# OAR Box 1413 Prepped byOllie Stewart



### Document

Number: 

# 2 ) 11-1- 2 Docket Number: 

# A-94-5 2

Printed 7/9/2008 3:11:20 PM Sheet 2 of 114 p. 1P. 2 

## A-94-5 2



## APPLICATION S FO R PULTRUDE D PRODUCTS

Autho r ROBER TDILLNE R Creative Pultrusions, Inc . Pleasantvill e Industria l Par k Alu m Bank

, Pennsytvani a 1552 1 Pultrusio n is a continuou s manufacturin g process utilizin g glass o rfibrou s reinforcemen t i n a polyeste ro rothe rthermosettin g resi n matrices . Pre-selecte d reinforcemen t material s like fiberglas s roving , ma t o rclot h ar e draw n throug h a resi n bat h wher e al l th e material s ar e thoroughl y impregnate d wit h a liqui d thermosettin g resin . Th e wet-ou t fibrou s laminat e i s forme d t o th e desire d geometri cshap e an d pulle d int o th e heate d stee l die . Onc e i n th e die . th e resi n cur e i s initiate d b ycontrollin g precis e elevate d temperatures . Th e laminat e solidifie s i n th e exac t shap e o fth e di e cavit ya

s i t is bein g continuousl ypulle d b yth e pultrusio n machine . Specifi cstrengt h characteristic s ca n b e designe d int o th e composit e optimizin g laminat e performanc e fo ra particula rapplicatio n b ystrategi cplacemen t o fhig h performanc e reinforcements . Colo ri s unifor m throughou t th e cross sectio n o fth e part , eliminatin g th e nee d fo rman ypaintin g requirements . The pultrusio n proces s produce s part s wit h constan t cross-sectio n shapes . Man yform s o f reinforcin g materia l (examples : rovings , continuou s stran d mats , wove n an d nonwove n fabrics , an d a variet yo fsurfacin g veils ) plu s a wid e selectio n o fresi n system s allo wth e designe rversatility i n engineerin g th e pultrude d structura l composit e t o mee t th e end-us e requirement s i n th e most cost-effectiv e way . Cos t o fth e produc t i s als o minimize d b ylo wtoolin g cos t an d th e lo wlabo r conten t o fth e pultrusio n process . Becaus e th e reinforcin g material s ar e processe d i n continuou s forms , produc t propertie s are veryconsistent . Last , th e lengt h o fth e pultrude d par t i s limite d onl y b yshippin g considerations . Pultrusio n is a continuou s proces s makin g constan t cross-sectio n profiles . Th e proces s i s designe d t o pul l flexibl e reinforcement s throug h a liqui d resi n bat h int o a heate d die . Apultrusio n proces s lin e i s lon g an d narro wwit h length s fro m 40 ' t o ove r80 ' wit h th e widt h bein g 5 ' t o ove r20' . Th e overal l spac e requiremen t depend s primaril yo n th e siz e an d numbe ro fth e creel s use d t o hol d th e reinforcements . Atypica l pultrusio n lin e consist s o fsi xbasi cstations :

B-1 2P. 3



### Robert Dillne r

•Reinforcement

dispensing %s Resin impregnation 4 Performing f Heated

die curing •Clamp/puller • > Cut-off. Fo rreinforcemen t dispensin g background , i n th e firs t station , continuou s fiberglas s rovin g i s dispense d fro m center-pul l package s tha t sit o n shelves calle d creels . Th e rovin g i s guide d throug h porcelai n eyelet s tha t eliminat e stati cbuildu p an d fuzzing . Th e rovin g the n passes i hroug h a cardin g inde xtha t orients th e fiber s prio rt o enterin g th e resi n bath . Othe rreinforcement s suc h as mat . veils , carbo n fibe rtows . etc. . ar e routinel yuse d an d ar e dispense d o n th e rolls . Resi n impregnatio n i

