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100% found this document useful (1 vote)

1K views255 pages

Creative FRP Design Guide

Uploaded by

Vincenzo Praturlon

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

The Pultex Pultrusion

Design Manual

of Standard and Custom Fiber Reinforced Polymer Structural Profiles

Imperial Version
Volume 4 Revision 9
TABLE OF CONTENTS

Featuring

Pultex Standard

Structural Profiles

Pultex SuperStructural
Profiles

Nuclear test tower constructed using

Pultex Standard Structural Profiles

Creative Pultrusions, Inc. reserves the right to edit and modify literature, please consult the web site for the
most current version of this document.

The first Pultex Design Manual was published in 1973. The New and Improved Pultex Pultrusion
Design Manual of Standard and Custom Fiber Reinforced Polymer Structural Profiles, 2004
Edition, Volume 4 Revision 9 is a tool for engineers to specify Pultex pultruded standard structural
profiles. Creative Pultrusions, Inc. consistently improves its information to function as a solid
reference for engineers.

No portion of this Design Manual may be reproduced in any form without the prior written consent of
Creative Pultrusions, Inc.
Volume 4 Revision 9
Copyright 2004 by
Creative Pultrusions, Inc.
All Rights Reserved
Flowgrip and Pultex are registered trademarks of Creative Pultrusions, Inc. Creative Pultrusions, Shaping the Future, Superstud!, Superstud!/Nuts!,
Superstik, SUPURTUF, Superplank, Superdeck, Supergrate, Tuf-dek, SuperLoc, SuperWale, SuperCap, SuperRod, Pultrusion Dynamics, DYNAPUL,
Pulshaping, TOPSCAN and TOPDIE are trademarks of Creative Pultrusions, Inc.

The New and Improved Pultex Pultrusion Global Design Manual

Contents

The New and Improved Pultex Pultrusion Design Manual

of Standard and Custom Fiber Reinforced Polymer Structural Profiles,
including Imperial Measurements
Table of Contents
Volume 4 Revision 9
Page Numbers
Chapter 1

Introduction To Pultrusion

Pultex ....................................................................................................................................... 1 2
Pultex Pultrusion Process .................................................................................................. 2 3
Process Advantages................................................................................................................... 3
Raw Materials Used in the Pultrusion Process.................................................................... 3 4
Pultex Resin Systems......................................................................................................... 4 5
Chapter 2

Value Engineering

Design Benefits.......................................................................................................................... 1 2
Applications ............................................................................................................................... 2 3
Cost Analysis for Standard and Custom Profiles....................................................................... 3 4
Raw Material Advantages................................................................................................................ 4
Fabrication Advantages ................................................................................................................... 4
Shipping Advantages ....................................................................................................................... 4
Chapter 3

Physical And Mechanical Properties

Introduction to Design with Pultruded Composites......................................................................... 1

Fiber Properties........................................................................................................................... 1
Resin Properties .......................................................................................................................... 2
Fillers .......................................................................................................................................... 2
Imperial Material Properties Sheets
Material Properties of Pultex Fiber Reinforced Polymer Structural Profiles .................... 3 4
Material Properties of Pultex Fiber Reinforced Polymer Flat Sheets................................ 5 6
Material Properties of Pultex Fiber Reinforced Polymer Rods and Bars ................................ 7
Material Properties of Superstud!/Nuts! Square Nuts and Isoplast* Flanged Hex Nuts Fiber
Reinforced Polymer Fastener Systems ...................................................................................... 8
Material Properties of Pultex SuperStructural Profiles Wide Flange and
I-Sections.................................................................................................................... 9 10
Material Properties of Pultex SuperStructural Profiles Angles ................................. 11 12
Procedures for Obtaining Properties ...................................................................................... 13 14
Safety Factors .......................................................................................................................... 15
Elements of Sections
Imperial Elements of Section .......................................................................................... 16 22
*Trademark of The Dow Chemical Company

The New and Improved Pultex Pultrusion Global Design Manual

Contents

The New and Improved Pultex Pultrusion Design Manual

of Standard and Custom Fiber Reinforced Polymer Structural Profiles,
including Imperial Measurements
Table of Contents
Volume 4 Revision 9
Chapter 4

Page Numbers

Load Tables For Flexural Members And Connections

Beam Deflections............................................................................................................................. 1
Allowable Stresses ........................................................................................................................... 1
Lateral Torsional Buckling ..................................................................................................... 2 4
Stress Calculations for Channels ............................................................................................... 5 9
Local and Global Buckling of FRP Channels................................................................................ 10
Beam Deflection Formula...................................................................................................... 11 13
Examples of Beam Selection of Pultex Profiles used as Flexural Members........................ 14 17
Channel Selection Example ................................................................................................... 17 18
Nomenclature......................................................................................................................... 19 20
Introduction to Pultex SuperStructural Profiles .......................................................................... 21
Comparison of Standard Structural Profiles and Pultex SuperStructural Profiles .............. 21 23
Span/Deflection Ratio Conversion Tables............................................................................. 24 25
Allowable Uniform Load Tables ........................................................................................... 26 92
Connections
Clip Connection Load Tables with Pultex SuperStructural Profiles ............................ 93 95
Bolt Hole Bearing Capacity ............................................................................................ 96 97
Design Example Using the Clip Connection Charts ............................................................... 98
Moment of Capacity of Pultex SuperStructural Angles ...............................................99 100
Designing a Connection with a Coped Flange ........................................................................101
End Notes .............................................................................................................................. 102
Chapter 5

Load Tables For Compression Members

Load Tables For Compression Members ......................................................................................... 1

Introduction...................................................................................................................................... 2
Pultex Column Test Program ................................................................................................... 3 8
Nomenclature................................................................................................................................... 9
Tables for Allowable Compressive Stresses and Loads ................................................................ 10
Imperial Tables for Allowable Compressive Stresses and Loads ................................... 11 45
Biography............................................................................................................................... 47 48
Chapter 6

Environmental Considerations

Temperature ..................................................................................................................................... 1
Weathering....................................................................................................................................... 1
UV Stabilizers.................................................................................................................................. 1
Resistance to Chemicals and Reagents ............................................................................................ 2
Chemical Compatibility Guide ................................................................................................ 3 10

The New and Improved Pultex Pultrusion Global Design Manual

Contents

iii

The New and Improved Pultex Pultrusion Design Manual

of Standard and Custom Fiber Reinforced Polymer Structural Profiles,
including Imperial Measurements
Table of Contents
Volume 4 Revision 9
Page Numbers
Chapter 7

Custom Profile Design

Wall-Section Thickness ................................................................................................................... 1

Radius Design ............................................................................................................................ 1 2
Shrinkage ......................................................................................................................................... 2
Surface Appearance and Performance ....................................................................................... 2 3
Parting Lines .................................................................................................................................... 3
Localized Stiffening......................................................................................................................... 3
Undercuts ......................................................................................................................................... 3
Dimensional Tolerances................................................................................................................... 3
Designer Checklist ..................................................................................................................... 4 5
Notes ................................................................................................................................................ 6
Chapter 8

Quality Assurance And Standard Tolerances

Quality Assurance System ............................................................................................................... 1

Standard Tolerances................................................................................................................... 1 8
Standard Tolerances for Pultruded Shapes Fabricated without CNC or Custom Fixtures........ 9
Standard Tolerances for Pultruded Shapes Fabricated with CNC or Custom Fixtures .......... 10
Chapter 9

Fabrication Techniques

Fabrication Techniques.............................................................................................................. 1 2
Fabrication of Pultex Structural Profiles.................................................................................. 2 3
Adhesives/Bonding .......................................................................................................................... 3
Advantage of Adhesives...................................................................................................... 3 4
Bonded Shear Joint Concepts.............................................................................................. 4 5
Surface Preparations.................................................................................................................. 5
Adhesives Comparison Guide used with Pultex Profiles ........................................................ 6
Comparison of Joining Techniques ........................................................................................... 6
Machining Operations...................................................................................................................... 7
Cutting Procedures .................................................................................................................... 7
Operating Tips..................................................................................................................... 7 8
Drilling ...................................................................................................................................... 8
Grinding .................................................................................................................................... 9
Turning .............................................................................................................................. 9 10
Routing ............................................................................................................................ 10 11
Punching.......................................................................................................................... 11 12
Press Tonnage Requirements .......................................................................................... 12 14
Shear Angle in Punching......................................................................................................... 14
Other Useful Guidelines for Punching .................................................................................... 15
Shearing................................................................................................................................... 16

The New and Improved Pultex Pultrusion Global Design Manual

Contents

The New and Improved Pultex Pultrusion Design Manual

of Standard and Custom Fiber Reinforced Polymer Structural Profiles,
including Imperial Measurements
Table of Contents
Volume 4 Revision 9
Page Numbers
Chapter 9

Fabrication Techniques (contd)

Painting .......................................................................................................................................... 16
Surface Preparation........................................................................................................................ 16
Joining Pultex Structural Profiles......................................................................................... 17 19
Mechanical Fastenings........................................................................................................... 20 23
Notes .............................................................................................................................................. 24
Chapter 10

Writing Specifications For Pultex Structural Profiles

Writing Specifications ............................................................................................................... 1 6

Appendices
Appendix A................................................................................................................................ 1 2
Appendix B ................................................................................................................................ 3 4
Works Cited................................................................................................................................................. 1
Pultex Product Availability List
Imperial Pultex Product Availability List ................................................................................ 1 2

1525
Fire Retardant
Polyesters
1600
Vinyl esters
1625
Fire Retardant
Vinyl esters
2020
Low Profile Modified
Polyester Resin System

Characteristics
Good chemical resistance combined with high
mechanical and electrical properties.

A flame spread rating of 25 or less when tested

per ASTM E-84 plus the attributes of 1500
Series profiles. UL 94 VO rating also available
on request.
Excellent corrosion resistance, as well as,
improved physical properties and elevated
service temperature capabilities.
Same as Series 1600 plus the added bonus of a
25 or less rating per ASTM E84 and low
smoke generation.
Profiles requiring optimum surface finish

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 1

Typical
Applications
Standard Structurals used in
moderately corrosive environments
Crossing gate arms
Dunnage bars
Ladders
Fire retardant standard structurals

High performance standard structurals

High performance standard structurals
for severely corrosive environments
Transportation

Table 1-1 Available Resin Systems (contd)

Pultex
Resin Series
3535
Modified Polyester

Characteristics
Halogen free, low flame and smoke.

Typical
Applications
Mass Transit
Electrical

Reference The Pultex Product Availability List for stocked items.

Other special resin systems are available; please contact the Engineering Department of Creative
Pultrusions, Inc.
Woven and Stitched Fabric
When the mix of required physical properties is not satisfied by conventional mat roving
construction, selected fabrics can be used to meet the end use requirements. Varieties of these
products can be used by themselves or in conjunction with the standard mat roving construction to
obtain the necessary results. The fiberglass fabrics are available in balanced, high longitudinal, high
transverse or 45 multi-ply construction. Since these materials are more costly, the composites
using these reinforcements are more expensive than standard construction pultrusion.
Other Reinforcing Material
Carbon and aramid fibers are also used in the pultrusion process in roving, woven fabric forms, or
in combination with fiberglass. These high modulus fibers add considerable stiffness to the
composite. Care must be taken when designing profiles with carbon and aramid fiber materials
since they are more costly. The composite should be designed for optimum performance.

Surfacing veils enhance the finished

profile and increase corrosion
resistance.

Woven/stitched goods increase transverse

properties of pultruded profiles.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 1

Chapter 2

Value Engineering

Design Benefits
Many advantages exist in using Pultex Profiles, compared to conventional materials, such as steel,
aluminum, wood or other plastics. Analyzing the benefits of Pultex can mean a cost savings to you.
The first step is to compile the total cost of the application, which includes: tooling, raw materials and any
required fabrication. Costs are easily obtained from the Sales and Estimating Department of Creative
Pultrusions.
The second step is to add the cost savings that would be realized by you and the end user, in comparison
to using conventional construction materials. These savings are realized in reduced maintenance cost,
lower installation cost and reduced freight, due to lighter weight properties. Savings in the life cycle of
the product should be considered with the products original cost when making cost comparisons.

Light weight, high strength and electrical insulating properties make FRP profiles ideal for
third-rail coverboard on electrical mass transit systems around the world.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 2

Table 2-1 Features & Benefits of Pultex Profiles

Features
Strength

Lightweight

Description
Unit strength in tension, flexure, and
compression is approximately 20
times that of steel when properties are
combined on the basis of unit density
Density of Pultex is 20% of steel and
60% of aluminum

Corrosion Resistance

Unaffected by a wide range of

corrosive chemicals and environments

Electrical Insulation

Structural strength and rigidity are

provided with dielectric material.

Part Consolidation

Many individual components can be

combined into one large profile.

Dimensional Stability

Stretch-, warp-, and swell-resistant

over a wide range of temperatures and
physical stresses.

Thermal Insulation

Low thermal conductivity rating of

1/250 of aluminum; 1/60 of steel

Benefits
Structural design capabilities
Optional strength in desired directions
Exceptionally high impact strengths
Higher performance at less weight
Reduced shipping costs
Reduced operational energy demands
Reduced labor expense for installations
Easily handled
Assembled and installed with ease
Minimal maintenance costs
Long-term safety
Installation longevity and increased service
life
Outdoor storage capabilities
Lower cost performance ratio
Less need for replacements
Less components for assemblies
Non-magnetic
Additional safety factors
Predictable insulation values
Reduced assembly costs
Reduced inventory requirements
Smooth aerodynamic surfaces
Improved reliability
No permanent set under high stress
Reduced damage to structure assemblies
Easy to repair misused parts
Close tolerances
Reduced insulation thickness requirements
Reduced energy operation requirements
No condensation problems

Applications
Construction/Industrial

Bridges
Bulk head frames
Cable trays
Complete building systems
Cooling tower components
Flooring supports
Grating and supports
Pipe supports
Prefabricated walkways, platforms and handrail systems
Structural supports for process equipment
Trusses and joists
Wind blades
Window frames

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 2

Applications (contd)
Automotive

Automobile springs
Automotive leaf springs and bumpers
Bus components
Bus window latch supports
Dunnage bars
Roll-up doors/ insulated roll-up door panels
Spring bumpers
Tank supports
Truck/trailer wall posts

Consumer

Ladders
Light poles
Mop, broom and brush handles
Pruning poles
Rake handles
Shovel handles

Wastewater

Cell partitions
Scrubber components
Traveling water screens
Water/waste water treatment sludge flights

Electrical

Composite utility poles

Crossarms
Crossing gate arms
Electrical enclosures
Mist eliminators
Mounting braces & backboards
Switch gear components
Third rail coverboards
Walk-in refrigeration door jambs

Marine

Boat dock power posts

Fender pilings
Sheetpiles

Cost Analysis for Standard and Custom Profiles

Careful study of end-use requirements for an application will establish the potential for use of Pultex. If
possible, designs should be drawn and the commercial feasibility determined.
The applied cost of the end uses of a pultruded profile is the sum of the tooling, raw material and
fabrication, plus the additional consideration of transportation, assembly and/or erection/installation cost.
In many cases of mechanical design or prototyping, standard Pultex Profiles can be used. The most
economical alternative for the designer is to evaluate the material, as it may eliminate elements of cost,
such as development time, tooling, and manufacturing for limited quantity runs. Even custom profiles can
be effectively fabricated and/or assembled from available standard profiles, aiding the designer in
determining the feasibility of an idea with minimal cost.
The New and Improved Pultex Pultrusion Global Design Manual

Chapter 2

Tooling Costs
When the feasibility is determined and a custom profile is required, the following factors must be
considered:
1. Products selected from the list of available Pultex standard structural profiles involve no
additional tooling cost and are normally available in any quantity through the distribution
network.
2. Tooling costs for custom pultruded profiles are dependent on the complexity of the profile and
the volume requirements, and are often less than those for traditional materials.
Raw Material Advantages
Pultex 1500 and 1525 Series are produced with high performance grades of polyester resin,
continuous strand mat and roving. The combination provides a quality product that is economically
priced.
When the application requires higher performance ratings for standard or custom profiles, it can be
engineered with specialized reinforcements and resins.
Although premium raw materials also affect the cost of a product by adding complexity and possibly
lowering production rates, the benefits realized can usually justify the additional costs. Highperformance resins or specialized reinforcements can improve usable life or ultimate strength of a
profile.
Fabrication Advantages
Creative Pultrusions provides a full-service Fabrication Network that offers painting, punching, multihead drilling and assembly. If you choose to do your own fabrication, Creative Pultrusions can
provide recommendations on methods and equipment to be used based on extensive experience.
Chapter 9 provides many helpful hints in determining the optimum fabrication techniques.
Shipping Advantages
Shipping of components or sections is one segment of costs sometimes neglected in early design stages.
It particularly applies to glass-reinforced products, such as pultrusions, due to their lower density. In
most shipments, the volume of a shipping container is completely filled before the maximum shipping
weight is reached; therefore, it is important for the designer to consider this fact when designing the
profile. The ability to stack or crate the profile will affect the end-product costs.
Another consideration is length. Since pultrusion is a continuous process, it allows the designer to use
any length product possible. The only limitation is that profiles must be practical shipping lengths.
Standard shipping lengths are usually 45 feet or less to fit the length of most common carriers.
Rods or smaller profiles, which can be coiled, have a theoretically unlimited length, although there are
some process limitations.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 2

Chapter 3

Physical and Mechanical Properties

Surface Veil
Continuous Strand Mat
Continuous Roving
Continuous Strand Mat

Continuous
Roving

Pultrusion Composite Diagram

Continuous Strand Mat

Surface Veil

Introduction To Design With Pultruded Composites

A pultrusion is a composite of several materials and reinforcements. It presents the opportunity to design
product components with properties to meet specific needs. Fiber reinforcements and loadings can be
varied to produce a wide range of structural properties in the end product.
Typical structural items contain 45% to 75% glass by weight. This composite type is widely used in the
pultrusion industry for determining the standard mechanical properties of pultrusion, and can be modified,
if necessary, for special applications. Tensile strengths, for example, can vary from 40 MPa to 1000 MPa,
depending on the glass loading, fiber orientation and resin selection.
Fiber Properties
A variety of continuous and woven reinforcement types is also available to the designer. The four
major types are E-GLASS, S-GLASS, ARAMID and CARBON. The primary type used is E-glass.
Other reinforcements are more costly; and, therefore, used more sparingly in construction.
Table 3-1 Typical Properties of Fibers Used in Pultruded Structural Profiles
Properties are displayed below for virgin fibers, as manufactured.
Property
Density lbs/in3
Tensile Strength (psi)
Tensile Modulus (106 psi)
Elongation to break (%)

E-Glass
.094
500,000
10.5
4.8

S-Glass
.090
665,000
12.6
5.4

Aramid
.053
400,000
9.0
2.3

Carbon
.064
275,000-450,000
33-55
0.6-1.2

Fiber reinforcements are available in a variety of single-strand woven, braided, stitched, and knitted
goods, thus adding to the range of properties of the end composite.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Resin Properties
Determination of resin is controlled by factors such as corrosive environments, temperature exposure,
and flame retardancy.
Polyesters are the primary resins used in pultrusion. A wide range of polyesters is available with
distinct characteristics. The capabilities and needs for these various resins can only be determined by
end-use applications. For the selection of a particular polyester, the designer should consult Creative
Pultrusions.
Fire-retardant polyesters are also available. Fire retardancy can be altered with the proper blending of
different resins. Some of the obtainable results on flammability specifications and tests are presented
further in the Material Properties. For superior fire retardancy, phenolic or other specialty resins may
be used.
Vinyl ester resins are also commonly used in the pultrusion process. They are used to improve the
chemical resistance of the laminate. Because of their chemistry with glass reinforcements, physical
properties of the laminate can be expected to increase up to 15%.
Epoxy resins are typically used with carbon fiber reinforcements in applications in which high
stiffness and strength requirements are critical. They can also be used with E-glass to improve the
physical properties.
Table 3-2 Typical Properties of Resins Used in Pultruded Structural Profiles
Property
Tensile Strength (psi)
% Elongation
Flexural Strength (psi)
Flexural Modulus
(106 psi)
Heat Distortion
Temperature (F)
Short Beam Shear (psi)

Polyester
11,200
4.5
17,800

Vinyl ester
11,800
5
20,000

Epoxy
11,000
6.3
16,700

Test Method
ASTM D638
ASTM D638
ASTM D790

0.43

0.54

0.47

ASTM D790

160
4,500

220
5,500

330
8,000

ASTM D648
ASTM D2344

Fillers
Various fillers are also used in the pultrusion process. Aluminum silicate (kaolin clay) is used for
improved chemical resistance, opacity, good surface finish and improved insulation properties.
Calcium carbonate offers improved surfaces, whiteness, opacity and general lowering of costs.
Alumina trihydrate and antimony trioxide are used for fire retardancy. Alumina trihydrate can also be
used in conjunction with clays for improved insulation properties.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

MATERIAL PROPERTIES
Pultex Fiber Reinforced Polymer Structural Profiles
Rectangular Tubes, Channels, Angles, Square Tubes, Round Tubes
Includes all angles except 4 x 1/4, 4 x 3/8, 6 x 3/8 and 6 x 1/2, which are SuperStructurals.
SuperStructurals

Please consult the Pultex Fiber Reinforced Polymer SuperStructural Profiles Angles Material Properties
1500 Series - Thermoset Polyester Olive Green
1525 Series - Thermoset Polyester Class 1 FR Slate Gray (Dark Gray)
1625 Series - Thermoset Vinyl Ester Class 1 FR Beige
The following data was derived from ASTM coupon and full section testing. The results are average values
based on random sampling and testing of production lots. Composite materials are not homogeneous; and therefore,
the location of the coupon extraction can cause variances in the coupon test results. Creative Pultrusions publishes
an average value of random samples from production lots.
Property
(coupon values)

