PULTRUSION 101

www.creativepultrusions.com 814.839.4186 Toll Free: 888.CPI.PULL Fax: 814.839.4276214 Industrial Lane, Alum Bank, PA 15521

Presented by Dustin Troutman

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We are known for our QUALITY.

WHY CHOOSE CPI?We are theBEST IN CLASSat pultruding

large structural profiles.

Our engineering team is UNMATCHED in the industry.

Our manufacturing technology is SUPERIOR to all others.

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PULTRUDING LARGE STRUCTURAL PROFILES

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ENGINEERING

• We use Solid Works simulation software for our Finite Element Analysis – Including linear static and Eigen value buckling capability

• Autodesk Design Suite for our geometry and design layouts

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PROCESSHigh pressure injection manufacturing technology permits a higher fiber volume fraction which equates to higher strength and stiffness with tight process variation.

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QUALITY

The Quality Management System has been modeled per the requirements of the ISO9000:2008 International Standard.

In 2012, Creative reinforced their commitment of providing the highest Quality of products and services with the addition of a certified LEAN / Six Sigma Black Belt who manages related Quality initiatives.

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MACHINE SHOP CAPABILITIES• Over 200 years experience in

design and manufacture of tooling for pultrusion

• CNC machining and grinding• In-house hard chrome plating• MACT compliant direct die

injection tooling is a standard• Tooling designed with

Autodesk Design Suite

“Lifetime Maintenance included in tooling cost”

                                                                                                           

COMPOSITES

A composite is a structural material that consists of two or more combined constituents that are combined at a macroscopic level and are not soluble in each other.

Resin being directly injected into the die

Glass fibers

The term pultrusion comes from combining the words pull and extrusion.

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Pultruded profiles are cut to length during the continuous manufacturing process.

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Resin and glass fiber reinforcements are combined and formed into the shape of the die on a continuous process.

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The resin is initiated by the thermal decomposition process. The initiator is heated until a chemical bond dissociation produces two radicals. The chain continues to build until the monomer is used resulting in a cured resin.

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The profiles are pulled through a die.

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THE PULTRUSION PROCESS

Pulling System*

Cut-Off Saw

Preformer

Continuous Strand Mat

Guide Plate

Rovings

Resin Impregnator

Surfacing Veil

Forming & Curing Die

*Caterpillar Pullers (shown) or Reciprocating Pullers

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• Superior Tensile Strength/Stronger than A-36 Steel• Linear Stress/Strain Curve with Little to No Yield

• Superior Compression Strength/Stronger 6061-T6 Aluminum• Compression Strength and Compression Buckling Normally Govern the Design when Strength Governs

MATERIAL PROPERTIES

TENSILE STRENGTH

COMPRESSION STRENGTH

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• 1/2 the Modulus of Aluminum and 1/10th the MOE of Steel• Deflection Governs Most Designs• Buckling Governs Most Strength Driven Designs. Local and Global Buckling

MODULUS OF ELASTICITY

• Lower Shear Strength than Steel and Aluminum• Lower Shear Modulus than Steel and Aluminum; Serviceability Calculations Should Include Shear Deflection Computations, Especially for Short Spans

SHEAR STRENGTH

MATERIAL PROPERTIES

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• 75% Lighter than Stainless Steel• 25% Lighter than Aluminum

DENSITY

MATERIAL PROPERTIES

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RESIN OPTIONS Series 1500/1525

POLYESTER (PE) RESINS – are manufactured for corrosion related applications. Polyester resins display excellent structural properties and are resistant to acids, salts, and many dilute chemicals at moderate temperatures.

The standard 1525 series contains fire retardant additives that permit the profiles to pass UL94 with a (V0) rating and ASTM E84 with a class A rating.

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RESIN OPTIONS Series 1625

VINYL ESTER (VE) RESINS – are based on bisphenol,an epoxy resin. VE resins provide resistance to a wide range of acids, alkalis, bleaches and solvents for use in many chemical environments. They also offer excellent toughness and fatigue resistance.

The standard 1625 series contains fire retardant additives that permit the profiles to pass UL94 with a (V0) rating and ASTM E84 with a Class A rating.

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RESIN OPTIONS Series 4000

POLYURETHANE (AROMATIC) – Are a blend of polyol and isocyanate that when joined, produce a resin system that offers superior strength and toughness. Polyurethane resins should be used when impact strength and toughness are required.

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RESIN OPTIONS Series 3000

EPOXY - Epoxy resins, also known as polyepoxides are a class of reactive prepolymers and polymers which contain epoxide groups. They are ideal for high strength, high temperature applications and perform well in chemical environments.

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RESIN OPTIONS Series 3535

SPECIALTY RESINS - Special application resins with unique flame smoke and toxicity (FST) attributes are available. Low FST resins are used extensively in the mass transit industry.

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REINFORCEMENT OPTIONSE GLASS – ELECTRICAL GRADE FIBERGLASS

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Pultruded in the form of Roving, Continuous Filament, Woven, or stitched fabric mats, depending on the mechanical and physical values being sought. 

