Fiberglass Fabrication Industry Information
IQS Newsroom Articles on Fiberglass Fabrication
About Fiberglass Fabrication and Fiberglass Fabricating
Including: Corrugated Fiberglass, Fiberglass Boxes, Fiberglass Enclosures, Fiberglass Fabricators, Fiberglass Molding, Fiberglass Panels, Fiberglass Pipes, Fiberglass Products, Fiberglass Reinforced Plastics, Fiberglass Rods, Fiberglass Sheets & Fiberglass Tanks.
Fiberglass fabrication is the process of
mixing material, containing thin fibers of glass that are formed into a
woven layer, with different resins to produce a heat-resistant and
light weight product that is used in a number of different industries
and applications. Since the introduction of fiberglass, it has been
used as a reinforcing agent for plastics, as insulation in buildings,
homes and appliances. Fiberglass is used in fabrication applications
that demand material with a lightweight, high strength and scratch
resistant performance. Fiberglass molding
shapes the fiberglass material, made of molten glass extruded through
ultra fine openings to create thread-like formations which are then
woven together to form a rough cloth or patch, and resin, often made of
thermoset polymers, by heat treatment or pressing to form many
different fiberglass products,
including panels, shells of racing cars, electric circuit boards and
machinery support because its properties are quite beneficial. It
doesn't expand or shrink with temperature change, isn't water
absorbent, has a high strength-to-weight ratio, is nonflammable,
chemical resistant and acts as an electric insulator. Fiberglass fabricators manufacture various types of fiberglass products, including corrugated fiberglass, which are 2-layer, fiberglass sheets and fiberglass panels used in building construction, fiberglass enclosures, which are large storage areas and include fiberglass tanks, and fiberglass reinforced plastics, which uses a polymer resin to produce enforced, laminated products like fiberglass pipes, fiberglass boxes and fiberglass rods.
There are a number of different types of fiberglass and resins used to
made fiberglass materials and products with different strengths,
aesthetics and applications. Fiberglass is classified into 7 main
types. These include E-glass, the most common that is used for glass
reinforced plastics, A-glass, which has little boron oxide, E-CR-glass,
which has a high acid resistance, C-glass, used for glass staple
fibers, D-glass, with a high dielectric constant, R-glass, which has
high mechanical properties, and S-glass, which has a high tensile
strength. These fiberglass types are mixed with thermosetting resins,
made of epoxy or polyester. Resins are used for molding, laminating and
casting. Epoxy resin has a higher performance and therefore a higher
cost, and is used in weight-critical, high strength applications.
Polyester resins are less expensive, more widely used, and have good
resistance to corrosion.
The three main methods of fiberglass fabricating are open molding,
closed molding and centrifugal molding. In open molding fiberglass
fabrication, a layer of gel coat is applied and cured in a one-piece
mold or structure. After being layered into the mold, the fiberglass
and sprayed resin are allowed to cure. Open molding releases more
emissions than the other two processes. In closed molding, the initial
gel coat is applied in a two-part mold. Fibers in the form of chopped
fibers or laminated sheets are sprayed or placed in the female part of
the mold on top of the gel coat. The part cures after being sealed in
the mold by a vacuum and catalyzed resin is injected into the
pressurized mold. In centrifugal molding, the gel coat is applied to
the sides of a spinning cylindrical mold. Layer by layer, catalyzed
resins saturated with short fibers are sprayed into the mold until
desired thickness is reached. Centrifugal molding is used to form
cylindrical products, such as pipes and tanks. In all processes, the
end products are then demolded and trimmed.
Corrugated fiberglass is perhaps the most widely used fiberglass
product used today. It is strong, may be either a solid color (often
green) or transparent for light transmission into buildings. It is
mostly used in building construction to make siding or roofing, and is
often used to build greenhouses and sheds. Corrugated fiberglass is
generally composed of two layers that are glued together. The outer
layer is a hard, weather-resistant resin surface, while the other
layers are made of fiberglass. Fiberglass reinforced plastic is also a
very common material. It is mostly used for enforcement of marine,
electronic, commercial and medical structures. It also serves as
protection for antennas and the material for building storage tanks,
above and underground piping for gas and water systems, and commercial
products such as kayaks.
Fiberglass is often the superior material in comparison to many others,
specifically aluminum, which is the main alternative to fiberglass.
Pultruded fiberglass shapes have several advantages over comparable
aluminum extruded shapes. Pultruded fiberglass has superior resistance
to a wide variety of chemicals, while aluminum can cause galvanic
corrosion. Fiberglass shapes are about 70% of the weight of aluminum
shapes with the same density. Pultruded fiberglass is non-conductive
with a high dielectric capability, while aluminum is a conductor,
meaning fiberglass can be used in electric applications. Fiberglass is
a much better insulator than aluminum, as it has much lower thermal
conductivity. Pigment added to the resins of fiberglass can provide
color throughout the part, while aluminum requires prefinishing, anodic
coatings or paint. Fiberglass is transparent to radio waves and EMI/RFI
transmissions and is often used for radar and antennae enclosures and
supports; aluminum is highly reflective. Pultruded fiberglass shapes
can be easily fabricated in the field with common carpenter tools and
do not require torches or welding, like aluminum shapes do. Finally,
the glass mat in pultruded fiberglass shapes evenly distributes the
load of an impact, while aluminum easily deforms.