Composite Fibre Technologies - Wagners Guide July 2016.pdf · Version 04 • July 2016 • Page ii...

Version 04 • July 2016 • Page AWagners CFT Manufacturing Pty Ltd A.B.N. 91 099 936 446 • PO Box 151 Drayton North QLD 4350 • Telephone: +61 7 4637 7777 • Email: [email protected] • Internet: www.wagnerscft.com.au

PRODUCT GUIDE

Composite Fibre Technologies

www.wagnerscft.com.au

Version 04July 2016

PRODUCT GUIDE

Wagners CFT Manufacturing Pty Ltd A.B.N. 91 099 936 446 • PO Box 151 Drayton North QLD 4350 • Telephone: +61 7 4637 7777 • Email: [email protected] • Internet: www.wagnerscft.com.au

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Version 04 • July 2016 • Page iiWagners CFT Manufacturing Pty Ltd A.B.N. 91 099 936 446 • PO Box 151 Drayton North QLD 4350 • Telephone: +61 7 4637 7777 • Email: [email protected] • Internet: www.wagnerscft.com.au

PRODUCT GUIDE

Product Guide

Published by Wagners CFT Manufacturing Pty Ltd ABN 91 099 936 446 339 Anzac Ave, Toowoomba Qld 4350 Australia

PO Box 151 Drayton North Qld 4350

Telephone: +61 7 4637 7777 Fax: +61 7 4637 7756

Email: [email protected] Website: www.wagner.com.au www.wagnerscft.com.au

© Wagners CFT Manufacturing Pty Ltd

DISCLAIMER:

The information provided in this publication, including any technical specification, is specific to pultruded fibre reinforced polymer (composite fibre) products supplied by Wagners CFT Manufacturing Pty Ltd (“Wagners CFT”), is provided primarily for marketing purposes, and is subject to change without notice. To the extent permitted by law, Wagners CFT excludes any and all liability in any way, no matter how arising, to any person which may arise out of, in connection with, or as a consequence of, the accuracy or correctness of the information provided or a person relying on some or all of the information provided in this publication.

Product Availability & Other Information

It is expected that the content of this Product Guide will change over time as a result of further development of the materials, properties and finishes of products, and due to changes to the product range. Therefore it is important to check that you are using the most up to date information by referring to the Wagners CFT website www.wagnerscft.com.au.

Version 04 • July 2016 • Page iiiWagners CFT Manufacturing Pty Ltd A.B.N. 91 099 936 446 • PO Box 151 Drayton North QLD 4350 • Telephone: +61 7 4637 7777 • Email: [email protected] • Internet: www.wagnerscft.com.au

PRODUCT GUIDE

Contents

Part 1: General Information

Part 2: Structural Hollow Sections

Part 3: Bonded Structural Sections

Part 4: Piping, Casing & Tubing

Part 5: Reinforcing

Part 6: Composite Nuts & Bolts

Part 7: Decking, Grating & Stair Treads

Part 8: Piles

Part 9: Hand Rails

Part 10: Accessories

Preface

Wagners Composite Fibre Technologies (CFT) is pleased to present this first edition of its “Product Guide”. This Product Guide is intended for all potential users of Wagner CFT products, including project owners and managers, architects, engineers, project certifiers, and builders. It provides users of this publication with the general characteristics of fibre reinforced polymers, and provides technical specifications for all of the Wagners pultruded products.

The vision of Wagners Composite Fibre Technologies is not just to be a supplier of Fibre Reinforced Polymer (FRP) structural products, but also to provide the market with innovative engineered structural solutions for many civil and structural applications where fibre composites have a distinct advantage. To support this vision, this Product Guide is the first of a suite of publications which will include member design, connection design, and many pre-engineered application and building system designs.

The goal of these publications is to enable designers, certifiers and builders to specify and use Wagners CFT products with ease and with confidence in the quality and integrity of the data presented and the products supplied.

However, the product specifications and properties presented in this Product Guide are the result of the materials, manufacturing processes and fibre layups chosen by Wagners CFT, and are therefore specific to these particular products. Other manufacturers will not necessarily use the same materials, manufacturing process and fibre layups, resulting in different mechanical properties. Therefore similar structural shapes produced by other manufacturers will not have identical properties and performance to the Wagners CFT products.

PRODUCT GUIDE Version 04 • July 2016 • Part 1 - Page 1Wagners CFT Manufacturing Pty Ltd A.B.N. 91 099 936 446 • PO Box 151 Drayton North QLD 4350 • Telephone: +61 7 4637 7777 • Email: [email protected] • Internet: www.wagnerscft.com.au

Part 1: General Information


Wagners is a family owned business established in 1989 in Toowoomba, Queensland by Henry, John, Denis, Neill, and Joe Wagner. Starting with three trading divisions - Wagners Concrete, Quarries and Transport - the company grew to incorporate Cement, Concrete Pumping, Composite Fibre Technologies, Pre-Cast Concrete, Steel Reinforcing, Projects and Global Services in their range of capabilities.

Today, Wagners is one of Queensland’s largest privately-owned construction materials and mining services companies.

In 2009, Wagners was acknowledged by the Premier of Queensland at the Smart Business Awards as the company that had made the most significant impact on regional Queensland in the State’s 150 year history.

Wagners employs over 700 staff worldwide and has performed work in 20 countries throughout the world. Wagners is a Third Party Quality endorsed company and is accredited by SAI Global as complying with the ISO 9001:2008 Quality Management System Standard.

Currently Wagners offers products and services to its customers through its 12 trading divisions:

• Composite Fibre Technologies • Transport • Aviation

• Mobile Concrete • Reinforcing Steel • Fly Ash

• Pre-Cast Concrete • Cement • Workshop

• Contract Crushing • Earth Friendly Concrete • International Services

Through its International Division, Wagners has a focus on servicing the international market, specialising in the manufacture of ready-mixed concrete, quarrying materials, bulk transport and composite fibre products.

The guiding principles of the Wagners business include:

• Integrity

• Health and Safety

• Excellence and Quality

• Innovation through Research & Development

Wagners Composite Fibre Technologies (CFT) is a world leader in the use and development of sophisticated composite engineering materials. Continued research and development allows Wagners CFT to remain at the forefront in the design and implementation of this exciting material.

Fibre reinforced polymers are now being used for transportation, sports, aerospace, marine, infrastructure and medical science applications. Many years of research and development have allowed Wagners to successfully apply fibre reinforced polymer technology to a number of applications including road bridges, electrical crossarms and pedestrian structures.

Wagners CFT possesses a highly skilled engineering team that can design and provide assistance for any structure that your site requires. With experience in hundreds of installations across Australia, the Wagners CFT team can provide sound solutions to difficult problems.

Wagners CFT can provide any of the following services.

• Supply – Wagners can supply all composite materials and required connections/accessories directly to your own installation crews to assemble on site

• Pre-Fabrication – Our projects team can pre-fabricate all or sections of the structure in our Toowoomba workshop and deliver it to the project site.

• Design & Certification – Our team of experienced engineers can design your structure to the required specifications using relevant Standards and provide external validation and certification.

• Installation – Our installation crews can fully install your structure and provide full project/site management for the duration of the project

Wagners Group Wagners Composite Fibre Technologies


Wagners Fibre Reinforced Polymer ProductsFibre reinforced polymers have proven themselves as the material of choice in high performance applications such as the Aerospace and Marine industries. As the use of Fibre reinforced polymers have become more common their benefits have been realised by other industries and their use and acceptance by civil engineers has greatly increased in recent years.

Fibre reinforced polymers offer high strength, low weight, and long service lives as they are not prone to corrosion, rot or shrinkage unlike other materials more traditionally used by the construction industry. Wagners CFT is expanding the use of fibre reinforced polymers in Australia and throughout the World, exporting products from Toowoomba Queensland to locations such as the United States, Russia, and Malaysia.

Wagners use the ‘Pultrusion Process’ to manufacture structural FRP sections. These sections are similar in geometry and shape to traditional cold-formed steel ‘RHS’ sections, but are made from glass fibres and vinyl ester resins. The material combination has been chosen by Wagners to provide the best structural solution for an economical cost.

Electrical-Corrosion Resistant (ECR) Type Glass has been selected as the initial building block for all Wagners FRP products. This high grade material has been selected for its impressive strength performance and workability. ECR Type Glass is also widely reported as having excellent chemical resistant characteristics.

To bind the glass fibres together, Wagners uses Vinyl Ester (VE) resin. VE resin has been selected over unsaturated polyester and epoxy resins because it provides strength and chemical resistant properties similar to epoxy resin to a significant cost advantage. In general Wagners does not recommend the use of polyester resins for structural applications.