Mechanical
Tensile Strength (LW)
Tensile Strength (CW)
Tensile Modulus (LW)
Tensile Modulus (CW)
Compressive Strength (LW)
Compressive Strength (CW)
Compressive Modulus (LW)
Compressive Modulus (CW)
Flexural Strength (LW)
Flexural Strength (CW)
Flexural Modulus (LW)
Flexural Modulus (CW)
Modulus of Elasticity
(Channels)
(Square and Rectangular Tubes)
Shear Modulus
Interlaminar Shear (LW)3
Shear Strength By Punch (PF)
Notched Izod Impact (LW)
Notched Izod Impact (CW)
Maximum Bearing Strength (LW)
Maximum Bearing Strength (CW)
Poissons Ratio (LW)
Poissons Ratio (CW)
In-plane Shear (LW)
LW = lengthwise

ASTM Test
D638
D638
D638
D638
D695
D695
D695
D695
D790
D790
D790
D790
Full Section2
Full Section2
Full Section2
Full Section2
D2344
D732
D256
D256
D953
D953
D3039
D3039
Modified D23444
CW = crosswise

Units

1500/1525 Series

1625 Series

psi
33,000
psi
7,500
106 psi
2.5
106 psi
0.8
psi
33,000
psi
16,500
106 psi
3.0
106 psi
1.0
psi
33,000
psi
11,000
106 psi
1.6
106 psi
0.8
106 psi
2.8-3.2
106 psi
2.8
106 psi
3.2
106 psi
0.42
psi
4,500
psi
5,500
ft-lbs/in
28
ft-lbs/in
4
psi
30,000
psi
18,000
in/in
0.35
in/in
0.15
psi
7,000
PF = perpendicular to laminate face

37,500
8,000
3.0
1.0
37,500
20,000
3.0
1.2
37,500
12,500
2.0
1.0
2.8-3.2
2.8
3.2
0.42
4,500
6,000
30
5
30,000
18,000
0.35
0.15
7,000

Additional properties located on page 4

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Property
(coupon values)

ASTM Test

Physical
Barcol Hardness1
Water Absorption
Density
Specific Gravity
Coefficient of Thermal Expansion (LW)
Thermal Conductivity (PF)
Electrical
Arc Resistance (LW)
Dielectric Strength (LW)
Dielectric Strength (PF)
Dielectric Constant (PF)

D2583
D570
D792
D792
D696
C177

D495
D149
D149
D150

Units

1500/1525 Series

1625 Series

10-6in/in/F
BTU-in/ft2/hr/F

45
0.6
0.060-0.070
1.66-1.93
4.4
4

seconds
KV/in
volts/mil
@60Hz

120
40
200
5.2

% Max
lbs/in3

Pultex uses a synthetic surface veil that reduces the Barcol Hardness, but does not reflect lack of cure.
Full section testing based on a 3-point bend with simply supported end conditions (Reference The New and Improved
Pultex Pultrusion Global Design Manual, Appendix B, for details).
3
Tested on a 3:1, span to depth ratio.
4
Follow ASTM D2344, but rotate coupon 90 (cut section of coupon length faces up).
5
In-plane Shear (CW) values for square tubes and rectangular tubes = 2,500 psi; angles = 3,800 psi
2

ASTM Test
Property
Flammability Classification
Tunnel Test
Flammability Extinguishing
NBS Smoke Chamber

UL94
ASTM E-84
ASTM D635
ASTM E662

UNC 13 UNC

11 UNC

Value
1525
(VO)
25 Max
Self extinguishing
650

10 UNC

Value
1625
(VO)
25 Max
Self extinguishing
650

8 UNC

Creative Pultrusions, Inc. believes the information put forth in this property sheet to be as accurate and reliable as of the date of publication.
However, we assume no obligation or liability, which may arise as a result of its use. While Creative Pultrusions, Inc. has no knowledge that the
information put forth infringes any valid patent, it assumes no responsibility with respect thereto and each user must satisfy oneself that ones
intended application process or product infringes no patent.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

MATERIAL PROPERTIES
Pultex Fiber Reinforced Polymer Flat Sheets
1500 Series - Thermoset Polyester Olive Green
1525 Series - Thermoset Polyester Class 1 FR Slate Gray (Dark Gray)
1625 Series - Thermoset Vinyl Ester Class 1 FR Beige
The following data was derived from ASTM coupon and full section testing. The results are average values
based on random sampling and testing of production lots. Composite materials are not homogeneous; and therefore,
the location of the coupon extraction can cause variances in the coupon test results. Creative Pultrusions publishes
an average value of random samples from production lots.
Property
(coupon values)

ASTM Test

Units

1500/1525 Series

1625 Series

psi
psi
106 psi
106 psi
psi
psi
106 psi
106 psi
psi
psi
106 psi
106 psi
ft-lbs/in
ft-lbs/in
psi
psi
in/in
in/in

35,000
15,000
2.0
1.1
20,000
10,000
1.8
1.0
24,000
16,000
1.8
1.0
20
5
32,000
32,000
0.32
0.25

40
0.6
0.060-0.070
1.66-1.93
8.0

120
40
200
5.2

Mechanical
Flexural Strength, Flatwise (LW)
Flexural Strength, Flatwise (CW)
Flexural Modulus, Flatwise (LW)
Flexural Modulus, Flatwise (CW)
Tensile Strength (LW)
Tensile Strength (CW)
Tensile Modulus (LW)
Tensile Modulus (CW)
Compressive Strength, Edgewise (LW)
Compressive Strength, Edgewise (CW)
Compressive Modulus, Edgewise (LW)
Compressive Modulus, Edgewise (CW)
Notched Izod Impact (LW)
Notched Izod Impact (CW)
Bearing Strength (LW)
Bearing Strength (CW)
Poissons Ratio (LW)
Poissons Ratio (CW)

D790
D790
D790
D790
D638
D638
D638
D638
D695
D695
D695
D695
D256
D256
D953
D953
D3039
D3039

Physical
Barcol Hardness1
Water Absorption
Density
Specific Gravity
Coefficient of Thermal Expansion (LW)

D2583
D570
D792
D792
D696

10-6in/in/F

40
0.6
0.060-0.070
1.66-1.93
8.0

D495
D149
D149
D150

seconds
KV/in
volts/mil
@60Hz

120
40
200
5.2

Electrical
Arc Resistance (LW)
Dielectric Strength (LW)
Dielectric Strength (PF)
Dielectric Constant (PF)
1

% Max
lbs/in3

Pultex uses a synthetic surface veil that reduces the Barcol Hardness, but does not reflect lack of cure.

Additional Properties located on page 6

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

MATERIAL PROPERTIES
Pultex Fiber Reinforced Polymer Flat Sheets
(contd)
ASTM Test
Property
Flammability Classification
Tunnel Test
Flammability Extinguishing
NBS Smoke Chamber

UL94
ASTM E-84
ASTM D635
ASTM E662

Value
1525
(VO)
25 Max
Self extinguishing
650

Value
1625
(VO)
25 Max
Self extinguishing
650

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

MATERIAL PROPERTIES
Pultex Fiber Reinforced Polymer Rods And Bars
1500 Series - Thermoset Polyester Olive Green
1525 Series - Thermoset Polyester Class 1 FR Slate Gray (Dark Gray)
1625 Series - Thermoset Vinyl Ester Class 1 FR Beige
The following data was derived from ASTM coupon and full section testing. The results are average values
based on random sampling and testing of production lots. Composite materials are not homogeneous; and therefore,
the location of the coupon extraction can cause variances in the coupon test results. Creative Pultrusions publishes
an average value of random samples from production lots.
Rod and Bar stock contain longitudinal reinforcements only.
Property
(coupon values)

Mechanical
Tensile Strength (LW)
Tensile Modulus (LW)
Compressive Strength (LW)
Flexural Strength (LW)
Flexural Modulus (LW)
Notched Izod Impact (LW)

Physical
Barcol Hardness Units
Water Absorption
Density
Coefficient of Thermal Expansion (LW)
LW - lengthwise

ASTM
Test

Units

Test Results

D638
D638
D695
D790
D790
D256

psi
106 psi
psi
psi
106 psi
ft-lb/in

100,000
6.0
60,000
100,000
6.0
40

D2583
D570
D792
D696

% Max
lbs/in3
-6
10 in/in/F

50
.25
0.073-0.076
3.0

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

MATERIAL PROPERTIES
Superstud!/Nuts! Square Nuts and Isoplast* Flanged Hex Nuts
Fiber Reinforced Polymer Fastener System

Diameter /Threads per Inch

Physical/Mechanical
Properties
Ultimate Thread
Shear Strength 1 2 3

Type of
Nut

ASTM Test

CP Square Nut
CP Molded Hex Nut

Units

3/8"
16 UNC

1/2"
13 UNC

5/8"
11 UNC

3/4"
10 UNC

1"
8 UNC

lbs.
lbs.

811
1,509

1,880
2,088

2,198
2,586

2,692
3,451

6,616
6,522

Flexural Strength 2 3 5

D790

psi

64,405

68,703

65,170

58,119

54,421

Flexural Modulus 2

D790

106 psi

2.4

2.8

2.7

2.8

2.6

Ultimate Double Shear

Strength2 3 4

B565

load lb.

4,142

7,071

7,186

Dielectric Strength

D149

kV/in

Water Absorption 24 hr
Immersion

D570

Coefficient of Thermal
Expansion (LW)

D696

10-6 in/in/F

5.0

ft-lbs
ft-lb

4
4

8
8

16
16

24
24

50
50

0.315
0.315

0.592
0.592

0.813
1.590
1.250
1.950

1.062
1.750
1.625
2.000

Maximum Recommended
Torque Strength Using CP
Square Nut Lubricated with
SAE 10W30 Motor Oil 1

CP Square Nut
CP Molded Hex Nut

Stud Weight
Flammability
Thickness Nut
Width Nut

lb/ft
lb/ft
CP Square Nut
CP Molded Hex Nut
CP Square Nut
CP Molded Hex Nut
CP Square Nut
CP Molded Hex Nut

D635
in
in
in
in

0.076
0.129
0.209
0.076
0.129
0.209
Self-Extinguishing on All
0.437
0.562
0.688
0.750
0.855
1.220
0.688
0.875
1.062
0.745
1.000
1.250

1 Applies to single nut only.

2 Values statistically derived per ASTM D7290 on the actual studs.
3 Appropriate safety factors shall be applied.
4 Single Shear can be estimated by dividing the double shear value in half.
5 Flexural strength governed by compression failure. Therefore, flexural and compression strength are the same in bending.
*Trademark of The Dow Chemical Company
Note: Superstud! is intended to be used only with the CP molded and square nuts. Steel nuts are excluded.

Creative Pultrusions, Inc. believes the information put forth in this property sheet to be as accurate and reliable as of the date of publication.
However, we assume no obligation or liability which may arise as a result of its use. While Creative Pultrusions, Inc. has no knowledge that the
information put forth infringes any valid patent, it assumes no responsibility with respect thereto and each user must satisfy oneself that ones
intended application process or product infringes no patent.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

MATERIAL PROPERTIES
Pultex Fiber Reinforced Polymer SuperStructural Profiles
Wide Flange Sections and I-Sections
Pultex SuperStructural Profiles are identified with
1500 Series - Thermoset Polyester Olive Green
1525 Series - Thermoset Polyester Class 1 FR Slate Gray (Dark Gray) imprinted veil.
1625 Series - Thermoset Vinyl Ester Class 1 FR Beige
The following data was derived from ASTM coupon and full section testing. The results are average values
based on random sampling and testing of production lots. Composite materials are not homogeneous; and therefore,
the location of the coupon extraction can cause variances in the coupon test results. Creative Pultrusions publishes
an average value of random samples from production lots.
Property
(coupon values)
ASTM Test
Units
1500/1525 Series
1625 Series
Full Section
Modulus of Elasticity
Full Section2
106 psi
3.9-4.0
3.9-4.0
2
(1/2" thick profiles)
Full Section
106 psi
3.9
3.9
(1/4" & 3/8" thick profiles)
Full Section2
106 psi
4.0
4.0
Shear Modulus (Modulus of Rigidity)
Full Section2
106 psi
0.50
0.50
2
Flexural Strength
Full Section
psi
33,000
33,000
Flange Section - Mechanical
Tensile Strength (LW)
D638
psi
40,000
46,000
Tensile Modulus (LW)
D638
106 psi
4.16
4.16
Compressive Strength (LW)
D695
psi
45,770
52,500
Compressive Strength (CW)
D695
psi
17,800
20,400
Compressive Modulus (LW)
D695
106 psi
3.85
3.85
Compressive Modulus (CW)
D695
106 psi
1.9
1.9
Flexural Strength (LW)
D790
psi
42,800
49,200
Flexural Modulus (LW)
D790
106 psi
2.0
2.0
5
Interlaminar Shear (LW)
D2344
psi
4,000
4,500
Shear Strength By Punch (PF)
D732
psi
5,500
6,000
Notched Izod Impact (LW)
D256
ft-lbs/in
28
32
Notched Izod Impact (CW)
D256
ft-lbs/in
21
24
Maximum Bearing Strength (LW)
D953
psi
33,000
38,000
Maximum Bearing Strength (CW)3
D953
psi
23,000
26,500
Poissons Ratio (LW)
D3039
in/in
0.35
0.35
Poissons Ratio (CW)
D3039
in/in
0.12
0.12
Web Section - Mechanical
Tensile Strength (LW)
D638
psi
30,300
35,000
Tensile Strength (CW)
D638
psi
10,500
12,000
Tensile Modulus (LW)
D638
106 psi
3.1
3.1
Tensile Modulus (CW)
D638
106 psi
1.4
1.4
Compressive Strength (LW)
D695
psi
37,500
43,125
Compressive Strength (CW)
D695
psi
14,200
16,330

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

MATERIAL PROPERTIES
Pultex Fiber Reinforced Polymer SuperStructural Profiles
Wide Flange Sections and I-Sections
(contd)
Property
(coupon values)
ASTM Test
Web Section - Mechanical
Compressive Modulus (LW)
D695
Compressive Modulus (CW)
D695
Flexural Strength (LW)
D790
Flexural Strength (CW)
D790
Flexural Modulus (LW)
D790
Flexural Modulus (CW)
D790
Interlaminar Shear (LW)5
D2344
Shear Strength By Punch (PF)
D732
Notched Izod Impact (LW)
D256
Notched Izod Impact (CW)
D256
Maximum Bearing Strength (LW)
D953
Maximum Bearing Strength (CW)3
D953
Poissons Ratio (LW)
D3039
Poissons Ratio (CW)
D3039
In-plane Shear (LW)
Modified D23444
Physical
Barcol Hardness1
D2583
Water Absorption
D570
Density
D792
Specific Gravity
D792
Coefficient of Thermal Expansion (LW)
D696
Thermal Conductivity (PF)
C177
Electrical
Arc Resistance (LW)
D495
Dielectric Strength (LW)
D149
Dielectric Strength (PF)
D149
Dielectric Constant (PF)
D150
LW = lengthwise
CW = crosswise

Units

1500/1525
Series

1625 Series

106 psi
106 psi
psi
psi
106 psi
106 psi
psi
psi
ft-lbs/in
ft-lbs/in
psi
psi
in/in
in/in
psi

2.8
1.9
43,320
17,360
1.9
1.75
3,400
5,500
38
19
33,980
30,000
0.35
0.12
7,000

2.8
1.9
49,800
19,900
1.9
1.75
3,900
6,000
43
22
39,000
34,500
0.35
0.12
7,000

33
0.6
0.060-0.070
1.66-1.93
4.4
4

39
0.6
0.060-0.070
1.66-1.93
4.4
4

% Max
lbs/in3
10-6 in/in/F
BTU-in/ft2/hr/F

seconds
120
120
KV/in
40
40
volts/mil
200
200
@60Hz
5.2
5.2
PF = perpendicular to laminate face

Pultex uses a synthetic veil that reduces the Barcol Hardness, but does not reflect lack of cure.
Full section testing is based on a 3-point bend with simply supported end conditions (Reference The New and Improved Pultex Pultrusion
Global Design Manual Appendix for details).
3
Crosswise bearing strength of the Web sections of 1/4" profiles = 20,500 psi.
4
Follow ASTM D2344, but rotate coupon 90 (cut section of coupon length faces up).
5
Tested on a 3:1, span to depth ratio.
2

ASTM Test
Property
Flammability Classification
Tunnel Test
Flammability Extinguishing
NBS Smoke Chamber

UL94
ASTM E-84
ASTM D635
ASTM E662

Value
1525
(VO)
25 Max
Self extinguishing
650

Value
1625
(VO)
25 Max
Self extinguishing
650

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

MATERIAL PROPERTIES
Pultex Fiber Reinforced Polymer SuperStructural Profiles
Angles
SuperStructural Angle sizes are: 4 x 1/4, 4 x 3/8, 6 x 3/8 and 6 x 1/2

1500 Series - Thermoset Polyester Olive Green

1525 Series - Thermoset Polyester Class 1 FR Slate Gray (Dark Gray)
1625 Series - Thermoset Vinyl Ester Class 1 FR Beige

Pultex SuperStructural Profiles are identified with

imprinted veil.

The following data was derived from ASTM coupon and full section testing. The results are average values
based on random sampling and testing of production lots. Composite materials are not homogeneous; and therefore,
the location of the coupon extraction can cause variances in the coupon test results. Creative Pultrusions publishes
an average value of random samples from production lots.
Property
(coupon values)

ASTM Test

Units

Mechanical
Tensile Strength (LW)
D638
Tensile Strength (CW)
D638
Tensile Modulus (LW)
D638
Tensile Modulus (CW)
D638
Compressive Strength (LW)
D695
Compressive Strength (CW)
D695
Compressive Modulus (LW)
D695
Compressive Modulus (CW)
D695
Flexural Strength (LW)
D790
Flexural Strength (CW)
D790
Flexural Modulus (LW)
D790
Flexural Modulus (CW)
D790
Modulus of Elasticity
Full Section2
Shear Modulus
Full Section2
4
Interlaminar Shear (LW)
D2344
Shear Strength By Punch (PF)
D732
Notched Izod Impact (LW)
D256
Notched Izod Impact (CW)
D256
Maximum Bearing Strength (LW)
D953
Maximum Bearing Strength (CW)
D953
Poissons Ratio (LW)
D3039
Poissons Ratio (CW)
D3039
In-Plane Shear (LW)
Modified D23443
In-Plane Shear (LW)
Full Section*
(through heel of angle)
*Note: Based on Full Section Connection Test

psi
psi
6
10 psi
106 psi
psi
psi
106 psi
106 psi
psi
psi
106psi
106psi
106psi
106psi
psi
psi
ft-lbs/in
ft-lbs/in
psi
psi
in/in
in/in
psi
psi

1500/1525 Series
31,000
16,500
3.5
1.0
38,800
25,500
3.0
2.2
43,500
24,000
1.9
1.6
2.8
0.5
3,400
5,500
34
33
33,000
33,000
0.35
0.12
7,000
3,400

1625 Series
35,600
18,900
3.5
1.0
44,500
29,000
3.0
2.2
50,000
27,500
1.9
1.6
2.8
0.5
3,900
6,000
39
38
38,000
38,000
0.35
0.12
7,000
3,900

Additional properties located on page 13

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

MATERIAL PROPERTIES
Pultex Fiber Reinforced Polymer SuperStructural Profiles
Angles
SuperStructural Angle sizes are: 4 x 1/4, 4 x 3/8, 6 x 3/8 and 6 x 1/2
Property
(coupon values)

ASTM Test

Units

1500/1525 Series

1625 Series

Physical
Barcol Hardness1
Water Absorption
Density
Specific Gravity
Coefficient of Thermal Expansion (LW)
Thermal Conductivity (PF)

D2583
D570
D792
D792
D696
C177

D495
D149
D149
D150

Electrical
Arc Resistance (LW)
Dielectric Strength (LW)
Dielectric Strength (PF)
Dielectric Constant (PF)

LW = lengthwise

10-6in/in/F
2
BTU-in/ft /hr/F

45
0.6
0.060-0.070
1.66-1.93
4.4
4

seconds
KV/in
volts/mil
@60Hz

120
40
200
5.2

% Max
lbs/in3

CW = crosswise

PF = perpendicular to laminate face

Pultex uses a synthetic surface veil that reduces the Barcol Hardness, but does not reflect lack of cure.
Full section testing based on a 3-point bend simply supported.
3
Follow ASTM D2344, but rotate coupon 90 (cut section of coupon length faces up).
4
Tested on a 3:1, span to depth ratio.
2

ASTM Test

Value
1525

Value
1625

UL94
ASTM E84
ASTM D635
ASTM E662

(VO)
25 Max
Self extinguishing
650

Property
Flammability Classification
Tunnel Test
Flammability Extinguishing
NBS Smoke Chamber

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Procedures For Obtaining Properties

The typical properties listed in this manual were obtained using random samples selected from the
production line, in tests performed according to ASTM or other standard procedures. These tests are
defined in detail in the referenced standards. A short description is provided herein as an introduction for
the designer.
Flexural Properties (ASTM D790)
Flexural strengths are determined by placing a specimen on supports. A center load is applied until
failure occurs and the load of failure is the ultimate flexural strength.
Compressive Strength (ASTM D695)
The ultimate compressive strength of a material is the force required to rupture a specimen, calculated
to psi values.
Bearing Strength of Plastics (ASTM D953)
This procedure is for determining the ultimate bearing capacity of a specimen. Please note that this
procedure is not being used for 4% elongation. Consult Creative Pultrusions, Inc. for 4% hole
elongation bearing load numbers.
Tensile Strength (ASTM D638)
A coupon is used to determine the modulus of elasticity of the material based on a ratio of stress and
strain.
Izod Impact (ASTM D256)
Impact values are determined by clamping a notched specimen, typically 1-inch, in a testing device,
employing a swinging pendulum to apply the force. The amount of force required to break the
specimen is then calculated in foot pounds per inch of notch in prepared specimens.
Shear Strength by Punch Tool (ASTM D732)
Shear strength values are obtained by mounting a specimen in a punch-type fixture with a 1-inch
diameter punch. The strengths are then determined by force/area.
Barcol Hardness (ASTM D2583)
Barcol hardness is determined by the resistance of a coupon to the indentation of a spring-driven
indentor. Reinforced materials will have a wide range of values; therefore, ten readings are taken and
the average is reported.
Water Absorption (ASTM D570)
Coupons are immersed in water for twenty-four hours or longer. The percentage of weight increase is
then reported as water absorption. This value is important when profiles are to be used in electrical
and corrosive applications.
Specific Gravity (ASTM D792)
Specific gravity is the ratio of the weight of a material to an equal amount of water. Specific gravity is
important in pricing.
The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Arc Resistance (ASTM D495)

