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.
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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