Composites USA's Custom Accessories

Composites USA has the wide range of custom accessories and product offerings you need to complete any corrosion resistant system. Choose from pre-piped and instrumented packaged skid systems, control consoles, enclosures, platforms and more. Most accessories required for a complete system are available from Composites USA.

Below are examples of our diverse line of product offerings:

ButtonButton ButtonButtonButtonButtonButtonButton

Chutes:

Fiberglass chutes may be designed and manufactured to fit any number of geometry, strength and corrosion requirements. Typical applications are for either adding or removing solids, pastes or sludges from process vessels. Chutes have been used for adding metal grain to acid dissolving vessels in refining operations and for discharging filter cake from waste water treatment sludge dewatering operations to name but two uses requiring strength and chemical corrosion resistance.

Fiberglass chutes may be used simply for ease in material handling. With a strength to weight ratio several times that of steel, fiberglass chutes are used in a number of industries due to ease of set up and break down for storage and cleaning.

Typical Specifications:

Chutes shall be designed for the loads imposed with maximum deflection of ½% of span. Design is to be supported by engineering calculations by a staff mechanical engineer experienced in fiberglass structural design. Materials of construction are to be suitable to meet the corrosion requirements.

Resin Polyester or Vinyl Ester Resin as required by corrosion resistance
Nominal Thickness 0.25" minimum with local reinforcement as required
Flex Strength 31,800 psi (ASTM D-790)
Flex Modulus 1,270,000 psi (ASTM D-790)
Tensile Strength 20,000 psi (ASTM D-638)
Tensile Modulus 1,430,000 psi (ASTM D-638)

Design & Construction:

  • All one piece molded construction
  • Corrosion resistant – Suitable for the application at the design temperature
  • Self supporting with local reinforcement as required
  • All cut edges to be resin sealed
  • Molded in color, white or gray standard, custom match available
  • Temperature resistance to 170oF unless otherwise specified

Clevis Hangers:

Clevis HangerComposites USA manufactures pipe hangers for your most demanding corrosion environments. Clevis hangers, in sizes ranging from 2" through 24" diameter (nominal, for IPS outside diameters) are designed and manufactured for rugged industrial use in corrosive environments, such as the 10" diameter example on this page.

Composites USA clevis hangers solve the problem of supporting your corrosion resistant duct or pipe in corrosive atmospheres. The resin and corrosion barrier can be tailored to provide protection from acidic and oxidizing exposures. The hangers are non-conductive and can be formulated to provide fire retardancy.

Cost effective applications include areas where maintenance or repair is expensive and difficult, or highly corrosive areas where the life cycle cost of fiberglass is lower than competing materials.

All major components are designed for the anticipated loads, using a minimum factor of safety of 3:1. Testing has shown the ultimate load to be well beyond the design load, For example, 3" diameter hangers, designed for 200 lb. loads, showed initial delamination at 850 lb., while the ultimate load was 1800 lb., after considerable deformation. Please contact our engineering department for additional details.

Typical Specifications:

Resin Vinyl Ester
Thickness As required to meet specified loads (0.250" min.)
Flex Strength (Min.) 23,800 psi (ASTM D-790)
Flex Modulus (Min. 1,100,000 psi (ASTM D-790)
Tensile Strength (Min.) 16,400 psi (ASTM D-638)
Tensile Modulus (Min.) 1,500,000 psi (ASTM D-638)
Flame Spread 25 (ASTM E-84)


Covers

Fiberglass Reinforced Plastic Equipment Covers:

Composites USA equipment covers are designed and manufactured for rugged industrial use where contact with aggressive chemicals might be a concern. Although designed for industrial environments, these panels also receive the same fit, finish and attention to detail that our electronic housings for radar and instruments have.

Each panel design is rigorously checked by our composites structural engineers to verify loadings and anticipated deflections. All reinforcement glass is precision hand cut (ie. no chopper gun allowed) and laid onto the mold, thus carefully controlling the part thickness and strength characteristics.

The laminate begins with a resin rich corrosion barrier, reinforced with a fiberglass or polyester veil and several layers of random chopped strand mat. The structural portion of the laminate is constructed with alternating layers of random chopped strand mat and continuous strand biaxial woven roving. These alternating layers are gradually built up to the final required thickness.

The top exterior layer is usually applied with a resin pigmented to the customer's preferred color choice, for long-term color stability, which will not chip or flake off. In this way, the color is molded in, part thickness and reinforcement uniformity is carefully controlled, and problems with typical trouble spots, such as voids and inside corners, are avoided. When requested, a grit surface is applied to increase safety for personnel access.

With a Composites USA cover, you get quality to audited MIL-I-45208 standards, and design to U.S. Bureau of Commerce Voluntary Guideline PS-15-69ASTM and ASME Guidelines, as applicable. All resins used are premium grade corrosion resistant and flame-retardant vinyl ester as standard (Class 1 flame spread to ASTM E-84).