Arc resistance is a measure of the ability of the laminate to resist the conduction of a high-voltage,
low-current charge to arc the surface.
Dielectric Strength (ASTM D149)
Dielectric strength is a measure of a profile as an insulator. Two electrodes are placed on either side
of a coupon. If a current passes through the laminate, this constitutes failure. Short-time in oil is the
most commonly used method for pultrusion. Longitudinal values are obtained using 1-inch sections
and the current is applied parallel to the fiber orientation.
Coefficient of Thermal Expansion - CTE (ASTM D696)
CTE value is obtained by measuring the linear expansion of a coupon in temperature ranges of -30 C
to +30 C.
Thermal Conductivity (ASTM C177)
The thermal conductivity test is performed using a guarded hot plate. The thermal transmission values
of the specimen are then recorded.
The above tests are primarily used for the determination of published physical values.
Weathering (ASTM G53)
The weathering test is very useful for profiles used in outdoor exposures. The test is performed by
exposing coupons to artificial weather conditions, simulating the deterioration caused by sunlight and
water, as rain or dew. The extent of this test and the results obtained are determined by the end-use
application.
Table 3-7 Typical Electrical Properties of Pultex Profiles
Pultex 1500 1525 & 1625 Series

Electrical Property
Dielectric Strength, ASTM D149
(tested perpendicular to laminate face)
Dielectric Strength, ASTM D149
(tested lengthwise)
Dielectric Constant, 60 Hz., ASTM D150
(tested perpendicular to laminate face)
Dissipation Factor 60 Hz., ASTM D150
(tested perpendicular to laminate face)
Arc Resistance, ASTM-D495
(indicates reported value-measured in longitudinal
direction)

7.9 kV/mm
1.58 kV/mm
5.2
0.03
120 Seconds

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Safety Factors
Because empirical mathematical analysis of strength characteristics of a composite are difficult to predict,
reliance on experimentally derived properties has been used. Factors of safety have thus been used to
compensate for any uncertainties or variables involved with the composite material.
Current practices have used safety factors from 2 to 10, depending on the application. When using
standard structural profiles, it is common practice to use a safety factor of 3 for shear and 2 for
bending. It is acceptable to use a safety factor of 1 for deflection, as full section bending tests can
verify the E-Modulus of a particular profile.
Elements Of Sections
The Elements of Section Tables contain the properties of profiles which are stocked or produced from
tooling owned by Creative Pultrusions. It is good practice to check on availability before designing from
these lists.
The properties were calculated from nominal dimensions. Actual size will vary within the parameters
allowed by the ASTM D3917 specification.
Some of the section weights are calculated based on density and slight variances may occur.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Elements of Sections

Pultex Equal Leg Angles

Part
Number

ThickDepth(h) Width(b)
in

ness(t)

AE120
AE140

1.00
1.00

in
1.00
1.00

in
0.125
0.250

AE122

1.50

AE130

1.50

AE142

X-X axis or Y-Y axis

Area
2

Weight

S
4

0.22
0.42

lb/ft
0.17
0.31

in
0.021
0.035

in
0.030
0.053

in
0.304
0.286

in
0.182
0.183

0.125

0.35

0.25

0.075

0.071

0.465

0.284

1.50

0.1875

0.51

0.38

0.106

0.101

0.455

0.282

1.50

0.250

0.67

0.51

0.133

0.129

0.445

0.281

AE220

2.00

0.125

0.47

0.35

0.186

0.129

0.626

0.386

AE230

2.00

0.1875

0.70

0.53

0.266

0.187

0.616

0.383

AE240

2.00

0.250

0.92

0.68

0.338

0.241

0.606

0.381

AE320

3.00

0.125

0.72

0.56

0.651

0.297

0.949

0.590

AE330

3.00

0.1875

1.08

0.78

0.947

0.435

0.938

0.587

AE340

3.00

0.250

1.42

1.06

1.223

0.568

0.927

0.584

AE360

3.00

0.375

2.09

1.74

1.721

0.815

0.908

0.578

AE440

4.00

0.250

1.92

1.59

3.002

1.034

1.250

0.787

AE460

4.00

0.375

2.84

2.28

4.290

1.499

1.230

0.780

AE480

4.00

0.500

3.72

3.01

5.451

1.934

1.211

0.774

AE640

6.00

0.250

2.92

2.29

10.491

2.382

1.895

1.194

AE660

6.00

0.375

4.34

3.57

15.230

3.492

1.874

1.185

AE680

6.00

0.500

5.72

4.66

19.654

4.552

1.854

1.177

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Pultex Square Tubes

Part

Width or

Thick-

Number

Depth(h)

ness(t)

X-X axis or Y-Y axis

Area

Weight

S
4

lb/ft

TQ120
TQ140

1.00
1.25

0.125
0.250

0.42
0.93

0.33
0.76

0.05
0.16

0.11
0.26

0.36
0.42

TQ124

1.50

0.125

0.67

0.48

0.21

0.28

0.56

TQ142

1.50

0.250

1.24

0.92

0.33

0.44

0.52

TQ126

1.75

0.125

0.80

0.54

0.35

0.40

0.66

TQ144

1.75

0.250

1.48

1.12

0.57

0.67

0.62

TQ220

2.00

0.125

0.92

0.69

0.53

0.76

TQ230

2.11

0.190

1.44

1.08

0.89

0.84

0.78

TQ240

2.00

0.250

1.73

1.40

0.89

0.72

TQ242

2.50

0.250

2.24

1.79

1.90

1.52

0.92

TQ340

3.00

0.250

2.74

2.16

3.47

2.31

1.13

TQ360

3.5

.375

4.68

3.70

7.71

4.40

1.28

TQ440

4.00

0.250

3.73

2.96

8.75

4.37

1.53

CT045

5.20

0.375

7.00

5.82

26.73

10.28

1.95

TQ660

6.00

0.375

8.48

7.47

44.93

14.98

2.30

Pultex Round Tubes

Part

Outside

Inside

Thick-

Number

Diameter (D)

Diameter (d)

ness(t)

Area
2

0.07

0.11

0.40

0.27

0.06

0.09

0.41

0.98

0.77

0.20

0.27

0.45

.125

0.54

0.42

0.13

0.17

0.49

1.25

.25

0.91

0.64

0.34

0.39

0.54

1.50

.125

0.64

0.50

0.21

0.24

0.58

2.00

1.50

.25

1.37

1.08

0.54

0.63

TU220

2.00

1.75

.125

0.73

0.64

0.33

0.66

TU242

2.50

2.00

.25

1.77

1.32

1.13

0.91

0.80

TU222

2.50

2.25

.125

0.93

0.62

0.66

0.53

0.84

TU340

3.00

2.50

.25

2.16

1.66

2.06

1.37

0.98

TU410

4.02

3.46

0.28

3.24

2.79

5.69

2.84

1.33

1.25

1.00

TU118

1.25

1.00

TU143

1.50

1.00

TU124

1.50

1.25

TU142

1.75

TU126

1.75

TU240

.125

0.44

.0937

0.34

.25

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

0.34

TU122

lb/ft
0.17
0.28

S
4

in
0.23
0.31

0.56
0.75

0.19
0.34

0.03
0.07

.75
1.00

Weight

0.01
0.03

TU005
TU120

in
.0937
.125

X-X axis
in

Pultex Wide Flange Sections

Part

Thick-

X-X axis

Number Depth(h) Width(b) ness(t) Area Weight

IW340
IW440

in
3.00
4.00

in
in2
.25 2.17
.25 2.92

IW640

6.00

IW660

6.00

IW860

8.00

IW880

Y-Y axis

Design
r

in4
in3 in
3.23 2.15 1.22
8.05 4.03 1.66

in4
in3
in
in4
1.11 0.74 0.71 0.047
2.63 1.32 0.95 0.063

in6
2.49
10.52

.25 4.42

3.64 28.58 9.53 2.54

8.91 4.46 1.42 0.094

80.21

6.00

.375 6.57

5.53 40.76 13.59 2.49

13.32 4.44 1.42 0.316

119.84

8.00

.375 8.82

7.26 100.35 25.09 3.37

31.65 7.91 1.90 0.422

506.46

8.00

.50 11.67

9.99 128.81 32.20 3.32

42.09 10.52 1.90 1.000

673.41

IW960

10.00

.375 11.07

9.07 200.45 40.09 4.26

61.94 12.39 2.37 0.527 1548.59

IW980

10.00

.50 14.67

12.03 259.36 51.87 4.20

82.38 16.48 2.37 1.250 2059.52

IW982

12.00

.50 17.67

14.92 457.26 76.21 5.09 142.59 23.77 2.84 1.500 5133.35

lb/ft
1.84
2.44

Pultex I-Sections

Part

Thick-

X-X axis

Number Depth(h) Width(b) ness(t) Area Weight

Y-Y axis
r

IB340
IB440

in
3.00
4.00

in
1.50
2.00

in
.25
.25

in2
1.42
1.92

IB640

6.00

3.00

.25

2.92

2.39 16.17

5.39 2.35

1.11

IB660

6.00

3.00

.375

4.32

3.78 22.93

7.64 2.31

IB860

8.00

4.00

.375

5.82

IB880

8.00

4.00

.50

IB960

10.00

5.00

.375

IB980

10.00

5.00

.50

IB982

12.00

6.00

Design
r

lb/ft
in4
in3
in
in4
in3
in
1.01 1.803 1.202 1.178 0.140 0.186 0.314
1.63 4.530 2.265 1.537 0.329 0.329 0.414

in4
0.031
0.042

in6
0.315
1.316

0.74 0.62

0.063

9.99

1.67

1.11 0.62

0.211

15.00

4.74 56.71 14.18 3.12

3.95

1.97 0.82

0.281

63.12

7.67

6.45 72.48 18.12 3.07

5.27

2.63 0.82

0.667

84.26

7.32

6.06 113.55 22.71 3.94

7.71

3.08 1.03

0.352 192.80

9.67

7.93 146.45 29.29 3.89 10.27

4.11 1.03

0.833 256.84

.50 11.67

9.83 258.76 43.13 4.71 17.76

5.92 1.23

1.000 639.33

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Pultex Rectangular Tubes

Part
Number

Thick-

X-X axis

Depth(h) Width(b) ness(t) Area Weight

0.80
4.40

in
1.165
1.43

TR422

4.74

1.72

0.125

1.57

1.17

TR440

4.00

1.74

0.250

1.74

1.37

TR522

5.08

2.00

0.125

1.77

1.44

TR620

*6.00

2.00

0.125

2.39

TR815

*8.00

1.00

0.125

2.45

TR120
TR420

in
in
0.110 0.366
0.130 1.38

lb/ft
0.264
1.03

S
4

in
0.033
2.89

Y-Y axis
r

in
0.083
1.31

in
0.300
1.45

4.20

1.77

1.64

3.92

1.96

1.50

5.75

2.26

1.80

2.00

9.34

3.11

1.84

14.14

3.54

S
4

in
0.059
0.49

in
0.101
0.68

in
0.402
0.59

0.79

0.91

0.71

0.78

0.90

0.67

1.20

0.82

1.98

1.61

0.82

2.40

0.40

0.81

0.41

*Contains internal webs

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Pultex Unequal Leg Angles

Part
Number

ThickDepth(h)
in

Width(b)
in

X-X axis

ness(t) Area Weight

lb/ft

S
4

Y-Y axis
r

S
4

r
in

AU122

1.5

1.0

0.125

0.29

0.21

0.065

0.066

0.477

0.024

0.032 0.288

AU220

2.0

1.0

0.125

0.35

0.27

0.144

0.114

0.643

0.026

0.033 0.271

AU230

2.0

1.0

0.1875

0.51

0.46

0.206

0.165

0.633

0.035

0.046 0.262

AU240

2.0

1.0

0.25

0.67

0.50

0.261

0.212

0.623

0.043

0.059 0.254

AU242

2.0

1.3

0.25

0.73

0.55

0.285

0.222

0.623

0.085

0.093 0.340

AU222

2.0

1.5

0.125

0.41

0.37

0.168

0.123

0.640

0.083

0.073 0.449

AU244

2.0

1.5

0.25

0.8

0.55

0.305

0.230

0.619

0.146

0.135 0.429

AU224

2.6

1.6

0.125

0.5

0.38

0.334

0.224

0.715

0.121

0.107 0.429

AU320

3.0

1.0

0.125

0.47

0.35

0.365

0.209

0.851

0.112

0.089 0.472

AU322

3.0

1.5

0.125

0.54

0.40

0.440

0.244

0.964

0.028

0.034 0.243

AU330

3.0

1.5

0.1875

0.8

0.60

0.511

0.264

0.977

0.092

0.077 0.415

AU332

3.0

2.0

0.1875

0.89

0.67

0.957

0.505

0.956

0.164

0.142 0.396

AU342

3.0

2.0

0.25

1.17

0.91

0.825

0.408

0.963

0.301

0.197 0.582

AU360

3.0

2.0

0.375

1.71

1.28

1.064

0.532

0.953

0.383

0.255 0.572

AU440

4.0

2.0

0.25

1.42

1.07

1.493

0.762

0.934

0.526

0.360 0.554

AU460

4.0

2.0

0.375

2.09

1.99

2.362

0.922

1.289

0.413

0.263 0.539

AU442

4.0

3.0

0.25

1.67

1.25

3.359

1.333

1.269

0.568

0.373 0.522

AU462

4.0

3.0

0.375

2.46

1.85

2.730

0.989

1.278

1.335

0.590 0.894

AU580

5.0

3.5

0.50

3.97

2.98

3.894

1.434

1.258

1.882

0.848 0.874

AU660

6.0

4.0

0.375

3.59

2.93

9.183

2.240

1.947

0.378

1.088 1.181

AU680

6.0

4.0

0.50

4.72

3.75 13.311

3.280

1.926

4.835

1.580 1.161

AU961

10.0

5.0

0.375

5.46

4.43 58.286

8.941

3.267 10.435

2.594 1.382

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Pultex Channels

Part

Thick-

Number

Depth(h) Width(b)
in

ness(t)

X-X axis
Area

Weight

lb/ft

S
4

Y-Y axis
r

S
4

CH130

1.50

1.00

.1875

0.55

0.49

0.167

0.222 0.551

0.048

0.076 0.297

CH222

2.00

0.56

.125

0.34

0.30

0.164

0.164 0.692

0.007

0.018 0.147

CH230

2.31

1.00

0.16

0.60

0.42

0.433

0.375 0.852

0.051

0.071 0.291

CH224

2.75

1.00

.125

0.56

0.45

0.586

0.426 1.024

0.046

0.061 0.286

CH340

3.00

.875

.25

1.00

0.78

1.018

0.678 1.011

0.050

0.080 0.223

CH330

3.00

1.00

.1875

0.83

0.63

0.945

0.630 1.068

0.062

0.086 0.275

CH342

3.00

1.50

.25

1.31

1.02

1.611

1.074 1.110

0.255

0.248 0.441

CH420

4.00

1.06

.125

0.71

0.58

1.456

0.728 1.431

0.060

0.072 0.290

CH434

4.00

1.75

.1875

1.10

0.87

2.850

1.425 1.607

0.333

0.275 0.550

CH440

4.00

1.13

.25

1.37

1.07

2.628

1.314 1.384

0.118

0.142 0.293

CH540

5.00

1.38

.25

1.75

1.36

5.385

2.154 1.756

0.231

0.223 0.364

CH640

6.00

1.63

.25

2.12

1.65

9.611

3.204 2.129

0.402

0.323 0.435

CH662

6.00

1.69

.375

3.10

2.64

13.427

4.476 2.081

0.621

0.503 0.447

CH740

7.00

2.00

.25

2.57

2.10

16.420

4.692 2.530

0.794

0.517 0.556

CH840

8.00

2.19

.25

2.91

2.30

24.300

6.075 2.890

1.068

0.628 0.606

CH860

8.00

2.19

.375

4.23

3.30

33.751

8.437 2.826

1.470

0.890 0.590

CH922

10.00

2.75

.125

1.88

1.47

25.885

5.177 3.706

1.180

0.534 0.791

CH980

10.00

2.75

0.50

7.01

5.95

86.876

17.375 3.519

3.828

1.855 0.739

CH995

11.50

2.75

0.50

7.78

6.35 124.581

21.666 4.001

4.054

1.930 0.722

CH800

14.00

6.00

0.50

12.17

10.44 349.085

49.869 5.357 40.762

9.273 1.831

CH810

18.00

2.50

0.25

5.56

4.86 204.772

22.752 6.070

1.840

0.865 0.575

CH990

24.00

3.00

.25

7.33

5.66 475.404

39.617 8.054

3.374

1.300 0.679

CH994

24.00

4.00

0.47

14.52

11.21 985.090

82.090 8.237 13.710

4.143 0.972

Pultex Solid Round Rods

Part
Number

X-X axis or Y-Y axis

Diameter(d)

Area
2

in
SO004
SO006

.25
.375

in
0.049
0.110

SO008

.50

0.196

SO010

.625

SO012
SO016
SO020

Weight
lb/ft
0.043
0.096

S
4

<0.001
0.001

0.002
0.005

0.063
0.094

0.173

0.003

0.012

0.125

0.307

0.275

0.008

0.024

0.156

.75

0.442

0.397

0.016

0.041

0.188

1.00

0.785

0.685

0.049

0.098

0.250

1.25

1.227

1.100

0.120

0.192

0.313

SO024

1.50

1.767

1.535

0.249

0.331

0.375

SO032

2.00

3.142

2.560

0.785

0.500

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Pultex Solid Bars

Part
Number

X-X axis
Depth(h)
in

Width(b)

Area
2

Weight

S
4

Y-Y axis
r

S
4

SQ040
SQ011

0.25
1.00

in
0.06
0.99

lb/ft
0.052
0.809

in
< .001
0.080

in
in
0.002 0.07
0.161 0.285

in
< .001
0.080

in
in
0.002 0.07
0.161 0.285

SQ020

1.23

1.51

1.27

0.189

0.306 0.354

0.189

0.306 0.354

SQ024

1.46

2.12

1.84

0.373

0.510 0.419

0.373

0.510 0.419

Pultex Sludge Flights

Part
Number

X-X axis
Depth(h)
in

SF011
SF021

Width(b)

Area
2

in
6.00
8.00

2.50
2.50

in
1.64
1.87

Weight
lb/ft
1.52
1.67

S
4

in
7.81
15.59

2.77
4.11

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 3

Y-Y axis
in
2.18
2.88

S
4

in
1.02
1.11

0.58
0.60

in
0.79
0.77

Chapter 4 Load Tables for Flexural Members and Connections

Beam Deflections - A pultruded beam will be designed for deflection, strength and buckling.
Fiber reinforced composite beams exhibit both flexural and shear deflections. Shear deflections are most
apparent when the spans to depth ratios are less than 20. At short spans, the shear deflections comprise a
significant portion of the actual deflections; therefore, the designer should always account for shear
deflections when designing with composites. Reference Pultex Fiber Reinforced Polymer Structural
Profiles Material Properties Sheets for the appropriate properties of the profiles for which you are
utilizing in your design.
Although coupon testing is a good quality control method, composite materials are not homogeneous and
will exhibit different properties in the web and flange areas. Deflection predictions should be made with
values based on full section testing. Please reference Appendix B per ASTM D198 for full section testing
procedure.
The Allowable Uniform Load Tables were calculated using physical properties that were derived from
full section testing. The Load Tables are based on simply supported end conditions with uniformly
distributed loads. For beam loadings and end conditions not represented in the Allowable Uniform Load
Tables, reference the Beam Deflection Formula and relative design tables.
The following formula was used to predict the deflections in The Allowable Uniform Load Tables:
= 5wL4 + w L2
Where:
384 EI
8AG
A = kAw (in2)
Aw = Shear area of profile (in2) (Ref. Table 2)
k = Shear coefficients (Ref. Table 2)
Ex = Modulus of elasticity (psi)
G = Modulus of rigidity (Shear Modulus) (psi)
I = Moment of inertia (in4)
L = Length of span (in)
= Deflection (in)
w = Load on the beam (lbs./in)

Allowable Stresses
Fiber reinforced composite beams exhibit compressive, flexural, and shear stresses under various load
conditions. The dominating failure mode for long span flexural members is typically local buckling of
the compressive flange, while short spans are dominated by in-plane shear failures.
Safety Factors
The allowable stresses used in The Allowable Uniform Load Tables are based on the ultimate
compressive buckling, flexural and shear strengths with applied safety factors. Specifically, a 2.5
safety factor is used for local buckling and flexural stresses while a 3 safety factor is used for shear. The
following shear and flexure formula were used to predict the Allowable Loads.
V=fv(Aw); where fv = allowable shear stress = 7,000/3 = 2,333psi (Equation P-4)
M= fb(Sx); where fb = allowable flexural stress = 33,000/2.5 = 13,200 psi (Equation P-5)
1
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Local Buckling of the Compression Flange for Wide Flange, I-Sections, Square Tube and
Rectangular Tube Sections
The local compression buckling strength of pultruded wide flange, I-Sections, square tubes and
rectangular tubes can be determined by utilizing the following equations. The local bucking equations
were derived from University research. (Reference Step by Step Design Equations for Fiber-reinforced
Plastic Beams for Transportation Structures)Davalos,Barbero and Qiao

