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Kenway Corporation is a manufacturer of corrosion resistant FRP pipes, flanges, elbows, tanks, hoods, ventilation ducts and certain molded products. Vinylester and polyester resin are used with C-glass reinforcement. Field service of all FRP products is available including vinylester, polyester, epoxy linings and floor topping.

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Manufacturing Process

Products manufactured and supplied by Kenway Corporation incorporate a variety of production processes....

Hand lay-up laminationHand Lay-Up Lamination: Roll stock fiberglass reinforcement is manually placed and laminating resin is applied through pouring, brushing, spraying, or using a paint roller. FRP rollers or squeegees are used to consolidate the laminate, thoroughly wetting the reinforcement and removing entrapped air. Subsequent layers of fiberglass reinforcement are added to build laminate thickness.

Chopper gunChopped Laminating: Continuous strand glass roving and catalyzed resin are fed through a chopper gun, which deposits the resin-saturated "chop". The laminate is then rolled to thoroughly saturate the glass strands and compact the chop. Additional layers of chop laminate are added as required for thickness. Roll stock reinforcements, such as woven roving or knitted fabrics, can be used in conjunction with the chopped laminates.

Filament windingFilament Winding: Continuous strand roving is fed through a resin bath and wound onto a rotating mandrel. The roving feed runs on a trolley that traverses the length of the mandrel. The filament is laid down in a predetermined geometric pattern to provide maximum strength in the directions required. When sufficient layers have been applied, the laminate is cured on the mandrel. The molded part is then stripped from the mandrel. Equipment is available for filament winding on a continuous basis and two axis winding for pressure cylinders. Filament winding can be combined with the chopping process and is known as the hoop chop process.

Vacuum Bagging: In the simplest form of vacuum bagging, a flexible film (PVA, nylon, mylar, or polyethylene) is placed over the wet lay-up, the edges sealed, and a vacuum drawn. A more advanced form of vacuum bagging places a release film over the laminate, followed by a bleeder ply of fiberglass cloth, non-woven nylon, polyester cloth, or other material that absorbs excess resin from the laminate. A breather ply of a non-woven fabric is placed over the bleeder ply, and the vacuum bag is mounted over the entire assembly. Pulling a vacuum from within the bag uses atmospheric pressure to eliminate voids and force excess resin from the laminate. The addition of pressure further results in high fiber concentration and provides better adhesion between layers of sandwich construction. When laying non-contoured sheets of PVC foam or balsa into a female mold, vacuum bagging is the technique of choice to ensure proper secondary bonding of the core to the outer laminate.

Vacuum Resin Transfer Molding (VARTM): Vacuum Resin Transfer Molding (VARTM): Dry reinforcement is positioned in the mold, including all the plies of the laminate and core material if required. A perforated release film is placed over the dry reinforcement. Next a flow media consisting of a coarse mesh or a "crinkle" ply is positioned, and perforated tubing is positioned as a manifold to distribute resin across the laminate. The vacuum bag is then positioned and sealed at the mold perimeter. A tube is connected between the vacuum bag and the resin container. A vacuum is applied to consolidate the laminate and the resin is pulled into the mold.

Pultrusion: Continuous strand fiberglass roving, mat, cloth, or surfacing veil is impregnated in a resin bath, then pulled (pul-trusion) through a steel die, by a powerful tractor mechanism. The steel die consolidates the saturated reinforcement, sets the shape of the stock, and controls the fiber/resin ratio. The die is heated to rapidly cure the resin. Many creels (balls) of roving are positioned on a rack, and a complex series of tensioning devices and roving guides direct the roving into the die.

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