In general, FRP (Fiberglass Reinforced Plastic) represents a wide variety of manufacturing processes that utilize similar glass reinforcements in combination with both thermo-set and thermo-plastic resin systems. These systems also incorporate other ingredients such as fillers, catalyst, (UV) Ultra-Violet inhibitors, and pigment. All of the different processes focus on a common goal: to produce non-metallic parts that offer many advantages over traditional materials such as wood, concrete, aluminum and the many types of steel.

However, considering the many types and methods of producing an FRP profile, the manufacturing method of Pultrusion results in the production and supply of one of the worlds strongest and most durable products available today. The major benefit of the Pultrusion process, which is Bedford Reinforced Plastics, Inc. only means of manufacturing, is the design flexibility the process offers. Unlike the given set of properties that are inherent with traditional building materials, Bedford Reinforced Plastics, Inc's. Engineering and PD & D departments can manipulate the glass reinforcement selection and orientation within the profile. Changes can also be made to the resin, and internal chemicals, allowing us to design a constant cross section profile for almost any application that offer the following advantages:

• High Strength
• Corrosion Resistant to many chemicals
• Light Weight- Weighs nearly 80% less than a steel profile of similar dimension.
• Electrically Non-Conductive
• Non-Metallic
• Flame Retardant: Fire Retardant Polyester and Vinylester Resin Series both exhibit flame spreads of 25 or less when tested per ASTM E-84
• Lower Life Cycle Cost
• Non-Leaching. Environmentally Friendly
• Dimensional Stability

The Pultrusion Process
People outside the fiberglass composite industry do not necessarily understand the word Pultrusion. However, most people in the industrial world understand the word Extrusion. The one simple difference between the both is Push versus Pull. In the extrusion process, material is typically pushed through a forming die. In the Pultrusion process, material is physically Pulled through the die by a pulling mechanism. Therefore, resulting in the industry naming it Pultrusion.

The pultrusion process as a whole is simple in theory, but yet somewhat complex in the actual process. First and foremost, the first step of successfully producing pultruded profiles that yield the mechanical strength and physical requirements start in Bedford Reinforced Plastics, Inc. Engineering and Design departments. The engineers must design and manufacture the pultrusion die to very strict tolerances of thickness, angularity, radius, etc. Working in parallel to the die design, a separate group of specialty Composite Engineers lay out the glass reinforcement of continuous strand mats, uni-directional roving, surfacing veils, resins, and internal chemicals that are then incorporated into the orientation of glass placement within the profile.

Once the die and preforming set-up reaches the Pultrusion machine, the operators and engineers start to string the profile according to the specification of the particular profile. Stringing the profile is as simple as pulling the glass reinforcements and surfacing veils through a series of preforming guides, then through the actual die itself. Once the raw reinforcements are pulled through the die and secured to the pulling mechanism, the specified resin is added to either a wet out bath, injection manifolds, or a combination of both.

As the glass passes through the wet out bath and through the injection manifolds, it is completely saturated with a thermo set resin that includes the fillers, catalyst, pigments, etc. As the glass enters the back of the die it is under extreme pressure forcing out any air and excess resin from the reinforcement. Once inside the controlled heated die, the part passes through various stages of heat, which initiates several catalyst systems to react within the laminate allowing the layers of reinforcements to be mechanically fixed to each other resulting in a solidified laminate exiting the die.

Upon exit of the die, the profile continues its journey towards the puller. The puller is typically made up of a caterpillar design that sandwiches the profile between a series of pads that is connected to a drive mechanism that keeps the laminate moving. Therefore resulting in what is also referred to as Continuous Laminating Process. Upon exiting the puller, the laminate passes through the final stage of a cut off saw where it is cut to its final length.