TECHNICAL DETAILS DOCUMENT

SECTION TABLE OF CONTENTS PAGE NUMBER

1 Manufacturing Process 3
2 Reinforcements 4
3 Typical Coupon Properties 6
4 General Tolerances 8
5 Section Properties 9
6 Allowable Loads 18
7 Fixing Mechanism 43

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 1. MANUFACTURING PROCESS

Pultrusion is the continuous process by pulling resin rich reinforcements through a

heated steel die to form profiles of constant cross section of continuous length.

Pultrusion gets its name from the method by which the profiles are made. Resin
rich reinforcements are literally pulled by puller. The puller is made of pulling pads,
which grip the product, and a drive system that keeps the puller along with the
product moving. The puller is located just before the cut off saw.

The process starts with the reinforcements (unidirectional glass roving called
fibers) that run along the length of the profile. Then, the fiberglass mat is added,
which is a multidirectional reinforcement. Next, the glass reinforcement is
“wet-out” with a thermoset resin, typically polyester or vinylester. Finally, just
before all the material is pulled into the heated die, a surface veil may be added to
enhance the surface appearance of the final product.

Next in the pultrusion process is the curing of the composite. The curing or
hardening occurs while the wet out reinforcement is being pulled through the
heated die. The heat from the die causes the resin to cure and by the time the
part exits the die, a hard part in the exact die shape with reinforcements
laminated within.

The puller then pulls the product exiting the die to the cut off saw, which cuts it to
the desired length.

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 2. REINFORCEMENTS

Roving

Roving is made up of fiberglass unidirectional filaments, which are manufactured

in continuous rolls. Roving is always present in Pultruded products comprising
50%to 70% of the total glass content. In addition to supplying the necessary
strength to pull the profile, roving supplies the product with high tensile, flexural
properties and a big contributor to overall section stiffness in longitudinal
direction.

Generally, fiberglass roving is used in pultrusion to achieve the required properties.

In special structural applications where more stiffness is required, roving with
higher stiffness properties can be used. Conversely, polyester roving may be used
in applications where more flex is needed.

Mat

Continuous strand mat is used in the pultrusion process. Typically, it is 30% to 50%
of the total glass content. Unlike hand laid up or press molded processes that use
short chopped fibers, the pultrusion process must have a multidirectional mat that
has good pull strength to facilitate getting it to the die after it has been wet out
with the resin. This continuous strand mat is designed specifically for the
pultrusion process and offers good wet out characteristics, conformability to a
variety of shapes, and good physical properties including the required pull
strength.

Generally, fiberglass continuous strand mat is used to obtain the desired

transverse properties of the product. Whereas the roving ties the composite
together in the longitudinal direction, the mat is responsible for tying the
composite together in all directions, but mainly in the transverse direction.
Although continuous strand mat is suitable for most applications, a variety of
products such as woven roving, stitched roving, and woven fabrics can be used in
custom applications to increase the desired transverse properties.

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Veil

Veils are used to enhance the surface of profiles. Most widely used today are
synthetic veils. A veil is added to the outside of the profile just prior to entrance
of the die. As a result, the finished profile has a resin rich surface that aids in
resistance to ultraviolet (UV) degradation and makes the profile more hand
friendly. Since the veil brings more resin to the surface and the resin is the
ingredient that gives corrosion resistance, adding the veil increases the corrosion
resistance.

All standard structural shapes are manufactured using a surface veil as well as
UV inhibitors to protect against UV degradation.

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3. TYPICAL COUPON PROPERTIES

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4. GENERAL TOLERANCES

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 5. SECTION PROPERTIES

Notations
A Cross sectional area (mm^2)
B Width of section (mm)
d Depth of section/diameter of rod (mm)
h Length of angle leg (mm)
I Moment of inertia (mm^4)
od Outside diameter of tube (mm)
r Radius of gyration (mm)
S Section modulus (mm^3)
t Thickness (mm)
tb Thickness of width dimension (mm)
tw Thickness of depth dimension (mm)
Wt. Weight of section (kg./m)

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6. ALLOWABLE LOADS

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7. FIXING MECHANISM

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