Current applications of the Wagners composite fibre products include:

• Power Pole Cross arms

• Boardwalks

• Foot Bridges

• Road Bridges

• Pontoons

• Jetties

• Various Mine Structures

• Piping, Casing & Tubing

• Reinforcing (Rebar)

Some of the benefits of Wagners FRP products over other structural materials include:

• Corrosion resistant (doesn’t rust or rot)

• Durable

• Borer and termite resistant

• Light weight

• Electrically insulating

• Thermally insulating

• Flexible in design and manufacture

• High tensile strength

Because Wagners pultruded FRP products have different properties to other materials such as steel, allowance needs to be made in design for:

• Greater flexibility in bending

• Concentrated transverse loads

• Bearing of bolts in holes

Wagners CFT also provides a range of accessories such as end caps and inserts for use with its products. These are listed under “Accessories” in this Product Guide.


Environmental PerformanceWagners believe that its business must be conducted in an environmentally responsible manner that leaves the environment healthy, safe, and does not compromise the ability of future generations to sustain their needs. Wagners are committed to reducing waste, the consumption of resources, and avoiding the pollution of land, air and water. This is achieved through recovering and recycling our waste products where possible, and by strict adherence to licensing conditions, industry codes and regulations.

The Wagners CFT pultruded fibre reinforced polymer (FRP) products have many inherent environmental advantages. These include:

• Low embodied energy

• Thermal insulator – conserving energy while reducing operating costs

• Durable – long life cycle reducing maintenance and replacement costs

Wagners CFT’s pultruded FRP products are currently used as substitutes for hardwood in marine and other corrosive environments where they offer longer life with no detrimental impact on these environments. With hardwood forests in decline around the world, the use of fibre reinforced polymer products in these applications will help preserve this important natural resource.

The same benefits apply to the use of Wagners pultruded FRP products in place of steel, aluminium and reinforced concrete.

Key findings of a cradle-to-grave life cycle analysis by Kara and Manmek (2009) from the Life Cycle Engineering & Management Research Group at The University of New South Wales were:

“In general, the life cycle of the fibre reinforced polymer products have significantly lower embodied energy than the traditional products. The embodied energy of each life cycle stage of the composite products is given as follows:

• Material stage: Fibre reinforced polymer products have significantly lower embodied energy during their material stage the traditional product. This is large due to the traditional materials require a relatively high amount of energy during their extraction process.

• Manufacturing process (process): Most of the fibre reinforced polymer products have higher embodied energy than the traditional products during the manufacturing process stage.

• Usage stage: Fibre reinforced polymer products perform significantly better than the traditional products at the usage stage. This is owing to their light-weight and corrosive resistance properties.

• End-of-Life stage: Despite many advantages, fibre reinforced polymer products have the shortcoming at the end-of-life stage where the composite products are currently 100% landfill but the traditional product such as steel and aluminium is 65 to 70% recyclable.

As a conclusion, based on the defined scopes and assumptions of this analysis, it was found that fibre reinforced polymer products are estimated to perform better than the traditional products in terms of their embodied

energy that incurred during their life cycle stages. At the material stage, they perform the best. Their outstanding material properties such as strength and lightness are genuinely an advantage over the traditional materials in this modern era.”

More specifically, the report made the following conclusion regarding a power pole cross-arm produced by Wagners CFT:

“A power-pole cross-arm that is made from the fibre composite has an environmental impact which is 77% less than that of a hardwood timber power-pole cross-arm. This equates to a lessening on the effects towards human health, the ecosystem quality and resource use during its life cycle.”

The full report can be downloaded from the Wagners CFT website at: www.wagnerscft.com.au/sustainability.

Today the end of life strategy for composites is disposal. Whilst this is not the preferred end of life strategy, it does no harm to the environment as the product once cured is inert. It must not be disposed of in fire as toxic fumes may be released. It is anticipated that recycling options will become available in the near future, based on research which is currently underway around the world.


Developed in the 1950’s by the person considered by many to be “the father of composites,” W. Brant Goldsworthy, pultrusion is the process of “pulling” raw composites through a heated die creating a continuous composite profile.

The term pultrusion combines the words, “pull” and “extrusion”. Extrusion is the pushing of material, such as a billet of aluminum, through a shaped die, whereas pultrusion, is the pulling of material, such as fibre and resin, through a shaped die.

The pultrusion process starts with racks holding rolls of fibre roving. The fibre reinforcement used by Wagners CFT is glass fibre. This raw fibre is pulled off the racks and is guided to the necessary shape, orientation and layers before entering a resin injection system. A surface veil is incorporated to improve surface finish and provide resistance to ultraviolet (UV) degradation.

The fibre reinforcement becomes fully injected (wetted-out) with the catalysed resin such that all the fibre filaments are thoroughly saturated with the resin mixture. This wetted fibre then enters the heated curing die. The heat initiates a chemical reaction in the resin which causes it to harden and the finished profile exits the die and is subsequently cooled. The movement for the process is created by puller clamps which act on the finished product and pull it on a continuous basis.

At the end of this pultrusion machine is a moving cut-off saw. The pultruded profiles are cut to the specific length and stacked.

GlassRovings

Guides

SurfaceVeil

ResinInjection

PultrusionDie & Heaters

PullingMechanism

MovingCut-off

Saw

FinishedProduct

While the structural products are generally manufactured by the pultrusion process, there are other FRP products supplied by Wagners CFT which are manufactured using other processes appropriate to the product. Some of these processes include:

• Hand layup

• Injection moulding

• Filament winding

• Infusion

QualityISO 9001 Certification:

Wagners has ISO 9001 certification accredited by SAI Global.

Manufacturing Processes

Pultrusion Process

Quality ISO 9001


Notations & Abbreviations

Symbol Description

Ag gross area of a cross-section

b width of a section

BRB Bonded Rectangular Beam

C torsional modulus for a cross-section; or Celcius

d depth of a section

ELc longitudinal compression modulus of elasticity

ELt longitudinal tension modulus of elasticity

ETc transverse compression modulus of elasticity

ETt transverse tension modulus of elasticity

e deviation from straightness

FRP Fibre Reinforced Polymer (or plastic)

fLc longitudinal compressive strength

fLt longitudinal tensile strength

fLv in-plane shear strength – longitudinal

fTc transverse compressive strength

fTt transverse tensile strength

fiv interlaminar shear strength

GL in-plane shear modulus of elasticity – longitudinal

In second moment of area about the n-axis through the corners of a SHS

Ix second moment of area about the cross-section major principal x-axis

Iy second moment of area about the cross-section minor principal y-axis

J torsion constant for a cross-section

n axis through the corners of a SHS

ro outside corner radius

ri inside corner radius

Symbol Description

rx radius of gyration about the major principal x-axis

ry radius of gyration about the minor principal y-axis

RHS Rectangular Hollow Section

SHS Square Hollow Section

Tg glass transition temperature

t thickness of a section

UV Ultra Violet

Vr fibre volume fraction

v total twist

Wr fibre mass fraction

x major principal axis co-ordinate

x1 concavity of a side of a square or rectangular hollow section

x2 convexity of a side of a square or rectangular hollow section

y minor principal axis co-ordinate

Zn elastic section modulus about the n-axis through the corners of a SHS

Zx elastic section modulus about the major principal x-axis

Zy elastic section modulus about the minor principal y-axis

aL coefficient of thermal expansion - longitudinal

Dv deviation from verticality of a web

nLPoisson’s ratio associated with transverse strain when strained in the longitudinal direction

nTPoisson’s ratio associated with longitudinal strain when strained in the transverse direction

r density of material


PRODUCT GUIDE Version 04 • July 2016 • Part 2 - Page 1

Part 2: Structural Hollow Sections



PRODUCT CODE DIMENSIONS SECTION PROPERTIES

Designation Outside Corner Radius

Inside Corner Radius

MassExternal Surface

Area

GrossSection

AreaAbout x- and y-axis About n-axis Torsion

ConstantTorsion

ModulusDepth Width Thick.

d b t ro ri per m per m Ag lx Zx rx ln Zn J C

mm mm mm mm mm kg/m m2/m mm2 106mm4 103mm3 mm 106mm4 103mm3 106mm4 103mm3

STR-VSHS-100x100x5.2 WCFT 100 x 100 x 5.2 SHS 10.0 4.75 3.87 0.383 1910 2.80 56.1 38.4 2.81 42.3 4.55 84.3

STR-VSHS-125x125x6.4 WCFT 125 x 125 x 6.4 SHS 10.0 4.75 6.03 0.483 2970 6.89 110 48.2 6.90 81.9 10.9 163

NOTE: The grade is a WCFT proprietary grade defined by the mechanical and physical properties specified in this section.

