NO: AC.2006.PG.01 شرکت کامپوزیت آسیا ( سهامی خاص ) تولید کننده انواع قطعات کامپوزیتی FRP سینی کابل )

Transcription

1 NO: AC.2006.PG.01 شرکت کامپوزیت آسیا ( سهامی خاص ) تولید کننده انواع قطعات کامپوزیتی FRP سینی کابل ) گریتینگ, ( پروفیل, SPECIFICATIONS OF PULTRUDED GRATINGS E- mail: Info@asiacomposite.com

2 THE PULTRUSION PROCESS Pultrusion is a manufacturing process for producing continuous lengths of reinforced polymer structural shapes with constant cross-sections. Raw materials are a liquid resin mixture (containing resin, fillers and specialized additives) and flexible textile reinforcing fibers. The process involves pulling these raw materials (rather than pushing, as is the case in extrusion) through a heated steel forming die using a continuous pulling device. The reinforcement materials are in continuous forms such as rolls of mat and doffs of roving. As the reinforcements are saturated with the resin mixture ("wet-out") in the resin bath and pulled through the die, the gelatin or hardening, of the resin is initiated by the heat from the die and a rigid, cured profile is formed that corresponds to the shape of the die. While pultrusion machine design varies with part geometry, the basic pultrusion process concept is described in the following schematic. The creels position the reinforcements for subsequent feeding into the guides. The reinforcement must be located properly within the composite and this is the function of the reinforcement guides. The resin bath saturates (wets out) the reinforcement with a solution containing the resin, fillers, pigment, and catalyst plus any other additives required. The interior of the resin bath is carefully designed to optimize the wet-out of the reinforcement. 1

3 On exiting the resin bath, the composite is in a flat sheet form. The performer is an array of tooling which squeezes away excess resin as the product is moving forward and gently shapes the materials prior to entering the forming and curing die. In the forming and curing die, the thermosetting reaction is heat activated (energy is primarily supplied electrically) and the composite is cured (hardened). On exiting the die, it is necessary to cool the hot part before it is gripped by the pull blocks (made of durable urethane foam) to prevent cracking and/or deformation by the pull blocks. Strong well uses two distinct pulling systems, one that is a caterpillar counter-rotating type and the other a hand-overhand reciprocating type to pull the cured profile to the saw for cutting to length. Pultruded Grating The pultruded grating product is a mostly mechanized process. Reinforcement of different shapes such as: strand, mat and veil are pulled through a liquid resin bath and a heated die where the bar is shaped and the resin is cured. These pultruded bars can be cut into requested lengths. The bars are then drilled on the sides to accept the crossbars. The drilled bars are spaced. The final step is to seal the entire crossbars and holes with corrosion resistant epoxy resin. The pultruded grating provides increased load capacity with moderate levels of corrosion resistance. The components (bearing bars and cross bars) are pulled by machine to have a higher reinforcement content. Its superior load capacity is a result of the higher reinforcement to resin ratio. The pultrusion process is automated and produces a consistent, high quality finished product. Assembled from bars, the pultruded grating can offer a wide variety of panel sizes and substantially reduce "scrap loss". 2

4 APPLICATIONS OF PULTRUDED GRATING Applications Markets Flooring Chemical Platform Electronics Walkways Marine (including Assembly Lines military vessels) Trench Covers Oil & Gas Stairs Petroleum Processing Catwalks Plating Ramps Pulp and Paper Greenhouse Shelving Water/Wastewater Pool Drainage Zoos/Aquariums Portable Building Recreational Facilities Floors Manufacturing Benefits and Characteristics of FRP Pultruded Grating Non-Slip Standard Bearing Surfaces Corrosion Resistance Design Fire Resistance Cost Savings Non-Magnetic Non-conductive Impact Resistance Low Installation Costs Non-sparking Superior Strength Maintenance Free Mechanical Strength Light Weight Conductive Grating Raised Floors High Performance 3

