p.1 

OAR Box 1394 

Prepped by Ollie Stewart 

Document Number: 

49) ll-C-19 

Docket Number: 

A-94-52 

Printed 7/3/2008 7:52:01 AM Sheet 49 of 56 
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A44-& 

»*t0 Sr<» 

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY 

^•«-r^ „, Office of Air Quality Planning and Standards 

o -VlV-- / Research Triangle Park, North Carolina 27711 

J UL 2 1 iS95 

REINFORCED PLASTIC COMPOSITES PRE-MACT MEETING 

Dear Pre-MACT Team and/or Work Group Member: 

This memorandum serves as a reminder of the upcoming 

pre-MACT teleconference on Monday, July 31, 1995, at 

1:00-4:00 pm EDT. The meeting will be held at the EPA/Mutual 

Building in Durham, NC. For team members who cannot attend in 

person, the call-in phone number is (919) 541-1591. 

Enclosed with this memo is a brief agenda for the meeting. 

Madeleine Strum and Jordan Spooner will conduct the meeting. A 

presentation will be given by Research Triangle Institute (RTI) 

on the pollution prevention process assessment studies sponsored 

by EPA's Office of Research and Development, and by Cook Composites & Polymers, Reichhold Chemicals, and Magnum Industries on 

the products supplied to RTI for testing purposes. Two vendors 

of equipment technologies for reducing styrene emissions will be 

available to discuss these process changes and answer questions. 

Hardcore Composites, Ltd. will give a presentation on the SCRIMP 

process and Liquid Control Corp. will give a presentation on the 

Resin Transfer Molding (RTM) process. Both of these processes 

are pollution prevention alternatives. Also enclosed is 

technical material on the processes and equipment that will be 

discussed. 

If anyone besides the vendors would like to reserve a spot 

on the agenda to make a presentation, express a view, etc., 

please notify Greg LaFlam or Jeffrey Best at PES at 

(919) 941-0333. If you have any questions prior to the meeting, 

please contact Madeleine Strum at (919) 541-2383. 

Sincerely, 

Madeleine Strum 

Project Leader 

Coatings and Consumer Products Group 

Enclosures 

!•'.! .£ !(¥•? \?.R 

• CY 

5 *•• •• -

\ mhi't m 
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ADDRESSEES: 

Mohan Balagopalan, SCAQMD 

Bob Burmark, Washington DOE 

Jane Caldwell, OAQPS/AQSSD (MD-15) 

Leonardo Ceron, Region IV 

Lisa Conner, OAQPS/AQSSD (MD-15) 

Patricia Embrey, OGC (2344) 

Bob Fegley, ORD (8105) 

Chuck French, OAQPS/AQSSD (MD-15) 

Christine McPhee, Ohio EPA 

Linda Herring, EPA/ESD (MD-13) 

Norm Kaplan, EPA/ORD (MD-61) 

Karen Levy, OPAR (6103) 

Maria Malave, OECA (2223A) 

Haile Mariam, OSW (5302W) 

Craig Matthiessen, OSWER (5101) 

Steve McNally, Composite Fabricators Assoc. 

Arnold Medbery, OSDBU (123 0-C) 

Richard Nielson, Clark County, NV 

Carlos Nunez, ORD (MD-61) 

Ben Pamar, Sierra Club 

Nancy Pate, OAQPS/ITPID 

Solomon Ricks, OAQPS/EMAD (MD-19) 

Ron Ryan, OAQPS/EMAD (MD-14) 

John Schweitzer, Composites Institute 

Jordan Spooner, OPPT/PPD (7409) 

Jeri Weiss, Region I 

Vendors 

Mark Callicut, Reichhold Chemicals 

Tom Hedger, Magnum Industries 

Mark Hollenbech, Cook Composites &.Polymers 

Kenneth Jacobs, Liquid Control Corp. 

George Tunis, Hardcore Composites, Ltd. 

Mark Bahner, RTI (Contractor) 

Greg LaFlam, PES (Contractor) 

X 
P.4 

REINFORCED PLASTIC COMPOSITES PRE-MACT MEETING #3 

POLLUTION PREVENTION TECHNOLOGIES 

EPA Mutual Bldg., Durham, NC 

July 31, 1995 1:00 pm EDT 

Call-in #(919) 541-1591 

* AGENDA * 

1. Introductions & General Discussion 1:00 

2. Pollution Prevention Study and Process Technologies 1:30 

3. Vendor Presentations 1:45 

A. Mr. Mark Bahner 

Research Triangle Institute (RTI) 

(Results of the pollution prevention testing 

sponsored by EPA's Office of Research and 

Development) 

B. Mr. Mark Hollenbech 

Cook Composites & Polymers 

(Supplier of gelcoats used by RTI in the tests) 

C. Mr. Mark Callicut 

Reichhold Chemicals, Inc. 

(Supplier of resins used by RTI in the tests) 

D. Mr. Tom Hedger 

Magnum Industries 

(Supplier of application equipment used by RTI 

in the tests) 

E. Mr. George Tunis 

Hardcore Composites, Ltd. 

(SCRIMP process) 

F. Mr. Kenneth Jacobs 

Liquid Control Corp. 

(RTM molding equipment and process) 

4. Additional Presentations as Requested 3:00 

5. General Discussion 3:30 

Next Steps 

°? 
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07/21/S 5 103 12 "0*919 541 7155 KT1- UlA lgJUU2 

RESEARCH TRIANGLE INSTITUTE 

/RTI 

mmLmmmm 

EPA OFFICE OF RESEARCH AND DEVELOPMENT (ORD) 

INVESTIGATION OF POLLUTION PREVENTION TECHNIQUES 

TO REDUCE STYRENE EMISSIONS FROM 

OPEN-MOLD REINFORCED PLASTIC COMPOSITES 

FABRICATION 

JUNE-JULY, 1995 

ACKNOWLEDGEMENTS: 

REICHHOLD CHEMICALS, INCORPORATED 

• MAGNUM INDUSTRIES 

• COOK COMPOSITES AND POLYMERS 

JULY 31,1995 

4 
PJL 

07/21/9 5 16:1 2 ??919 541 7155 RTI- CEA |fi003 

OBJECTIVES 

GENERAL 

1. COMPARE MASS-BALANCE-BASED EMISSION MEASUREMENTS WITH 

EPA METHOD 25A (TOTAL HYDROCARBON ANALYZER) EMISSION 

MEASUREMENTS. 

2. ESTABUSH "BASEUNE" RESULTS (USING AIRLESS-AIR-ASSIST GUN AND 

METHYL ETHYL KETONE PEROXIDE "CATALYST") TO COMPARE WITH 

RESULTS FROM VARIOUS POTENTIAL POLLUTION PREVENTION 

MEASURES. 

3. DETERMINE THE EMISSION REDUCTIONS ACHIEVED BY THE 

FOLLOWING: 

PILOT TESTING 

A. LOWERING AH< VELOCITY IN THE APPLICATION AREA, 

B. IMPROVED OPERATOR SPRAYING TECHNIQUES, 

GEL COAT TESTING 

C. HIGH-VOLUME-LOW-PRESSURE (HVLP) EXTERNAL MTX SPRAY GUN, 

D. HIGH-VOLUME-LOW-PRESSURE (HVLP) INTERNAL MTX SPRAY GUN, 

E. LOWER-STYRENE CONTENT GEL COAT 

RESIN TESTING 

F. FLOW COATER (NON-SPRAYING TECHNIQUE), 

G. PRESSURE-FED ROLLER (NON-SPRAYING TECHNIQUE), 

H. LOWER-STYRENE CONTENT RESm, 

L STYRENE-SUPPRESSED RESIN, 

J. STYRENE-SUPPRESSED RESIN PLUS ADDITIONAL WAX, 

K. BENZOYL-PEROXIDE (BPO)-CATALYZED RESIN, AND 

L. WATER-EMULSIFICATION-TECHNOLOGY (W.E.T.) RESIN...NOT 

AVAILABLE. 

$ 
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07/21/9 5 16:1 3 'OT919 541 7155 K11- UUA iajou» 

PROCEDURES 

1. SPRAY BOOTH SERVING AS TOTAL TEMPORARY ENCLOSURE. 

2. ISOLATED FROM OTH ER VOLATILE ORGANIC COMPOUND SOURCES. 

3. RANDOMIZED TESTING SEQUENCE. 

4. TRIPLICATE TESTING FOR POTENTIAL POLLUTION PREVENTION 

TECHNIQUES, SIX TESTS FOR BASELINE CONDITIONS. 

5. APPROXIMATELY THREE RUNS PER DAY (55 RUNS, OVER A PERIOD OF 

FIVE WEEKS). 