Specifications:

Resin Fire Retardant Vinyl Ester
Exterior Surface  Non Skid Grit 
Minimum Thickness 0.375" (with ribs as required)
Flex Strength (Min) 23,800 psi (ASTM D-790)
Flex Modulus (Min) 1,100,000 psi (ASTM D-790)
Tensile Strength (Min) 16,400 psi (ASTM D-638)
Tensile Modulus (Min) 1,500,000 psi (ASTM D-638)
Flame Spread (Max) 25 (ASTM E-84


Enclosures:

Custom EnclosuresComposites USA enclosures are designed and manufactured for rugged industrial use where part weight and contact with corrosive chemicals or sea water might be a concern. Although designed for industrial environments, these enclosures also receive the same fit, finish and attention to detail that our electronic housings for radar and instruments have.

Shown on this page are several styles of enclosures, including the three sided instrument enclosure above and the process tank with integral equipment enclosure below. This part was used to temporarily enclose gas chromatographs in an oil refinery. Other enclosures might typically protect remote pump stations from unwanted tampering, or protect personnel from rotating machinery parts.

Each enclosure design is rigorously checked by our composite structural engineers for wind, snow and operating loads.

The laminate begins with a resin rich corrosion barrier, reinforced with a fiberglass or synthetic veil and several layers of random chopped strand mat. The structural portion of the laminate is constructed with random chopped strand mat and continuous strand glass, biaxial, unidirectional or otherwise oriented to meet the design considerations. These layers are gradually built up to the final required thickness, sometimes incorporating structural cores on large flat panels to increase stiffness and strength.

The top exterior layer is usually applied with a resin pigmented to the customer's preferred color choice, for long-term color stability, which will not chip or flake off. In this way, the color is molded in, part thickness and reinforcement uniformity is carefully controlled, and problems with typical trouble spots, such as voids and inside corners, are avoided. Non skid grit surfaces are available for increased personnel safety.

With a Composites USA enclosure, you get a cover designed to the latest codes, and quality audited to MIL-I-45208 and Factory Mutual standards. All resins used are corrosion resistant polyester or vinyl ester, with flame retardant options available.

Typical Specifications:

Resin Fire Retardant Polyester or Vinyl Ester
Thickness 0.375" minimum with local reinforcement as required
Flex Strength (Min) 23,800 psi (ASTM D-790)
Flex Modulus (Min) 1,100,000 psi (ASTM D-790)
Tensile Strength (Min) 16,400 psi (ASTM D-638)
Tensile Modulus (Min) 1,500,000 psi (ASTM D-638)
Flame Spread (Max)  25 (ASTM E-84)


Flumes

Fiberglass Reinforced Plastic Flumes:

Composites USA flumes are one piece molded units designed for metering liquids in open channels. The unbroken flow lines present no obstructions which would cause a build up of debris. The unbroken lines also create low head loss characteristics which make the flume ideal for measurements under gravity head requirements.

Each flume design is rigorously checked by our composites structural engineers to verify loadings and anticipated flat plate deflections, if any. All reinforcement glass is precision hand cut (ie., no chopper gun allowed) and laid on the mold for gradual built up to the final required thickness with the specified resin. In this way, the color (if requested) is molded in, part thickness and uniformity is carefully controlled, and problems with typical trouble spots, such as inside corners, are avoided.

With a Composites USA flume, you get quality to audited MIL-I-45208 standards, and design to U.S. Bureau of Commerce Voluntary Guideline PS-15-69ASTM and ASME Guidelines, as applicable. All resins used are corrosion resistant isophthalic polyester as standard. Premium grade vinyl ester, epoxy or furan, as well as flame and smoke resistant grades are also available as options.

Typical Specifications:

Resin Isophthalic Polyester
Nominal Thickness 0.25" ( with ribs as required )
Flex Strength 31,800 psi (ASTM D-790)
Flex Modulus 1,270,000 psi (ASTM D-790)
Tensile Strength  20,000 psi (ASTM D-638)
Tensile Modulus 1,430,000 psi (ASTM D-638)

Design & Construction:

All one piece molded construction
Corrosion resistant
Self-supporting with ribs as required
Undrilled flange ends, all cut edges to be resin sealed
Optional taps for flow measurement, stilling wells & staff gauges
Molded in color, white or gray standard, custom match available
Temperature resistance to 170oF


Filters - Liquid & Gas:

Luquid & Gas FiltersComposites USA filters are designed and manufactured for rugged industrial use in corrosive environments. Filters are manufactured for liquid or gas service as shown by the two examples on this page.

The glove box filter assembly allows discharge of corrosive/ toxic slurries into the filter assembly through the flanged nozzles on the back side of the enclosure. The slurry falls to the filter cloth, held in place on the ribbed bottom bed. A vacuum connection on the bottom of the bed draws the liquid off, leaving the cake. The cake may then be washed using the same or different nozzles, or dug off to the integral discharge chute on the left side of the housing, using impervious gloves (not shown) mounted on the clear polycarbonate cover.

The housing is built in a single section on a multipart mold, resulting in a smooth, easy to maintain surface with no seams. The laminate begins with a resin rich corrosion barrier, reinforced with a fiberglass or synthetic veil and several layers of random chopped strand mat. The structural portion of the laminate is constructed with random chopped strand mat and biaxial continuous strand glass.

Filter housings for air handling systems are also available from Composites USA in a number of configurations. Shown is a multi-component trayed system, with angled shelves, sample ports, access doors and housing all constructed of corrosion resistant fiberglass.

With a Composites USA filter housing, you get a cover designed to the latest codes, and quality audited to MIL-I-45208 and Factory Mutual standards. All resins used are corrosion resistant polyester or vinyl ester, with flame retardant options available.

Typical Specifications:

Resin Fire Retardant Polyester or Vinyl Ester
Thickness 0.375" minimum with local reinforcement as required
Flex Strength (Min) 23,800 psi (ASTM D-790)
Flex Modulus (Min) 1,100,000 psi (ASTM D-790)
Tensile Strength (Min) 16,400 psi (ASTM D-638)
Tensile Modulus (Min) 1,500,000 psi (ASTM D-638)
Flame Spread (Max)  25 (ASTM E-84)


Platforms:

Fiberglass PlatformsFiberglass platforms may be designed and manufactured to fit any number of geometry, strength and corrosion requirements. The reactor platform in the picture was specially designed to ship in three sections, the ladder, the lower 72" of platform framing, and the upper 36", allowing all sections to be moved by fork lift through doors and hallways to its final assembly point. Factory pre-fit with all bolt-up connections made this a 4-hour installation in the field, from truck unloading to completion.

Fiberglass composite's outstanding corrosion resistance, lightweight, and availability in many common shapes make it a natural solution for many process plant problems. Platforms, grating and railings are available in flame and non flame-retardant versions of polyester and vinyl ester resins. Specialty resins, such as phenolics are available for installations requiring low smoke generation.

Qualified personnel familiar with composite structural design and OSHA regulations should perform design of platforms and connection details. Failure mechanisms can be different between steel and fiberglass structures, and these must be taken into account.

Typical Specifications:

Platforms shall meet OSHA requirements and be designed for the loads imposed with maximum deflection of 1% of span. Design is to be supported by engineering calculations by licensed professional engineer experienced in fiberglass structural design. Materials of construction are to be suitable to meet the corrosion requirements.

Resin Polyester or Vinyl Ester Resin as required by corrosion resistance
Attachment Hardware Stainless steel (FRP or plated steel also available)
Grating Thickness 1.5" unless otherwise specified
Structural Members:  
Flex Strength 30,000 psi (ASTM D-790)
Flex Modulus 2,000,000 psi (ASTM D-790)
Tensile Strength 30,000 psi (ASTM D-638)
Tensile Modulus 2,500,000 psi (ASTM D-638)

 

Design & Construction:

Corrosion resistant – Suitable for the application at the design temperature
Meet OSHA requirements, including requirements for allowable deflection, ladders, cages, and handrail systems
All cut edges to be resin sealed


Strainers:

Composites StrainersComposites USA strainers are designed and manufactured for rugged industrial use in corrosive environments. Basket, as well as wye strainers are manufactured for liquid or gas service as shown by the 8" diameter (pipeline) basket strainer example on this page.

The basket strainer assembly allows in-line filtering and straining of particulate matter from process liquids. The flanged top assembly allows removal and thorough cleaning of filter media during regularly scheduled maintenance outages. The removable basket/ filter media is typically a thermoplastic or high nickel alloy such as Monel or Hastelloy. A low point drain connection permits periodic flushing without disassembly.

The strainer laminate begins with a resin rich corrosion barrier, reinforced with a fiberglass or synthetic veil and several layers of random chopped strand mat. The structural portion of the laminate is constructed with random chopped strand mat and biaxial continuous strand glass. The resin selected may be matched to the process piping, but typically high performance vinyl esters are chosen for this service.

With a Composites USA strainer, you get equipment designed to the latest codes, and quality audited to MIL-I-45208 and Factory Mutual standards. All resins used are corrosion resistant and specifically selected for the service, polyester, vinyl ester, epoxy or furan, with flame retardant options available.

Typical Specifications:

Resin Vinyl Ester
Nominial Thickness As required to meet specified loads (0.375" min.)
Flex Strength (Min) 23,800 psi (ASTM D-790)
Flex Modulus (Min) 1,100,000 psi (ASTM D-790)
Tensile Strength (Min) 16,400 psi (ASTM D-638)
Tensile Modulus (Min) 1,500,000 psi (ASTM D-638)
Filter Media Monel 8 gauge wire mesh, or other as specified


Mill Spec & Production Parts

 

Mill Spec & Production Parts

Composites USA has been independently audited and approved to MIL-I-45208-A.  We have completed demanding projects for every branch of the military, as well as close tolerance production projects for aerospace, communication, and other high tech industries.  The nature of composite part fabrication makes it ideally suited to large part or short to medium run production cycles.  Some product examples follow.  Contact Composites USA to explore your options.

Below are examples of our line Mil-Spec and Production Part product offerings

ButtonButtonbuttonButtonbuttonbuttonbutton


Aircraft Nancelles

Aircraft Nacelles:

These nacelles were resin transfer molded with mil-spec fiberglass cloth and polyester resin for Lavelle Aircraft.Metal tooling was used to assure maintenance of tight tolerances.


Assorted cases

Cases:

FRP is commonly used for industrial case applications such as industrial cases.  The qualities which make FRP among the materials of choice for this application are FRP’s excellent strength to weight ratio, impact and corrosion resistance, relatively low tooling cost.  FRP also possesses the ability to be molded while incorporating inserts, bosses and color throughout the part, often eliminating some secondary operations.

The instrument case shown at the right is one of more than 100 specialty cases produced for Pringle Electric Co. The cases were manufactured from Class 1 fire retardant polyester resin and fiberglass. All attachment hardware is stainless steel..

Cases may be manufactured in a variety of configurations to fit any number of needs. Two examples are shown left and below. The Mil-Spec battery case on the left incorporates extra heavy wall sections and bosses in a resin transfer molded housing to meet the required mechanical loads. The wire shown is for an integrally molded heater cable. The case below incorporates a custom geometry to meet its performance needs.


Mass Transit Components:

FRP is commonly used in mass transit part manufacturing due to its excellent strength Mass Transit Componanats
to weight ratio, impact and corrosion resistance, relatively low tooling cost and ability to be molded into complex shapes with color throughout the part, often eliminating secondary operations such as painting.

The 6’-0" long protective shield shown at the right for the third rail pick-up (power rail) on a high speed car is one of more than 1500 produced via Resin Transfer Molding (RTM) for the Chicago Transit Authority. The parts were produced from a single light weight tool. Resin Transfer Molding was chosen for the process due to its excellent economics and part to part reproducibility.

The air handling system damper blades shown at the left were also resin transfer molded, this time for a rail car system sold to Westcode/ Kawasaki for use in China. The resin is a low flame/ low smoke polyester, with color molded in. The blade shafts are stainless steel, and are integrally molded with the blade itself, eliminating secondary operations. Use of RTM resulted in economic processing for the over 1000 pieces required, as well as resulting in a mold finish on both sides of the part, allowing maintenance of tight tolerances and damper seal properties.


Mine Sweeping Floats

Mine Sweeping Floats:

These mine sweeping floats were contact molded with mil-spec fiberglass cloth and epoxy resin for Deval for resale to the U.S. military. Metal inserts were integrally bonded to the assembly, minimizing customer secondary assembly labor.


Randome Mounting Brackets

Randome Mounting Brackets:

These radome mounting brackets were manufactured for R.C.A. using resin transfer molding (RTM) with polyester and fiberglass. Fiber loading is 65% at 0.375" thick, suitable for the high physical loadings. The holes shown were to accommodate cable mounting hardware, also supplied and installed by Composites USA.

FRP is commonly used in these applications for its high strength, low weight, and good dielectric properties.


Radio Tower CoversRadio Tower Covers:

These radio tower covers were manufactured for RCA. FRP is commonly used in these applications for its high strength, low weight, and good dielectric properties. These covers were mounted on a 80 ft tall tower subjected to 200 mph wind loads.


Radomes / Glass / Kevlar / Epoxy / Vinyl Ester:Assorted Randomes

FRP is commonly used in radome manufacturing due to its favorable dielectric properties, excellent strength to weight ratio, impact and corrosion resistance, relatively low tooling cost and ability to be molded into complex shapes.

The 3’-0" long radome shown at the right are manufactured using vinyl ester resin with Kevlar aramid reinforcement. Divinycil PVC closed cell foam core is also incorporated into the laminate to minimize weight of the part. These radomes are contact molded on machined metal molds to exacting tolerances.

Radomes are manufactured in a wide range of geometries, from long tubes to flat dishes, and almost every shape in between. Some additional examples, contact molded and resin transfer molded (RTM) are shown below. Materials of construction typically include Mil-Spec grades of polyester, vinyl ester or epoxy resins with fiberglass or aramid reinforcement.