Report on Fiber Reinforced Polymers

Done By:
Marwan Hesham Salaheldine Ibrahim Khashaba
Code: 1902195
Graduate Course CES:625 ADVANCED COMPOSITE MATERIALS
Fiber Reinforced Polymer as a Material:
Composite materials are engineered or naturally occurring materials made from two or more
constituent materials with significantly different physical or chemical properties which remain
separate and distinct within the finished structure. Most composites have strong, stiff fibres in a
matrix which is weaker and less stiff. The objective is usually to make a component which is strong
and stiff, often with a low density.
Fibre-reinforced polymer (FRP), also Fibre-reinforced plastic, is a composite material made of a
polymer matrix reinforced with fibres.
The fibres are usually:
• Glass: Glass is generally a good impact resistant fibre but weighs more than carbon or
aramid. Glass fibres have excellent characteristics equal to or better than steel in certain
forms.

• Carbon: Carbon fibres have a high modulus of elasticity, 200-800 GPa. The ultimate
elongation is 0.3-2.5 % where the lower elongation corresponds to the higher stiffness and
vice versa. Carbon fibres do not absorb water and are resistant to many chemical solutions.
They withstand fatigue excellently and neither corrode nor show any creep or relaxation.

• Aramid: The moduli of the fibres are 70-200 GPa with an ultimate elongation of 1.5-5%
depending on the quality. Aramid has a high fracture energy and is therefore used for
helmets and bullet-proof garments. They are sensitive to elevated temperatures, moisture and
ultraviolet radiation and therefore not widely used in civil engineering applications. Finally,
Aramid fibres do have problems with relaxation and stress corrosion.
 Shown in the following figure the stress-strain curve of FRP manufactured from different types
of fibers relative to the conventional steel stress-strain curve.

The polymer is usually:

• Epoxy
• Vinyl ester
• Also, Polyester thermosetting plastic, and phenol formaldehyde resins are still in use.
Fibre reinforced polymer (FRP) are composites used in almost every type of advanced engineering
structure, with their usage ranging from aircraft, helicopters and spacecraft through to boats, ships
and offshore platforms and to automobiles, sports goods, chemical processing equipment and civil
infrastructure such as bridges and buildings. The usage of FRP composites continues to grow at an
impressive rate as these materials are used more in their existing markets and become established in
relatively new markets such as biomedical devices and civil structures. A key factor driving the
increased applications of composites over the recent years is the development of new advanced
forms of FRP materials. This includes developments in high performance resin systems and new
styles of reinforcement, such as carbon nanotubes and nanoparticles.
The Main Applications of Fiber-Reinforced Polymers in Structural Engineering practice are:
• Carbon FRPs are used in prestressed concrete for applications where high resistance to
corrosion and electromagnetic transparency of CFRP are important.
• CFRP composites are employed for underwater piping and structural parts
of offshore platform. Added to that, FRP declines the risk of fire.
• Carbon fibre reinforced polymers are used to manufacture underwater pipes for great depth
because it provides a significantly increased buoyancy (due to its low density) compared to
steel.
 • The stairways and walkways are also made of composites for weight saving and corrosion
resistance.
• It is used in high-performance hybrid structures.
• FRP bars are used as internal reinforcement for concrete structures.
• FRP bars, sheets, and strips are used for strengthening of various structures constructed from
concrete, masonry, timber, and even steel.
• FRPs are employed for seismic retrofitting.
• Fibre reinforced polymers are used in the construction of special structures requiring
electrical neutrality.
• The high energy absorption of aramid fibre reinforced polymer (AFRP) composites makes
them suitable for strengthening engineering structures subjected to dynamic and impact
loading.
So, it can take the shape of structural sections or reinforcing bars or even strengthening sheets as
shown.
Advantages and Disadvantages:
FRP composites are lightweight, non-corrosive, exhibit high specific strength and specific stiffness,
are easily constructed, and can be tailored to satisfy performance requirements. Due to these
advantageous characteristics, FRP composites have been included in new construction and
rehabilitation of structures through its use as reinforcement in concrete, bridge decks, modular
structures, formwork, and external reinforcement for strengthening and seismic upgrade.
FRP reinforcements offer several advantages such as corrosion resistance, non-magnetic properties,
high tensile strength, lightweight and ease of handling. However, they generally have a linear
elastic response in tension up to failure (described as a brittle failure) and a relatively poor
transverse or shear resistance. They also have poor resistance to fire and when exposed to high
temperatures. They lose significant strength upon bending, and they are sensitive to stress-rupture
effects. Moreover, their cost, whether considered per unit weight or based on force carrying
capacity, is high in comparison to conventional steel reinforcing bars or prestressing tendons. From
a structural engineering viewpoint, the most serious problems with FRP reinforcements are the lack
of plastic behavior and the very low shear strength in the transverse direction.
Solutions and limitations of use have been offered and continuous improvements are expected in
the future. The unit cost of FRP reinforcements is expected to decrease significantly with increased
market share and demand. However, even today, there are applications where FRP reinforcements
are cost effective and justifiable. Such cases include the use of bonded FRP sheets or plates in
repair and strengthening of concrete structures, and the use of FRP meshes or textiles or fabrics in
thin cement products. The cost of repair and rehabilitation of a structure is always, in relative terms,
substantially higher than the cost of the initial structure. Repair generally requires a relatively small
volume of repair materials but a relatively high commitment in labor. Moreover, the cost of labor in
developed countries is so high that the cost of material becomes secondary. Thus, the highest the
performance and durability of the repair material is, the more cost-effective is the repair. This
implies that material cost is not really an issue in repair and that the fact that FRP repair materials
are costly is not a constraining drawback.
When considering only energy and material resources it appears, on the surface, the argument for
FRP composites in a sustainable built environment is questionable. However, such a conclusion
needs to be evaluated in terms of potential advantages present in use of FRP composites related to
considerations such as:
• Higher strength
• Lighter weight
• Higher performance
• Longer lasting
• Rehabilitating existing structures and extending their life
• Seismic upgrades
• Defense systems
• Space systems
• Ocean environments