& 
07/21/95 16:13 ©91 9 541 7155 RTI- CEA 

P.8 

14)005 

Emission and Air Row 

Rate Monitoring Location 

2nd Floor 

Makeup 

Air Duct 

Ground-Floor 

7'x6' (W) 

Double Door 

Application Equipment 

(Could be Placed Inside 

or Outside the Enclosure) 

Figure 1-2. Side view of the Reichhold Chemicals spray booth In 

a permanent total enclosure (19'H x 12'W x 15'L) 

1 
P.9 

uf/ii/s o 10:1 1 TQ-ais &41 via a KT1- Ufc.A IfljUUb 

2' Range surrounding 

the bottom of the mold 

to ease part removal 

Figure 1-3. Sketch of a male mold. 

1 
P 10 

lH/il/» 0 10:1 1 -Q*S1» 34 1 /io o KH - UKA lg)UU7 

EQUIPMENT 

1. TOTAL HYDROCARBON ANALYZER WITH A FLAME IONIZATION 

DETECTOR (FDD). 

2. SARTORIUS SCALES, ACCURATE TO 1 GRAM IN ISO KILOGRAMS. 

3. KRAFT PAPER, FIBERGLASS VEILS. 

4. MALE MOLD, APPROXIMATELY 25 SQUARE-FOOT TOTAL SURFACE AREA. 

5. MAGNUM INDUSTRIES APPLICATTON EQUIPMENT: 

A. GEL COAT SPRAY SYSTEM 

1. AIRLESS AIR-ASSIST SPRAY GUN, EXTERNAL MIX. 

2. HVLP SPRAY GUN, INTERNAL MIX. 

3. HVLP SPRAY GUN, EXTERNAL MK. 

B. RESIN SPRAY SYSTEM(S) 

1. AIRLESS AIR-ASSIST SPRAY GUN, EXTERNAL MIX. 

2. AIRLESS AIR-ASSIST SPRAY GUN, EXTERNAL MIX, FOR BPOCATALYZED RESINS. 

C. RESIN NON-SPRAY SYSTEMS 

1. FLOW-COATER (NON-ATOMIZED SPRAYING TECHNIQUE). 

2. PRESSURE-FED ROLLER (NON-SPRAY SYSTEM). 

6. COOK COMPOSITES AND POLYMERS (CCP) GEL COATS 

A. "REGULAR" GEL COAT (APPROXIMATELY 39% STYRENE). 

B. "LOW"-VOC GEL COAT (APPROXIMATELY 25% STYRENE). 

7. REICHHOLD RESINS 

A. "REGULAR"-STYRENE (APPROXIMATELY 40% STYRENE, MEKPCATALYZED). 

B. "LOW"-STYRENE (APPROXIMATELY 35% STYRENE). 

C. STYRENE-SUPPRESSED RESIN (APPROXIMATELY 43% STYRENE). 

D. STYRENE-SUPPRESSED-PLUS-ADDITIONAL-WAX RESIN 

(APPROXIMATELY 43% STYRENE). 

E. BPO-CATALYZED RESIN (APPROXIMATELY 43% STYRENE). 
P.11 

07/21/95 16:15 ©919 541 7155 RTI- CEA 12)008 

PRELIMINARY SUMMARY OF EPA OFFICK OF RESEARCH AND DEVELOPMENT 

POLLUTION PREVENTION TESTING RESULTS 

(CONDUCTED BY RTI AT REICHHOLD CHEMICALS FROM JUNE TO JULY, 1995) 

GENERAL RESULTS 

ON AVERAGE, TOTAL HYDROCARBON ANALYZER AND MASS BALANCE 

MEASUREMENTS WERE IN GOOD AGREEMENT. 

• "BASELINE" EMISSIONS WERE COMPATIBLE WITH RECENT TESTING BY 

EPA AND OTHERS (IE., HIGHER THAN AP-42). 

INDIVIDUAL EMISSION REDUCTION TECHNIQUES REDUCED EMISSIONS BY 

UP TO APPROXIMATELY 40 PERCENT. 

PILOT TESTING RESULTS 

VELOCITY NOT FOUND TO HAVE SIGNIFICANT EFFECT ON EMISSIONS, OVER 

THE VELOCITY RANGE TESTED. 

OPERATOR SPRAY TECHNIQUE FOUND TO HAVE AN EFFECT. 

GEL COAT TESTING RESULTS 

LOW-STYRENE GEL COAT FOUND TO SIGNIFICANTLY REDUCE EMISSIONS, 

BUT SOME APPLICATION PROBLEMS WERE EXPERIENCED. 

NO SIGNIFICANT DIFFERENCE IN EMISSIONS BETWEEN THE THREE GUN 

TYPES TESTED (AIRLESS AIR-ASSIST/EXTERNAL MTX, HVLP/EXTERNAL MIX, 

HVLP/INTERNAL MIX). 

RESIN TESTING RESULTS 

FLOW COATER AND PRESSURE-FED ROLLER SIGNIFICANTLY REDUCE 

EMISSIONS COMPARED TO SPRAYING. 

LOW STYRENE RESIN, STYRENE-SUPPRESSED RESIN, AND STYRENESUPPRESSED RESIN WITH ADDITIONAL WAX ALL REDUCE EMISSIONS 

COMPARED TO REGULAR RESIN. 

THE BENZOYL PEROXIDE-CATALYZED RESIN THAT WAS TESTED WAS NOT 

FOUND TO SIGNIFICANTLY REDUCE EMISSIONS COMPARED TO THE MEKPCATALYZED RESIN TESTED. 

10 
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07/20 '95 14:09 ID-CCP RESEARCH FPX.816-391-6026 PAGE 2 

v •• , r 

CCP POLYCOR / STYPOL SSBSSSS 

962-WA-196 

LOW VOC/BUFFBACK* WHITE GEL COAT 

DESCRIPTION; 

This gel coat is a high performance^ ISO/NPG** product which has low volatile organic 

compound properties, and BUFFBACK* characteristics. These qualities are demonstrated 

as: 

» Reduced monomer lossek into the air 

» Superior weathering properties (compared to conventional gel coats) 

• Blister resistance acceptable for marine applications 

• High-gloss BUFFBACKj* characteristics. 

- Cured film thickness cart be 5 - 15% more than other gel coats 

• Less odor 

• Smoother sprayed film (less orange peel) 

While offering these benefits, 962-WA-196 has retained the important construction 

application qualities you have come j to expect in Cook Composite and Polymers gel coats, 

such as resistance to porosity, tearing, and color separation; sag resistance; consistent liquid 

properties; good patchability; and iriore. These all add up to higher quality appeal in FRP 

parts made from CCP's 962-WA-196. 

j 

962-WA-196 resists weathering and.blistering because it is formulated to give high 

perfonnance against water and certain chemicals. 962-WA-196 is made with NEOPENTYL 

GLYCOL and was primarily developed for sanitary and quaUty marine applications; 

however it should be used in any FljlP application where high performance characteristics are 

desired. 962-WA-196 utilizes this unique glycol to provide a gel coat which surpasses 

previous commercial gel coats in its. resistance to blistering. It also contains Isophthalic acid 

as a co-component rather than Orthophthalic acid. The Iso is used, (rather than the Ortho) to 

complement the NPG for better end! use properties. This gel coat provides durable, reduced 

maintenance products. 

*NPG is a registered trademark of Eastman Kodak Company. 

Copyright 'I99» by Cook Composites nnd Polymers Co. 

COOK CDMP0SPEE3 AND POLYMERS 

P.O. Bos 1*19389 Kansas City. MO 64141-6389 

(816)391-6000 F«x: (616) 391*6215 
P.13_ 

07/20 '95 14=10 1D-CCP RESEARCH FAX:816-391-6026 PAGE 3 

062-WA-I96 

Piiye 2 of 6 

0504 

CCP's ISO/NPG gel coats have enabled customers to meet and surpass all requirements of 

the American National Standard for plastic bath tubs, shower receptors and shower stalls. 

ANSIZ124.1, .2 and .3. 

962-WA-196 requires only the addition of the proper amount of the appropriate Methyl 

Ethyl Ketone Peroxide to cure. 

TYPICAL PROPERT Y fat 77'fr 

These values may or may not be a manufacturing control criteria; they are listed for a 

reference guide only. Particular batches will not conform exactly to the numbers listed 

because storage conditions, temperature changes, age, testing equipment (type and procedure) 

can each have a significant effect on the test results. Gel coats outside of these, readings can 

perform acceptably. Final suitability is in the end use performance. 