Table 2.1

DIMENSIONS & SECTION PROPERTIESSQUARE HOLLOW SECTIONS

WCFT Grade GV36-SFibre Reinforced Polymer (FRP)

x x

y

yn

n

d

b

t

ro

ri

SQUARE HOLLOW SECTIONS – WCFT Grade GV36-S

Explanation of grade designation (e.g. WCFT Grade GV36-S):G = Glass fibre reinforcementV = Vinyl Ester resin36 = nominal tensile modulus of elasticity - longitudinal (GPa)S = Standard

Supply ConditionsFinishThe standard finish for the SHS product is painted. Contact Wagner CFT Manufacturing for more details relevant to your specific requirement.

LengthsSquare Hollow Sections (SHS) can be manufactured to any length up to 12 metres. Longer lengths are possible subject to negotiation. Contact Wagner CFT Manufacturing for more details relevant to your specific requirement.

Mass & BundlingCurrently all SHS product is manufactured to order. As such there is no standard pack size. Contact Wagner CFT Manufacturing for more details relevant to your specific requirement.

Post-ProcessingWagners CFT are able to provide members cut to length with holes and inserts in accordance with Client drawings. Contact Wagners CFT for further details and pricing.

MSDS - FRP Structural Hollow SectionsThis product is not classified as hazardous according to the criterion of the NOHSC Australia. Consult MSDS No. WCFT 1004 for details at www.wagnercft.com.au/technical/.

Product Code designation (e.g. STR-VSHS-100x100x5.2):STR = Structural ProfileV = Vinyl Ester resinSHS = Square Hollow Section



Mechanical Properties

Property Notation Value Unit Test Method

Tensile Strength – Longitudinal fLt 610 MPa

ISO 527-4Tensile Modulus of Elasticity – Longitudinal ELt 36300 MPa

Poisson’s Ratio – Longitudinal nL 0.28

Tensile Strength – Transverse fTt 55.0 MPa

ISO 527-4Tensile Modulus of Elasticity – Transverse ETt 10800 MPa

Poisson’s Ratio – Transverse nT 0.09

Compressive Strength – Longitudinal fLc 485 MPaASTM D6641

Compressive Modulus of Elasticity – Longitudinal ELc 33300 MPa

Compressive Strength – Transverse fTc 120 MPaASTM D6641

Compressive Modulus of Elasticity – Transverse ETc 11600 MPa

In-Plane Shear Strength – Longitudinal fLv 84.0 MPaASTM D7078

In-Plane Shear Modulus of Elasticity – Longitudinal GL 4280 MPa

Interlaminar Shear Strength fiv 44.0 MPa ASTM D2344

NOTE:The values in the table are the characteristic values to be used for design in normal ambient conditions. It does not include adjustment factors to account for temperature, humidity, and chemical environments.

Physical Properties


Density r 2030 kg/m3 ASTM D792

Barcol Hardness 60 ASTM D2583

Water Absorption 0.2 % ISO 62

Glass Transition Temperature Tg 130 °C ASTM D7028

Fibre Mass Fraction Wr 77.4 %ISO 1172

Fibre Volume Fraction Vr 57.7 %

Coefficient of Thermal Expansion – Longitudinal aL 5.03x10-6 / °C ISO 11359-2

NOTE: The values in the table are mean values obtained from tests at ambient temperature and relative humidity.

Composite Materials

Component Material

Reinforcement Continuous ECR Type glass fibre

Matrix Vinyl Ester resin

Veil Thermoplastic non-woven

Additives Proprietary catalysts, mould release and polymer additives

NOTE:For further information contact Wagners CFT.

STRUCTURAL HOLLOW SECTIONS DIMENSIONAL TOLERANCES

Parameter Tolerance Illustration

Depth, d ± 0.5% with a minimum of ± 0.5 mm

d

b

t

ro

d

b

t

ro

Width, b ± 0.5% with a minimum of ± 0.5 mm

Thickness, t ± 10%

Outside corner radius, ro ± 0.5 mm

Concavity, x1 Convexity, x2

≤ 0.8% with a minimum of 0.5 mm

x1 x2

side dimension b or dside dimension b or d

Squareness of sides 90º ± 1º

Twist, v ≤ 2 mm + 0.5 mm per metre length

v

Straightness, e (in any one plane)

≤ 0.1% of total length

e

Mass of a section length ± 4%

Length of a member - 0, + 20 mm

NOTE: The tolerance on member length applies to manufactured product only. Tolerances on post-processed (fabricated) product are determined on a project by project basis. Contact Wagners CFT for details.



Table 2.2

DIMENSIONS & SECTION PROPERTIESRECTANGULAR HOLLOW SECTIONS


x x

y

y





Area

GrossSection

AreaAbout x-axis About y-axis Torsion

ConstantTorsion

ModulusDepth Width Thick.

d b t ro ri per m per m Ag lx Zx rx ly Zy ry J C

mm mm mm mm mm kg/m m2/m mm2 106mm4 103mm3 mm 106mm4 103mm3 mm 106mm4 103mm3

STR-VRHS-100x75x5 WCFT 100 x 75 x 5.0 RHS 10.0 4.75 3.21 0.333 1580 2.14 42.8 36.8 1.37 36.5 29.4 2.76 59.2


d

b

t

ro

ri

RECTANGULAR HOLLOW SECTIONS – WCFT Grade GV36-S


Supply ConditionsFinishThe standard finish for the RHS product is painted. Contact Wagner CFT Manufacturing for more details relevant to your specific requirement.

LengthsRectangular Hollow Sections (RHS) can be manufactured to any length up to 12 metres. Longer lengths are possible subject to negotiation. Contact Wagner CFT Manufacturing for more details relevant to your specific requirement.

Mass & BundlingCurrently all RHS product is manufactured to order. As such there is no standard pack size. Contact Wagner CFT Manufacturing for more details relevant to your specific requirement.

Post-ProcessingWagners CFT are able to provide members cut to length with holes and inserts in accordance with Client drawings. Contact Wagners CFT for further details and pricing.


Product Code designation (e.g. STR-VRHS-100x100x5.2):STR = Structural ProfileV = Vinyl Ester resinRHS = Rectangular Hollow Section



RECTANGULAR HOLLOW SECTIONS – WCFT Grade GV36-S

Mechanical Properties



ISO 527-4Tensile Modulus of Elasticity - Longitudinal ELt 37600 MPa

Poisson’s Ratio – Longitudinal nL 0.30


ISO 527-4Tensile Modulus of Elasticity - Transverse ETt 9190 MPa

Poisson’s Ratio – Transverse nT 0.07


Compressive Modulus of Elasticity - Longitudinal ELc 34000 MPa


Compressive Modulus of Elasticity - Transverse ETc 11000 MPa

In-Plane Shear Strength - Longitudinal fLv 54.0 MPaASTM D7078

In-Plane Shear Modulus of Elasticity - Longitudinal GL 4690 MPa



Physical Properties


Density r 2030 kg/m3 ASTM D792






Coefficient of Thermal Expansion – Long. aL 5.03x10-6 / °C ISO 11359-2

NOTE:The values in the table are mean values obtained from tests at ambient temperature and relative humidity.

Composite Materials

Component Material






Unpainted SHS Section


PRODUCT GUIDE Version 04 • July 2016 • Part 3 – Page 1

Part 3: Bonded Structural Sections



Table 4.1

DIMENSIONS & SECTION PROPERTIESBONDED RECTANGULAR BEAMS






Area

GrossSection

AreaAbout x-axis About y-axis Torsion

ConstantDepth Width Thick.

d b t ro ri per m per m Ag lx Zx rx ly Zy ry J

mm mm mm mm mm kg/m m2/m mm2 106mm4 103mm3 mm 106mm4 103mm3 mm 106mm4

STR-VBRB-625x125x6.4 WCFT 625 x 125 x 6.40 BRB 10.0 4.75 30.1 1.57 14800 498 1595 183 34.4 551 48.2 94.3



STR-VBRB-250x125x6.4 WCFT 250 x 125 x 6.40 BRB 10.0 4.75 12.1 0.756 5940 37.0 296 78.9 13.8 220 48.2 30.0






d

b

t

ro

ri

x x

y

y

BONDED RECTANGULAR BEAMS – WCFT Grade GV36-S


Product Code designation (e.g. STR-VBRB-200x100x5.2):STR = Structural ProfileV = Vinyl Ester resinBRB = Bonded Rectangular Beam



BONDED RECTANGULAR BEAMS – WCFT Grade GV36-SMechanical Properties



ISO 527-4Tensile Modulus of Elasticity – Longitudinal ELt 36300 MPa

Poisson’s Ratio – Longitudinal νL 0.28


ISO 527-4Tensile Modulus of Elasticity – Transverse ETt 10800 MPa

Poisson’s Ratio – Transverse νT 0.09


Compressive Modulus of Elasticity – Longitudinal ELc 33300 MPa


Compressive Modulus of Elasticity – Transverse ETc 11600 MPa

In-Plane Shear Strength – Longitudinal fLv 84.0 MPaASTM D7078

In-Plane Shear Modulus of Elasticity – Longitudinal GL 4280 MPa



Physical Properties


Density ρ 2030 kg/m3 ASTM D792






Coefficient of Thermal Expansion – Longitudinal aL 5.03x10-6 / °C ISO 11359-2

NOTE: The values in the table are mean values obtained from tests at ambient temperature and relative humidity.

