Pultrusion 101 - General capabilities of Creative Pultrusions, Inc., a leader in the fiber reinforced polymer composites industry. We are best in class and offer in-house design, manufacture of profiles, fabrication and cnc machining and in-house testing.

1. PULTRUSION 101
www.creativepultrusions.com 814.839.4186 Toll Free: 888.CPI.PULL Fax: 814.839.4276
214 Industrial Lane, Alum Bank, PA 15521
Presented by Dustin Troutman
1

2. We are known for our QUALITY.
WHY CHOOSE CPI?
We are the
BEST IN CLASS at pultruding
large structural profiles.
Our engineering team is
UNMATCHED in the industry.
Our manufacturing
technology is SUPERIOR to
all others.
2

3. 3
PULTRUDING LARGE
STRUCTURAL PROFILES

4. 4
ENGINEERING
• We use Solid Works simulation software for our Finite Element
Analysis – Including linear static and Eigen value buckling
capability
• Autodesk Design Suite for our geometry and design layouts

5. 5
PROCESS
High pressure injection
manufacturing technology permits
a higher fiber volume fraction
which equates to higher strength
and stiffness with tight process
variation.

6. 6
QUALITY
The Quality Management System has been
modeled per the requirements of the
ISO9000:2008 International Standard.
In 2012, Creative reinforced their
commitment of providing the highest
Quality of products and services with the
addition of a certified LEAN / Six Sigma Black
Belt who manages related Quality initiatives.

7. 7
MACHINE SHOP CAPABILITIES
• Over 200 years experience in
design and manufacture of
tooling for pultrusion
• CNC machining and grinding
• In-house hard chrome plating
• MACT compliant direct die
injection tooling is a standard
• Tooling designed with
Autodesk Design Suite
“Lifetime Maintenance included in tooling
cost”

8. COMPOSITES
A composite is a structural
material that consists of two or
more combined constituents
that are combined at a
macroscopic level and are
not soluble in each other.
Resin being directly injected
into the die
Glass fibers
The term pultrusion comes
from combining the words pull
and extrusion.
8

9. Pultruded profiles are cut to
length during the continuous
manufacturing process.
4.
Resin and glass fiber
reinforcements are combined
and formed into the shape of
the die on a continuous
process.
1. The resin is initiated by the
thermal decomposition
process. The initiator is heated
until a chemical bond
dissociation produces two
radicals. The chain continues
to build until the monomer is
used resulting in a cured resin.
2.
The profiles are pulled
through a die.
3.
THE PULTRUSION PROCESS
Pulling
System*
Cut-Off Saw
Preformer
Continuous
Strand Mat
Guide Plate
Rovings
Resin Impregnator
Surfacing Veil
Forming &
Curing Die
*Caterpillar Pullers (shown)
or Reciprocating Pullers
9

10. 120
100
80
60
40
20
0
ULTIMATE(KSI)
MATERIAL
WHITE PINE ALUMINUM
6061-T6
STEEL A-36 STAINLESS STEEL
304
PULTRUSION
STANDARD
STRUCTURAL
PULTRUSION
CUSTOM
CONSTRUCTION
PULTRUSION
ALL ROVING
• Superior Tensile Strength/Stronger than A-36 Steel
• Linear Stress/Strain Curve with Little to No Yield
80
70
60
50
40
30
20
10
0
ULTIMATE(KSI)
MATERIAL
WHITE PINE ALUMINUM
6061-T6
STEEL A-36 STAINLESS STEEL
304
PULTRUSION
STANDARD STRUC-
TURAL
PULTRUSION
CUSTOM
CONSTRUCTION
PULTRUSION
ALL ROVING
• Superior Compression Strength/Stronger 6061-T6 Aluminum
• Compression Strength and Compression Buckling Normally Govern
the Design when Strength Governs
MATERIAL PROPERTIES
TENSILE STRENGTH
COMPRESSION
STRENGTH
10

11. • 1/2 the Modulus of Aluminum and 1/10th the MOE of Steel
• Deflection Governs Most Designs
• Buckling Governs Most Strength Driven Designs. Local and Global Buckling
MATERIAL
35
30
25
20
15
10
5
0
Msi
WHITE PINE ALUMINUM
6061-T6
STEEL A-36 STAINLESS STEEL
304
PULTRUSION
STANDARD
STRUCTURAL
PULTRUSION
CUSTOM
CONSTRUCTION
PULTRUSION
ALL ROVING
50
45
40
35
30
25
20
15
10
5
0
ULTIMATE(KSI)
MATERIAL
WHITE PINE ALUMINUM
6061-T6
STEEL A-36 STAINLESS STEEL
304
PULTRUSION
STANDARD
STRUCTURAL
PULTRUSION
CUSTOM
CONSTRUCTION
PULTRUSION
ALL ROVING
MODULUS
OF ELASTICITY
• Lower Shear Strength than Steel and Aluminum
• Lower Shear Modulus than Steel and Aluminum; Serviceability Calculations Should
Include Shear Deflection Computations, Especially for Short Spans
SHEAR
STRENGTH
MATERIAL PROPERTIES
11

