When selecting a building material for an infrastructure project, there are a few key factors to consider before making a decision. Engineers must be sure to make selections that will benefit both the people within their agency, who will be working with the material, as well as the project&#;s end users.
One such material is fiber-reinforced polymer (FRP), which can be hugely beneficial for both builders and users. Read more below to find out how this unique material can work for you.
When developing the design for your overall infrastructure plan, it&#;s important to factor in the amount of time that will be needed not only for the whole project, but also for each step within the process. Obviously, saved time translates to saved costs, but you certainly don&#;t want to sacrifice quality for efficiency. FRP can provide an ideal balance, helping to save valuable production time while still providing the necessary quality, strength and durability. Below, compare the production and installation time of FRP to that of precast concrete:
As you can see from the chart, FRP&#;s total production time is 15 days less than that of precast concrete. This translates to more than two weeks&#; worth of saved labor costs and overall downtime for infrastructure development. FRP also requires less total installation time than precast concrete &#; almost five days less, on average.
Thanks to this shorter installation time, engineers using FRP don&#;t have to complete their work solely during the workweek. Instead, they can opt to do installation work on the weekends, too, when there is less traffic congestion and end users will experience less inconvenience and fewer interruptions to their commutes.
Going hand-in-hand with a quicker installation time is FRP&#;s weight. FRP is known for being lightweight. In fact, it&#;s about eight times lighter than reinforced concrete &#; meaning FRP is also less labor-intensive to use and install, and requires less equipment. This material also requires less labor during removal processes. See below to compare the total weight of FRP to the total weight of precast concrete.
As you can see from the chart, FRP is significantly lighter than precast concrete, with an FRP panel weighing about 5,000 lb and a precast concrete panel weighing nearly 41,000 lb. Using a lighter material makes it easier on your workers, saves on labor costs and places less stress on the infrastructure. The lower the weight of the material being used, the less wear and tear the infrastructure will experience as a whole.
Offering high durability and strength, as well as reliable resistance to corrosion, FRP is long-lasting and mitigates the need for ongoing maintenance. The lack of frequent maintenance and repairs helps to save on expensive labor and material costs and also prevents inconvenience to end users, since repair downtime is minimized.
And, since FRP is long-lasting and resistant to corrosion, the long-term costs end up being less as well.
Though FRP does have a slightly higher price point per square foot at initial installation, the material allows for many benefits in terms of long-term cost savings. Because FRP causes less stress on the infrastructure and is more durable than other materials, it diminishes the need for costly repairs or reconstruction down the road. For example, bridges and platforms constructed from materials such as reinforced concrete, steel, or wood often fall apart 15 to 20 years after initial installation &#; requiring extremely expensive repairs or even a whole new investment to rebuild from scratch. FRP, however, is built to last and won&#;t experience corrosion over time like many other construction materials.
FRP structures are highly reliable and low-maintenance, but they shouldn&#;t be considered maintenance-free. Repairs requiring field service will need to be performed on rare occasions. Performing yearly routine inspections (at minimum) will help ensure potential issues can be caught before they become a problem. If an issue has been identified and reported (ex. cracks, crazing, discoloration, excessive wear, etc.), a field service technician will be sent out to complete the repair.
As mentioned, structures made from steel, concrete and wood are prone to regular repair work, as well as those made with brick and tile &#; that&#;s also where FRP can come in. Fiberglass can be used for patch repairs on bridge decking and liners can be applied to culverts, pumps, storage tanks and pipes to protect less-resistant materials from future damage. FRP can even be used for wrapping bridge piers and columns.
Repairs made with FRP add up to long-term cost savings. Since the material is corrosion-resistant and has a much longer service life, it&#;s a great option to use when repairing and protecting existing structures. Take a look at our brief case study to learn more about how FRP repairs reduce costs.
FRP is ideal for any type of job that requires customization, as it is engineered to meet exact specifications. Regardless of complexity, engineers can create panels of all different sizes and shapes. This allows for aesthetic versatility, as there is a range of possible colors. It is also possible to add functional features to facilitate a smooth and easy installation process.
FRP offers a wide range of unique benefits &#; short production and installation time, light weight, long-term cost savings, corrosion resistance, and superior longevity. An ideal material for use in almost any infrastructure project, FRP is very dynamic, making it the perfect choice for all types of infrastructure &#; including vehicle, pedestrian, and trail bridges, cantilever sidewalks, rail platforms, waterfront frameworks, storage tanks and pipes, stairs and handrails, and much more.
