Fiberglass Pipe Manufacturer, FRP Pipes, GRP Pipes
Introducing IntegraLine Fiberglass Pipe – FRP (Fiberglass Reinforced Plastic) Pipe
After years of serving corrosion-related industries, Fibrex noticed there seemed to be no easy approach to selecting and designing fiberglass reinforced plastic (FRP) pipe (also known as GRP pipes). Most plants have worked with fabricators and engineers to custom design all fiberglass pipe (FRP) equipment. Yet there is considerable cost and effort to custom design fiberglass pipe or a fiberglass pipe system and it is not always necessary. Fibrex has found there are many applications where a standard frp pipe product will meet all of the requirements. That’s why Fibrex has developed a standard pipe product line called IntegraLine.
IntegraLine is a standard production fiberglass pipe with custom corrosion resistance. Simple to specify and select, this fiberglass pipe is ideal for new system installation or replacement of existing pipe. IntegraLine pipe will meet many of the applications and life-span requirements at your plant or facility.
For special design requirements, Fibrex also offers custom fiberglass pipe solutions. Custom fiberglass pipe solutions may require thicker corrosion or abrasion barriers with different resins. Also, heavier structural laminates and special glass reinforcements are available to meet installation and temperature requirements. Fibrex can provide design recommendations for a proposed installation.
And because Fibrex understands the industries we serve, Fibrex products are designed to meet the most demanding and specialized conditions at each site. In standard pipe, custom pipe, special header systems, duct or stacks, Fibrex delivers long-term corrosion solutions and absolute maximum product life. We call this “performance-based manufacturing.”
cost savings
faster production and quicker delivery
fast and easy fiberglass pipe selection
Corrosion Resistance
IntegraLine fiberglass pipe ( fiberglass reinforced plastic pip – FRP) is designed to be “user friendly.” The resin, glass reinforcement
materials and composite construction were selected to provide consistent corrosion resistance for the majority
of chemical applications for which FRP pipe is considered appropriate. There remain certain extreme chemical services
for which special construction and alternative resins should be considered. Fibrex can advise if this is required for
your application.
Weather Resistance
IntegraLine pipe utilizes a heavily resinated exterior coat containing an ultraviolet stabilizer to impart long term
resistance to the effects of sunlight and other weathering elements. Should pipe become weathered after many years in
particularly severe environments, the exterior can be sanded and resin coated or painted.
Color
Pigmented exterior gel coats are not used on IntegraLine pipe in order to take advantage of the natural translucency
of FRP. Visual inspection of the pipe, both new and after years of service, is more reliable with a “natural” laminate.
Additionally, the liquid contents can often be observed in the pipeline… sometimes a process control advantage.
When special color coding is required, however, this can be provided at a nominal added cost and slightly longer
delivery time.
Durability
The high tensile elongation properties of the vinyl ester resins utilized in IntegraLine pipe impart a superior
toughness to the pipe enabling it to resist cracking and crazing of the resin when subjected to heavy design loads.
In addition to high fatigue resistance, this toughness also provides a safety factor against impact damage during
shipping and installation.
Resin
IntegraLine pipe is manufactured with a premium vinyl ester resin as the standard production resin. Other vinyl ester resins specified by the customer are available, however delivery lead times will generally be longer. Epoxy vinyl ester resins are
premium corrosion resistant resins. At both room and elevated temperatures, these resins offer resistance to a broad range of acids, alkalis, bleaches and solvents making them the appropriate choice of resins in many chemical processing industry applications. These
resins, when properly formulated and cured, comply with FDA regulation 21 CFR 177.2420 covering materials intended
for repeated use in contact with food. Specific chemical resistance information can be found in the Chemical Resistance
and Engineering Guides, available from FIBREX or directly from the resin manufacturers.
Reinforcement Materials
A “C” glass (chemical grade) veil is provided on all surfaces exposed to corrosive media. Fiberglass used in
all subsequent layers of the laminate has excellent electrical resistivity, high tensile strength, moderate thermal
conductivity and is noncombustible. The basic types of fiberglass materials used; mat, woven roving and continuous
strand, are selected for their physical properties, manufacturing characteristics and the chemical resistance of the
laminate resulting from their use.
