This document discusses Solanki Utkarshsinh B's final year project on composite materials and fiber reinforced polymer matrix composites. It provides an overview of composites, including a definition, the reinforcement and matrix materials used, and applications. Specifically, it discusses polymer matrix composites, including common fibers like glass, carbon, and aramid. It also summarizes the pultrusion process for manufacturing fiber reinforced polymer rebar and provides test results showing the microstructure of the rebar.

1. Solanki Utkarshsinh B
Roll no: 618
Final year Student
Department ofTextile Engineering
The M. S. University of Baroda,
Kalabhavan,Vadodara.

3. composites
Two inherently different materials that when
combined together produce a material with
properties that exceed the constituent materials.
A broad definition of composite is:Two or more
chemically distinct materials which when combined
have improved properties over the individual
materials. Composites could be natural or synthetic.

4. Composites are combinations of two materials in which
one of the material is called the reinforcing phase, is in
the form of fibers, sheets, or particles,
and is embedded in the other material called the matrix
phase.
Typically, reinforcing materials are strong with low
densities while the matrix is usually a ductile or
tough material. If the composite is designed and
fabricated correctly, it combines the strength of the
reinforcement with the toughness of the matrix to
achieve a combination of desirable properties not
available in any single conventional material.

5. Reinforcement:
fibers
Glass
Carbon
Organic
Boron
Ceramic
Metallic
Matrix materials
Polymers
Metals
Ceramics
Interface
Bonding
surface
Components of composite materials

7. Composites – Polymer Matrix
7
Polymer matrix composites (PMC) and fiber reinforced
plastics (FRP) are referred to as Reinforced Plastics.
Common fibers used are glass (GFRP), graphite (CFRP),
boron, and aramids (Kevlar).These fibers have high
specific strength (strength-to-weight ratio) and specific
stiffness (stiffness-to-weight ratio)

8. Applications of Reinforced
Plastics
Phenolic as a matrix with asbestos fibers was the first reinforced plastic developed.
It was used to build an acid-resistant tank. In 1920s it was Formica, commonly used
as counter top., in 1940s boats were made of fiberglass. More advanced
developments started in 1970s.
Typically, although not always, consumer composites involve products that
require a cosmetic finish, such as boats, recreational vehicles, bathwear, and
sporting goods. In many cases, the cosmetic finish is an in-mold coating known
as gel coat.
Consumer Composites
A wide variety of composites products are used in industrial applications, where
corrosion resistance and performance in adverse environments is critical. Generally,
premium resins such as isophthalic and vinyl ester formulations are required to meet
corrosion resistance specifications, and fiberglass is almost always used as the
reinforcing fiber. Industrial composite products include underground storage tanks,
scrubbers, piping, fume hoods, water treatment components, pressure vessels, and a
host of other products.
Industrial Composites

9. Applications of Reinforced Plastics
This sector of the industry is characterized by the use of
expensive, high-performance resin sycomposites stems and
high strength, high stiffness fiber reinforcement.The
aerospace industry, including military and commercial aircraft
of all types, is the major customer for advanced composites.
These materials have also been adopted for use in sporting
goods, where high-performance equipment such as golf clubs,
tennis rackets, fishing poles, and archery equipment, benefits
from the light weight – high strength offered by advanced
materials.There are a number of exotic resins and fibers used
in advanced composites, however, epoxy resin and
reinforcement fiber of aramid, carbon, or graphite dominates
this segment of the market.
Advanced Composites

10. Applications of composites

11. Carbon Fiber Reinforced Composites

12. Glass Fiber Reinforced Composites
Ferrari 308 GT4
Glass Fiber Composite

13. Wind Blades/Wind Mills

14. Merits of composites
•Light weight
• Resistance to corrosion
• High resistance to fatigue damage
• Reduced machining
•Tapered sections and compound contours easily
accomplished
• Can orientate fibers in direction of
strength/stiffness needed
• Possible reduced number of assemblies and
reduced fastener count when consolidation is
used
• Absorb radar microwaves (stealth capability)
•Thermal expansion close to zero reduces
thermal problems in outer space applications .

15. Fiber Reinforced Polymer
Matrix
 Matrix
•Transfer Load to
Reinforcement
•Temperature Resistance
•Chemical Resistance
Reinforcement
•Tensile Properties
•Stiffness
•Impact Resistance

18. 1. Matrix
Polyester
Polyesters have good mechanical properties, electrical properties and
chemical resistance. Polyesters are amenable to multiple fabrication
techniques and are low cost.
Vinyl Esters
Vinyl Esters are similar to polyester in performance. Vinyl esters have
increased resistance to corrosive environments as well as a high degree of
moisture resistance.
Epoxy
Epoxies have improved strength and stiffness properties over polyesters.
Epoxies offer excellent corrosion resistance and resistance to solvents and
alkalis. Cure cycles are usually longer than polyesters, however no by-
products are produced.
Flexibility and improved performance is also achieved by the utilization of
additives and fillers.

