GLASS REINFORCED PLASTIC

(GRP)

Prepared & Presented By: Abdallah Sayed Ahmed El-gharbawy

 What Is Problem

• Corrosion.

• Fluid Contamination
 What Is Problem

• Fracture under Thermal Stress or

Mechanical Stresses
 COMPOSITE MATERIALS
• Reinforcement Fibers: Glass fiber

• Polymer matrix: Thermoset/Thermoplastic.

• Other Components: Filler/Pigment

OTHER COMPONENTS
• Fillers: Inorganic materials, such as hydrated alumina, glass
microspheres, clay, talc, calcium carbonate, sand, and calcium silicate,
may yield economic, appearance, or performance advantages in fiberglass
pipe.

• Promoters, accelerators, and inhibitors: Promoters and accelerators

advance the action of the catalyst to reduce the processing time. Inhibitors
provide control over the cure cycle and increase the shelf life of the resin
mix.
OTHER COMPONENTS
• Pigments: The pigment choice affects the difference in reflected and
transmitted color, clarity of the resin mix, reaction between dyes and other
additives, such as catalysts, and the end-product color fastness and heat
resistance.
 POLYMERS
Thermoplastic Thermosets

• Polyethylene Epoxides
• Polypropylene
• Polycarbonate
• Polyamide
• Polybutylene terephthalate
 GLASS DEFINITION
• Glass is an amorphous, hard, brittle,
transparent obtained by fusing a
mixture of a number of metallic
silicates or borates of Sodium,
Potassium, Calcium, and Lead. It
possess no definite formula or
crystalline structure.
PROPERTIES OF GLASS

• Amorphous
• Brittle
• Transparent / Translucent
• Good electrical insulator
• Unaffected by air, water, acid or chemical reagents except HF
• No definite crystal structure means glass has high Compressive
strength
• Can absorb, transmit and reflect light
RAW MATERIALS USED IN MANUFACTURING
GLASS
• Silicon dioxide (SiO2).
• Sodium as Na2Co3 (used in soft glass).
• Potassium as K2Co3 (used in Hard Glass).
• Calcium as lime stone, chalk and lime (CaO).
• Zinc is zinc oxide (Heat and shock proof glass).
• Borates are borax, Boric acid (Heat and shock proof
glass).
Manufacturing Steps
 Melting

 Forming and Shaping

 Annealing

 Finishing
Melting process
• Raw materials in proper proportions are mixed with cullets. It is finely powdered and
intimate mixture called batch is fused in furnace at high temperature of 1800°C this
charge melts and fuses into a viscous fluid.

CaCO3 + SiO2  CaSiO3 + CO2 

Na2CO3 + SiO2  Na2SiO3 + CO2

• After removal of CO2 decolorizes like MnO2 are added to remove traces of ferrous
compounds and Carbon. Heating is continued till clear molten mass is free from
bubbles is obtained and it is then cooled to about 800°C.
 Forming, shaping, and annealing
Forming and Shaping
The viscous mass obtained from melting is poured into moulds to get different
types of articles of desired shape by either blowing or pressing between the
rollers.

Annealing
Glass articles are then allowed to cool gradually at room temperature by
passing through different chambers with descending temperatures. This
reduces the internal Strain in the glass.
Finishing

Finishing is the last step in glass manufacturing. It involves following steps:

 Cleaning

 Grinding

 Polishing

 Cutting

 Sand Blasting
HISTORY
• It was announced FRP invention on February 5, 1909.
• The first fibre-reinforced plastic plane was either the Fairchild F-46, first
flown on 12 May 1937.
• The first car to have a fibre-glass body was the 1946.
• Global polymer production on the scale present today began in the mid
20th century, when low material and productions costs, new production
technologies and new product categories combined to make polymer
production economical. The industry finally matured in the late 1970s
when world polymer production surpassed that of steel
HISTORY
• Fiberglass pipe was introduced in 1948. The earliest application for
fiberglass piping, and still one of the most widely used, is in the oil
industry.
• Since the 1960s, fiberglass pipe products have been used for municipal
water and sewage applications thus eliminating the need for interior
linings, exterior coatings, and cathodic protection.
• Fiberglass pipe is available in diameters ranging from 1 in. through 144
in. (25 mm through 3,600 mm).
Financial & Application
Advantages

• Light weight to strength ratio

• Corrosion resistant
• Water resistant
• Non-conductive
 CHARACTERISTICS
• Corrosion resistance: Fiberglass pipe systems are resistant to
corrosion, both inside and out, in a wide range of fluid-handling
applications. As a result, additional linings and exterior coatings are not
required.

