Glass Fiber Composites: Properties, Manufacturing

and Applications
September 20, 2012 by Mazharul Islam Kiron

Last Updated on 19/08/2021

Glass Fiber Composites (GFC)

Moin.S Khan
DKTE’s Textile and Engineering Institute,
Ichalkaranji, Maharashtra, India
Email: moinkhn024@gmail.com

INTRODUCTION
Glass fiber composites (GFC) are one kind of fiber reinforced polymer
composites. It holds good properties such as low density, high strength, and
easy processing, so widely used in aerospace, automotive, and construction.
Today, almost any specialization for structural material can be met by
combination of glass fiber and plastic resin, which are characterized by many
outstanding properties. During 1942 glass fiber reinforced composites were
first used in structural aerospace parts. In the early 1960’s high strength glass
fibers, S-Glass were first used in joint work between Owens corning textile
product and the United States air force later in 1968 S-2 glass began evolving
into a variety of commercial application. High strength glass fiber combines
high strength, high stability, transparency and resilience at a very reasonable
cost-weight performance. The utilities of high strength glass fiber composites
are compared by physical, mechanical, electrical, thermal, acoustical, optical
and radiation properties.

The glass fiber composites strength/weight ratios are higher than those of
most other materials and their impact resistance is phenomenal. Further they
possess good electrical properties, resistance to moisture and outdoor
weathering and resistance to heat and chemicals. These properties are coupled
with ease of fabrication.

Composites
Composites are artificially produced multiphase materials having a desirable
combination of the best properties of the constituent phases or more precisely
these are the materials consist of fibers of high strength and modulus
embedded in or bonded to a matrix with distinct interfaces between them.
Properties of glass fibers

1. Incombustibility
2. Corrosion resistance
3. High strength at low densities
4. Good thermal.
5. Sound insulation
6. Special electrical properties.

Typical Properties of Glass Fibers:

Manufacturing of glass fiber:

Glass fibers basically made by,

• Mixing silica sand, limestone, boric acid and other minor

ingredients.
• The mixture is heated until it melts at about 1260oC/2300oF.
• Letting the molten glass flow through fine holes. (In a platinum
plate)
 • The glass strands are cooled, gathered and wound. (Protective
coating may be added.)
• The fibers are drawn to increase the directional strength.
• The fibers are woven into various forms for use in composites.

Types of glass fiber:

Types:

• A Soda-lime glass.
• E Electrical type (Borosilicate)
• C Chemical resistant type
• AR Alkali resistant type
• S High performance application

Grades:

• General purpose glass fiber

• Quartz fiber
• Protective fiber
• Hollow fiber
• Conducting/Semi-conducting

Various properties of different glass fibers

Properties E-glass AR-glass S-glass

Tensile Strength (Gpa) 3.5 3.5 4.6

Modulus (Gpa) 73.5 175 86.8

Elongation (%) 4.8 2 5.4

Density (g/cc) 2.57 2.68 2.46

Refractive Index 1.547 1.561 –

 Coefficient of Thermal Expansion
50-52.0 75.0 23-27.0
(107/0C)

Dielectric Constant RT, 1010 Hz 6.1-6.3 – 5.0-5.1

FORMS OF THE GLASS FIBER REINFORCEMENT

Glass fabric:
This form of glass fiber is particularly suitable for high strength, low weight
laminates. Continuous filament glass is preferred in these applications on
account of it’s greater strength and low bulk factor. The fabric woven from
continuous filament yarn ranges in thickness from 0.002-0.02 inches. In
general directional properties of laminates depend on the type of weave and
cloth setting employed. (We’ll discuss this later). The example of fabric-
reinforced plastic is aircraft radar. In this application, a material is required
which will allow the radar rays to go without distortion from the rays sending
equipment out of the target and then back to the radar receiving equipment on
the plane. It must also stand the air pressure strain of a sonic or supersonic
speed. Combination of glass fabric and low-pressure plastic resin provides an
excellent answer to these requirements.

Combination of glass fabrics and fire-proofed polyester resin are also used for
making high strength flat and shaped laminates for aircraft components such
as a ducting, panels, nose, wings tips, rudder parts, covers, dash-boards,
shelves, floors.

This material is also used for hollow fishing rods, where unidirectional fabric
lends itself to winding round a solid mandrel, for body armor and for the
manufacture of large article such as boats by the low pressure technique and
for many other products.

Molding techniques
Molding methods are almost legion. At present count more than 22 general
molding methods is basic process categories are widely used. These includes:

1. Hand and spray saturating and mixing.

2. Continuous impregnation, laminating.
3. Cure or flat or corrugated panels, solid rods, hollow bar stock.
4. Compression, transfer and injection molding.
5. Filament wrapping and winding.
6. Centrifugal and static casting.
7. Rotational molding.
8. Cold forming.
 9. Combination of those above.

