GENERAL SPECIFICATION OF Poly Fibre Products
|1||Poly fibre chopped strands MAT (CSM) as res ISI-11551-1986|
|2||Poly Fibre Roving as per ISI-11320-1985|
|3||Isophthelic resin as per ISI-6746-1972|
|5||Accelerator used will be Cobalt Napthalate|
|6||Permissible Fillers are Calcium Carbonate Powder|
|9||UV – Primer Paint and Laquer|
|10||Antimony Trioxide, minimum 5% by weight of isophthalic resin, shall be used for fire retardancy|
|11||The filler and additive content shall not exceed 10% by weight of isophthalic resin|
|13||Polyvinyl Alcohol (PVA) and wax shall be used as a mould release agent|
|14||Pigments compatible with isophthalic resin and gelcoat will be used to get the shad of finish as mutually agreed between the manufacturer and the purchaser.|
|17||Catalyst used shall be Methyl Ethyl Ketone Peroxide (MEKP)|
|19||Fillers , Additives and Bonding Paste.|
|20||Permissible Fillers are French chalk powder (Talc) and Calcium Carbonate.|
PROCEDURE OF MANUFACTURING OF Poly Fibre PRODUCTS
|1||With the help of Gelcoat and Chopper Machine, a coat of Isophthallic UV Gelcoat mixed with 15% by weight arcelon powder (500 micrgram Silica) with UV pigments (for resistance against color fading), suitably formulated to high viscosity is applied at 1000gsm over the moulds in two layers of fibre Poly chopped stand [email protected] 450gsm in each layer and one layer of Poly roving about 450gsm (for better strength), in order to provide a smooth glossy finish enhancing aesthetic and improved weathering and water resistant property of the Poly Fibre Reinforced Polymer products. The CSM Mat shall be bounded with Isophthallic FR and UV resin in the ratio not less than 1:2 (one part of CSM Mat to two parts of Isophthallic resins and fibres and additives). The edges shall be sealed with Gelcoat, Resin and CSM to obtain smooth finish. Sufficient 4021 roving shall be laid in the corner to have smooth curve while laying the CSM MAT. Applying glossy finished Poly Fibre Reinforced Polymer sheet with same color as product is fixed over the back of the product with gelcoat, resin and CSM. Filling cavities with filler material and prepare for compaction on vibratory bed. Release from mould with the help of technical tools and send for trimming and final finishing and polishing with chemical and packing with scratch proof film. The surface of the product shall be free from any visible defects such as small pores, crazing, blistering, wrinkling, impurities, defective impregnation, color blots and aggregates defects. Scattered pin holes, if any shall be repaired and finished by applying Gelcoat and Resins.The product is ready for dispatch.|
PROCEDURE OF MANUFACTURING OF Poly Fibre PRODUCTS
|S.No||Test||Test Method as per||Acceptable Value|
|1||Fibre Poly Content||ISO: 1172-1975||Not less than 25%|
|2||Barcol Hardness||ASTM:D2583-1987||Not less than 26 BIU when tested on the face of laminate finished with gel coat|
|3||Ultimate Tensile Unit Strength||BS: 4994-1973||Not less than 150 N/mm per Kg/m2 of Poly Fibre|
|4||Tensile Unit Modulus||ISO: 3268-1978||Not less than 6500N/mm per kg/m2 of Poly|
|5||Flexural Strength||ISO: 178-1975||Not less than 110 N/mm2|
|6||Flexural Modulus||ISO: 175-1975||Not less than 7000 N/mm2|
|7||Izod Impact||ISO: 180-1982||Not less than 10 J/cm|
|8||Water Absorption after seven days of immersion||ISO: 62-1980||Not less than 0.5% by weight|
TYPICAL FIBRE glass PROPERTIES
|S.No||Test Method as per||Acceptable Value|
|1||Flexural strength, psi @ 77 degrees F||28000|
|2||Flexural modulus, psi @ 77 degrees F||1.07 x 106|
|3||Tensile strength, psi @ 77 degrees F||16800|
|5||Elongation||1.0% to 2.5%|
|6||Barcol hardness||45 to 50|
|10||ASTM E-84 (Tunnel test)||25|
|11||UL Subject 94||V|
Testing of Poly Fibre Reinforced Polymer product material can be done at the following labs at the following .
