Composites 101 - Creative Pultrusions, Inc. Capabilities Presentation

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Pultrusion 101 - General capabilities of Creative Pultrusions, Inc., a leader in the fiber reinforced polymer composites industry. We are best in class and offer in-house design, manufacture of profiles, fabrication and cnc machining and in-house testing.

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Composites 101 - Creative Pultrusions, Inc. Capabilities Presentation

  1. 1. PULTRUSION 101 www.creativepultrusions.com 814.839.4186 Toll Free: 888.CPI.PULL Fax: 814.839.4276 214 Industrial Lane, Alum Bank, PA 15521 Presented by Dustin Troutman 1
  2. 2. We are known for our QUALITY. WHY CHOOSE CPI? We are the BEST IN CLASS at pultruding large structural profiles. Our engineering team is UNMATCHED in the industry. Our manufacturing technology is SUPERIOR to all others. 2
  3. 3. 3 PULTRUDING LARGE STRUCTURAL PROFILES
  4. 4. 4 ENGINEERING • We use Solid Works simulation software for our Finite Element Analysis – Including linear static and Eigen value buckling capability • Autodesk Design Suite for our geometry and design layouts
  5. 5. 5 PROCESS High pressure injection manufacturing technology permits a higher fiber volume fraction which equates to higher strength and stiffness with tight process variation.
  6. 6. 6 QUALITY The Quality Management System has been modeled per the requirements of the ISO9000:2008 International Standard. In 2012, Creative reinforced their commitment of providing the highest Quality of products and services with the addition of a certified LEAN / Six Sigma Black Belt who manages related Quality initiatives.
  7. 7. 7 MACHINE SHOP CAPABILITIES • Over 200 years experience in design and manufacture of tooling for pultrusion • CNC machining and grinding • In-house hard chrome plating • MACT compliant direct die injection tooling is a standard • Tooling designed with Autodesk Design Suite “Lifetime Maintenance included in tooling cost”
  8. 8. COMPOSITES A composite is a structural material that consists of two or more combined constituents that are combined at a macroscopic level and are not soluble in each other. Resin being directly injected into the die Glass fibers The term pultrusion comes from combining the words pull and extrusion. 8
  9. 9. Pultruded profiles are cut to length during the continuous manufacturing process. 4. Resin and glass fiber reinforcements are combined and formed into the shape of the die on a continuous process. 1. The resin is initiated by the thermal decomposition process. The initiator is heated until a chemical bond dissociation produces two radicals. The chain continues to build until the monomer is used resulting in a cured resin. 2. The profiles are pulled through a die. 3. THE PULTRUSION PROCESS Pulling System* Cut-Off Saw Preformer Continuous Strand Mat Guide Plate Rovings Resin Impregnator Surfacing Veil Forming & Curing Die *Caterpillar Pullers (shown) or Reciprocating Pullers 9
  10. 10. 120 100 80 60 40 20 0 ULTIMATE(KSI) MATERIAL WHITE PINE ALUMINUM 6061-T6 STEEL A-36 STAINLESS STEEL 304 PULTRUSION STANDARD STRUCTURAL PULTRUSION CUSTOM CONSTRUCTION PULTRUSION ALL ROVING • Superior Tensile Strength/Stronger than A-36 Steel • Linear Stress/Strain Curve with Little to No Yield 80 70 60 50 40 30 20 10 0 ULTIMATE(KSI) MATERIAL WHITE PINE ALUMINUM 6061-T6 STEEL A-36 STAINLESS STEEL 304 PULTRUSION STANDARD STRUC- TURAL PULTRUSION CUSTOM CONSTRUCTION PULTRUSION ALL ROVING • Superior Compression Strength/Stronger 6061-T6 Aluminum • Compression Strength and Compression Buckling Normally Govern the Design when Strength Governs MATERIAL PROPERTIES TENSILE STRENGTH COMPRESSION STRENGTH 10