Effect of different weaves

The plain weave fabric having square setting i.e. equal number per inch of
ends in the warp as picks, is employed where uniformity in strength is desired.
Another popular structure is 8-shaft satin weave, in which each weft yarn
goes under one and over seven warp yarns. It is mostly used in heavier fabrics
when lamination calls for high strength in all direction and where a smooth
surface and decorative appearance are desired. Due to lower crimp or ‘weaving
take up’ the strength of a satin weave fabric is comparatively greater then of a
plain weave fabric.

When maximum strength in one direction is required at a maximum weight, a

unidirectional weave is employed. In order to produce such a fabric, usually a
large amount of relatively strong warp yarn and fewer weaker weft yarns are
employed.

Nonwoven materials from glass fiber are dominated because least labor
intensive and most efficient to manufacture.

APPLICATION OF GLASS FIBER COMPOSITES

Glass fiber composites making inroads many markets due to general
properties of excellent molded surface finish almost unlimited size, lightness
of weight, insulation against heat transfer and electricity and many other
attributes. These will become evident in ensuring discussion, build around in
nine major markets for GFC which includes following:

1. Aircraft and Aerospace

2. Appliances and equipments
3. Constructions
4. Consumer goods
5. Corrosion resistant product
6. Electrical rods, tubes and components
7. Marin and Marin accessories
8. Land transportation
9. Miscellaneous (Protective gears, Farming, industrial tools,
material handling).
Aircraft and aerospace market
Stability is an important criterion for any material used. Light weight with the
ability to withstand heavy loads and provide excellent resistance to bumps and
impact. Aerospace and aircraft applications include overhead storage
bins, aircraft toilets and helicopter rotor blades. Other benefits from using
composites for these applications include cost performance, dimensional
stability and corrosion resistance.

Entire external fuselages of smaller planes have been constructed using GFC,
interior and commercial plane (Boeing 747) entire exterior of flight vehicle
guided missile.

S-glass, which is the more exotic of the current reinforced glass products, has a
much higher strength and modulus than E-glass. It also has a high laminate
strength-to-weight ratio, high strength retention at elevated temperatures and
a high fatigue life. It is very often used for aircraft components such as flight
deck armor, and helicopter armor, seats and floors. Apart from their high
mechanical performance, S-glass composites are inherently non-conductive
and offer low radar thermal profiles, thereby providing the military with the
opportunity to see without being seen S-glass fiber has proved itself by
performing superbly in hazardous environments. Its strength and reliability
have encouraged various manufacturers to use the fiber in fabricating
composite blades for different models of helicopter. A new dimension to the
applications of glass fibers is the use of hollow S-glass in fiber reinforced
composites. In general, the mechanical properties of hollow S-2 glass compare
favorably with standard fiber glass composites and show significant weight
savings of approximately 16-18%.

Reinforcements commonly used:

• Preform Rovings
• Roving for weaving
• Woven Roving
• Plied yarns

Construction and Infrastructure

Composites are ideal for use in the construction market because of their
dimensional stability, high strength, reduced weight, impact resistance, low
flammability, given an appropriate choice of resins and additives, low
maintenance and design flexibility.

Use in both interior and exterior building components for residential,

commercial industrial and farm construction, tub, and shower units.
Corrugated translucent architectural paneling, solar heating elements.
Industrial building sky light, yard swimming pool fences and bathroom
fixtures. (Resistant to mechanical impact and billing water
Exterior

1. Composites for exterior design are present in columns, pediments,

domes, cornices
2. Composites are used for paneling, cladding and covering for
protection and insulation panels, shingles, translucent flat or
corrugated sheets (facing systems, decorative fascia)
3. Fascia renovation using glass-cement composites contributes to
improving the appearance of buildings, external insulation and
coatings of facades where dimensional stability and prevention
against cracking is required.
4. Composites form work and moulds for concrete, easy to make and
corrosion-resistant.
5. Roofing applications include sealing and waterproofing.
6. Technical glass fabrics are used in the industrial filtration of gases,
vapors and smoke.
7. Doors and windows.