s a reinforcemen t packag e tha t passes throug h th e wet-ou t tank . Pa n guide s functio n withi n th e resi n bat h t o kee p th e rovin g separat e an d t o maintai n tensio n o n th e strand s t o permi t th e resi n t o wet-ou t eac h fiber . Th e resi n bat h ca n b e o fth e standar d di p tan k desig n o rth e straight-throug h resi n pa n as fo rhollo wsection s o rcomple xprofiles . Pressur e impregnatio n is a thir d metho d use d fo runiqu e application . I n thi s method , th e resi n polymerizatio n al l occurs insid e a close d die . This-area i s th e mai n concer n fo rVO C releas e i n th e for m o ffugitiv e styren e vapors . However , becaus e o fth e close d die . processing/pultrusio n i s typicall ylowe rtha n spra y u p o rwindin g processes (wit h th e profil e chop s havin g releases o f3 % t o 5 % an d ro d producers approachin g 0.8%) . Whe n th e reinforcemen t packag e exits th e resi n bath , i t the n passes throug h a series o fbushing s o rformin g guide s tha t ar e designe d t o stri p offexcess resi n an d guid e th e uncure d composit e int o th e fina l composit e shape . Thi s i s calle d th e performin g section . Th e heart o fth e pultrusio n process i s th e curin g die . Afte rth e resin-impregnate d reinforcemen t packag e leave s th e fina l pre-shapin g section , i t enter s a heate d stee l di e o rdie s tha t ar e i n th e shap e o fth e finishe d composite . Th e die s rang e i n lengt h fro m 3 0 t o 6 0 inche s an d ar e heate d eithe rb yelectri cstri p heaters o rplate s o n th e to p an d botto m o fth e di e surfaces . Th e interio r di e surface s ar e generall ychrom e plate d fo rincrease d di e lif e an d improve d surfac e finish . Th e ter m "pultrusion " come s fro m th e fac t tha t th e composit e i s pulle d throug h th e entir e proces s b ya gripper/pulle rsystem . Ther e ar e tw o differen t type s o fgripper/pul l system s used , th e reciprocatin g clam p desig n an d th e oppose d trea d caterpillar-tracto rtype . Th e forme rmetho d utilize s tw o identica l puller s tha t operat e i n tande m t o alternatel ygri p an d continuousl ypul l th e profil e throug h th e process . The pulle rproces s is mainl yuse d fo rmat/rovin g composite s i n whic h urethan e cleat s gri p th e part an d pul l i t throug h th e mold . Th e fina l statio n is th e cut-offstatio n o fth e pultrusio n process . Thi s statio n consists o fa diamon d abrasiv e cut-of fsaw . Thi s sa wi s synchronize d wit h th e movemen t o fth e puller s an d i s activate d b ya prese t cut-to-lengt h limi t switch . Th e ra wmaterial s tha t make u p th e bul k ofpultrude d product s consist mainl yo freinforcemen t an d matrix . Th e reinforcement s includ e glass fiber s i n th e for m o fcontinuou s roving , continuou s stran d mats , knitte d an d wove n fabrics , tape s an d cloths . More exoti creinforcement s includ e 

# I

B-1 3P. 4

Application s fo rPultrude d Products carbo n fiber , aramid . boro n an d severa l ne wthermoplasti cfibers an d veils . Fiber s ar e forme d from severa l glass compositions , th e most commo n o fwhic h are A(alkaline) , C (chemical) , E (electrical) , an d S (strength) . Continuou s rovin g ofth e E-glasstyp e comprise s th e bul k o fth e reinforcemen t use d i n pultrusion . Continuou s rovin g is a collectio n o ffilament s coate d wit h a sizin g that , is compatibJ e wit h th e resi n syste m an d brough t togethe rint o a singl e stran d calle d a n end . Bul k rovin g i s als o use d i n pultrusion . Thi s produc t for m i

s designe d t o improv e th e transvers e propertie s i n localize d area s o fpultrude d composite s wher e ma t canno t b e formed . C-glass . A-glas s an d thermoplasti car e som e ofth e surfacin g material s use d i n pultrusion . Polyeste r veil s ar e th e mos t commonl yuse d surfacin g fabric s an d provid e a n 8 - t o 11-mi l resin-ric h barrie r tha t improve s corrosio n resistance , reduce s fibe rexposure o n th e surface , an d improve s resistanc e

. t o U V attack . Surfac e veil s hav e bee n processe d whic h withstoo d 4,000 hour s accelerate d weatherin g wit h onl ya sligh t los s o fgloss . Th e tw o majo rfamilie s o fresi n matrice s ar e thermose t an d thermoplastic . Todayth e majorit yo f resi n matrice s use d i n pultrusio n are thermoset . Severa l thermose t resi n type s are use d i n pultrusio n wit h standar d polyeste ran d flame-retardan t polyeste rresin s bein g th e most widel yused . However , ne wapplication s an d processin g technologie s ar e increasin g th e demand s fo r vinylesters , epoxies . flame-retardant vinylesters , lo wshrin k system s an d eve n thermoplasti cresins . Th e choic e o fth e resi n wil l determin e th e degre e o fcorrosio n resistance , th e uppe roperatin g temperatur e limit , performanc e i n fatigu e applications , an d t o a limite d degree , th e mechanica l propertie s o fth e pultrude d laminate . Th e reinforcemen t primaril ydetermine s th e strengt h an d electrica l propertie s ofth e pultrude d laminate . Filler s ma yb e adde d t o improv e flam e retardanc y an d processabilityan d t o reduc e cost . Pultrude d composite s ar e generall ydivide d int o tw o parts . On e bein g al l unidirectiona l rovin g part s (ro d an d ba rstock) , an d tw o bein g continuou s stran d mat/unidirectiona l rovin g part s (shape s an d fla t sheet) . Typically , al l unidirectiona l rovin g part s hav e superio rmechanica l propertie s i n th e longitudina l direction , wher e glass content s rang e fro m 65 % t o 85 % b yweight . These value s fo rshapes , fla t shee t an d rod/ba rstoc k ar e take n fro m ASCE'

