical insulation, milk and water – Injection moulding
bottles,
•Polypropylene: automotive bumpers, microwave containers – Compression moulding
•Polyvinyl chloride (PVC): electrical cables cover, credit – Transfer moulding
cards, car panels
•Polystyrene: disposable spoons, forks – Rotational moulding
•Polyamide (nylon): textiles and fabrics, gears, bushing and – Thermoforming
washers, bearings
•PET (polyethylene terephthalate): bottles for acidic foods like
– Casting
juices, food trays
•PTFE (polytetrafluoroethylene): non-stick coating, raincoats

Injection Moulding Injection Molding

• Plastic is heated to highly plastic state and then
forced to flow into a mould cavity under high
pressure where it solidifies. Mostly used for
thermoplastics.
• The moulded parts, mostly of near net shape are
called moulding is then removed.
• Production cycle is very short 10-20s.
• Multiple moulding can be used for further higher
production rates

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Blow Molding
 Blow molding is a modified extrusion and
injection molding process for developing hollow BLOW MOLDING
products using a tube called parison.
 Extrusion blow molding, a tube is first extruded,
then after clamping into a mold blowing into the
cavity.
 In injection blow molding, parison is first
injection molded then hot air is injected into the
parison for blowing.
 Typical products: plastic beverage bottles and
hollow containers.

COMPOSITES Constituents of FRPs

Matrix Reinforcement

Polymer (PMCs) Shape Orientation Chemical

nature
Continuous fibers

Ceramic (CMCs) Oxides

Short fibers

Carbides
Whiskers

Metal (MMCs) Particulates Nitrides

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FRP Composites : Advantages with FRPs

• Fiber Reinforced Plastics are an important class • Maintains critical tolerance required for most demanding
applications.
of structural materials
• FRP equals or exceeds the flexural strength and impact
• Matrix and reinforcement are two important resistance of many metals.
phases of a typical composite material • High resistance to most chemicals.
• A plastic matrix is reinforced with fibers to • Low moisture absorption.
develop a FRP • Integral color, hence an elimination of recurring painting
jobs.
• The matrix can be thermosetting or • First choice when flammability is a problem.
thermoplastic whereas the reinforcing fibers can • FRP has high strength to weight ratio.
be glass, carbon, aramid or boron fibers • Low conductor of electricity

Cost Vs Performance aspect of Design Advantages in Construction

• Product and system design can be optimized for specific

loads.
• Reduced structure dead load can increase load ratings.
• Increased structure service life.
• Reduced maintenance costs due to resistance from
deicing salts and other corrosive agents.
• Engineered system packing reduces field installation
time.
• Faster construction, reducing traffic delays.

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Applications in Construction FRP Rebars

• The application of FRPs in civil engineering infrastructure

can be broadly classified as
- Application in new construction
- Repair and rehabilitation
- Architectural applications
• Some of the important applications are
- FRP bars
- Structural strengthening
- Infrastructure repair
- FRP bridge deck
Hall's Harbor - World's first fully composite reinforcement structure

FRP Rebars Structural Strengthening

Concrete structures need to be strengthened for any of the
following reasons:
• Good mechanical characteristics, comparable to that of
steel reinforcement
• Load increases due to higher live loads, increased wheel loads,
• Good chemical behavior, resistant to corrosion installations of heavy machinery, or vibrations.
• Lighter than steel reinforcement • Damage to structural parts due to aging of construction materials or
fire damage, corrosion of the steel reinforcement and impact of
• Electrically and thermally non-conducting vehicles.
• Good bond characteristics, effective transfer of load from • Improvements in suitability for use due to limitation of deflections,
concrete to FRP bars reduction of stress in steel reinforcement or reduction of crack
widths.
Limitations – Bends not allowed in FRPs, welding • Modification of structural system due to the elimination of
characteristics not completely understood walls/columns or openings cut through slabs.
• Errors in planning or construction due to insufficient design
dimensions and insufficient reinforcing steel.