12. • 75% Lighter than Stainless Steel
• 25% Lighter than Aluminum
50
45
40
35
30
25
20
15
10
5
0
ULTIMATE(KSI)
MATERIAL
WHITE PINE ALUMINUM
6061-T6
STEEL A-36 STAINLESS STEEL
304
PULTRUSION
STANDARD
STRUCTURAL
PULTRUSION
CUSTOM
CONSTRUCTION
PULTRUSION
ALL ROVING
DENSITY
MATERIAL PROPERTIES
12

13. RESIN OPTIONS Series 1500/1525
POLYESTER (PE) RESINS –
are manufactured for
corrosion related
applications. Polyester
resins display excellent
structural properties and
are resistant to
acids, salts, and many
dilute chemicals at
moderate temperatures.
The standard 1525 series contains fire retardant
additives that permit the profiles to pass UL94 with
a (V0) rating and ASTM E84 with a class A rating.
13

14. RESIN OPTIONS Series 1625
VINYL ESTER (VE) RESINS –
are based on bisphenol,
an epoxy resin. VE resins
provide resistance to a
wide range of
acids, alkalis, bleaches
and solvents for use in
many chemical
environments. They also
offer excellent toughness
and fatigue resistance.
The standard 1625 series contains fire retardant
additives that permit the profiles to pass UL94 with
a (V0) rating and ASTM E84 with a Class A rating.
14

15. RESIN OPTIONS Series 4000
POLYURETHANE (AROMATIC) –
Are a blend of polyol and isocyanate
that when joined, produce a resin
system that offers superior strength and
toughness. Polyurethane resins should
be used when impact strength and
toughness are required.
15

16. RESIN OPTIONS Series 3000
EPOXY -
Epoxy resins, also known as polyepoxides are a class of reactive prepolymers and
polymers which contain epoxide groups. They are ideal for high strength, high
temperature applications and perform well in chemical environments.
16

17. RESIN OPTIONS Series 3535
SPECIALTY RESINS -
Special application resins
with unique flame smoke
and toxicity (FST) attributes
are available. Low FST
resins are used extensively
in the mass transit industry.
17

18. REINFORCEMENT
OPTIONS
E GLASS – ELECTRICAL
GRADE FIBERGLASS
18
Pultruded in the form of
Roving, Continuous
Filament, Woven, or stitched
fabric mats, depending on the
mechanical and physical
values being sought.
E-glass fiberglass exhibits high
tensile strength and Modulus
of Elasticity properties. The
volume fraction of fiberglass to
resin dictates the mechanical
and physical properties of the
pultruded profile

19. REINFORCEMENT
OPTIONS
CARBON FIBER
19
Carbon atoms are bonded together in
crystals that are more or less aligned
parallel to the long axis of the fiber. The
crystal alignment gives the fiber high
strength-to-volume ratio. Several
thousand carbon fibers are bundled
together to form a tow, which may be
used by itself or woven or stitched into a
fabric.
The properties of carbon fibers, such as
high stiffness, high tensile strength, low
weight, high chemical resistance, high
temperature tolerance and low thermal
expansion, make them very popular in
aerospace, civil
engineering, military, and motorsports.

20. PRODUCT LINES
Standard Structural Profiles Used
for Fabricated Structures
• W and I Beams
• Channels
• Angles
• Tubes
• Flatsheet
• And many more...
20

21. DECKING PRODUCTS
SUPERGRATETM PULTRUDED GRATING
SUPERDECKTM
SUPERPANEL PA004
SUPERPANEL CP150
21

22. SUPERDECKTM RAIL PLATFORM PANEL
SUPERGRATETM MOLDED GRATING
SUPERPANEL WALL PANEL CT066
DECKING PRODUCTS
SUPERPLANKTM DECKING
22