s Structura l Plasti c Desig n Manua l an d tel l yo u th e rang e o fpropertie s on e migh t expec t wit h fiberglas s polyeste r pultrusions . Th e reinforcement s i n fla t sheet ar e ma t an d roving . Fla t shee t is commonl yproduce d i n thicknes s u p t o 1 " and-width s u p t o 56" . wit h 48 " bein g standard . Pultrusion s ar e use d i n a variet yo fmarkets , th e first bein g th e electrica l industry . This is on e o fth e larges t market s fo rpultrude d composite s becaus e o fthei rhig h strength-to-weigh t rati o an d excellen t dielectri cinsulatio n properties . Th e use o fpultrude d sid e rail s hav e almos t completel y antiquate d th e woode n ladde ran d th e electrica l nonconductivit yo ffiberglas s has allowe d almos t complet e replacemen t o fth e aluminu m ladde rb yelectrica l utilities . Th e colo ri n th e ladde r channe l is molde d throug h th e laminate . Orang e an d yello war e safetycolor s an d ca n b e see n o n almos t an yutilitytruc k today . Usag e o fpultrude d product s ar e foun d i n pol e lin e hardwar e

B-1 4P. 5

t i Rober t Dillne r wher e pultrude d tube s an d rod s ar e use d fo rtool s fo rwor k o n hig h powe rline s becaus e o fth e adde d benefi t o fbein g electricall ynonconductive . Also , th e pultrusio n proces s i s use d t o manufactur e structura l component s whic h wil l withstan d severe corrosive environments . Al l fiberglas s product s ca n b e considere d t o b e corrosio n resiston t wit h th e choic e o fth e resi n determinin g th e degre e o fcorrosio n resistance . Gratin g manufacture d wit h pultrude d component s i s als o th e strongest fiberglas s gratin g o n th e market . Th e metho d o fconstructio n o fth e pultrude d shape s ensures excellen t corrosio n resistance . Bearin g bar

s an d cross rod s ar e pultrude d an d fabricate d int o gratin g fo rman yindustrie s suc h a s electroplating , wate ran d waste , marine , offshor e an d others . Anothe rexampl e o fth e us e o fpultrude d product s fo rcorrosio n resistanc e i s mis t eliminators . Louve rblade s separat e vapors an d soli d particle s fro m stac k emission s suc h as i n coa l burnin g utilities . Pultrude d blade s ar e replacin g wood , stainless stee l an d thermoplastic s givin g a n increase d usabl e life . I n th e constructio n industr ypultrude d product s ar e viabl e material s becaus e o fthei rstrength , ligh t weight , corrosio n resistance , molded-i n colo ran d therma l an d electrica l insulation . Fo rexample , pultrude d component s mak e nonmetalli cwindo wfram e an d sas h lineal s th e ultimat e i n performance . Thes

e component s ar e quickl yreplacin g aluminu m an d othe rcompetitiv e material s wit h a ne wgeneratio n o fthermall yefficient , dimensionall ystabl e windo wframes . Anothe rexampl e fo rth e constructio n industr yi s roofsupports . Roofin g system s wit h o four-to-on e safetyfacto rfo rwin d an d snowload s an d th e adde d benefi t o fcorrosio n resistance hav e bee n installe d fo rpol e enclosures . Pultrusion s hav e lon g bee n accepte d i n th e transportatio n market . Pultrude d panel s ru n th e entir e lengt h o fth e IntercityTransit Bu s an d provid e insulatio n an d den t resistanc e as wel l as long-ter m improve d appearance . Automotiv e Clas s Asurfac e is attainabl e wit h pultrude d parts . Par t consolidatio n an d a loc k togethe rdesig n o ftw o pultrude d part s cu t production lin e tim e b y replacin g 22 roll-forme d aluminu m parts . Th e pultrusio n process , becaus e o fit s man ybenefits , lend s itsel ft o a variet yo fothe rapplications , th e mos t popula rbein g standar d structura l shapes . Fro m 1 /8 " ro d t o 48 " wid e fla t sheet , pultrude d component s ar e stocke d b ymanufacturers , distributor s an d fabricator s i n al l majo rcitie s i n th e Unite d State s an d throughou t th e worl d fo rcorrosion , electrica l an d constructio n applications . I n conclusion , althoug h th e pultrusio n proces s i s almost 4 0 year

s old . i t is stil l basicall yi n it s Infancy . Ne wproduct s an d processin g technique s ar e bein g develope d everyday . Carbo n an d thermoplasti cfibers an d cloth s provid e a n eve n wide rrang e o fpropertie s t o th e pultrude d produc t lin e fo rcusto m applications . Ne wthermosettin g resin s an d pultrudabl e phenoli can d th e wor k currentl ybein g don e i n thermoplasti cresin s offe ra potentia l fo ra n unlimite d combinatio n o ffibers an d resi n matrices . Th e pultrusio n industr

yhas bee n growin g steadil yan d ne widea s an d proces s developmen t ar e makin g pultrude d product s th e syste m o fchoic e fo rman ycurren t an d potentia l applications .

B-1 5