Pultrusion and Gratings

Pultrusion is a manufacturing process for converting reinforced fibers and liquid resin into a fiber-reinforced plastic, also known as fiber-reinforced polymer (FRP). The pultrusion process allows the continuous production of FRP structural shapes in an automated, energy-efficient process by pulling fiberglass rovings through a resin bath or resin impregnator that completely saturates the reinforcements. The resin hardens from the heated steel pultrusion die, resulting in a strong, lightweight final product that follows the shape of the die.

What Do We Mean By "Custom Pultrusions"?

Shape: Virtually any constant cross-section part can be pultruded.
Resin Matrix: Standard resin systems can be modified or special resins used to address such needs as elevated temperatures or special environments. Typical resins include polyesters, vinyl esters, epoxies, phenolics, urethanes and blend.
Reinforcements: Typical reinforcements are fiberglass or carbon fibers in multi-filament strands, mat, woven fabrics or stitched fabric. Other reinforcement types and forms are possible.
Composite Design: The selection of the resin mix, the type and form of reinforcements and the placement of reinforcements within the composite are all the ways a composite design can be customized.

Custom pultrusion’s contrast with standard “off-the-shelf” pultruded products in which all of the above elements are pre-established.

Why Choose PRAZASTINAV for Custom Pultrusion’s?

Quality: All PRAZASTINAV Pultrusion facilities operate under strict quality programs and are focused on continuous improvement.
Capability: Large parts or small, thick or thin, complex or simple, glass or carbon reinforcements (or both) - if it can be pultruded, we can do it!
Structural/Mechanical Engineering: PRAZASTINAV has multiple registered professional structural engineers on-staff to help you design a part, system of parts, or structure that utilizes custom pultruded components. PRAZASTINAV utilizes both mechanical and structural CAD detailing. Finite Element Analysis (FEA) is used when appropriate.
Chemical/Process/Composites Engineering: PRAZASTINAV has experienced engineers to help you tailor the reinforcement design and resin system to meet your requirements - and to advise you how to optimize the part for low cost production.
Laboratory: All PRAZASTINAV Pultrusion facilities operate under strict quality programs, are focused on continuous improvement. Machine and Tooling Design and Construction: Based on the requirement, a variety of Pultrusion profile sections can be manufactured to the extent of up to 3-4 same/different forms per machine.

Large to Small

PRAZASTINAV produces very large parts to very small parts. Parts can be produced in any transportable length.

Thick to Thin

PRAZASTINAV can manufacture thin-walled profiles with wall thicknesses under .070" (1.78 mm). Parts can also be as thick as 2" (50.8 mm) or more.

Complex to Simple

Pultrusions range from multi-cavity, thin-walled, close tolerance parts to simple strips, angles or tubes.

Cores

Core materials include aluminium or steel, foam, wood, polyethylene and others.

Prazastinav Products manufactured under this technology are widely used in the following industries

In the agriculture and chemical industries for manufacturing of chemically resistant to aggressive media slatted floors with enhanced strength characteristics used in the construction of livestock facilities, chemical plants, etc
in the construction industry for the production of glass-fiber reinforcement, profiles, carcasses, stiffening bars for PVC-windows, etc.
in the aerospace industry for manufacturing of structure components of aircraft;
in the sports and tourism industries for manufacturing of equipment exhibiting enhanced strength properties: skis, ski poles, golf course flagsticks, tent and hovel constructions, etc.
in electrical power engineering for manufacturing of dielectric structures, fiberglass rods used in composite insulators and as supporting structures for elements of signaling blocks, and fiberglass profiles used in manufacturing of transformers and electric motors
in commercial production, using grains of long-fiber molding material (LLM) as a raw material for subsequent manufacturing of structures and products with enhanced strength and chemical properties
of the vehicles with enhanced stiffness, rigidity and lightness;
and in many other industries and plants, using mechanisms, structures, and materials, which meet high standards of chemical, dielectric, and strength stability

Pultruded Structural profiles are being used in almost all Industrial segments. The major products/application of Pultruded Profiles are

Cooling Tower Structural Profiles
Cooling Tower Fan Blades
Pultruded Grating
Perforated type Cable Trays/Ladder type Cable Trays
Staircase and Platform
Staircase and Platform
Ladder & Cage Ladder
Decking System

Walkway
Bridges
Poles
FRP Plates / Chequered Plate
Chemical and petrochemical
Metal processing
Oil and gas
Waste and water treatment

Agri-chem and fertilizer
Food processing
Mass transit
Militry
Mining and minerals
Power
Pulp and paper

Each of these applications present unique and challenging conditions that require reliable materials and performance. For additional information and assistance, please contact If you want to learn more about the features of this working process, contact us and we will lead you to the discovery of pultrusion and pultruded profiles in fiberglass and carbon fibre.

