Transcript Slide 1

PULTRUSION 101
Presented by Dustin Troutman
214 Industrial Lane, Alum Bank, PA 15521
www.creativepultrusions.com 814.839.4186 Toll Free: 888.CPI.PULL
Fax: 814.839.4276
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WHY CHOOSE CPI?
We are the
BEST IN CLASS at pultruding
large structural profiles.
Our engineering team is
UNMATCHED in the industry.
Our manufacturing
technology is SUPERIOR to
all others.
We are known for our QUALITY.
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PULTRUDING LARGE
STRUCTURAL PROFILES
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ENGINEERING
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We use Solid Works simulation software for our Finite Element
Analysis – Including linear static and Eigen value buckling
capability
Autodesk Design Suite for our geometry and design layouts
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PROCESS
High pressure injection
manufacturing technology permits
a higher fiber volume fraction
which equates to higher strength
and stiffness with tight process
variation.
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QUALITY
The Quality Management System has been
modeled per the requirements of the
ISO9000:2008 International Standard.
In 2012, Creative reinforced their
commitment of providing the highest
Quality of products and services with the
addition of a certified LEAN / Six Sigma Black
Belt who manages related Quality initiatives.
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MACHINE SHOP CAPABILITIES
•
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Over 200 years experience in
design and manufacture of
tooling for pultrusion
CNC machining and grinding
In-house hard chrome plating
MACT compliant direct die
injection tooling is a standard
Tooling designed with
Autodesk Design Suite
“Lifetime Maintenance included in tooling
cost”
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COMPOSITES
A composite is a structural
material that consists of two or
more combined constituents
that are combined at a
macroscopic level and are
not soluble in each other.
Glass fibers
The term pultrusion comes
from combining the words pull
and extrusion.
Resin being directly injected
into the die
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THE PULTRUSION PROCESS
1. Resin and glass fiber
reinforcements are combined
and formed into the shape of
the die on a continuous
process.
2. The resin is initiated by the
thermal decomposition
process. The initiator is heated
until a chemical bond
dissociation produces two
radicals. The chain continues
to build until the monomer is
used resulting in a cured resin.
Rovings
Guide Plate
Resin Impregnator
Surfacing Veil
Forming &
Curing Die
Pulling
System*
Cut-Off Saw
Continuous
Strand Mat
Preformer
*Caterpillar Pullers (shown)
or Reciprocating Pullers
4. Pultruded profiles are cut to
length during the continuous
manufacturing process.
3. The profiles are pulled
through a die.
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MATERIAL PROPERTIES
TENSILE STRENGTH
ULTIMATE (KSI)
120
100
80
60
40
20
0
WHITE PINE
ALUMINUM
6061-T6
STEEL A-36
STAINLESS STEEL
304
PULTRUSION
STANDARD
STRUCTURAL
PULTRUSION
CUSTOM
CONSTRUCTION
PULTRUSION
ALL ROVING
MATERIAL
• Superior Tensile Strength/Stronger than
A-36 Steel
• Linear Stress/Strain Curve with Little to No Yield
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COMPRESSION
STRENGTH
ULTIMATE (KSI)
70
60
50
40
30
20
10
0
WHITE PINE
ALUMINUM
6061-T6
STEEL A-36
STAINLESS STEEL
304
PULTRUSION
STANDARD STRUCTURAL
PULTRUSION
CUSTOM
CONSTRUCTION
PULTRUSION
ALL ROVING
MATERIAL
• Superior Compression Strength/Stronger 6061-T6 Aluminum
• Compression Strength and Compression Buckling Normally Govern
the Design when Strength Governs
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MATERIAL PROPERTIES
35
30
Msi
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MODULUS
OF ELASTICITY
20
15
10
5
0
WHITE PINE
ALUMINUM
6061-T6
STEEL A-36
STAINLESS STEEL
304
PULTRUSION
STANDARD
STRUCTURAL
PULTRUSION
CUSTOM
CONSTRUCTION
PULTRUSION
ALL ROVING
• 1/2 the Modulus of Aluminum and 1/10th