Corrosion Barrier
The corrosion barrier of IntegraLine pipe is nominally 100 mils thick and is comprised of 70% to 80% resin. This
highly resinated laminate is reinforced by one layer of “C” glass veil followed by two layers of randomly oriented fiber
strand mat.
Structural Laminate
Straight Pipe
IntegraLine pipe is manufactured by the filament winding process utilizing continuous fiberglass strand wound in a
helical pattern at a nominal 55 degree wind angle to produce an optimum combination of hoop and axial properties
for most typical applications. The high glass content resulting from the filament winding process imparts excellent
strength characteristics to the laminate providing superior protective structural backup to the resin rich corrosion barrier.
Fittings
IntegraLine pipe fittings are manufactured utilizing a highly efficient contact-molded laminate consisting of
alternating layers of glass fiber strand mat and bi-directional woven glass roving. The high glass content resulting
from the specific laminating process used for IntegraLine pipe fittings permits the wall thickness of this hand-layup
process to closely approximate the wall thickness of filament wound straight pipe in equivalent pressure rated classes.
Fiberglass Pipe Laminate Construction
Fiberglass Pipe Design and Selection, System Design, Field Installation:
Click Here to Print the Fiberglass Pipe Manual for Chemical Plants
Click Here to Print the Fiberglass Pipe Manual for Power Plants
Click Here to Learn More About Fiberglass Pipe IntegraHeader – The Long-Term Chlorine Header Solution
How to Maintain and Repair FRP Tanks and Pipes
FRP tanks, known as Fiberglass Reinforced Tanks, are high-strength, cost-effective, lightweight, reliable, strong, and highly corrosion-resistant. They can also withstand high-temperature chemicals, which makes them ideal for chemical processing. As a cost-effective investment, they are a top choice for the industrial industry, from pulp and paper mills to chemical plants.
Understanding the tips and tricks for maintaining and repairing FRP tanks and Pipes can make the difference between a tank lasting 5-10 years to 30+. Fiberglass Tanks are composite materials of varying thicknesses (Resin / Epoxy-Resin, Fiberglass Mat, Wax coating, etc.
What causes areas of failure in
FRP Tanks
?
FRP Tank Filament Wound
Air pockets are the enemy of the FRP Tank manufacturing process. If not rolled out properly, air can become trapped and lead to a partially filled or empty space, e.g., voids, in the finished laminate. Voids lead to leaks and cracks that need to be repaired.
Voids can be caused by the viscosity of the resin (i.e., the thickness of liquids), poor mixing process, inaccurate cure temperature, and insufficient reinforcement compaction to remove their air bubbles before curing.
FRP Tanks can lose their hardness, stiffness, and toughness from one air pocket, but we can easily repair these defects.
How can I prevent UV Damage to my FRP Tank?
UV Gel Coat Repair for Fiberglass Tank Protect
FRP structures exposed to extended periods of ultraviolet light can not only cause the structure to fade but expose the fibers and corrode the FRP's ability to resist chemicals. This is known as Fiber Blooming.
As time passes, the resin breaks down and exposes the glass fibers within. As a result, the surface texture changes and reduces chemical resistance.
You can prevent UV damage by applying a UV-resistant gel coat to protect the structure from damaging rays. If the tank is located inside a building, a gel coat may not be necessary, but if the Tank is exposed to UV through windows, a gel coat may be required.
How do I respond to a lining failure inside my FRP Tank?
Over time, chemicals stored inside the fiber-reinforced tank will corrode wax layer (a protective coating for additional chemical resistance) and eventually cause the inner lining to fail. The inner lining can bubble, crack, shrink, delaminate, and scratch. These areas of failure will need to be ground down and patched. In many cases, a full reline of the tank will be necessary.
FRP Tank Crack Example
These tank failures will allow the chemicals to permeate the corrosion barrier into the structure of the tank or pipe and lead to leaking. This is why secondary containment is critical when dealing with harsh chemicals. Furthermore, high temperatures can cause the laminate to soften and lose its rigidity, thus becoming prone to erosion and damage, which will break down over time.
Before performing a tank reline, it's vital to assess the following: - What chemical is being stored inside the tank?
- What temperature will the tanks be stored at?