Viscosity, Brookfield RVF 

#4 at 4 rpm 10,000 -13,000 cps 

Thix Index (2/20) 4.2-5.0 

Flashpoint 82°F 

Non-Volatile Material 74.5% 

Weight/Gallon 11.5 lbs. 

Gel Time at 77 °F with 

1.8% THERMACURE* ITS 14 - 17 minutes 

Lay-up Time 45 -90 minutes 

Sag Resistance Good at 20 mils 

Hide Complete at 10 mils 

VOC data as compared to 952-W-A40: 

962-WA--196 952-W-A40 

Volatile material 

By weight 3.0 lbs. per gallon 4.0 lbs. per gallon * 

By volume .40 per gallon .52 per gallon 

Rule 1162* 90.20 grams per meter2 132.60 grams per meter2 

'SCAQMD procedure (South Coast Air Quality Management District') 

Copyright 1994 by Cook Composites and Polymers Co. 
P.M 

07/20 '95 14:10 

-

ID:CCP RESEARCH 

... . . . j . 

i 

FAX:816-391-6026 PAGE 4 

%2-WA-l% 

l';ige 3 ol'fi 

05/94 

APPLICATION; 

Although 962-WA-196 is formulated as a low VOC product, it should be noted that high 

atomization of a gel coat means more| volatization (more overspray.. more monomer and 

solids loss, more odor). It is important, then, to strive for good atomization (good fan 

pattern, no fingers or tails, uniform particle size of about 1/16") while maintaining lowest 

pump and atomizing pressures as practical. 

962-WA-196 is formulated for airless as well as conventional spray application. Brushing or 

rolling is not recommended. Refer tp PB-16 (Application Guide) and PB-3 (Equipment 

Selection) Bulletins for additional specific recommendations. 

We recommend a gel coat delivery r^te of no more than 2.5 pounds per minute, with 

conventional air atomized equipment,; and no more dian 4 pounds per minute wjth airless 

equipment. 

i 

Batch mixing is recommended to achieve the best catalyst mix and cure, because even with 

die equipment properly calibrated, potential problems can occur due to poorly atomized 

catalyst; surging problems (gel coat or catalyst); poor tip alignment (catalyst to gel coat mix); 

contamination; and poor application procedures, which will quickly negate all benefits of 

calibration. The equipment (and application procedures) must be monitored on a routine 

basis to ensure proper application and cure of the gel coat. Inquire of and adhere to all 

equipment manufacturers' recommendations. 

For best overall end performance properties, a wet film thickness of 18 ± 2 mils is 

recommended as ideal. Films less than 12 mils may not cure properly, may be hard to 

patch, have more print-through, and are more susceptible to water blisters. Films above 24 

mils may pre-release, trap porosity, crack and are more subject to weathering discoloration. 

If water blisters are of a great concenti (boat hulls), 20 to 24 mils would perform better than 

a thinner film, but sag, porosity and ^racking resistance could suffer. If weathering 

(yellowing from sunlight, decks) is of great concern, then thinner films (12 to 16 mils) 

would perform better, but patchability, print-through and blister resistance could suffer. 

In addition to die low VOC chemistry of 962-WA-196 , die lower viscosity and Thix Index 

result in both less overspray and less jmonomer loss, but die total film thickness should be 

sprayed in multiple passes (at least 3 at 18 mils, 4 at 20 to 24 mils). More rapid film build 

could result in some sag. | 

t 

Proper mold maintenance is importanjt. Although 962-WA-196 has excellent patching 

properties, minimal repair work is always desirable. Sanding and compounding can hasten 

the chalking and loss of gloss of all gel coats. 

Avoid overspray settling on mold surfaces by beginning spray pattern closest to the vapor/air 

exhaust and progressing to die opposite mold end. Maintain recommended spray distances 

from the mold surface. 

Copyright 1994 fyy Cook Composites Md Polymers Co. 
P.15 

07/20 '95 14:11 ID=CCP RESEARCH FAX:816-391-6026 PAGE 5 

• • . i 

, i 

.*' ' I 

; %2-WA.|>.)fi 

Paye 4 or" 6 

| * 05'^ 

CURE: 

It is recommended that gel time be checked in the customer's plant, because age, 

temperature, humidity, and catalyst will produce varied gel times. Gel time/cure data refers 

specifically to THERMACURE* JTSJ catalyst. Recommended catalyst to be used with this 

product is JTS. THERMACURE* Regular EX, Norac MEKP-925, Witco HP-90 and 

Lupersol DHD-9 can also be used, but they may give slightly shorter gel and cure times. 

The catalyst level should not exceed 3% or fall below 1.2% for proper cure. Recommended 

range is 1.2% to 3.0%, widi 1.8% at 77°F being ideal. Normally, the gel coat film is ready 

for lamination in 45 to 80 minutes. This time element is dependent on die material 

temperature, room temperature, humidity, air movement, and catalyst concentration. Note: 

ISO/NPG films have a tendency to air dry and lay-up times may be deceiving.. If lay-up time 

is checked by the finger method, slight pressure and rubbing should be used. „ 

i 

t 

Special fast-cure versions are available but must be requested. These products offer lay-up 

times of 30 minutes or less, depending on gel times. Fast cure products have shoner stability 

and should not be inventoried over 45 days. 

These products (standard or fast cure) should not be used when temperature conditions are 

below 60°F, as curing may be adversely affected. 

EXPOSURE DATA; 

Preliminary accelerated (QUV-340) and Soudi Florida exposure indicates mat 962-WA-196 

has superior gloss retention over standard gel coats. 

CAUTION: 

ISO/NPG Gel Coats are not compatible in the liquid state widi 944 ISO Gel Coats or ISO 

resins. Spray and pumping equipment must be completely clean of these gel coats before 

962-WA-196 can be used. 

Do not ovennix gel coats. Overmixigg breaks down gel coat viscosity, increasing tendencies 

to sag, and causes styrene loss, which could contribute to porosity. Gel coats should be 

mixed once a day for 10 minutes. The gel coat should be mixing to the sides ind bottom of 

die container with the least amount of turbulence possible. Air bubbling should not be used 

for mixing. It is not effective and only serves as a potential for water or oil contamination. 

Do not add any material', other than a recommended Methyl Ethyl"Ketone Peroxide, to diis 

product widiout die advice ofa representative of the Cook Composites and Polymers Co. 

Under no circumstances should glycerin be added to mis product. 

I 

Copyright 1994 by Cook Composites and Polymers Co. 
P.16 

07/20*95 14:11 ID:CCP RESEARCH FAX:816-391-6026 PAGE 6 

%2-WA-l% 

i Pnyc 5 ol* 6 

05/94 

STORAP.E UMTTATIONS: 

Uncaialyzcd 962-WA-196 has a usage life of three months from dale of manufacture when 

stored at 73 °F or below, in a closed, factory sealed, opaque container, and out of direct 

sunlight. Fast cure gel coats are stable for 45 days. The usage life is cut in half for every 

20°F over 73 °F. Totes of product dan have even shorter usage life - 66% of that for drums. 

j 

SHIPPTNfl; 

Shipping is normally in open head 5^-gallon drums. 

Copyright 1994 jby Cook Composites and Polymers Co. 
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07/20 '95 14:11 ID:CCP RESEARCH FAX:816-391-6026 PAGE 7 

962->WA-IV6 

v

 Page C ol" 6 

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i 

POLYESTER SAFETV INFORMATION 

(Revised OVM) 

.11 saL-i of products manufactured by the Cook Composites and Polymers Co. and described herein are made solely on condition tlioi our customers comply with applicable 

colih and safely laws, regulations and orders relating to the handling of our products in the workplace. Before using, read the following information and both die product 

•bei and Matcriol Safely Data Sheet pertaining lo eaeh product. Most polyester products contain styrene. Styrene can cause eye. skin and respiratory "acl irritation. Avoid 

-iniaet with eyes, skin ond clothing. Impermeable gloves, safety eyewear and protective clothing should bc worn during use to avoid skin and eye contact. Wash thoroughly 

iter use. 

i 

• 

tyrene is a solvent and may be harmful if inhaled. Reporo have nssocialted repeated ind prolonged occupational ovenxposure to solvenu with permanent brtln and nervous 

•siem damage. Extended exposure to styrene at concentrations above the recommended exposure limits may cause central nervous system depression causing dizziness, hoadaches 

' nausea and if overexposure is continued indefinitely, loss of consciousness, liver and kidney damage. 

o not breathe or Ingest vapor, spray mists and dujti caused by applying sanding, grinding and sawing polyester products. Wear an appropriate NIOSWMSHA approved, 

operly fitted, respirator during application and use of these products until vapors, mlsu and dusts are exhausted, unless air monitoring demonstrates vapors, mint and dusts 

e below applicable exposure limits. Follow respirator manufacturer's directions for respirator us*. 

