Fiberglass: Fiberglass (American English), or Fibreglass (Commonwealth English) Is A Common Type of Fiber
Fiberglass: Fiberglass (American English), or Fibreglass (Commonwealth English) Is A Common Type of Fiber
Fiberglass: Fiberglass (American English), or Fibreglass (Commonwealth English) Is A Common Type of Fiber
Fiberglass
Fiberglass (American English), or fibreglass (Commonwealth English) is a common type of fiber-
reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet (called a
chopped strand mat), or woven into a fabric. The plastic matrix may be a thermoset polymer matrix—
most often based on thermosetting polymers such as epoxy, polyester resin, or vinylester—or a
thermoplastic.
Cheaper and more flexible than carbon fiber, it is stronger than many metals by weight, is non-magnetic,
non-conductive, transparent to electromagnetic radiation, can be molded into complex shapes, and is
chemically inert under many circumstances. Applications include aircraft, boats, automobiles, bath tubs
and enclosures, swimming pools, hot tubs, septic tanks, water tanks, roofing, pipes, cladding, orthopedic
casts, surfboards, and external door skins.
Other common names for fiberglass are glass-reinforced plastic (GRP),[1] glass-fiber reinforced
plastic (GFRP)[2] or GFK (from German: Glasfaserverstärkter Kunststoff). Because glass fiber itself is
sometimes referred to as "fiberglass", the composite is also called "fiberglass reinforced plastic". This
article will adopt the convention that "fiberglass" refers to the complete glass fiber reinforced composite
material, rather than only to the glass fiber within it.
Contents
History
Fiber
Production
Chopped strand mat
Sizing
Properties
Types of glass fiber used
Table of some common fiberglass types
Applications
Storage tanks
House building
Oil and gas artificial lift systems
Piping
Examples of fiberglass use
Construction methods
Filament winding
Fiberglass hand lay-up operation
Fiberglass spray lay-up operation
Pultrusion operation
Warping
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Health hazards
See also
References
External links
History
Glass fibers have been produced for centuries, but the earliest patent was awarded to the Prussian
inventor Hermann Hammesfahr (1845–1914) in the U.S. in 1880.[3][4]
Mass production of glass strands was accidentally discovered in 1932 when Games Slayter, a researcher
at Owens-Illinois, directed a jet of compressed air at a stream of molten glass and produced fibers. A
patent for this method of producing glass wool was first applied for in 1933.[5] Owens joined with the
Corning company in 1935 and the method was adapted by Owens Corning to produce its patented
"Fiberglas" (spelled with one "s") in 1936. Originally, Fiberglas was a glass wool with fibers entrapping a
great deal of gas, making it useful as an insulator, especially at high temperatures.
A suitable resin for combining the fiberglass with a plastic to produce a composite material was
developed in 1936 by du Pont. The first ancestor of modern polyester resins is Cyanamid's resin of 1942.
Peroxide curing systems were used by then.[6] With the combination of fiberglass and resin the gas
content of the material was replaced by plastic. This reduced the insulation properties to values typical of
the plastic, but now for the first time, the composite showed great strength and promise as a structural
and building material. Many glass fiber composites continued to be called "fiberglass" (as a generic
name) and the name was also used for the low-density glass wool product containing gas instead of
plastic.
Ray Greene of Owens Corning is credited with producing the first composite boat in 1937 but did not
proceed further at the time due to the brittle nature of the plastic used. In 1939 Russia was reported to
have constructed a passenger boat of plastic materials, and the United States a fuselage and wings of an
aircraft.[7] The first car to have a fiber-glass body was a 1946 prototype of the Stout Scarab, but the
model did not enter production.[8]
Fiber
Unlike glass fibers used for insulation, for the final structure to be strong, the fiber's surfaces must be
almost entirely free of defects, as this permits the fibers to reach gigapascal tensile strengths. If a bulk
piece of glass were defect-free, it would be equally as strong as glass fibers; however, it is generally
impractical to produce and maintain bulk material in a defect-free state outside of laboratory
conditions.[9]
Production
The process of manufacturing fiberglass is called pultrusion. The manufacturing process for glass fibers
suitable for reinforcement uses large furnaces to gradually melt the silica sand, limestone, kaolin clay,
fluorspar, colemanite, dolomite and other minerals until a liquid forms. It is then extruded through
bushings, which are bundles of very small orifices (typically 5–25 micrometres in diameter for E-Glass, 9
micrometres for S-Glass).[10]
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Chopped strand mat or CSM is a form of reinforcement used in fiberglass. It consists of glass fibers
laid randomly across each other and held together by a binder.
