One of the latest innovative methods for manufacturing glass-composite products is pultrusion. This innovative technology guarantees the production of modern, high-quality products.
Ivanovo Mechanical Plant fully possesses this innovative technology, which was developed by the research laboratory of Ivanovo State University of Chemistry and Technology (ISUCT). The pultrusion machines manufactured by Ivanovo Mechanical Plant have many features that competing machines do not offer. These features provide production advantages.
Advantages of the New Method
Pultrusion makes it possible to produce high-quality products widely used in various industries. Pultrusion provides:
- excellent strength characteristics;
- high process productivity;
- environmental safety.
Ivanovo Mechanical Plant machines offer the following distinctive advantages:
- Constant-speed control;
- Equipment stability under various pulling loads;
- Efficiency and low energy consumption;
- Operational safety.
The design features of Ivanovo Mechanical Plant machines prevent profile slippage. The clamping units on our pultrusion machines have an adjustable clamping force of up to 25 000 kg per clamping unit. At the same time, the long clamping modules distribute this force evenly over a large area, preventing profile damage. This is especially important when working with thin profiles. All Ivanovo Mechanical Plant machines can provide twice the maximum force permitted on other machines.
The Ivanovo Mechanical Plant machine range uses highly efficient hydraulic drive systems. This makes it possible to control speed with maximum precision at low power levels to achieve the required pulling force.
The pulling and cutting units on Ivanovo Mechanical Plant pultrusion machines are fully enclosed, protecting machine operators from injury.
Technology Features
Pultrusion is a continuous process for producing GFRP profiles.
Previously, glass fiber-reinforced plastic was used only to a limited extent because there was no industrial technology capable of establishing mass production of the required products. After pultrusion technology was developed, production of GFRP profiles, GFRP rebar, rods, and other products was established.
The pultrusion method is a continuous process in which glass-fiber materials are pulled through a heated die at 130-150 degrees Celsius. Depending on the product type, these materials are impregnated with resin, either polyester or another thermosetting resin.
The fiber-lamination process produces profiles with a high fiber-volume fraction and a constant cross-section. The high fiber-volume fraction makes pultruded profiles ideal in terms of quality.
The following fibers are used:
- glass;
- carbon;
- aramid;
- mat, woven, or stitched roving.
The material is drawn into the feed area, where it is precisely formed into the required shape and impregnated with a resin matrix. The resin matrix may be:
- polyester;
- vinyl ester;
- epoxy resin;
- phenolic resin.
From the impregnation zone, the material enters a hot pultrusion die, where the resin matrix cures. After the cured material exits the die, it is allowed to cool before being clamped by the pullers. Reciprocating pullers draw the profile with a return-stroke acceleration greater than the tension to ensure a smooth, continuous, constant speed.
This technology makes it possible to obtain a highly durable material. The special die through which the glass fiber is pulled makes it possible to produce products in various configurations:
- plate;
- angle;
- rod;
- channel;
- tube;
- box-shaped sheet piles.
Advantages of Pultrusion
This technology makes it possible to produce high-quality GFRP profiles with the required properties and shapes. At the same time, you can be confident that these products will not deform and will withstand loads effectively at temperatures from 70 to 170 degrees Celsius.
Ivanovo Mechanical Plant pays close attention to controlling the raw-material composition. Modern instruments make it possible to identify the most effective formulations. The work also uses the latest scientific developments created by researchers at our institute. Experiments conducted in a modern laboratory help identify the optimal production method.
Application Prospects
Pultrusion technology (pultra) is highly promising. Every year, products manufactured using this method find broader application in various industries:
- strengthening construction excavations;
- protecting the banks of water bodies from erosion and destruction;
- reinforcing foundation trenches;
- increasing the strength of underground-structure walls, including parking facilities, garages, and warehouses;
- reinforcing roads.
Glass-fiber profiles manufactured by the pultrusion method (pultra) are increasingly used in construction. These products improve facility safety, increase strength, and extend the service life of structures. The high corrosion resistance of glass-fiber products also enables them to compete effectively with traditional materials previously used.
Ivanovo Mechanical Plant offers modern, proven pultrusion technology. We guarantee excellent quality, low production costs, and outstanding results.