2 tf

12 b

[ q (2

(Ex ) f (E y ) f

)+ p((E ) (
y f

xy f

+ 2(Gxy ) f

)]

(Equation P-3)

Where, x is the critical stress, and p and q are constants that are defined by the coefficient of
restraint () at the junction of the plates:
I/W sections:

2bw (E y ) f
bf
0.004
0.065
; q = 0.025 +
; =
p = 0.3 +
;b =
b f (E y )w
2
0.5
+ 0.4
Box sections:

bw (E y ) f
0.002
0.08
; q = 1.0 +
; =
p = 2.0 +
;b = bf
b f (E y )w
1.3
+ 0.2
Where:
xcr
b
b
bf
bw
Ex
Ey
f
Gxy
p
q
t

= Critical buckling stress in (psi)

= Half the width of the compression flange for I/W sections (in)
= The width of the compression flange for box sections, b=bf (in)
= Width of the compression flange (in)
= Height of the section (in)
= Longitudinal modulus of elasticity (psi)
= Transverse modulus of elasticity (psi)
= Flange
= Modulus of rigidity (Shear Modulus) (psi)
= Constant defined by the coefficient of restraint ()
= Constant defined by the coefficient of restraint ()
= Thickness of the compression flange (in)
= Coefficient of restraint of the compression plates
= Web

2
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Lateral-Torsional Buckling

The Allowable Uniform Loads in the Allowable Uniform Load Tables are derived assuming that adequate
lateral support is provided for the flexural members. The degree of lateral support for structures is
difficult to predict. Figures a. d. represent common bracing scenarios that are considered to provide
adequate lateral support. Note that the bracing intervals must be adequate. In the event that lateral
support is not used, the designer must investigate lateral torsional buckling criteria. The Allowable
Uniform Load Tables contain a column titled Allowable load, laterally unsupported beam global buckling
capacity. Please note that the global buckling load tables include a 2.5x safety factor.
For I-Sections or Wide Flange Sections, the lateral torsional buckling load for various loading conditions
can be determined by using the following equation:
Design Equation for Lateral-Torsional Buckling

M cr = Cb

KLb

E y

Cw I y + E y I y G J
KL
b

(Equation P-1)

Where, for Wide Flange Sections and I-Sections

h2I y

Cw =
4
1
J = (2bt 3f + ht w3 )
3

3
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Cw
J
Cb
Mcr
Lb
Ey
G
K
Iy

= Warping constant (in6)

= Torsion constant (in4)
= Moment variation constant (Ref. Table 4-1)
= Critical moment (in-lbs.)
= Unsupported length between points that have lateral restraint (in)
= Modulus of elasticity for bending about minor axis y-y (psi)
(Use same value as Ex, for simplicity. Values are very similar) Ey Ex
= Shear modulus (psi)
= Effective length coefficient (Ref. Table 4-1)
= Moment of Intertia about the minor axis

Cb is a moment gradient adjuster, that depends on the type of load and end restraint conditions. Values
for Cb can be located in Table 4-1.
Table 4-1
Lateral Buckling Coefficient for Various End Conditions1
Lateral Support
about y-axis

Moment gradient
adjuster (Cb)

Effective length
coefficient (K)

None

1.0

None
Full

1.13
0.97

1.0
0.5

None
Full

1.30
0.86

1.0
0.5

None
Full

1.35
1.07

1.0
0.5

None
Full

1.70
1.04

1.0
0.5

4
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Stress Calculations for Channels

INTRODUCTION
Channel sections are used extensively in composite structures. Due to the fact that channel sections are
rarely, if ever loaded through the shear center (see Figure 1), a firm understanding of the behavior of
loaded channels must be understood. The following design equations were developed based on combined
experimental, analytical and numerical study of five FRP channel sections, which are representative of the
shapes currently used in practice.

The information gained from the five channel sections was used to

derive the local and lateral buckling loads for all of the channel sections produced by CPI.
The five beams studied include the following channels 4x1-1/8x1/4, 6x1-5/8x1/4, 6x111/16x3/8, 8x2-3/16/3/8, 10x2-3/4x1/2. All the five channel sections were analyzed, and the
developed analytical solutions and design formulas were compared with the commercial finite element
modeling using ANSYS (Qiao 2003).

y
t

Shear
center

Centroid
e
x

w
y

Figure 1 FRP channel shapes

Local Buckling of FRP Channels

A variational formulation of Ritz method (Qiao and Zou 2002; Qiao and Zou 2003) was used to establish
an eigenvalue problem, and the flange and web critical local buckling coefficients were determined. In
the local buckling analysis, the panels of FRP channel shapes were simulated as discrete laminated plates
or panels (Figure 2) (Qiao et al. 2001), and the effects of restraint at the flange-web connection are
considered. The flange of pultruded FRP channel sections were modeled as a discrete panel with elastic
restraint at one unloaded edge and free at the other unloaded edge (restrained-free (RF) condition) and
subjected to uniform distributed axial in-plane force along simply supported loaded edges; whereas for
the web, the panel is modeled as a discrete plate with equal elastic restraints at two unloaded edges
(restrained-restrained (RR) condition) (Figure 2b).
5
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

y
Free edge
w

Ncr

Flange

Ncr

Restraint from web

(a) discrete plate of flange
y

Restraint from flange

Ncr

Web

Ncr
x

Restraint from flange

(b) discrete plate of web
Figure 2 Modeling of Local Buckling of FRP Channel Shapes

For the flange panels under compression, the formula of plate local buckling strength, (Nx)cr, with
elastically restrained at one unloaded edge and free at the other (Figure 2a) is given as (Qiao and Zou
2003)

(N x )cr

t3
20(2 + 3 ) E y v xy + 15.49 (2 + ) (6 + 15 + 10 2 ) E x E y
2
2
12b f (6 + 15 + 10 )

+ 40(4 + 6 + 3 2 )G xy

(1)

where, Ex, Ey, Gxy and vxy are the material properties of the channel sections. t and bf are the thickness and
width of the flange; is the coefficient of restraint for flange-web connection and is given as

bw
bf

1
G xy
6 (b )
1 2 f 2
(b ) ( E x E y + E y v xy + 2G xy )
w 2

(2)

where bw is the width of the web panel (Figure 2). The critical aspect ratio ( = a/b, where a is the length
of the panel) of the flange panel is defined as

6
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

(10 2 + 18 + 9) E x 4
= 1.1287m

( 2 + 2) E y

(3)

where m is the number of buckling half waves.

Thus, the critical stress due to the local buckling of the channel can be computed as

cr =

(N x )cr
t

(4)

The explicit formulas for the critical aspect ratio ( = a/b, where a = length and b = width) are also given
in Equation (3). From Equation (3), the desirable locations of restraint supports or bracings can be
obtained. Based on the critical aspect ratios for local buckling, the number and locations of restraint (or
lateral) supports can be recommended and properly designed.
Lateral Buckling of FRP Channels

Figure 3 Experimental testing for lateral buckling of FRP channel shapes

Since two back-to-back channels have similar behavior of I-section, the lateral buckling behavior of a
single channel may be similar to the one of I-section; however, the applied load in the channel section
must be acted at the shear center of the channel section (see Figure 1). For uniform FRP channel section
(i.e., both the web and flanges have the same material properties and thickness), the shear center (e in
Figure 1) can be simply defined as (Boresi and Schmidt 2003):

3b f

3w 2
e=
or =
bw + 6b f
h + 6w

(5)

where bf (= w) and bw (= h) are the widths of flange and web, respectively (Figure 1).
7
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

For long-span FRP channel beams without lateral supports and with relatively large slenderness ratios,
lateral buckling is prone to happen.

Based on Vlasovs theory (Pandey et al. 1995), a simplified

engineering equation for lateral buckling of an I section is adapted for prediction of lateral buckling of
channel section. The lateral buckling of channel sections under a tip load (cantilever beam) through the
shear center is approximated as:

Pcr =

E x I yy JG

(6)

where

= 5.08 1 +

19.3 ( + 13)( + 3)
( + 10) 2

=
JG =

I ww =

JGL2
I ww

2 ( Gxy ) f t f 3b f
3

( E x ) f t f bw 2 b f 3
24

( Gxy ) w t w 3bw

( E x ) f t f 3b f 3
36

( E x ) w t w 3bw 3
144

and Iyy is the moment of inertial of the channel section along the weak axis.
The Pcr or tip load applied through the shear center that causes the channel to lateral buckle can be related
back to a moment applied to the beam. The moment relation can be used to predict the lateral buckling
capacity of channel sections for any given load scenario. The buckling loads derived from Equation (5)
were characterized for all the channel sections offered by CPI.
Master Design Curves
Based on the design formulas and critical loads for local buckling and global (lateral) buckling, a master
design chart for stability of FRP channel beams was developed. The master design curve provides the
relationship between moment capacity and unbraced length.

8
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

The moment capacity can be utilized for channel beams with various end conditions and load scenarios.
The moment charts are based on equation (6):

M cr = Pcr L
where the maximum load Pcr was determined from the cantilever beam loadings.

(7)

The ultimate local

buckling moment is also applied to the charts. The ultimate local buckling moment should always be
evaluated against the ultimate lateral or global buckling capacity. Corresponding to the lateral or global
buckling, the critical stress can be defined as

cr =

M cr h
I xx 2

(8)

where Ixx is the moment of inertial of the channel section along the strong axis (Figure 1), and h is the
height of the channel.
To facilitate the design of stability of FRP channel sections, a step-by-step design guideline is
recommended as follows:
1. Obtain the channel material properties from the Channel Material Property Sheets.
2. Use Eq. (1) to predict the local buckling strength of flange.
3. Predict the global (lateral) buckling of channel sections using Eq. (6).
Obtain the critical stress of the channel using Eq. (4) or (8) based on the mode of buckling (either local or
lateral buckling).
4. Determine the shear capacity based on Equation P-4.
5. Determine the flexural capacity based on Equation P-5.
To simplify the complex equations, reference Local and Global Buckling of FRP Channels Equation
Solutions spreadsheet on the following page. For information on Ultimate Moment Capacity versus
Lateral Restraint, reference graphs in Uniform Load
Table Section.
Please reference Example 4 and 5 of the Examples Section for details on how to use the channel load
tables.

9
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Local and Global Buckling of FRP

Channels
Part# CH340
3 x 7/8 x 1/4
t
bw
bf
H
L

0.25
3
0.875
3
24

21.5180
-465878835
9162437283
3.0444E+10
13,423
5.8011

n1
n2
n3
Ncr

Iyy

JG
Iww
Ixx

0.0495
6.1895
35.9709
12369.7917
198,077
1.0181

Part# CH342
3 x 1-1/2 x 1/4
t
bw
bf
H
L

0.25
3
1.5
3
24

3.3030
-83363686.6
792774089
1130965423
6,469
3.8565

n1
n2
n3
Ncr

Iyy

JG
Iww
Ixx

0.2545
8.0666
9.3516
15625
962,402
1.6106

Part# CH440
4 x 1-1/8 x 1/4
t
bw
bf
H
L

0.25
4
1.12
4
24

n1
n2
n3
Ncr

0.1163
7.4907
12.9081
16250
725,127

5.2454

0.25
5
1.375
5
18

n1
n2
n3
Ncr

11.9570609
-265098279
4028140115
1.0093E+10
5,909
5.07661682

Iyy

JG
Iww
Ixx

0.2392
10.7978971
3.1513253
20182.2917
2,075,020
5.4233

Part# CH640
6 x 1-5/8 x 1/4
t
bw
bf
H
L

0.25
6
1.625
6
24

n1
n2
n3
Ncr

10.7162
-239040145
3469540947
8256156885
4,307
4.9554

Iyy

JG
Iww
Ixx

0.4021
11.1573204
2.82973134
24088.5417
4,903,292
9.6207

Part# CH662
6 x 1-11/16 x 3/8
t
bw
bf
H
L

0.375
6
1.688
6
24

n1
n2
n3
Ncr

14.4455
-317355211
5228598198
1.4334E+10
12,852
5.2957

Iyy

JG
Iww
Ixx

n1
n2
n3
Ncr
cr

0.25
7
2
7
24

16.8153185
-367121688
6464727906
1.9063E+10
2,654
5.48116546

Iyy

JG
Iww
Ixx

0.7944
14.3667987
1.33364906
28645.8333
12,372,070
16.4203

Part# CH840
8 x 2-3/16 x 1/4
t
bw
bf
H
L

0.25
8
2.188
8
24

n1
n2
n3
Ncr

t
bw
bf
H
L

0.375
8
2.188
8
36

11.4811
-255103569
3810621431
9366704901
2,349
5.0312

0.6213
9.1504
5.6677
82406.25
8,374,797
13.4285

Iyy

JG
Iww
Ixx

1.069
16.8423
0.8786
32229.1667
21,129,723
24.3035

n1
n2
n3
Ncr

11.4811
-255103569
3810621431
9366704901
7,927
5.0312

Iyy

JG
Iww
Ixx

1.4698
9.8023
4.4008
108773.438
32,032,657
33.7508

Part# CH955
11-1/2 x 2-3/4 x 1/2
t
bw
bf
H
L

0.5
11.5
2.75
11.5
36

n1
n2
n3
Ncr

5.7704
-135179215
1542776744
2770330492
13,523
4.3403

Iyy

JG
Iww
Ixx

4.0538
11.4456
2.60682271
354166.667
176,076,416
124.5807

68.3375
-2173631139
6.5032E+10
2.8848E+11
10,139
7.1785

Iyy

JG
Iww
Ixx

3.8279
10.0450
4.0350
322916.667
154,934,814
86.876

2.3525
-63402801.2
550224952
694361146
6,695
3.5687

Iyy

JG
Iww
Ixx

13.7
23.2843
0.4068
560821.589
2,205,821,187
985

Part# CH980
10 x 2-3/4 x 1/2
t
bw
bf
H
L

0.5
10
2.75
10
44

n1
n2
n3
Ncr

Part# CH994
24 x 4 x 1/2
t
bw
bf
H
L

0.472
24
4
24
40

10
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

2.6197

Part# CH540
5 x 1-3/8 x 1/4
t
bw
bf
H
L

t
bw
bf
H
L

Part# CH860
8 x 2-3/16 x 3/8

Iyy

JG
Iww
Ixx

13.8450
-304744205
4929454298
1.3242E+10
8,705

Part# CH740
7 x 2 x 1/4

n1
n2
n3
Ncr

Beam Deflection Formula

Uniform load on simple beam

Load

max. (at midpoint)

Total Equiv. Uniform

R is V

=
=

M max. (at midpoint)

wl
5 wl 4
wl 2
+
384 EI
8 G A

wx
l 3 2 lx 2 + x 3
24 EI
wl
2
1

w x
2

wl 2
8
wx
(l x )
2

Note: Reference Table 4-2. Shear Areas and Shear Coefficients for Various Cross Sections A', A'=kAw.

Uniform load on beam fixed at both ends

Total

Load

max. (at midpoint)

Equiv.

Uniform

R is V

M max. (at ends)

(at midpoint)
M

2 wl
3
w l4
wl 2
+
384 EI
8G A
wx2
(l x )2
24 EI l 2
wl
2
1

x
w
2

wl2
12
wl2
24
w
6 lx l 2 6 x 2
12

Point load on simply supported beam

Total

Equiv.
max.

Uniform

(at

M max.

point

(at
M

when

point

when

Load

x <

load)
1

=
=

load)
x <

2P
Pl3
48 EI
Px
48 EI
P
2
Pl
4
Px
2

(3 l

Pl
4GA
2

4 x

11
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Point load on beam with fixed ends

Total

Load

max. (at midpoint)

Equiv.

Uniform

x when

M max. (at center

x <

and

when

Pl3
192 EI

Pl
4 G A

Px 2
48 EI l 2

(3 l

4x)

P
2
Pl
8
P
(4 x l )
8

ends)
x <

Point load on cantilever beam

Total

Equiv. Uniform

max.

M max.

(at

Load

free end

fixed

8P
Pl3
Pl
+
3 EI
G A
P
2l 3 3l 2 x + x 3
6 EI

=
=
=

R is V
end )
M x

P
Pl
Px

Uniform load on cantilever beam

Total

Equiv.

Uniform

max.

Load

M max.

(at free end)

(at fixed

R is V
Vx

=
=

end)

4 wl
wl 2
wl4
+
8 EI
2 GA
w
24 EI
wl
wx

4l 3 x + 3l

wl 2
2
wx2
2

12
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Two Concentrated Loads Equally Spaced on

a Simply Supported Beam
Total

Equiv. Uniform

max.

(at

Load
center

x (when

8 Pa
l
Pa l 2
a2
Pa

EI 8
6
G A
Px
3 la 3 a 2 x 2
6 EI

x < a)

x > a and < ( l - a) )

Pa
6 EI

R is V
M max. (between loads)
M x (when x < a )

=
=
=

P
Pa
Px

x (when

(3 l x 3 x

)
)

Table 4-2

Shear Areas and Shear Coefficients for Various Cross Sections

for calculating A',
Cross Section

Type

Shear Area

Rectangular
Section

Aw= bd

I or W-Section

A' = kAw
Type

Shear Area

5/6

Channel
Section

Aw= 2bt

5/6

Aw= 2bt

5/6

Channel
Section

Aw= ht

I or W-Section

Aw= th

Solid Round

Aw=

8/9

Square Tube

Aw= 2th

Angle Section

Aw= th

Rectangular
Tube

Aw= 2tb

5/6

Circular Tube

Aw= 2Rt

= Half the width of the compression flange for I/W sections (in)
= The width of the compression flange for box sections, b=bf (in)
= width of the compression flange (in)
= Height of the section (in)
= Longitudinal modulus of elasticity (psi)
= Transverse modulus of elasticity (psi)

16
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

)]

f
Gxy
p
q
t

xcr

= Flange
= Modulus of rigidity (Shear Modulus) (psi)
= Constant defined by the coefficient of restraint ()
= Constant defined by the coefficient of restraint ()
= Thickness of the compression flange (in)
= Coefficient of restraint of the compression plates
= 22,647 psi

Step 7. The allowable local buckling load is determined by evaluating the critical buckling stress to
bending stress and applying the appropriate safety factor. In this case use 2.5.
Use =M/Sx where, M=PL/4
Therefore, P =(xcr Sx4)/L
Pbuckling=(22,647psi*13.58*4)/144" = 8,542 lbs./2.5
Pallowable =3,417 lbs.> Pglobal buckling 1,484 lbs; therefore, global buckling governs the design.
The design is governed by Mcr Lateral Torsional Buckling (Global buckling) and is limited to
1,484 lbs.
Reference the Chemical Compatibility Guide to determine the proper Pultex Series.
Choose Pultex 1625 Series.
Channel Selection Example
Example 4.

Determine the Channel section that is required to support a uniform load of 70 lbs./ft at a span of 24with
a maximum deflection criteria of L/D= 180.
Step 1. Locate the channel uniform load tables in chapter 4. Next, locate the Simply Supported Beam
with Uniform Loads at various L/D ratio section of the allowable uniform load tables.
Step 2. Locate the column with the 180 heading. This stands for the L/D ratio of 180. Next, refer to the
left hand side of the page until you see the Span section. Locate the 24 span section. Find the
intersection of the 24 span and the L/D ratio of 180.
Step 3. Page through the channel sections until a number greater than or equal to 70 lbs/ft is obtained.
You will conclude that an 11-1/2x2-3/4x1/2 channel is required. The actual value is 72 lbs/ft.
Step 4. Scan across the columns and review the allowable uniform loads. The allowable uniform loads
will be based on the shear, flexural, local buckling and lateral support spacing. The lowest number
between the values at the 24 span will dictate the allowable uniform load according to the strength of the
beam. The L/D=180 column is based strictly on deflection.
Step 5. Referencing the 24 span tab, once concludes that the lowest value is 271 lbs./ft with lateral
restraint and 12 lbs./ft with lateral restraints. As one can conclude, lateral restraint is very important.

17
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Example 4. (contd)

Step 6. Determine the number of lateral restraints and the maximum spacing by referencing the
Maximum Lateral Support Spacing column. One can conclude that the maximum spacing distance is
36. Therefore, in order for the charts to hold true, a minimum of nine restraints with a maximum spacing
of 36 is required.
Note: The lateral restraint spacing can be modified, however the loads must be reevaluated based on the
lateral restraint spacing. The graphs that depict the ultimate moment capacity versus lateral restraint can
be utilized to make the necessary adjustments to the allowable uniform loads.
Example 5.

Determine the lateral spacing of the diaphragms that are necessary for a structure of two 8x2-3/16x3/8
channels that are positioned 36 apart and span 20. The structure is required to hold an ultimate point
load of 4,000 lbs. located over the center of the 20 span. The 4,000 lbs. had been factored to include a
2.5 times safety factor.
Step 1. Locate the Ultimate Moment Capacity versus Lateral Restraint graph in the channel uniform load
tables. Reference the 8x2-3/16x3/8 graph.
Step 2. Determine the moment acting on the two channels. The moment is calculated by PL/4 for the
simply supported structure with a point load in the middle. The corresponding moment is 20,000 lb.*ft.
Step 3. In referencing the graph and concluding that the two channels will be required to resist a total
moment of 20,000 lb*ft. One concludes that one of the channels must support a moment of 10,000
lb.*ft. Scan across the graph at the 10,000 lb.*ft mark. The lateral buckling curve is intersected at
approximately the 48 bracing spacing. Therefore, the channels must be braced at a maximum support
spacing of 48. One must note that the values are not factored and that appropriate safety factors must be
applied. In this case the factors were applied to the 4,000 lb. point load prior to determining the lateral
spacing required.
Step 4. Design the structure with diaphragms spaced at 48 on center. The deflection and shearing,
flexural and local compression stresses should always be checked.