  11. 11. • 1/2 the Modulus of Aluminum and 1/10th the MOE of Steel • Deflection Governs Most Designs • Buckling Governs Most Strength Driven Designs. Local and Global Buckling MATERIAL 35 30 25 20 15 10 5 0 Msi WHITE PINE ALUMINUM 6061-T6 STEEL A-36 STAINLESS STEEL 304 PULTRUSION STANDARD STRUCTURAL PULTRUSION CUSTOM CONSTRUCTION PULTRUSION ALL ROVING 50 45 40 35 30 25 20 15 10 5 0 ULTIMATE(KSI) MATERIAL WHITE PINE ALUMINUM 6061-T6 STEEL A-36 STAINLESS STEEL 304 PULTRUSION STANDARD STRUCTURAL PULTRUSION CUSTOM CONSTRUCTION PULTRUSION ALL ROVING MODULUS OF ELASTICITY • Lower Shear Strength than Steel and Aluminum • Lower Shear Modulus than Steel and Aluminum; Serviceability Calculations Should Include Shear Deflection Computations, Especially for Short Spans SHEAR STRENGTH MATERIAL PROPERTIES 11
  12. 12. • 75% Lighter than Stainless Steel • 25% Lighter than Aluminum 50 45 40 35 30 25 20 15 10 5 0 ULTIMATE(KSI) MATERIAL WHITE PINE ALUMINUM 6061-T6 STEEL A-36 STAINLESS STEEL 304 PULTRUSION STANDARD STRUCTURAL PULTRUSION CUSTOM CONSTRUCTION PULTRUSION ALL ROVING DENSITY MATERIAL PROPERTIES 12
  13. 13. RESIN OPTIONS Series 1500/1525 POLYESTER (PE) RESINS – are manufactured for corrosion related applications. Polyester resins display excellent structural properties and are resistant to acids, salts, and many dilute chemicals at moderate temperatures. The standard 1525 series contains fire retardant additives that permit the profiles to pass UL94 with a (V0) rating and ASTM E84 with a class A rating. 13
  14. 14. RESIN OPTIONS Series 1625 VINYL ESTER (VE) RESINS – are based on bisphenol, an epoxy resin. VE resins provide resistance to a wide range of acids, alkalis, bleaches and solvents for use in many chemical environments. They also offer excellent toughness and fatigue resistance. The standard 1625 series contains fire retardant additives that permit the profiles to pass UL94 with a (V0) rating and ASTM E84 with a Class A rating. 14
  15. 15. RESIN OPTIONS Series 4000 POLYURETHANE (AROMATIC) – Are a blend of polyol and isocyanate that when joined, produce a resin system that offers superior strength and toughness. Polyurethane resins should be used when impact strength and toughness are required. 15
  16. 16. RESIN OPTIONS Series 3000 EPOXY - Epoxy resins, also known as polyepoxides are a class of reactive prepolymers and polymers which contain epoxide groups. They are ideal for high strength, high temperature applications and perform well in chemical environments. 16
  17. 17. RESIN OPTIONS Series 3535 SPECIALTY RESINS - Special application resins with unique flame smoke and toxicity (FST) attributes are available. Low FST resins are used extensively in the mass transit industry. 17
  18. 18. REINFORCEMENT OPTIONS E GLASS – ELECTRICAL GRADE FIBERGLASS 18 Pultruded in the form of Roving, Continuous Filament, Woven, or stitched fabric mats, depending on the mechanical and physical values being sought. E-glass fiberglass exhibits high tensile strength and Modulus of Elasticity properties. The volume fraction of fiberglass to resin dictates the mechanical and physical properties of the pultruded profile
  19. 19. REINFORCEMENT OPTIONS CARBON FIBER 19 Carbon atoms are bonded together in crystals that are more or less aligned parallel to the long axis of the fiber. The crystal alignment gives the fiber high strength-to-volume ratio. Several thousand carbon fibers are bundled together to form a tow, which may be used by itself or woven or stitched into a fabric. The properties of carbon fibers, such as high stiffness, high tensile strength, low weight, high chemical resistance, high temperature tolerance and low thermal expansion, make them very popular in aerospace, civil engineering, military, and motorsports.
