COMPOSITES SA

southern africa IS SU E0 1D EC EM BER2 0 1 7

Accelerated growth in composites in SA

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Composite brakes in 2018 Porche

composite replica Spitfire fighter aircraft for Lesotho

Point Break Composites hosts MVP

flex moulding 1 8

Aerontec lands Sicomin distributor rights

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South Africa, France co-operation on composites hailed

expert

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Editor: Tessa O’Hara tessa@summitpub.co.za Editorial assistant: Heather Peplow heather@summitpub.co.za Financial manager: Lisa Mulligan lisa@summitpub.co.za Design: Bronwen Moys

Summit Publishing cc T: +27 (21) 712 1408 F: 086 519 6089 C: 083 286 7118 Postnet Suite 42, Private Bag X16 Constantia, 7848, Cape Town, South Africa Unit 8, Bergvliet Village Centre, Cnr Hiddingh & Children’s Way roads, Bergvliet, 7945

Composites SA is published three times a year and focuses on this industry in South and southern Africa. We welcome news, articles, technical reports, information in general and photographs about events and development relates to the composites industry.

The views expressed in the magazine are not necessarily those of the publisher.

Copyright: All rights reserved Summit Publishing: CK 9863581/23 Vat reg: 4600187902

ng to If you have somethi us at say, please write to .co.za tessa@summitpub

Composites industry worldwide will see good growth over next 5 years According to Lucintel, a leading global management consulting and market research firm, the global composites market is anticipated to witness good growth with a compound annual growth rate (CAGR) of 3.5% over the next five years. Major drivers of growth for this market are double-digit growth in wind energy and strong growth in the aerospace market. Increasing urban population and high growth in the building and infrastructure development are other major drivers.

Lucintel’s full report can be downloaded at www.reportbuyer.com/ product/3871133/ SA industry growing And the good news is that South Africa’s composites industry is alive, well and growing rapidly. We have an excellent composites manufacturing ability, one which we need to promote throughout the rest of Africa, and ultimately, globally.

One of our industry’s most vehement protagonists, Oliver Dawson, who heads up the Composites Training Academy, believes that local composites companies need to take advantage of the opportunities offered to promote their capabilities.

“Composites are still one of the fastest growing manufacturing sectors globally. The Composites Training Academy is mobilising behind some fantastic initiatives spearheaded by the Department of Science and Technology and the Department of Trade and Industry, in close cooperation with the private sector. If we continue in this vein, the future looks good – difficult, but good! We can’t sit by, and watch the rest of the BRICS countries take advantage of the opportunities this sector offers and be left behind, it would be madness!” he adds.

Meanwhile, the Mandela Bay Composites Cluster (MBCC) is also doing great things to promote the industry. According to CEO, Andy Radford: “Composites can provide new avenues for industrial and economic competitive advantage and we are showcasing this by creating a composites corridor in Port Elizabeth, where composite applications will replace metal and cement where appropriate.”

The MBCC has also mapped the value chain for the production and application of Basalt in composites and is at an advanced stage of securing local and global beneficiators and buyers for the mineral for use in composite materials. Read more about this on page 4.

We also have a host of other great articles for you to enjoy – read on!

Tessa O’Hara, Editor

editor’s note

Publisher: Martin Wells martin@summitpub.co.za

Two lightweight composite decks which make up a new lifting bridge over Rhyl Harbour in North Wales are causing quite a stir in the composites world.

The mast, almost 50m tall, makes the bridge visible from miles around. The mast houses the pulley mechanism and lifting cables. To balance the lift, the decks, engineered by Gurit (UK) and built at AM Structures using many Gurit materials, are lifted simultaneously. Read more on page 10

02 Contents

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The massive 500kg composite ‘floating yacht’ at the new Table Bay Mall in Cape Town

IN THE NEWS 04

Accelerated growth in composites in SA

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Mandela Bay Composites Cluster to organise world class show for 2018 Aerontec and Maricell strike deal on PV Cstructural foam Skilled composite artisans seeking employment

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Point Break Composites hosts MVP flex moulding expert

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Full size composite replica Spitfire fighter aircraft for Lesotho

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Pedestrian bridge presents interesting challenge for Gurit Decolite solution to an architectural challenge

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AMS ballistic protection solution defends against pirate attack

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Composites version of S/V14 boat may become reality

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Resins that resonate with industry Composite brakes in 2018 Porche

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Continuous fibre reinforced backseat

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Seabubbles flying taxi

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Software can speed up composite analysis

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Aerontec lands Sicomin distribution rights

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The S\V14 – designed by naval architects Alex Simonis and Maarten Voogd of Simonis Voogd Design

SA, France co-operation on composites hailed

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The 2018 Porsche 911 GT2 RS features ceramic composite brakes as standard

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COMPOSITES TESTING DIRECTORY, FIRST TIME IN SA Mandela Bay Composites Cluster (MBCC) have mapped SA’s testing capability for composites and compiled a handy table.

By using the table you can quickly see which of the country’s 23 testing entities can test what, and whether the test has SANAS or ISO accreditation. The matrix, showing details for up to 300 specific tests, includes mechanical, chemical, physical, NDT and optical test methods.

If you’re a member of the MBCC, you can download it for free from their website: www.mandelabaycompositescluster.co.za

number of innovative technologies enables researchers to explore processes that can then be scaled-up and commercialised to speed production times, reduce manufacturing costs and provide stronger, more energy efficient blades. A number of innovations are integrated into the design of the blade including impact resistant components, continuous fibre reinforced thermoplastic parts, and exterior shell components produced with less than half the emissions associated with wind blade manufacturing. www.iacmi.org

NASCAR TEAM TO HAVE FLANGE-FIT COMPOSITE OPTION

MBCC TEAM GROWS Two new faces at the Mandela Bay Composites Cluster are Sabelo Sibanda and Thulisile Volwana. Sabelo and Thulisile extend the reach of the Cluster and will be interacting with industry and particularly official cluster participants to assist in facilitating company benefits.

“I believe the Cluster's new staff have the skills set and approach to assist a fragmented composites industry, comprising highly advanced and emerging start-ups make gains through product development, market access and supplier development initiatives that are part of the Cluster's services,” said Cluster CEO, Andy Radford.