18
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Nomenclature

c
xcr
xy
yx
a
Aw
A
b
b
bf
bw
Cb
Cw
D
D11, D22
ExorEy
Ey local
f
fb
fv
G
Gxy
h
Ix or y
J
K
k
L
Lb
M
Mcr
P
p
q
r
Sx
t
V
Wt.
Wlb
Wf
Wv
Wlu
L/D

=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=

Deflection (in)
1-(xyyx)
Coefficient of restraint of the compression plates
Compressive stress (psi)
Critical buckling stress in (psi)
Poissons ratio (longitudinal)
Poissons ratio (transverse)
Unsupported length or region over which Nx acts (length of beam) inches
Shear area of profile (Table 2) (in2)
kAw, Shear coefficient x shear area of profile (in2)
Half the width of the compression flange for I/W sections (in)
The width of the compression flange for box sections, b=bf (in)
Width of the compression flange (in)
Height of the section (in)
Moment Variation Constant
Warping Constant (in6)
Deflection (in)
Flexural rigidity in 1, 2 and radial directions
Modulus of elasticity of the major or minor axis(psi)
Local transverse modulus of Elasticity (psi)
Flange
Flexural stress (psi)
Shear stress (psi)
Shear modulus (modulus of rigidity) (psi)
Shear modulus (psi)
Depth of section (in)
Moment of Inertia about desired axis (in4)
Torsion Constant (in4)
Effective length coefficient
Shear coefficient (Table 2.)
Length (inches)
Unsupported length between points that have lateral restraint (in)
Maximum moment (in-lbs)
Critical Moment that causes lateral buckling (in-lbs)
Point load (lbs.)
Constant defined by the coefficient of restraint ()
Constant defined by the coefficient of restraint ()
Radius of gyration (in)
Section modulus (in3)
Thickness of compression flange (in)
Shear Force (lbs.)
Weight of profile in lbs./ft
Maximum load governed by critical local buckling (lbs./ft)
Maximum load governed by flexural stress (lbs./ft)
Maximum load governed by shear strength (lbs./ft)
Maximum laterally unsupported load (lbs./ft)
Ratio of length of the span to the deflection

19
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Channel Section Nomenclature

the length of the plate (panel)

the width of the plate (panel)

bf (= w)

the widths of flange (Figure 1)

bw (= h)

the widths of web (Figure 1)

the panel stiffness in x-direction

the panel stiffness in y-direction

Gxy

the panel in-plane shear stiffness

the height of the channel (Figure 1)

Ixx

the moment of inertial of the channel section along the strong axis

Iyy

the moment of inertial of the channel section along the weak axis

Iww

the warping stiffness of the channel section

the torsional stiffness of the channel section

the span length

the number of buckling half waves

Mcr

the critical moment of the channel section subject to buckling

(Nx)cr

the plate local buckling strength

Pcr

the lateral buckling load through the shear center of channel section

the thickness the flange

vxy

the panel Poissons ratio

the widths of the channel (Figure 1)

the coefficient of restraint for flange-web connection

the critical aspect ratio

the critical stress

20
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Introduction to Pultex SuperStructural Profiles

Product Advantage Summary

When comparing pultruded fiber reinforced polymer composites to traditional building materials such as
steel, one will notice that the strengths of the materials are generally comparable while the stiffness
characteristics are dissimilar. For example, the modulus of elasticity of steel is approximately 29E6 psi.,
while the modulus of elasticity of a typical pultruded Wide Flange Section is 2.5-2.8E6 psi. The stiffness
difference is 11.5 times between the two materials. In an effort to improve stiffness, Creative Pultrusions,
has modified the fiber architecture of selected structural profiles. The result improved the modulus of
elasticity from 2.5-2.8E6 psi to 3.9-4.0E6 psi., an average improvement in E-Modulus of 49%. Pultex
SuperStructural profiles offer the designer the ability to design longer spans with heavier loads. The
most important advantage is a more economical design, as material and labor costs are greatly reduced.
The following example is a comparison of a standard pultruded section to a Pultex SuperStructural
profile.
Example 1.0
Reference Creative Pultrusions former Design Guide, Volume 2, Revision 1, Allowable Uniform Load
Tables, page 3-17. The allowable uniform load of a standard 6" x 6" x 3/8" Wide Flange Section at a
span of 10 and L/D ratio of 360 is 149 lbs./ft. Referencing The New and Improved Pultex Pultrusion
Design Manual, the allowable uniform load for the same loading, span and deflection criteria is 220
lbs./ft. The difference is a 48% increase in E-Modulus. The graph below demonstrates the difference
between the Pultex SuperStructural 6" x 6" x 3/8" Wide Flange Section and a standard pultruded 6" x
6" x 3/8" Wide Flange Section. The graph demonstrates the allowable uniform loads for each beam at
various spans with the deflection limit of L/D = 360.

(Uniform Load (lbs./ft

Pultex SuperStructural vs Pultex Standard Structural

Allowable Uniform Load Comparison

400
300
48% increase in E-Modulus

200
100
0
8

11
12
Span (ft)

Pultex SuperStructural Profiles 6" x 6" x 3/8" Wide Flange Section

Pultex Standard Structural Profiles 6" x 6" x 3/8" Wide Flange Section

Comparison of Standard Structural Profiles and Pultex SuperStructural Profiles

21
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Project example: Plating Tank Cover Design

1. Standard Structural Project Design Factors
Description: Plating tank cover 10' x 60'
Design load: 80 psf
Maximum deflection: L/180 or .67"
Service temperature: 80F
5% concentration of Chromic Acid
Step 1. Based on the 80 psf + the 3.46 psf DL of Flowgrip, determine the allowable beam
spacing.

Step 2. Reference Creative Pultrusions former Design Guide, Volume 2, Revision 1.

For a 6"x6"x3/8" Wide Flange Beam, the allowable uniform load at L/180 is 298 lbs/ft.
Step 3. Determine the allowable spacing by dividing the allowable load by the design load, i.e.,
(298 lbs/ft)/83.46lbs/ft2= 3.57' O.C.
Step 4. Space the beams @ 3.5' O.C. (Note: beam weight excluded)
Bill of Materials for Standard Structural Project Design
Item
6"x6"x3/8" W-Section; 1625; Spaced 3.5' O.C.
Flowgrip Solid Panel
Misc., i.e., fasteners, adhesive
Total Material Price

Quantity
19 pcs. @11'
21 pcs. @20'

Pultex SuperStructural Profiles

Price $
Total
$24.28/ft $5,074.52
$33.14/ft $13,918.80
$18,993.32

Pultex Standard Structural Profiles

2. Pultex SuperStructural Project Design Factors

Description: Plating tank cover 10' x 60'
Design load: 80 psf
Maximum deflection: L/180 or .67"
Service temperature: 80F
5% concentration of Chromic Acid

Step 1. Determine the maximum span of Flowgrip Solid Floor Panel.

a. Reference page 7 of the Solutions that Work---The Most Complete Line of Grating and
Access Structure Products in the Industry
Note: The Flowgrip Solid Floor Panel will span 60" and satisfy the above design criteria.
(The beam spacing is based on 5' O.C.)

22
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Step 2. Determine which Wide Flange Section profile will satisfy the loading condition above.
a. 80 psf x 5' panel width = 400 lbs/ft live load on the beams.
b. Calculate the dead load. Assume that a 6" x 6" x 3/8" Wide Flange Section profile is
sufficient.
c. The weight of the 6" x 6" x 3/8" section is 4.92 lbs/ft.
d. Calculate the weight of the Flowgrip 3.46 psf x 5' = 17.3 lbs/ft.
Step 3. Determine the total live load (LL) and dead load (DL) combination.
a. 400 lbs/ft LL + 4.92 lbs/ft DL + 17.3 lbs/ft DL = 422.2 lbs./ft.
Step 4. Determine if the 6" x 6" x 3/8" Wide Flange Section profile is adequate.
a. Reference the 6" x 6" x 3/8" Wide Flange Section in the Allowable Uniform Load Tables.
b. Locate the 10' span row and look across to the l/180 deflection column.
c. The Pultex SuperStructural 6" x 6" x 3/8" Wide Flange Section will hold 441 lbs/ft and
deflect less than L/180; therefore, the 6" x 6" x 3/8" Wide Flange Section profile is adequate.
Step 5. Space all beams at 5' O.C. across the 10' section of the span.
Bill of Materials for Pultex SuperStructural Project Design
Item
Quantity
6"x6"x3/8" W-Section; 1625; Spaced 5' O.C.
13 pcs. @11'
Flowgrip Solid Floor Panel
21 pcs. @ 20'
Misc., i.e., fasteners, adhesives
Total Material Price

Price $
$24.28/ft
$33.14/ft

Total
$3,472.04
$13,918.80
$17,390.84

Pultex Supe r Str uctur a l vs Pultex Standard Structural Profiles

Price Advantage Comparison

$18,993
$19,000
$18,500
$18,000

$17,391

$17,500
$17,000
$16,500

Pultex
SuperStructural
Pultex SuperStructural
Profiles
Profiles

Pultex
PultexStandard
Standard
Structural
StructuralProfiles
Profiles

Total Material Cost

23
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Span/Deflection Ratio Conversion Tables

Span Span
feet Inches
1.0
12
1.5
18
2.0
24
2.5
30
3.0
36
3.5
42
4.0
48
4.5
54
5.0
60
5.5
66
6.0
72
6.5
78
7.0
84
7.5
90
8.0
96
8.5
102
9.0
108
9.5
114
10.0
120
10.5
126
11.0
132
11.5
138
12.0
144
12.5
150
13.0
156
13.5
162
14.0
168
14.5
174
15.0
180
15.5
186
16.0
192
16.5
198
17.0
204
17.5
210
18.0
216
18.5
222
19.0
228
19.5
234

L/D=80

0.15
0.23
0.30
0.38
0.45
0.53
0.60
0.68
0.75
0.83
0.90
0.98
1.05
1.13
1.20
1.28
1.35
1.43
1.50
1.58
1.65
1.73
1.80
1.88
1.95
2.03
2.10
2.18
2.25
2.33
2.40
2.48
2.55
2.63
2.70
2.78
2.85
2.93

L/D=100

0.12
0.18
0.24
0.30
0.36
0.42
0.48
0.54
0.60
0.66
0.72
0.78
0.84
0.90
0.96
1.02
1.08
1.14
1.20
1.26
1.32
1.38
1.44
1.50
1.56
1.62
1.68
1.74
1.80
1.86
1.92
1.98
2.04
2.10
2.16
2.22
2.28
2.34

L/D=150 L/D=180 L/D=240

L/D=360 L/D=500
Deflection (in)
0.08
0.07
0.05
0.03
0.02
0.12
0.10
0.08
0.05
0.04
0.16
0.13
0.10
0.07
0.05
0.20
0.17
0.13
0.08
0.06
0.24
0.20
0.15
0.10
0.07
0.28
0.23
0.18
0.12
0.08
0.32
0.27
0.20
0.13
0.10
0.36
0.30
0.23
0.15
0.11
0.40
0.33
0.25
0.17
0.12
0.44
0.37
0.28
0.18
0.13
0.48
0.40
0.30
0.20
0.14
0.52
0.43
0.33
0.22
0.16
0.56
0.47
0.35
0.23
0.17
0.60
0.50
0.38
0.25
0.18
0.64
0.53
0.40
0.27
0.19
0.68
0.57
0.43
0.28
0.20
0.72
0.60
0.45
0.30
0.22
0.76
0.63
0.48
0.32
0.23
0.80
0.67
0.50
0.33
0.24
0.84
0.70
0.53
0.35
0.25
0.88
0.73
0.55
0.37
0.26
0.92
0.77
0.58
0.38
0.28
0.96
0.80
0.60
0.40
0.29
1.00
0.83
0.63
0.42
0.30
1.04
0.87
0.65
0.43
0.31
1.08
0.90
0.68
0.45
0.32
1.12
0.93
0.70
0.47
0.34
1.16
0.97
0.73
0.48
0.35
1.20
1.00
0.75
0.50
0.36
1.24
1.03
0.78
0.52
0.37
1.28
1.07
0.80
0.53
0.38
1.32
1.10
0.83
0.55
0.40
1.36
1.13
0.85
0.57
0.41
1.40
1.17
0.88
0.58
0.42
1.44
1.20
0.90
0.60
0.43
1.48
1.23
0.93
0.62
0.44
1.52
1.27
0.95
0.63
0.46
1.56
1.30
0.98
0.65
0.47

24
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Span/Deflection Ratio Conversion Tables - Contd

Span Span
feet Inches
20.0
240
20.5
246
21.0
252
21.5
258
22.0
264
22.5
270
23.0
276
23.5
282
24.0
288
24.5
294
25.0
300
25.5
306
26.0
312
26.5
318
27.0
324
27.5
330
28.0
336
28.5
342
29.0
348
29.5
354
30.0
360
30.5
366
31.0
372
31.5
378
32.0
384
32.5
390
33.0
396
33.5
402
34.0
408
34.5
414
35.0
420
35.5
426
36.0
432
36.5
438
37.0
444
37.5
450
38.0
456
38.5
462
39.0
468
39.5
474
40.0
480

L/D=80

3.00
3.08
3.15
3.23
3.30
3.38
3.45
3.53
3.60
3.68
3.75
3.83
3.90
3.98
4.05
4.13
4.20
4.28
4.35
4.43
4.50
4.58
4.65
4.73
4.80
4.88
4.95
5.03
5.10
5.18
5.25
5.33
5.40
5.48
5.55
5.63
5.70
5.78
5.85
5.93
6.00

L/D=100

2.40
2.46
2.52
2.58
2.64
2.70
2.76
2.82
2.88
2.94
3.00
3.06
3.12
3.18
3.24
3.30
3.36
3.42
3.48
3.54
3.60
3.66
3.72
3.78
3.84
3.90
3.96
4.02
4.08
4.14
4.20
4.26
4.32
4.38
4.44
4.50
4.56
4.62
4.68
4.74
4.80

L/D=150 L/D=180 L/D=240

L/D=360 L/D=500
Deflection (in)
1.60
1.33
1.00
0.67
0.48
1.64
1.37
1.03
0.68
0.49
1.68
1.40
1.05
0.70
0.50
1.72
1.43
1.08
0.72
0.52
1.76
1.47
1.10
0.73
0.53
1.80
1.50
1.13
0.75
0.54
1.84
1.53
1.15
0.77
0.55
1.88
1.57
1.18
0.78
0.56
1.92
1.60
1.20
0.80
0.58
1.96
1.63
1.23
0.82
0.59
2.00
1.67
1.25
0.83
0.60
2.04
1.70
1.28
0.85
0.61
2.08
1.73
1.30
0.87
0.62
2.12
1.77
1.33
0.88
0.64
2.16
1.80
1.35
0.90
0.65
2.20
1.83
1.38
0.92
0.66
2.24
1.87
1.40
0.93
0.67
2.28
1.90
1.43
0.95
0.68
2.32
1.93
1.45
0.97
0.70
2.36
1.97
1.48
0.98
0.71
2.40
2.00
1.50
1.00
0.72
2.44
2.03
1.53
1.02
0.73
2.48
2.07
1.55
1.03
0.74
2.52
2.10
1.58
1.05
0.76
2.56
2.13
1.60
1.07
0.77
2.60
2.17
1.63
1.08
0.78
2.64
2.20
1.65
1.10
0.79
2.68
2.23
1.68
1.12
0.80
2.72
2.27
1.70
1.13
0.82
2.76
2.30
1.73
1.15
0.83
2.80
2.33
1.75
1.17
0.84
2.84
2.37
1.78
1.18
0.85
2.88
2.40
1.80
1.20
0.86
2.92
2.43
1.83
1.22
0.88
2.96
2.47
1.85
1.23
0.89
3.00
2.50
1.88
1.25
0.90
3.04
2.53
1.90
1.27
0.91
3.08
2.57
1.93
1.28
0.92
3.12
2.60
1.95
1.30
0.94
3.16
2.63
1.98
1.32
0.95
3.20
2.67
2.00
1.33
0.96

12 x 6 x1/2 (Part # IB 982)

Ultimate In-Plane Shear Strength (psi)
48.3 Simply Supported beam with Uniform
1500/1525/1625 Series
Ultimate Flexural Strength (psi)
227.6
Loads at various L/D ratios
6
5
250.1
(lbs/ft)
E= 3.9 x 10 psi G = 5.0 x 10 psi Ultimate Local Buckling Strength (psi)
4
3
Ix= 258.76in
Sx=43.13 in
Simply Supported with a Uniform Load
Maximum Lb = 3.5 ft.
Aw= 6.0 in2
Wt.= 8.75 lbs/ft
Laterally Supported beams
L/D ratio
Allowable Allowable
load, local
load,
Allowable load,
Allowable load, laterally compression flexural
In-plane shear
unsupported beam
buckling
capacity,
of the web
global buckling capacity,
capacity, 2.5x Safety capacity, 3x
Span
2.5x Safety Factor
2.5x S.F.
Factor
Safety Factor
(feet)
(lbs/ft)
(lbs/ft)
(lbs/ft)
(lbs/ft)
100
150
180
240
360
10
976
4170
3795
2442
1832 1221
2800
11
682
3447
3137
2274
1895
1421
948
2545
12
493
2896
2636
1797
1497
1123
749
2333
13
367
2468
2246
1442
1202
901
601
2154
14
280
2128
2000
1760
1173
978
733
489
1936
15
218
1854
1867
1450
967
806
604
403
1687
16
173
1629
1750
1208
805
671
503
336
1483
17
140
1443
1647
1017
678
565
424
282
1313
18
114
1287
1556
863
575
480
360
240
1171
19
94
1155
1474
739
493
410
308
205
1051
20
79
1043
1400
637
425
354
265
177
949
21
67
946
1333
553
369
307
230
154
861
22
57
862
1273
483
322
268
201
134
784
23
49
788
1217
424
283
236
177
118
717
24
42
724
1167
375
250
208
156
104
659
25
37
667
1120
333
222
185
139
92
607
26
32
617
1077
296
198
165
123
82
561
27
29
572
1037
265
177
147
111
74
521
28
25
532
1000
238
159
132
99
66
484
29
23
496
966
215
143
119
90
60
451
30
20
463
933
194
130
108
81
54
422
31
18
434
903
177
118
98
74
49
395
32
16
407
875
161
107
89
67
45
371
33
15
383
848
147
98
82
61
41
349
34
13
361
824
134
90
75
56
37
328
35
12
340
800
123
82
68
51
34
310
Note: Bold numbers in the Factored Load Tables represent the governing load

41
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Pultex Standard Structural Profiles

Channels
3" x 7/8" x 1/4" (Part # CH 340)
1500/1525/1625 Series
7,000
Ultimate Flexural Stress (psi)
33,000
Ex =2.8x106 psi
Ey =1.0x106 psi Ultimate Local Flange Buckling Stress (psi)
53,692
4
Ix=1.02 in
G =5.0x105 psi Ultimate Lateral-torsional Buckling Stress
Aw=.56 in2
Sx=.68 in3 with Maximum Lateral Support bracing (psi)
56,328
Wt.=0.77 lbs/ft
Simply Supported Beam with a Uniform Load
Load Tables Based on Laterally Supported Beams Unless Noted
Allowable
load, local
Number of
Allowable
Allowable
lateral
compression
load based
load, In-plane
Allowable
restraints
Maximum
load without
buckling
on the beam
shear parallel
lateral
capacity of
per total
lateral
flexural
to the web,
span
support
flange, 2.5x
capacity,
capacity, 3x
support 2.5x
Span
(Including
spacing
safety factor
safety factor
2.5x safety
safety factor
(feet)
(inches)
(lbs/ft)
Ends)
(lbs/ft)
factor (lbs/ft)
(lbs/ft)
2
4
10
428
2429
1493
1307
2.5
4
10
218
1555
1045
956
3
5
10
126
1080
871
664
3.5
6
10
79
793
747
488
4
6
10
53
607
653
373
4.5
7
10
37
480
581
295
5
7
10
27
389
523
239
5.5
8
10
20
321
475
197
6
9
10
16
270
436
166
6.5
9
10
12
230
402
141
7
10
10
10
198
373
122
7.5
10
10
8
173
348
106
8
11
10
7
152
327
93
8.5
12
10
6
134
307
83
9
12
10
5
120
290
74
9.5
13
10
4
108
275
66
10
13
10
3
97
261
60
Note: Bold numbers in the Factored Load Tables represent the governing load
Reduction for weight of profile has not been applied to the charts
Ultimate In-Plane Shear Stress (psi)

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

42
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

100
878
524
336
228
161
118
89
69
54
44
36
29
25
21
18
15

150
1083
585
349
224
152
108
79
60
46
36
29
24
20
16
14
12
10

180
903
488
291
187
127
90
66
50
38
30
24
20
16
14
11
10
8

240
677
366
218
140
95
67
49
37
29
23
18
15
12
10
9
7
6

360
451
244
145
93
63
45
33
25
19
15
12
10
8
7
6
5
4

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

Moment (lb.*ft)

Ultimate moment capacity V.S. Laterial restraint

Pultex CH340 3"x 7/8"x 1/4"
3,500
3,000
2,500
2,000
1,500
1,000
500
0

lateral buckling
local buckling

Bracing Distance (in)

43
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Pultex Standard Structural Profiles

Channels

3" x 1-1/2" x 1/4" (Part # CH 342)