5 DESCRIPTION NON-SLIP Composite Grating s integral grit top surface provides outstanding anti-slip protection for personnel in wet and oily environments. The grit is embedded in the top surface of each panel prior to curing. This combination of integral construction, plus depth of the embedded grit, creates a long-lasting maximum anti-slip top surface. CORROSION RESISTANCE The ability of Composite grating is to guard against deterioration from industrial chemicals and environmental factors makes it a logical and cost-effective alternative to carbon steel, aluminium, wood or other conventional materials. Whether the grating is exposed to continuous submersion, splash, spills, fumes or gases, you can be assured that Composite grating will outperform other mediums. FIRE RESISTANCE Composite Grating is available in various resin systems, two of which meet the Class 1 flame spread rating of 25 or less, in accordance with ASTM E-84 Tunnel Test Method. If a flame spread of 10 or less is required, it will be available in request. NON-MAGNETIC The non-magnetic properties allow the Composite grating to be used in sensitive installations where the inherent magnetic properties of metallic grating would prove unsuitable. IMPACT RESISTANCE The impact resistance of Composite Grating allows repeated deflection without permanent deformation. A certain amount of deflection can occur with loading. However, once the load is removed, the grating will return to its original shape, unlike metallic grating, which will remain deformed and require costly repairs or replacement. 4

6 NON-SPARKING The non sparking qualities of Composite Grating systems are ideally suited for those installations where hydrogen or other combustible gases may be found and which may explode or cause a fire from sparks produced from accidental dropping of tools onto the grating. MAINTENANCE FREE The use of Composite Grating virtually eliminates maintenance costs since painting is not required, and UV inhibitors protect against degradation from the sun. LIGHTWEIGHT Composite Grating weighs about one-quarter as much as steel grating. Two men can easily handle full panels, without the need for hoists, pulleys or dollies. If the Composite Grating needs to be moved for cleaning, maintenance or utility access, there is less chance of back injuries. The lightweight design of the grating reduces installation and fabrication costs, weighing only 12 kilos per sq mtr for 25mm and 18 kilos per sq mtr for 38mm. RAISED FLOORS Many plant operations have a need for slightly elevated Floor Grating. Fixed or adjustable pedestals can be used for applications up to a height of 600mm. Plastic insert mouldings, which raise the Composite Grating panels 7mm off the floor, are ideal for allowing liquid drainage below the Grating. STANDARD BEARING SURFACES On most installations, a minimum of 38mm bearing support should be provided under the edges of Composite Grating panels. 5

7 DESIGN The design procedures associated with Composite Grating are entirely different from those associated with other materials. The prime consideration in designing with this reinforcement is allowable deflection as opposed to ultimate loading used with steel and aluminium. The reason for this is the inherent elasticity of reinforced plastic, permitting far greater deflection than steel, without the danger of structural failure. Load and deflection tables are available on request. COST SAVINGS In a review of costs, Composite grating showed significant savings over the use of stainless steel grating, and when consideration is given to life cycle costs, combining anti-slip benefits, the saving over the use of metal grating alternatives is quite considerable. NON-CONDUCTIVE The non-conductive properties make Composite Grating ideally suited for work platforms and flooring situated in electrically hazardous locations. LOW INSTALLATION COSTS Composite Grating weights considerably less than conventional metal gratings, and is easier and less expensive to transport, install and remove. Only simple hand tools are required for installation and removal, eliminating the need for costly equipment and labour costs associated with heavy lifting, cutting and welding. SUPERIOR STRENGTH The high glass-to-resin ratio of Composite grating provides superior strength and load-bearing characteristics. With structural integrity protected by its unique corrosion resistance capabilities, Composite grating lasts longer than traditional materials. 6

8 MECHANICAL STRENGTH Breaking strength under a lateral force is exceptional. The uni-directional continuous Composite reinforcement offers numerous advantages, including rigidity, shock-resistance and no permanent deformation after overloading. These factors provide excellent mechanical strength and a generous factor of safety. Composite Grating is designed for maximum safety in intensive industrial use. CONDUCTIVE GRATING Composite Conductive Grating provides a specially formulated carbon, black surface, which will eliminate hazardous static electricity when properly grounded. This anti-static property is most advantageous in high-tech electronic industries where sophisticated equipment may be damaged due to static electricity. It also provides a safe environment in combustible areas by not allowing static sparks. Conductive Grating can be used in Railway Fuel Stations, Circuit Board Manufacture, Oil Refineries, Underground Mining Operations, Ammunition Factories etc. HIGH PERFORMANCE Composite structural Composite grating materials have demonstrated a proven ability to withstand the harsh side effects of corrosive conditions better than galvanized steel. For many years, composites have been reliably used in traditionally corrosive industries such as chemical processing, plating and marine construction. While the cost of material is an important criteria in the design of a project, it does not reflect the total cost of the project. Beyond material purchase price, the engineer also should consider the related costs of installation, maintenance over time and replacement of debilitated materials. 7