• Strength-to-weight ratio. Fiberglass composite piping systems have

excellent strength-to-weight properties. The ratio of strength per unit of
weight of fiberglass composites is greater than that of iron, carbon, and
stainless steels.
 CHARACTERISTICS
• Lightweight. Fiberglass composites are lightweight. Fiberglass piping
is approximately one-sixth the weight of similar steel products and
one-tenth the weight of similar concrete products.

• Electrical properties. Standard fiberglass pipes are nonconductive.

Some supplier offer conductive fiberglass piping systems for
applications that require dissipation of static electricity buildup when
transporting certain fluids, such as jet fuel.
CHARACTERISTICS

• Dimensional stability. Fiberglass composites can maintain the

critical tolerances required of the most demanding structural and
piping applications. The material meets the most stringent material
stiffness, dimensional tolerance, weight, and cost criteria.

• Low maintenance cost. Fiberglass piping is easy to maintain

because it does not rust, is easily cleaned, and requires minimal
protection from the environment
 GLASS FIBER
MANUFACTURING
Filament Winding

• Filament winding is the process of impregnating glass fiber

reinforcement with resin, then applying the wetted fibers onto a
mandrel in a prescribed pattern. Fillers, if used, are added during the
winding process.

• A multilayered structural wall construction of the required thickness.

• Finished pipe emerging from the curing oven

Filament Winding
CENTRIFUGAL CASTING
• Centrifugal casting is used to manufacture tubular goods by
applying resin and reinforcement to the inside of a mold that is
rotated and heated.

• Other materials, such as sand or fillers, may be introduced in the

process during manufacture of the pipe.
CENTRIFUGAL CASTING
 GLASS FIBER MATERIAL
• Glass fibres begin as varying combinations of SiO2, Al2O3, B2O3, CaO, or
MgO in powder form. These mixtures are then heated through direct
melting to temperatures around 1300 degrees Celsius, after which dies are
used to extrude filaments of glass fibre in diameter ranging from 9 to
17 µm. These filaments are then wound into larger threads and spun onto
bobbins for transportation and further processing. Glass fibre is by far the
most popular means to reinforce plastic and thus enjoys a wealth of
production processes, some of which are applicable to aramid and carbon
fibres as well owing to their shared fibrous qualities.
 GLASS FIBER MATERIAL
• Roving is a process where filaments are spun into larger diameter threads. These threads
are then commonly used for woven reinforcing glass fabrics and mats, and in spray
applications.
• Fibre fabrics are web-form fabric reinforcing material that has both warp and weft
directions. Fibre mats are web-form non-woven mats of glass fibres. Mats are
manufactured in cut dimensions with chopped fibres, or in continuous mats using
continuous fibres. Chopped fibre glass is used in processes where lengths of glass threads
are cut between 3 and 26 mm, threads are then used in plastics most commonly intended
for moulding processes. Glass fibre short strands are short 0.2–0.3 mm strands of glass
fibres that are used to reinforce thermoplastics most commonly for injection moulding
FIBER ORIENTATION
• Aligned in the direction of load
• Aligned in the direction perpendicular to load
• Randomly distribution of fibers.
It is observed that fibers aligned parallel to applied load offered more tensile
strength and toughness than randomly distributed or perpendicular fibers.
 THERMAL PROPERTIES

GRP Carbon Steel

Thermal Expansion α/(10−6 K−1) 8-14 14.1

Application Temperature (C) -40 to 150 -29 to 420

Thermal conductivity W/K•m 0,25-0,35 54

MECHANICAL PROPERTIES
 GRP STEEL HDPE PVC

1 Design Life Time 50 15-20 8-10 5-8

2 Specific Gravity 1.8 7.85 7.1 1.4

3 Tensile Strength 380-550 344 3.5 50

(Mpa)
4 Modulus of 5* 22* 7* 5*
Elasticity
5 Maintenance No Periodical Repair not possible Repair not possible
inspection

6 Corrosion No Yes No No

7 Surge pressure Excellent High protection Poor Poor

needed

8 Temperature (C) 150 150-200 80 50