Fiber-Reinforced Polymers properties control:

A true advantage of using Fiber-reinforced polymers in many Engineering applications is the ability
to tailor its properties to achieve certain required characteristics according to the function needed.
Such change in properties can be done through controlling:
• Type of fiber used where properties of fiber highly affect the final mechanical and chemical
properties of the final product material and thus reaching the required strength and durability.
• Type of matrix (polymer) used.
• The volume of the constituents (fibers and matrix).
• The method of fabrication.
• The fiber orientation as FRP is an orthotropic material whose mechanical properties depend
on the loading direction.
• All are factors contributing to the final characteristics of the material which the designer can
control in order to achieve the desired properties.
Fabrication Methods of FRP:
Fiber reinforced polymer material is very complex, particularly when a definition of the
material is required. For instance, the variabilities in the polymer include its manufacturing
techniques and whether additives or modifiers have been incorporated. However, most
polymers do exhibit similar characteristics, differing only in magnitude but compared with
conventional materials, are more complex with more pronounced viscoelastic behavior,
temperature effects, and environmental factors. Fiber reinforced polymers are less complex
than the polymer, considered separately. The fibers stabilize the polymer with the effect that
the composite material has elastic characteristics compared with the viscoelastic properties
of the polymer.
FRP involves two distinct processes, the first is the process whereby the fibrous material is
manufactured and formed, and the second is the process whereby fibrous materials are
bonded with the matrix during the molding process.
1. Fibre process
• The manufacture of fibre fabric
Reinforcing Fibre is manufactured in both two dimensional and three-dimensional
orientations. Two Dimensional Fibre Reinforced Polymer are characterized by a laminated
structure in which the fibres are only aligned along the plane in x-direction and y-direction of
the material. This means that no fibres are aligned in the through thickness or the z-direction,
this lack of alignment in the through thickness can create a disadvantage in cost and
processing. Costs and labour increase because conventional processing techniques used to
fabricate composites, such as wet hand lay-up, autoclave, and resin transfer molding, require
a high amount of skilled labour to cut, stack and consolidate into a preformed component.
Three-dimensional Fibre Reinforced Polymer composites are materials with three
dimensional fibre structures that incorporate fibres in the x-direction, y-direction, and z-
direction. The development of three-dimensional orientations arose from industry's need to
reduce fabrication costs, to increase through-thickness mechanical properties, and to improve
impact damage tolerance; all were problems associated with two dimensional fibre
reinforced polymers.
• The manufacture of fibre preforms
Fibre preforms are how the fibres are manufactured before being bonded to the matrix. Fibre
preforms are often manufactured in sheets, continuous mats, or as continuous filaments for
spray applications. The four major ways to manufacture the fibre preform is though the
textile processing techniques of Weaving, knitting, braiding, and stitching.
Weaving can be done in a conventional manner to produce two-dimensional fibres as well in
a multilayer weaving that can create three-dimensional fibres. However, multilayer weaving
is required to have multiple layers of warp yarns to create fibres in the z- direction creating a
few disadvantages in manufacturing, namely the time to set up all the warp yarns on the
loom. Therefore, most multilayer weaving is currently used to produce relatively narrow
width products or high value products where the cost of the preform production is
acceptable. Another Fibre-reinforced plastic 3D one of the main problems facing the use of
