Process

Dual Helical Winding

Filament winding is the technique for manufacturing composite material structures. It is the process for fabricating a composite structure in which continuous fiber reinforcement (glass, boron, silicon carbide), either previously impregnated with a matrix material or impregnated during winding, are wound under tension over a rotating core. Once the material is wound it is heated in the oven to speed up the curing.

Dual Helical Winding

In this process the fiber glass woven roving wetted with resin is wound on the steel mandrel at pre-calculated winding angles. The dual helical winding pattern is responsible for providing the composite product with maximum mechanical durability. The resin used will decide the extent of its chemical and temperature resistance. The entire process is controlled via the software in which we determine the winding angles as well as the number of layers to be wound on to the product. More the winding angle, the greater the elasticity of the pipe.

Four Axis Helical Winding

The inner line is mostly impregnated with Vinyl Ester resin to provide maximum chemical resistance. The structural wall is generally 70% resin and 30% glass providing it the optimum mechanical strength. The winding of the structural layer is usually done on a dry surface in case of GRP and wet liner surface in case of GRE. Use of ovens help in hastening the curing process and also makes sure the bonding takes place well. Once the pipes are extracted, they are calibrated at the ends.

Pipes manufactured through this process can be from 25mm up to 2000mm diameter based on the mandrels used.

Pipes are available in stiffness classes of 1250N/M2, 2500N/M2, 5000 N/M2 and 10000 N/M2. In nominal pressure classes, it is available in PN3, PN6, PN10, PN16 and PN20. We can also manufacture high pressure pipes & joints that can withstand pressure of up to 50 bar for 25mm-250mm diameter, up to 32 bar for 300m-1000mm diameter and up to 16 bar for 1100mm diameter and above.

Four Axis Helical Winding

FRP tanks and vessels designed as per BS 4994 are widely used in the chemical industry in the following sectors: chlor-alkali manufacturers, fertilizer, wood pulp and paper, metal extraction, refining, electroplating, brine, vinegar, food processing, and in air pollution control equipment, especially at municipal waste water treatment plants and water treatment plants. The 4-axis filament winding machine we have is computer numerical controlled and can manufacture pressure vessel/tanks up to the diameter of 3000mm internal diameter.

The 4 axis filament winding machine has the most advanced software right now in the market which helps us to manufacture helical wound complex shaped fittings like elbow, reducer etc.

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