E-glass fiberglass exhibits high tensile strength and Modulus of Elasticity properties. The volume fraction of fiberglass to resin dictates the mechanical and physical properties of the pultruded profile

REINFORCEMENT OPTIONSCARBON FIBER

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Carbon atoms are bonded together in crystals that are more or less aligned parallel to the long axis of the fiber. The crystal alignment gives the fiber high strength-to-volume ratio. Several thousand carbon fibers are bundled together to form a tow, which may be used by itself or woven or stitched into a fabric. 

The properties of carbon fibers, such as high stiffness, high tensile strength, low weight, high chemical resistance, high temperature tolerance and low thermal expansion, make them very popular in aerospace, civil engineering, military, and motorsports.

PRODUCT LINES

Standard Structural Profiles Used for Fabricated Structures

• W and I Beams• Channels• Angles• Tubes• Flatsheet• And many more...

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DECKING PRODUCTS

SUPERGRATETM PULTRUDED GRATING

SUPERDECKT

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SUPERPANEL PA004

SUPERPANEL CP150

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SUPERDECKTM RAIL PLATFORM PANEL

SUPERGRATETM MOLDED GRATING

SUPERPANEL WALL PANEL CT066

DECKING PRODUCTS

SUPERPLANKTM DECKING

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SUPERDECKING

TUF-DEKTM FLOORING

HEAVY DUTY PLANK

DECKING PRODUCTS

FLOWGRIP® FLOORING PANEL

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BALLISTIC PANELS

- The Ultimate Panel for Ballistic and Fragmentation Protection

- UL 752 Level III Compliant

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CUSTOM PULTRUSIONS

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MASS TRANSIT DECKS

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FRP DISTRIBUTION AND TRANSMISSION POLES AND CROSSARMS

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SUPERLOCTM SHEET PILE SYSTEM

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PIPE PILES

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PULTRUDED STRUCTURES DESIGN METHODOLOGY OPTIONS

LRFD or ASD

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ALLOWABLE STRESS DESIGN

2.5 in Flexure3.0 in Shear3.0 for Connections

• Material Properties are Reduced to Satisfy an Appropriate Safety Factor• Typical Safety Factors for Pultruded Structures

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• Load & Resistance Factor Design (LRFD) of Pultruded Fiber Reinforced Polymer (FRP) Structures

• Developed by the Pultrusion Industry Council (PIC) and the American Society of Civil Engineers (ASCE)

• A design standard exists for the

pultrusion industry. Our industry joins ranks with steel, wood, concrete and aluminum as a standard material of construction.

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LRFD Design

CHARACTERISTIC DESIGN PROPERTIES ARE DETERMINED PER ASTM D7290WHY ASTM D7290?It is an internationally recognized standard for evaluating material property characteristic values for polymeric composites for civil engineering structural applications.

The characteristic value is a statistically-based material property representing the 80% lower confidence bound on the 5th percentile value of a specified population.

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WHY DO ENGINEERS AND OWNERS SPECIFY PULTRUDED PROFILES?

• To Reduce Maintenance Costs• To Reduce Downtime• To Reduce Future Capital Expenditures• To Increase Safety• To Save Money

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SUPERIOR DURABILITY OVER A LONG SERVICE LIFE

• Estimated Service Life of 80+ years• The theory is based on the Arrhenius principle used by Litherland et al. in 1981 and Vijay and GangaRao in 1991. (Litherland et all, have correlated their data with naturally weathered samples of about 10 years.)

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PULTRUSION THE GREEN CHOICE

EMBODIED ENERGY COMPARISON

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BC HYDRO 287kV TRANSMISSION CHANNEL

DESIGNED BY CPI

TESTED BY POWERTECH LABS

INSTALLED AND VETTED BY BC HYDRO

APPLICATION PROFILES

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APPLICATION PROFILE

PULTRUDED DISTRIBUTION POLES AND CROSSARMS FOR NATIONAL GRID

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APPLICATION PROFILELIGHTWEIGHT POLE FOR LIMITED ACCESS SETS

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APPLICATION PROFILEPULTRUDED HS25-44 BRIDGE DECK 200’ x 60’ INSTALLED IN 14 HOURS

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APPLICATION PROFILECOMMUNICATION TOWER FOR EMERGENCY SERVICES. RADAR AND RF TRANSPARENCY DESIGNED BY CREATIVE

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APPLICATION PROFILEMOVEABLE POOL FLOORS AND STARTING BULKHEADS

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APPLICATION PROFILERAILS TO TRAILS DECKING

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APPLICATION PROFILEMASS TRANSIT ELEVATED PLATFORM DECKS

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APPLICATION PROFILECOVERBOARDS, TIE EXTENSIONS, UTILITY AND COMMUNICATION STRUCTURES for the MASS TRANSIT MARKET

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APPLICATION PROFILEPULTRUDED COOLING TOWER

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APPLICATION PROFILENUCLEAR INTAKE RACK

