Pultrusion process

• Pultrusion is a continuous process of molding, whereby reinforcing

fibers are saturated with the help of liquid polymer resins and then
carefully formed and pulled through a heated die to form a part.
• GRP Pultruded Profiles are straight constant cross-section parts of
shippable lengths.
• It gives a sustainable and long lasting product.
• The word comes from a combination of two words “pull” and
“extrusion”.
• The process of intrusion is achieved by a series of necessary steps
that tend to gear up towards creating a quality FRP product.
• It gives quality products that are reliable and lasts long.
Importance Components of Pultrusion Process
• Fiber Creels
• A rack holding cylinder or cone holding threads or spools when spinning.
• Resin impregnation systems
• It allows the reinforcement travelling from the creels down into the bath and the
resin coated fibers comes out through a guided bar.
• Pre-former
• Preform plates are critical component of pultrusion system as it properly aligns and
feeds the reinforcement to the heated die.
• Hot dies
• The main component of any pultrusion system where part to be produced is given
shape and is cured. Heated dies are often about 1 m long, there is sufficient time to
fully cure the resin.
• Pulling mechanism
• Pulling system pulls the product from the heated dies on a continuous basis.
Generally, a caterpillar belt is used in the pulling system.
• Cut off saws
• The last unit of pultrusion system is cut off saw which cuts the pultruded product in
desired size. Flying type of cut off saws commonly used.
Raw Materials Used In The Pultrusion Process
• Reinforcing materials
• Glass (E-glass and S-glass), Carbon , Aramid fibers in the form of roving
strands, mat (continuous filament mat, chopped strand mat) and fabrics.
• Veils
• Matrix materials
• Unsaturated polyester, epoxy, vinyl ester resin and phenolic resins are used.
 Advantages
• They are lighter to transport and most
effectively have a low cost of
installation and maintenance.
• It is used in places or environments
where there is a risk of corrosion or
damage due to the presence of harsh
environmental conditions or fire.
• It’s spark resistant property makes it
free to be used in places of electric or
fire sparks.
• It’s characteristics also makes it last a
longer span of time than most other
metals.
• These easily replace metals like
aluminum and steel in the market.
Disadvantages
• The process is mainly suitable for
constant cross sectional areas.
Tapered and complex shapes cannot
be produced with this method.
• Control of fiber orientation is not
possible in the pultrusion system.
• Quick curing resin systems typically
have lower mechanical properties.
• Voids may result in parts if excessive
opening given at die entrance.
• High initial investments
 Applications
• Highway structures- prodeck bridge system and auto skyway
• Utility poles
• Pipes
• Wind energy Blast protection of structures
• Decking for navy and marina Sea blazing
• Army bridging
• Air force towers
• Bridge deck
• StringerBeam
• Abutment panel
• Rebar Dowel bar
• Pole and post
• Signboard and signpost