IACMI DEVELOPS PROTOTYPE 9M WIND BLADE The Institute for Advanced Composites Manufacturing Innovation (IACMI) has developed an advanced technology prototype wind blade. The team investigated new technologies in a novel 9-metre prototype blade, exploring new materials and processes that could be used in manufacturing. Full-scale wind turbine blades average between 35 and 45 metres. Using the smaller prototype blade to test and validate a

NASCAR XFINITY Series teams will have the option of using a flange-fit composite body at three races later this season as the series moves toward incorporating the body into competition full-time by 2019.

Approximately 90% of those expected to compete in the Richmond XFINITY Series race indicated they would compete with the new composite body. Unlike steel bodies which are welded to the chassis, composite bodies are bolted via bracing onto the chassis and can be removed and replaced much easier. The laminate blend material can be broken, but for the most part it retains its shape when struck.

FIRST 3D-PRINTED SUBMERSIBLE HULL Oak Ridge National Laboratory (ORNL) and the US Navy’s Disruptive Technology Lab, have created what they say is the military’s first 3D-printed submersible hull out of carbon fibre composite.

The Optionally Manned Technology Demonstrator is a prototype vessel that could be used to deploy logistics capabilities and sensors. The company used big area additive manufacturing (BAAM) to make the six carbon fibre composites pieces of the hull in around four weeks, according to the researchers.

While the cost of a traditional hull ranges from US$600,000 to US$800,000 and typically takes 3-5 months to manufacture, using BAAM reportedly reduced hull production costs by 90% and shortened production time to a matter of days.

PORSCHE ROLLING OUT CARBON FIBRE WHEELS Porsche is bringing an all-carbon-fibrereinforced plastic wheel to the market, saying it will be the first global automaker to offer the CFRP wheel when it debuts in early 2018 as an option on the 911 Turbo S Exclusive series. At 8.8kg, the composite wheel is 20% lighter than an equivalent aluminium alloy wheel, but Porsche says the wheels are also 20% stronger.

That strength combined with lighter weight will improve performance with “more spontaneity in both acceleration and braking,” Porsche said. The wheels will be priced at more than 15,000 euros for a complete set.

round up

etcetera …

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Accelerated growth in composites in SA PRODUCTION AND APPLICATION OF BASALT IN COMPOSITES BEING PURSUED THE development and application of composites in manufacturing in South Africa is accelerating up a steep growth curve, according to the country's national composites collective, the Mandela Bay Composites Cluster (MBCC).

Basalt fibre reinforced LFT composites

Created with support from South Africa's Department of Trade and Industry, the Cluster has implemented projects to boost the productivity of local manufacturers and establish value chains to commercialise South Africa's emerging composites resources.

Mandela Bay Composites Cluster MD, Andy Radford, said the Cluster had mapped the value chain for the production and application of Basalt in composites and was at an advanced stage of securing local and global beneficiators and buyers for the mineral for use in composite materials.

JUST BRIEFLY SOFTWARE CAN SPEED UP COMPOSITE ANALYSIS METROLOGY company Hexagon Manufacturing Intelligence has launched a composite inspection system which it says can inspect and analyse lightweight carbon-fibre components more quickly. The system includes HP-C-V3D Apodius Vision Sensor camera-based scanning hardware

designed to fit to a ROMER Absolute Arm with Integrated Scanner and the Apodius Explorer 3D software package. The system can carry out fibre orientation, geometry measurement and three-dimensional model creation and analysis, the company says.

Until now, three-dimensional digitisation has required the sensor to be robot-mounted. www.hexagonmi.com

“The country and particularly the rural areas of the Eastern Cape, has vast dolerite reserves, from which global-standard Basalt can be viably extracted,” Radford said.

“Basalt fibre mined from dolerite in the poorest regions of the Eastern Cape could be an economic game changer for the region. Processed at Mthatha, Butterworth, East London or Coega, basalt product such as reinforced bar can be shipped to Europe through France”, Radford said.

The Cluster is doing the same with a crop grown largely in Kwazulu-Natal called Kenaf,

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BASALT FIBRES Derived from volcanic rock, the beneficial characteristics of basalt fibre include excellent corrosion resistance, high abrasion resistance, and inherent fire resistance. Basalt fibre is known for retaining its performance at cold temperatures and for not being degraded by UV or electromagnetic radiation.

It has uses in marine environments, concrete contact, and underground applications because of its high corrosion resistance.

rather than using energy, resinbased thermoset manufacturing is exothermic – it gives off heat,” Radford added. www.mandelabaycompositescluster.co.za

COMPOSITES CLUSTER TO ORGANISE WORLD-CLASS SHOW FOR 2018 HEARTENING news for the South African composites industry is that the Mandela Bay Composites Cluster (MBCC), with support from government and industry, plan to host a worldclass composites and advanced manufacturing exhibition and conference during the second half of 2018.

Andy Radford, Managing Director of the MBCC says the

event is aimed at providing role-players with market access opportunities, both national and international.

The trade event will be designed around the needs of buyers and suppliers in the advanced manufacturing sector, including composites, 3d printing, CNC, lasers and robotics.

• For marketing and sponsorship opportunities, contact Andy Radford at email: andy@mandelabaycompositescluster, or Andrew Binning at email: andrew@inkanyezi.co.za, or Tel: 041 363 0310.

AERONTEC AND MARICELL STRIKE DEAL ON PVC STRUCTURAL FOAM AERONTEC has been appointed the official distributor for Maricell PVC foams in Southern Africa.

Maricell has been manufacturing rigid PVC foam since the 1970s and has an annual production capacity of over 100,000 cubic metres.

Maricell supplies the Mycell and Lycell PVC brands of expanded rigid foam with 100% closed cells, both of which have

marine approvals.

Mycell is the standard PVC product, while Lycell is manufactured from the upcycled Mycell trimmings which are bonded and heat-cured to produce a laminated foam that boasts improved structural properties.

Both Mycell and Lycell can be thermoformed at 100-120°C, at which temperature the foam can be moulded to any curvature.

This obviates the requirement for sawing kerfs in the foam to make it contourable. The kerfs increase lead time for supply of

the foam, increase the mass of the core and reduce the shear properties.