1500/1525/1625 Series
7,000
Ultimate Flexural Stress (psi)
33,000
Ex =2.8x106 psi
Ey =1.0x106 psi Ultimate Local Flange Buckling Stress (psi)
25,876
4
Ix=1.61 in
G =5.0x105 psi Ultimate Lateral-torsional Buckling Stress
Sx=1.07 in3 with Maximum Lateral Support bracing (psi)
27,372
Aw=.75 in2
Wt.=1.03 lbs/ft
Simply Supported Beam with a Uniform Load
Load Tables Based on Laterally Supported Beams Unless Noted
Allowable
load, local
Number of
Allowable
Allowable
lateral
compression
load based
load, In-plane
Allowable
restraints
Maximum
load without
buckling
on the beam
shear parallel
lateral
capacity of
per total
lateral
flexural
to the web,
span
support
flange, 2.5x
capacity,
capacity, 3x
support 2.5x
Span
(Including
spacing
safety factor
safety factor
2.5x safety
safety factor
(feet)
(inches)
(lbs/ft)
Ends)
(lbs/ft)
factor (lbs/ft)
(lbs/ft)
2
2
28
1091
1846
2354
1750
2.5
3
28
556
1507
1400
1181
3
3
28
321
1046
1167
820
3.5
3
28
202
769
1000
603
4
3
28
135
589
875
461
4.5
3
28
95
465
778
365
5
4
28
69
377
700
295
5.5
4
28
52
311
636
244
6
4
28
40
262
583
205
6.5
4
28
31
223
538
175
7
4
28
25
192
500
151
7.5
5
28
20
167
467
131
8
5
28
17
147
438
115
8.5
5
28
14
130
412
102
9
5
28
12
116
389
91
9.5
6
28
10
104
368
82
10
6
28
9
94
350
74
Note: Bold numbers in the Factored Load Tables represent the governing load
Reduction for weight of profile has not been applied to the charts
Ultimate In-Plane Shear Stress (psi)

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

44
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

100
****
1364
818
526
358
254
186
141
109
86
69
56
46
39
33
28
24

150
1669
909
545
351
238
169
124
94
73
57
46
37
31
26
22
19
16

180
1391
758
454
292
199
141
104
78
60
48
38
31
26
22
18
15
13

240
1043
568
341
219
149
106
78
59
45
36
29
23
19
16
14
12
10

360
695
379
227
146
99
70
52
39
30
24
19
16
13
11
9
8
7

Ultimate Moment Capacity v.s. Lateral Restraint

Pultex

CH342 3"x 1 1/2"x 1/4" Channel

3,500

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

Moment (lb.*ft)

3,000
2,500
lateral buckling
local buckling

2,000
1,500
1,000
500
0
10

100

110

120

Bracing Distance (in)

45
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Pultex Standard Structural Profiles

Channels

4" x 1-1/8" x 1/4" (Part # CH 440)

1500/1525/1625 Series
7,000
Ultimate Flexural Stress (psi)
33,000
Ex =2.8x106 psi
Ey =1.0x106 psi Ultimate Local Flange Buckling Stress (psi)
34,820
4
Ix=2.62 in
G =5.0x105 psi Ultimate Lateral-torsional Buckling Stress
Sx=1.31 in3 with Maximum Lateral Support bracing (psi)
36,181
Aw=1.0 in2
Wt.=1.11 lbs/ft
Simply Supported Beam with a Uniform Load
Load Tables Based on Laterally Supported Beams Unless Noted
Allowable
load, local
Number of
Allowable
Allowable
lateral
compression
load based
load, In-plane
Allowable
restraints
Maximum
load without
buckling
on the beam
shear parallel
lateral
capacity of
per total
lateral
flexural
to the web,
span
support
flange, 2.5x
capacity,
capacity, 3x
support 2.5x
Span
(Including
spacing
safety factor
safety factor
2.5x safety
safety factor
(feet)
(inches)
(lbs/ft)
Ends)
(lbs/ft)
factor (lbs/ft)
(lbs/ft)
2
3
15
758
3041
2882
2333
2.5
3
15
386
1946
1867
1844
3
4
15
222
1352
1556
1281
3.5
4
15
140
993
1333
941
4
5
15
94
760
1167
721
4.5
5
15
66
601
1037
569
5
5
15
48
487
933
461
5.5
6
15
36
402
848
381
6
6
15
28
338
778
320
6.5
7
15
22
288
718
273
7
7
15
17
248
667
235
7.5
7
15
14
216
622
205
8
8
15
12
190
583
180
8.5
8
15
10
168
549
160
9
9
15
8
150
519
142
9.5
9
15
7
135
491
128
10
9
15
6
122
467
115
Note: Bold numbers in the Factored Load Tables represent the governing load
Reduction for weight of profile has not been applied to the charts
Ultimate In-Plane Shear Stress (psi)

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

46
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

100
****
2165
1307
845
576
410
301
228
176
139
112
91
75
63
53
45
39

150
2620
1443
871
563
384
273
201
152
118
93
75
61
50
42
35
30
26

180
2183
1203
726
469
320
228
167
127
98
77
62
51
42
35
29
25
22

240
1637
902
545
352
240
171
126
95
73
58
47
38
31
26
22
19
16

360
1092
601
363
235
160
114
84
63
49
39
31
25
21
17
15
13
11

Ultimate Moment Capacity V.S. Lateral Restraint

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

Moment (lb.*ft)

Pultex

CH440 4" x 1-1/8" x 1/4"

4,500
4,000
3,500
3,000
2,500
2,000
1,500
1,000
500
0

Moment (lb.*ft)

Ultimate Moment Capacity V.S. Lateral Restraint

Pultex CH540 5" x 1-3/8" x 1/4"

5,000
4,500
4,000
3,500
3,000
2,500
2,000
1,500
1,000
500
0

lateral buckling
local buckling

100 110 120

Bracing Distance (in)

49
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Pultex Standard Structural Profiles

Channels

6" x 1-5/8" x 1/4" (Part # CH 640)

The New and Improved Pultex Pultrusion Design Manual

52
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

100
****
****
****
1473
874
559
378
268
196
148
114
90
72
59
49
41
34

150
****
****
1833
982
583
373
252
178
131
99
76
60
48
39
32
27
23

180
****
3307
1528
818
486
311
210
149
109
82
63
50
40
33
27
23
19

240
****
2480
1146
614
364
233
158
112
82
62
48
38
30
25
20
17
14

360
4472
1654
764
409
243
155
105
74
54
41
32
25
20
16
13
11
9

Ultimate Moment Capacity V.S. Lateral Restraint

Pultex

CH662 6"x 1-11/16" x 3/8"

16,000
12,000
Moment (lb.*ft)

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

14,000
lateral buckling
local buckling

10,000
8,000
6,000
4,000
2,000
0
20

100

110

120

Bracing Distance (in)

53
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Pultex Standard Structural Profiles

Channels

7" x 2" x 1/4" (Part # CH 740)

1500/1525/1625 Series
7,000
Ultimate Flexural Stress (psi)
33,000
Ex =2.8x106 psi
Ey =1.0x106 psi Ultimate Local Flange Buckling Stress (psi)
10,616
4
Ix=16.42 in
G =5.0x105 psi Ultimate Lateral-torsional Buckling Stress
Sx=4.69 in3 with Maximum Lateral Support bracing (psi)
11,525
Aw=1.75 in2
Wt.=2.00 lbs/ft
Simply Supported Beam with a Uniform Load
Load Tables Based on Laterally Supported Beams Unless Noted
Allowable
load, local
Number of
Allowable
Allowable
lateral
compression
load based
load, In-plane
Allowable
restraints
Maximum
load without
buckling
on the beam
shear parallel
lateral
capacity of
per total
lateral
flexural
to the web,
span
support
flange, 2.5x
capacity,
capacity, 3x
support 2.5x
Span
(Including
spacing
safety factor
safety factor
2.5x safety
safety factor
(feet)
(inches)
(lbs/ft)
Ends)
(lbs/ft)
factor (lbs/ft)
(lbs/ft)
5
3
46
166
1651
1633
531
6
3
46
96
1146
1361
369
7
3
46
60
842
1167
271
8
4
46
40
645
1021
207
9
4
46
28
510
907
164
10
4
46
21
413
817
133
11
4
46
16
341
742
110
12
5
46
12
287
681
92
13
5
46
9
244
628
79
14
5
46
8
211
583
68
15
5
46
6
183
544
59
16
6
46
5
161
510
52
17
6
46
4
143
480
46
18
6
46
4
127
454
41
19
6
46
3
114
430
37
20
7
46
3
103
408
33
Note: Bold numbers in the Factored Load Tables represent the governing load
Reduction for weight of profile has not been applied to the charts
Ultimate In-Plane Shear Stress (psi)

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

54
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

100
****
****
****
****
****
****
****
****
****
****
****
****
****
****
35
30

150
****
****
****
****
****
****
****
92
73
59
48
39
33
28
24
20

180
****
****
****
****
****
132
99
77
61
49
40
33
27
23
20
17

240
****
****
****
189
134
99
75
58
46
37
30
25
21
17
15
13

360
478
287
185
126
90
66
50
38
30
24
20
16
14
12
10
8

Ultimate Moment Capacity V.S. Lateral Restraint

The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Moment (lb.*ft)

Pultex

CH740 7" x 2" x 1/4"

5,000
4,500
4,000
3,500
3,000
2,500
2,000
1,500
1,000
500
0

lateral buckling
local buckling

100

110

120

Bracing Distance (in)

55
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Pultex Standard Structural Profiles

Channels

14 x 6 x 1/2" (Part # CH 800)

1500/1525/1625 Series
7,000
Ultimate Flexural Stress (psi)
33,000
Ex =3.0x106 psi
Ey =1.5x106 psi Ultimate Local Flange Buckling Stress (psi)
6,506
4
Ix=349.085 in
G =5.0x105 psi Ultimate Lateral-torsional Buckling Stress
Sx=49.87 in3 with Maximum Lateral Support bracing (psi)
6,643
Aw=7.0 in2
Wt.=10.4 lbs/ft
Simply Supported Beam with a Uniform Load
Load Tables Based on Laterally Supported Beams Unless Noted
Allowable
load, local
Number of
Allowable
Allowable
lateral
compression
load based
load, In-plane
Allowable
restraints
Maximum
load without
buckling
on the beam
shear parallel
lateral
capacity of
per total
lateral
flexural
to the web,
span
support
flange, 2.5x
capacity,
capacity, 3x
support 2.5x
Span
(Including
spacing
safety factor
safety factor
2.5x safety
safety factor
(feet)
(inches)
(lbs/ft)
Ends)
(lbs/ft)
factor (lbs/ft)
(lbs/ft)
8
2
207
1271
1352
6857
4083
9
2
207
891
1068
5418
3630
10
2
207
648
865
4388
3267
11
2
207
486
715
3627
2970
12
2
207
374
601
3048
2722
13
2
207
294
512
2597
2513
14
2
207
235
441
2239
2333
15
2
207
191
385
1950
2178
16
2
207
158
338
1714
2042
17
2
207
131
299
1519
1922
18
3
207
111
267
1354
1815
19
3
207
94
240
1216
1719
20
3
207
81
216
1097
1633
21
3
207
70
196
995
1556
22
3
207
61
179
907
1485
Note: Bold numbers in the Factored Load Tables represent the governing load
Reduction for weight of profile has not been applied to the charts
Ultimate In-Plane Shear Stress (psi)

56
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

100
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****

150
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****

180
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****

240
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****

360
****
****
****
****
****
****
****
****
330
277
235
201
173
150
131

Pultex Standard Structural Profiles

Channels

14 x 6 x 1/2" (Part # CH 800)

1500/1525/1625 Series
7,000
Ultimate Flexural Stress (psi)
33,000
Ex =3.0x106 psi
Ey =1.5x106 psi Ultimate Local Flange Buckling Stress (psi)
6,506
4
Ix=349.085 in
G =5.0x105 psi Ultimate Lateral-torsional Buckling Stress
Sx=49.87 in3 with Maximum Lateral Support bracing (psi)
6,643
Aw=7.0 in2
Wt.=10.4 lbs/ft
Simply Supported Beam with a Uniform Load
Load Tables Based on Laterally Supported Beams Unless Noted
Allowable
load, local
Number of
Allowable
Allowable
lateral
compression
load based
load, In-plane
Allowable
restraints
Maximum
load without
buckling
on the beam
shear parallel
lateral
capacity of
per total
lateral
flexural
to the web,
span
support
flange, 2.5x
capacity,
capacity, 3x
support 2.5x
Span
(Including
spacing
safety factor
safety factor
2.5x safety
safety factor
(feet)
(inches)
(lbs/ft)
Ends)
(lbs/ft)
factor (lbs/ft)
(lbs/ft)
23
3
207
53
164
830
1420
24
3
207
47
150
762
1361
25
3
207
41
138
702
1307
26
3
207
37
128
649
1256
27
3
207
33
119
602
1210
28
3
207
29
110
560
1167
29
3
207
26
103
522
1126
30
3
207
24
96
488
1089
31
3
207
22
90
457
1054
32
3
207
20
84
429
1021
33
3
207
18
79
403
990
34
3
207
16
75
380
961
35
4
207
15
71
358
933
Note: Bold numbers in the Factored Load Tables represent the governing load
Reduction for weight of profile has not been applied to the charts
Ultimate In-Plane Shear Stress (psi)

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

100
****
****
****
****
****
****
****
****
****
****
****
****
****

150
****
****
****
****
****
****
****
****
****
****
****
****
****

180
****
****
****
****
****
****
****
****
****
****
79
73
67

240
****
****
135
120
108
97
87
79
72
65
59
54
50

360
115
101
90
80
72
64
58
53
48
43
40
36
33

57
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Ultimate Moment Capacity V.S. Lateral Restraint

Pultex CH800 14"x6"x1/2"

350,000

Moment (lb.*ft)

300,000
250,000

lateral buckling
local buckling

200,000
150,000
100,000
50,000
0
50

100

125

150

175

Bracing Distance (in)

58
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

200

225

250

Pultex Standard Structural Profiles

Channels

8" x 2-3/16" x 1/4" (Part # CH 840)

1500/1525/1625 Series
7,000
Ultimate Flexural Stress (psi)
33,000
Ex =2.8x106 psi
Ey =1.0x106 psi Ultimate Local Flange Buckling Stress (psi)
9,396
4
Ix=24.30 in
G =5.0x105 psi Ultimate Lateral-torsional Buckling Stress
Sx=6.07 in3 with Maximum Lateral Support bracing (psi)
10,158
Aw=2.0 in2
Wt.=2.32 lbs/ft
Simply Supported Beam with a Uniform Load
Load Tables Based on Laterally Supported Beams Unless Noted
Allowable
load, local
Number of
Allowable
Allowable
lateral
compression
load based
load, In-plane
Allowable
restraints
Maximum
load without
buckling
on the beam
shear parallel
lateral
capacity of
per total
lateral
flexural
to the web,
span
support
flange, 2.5x
capacity,
capacity, 3x
support 2.5x
Span
(Including
spacing
safety factor
safety factor
2.5x safety
safety factor
(feet)
(inches)
(lbs/ft)
Ends)
(lbs/ft)
factor (lbs/ft)
(lbs/ft)
6
3
52
118
1485
1556
423
7
3
52
74
1091
1333
311
8
3
52
50
835
1167
238
9
4
52
35
660
1037
188
10
4
52
25
535
933
152
11
4
52
19
442
848
126
12
4
52
15
371
778
106
13
4
52
12
316
718
90
14
5
52
9
273
667
78
15
5
52
8
238
622
68
16
5
52
6
209
583
59
17
5
52
5
185
549
53
18
6
52
4
165
519
47
19
6
52
4
148
491
42
20
6
52
3
134
467
38
21
6
52
3
121
444
35
22
7
52
2
110
424
31
Note: Bold numbers in the Factored Load Tables represent the governing load
Reduction for weight of profile has not been applied to the charts
Ultimate In-Plane Shear Stress (psi)

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

100
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****

150
****
****
****
****
****
****
****
****
****
****
58
48
41
35
30
26
23

180
****
****
****
****
****
****
****
89
72
59
48
40
34
29
25
22
19

Channels
8" x 2-3/16" x 3/8" (Part # CH 860)
1500/1525/1625 Series
7,000
Ultimate Flexural Stress (psi)
33,000
Ex =2.8x106 psi
Ey =1.0x106 psi Ultimate Local Flange Buckling Stress (psi)
21,139
4
Ix=33.75 in
G =5.0x105 psi Ultimate Lateral-torsional Buckling Stress
Sx=8.43 in3 with Maximum Lateral Support bracing (psi)
12,800
Aw=3.0 in2
Wt.=3.41 lbs/ft
Simply Supported Beam with a Uniform Load
Load Tables Based on Laterally Supported Beams Unless Noted
Allowable
load, local
Number of
Allowable
Allowable
lateral
compression
load based
load, In-plane
Allowable
restraints
Maximum
load without
buckling
on the beam
shear parallel
lateral
capacity of
per total
lateral
flexural
to the web,
span
support
flange, 2.5x
capacity,
capacity, 3x
support 2.5x
Span
(Including
spacing
safety factor
safety factor
2.5x safety
safety factor
(feet)
(inches)
(lbs/ft)
Ends)
(lbs/ft)
factor (lbs/ft)
(lbs/ft)
4
2
52
869
4637
3500
2970
6
3
52
255
2061
2333
1320
8
3
52
107
1159
1750
742
10
4
52
55
742
1400
475
12
4
52
32
515
1167
330
14
5
52
20
378
1000
242
16
5
52
13
290
875
186
18
6
52
9
229
778
147
20
6
52
7
185
700
119
22
7
52
5
153
636
98
24
7
52
4
129
583
82
Note: Bold numbers in the Factored Load Tables represent the governing load
Reduction for weight of profile has not been applied to the charts
Ultimate In-Plane Shear Stress (psi)

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

100
****
****
****
****
283
180
121
85
62
47
36

150
****
****
616
322
189
120
81
57
42
31
24

180
****
1161
513
269
157
100
67
47
35
26
20

240
****
871
385
202
118
75
50
36
26
20
15

360
1733
580
257
134
79
50
34
24
17
13
10

61
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

62
Chapter 4

The New and Improved Pultex Pultrusion Design Manual

Moment (lb.*ft)

Ultimate Moment Capacity V.S. Lateral Restraint

Pultex CH860 8"x 2-3/16" x 3/8"
18,000
16,000
14,000
12,000
10,000
8,000
6,000
4,000
2,000
0

lateral buckling
local buckling

Bracing Distance (in)

62
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

100

110

120

Pultex Standard Structural Profiles

Channels
11-1/2" x 2-3/4" x 1/2" (Part # CH 955)
1500/1525/1625 Series
7,000
Ultimate Flexural Stress (psi)
33,000
Ex =2.8x106 psi
Ey =1.0x106 psi Ultimate Local Flange Buckling Stress (psi)
27,046
4
Ix=124.58 in
G =5.0x105 psi Ultimate Lateral-torsional Buckling Stress
Sx=21.67 in3 with Maximum Lateral Support bracing (psi)
30,452
Aw=5.75 in2
Wt.=6.08 lbs/ft
Simply Supported Beam with a Uniform Load
Load Tables Based on Laterally Supported Beams Unless Noted
Allowable
load, local
Number of
Allowable
Allowable
lateral
compression
load based
load, In-plane
Allowable
restraints
Maximum
load without
buckling
on the beam
shear parallel
lateral
capacity of
per total
lateral
flexural
to the web,
span
support
flange, 2.5x
capacity,
capacity, 3x
support 2.5x
Span
(Including
spacing
safety factor
safety factor
2.5x safety
safety factor
(feet)
(inches)
(lbs/ft)
Ends)
(lbs/ft)
factor (lbs/ft)
(lbs/ft)
4
3
36
2641
9767
11917
6708
6
3
36
770
5296
4472
4341
8
4
36
323
2979
3354
2442
10
5
36
165
1907
2683
1563
12
5
36
95
1324
2236
1085
14
6
36
60
973
1917
797
16
7
36
40
745
1677
610
18
7
36
28
588
1491
482
20
8
36
21
477
1342
391
22
9
36
15
394
1220
323
24
9
36
12
331
1118
271
26
10
36
9
282
1032
231
28
11
36
7
243
958
199
30
11
366
6
212
894
174
32
12
36
5
186
839
153
34
13
36
4
165
789
135
36
13
36
4
147
745
121
Note: Bold numbers in the Factored Load Tables represent the governing load
Reduction for weight of profile has not been applied to the charts
Ultimate In-Plane Shear Stress (psi)

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

100
****
****
****
****
****
651
440
311
228
172
133
105
84
68
56
47
40

150
****
****
2151
1147
680
434
294
207
152
115
88
70
56
46
38
31
26

180
****
3907
1792
956
566
362
245
173
127
95
74
58
47
38
31
26
22

240
****
2930
1344
717
425
271
183
130
95
72
55
44
35
28
23
20
17

360
5363
1954
896
478
283
181
122
86
63
48
37
29
23
19
16
13
11

63
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Ultimate Moment Capacity V.S. Lateral Restraint

66
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

100

110

120

Pultex Standard Structural Profiles

Channels

24" x 4" x 15/32" (Part # CH 994)

1500/1525/1625 Series
7,000
Ultimate Flexural Stress (psi)
33,000
Ex =2.8x106 psi
Ey =1.0x106 psi Ultimate Local Flange Buckling Stress (psi)
14,184
4
Ix=985.10 in
G =5.0x105 psi Ultimate Lateral-torsional Buckling Stress
Sx=82.0 in3 with Maximum Lateral Support bracing (psi)
14,419
Aw=11.32 in2
Wt.=10.89 lbs/ft
Simply Supported Beam with a Uniform Load
Load Tables Based on Laterally Supported Beams Unless Noted
Allowable
load, local
Number of
Allowable
Allowable
lateral
compression
load based
load, In-plane
Allowable
restraints
Maximum
load without
buckling
on the beam
shear parallel
lateral
capacity of
per total
lateral
flexural
to the web,
span
support
flange, 2.5x
capacity,
capacity, 3x
support 2.5x
Span
(Including
spacing
safety factor
safety factor
2.5x safety
safety factor
(feet)
(inches)
(lbs/ft)
Ends)
(lbs/ft)
factor (lbs/ft)
(lbs/ft)
10
3
64
387
7216
5286
3102
12
4
64
223
5011
4405
2154
14
4
64
140
3682
3776
1582
16
4
64
93
2819
3304
1212
18
5
64
65
2227
2937
957
20
5
64
48
1804
2643
775
22
6
64
36
1491
2403
641
24
6
64
28
1253
2203
538
26
6
64
22
1067
2033
459
28
7
64
17
920
1888
396
30
7
64
14
802
1762
345
32
7
64
12
705
1652
303
34
8
64
10
624
1555
268
36
8
64
8
557
1468
239
38
9
64
7
500
1391
215
40
9
64
6
451
1322
194
Note: Bold numbers in the Factored Load Tables represent the governing load
Reduction for weight of profile has not been applied to the charts
Ultimate In-Plane Shear Stress (psi)

