Fiberglass Composites and How the Industry Has Evolved Using Spray Coating Systems

Fiberglass is used in a number of different industries because of its versatility, durability and cost-effectiveness. Once fiberglass hardens, it is very resistant to damage and can be repaired if impact damage or wear does occur. Fiberglass is also highly moldable, allowing it to be shaped into nearly any design. It doesn't rust and rarely corrodes. As a result, it typically lasts longer than wood, metal and non-reinforced plastic when placed in a corrosive environment. It does not conduct electricity and it does not react chemically with other materials around it. The process of making fiberglass and repairing it has evolved over the years and spray coating systems have made fiberglass even faster and easier to work with.

Origins

Fiberglass used to be made by hand-laying sheets down into a mold. A resin was then applied to them with a roller and then mixed with a hardener to bond the individual sheets together. It was imperative to not let air seep in between the sheets or else the structural integrity of the entire piece would be threatened. The sheets were then compressed by hand or using a tool to ensure they remained tightly together during the drying and hardening process. The process of putting the sheets together had to be done quickly or else the resin would start drying too soon, ruining the entire piece before it was completed.

As time went on, more advanced methods were used to construct fiberglass pieces and panels. High temperature resins were designed so the fiberglass wouldn't start drying or hardening until it was warmed in an oven. This allowed workers more time to assemble the piece without the risk of early curing. Vacuum systems removed air bubbles from between the fiberglass sheets, ensuring a more consistent structural integrity.

Resins became more advanced as well, using polymers of epoxy, vinyl ester, phenolic, methyl methacrylate, or polyester as hardening and strengthening agents. Mineral fillers became more common as a means of reducing flammability.

While the process of hand-laying fiberglass was effective and reliable, it was a time consuming endeavor. Spray coating systems eliminated those problems by rapidly speeding up the fiberglass construction and repair process without sacrificing quality or reliability.

Spray Systems

Spray systems still require a mold when a fiberglass piece is first made because the mold gives the piece its shape. However, instead of a worker having to apply a resin to the fiberglass sheets by hand using a roller or other tool, he can use a spray system to rapidly coat each layer of the fiberglass and ensure an even, thorough application. The resin and the reinforced glass are sometimes applied through separate spray systems or they can be combined into a single spray nozzle. Combining the two streams is called "chopping" and is accomplished with specialized spray equipment called a chopper gun, such as the Graco sprayer. A layer of material is placed into the mold, sprayed and then another layer gets added to it. Filling materials such as wood or foam are sometimes placed in between sheets, depending on what the piece is being used for.

The evolution of fiberglass and the spray systems that are now commonly used in their application were driven by the needs of both the automotive and the boating industries. Boats are often made out of fiberglass because the material is lightweight and resistant to moisture. The automotive industry was looking for a durable alternative to steel that was more cost-effective. Spray systems made the use of fiberglass in both of these endeavors a lot faster and more practical.

This also benefited the repair process. It was previously difficult to fill small cracks with a resin using a hand tool or roller. A spray nozzle can now be fitted with an attachment to fit right into a small crack or opening to get the polymers exactly where they need to be for the most reliable and durable repair possible. This also saves money on replacements because repair work is possible now that wouldn't have been earlier in fiberglass's evolution.

Gel Coat

Gel coat is often applied as the outer layer of fiberglass to give it its glossy finish. The gel coat also provides a protective finish the fiberglass as well. Spray systems allow a gel coat to be applied much faster and with greater consistency than ever before, making fiberglass maintenance a do-it-yourself process even for people not normally familiar with fiberglass construction or usage.

Today's Usage

Fiberglass is now used in a lot more than just cars and boats. Surfboards are now often made with fiberglass and the spray resins help protect the board against the harsh salts of the ocean and the impact damage of small rocks and stones in the waves. Some bicycles are now made of fiberglass because the reduced weight helps increase speed. Many circuit boards are fitted with fiberglass, which works as an insulator. Spray systems are useful in these instances of very small pieces to ensure proper application of hardeners without over-saturating the piece.

Asphalt is sometimes reinforced with fiberglass layers. Chemical plants often construct their holding tanks out of fiberglass because of its corrosion resistance and because it won't react dangerously with any other chemical or material.