Composite Materials

Component Material






Adhesive Properties

The adhesive used for Bonded Rectangular Beams is Tenchniglue-HP R26 produced by ATL Composites Pty Ltd. It is a thixotropic, solvent free, toughened epoxy resin which is mixed with H26 hardener.


Tensile Strength ft 34.1 MPa ISO 527-2

Tensile Modulus Et 2409 MPa ISO 527-2

Lap Shear Strength fv 11.9 MPa ASTM D3161

Heat Deflection Temperature HDT 85 °C ISO 75

NOTES: 1. The properties in the table are as per the ATL Engineering Data sheet dated 23/9/09. 2. The values in the table are based on a cure schedule of 24 hours @ ambient + 8 hours @ 80 °C. 3. The values in the table are the design values to be used in normal ambient conditions. It does not include adjustment factors to account for temperature, humidity, and chemical environments.



Supply ConditionsFinishThe standard finish for the BRB product is painted.

LengthsBonded Rectangular Beams (BRB) can be manufactured to any length up to 12 m. Longer lengths are possible subject to negotiation.

Mass & BundlingCurrently all BRB product is manufactured to order. As such there is no standard pack size.

Post-ProcessingWagners CFT are able to provide members cut to length with holes and inserts in accordance with Client drawings.


NOTE:Contact Wagner CFT Manufacturing for more details relevant to your specific requirement.

BONDED RECTANGULAR BEAMS – WCFT Grade GV36-SBONDED RECTANGULAR BEAMS DIMENSIONAL TOLERANCES

Parameter Tolerance Illustration

Depth, d ± 0.5% with a minimum of ± 0.5 mm

d

b

t

ro

Width, b ± 0.5% with a minimum of ± 0.5 mm

Thickness, t ± 10%

Outside corner radius, ro ± 0.5 mm

Concavity, x1 Convexity, x2

≤ 0.8% with a minimum of 0.5 mm

x1 x2

side dimension b or dside dimension b or d

Deviation from verticality, Δv ± 2 mmd

∆v

Twist, v ≤2 mm + 0.5 mm per metre length v

Straightness, e (in any one plane) ≤ 0.1% of total length

e

Mass of a section length ± 4%

Length of a member - 0, + 20 mm

NOTE:The tolerance on member length applies to manufactured product only. Tolerances on post-processed (fabricated) product are determined on a project by project basis. Contact Wagners CFT for details.Bonded Section as a Bearer



Part 4: Piping, Casing & Tubing



PIPING, CASING & TUBINGOur standard Glass Reinforced Epoxy (GRE) casing, tubing and pipe products are mostly manufactured by filament winding process, with the main material being fibre glass rovings and acid anhydride epoxy resin.

Wagner’s has been manufacturing or supplying these materials for different applications for more than 10 years and continues to expand these products with even better and more reliable designs.

AvailabilityCasing and tubing is available in a variety of sizes up to 16” Diameter (407mm) with a maximum pressure rating of 5000 psi (34.47 MPa).

Product Characteristics• Light Weight

• Easily transportable

• Low surface co-efficient, maintains this throughout the service life

• Corrosion Resistant

• Excellent pressure capacity

• Long service Life- 20 years

• Low Maintenance

• Excellent flow Characteristics

• Electrically non-conductive

• Low installation costs

Connection methods and StandardsThe GRE high-pressure casing is designed and manufactured according to the following API standards.

• API 5B

• API 5B1

• API 15HR

• API 15LR

Connection types • EUE 8 RND , Tube and Collar or upset end

• Buttress Threads, Tube and collar, upset end and flush joint

Applications• Vertical Gas Wells

• Lateral Gas well

• Reinjection Wells

• Water Monitoring Wells

• Replacing Corroded Steel Liners

• Chemical Disposal Wells

• In seam Coal degassing

Dimensional RangeThe dimensional range of the composite casing ranges from 38mm to 405mm in diameter.

Pressure & TemperatureWagners composite casing offers a long service life with high-pressure resistance and good corrosion resistance. It has a working pressure range up to 25 MPa and a high working temperature of up to 100°C.

Installation & ServiceWagners composite casing is fitted with a screw connection allowing for a perfect seal. The composite material causes very little friction leaving little to no build up inside the tubing.

Durability, Chemicals and EnvironmentThe 25 year design allows the Wagners Composite Casing to not rust nor cause any leaks or contaminate the underground water systems. These tubular sections are highly resistant to salt water and other chemicals making it the perfect material to use in harsh salt water environments. There is a chemicals resistance table available on our website.



Wagners GRE Casing SI Units

PRODUCT CODE

Nominal Dia. Thread Form Connection Type

ID OD Wall Collar OD

Rated Ultimate

Weight

Inches BTC or RND T&C, FJ or EUE Burst Collapse Tensile Burst Collapse Tensile Compression

Inches BTC or RND T&C, FJ or EUE mm mm mm mm MPa MPa Kgs MPa MPa kgs kgs kg/m

PCT-EBTC-244x12 9 5/8” BTC Tube and Collar 223.00 247.00 12.00 26.00 9 6 44799 20.50 9.00 67,199 97,280 21

PCT-EBTC-244x13 9 5/8” BTC Tube and Collar 215.90 247.00 15.55 308.17 12 8 57176 27.44 11.66 85,763 124,154 27

PCT-EBTC-178x16 7” BTC Tube and Collar 139.70 172.50 16.40 222.25 23 18 57945 65.09 21.70 74,501 97,977 17

PCT-ERND-178x10 7” 8 RND Long Tube and Collar 152.50 172.50 10.00 205.00 15 8 27591 38.00 12.00 41,386 61,162 11.60

PCT-EBTC-178x10 7” BTC Tube and Collar 152.5 172.5 10.00 205.00 15 8 26176 38.00 12.00 41,386 61,162 11.60



PCT-EBTC-178x6P 7” Perf BTC Tube and Collar 159.80 172.50 6.50 205.0 n/a n/a 13936 n/a n/a 22,034 32,562 8.80

Product Code designation (e.g. PCT-EBTC-244x12):PCT = Piping Casing TubingE = Epoxy resinBTC = Buttress ThreadRND = 8 Round ThreadT&C = Tube and CollarFJ = Flush JointEUE = External Upset Ends



Wagners GRE Casing Imperial Measurements

PRODUCT CODE

Nominal Dia Thread Form Connection Type

ID OD Wall Collar OD

Rated Ultimate

Weight

Inches BTC or RND T&C, FJ or EUE Burst Collapse Tensile Burst Collapse Tensile Compression

Inches BTC or RND T&C, FJ or EUE inch inch inch inch psi psi lbs psi psi lbs lbs ppf

PCT-EBTC-244x12 9 5/8” BTC Tube and Collar 8.78 9.72 0.47 11.65 1292 932 98766 2,972 1,305 148,148 214,465 14.1

PCT-EBTC-244x13 9 5/8” BTC Tube and Collar 8.50 9.72 0.61 12.13 1730 1208 126050 3,980 1,692 189,075 273,713 18.0

PCT-EBTC-178x16 7” BTC Tube and Collar 5.50 6.79 0.65 8.75 3331 2665 127749 9,438 3,146 164,248 215,843 11.4

PCT-ERND-178x10 7” 8 RND Long Tube and Collar 6.00 6.79 0.39 8 2210 1163 20827 5,525 1,745 91,241 134,839 7.8

PCT-EBTC-178x10 7” BTC Tube and Collar 6.00 6.79 0.39 8 2210 1163 57707 5,525 1,745 91,241 134,839 7.8

PCT-EBTC-178x8 7” BTC Tube and Collar 6.16 6.79 0.31 8 1734 897 46734 4,336 1,321 73,891 109.199 6.6

PCT-EBTC-178x6 7” BTC Tube and Collar 6.29 6.79 0.26 8 1396 679 37468 3,490 1,018 59,240 87,546 5.3

PCT-EBTC-178x6P 7” Perf BTC Tube and Collar 6.29 6.79 0.26 8 n/a n/a 30723 n/a n/a 48,576 71,788 5.2

