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ARCHITECTURAL APPLICATIONS
This paper deals with glass fibre reinforced plastic, its composition, property,
advantages, manufacturing technology and its application in civil engineering. It
includes the architectural application of glass fibre reinforced plastic and its
application techniques.
1.0 INTRODUCTION
Over the last 30 years composite materials, plastic and ceramics have been
dominating emerging materials. The volume and number of application of
composite materials have grown steadily penetrating and conquering new market
relentlessly.
Traditional construction materials like steel and concrete have exhibited signs of
deterioration over the years in their long term performance due to the inherent
nature of materials or weak resistance offered by these materials to adverse
environmental condition. Retrofitting and rejuvenation of such structures require
use of skilled labor, heavy equipment and excessive energy and is time consuming
resulting in the rapid increase in the overall cost. These factors motivated
researches to bring out the use of composite material to retrofit and strengthen
structures.
A composite material is a three dimensional combination of at least two chemically
and mechanically distinct material with a discrete interface separating them.
Polymer composites are multi phase materials produced by combining polymer
resins such as polyester, vinyl ester and epoxy with fillers and reinforcing fibres to
produce a bulk material with properties better than those of the individual base
material and offer the advantage of flexible design.
The polymer composites have a variety of products of which glass fibre reinforced
plastic (GFRP) is one of them. The varieties of products are mainly due to various
types of fibres and their arrangements in the products.
Glass fibre
Matrix
Fibre matrix
2.2. Matrix
Matrix is used as a binder to bind the fibres together and transfer the stress to the
individual fibre. It protects the fibres against abrasion, high impact and exposure to
adverse environmental conditions. Generally unsaturated polyester resin and epoxy
resin are used for GFRP.
Fibre matrix interface is a bond between fibre and matrix to resist stress due to
uneven thermal expansion of fibres and matrices, shrinkage of resin during curing
and to provide load transfer from matrix to reinforcement. Various additives are
used to improve mechanical properties, protection and appearance.
Tensile strength
MPa
Youngs modulus
GPa
Coefficient of Thermal expansion 10-6/ K
Density
g/cm3
1750
70
4.7
2.55
The commonly used polymer matrices are polyester and epoxy resins polyester
shrinks about 4% to 8% on curing and a good adhesion with glass fibres. But epoxy
resins are co0stlier than polyester.
Density
g/cm3
Tensile strength
MPa
Flexural modulus
MPa
1.38
35-85
3000
8-11
25-85
The salient features of glass fibre reinforced plastic is its competitive installed cost,
high strength, light weight, translucency, good resistance to weathering and fire the
versatility of fabrication methods make it an ideal material in building construction.
Weather resistance
Chemical resistance
Design flexibility
Light weight
Part consolidation
Colourability
Zero maintenance
Ease to repair
Durability
Light transmission
Property
GRP
Aluminium
Steel
Corrosion resistance
Weight
30%less than aluminium
Electrical resistance
Non conductor
Conducts electricity
Conducts electricity
Thermal property
Non conductor
Conducts heat
Conducts heat
Silver colour
Grey/black
Need to be painted
Two third portion of GFRP is polyester resin, which is a hydrocarbon and therefore
combustible. In an actual fire the behaviour of GRP compares very well with other
roofing materials even with some of those, which are non-combustible. Glass and
asbestos-cement splinter crack in heat and send particle flying. Acrylics send down
flaming droplets GRP burns away producing only smoke and leaving a black mat of
the incombustible glass fibre itself. This mat prevents the spread of radiant heat into
other parts of the roof structure. In particular with roof cladding it is some time
advantageous for the roof to burn away over the source of a fire thus venting it,
than to remain as a heat and smoke barrier forcing the fire to spread along the
under side of the roof.
By the addition of inert fillers and certain chemicals, the spread of flame can be
reduced and can make the product difficult to burn, but cannot make it
incombustible. Fire protection can be given by coating GRP with infumescent paint
and can be used for internal surface.
6.0 MANUFACTURING TECHNOLOGY OF GFRP
It is a simple technique .An open mould is used to prepare a mat of glass roving.
Epoxy resin is prepares by the stirrer. A small layer is applied on releasing film, on
which the mould is kept. Epoxy resin is applied followed by a releasing film. Roller
eliminates air bubbles. Complex shapes of bigger/smaller size can be produced.
Hand lay up technique need skilled labour. The quality of the product depends upon
the operator skill.
The glass rovings are drawn through a resin bath to impregnate them with resin.
The impregnate rovings are then wound under tension round the rotating mandrel;
the mandrel is generally wrapped with a release film prior to wrapping with glass
and resin. The winding angle depends on the strength and requirements. Some
times mandrel may incorporate some means of heating systems. This method is
suitable for manufacture of pipes, tubes, cylinders, sphere etc.
It is also known as resin injection, this technique produce better quality smooth
moulding surfaced but it is more expensive.
6.4. PULTRUSION
It is a suitable technique for both polyester and epoxy resin systems as well as for
reinforced sections with glass, carbon, and synthetic fibres. This method is useful for
sections of varying thickness and shapes.
The advantages 3-D weaving to obtain 3-D fabric is widely known but is costlier.
Although 3-D weaving is still in its infancy, it has the potential to replace expensive
titanium fittings, hinges, engine bladders etc.
These manufacturing methods have great potential for high volume production,
especially when combined with the use of thermo plastics. Application is limited to
small to medium size parts. Sport goods and industrial products will benefits from
this group of technologies.