K International Agency For Research on Cancer (IARC) has reclassified styrene as Croup 2B "possibly carcinogenic to humans*. This new classification Is not based on now 

alth dau relating u either humans or animals, but on a change in the (ARC classification system. The Styrene Infonnation and Research Center doei not agree with the 

falsification and has published the following statement. 'Recendy published studies tracing 50.000 workers exposed to high occupational levels of styrene over a period of 

yean showed no association between styrene and cancer, no inaease In cancer among styrene wvken (as opposed to the average among all workers), and no increase in 

-tnality related to styrene. 

rrene is classified by OSHA and the Department of Transportation as a flammable liquid. Flammable polyester products should be kepi away from heat, sparks, and flame, 

gluing and other electrical systems in the work place should be vapor-proof and protected (rem breakage. 

ipon from styrene may cause flash tire. Styrene vapors are heavier than air and may concentrate fat the lower levels of molds and the work area. General du n air dilution 

local exhaust ventilation should be provided In volume and paisem to keep vapon well below the lower explosion limit and all air contaminants (vapor, mlsu and dusts) below 

: current permissible exposure limits m the mixing, application, curing'end repair areas. 

-he label or Material Safety Data Sheet indicates lead or lead chromau Is present, do not use on ays, furniture or surfeees that might be chawed by children. Wash hands 

•roughly after using n d before smoking or citing. Long-term overexposure by inhalation or ingestion of mists and dusts from products containing lead compounds and lead 

-ornate can cause harmful effects to the urinary, blood, reproductive end. nervous system and may create risk of cancer. Use a respirator as explained in Paragraph 4 of th' 

brmation Sheet 

•ne polyester products may contain additional hazardous Ingredients. To determine the hazardous Ingredients present, their applicable exposure limits and other safety 

jrmition, read the Material Safety Data Sheet fer each product (identified by product number) before using. If unavailable, these can be obtained, free of charge, from your 

ok representative or from: Cook Composites and Polymers Co., P.O. Box 419389, Kansas City, MO 64)4]<6389, (116) 391*4003. 

1ST AID: In eaae of eye contact, fluah immediately -with plenty of wat^r fer at least 15 minutes and get medical attention; for skin, wash thoroughly with soap and water-

(fleeted by inhalation of vapors or spray mist, remove to fresh air. If swallowed, gat medical attention. 

yester products have at least two components that must bc mixed before use. Any mixture of components will have hazard* of all components. Before opening the packages, 

i all warning labels. Observe all precautions. 

•p polyester container! closed when not in use. In case of spillage, absorb with inert material and dispose of in accordance with applicable regulations. Emptied containers 

/ retain hazardous residue. Do not cut, puncture or weld oo or near these containers. Follow container label warnings until containers are thoroughly cleaned or destroyed. 

FOR INDUSTRIAL USE AND PROFESSIONAL APPUCATION ONLY. KEEP OUT OF REACH OF CHILDREN. 

DISCLAIMER' AND UMITATION or UABIUTY 

(03/19) 

i 

he best of our knowledge, the information contained herein is accurate. THE WARRANTY DESCRIBED HEREIN SHALL BE IN LIEU OF ANY OTHER WARRANTO. 

•RESS OR IMPLIED. INCLUDING BUT NOT LIMITED TO. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE 

•RE ARE NO WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. The Buyer's sole and exclusive remedy against Seller shall 

**r the replacement ofthe produets or refund nf die purchase price in thai event diet a defective eoedltioo ofthe products should ba found to exist. NO OTHER REMEDY 

nUDINO, BUT NOT UMITED TO. INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR LOST PROFITS. LOST SALES. INJURY TO PERSON OR PROPERTY. 

ANY OTHER INCIDENTAL OR CONSEQUENTIAL LOSS) SHALL PE AVAILABLE TO THE BUYER. Tha sole purpose ofthis exclusive remedy shall be to provide 

er with replacement ofthe products or refund ofthe purchase price of the products If any defect in materials or workmanship is found to exist. This exclusive remedy shall 

x deemed to have felled iu essential purpose so long as Seller is willing and able to replace the defective produets or reftmd the purchase price. Buyer must give Seller 

:e In writing of any alleged defect covered by this warranty (together with all identifying details, including the Product Code(s), description and date of purchase) within 

y (30) days of the discovery ol" such defect. Final determination of lhe suitability of lhe material for the use contemplated, the manner of use and wlt-rilicr the suggest* 

infringes nny p-ucms is the sole responsibility of the buyer. , 

RS 0J/9J 

i 

I 

i 

Copyright 1994 by Cook Composites and Polymers Co. 

Ib 
07/19/95 17:52 ©20 2 260 0178 EPA PPD 14)002 

P.18 

SCRIMP": Cost affective 

materials combined 

more effectively 

SCRIMP is the acronym for tho 

Seemann Composite Resin 

Infusion Molding Process. 

Developed as the result 

of yesrs of research on the 

shop floor and in the lab, the 

process has proven to be e 

superior method for producing 

high quality composite parts 

made from a wide range of 

fiber and resin combinations. 

All commercial fibers, core 

materials and any resin In the 

range of 50 cps to 1000 

cps will "SCRIMP1' with 

outstanding results. To cover 

the wide range of available 

resin systems, the process can 

be run at room or elevated 

temperatures. 

Similar in concept to RTM, but 

requiring only one tool side 

snd a simple vacuum bag, 

* SCRIMP routinely produces 

large (2000 sq. ft.) parts, using 

both single akin end cored 

eonatruetlon, snd highly 

complex 3-D trussed ports 

weighing up to 3000 lis. In aH 

cases, th» resulting composite 

meterlel properties directly 

compare to properties thet tied; 

only beetr- ochlevable In 

highly controlled, expensive 

autoclave processes. ' . . 

SCRIMP: Ultimate Composite Quality 

In contrast to most composite processes, 

the SCRIMP process is inherently 

repeatable. Once equilibrium resin content 

is achieved (55% to 60% fiber volume, 

depending on fabric architecture) the 

process stops. Aerospace grade quality is 

ensured by first eliminating all air voids 

before the resin is infused, enabling the 

fabric pre-form to act as an effective 

breather layer. As the resin is infused, it 

travels in controlled waves that work to 

completely wet out the reinforcing fibers 

and eliminate any voids that could be 

created by the VOC's emitted by the resin 

during the cure cycle. 

The process has been used to infuse 

laminates up to 6" thick with the same high 

quality results as a simple 1/8" laminate. 

The Navy has extensively tested SCRIMP 

laminates and has concluded that the void 

content cannot be detected with standard -

ASTM methods. With or without a gel 

coat, composites produced using SCRIMP 

exhibit pinhole free surfaces. 

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07/19/95 17:53 ©20 2 260 0178 EPA PPD Iffl 003 

SCRIMP: Reduce Labor and Save Materials 

SCRIMP allows any licensed fabricator to 

perfectly produce the parts they have 

designed. Controlled bagging of dry prefomis, coupled with repeatable resin . 

infusion results in high quality precision 

parts. Compared with prepreg, SCRIMP 

eliminates the following: the need for 

refriaenited storage, the need for time 

consuming debulking, expensive breathers, 

bleeders and porous releases, and the scrap 

causing phenomenon of bridg,ing. 

Medium 

SCRIMP, much like RTM, offers the 

benefit of pre-foiming parts using dry fabrics 

and cores. However, unlike RTM, SCRIMP 

does not require a two sided high pressure 

mold or a press. Parts molded using the 

SCRIMP technology only require a one 

sided vacuum tight surface. Standard FRP, 

mass cast or metal tooling all function well. 

. At constant stress levels, superior 

mechanical properties mean less material 

cut be used to achieve the same results. 

Perfect surface quality eliminates the need 

for pinhole filler in painted applications, 

and where gel coats are used, SCRIMP 

eliminates "egg shells" that cause expensive 

rework. 

Driven solely by vacuum pressure and 

utilizing the patented SCRIMP resin 

distribution system, resin will wet out 

laminates completely. With both single skin 

or cored construction, the entire laminate is 

wet in one infusion step, eliminating 

weaker secondary bonds and the time and 

mess that accompany them. Very thick 

fabrics, knits and mats (up to 200 oz per sq. 

yd.) and cores' can be used to greatly speed 

the lay-up process. As a result, a SCRIMP 

factory looks more like an upholstery or 

carpeting operation than a classic FRP or 

composite shop. Cleaning solvents and the 

associated tool cleaning time are also 

completely eliminated. 