multilayer woven fabrics is the difficulty in producing a fabric that contains fibres oriented
with angles other than 0º and 90º to each other respectively.
The second major way of manufacturing fibre preforms is braiding. Braiding is suited to the
manufacture of narrow width flat or tubular fabric and is not as capable as weaving in the
production of large volumes of wide fabrics. Braiding is done over top of mandrels that vary
in cross-sectional shape or dimension along their length. Braiding is limited to objects about
a brick in size.
Knitting fibre preforms can be done with the traditional methods of Warp and [Weft]
Knitting, and the fabric produced is often regarded by many as two-dimensional fabric, but
machines with two or more needle beds are capable of producing multilayer fabrics with
yams that traverse between the layers. Developments in electronic controls for needle
selection and knit loop transfer and in the sophisticated mechanisms that allow specific areas
of the fabric to be held and their movement controlled. This has allowed the fabric to form
itself into the required three-dimensional perform shape with a minimum of material
wastage.
Stitching is arguably the simplest of the four main textile manufacturing techniques and one
that can be performed with the smallest investment in specialized machinery. Basically the
stitching process consists of inserting a needle, carrying the stitch thread, through a stack of
fabric layers to form a 3D structure. The advantages of stitching are that it is possible to
stitch both dry and prepreg fabric, although the tackiness of prepare makes the process
difficult and generally creates more damage within the prepreg material than in the dry
fabric. Stitching also utilizes the standard two-dimensional fabrics that are commonly in use
within the composite industry therefore there is a sense of familiarity concerning the material
systems. The use of standard fabric also allows a greater degree of flexibility in the fabric
lay-up of the component than is possible with the other textile processes, which have
restrictions on the fibre orientations that can be produced.
• Molding processes
There are two distinct categories of molding processes using FRP plastics; this includes
composite molding and wet molding. Composite molding uses Prepreg FRP, meaning the
plastics are fibre reinforced before being put through further molding processes. Sheets of
Prepreg FRP are heated or compressed in different ways to create geometric shapes. Wet
molding combines fibre reinforcement and the matrix or resist during the molding process.
The different forms of composite and wet molding are listed below.
2. Composite molding
• Bladder molding
Individual sheets of prepreg material are laid -up and placed in a female-style mould along
with a balloon-like bladder. The mould is closed and placed in a heated press. Finally, the
bladder is pressurized forcing the layers of material against the mould walls. The part is
cured and removed from the hot mould. Bladder molding is a closed molding process with a
relatively short cure cycle between 15 and 60 minutes making it ideal for making complex
hollow geometric shapes at competitive costs.
• Compression molding
A "preform" or "charge", of SMC, BMC or sometimes prepreg fabric, is placed into mould
cavity. The mould is closed and the material is compacted & cured inside by pressure and
heat. Compression molding offers excellent detailing for geometric shapes ranging from
pattern and relief detailing to complex curves and creative forms, to precision engineering all
within a maximum curing time of 20 minutes.
• Autoclave − Vacuum bag
Individual sheets of prepreg material are laid-up and placed in an open mold. The material is
covered with release film, bleeder/breather material and a vacuum bag. A vacuum is pulled
on part and the entire mould is placed into an autoclave (heated pressure vessel). The part is
cured with a continuous vacuum to extract entrapped gasses from laminate. This is a very
common process in the aerospace industry because it affords precise control over the