It is typically processed using the hand lay-up technique, where sheets of material are placed on a mold
and brushed with resin. Because the binder dissolves in resin, the material easily conforms to different
shapes when wetted out. After the resin cures, the hardened product can be taken from the mold and
finished.
Using chopped strand mat gives the fiberglass isotropic in-plane material properties.
Sizing
Properties
An individual structural glass fiber is both stiff and strong in tension and compression—that is, along its
axis. Although it might be assumed that the fiber is weak in compression, it is actually only the long
aspect ratio of the fiber which makes it seem so; i.e., because a typical fiber is long and narrow, it buckles
easily.[9] On the other hand, the glass fiber is weak in shear—that is, across its axis. Therefore, if a
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collection of fibers can be arranged permanently in a preferred direction within a material, and if they
can be prevented from buckling in compression, the material will be preferentially strong in that
direction.
Furthermore, by laying multiple layers of fiber on top of one another, with each layer oriented in various
preferred directions, the material's overall stiffness and strength can be efficiently controlled. In
fiberglass, it is the plastic matrix which permanently constrains the structural glass fibers to directions
chosen by the designer. With chopped strand mat, this directionality is essentially an entire two-
dimensional plane; with woven fabrics or unidirectional layers, directionality of stiffness and strength
can be more precisely controlled within the plane.
A fiberglass component is typically of a thin "shell" construction, sometimes filled on the inside with
structural foam, as in the case of surfboards. The component may be of nearly arbitrary shape, limited
only by the complexity and tolerances of the mold used for manufacturing the shell.
The mechanical functionality of materials is heavily reliant on the combined performances of both the
resin (AKA matrix) and fibers. For example, in severe temperature conditions (over 180 °C), the resin
component of the composite may lose its functionality, partially due to bond deterioration of resin and
fiber.[12] However, GFRPs can still show significant residual strength after experiencing high
temperatures (200 °C).[13]
Composition: the most common types of glass fiber used in fiberglass is E-glass, which is alumino-
borosilicate glass with less than 1% w/w alkali oxides, mainly used for glass-reinforced plastics. Other
types of glass used are A-glass (Alkali-lime glass with little or no boron oxide), E-CR-glass
(Electrical/Chemical Resistance; alumino-lime silicate with less than 1% w/w alkali oxides, with high
acid resistance), C-glass (alkali-lime glass with high boron oxide content, used for glass staple fibers and
insulation), D-glass (borosilicate glass, named for its low Dielectric constant), R-glass (alumino silicate
glass without MgO and CaO with high mechanical requirements as Reinforcement), and S-glass
(alumino silicate glass without CaO but with high MgO content with high tensile strength).[14]
Naming and use: pure silica (silicon dioxide), when cooled as fused quartz into a glass with no true
melting point, can be used as a glass fiber for fiberglass but has the drawback that it must be worked at
very high temperatures. In order to lower the necessary work temperature, other materials are
introduced as "fluxing agents" (i.e., components to lower the melting point). Ordinary A-glass ("A" for
"alkali-lime") or soda lime glass, crushed and ready to be remelted, as so-called cullet glass, was the first
type of glass used for fiberglass. E-glass ("E" because of initial Electrical application), is alkali-free and
was the first glass formulation used for continuous filament formation. It now makes up most of the
fiberglass production in the world, and also is the single largest consumer of boron minerals globally. It
is susceptible to chloride ion attack and is a poor choice for marine applications. S-glass ("S" for "stiff") is
used when tensile strength (high modulus) is important and is thus an important building and aircraft
epoxy composite (it is called R-glass, "R" for "reinforcement" in Europe). C-glass ("C" for "chemical
resistance") and T-glass ("T" is for "thermal insulator"—a North American variant of C-glass) are
resistant to chemical attack; both are often found in insulation-grades of blown fiberglass.[15]
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Applications
Fiberglass is an immensely versatile material due to its lightweight,
inherent strength, weather-resistant finish and variety of surface
textures.
Advanced manufacturing techniques such as pre-pregs and fiber rovings extend fiberglass's applications
and the tensile strength possible with fiber-reinforced plastics.