the MOE of Steel
MATERIAL
• Deflection Governs Most Designs
• Buckling Governs Most Strength Driven Designs. Local and Global Buckling
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SHEAR
STRENGTH
ULTIMATE (KSI)
45
40
35
30
25
20
15
10
5
0
WHITE PINE
ALUMINUM
6061-T6
STEEL A-36
STAINLESS STEEL
304
PULTRUSION
STANDARD
STRUCTURAL
PULTRUSION
CUSTOM
CONSTRUCTION
PULTRUSION
ALL ROVING
• Lower Shear Strength than Steel and MATERIAL
Aluminum
• Lower Shear Modulus than Steel and Aluminum; Serviceability Calculations Should
Include Shear Deflection Computations, Especially for Short Spans
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MATERIAL PROPERTIES
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DENSITY
ULTIMATE (KSI)
45
40
35
30
25
20
15
10
5
0
WHITE PINE
ALUMINUM
6061-T6
STEEL A-36
STAINLESS STEEL
304
PULTRUSION
STANDARD
STRUCTURAL
PULTRUSION
CUSTOM
CONSTRUCTION
PULTRUSION
ALL ROVING
MATERIAL
• 75% Lighter
than Stainless Steel
• 25% Lighter than Aluminum
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RESIN OPTIONS
Series 1500/1525
POLYESTER (PE) RESINS –
are manufactured for
corrosion related
applications. Polyester
resins display excellent
structural properties and
are resistant to acids,
salts, and many dilute
chemicals at moderate
temperatures.
The standard 1525 series contains fire retardant
additives that permit the profiles to pass UL94 with
a (V0) rating and ASTM E84 with a class A rating.
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RESIN OPTIONS
Series 1625
VINYL ESTER (VE) RESINS –
are based on bisphenol,
an epoxy resin. VE resins
provide resistance to a
wide range of acids,
alkalis, bleaches and
solvents for use in many
chemical environments.
They also offer excellent
toughness and fatigue
resistance.
The standard 1625 series contains fire retardant
additives that permit the profiles to pass UL94 with
a (V0) rating and ASTM E84 with a Class A rating.
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RESIN OPTIONS
Series 4000
POLYURETHANE (AROMATIC) –
Are a blend of polyol and isocyanate
that when joined, produce a resin
system that offers superior strength and
toughness. Polyurethane resins should
be used when impact strength and
toughness are required.
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RESIN OPTIONS
Series 3000
EPOXY Epoxy resins, also known as polyepoxides are a class of reactive prepolymers and
polymers which contain epoxide groups. They are ideal for high strength, high
temperature applications and perform well in chemical environments.
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RESIN OPTIONS
Series 3535
SPECIALTY RESINS Special application resins
with unique flame smoke
and toxicity (FST) attributes
are available. Low FST
resins are used extensively
in the mass transit industry.
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REINFORCEMENT
OPTIONS
E GLASS – ELECTRICAL
GRADE FIBERGLASS
Pultruded in the form of
Roving, Continuous Filament,
Woven, or stitched fabric
mats, depending on the
mechanical and physical
values being sought.
E-glass fiberglass exhibits high
tensile strength and Modulus
of Elasticity properties. The
volume fraction of fiberglass to
resin dictates the mechanical
and physical properties of the
pultruded profile
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REINFORCEMENT
OPTIONS
CARBON FIBER
Carbon atoms are bonded together in
crystals that are more or less aligned
parallel to the long axis of the fiber. The
crystal alignment gives the fiber high
strength-to-volume ratio. Several
thousand carbon fibers are bundled
together to form a tow, which may be
used by itself or woven or stitched into a
fabric.
The properties of carbon fibers, such as
high stiffness, high tensile strength, low
weight, high chemical resistance, high
temperature tolerance and low thermal
expansion, make them very popular in
aerospace, civil engineering, military,
and motorsports.
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PRODUCT LINES
Standard Structural Profiles Used
for Fabricated Structures
• W and I Beams
• Channels
• Angles
• Tubes
• Flatsheet
• And many more...