molding process due to a long slow cure cycle that is anywhere from one to two hours. This
precise control creates the exact laminate geometric forms needed to ensure strength and
safety in the aerospace industry, but it is also slow and lab our intensive, meaning costs often
confine it to the aerospace industry.
• Mandrel wrapping
Sheets of prepreg material are wrapped around a steel or aluminum mandrel. The prepreg
material is compacted by nylon or polypropylene cello tape. Parts are typically batch cured
by hanging in an oven. After cure, the cello and mandrel are removed leaving a hollow
carbon tube. This process creates strong and robust hollow carbon tubes.
• Wet layup
Fibre reinforcing fabric is placed in an open mould and then saturated with a wet (resin) by
pouring it over the fabric and working it into the fabric and mould. The mould is then left so
that the resin will cure, usually at room temperature, though heat is sometimes used to ensure
a proper curing process. Glass fibres are most used for this process, the results are widely
known as fiberglass, and are used to make common products like skis, canoes, kayaks, and
surf boards.
• Chopper gun
Continuous strand of fiberglass is pushed through a hand-held gun that both chops the
strands and combines them with a catalyzed resin such as polyester. The impregnated
chopped glass is shot onto the mould surface in whatever thickness the design and human
operator think is appropriate. This process is good for large production runs at economical
cost but produces geometric shapes with less strength than other molding processes and has
poor dimensional tolerance.
• Filament winding
Machines pull fibre bundles through a wet bath of resin and wound over a rotating steel
mandrel in specific orientations Parts are cured either room temperature or elevated
temperatures. Mandrel is extracted, leaving a final geometric shape but can be left in some
cases.
• Pultrusion
Fibre bundles and slit fabrics are pulled through a wet bath of resin and formed into the
rough part shape. Saturated material is extruded from a heated closed die curing while being
continuously pulled through die. Some of the end products of the pultrusion process are
structural shapes, i.e. beam, angle, and flat sheet. These materials can be used to create all
sorts of fiberglass structures such as ladders, handrail systems tank, pipe, and pumps.
3. Resin infusion
Fabrics are placed into a mould which wet resin is then injected into. Resin is typically
pressurized and forced into a cavity which is under vacuum in the RTM (Resin Transfer
Molding) process. Resin is entirely pulled into cavity under vacuum in the VARTM
(Vacuum Assisted Resin Transfer Molding) process. This molding process allows precise
tolerances and detailed shaping but can sometimes fail to fully saturate the fabric leading to
weak spots in the final shape.

Conclusion:
This brief review of FRP has summarized the very broad range of unusual functionalities that
FRP bring. Along with the merits and demerits of using FRP in various Engineering
applications specilly structural Engineering.
The report gives a brief overview of how designers can tailor the material into their desired
characteristics and the fabrication processes of FRP composite material. However, studying
FRP is an ongoing process that needs further research efforts in order to identify all the
different engineering aspects and design considerations to be widely used in engineering
practice as it is considered the material of the future.
References
❖ “Introduction of Fibre-Reinforced Polymers and Composites: Concepts, Properties
and Processes” by Martin Alberto Masuelli, 2012, DOI: 10.5772/54629.
❖ ACI 440.1R-15: Guide for the Design and Construction of Structural Concrete
reinforced with Fiber-Reinforced Polymer Bars.
❖ L.C. Hollaway, P.R. Head, in Comprehensive Composite Materials, 2000.
❖ C. Zhang, in Eco-efficient Construction and Building Materials, 2014.
❖ A. Belarbi, B. Acun et al, in Sustainability of Construction Materials (Second
Edition), 2016.