9 PULTRUDED GRATING SELECTION Type Thickness Bar Width (mm) Open Space (mm) Open Area (%) Appro. Wt. (kg/m 2 ) G1.5 I " G1.5 I " G1.5 I " G1.0 I " G1.0 I " G1.0 I " G40I mm G40I mm G65I mm G65I mm G1.5 I

10 PULTRUDED GRATING CHEMICAL RESISTANCE GUIDE CHEMICAL VINYL ESTER RESIN ISOPHATHALIC POLYESTER ENVIRONMENT % CONCENTRATION MAX. OPEN. TEMP. F/C % CONCENTRATION MAX. OPEN. TEMP. F/C Acetic Acid / /52 Aluminum Hydroxide / /71 Ammonium Chloride ALL 190/88 ALL 170/77 Ammonium Hydroxide Ammonium Bicarbonate /38 28 N/R / /52 Ammonium Sulfate ALL 200/93 ALL 170/77 Benzene N/R N/R N/R N/R Benzoic Acid SAT 200/93 SAT 150/66 Borax SAT 200/93 SAT 170/77 Calcium Carbonate ALL 180/82 SAT 170/77 Calcium Nitrate ALL 200/93 ALL 180/82 Carbon Tetrachloride /24 N/R N/R Chlorine, Dry Gas / /60 Chlorine Water SAT 180/82 SAT 80/27 Chromic Acid / /21 Citric Acid ALL 200/93 ALL 170/77 Copper Chloride ALL 200/93 ALL 170/77 Copper Cyanide ALL 200/93 ALL 170/77 Copper Nitrate ALL 200/93 ALL 170/77 Ethanol 50 90/ /24 Ethylene Glycol / /32 Ferric Chloride ALL 200/93 ALL 170/77 Ferrous Chloride ALL 200/93 ALL 170/77 Formaldehyde ALL 100/ /24 Gasoline / /27 Glucose / /77 Glycerin / /66 Hydrobromic Acid / /49 Hydrochloric Acid / /24 Hydrogen Peroxide / /38 Lactic Acid ALL 200/93 ALL 170/77 Lithium Chloride SAT 200/93 SAT 150/66 Magnesium Chloride ALL 200/93 ALL 170/77 9

11 CHEMICAL VINYL ESTER RESIN ISOPHATHALIC POLYESTER ENVIRONMENT % CONCENTRATION MAX. OPEN. TEMP. F/C % CONCENTRATION MAX. OPEN. TEMP. F/C Magnesium Nitrate ALL 180/82 ALL 140/66 Magnesium Sulfate ALL 190/88 ALL 170/77 Mercuric Chloride / /66 Mercurous Chloride ALL 180/82 ALL 140/60 Nickel Chloride ALL 200/93 ALL 170/77 Nickel Sulfate ALL 200/93 ALL 170/77 Nitric Acid / /21 Oxalic Acid ALL 120/96 ALL 75/24 Perchloric Acid 30 80/27 N/R N/R Phosphoric Acid / /49 Potassium Chloride ALL 200/93 ALL 170/77 Potassium Dichromate ALL 200/93 ALL 170/77 Potassium Nitrate ALL 200/93 ALL 170/77 Potassium Sulfate ALL 200/93 ALL 170/77 Propylene Glycol ALL 200/93 ALL 170/77 Sodium Acetate ALL 200/93 ALL 160/71 Sodium Bisulfate ALL 200/93 ALL 170/77 Sodium Bromide ALL 200/93 ALL 170/77 Sodium Cyanide ALL 200/93 ALL 170/77 Sodium Hydroxide /66 N/R N/R Sodium Nitrate ALL 200/93 ALL 170/77 Sodium Sulfate ALL 200/93 ALL 170/77 Stannic Chloride ALL 190/88 ALL 160/71 Sulfuric Acid / /24 Tartaric Acid ALL 200/93 ALL 170/77 Vinegar / /77 Water, Distilled / /77 Zinc Nitrate ALL 200/93 ALL 170/77 Zinc Sulfate ALL 200/93 ALL 170/77 ALL Concentrations; SAT Saturated Solution; N/R Not Recommended; - No Information Available. 10