Creative Composites Group has extensive expertise in both FRP materials, installation, and field services, and we&#;re a proud FRP manufacturer. To learn more about how FRP compares to competing materials such as reinforced concrete, steel and wood, download our eBook today.
In the world of construction and manufacturing, there are many materials used to create strong and reliable products. Engineers need to be aware of the materials that can help them develop reliable products that function as users intend.
Fiberglass and fiber-reinforced polymers (FRP) are two such materials. These terms are often used interchangeably, though there is technically a difference between the two.
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Understanding the difference between the materials can help engineers understand which material is best for their product.
What is Fiberglass?
Fiberglass is made by spinning melting glass in such a way that it creates fibers of glass. Minerals, such as limestone or silica sand, are placed in a furnace until they reach their melting point. The melted material is then extruded through tiny orifices, known as brushings, to create filaments.The filaments are then coated in a chemical finish and bundled together into rovings. The overall weight of the fiberglass is determined by how many filaments are in the roving and how thick the individual fibers are.
These fibers can be used on their own or in a composite, which is a combination of materials that create a new substrate. The matrix of a composite can be metal, plastic, or even ceramic, with fiberglass acting as the reinforcement material that makes the composite stronger than its parts on their own.
It is used in a variety of applications, including thermal insulation and reinforcing composite materials. When used as insulation, fiberglass typically comes in the form of blankets or rolls. It is installed between studs in walls, on attic floors, and around pipes and ductwork. Fiberglass insulation is known for its high R-value, which measures its ability to resist heat flow.
Fiberglass is an ideal reinforcement for printed circuit boards in computers and other electronics as an electrical insulator and resistive material. The rising demand for PCBs in consumer electronics, automotive, and telecommunication products is driving up the demand for fiberglass fabrics.
When used as a reinforcing agent, fiberglass can greatly improve the strength and durability of composite materials. Aerospace and automotive industries often utilize fiberglass composites in the construction of aircraft and vehicles. Overall, fiberglass is a versatile material with a wide range of potential applications.
What is FRP?
Fiber-reinforced polymers are a type of composite material. As the name suggests, they are made up of two primary constituents: fibers and a polymer matrix. In an FRP, the fiber is embedded in the polymer matrix. This structural arrangement confers completely different chemical and physical properties onto the materials than those possessed by the individual constituents.
FRPs offer a number of advantages over traditional materials, but one of the most significant is the advantage inherent in their manufacturing process. Pultrusion is an automated composite manufacturing system that pulls fiber rovings through a resin bath, impregnating and reinforcing the fibers to create a strong, lightweight material. The entire process can be completed quickly and on a large or small scale without compromising quality. As a result, FRPs are an excellent choice for a wide range of applications.
FRP composites are lighter than steel and concrete, yet they have a high strength-to-weight ratio. They also offer superior corrosion resistance and durability. As a result, FRP composites are an increasingly popular choice for a wide range of applications.
FRPs are becoming increasingly popular in a variety of industries due to their exceptional performance properties. For example, FRP doors and windows are resistant to a wide range of corrosive substances and extreme temperature fluctuations. In addition, FRPs are lightweight, have excellent electrical and thermal insulation properties, and boast high stiffness ratings.
FRP Advantages
Lasting Sustainability
As sustainability becomes increasingly important to consumers and manufacturers alike, companies are innovating to meet these needs. One of the ways they are meeting these requirements is with durability. FRPs are durable, meaning they&#;re not replaced as frequently as traditional materials like concrete and steel.
Products designed with FRP often have lower weights as compared to products designed with traditional materials. The lower weight of composite products compared lowers energy consumption, which in turn reduces CO2 emissions. This lower weight is crucial in the aerospace and automotive industries.
Reduced Costs
In addition to their environmental advantages, FRPs also offer economic benefits. Because they last longer, manufacturers don&#;t have to replace them as often, saving money in the long run. Companies may also spend less capital on maintenance And because they&#;re lighter, they can often be shipped at a lower cost than traditional materials.
Additionally, pultruded products are substantially cheaper to manufacture than traditional materials. This reduced cost allows for increased budgets and improved allocation of resources without compromising quality or performance.
Unique Designs
FRPs can be formed into nearly any shape imaginable, making it possible to create structures and designs that would be impossible or impractical to create with traditional materials. Engineers can use FRPs to develop unique designs with the colors they desire. During the production process, FRPs can also be custom colored or painted after production. For example, FRPs can be shaped into complex curves or even woven into fabric-like structures.
Overall, FRPs offer a number of advantages over traditional materials like fiberglass. They are stronger, more durable, and more resistant to damage. As a result, they are often the preferred choice for products that require high performance standards.
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