Fiberglass is also used in the telecommunications industry for shrouding antennas, due to its RF
permeability and low signal attenuation properties. It may also be used to conceal other equipment
where no signal permeability is required, such as equipment cabinets and steel support structures, due
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to the ease with which it can be molded and painted to blend with existing structures and surfaces. Other
uses include sheet-form electrical insulators and structural components commonly found in power-
industry products.
Because of fiberglass's lightweight and durability, it is often used in protective equipment such as
helmets. Many sports use fiberglass protective gear, such as goaltenders' and catchers' masks.
Storage tanks
In rod pumping applications, fiberglass rods are often used for their
high tensile strength to weight ratio. Fiberglass rods provide an advantage over steel rods because they
stretch more elastically (lower Young's modulus) than steel for a given weight, meaning more oil can be
lifted from the hydrocarbon reservoir to the surface with each stroke, all while reducing the load on the
pumping unit.
Fiberglass rods must be kept in tension, however, as they frequently part if placed in even a small
amount of compression. The buoyancy of the rods within a fluid amplifies this tendency.
Piping
GRP and GRE pipe can be used in a variety of above- and below-ground systems, including those for:
desalination
water treatment
water distribution networks
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Construction methods
Filament winding
Filament winding is a fabrication technique mainly used for manufacturing open (cylinders) or closed-
end structures (pressure vessels or tanks). The process involves winding filaments under tension over a
male mandrel. The mandrel rotates while a wind eye on a carriage moves horizontally, laying down
fibers in the desired pattern. The most common filaments are carbon or glass fiber and are coated with
synthetic resin as they are wound. Once the mandrel is completely covered to the desired thickness, the
resin is cured; often the mandrel is placed in an oven to achieve this, though sometimes radiant heaters
are used with the mandrel still turning in the machine. Once the resin has cured, the mandrel is
removed, leaving the hollow final product. For some products such as gas bottles, the 'mandrel' is a
permanent part of the finished product forming a liner to prevent gas leakage or as a barrier to protect
the composite from the fluid to be stored.
Filament winding is well suited to automation, and there are many applications, such as pipe and small
pressure vessels that are wound and cured without any human intervention. The controlled variables for
winding are fiber type, resin content, wind angle, tow or bandwidth and thickness of the fiber bundle.
The angle at which the fiber has an effect on the properties of the final product. A high angle "hoop" will
provide circumferential or "burst" strength, while lower angle patterns (polar or helical) will provide
greater longitudinal tensile strength.
Products currently being produced using this technique range from pipes, golf clubs, Reverse Osmosis
Membrane Housings, oars, bicycle forks, bicycle rims, power and transmission poles, pressure vessels to
missile casings, aircraft fuselages and lamp posts and yacht masts.
A release agent, usually in either wax or liquid form, is applied to the chosen mold to allow the finished
product to be cleanly removed from the mold. Resin—typically a 2-part thermoset polyester, vinyl, or
epoxy—is mixed with its hardener and applied to the surface. Sheets of fiberglass matting are laid into
the mold, then more resin mixture is added using a brush or roller. The material must conform to the
mold, and air must not be trapped between the fiberglass and the mold. Additional resin is applied and
possibly additional sheets of fiberglass. Hand pressure, vacuum or rollers are used to be sure the resin
saturates and fully wets all layers, and that any air pockets are removed. The work must be done quickly
before the resin starts to cure unless high-temperature resins are used which will not cure until the part
is warmed in an oven.[21] In some cases, the work is covered with plastic sheets and vacuum is drawn on
the work to remove air bubbles and press the fiberglass to the shape of the mold.[22]
The fiberglass spray lay-up process is similar to the hand lay-up process but differs in the application of
the fiber and resin to the mold. Spray-up is an open-molding composites fabrication process where resin
and reinforcements are sprayed onto a mold. The resin and glass may be applied separately or
simultaneously "chopped" in a combined stream from a chopper gun.[23] Workers roll out the spray-up
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to compact the laminate. Wood, foam or other core material may then be added, and a secondary spray-
up layer imbeds the core between the laminates. The part is then cured, cooled, and removed from the
reusable mold.
Pultrusion operation
Warping
One notable feature of fiberglass is that the resins used are subject to contraction during the curing
process. For polyester this contraction is often 5–6%; for epoxy, about 2%. Because the fibers do not
contract, this differential can create changes in the shape of the part during curing. Distortions can
appear hours, days, or weeks after the resin has set.
While this distortion can be minimised by symmetric use of the fibers in the design, a certain amount of
internal stress is created; and if it becomes too great, cracks form.
