GENERAL INFORMATION

DURADeckTM and DuraGratTM Grating is optimal in conditions where fire resistance, low smoke and low toxic fumes are critical concerns. It can stand up to the harshest environments and provide years or service. Each panel is produced in one solid piece with no joints, which provides maximum corrosion resistance, and bi-directional strength. Non-flammability enables it to withstand direct flame for an extended time without sustaining major structural damage. DURADeckTM Molded Grating is as strong as Iso-Polyester or Vinyl Ester Resin Grating but with lower smoke and flame levels.

What are Phenolics?

GRP Pipes and Rods using Phenolics Resin

Phenolics are in the same family of polyester, vinyl ester and epoxy resins. They are not new and have been used in major commercial applications before unsaturated polyesters became popular. Phenolics are composed of phenol and formaldehyde. They are the best organic material when it comes to safety in the event of fire. Phenolics have long been used in household items such as toaster handles, wiring devices, switch gears, pot and cutlery handles.

Features:

Approval for this product allows fiberglass grating to replace steel which results in significant savings in weight, ease of fabrication, and installation. DURADeckTM and DuraGratTM Grating can be used in offshore platforms such as the following:

· Wave Zone Areas
· Wind Walls
· Mud Pits
· Preload Tanks
· Walkways
· Stairs

COMPARISON TO POLYESTER RESINS

We may achieve Class 1 flame spread ratings (flame spread < 25) with halogenated polyesters (resin with chlorine or bromine), however, smoke density values for these systems range from 500-800. Smoke generated by halogenated resins is toxic and may contain halogen acids, antimony oxide, halides and oxyhalides, etc., all very toxic. The only gases generated by combustion of phenolics are carbon dioxide (CO2) with trace amounts of carbon monoxide (CO) andsulphur dioxide (SO2). No phenol or formaldehyde was detected.

Phenolics have superior flame spread (< 10) and superior smoke density value (< 10). Oxygen index (ASTM D2863) for phenolics (35% glass) is 45-80%.

Those concerned about the potential health hazards posed by phenol and formaldehyde may rest assured that material safety data sheets indicate that the amounts of residual phenol and formaldehyde in phenolics are at low and very safe levels. This is a valid concern since our industry has spent millions addressing styrene and toxicity issues. COLOR LIMITATION Phenolics are limited to a range of light brown to black, whereas most phenolics are reddish brown, dark brown or black. This makes phenolic gel coats impossible. Using an epoxy or polyester gel coat will diminish the phenolics flammability characteristics slightly. Source: James E. Maas, Director of Marketing Reichhold Chemicals

APPLICATIONS

The advanced resin and glass systems and manufacturing techniques employed in the production of DURADeck^TM and DuraGrat^TM GRP grating makes it ideal for use in the following areas:

Select DURADeck^TM and DuraGrat^TM GRP grating and rest assured that you have a grating that not only has a quality appearance, but that is strong, providing a longer service life over materials such as steel, aluminum, and wood. By selecting DURADeck^TM and DuraGrat^TM GRP grating, you can rest assured.

The Pultrusion Process

Pultrusion is a manufacturing process for producing continuous lengths of reinforced polymer structural shapes with constant cross-sections. Raw materials are a liquid resin mixture (containing resin, fillers and specialized additives) and flexible textile reinforcing fibers. The process involves pulling these raw materials (rather than pushing, as is the case in extrusion) through a heated steel forming die using a continuous pulling device. The reinforcement materials are in continuous forms such as rolls of fiberglass mat and doffs of fiberglass roving. As the reinforcements are saturated with the resin mixture ("wet-out") in the resin bath and pulled through the die, the gelation, or hardening, of the resin is initiated by the heat from the die and a rigid, cured profile is formed that corresponds to the shape of the die.

While pultrusion machine design varies with part geometry, the basic pultrusion process concept is described in the following schematic.

1. The creels position the reinforcements for subsequent feeding into the guides. The reinforcement must be located properly within the composite and this is the function of the reinforcement guides.
2. The resin bath saturates (wets out) the reinforcement with a solution containing the resin, fillers, pigment, and catalyst plus any other additives required. The interior of the resin bath is carefully designed to optimize the wet-out of the reinforcement.
3. On exiting the resin bath, the composite is in a flat sheet form. The pre-former is an array of tooling which squeezes away excess resin as the product is moving forward and gently shapes the materials prior to entering the forming and curing die. In the forming and curing die, the thermosetting reaction is heat activated (energy is primarily supplied electrically) and the composite is cured (hardened).
4. On exiting the die, it is necessary to cool the hot part before it is gripped by the pull blocks (made of durable urethane foam) to prevent cracking and/or deformation by the pull blocks. DURA® uses two distinct pulling systems, one that is a caterpillar counter-rotating type and the other a hand-over-hand reciprocating type to pull the cured profile to the saw for cutting to length.
5. In certain applications an RF (radio frequency wave generator) unit is used to preheat the composite before entering the die. When in use, the RF heater is positioned between the pre-former and the die.