Aerontec has invested heavily in automated equipment to cut and drill the PVC foam products at their warehouse in Cape Town. This significantly reduces the lead time to supply the customers their required foam thickness and finish.

www.aerontec.co.za www.maricell.it

SKILLED COMPOSITE ARTISANS SEEKING EMPLOYMENT A JOB portal is available on the Mandela Bay Composites Cluster website at. The CV's of skilled artisans, seeking employment, are posted on a regular basis. Go to www. mandelabaycompositescluster. co.za/job-portal/ for more information. Only registered members of the cluster can access the listed CV's. However, it is very simple to register, details are also available on the website.

in the news

South Africa up until now. the fibre of which is used in the “Composites can provide new production of composite avenues for industrial components, and economic including at the competitive Mercedes “COMPOSITES advantage Benz CAN PROVIDE and we are automotive showcasing plant NEW AVENUES this by in East FOR INDUSTRIAL creating a London.

AND ECONOMIC composites Closer corridor in to home, COMPETITIVE Port Elizabeth, Radford ADVANTAGE.” where composite believes that applications will composites replace metal and provide South cement where appropriate,” Africans with solutions he said. to unique challenges and that From man-hole covers, could transform communities. street poles and railings, to “South Africa has a legacy motorised drones, composites based on iron, steel and are the answer to several age-old other metals, yet our global problems and new opportunities. competitiveness in steel is “In Africa, composites can be marginal. Metals are heavy, they manufactured anywhere. You rust and have driven industrial don't even need electricity. In fact and engineering thinking in

in the news

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Point Break Composites hosts MVP flex moulding expert

PHOTOS: TESSA O’HARA & JORDAN WILLETT

A MORE EFFICIENT WAY OF CLOSED MOULDING CAPE Town based Point Break Composites (PBC) welcomed a group of around 40 local composite industry members to a one-day workshop presented by MVP’s resin infusion specialist, Charles Tur from France, earlier this year to showcase the latest in flex moulding systems from MVP (Magnus Venus Products).

The workshop gave attendees an insight into how this transfer of technology would allow them to easily incorporate the flex moulding process into their production.

Matthew Willett, MD of Point Break said that MVP closed moulding systems focus on customers in the composite industry who are looking to go from open moulding parts to a more efficient way of closed moulding.

“When the switch happens, there are many benefits for the customer with reduced emissions, higher quality parts, cleaner facilities, and more efficient work environments,” he explained.

Many customers have been able to successfully move production from open moulding or light RTM, to the flex moulding process in a very short period.

“PBC has been an authorised MVP distributor for around three years now. I have been for training in the USA and continue to stay close to MVP developments. We sell and service their equipment and carry most spares needed for the equipment my customers use,” said Willett.

PBC will also offer training and work closely with customers for MVP resin infusion equipment

MVP’s infusion specialist, Charles Tur, stands by while the infusion process is underway

and processes.

Willett said that the flex moulding process offers the following advantages: • a mix/meter infusion system provides a direct feed to the infusion membrane, eliminating the need to pre-mix resin and the use of consumable tubing and fittings • increased precision through the use of new accessories, including the pneumatic pressure vacuum sensor (PPVS-Infusion) • a new ‘lockable’ reusable membrane in addition to traditional vacuum bag infusion • MVP’s patented seals lead to large resin channels that collapse and disperse the resin in the

Matthew Willett (MD of Point Break) and Charles Tur (MVP) stand by while the silicone membrane is loaded and the IVx3 3 position injection valve fitted

Priming the catalyst and all accessories in place Removing the membrane – the part was infused in about 6 minutes. Once gelled, the membrane is removed to allow the part to further cure. The part can be ready to demould in roughly 1 hour

and very efficiently. PBC with the backing of MVP follow the process all the way with the best service ensuring the best possible results are achieved,” he added.

channel, reducing costs with resin wastage, and leave little visible evidence of the resin channels.

• universal membrane fittings provide a secure and quick connection for the connection valves.

• MVP supply universal fittings that can be used for plastic bag infusion, silicone membrane infusion and light RTM. “The silicone membrane gives a little more leeway than LRTM, and it is much faster than the plastic film. The biggest value is actually the Resin Infusion Machine, which can be used with plastic, silicone or LRTM. MVP boasting rights are the metering and mixing systems that they have, and this is essential for this process. Why leave it to chance of mixing catalyst by hand, and leaving it in a bucket?” said Willett.

“Using the MVP Patriot Innovator with all the MVP accessories as a system to infuse your part gives you the means to reproduce a part, time after time, consistently

Why use the flex moulding process?

Film infusion moulding, using either infusion films or reusable films made with silicon, polyurethane or latex membranes, has slowly gained popularity over traditional closed mould methods. The costs and learning curve involved in mould tooling are much lower with film infusion than the traditional rigid light RTM double mould set alternative.

However, one of the challenges in the film infusion process has been a lack of emphasis on the improvements of feeding resin under the membrane. In the past, it has been normal to pre-mix the resin in a separate container and have the vacuum ‘draw’ the resin into the mould through a number of ports strategically placed in the infusion membrane. This method produces good results, particularly with large parts such as boat hulls and large wind turbine blades. However, there was still a need for a better solution to the continuous renewal of feed pipes, reservoir cleanout, waste of resin after infusion and the labour required for each moulding cycle in setting up the tubing and establishing the vacuum connection security.

In answer to these challenges MVP developed a flex moulding process package that consists of injection systems, accessories and seals designed to optimise infusion. www.mvp.com www.pointbreakcomposites.co.za

December 2017

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Full size composite replica Spitfire fighter aircraft for Lesotho ALL (GRP) AIRCRAFT BODY PARTS USED MATERIALS FROM SCOTT BADER THE Spitfire Heritage Trust has recently completed a major project, successfully building from scratch an exact, full size ‘all fibreglass’ replica of the iconic WWII ‘Battle of Britain’ Supermarine Spitfire Mk VB (Type 359). Designed by Reginald Mitchell and produced from 1938-1948 at Supermarine Aviation where Mitchell was employed as an engineer, the original Spitfire fighter-interceptor was the first ‘all-metal’ stressed-skin aircraft.

All of the glass reinforced plastic (GRP) aircraft body parts manufactured for this replica plane were moulded using laminating resins and structural adhesive materials supplied by the project’s principal sponsor Scott Bader, which donated the majority of the composite materials used to construct the Lesotho replica Spitfire.

