04 February 2011

FRP ROOFING TILE


    
  FRP ROOFING TILE

BY

ABDUL RASHEED.M.P

 
CONTENTS


v INTRODUCTION

v OBJECTIVE

v FRP RAW MATERIALS

v FRP TECHNOLOGY

v MANUFACTURING PROCESS

v PODUCTION PROCEDURE

v PRODUCTION FLOW CHART

v COMPARISON WITH OTHER ROOFING TILE

v COST ANALYSIS

v PLANT LAYOUT

v CONCLUSION

v REFERENCE

INTRODUCTION

   
Reinforcing plastic matrix with high strength fibre material result in production of what is called fibre reinforced plastic. FRP’S have outstanding properties such as high strength to weight ratio and excellent corrosion resistance and are easy to fabricate. A wide variety of articles are made by the fibre reinforcing process. A remarkably high strength to weight raio is the main feature. Attracting space craft designers. Elegance light weight and corrosion resistant quqlities make it suitable material in a salt water application. Corrosion resistance property of the reinforced plastic is fully utilized when they are employed in huge quantities.

         Different types of roofing tiles are available in the market. But the price of those are very high. FRP Roofing tile has light weight, good finish etc. More over the manufacturing process is simple and it need less manufacturing material.


OBJECTIVE

To produce an FRP roofing tile

Colour                     : Brown red
 
No. of layers           :  2

Weight of product  :  400 gm



F R P RAW MATERIALS

1.    POLY ESTER RESIN

2.    M E K P

3.    COBALT NAPHTHANATE SOLUTION

4.    GLASS FIBRE

5.    POLY VINYL ALCHAHOL

6.    PIGMENTS



POLYESTER RESIN

Polyester resin is the main raw material in the composite. It is the base part of the FRP. It is widely used plastis resin because of its adhesive and strength property are high. Two grades of polyester resin are available in the market. One is high viscous a[polyester the second is low viscous polyester resin.

METHYL ETHYL KETONE PEROXIDE [ M E KP ]

It is termed as MEKP, it is used as the catalyst of this product. It is used to speed up the reaction.

COBALT NAPHTHANATE

It is used as the promoter in the F R P product so it helps to speed up the reaction.

GLASS FIBRE

It acts as a reinforcing material. Good clarity, mixing capacity,
Good strength , resistance to corrosion are the major advantages of this fibre.

POLY VILYL ALCHAHOL

PVA is used as the mould releasing agent it is applied to prevent the final fabricated article from sticking.



OTHER REQUIREMENTS

1.    Mould
2.    Mixing bowl
3.    Brushes
F R P TECHNOLOGY

F RP is low priced fabrication process which can be carry out in a cottage industry. The size of the articles which can produce from small to big. The major fabrication techniques is used for making FRP products are sub divided in to two they are open moulded and close moulded techniques.


Major steps involved are,
1.    Cleaning the mould
2.    Applying the mould releasing agent

3.    Apply gelcoat
4.    Apply surface tissue
5.    Consolidate the gelcoat
6.    Apply reinforce ment
7.    Consolidate the reinforcement with compounded resin using brush or hand roller
8.    Repeat the consolidation with resin and reinforcement
9.    Apply top coat and brush it to the required finish.
A precut glass cloth or mat is then laid over the glass  cloth. Rollers are used to press the glass cloth on the resin uniformly and also remove the air entrapped air bubbles. Alternate layers of resins and glass cloths are laid in a similar sequence until the required thickness is build up. The whole set up is then cured eieher at the ambient on elevated temperature. After curing is completed the reinforced plastic material is thus trimmed and is removed from the mould and subjected to trimming and finishing.


MANUFACTURING PROCESS



The first step in the production of FRP based roofing tile is cleaning the mould and wax paste to avoid scratches and for surface smoothness. Mould releasing agent PVA applied using sponge. PVA is a water soluble polymer. So mould releasing easy.
After PVA drying gelcoat is applied using laminating brush. For the production of FRP based roofing tile general purpose resin is used. The gel coat in the ratio of 1 kg resin for 100 gm of pigment.
It is stirred thoroughly and mixed with Cobalt Naphthanate and MEKP. Gelcoat is applied whole of the mould surface with a brush. After that required size fibre adhered to the gelcoat surface by applying resin compound using laminating brush. Process is repeated to get the required thickness and allowed to setting the product.
                        

Usually within half an hour moulding become cured. Then the product is released from the mould using water with force. 






PRODUCTION  PROCEDURE

    
HAND LAYUP METHOD




This is probably the simplest method for producing reinforced plastic products. The quality of the end product depends to a large extent on the skill of the operator. Polyester resin , MEKP, Cobalt Naphthanate and colours are mixed veryb well and then coating of mould releasing agent such as PVA silicone and wax are applied on mould. After the application of emulsion , it is allowed to stand for 10 minutes: because evaporation time is essential for the FRP product. After 10 minutes the mould is washed with resin matrix with the help of a brush.


PRODUCTION FLOW CHART

                                                                 
Clean the mould
Mixing the ingradients

                                  
Apply release agent
                     

Apply gelcoat

                  

Precut glass cloth is placed

Apply resin


Placed to cure


Ejection of product


Trimming


Finishing

              
↓           
Inspection


CPMPARISON WITH OTHER TILE

FRP BASED
CLAY BASED
Light weight
      High weight

Low cost

       High cost
Easy processability
   Processing is complicated
No painting and polishing
required
  Painting and polishing 
   required








APPLICATION

It is used for roofing purposes.

 COST ANALYSIS
               
INGRADIENTS
QUANTITY
COST
Glass fibre
100 gm
8.00
Polyester resin
200 gm
18.00
MEKP
3 ml
2.00
Cobalt Naphthanate
5 ml
4.00
PVA
5 ml
3.00
Sand paper 1 sheet
1
3.00
Cotton waste
1
2.00
TOTAL

40.00
          


REQUIREMENTS

         Labours          2 Person

         Mould             1



CONCLUSION

        In modern life FRP based products are more useful. This is used for a variety of application. This is a development of plastic product. Compared to another manufacturing process of plastic products it has more advantages.


    

REFERENCE

    
FRP technology by R.G Whetherhead

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