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

100
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****

150
****
****
****
****
****
****
****
****
****
****
****
****
243
205
175
150

180
****
****
****
****
****
****
****
****
****
357
292
242
202
171
146
125

240
****
****
****
****
****
709
539
420
333
268
219
181
152
128
109
94

360
****
1930
1277
885
637
472
360
280
222
179
146
121
101
85
73
63

67
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Mom ent Capacity V.S. Lateral Restraint

Pultex CH994 24" x 4" x 15/32"

120,000
lateral buckling
local buckling

Chapter 4

The New and Improved Pultex Pultrusion Design Manual

Moment (lb.*ft)

100,000
80,000
60,000
40,000
20,000
0
50

80 90 100 110 120 130 140 150 160 170 180

Bracing Distance (in)

68
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Pultex Standard Structural Profiles

Channels
18" x 2-1/2" x 1/4" (Part # CH 810)
1500/1525/1625 Series
7,000
Ultimate Flexural Stress (psi)
33,000
Ex =2.8x106 psi
Ey =1.0x106 psi Ultimate Local Flange Buckling Stress (psi)
11,064
Ix= 204.77 in4
G =5.0x105 psi Ultimate Lateral-torsional Buckling Stress
Sx=22.75 in3 with Maximum Lateral Support bracing (psi)
32,750
Aw=4.5 in2
Wt.= 4.86 lbs/ft
Simply Supported Beam with a Uniform Load
Load Tables Based on Laterally Supported Beams Unless Noted
Allowable
load, local
Number of
Allowable
Allowable
lateral
compression
load based
load, In-plane
Allowable
restraints
Maximum
load without
buckling
on the beam
shear parallel
lateral
capacity of
per total
lateral
flexural
to the web,
span
support
flange, 2.5x
capacity,
capacity, 3x
support 2.5x
Span
(Including
spacing
safety factor
safety factor
2.5x safety
safety factor
(feet)
(inches)
(lbs/ft)
Ends)
(lbs/ft)
factor (lbs/ft)
(lbs/ft)
10
6
24
46
671
2002
2100
12
7
24
26
466
1390
1750
14
8
24
17
342
1021
1500
16
9
24
11
262
782
1313
18
10
24
8
207
618
1167
20
11
24
6
168
501
1050
22
12
24
4
139
414
955
24
13
24
3
117
348
875
26
14
24
3
99
296
808
28
15
24
2
86
255
750
30
16
24
2
75
222
700
32
17
24
1
66
196
656
34
18
24
1
58
173
618
36
19
24
1
52
154
583
38
20
24
1
46
139
553
40
21
24
1
42
125
525
42
22
24
1
38
113
500
Note: Bold numbers in the Factored Load Tables represent the governing load
Reduction for weight of profile has not been applied to the charts
Ultimate In-Plane Shear Stress (psi)

Simply Supported beam with Uniform

Loads at various L/D ratios
(lbs/ft)
Load Tables Based on Minimum Lateral Support
L/D ratio

100
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****
****

150
****
****
****
****
****
****
****
****
****
****
74
61
51
43
37
32
27

180
****
****
****
****
****
****
****
****
94
76
62
51
43
36
31
26
23

240
****
****
****
****
****
153
116
90
71
57
46
38
32
27
23
20
17

360
****
440
285
194
138
102
77
60
47
38
31
25
21
18
15
13
11

69
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Moment Capacity V.S. Lateral Restraint

Pultex CH810 18"x2 1/2"x1/4"
100,000
90,000
lateral buckling
local buckling

Moment (lb.*ft)

80,000
70,000
60,000
50,000
40,000
30,000
20,000
10,000
0
20

50
Bracing Distance (in)

70
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Pultex Standard Structural Profiles

Square Tubes

1-1/2" x 1-1/2" x 1/4" (Part # TQ 142) Ultimate In-Plane Shear Strength

7,000
1500/1525/1625 Series
Ultimate Flexural Strength (psi)
33,000
E = 3.2x106 psi
G =4.2x105 psi Ultimate Local Buckling Strength
126,511
4
3
Ix= .33 in
Sx= 44 in
Simply Supported with a Uniform Load
Aw= .75 in2
Wt.= .92 lbs/ft
Laterally Supported beams
Allowable
Allowable
load, local
load,
Allowable load,
compression
flexural
In-plane shear
buckling
capacity,
of the web
capacity, 2.5x 2.5x Safety capacity, 3x
Span
Safety Factor
Factor
Safety Factor
(feet)
(lbs/ft)
(lbs/ft)
(lbs/ft)
100
1
14844
3872
3500
2
3711
1750
667
968
3
1649
1167
204
430
4
928
875
87
242
Note: Bold numbers in the Factored Load Tables represent the governing load
1-3/4" x 1-3/4" x 1/8" (Part # TQ 126) Ultimate In-Plane Shear Strength
7,000
1500/1525/1625 Series
Ultimate Flexural Strength (psi)
33,000
E =3.2x106 psi
G =4.2x105 psi Ultimate Local Buckling Strength (psi)
23,237
4
3
Ix=.35 in
Sx=.40 in
Simply Supported with a Uniform Load
Aw=.438 in2
Wt.=.54 lbs/ft
Laterally Supported beams
Allowable
Allowable
load, local
load,
Allowable load,
compression
flexural
In-plane shear
buckling
capacity,
of the web
capacity, 2.5x 2.5x Safety capacity, 3x
Span
Safety Factor
Factor
Safety Factor
(feet)
(lbs/ft)
(lbs/ft)
(lbs/ft)
100
1
2479
3520
2042
2
880
1021
620
3
391
681
212
275
4
220
510
91
155
Note: Bold numbers in the Factored Load Tables represent the governing load

Simply Supported beam with

Uniform Loads at various
L/D ratios (lbs/ft)
L/D ratio

150
3069
444
136
58

180
2557
370
113
48

240
1918
278
85
36

Simply Supported beam with

Uniform Loads at various
L/D ratios (lbs/ft)
L/D ratio

150
452
141
61

180
377
118
51

240
1770
282
88
38

71
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

360
1279
185
57
24

360
1180
188
59
25

Pultex Standard Structurals

Square Tubes

1-3/4" x 1-3/4" x 1/4" (Part # TQ 144) Ultimate In-Plane Shear Strength (psi)
7,000
1500/1525/1625 Series
Ultimate Flexural Strength (psi)
33,000
E =3.2x106 psi
G =4.2x105 psi Ultimate Local Buckling Strength (psi)
92,947
4
3
Ix=.57 in
Sx=.67 in
Simply Supported with a Uniform Load
Aw=.875 in2
Wt.=1.12 lbs/ft
Laterally Supported beams
Allowable
Allowable
load, local
load,
Allowable load,
compression
flexural
In-plane shear
buckling
capacity,
of the web
capacity, 2.5x 2.5x Safety capacity, 3x
Span
Safety Factor
Factor
Safety Factor
(feet)
(lbs/ft)
(lbs/ft)
(lbs/ft)
100
1
16606
5896
4083
2
4152
2042
1123
1474
3
1845
1361
348
655
4
1038
1021
149
369
5
664
817
77
236
Note: Bold numbers in the Factored Load Tables represent the governing load
2" x 2" x 1/8" (Part # TQ 220)
Ultimate In-Plane Shear Strength (psi)
7,000
1500/1525/1625 Series
Ultimate Flexural Strength (psi)
33,000
E =3.2x106 psi
G =4.2x105 psi Ultimate Local Buckling Strength (psi)
17,791
4
Ix=.53 in
Sx=.53 in3
Simply Supported with a Uniform Load
Aw=.5 in2
Wt.=.69 lbs/ft
Laterally Supported beams
Allowable
Allowable
load, local
load,
Allowable load,
compression
flexural
In-plane shear
buckling
capacity,
of the web
capacity, 2.5x 2.5x Safety capacity, 3x
Span
Safety Factor
Factor
Safety Factor
(feet)
(lbs/ft)
(lbs/ft)
(lbs/ft)
100
1
2514
4664
2333
2
1166
1167
629
3
518
778
279
4
292
583
137
157
5
187
467
71
101
Note: Bold numbers in the Factored Load Tables represent the governing load

72
The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Simply Supported beam with

Uniform Loads at various
L/D ratios (lbs/ft)
L/D ratio

150
749
232
99
51

180
4061
624
193
83
43

240
3046
468
145
62
32

360
2030
312
97
41
21

Simply Supported beam

with Uniform Loads at various
L/D ratios (lbs/ft)
L/D ratio

150

211
91
47

180
554
176
76
39

240
415
132
57
30

360
1633
277
88
38
20

Pultex Standard Structural Profiles

Square Tubes

2" x 2" x 1/4" (Part # TQ 240) Ultimate In-Plane Shear Strength (psi)
7,000
1500/1525/1625 Series
Ultimate Flexural Strength (psi)
33,000
Simply Supported beam
E =3.2x106 psi
G =4.2x105 psi Ultimate Local Buckling Strength (psi)
71,162
with Uniform Loads at various
Ix= .89 in4
Sx= .89 in3
Simply Supported with a Uniform Load
L/D ratios (lbs/ft)
2
Aw=1.0 in
Wt.=1.40 lbs/ft
Laterally Supported beams
L/D ratio
Allowable
Allowable
load, local
load,
Allowable load,
compression
flexural
In-plane shear
buckling
capacity,
of the web
capacity, 2.5x 2.5x Safety capacity, 3x
Span
Safety Factor
Factor
Safety Factor
(feet)
(lbs/ft)
(lbs/ft)
(lbs/ft)
100
150
180
240
360
2
4222
2333
1706
1137
948
711
474
1958
3
1877
1556
536
357
298
223
149
870
4
1056
1167
231
154
128
96
64
490
5
676
933
119
80
66
50
33
313
Note: Bold numbers in the Factored Load Tables represent the governing load
2.11" x 2.11" x .20" (Part # TQ 230) Ultimate In-Plane Shear Strength (psi)
7,000
1500/1525/1625 Series
Ultimate Flexural Strength (psi)
33,000
E =3.2x106 psi
G =4.2x105 psi Ultimate Local Buckling Strength (psi)
40,919
4
3
Ix=.91 in
Sx= .86 in
Simply Supported with a Uniform Load
Aw=.84 in2
Wt.=1.07 lbs/ft
Laterally Supported beams
Allowable
Allowable
load, local
load,
Allowable load,
compression
flexural
In-plane shear
buckling
capacity,
of the web
capacity, 2.5x 2.5x Safety capacity, 3x
Span
Safety Factor
Factor
Safety Factor
(feet)
(lbs/ft)
(lbs/ft)
(lbs/ft)
100
2
2346
1969
1708
1892
3
1043
1313
542
841
4
587
985
235
473
5
375
788
122
303
6
261
656
71
210
Note: Bold numbers in the Factored Load Tables represent the governing load

Simply Supported beam with

Uniform Loads at various
L/D ratios (lbs/ft)
L/D ratio

150
1138
361
156
81
47

Uniform Loads at various
L/D ratios (lbs/ft)
L/D ratio

150

434
278
188
133
97
73
57

180
1138
610
362
231
157
111
81
61
47

240
1848
854
457
271
174
117
83
61
46
35

360
1232
569
305
181
116
78
55
41
31
24

Pultex Standard Structural Profiles

Square Tubes

6" x 6" x 3/8" (Part # TQ 660)

Ultimate In-Plane Shear Strength (psi)
7,000
1500/1525/1625 Series
Ultimate Flexural Strength (psi)
33,000
E =3.2x106 psi
G =4.2x105 psi Ultimate Local Buckling Strength
17,791
Ix= 44.93 in4
Sx= 14.98 in3
Simply Supported with a Uniform Load
2
Aw=4.5 in
Wt.=7.0 lbs/ft
Laterally Supported beams
Allowable
Allowable
load, local
load,
Allowable load,
compression
flexural
In-plane shear
buckling
capacity,
of the web
capacity, 2.5x 2.5x Safety capacity, 3x
Span
Safety Factor
Factor
Safety Factor
(feet)
(lbs/ft)
(lbs/ft)
(lbs/ft)
100
3
7896
14647
7000
4
8239
5250
4442
5
5273
4200
2843
6
3662
3500
1974
7
2690
3000
1450
8
2060
2625
1110
9
1627
2333
877
10
1318
2100
711
11
1089
1909
553
587
12
915
1750
429
494
13
780
1615
339
421
14
673
1500
272
363
15
586
1400
222
316
16
515
1313
184
278
17
456
1235
153
246
18
407
1167
129
219
19
365
1105
110
197
20
330
1050
95
178
Note: Bold numbers in the Factored Load Tables represent the governing load

Simply Supported beam

with Uniform Loads at various
L/D ratios (lbs/ft)
L/D ratio

150

1351
925
660
487
369
286
226
182
148
122
102
86
73
63

180

Flat Sheets
1/8" (Part # FS 020)
Pultex 1500/1525 & 1625 Series

span
(inches)
12
18
24

E = 2.0x 106 psi

Weight = 1.09 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Lengthwise Direction
100

150
21
6
3

1/8" (Part # FS020)

Pultex 1500/1525 & 1625 Series

span
(inches)
12
18
24

L/D
180
14
4
2

240
12
3
1.4

360

9
3
1.1

6
2
0.7

E = .8x 106 psi

Weight = 1.09 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Crosswise Direction
100

L/D
180

150
8
2
1.0

6
2
0.7

240

5
1.37
0.58

360

3
1.03
0.43

2
0.69
0.29

Pultex Standard Structural Profiles

Flat Sheets
1/4" (Part # FS 040)
Pultex 1500/1525 & 1625 Series
span
(inches)
12
18
24

100

L/D
180

150
167
49
21

1/4" (Part # FS 040)

Pultex 1500/1525 & 1625 Series
span
(inches)
12
18
24

E = 2.0x 106 psi

Weight = 2.27 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Lengthwise Direction

111
33
14

240
93
27
12

360
69
21
9

46
14
6

E = .8x 106 psi

Weight = 2.27 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Crosswise Direction
100

L/D
180

150
67
20
8

44
13
6

240
37
11
5

360
28
8
3

19
5
2

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Chapter 4

Pultex Standard Structural Profiles

Flat Sheets
E = 2.0x 106 psi
Weight = 3.43 lb/ft2
3/8" (Part # FS 060)
All Allowable Uniform Loads are in lbs./ft2.
Pultex 1500/1525 & 1625 Series
Sheet Spanning in Lengthwise Direction
span
(inches)
12
18
24
30
36

100
563
167
70
36
21

150
375
111
47
24
14

L/D
180
313
93
39
20
12

240
234
69
29
15
9

360
156
46
20
10
6

E = .8x 106 psi

Weight = 3.43 lb/ft2
3/8" (Part # FS 060)
All Allowable Uniform Loads are in lbs./ft2.

Pultex 1500/1525 & 1625 Series

Sheet Spanning in Crosswise Direction
span
(inches)
12
18
24
30
36

100
225
67
28
14
8

150
150
44
19
10
6

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Chapter 4

L/D
180
125
37
16
8
5

240

360
94
28
12
6
3

63
19
8
4
2

Pultex Standard Structural Profiles

Flat Sheets
1/2" (Part # FS 080)
Pultex 1500/1525 & 1625 Series

span
(inches)
12
18
24
30
36
42
48

100
1333
395
167
85
49
31
21

1/2" (Part # FS 080)

Pultex 1500/1525 & 1625 Series

span
(inches)
12
18
24
30
36
42
48

E = 2.0x 106 psi

Weight = 4.64 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Lengthwise Direction
L/D
180

150
889
263
111
57
33
21
14

741
219
93
47
27
17
12

240
556
165
69
36
21
13
9

360
370
110
46
24
14
9
6

E = .8x 106 psi

Weight = 4.64 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Crosswise Direction
100

L/D
180

150
533
158
67
34
20
12
8

356
105
44
23
13
8
6

296
88
37
19
11
7
5

240
222
66
28
14
8
5
3

360
148
44
19
9
5
3
2

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Chapter 4

Pultex Standard Structural Profiles

Flat Sheets
5/8" (Part # FS 090)
Pultex 1500/1525 & 1625 Series

span
(inches)
12
18
24
30
36
42
48
54
60

100
2604
772
326
167
96
61
41
29
21

5/8" (Part # FS 090)

Pultex 1500/1525 & 1625 Series

span
(inches)
12
18
24
30
36
42
48
54
60

E = 2.0x 106 psi

Weight = 5.77 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Lengthwise Direction
150
1736
514
217
111
64
40
27
19
14

L/D
180
1447
429
181
93
54
34
23
16
12

240
1085
322
136
69
40
25
17
12
9

360
723
214
90
46
27
17
11
8
6

E = .8x 106 psi

Weight = 5.77 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Crosswise Direction
100
1042
309
130
67
39
24
16
11
8

L/D
180

150
694
206
87
44
26
16
11
8
6

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Chapter 4

240
579
171
72
37
21
13
9
6
5

360
434
129
54
28
16
10
7
5
3

289
86
36
19
11
7
5
3
2

Pultex Standard Structural Profiles

Flat Sheets
3/4"(Part # FS 100)
Pultex 1500/1525 & 1625 Series

span
(inches)
12
18
24
30
36
42
48
54
60

100
4500
1333
563
288
167
105
70
49
36

3/4" (Part # FS 100)

Pultex 1500/1525 & 1625 Series
span
(inches)
12
18
24
30
36
42
48
54
60

E = 2.0x 106 psi

Weight = 6.57 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Lengthwise Direction
150
3000
889
375
192
111
70
47
33
24

L/D
180
2500
741
313
160
93
58
39
27
20

240
1875
556
234
120
69
44
29
21
15

360
1250
370
156
80
46
29
20
14
10

E = .8x 106 psi

Weight = 6.57 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Crosswise Direction
100
1800
533
225
115
67
42
28
20
14

150
1200
356
150
77
44
28
19
13
10

L/D
180
1000
296
125
64
37
23
16
11
8

240
750
222
94
48
28
17
12
8
6

360
500
148
63
32
19
12
8
5
4

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Chapter 4

Pultex Standard Structural Profiles

Flat Sheets
1" (Part # FS 110)
Pultex 1500/1525 & 1625 Series

span
(inches)
12
18
24
30
36
42
48
54
60

100
10667
3160
1333
683
395
249
167
117
85

1" (Part # FS 110)

Pultex 1500/1525 & 1625 Series

span
(inches)
12
18
24
30
36
42
48
54
60

E = 2.0x 106 psi

Weight = 9.45 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Lengthwise Direction
150
7111
2107
889
455
263
166
111
78
57

L/D
180
5926
1756
741
379
219
138
93
65
47

240
4444
1317
556
284
165
104
69
49
36

360
2963
878
370
190
110
69
46
33
24

E = .8x 106 psi

Weight = 9.45 lb/ft2
All Allowable Uniform Loads are in lbs./ft2.
Sheet Spanning in Crosswise Direction
100
4267
1264
533
273
158
100
67
47
34

150
2844
843
356
182
105
66
44
31
23

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Chapter 4

L/D
180
2370
702
296
152
88
55
37
26
19

240
1778
527
222
114
66
41
28
20
14

360
1185
351
148
76
44
28
19
13
9

Clip Connection Load Tables with Pultex SuperStructural Angles

The following Clip Connection Load Tables were developed based on full section testing of the Pultex
SuperStructural angles. The experimental procedure can be located in Appendix A. The load tables
were developed based on the following:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Experimental test results

Room temperature (73)
A safety factor has not been applied. All loads are ultimate unless noted.
An ultimate bearing strength of 33,000 psi
A 4% hole deformation bearing stress of 12,000 psi
No damage to the composite materials
No chemical exposure
Bolted connection only; no adhesive.
Full section shear strength through angle heel = 3,400 psi (1500/1525 Series); 3,900 psi (1625 Series)

Note: Clip angle connection dimensions are governed by internal dimensions of beams and external
dimensions of the flanges on the columns.

