Glass fiber reinforced (GFRP) composites is the largest segment in the composites industry, worth several billion. Glass fiber is made from extremely fine fibers of glass. It is a lightweight, strong, and robust material. Although strength properties are somewhat lower than carbon fiber and it is less stiff, the material is typically far less brittle, and the raw materials are much less expensive. Its bulk strength and weight properties are also very favorable when compared to metals, and it can be easily formed using molding processes.
Glass fibers are most extensively used as a raw material for composite materials. Glass fiber accounts for about 90% of the reinforcements used in composite consumption, globally. Most of the GFRP Composites are used in the construction and transportation sectors. The demand for renewable energy in the form of wind turbines, demand for light-weight fuel-efficient aircrafts & cars, and the demand for GFRP pipe, tank and other corrosion-resistant equipment are major drivers increasing its demand in the coming years.
The GFRP composites report analyzes GFRP composites market by type of raw materials, manufacturing processes, and applications; globally and regionally. The report familiarizes the industry players with the market trends, opportunities, drivers, and challenges. This report identifies the factors driving or inhibiting the growth of each segment to support its analysis of market trends and forecasts. In addition to the market size, data trends, and forecasts; the report also highlights the key market opportunities for the stakeholders and draws a competitive landscape in which the key market developments of the top companies in the market are profiled.
The GFRP composites market by raw material type is projected to grow at a CAGR of 7.1% during the review period. Due to increasing infrastructure & construction projects in Asia-Pacific, especially in India and China, the emerging regions are expected to register maximum growth. Asia-Pacific and North America dominate the global GFRP Composites market, accounting for 67% of the overall market in 2013.
The manufacturing process of GFRP
Step 1 – Batching
In the initial stage of producing GFRP, materials must be carefully weighed in exact quantities and thoroughly mixed (batched). More than half the mix is silica sand, which is the basic building block of any glass.
Step 2 – Melting
From the batch house, a pneumatic conveyor sends the mixture to a high temperature (ca. 1400ºC) furnace for melting. The furnace is typically divided into three sections, with channels that aid glass flow. The first section receives the batch, where melting occurs and uniformity is increased, ensuring there’s no bubbles. The high temperature see to it that the sand and other ingredients dissolve into molten glass. The molten glass then flows into the refiner, where its temperature is reduced to 1370ºC.
Step 3 – Fiberization
GFRP formation, or fiberization, involves a combination of extrusion and attenuation. In extrusion, the molten glass passes out of the forehearth through a bushing made of an erosion-resistant platinum alloy with very fine orifices. Bushing plates are heated electronically, and their temperature is precisely controlled to maintain a constant glass viscosity. Water jets cool the filaments as they exit the bushing at approximately 1204ºC.
Attenuation is the process of mechanically drawing the extruded streams of molten glass into fibrous elements called filaments. A high-speed winder catches the molten streams and because it revolves at a circumferential speed of ca. 3 km per minute (much faster than the molten glass exiting the bushing), tension is applied, drawing them into thin filaments.
Step 4 – Coating
In the final stage, a chemical coating is applied. This typically adds 0.5 to 2.0 percent of the weight and may include lubricants, binders and/or coupling agents. The lubricants help to protect the filaments from abrading and breaking as they are collided and wound into forming packages, and later, when the filaments are processed by weavers or other converters into fabrics or other reinforcement forms.
Step 5 – Drying and packaging
Finally, the drawn, sized filaments are collected together into a bundle, forming a glass strand composed of 51 to 1,624 filaments. The strand is wound onto a drum into a forming package that resembles a spool of thread. The forming packages, still wet from water cooling and sizing, are then dried in an oven. Afterwards, they are ready to be packaged and shipped or further processed into chopped fibre, roving or yarn.
Properties of GFRP
- Mechanical strength: GFRP has a specific resistance greater than steel.
- Lightweight: Low weights ensure faster installation, less structural framing, and lower shipping costs.
- Electrical characteristics: Good electrical insulator even at low thickness.
- High resistance: Resistant to salt water, chemicals, and is unaffected by acid rain.
- Incombustibility: Being a mineral material, GFRP is naturally incombustible. It does not propagate or support a flame, and it does not emit smoke or toxicity when exposed to heat.
- Thermal conductivity: Low thermal conductivity makes it highly useful in the building industry.
- High durability: GFRP does not rot and remains unaffected by rodents and insects. It does not show loss of laminate properties after 30 years.
Applications of GFRP
GFRP can be used for both interior and exterior fixtures in a variety of shapes, styles, and textures, in new buildings or restorative projects. GFRP finds application in an extensive array of markets.
- Aerospace and defense
- Automotive industry
- Power generation
- Docks and marinas
- Fountains and aquariums
- Cooling towers
- Manufacturing
- Food processing
- Beverage industry
- Metals and mining
- Plating plants
- Pulp and paper industry
- Car washes