Composite materials – possibilities in the scaffold industry Carl Østervig M.Sc. Mech. Eng, CTO & Partner Nordic Platform P/S Denmark

A relatively new company but with many years of experience in: Scaffold industry Composite materials HQ in Søndersø, DK (PUR resin pultrusion) 2 factories in Guandong provins China (PE/VE pultrusion) Who are we?

What is a composite material? (here limited to thermohardening resins) Resins Polyester Vinylester Epoxy Polyurethane Reinforcements Glass fibers Carbon fibers Additives Release agents

Manufacturing processes Compresion Moulding Hand lay up Pultrusion Filament Winding

Manufacturing processes Pultrusion

Examples, passenger aircraft

Examples, wind turbine blades

Some advantages by using GRP Low weight to strength ratio Easy handling Damage tolerant Corrosion resistance UV, alkali and acid resistant High design flexibility Cost effective Flame resistant Custom colors without subsequent paint Electrically non conductive Water absorption very low Long service life Risc of theft very low Recycling possibilities

Some challenges by using GRP Requires expert knowledge to obtain near optimal products Market conservatism Relatively new to certifying bodies Relatively high production costs at sub suppliers in EU

Finite element analysis Example: La Bank

Finite element analysis Example: 3000x600mm platform

Some tests Tests in Germany Tests in China

Some tests Tests in Sweden Ceritificate SC

Some tests Tests in Norway

Some tests Tests in Denmark

Mechanical properties Tensile tests with strain gauge measurements

Load tests 2.17x0.49 m deck Acc to EN Load class 6 requirements

Environmental resistance tests HCl Tests with 30% HCl causes no damage CaOH 2 Tests with saturated solution causes no damage UV Tests acc. to ISO hours exposure causes no damage or decrease in mechanical properties Tests continues for 2000 hours exposure Heat. Exposure 500 hours at +80 o C exposure causes no damage or decrease in mechanical properties Tests continues for 2000 hours exposure

Conclusion Use of composite materials in scaffold industry has a very large potential Optimal design requires expert knowledge