Interior

1. Blinds (against sun or for decoration)

2. Aesthetic coverings for use on walls, partitions, ceilings, doors and
furniture
3. Glass-reinforced plaster in a wide variety of shapes: columns,
ceilings, cornices etc.
4. Decor and furnishings of reinforced plastics and glass-cement
composites
5. Gypsum boards and partitions
6. Dry wall tapes
7. Partitions of glass-cement composites
8. Composite panels (double-sided insulated, phenolic resins treated)
9. Sanitary-ware (baths, wash basins, showers, sinks, toilets)
10. Flooring (flexible flooring, hard flooring
11. Functional items (letter boxes, meter boxes)
12. Decorative items.
For rebuilding or creating new infrastructures, composite materials bring a
number of benefits to various applications, including high strength, reduced
weight, corrosion resistance, lower maintenance, dimensional stability, low
installation costs and design flexibility. In bridge construction, for instance,
composites provide a high load capacity with low material weight. This low
composite weight eliminates the costs of heavy equipment needed to build the
bridge, which in turn reduces the installation time. Composites are also very
durable; they won’t corrode like steel or rot like wood, so maintenance and
replacement costs are reduced.

Consumer goods
Properties –leisure, recreational, basic frames for furniture as well as finished
items both traditional and modern, also includes divider screens, decorative
and utilities trays, wall plaques, luggage. In sports equipments skis, patio
furniture, swimming pool, plays ground equipments, portable tennis courts
tennis racquets fishing rods vaulting polls snow mobiles garden tractors skate
boards and surf boards.
Properties: controlled flexibility, high mechanical strength, lightness of
weight, easy formability, durability, molded in colors excellent surface and
resistant to corrosion and wear.

Corrosion resistant products/equipments

Exhaustive analyses of mechanism of corrosion in fiberglass and their
composite structure are available in literature. Engineers and Managers have
realized that superior corrosion resistant properties exist in glass fiber
composites as compared to traditional material. Composites are ideally suited
for corrosive, hostile environments. Applications in this market include all
types of pipes, oilfield pipes, fume handling ducts, underground petrol tanks,
sucker rods, water, wastewater, drainage and irrigation piping (potable
water, sewage, storm drains), cooling towers, component for water and sewage
treatment facilities in textile processing, flood control and navigational
waterway structures (dam gates, pipes, grating, weirs), energy production
structures for oil and gas production (offshore platforms, grating, piping).
Reinforcements commonly used:

• Chopped Strand Mat

• Roving
• Continuous filament mats
• Woven Roving
• Yarns
• Glass mats

Electrical and Electronics

Substantial incursion of glass fiber composites into field requiring desirable
properties for electrical and electronics applications. Mechanical strength and
temperature stability were the factors, which favored the use of glass filament
technical fabrics in industry as an insulator for electrical conductors. In
association with lacquers and coatings, it is used for covering wires and cables.
Weather stability, high dielectric strength, high arc resistance and good
mechanical toughness were rapid once. These materials were proven in critical
areas. They are used in distribution-pole hardware, switchgear, and
transformers, telephone equipments, PCB’s, computer parts.

Reinforcements commonly used:

• Continuous Filament Mat

• Roving for pultrusion
• Roving for weaving
• Yarns
• Plied yarns
• Technical fabrics
• Chopped Strands for thermoplastic reinforcement

A major breakthrough in glass fiber application came when the material

established its potential for use as optical frequency communication wave
guides conveniently known as ‘optical fiber’. Fiber glass is selected for its
transparency to a particular wavelength. Glass fibers, suitable for optical
transmission materials should not have a transmission loss of more than
20dB/km. In 1970, Owens-Corning produced the first of such fibers which had
less than 20dB/km transmission loss. Today, they produce optical fiber with a
transmission loss of less than 5dB/km. One of the major application areas for
fiber optics is in communications such as the telephone, television networks,
in aircraft, aerospace, and satellite communications. It is important to
mention here that the current advanced state of the communication industry
has only been made possible by the major advances achieved in glass
technology, transmission and detection devices and methods of packaging
glass fibers. The high mechanical performance of glass is essential to prevent
any fiber breakage during the handling and laying of communication cables.
Optical fibers are made from extremely pure silica produced under finely-
controlled process conditions.

Marine products/Accessories
Properties of fiber glass composites so favorable that approx. 70% of all out
board pleasure boats is now constructed with it. The major benefit of using
GFC’s in any boat construction are mouldability to almost any boat design or
size, seamless construction, high strength and great durability, minimum
maintenance, freedom from corrosion, rust, dry rot and water logging.

Small motorcrafts, water sports surf, ski boats, sailboats of all size and
description are being fabricated using GFC’s. Commercial and military hulls
including the following fishing boats, lighters (LASH) (saving 40 tons per unit
compared to steel construction) submersibles, hovercraft for fast commuter
service.