|S.No||Test Method as per||Acceptable Value|
|1||Flexural strength, psi||16,000 to 32,000|
|2||Flexural modulus, psi||0.8 to 1.4 X 106|
|3||Tensile strength, psi||9,000 to 18,000|
|4||Tensile modulus, psi||0.8 to 1.4 X 106|
|5||Elongation||1.0% to 2.5%|
|6||Compressive strength, psi||15,000 to 25,0000|
|7||Impact strength izod,Ib.In. of notch||4 to 12|
|8||Specific gravity||1.0 to 1.8|
|9||Density, Ibs./ft.3||80 to 110|
|10||Continuous heat resistance||150 to 350|
|11||Thermal Coefficient of Expansion, in/in/Fx 10-||12 to 20|
|12||Barcol hardness||40 to 60|
LIST OF REFERRED INDIAN AND OTHER STANDARDS OF Poly Fibre Reinforced Polymer PRODUCTS
|IS: 6746-1972||Unsaturated polyester resin system for low pressure fibre reinforced plastic|
|IS: 11320-1985||Poly fibre rovinings for reinforcement and of epoxide resin system.|
|IS: 11551-1986||Poly fibre chopped strand mat for the reinforcement of polyester resin system|
|IS: 12406-1988||Specification for medium density fibre board for general purposes|
|ISO: 62-1980||Plastic – Determination of water absorption|
|ISO: 178-1975||Plastic – Determination of flexural properties of rigid plastic.|
|ISO: 180-1982||Plastic – Determination of Izod impact strength of rigid material.|
|ISO: 1172-1975||Textile Poly Fibre reinforced plastic – Determination of loss on ignition|
|ISO: 3268-1978||Plastic – Poly Fibre reinforced materials- Determination of Tensile properties|
|BS: 4994-1973||Specification for vessels and tanks in reinforced plastics|
|ASTM: D2583-1987||Test method for indentation hardness of rigid plastic|
COMPARISON AND ADVANTANGES OF Poly FIBRE REINFORCED POLYMER OVER Poly FIBRE REINFORCED CONCRETE AND ALUMINIUM COMPOSITE PANEL
|1||30% Poly Fibre Reinforcements||4% to 6% Poly Fibre Reinforcements||No Reinforcements|
|2||Woven Continues Roving + CSM 35mm length + Polyester Honey Comb.||6mm to 10mm length||Nil|
|3||Quartz on surface||Limestone and Cement||Aluminium Foil|
|4||High abrasion resistance||No abrasion resistance||No abrasion resistance|
|5||High impact resistance||Poor impact resistance||No impact resistance|
|6||Does not develop fungus||Fungus can develop easily||Does not develop fungus|
|7||Can take localized impact||Does not take impact||Does not take impact|
|8||Does not absorb moisture||Absorbs moistures||Does not absorb moisture|
|9||Available in various natural finishes and textures||Available in stucco only||No natural or texture finish available|
|10||Product thickness 4 to 6mm||20mm minimum||3 to 4mm|
|11||16.5 Ibs P. Meter Square||85.8 to 221 Ibs. P. Meter Square||Weight per meter 8.25Ibs P. Meter square|
|12||Various colors in same product||Single color||Single color|
|13||Can be stained||Can be stained||Can be stained|
|14||Can be directly mounted on brick wall or M.S. frame||Needs RCC structure||Needs M.S. Or Aluminium Frame|
|15||Widely used in developed countries||Hardly used in developed countries||Widely used in developed countries|
|16||Low installation cost||High installation cost||High installation cost|
|17||Easy for fitment||Difficult for fitment due to weight||Difficult for fitment due to extensive metal structure|
|18||Low processing time||High processing time||Low processing time|
|19||Does not get discoloured due to moisture||Can get discoloured due to moisture and fungus||Does not get discoloured due to moisture|
|20||Fire Retardant||Fire Retardant||Flammable|
Poly Fibre Reinforced Polymer products are recreated with various composites i.e. wood, stone, steel, GRC and ACP available in various finishes and textures.
Poly Fibre Reinforced Polymer products are unique with Poly fibres, and with very high impact and weather resis tance. Due to its light weight, large product in single peice can be moulded in various forms and textures. Very intricate forms including undercuts can be managed.
RELATIVE ADVANTAGE OF Poly Fibre Reinforced Polymer
Poly Fibre Reinforced Polymer is a material with higher tensile, flexural and impact strength, complete elastic behaviour under stress and its impact is absorbed without deformation.
Poly Fibre Reinforced Polymer products are lighter in weight compared to GRC. With minimum GRC product thickness of 15mm, GRC weight is 30Kg per sqr.mtr, while 3 mm Poly Fibre Reinforced Polymer can weigh 4.5 to 5 Kg per Sqr.mtr.
Poly Fibre Reinforced Polymer has higher strength to weight ratio as compared to GRC
Poly Fibre Reinforced Polymer is structural material, while GRC is Non-Structural Cladding material.
Even though GRC has right properties, nobody goes for slabs or support columns in GRC
Poly Fibre Reinforced Polymer has better chemical resistance especially to acids while cement from GRC is affected. Poly Fibre Reinforced Polymer has no joint issues like GRC.
