This document discusses glass reinforced plastic (GRP), including its composition, manufacturing processes, properties, and applications. GRP consists of glass fibers embedded in a thermosetting plastic matrix. It offers advantages over other materials like steel due to its light weight, corrosion resistance, strength, and low maintenance. GRP can be manufactured through filament winding or centrifugal casting processes and is used in applications like pipes where its properties make it suitable for transporting chemicals and fluids.

1. GLASS REINFORCED PLASTIC
(GRP)
Prepared & Presented By: Abdallah Sayed Ahmed El-gharbawy

2. What Is Problem
• Corrosion.
• Fluid Contamination

3. What Is Problem
• Fracture under Thermal Stress or
Mechanical Stresses

4. COMPOSITE MATERIALS
• Reinforcement Fibers: Glass fiber
• Polymer matrix: Thermoset/Thermoplastic.
• Other Components: Filler/Pigment

5. OTHER COMPONENTS
• Fillers: Inorganic materials, such as hydrated alumina, glass microspheres,
clay, talc, calcium carbonate, sand, and calcium silicate, may yield economic,
appearance, or performance advantages in fiberglass pipe.
• Promoters, accelerators, and inhibitors: Promoters and accelerators
advance the action of the catalyst to reduce the processing time. Inhibitors
provide control over the cure cycle and increase the shelf life of the resin
mix.

6. OTHER COMPONENTS
• Pigments: The pigment choice affects the difference in reflected and
transmitted color, clarity of the resin mix, reaction between dyes and other
additives, such as catalysts, and the end-product color fastness and heat
resistance.

7. POLYMERS
Thermoplastic Thermosets
• Polyethylene
• Polypropylene
• Polycarbonate
• Polyamide
• Polybutylene terephthalate
Epoxides

8. GLASS DEFINITION
• Glass is an amorphous, hard, brittle,
transparent obtained by fusing a mixture
of a number of metallic silicates or
borates of Sodium, Potassium, Calcium,
and Lead. It possess no definite formula
or crystalline structure.

9. PROPERTIES OF GLASS
• Amorphous
• Brittle
• Transparent / Translucent
• Good electrical insulator
• Unaffected by air, water, acid or chemical reagents except HF
• No definite crystal structure means glass has high Compressive strength
• Can absorb, transmit and reflect light

10. RAW MATERIALS USED IN MANUFACTURING
GLASS
• Silicon dioxide (SiO2).
• Sodium as Na2Co3 (used in soft glass).
• Potassium as K2Co3 (used in Hard Glass).
• Calcium as lime stone, chalk and lime (CaO).
• Zinc is zinc oxide (Heat and shock proof glass).
• Borates are borax, Boric acid (Heat and shock proof
glass).

11. Manufacturing Steps
 Melting
 Forming and Shaping
 Annealing
 Finishing

12. Melting process
• Raw materials in proper proportions are mixed with cullets. It is finely powdered
and intimate mixture called batch is fused in furnace at high temperature of 1800°C
this charge melts and fuses into a viscous fluid.
CaCO3 + SiO2  CaSiO3 + CO2 
Na2CO3 + SiO2  Na2SiO3 + CO2
• After removal of CO2 decolorizes like MnO2 are added to remove traces of
ferrous compounds and Carbon. Heating is continued till clear molten mass is free
from bubbles is obtained and it is then cooled to about 800°C.

13. Forming, shaping, and annealing
Forming and Shaping
The viscous mass obtained from melting is poured into moulds to get different
types of articles of desired shape by either blowing or pressing between the
rollers.
Annealing
Glass articles are then allowed to cool gradually at room temperature by passing
through different chambers with descending temperatures. This reduces the
internal Strain in the glass.

14. Finishing
Finishing is the last step in glass manufacturing. It involves following steps:
 Cleaning
 Grinding
 Polishing
 Cutting
 Sand Blasting

15. FIBER GLASS

16. HISTORY
• It was announced FRP invention on February 5, 1909.
• The first fibre-reinforced plastic plane was either the Fairchild F-46, first
flown on 12 May 1937.
• The first car to have a fibre-glass body was the 1946.
• Global polymer production on the scale present today began in the mid 20th
century, when low material and productions costs, new production
technologies and new product categories combined to make polymer
production economical. The industry finally matured in the late 1970s when
world polymer production surpassed that of steel

17. HISTORY
• Fiberglass pipe was introduced in 1948. The earliest application for fiberglass
piping, and still one of the most widely used, is in the oil industry.
• Since the 1960s, fiberglass pipe products have been used for municipal water
and sewage applications thus eliminating the need for interior linings,
exterior coatings, and cathodic protection.
• Fiberglass pipe is available in diameters ranging from 1 in. through 144 in.
(25 mm through 3,600 mm).