Reinforcements commonly used:

• Chopped Strand Mats

• Continuous filament mats
• Woven Roving
• Yarns and Glass mats

Land transportation
The first real success splash of glass fiber composites in automotive or land
transportation field was the 1953 corvette, which had complete glass fiber
body. At the most recent count, more than 154 different automotive
applications in GFC existed. The prime contribution of GFC is weight saving
and this factor alone will go a long way toward helping automakers satisfy
future energy consumption requirements. This is energy effectiveness at it’s
best.
Reinforcements commonly used:

• Chopped Strands
• Chopped Strand Mat
• Continuous Filament Mat
• Yarns
• Rovings for thermoplastic reinforcement
• Woven Roving
• Chopped Strands for thermoplastic reinforcement

Glass fibers are used in both radial and bias-ply automotive tyre
reinforcement. The Owens-Corning Corporation introduced glass as a tyre
cord in a composite impregnated with 15-30% resorcinol-formaldehyde-latex
(RFL) resin which coated and protected the individual glass filaments. Glass
fiber was first used as a belt in a belted-bias tyre with a nylon carcass. It
enables the crown region of the tyre to be reinforced, which in turn increased
the trade life by about 1.5 times compared to that of a conventional bias tyre.
Compared to the conventional bias-ply and steel reinforced belted-bias tyre,
the glass reinforced tyre provides a softer ride, greater resistance to damage,
better stability, lower reinforcement cost, ready availability and a superior
total performance in long distance driving. Fiber glass is also successfully used
in the reinforcement of various other rubber products such as vee-belts, timing
belts, and solid tyres. All fiber glass products used for the reinforcement of
rubber and elastomers are treated in RFL resin. The RFL content of the fiber is
normally between 15-17%.

Glass fiber is also used successfully in railway fishplates. These are produced
from a combination of woven fabric and unidirectional nonwoven E-glass
reinforcement by using an epoxy resin matrix.

Miscellaneous/Specialty products
The tooling industries are largest single facet making up this final marketing
category for GFC parts. A comprehensive list would include such highly
serviceable and behind-the-scenes component as temporary or short run
forming dies for plastic and metals, checking fixture, hydro forming shapes,
hammer forms, stretch dies, foundry patters and many other creative and
utilitarian elements.

Orthopedic casts and prosthetic appliances. Prosthetics concerns fabrication

of artificial parts for therapeutic treatment of such deformities. Due to their
greeter softness, porosity and flexibility. Knitted fiberglass fabrics are
frequently used in orthopedic casts. Prosthetic appliances are usually
fabricated using fiberglass fabrics with polyester veil mat for surfacing inside
and out.

By using their light and image transmission characteristics, optical fibers are
also employed in the manufacture of medical instruments such as the
gastroscope, in traffic-control signals, in various control instrumentation, in
sales-code reading devices and so on.

Other applications are: Screening and filtration. Glass reinforced

mortar/cement.

Appliance and equipment

Properties – heat insulation, noise reduction, excellent molded surfaces,
dimensional stability, high dielectric strength frames, bases and housing for
composites, time-share terminal units, similar appliances
Conclusion
With this, I want to conclude that these glass fiber composites really taking
away the ”market” from conventional materials like metals. With further new
technological advancement in fiberglass and resins, their composites always
have been able to satisfy the need of any engineering field. At last I want to say
that these GFC’s are solution for growing building engineering avenues.

References

1. Fiber science and technology By V.I.Kostikov.

2. Fiberglass By Mohr & Rowe.
3. Inorganic fibers
4. Fiber reinforced composites – A seminar report.
5. “Composite material in Health care & wound Management”
Technical Textiles International, July-Aug 2003
6. New Fibers By Tatsuya Houngu & Glyn O. Phillips
7. Wellington Sears Handbook of Industrial Textiles By S. Adanur
8. Handbook of Technical Textiles By A.R. Horrocks & S.C. Anand
9. www.cgtltd.co.uk
10. www.netcomposites.com
11. www.composites.co.nw
12. Au.encartra.com
13. Textile Progress.
14. Construction World, Jan. 2005.
15. Composite Technology, Aug. 2003.
16. Composite Technology, June 2003.

You may also like:

1. Glass Fiber: Types, Properties, Manufacturing Process

and Uses
2. What is Composite | Textile Structural Reinforced
Composites
 3. Acoustic Absorption Performance of Natural Fibers &
Their Reinforced Composites
4. Textile Reinforced Concrete: Light, Stable and Sustainable
5. Application of Textiles in Building and Construction
6. Aerospace Textiles: Raw Materials and Applications
7. Green Composites: Types, Properties and Manufacturing
Process

Mazharul Islam Kiron

Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. He is
working as a textile consultant in several local and international companies. He is also a
contributor of Wikipedia.

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