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P.20 

07/19/95 17:53 ©20 2 260 0178 EPA PPD l£]UU4 

SCRIMP": Applications 

i 

SCRIMP has finally unlocked the full 

potential of composite materials by 

allowing for the manufacture of very large 

parts in a high quality, environmentally 

sound fashion without large capital 

investments. Today, manufacturers licensed 

to use the SCRIMP System are producing 

parts for applications ranging from 

sailboats to bridge structures. SCRIMP 

laminates are used to stop bullets and fend 

ships. Trains built using "SCRIMPed" 

laminates are lighter, better insulated and 

more fatigue and corrosion resistant than 

similar strucmres built from conventional 

materials. Even structures that require the 

ultimate material properties for defense 

purposes utilize SCRIMP because it 

performs better than more expensive 

alternatives. 

Offshore Reil 

Trsnsportetlon Marine Infrastructure 

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P.21 

07/19/95 17:54 ©20 2 260 0178 EPA PPD Iffl 005 

SCRIMP": Perforins 

Laboratory testing has confirmed that 

SCRIMP produces composites with the 

quality and performance of substantially 

more expensive materials and 

manufacturing processes. The attached data 

is summarized from a comprehensive 

testing program completed by the Naval 

Surface Warfare Center to evaluate the use 

of SCRIMP for primary hull structure of 

future combatant vessels. As a result of the 

study, the Navy, concluded that SCRIMP 

used with cost-effective fiber and resin 

combinations gave composite performance 

equivalent or superior to more expensive 

materials processed using costly and size 

limiting aerospace processes. 

SCRIMP: Environmentally 

• Responsible 

SCRIMP is a completely closed system 

that traps VOC's instead of just sending 

them up the stack. Reduced need for 

solvents coupled with the closed SCRIMP 

SYSTEM will reduce styrene levels to well 

below the most stringent current or 

proposed standards. Worker exposure to 

wet resins during the lay-up process is 

completely eliminated. 

Real world shop data taken from SCRIMP 

licensed facilities has shown that the 

combination of SCRIMP and 

environmentally responsible solvents can 

reduce VOC emissions by as much as 90% 

over corrent open molding practices. 

SCRIMP will fundamentally change your 

business. If you are a customer of 

composite material. SCRIMP will ensure 

you the best performing product at the 

lowest possible price. If you are a 

fabricator of composite material. SCRIMP 

will minimize or eliminate your 

environmental problems and open new 

doors to large, repeatable, composite 

products. 

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A Comparison of Composite Properties 

From Low Cost fabrication Methods 

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Resin-transfer molding: 

A cost-effective alternative 

By Ed Galli, Eastern editor 

This GRP process occupies the large gap in part cost and rate 

of output between open molding and compression molding. 

It's a cost-effective alternative for intermediate-volume production runs. 

The part designer who makes glass* 

t/2~P- reinforced polyester the material, of 

choice must then make a choice of production methods. Either one of the 

open-molding techniques (sprayup and 

layup) or else compression molding is 

usually selected. Open molding carries 

a high per-piece cost; compression 

molding can reduce that cost, but only 

with volumes suffident to spread out 

the high cost of the matched-metal dies. 

There is another GRP process that 

has been quietly working the spacious 

gap between these two methods for 

some years but has only recently seen a 

surge in interest. It's resin-transfer 

molding (RTM), sometimes called resin 

injection, and it offers many advantages^ 

to the company mat seeks production 

of roughly 100 to 10.000 parte! " 

Designers will find the process attractive. RTM-molded parts have two 

finished sides, rather than the one-Sided 

product of open moldinq. Class A gelcoated finishes are available right out of 

the mold. Various types of glass reinforcement are used, with type and 

amount closely tailored to the part's 

physical requirements. In addition, 

cores, stiff eners and other materials can 

be encapsulated in the part with much 

greater ease than in open molding (this 

can't be done at all in compression 

molding). 

RTM is a low-pressure molding process: the use of lightweight, otass-reinforced poluester or epoxy •»nu

 '** »lmr>«tt 

universal. That means, of course, that 

lead time for the tooling is short and cost 

is moderate, as compared to metal 

'molds. Fart design Is affected by the 

specific capabilities and limitations of 

ttie process. Most important, the cost 

and qualirjTof the parts depend on the 

quafity of the tooling. No other technique in plastics molding exhibits such 

dependence, except perhaps the RIM 

process... and RTM might be thought 

of as RIM at a leisurely pace. 

RTM will entertain the molding of 

parts throughout the GRP spectrum. 

RTM housings and shrouds have found 

appftcation in electronics, recreational 

.vehicles and consumer products.. Marine use of the process Is widespreadRTM parts are seen In corrosion-resUtant equipment, containers of all sorts, 

seating and furniture, protective gear 

and sporting goods. The current RTMpart roster also indudes sanitary ware, 

pool sides, caskets, cherry-picker buckets and solar collectors. 

One of the most elegant—as well as 

growing—users of RTM parts is the custom-built Excalibur automobile (Figure 

1). President David Stevens says that 

the automotive company was attracted 

especially to the tolerance control and 

two-sided smoothness of the process. 

Major interior parts of the Excalibur now 

in RTM indude seat backs, duct work, 

the console over the transmission runnel and the dashboard. The dashboard, 

with 90-deg returns and other complexities, was originally laid up, requiring 

that thickness variations be ground 

down in order for instrumentation to be 

fixed in place; RTM has eliminated that 

problem. Stevens is now evaluating the 

benefits of replacing exterior layup of 

bodywork, an area where RTM can 

provide sharper corners, which his designers prefer. The doors are the first 

target, with the internal structure as well 

Figure 1. Excalibur automobtle Interior wtth 

RTM dashboard and 

other parts. (Photo: 

Excalibur) 

1 MARCH/ APRIL 1982 PLASTICS DESIGN FORUM 47 
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EPA PPD lg|UU7 

as the outer shell a candidate for conversion to one-piece RTM production. 

PROCESS CONSIDERATIONS 

RTM is carried out in a closed mold at 

ambient temperature^ A geicoat, if required, is first*applied to one or both 

mold halves. Cjiass reinforcement and 

'^mmtmt-mt**tm^^mmtfmm 

any other components are then Laid in 

the bottom half. The mold is closed and 

damped; catalyzed resin is injected 

through a port geometrically centered 

in the top mold half. (Additional ports 

may be used for large, complex parts.) 

Molding pressures typically range 

between 40 and 80 psi. Thus, one may. 

en)oy the lower cost, lighter weight and 

faster lead time of "soft" tooling, fabricated from reinforced polyester br 

epoxy, usually with gelcoated cavity 

surfaces. Rgure 2 shows the mold 

"halves and the RTM part made from it 

—a 42-lnch housing for a riding lawn 

mower. Note the geicoat on the mold 

halves and part. 

The auahtv of RTM tooting determines the quality of the part and has a 

maior effect on the molding cycle. 

Moldmakers differ on Just how hefty— 

and thus how expensive and durable— 

the tooling should be. A major concern 

for the designer is control of wall thickness. K ttie walls of the cavities defied 

under the pressure of the resin being 

pumped in, thickness tolerances will be 

exceeded and resin wasted. That prob-. 

lem can be forestalled by well-reinforced tooling, or at least tooling substantial enough that it can be clamped in 

a press. Use of a press, usually the pressure-pod (pneumatic) type, is not widespread; but the added cost of the press 

also brings better tolerance control and 

faster cycles through semiautomation. 

(continued) 

Figure 2. Riding. 

iouinmoioer finis/ted port (at left) 

and moid halites 

(below). 

Geicoat Is first applied to the bottom 

moid half. 

Both mold halves 

are built wtth a gelcoat/or good partsurface finish. 

(Photos: Fiber 

Glass Tooling & 

Specialties) 

Table I. Comparative production costs 

Production 

method 

Open mold 

Cold mold 

RTM mold 

Matchedmetal mold 

P.rt./mnbt, MnbUCnr-Vl/ Tort moldsneeded 

8-hr day day production lyr Syr 

4 

47 

32 

160 

. 8 8 

1 2 

1 2 

1 1 

Not*: Bawtf on production o/30pon(/day. 6000paru/y«ar 

Source: Molded FUxrGhu Cos. 

15 

10 

10 

1 

Cost/mold 

S 2.000 

9,000 

10,000 

60.000 

Total mold cost 

lyr 5yr 

$16,000 S 30.000 

18,000 90,000 

20,000 100.000 

60.000 60.000 

Piece price, 

cxdudlngtool 

amortization 

$16.00 

11.20 

12.00 

8.00 

Total piece price 

lyr Syr 

$1867 $17.00 

14.20 14.20 

15.33 15.33 

18.00 10.00 

<• Di»«TtrsDESIGNfOPJJM MARCH/APWLIW2 1-V 

Circle 31 on Reeder Service Card 
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P.24 

l£)008 

Cycle time varies widely. Seats for 

fast-food restaurants are being molded 

in a 6-minute cyde. Large, complex 

parts may require overnight cure. The 

factors that affect cycle length are 

many: the degree of automation in handling the molds, time to place the reinforcement, type of damping,.reactivity 

of resin and pumping speed. 