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Concrete being strengthened with FRP

Beam Strengthened with FRP Sheet

Infrastructure Repair

Wrapping Preformed FRP sheet to the damaged part

Dry Dock #4 Pearl Harbor, Hawaii
(Hughes Brothers, Inc)

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Infrastructure Repair
Composite Bridge Deck

• Nearly 575,600 highway bridges in United States are

either structurally deficient or functionally obsolete
• New materials are the need of the hour that can act as a
permanent “Band-Aid”, thus eliminating the need of
demolition before rework
• The process involves either on-site filament winding or
wrapping preformed composite sheets around the
damaged parts of the structure
• It has been established that wrapped structural elements
show an increase in strength up to 500%
Beams are installed at site

Prefabricated SuperdeckTM is installed

using minimal equipment
FRP Bridge Deck

• FRP composite bridge deck is designed and engineered

into a lightweight, strong and rigid structure that will not
corrode.
• Safety is enhanced as minimal equipment is needed
• Long traffic delays are eliminated
• There are no long-term studies on the performance of
the bridge as FRPs are comparatively new class of
materials.

On-site assembly takes only a few hours

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Architectural Applications Primary Manufacturing of FRPs

• Aesthetic appeal Various manufacturing processes are:
• Ability to mould complex shapes
• Various surface finishes available 1. Hand lay-up
• Lightweight – reduced support structure, ease of 2. Spray lay-up
installation etc 3. Pultrusion
• Durability / corrosion resistance – long maintenance-free 4. Filament Winding
life leading to low through-life costs 5. Resin Transfer Molding
• Parts integration – cost reduction, rapid installation 6. Compression Molding
• Cost effectiveness 7. Injection Molding
• Can be electrically non-conductive and radio transparent

FILAMENT WINDING

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Machining of FRPs FRP’s Machining - Challenges

• The anisotropic nature of FRP composite
materials
• Though most of the FRP composite products are
made to a near-net shape, machining in general
• The difference in the properties of the
constituents
and drilling in particular sometimes becomes • The highly abrasive nature of some typical
imperative to ascertain the structural integrity of fibers
intricate final products. • Tool wear and optimum tool point geometry
• Assembly of individual parts manufactured • Stacking sequence
independently into the intricate final product • Machining induced damage
require drilling of holes. • Decision to use a coolant or not
• Health hazards

Drilling Induced Damage Circularity Defect

Faraz et al. 2009, Int. J Mach Tools Manuf. 1185-96

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Issues to be addressed Concluding Remarks

• Cost FRP composite materials are a viable alternative to the

conventional material systems in use today.
• Technical Issues The application areas have increased manifold, from
• Fire Protection simple sporting goods to aerospace and marine
applications
• Waste Disposal The issues highlighted in terms of cost, waste disposal,
• Standardization and Regulation standardization need to be addressed by the composite’s
fraternity to make these materials “The Wonder Material
• Publicity and Training of the 21st Century”.

REFERENCES

Griffith, J. R. "Plastic Highway Bridges", Cambridge Scientific Abstracts, 2000

Benmokrane "Mechanical and Bond Properties of New Generation of ISOROD
CFRP Reinforcing Bars for Concrete Structures", technical progress report,
2001, ISIS Canada.

Hughes Brothers, Inc. Website: http://www.hughesbros.com

Thank You Robert J. Odello, “Polymer Composite Retrofits Strengthen Concrete
Structures”, The AMPTIAC Quarterly, Vol. 6, Number 4.

Benjamin Tang, W. Podolny, “A Successful Beginning for FRP Composite

materials in Bridge Applications” Proceedings of International conference on
Corrosion and Rehabilitation of Reinforced Concrete Structures, Dec. 7-11,
1998, Orlando, FL.

Nanni A., “ Composites: Coming on Strong”, Concrete Construction, Vol. 44

(1999), p.120

http://www.pultrall.adsinc.ca

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www.creativepultrusions.com
www.sikaconstruction.com
http://www.fyfe.com
http://www.c-bar.com
http://www.MDAcomposites.org

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