This authentic, GRP replica Spitfire has been specially built in the UK for the Kingdom of Lesotho

The bare FRP mouldings, manufactured in early 2015 using Crystic 489PA and Crystic® 2.414PA UPR hand layup laminating resins, supplied by the project’s principal sponsor Scott Bader

in southern Africa by a dedicated team of volunteers from The Spitfire Heritage Trust. The Lesotho replica Spitfire project came about to recognise and pay tribute to the generous ‘Gift of War’ given in June 1940 by the people of Basutoland, with a population of only 400 000 at the time.

The response to the war funds appeal was overwhelming, raising sufficient money from donations to pay for the (then) costs of manufacturing 24 Spitfires, so providing much needed new fighter-aircraft for two full strength Royal Air Force (RAF) Spitfire fighter squadrons.

From this ‘Gift of War’ donation, No. 72 (Basutoland) Squadron was born in 1940 and continues today as an active RAF training squadron, in which trainee pilots now fly the RAF’s advanced trainer the Tucano T1, built under licence by Shorts of Belfast, before going on to fast–jet training.

Replica production team The Lesotho replica Spitfire was manufactured in Victoria, close to St Austell, Cornwall in the south west of England, using factory space, facilities and GRP expertise provided by Paul Ching, MD of Evolution Boats Ltd. Paul Ching is a master mould designer and keen Spitfire enthusiast, who brought invaluable experience to the team having previously built a FRP replica Spitfire IIa for the RAF, which is still on permanent display at RAF High Wycombe (www.raf.mod.uk/ rafhighwycombe/).

Being a volunteer-manned project, it took a little over four years for the small production team to complete the Lesotho Spitfire replica, which had to be completed and supplied this year to tie in with it being the 50th Anniversary of Lesotho’s Independence from Great Britain. Working alongside Ching, and the mainstay of the Spitfire Heritage Trust Lesotho

Work in progress – closing the wings and camouflage painting the fuselage and then the wings prior to applying the decals represented an enormous step forward for the project in 2016. The stressed wing skins, supported by rib and I-beam spar components, were all specified with Crystic 489PA UP backup resin due to its elevated temperature performance and were fully post cured. Crestabond M1-30 structural adhesive was used to join the upper and lower FRP wing sections together, as well as for the internal FRP spars in the tail and fuselage, as well as for bonding in metal inserts where needed

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project production team, was replica manufacturing veteran Patrick J. Mitchell, who has worked on many similar projects, including previously building four other replica Spitfires; while not related to the famous Spitfire designer R.J Mitchell, with whom he shares the same surname, Pat (P.J. Mitchell) feels connected ‘in spirit’, given his passion for the aircraft.

The team started from scratch, with the key first stage of the project being to fabricate the individual patterns and plugs. New moulds were produced for each of the GRP parts required to produce the replica propeller, and the monocoque composite sections which make up the fuselage, wings and tail sections; exact dimensions were achieved at this critical mould making stage by copying off an existing original aircraft. Once all the moulds had been produced and checked, the next stage of the project was to start laminating the FRP parts, section by section.

FRP technical challenges For this static, display replica aircraft, using hand lay-up glass fibre - UPR resin based laminate systems were

technically sufficient for moulding the GRP parts. However, there were still a number of technical performance-in-use considerations to ensure the correct choice of laminate system for specific sections of the aircraft to ensure that key areas would have the necessary mechanical and physical properties needed to cope with being exposed long term to the elements.

Annual climatic conditions in Maseru, the capital of Lesotho where the Spitfire is destined as a permanent outdoor display show piece, typically have seasonal wet and very dry conditions, high winds, extensive periods of intense sunlight and a range of extremes in the ambient temperaWXUH IURP DV ORZ DV Ăœ& DW QLJKW LQ winter up to an average daytime of Ăœ& LQ KLJK VXPPHU ZLWK PD[LPXP temperatures sometimes exceeding Ăœ& 7R FRSH ZLWK WKHVH H[WUHPH outdoor conditions, after taking advice from Scott Bader’s technical support WHDP WZR GLIIHUHQW &U\VWLF SRO\HVWHU back-up resin grades were specified.

For the wings, given the dark paint colours used to camouflage the upper sides along with prolonged periods in direct sunlight the upper surface tem-

perature of the wings was expected to UHJXODUO\ H[FHHG Ăœ& LQ KLJK VXPPHU In these sorts of high ambient temperatures, to ensure that the wing sections maintained stiffness, did not warp or twist, and could support their RZQ ZHLJKW &U\VWLF 3$ LVRSKWKDOLF unsaturated polyester (UP) resin was specified due to its elevated temperature performance, providing excellent VWUHQJWK UHWHQWLRQ XS WR Ăœ& ,Q addition to the upper and lower GRP wing sections and inner cross stays, the inner ‘I’ beam shaped GRP main spars (one for each wing) which run the length of the wing and fit into a rectangular ‘carry-through’ tube through the lower fuselage section in front of the cockpit, were also laminated using glass UHLQIRUFHG &U\VWLF 3$ UHVLQ RQ WKH primary structural bulkhead immediately after the engine nose section. &U\VWLF 3$ LV DFWXDOO\ D /OR\GÂśV approved marine resin grade, with proven long-term performance in composite boatbuilding for both deck and hull applications. According to published Scott Bader technical data, performance values for fully cured laminate test SLHFHV PDGH XVLQJ &U\VWLF 3$ EDFN XS UHVLQ ZLWK IRXU OD\HUV RI J VTP 3% &60 JODVV FRQWHQW LQFOXGH tensile strength figures of 128 MPa, ZLWK D IOH[XUDO PRGXOXV RI 03D and flexural strength of 212 MPa. For the main fuselage sections and WKH WDLO &U\VWLF 3$ D ORZ VW\UHQH low exotherm, rapid hardening orthophthalic resin (also a Lloyd’s approved marine grade resin) was recommended, being an easy to use, high productivity hand lay-up laminating resin • Aerontec also supplied composite materials for the Spitfire build www.scottbader.com www.aerontec.co.za

in the news

The finished FRP composite replica Supermarine Spitfire Mk VB (Type 359) aircraft built by the Spitfire Heritage Trust. The Spitfire ‘Bahlabani’ (which in Sesotho, means ‘Warrior’) was ready for its first public display in the UK on Battle of Britain Day, 15 September 2016

December 2017

Pedestrian bridge presents FRP DECKS RESULT IN CONSIDERABLE SAVINGS COMPARED WITH A STEEL STRUCTURE THE new lifting bridge over Rhyl Harbour in North Wales, serves as an additional crossing for pedestrians and cyclists. Spanning the River Clwyd from Rhyl’s West Parade to a newly created public area on the Kinmel Bay side of the river, the elegantly opening lightweight bridge named ‘Pont y Ddraig’ has become an iconic landmark attracting visitors. Hundreds watched the two lightweight composite decks – or

dragon wings – being lifted into place earlier this year.