The labor involved in pladng (and 

sometimes tailoring) the reinforcement 

can bc reduced by use pf a preform; 

higher volume is needed to offset the 

cost of the equipment needed to spray 

up the preform on a screen pattern and 

oven cure tt. If a geicoat Is required on 

one side, that mold half can be duplicated to speed up the production line -

added tooling cost for a shorter cycle. 

A simple example of how part-production rates can vary is offered by 

John Plcssinger, president of Design 

Evolution 4 of Lebanon, Ohio, a company specializing in RTM design, tooling and low-volume production. A tool 

for a 10-lnch-diameter, 6-inch-deep 

part originally managed to produce 15 

parts per 8-hour shift. Reinforcing the < 

tool for press mounting doubled the 

rate; an additional 30 percent increase 

was available by mounting the male tool 

in the press and shuttling two female 

tools (containing the reinforcement) In 

and out. (Even shorter cycles would 

have been available had the tool been 

built with temperature control.) 

The example is presented to convince designers that it te Imperative to 

know the capabilities of the toolmaker 

and the methods of the molder, because of the impact on part quality and 

cost; the data In Table I are displayedin 

the same spirit. The cost comparison 

was developed by Molded Fiber Glass 

Cos., Ashtabula, Ohio; the data describe the relative costs of four GRP 

methods and are not based on a specificpart. The one- and five-year total part 

costs, Including mold amortization, 

show how the relationship between 

RTM and matched-metal-die molding 

(SMC) changes as the long life of the 

steel tooling takes effect. When per-part 

costs are plotted against volume for the 

two methods, the RTM curve crosses 

the SMC curve at 8400 parts. Compression molding is usually considered 

' for applications in the neighborhood of 

Functional cores 

Cores In RTM parts do serve as weight 

inducers and softeners; but Viking Yacht 

'Do., New Gretna, N. J„ builds a radar • 

«eh (see photo) that does more. 

. The lightweight rtt-udtnenuat 

:wppcrtal50-bradarunitat4G ' 

•dec-deration. Mounting studs and. •.-•.'•• 

condufoforwMng-mustbelntegMtotitt 

pert. The arch is molded In four ptocesf.i. 

two of which are the end pieces -.-«- -Y{ 

containing the mounting st^ds.-The:-W'--

cores of the two large Identical pieces that 

form the arch are molded bom rigid "•••..• 

urethane foam (114b/cu-ft density) -

around three aluminum condutt. 

The cove, with glass mat on botii 

•>"*;V'.*7l3£? 

rides. Is placed tn theRmn»Jdilfli|j 

otder to producettds partbyliuind law 

with two fintehedsurfacss, KwoiiUp«(f 

been necessary to sandwich two{ - * 

around the con, entailing i 

handfaisl-ilngdhhiii.Y.'-.-

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•'"*••*< * 

yacht radar arch {topmost part, rooWun«rK»lpWureaV;aVoutlnfl shows cross 

(Photo: VflrlngYaehtCo.) •>•-••* 

Heavy-duty use 

Trfe tfaee-plecefohouriitg for cooling 

an alternator on 85-ton bucks was 

adapted hom tiie original metal design at 

one-fourth ofthe weight. The molder, 

Sherwood Pattem, Hartviilc, Ohio, 

selected RTM because It offered better 

dimensional control than layup—the (an 

operates within Vs Inch of the housing.' 

The RTM parts are made in less than half 

the cyde time required to lay up the 

prototypes. 

The housing consists of three pieces 

bolted together; boh spacers and other 

hardware are Inserted after molding. The 

V«-lnch-thtck parts have Vt-inch 

mounting flanges, l«/a inches wide. 

Producing this tricky change In thickness 

is notable because the parts are molded 

to size; they aren't trimmed. The housing 

is 42 Inches in diameter. 

Because of the severe 

expected In use, tne assembled until' ..•.._Tr|,1. 

were subjected to vfarptory testing. Mocl|' 

than a half bUBon cydes failed to destroy1?; 

thetategrttyofthehouslngs.- ' '*'•:•$?; 

.Fan housing. (Photo: Liquid Control 

Corp.) 

23 
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ifljuua 

10,000 parts, assuming that time is 

available for fabrication of the tooling. 

DESIGN CONSIDERATIONS 

The following sections discuss materialand part-design considerations in general terms. Spedfic applications described in the accompanying boxes suggest how the versatiUty'of RTM permits 

some bending of the rules. 

The upper part-size limit is not 

known: parts in excess nt KKl lb have 

been molded. Much larger parts have 

been produced overseas—complete 

boat bulls, more than 30 ft long. 

Materials. Most RTM parts are molded 

with polyester resin; epoxy is occasionaliy used. Special grades for chemical, 

electrical, flame and weathering re-

' quirements can be matched to.performance criteria. 

Low-cost fillers (day and caldum 

carbonate) may be added to the resin to 

reduce cost, improve surface quality. 

minimize shrinkage and cracking in 

resin-rich areas, and inaease stiffening. 

Alumina trihydrate also adds flame retardance. Low-profile additives, as 

.used in SMC, ate not effective because 

they require the higher processing temperatures of compression molding; 

RTM versions are being sought. 

Part weight may be reduced by 

foaming. The expansion molding compounds (EMC) offered by Whitney & 

Co.. Stratham, N.H., are being used in * 

several proprietary RTM applications, 

where they reduce weight by as much 

as 50 percent. A small reduction in 

modulus is also experienced. It can be 

nullified by opening the mold slightly to 

inaease wall thickness, thereby allowing additional foaming to take place; no 

additional resin is needed. The EMC 

additives must be used with special resin 

systems, as their chemistry is complex. 

Uniroyal's Celogen XP-100, introduced last year" for unsaturated polyesters, is suitable for RTM. 

Glass reinforcement is available in 

several forms. Continuous-strand mat 

is the most popular method of reinforcement, for formability and other 

reasons. Woven roving and glass fabric 

provide the highest glass content for 

added strength but are more difficult to 

form to the dimensions of the part and 

more likely to cause strike-through on 

Tubs, etc. 

Tubs(conventionalandhot),shower 

enclosures, whirlpools... in short, 

sanitary ware is an excellent RTM 

appficatton. The glossy gelroated auface 

comes right out of the mold. Units ate 

lighter for the hauler and wanner for the 

redlner, compared to metaL Bob RlddeD 

of Molded Fiber Glass Cos., Ashtabula, 

Ohio, puts the retail cost of RTM tubs as 

lower than cast-iron or spcayup-backed 

aaytcmodeb but higher than steal; the 

economy- minded remodeOer is the 

market. 

MFGbmoUtaga32-fc(Wmn*-ed) 

bathtub that, as the photo shows, 

Incorporates a sort of S-shaped 

transverse crass section; additionally, 

thee sides have upward flanges for wall 

mounting. WaB thickness Is0.l25to 

0.150 inch; a preform it used for 

rdnforesment, ataajass loading of 22to 

26 percent. The resin Is fiBed with SO 

percent dut-nlna trihydrate far flame 

retardanca.MFGaixpedstomaksas . 

many as 10,000 tubs, which Is within 

SMC economics, but the company 

selected RTM for the better gekoat 

finish. 

Bathtub with glossy gekoat finish. 

(Photo: Molded FiberGianCosJ 

100-pounders 

Design Evolution 4, Lebanon, Ohio, 

molds 12 sets of three different RTM 

parts that can be assembled to ferm a 40-

ft-dlameter solar-collector dish. (Imagine 

that the dish Is cut into 12 wedges, and 

that each wedge Is cut concentrically Into 

thee pieces.) The largest segments of 

the part weigh 100 fc each (see photo). 

Each section hasalV*tnch end-grain 

balsa core, wtthaglast-reinforcedpdyester shim about 0.080 Inch thick on 

each side*. 

The parts are molded ln a pneumatic 

press, with the resin injected through a 

single port. Circumferential tolerances 

are held to within 0.010 Inch. 

Section of 40-ft-dk.mettr solar-collector 

dish. (Photo: Design Evolution 4) 

the surface. Chopped strand mat is 

used mainly for flat surfaces because of 

its low formability. Surface veils can be 

added to improve surface finish and 

wear resistance. 