Product Code designation (e.g. PCT-EBTC-244x12):PCT = Piping Casing TubingE = Epoxy resinBTC = Buttress ThreadRND = 8 Round ThreadT&C = Tube and CollarFJ = Flush JointEUE = External Upset Ends



WAGNERS GRE TUBING

PRODUCT CODE

Nominal Sizes

Dia ID OD Wall Collar OD Weight Int Collapse Tensile Burst Collapse Tensile

Inch mm mm mm mm kg/m psi psi kgs psi psi kgs

PCT-ERND-38.1x2.9

1 1/2”

38.1 43.9 2.9 64 0.89 1494 1578 2000 3734 3944 6100

PCT-ERND-38.1x3.4 38.1 44.9 3.4 69 1.06 1755 1868 2400 4386 4669 7300

PCT-ERND-38.1x4.1 38.1 46.3 4.1 69 1.37 2001 2076 2850 5003 5191 8980

PCT-ERND-38.1x5.7 38.1 49.5 5.7 69 1.74 2494 2494 4200 6235 6235 13060

PCT-ERND-38.1x6.9 38.1 51.9 6.9 69 1.96 3002 2871 5100 7504 7178 15100

PCT-ERND-49.5X3.2

2 3/8”

49.5 55.9 3.2 76 1.58 1247 1346 2800 3118 3364 8980

PCT-ERND-49.5X4.2 49.5 57.9 4.2 84 1.82 1494 1543 4000 3734 3857 12200

PCT-ERND-49.5X4.6 49.5 58.7 4.6 84 2.34 1755 1798 4400 4386 4495 13400

PCT-ERND-49.5X5.3 49.5 60.1 5.3 84 2.47 2001 2030 5300 5003 5075 15920

PCT-ERND-47.8X6.6 47.8 61 6.6 89 2.84 2494 2465 5300 6235 6163 18770

PCT-ERND-47.8X7.9 47.8 63.6 7.9 89 3.1 3002 2796 7340 7504 6989 21630

PCT-ERND-61.7X3.9

2 7/8”

61.7 69.5 3.9 89 2.16 1247 1305 4450 3118 3263 13420

PCT-ERND-61.7X4.7 61.7 71.1 4.7 99 2.63 1494 1508 5510 3734 3770 16320

PCT-ERND-61.7X5.3 61.7 72.3 5.3 99 3.18 1755 1740 61420 4386 4350 18770

PCT-ERND-61.7X5.7 61.7 73.1 5.7 99 3.38 2001 1972 6930 5003 4930 20820

PCT-ERND-56.5X7.9 56.5 72.3 7.9 104 4.09 2494 2436 8160 6235 6090 24410

PCT-ERND-56.5X9.5 56.5 75.5 9.5 104 4.4 3002 2726 8980 7504 6815 27350

Product Code designation (e.g. PCT-ERND-38.1x2.9):PCT = Piping Casing TubingE = Epoxy resinBTC = Buttress ThreadRND = 8 Round ThreadT&C = Tube and CollarFJ = Flush JointEUE = External Upset Ends



WAGNERS GRE TUBING CONTINUED

PRODUCT CODE

Nominal Sizes

Dia ID OD Wall Collar OD Weight Int Collapse Tensile Burst Collapse Tensile

Inch mm mm mm mm kg/m psi psi kgs psi psi kgs

PCT-ERND-76x4.6

3 1/2”

76 85.2 4.6 109 3.27 1247 1230 6530 3118 3074 19590

PCT-ERND-76x5.7 76 87.4 5.7 117 3.65 1494 1485 8160 3734 3712 24490

PCT-ERND-76x6.4 76 88.8 6.4 117 4.46 1755 1711 8980 4386 4278 27760

PCT-ERND-76x7 76 90 7 117 5.21 2001 1943 10610 5003 4858 31840

PCT-ERND-69.1X9.4 69.1 87.9 9.4 124 6.09 2494 2378 11430 6235 5945 34690

PCT-ERND-95.3X5.7

4”

95.3 106.7 5.7 134 3.96 1247 1177 10610 3118 2944 31800

PCT-ERND-95.3X7.1 95.3 109.5 7.1 144 4.53 1494 1421 13060 3734 3553 39190

PCT-ERND-95.3X7.9 95.3 111.1 7.9 144 5.85 1755 1688 13870 4386 4220 42040

PCT-ERND-95.3X9.7 95.3 114.7 9.7 144 6.76 2001 1885 14600 5003 4713 44370

PCT-ERND-85.1X11.4 85.1 107.9 11.4 156 7.51 2494 2262 16300 6235 5655 48980

PCT-ERND-101X7

4 1/2”

101 115 7 135 5.04 1000 600 13154 4200 1500 40824

PCT-ERND-102X8 102 118 8 147 5.83 1500 900 14969 5000 2700 46721

PCT-ERND-95X10.5 95 116 10.5 147 7.07 2000 1600 16330 5600 4700 49306

PCT-ERND-85X12 85 109 12 147 8.06 2500 3400 17373 6000 10000 52209

PCT-ERND-85X16.5 85 118 16.5 160 8.33 3000 4500 21138 6000 10000 63504

Product Code designation (e.g. PCT-ERND-38.1x2.9):PCT = Piping Casing TubingE = Epoxy resinBTC = Buttress ThreadRND = 8 Round ThreadT&C = Tube and CollarFJ = Flush JointEUE = External Upset Ends

Wagners GRE Tubing



Part 5: Reinforcing



FRP/Basalt RebarReinforced Concrete is a common building material for construction of facilities and structures. While concrete has high compressive strength, it has limited tensile strength. To overcome these tensile limitations, reinforcing bars are used in the tension side of concrete structures, and steel has historically been used as an effective and cost-efficient reinforcement material.

However, steel is susceptible to oxidation (rust), especially in coastal areas, locations where salt contaminated aggregates are used in the concrete mixture, and sites where aggressive chemicals and ground conditions exist. Where corrosion of steel reinforcement occurs, the resulting materials have a larger volume (2-5 times) than the metal product from which they were originally derived, leading eventually to cracking and spalling and further deterioration of the steel. The combination of ongoing deterioration and loss of reinforcement properties ultimately requires potentially significant and expensive outlays for repair and maintenance, and possibly the endangerment of the structure itself.

Applications & the Benefits of FRP/Basalt Rebar• Corrosion Resistance - will not rust, and are impervious to the action of salt ions, chemicals, and the

alkalinity inherent in concrete.

• Superior Tensile Strength - composite rebar offers a tensile strength up to twice that of steel.

• Thermal Expansion - Basalt rebar offers a level of thermal expansion comparable to concrete.

• Electrical and Magnetic Neutrality - contains no metal, and will not interfere with the operation of sensitive electronic devices such as medical MRI units or electronic testing devices.

• Thermal insulation - highly efficient in resisting heat transfer, such as from building exteriors to interiors.

• Lightweight - weighs approximately one-quarter the weight of an equivalent size steel bar, offering significant savings in both placement and use. One man can easily lift a 150 m coil of 10 mm basalt rebar!

• Structures built in or close to sea water - quays, retaining walls, piers, jetties, caissons, decks, piles, bulkheads, floating structures, canals, roads and buildings, offshore platforms, swimming pools and aquariums.

• Applications subjected to corrosive agents - wastewater treatment plants, petrochemical plants, pulp/paper mills, liquid gas plants, pipelines / tanks for fossil fuel, cooling towers, chimneys,

• Applications requiring low electric conductivity or electromagnetic neutrality - aluminium and copper smelting plants, manholes for electrical and telephone communication equipment, bases for transmission / telecommunication towers, airport control towers, magnetic resonance imaging in hospitals, railroad crossing sites and specialized military structures.

• Tunnelling / boring applications requiring reinforcement of temporary concrete structures - mining walls, underground rapid transit structures and underground vertical shafts. Thermally sensitive applications - apartment patio decks, thermally insulated concrete housing and basements, thermally heated floors and conditioning rooms.

• Weight sensitive structures - concrete construction in areas of poor load bearing soil conditions, remote geographical locations, sensitive environmental areas, or active seismic sites posingspecial issues that the use of lightweight reinforcement will solve.

• Thermally sensitive applications - apartment patio decks, thermally insulated concrete housing and basements, thermally heated floors and conditioning rooms.