  20. 20. PRODUCT LINES Standard Structural Profiles Used for Fabricated Structures • W and I Beams • Channels • Angles • Tubes • Flatsheet • And many more... 20
  21. 21. DECKING PRODUCTS SUPERGRATETM PULTRUDED GRATING SUPERDECKTM SUPERPANEL PA004 SUPERPANEL CP150 21
  22. 22. SUPERDECKTM RAIL PLATFORM PANEL SUPERGRATETM MOLDED GRATING SUPERPANEL WALL PANEL CT066 DECKING PRODUCTS SUPERPLANKTM DECKING 22
  23. 23. SUPERDECKING TUF-DEKTM FLOORING HEAVY DUTY PLANK DECKING PRODUCTS FLOWGRIP® FLOORING PANEL 23
  24. 24. BALLISTIC PANELS - The Ultimate Panel for Ballistic and Fragmentation Protection - UL 752 Level III Compliant 24
  25. 25. CUSTOM PULTRUSIONS 25
  26. 26. MASS TRANSIT DECKS 26
  27. 27. FRP DISTRIBUTION AND TRANSMISSION POLES AND CROSSARMS 27
  28. 28. SUPERLOCTM SHEET PILE SYSTEM 28
  29. 29. PIPE PILES 29
  30. 30. PULTRUDED STRUCTURES DESIGN METHODOLOGY OPTIONS LRFD or ASD 30
  31. 31. ALLOWABLE STRESS DESIGN 2.5 in Flexure 3.0 in Shear 3.0 for Connections • Material Properties are Reduced to Satisfy an Appropriate Safety Factor • Typical Safety Factors for Pultruded Structures 31
  32. 32. • Load & Resistance Factor Design (LRFD) of Pultruded Fiber Reinforced Polymer (FRP) Structures • Developed by the Pultrusion Industry Council (PIC) and the American Society of Civil Engineers (ASCE) • A design standard exists for the pultrusion industry. Our industry joins ranks with steel, wood, concrete and aluminum as a standard material of construction. 32 LRFD Design
  33. 33. CHARACTERISTIC DESIGN PROPERTIES ARE DETERMINED PER ASTM D7290 WHY ASTM D7290? It is an internationally recognized standard for evaluating material property characteristic values for polymeric composites for civil engineering structural applications. The characteristic value is a statistically-based material property representing the 80% lower confidence bound on the 5th percentile value of a specified population. 33
  34. 34. WHY DO ENGINEERS AND OWNERS SPECIFY PULTRUDED PROFILES? • To Reduce Maintenance Costs • To Reduce Downtime • To Reduce Future Capital Expenditures • To Increase Safety • To Save Money 34
  35. 35. SUPERIOR DURABILITY OVER A LONG SERVICE LIFE • Estimated Service Life of 80+ years • The theory is based on the Arrhenius principle used by Litherland et al. in 1981 and Vijay and GangaRao in 1991. (Litherland et all, have correlated their data with naturally weathered samples of about 10 years.) 35
  36. 36. PULTRUSION THE GREEN CHOICE EMBODIED ENERGY COMPARISON 36
  37. 37. BC HYDRO 287kV TRANSMISSION CHANNEL DESIGNED BY CPI TESTED BY POWERTECH LABS INSTALLED AND VETTED BY BC HYDRO APPLICATION PROFILES 37
  38. 38. APPLICATION PROFILE PULTRUDED DISTRIBUTION POLES AND CROSSARMS FOR NATIONAL GRID 38
  39. 39. APPLICATION PROFILE LIGHTWEIGHT POLE FOR LIMITED ACCESS SETS 39
  40. 40. APPLICATION PROFILE PULTRUDED HS25-44 BRIDGE DECK 200’ x 60’ INSTALLED IN 14 HOURS 40
  41. 41. APPLICATION PROFILE COMMUNICATION TOWER FOR EMERGENCY SERVICES. RADAR AND RF TRANSPARENCY DESIGNED BY CREATIVE 41
  42. 42. APPLICATION PROFILE MOVEABLE POOL FLOORS AND STARTING BULKHEADS 42
  43. 43. APPLICATION PROFILE RAILS TO TRAILS DECKING 43
  44. 44. APPLICATION PROFILE MASS TRANSIT ELEVATED PLATFORM DECKS 44
  45. 45. APPLICATION PROFILE COVERBOARDS, TIE EXTENSIONS, UTILITY AND COMMUNICATION STRUCTURES for the MASS TRANSIT MARKET 45
  46. 46. APPLICATION PROFILE PULTRUDED COOLING TOWER 46
  47. 47. APPLICATION PROFILE NUCLEAR INTAKE RACK 47
  48. 48. APPLICATION PROFILE PEDESTRIAN BRIDGE 48
  49. 49. APPLICATION PROFILE AZERBAIJAN 3,280 FT RETAINING WALL 1580 SUPERLOC™ AND SUPERWALE 49
  50. 50. APPLICATION PROFILE SHEET PILE WALL SERIES 1560 SUPERLOC™ 50
  51. 51. APPLICATION PROFILE SHEET PILE WALL AFTER HURRICANE SANDY 2012 SERIES 1580 SUPERLOC™ 51
  52. 52. KEYPORT, NJ PHOTOS OF WALL TAKEN DURING HURRICAN SANDY 52
  53. 53. KEYPORT, NJ PHOTO TAKEN AFTER HURRICAN SANDY, 2012 NO DAMAGE TO THE FRP WALL 53
  54. 54. APPLICATION PROFILE MILITARY 54
  55. 55. FT. MEYERS, FLORIDA SHEET PILE WALL 55
  56. 56. PIANKATANK RIVER, VIRGINIA BRIDGE PIER FENDER SYSTEM CONSTRUCTED OF POLYURETHANE PIPE PILES 56