In response to a tender call from Denbighshire County Council, Ramboll and Dawnus developed a design proposal consisting of two mirroring, 30m-long decks, which are hinged on a central caisson and lifted by cables running up to a central mast.

At almost 50m tall, the mast is stayed by a rigging similar to a sail boat and makes the bridge and the

harbour visible from miles around.

The mast houses the pulley mechanism and lifting cables. To balance the lift, the decks, engineered by Gurit (UK) and built at AM Structures using many Gurit materials, are lifted simultaneously.

The use of advanced moulded fibre reinforced plastic (FRP) for the bridge decks was an integral part of the design concept to save as much weight as possible to make lifting

Solution to an architectural challenge!

EXTREMELY LOW-WEIGHT, HIGH STIFFNESS STRUCTURE WITH DECOLITE™ FRASCADA Projects, a specialist manufacturer of composite architectural cladding panels using unique and innovative processes, recently completed a massive ‘floating yacht’ light fitting for the new Table Bay Mall in Cape Town using a unique product range called Decolite™.

Decolite™ was introduced in 2002 by the company and has evolved into an industry standard for high quality lightweight decorative finishing products.

The original spec was to construct the light fitting/mo-

bile from steel and timber which would have weighed in at a mammoth 6 tons! However, this proved to be far too heavy for the support. Frascada Projects, together with AMT Composites, investigated how this structure could be dramatically reduced in weight, whilst maintaining the excellent architectural appeal.

Derek Frasca from Decolite™ opted for a flame retardant EPS core and then laminated thin glass-fibre skins with a specialised FR resin system from AMT Composites. The result was an extremely low-weight,

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AMT is a proud distributor of Gurit products in South Africa

interesting challenge cycles fast and energy efficient. It also would result in considerable savings compared with a steel structure and allowed a sculptured deck shape, which provides a striking, iconic sight when the bridge is opened.

The design proved to be successful, and AM Structures was approached for the fabrication of the decks. Gurit was contracted by AM Structures to carry out the detailed engineering of the bridge decks, which presented some interesting challenges.

The decks are very slender, partially for aesthetic reasons, but also to ensure that the inshore lifeboat would have sufficient headroom to

pass under the lowered bridge at all tide levels. Detailed consideration of the dynamic behaviour of the bridge under pedestrian loading was also required. The bridge was designed with predominantly glass reinforcements with longitudinal stiffness enhanced by local planks of carbon fibre. Gurit made extensive use of finite element analysis to carry out transient dynamic analysis of the bridge using load models from Eurocodes. A number of load conditions were analysed, corresponding to groups of pedestrians walking and running over the bridge, in addition to a crowd loading case. This analysis led to optimisation

high stiffness structure that weighs one-12th of the proposed wood and steel structure at only 500kg - with all lights and fittings.

moulded systems.

The company’s expertise in engineering designs, from fast coupling ceilings to replacement of large concrete elements, places it in a unique position to offer solutions to a wide range of architectural challenges.

More about Decolite™ Decolite™ is produced in Frascada Projects’ manufacturing facility in Chamdor, Johannesburg, for distribution to agencies throughout Africa.

New products ranges are constantly being developed and introduced to the market using various forms of fabrication from CNC cut forms, to soft rubber mould casting, and injection

The massive 500kg ‘floating yacht’ light fitting/ mobile installed at the new Table Bay Mall in Cape Town. A flame retardant EPS core, covered with laminated thin glass-fibre skins with a specialised FR resin system www.amtcomposites.co.za www.decolitemouldings.com

of the laminates for both longitudinal and torsional stiffness of the bridge decks to meet the required comfort criteria.

AM Structures built the decks using Gurit® Corecell™ M, Ampreg 21 resin, and a mixture of glass and carbon reinforcements supplied by Gurit. The build of the decks was already a spectacular sight. But the shipment from the Isle of Wight to the mainland, the transportation to Wales and the lifting of the decks into place, all attracted crowds. www.gurit.com www.amtcomposites.co.za

in the news

The two lightweight composite decks – or dragon wings which form the new lifting bridge over Rhyl Harbour in North Wales

The 35-metre sentinel, the vessels for which AMS designed and manufactured the wheelhouses and masts before delivery to the clients in West Africa

December 2017

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AMS ballistic protection solution defends against pirate attack THE SOLUTION HAS RECEIVED STANAG LEVEL II CERTIFICATION FOR ARMOUR PIERCING PROTECTION THE true value or quality of something can only be judged when it's put to use - the results are what counts!

Advanced Materials Solutions (AMS) in Stikland, Bellville in the Western Cape, recently received unambiguous evidence that their lightweight, composite ballistic protection solution for a series of wheelhouse structures installed on patrol vessels off Nigeria did just what they were supposed to – protect the crew from automatic gun fire!

AMS was commissioned to develop and construct 10 composite ballistic protected wheelhouse structures for Nautic Africa who was supplying patrol vessels to the oil industry off West Africa. The project was completed and the wheelhouses delivered. In September one of the patrol vessels came under heavy attack from pirates.

The patrol vessel suffered multiple hits, but nothing penetrated the

wheelhouse structure.

Johan van Niekerk, MD of AMS said the clients were obviously very happy. “We were also very pleased to learn that our composite solution had been so effective,” he added. AMS will send a team to Nigeria to repair the wheelhouse.

AMS is the only company in the Western Cape who have the intellectual property (IP) to manufacture components using their composite ballistic protection solution. The IP used was developed by Johan and his team at AMS over several months of trial and error, testing and more testing done at Armscor.

Johan explained that the composite ballistic protection solution AMS developed includes several layers of different composites laminated together. Using a vacuum infusion process, the protected areas of the wheelhouse were manufactured using 16mm foam

Ballistic Ceramics in various forms and compositions, Al2O3 in different grades (white to cream), SiC (dark gray) and B4C (black)

on the outside with a 20mm layer inside, providing thermal and sound insulation. The ballistic protection layer – comprising specialised ceramics – is integrated into the inside layers.

