Manufacturing and Fabrication

Industrial Plastic Systems is a full line, custom manufacturer of fiber reinforced plastics. IPS manufactures a variety of industrial fiberglass equipment and structures as noted on our home page. IPS uses a multitude of FRP laminate molding techniques to manufacture, fabricate and build our products. It should be noted that our fabrication technicians are highly trained and experienced in all phases of FRP fabrication and manufacturing.

The molding techniques mentioned above are hand lay-up contact molding, spray/chopper gun contact molding, filament winding and vacuum infusion. While IPS does not produce pultruded fiberglass laminates it does fabricate structures using this type of fiberglass product. Below is a a short description of each technique and list of products or product components IPS produces per their molding/fabrication technique.

OPEN MOLDING (MANUAL/HAND LAY-UP):
Description: FRP laminate is laid up and rolled out on a mold surface manually by fabrication technicians such as a duct end cap or flange. Additionally, FRP is manually laid on FRP surfaces to join two adjacent pieces of FRP equipment such as pipe ends.

Products: Pipe and duct corrosion barriers; pipe and duct elbows, pipe and duct flanges, pipe end caps and blind flanges; pipe and duct reducers/transitions; butterfly and blast gate damper blades; vessel conical gusseted nozzles; lugs and brackets; lateral welds; mitered welds; tee welds; butt welds; custom items


OPEN MOLDING (SPRAY/CHOPPER):
Description: FRP spray gun laminate laid up is similar to manual lay-up but its done with a glass chopper/resin spraying gun. Glass and resin are sprayed on a large surface areas where glass and resin will not be wasted in “over spray” due to smallish molds.
Products: Large pipe and duct corrosion barriers; large pipe and duct elbows, tank bottoms and tops (flat, dished or coned) up to 13′-6″ diameter, rectangular ductwork, troughs, and tanks; large pipe and duct reducers/transitions; large butterfly and blast gate damper blades; large custom items


FILAMENT WINDING (up to 13’6″ diameter):
Description: IPS continuously filament winds large cylindrical FRP equipment using a helical angle of wind from 50 deg. to 75 deg. Low helical angles are used to increase axial cylinder strength. Higher helical angles are used to increase cylinder hoop strength. Typically, all IPS manufactured equipment’s helical angle is engineered to optimize equipment strengths in regards to it’s service loads.

Products: Pipe; round duct; tank bodies; stack bodies; large smooth pipe elbows; pipe flanges; pressure vessel bodies; damper bodies; large hoods; large custom items


VACUUM INFUSION MOLDING:

Description: Vacuum infusion is a process in which glass is arranged on a mold and then sealed in a air tight plastic container. The container then has a vacuum introduced to the cavity containing a glass matrix on a mold. This is done using a vacuum pump. The pump is connected to the part with various hoses located at strategic points to induce smooth resin flow throughout the part. When a full vacuum is present, the vacuum pump hose valves are closed and the resin reservoir valves are open. This induces resin flow throughout the glass matrix creating a piece of FRP equipment.

Products: Bulkheads; large tank heads, large hoods; large custom items


PULTRUDED FRP STRUCTURAL SHAPES:

Description: Continuous glass is pulled through a resin bath into a die which creates a engineered part with a constant cross section.

Products: Platforms, hand rails; ladders, pipe support framework; elevated tank legs; duct damper axles