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Demystifying Composites: Why They’re the Secret Hero of Almost Every Industry

By Dura Composites November 6, 2018

If you’re new to the world of composites, then read on to discover why their flexibility and unique material properties are opening up a whole new world of possibilities for architects, designers and engineers ...

 

  1. Composites occur in nature

You probably don’t know it, but wood is a naturally occurring composite material made of cellulose and lignin. The long fibres of cellulose (the reinforcement) are held together by the lignin. The fibres give wood its strength, whilst lignin is the matrix (or natural glue) that binds and stabilises them.

Amazingly, the bones in your body are also a composite! They are made from a hard, but brittle material called hydroxyapatite and a soft and flexible protein material called collagen. Collagen on its own it would not be strong enough to support the body as a skeleton, but when combined with the hydroxyapatite, it gives the bone the properties it needs.

 

  1. Your office building is probably made of a composite material

Although the word “composite” may sound techie, it’s really just an umbrella term to describe materials that have been put together to make another substance that is superior than the original form in some way - making it stronger, easier to handle or more fire resistant for example. Composites that you will have heard of, but perhaps didn’t realise were composites include, bricks made from mud or clay that are then reinforced with ‘straw’ – a man-made composite which has been in common use for thousands of years. Steel is also a kind of composite, (commonly known as an alloy), which is made by combining iron and carbon. It has been in use as a building material since the late 1800s and became popular for building skyscrapers thanks to its strength and durability. Another great example is ‘concrete,’ which is made from small stones or gravel combined with cement and sand to create a material which resists being squashed under pressure better than any of those things would on their own. Concrete has been at the heart of many impressive feats of engineering such as the Hoover Dam, but its environmental credentials are now coming under scrutiny, prompting industry to look at which other composite materials have the potential to become as mainstream as concrete, wood and steel.

 

  1. Modern composites are found in almost every industry

The biggest advantage of modern composite materials is that they are light as well as strong. Composites also provide design flexibility because many of them can be moulded into complex shapes. This means that composite materials are increasingly replacing traditional metallic components in several industrial applications, such as aerospace engineering, construction and the automotive and rail industries. In the latest twin-engine wide-body jet airliners developed by European aerospace manufacturer Airbus for example – the A350 XWB – over 50% of the aircraft’s structure is made from composites!

The construction industry has also been revolutionised by the adoption of man-made composites. Glass Reinforced Plastic (GRP) is commonly known as fibreglass and has fast become the material of choice for the demanding building and construction industry. The combination of the high-strength glass fibre and highly-resilient plastic used by Dura Composites to manufacture its GRP ensures that it is strong, lightweight and both chemical and corrosion resistant. It can also be produced with phenolic properties for use in high risk areas and does not conduct electricity or necessitate the use of hot works permits – making it suitable for a vast range of applications.

 

 

Dura Composites GRP is easy to install, durable and low maintenance and can be used to create profiles, frames and structural alternatives to steel for applications such as stairs, walkways, structural treads, riser void coverings and ladder systems. Our mission is to ‘make composites mainstream’, so they become the material of choice when you need to raise performance levels, address design limitations or develop new solutions that are designed for the future.

 

  1. Designing with composite materials doesn’t have to cost the earth

Although they can initially be more expensive to produce than traditional materials, it’s not just the initial outlay costs that you should consider when deciding on material for your project. It’s important to consider the whole lifecycle of the material and all its associated costs, including; installation, how long it will last and what kind of maintenance (if any) it will require to keep it functioning and looking its best.

GRP products offer considerably lower life cycle costs due to their low maintenance, corrosion-resistant and impact-resistant characteristics compared with traditional materials, and market leading products such as Dura Grating come with a reassuring 25 year warranty so you can design and buy with confidence from Dura Composites.

If it’s a wood look you need, such as for decking or cladding, then wood plastic composite has come a long way in the past few years, with today’s composite timbers reflecting the beauty of natural and exotic hardwoods. If keeping labour costs down is a key priority, there are some innovative products out there that can help. Ultra Deck type 295 from Dura Composites is a double width board with the appearance of single boards which can halve installation times and enhances long term performance, so you can have peace of mind that your project will stand the test of time.

 

  1. The growth opportunity for composites is phenomenal, and Dura Composites can help ensure your business is able to capitalise on it.

From the outset the UK has been leading the way developing scientific research into new composite materials and supporting technology. As a result the opportunities to transform the rail, energy, construction and other sectors through the use of composites are huge.

 

Image Source - The 2016 UK Composites Strategy

 

One of the major inhibitors to the uptake of composites in new sectors until now has been the lack of appropriate regulations, codes and standards. As a market leader, Dura Composites has committed to work with regulators and standards bodies to adapt regulations to enable the use of composites, as well as establishing a database of materials tests and capabilities.

In the Rail Industry for example, Dura Composites have been working closely with Network Rail to put in place stringent fire safety standards for composite products used for important applications such as station platforms, bridge walkways and stairs and driver walkways.

 

 

All Network Rail projects are obligated to use products that meet British and European Fire Safety Standards, but until recently, these tests had not been conducted for GRP composite materials used in the rail sector. Dura Composites worked with both the railway infrastructure and construction industries, including Network Rail, London Underground, Crossrail and major rail contractors to ensure that classifications were published that cover both structural and non-structural applications and include fire tests such as flame spread, burn time and load bearing testing. The findings of the tests were that Dura Composites solutions exceeded all Network Rail specified fire safety standards, so you can be confident in choosing us as your composite supplier.

If you’d like to talk to Dura Composites about an upcoming project, we’d be happy to help. Our client base includes rail operators, government agencies, major construction firms, marinas, the RNLI and, and our value-added services include Technical Manuals, CAD Design support and Live Load Test Data for our products. For more information visit http://www.duracomposites.com/about-dura/submit-enquiry/ or call us on +44 1255 423601.