For more complex parts, placement 

of the reinforcement is more labor-intensive. Corners can entail intricate cutting and tucking maneuvers, since overlaps cause strike-through. Preforms offer a solution for higher-volume runs. 

Core materials such as end-cut 

balsa, mat and syntactic foam can be 

placed In the mold to cut costs, stiffen 

the part and reduce resin-layer thickness (and thus cure time). Rib formers 

ahd other structural Inserts can also be 

strategically located in the mold. Metal 

inserts, preferably the flanged type, are 

sometimes molded in. • (continued). 

r-rr^crXmCtviim MARCH/APRIL 1982 Z4 
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Ifl] UIU 

Gelcoats provide a smooth, glossy 

colored surface and can be formulated 

for corrosion resistance or other purposes. Resin pigmentation will often 

suffice for parts with less stringent cosmetic*heeds, and, of course, the parts 

are easily painted. 

Part design. A basic design guide for 

RTM parts TTyiwn in Tdbte U. The 

guide provides some clear aistincoons 

among several GRP processes in terms 

of design. There are numerical differences in matters like draft and also some 

substantial differences in what can and 

cannot be done—molded-in holes, for 

instance. 

Careful consultation with molder 

and toolmaker can lead to relaxation of 

the ground mles. For instance, ribs and 

bosses are accounted difficult to embody in RTM parts. They are not, as 

some of the accompanying illustrations 

show, impossible. These and other 

geometrical considerations (such as 

Part consolidation 

The seat backs for the Excalibur were 

originally laid up In three pieces and 

assembled with adhesive. That 

technique encountered tolerance 

problems, creaking and possible 

adhesion failure In the structure, plus 

extensive labor. The photo shows the 

one-piece RTM conversion. The tooling, 

bulk by RTM Corp., Hardand, Wis., uses 

two tree cores that hook Into the bottom 

mold to fonn the sc<kets fo nwunttng 

the seat back on two steel posts; the \ 

cores demold with the part. The part Is' 

molded to dimensions- no trimming at 

the parting fine 1s required. 

The thickness of the seat back tapers; 

it's thickest at the base. This produces a 

Excalibur seal backs. (Photo:R7MCorp.J 

somewhat flexible structure that 

dampens toad Impacts. 

abrupt changes in thickness) are concerned with the ability of the glass reinforcement to resist any movement (or 

"wash," in the parlance) as the resin is 

pumped into the mold. Use of cores In 

ribs and bosses, together with glass, wUT 

Table U. Comparative design guides for resin-transfer, open and compression molding 

Design 

parameter 

Minimum Inside 

radius. Inches 

Molded-ln holes 

In-fnold trimming 

Core pull and slides 

Undercuts 

. Minimum recommended 

draft, deg 

Minimum practical 

thickness, inches 

Maximum practical 

thickness, inches 

Nonnal thickness 

variation, inches 

Maximum thickness buildup, 

heavy buildup, ratio 

Corrugated sections 

Metal inserts 

Bosses 

Ribs 

Hat section 

Raised numbers 

Finished surfaces 

Source: OlMiu-Ccwnfng Flbcrgta 

Resin-transfer 

molding 

'/• 

No 

No 

Difficult 

Difficult 

2to3 

0.080 

0500 

±0.010 

2:1 

Yes 

Yes 

Difficult 

Difficult 

Yes 

Yes 

Two 

Open 

Sprayup 

>/« 

Large 

No 

Difficult 

Difficult 

0 

0.060 . 

No limit 

±0.020 

As required 

Yes" 

Yes 

Yes 

No 

Yes 

Yes 

One 

molding 

Hand layup 

V« 

Large 

No 

Difficult 

Difficult 

0 

0.060 

No limit 

±0.020 

As required 

Yes 

Yes 

Yes 

No 

Yes 

Yes 

One 

Compression molding 

Mat/Prefcnn 

»/• 

Yes 

Yes 

No 

No 

Sheet molding compound 

Via 

Yes 

Yes 

Yes 

Yes 

Vs to 6-Inch depth, Ito 3: 

above 6-Inch depth, 3 or as required 

0.030 

0.500 

±0.008 

2:1 

Yes 

Not recommended 

Difficult 

Difficult 

Difficult 

Yes 

Two 

0.050 

1 

±0.005 

As required 

Yes 

Yes 

Yes 

Yes 

No 

Yes 

Two 

^ £ 
.07/19/95 18:00 ©202 260 0178 EPA PPD 

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1011 

Small-quantity prototyping 

RTM Corp.. Hartland, Wis., has molded 

RTM prototypes in very low quantities— 

as few as five—for parts destined for 

SMC, BMC structural foam and even 

Injection molding. (WaUs as thin as Vis 

inch have been produced.) the 

company points out that even such low 

quantities are economical in terms of the' 

fast start the customer can obtain for 

evaluating new designs. 

The three parts shown here, 

components for a slide projector, arc a 

good example. The prototypes can be 

used to prove out complex mechanical 

and optical dimensional relationships. 

Note that the large base unit requires a 

skk core (for the top of the part as seen 

hue). A three-piece mold was used to 

produce it. Production parts are injection 

and structural-foam molded. 

Slide-projector prototype parts. (Photo: 

RTM Corp.) 

Building in ribs 

The part shown here—bottom view, 

untrimmed—is one of five identical 

wedge-shaped pieces that assemble to 

form the base, or receptor, for a ftvehead industrial shower with central 

plumbing. Ribs strengthen the part. Their 

dimensions: 1V5 Inches deep, the width 

tapering from l*/« Inches at the top to a 

* weD-radiused V«inch. The parts are 

produced at a rate of 8000 per year. 

Cores hold the glass reinforcement 

In place; the cores are 1-inch-wide strips -

of plywood. Slight sink marks do form on 

the flat opposite surface. The molder/ 

toolmaker, FfcerGlassToollng& 

Specialties, Sheboygan Falls, Wis., 

advises that the tooBng cost for the part 

was one-sixteenth that of matched-metal 

dies for SMC production. Each 46-fc 

component replaces a 2500-tb concrete 

unit. 

Bottom view of untrimmed Industrial 

shower base. (Photo: Fiber Glass Tootbig & Specialties) 

minimize wash, but there is the likelihood of sink on the opposite surface. 

Large, flat expanses should be 

slightly crowned, as is good GRP practice, perhaps V* inch of crown per foot. 

.The molded part will flatten out during 

curing; uncrowned parts may dish. 

Raised lettering and logos can easily 

be molded in (provided there is enough 

draft), a feature difficult to obtain in 

open molding in terms of getting glass 

into the raised areas. Although RTM 

delivers two finished surfaces, one will 

contain the injection port. If its .location 

is obtrusive, it will have to be patched or 

masked. 

RTM parts conventionally require 

. trimming around the parting line. The 

tooling is built with a flanged area at the 

parting line. Some parts molded to full 

dimensions require only resin deflashing in certain cases; proprietary methods of handling the reinforcement eliminate resin-rich edges. 

All holes must be drilled and larger 

openings cut out. for which computerized equipment is available. 

It's difficult to pin down the tightness 

of tolerance control in RTM. the matter 

being so dependent on tool quality and 

molding methods. Maintaining thickness tolerances to 0.010 inch is within 

the capability of many molders. Part 

shrinkage can be as little as 0.001 inch/ 

inch. 

The strength of RTM parts, like 

other facets of the process, falls between the extremes of open and compression molding. The amount of glass 

loading is obviously a factor. Loadings 

usually run between 25 and 35 percent 

but can be much higher. Hood Mfg., 

Santa Clara, Calif., for Instance, reports 

that a medical cover with a Via-lnch wall 

contains 65 percent glass (continuousstrand mat). One of the advantages of 

RTM is the ability to place glass and 

other materials with great accuracy precisely where they're needed. 

RTM vs layup. One of the papers at this 

year's SPI RP/C Conference* presented a rare comparison of ttie physi-

. cat properties of a part made by both 

layup and RTM. The part is a commerdal generator cover. As Table III Indicates, the RTM part, with a slightly 

higher glass content, shows Improvement in aD physical properties. Thickness of molded parts via both processes 

is V<* inch. Part-removal time ln RTM 

was 23 minutes, as compared to 1 hour 

for layup. 

FUTURE CONSIDERATIONS 

It is the curse of intermediate-volume 

processes that development money is 

not in generous supply. Thus. RTM has 

grown slowly. But the pace is quickening, and more molders have Joined up. 

The resins, reinforcements, pumping 

equipment and, especially, tooling are 

being Improved. 

Two major goals, are being pursued: 

largeTparts and taster cycles. RTM*s future will be populated with more automated molding and more sophisticated 

tools. Some metal tools are being used 

now, for those Jobs with unusual design 

requirements. While RTM cycle time 

won't be pared to that of compression 

molding, faster cycles will make larger 

runs more cost effective. 