12 Physical Properties of Pultruded Grating Property Test Method Units I-Bar % Glass I-Bar % Glass Tensile Strength ASTM D-638 PSI 125, ,000 Tensile Modulus ASTM D-638 PSI Flexural Strength ASTM D-790 PSI 125, ,000 Flexural Modulus ASTM D-790 PSI Compressive Strength ASTM D-695 PSI 65,000 60,000 Izod Impact Notch ASTM D-256 Ft.-Lbs./In Barcol Hardness 50 (Min.) 50 (Min.) Specific Gravity ASTM D Water Absorption ASTM D-570 Max. % Flame Retardant ASTM E-84 Less than 25 Less than 25 Flame Retardant ASTM D-635 Self-Extinguishing Self-Extinguishing 11

13 LOAD DESCRIPTION NOTES: 1- The designer should not exceed MAXIMUM RECOMMENDED load at any time. MAXIMUM LOAD represents a 2:1 factor of safety on ULTIMATE CAPACITY. 2- ULTIMATE CAPACITY represents a complete and total failure of the grating. 3- Walking loads, typically 2.4 KN/M 2 is recommended for pedestrian traffic. Deflections for worker comfort are typically limited to 9mm or SPAN divided by 120 under full live load. For a firmer feel under full live load or a 3.6 KN/M load, limit deflection to 6mm or SPAN divided by The allowable loads are for STATIC LOAD CONDITIONS at ambient temperatures. Allowable loads for impact or dynamic loads should be a maximum of ONE-HALF the value shown. Long term loads will result in added deflection due to creep in the material and will also require higher safety factors to ensure acceptable performance. 5- For applications at elevated temperatures, consult your manufacture. 12

14 NOTES: 1- The designer should not exceed MAXIMUM RECOMMENDED load at any time. MAXIMUM LOAD represents a 2:1 factor of safety on ULTIMATE CAPACITY. 2- ULTIMATE CAPACITY represents a complete and total failure of the grating. 3- Walking loads, typically 2.4 KN/M 2 is recommended for pedestrian traffic. Deflections for worker comfort are typically limited to 9mm or SPAN divided by 120 under full live load. For a firmer feel under full live load or a 3.6 KN/M load, limit deflection to 6mm or SPAN divided by The allowable loads are for STATIC LOAD CONDITIONS at ambient temperatures. Allowable loads for impact or dynamic loads should be a maximum of ONE-HALF the value shown. Long term loads will result in added deflection due to creep in the material and will also require higher safety factors to ensure acceptable performance. 5- For applications at elevated temperatures, consult your manufacture. 13

15 PULTRUDED GRATING FASTENERS Type "M" stainless steel hold down clips used to secure panels to a support using two adjacent grating bars for a secure fit. Type "G" stainless steel hold clips designed to attach grating to any structural member flange, 3/4" or smaller in thickness, with no drilling required. Type "FB" stainless steel flange blocks fit inside close mesh products allowing for installation of cap screws from the top surface of the grating. Type "RK" stainless steel fasteners offer effective and more secure means for installing pultruded grating. 14

16 STANDARDS OF FRP COMPOSITES The Following Standards are used in composite productions: ASTM C ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D b ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM E ASTM E ASTM E ASTM F ASTM G ASTM G Heat Flux Dielectric Strength Testing Rigid Sheet for Electrical Insulation (Ladder) Impact Resistance Electrical Resistance Water Absorption Flammability Tensile Strength Compressive Strength Thermal Expansion Specifications for Laminated Thermosetting Materials Shear Strength by Punch Flexural Strength Specific Gravity Bearing Strength Weathering Density Interlaminar Short Beam Shear Strength Hardness Ignition Loss Classifying Pultruded Shapes In-plane Shear Strength In Plane Shear Tensile Dimensional Tolerances Pultrusion Terms Visual Defects Short Beam Shear Strength Flexural Properties Tunnel Beam Test Smoke Chamber Linear Thermal Expansion (CTE) Handrails Weathering Weathering 15

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