NetComposites
Thermwood

KraussMaffei adds Rebar Pultrusion System to TechCentre

23 January 2018

KraussMaffei adds Rebar Pultrusion System to TechCentre

KraussMaffei is expanding its expertise in the field of pultrusion, the process for continuously manufacturing fibre reinforced plastic (FRP) components, with the commissioning of a second pultrusion system at its TechCentre in Munich, Germany.

The newly developed rebar system is designed to manufacture fibreglass-reinforced rebar for concrete elements in the construction industry. Together with the first pultrusion system of the TechCentre – an iPul system for flat sections – KraussMaffei now offers its customers a research environment to develop and test new processes and applications in pultrusion.

"Pultrusion is a simple way to produce cost-effective profiles, there are hardly any turnkey offers and it is a growth technology,” states Sebastian Schmidhuber, Head of Development for Reaction Process Machinery at KraussMaffei. “In addition, we are knowledgeable about fibres, metering technology and associated process technology."

KraussMaffei entered the pultrusion market a year ago. The result of its recent development work is the iPul system, launched in 2017, which is designed to open up new applications in pultrusion with significantly higher production speeds than the conventional tub or pull-through processes. The second pultrusion system is designed to manufacture pultruded rebar. Pultruded rebar based on epoxy and reinforced with glass or carbon fibre offers an enormous potential in the construction industry.

"They are corrosion-resistant compared to classical steel reinforcements,” Schmidhuber explains. “Therefore, the overlaying concrete layers can be considerably thinner."

Further advantages include the low weight and consequently cheaper transport, the easier handling at the construction site and the fact that the composite rebar can be produced endlessly and wound onto drums at the end of the pultrusion system. Typical application areas are in infrastructure, for example, in bridges or in road construction or in environments susceptible to corrosion in buildings.

To date, finding a means of efficient production has been point of failure of an implementation suitable for series production.

"The classic production speeds for rebar in the conventional tub or pull-through processes are still at relatively low haul-off speeds, in some cases under 0.5 m/min,” Schmidhuber reports. “With the new iPul system, we are aiming at up to six times faster speeds in our TechCentre and therefore offer a cost-effective alternative to conventional steel reinforcements."

KraussMaffei works closely with Evonik, which has developed an epoxy resin for this application. Additional partners are Thomas Technology (radius pultrusion) and Alpex (mould technology).

In pultrusion, continuous fibres, usually of glass, carbon or aramid, are infiltrated with a reactive plastic matrix and formed to the desired profile in a heated mould. Grippers pull the cured profile continuously and feed it to a sawing unit. The new iPul system by KraussMaffei encapsulates the soaking of the fibres, which so far mostly takes place in open tubs, in an injection box, which permits the use of fast-reacting systems (epoxy, polyurethane). It is reported to increase the production speed from the usual 0.5-1.5 m/min to approximately 3 m/min.


Photo provided by KraussMaffei





Related / You might like...

TUBALL Graphene Nanotubes Protect Storage Tanks

Manufacturers of storage tanks and anti-static lining coatings can gain a competitive edge by switching to TUBALL graphene nanotube-based concentrates for their products, according to OCSiAl.

Global Composites Conference 2018 Speaker Spotlight: Shridhar Nath, Wind Blade Technology Leader, GE Global Research

With just two weeks to go until the first Global Composites Conference, co-hosted by the American Composites Manufacturers Association (ACMA) and NetComposites, Communications Manager Siobhan Longhurst caught up with speaker Shridhar Nath of GE Global Research. Shridhar will be presenting on ‘Technology Trends on Additive, Energy and Other Composite Applications.’

ACIC 2019 Issues Call for Papers

The 9th International Conference on Advanced Composites in Construction, ACIC 2019, will take place on 3-5 September 2019 at the University of Birmingham, UK, and abstracts are invited on relevant subjects.