For the unprotected sections of the wheelhouse, AMS used 600g/m2 glass fibre with a PVC foam skin of 55kg/m3.

“We’ve recently completed even more testing and have managed to reduce the area density from 48kg/ m2 to just 26kg/m2,” said Johan. “The same protection using steel would weigh about 70kg/m2 if 9mm Armox 500 – a Swedish ballistic armour steel – was used.

The solution is certified to the STANAG Level II protection level.

This means that the composite ballistic protection solution can protect against penetration by gunfire using ammunition up to 7.62x51mm NATO and includes 5.56x45mm SS109 and 7.62x39mm or AK-47 armour piercing

The wheelhouses and prone firing stations near completion on the vessels

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Johan van Niekerk, MD of AMS with recent development with Dyneema for ultra-light weight protection. STANAG level IV – 14.5x114mm AP at 86kg/m2 stand-alone armour.

in the news

This photo shows the impacts of the shots fired on the vessel in Nigeria: the windows, the side of the wheelhouse and the firing positions. The wheelhouse as well as the firing positions were manufactured by AMS, while AMS also supplied the windows (PHOTO: NAUTIC AFRICA)

incendiary rounds.

“Through trial and error, and a lot of testing, over a period of about six months we decided on using a specific ceramic that fractures and absorbs energy, as well as developed a specialised adhesive that can resist the very high temperatures that would be caused by incendiary ammunition.”

It was a significant learning experience for the team at AMS, but one they eagerly took on and successfully achieved. www.advancedmaterials.co.za

ADVANCED ENGINEERING - MATERIALS TECHNOLOGY - REAL WORLD SOLUTIONS Advanced Materials Solutions (Pty) Ltd (021) 824 2240 www.advancedmaterials.co.za ams@advancedmaterials.co.za

Our results speak for themselves - with more than 15 years experience in the design and manufacture of mechanical systems, finite element analysis of and the application of advanced composites technology. Innovation. Precision. Excellence.

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December 2017

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Composites version of S\V14 may become reality A 4-METRE OCEAN SAILING BOAT FOR DISABLED SAILORS Part 1: Over the next couple of issues of Composites SA, we’ll take you through the fascinating process followed to build the S/V14.

WHAT began as a philanthropic gesture to design a low-cost sailing keelboat specifically for disabled sailors, has morphed into a significant challenge and serious passion for Cape Town-based naval architects, Alex Simonis and Maarten Voogd of Simonis Voogd Design.

It all started in October 2015 when Peter Jacops, a specialist inspector for the certification of yachts, posted on Facebook challenging naval architects to design a low-cost sailing boat specifically for disabled people and make it freely available to all.

The result – with 200 to 300 hours of labour, approximately R115 000 for materials (including plywood, steel and a revolutionary seat tilting mechanism), disabled sailors around the world now have the opportunity to own a fullyfledged open sailing boat – the S/V14 – that caters for a wide range of disabilities in a oneman and two-man version. All the information needed to build the boat, including 120 detailed drawings are available free on the internet. The only requirement to download and start building is a pledge that the boat will be used by or with a disabled person.

The first prototype of the S/V14 was built by the Robertson & Caine shipyard in Cape Town, using 11 sheets of plywood and one sheet of steel. Ten further prototypes are going to be tested around the world, including Thailand, New Zealand, USA, Belgium and The Netherlands. The project has received support both far and wide from the industry, including companies like Aerontec, AusThai Marine, Blue Peter Marine, Northern Sails, Nautique TV, Southern Spars, Advanced Material Solutions and many more.

A composites alternative – even more affordable This is a significant milestone in the sailing world; however, Alex explains that the mammoth task of reading through and understanding 120 drawings and other detailed instructions could put off the more feint-hearted. And because of this consideration, Alex and his partner are now in the process of investigating ingenious ways of manufacturing the hull and deck from composites, but still keeping

Russel Vollmer, an active quadriplegic sailor, is helped into the S\V14 by naval architect Alex Simonis and a custom-built mini-gantry built specially for disabled sailors

it affordable.

In the early design stages of the plywood version of the S\V14, Alex investigated the feasibility of a GRP boat made in a female mould so that it could be produced quickly and cost-efficiently. However, it soon became obvious that this option could only be realised using professional boat builders who would have to add their costs, resulting in a boat that was not affordable. Another problem was that manufacturing the moulds needed would also be expensive and add to the overall costs.

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in the news

Disabled sailors around the world now have the opportunity to own a fullyfledged open sailing boat – the S\V14 – designed by naval architects Alex Simonis and Maarten Voogd of Simonis Voogd Design

Alex explains that the actual composite materials needed would cost just half of the plywood version and the labour hours needed to build the entire boat would also be significantly reduced.

However, never one to back off from a challenge, Alex has used his passion and connections to encourage companies like KZNbased NCS Resins to manufacture the moulds needed for free, while the University of the Transkei has offered to do the CNC milling at no charge.

Also, working together with Oliver Dawson at the Composites Training Academy in Cape Town, Alex hopes to be able to convince the Academy to use the laminating of the hull and deck as a training exercise. Trainees will be given the opportunity to work on a ‘real’ project – a 4-metre “miniature Volvo Ocean racing boat”, as Alex describes it.

“I am very impressed with the industry’s response here and abroad,” says Alex.

The detailed drawings and instructions to manufacture the composite version of the boat will also include various moulding

options – hand lamination, vacuum infusion and resin transfer moulding.

“It would be wonderful if individuals could be trained using these different methods, using our boat to work on – a true synergy of outcomes,” says Alex.

“Essentially, the aim is to use the building of the hulls and decks as a training experience, then have these transported to a central point where they will all be quality checked.

From there we can sell the hull and decks as part of the home-build kit for much cheaper than the plywood version,” he explains.

And Alex’s vision doesn’t end there! He would like the project to “go global” so that more disabled sailors around the world are given the chance to buy and build an affordable sailing boat. As more and more disabled sailors around the world start sailing, the sport will once again gain momentum and ultimately be re-instated as an Olympic sport.