The conventional (concrete/GI/MS) tanks are now replacing GRP tanks. The GRP
tanks can be made in any shapes (rectangular, cylindrical etc). The main advantage
of GRP is its lightweight and low maintenance cost.
Material
Specific gravity
GRP
1.5-1.8
40-60
40-80
Steel
7.8
34-50
34-50
Aluminium
2.7
9-17
14
Concrete slabs
Seismic resistant structures (due to its light weight and shock absorption property
Strength
Functional utility
Aesthetics
Modern architecture has improved with the invention of new materials and new
techniques. GFRP is an attractive material for both construction and architecture .it
has limitless architectural application in the construction industry. It offers
combination of properties net available in any other conventional material.
Surface of GFRP can be treated to get aesthetic importance and fire resistance.
It has maximum freedom of design as the constituents of GFRP have no inherent
shape and hence it is possible to make use of efficient structural shapes and
appearance requiring minimum of material for maximum strength and stiffness
Architectural aesthetics is an additional feature of GFRP with out any damage to the
original shape, appearance and strength. It fulfills the following objectives for better
architectural applications:
Raised or depressed designs with paint and lacquer provide more decorative
effects
GFRP gives a variety of surface finishes, shape, size and colour. It provides
considerable scope for designers to take due considerations for architectural
treatments of GFRP such as
Material selection
Moulding process
Section thickness
Polyester and epoxy resins system can be coloured with transparent dyes or
pigments. Transparent dyes are normally dissolved in suitable solvent and added to
the resin system. Pigments are available in powders and dispersion forms for both
polyester resin, epoxy resin etc.
Pigment pastes are prepared by dispersing the powder pigment in suitable resin.
Thus GFRP components can be manufactured in wide varieties of colour shades,
textures, tones etc. to meet the various aesthetic requirements.
8.2.2. Spray Painting
GFRP surfaces can be coated by spray painting. Coating consists of enamels and
lacquers. The enamels are coating containing thermosetting resins dissolved in
solvents. Enamels have good properties of high gloss and hardness. Resins such as
epoxies and polyurethanes have been used in making enamels
The filaments temperature is raised up to 982 C by electric power source and the
chamber is then vacuumed. Increase in temperature flashes the molten aluminium
from the filament and condense on all the surfaces of the plastic parts. The plastic
parts are rotated to ensure complete metal coverage. The complete cycle takes only
15 minutes
It is the process used to force paint or ink through a stencil fabric (i.e. silk screen)
on to the plastic that is to be decorated. It consist of a rectangular frame
marked with a stencil in such a way that allows the paint to be pressed through the
screen only where the stencil is open. The screen is placed above the plastic to be
decorated and a flexible rubber squeeze the paint link through the opening in the
screen to the surface. It can be done on flat and curved surface.
Text Box: Figure 4. Statue and column Out door land scape elements such
as lamp post, benches, chairs, colourful boards, statues, sign boards etc can be
made in various colours and designs. They have functional, structural and aesthetic
importance. Chairs and benches in stadium, auditorium, airport lounge, lobby seat,
bar stool, bathing stool
GFRP fancy sheets can be used for partition walls and panelings inside the
buildings. They can be used in walls and floors of swimming pools. Side walls of
green house can be made of GFRP sheets. They can be easily machined, bolted and
riveted.
Glass fibres and vinyl ester by using filament winding technique are used in the
fabrication of ventilating and ducting pipes. It can withstand corrosive condition and
retain properties even at high temperature.
8.3.6. Cladding
GFRP is used for cladding other structural materials or as an integral part of either a
structural or non load bearing wall panel, for cladding structures of concrete or brick
flat sheets can be used. The advantages of GFRP here are the ease of fabricating
large panels to minimum joints and the infinite range of coloured and textured
surface.
GFRP can be molded with raised on depressed design with paints or enamels. This
type of GFRP plates can be used for any decorative purpose.
Wash basins, cisterns, bath tubs are made by press moulding or contact moulding
techniques. The advantages are its light weight and minimum maintenance, stain
resistance and longevity of the product.
Light weight GFRP doors are use for office cabins and residential application.
zero maintenance
ready to use
Used in automobiles due to its lighter weight, durability, and corrosion resistance.
The glass fibre mainly E glass having high electrical insulating property made it
useful in the construction of distribution pillar, link boxes, profiles, separation of
current carrying phases to prevent short circuiting.
10.0 CONCLUSIONS
In this century the role of internet, electronic and print media has brought the
knowledge at the door step. In spite of that it is necessary to create awareness
among the users, architects, engineers etc. regarding the utilization of GFRP both as
architectural and construction material. It is costlier than the conventional method,
but is economical in long run, if further investigation is done in proper selection of
reinforcement and matrix material, fabrication treatment techniques, design of
components etc.
ACKNOWLEDGEMENT
I thank Prof. T. DIVAKARAN, Head of the Department of Civil Engineering for the
good will and encouragement extended to me.
Last but not the least I thank almighty, for giving me the strength and power to
complete this project on time.
REFERENCES
1. A. J. Leggatt, GRP And Buildings, The Structural Engineer. Vol. No: 12. December
1970.
2. HON.Y and Yogesh Chhabbra. Use Of Glass Fibre Reinforced Plastic For Structural
Strengthening Of Reinforced Concrete, ICJ April 1999.