Glass ‘GFRP’ Rebar Technical Data

PROPERTIES OF GFRP REBAR

Diameter (mm) ASTM Diameter (mm) Cross-Section Area (mm2) Density (g/cm3) Weight (g/m) Ultimate Tensile (kN) Ultimate Tensile (MPa) Ultimate Shear (MPa) E - Modulus (GPa)

3 - 7 2.2 16 13.5 1900 >150 >40

4 - 12 2.2 32 18 1500 >150 >40

6 #6 28 2.2 51 36 1280 >150 >40

8 - 50 2.2 98 54 1080 >150 >40

10 #10 73 2.2 150 72 980 >150 >40

12 - 113 2.1 210 99 870 >150 >40

14 - 153 2.1 275 117 764 >150 >40

16 #16 198 2.1 388 149 752 >150 >40

18 - 254 2.1 485 189 744 >150 >40

20 - 314 2.1 570 225 716 >150 >40

22 #22 388 2.1 700 270 695 >150 >40

25 #25 506 2.1 970 342 675 >150 >40

28 - 615 2.1 1195 405 658 >150 >40

30 - 706 2.0 1350 450 637 >150 >40

32 #32 804 2.0 1520 504 636 - >40

34 - 907 2.0 1800 540 595 - >40

36 #36 1017 2.0 2044 585 575 - >40

40 - 1256 2.0 2380 640 509 - >40



Basalt ‘BFRP’ Rebar Technical Data

PROPERTIES OF BFRP REBAR

Diameter (mm) ASTM Diameter (mm) Cross-Section Area (mm2) Density (g/cm3) Weight (g/m) Ultimate Tensile (kN) Ultimate Tensile (MPa) Ultimate Shear (MPa) E - Modulus (GPa)

3 - 7.1 2.2 15.6 14.5 2050 >150 >40

4 - 12.6 2.2 27.6 20.4 1620 >150 >40

6 #6 28.3 2.2 62.2 38.9 1377 >150 >40

8 - 50.3 2.2 110.6 58.1 1156 >150 >40

10 #10 78.5 2.2 172.8 82.6 1052 >150 >40

12 - 113.1 2.2 248.8 105.9 937 >150 >40

14 - 153.9 2.2 338.7 126.9 824 >150 >40

16 #16 201.1 2.2 442.3 162.4 808 >150 >40

18 - 254.5 2.2 559.8 203.5 800 >150 >40

20 - 314.2 2.2 691.2 241.1 768 >150 >40

22 #22 380.1 2.2 836.3 283.0 745 >150 >40

25 #25 490.9 2.2 1079.9 354.5 722 >150 >40

28 - 615.8 2.2 1354.7 431.4 701 >150 >40

30 - 706.9 2.2 1555.1 480.3 680 >150 >40

32 #32 804.2 2.2 1769..3 535.6 666 - >40

34 - 907.9 2.2 1997.4 574.4 633 - >40

36 #36 1017.9 2.2 2239.3 624.6 614 - >40

40 - 1256.6 2.2 2764.6 686.3 546 - >40



Part 6: Composite Nuts & Bolts



Composite Nuts & BoltsFRP bolts are made of a pultruded stud which the threads are cut from the outer layers. Means the core has unidirectional fibres to take the load. The strength of FRP nuts is less than the similar steel bolt, but is much more durable where fastener corrosion is important or metal fasteners are not permitted (communications, electronics, high voltages, etc.).

Advantages• Does not rot

• Easy to use

• Low maintenance

• Not conductive

• Very low radar cross section (RCS)

COMPOSITE NUTS & BOLTS

Fastener Product Code Size

FRP Bolts FSN-EBLT-M10 M10

FSN-EBLT-M12 M12

FSN-EBLT-M16 M16

FSN-EBLT-M20 M20

FSN-EBLT-M24 M24

FRP Nuts FSN-ENUT-M10 M10

FSN-ENUT-M12 M12

FSN-ENUT-M16 M16

FSN-ENUT-M20 M20

FSN-ENUT-M24 M24

NOTE: The standard length is 600mm and the resin system used is Epoxy.

Composite Nuts & Bolts

Product Code designation (e.g. FSN-EBLT-M10):FSN = FastenerE = Epoxy resinBLT = BoltNUT = Nut

Applications• Chemical processes

• Polluted environments

• Marine and salt water applications

• Electrical and high voltage applications

• Communications

Composite Nuts & Bolts used on Port of Airlie Pontoon



Part 7: Decking, Grating & Stair Treads



BridgedecksBridgedeck 104 is an innovative product solution which comply with engineering and safety standards within Australia and around the world including the United States, United Kingdom and the European Union.

Light-WeightPending inspection, bridgedeck 104 can be used on existing timber and concrete bridge abutments reducing both the time frame and cost of the project.

Low MaintenanceBridgedeck 104 will not rot, rust, corrode or decay; making it an ideal material in high risk environments near the sea or in flood prone areas. Bridgedeck 104 is not susceptible to freeze- thaw cycles, and has very low thermal expansion/contraction characteristics.

Low-Cost InstallationPrefabrication and experience allows bridgedeck 104 to greatly reduce install times over traditional procedures. In high traffic areas, Wagners will work closely with stakeholders to insure a quick turnaround.

Robust Long Life DesignsBridgedeck 104 is ideally suited for extended use in high fatigue structures. As a result of strenuous testing in partnership with Main Roads Queensland our structures possess an extremely high strength reserve, allowing full load service for decades to come.

BRIDGEDECKS

Product Product Code Dimensions (WxHxT) Weight (kg/m)

Bridgedeck 104 DGS-VDEK-104x1230 1230x104x12 66.3

105m

m

1236mm (Standard Width)

Bridgedeck 104

Product Code designation (e.g. DGS-VDEK-104x1230):DGS = Decking Grating Stair TreadsV = Vinyl Ester resinDEK = Bridge Deck



MICRO-MESH

PRODUCT CODE Thickness (mm)

Bar Thickness (Top/Bottom)

Mesh Size (mm) Panel Size (mm) Weight

(kg/m2)Open Rate

(%) Colour Pattern Loading

Max. Joist Span (mm)

Point Load

1.4 kN 2.5 kN 4.5 kN

DGS-VMIC-12.7x30 30 7.5 & 4.5/6.0 12.7x12.738x38 1220x3660,1220x2440, 915x3050 22 30 CH, LG, BK, BR

3 kPa 750 600 400

5 kPa 750 600 400

DGS-VMIC-13x30 30 6.5/4.5/5.013x1340x40 1527x4047, 1247x4047, 1007x3007, 1007x4047

18.8 30

CH, LG, BK, BR

3 kPa 750 600 400

5 kPa 750 600 400

DGS-VMIC-13x38 38 6.5/4.5/5.0 23.8 303 kPa 1000 1000 750

5 kPa 900 900 750 NOTE:Charcoal (Dark Grey) = CH; Light Grey = LG; Black = BK; Brown = BR

Decking, Grating & Stair TreadsWagners CFT have supplied pedestrian structural elements sch as gratings, mesh and covertops all across Australia, from the sweltering tropics to the burning deserts. Our products are uniquely suited to withstand the harshest environments while providing a low maintenance, long life asset to the local community. Wagners mesh, gratings and cover tops are perfect for coastal, marine and environmentally sensitive areas. From tidal flood plains and protected mangrove swamps to alkaline desert and corrosive mining or oil/gas facilities. Wagners products have proven time and time again their unique durability and strength. Possessing a full in-house test and certification team, Wagners will work hand in hand with the clients’ staff to insure a robust, aesthetically pleasing pedestrian asset that will provide decades of service.

Benefits • Low maintenance • Long life span • Will not rust rot or corrode • Termite proof

• Prefabrication and scheduled works delivery

• Inert, environmentally stable material

• Light weight • Quick & easy installation

Product Code designation (e.g. DGS-VMIC-13x25):DGS = Decking Grating Stair TreadsV = Vinyl Ester resinDEK = Bridge DeckMIC = Micro-MeshMIN = Mini-MeshMSH = MeshCOV = Cover Mesh

Mini-Mesh Decking



MINI-MESH




(kg/m2)Open Rate



Point Load

1.4 kN 2.5 kN 4.5 kN

DGS-VMIN-19x30 30 6.5/5.019x1938x38

1220x3660, 1220x2440, 915x3050, 1524x4027, 1220x4000, 1530x4047 19.1 30

CH, LG, BK, BR

3 kPa 750 600 400

5 kPa 750 600 400

DGS-VMIN-19x38 38 6.5/5.0 1220x3660, 1220x2440, 915x3050, 1220x4000, 1226x4010 23.5 30