23. SUPERDECKING
TUF-DEKTM FLOORING
HEAVY DUTY PLANK
DECKING PRODUCTS
FLOWGRIP® FLOORING PANEL
23

24. BALLISTIC PANELS
- The Ultimate Panel for Ballistic
and Fragmentation Protection
- UL 752 Level III Compliant
24

25. CUSTOM PULTRUSIONS
25

26. MASS TRANSIT DECKS
26

27. FRP DISTRIBUTION AND
TRANSMISSION POLES
AND CROSSARMS
27

28. SUPERLOCTM SHEET PILE SYSTEM
28

29. PIPE PILES
29

30. PULTRUDED STRUCTURES DESIGN
METHODOLOGY OPTIONS
LRFD or ASD
30

31. ALLOWABLE STRESS DESIGN
2.5 in Flexure
3.0 in Shear
3.0 for Connections
• Material Properties are
Reduced to Satisfy an
Appropriate Safety Factor
• Typical Safety Factors for
Pultruded Structures
31

32. • Load & Resistance Factor
Design (LRFD) of Pultruded Fiber
Reinforced Polymer (FRP) Structures
• Developed by the Pultrusion
Industry Council (PIC) and the
American Society of Civil
Engineers (ASCE)
• A design standard exists for the
pultrusion industry. Our industry
joins ranks with steel, wood,
concrete and aluminum as a
standard material of construction.
32
LRFD Design

33. CHARACTERISTIC DESIGN
PROPERTIES ARE DETERMINED
PER ASTM D7290
WHY ASTM D7290?
It is an internationally recognized standard for
evaluating material property characteristic values
for polymeric composites for civil engineering
structural applications.
The characteristic value is a statistically-based
material property representing the 80% lower
confidence bound on the 5th percentile value of a
specified population.
33

34. WHY DO ENGINEERS AND OWNERS
SPECIFY PULTRUDED PROFILES?
• To Reduce Maintenance Costs
• To Reduce Downtime
• To Reduce Future Capital Expenditures
• To Increase Safety
• To Save Money
34

35. SUPERIOR DURABILITY OVER A LONG SERVICE LIFE
• Estimated Service Life of 80+ years
• The theory is based on the Arrhenius principle used by Litherland
et al. in 1981 and Vijay and GangaRao in 1991. (Litherland et all,
have correlated their data with naturally weathered samples of about 10 years.)
35

36. PULTRUSION THE GREEN CHOICE
EMBODIED ENERGY COMPARISON
36

37. BC HYDRO 287kV TRANSMISSION
CHANNEL
DESIGNED
BY CPI
TESTED BY
POWERTECH
LABS
INSTALLED AND
VETTED BY BC
HYDRO
APPLICATION PROFILES
37