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DECKING PRODUCTS
SUPERGRATETM PULTRUDED GRATING
SUPERPANEL CP150
SUPERDECKTM
SUPERPANEL PA004
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DECKING PRODUCTS
SUPERGRATETM MOLDED GRATING
SUPERPANEL WALL PANEL CT066
SUPERDECKTM RAIL PLATFORM PANEL
SUPERPLANKTM DECKING
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DECKING PRODUCTS
SUPERDECKING
HEAVY DUTY PLANK
FLOWGRIP® FLOORING PANEL
TUF-DEKTM FLOORING
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BALLISTIC PANELS
- The Ultimate Panel for Ballistic
and Fragmentation Protection
- UL 752 Level III Compliant
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CUSTOM PULTRUSIONS
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MASS TRANSIT DECKS
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FRP DISTRIBUTION AND
TRANSMISSION POLES
AND CROSSARMS
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SUPERLOCTM SHEET PILE SYSTEM
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PIPE PILES
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TRANSONITE® PANEL SYSTEM
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PULTRUDED STRUCTURES DESIGN
METHODOLOGY OPTIONS
LRFD or ASD
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ALLOWABLE STRESS DESIGN
• Material Properties are
Reduced to Satisfy an
Appropriate Safety Factor
• Typical Safety Factors for
Pultruded Structures
2.5 in Flexure
3.0 in Shear
3.0 for Connections
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LRFD Design
• Load & Resistance Factor
Design (LRFD) of Pultruded Fiber
Reinforced Polymer (FRP) Structures
• Developed by the Pultrusion
Industry Council (PIC) and the
American Society of Civil
Engineers (ASCE)
• A design standard exists for the
pultrusion industry. Our industry
joins ranks with steel, wood,
concrete and aluminum as a
standard material of construction.
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CHARACTERISTIC DESIGN
PROPERTIES ARE DETERMINED
PER ASTM D7290
WHY ASTM D7290?
It is an internationally recognized standard for
evaluating material property characteristic values
for polymeric composites for civil engineering
structural applications.
The characteristic value is a statistically-based
material property representing the 80% lower
confidence bound on the 5th percentile value of a
specified population.
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WHY DO ENGINEERS AND OWNERS
SPECIFY PULTRUDED PROFILES?
• To Reduce Maintenance Costs
• To Reduce Downtime
• To Reduce Future Capital Expenditures
• To Increase Safety
• To Save Money
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SUPERIOR DURABILITY OVER A LONG SERVICE LIFE
• Estimated Service Life of 80+ years
• The theory is based on the Arrhenius principle used by Litherland
et al. in 1981 and Vijay and GangaRao in 1991. (Litherland et all,
have correlated their data with naturally weathered samples of about 10 years.)
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PULTRUSION THE GREEN CHOICE
EMBODIED ENERGY COMPARISON
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APPLICATION PROFILES
BC HYDRO 287kV TRANSMISSION
CHANNEL
TESTED BY
POWERTECH
LABS
DESIGNED
BY CPI
INSTALLED AND
VETTED BY BC
HYDRO
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APPLICATION PROFILE
PULTRUDED
DISTRIBUTION POLES
AND CROSSARMS
FOR NATIONAL GRID
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APPLICATION PROFILE
LIGHTWEIGHT POLE FOR
LIMITED ACCESS SETS
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APPLICATION PROFILE
PULTRUDED HS25-44
BRIDGE DECK 200’ x 60’
INSTALLED IN 14 HOURS
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APPLICATION PROFILE
COMMUNICATION
TOWER FOR EMERGENCY
SERVICES. RADAR AND
RF TRANSPARENCY
DESIGNED BY CREATIVE
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APPLICATION PROFILE
MOVEABLE POOL FLOORS
AND STARTING BULKHEADS
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APPLICATION PROFILE
RAILS TO TRAILS DECKING
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APPLICATION PROFILE
MASS TRANSIT ELEVATED
PLATFORM DECKS
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APPLICATION PROFILE
COVERBOARDS, TIE EXTENSIONS, UTILITY
AND COMMUNICATION STRUCTURES for
the MASS TRANSIT MARKET
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APPLICATION PROFILE
PULTRUDED COOLING TOWER
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APPLICATION PROFILE
NUCLEAR INTAKE RACK
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APPLICATION PROFILE
PEDESTRIAN BRIDGE
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APPLICATION PROFILE
STATUE OF LIBERTY HURRICANE SANDY REBUILD WITH
FRP PIPE PILES - FHWA PROJECT
APPLICATION PROFILE
AZERBAIJAN
3,280 FT
RETAINING WALL 1580
SUPERLOC™ AND
SUPERWALE
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APPLICATION PROFILE
SHEET PILE WALL SERIES
1560 SUPERLOC™
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APPLICATION PROFILE
SHEET PILE WALL AFTER
HURRICANE SANDY 2012
SERIES 1580 SUPERLOC™
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KEYPORT, NJ
PHOTOS OF WALL TAKEN
DURING HURRICAN SANDY
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KEYPORT, NJ
PHOTO TAKEN AFTER
HURRICAN SANDY, 2012
NO DAMAGE TO THE FRP WALL
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APPLICATION PROFILE
MILITARY
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FT. MEYERS, FLORIDA
SHEET PILE WALL
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PIANKATANK RIVER, VIRGINIA
BRIDGE PIER FENDER SYSTEM
CONSTRUCTED OF
POLYURETHANE PIPE PILES
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APPLICATION PROFILE
PINELLAS BAYWAY BRIDGE
PIPE PILE FENDER
INSTALLATION
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APPLICATION PROFILE
PINELLAS BAYWAY BRIDGE
PIPE PILE FENDER
INSTALLATION
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WHAT CAN WE DO FOR YOU?