Health hazards
In June 2011, the National Toxicology Program (NTP) removed from its Report on Carcinogens all
biosoluble glass wool used in home and building insulation and for non-insulation products.[24]
However, NTP considers fibrous glass dust to be "reasonably anticipated [as] a human carcinogen
(Certain Glass Wool Fibers (Inhalable))".[25] Similarly, California's Office of Environmental Health
Hazard Assessment ("OEHHA") published a November, 2011 modification to its Proposition 65 listing to
include only "Glass wool fibers (inhalable and biopersistent)."[26] The actions of U.S. NTP and
California's OEHHA mean that a cancer warning label for biosoluble fiber glass home and building
insulation is no longer required under federal or California law. All fiberglass wools commonly used for
thermal and acoustical insulation were reclassified by the International Agency for Research on Cancer
(IARC) in October 2001 as Not Classifiable as to carcinogenicity to humans (Group 3).[27]
People can be exposed to fiberglass in the workplace by breathing it in, skin contact, or eye contact. The
Occupational Safety and Health Administration (OSHA) has set the legal limit (permissible exposure
limit) for fiberglass exposure in the workplace as 15 mg/m3 total and 5 mg/m3 in respiratory exposure
over an 8-hour workday. The National Institute for Occupational Safety and Health (NIOSH) has set a
recommended exposure limit (REL) of 3 fibers/cm3 (less than 3.5 micrometers in diameter and greater
than 10 micrometers in length) as a time-weighted average over an 8-hour workday, and a 5 mg/m3 total
limit.[28]
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The European Union and Germany classify synthetic vitreous fibers as possibly or probably carcinogenic,
but fibers can be exempt from this classification if they pass specific tests. Evidence for these
classifications is primarily from studies on experimental animals and mechanisms of carcinogenesis. The
glass wool epidemiology studies have been reviewed by a panel of international experts convened by the
IARC. These experts concluded: "Epidemiologic studies published during the 15 years since the previous
IARC monographs review of these fibers in 1988 provide no evidence of increased risks of lung cancer or
mesothelioma (cancer of the lining of the body cavities) from occupational exposures during the
manufacture of these materials, and inadequate evidence overall of any cancer risk."[27] A 2012 health
hazard review for the European Commission stated that inhalation of fiberglass at concentrations of 3,
16 and 30 mg/m3 "did not induce fibrosis nor tumours except transient lung inflammation that
disappeared after a post-exposure recovery period."[29] Similar reviews of the epidemiology studies have
been conducted by the Agency for Toxic Substances and Disease Registry ("ATSDR"),[30] the National
Toxicology Program,[31] the National Academy of Sciences[32] and Harvard's Medical and Public Health
Schools[33] which reached the same conclusion as IARC that there is no evidence of increased risk from
occupational exposure to glass wool fibers.
Fiberglass will irritate the eyes, skin, and the respiratory system. Potential symptoms include irritation
of eyes, skin, nose, throat, dyspnea (breathing difficulty);sore throat, hoarseness and cough.[25] Scientific
evidence demonstrates that fiberglass is safe to manufacture, install and use when recommended work
practices are followed to reduce temporary mechanical irritation.[34] Unfortunately these work practices
are not always followed, and fiberglass is often left exposed in basements that later become occupied.
Fiberglass insulation should never be left exposed in an occupied area, according to the American Lung
Association.[35]
While the resins are cured, styrene vapors are released. These are irritating to mucous membranes and
respiratory tract. Therefore, the Hazardous Substances Ordinance in Germany dictates a maximum
occupational exposure limit of 86 mg/m3. In certain concentrations, a potentially explosive mixture may
occur. Further manufacture of GRP components (grinding, cutting, sawing) creates fine dust and chips
containing glass filaments, as well as tacky dust, in quantities high enough to affect health and the
functionality of machines and equipment. The installation of effective extraction and filtration
equipment is required to ensure safety and efficiency.[36]
See also
Bulk moulding compound
Carbon fiber reinforced polymer
Ignace Dubus-Bonnel
Fiberglass sheet laminating
G10 (material)
Glass fiber reinforced concrete
Glass fiber
Sheet moulding compound
References
1. Mayer, Rayner M. (1993). Design with reinforced plastics (https://books.google.com/books?id=XQFJ
ego9nGUC&pg=PA7). Springer. p. 7. ISBN 978-0-85072-294-9.
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External links
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