Comparison of Steel Wooden PVC Poly Fibre Reinforced Polymer ARCHITECTURAL PRODUCT
|S.No||Features||Steel products||Wooden products||PVC products||Composite Poly Fibre Reinforced Polymer products|
|2||Surface Finish||Poor||Poor||Extremely Flimsy & Shabby looking||Extremely Smooth, One piece moulded|
|3||Effect of heat or sunlight||No effect but remain heat for much longer period||Quick ageing due to direct heat & sunlight||Deformation occurs due to heat & colour fades due to UV rays from sunlight||No effect of heat or sunlight as it is made with UV protected additives|
|4||Rattling||Rattles very much & produces uncomfortable sound||Rattles less but makes cracking sound because of joints.||No rattling but other sounds due to corrosion or screws in frame work||Poly Fibre Reinforced Polymer produces being made from sound dampening material do not make any noise|
|5||Safety against accidental/natural calamity||Dangerous due to heavy weight & possibility of joint failure due to corrosion in rains||Due to heavy weight & possibility of joint failure due to corrosion in rains they are unsafe.||Not very safe as sharp edges of aluminum frame work may injure people around||Safest due to light weight & low specific gravity. No harm even in the most critical circumstances|
|6||Insulation for heat||Bad||Better||Average||Very Good|
|7||Corrosion||Maximum Corrosion||Expansion due to high water absorption||Speedy bio-chemical degradation||No Corrosion since all the products are moulded|
|8||Repairing||More difficult as involves hot process||Difficult & time consulting||Can be done by specialized person only||Repairing can be easily done on site by skilled labour|
|9||Sizing/Machining||Not possible easily||Possible by expert carpenters||Can be done by specialized person only||Sizes can’t be altered since places are moulded.|
|10||Maintenance||Very frequent painting is required||Frequent painting/Polishing is required. Matching the swelling in wood during rains is required for maintaining smooth operation||Less possibility for maintenance. Aesthetics have to be sacrificed if maintenance is attended||Zero maintenance & no recurring cost since no absorption of water and negligible effect of UV rays/Sunlight|
OTHER ADVANTAGES OF POLY FIBRE REINFORCED POLYMER PRODUCTS
Poly Fibre Reinforced Polymer products are made of Ultra Violet stable polymer with fire retardant material to withstand temperatures of -40C to +75C. Structures can be made by using sections in various forms with variants of Poly fibre or woven rovings and polyester honeycomb to give added stability. Paint can be used as the surface finish or color. A protective coating of aliphatic grade 2k polyurethane scratch resistant automotive paint, with capacity to withstand -40C to +75C is used. Poly Fibre Reinforced Polymer products are installed like any dry cladding material as granite and sandstone or with stainless steel dowels. These are developed to meet international standards and to withstand extreme temperatures and weather conditions. These are also designed to withstand high wind pressures of coastal states.
What are Poly Fibre Reinforced Polymer products
Poly Fibre Reinforced Plastic products are a composite of Poly Fibre and polymer resin that, when combined, offer a stronger, more durable, corrosion resistant and heat-resistant product; not found in any other type of metal products. Using a mold to create the finished product, Poly Fibre is generally thermoset with a type of polymer resin, when cured, the end product will hold its shape because of the resin while the Poly will provide strength and stiffness. Just as important Fibre, the resin has additional corrosion-resistant and heat–resistant properties. This technology has led to increased durability and strength in hostile and corrosive environments.
The utilization of composite materials, in particular Poly Fibre Reinforced Polymer, offer new application and new markets every day. Thanks to the development of new products and the constant improvement of the fabrication processes.
Aside the environmental benefit, Poly Fibre Reinforced Polymer has many advantages over other common materials such as steel, almunium and wood.
Composites are an innovative and cost effective solution! The advantages are:
- High strength to weight ratio- Composites weigh 32% less than aluminum and the fibre can be oriented to maximize performance.
- Radar transparency- Poly fibre and organic matrix are relatively invinsible to microwave (radar) transmissions.
- productivity – In some application, such as highly contoured parts. Composites are more economical to produce than metals • Fire resistance – Composites can be designed to withstand 2000 of open flames-surpassing aluminum.
- Corrosion resistant – Composites exhibit exceptional corrosion resistant properties.
- Retards Chemical Attacks – Protect steel, concrete, wood and other surfaces against acid salt, solvents, alkalies and other chemicals.
- Fight Moisture Damage – Safeguard floor, trenches, wells, pump bases, reservoirs and tanks against moisture and water exposure.
- Eliminate downtime for repairs – Hardens/cures within hours. The molding can be repaired/reworked easily at site.
- Desired Finish – Poly Fibre Reinforced Polymer products can be molded as per the design needs. Exteremely smooth one piece molding replaces shabby looking fabricated. The product can be easily modified to get the desired surface finish.
- Other – Impact resistence, electrical insulation, thermal insulation, shock absorption and more.
We Deliver Defect-Free products
- Presence of impurities like pin holes, traces of mending at localized places.
- Color blots due to uneven distribution of coloring material.
- Crazing and defective impregnation, fine surface cracks etc.
- Gelcoat errors, as the compatible fire-resistant gelcoat is often forgotten by the manufacturers.
- Impurities like foreign matter and blisters in the material.
- Improper Lamination and uneven spread of laminates.
- Pinhole defects.
- Small Pores more than 1 mm, which is not acceptable.
- Wrinkles due to under curing of gelcoat and improper application.