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Large Structural Panels Using
Thermoplastic Composite
ACMA January 2011
Who Are We
AS Composite Inc. is a privately owned Research & Development Canadian company founded in 2003.
Products ServicesSandwich Panels Continued Research & Development
Plates Analysis, Prototyping & Design
Moulded Parts Process Development & Fabrication
Technology Transfer
Thanks to our innovative technology, leading edge equipment, highly qualified, and talented team, we have gained recognition as the leader in this industry
Who Are We Certification & Patents
• Process and machine for producing lightweight
thermoplastic composite products in a continuous
manner (Patented)
• Fibre reinforced thermoplastic composite panel
(Patented)
• Fibber reinforced thermoplastic composite bridge deck
(Patented)
Product
• All of our products are based on Thermoplastic reinforced with continuous fibres (composites)
Thermoplastic Advantage
• Clean Fabrication
• Better performance, in climates (-40c to 80c) • Impact resistant, 100% Non-Toxic +
Environmentally Friendly
Fibre & Matrix• Glass
• Carbon• Kevlar
• Thermoplastic
• Extremly light, non-corrosive, durable, Reusable, Weldable
What is a Sandwich Panel? A panel with plastic, metal, paper or
other material enclosed between two
layers of a different material.
Generally, face plates may be fabricated with
stiff materials as compared to the core that is
fabricated by materials like plastics, composites
etc….
A.S. Panel
Composite (Commingled yarn
of polypropylene and fibreglass)
used as face plates.
Core material is generally
fabricated by PP Honeycomb
or Foam
Composite Material
Fiber:
Glass
Carbon
Kevlar
Matrix:
Thermoplastic
Thermoset
Advantages of Thermoplastic
Clean fabrication
Reusable, reformable, weldable, flexible
Non-toxic and environmental friendly
Better performance in low & high temperature
More resistant in impact
Low cost
OUR
SOLUTION?
Solution
Sandwich structure
+
Using a continuous Process (sequentially heating - compacting - cooling )
=
(Innovative Machine)
Solution (Cont.)
Capabilities
• Length up to 20 ft and more (7.0 m)
• Production rate: 4 ft/min (1.2m /min)
• Thickness of panels 0.25 to 4 in (6 to 100 mm)
• Core and face plates are fused (not adhered in pp
cores)
• Flexibility in forming; drums can be
altered to obtain any desired shape (not just flat)
Advantages of A.S Panel
Compared to other alternatives:• Lighter
• Easy to transport, to manipulate and to install
• Energy dissipation in impact especially at low temperature
Applications
Applications
Concrete Forming
• Easy Manipulation
• Durability
• Recyclable
Applications
Prefab. Housing
• Light Weight• Insect Resistant• Water resistant• Rust proof• Flame retardant• Easy Assembly• Permanent Construction
Applications
Advertisement Signs
• Non-adhesion to ice and snow
Applications
Truck Trailer
• Corrosion free
• Weight reduction
• Recyclable
• Non toxic
• High impact resistance
Applications
Guard Rail
• Corrosion free
• Recyclable
• Easy Manipulation
• High impact resistance
Applications
Bridge Deck Slab
• Corrosion free
• Long life span
• Weight reduction
Plates & Molded Parts• Thermoplastic polymer reinforced with Fiberglas• 0.5 mm to 6 mm thick• Up to 3mm in width, Unlimited length• • Superior to competitive panels such as plywood, steel,
Aluminum, Fiberglas, etc
Military Applications• Some applications in production through our partners• Some applications tested successfully, and ready to be used• Some application under testing directly with AS Composite
• (*More information on testing available upon request due to confidentiality
Structural Performance
One floor buildings:Used for wall, roof and floor without any extrastructure and can resist harsh climateloadings (ex: abundant snow in Canada, violent wind in Mexican Gulf up to 200 km/hrs,strong seismic load)
Two floors and more:• Used as internal and external self supporting
walls
Structural Performance(cnt’d)
• Bending Strength (3 Points test, ASTM3931):
61.8 Mpa• Compression Strength (ASTM C365):
21.7 Mpa• Impact Strength (Room temperature,
appraised by a falling dart impact test with Ф20 mm spherical head
> 250J/m2• Missile Impact Test TAS 201 based on
FloridaBuilding Code results:
No penetration in exterior skin
Coating AS Panel
Covering AS Panel surface by interlayer (Polyester/Glass fiber mat) during the fabrication process allows a perfect adhesion to:
• Concrete
• Acrylic Latex Paint • Plaster or other similar materials
Thermal Performance
• For 100 mm thick: Minimum R value : R20 = 0.9 m2 ºCJW
• No Thermal Bridge in walls or roof
• Thermal Stability within -29ºC to 100ºC, 97% Humidity is 2%
• Water vapor permeability < 1
Fire performance (using Fire Retardant)
Test ASTM E 84-05
Specimen:
Panel: 100 mm thick (1.5 mm skin),
0.6 m x 7.3m,
core: Fiber Glass/EPS fire retardant
Results:Flame spread Index (FSI) 5
Smoke Developed Index (SDI) 135
Time to ignition 502 sec
Dripping and flamming Non
No Dangerous Gas emited in fire
Fire Performance
AS panel may be used as Structural Insulated panel for internal or external walls in Multi floor building if:
Coated with fire retardant cover such as:
•Ferox 18 mils or •Firetec•Coated with chalk or concrete•Finished with chalk sheet (Dry wall)
AS Panels with these coatings meet:
•Class A of International Building Code Chapter 8 interior finish, Section 803•NFPA 5000 Chapter 10 interior finish, section 10.3•Testing based on ASTM E84-05
Partners
National Research Council Canada (NRC / IMI)
Sherbrooke University
Massachusetts Institute of Technology (M I T)
British Columbia (UBC)Industrial Material Initiative (IMI)Industrial Research Assistance Program (IRAP)
Opportunities
• Unique process and product (patent-pending)
• Became a reference of this domain of activity
• Creates possibilities for development of new industrial applications
• Energize technology transfer
Conclusion
Although it seems the A.S. Panels costs
more compared to materials like metal
and Aluminum, its lower cost for
handling, assembly, transportation and
maintenance makes it more competitive
and efficient on the market.
Think AboutDurability – Cost & Maintenance - Time
Think About