FRP / GRP Pultruded Profiles for the Rail Industry
Dura Profiles are a practical proposition for more applications than ever before, thanks to the very wide range of standard profiles available.
We carry one of the largest stock holdings of profile, including standard Angle, Channel, Beam and Box, Tube, Bar and Rod sections. We supply a cost-effective solution for virtually every common application, with no tooling costs and minimal delivery lead time. All profiles can be produced in a vast number of dimensions and are available in five different resin systems depending on the application. Polyester is suitable for most industrial applications. Vinylester provides additional corrosion resistance. Epoxy offers superior thermal stability. Modar improves fire and smoke performance. Phenolic also maximises fire performance as an alternative to Modar.
The versatility and accuracy of the pultrusion process offers tremendous possibilities for complex shapes or special properties. For extended production runs, it can be a highly cost-effective method of producing customised profiles, using special dyes to form the material directly into the finished shape, with no need for extra machining operations. Resin and reinforcement materials can be mixed and matched to create an almost limitless blend of colours and properties. Aramid or carbon fibres can be used instead of glass fibre and resin systems can be modified to meet special requirements. Pultrusions can be produced with extra flame retardancy or self extinguishing properties.
Pultrusion die sizes up to 600mm x 200mm can be accommodated.
Fibreglass pultruded profiles including channel, I-beam, box, tube and angles. Light, strong, fire and chemical resistant.
Dura Profile comprises of a range of FRP sections made using pultruded technology that has a range of applications typically to replace steel or wood. Weighing around 50% less than steel, Dura Profile offers equivalent performance for considerably less weight. This results in major cost savings due to more economical transportation, handling and on-site fitting. Supplied as single profiles, flat pack or pre-fabricated structures anywhere in the world, Dura Profile is fast becoming the material of choice for work platforms, ladders, handrailing, cable trays, flow sub-structures and much, much more.
Fabrication methods used with conventional materials can also be used with Dura Profile. The most common form of connections are made by mechanical fasteners. Bonded joints are also an option and selection of the appropriate method will depend on the:
- Distribution of loads within the assembled structure.
- Necessity to disassemble the structure components at a later stage.
- The environmental conditions during fabrication
- The environment in which the assembled structure will be used.
Bolted connections are the most common method of jointing Dura Profile. Stainless steel (or galvanised) nuts and bolts are used, with washers larger than usual to reduce local compressive stresses. It is good practice for the bolt to be a tight fit in the hole as this substantially reduces local stresses. It is also important that the bolt shank length (unthreaded) is sufficient to avoid threaded sections within the thickness of the joint materials.
Typical bolt separation distances are:
- Bolt dia x 3 from end of profile/x 2.5 from edge of profile/x 5 bolt centre to centre
- In certain circumstances, FRP nuts, bolts and washers can be specified to suit aggressive environments or for electrical isolation.
- Due to the transverse mechanical properties of Pultruded profiles, the following connections should be avoided.
Stainless steel and aluminium riveting is a very effective method of joining Dura Profiles. Pop-rivets are commonly used in conjunction with back washers to help distribute and minimize local stresses. The assembly should be designed so that the rivets are not in tension.
Captive Inserts are a fast, blind fixing system suitable for use with all materials. They are of particular use when there is no reverse access and can be installed at any stage of fabrication.
Self-tapping screws can be used successfully in many applications involving mechanical connections when high-strength fasteners are not required. Self-tapping screws may also be used in combination with adhesives.
Bonded Joints & Preparation
Structural adhesives distribute stress more evenly and are used successfully to join Dura Profile and for sealing joints and exposed surfaces. Exceptional bonds can be obtained as long as the joint is designed to avoid excessive peeling stresses, the surfaces are properly prepared and the correct adhesive is used. Epoxies and toughened acrylics are suitable for use with Dura Profiles.
To achieve an optimum bond, the surfaces must be degreased with a suitable solvent. The bonding areas must be abraded until the surface gloss is removed then cleaned of dust and degreased again. The adhesive should be mixed and applied according to the manufacture’s recommendations. The bond area should be clamped or mechanically fastened to maintain bond pressure and to ensure that there is no movement until the adhesive has fully cured.
Almost all assembly methods used for wood, aluminium, steel or other materials can be adopted to assemble Dura Profiles. The following techniques should be followed:
- Router bits and saw blades should be diamond-coated.
- Carbide tipped drill bits. Speeds should take whole size and thickness into consideration.
- Counter support is necessary when drilling hollow profiles.
- A medium course grinding wheel is preferable to the finer grades.
- ‘Lag’ screws/bolts are not recommended for fastening Dura Profile.
- Punches work better with a slight sheer edge.
- Solvents, such as methylene chloride or acetone should be used to prepare surface for bonding.
It is good practice to seal all exposed edges with a suitable resin sealant.
- Work / Public Platforms
- Sub Floor Platforms
- Bridge Decking / Structures
- Ladders / Stair Cases
- Cable Trays
- Corrosion Resistant
- High Strength / Low Weight
- Non Conductive
- Fire Resistant
- UV Resistant
- 25 Yr Warranty / 50 Yr Life Span
- Suitable For Harsh Environments
- Ideal For Manual Handling
- Suitable For High Voltage Areas
- Suitable For Fire Escapes
- No Painting
- Fit and Forget
Why use DURA PROFILE Pultruded Sections?