PULTRUSION :MANUFACTURING PROCESS OF BRIDGE COMPONENT

1. Pultrusion :
Manufacturing of bridge
component

2. CONTENT
 INTRODUCTION
 EXAMPLES OF COMPOSITE BRIDGE AROUND
THE WORLD
 PULTRUSION METHOD OF MANUFACTURING
OF BRIDGE COMPONENT
 CASE STUDY

4. PIER
TRUSS
MADE OF CONCRETE
MADE OF FRP

5. 1. 38m span Lleida Footbridge,
Spain
2.60m long opening Fredrikstad
Bridge in Norway
3. 40m long Fiberline Bridge
Kolding, Denmark
EXAMPLES:-

6. 4.Pratt Truss Footbridge, Chalk
Bridge
Lee Valley Park, Walthamstowe
5.West Mill FRP Road Bridge
(Oxford, UK)

7. PULTRUSION
Pultrusion is a continuous molding process whereby reinforcing
fibers are saturated with a liquid polymer resin and then carefully
formed and pulled through a heated die to form a part.
Pultrusion results in straight constant cross section parts of
virtually any shippable length
Continuous fibre tows are drawn through a resin bath
The tows are then pulled through a heated die and cured

8. 1 - Continuous roll of reinforced fibers/woven fiber mat
2 - Tension roller
3 - Resin Impregnator
4 - Resin soaked fiber
5 - Die and heat source
6 - Pull mechanism
7 - Finished hardened fiber reinforced polymer

9. PULTRUDED SECTION

10. There are two forms of pultrusion products:
The first category consists of solid rod and bar stock produced
from axial fiberglass reinforcements and polyester resins.
These are used to make fishing rods and electrical insulator rods,
which require high axial strength
The second category is structural profiles, which use a
combination of axial fibers and multidirectional fiber mats to
increase a set of properties that meet the requirements of the
application in the transverse and longitudinal directions.

11. Raw materials
Resins
Unsaturated polyester resin (UP)
Phenol resins
Polyurethane
Reinforcing fibers
Glass fibre reinforcements
Continuous filament mats
Woven fabrics
non-woven fabrics

12. APPLICATIONS
Pipes
Electrical insulators
Structural applications Supports and panels for
truck trailers, door supports for cars, ladder rails
Pressure tanks
Aircraft flooring
Rods, stringers and stiffeners in
aircraft, car leaf springs

13.  Advantage
-Increased Strength (fiber
processed under
tension)
-High Fiber Content
-Consistent Quality
-High Production
-Low Labor Required
-Low Cost
 Disadvantages
• The process is mainly
suitable for constant
cross sectional areas.
Tapered and complex
shapes can not be
produced with this
method.
• Control of fiber
orientation is not
possible in the
pultrusion system.
• Thin wall parts can not
be produced with this
system.

14. CASE STUDY ON FIBRELINE
BRIDGES: KOLDING, DENMARK

15. TECHNICAL SPECIFICATIONS
• Total Length - 40 m
•Number of stays -8
•Width, total -3.2 m
•Tower, height -18.5 m
•Total weight -12 tonnes
•Designed load capacity -500 kg/m2

16. The Fiberline pedestrian and cyclist bridge was the first of its kind
to cross a railway line.
The Fiberline bridge is an asymmetric cable-stayed bridge
manufactured of Fiberline standard GRP profiles. Only the bolts for
assembly and the abutments at the foundations are made of
stainless-steel
Fiberline structural profiles are manufactured by PULTRUSION, a
method which ensures consistent quality that can be reproduced.

17. Standard profiles
 The bridge was constructed of 12 different Fiberline
standard profiles.
 The expected life time is minimum 100 years.
 The bridge, which is uninfluenced by rain, salt and sub-
zero temperatures, is expected to require only cosmetic
maintenance over the coming 50 years or more, reducing
maintenance costs considerably compared to traditional
bridges of steel, concrete or wood.

18. CONCLUSION
It has been shown that FRP composites have the
potential to revolutionize the construction of long span
bridges, producing more efficient and cost-effective
structures. They will also dramatically increase
durability, reducing through-life costs and disruption
due to maintenance.
 Initial long span applications are expected to be in
footbridges, but the same advantages and possibilities
are considered viable for road and possibly rail bridges.

19. THANK YOU