Sailing was introduced to the Paralympic Games as a demonstration sport in 1996 and became an official Paralympic

The S\V14 with her mainsail, jib and spinnaker

sport in the 2000 Summer Games. In late January 2015, the International Paralympic Committee dropped Paralympic Sailing from the 2020 Tokyo Paralympic Games as “it did not fulfil the IPC Handbook’s minimum criteria for worldwide reach.”

“I’d like to see 3000 boats built over the next three years and back in the Olympics,” says Alex. “All the tooling work is ready – we just have to begin.” www.sv14.org

December 2017

16

Resins

that resonate with industry

ALSO A LEADER IN THE DEVELOPMENT AND SUPPLY OF INNOVATIVE TEST TECHNOLOGY AFRICA’S largest manufacturer of unsaturated polyester resins, NCS Resins, has been delivering a wide range of products and technical services to the composites industry for the past 110 years.

Operating today as a subsidiary of Ferro South Africa, NCS Resins manufactures and supplies a complete range of high quality resins, ancillary products and accessories, and processing equipment suitable for all fabricating methods.

After-sales support in the form of expert training – from basic to advanced level – is available on request, ensuring that products are put to op-

timal use in a variety of applications.

Testing the boundaries As clients in the composites and allied industries push the boundaries in their quest to develop better products, NCS Resins’ technical services is with them every step of the way.

The company serves the needs of customers in every sector – from construction to fashion, marine to mining, sanitaryware to electrical and automotive to corrosion industries.

A national leader in the development and supply of innovative test technology, NCS Resins delivers reliable applications support, custom-

er-specific products and innovative analytical services in materials characterisation and analysis.

A state-of-the-art analytical laboratory provides specialised analytical services in the fields of reverse engineering and non-destructive analyses.

The mechanical testing lab features universal testing equipment that subjects materials to tension, compression and bending forces, enabling specifiers to select the right composite materials for their particular service conditions. NCS Resins helps customers meet the critical requirements for certification by government and other regulatory bodies.

Composite brakes in 2018 Porsche THE 2018 Porsche 911 GT2 RS features ceramic composite brakes as standard. At the heart of this high-performance sports car is a 700-horsepower twin-turbo flat-six

engine. Weighing in at 1 457kg with a full tank of fuel, the lightweight two-seater accelerates from zero to 100km per hour in 2.7 seconds.

The front fenders, wheel housing

vents, outer shells on the sport design exterior mirrors, air intakes on the rear quarter panels and parts of the rear are made from carbon fibre reinforced plastic (CFRP), as are many of the interior components. The front luggage compartment lid is also made from carbon fibre to make the vehicle as light as possible.

The optional Weissach package reduces weight by nearly 20kg. The package includes numerous elements made of carbon fibre. For instance, the roof and anti-roll bars are made of carbon fibre, as are the end links on both axles. www.porsche.com

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• Polyester resins • Vinyl ester resins • Epoxy for hi tech applications • Gelcoats • Topcoats • Pigment pastes • Reinforcements • Core materials • Catalysts • Additives & solvents • Release agents • Barriers and primers • Adhesives and bonding agents • Master mould and plug making • Mould making (tooling) • Equipment for fibreglass

NCS Resins has manufacturing plants in Pinetown and Isipingo. NCS Resins is the sole global licensee of Reichhold, the world’s largest manufacturer of polyester resins.

Under a technology licence agreement, it manufactures the Norpol, Polylite, Hydrex and Dion brands, as well as producing its own in-house technology, giving customers access to the latest global technologies.

Compliance and consulting When it comes to dealing with hazardous chemicals, a protected working environment is key. NCS Resins offers guidance in Occupational Health and Safety Act and municipal bylaw compliance, health and safety surveys and on-site styrene vapour measurements.

Engineering consultancy services cover plant design – including bulk storage tanks, resin mixing plants & resin articulation systems – as well as troubleshooting.

African footprint Headquartered in Pinetown, KwaZulu-Natal, with manufacturing plants in Pinetown and Isipingo and sales branches in Durban, Cape Town, Jo-

hannesburg, Pretoria, East London and Port Elizabeth, NCS Resins serves the whole of South Africa and maintains a strong presence in East and West Africa and the Indian Ocean islands.

International relationships NCS Resins is the sole global licensee of Reichhold, the world’s largest manufacturer of polyester resins. Under a technology licence agreement, it manufactures the Norpol, Polylite, Hydrex and Dion brands, as well as producing its own in-house technology, giving customers access to the latest global technologies.

Strategic partnerships include leading suppliers of accessory products such as Akzo Nobel, Axel, CTG Tais-

All resins are manufactured according to ISO 9001: 2008 Quality Management Systems, with a number of individual products on the Lloyds register.

han, Farecla, Coosa Composites, Hawkeye/Duratec, Magnum Venus, Owens Corning, ITW Plexus, Plastech, Spheretex, Saertex and Vivian Regina.

Continuous-fibre-reinforced backseat 40% lighter TEPEX dynalite continuous-fibre-reinforced, semi-finished thermoplastic composites are finding new applications in vehicle interiors. One example is the backseat system of an off-road vehicle made by a European automobile manufacturer.

The centre backseat is equipped with a load-through that enables the backrest of each seat to be folded down individually.

This load-through component is produced by shaping and back-injecting Tepex dynalite. The new component is more than 40% lighter than its steel counterpart.

Multiaxial Tepex is a new development from Bond-Laminates, which makes the

composite sheets significantly stronger than before by combining the Tepex fabric with tapes in a technically complex process. The semi-finished product for the load-through has a core consisting of four layers, each 0.25mm thick, which have a fibre orientation of +45 and -45 degrees relative to the component’s longitudinal axis and are arranged symmetrically. They absorb the torsion forces. In contrast, the bending forces are absorbed by the two outer layers, each 0.5mm thick, in which 80% of the continuous fibres are in the direction of force. www.bond-laminates.com

www.ncsresins.com

products & stuff

NCS RESINS PRODUCES

December 2017

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SeaBubbles is committed to providing their water taxi service at the cost of regular taxi journey and plans to operate in 50 cities within the next five years

SeaBubbles flying ECOCONSCIOUS TRANSPORT SOLUTION FOR WORLD’S URBAN WATERWAYS

A VISION to create an ecoconscious transport solution for the world’s urban waterways has come to fruition with the support of Décision SA (Switzerland), a specialist in the development and prototyping of complex composite structures, and Sicomin (France) a leading formulator and supplier of high performance epoxy systems.