19. 2.Reinforcement
 FiberType
 Fiberglass(i.e Glass)
 Carbon
 Aramid

 Textile Structure
 Unidirectional
 3DWoven
 3DBraid

20. Fiberglass
 E-glass: Alumina-calcium-borosilicate glass
 (electrical applications)
S-2 glass: Magnesuim aluminosilicate glass
(reinforcements)
Glass offers good mechanical, electrical, and thermal properties at a
relatively low cost.
E-glass S-2 glass
Density 2.56 g/cc 2.46 g/cc
Tensile Strength 390 ksi 620 ksi
Tensile Modulus 10.5 msi 13 msi
Elongation 4.8% 5.3%

22. Rebar is a reinforcing steel bar or mesh of steel wires
commonly used in reinforced masonry structures and
reinforced concrete(RCC) to strengthen and hold the
concrete in compression.
What is REBAR?

23. The surface of the rebar may be patterned to
form better bond with the concrete.
Pultruded FRP rebar is different than that of
steel bars in two ways. Pultruded FRP rebar
is anisotropic having high strength in the
direction of fibres which improves the shear
strength, dowel action and bond
performance. Moreover it does not yield and
is linear elastic until failure.
Introduction to rebar and its applications:

24. Practical applications of Pultruded Rebar:
•Concrete Exposed to De-Icing Salts: Bridge
decks, median barriers, approach slabs,
parking structures, railroad crossings, salt
storage facilities, concrete exposed to marine
salts seawalls, buildings and structures near
waterfronts, aquaculture operations, artificial
and water breaks, floating marine docks.
•Tunnelling and Mining Applications: Soft-
eye openings for tunnel boring machines
(TBM's) and temporary works, rock nails,
electrolytic and ore extraction tanks corrosive
applications.

25. Features of Rebar:
impervious to chloride ion and
chemically inert higher tensile strength
lighter in weight than steel rebar
It also does not interfere with magnetic
and radar frequencies and are electrically
non-conductive and thermally stable.
•Electromagnetic Applications: MRI rooms in
hospitals, airport, radio and compass calibration
pads, concrete near high voltage cables,
transformers and substations and cast stone
elements.

26. PROBLEM IS STEEL
Reinforced Concrete with Steel Rebar is
the cause of the failing infrastructure
Steel rebar has been used since the early
1900’s
Steel expands 10x in volume when it
rusts, and causes concrete to crack and
fail
Iron Iron Oxide

27. STEEL CORROSION

28.  Epoxy Coated Steel: Corrodes
 Galvanized Steel: Corrodes
 Stainless Steel: Susceptible
CORROSION
Cracking with Epoxy Coated Steel,
19Year Old Ontario Bridge, MTO 2005
Cracking with Galvanized Steel,
23Yr Old Ontario Bridge, MTO 2007
Failure with Stainless Steel,
Roof of 13Year Old Swimming Pool
Collapses, Switzerland
Rusting Stainless Steel in Bridge Install
Anthony Henday, EdmontonAB

29. Materials used for rebar:
Glass Fibre Roving(4800 Tex),
 Resin(vinyl ester),
Additives (Phenolex),
 Hardner (TBPB),
Filler(calcite) materials are ued for
manufacturing of Rebar.

30. Methods used for manufacturing rebar:
Pultrusion
Pultrusion process:
Pultrusion is a combination of pull and extrusion.
Extrusion is pulling of material such as fibre glass and
resin, through a heated die. Process begins with the fibres
coming from the roving from creel. Then there is wetting
by resins called as Resin Impregnation . Impregnated
Fibre and Mattings are passed through preformers and
guidance devices. Emerging profile is preheated and
passed through heated die. Through heated dies
polymerizing and curing takes place. Meanwhile pulling of
the formed section.

31. Pultrusion machine

32. Pultrusion process

33. Test results of rebar:
SEM image of GFRP
SEM image shows the
even distribution of roving
in resin hence there is a
proper consolidation
between roving and resin .
Voids in the image may
enhance the poor quality
of rebar and this may be
caused due to material and
condition used in the
process of manufacturing
rebar.

34. GFRP is more effective than the metallic TMT bars used in
geo-tech and infrastructure applications.
The advantages of pultrusion are as follows:
1. Increased Strength
2. High Fibre Content
3. Highly Automated
4. Consistent Quality
5. High Production
6. Low Labour Required
7. Low Cost
Therefore, pultruded rebars are costly effective and can
replaced present TMT bars.
Conclusion: