Ultimate Fiberglass and Resin Guidebook for Beginners

The first step when looking at fiberglass projects is to decide what is important.  Are you concerned about weight? Is strength the most important? Do you need it to be abrasion, corrosion or UV resistant?  Do you want to build up thickness quickly? Answering questions like these first will help you choose the best reinforcement and resins for your project.

If you are looking for more details, kindly visit our website.

To make a durable composite laminate you need to have both a reinforcement and a resin.  Reinforcements include fiberglass cloth, fiberglass mat, carbon fiber and aramid. Resin holds the reinforcement together and helps it conform to the wanted shape. The most popular resins are polyester, vinyl ester and epoxy.

Fiberglass Reinforcements

Many things will determine what fiberglass reinforcement you choose.  It will depend on where you are applying it, what properties you need, why you will be using it, the type of resin you want to use and the cost.

-Fiberglass cloth

Fiberglass cloth, also known as fiberglass fabric, is low in weight and becomes strong when combined with resin.  It works well for building composite parts, making molds and for fiberglass repairs. The lower weight fabrics are great for waterproofing. It becomes transparent when resin is added.  The heavier fabrics are stronger and build up thickness quicker.

The 6, 7.5 and 10 ounce plain weave fabrics are the most commonly used. They have a simple plain weave pattern that is uniform in strength both horizontally and vertically. This pattern has warp and fill yarns that are interlaced over and under each other in alternating fashion. The plain weave is the easiest to handle since it does not unravel as much as the other weaves when cut.

Most fabrics are sold by the yard and come in 38”, 50” and 60” widths. There is also the option of fiberglass tape.  The widths on these range from 1” to 12” and come in 50 yard rolls. Fiberglass tape has selvage edges to keep it from un-raveling and do not have an adhesive backing. They are used with resin just like the regular fabrics.

-Chopped Strand Mat

Chopped strand mat is also known as fiberglass mat. It is made up of short strands of fibers that are randomly oriented and held together with a resin binder. The resin binder needs styrene to dissolve properly. This makes it incompatible with epoxy resin.  It is only compatible with polyester and vinyl ester resin which contains styrene. When polyester or vinyl ester resin is added to the mat, the binder dissolves and the fibers can be moved around. This makes it easy to conform to tight curves and corners.

Chopped strand mat is the most affordable fiberglass and is frequently used in mold construction or projects where thickness is needed. It is meant for non-structural application as it does not have much strength. If you need strength you should choose a woven cloth or you could mix the two. Mat can be used between layers of woven fabric to help build thickness quickly and to aid in all layers bonding well together.

Mat is also often used as the first layer, right before the gelcoat, in a laminate to hide print through from heavier fabrics. Print through is when the fabric weave texture shows through the resin. Mat is also easy to handle and can be torn instead of cut.

-Carbon fiber 

Carbon fiber is known for being light weight, strong and for having great cosmetics.  It is often used in the automobile, sporting goods and aerospace industry.  A yard of carbon fiber cloth has millions of microscopic filaments all bundled together. For example, in a 3k fiber fabric, each bundle of fiber has 3000 filaments in it.  Each filament carries part of the load. The bundles are woven together to form a strong fabric.

In cars, the 2x2 twill weave carbon fiber fabric is used to make hoods and dashboards.  Usually, the carbon fiber is only there for its good looks.  It doesn’t add strength or durability.  It looks especially nice when it has a glossy clear coat on top of it.

Carbon comes in 3k, 6k and 12k varieties.  The larger the k the larger the weave.

-Aramid (aka Kevlar® or Twaron®)

Kevlar® has great impact, heat and abrasion resistance.   It also has excellent tensile strength, but poor compression strength. Kevlar® is used in bullet-proof vests, motorcycle racing cloth and gloves, kayaks and canoes.   If a project needs abrasion resistance Kevlar® can be a good option.

One thing to note is that Kevlar® can be very difficult to cut. A separate pair of scissors should be used.

-Woven roving

Woven roving is a heavy, coarse plain weave cloth that comes in 18 and 24 oz weights. It is made up of bundles of roving that are woven together loosely at 90 degrees and is ideal for laminating large flat areas. It is a great option to use in boat building, especially when used in conjunction with chopped strand mat. The mat will help the woven roving adhere well to subsequent layers and fill in the voids. Just be aware that if you use it with mat, it will not be compatible with epoxy resin.

Woven roving builds up thickness quickly and provides strength. A drawback is that there can be some crimping in the woven bundles. These crimp points can fracture. It is also a very heavy fabric that does not conform to curves.

-Knitted Fabric

Knitted fabric is bundled and stitched together. It wets out fast and provides maximum directional strength. It saves time in multi-layer layups. There is no crimping since the fabric is stitched instead of woven.

Knitted fabric is also a good option in boat building and in the composite industry. The most common knitted fabric is DBM 1708. The 1708 is a 17 ounce +/-45 bias fabric with a 3/4 ounce chopped strand mat stitched to it.

Knitted fabric is compatible with polyester, vinyl ester and epoxy resin. It is compatible with epoxy even though it has mat with it.  The mat that is stitched to the fabric does not have a styrene binder like the regular chopped strand mat.

Resins

The resin that is chosen also depends on many variables.  Some of those variables are similar to the ones used when choosing a reinforcement- where you are applying it, what properties you need, why you will be using it and cost.  It will also depend on the type of reinforcement you want to use, whether you will be finishing with a gel coat or not and whether you need it to be corrosion, abrasion or UV resistant. If it is a repair, it will depend on what resin was originally used.  Once you have made a list of what is important to you in your laminate, you can research the different types of resins available.

-Polyester Resin

The most commonly used resin is polyester.  It is the easiest to use when compared to vinyl ester and epoxy resin. It is also the most economical. Polyester resin has a quick cure and adds dimensional stability.  It has many different uses and is often used in building/repairing boats, car bodies, patio decks, surfboards, kayaks, decorative surfaces, outdoor ponds, bath tubs, plus more. If you will be finishing with a gel coat, it is important to use either polyester or vinyl ester resin as your laminating resin.  Gel coats are polyester resins and will not adhere well if epoxy resin is used first.

There are several grades of polyester resins including ISO (isophthalic) and Ortho (orthophthalic). The most popular is the Ortho General Purpose Laminating Resin.

Ortho General Purpose Laminating Resin

Ortho general purpose laminating resin is used for a wide variety of general fiberglass applications. It cures with a surface tack which holds the reinforcement in place and helps the multiple layers adhere well to each other. Another benefit to the surface tack is that it is not necessary to sand between layers.  If you need a hard tack free surface, wax can be added (surface agent or surface seal) to the resin.  This is typically done on the final layer. A Finishing resin can be used for the final layer as well.  There is wax in a Finishing resin that rises to the top when cured and seals off the air thus providing that hard-finished surface. There will be no tack.

ISO Resin

ISO (isophthalic) resin is a superior grade polyester laminating resin. It has higher heat distortion, is more impermeable to moisture and has better corrosion resistance. ISO resin also has a better tensile strength.  It is often used in mold making because it is a stiffer resin and less likely to distort.  It is also used on pipes or parts that require the higher corrosion and temperature resistance.

Surfboard Resin

Surfboard Resin is another popular polyester.  It is a water clear, UV and impact resistant resin.  It provides some flex to help resist impact damage and also has UV inhibitors to protect the water clear appearance.

****Polyester and vinyl ester are not compatible with epoxy resin.  Epoxy can be applied over polyester and vinyl ester resin for repairs etc., but not vice versa.

-Vinyl ester resin

Vinyl ester resin falls between the polyester and epoxy resin when it comes to different characteristics and cost.  It has a longer molecular chain than polyester resin which helps it absorb impact better than polyester and it shrinks less.  There is also less chance of de-lamination when using VE resin.  Vinyl ester can be used as a final coat after polyester resin to create a better water barrier.

Vinyl Ester resin is also more resistant to solvents and water degradation.  It is typically used in boat hulls, gas tanks, kayaks, canoes and other items that will be exposed to chemicals such as fuel or water for extended periods of time.

VE resin is a tougher resin because of its longer molecular chains.  It can withstand repeated bending better than both polyester and epoxy resin. Vinyl ester resin cures with a tack.

The price falls in between polyester and epoxy resin. It costs more than polyester resin and less than epoxy resin.

-MEKP- Catalyst for Vinyl Ester Resin and Polyester Resins

MEKP (methyl ethyl ketone peroxide) is the necessary catalyst for polyester and vinyl ester resins and gel coats. Without MEKP there will not be the needed chemical reaction that turns the liquid resin into a solid. It is designed for a room temperature cure.

If you want to learn more, please visit our website Rondy.

More or less catalyst can be added depending on how long of a pot life and working time is desired.  Pot life is the amount of time it takes before the resin hardens in a mixing cup.  Unlike epoxy resin, polyester and vinyl ester cure time can be manipulated by the amounts of MEKP added. Typically, catalyst is used between 1.25% to 1.75% (1 2/3 ounce to 2 1/3 ounces per gallon).

The less MEKP added, the longer the pot life/working time will be.  The more MEKP added, the shorter the pot life and working time.  Be careful when adding more or less than the recommended amounts. Too much catalyst and the finished product can be prone to fractures or the resin in the cup will form a rubbery material before it can be used.  If not enough catalyst is added, your resin will never cure. Cure time can be affected also by how thick the product is and how much resin is mixed per batch.  It is best to work in smaller quantities.

The ideal temperature to work in is 70 degrees.  It is not recommended to work in temps under 60 degrees Farenheit and the product could cure too fast if the temperature is above 80 degrees Farenheit.

***MEKP is hazardous.  It needs to be handled with care.

-Epoxy Resin

Epoxy resin is an advanced system that comes in two parts.  The resin side is typically designated as the ‘A’ side.  The ‘B’ side is the hardener side.  It comes in a variety of mix ratios including 2:1 or 4:1 ratios by weight or volume. For example, a gallon of Part A would require a half gallon of Part B with a 2:1 by weight system.

Epoxy resin is stronger than polyester and vinyl ester resin and is ideal for high performance and light weight parts.  It is water resistant and has good flexibility.  It has great bonding capability and a fast wet out.  Epoxies have a low odor compared to other resins. One of the only downsides to epoxy is that it is more expensive than polyester and vinyl ester resin. It can be used with carbon fiber, Kevlar and fiberglass cloth (NOT compatible with chopped strand mat).

There is a choice of three different hardeners for epoxy resin: fast, medium and slow. Which speed of hardener chosen depends on the working temperature, the desired working time and the needed drying time. Epoxies dry with a full surface cure.

It is ideal to work in temperatures around 75-80 degrees. It is also important to warm up the resin and the working surface to room temperature if it is too cold. Mixing cold resin will create many air bubbles. The room and surface should stay warm through the whole curing process (approx. 3 days).

Measuring the correct ratio of A:B is EXTREMELY important.  Most problems that occur with improper cure is due to not measuring the correct ratio or not mixing thoroughly. When mixing, the sides and bottom of the mixing cup should be scraped down well.

***It is very important that you do not add extra hardener to try and speed up the cure time.  This will ruin your project.  Instead, heat up the room to accelerate the process.

Safety

Working with fiberglass and resin can be hazardous if you are not careful. It is imperative to work in a well-ventilated area. The styrene in polyester and vinyl ester resins evaporate into the air during lay-up.  Strong fumes come from the styrene and it is highly flammable.  The same rules apply when working with epoxy.  While the fumes are not as strong, it can still be hazardous to work with.

It is important to wear proper safety clothing to protect you from fumes and from getting hazardous material on your skin. Always wear a good respirator mask to protect from the fumes during the laminating process. You should also wear a respirator mask when cutting fiberglass, spraying gel coat or resin, working with solvents or sanding the finished laminate.

Wear gloves when working with fiberglass and resin.  Nitrile gloves work best with epoxies. Also, eye protection is a must.  Getting resin or catalyst in your eyes can cause permanent damage. Just the fumes alone could irritate your eyes making it very uncomfortable to work. Make sure the protective eye wear you choose is shatter proof.

Material Safety Data Sheets (SDS) are available for all hazardous materials including resin and MEKP. Read these carefully.  They contain the known health and safety hazards, first aid measures, handling and storage instructions etc.

***A good recommendation is to keep a fire extinguisher and some sand in the shop.  There is always a chance of fire.  Plastic fires cannot be put out easily with water.

Accessories

There are many different accessories you will need depending on your project. Some of these include mixing and measuring cups, spreaders, squeegees, rollers and brushes.

Graduated measuring cups are great when mixing and measuring resin. Stir sticks or tongue depressors can be used to stir the resin thoroughly.

Squeegees and spreaders are helpful when working with fiberglass and resin. The squeegee and spreader will help spread and evenly saturate the fabric.

A roller is also used to evenly saturate the fabric and will in addition help get rid of air pockets and excess resin in the fabric.  If you have too much resin, spots without resin or bubbles in your finished product, you run the risk of it being weak and breaking. Using a good roller will help in creating a strong finished product.

There are several different roller options including deluxe aluminum rollers, corner rollers and barrel rollers. Deluxe aluminum rollers have grooves or fins to help distribute resin and get rid of air trapped within the fabric weave. The aluminum rollers are recommended when increased pressure is needed particularly on larger applications.

Corner rollers are designed for concave surfaces and filets where flat rollers are not effective. They eliminate bubbles in critical inside corners. They save time when rolling out non-flat surfaces.

Barrel rollers are also designed for curved and concave surfaces where flat rollers are not effective. They are wider in the middle and smaller on the ends. Radius/barrel rollers are perfect for small areas. They have deep fins.

Additional Supplies

Depending on your project, you may need some other items to complete your job-

Mold Release (PVA film or paste wax)

Surface seal (wax to create a tack free surface)

Styrene Monomer (thins gel coat or resin for spraying)

Gel Coats or pigments

Acetone

Fillers (glass bubbles, fumed silica, milled glass fibers etc. to create a putty)

Once you have picked out all of your supplies, you are ready to prep your area and start the layup process. If you have any questions on the process, you can email us at sales@fiberglasswarehouse.com .

A few tech tips:

Do not use polyester or vinyl ester resin on Styrofoam.  The styrene in the polyester or vinyl ester resin will melt it. Epoxy resin should be used.

Resin has a short shelf life.  Try to store the resin in a cool dry place, or refrigerate (do not freeze) it to extend the life of the resin. When using Vinyl Ester resin, be sure to use it quickly after purchasing. Vinyl Ester has a shelf life of 3 months.

One of the most important steps when working with fiberglass is surface preparation. Your surface must be clean and dry. The surface needs to be free of contaminates such as dust, existing paint, grease, oil etc. You can prepare your surface by sanding with a coarse sand paper and power sander. It can be time consuming but well worth it. Clean the surface with acetone to remove dust or grease.

A fiberglass is a form of fiber-reinforced plastic where glass fiber is the reinforced plastic. This is the reason perhaps why fiberglass is also known as glass reinforced plastic or glass fiber reinforced plastic. The glass fiber is usually flattened into a sheet, randomly arranged or woven into a fabric. According to the use of the fiberglass, the glass fibers can be made of different types of glass.

Fiberglass is lightweight, strong and less brittle. The best part of fiberglass is its ability to get molded into various complex shapes. This pretty much explains why fiberglass is widely used in bathtubs, boats, aircraft, roofing, and other applications.

In this article, we’ll talk more about the types of fiberglass, along with their properties and applications. Let’s get started.

Types and forms of fiberglass: 

Depending on the raw materials used and their proportions to make fiberglass, fiberglass can be classified into following major types:

• A-glass: A glass is also called as alkali glass and is resistant to chemicals. Due to the composition of A glass fiber, it is close to window glass. In some parts of the world, it is used to make process equipment.
• C-glass: C-glass offers very good resistance to chemical impact and is also called as chemical glass.
• E-glass: It is also called as electrical glass and is a very good insulator of electricity.
• AE-glass: This is alkali resistant glass.
• S glass: It is also called as structural glass and is known for its mechanical properties.

Fiberglass comes in various forms to suite various applications, the major ones being:

• Fiberglass Tape: Fiberglass tapes are made up of glass fiber yarns and are known for their thermal insulation properties. This form of fiberglass finds wide applications in wrapping vessels, hot pipelines, and the likes.
• Fiberglass Cloth: Fiberglass cloth is smooth and is available in various variants like glass fiber yarns and glass filament yarns. It is widely used as heat shields, in fire curtains and others.
• Fiberglass Rope: Ropes are braided from glass fiber yarns and are used for packing purposes.

Properties of fiberglass

• Mechanical strength: Fiberglass has a specific resistance greater than steel. So, it is used to make high-performance
• Electrical characteristics: Fiberglass is a good electrical insulator even at low thickness.
• Incombustibility: Since fiberglass is a mineral material, it is naturally incombustible. It does not propagate or support a flame. It does not emit smoke or toxic products when exposed to heat.
• Dimensional stability: Fiberglass is not sensitive to variations in temperature and hygrometry. It has a low coefficient of linear expansion.
• Compatibility with organic matrices: Fiberglass can have varying sizes and has the ability to combine with many synthetic resins and certain mineral matrices like cement.
• Non-rotting: Fiberglass does not rot and remains unaffected by the action of rodents and insects.
• Thermal conductivity: Fiberglass has low thermal conductivity making it highly useful in the building industry.
• Dielectric permeability: This property of fiberglass makes it suitable for electromagnetic windows.

Applications of Fiberglass in various Industries

Materials with high-temperature insulation provide an effective thermal barrier for industrial gaskets. Since fiberglass is durable, safe and offers high thermal insulation, fiberglass is one of the widely preferred materials in industrial gaskets. They not only provide a better insulation but also help in protecting the machinery, conserving the energy and ensure the safety of the professional workforce. This is the reason perhaps why fiberglass is widely used in industries given below:

• Beverage industry: Fiberglass grating is used in many areas like bottling lines and in brew houses.
• Car washes: Recently, fiberglass grating is greatly used for rust resistance and to give a contrast color to areas that previously looked forbidden. It brightens the inside of the carwash tunnel making the car look cleaner than it was.
• Chemical industry: In this industry, the fiberglass grating is used for anti-slip safety feature of the embedded grit surface and the chemically resistant feature of different resin compounds. The chemicals being used are matched with the resins.
• Cooling towers: Since cooling towers are always wet, they have to be protected from rust, corrosion, and other safety issues. Due to the excellent properties of fiberglass, it is used in these towers as screening to keep people and animals away from the danger zones.
• Docks and marinas: The docks get corroded, rusted and damaged by the salty sea water. So, fiberglass is used here for protection.
• Food processing: In the chicken and beef processing plants, fiberglass grating is used for slip resistance and for holding up to blood which is corrosive. Most of the areas of food processing also use fiberglass as other grating materials are not suitable.
• Fountains and aquariums: All sizes of fountains and aquariums use fiberglass to support rocks to help in circulation and filtering from under the rocks. In large public fountains, fiberglass grating is used to protect spray headers and lights from getting damaged. This also keeps people from drowning in the fountains.
• Manufacturing: The embedded grit surface of fiberglass grating ensures slip resistance in the areas that are wet or in places where hydraulic fluids or oils are present.
• Metals and mining: Fiberglass grating is used in electronic refining areas prone to chemical corrosion. Other grating materials cannot be used here.
• Power generation: Many areas of the power generation industry like tank farms, scrubbers, and others use fiberglass. The reason for this is the non-conductive property of fiberglass.
• Plating plants: This application uses fiberglass grating due to the anti-slip property of the surface.
• Pulp and paper industry: The property of fiberglass which makes it chemical corrosion resistant is useful in pulp and bleach mills. Recently, fiberglass is used in many areas due to its corrosion resistance and anti-slip properties.
• Automotive industry: Fiberglass is extensively used in automobile industry. Almost every car has fiberglass components and body kits.
• Aerospace & Defense: Fiberglass is used to manufacture parts for both military and civilian aerospace industry including test equipment, ducting, enclosures, and others.

Learn more about Phelps' Fiberglass portfolio

Fiberglass is an essential component of a range of industries including the likes of waste water treatment plants, HVAC, fireproofing, and oil fields. To know more about fiberglass and their applications, call Phelps @ 1-800-876-SEAL today for better guidance, and check out Phelps fiberglass portfolio.

For more Fiberglass Mesh For Saleinformation, please contact us. We will provide professional answers.