WE CAN DESIGN YOUR CUSTOM PROFILE
BASED ON FINITE ELEMENT ANALYSIS
AND PROVEN ENGINEERING MEANS
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TEST THE DESIGN IN ONE OF
OUR IN-HOUSE TEST FACILITIES
FULL SECTION AND COUPON LEVEL TESTING
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PULTRUDE YOUR PROFILE
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FABRICATE YOUR PROFILE OR STRUCTURE
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FACILITIES OVERVIEW
Creative Pultrusions, Inc. was
established in 1973 and is located
in Alum Bank, Pennsylvania.
FACILITIES (SQ. FT) = 160,000
PRODUCTION MACHINES = 18
EMPLOYEES = 148
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HILL & SMITH HOLDINGS PLC
• Hill & Smith Holdings PLC is an international group with leading positions in the
design, manufacture and supply of infrastructure products and galvanizing
services to global markets. It serves its customers from facilities principally
Australia, France, India, Norway, Sweden, Thailand, the UK and the USA.
• The Group's operations are organized into two main business segments:
Infrastructure Products & Galvanizing Services.
• 2014 Revenue of £454.7m ($682m)
• Infrastructure – 71%
Roads - 28%
Utilities - 43%
• Galvanizing - 29%
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WHERE HILL & SMITH OPERATES
• AUSTRALIA: office in Queensland for
• NORWAY: a division of ATA, the road
the development of our wire rope and
safety barrier products.
safety barrier and signage business.
• THAILAND: location of the major part of
• FRANCE: the base of France Galva
our pipe supports manufacturing capability,
where we have plants near Bangkok.
and Conimast, where we have ten
galvanizing plants and a lightning
column business.
• INDIA: manufacturing facility for
pipe supports and offices for
development of our Hill & Smith
infrastructure product business.
• SWEDEN: location of ATA, the road safety
barrier and signage business.
• UK: head office and various group site
V
locations covering our main infrastructure
products businesses and network of UK
galvanizing plants.
• USA: our V&S galvanizing and utilities
plants are situated on the east coast along
with the Bergen and Carpenter & Paterson
pipe support businesses and the fiber
reinforced composite profiles business,
Creative Pultrusions.
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HILL & SMITH REVIEW OF 2014
INFRASTRUCTURE PRODUCTS
For the core markets Roads and Utilities – supplying products and services such as permanent and
temporary road safety barriers, fencing, industrial platforms and flooring, street lighting columns, bridge
parapets, glass reinforced composite railway platforms and flood prevention barriers, variable road
messaging solutions, traffic data collection systems, plastic drainage pipes and pipe supports for the power
and liquefied natural gas markets, energy grid components and security fencing.
Operating in subsidiaries in Australia, France, India, Norway, Sweden, Thailand, the UK and the USA.
In 2014 the division accounted for 71% (2013: 71%) of the Group’s revenue and 46% (2013: 43%) of the
Group’s underlying operating profit.
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QUESTIONS?
CELEBRATING OVER 42 YEARS OF PROVIDING PULTRUSION SOLUTIONS
www.creativepultrusions.com