3 kPa 1000 1000 750


MINI-MESH




(kg/m2)Open Rate



Point Load

1.4 kN 2.5 kN 4.5 kN

DGS-VMIN-20x30 30 6.5/5.020x2040x40 1007x4047, 1007x3007, 1247x4047, 1527x4047

18.3 42

CH, LG, BK, BR

3 kPa 750 600 400

5 kPa 750 600 400

DGS-VMIN-20x38 38 6.5/5.0 22.8 423 kPa 1000 1000 750


MESH




(kg/m2)Open Rate



Point Load

1.4 kN 2.5 kN 4.5 kN

DGS-VMSH-38x38 38 7.0/5.0

38x38

1220x3660, 1220x4010, 1524x4038, 2100x4010, 998x4010, 1220x4010, 915x3050, 1532x4010, 1532x3050,

1000x400019.5 68

CH, LG, BK, BR

3 kPa 750 600 400

5 kPa 750 600 400

DGS-VMSH-38x50 50 9.5/7.5 1220x3660, 1220x4010, 1230x4010, 1220x2440, 915x3050 42 56

3 kPa 1000 1000 750




Covertop MeshMoulded grating is manufactured in an open, heated mould system. Continuous E-glass roving’s are placed in the mould in alternating layers (on one side or two) and completely wetted out with resin. This continuous process produces an integral, one piece construction which provides excellent corrosion resistance as well as bi-directional strength. There are a number of different moulds available resulting in a

COVERTOP MESH




(kg/m2)Open Rate



Point Load (kN)

1.4 2.5 4.5 10

DGS-VCOV-30 30 (25+5) 6.0/5.0

38x38

1220x3660, 1226x4010, 1532x4010, 915x3050, 1524x4000, 997x3012 21.8 0

CH, LG, BK, BR

3 kPa 1000 1000 750 n/a

5 kPa 1000 1000 750 n/a

DGS-VCOV-43 43 (38+5) 7.0/5.0

1220x3660, 1220x4010, 1524x4038, 2100x4010, 998x4010, 1220x4010, 915x3050, 1532x4010, 1532x3050,

1000x400029.0 0

3 kPa 1200 n/a 1200 1000

5 kPa 1200 n/a 1200 1000

DGS-VCOV-55 55 (50+5) 9.5/7.5

50x50

1220x3660, 1220x4010, 1230x4010, 1220x2440, 915x3050 33.2 0

3 kPa 1500 n/a 1500 1200

5 kPa 1500 n/a 1500 1200

DGS-VCOV-70 70 (65+5) 10.5/8.5 1230x4010 38.3 0

3 kPa 1500 n/a 1500 1500

5 kPa 1500 n/a 1500 1500 NOTE:Charcoal (Dark Grey) = CH; Light Grey = LG; Black = BK; Brown = BR

Industries Functions Advantages• Chemical plant and metal finishing • Anti-slip floor, stair tread, foot bridge • Anti-fire, anti-corrosion and anti-aging

• Construction engineering, traffic and transportation • Operation platform, trench cover • Anti-slippery

• Petrochemical engineering, ocean survey, water engineering • Security and safety fence, handrail • Light but high loaded strength

• Food and beverage plants • Off-shore oil rig, moor shipyard, shipping deck, ceiling • Long service life and maintenance free

• Textile printing and dyeing and electronics industry • Ramp ladder, scaffold, railway footpath • Non-conduction or magnetic

• Decorative grid, man-made fountain pool grid • Easy installation and rich colours

• Non-conductive and non-magnetic • Various sizes and colours available



TredDeckTredDeck is an advanced composite, high strength decking system. It consists of two layers, (ECC) and a top layer of hard wearing stone non slip surface combined with thermoset UV stabilized Epoxy resin placed on to a variety of available decking materials.

Ubiq Inex (UI-19-11) Span Table

Span Live Load or concentrated action (kN) Uniformly Distributed Load (kPa)

300 10.0 5.0

450 4.5 5.0

600 2.7 3.5

TredDeck Code Overall Thickness (mm) Board Type

UI-19-11 30 Ubiq Inex

CT-19-5 24

Cover Top Mesh(see next page for

span details)

CT-19-10 29

CT-30-5 35

CT-30-10 40

CT-43-5 48

CT-43-10 53

NOTE: TredDeck Code UI = Ubiq Inex Board, CT = Covertop Mesh

TredDeck Decking



Part 8: Piles



PilesFibre OrientationEnormous design flexibility is available by utilizing different combinations of glass weight and orientation.

Depending on project requirements, axial loading requirements, transverse loading requirements, deflection limits, etc, we can design custom laminate configurations to maximize performance.

Concrete FillFilling with concrete is optional and most projects do not require it. The FRP wall is structural and sufficient on its own for the majority of applications.

PigmentsPigments and UV inhibitors can be added to the resin to provide colour stability and UV protection. By default we provide black pigment impregnated resin, but a full range of colour options are available.

Pile CapsCustomers can order standard Conical and Flat Caps or Custom Flat Insert Caps to accompany their order of Piles.

Conical and Flat Pile Caps are plastic and fit over the pile, while Flat Inset Pile Caps are fiberglass laminates and fit within the pile. Inset Caps are useful for situations where lines are thrown over the pile which might catch on and damage a non-inset cap.

Connection DetailsPile can be used as a pier/wharf fender pile.

Pile can be used as a guide / mooring piling for floating structures such as marinas.

Pile can be used as a structural / support piling, either hollow or filled with concrete. Many different connections exist depending on your application and our engineers are available to help with any questions.

High Density PolyethyleneOptional sleeve provides additional abrasion resistance and UV protection. Piles can be sleeved for any length and along any specified portion. Sleeves typically do not extend below the low water line, as the benefits of sleeves are primarily realized near and above the waterline.

HARBORTECH PILES

Product CodeNominal

Pile Outside

Diameter

Actual Pile

Outside Diameter

# of Plies Area Weight Moment

of InertiaUltimate Strength

Ultimate Moment

mm mm mm2 kg/m mm4 MPa kN-m

PIL-E4PL-400

450

444 4 ply 17225 35.88 4.04E8 186.2 336.6

PIL-E6PL-400 444 6 ply 25464 53.02 5.77E8 186.2 483.5

PIL-E8PL-400 444 8 ply 33445 69.65 7.37E8 186.2 617.3

PIL-E10PL-400 444 10 ply 41167 85.73 8.81E8 186.2 738.7

PIL-E4PL-600

600

597 4 ply 23309 48.54 9.95E8 179.3* 597.5

PIL-E6PL-600 597 6 ply 34581 72.01 1.44E9 179.3* 868.0

PIL-E8PL-600 597 8 ply 45606 94.96 1.86E9 179.3* 1120.6

PIL-E10PL-600 597 10 ply 56374 117.39 2.25E9 179.3* 1356.1

NOTE:* Values are theoretical and extrapolated from the test results of similar piles.Sizes and thicknesses shown are merely illustrative of common requests.



Part 9: Industrial Hand Rails



Industrial HandrailsAll pultruded profiles used in handrails are made of premium grade isophthalic polyester or vinyl ester resin and meet the fire retardancy requirements of UL94 V-0, ASTM D635 and ASTM D84.

These handrail systems is designed to meet the specified loading requirements of OSHA federal register Vol. 39, No. 125, Section 1910.27, “Fixed handrails’. Have minimum live load requirements of a 200 lb concentrated load at any point or uniform load of 75 kg/m with a safety factor of 4.

Two types are available: the round and square handrails.

Round tubes handrail consist of 50x3.2 mm for top/middle rail and post. Top and middle rails shall be connected using tee and cross connectors. Kickrails shall be 100x5 mm thickness and using side or base plate connectors.

Square tube handrail consists of 55x6mm for post and rails. Top and middle shall be connected using 45x3mm connectors. Kickrail shall be 100x5mm thickness and using side or base plate connector.

Type 316 SS bolts/nuts/washers shall be provided for handrail assembly and fixation.

• Vertical post spacing 1000mm maximum.

• Inclined post spacing 1000mm maximum.

Post location shall be no greater than 450mm nor less than 250 mm from change in handrail direction

• Horizontal handrail height standard is 1000mm.

• Inclined handrail height standard is 900mm.

Types Of Post Installation Details

HANDRAILS

Product Code Part Details

HRL-VSHS-55X6 SHS 55X6

HRL-VCHS-50X3.2 CHS 50X3.5

HRL-VKRL-100X5 Kick Rail 100X5

HRL-VSHS-ELBOW Elbox Connection for SHS

HRL-VSHS-3WAY 3 Way Connection for SHS

HRL-VSHS-4WAY 4 Way Connection for SHS

HRL-VSHS-Side Plate Side Plate connection for SHS

HRL-VSHS-BASE PLATE Base Plate Connection for SHS

HRL-VCHS-ELBOW Elbow Connection for CHS

HRL-VCHS-3WAY 3 Way Connection for CHS

HRL-VCHS-4WAY 4 Way Connection for CHS

HRL-VCHS-Side Plate Side Plate Connection for CHS

HRL-VCHS-BASE PLATE Base Plate Connection for CHS

Side Mounted Post Plate Surface Mounted Post Plate



SQUARE HANDRAIL

ROUND HANDRAIL

Handrail Post Plate to FRP or

Steel Beam

Handrail Post to FRP or

Steel Beam

Handrail Post Plate to FRP or

Steel Channel

Handrail Post to FRP or

Steel Channel



HANDRAIL ASSEMBLY GUIDE



Part 10: Accessories



End CapsWagners CFT can supply a range of custom manufactured plastic accessories to assist in the application of the composite products in structures. All accessories are corrosion resistant and designed to match the long life of the composite structure. These are shown in the tables below.