The SeaBubbles project is the brainchild of hydrofoiling yachtsman Alain Thébault and champion windsurfer Anders Bringdal.

The SeaBubbles are based on

a futuristic hydrofoil design that glides silently above the water when the craft reaches 12km/h.

A clean charging electric drive system converts solar, wind and water power so the vessel does not generate any CO2 emissions.

Décision SA, part of the Carboman group, working both with SeaBubbles and Sicomin, has so far completed the first of five SeaBubbles water taxi prototypes and these were launched in June 2017 on the River Seine in Paris.

The remaining four prototypes

Aerontec lands Sicomin distributor rights SA WILL BENEFIT FROM RAPID ACCESS TO ADVANCED EPOXY SYSTEMS LEADING South African composite materials supplier, Aerontec, has landed the distribution rights in South Africa for Sicomin high-performance epoxy resin systems.

Graham Blyth, Aerontec MD said that Sicomin’s competitive pricing and excellent lead times were just two of the stand-out features that convinced him to pursue the distribution rights.

Customers in South Africa will benefit from rapid access to Sicomin’s most advanced epoxy systems, including the GreenPoxy® bio range with the highest bio content of anything

similar on the market, flexible, clear, Sicomin’s President. infusion, foaming and fire Established in 1983 as retardant products. a family business, Sicomin will Sicomin’s state-ofinitially target the the-art facility in “SICOMIN’S boat building southern France LEAD TIMES ARE sectors in formulates highly ONE OF THE BEST South Africa. specialised, THAT WE HAVE “We are custom-made ENCOUNTERED, A confident epoxies and HUGE ADVANTAGE Aerontec’s off-the-shelf FOR US." superb sales solutions. Sicomin experience in the products are used in region, combined a variety of applications, with a prompt and reliable including Infusion, RTM, distribution service, will appeal pultrusion, hand lay up and onto many marine manufacturers”, site prepreg techniques. Sicomin comments Philippe Marcovich, also offers high performance

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water taxis! began service in Paris in September.

Working alongside the SeaBubbles team, DĂŠcision analysed the initial design and delivered a production ready tooling and composite manufacturing process.

All of the SeaBubbles composite parts are produced using a vacuum infusion process where the sandwich structure comprising of reinforcement fibres and a natural cork core are infused with Sicomin’s GreenPoxyŽ InfuGreen810 advanced resin system.

InfuGreen 810 contains 30%

carbon content that is derived from plant-based origins. It also has extremely low viscosity at room temperature. Sicomin has formulated the advanced bio product to support manufacturers producing parts for mass production using injection or infusion techniques and the system is available with a variety of hardeners making it suitable for small to very large components. InfuGreen 810 also holds DNV GL certification, a marine industry standard, providing extra assurance of the products

Graham Blyth, Aerontec MD, with Marc Denjean, export manager for Sicomin who visited South Africa earlier this year to meet with potential customers

composite solutions with a range of core materials, fabric reinforcements, fillers and consumables. About 80% of their products are exported.

The company places a strong emphasis on product innovation and to ensure they remain at the forefront of advancements it has a dedicated R&D facility, employing 10% of their staff complement, where it creates unique, custom-made formulations and works on global composite solutions, as well as analyses and enhances emerging technologies. www.aerontec.co.za

www.sicomin.com

quality, efficiency and safety standards.

Sicomin also supplied a range of complimentary materials to provide a package of infusion specific products including glass fibre multiaxial fabrics, PVC foams with bespoke perforation patterns for infusion, release agents and epoxy spray adhesives to securely position dry fabrics in the moulds.

www.sicomin.com www.decision.ch/en

in the news

The SeaBubbles are based on a futuristic hydrofoil design that glides silently above the water when the craft reaches 12km/h

December 2017

20

South Africa, France co-operation on composites hailed SERIOUS INTENT TO EXTRACT ECONOMIC BENEFITS THROUGH DEVELOPMENT OF COMPOSITES IN MANUFACTURING SOUTH Africa's discussion with France on co-operation around the development of composites has been hailed by the burgeoning composites sector in South Africa.

The recent handshake between SA Trade and Industry Minister, Rob Davies, and the newly appointed French ambassador, Christophe Farnaud, will be followed up by a number of Industry-to-Industry and Government-to-Government meetings facilitated by the governments of both countries taking place in both France and South Africa.

The aim of these meetings is to identify opportunities for collaboration and related funding mechanisms to roll out projects that address the needs at individual company level, as well as at broader industry level. Topics for discussion could be trade, business partnerships, localization, export, distribution, skills development, technology, etc.

The Mandela Bay Composites Cluster (MBCC), supported by the DTI, and tasked with representing and advancing the interests of and commercial opportunities in the composites sector in South Africa, said the development showed

manufacturing is viewed as a serious intent from South Africa to sector for future economic growth. extract economic benefits through There are several investment the development of composites in opportunities for French businesses manufacturing. in the South African composite “The fact that local companies sector and advanced have been visiting manufacturing,” said the annual JEC "TOTAL composites TRADE BETWEEN Minister Davies.

Total trade exhibition in SOUTH AFRICA between Paris over the AND FRANCE HAS South Africa past few years GROWN BY AN and France provides the ANNUAL AVERAGE has grown context for by an annual the historical RATE OF 6.2% average rate of composites link FROM 2010 TO 6.2% from 2010 to between the two 2015."

2015. Currently major countries and the South Africa’s exports to foundation for expanding France include vehicles, aircrafts, the level of collaboration,” says machinery and automobiles, while Andy Radford, CEO of the MBCC. imports from France include “What is clear and highly pharmaceuticals, electrical and satisfying is that the DTI is electronic equipment, turbo jets implementing tangible initiatives and vaccines for human use. to boost advanced manufacturing The MBCC and its cluster in the country, which has pockets participants will continue to work of excellence, but on the whole requires development and support,” together with the DTI and the French Embassy to turn the recent he added. agreement into a portfolio of com“Strengthening of relations posite relevant activities, which will between the South African and include attending the JEC composFrench businesses on composites ites trade show in France in 2018. and advanced manufacturing in general will create opportunities for both countries. Advanced www.mandelabaycompositescluster.co.za

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