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APPLICATION PROFILEPEDESTRIAN BRIDGE

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APPLICATION PROFILEAZERBAIJAN3,280 FTRETAINING WALL 1580 SUPERLOC™ AND SUPERWALE

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APPLICATION PROFILESHEET PILE WALL SERIES 1560 SUPERLOC™

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APPLICATION PROFILESHEET PILE WALL AFTER HURRICANE SANDY 2012 SERIES 1580 SUPERLOC™

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KEYPORT, NJPHOTOS OF WALL TAKEN DURING HURRICAN SANDY

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KEYPORT, NJPHOTO TAKEN AFTER HURRICAN SANDY, 2012NO DAMAGE TO THE FRP WALL

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APPLICATION PROFILEMILITARY

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FT. MEYERS, FLORIDASHEET PILE WALL

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PIANKATANK RIVER, VIRGINIABRIDGE PIER FENDER SYSTEM CONSTRUCTED OF POLYURETHANE PIPE PILES

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APPLICATION PROFILEPINELLAS BAYWAY BRIDGE PIPE PILE FENDER INSTALLATION

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APPLICATION PROFILEPINELLAS BAYWAY BRIDGE PIPE PILE FENDER INSTALLATION

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WHAT CAN WE DO FOR YOU?WE CAN DESIGN YOUR CUSTOM PROFILE BASED ON FINITE ELEMENT ANALYSIS AND PROVEN ENGINEERING MEANS

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TEST THE DESIGN IN ONE OF OUR IN-HOUSE TEST FACILITIESFULL SECTION AND COUPON LEVEL TESTING

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PULTRUDE YOUR PROFILE

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FABRICATE YOUR PROFILE OR STRUCTURE

FACILITIES OVERVIEWCreative Pultrusions, Inc. was established in 1973 and is located in Alum Bank, Pennsylvania.

PRODUCTION MACHINES = 18

FACILITIES (SQ. FT) =

160,000

EMPLOYEES = 148

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HILL & SMITH HOLDINGS PLC

• Hill & Smith Holdings PLC is an international group with leading positions in the

design, manufacture and supply of infrastructure products and galvanizing services to global markets. It serves its customers from facilities principally in the UK, France, USA, Thailand, Sweden and China. • The Group's operations are organized into two main business segments: Infrastructure Products & Galvanizing Services.

• 2012 Revenue of £440.7m

• Infrastructure - 73%

• Roads - 26% • Utilities - 47%

• Galvanizing - 27%

£319.8m £120.9m

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WHERE WE OPERATE

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• AUSTRALIA: New office in Queensland for

the development of our wire rope and safety barrier products.

• CHINA: Manufacturing and trading facilities located in the Jiangsu province for the further expansion of our pipe support business.

• FRANCE: The locations of France Galva

and Conimast, where we have ten galvanizing plants and a lightning column business.

• INDIA: New manufacturing facility for

pipe supports and also offices for development of our Hill & Smith infrastructure product business.

• SWEDEN: Location of ATA Bygg-och Marckprodukter AB, the road safety barrier and signage business.

• THAILAND: Location of part of our pipe

supports manufacturing capability, where we have plants near Bangkok.

• UK: Head office and various group site

locations covering our main infrastructure products business and network of UK galvanizing plants.

• USA: Our V&S galvanizing and utilities

plants are situated on the East Coast along with the Bergen and Carpenter & Paterson pipe support business and the fiber reinforced composite profiles business, Creative Pultrusions.

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HILL & SMITH REVIEW OF 2012

INFRASTRUCTURE PRODUCTSThe division is focused on supplying engineered products to the roads and utilities markets in geographies where there is a prospect of sustained long term investment in infrastructure.

In 2012 the division accounted for 73% (2011: 68%) of the Group’s revenue and 43% (2011: 48%) of the Group’s underlying operating profit.

UTILITIESThe requirements for new power generation in emerging economies and replacement of aging infrastructure in developed countries provide an excellent opportunity for the Group’s utilities businesses.

Revenues increased to £205.7m (2011: £167.0m), which after adjusting for acquisitions and currency impacts, reflects 13% organic growth of £22.5m. Underlying operating profit increased by £1.9m to £13.4m (2011: £11.5m) with acquisitions contributing £0.9m of the growth.

The organic growth was driven mainly by our US based businesses, V&S Utilities and Creative Pultrusions, which benefitted from a more active USA utilities market.

delivering a number of large projects in the transmission, rail and cooling tower markets. Over the year, we further developed high value products for niche markets.

These products are lightweight, corrosion resistant and offer improved installation times, thereby substituting traditional materials. There is a growing demand for composite products and this was evident in the supply of 85 railway platform extensions for the upgrade to the Wessex Line in the UK.

CREATIVE PULTRUSIONS ACHIEVED A RECORD PERFORMANCE

CELEBRATING 40 YEARS OF PROVIDING PULTRUSION SOLUTIONS

QUESTIONS?

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