- Have I emptied the tank of its contents and cleaned it in preparation for inspection and repair work?
- Have I performed an adhesion or pull test with my materials to ensure a proper bond?
FRP Tank Spider Crack Inspection
After answering these questions, the tank will need to have the damaged material removed, the surface sanded and ground, application of the glass reinforcement and resin, followed by a post-cure wax coating.
Extending the Life of
FRP Tanks
and Pipes
Fiberglass Tanks and Piping are low-maintenance and dependable solutions, but they do require maintenance. Identifying and repairing early failures and help avoid spills, leaks, and structural failures.
Our suggestion is to perform routine maintenance to maximize performance. What should you look for when inspecting a Fiberglass Tank?
Extensive cracking or crazing
Lack of "shine" on Fiberglass (e.g., losing wax coating)
Cracks and leaks around flanges and metal supports/hangers
Buildup of crystals
Discoloration in Fiberglass lining
Excessive wear on flanges
Blistering or bubbles on pipes or tank surfaces
Joints or elbows that are discolored or cracked
How FRP Pipes Are Constructed
Manufacturing Process of FRP Pipes
FRP pipes can be divided into three layers: liner layer, structural layer and outer anti-aging layer. The liner layer featuring excellent corrosion resistance, can effectively prevent seepage; while, the structural layer can reinforce the FRP pipe by improving its rigidity and strength. And the outer anti-aging layer is characterized by excellent resistance to aging, corrosion as well as UV.
Filament winding, as the most extensively method, is generally used to manufacture FRP pipes such as pressure pipes, drainage pipe and chimney pipes. Here is a simple introduction of FRP pipe manufacturing process.
Mandrel preparation.
Clean and polish the mandrel to ensure a smooth surface without any potholes, dust, debris or other fixtures affecting the quality of FRP pipes. Then wrap a thin mylar parting film around the mandrel to make the pipe extraction much easier.
Machine & material preparation.
Check up on the equipment and make sure it is operating properly, especially resin and curing agent are in correct composition and the dual pump performs well without any clogging. All of this is to ensure high precision and stable operation of your equipment.
Liner production.
Compound the resin for liner layer according to the requirements of local regulations, working environments and temperature conditions.
Prepare the reinforce materials of liner layers. Cut reinforce materials into certain width and mounted them to specific position for easy winding.
Manufacture the liner layers based on the design requirements. Impose reasonable tension during the winding process for excellent lapping. Meanwhile, use compression rollers to press bubbles out and ensure the reinforce materials are fully steeped with resin.
Check the liner layer to ensure required thickness is achieved without white patch, bubbles, poor adhesive and adhesive hanging phenomena.
Liner curing.
The liner layers are cured through far infrared depth curing process to enhance solidification degree and improve anti-corrosion properties.
Liner inspection.
Check the pipe again to ensure liner layers in manufactured without bubbles, impurity, white patch, part curing phenomena. Most all, ensure the liner layer is qualified with reasonable resin ratio.
Filament winding.
The filament is automatically impregnated in the resin tank, and then reciprocating winded around the rotating mandrel at a specific angle. Normally, different helical angles impart different strength in the hoop or axial direction as required.
Pipe curing.
After the filament winding process, FRP pipes are far infrared cured about 1 hour to 2 hours based on weather condition. Meanwhile, the mandrel rotates at an even speed to ensure the pipe is cured evenly.
Trimming & extraction.
When the Barcol hardness of the FRP pipe is more than 30, then trim the pipe and separate it from the mandrel.
Pipe testing.
Test the pipe through following aspects:
Visual inspect: Ensure the surface of FRP pipes is smooth without cracking, delamination, holes, debris, burrs, bubbles and obvious defects that affect pipe performance. In addition, the pipe end should be flush.
Dimensional inspection: check the length, thickness, Barcol hardness and socket size of FRP pipes.
Hydraulic pressure leakage test: Fill the pipe with water until the pressure reach about 1.5 times of pipeline design pressure and then retain the water no less than 2 minutes. Check the surface of FRP pipe and piezometer carefully. The pipes without leakage are qualified.
Mechanical property testing.
Inquiry for Our Product
Hengshui Fangchen FRP Equipment Technology Co., Ltd.
E-mail: info@frpmachine.com
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