Large Structural Panels Using
Thermoplastic Composite
ACMA January 2011
AS Composite Inc. is a privately owned Research & Development
Canadian company founded in 2003.
Sandwich Panels
Plates
Moulded Parts
Continued Research & Development
Analysis, Prototyping & Design
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
•
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)
• All of our products are based on Thermoplastic reinforced with
continuous fibres (composites)
Fibre
• Glass
• Carbon
• Kevlar
&
Matrix
• Thermoplastic
• Extremly light, non-corrosive, durable, Reusable, Weldable
• Better performance, in climates (-40c to 80c)
• Impact resistant, 100% Non-Toxic + Environmentally Friendly
• Clean Fabrication
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:
Matrix:

Glass

Thermoplastic

Carbon


Kevlar
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
•
•
•
••
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
• 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 extra
structure and can resist harsh climate
loadings (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
Florida
Building 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)
Smoke Developed Index (SDI)
Time to ignition
Dripping and flamming
No Dangerous Gas emited in fire
5
135
502 sec
Non
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 About
Durability – Cost &
Maintenance - Time
Think About