Encouragement to expand the capabilities also comes from overseas. 

• "RTM - The Right Choice /or the '80s." by N.E. 

Michaels (Fiber Glas* Tooling tt Specialties. Sheboygan Falls, Wit.) and J. Lot-en and J. Bauer 

(Freeman Chemical Corp.. Port Washington. 

Wis.). Presented af the 1982 SPI RP/C Confer. 

ence. Washington. O.C. ,conl(l,u,d) 

M 
P.28 

07/19/95 18:01 ©20 2 260 0178 EPA PPD IfflUIZ 

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O m. Cm 

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33 < X O -J 

Table III. Comparative physical properties of RTM and 

sprayup 

Property 

Tensile strength, psi 

Tensile modulus, psi 

Tensile elongation, % 

Impact, izod, unnotohed, ft-Ib/lnch 

Flexural strength, psi 

Flexural modulus, pri 

Barcol hardness 

Glass content, % 

RTM process 

14,400 

980,000 

1.64 

14.75 

23,400 

847,000 

48 

28 

Sprayup process 

11.950 

890,000 

1.4 

13.9 

22.000 

830.000 

45 

25 

Source:N.E.Mfc-tos*(FiberdmTooKr**Sftdalt^Sltebovgo-Fa^V^.lendJ. LnmnandJ. 

Bauer (Freemen Chemical Corp., Port Wathlngton, Wk.). 

EDP housings 

EDP cabinetry puts many demands on 

the designer. This highly competitive 

field places a premium on moving fast— 

ahd RTM meets that challenge wtth fast 

tod delivery and the ability to make 

changes Inexpensively. The process can 

be used for prototype and pceproduction 

parts as -well as for medium volumes of 

the many specialty products in the 

medical and otherfklds. . . 

The bousing shown here was molded 

by Risco Inc., Seattle, which specializes 

in this area. The company uses press 

mountings for best tolerance control es 

weU as a numerical trimmer for accurate 

cutting of openings. Ribs and bosses are 

molded in with cores; slots for card racks 

can be routed out of the housing. The 

company has produced several housings 

wtthintegral EMI shielding by 

incorporating alumlnlxed glass mat with 

the reinforcement, Including the one 

shown. 

Press-mounted, numerically trimmed 

EDP housing. (Photo: Risco Inc.). 

Boat hulls are being built in England; 

complex molds allow RTM production 

of not only the hull itself but integral 

stringers, bulkheads, motor mounts 

and other structural members. 

In the automotive-parts area, Colin 

Chapman has refined the RTM process 

to produce bodywork for several Lotus 

models and has also provided technology for the RTM parts being used in the 

De Lorean. The stainless-steel skin of 

the De Lorean is applied to the twopiece monocoque structural body shell 

produced via RTM. Urethane-foam 

beams wrapped with glass mat are used 

as inserts ln the shell to provide additional impact and shock resistance. 

Automotive and marine ventures in 

RTM in the United States have not 

reached the British levels, but interest is 

-z>7 •• 

high. The Excalibur efforts have already 

been mentioned, and Viking Yacht last 

year built the female mold for its new 

44-ft yacht so that it could be converted 

to RTM from layup at some point in the 

future. Since it takes a layup crew five 

days to produce the hull, the prospects 

of RTM production ln even half that 

time are enticing. 

Certainly many layup and sprayup 

lobs are *ju1nffir-*)hlp

 tn **"> f*-"*|,

«'T W^** 

improved cosmetics, better properties 

"and improved working environment of 

K f M. Molders who effect such conversions can then build up their volume until they face the ultimate manifestation 

of commercial success: conversion to 

compression molding. 

For information on res/n-trans/er molding, 

circle 200 on the reader service card. 
P.29 

07/19/95 18:02 ©20 2 260 0178 EPA PPD tffluu 

MAGNUM 

INDUSTRIE S 

THE RESIN ROLLER 

IMPREGNATOR 

The resin roller impregnator is one of our 

newest developments. It was designed for 

those doing hand-lay-up and bucket and 

brush wet out. The resin roller was also 

designed tb eliminate ali spray-up fumes, 

which it does. This system will not only 

eliminate fumes but also mixes the resin 

and catalyst intemally blending the catalyst 

and resin together. Widi this system waste 

will be cut by 5 to 10%. Time in lay-up Is 

. also reduced because one operator is 

wetting-out and rolling out at the same 

time. 

• 

The weight of your product can be 

reduced because when properly used, the 

roller will soak up excess resin and this can 

then be used where needed. 

Glass to resin ratio will be constantly maintained. In fact you will probably get a 

higher amount of glass to resin than 

achieved ever before. 

Here is how the system operates. Catalyst 

and resin are pumped from the main 

source already metered by the slave pump 

as to correct percentages out to the 

dispensing block. When the block, is 

opened catalyst ahd resin then flow 

together and are mixed in the static tube. 

After they are mixed the flow continues 

down the extension tube and out of the 

roller tube. The catalyzed resin flows 

through the roller tube into an auger and 

out into the roller. At the end of a day, 

simply take the roller off and either clean 

or dispose. Then, flush the tube which will 

take only seconds. This system can go as 

slow or as fast as anyone can handle it, so 

all applications of hand lay-up or bucket 

and brush should seriously take a close 

look at this new system. 

A special note, for those of you plagued' 

by O.S.H.A. and the 

E.PA If your product will 

permit the use of a Resin 

Roller Impregnator, you 

can reduce your fumes to 

that of the curing resin 

only. 

11701 - 56th Coun North 

Clearwater, FL 34620 

FAX 11-813-572-6895 

Clearwater, FL 1-813-573-2955 

Montreal. Quebec 514-638-4330 

Standard Features: 

I - BOS-3000-6 Catalyst Slave System 

with AP 0600 Resin Pump 

I -MA-MRD Air Manifold 

I - CM-4000 Catalyst Manifold System 

I - MBA-1000 Mixing Block Assembly 

I - MRD-1000 RHD Roller Head Assembly 

I - WMM-1000 Wall Mount Mast 

1-MFP-IOOORushPot 

Optional Features: 

• Booms 12 foot, 12, 16, 18,20, up to 

34 foot long 

• PC-2000 Cart Assembly 

• DC-1000 Drum Cart Assembly 

•FM-IOOORoor Mount 

• 3 foot and 6 foot Roller Extensions 

RESIN ROLLER 

IMPREGNATOR 

Z8 
P.30 

07/19/95 18:03 ©202 260 0178 EPA PPD UtI 014 

MAGNUM 

INDUSTRIE S 

FLO-COATER - WET-OUT SYSTEM 

In today's environment with air quality 

controls becoming stricter, Magnum 

Industries continues to fight to help F.R.P. 

manufacturers meet the new codes. Ih 

our efforts to do this we have now come 

out with a new way of applying resin. The 

Flo-Coater. 

The key to efficient wet-out is to reduce 

over-spray, fuming, and air entrapment 

while still getting good resin penetration. 

This new system offers several advantages 

to the F.R.P. shop that uses hand lay-up or 

wets out with a gun. The resm that comes 

through these holes is stream. The 

resulting spray pattern is unique. This pattern eliminates over-spray and misting even 

at high flow rates. 

Using this resin saturating system will 

reduce styrene emissions, resin waste, 

roll-out time, ahd should increase 

production. 

Don't let the new codes influence you into 

buying some elaborate and expensive air 

exhausting system. For those of you 

needing to reduce styrene emissions or 

just boking for a way to save yourself 

some money, a Magnum Flo-Coater or a 

Resin Roller Impregnator is the answer. 

These systems will reduce the styrene 

levels to that of the curing resin. What 

more could you want! 

See a demonstration today! 

II701 - 56th Court Norch 

Clearvmer. FL 34620 

FAX # 1-813-572-6895 

Clearwater. FL 1-813-573-2955 

Montreal, Quebec 514-638-4330 

Standard Features: 

Resin Pump 6:1 Ratio, 4.6 G.P.M. 

MRD-MS-IOII Catalyst Slave Pump 

MRD-I000-BLK Mixing Block Assy. 

Flo-Coat Nozzle and Gun 

MA-2000 Air Manifold 

CM-1000 Catalyst Manifold and Relief Valve 

Optional Features: 

DC-1000 Drum Cart 

BA-1200 Boom Assy. 

WMM-1000 Wall Mount 

FM-1000 Floor Mount 

Resin Pump 11:1 Ratio, 4.6 G.P.M. 

Longer Hose Lengths 

INTERNAL MIX 

FLOCOA T SYSTEM 

z? FLOCOAT GUN