38. APPLICATION PROFILE
PULTRUDED
DISTRIBUTION POLES
AND CROSSARMS
FOR NATIONAL GRID
38

39. APPLICATION PROFILE
LIGHTWEIGHT POLE FOR
LIMITED ACCESS SETS
39

40. APPLICATION PROFILE
PULTRUDED HS25-44
BRIDGE DECK 200’ x 60’
INSTALLED IN 14 HOURS
40

41. APPLICATION PROFILE
COMMUNICATION
TOWER FOR EMERGENCY
SERVICES. RADAR AND
RF TRANSPARENCY
DESIGNED BY CREATIVE
41

42. APPLICATION PROFILE
MOVEABLE POOL FLOORS
AND STARTING BULKHEADS
42

43. APPLICATION PROFILE
RAILS TO TRAILS DECKING
43

44. APPLICATION PROFILE
MASS TRANSIT ELEVATED
PLATFORM DECKS
44

45. APPLICATION PROFILE
COVERBOARDS, TIE EXTENSIONS, UTILITY
AND COMMUNICATION STRUCTURES for
the MASS TRANSIT MARKET
45

46. APPLICATION PROFILE
PULTRUDED COOLING TOWER
46

47. APPLICATION PROFILE
NUCLEAR INTAKE RACK
47

48. APPLICATION PROFILE
PEDESTRIAN BRIDGE
48

49. APPLICATION PROFILE
AZERBAIJAN
3,280 FT
RETAINING WALL 1580
SUPERLOC™ AND
SUPERWALE
49

50. APPLICATION PROFILE
SHEET PILE WALL SERIES
1560 SUPERLOC™
50

51. APPLICATION PROFILE
SHEET PILE WALL AFTER
HURRICANE SANDY 2012
SERIES 1580 SUPERLOC™
51

52. KEYPORT, NJ
PHOTOS OF WALL TAKEN
DURING HURRICAN SANDY
52

53. KEYPORT, NJ
PHOTO TAKEN AFTER
HURRICAN SANDY, 2012
NO DAMAGE TO THE FRP WALL
53

54. APPLICATION PROFILE
MILITARY
54

55. FT. MEYERS, FLORIDA
SHEET PILE WALL
55

56. PIANKATANK RIVER, VIRGINIA
BRIDGE PIER FENDER SYSTEM
CONSTRUCTED OF
POLYURETHANE PIPE PILES
56

57. APPLICATION PROFILE
PINELLAS BAYWAY BRIDGE
PIPE PILE FENDER
INSTALLATION
57

58. 58
APPLICATION PROFILE
PINELLAS BAYWAY BRIDGE
PIPE PILE FENDER
INSTALLATION

59. 59
WHAT CAN WE DO FOR YOU?
WE CAN DESIGN YOUR CUSTOM PROFILE
BASED ON FINITE ELEMENT ANALYSIS
AND PROVEN ENGINEERING MEANS

60. 60
TEST THE DESIGN IN ONE OF
OUR IN-HOUSE TEST FACILITIES
FULL SECTION AND COUPON LEVEL TESTING

61. 61
PULTRUDE YOUR PROFILE

62. 62
FABRICATE YOUR PROFILE OR STRUCTURE

63. FACILITIES OVERVIEW
Creative Pultrusions, Inc. was
established in 1973 and is located
in Alum Bank, Pennsylvania.
PRODUCTION MACHINES = 18
FACILITIES (SQ. FT) = 160,000
EMPLOYEES = 148
63

64. 64
HILL & SMITH HOLDINGS PLC
• Hill & Smith Holdings PLC is an international group with leading positions in the
design, manufacture and supply of infrastructure products and galvanizing
services to global markets. It serves its customers from facilities principally in the
UK, France, USA, Thailand, Sweden and China.
• The Group's operations are organized into two main business segments:
Infrastructure Products & Galvanizing Services.
• 2013 Revenue of £444.5m
• Infrastructure – 71%
Roads - 25%
Utilities - 46% • Galvanizing - 29%
£316.9m £127.6m

65. 65
WHERE HILL & SMITH OPERATES
UNITED STATES
FRANCE
UNITED
KINGDOM
SWEDEN
THAILAND
INDIA
CHINA
AUSTRALIA
V
• AUSTRALIA: New office in Queensland for
the development of our wire rope and
safety barrier products.
• CHINA: Manufacturing and trading
facilities located in the Jiangsu province
for the further expansion of our pipe
support business.
• FRANCE: The locations of France Galva
and Conimast, where we have ten
galvanizing plants and a lightning
column business.
• INDIA: New manufacturing facility for
pipe supports and also offices for
development of our Hill & Smith
infrastructure product business.
• SWEDEN: Location of ATA Bygg-och
Marckprodukter AB, the road safety barrier
and signage business.
• THAILAND: Location of part of our pipe
supports manufacturing capability, where
we have plants near Bangkok.
• UK: Head office and various group site
locations covering our main infrastructure
products business and network of UK
galvanizing plants.
• USA: Our V&S galvanizing and utilities
plants are situated on the East Coast along
with the Bergen and Carpenter & Paterson
pipe support business and the fiber
reinforced composite profiles business,
Creative Pultrusions.

66. 66
HILL & SMITH REVIEW OF 2012
INFRASTRUCTURE PRODUCTS
The division is focused on supplying
engineered products to the roads
and utilities markets in geographies
where there is a prospect of
sustained long term investment in
infrastructure.
In 2012 the division accounted for
73% (2011: 68%) of the Group’s
revenue and 43% (2011: 48%) of the
Group’s underlying operating profit.
UTILITIES
The requirements for new power generation in emerging
economies and replacement of aging infrastructure in developed
countries provide an excellent opportunity for the Group’s utilities
businesses.
Revenues increased to £205.7m (2011: £167.0m), which after
adjusting for acquisitions and currency impacts, reflects 13%
organic growth of £22.5m. Underlying operating profit increased
by £1.9m to £13.4m (2011: £11.5m) with acquisitions contributing
£0.9m of the growth.
The organic growth was driven mainly by our US based
businesses, V&S Utilities and Creative Pultrusions, which benefitted
from a more active USA utilities market.
delivering a number of large projects in the transmission, rail and cooling tower markets. Over the year, we
further developed high value products for niche markets.
These products are lightweight, corrosion resistant and offer improved installation times, thereby substituting
traditional materials. There is a growing demand for composite products and this was evident in the supply of
85 railway platform extensions for the upgrade to the Wessex Line in the UK.
CREATIVE PULTRUSIONS
ACHIEVED A RECORD PERFORMANCE

67. CELEBRATING OVER 40 YEARS OF PROVIDING PULTRUSION SOLUTIONS
QUESTIONS?
www.creativepultrusions.com