1. FiBrEgLaSs Materials Assingment By: David Wilksch

2. Manufacturing Processes; Fibreglass is a material made up of extra fine glass fibres bonded together by a resin. Fibreglass is strong in tension and compression, but weak in shear- across it axis. Fibreglass is a composite material and is formally known as either; Glass reinforced plastic Fibre reinforced plastic/polymer These two types have differing methods of construction

3. Manufacturing Processes; Glass Reinforced Plastic (GRP); Made by using large furnaces to slowly melt the sand/chemical mix until it becomes liquid. Its then extruded through bundles of tiny orifices as small as 9 micro-metres thick, before getting sized with a chemical solution. They then get bundled together into rovings (process where filaments are spun into larger Ø threads before being implemented to a construction method, which includes....................

4. Manufacturing Processes; GRP Construction Methods; Hand lay up operation-(sheets of fibre glass, wetted with resin, placed in mold and pressed with steel rollers) Spray lay up operation- similar to hand lay up, but resins and reinforcement are sprayed onto the mould with a chopper gun) Pultrusion- (fibres are pulled from spools and coated with resin, then heat treated and cut to length)

5. Manufacturing Processes; GRP Mould Making Process; A ‘plug’ or ‘buck’ (which is an exact negative copy of the desired product to be made) is used. It is usually made out of ‘a certain type of foam’ It then gets sprayed with a releasing agent and a coloured gel coat for a harder, durable finish After this point the mold is ready to be used in construction.

6. Manufacturing Processes; Fibre Reinforced Plastic/Polymer (FRP); Is made up of a polymer matrix reinforced with fibres The fibres are usually fibreglass, carbon or arimid, while the polymer is a epoxy, vinylester or polyester thermosetting plastic. To make FRP there are 2 distinct processes..............................

7. Manufacturing Processes; Fibre Reinforced Plastic/Polymer (FRP); Process 1- ‘The fibrous material is manufactured and formed’ Process 2- ‘The fibrous material is bonded with the matrix during the molding process’

8. Manufacturing Processes; Fibre Reinforced Plastic/Polymer (FRP); Process 1- ‘The fibrous material is manufactured and formed’ This can be achieved in both 2 and 3 dimensional oreintations. The main difference between the two methods is that the FRP is aligned along the X and Y axis for 2D, where for 3D the FRP is layed on the Z axis as well.

9. Manufacturing Processes; Fibre Reinforced Plastic/Polymer (FRP); Process 2- ‘The fibrous material is bonded with the matrix during the molding process’ 4 main ways you can do this. Which are: Weaving-(weaved as per Process 1) Braiding-(fibres fed through mandrels that vary in size. 45˚pattens possible unlike conventional weaving) Knitting-(Talk to your granny) Stitching-(This too)

10. Manufacturing Processes; FRP Mould Making process; 2 categories- Composite- Uses ‘pre-preg’ FRP which means plastics are fibre reinforced before being put through the mould Wet- Combines the fibre reinforcement and the matrix during the moulding process Some types of each are listed in the next slide................................................

11. Manufacturing Processes; FRP Mould Making process; Composite:Wet: BladderChopper gun CompressionFilament Winding Autoclave/Vacumn bag Pultrusion

12. Manufacturing Processes; The two most popular types of fibreglass are; E-Glass- good insulation properties and will maintain its properties up to 816 ˚C S-Glass- high tensile strength, stiffer than E glass and is the type to use if looking for max strength. Other variants include C-Glass (chemical resitant), T-Glass (American C-Glass), A- Glass (bottles made into fibreglass), AR- Glass (alkali resistant glass)

13. Uses; Insulation- thermal, electrical and general Door surrounds, window and over-door canopies, dormers, chimneys, coping systems, keystones and sills. Translucent roofing panels FRP tanks for both rainwater and sewerage Pipes for drinking water, sewerage and gas Bath hobs, spas and pools

14. Defects; Structural failure can occur in FRP materials when: Tensile forces stretch the matrix more than the fibres, causing the material to shear at the interface between matrix and fibres. Tensile forces near the end of the fibres exceed the tolerances of the matrix, separating the fibres from the matrix. Tensile forces can also exceed the tolerances of the fibres causing the fibres themselves to fracture leading to material failure.

15. Enviromentals; Fibreglass has a few issues when the time comes to bin the fibreglass product you may have. Its hard for fibreglass returned to a virginal state, because the fibres are difficult to separate from the matrix which faces the same challenges in separating it into usable plastic, polymers and monomers. Fibreglass does offer monetry and energy savings compared to its competition Bio plastics and UV-degradable plastics will help in the future though

16. Handling Recommendations; For fibreglass bats (glass-wool) there are a few things to keep in mind when handling it; Skin Wear loose-fitting, long-sleeved clothing and long pants. Do not tape sleeves or pants at wrists or ankles. Wear gloves. Do not scratch or rub your skin if fibre glass particles accumulate on your skin. When you finish, wash skin or shower with mild soap and warm, running water.

17. Handling Recommendations; Eyes Wear safety glasses with side shields. Do not rub your eyes while you are working with fibreglass. Be sure to complete clean up before rubbing your eyes or scratching your skin. Nose/Mouth/Throat Wear a respirator

18. Handling Recommendations; Installation & Clean-up Do not handle fibreglass scrap more than necessary. Be organized in cleaning your work area so that you dont spread fibres Make sure all installed insulation is never left exposed in an occupied area. Wash work clothes separately and wipe out washer after cycle is complete.

19. Australian Standards; AS4859.1-Materials For Thermal Insulation AS 4748-2001-Acoustic emission testing of fibreglass-insulated booms on elevating work platforms AS 3999-1992-Thermal insulation of dwellings - Bulk insulation AS 2764-2002-Fibre reinforced plastics (FRP) aluminium alloy gas cylinders - Hoop overwrapped

20. Bibliography; www.wikipedia.org www.lungusa.org