18. Financial & Application

23. Advantages
• Light weight to strength ratio
• Corrosion resistant
• Water resistant
• Non-conductive

24. CHARACTERISTICS
• Corrosion resistance: Fiberglass pipe systems are resistant to corrosion,
both inside and out, in a wide range of fluid-handling applications. As a
result, additional linings and exterior coatings are not required.
• Strength-to-weight ratio. Fiberglass composite piping systems have
excellent strength-to-weight properties. The ratio of strength per unit of
weight of fiberglass composites is greater than that of iron, carbon, and
stainless steels.

26. CHARACTERISTICS
• Lightweight. Fiberglass composites are lightweight. Fiberglass piping is
approximately one-sixth the weight of similar steel products and one-
tenth the weight of similar concrete products.
• Electrical properties. Standard fiberglass pipes are nonconductive.
Some supplier offer conductive fiberglass piping systems for applications
that require dissipation of static electricity buildup when transporting
certain fluids, such as jet fuel.

27. CHARACTERISTICS
• Dimensional stability. Fiberglass composites can maintain the critical
tolerances required of the most demanding structural and piping
applications. The material meets the most stringent material stiffness,
dimensional tolerance, weight, and cost criteria.
• Low maintenance cost. Fiberglass piping is easy to maintain because
it does not rust, is easily cleaned, and requires minimal protection from
the environment

28. GLASS FIBER
MANUFACTURING

29. Filament Winding
• Filament winding is the process of impregnating glass fiber
reinforcement with resin, then applying the wetted fibers onto a
mandrel in a prescribed pattern. Fillers, if used, are added during the
winding process.
• A multilayered structural wall construction of the required thickness.
• Finished pipe emerging from the curing oven

30. Filament Winding

32. CENTRIFUGAL CASTING
• Centrifugal casting is used to manufacture tubular goods by applying
resin and reinforcement to the inside of a mold that is rotated and
heated.
• Other materials, such as sand or fillers, may be introduced in the
process during manufacture of the pipe.

33. CENTRIFUGAL CASTING

35. GLASS FIBER MATERIAL
• Glass fibres begin as varying combinations of SiO2, Al2O3, B2O3, CaO, or
MgO in powder form. These mixtures are then heated through direct melting
to temperatures around 1300 degrees Celsius, after which dies are used to
extrude filaments of glass fibre in diameter ranging from 9 to 17 µm. These
filaments are then wound into larger threads and spun onto bobbins for
transportation and further processing. Glass fibre is by far the most popular
means to reinforce plastic and thus enjoys a wealth of production processes,
some of which are applicable to aramid and carbon fibres as well owing to
their shared fibrous qualities.

36. GLASS FIBER MATERIAL
• Roving is a process where filaments are spun into larger diameter threads. These
threads are then commonly used for woven reinforcing glass fabrics and mats, and
in spray applications.
• Fibre fabrics are web-form fabric reinforcing material that has both warp and weft
directions. Fibre mats are web-form non-woven mats of glass fibres. Mats are
manufactured in cut dimensions with chopped fibres, or in continuous mats using
continuous fibres. Chopped fibre glass is used in processes where lengths of glass
threads are cut between 3 and 26 mm, threads are then used in plastics most
commonly intended for moulding processes. Glass fibre short strands are short 0.2–
0.3 mm strands of glass fibres that are used to reinforce thermoplastics most
commonly for injection moulding

37. FIBER ORIENTATION
• Aligned in the direction of load
• Aligned in the direction perpendicular to load
• Randomly distribution of fibers.
It is observed that fibers aligned parallel to applied load offered more tensile
strength and toughness than randomly distributed or perpendicular fibers.

39. THERMAL PROPERTIES
GRP Carbon Steel
Thermal Expansion α/(10−6 K−1) 8-14 14.1
Application Temperature (C) -40 to 150 -29 to 420
Thermal conductivity W/K•m 0,25-0,35 54

40. MECHANICAL PROPERTIES

42. GRP STEEL HDPE PVC
1 Design Life Time 50 15-20 8-10 5-8
2 Specific Gravity 1.8 7.85 7.1 1.4
3 Tensile Strength
(Mpa)
380-550 344 3.5 50
4 Modulus of
Elasticity
5*𝟏𝟎𝟔 22*𝟏𝟎𝟔
7*𝟏𝟎𝟓
5*𝟏𝟎𝟓
5 Maintenance No Periodical
inspection
Repair not possible Repair not possible
6 Corrosion No Yes No No
7 Surge pressure Excellent High protection
needed
Poor Poor
8 Temperature (C) 150 150-200 80 50