FRP Manufacturing

Manufacturing FRP for Infrastructure, Equipment and Buildings

Traditional construction materials are susceptible to weather and normal wear over time. Concrete, wood or steel can deteriorate, impacting the integrity of the structure. While these materials may initially meet the municipal, commercial or industrial stakeholders' performance and investment objectives, they can end up costing more over the long term due to repair and replacement. A cost-effective alternative is FRP - a lightweight, high strength, highly durable material used for buildings, equipment, infrastructure and many other products.

What to Look For in an FRP Manufacturer

FRP is a material widely used in industries that often must adhere to stringent standards and requirements. To ensure your FRP manufacturer can provide a quality product that meets each application and industry's specifications, look for the following:

Experience

Your manufacturer should have demonstrable and verifiable experience manufacturing FRP solutions for the target application. Depending upon the project, the manufacturer may have to meet a minimum level of experience with various applications.

Standards & Certifications

An experienced FRP manufacturer will have extensive knowledge of regulatory requirements and can demonstrate compliance with these codes. Look for certifications that ensure a high standard of quality management to ensure they will meet your project's specifications.

On-site Availability

Though many FRP products can be delivered ready-to-use remanufactured, there are some products like equipment and infrastructure often other related needs that require specific expertise that many general contractors don't have. You'll want to ensure that your manufacturer can provide services on-site, such as installation guidance, product maintenance, modifications or required inspections.

How FRP Is Made

There are several manufacturing methods for producing FRP and the chosen technique depends on factors such as order volume, aesthetic requirements, size and desired function. Common manufacturing methods include:

Pultrusion

Pultrusion is a technique that uses a series of rollers to pull strands or fiberglass fabrics into a resin bath to infuse them with polymer. The fiberglass strands are passed through a heated die which cures the resin around the fibers to produce an FRP profile with a consistent cross-section shape ready for cutting into any length. This energy-efficient process is eco-friendly, affordable and produces minimal waste. It is the desired method for continuous manufacturing and rapid production.

Vacuum Infusion

Vacuum infusion is the most cost-effective option for creating large parts including boat hulls, wind turbine blades and bridges. During the process, dry fiber materials are placed into a shaped mold and covered with a sealing plastic. Once the reinforcement materials are under complete vacuum conditions, precisely positioned tubes introduce liquid polymer resin into the mold. A catalyzed chemical reaction cures the resin throughout the part. Though more time-consuming than other methods, vacuum infusion is a more customizable process that creates a maximum fiber-to-resin ratio and produces large, high-strength FRP panels.

Filament Winding

Filament winding is an automated process that applies resin-saturated, continuous strands of fiber reinforcements over a rotating cylindrical mold. This process creates parts that can handle high friction and operating pressures.

Open Molding

Open molding is an economical yet effective method for manufacturing composites. Resins and fiber reinforcements are exposed to air as they cure. Open molding can use processes that include spray-up and filament winding. Open mold methods also allow for rapid product development and production of custom parts because tooling is simple and low cost.

Compression Molding

Compression molding starts with rapidly closing a heated mold and applying pressure to force FRP material to flow throughout the mold until the charge fills the entire cavity. The process is primarily used to produce structural car body parts including wheels, fiberglass bumpers and manhole covers. It can generate complex geometric shapes in a short period of time. Compression molding also eliminates some secondary finishing operations such as drilling and forming.

Resin Transfer Molding

RTM is a vacuum-assisted resin transfer process that yields increased laminate compression, a high glass-to-resin ratio and superior strength-to-weight characteristics. A catalyst or hardener is mixed with a resin and then injected into a mold that contains fiberglass. RTM can be used to produce complex forms and shapes such as compound curves. It is lightweight and durable. The molding process can provide finished sides from outside and inside with a multi-color capability.

Continuous Lamination

Used to produce composite panels, continuous lamination is an automated process where fiber reinforcements are saturated with resin before moving through a conveyor process which controls thickness and resin content to meet end product requirements. The material passes through a heating zone where the resin is cured to form a composite panel. FRP composite panels can be used for a variety of products including building and roofing panels, RV sidewalls and other industry applications.

Spray-Up

Spray-up is an open-molding fabrication process where resin and fiber reinforcements are sprayed on to a reusable mold. The resin and glass can be applied separately or simultaneously chopped in a combined stream from a chopper gun. The spray-up is then rolled out to compact the laminate. A chopped laminate is sometimes faster to produce than a part made with hand lay-up when molding complex shapes.

Structural Fabrication

Structures are fabricated and assembled using standard fiberglass profiles that include basic shapes such as angles, channels, tubes, plates and I-beams. These profiles can be turned into custom assemblies for a range of applications from support structures such as electrical, telecom, maintenance platforms to walkways, handrails, ladders and stairs.

Structural Assembly

A process of composite fabrication when manufactured and finished FRP components are assembled into larger and more complex products that will be installed at a job site.

CCG is the Largest Manufacturer of Structural FRP
in the U.S.

FRP is a resilient, lightweight and corrosion-resistant alternative for construction projects. CCG is a leader in manufacturing FRP composite products. We can manufacture and fabricate innovative FRP projects to meet your specifications and requirements.

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