Item: End Cap Description

Fitted with locking tabs, the end cap provides an easy and attractive way to finish the ends of composite material. They are normally glued in

position.

Made from lightweight and durable thermoplastic alloy, corrosion and pest resistant.

Part Numbers Application

ACC-NCAP-100x100 WCFT 100 x 100 x 5.2 SHS

ACC-NCAP-125x125 WCFT 125 x 125 x 6.4 SHS

ACC-NCAP-100x75 WCFT 100 x 75 x 5.0 RHS

Item: End Cap (Flush) Description

Used in the same function as the full end cap, but where a flush finish is required.

They are normally glued in position.

Made from lightweight and durable thermoplastic alloy, corrosion and pest resistant.


ACC-FCAP-100x100 WCFT 100 x 100 x 5.2 SHS

ACC-FCAP-125x125 WCFT 125 x 125 x 6.4 SHS

ACC-FCAP-100x75 WCFT 100 x 75 x 5.0 RHS

Item: End Cap for Tee Joint Description

To be used in all tee connections.The use of this adaptor ensures a neat tee

connection, giving protection to the end of the section at the joint.

Made from lightweight and durable thermoplastic, corrosion and pest resistant.


ACC-TCAP-100x100 WCFT 100 x 100 x 5.2 SHS

ACC-TCAP-100x75 WCFT 100 x 75 x 5.0 RHS



Stainless Steel Brackets and FastenersWagners CFT are also able to supply an extensive range of stainless steel connectors and fasteners to suit the use of the composite products in many applications, maintaining a high level of corrosion resistance as well as strength. These include:

• Stainless steel brackets

• Stainless steel bolts, nuts and washers

• Stainless steel screws

• Stainless steel rivets

Contact Wagners CFT Manufacturing for further details of components available.

Inserts

Item: Anti-Crush Insert Description

Anti-crush inserts are available with bolt hole diameters of 14,18, 22 and 26 mm.

These are to be used in all bolted connections, and are generally glued in position to provide the

maximum strength.

Made from lightweight and durable 50% glass fibre filled thermoplastic alloy, corrosion and pest

resistant.


ACC-INST-125x125xM12 WCFT 125 x 125 x 6.4 SHS - M12 Bolt




ACC-INST-100x100xM12 WCFT 100 x 100 x 5.2 SHS – M12 Bolt



ACC-INST-100xx100xM24 WCFT 100 x 100 x 5.2 SHS – M24 Bolt

ACC-INST-100x75xM20 WCFT 100 x 75 x 5.0 RHS – M20 Bolt

ACC-INST-100x75xM24 WCFT 100 x 75 x 5.0 RHS – M24 Bolt



Glossary

Term Description

AdditivesSubstances added to the polymer resin to aid in the processing of the FRP material.

Adhesive A substance capable of holding materials together by surface attachment.

CompositeA combination of high modulus, high strength and high aspect ratio reinforcing material encapsulated by and acting in concert with a polymeric matrix.

Cure

To change the properties of a thermosetting resin irreversibly by chemical reaction, i.e. condensation, ring-closure, or addition. Cure may be accom-plished by addition of curing (cross-linking) agents, with or without catalyst, and with or without heat.

Fibre Reinforced Polymer (FRP)

A Fibre Reinforced Polymer (or plastic) material consists of a polymer resin based matrix reinforced by fibres of either glass, carbon or aramid, and hybrid combinations of these fibre types.

FibreOne or more filaments in the form of a continuous strand or roving in an FRP material.

Fibre mass fractionThe mass of reinforcement fibre in a cured composite divided by the mass of the composite section.

Fibre orientationThe orientation or alignment of the longitudinal axis of the fibre with respect to a stated reference axis.

Fibre volume fractionThe volume of reinforcement fibre in a cured composite divided by the volume of the composite section.

FillerNon adhesive substance added in the matrix or adhesive material to alter its engineering properties, performance, and/or cost.

Glass fibreA fibre spun from an inorganic product of fusion which has cooled to a rigid condition without crystallisation.

Glass transition temperatureTemperature at which the polymer matrix changes from a glassy to a rub-bery state as temperature increases.

MatrixThe continuous constituent of an FRP material that surrounds the fibres. It consists of a polymer resin with fillers and additives.

Orthotropic Having three mutually perpendicular planes of elastic symmetry.

PlasticA material that contains one or more organic polymers of large molecular weight, is a solid in its finished state and at some stage of its manufacture or processing into finished articles, can be shaped by flow.

PolymerAn organic material composed of molecules characterised by the repetition of one or more types of monomeric units.

PultrusionA continuous manufacturing process used to manufacture constant cross-section shapes of any length.

Release agent An additive which promotes release from the manufacturing mould.Resin The polymeric material used to bind together the reinforcing fibres in FRP.

Term Description

Resin contentThe amount of matrix present in a composite either by percent weight or by percent volume.

Resin systemA mixture of resin, with ingredients such as catalyst, initiator (curing agent), diluents, etc. required for the intended processing and final product.

Roving / TowLarge number of continuous parallel filaments or a group of untwisted parallel strands.

Thermoplastic

A plastic that repeatedly can be softened by heating and hardened by cooling through a temperature range characteristic of the plastic, and when in the softened stage, can be shaped by flow into articles by moulding or extrusion.

ThermosetA plastic that is substantially infusible and insoluble after being cured by heat or other means, e.g. polyester, epoxy, phenolic resin.

VeilA thin layer of mat similar to a surface mat, often composed of organic fibres as well as glass fibres.

Vinyl ester resinThermosetting resins that consist of a polymer backbone with an acrylate or methacrylate termination.



ReferencesReferenced StandardsASTM D792-08: Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement.

ASTM D2344-13: Standard Test Method for Short-Beam Strength of Polymer Matrix Composite Materials and their Laminates.

ASTM D2583-07: Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a Barcol Impressor.

ASTM D6641-09: Standard Test Method for Compressive Properties of Polymer Matrix Composite Materials using a Combined Loading Compression (CLC) Test Fixture.

ASTM D7028-07: Standard Test Method for Glass Transition Temperature (DMA Tg) of Polymer Matrix Composites by Dynamic Mechanical Analysis (DMA).

ASTM D7078-12: Standard Test Method for Shear properties of Composite Materials by V-Notched Rail Shear Method.

ASTM D7290-06 (2011): Standard Practice for Evaluating Material Property Characteristic Values for Polymeric Composites for Civil Engineering Structural Applications.

ISO 62: 2008: Plastics - Determination of Water Absorption.

ISO 75-1: 2013: Plastics – Determination of Temperature of Deflection under Load – Part 1: General Test Method.

ISO 1172: 1996: Textile-glass-reinforced Plastics – Prepregs, Moulding Compounds and Laminates – Determination of the Textile-glass and Mineral-filler Content – Calcination Methods.

ISO 527-2: 2012: Plastics – Determination of Tensile Properties – Part 2: Test Conditions for Moulding and Extrusion Plastics.

ISO 527-4: 1997: Plastics – Determination of tensile properties – Part 4: Test Conditions for Isotropic and Orthotropic Fibre-reinforced Plastic Composites.

ISO 11359-2: 1999: Plastics - Thermomechanical Analysis (TMA) - Part 2: Determination of Coefficient of Linear Thermal Expansion and Glass Transition Temperature.

Other References

Kara, S & Manmek, S 2009, Composites: Calculating Their Embodied Energy, Final Report, Life Cycle Engineering & Management Research Group, The University of New South Wales. (A multi-partner collaboration project led by the Department of Employment, Economic Development and Innovation (DEEDI), the State of Queensland).



NOTES:

Version 04 • July 2016 • Page BWagners CFT Manufacturing Pty Ltd A.B.N. 91 099 936 446 • PO Box 151 Drayton North QLD 4350 • Telephone: +61 7 4637 7777 • Email: [email protected] • Internet: www.wagnerscft.com.au

PRODUCT GUIDE

Composite Fibre Technologies

www.wagnerscft.com.au

PRODUCT GUIDE Version 04 – July 2016WCFT-01-01-001


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