JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 69

THE WORLD’S LEADING COMPOSITES HUB Nominee: Ranger France (France) Moulder, composite part manufacturer, automotive market especially Partnership Network: Menzolit (F) SMC & BMC compound supplier Name of Product or Process: Moulding panels (a line of five different products) for private swimming pools using a compound that includes a high percentage (20-40%) of recycled thermoset resin. The focus is the use of recycled products. Description: Standard thermoset compound moulding process. The originality resides in the formulation using 20-40% of ground-up recycled composite and the type of construction: the modular elements can be used to create different pool shapes. Recycling of a material that is not currently utilized. The current production utilizes factory production scrap. According to the company, the volumes of thermoset materials available will increase as more and more end-of-life vehicles are collected for recycling and with the sorting of demolition and dismantling materials. The project contributes to the waste utilization effort. CONSTRUCTION AND EQUIPMENTS Winner: Ayres Composite Panels (Australia) Designed the panels and the full assembly system Partnership Network: Colbeck & Gunton (Australia) Developed the panel assembly and installation details, Thermal Ceramics (UK). Name of Product or Process: Fire insulation panels along with the full assembly and mounting system. The system was specifically developed for high-speed boats, ferries and other boats. Description: The focus was on the fire-insulation properties, and therefore on panel design: aluminium honeycomb with glass/epoxy skins, with one side covered with a layer of special intumescent insulating felt, itself protected by a sheet of glass fabric to provide an attractive surface finish. In case of fire, the felt expands nine fold to create thermal insulation. The patented panels are certified to International Maritime Organisation High Speed Craft Code requirements. The lightweight panels are mass-produced using a hot-press moulding process. They were developed along with the entire system for assembling them and the mountings required for integrating equipment like sensors, sprinklers, valve systems and extinguishers. Advantages or Salient Features: : The system was developed for the boating industry, although the materials would be suitable for use in public ground transport or the building industry. It is lightweight at 4 kg/m 2, which is only half as heavy as standard solutions. On a standard-sized boat, the savings can be as much as 12 metric tons, with positive effects on boat performance in terms of speed or payload. The fire protection provided (temperature resistance one hour up to 1,000°C) also helps to keep the boat afloat in case of fire and gives more time to evacuate. The panels cost more than standard ones, but their large size facilitates installation and reduces installation time by onethird, which helps to level the price difference. The fastening system allows rapid disassembly for boat maintenance operations. No corrosion compared to “steel cassettes” systems. State of Development: The project took four years to develop, in response to demand from boat builders, always eager to cut down on weight. A review of current “cassette” systems showed that the system could be improved, as long as the panel assembly method was also worked on and a full joining system was provided for. Designing the solution and adapting the fire insulation material involved close collaboration. The concept was fire tested using pieces that were representative of a boat hull (with improved design). Several boats have already been built (see pictures). There is a large potential market that includes freight and military ships. No39 March-April 2008 / JEC Composites Magazine

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JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008

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