Fiber reinforced plastics, commonly referred to as FRP, are composite materials that are composed of a polymer matrix that is reinforced with fibers. FRP can vary based on the types of polymer and fibers used in manufacturing. One of the most common and well known fiber reinforced plastic is fiberglass in which glass fibers are used to reinforce a thermoset polymer matrix.
Uses and Benefits of FRP
When compared to metals, plastics, and other traditional materials used for structural applications, fiberglass reinforced plastics offer a number of benefits including:
Increased strength to weight ratio
Lower cost
Low conductivity
Improved flexibility
The ability to be molded into complex shapes
Chemically inert
For the reasons listed above the uses for fiberglass reinforced plastics are commonly used as alternatives to metal or plastics. The applications are nearly endless and include storage tanks, piping, automobile parts, ship hulls, and general building & construction materials.
Common Types of Resin Used in FRP
As mentioned above FRP material consists of a thermosetting resin that is reinforced with glass fibers. There are a number of resins used in reinforced plastics including epoxy, vinyl-ester, and polyester resins. By far the most common type of FRP resin is polyester. Polyester based FRP resins are popular due to their ease of use and provide good temperature and chemical resistance. In some applications, however, the chemical or heat resistance of polyester FRP material is not enough and a more durable material is needed.
QuaCorr® - Corrosion & Flame Resistant FRP Resins
QuaCorr® is a line of furfuryl alcohol based resin systems that are designed to be used in the manufacture of corrosion resistant and flame retardant FRP products. FRP composites based on QuaCorr® exhibit superior chemical resistance, temperature resistance, and fire retardant properties than polyester composites.
Chemical Resistance
QuaCorr® FRP is highly resistant to aggressive solvents, strong acids, and strong bases. It is especially useful in applications where the presence of a solvent is in combination with an acid or base such as chemical processing, agricultural chemical manufacturing, and acrylate production. In the table below, the corrosion resistant properties of QuaCorr® composites are compared to common metals and polyester composites.
Material of Construction
H₂SO₄
HCL
NaOH
CS₂
Toluene
MEK
Chloro Benzene
Ethylene Dichloride
Carbon Steel
R
A
R
R
R
R
R
R
Stainless Steel
R
A
A
R
R
R
R
R
Hastelloy C®
R
R
R
R
R
R
R
R
Aluminum
A
A
A
R
R
R
R
R
Polyester
R
R
A
A
R
A
A
A
QuaCorr®
R
R
R
R
R
R
R
R
A = Attacked, R = Resistant
Flame Resistance
In addition to outstanding corrosion resistance, QuaCorr® composites have inherent fire retardant properties. The highly cross-linked nature of cured furan resin coupled with a high char yield gives QuaCorr® resin natural low flame spread and low smoke development properties. Typical fire and smoke test results for laminates made of QuaCorr® 1001 are listed in the table below.
Test
Result
Flame Spread ASTM E-84
70
Smoke Development ASTM E-84
120
Radiant Panel Test ASTM E-162
61
NBS Smoke Density ASTM E-662
62
Limited Oxygen Index ASTM D-2863
25
Temperature Resistance
Temperature should be an important consideration when selecting materials for the development of composites. With polymeric material physical strength tends to decreases as temperature increases. With QuaCorr® resins, however, this decrease in strength is essentially linear between -50°F and 450°F rather than the sharp decrease in properties exhibited by styrenated polyester laminates.
Flexural Strength vs. Temperature
How to Use QuaCorr®
FRP products can be fabricated from QuaCorr® by hand lay-up, spray-up, and filament winding techniques. QuaCorr® is an acid catalyzed, modified furfural alcohol system that consists of two parts: the resin, QuaCorr® 1001 or QuaCorr® 1300, and the catalyst QuaCorr® 2001. Once the resin and catalyst are blended, curing proceeds via a condensation mechanism with water produced as a byproduct. The reactivity of the QuaCorr® system has been optimized to allow a reasonable balance between pot-life and viscosity, as well as allow for rapid hardness development at ambient temperatures.
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