  57. 57. APPLICATION PROFILE PINELLAS BAYWAY BRIDGE PIPE PILE FENDER INSTALLATION 57
  58. 58. 58 APPLICATION PROFILE PINELLAS BAYWAY BRIDGE PIPE PILE FENDER INSTALLATION
  59. 59. 59 WHAT CAN WE DO FOR YOU? WE CAN DESIGN YOUR CUSTOM PROFILE BASED ON FINITE ELEMENT ANALYSIS AND PROVEN ENGINEERING MEANS
  60. 60. 60 TEST THE DESIGN IN ONE OF OUR IN-HOUSE TEST FACILITIES FULL SECTION AND COUPON LEVEL TESTING
  61. 61. 61 PULTRUDE YOUR PROFILE
  62. 62. 62 FABRICATE YOUR PROFILE OR STRUCTURE
  63. 63. FACILITIES OVERVIEW Creative Pultrusions, Inc. was established in 1973 and is located in Alum Bank, Pennsylvania. PRODUCTION MACHINES = 18 FACILITIES (SQ. FT) = 160,000 EMPLOYEES = 148 63
  64. 64. 64 HILL & SMITH HOLDINGS PLC • Hill & Smith Holdings PLC is an international group with leading positions in the design, manufacture and supply of infrastructure products and galvanizing services to global markets. It serves its customers from facilities principally in the UK, France, USA, Thailand, Sweden and China. • The Group's operations are organized into two main business segments: Infrastructure Products & Galvanizing Services. • 2013 Revenue of £444.5m • Infrastructure – 71% Roads - 25% Utilities - 46% • Galvanizing - 29% £316.9m £127.6m
  65. 65. 65 WHERE HILL & SMITH OPERATES UNITED STATES FRANCE UNITED KINGDOM SWEDEN THAILAND INDIA CHINA AUSTRALIA V • AUSTRALIA: New office in Queensland for the development of our wire rope and safety barrier products. • CHINA: Manufacturing and trading facilities located in the Jiangsu province for the further expansion of our pipe support business. • FRANCE: The locations of France Galva and Conimast, where we have ten galvanizing plants and a lightning column business. • INDIA: New manufacturing facility for pipe supports and also offices for development of our Hill & Smith infrastructure product business. • SWEDEN: Location of ATA Bygg-och Marckprodukter AB, the road safety barrier and signage business. • THAILAND: Location of part of our pipe supports manufacturing capability, where we have plants near Bangkok. • UK: Head office and various group site locations covering our main infrastructure products business and network of UK galvanizing plants. • USA: Our V&S galvanizing and utilities plants are situated on the East Coast along with the Bergen and Carpenter & Paterson pipe support business and the fiber reinforced composite profiles business, Creative Pultrusions.
  66. 66. 66 HILL & SMITH REVIEW OF 2012 INFRASTRUCTURE PRODUCTS The division is focused on supplying engineered products to the roads and utilities markets in geographies where there is a prospect of sustained long term investment in infrastructure. In 2012 the division accounted for 73% (2011: 68%) of the Group’s revenue and 43% (2011: 48%) of the Group’s underlying operating profit. UTILITIES The requirements for new power generation in emerging economies and replacement of aging infrastructure in developed countries provide an excellent opportunity for the Group’s utilities businesses. Revenues increased to £205.7m (2011: £167.0m), which after adjusting for acquisitions and currency impacts, reflects 13% organic growth of £22.5m. Underlying operating profit increased by £1.9m to £13.4m (2011: £11.5m) with acquisitions contributing £0.9m of the growth. The organic growth was driven mainly by our US based businesses, V&S Utilities and Creative Pultrusions, which benefitted from a more active USA utilities market. delivering a number of large projects in the transmission, rail and cooling tower markets. Over the year, we further developed high value products for niche markets. These products are lightweight, corrosion resistant and offer improved installation times, thereby substituting traditional materials. There is a growing demand for composite products and this was evident in the supply of 85 railway platform extensions for the upgrade to the Wessex Line in the UK. CREATIVE PULTRUSIONS ACHIEVED A RECORD PERFORMANCE
  67. 67. CELEBRATING OVER 40 YEARS OF PROVIDING PULTRUSION SOLUTIONS QUESTIONS? www.creativepultrusions.com

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