Gratings

Composite Gratings

Moulded Grating

Pultruded Grating

PRAZASTINAV offers wide range of Moulded Grating & Pultruded Grating,
Traditionally Steel gratings were being used for various applications. But COMPOSITE GRATINGS due to various advantages over steel like better strength, durability, lightweight, non-corrosion, aesthetics, etc. have been extensively tested and increasingly used across industries for various innumerable applications.

Composite Gratings are also known as FRP (Fibre Reinforced Plastic) gratings or GRP (Glass glass-reinforced plastic) gratings or FRP Composite gratings. FRP/GRP are basically composite materials made of plastic reinforced by fine fibres made of glass and other additives

Provides superior corrosion resistance in addition to significant bi-directional strength (square mesh panels). With 35% glass and 65% resin content Moulded grating is the choice for exceptional resistance to chemical attack along with the benefit of bi-directional strength to reduce the need for additional support to be added when cutting penetrations through the grating. With 11 standard resin systems on hand to meet the most demanding corrosive environments along with 'special' formulations that can be created to suit exceptional requirements. The high percentage of resin (65%) in moulded fiberglass grating offers superior corrosion resistance and optimal impact resistance. Moulded fiberglass gratings with a square mesh pattern offer increased load capacity and panel utilization due to its bi-directional trait. Numerous cut-outs for piping, valve access, and column penetrations can be made without the need for additional structural framing. Being of one-piece construction, the fiberglass grating performs as a plate, distributing loads throughout the fiberglass grating section and around cut-outs. Cutting access holes in the moulded fiberglass grating does not weaken the panel and does not generally require additional or costly supports (unlike Pultruded fiberglass grating that will require additional supports at cut-outs).

Pultruded fiberglass grating offers the highest levels of uni-directional strength and stiffness. With 65% glass and 35% resin content Pultruded grating is the choice for larger span requirements.
Three resin systems are available to meet the need for every environment:
• ISOFR - isophthalic polyester resin formulation with a low flame spread rating of 25 or less designed for applications where there is a moderate exposure to corrosive elements.
• VEFR - vinyl ester resin system with a flame spread of 25 or less for dependable resistance to both acidic and alkaline environments.
• PHENOLIC - flame resistant phenolic resin with an extremely low flame spread of 5 or less and a smoke index of 45 or less - designed primarily for the offshore industry.
This type of FRP grating offers builders a wide variety of panel sizes, and flexibility because it is assembled and not moulded. This helps to reduce waste, or scraps of FRP in comparison to the moulded fiberglass grating process.

Advantages of Pultrusion process

Pultruded composite profiles have seen an increase in demand in recent years and for good reason. With the high durability and non-corrosive character traits of fiberglass reinforced polymers, it is a clear advantage to the customer to select a Pultruded profile.

Comparison with conventional materials

PARAMETERS	FRP GRATINGS	HOT DIP GI	SS
Life span	High	Moderate	High
Strength to weight ratio	High	Low	Low
Life cycle cost	Low	High	High
Corrosion resistivity	Very High	Moderate	High
Chemical resistivity	High	High	Moderate
Electrical conductivity	Low	High	High
Installation cost	Low	Moderate	Moderate
Handling	Very Easy	Difficult	Difficult
Anti-skid	Available	NA	NA
Colour range	Available	NA	NA

The main features of our fiberglass gratings are

load capacity: our gratings can bear very high loads;
corrosion resistance: our gratings have excellent corrosion resistance against chemical exposure, and this can be increased even further with specific resins;
impact strength: according to the EUROCOMP (Structural Design of Polymer Composites) design code and EN 13706 (Reinforced Plastic composites – Specification for pultruded profiles), the impact strength of our fiberglass gratings is equal to: 40 – 125 kJ/m² at 0 degrees, and 20 – 100 kJ/m² in the 90° transverse direction (tests performed according to DIN 53453-71);
heat resistance: (from –40°C to 180°C): thermosetting resins such as iso-polyester can withstand sudden temperature changes. For this reason, fiberglass gratings are widely used in areas with unstable climates

Fields of application

The structural characteristics of our fiberglass gratings, their corrosion and heat resistance, and their impact strength make them very versatile for use in a number of different industrial and manufacturing sectors. In particular, we recommend their use in highly corrosive environments such as chemical plants, marine, and other wet environments, in the transport and public transit sector, and in the cooling towers and offshore platforms of the oil industry. Prazasrtinav manufactures high-quality fiberglass gratings and is formed of a team of specialist design engineers who continue their research into increasingly high-performance solutions.