1500/1525 Series Pultex SuperStructural Angles

# of
Ultimate
Ultimate
Allowable
Clip
Bolt
# of
Bolts
Shear Load
Bearing Bearing Load Clip Angle
Angle
Angle
Hole Bolt # of Angles Bolts through # of Bolts
through
Load of
for 4% Hole
Ultimate
Thickness Connection Dia. Dia.
in
in
Beam Connected Angle Heels Connection Deformation Load before
(in)
Length (in) (in) (in) Connection Shear Web to Column
(lbs.)
(lbs.)
(lbs.)
Failure (lbs.)
3/8
4 1/2
9/16 1/2
2
4
2
4
11,475
24,750
9,000
11,475
3/8
4 1/2
11/16 5/8
2
4
2
4
11,475
30,938
11,250
11,475
1/2
4 1/2
9/16 1/2
2
4
2
4
15,300
33,000
12,000
15,300
1/2
4 1/2
11/16 5/8
2
4
2
4
15,300
41,250
15,000
15,300

1500/1525 Series Pultex SuperStructural Angles

# of
Ultimate
Ultimate
Allowable
Clip
Bolt
# of
Bolts
Shear Load
Bearing Bearing Load Clip Angle
Angle
Angle
Hole Bolt # of Angles Bolts through # of Bolts
through
Load of
for 4% Hole
Ultimate
Thickness Connection Dia. Dia.
in
in
Beam Connected Angle Heels Connection Deformation Load before
(in)
Length (in) (in) (in) Connection Shear Web to Column
(lbs.)
(lbs.)
(lbs.)
Failure (lbs.)
3/8
6
9/16 1/2
2
4
2
4
15,300
24,750
9,000
15,300
3/8
6
11/16 5/8
2
4
2
4
15,300
30,938
11,250
15,300
1/2
6
9/16 1/2
2
4
2
4
20,400
33,000
12,000
20,400
1/2
6
11/16 5/8
2
4
2
4
20,400
41,250
15,000
20,400

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Chapter 4

1500/1525 Series Pultex SuperStructural Angles

Clip
Bolt
Angle
Angle
Hole
Thickness Connection Dia.
(in)
Length (in) (in)
3/8
8 1/4
9/16
3/8
8 1/4
11/16
1/2
8 1/4
9/16
1/2
8 1/4
11/16

Bolt
Dia.
(in)
1/2
5/8
1/2
5/8

# of
Ultimate
Ultimate
Allowable
# of
Bolts
Shear Load Bearing Bearing Load Clip Angle
# of Angles Bolts through # of Bolts
through
Load of
for 4% Hole
Ultimate
in
in
Beam Connected Angle Heels Connection Deformation Load before
Connection Shear Web to Column
(lbs.)
(lbs.)
(lbs.)
Failure (lbs.)
2
6
3
6
21,038
37,125
13,500
21,038
2
6
3
6
21,038
46,406
16,875
21,038
2
6
3
6
28,050
49,500
18,000
28,050
2
6
3
6
28,050
61,875
22,500
28,050

1625 Series Pultex SuperStructural Angles

Clip
Bolt
Angle
Angle
Hole
Thickness Connection Dia.
(in)
Length (in) (in)
3/8
4 1/2
9/16
3/8
1/2
1/2

4 1/2
4 1/2
4 1/2

Bolt
Dia.
(in)
1/2

11/16 5/8
9/16 1/2
11/16 5/8

# of
Ultimate
Ultimate
Allowable
# of
Bolts
Shear Load Bearing Bearing Load Clip Angle
# of Angles Bolts through # of Bolts
through
Load of
for 4%Hole Ultimate Load
in
in
Beam Connected Angle Heels Connection Deformation before Failure
Connection Shear Web to Column
(lbs.)
(lbs.)
(lbs.)
(lbs.)
2
4
2
4
13,163
24,750
9,000
13,163
2
2
2

4
4
4

2
2
2

4
4
4

13,163
17,550
17,550

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Chapter 4

30,938
33,000
41,250

11,250
12,000
15,000

13,163
17,550
17,550

1625 Series Pultex SuperStructural Angles

Clip
Bolt
Angle
Angle
Hole
Thickness Connection Dia.
(in)
Length (in) (in)
3/8
6
9/16
3/8
6
11/16
1/2
6
9/16
1/2
6
11/16

Bolt
Dia.
(in)
1/2
5/8
1/2
5/8

Ultimate
Shear
# of
Load
# of
Bolts
through
# of Angles Bolts through # of Bolts
Angle
in
in
Beam Connected
Heels
Connection Shear Web to Column
(lbs.)
2
4
2
4
17,550
2
4
2
4
17,550
2
4
2
4
23,400
2
4
2
4
23,400

Ultimate
Allowable
Bearing Bearing Load Clip Angle
Load of
for 4% Hole Ultimate Load
Connection Deformation before Failure
(lbs.)
(lbs.)
(lbs.)
24,750
9,000
17,550
30,938
11,250
17,550
33,000
12,000
23,400
41,250
15,000
23,400

1625 Series Pultex SuperStructural Angles

# of
Ultimate
Bolt
# of
Bolts
Shear Load
Clip Angle
Angle
Hole Bolt # of Angles Bolts through # of Bolts
through
Thickness Connection Dia. Dia.
in
in
Beam Connected Angle Heels
(in)
Length (in) (in) (in) Connection Shear Web to Column
(lbs.)
3/8
8 1/4
9/16 1/2
2
6
3
6
24,131
3/8
8 1/4
11/16 5/8
2
6
3
6
24,131
1/2
8 1/4
9/16 1/2
2
6
3
6
32,175
1/2
8 1/4
11/16 5/8
2
6
3
6
32,175

Note:

Clip
Angle
Ultimate
Allowable Ultimate
Bearing
Bearing Load Load
Load of
for 4% Hole before
Connection Deformation Failure
(lbs.)
(lbs.)
(lbs.)
37,125
13,500
24,131
46,406
16,875
24,131
49,500
18,000
32,175
61,875
22,500
32,175

The maximum slip of the connection at failure is approximately 0.35"without adhesive.

The maximum slip of the connection at failure is approximately 0.101" with adhesive. The
adhesive does not affect the ultimate load capacity of the connection, but does affect the amount
of slip of the connection.
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Chapter 4

Bolt Hole Bearing Capacity of Pultex SuperStructural Beams and Columns

Tables 4-3 and 4-4 represent the bearing capacity of the flange and web sections of various beams and
columns. The load table is based on the following:
The ultimate lengthwise bearing strength of the flange sections is 33,000 psi.
The ultimate crosswise bearing strength of the web section is 30,000 psi.
The 4% hole deformation longitudinal bearing strength of the flange is 12,000 psi.
The 4% hole deformation transverse bearing strength of the web is 11,000 psi.
No safety factors are applied.
Testing performed at room temperature (73F)
No adhesive is used.
Bolt torque is not considered.

1.
2.
3.
4.
5.
6.
7.
8.

Table 4-3
Bolt Hole Bearing Capacity of Pultex SuperStructural Columns and Beams for 1500/1525 Series
Design Chart
4% Hole
Ultimate Beam
4% Hole
Deformation Beam Web Bearing Deformation Column Ultimate Column
Web Bearing Load
Load in
Flange Bearing Load Flange Bearing Load
# of Bolts # of Bolts
in Transverse
Transverse
in Longitudinal
in Longitudinal
in Column in Beam
Direction (lbs.)
Direction (lbs.)
Direction (lbs.)
Direction (lbs.)

Member
Thickness
(inches)

Bolt
Diameter
(inches)

1/4

1/2

938

2,563

3,000

8,250

1/4

1/2

1,875

5,125

6,000

16,500

1/4

1/2

2,813

7,688

9,000

24,750

3/8

1/2

2,063

5,625

4,500

12,375

3/8

1/2

4,125

11,250

9,000

24,750

3/8

1/2

6,188

16,875

13,500

37,125

1/2

2,750

7,500

6,000

16,500

1/2

5,500

15,000

12,000

33,000

1/2

8,250

22,500

18,000

49,500

1/4

5/8

1,172

3,203

3,750

10,313

1/4

5/8

2,344

6,406

7,500

20,625

1/4

5/8

3,516

9,609

11,250

30,938

3/8

5/8

2,578

7,031

5,625

15,469

3/8

5/8

5,156

14,063

11,250

30,938

3/8

5/8

7,734

21,094

16,875

46,406

1/2

5/8

3,438

9,375

7,500

20,625

1/2

5/8

6,875

18,750

15,000

41,250

1/2

5/8

10,313

28,125

22,500

61,875

Note: Values are representative for bolted connections without adhesives.

Transverse bearing stress of 1/4" Pultex SuperStructural profiles, Web sections = 20,500 psi., 4% Elongation = 7,500 psi

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Chapter 4

Table 4-4
Hole Bearing Capacity of Pultex SuperStructural Columns and Beams for 1625 Series
Design Chart
4% Hole Deformation
4% Hole Deformation Ultimate Column
Beam Web
Ultimate Beam Web
Column Flange
Flange Bearing
Member
Bolt
# of Bolts
Bearing Load in
Bearing Load in
Bearing Load in
Load in
Thickness Diameter
in
# of Bolts Transverse Direction Transverse Direction Longitudinal Direction
Longitudinal
(inches)
(inches)
Column in Beam
(lbs.)
(lbs.)
(lbs.)
Direction (lbs.)
1/4

1/2

1,175

2,938

3,500

9,500

1/4

1/2

2,350

5,875

7,000

19,000

1/4

1/2

3,525

8,813

10,500

28,500

3/8

1/2

2,372

6,469

5,250

14,250

3/8

1/2

4,744

12,938

10,500

28,500

3/8

1/2

7,116

19,406

15,750

42,750

1/2

3,163

8,625

7,000

19,000

1/2

6,325

17,250

14,000

38,000

1/2

9,488

25,875

21,000

57,000

1/4

5/8

1,469

3,672

4,375

11,875

1/4

5/8

2,938

7,344

8,750

23,750

1/4

5/8

4,406

11,016

13,125

35,625

3/8

5/8

2,965

8,086

6,563

17,813

3/8

5/8

5,930

16,172

13,125

35,625

3/8

5/8

8,895

24,258

19,688

53,438

1/2

5/8

3,953

10,781

8,750

23,750

1/2

5/8

7,906

21,563

17,500

47,500

1/2

5/8

11,859

32,344

26,250

71,250

Note: Values are representative for bolted connections without adhesives.

Transverse bearing stress of 1/4" Pultex SuperStructural profiles 1625 Series, Web sections = 23,500 psi., 4% elongation = 9,400 psi

Connection Fastener Edge Distance and Torque Level Recommendations2

Ratio of distance to fastener diameter
Range
Edge Distance- End
2.0-4.5
Edge Distance- Side
1.5-3.5
Pitch (Distance between holes)
4.0-5.0

Recommended
3.0
2.0
5.0

Reference: Structural Plastics Design Manual

ASTM A325
Bolt
Size
1/2" -13
5/8" - 11

Low Torque
37.5% of Bolt Proof Load
Torque
ft-lbs. (N m)
29 (39)
57 (77)

High Torque
75% of Bolt Proof Load
Torque
ft-lbs. (N m)
57 (77)
113 (153)

Bolt recommendations based on ASTM A325 grade five coarse threaded bolts
Connection testing performed with grade 8 oversized washers (2.5 times hole dia.)
Proof strength for ASTM A325 bolt equals 75,000 psi (0.5 GPa)

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The New and Improved Pultex Pultrusion Design Manual

Chapter 4

Design Example Using the Clip Connection Charts

Task
Design a connection for a 6" x 6" x 3/8" Wide Flange Section beam that is clipped into a 8" x 8" x 3/8"
Wide Flange Section column. (Reference drawing below.)
Given
Design load on connection is a static load of 6,000 lbs.
The corrosive environment requires 1625 Series.
Operating temperature = 73F.
Minimum Safety Factor = 2.5

Solution:
1. Reference the 1625 Series of Pultex SuperStructural angle clip connection charts for the 4.5" clip
angle length (depth of the 6" x 6" x 3/8" section dictates the 4.5" angle length).
2. First, investigate the 3/8" thick angles. Looking across to the Ultimate Load Before Failure
Column, the ultimate load of the 3/8" thick clip angle connection is 13,163 lbs.
3. The design load is 6,000 lbs.(2.5 S.F.) = 15,000 lbs.; therefore, the 3/8" section is not adequate.
4. Investigate the 1/2" thick angles. The Ultimate load is 17,550 lbs.; therefore, the 1/2" angle is
adequate.
5. Specify the 4" x 4" x 1/2" angle 4.5" long 1625 Series of Pultex SuperStructural angle.
6. Determine the bearing capacity of the two holes in the web of the 6" x 6" x 3/8" Wide Flange Section
and the bearing capacity of the four holes in the column.
7. Reference the Hole Bearing Capacity of Pultex Columns and Beams Design Chart. Determine
the row that satisfies the desired bolting condition and member sizes.
8. Enter the row for the 3/8" member thickness and two bolts in the beam. The ultimate beam web
bearing load in the transverse direction is 16,172 lbs. for the 5/8" diameter bolts. The design load
with the 2.5 S.F. is 15,000 lbs.; the connection is adequate.
10. From Table 1a, the column bearing load is adequate at 35,625 lbs.

98
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Chapter 4

Moment Capacity of Pultex SuperStructural Angles

Table 4-5
M o m e n t C a p a c ity o f 3 /8 " th ic k P u lte x S u p e r S tr u c tu r a l A n g le s
1 5 0 0 /1 5 2 5 /1 6 2 5 S e r ie s

8 .0

7 .0

6 .0

5 .0

4 .0

3 .0

U ltim a te M o m e n t a t F a ilu re = 5 0 6 in -lb s./in

2 .0

1 .0

0 .0
0

100

150

200

250

300

350

400

450

M o m e n t (in -lb s ./in )

Moment capacity is in (in-lbs.) per longitudinal inch of angle

Table 4-6

M om en t C ap acity of 3/8" th ick P u ltex S u p e rS tru c tu ra l A n gles

1500/1525/1625 S eries
2

U ltim ate M o m en t at F ailu re = 15 0 in -lb s./in

0
0

100

120

M o m e n t (in -lb s ./in )

Moment capacity is in (in-lbs.) per longitudinal inch of angle

99
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Chapter 4

Table 4-7

M om ent C apacity of 1/2" thick Pultex SuperStructural A ngles

1500/1525/1625 Series

Degrees of Rotation

U ltimate M oment at Failure = 235 in0

M om ent (in-lbs./in)

Moment capacity is in (in-lbs.) per longitudinal inch of angle

Table 4-8

M o m e n t C a p a c ity o f 1 /2 " th ic k P u lte x S u p e r S tr u c tu r a l A n g le s

1 5 0 0 /1 5 2 5 /1 6 2 5 S e r ie s
1 0 .0

9 .0

8 .0

7 .0

6 .0

5 .0

4 .0

3 .0

U ltim a te M o m e n t a t F a ilu re = 9 5 4 in -lb s./in

2 .0

1 .0

0 .0
0

100

200

300

400

500

600

M o m e n t (in -lb s ./in )

Moment capacity is in (in-lbs.) per longitudinal inch of angle

100
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Chapter 4

700

800

Designing a Connection With a Coped Flange

Figure 4-1

Coped Flange Connection

Figure 4-2

When designing a connection with a coped flange, block shear must be checked to insure that the
connection is adequate. The two factors affecting block shear are the transverse tensile and shear
strengths of the web section of the beam. Values for transverse tensile strength and in-plane shear
strengths can be located in the Material Properties Sheets of Pultex Fiber Reinforced Polymer Structural
Profiles and Pultex SuperStructural Profiles for Wide Flange Sections and I-Sections.
The procedure for determining the block shear (Vblock) allowable load is as follows:
1. Determine the in-plane shear and tensile strengths of the beam profile
with which you are designing. (Material Properties Sheets of PultexFiber Reinforced
Polymer Structural Profiles and Pultex SuperStructural Profiles for Wide Flange
Sections and I-Sections).
2. Determine the shear length (Lv) of the bolted connection. (Reference Figure 4-2)
3. Determine the net tensile length (Lt) of the bolted connection. (Reference Figure 4-2)
4. Apply the proper safety factors to the connection. (Use 2 for demonstration.)
Determine if Vblock allowable is greater than the design load.
Example
Design a framed connection using a Pultex SuperStructural 6" x 6" x 3/8" Wide Flange Section coped
into an Pultex SuperStructural 8" x 8" x 3/8" beam. The holes are 9/16" to accommodate 1/2" bolts.
(Reference Figure 4-1)
1. Referencing the Material Properties Sheets for Pultex SuperStructural Profiles, the in-plane
shear and tensile strengths of the web section are 7,000 psi and 10,500 psi, respectively.
2. Calculate the shear length (Lv) of the Figure 1. connection,
i.e., (.130 + 2 + 1.25 -9/16 - 9/32) = 2.53"
3. Calculate the net tension length (Lt) of the above connection,
i.e., (1.5 .5(9/16)) =1.219"
4. Apply the proper safety factors to the transverse shear and tensile strengths,
i.e., (Allowable shear = 7,000/2 = 3,500 psi)
(Allowable tension = 10,500/2 = 5,250 psi)
5. Calculate the allowable shear force for block shear Vblock
i.e., (5000(1.219)(.375) + 3,500(2.53)(.375) = 5,720 lbs.
6. Compare Vblock allowable to the design load.3
101
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Chapter 4

Endnotes
1

Task Committee on Design of the Structural Plastics Research Council of the Technical Council

on Research of the American Society of Civil Engineers. Structural Plastics Design Manual
Vol. 2. New York: American Society of Civil Engineers, 1984, pg. 732.
2

Task Committee on Design of the Structural Plastics Research Council of the Technical Council

on Research of the American Society of Civil Engineers. Structural Plastics Design Manual
Vol. 1. New York: American Society of Civil Engineers, 1984, pg. 439.
3

Bank, L.C. Bolted Connections for Pultruded Frame Structures. Diss. The Catholic

University of America, 1996, pg. 29.

Boresi, A.P. and Schmidt, R.J. 2003. Advanced Mechanics of Materials. 6th edition, John

Wiley & Sons, Inc. New York, NY.

Pandey, M.D., Kabir, M.Z., and Sherbourne, A.N. 1995. "Flexural-torsional stability of

thin-walled composite I-section beams," Composites Engineering, 5(3): 321-342.

Qiao, P.Z, Davalos, J.F., and Wang, J.L. 2001. "Local buckling of composite FRP shapes by

discrete plate analysis," Journal of Structural Engineering, ASCE, 127 (3): 245-255.
7

Qiao, P.Z. and Zou, G.P. 2003. Local Buckling of Composite Fiber-Reinforced Plastic

Wide-Flange Sections, Journal of Structural Engineering, ASCE, 129(1): 125-129.

Qiao, P.Z. and Zou, G.P. (2002). Local Buckling of Elastically Restrained Fiber-

Reinforced Plastic Plates and its Applications to Box-Sections, Journal of Engineering

Mechanics, ASCE, 128 (12): 1324-1330.
9

Qiao, P.Z. 2003. Design equations and guidelines for fiber-reinforced polymer (FRP)

composite channel sections, Final Report to Creative Pultrusions, Inc., July 2003. 36 pages.

102
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Chapter 4

Reaction Frame

Short vertical column members were tested on a MTS machine; long column members were tested on a
30-ft. reaction frame. During the test, a microprofiler was used to generate the displacement rate of
loading at a 0.1 in./min. The measurements included strains, ultimate loads, axial displacements and
lateral deflections.
The composite materials for the column members are constructed of polyester-based and vinyl ester-based
resin matrices, with and without fire retardancy, reinforced with E-glass fibers.
Analysis and Discussion
Columns with Box Sections (Imperial)
For the short columns with box sections, the ultimate load capacity is a function of the bearing
strength of the composite material and the column cross-sectional area. In general, the bearing
strength of a structural composite is approximately 30 ksi; therefore, the ultimate strength of short
columns with box sections depends upon the cross-sectional area; for a given area, the columns with
box sections appear to have the highest ultimate load capacities among the columns with other section
configurations. For a given wall thickness of a box section, the ultimate load capacity appears to
increase linearly with an increase in the section dimensions, e.g., for thickness t = 1/4", length L = 2
ft., the ultimate load strength was 40 kips for 1 3/4" x 1 3/4" box section; 58 kips for 2" x 2" section;
and 88 kips for a 3" x 3" section.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

For the long columns, the ultimate column strength is a function of the slenderness ratio KL/r. The
column strength decreases with an increase in the slenderness ratio. For columns with box sections,
the dividing line at the slenderness ratio for short and long columns appears to be 35. For columns
with KL/r less than 35, the bearing strength of the composite controls the ultimate load. For columns
with KL/r greater than 35, global buckling strength controls the ultimate load.
Columns with Round Sections
Similar to the columns with box sections, the ultimate load capacity of the short round column is also
a function of the bearing strength of the composites and column cross-sectional area. For a given area
and length, the ultimate column strength of a short round column is approximately 20% less than that
of a short box column.
For the long round columns, the ultimate column strength is a function of the slenderness ratio KL/r.
The round column strength decreases with an increase in the slenderness ratio. For round columns,
the dividing line at the slenderness ratio appears to be between 30 to 40. For round columns with
KL/r greater than 40, the columns have the characterization of an Euler behavior. For round columns
with KL/r less than 30, bearing mode of failure dominates the ultimate column strength. At KL/r =
25, the ultimate stress of the round column from test results is less than the bearing strength of 30 ksi
of the composites; therefore, the prediction curve in the short round column region becomes an
inclined straight line.
Columns with Wide Flange Sections
From experimental results, the ultimate strength of columns with Wide Flange Sections is about 30
percent of the ultimate strength of columns with box sections for a given cross-sectional dimension
and member length.
For the long columns, the ultimate column strength is a function of the slenderness ratio KL/r. The
column strength decreases with an increase in the slenderness ratio. For columns with Wide Flange
Sections, the dividing line at the slenderness ratio for short and long columns appears to be in the
range of 40 to 60. For columns with KL/r less than 60, the column ultimate load depends on one-half
of the flange width to the flange thickness ratio of bf/2tf. The higher the bf/2tf ratio, the less the
ultimate load capacity.
Columns with I-Sections
Similar to the columns with Wide Flange Sections, the ultimate load capacity of the columns with
I-sections is a function of the slenderness ratio KL/r. The column strength decreases with an increase
in the slenderness ratio. For columns with I-sections, the dividing line at the slenderness ratio for
short and long columns appears to be in the range of 30 to 40. For columns with KL/r greater than
40, the Euler characteristics of the column with I-sections are close to that of the column with Wide
Flange Sections; however, for I-section columns with KL/r less than 30, the ultimate stress is
significantly higher than the ultimate stress of the Wide Flange Section column due to a smaller bf/tf
ratio. The crippling of the flange in the testing of I-section columns was not observed. At KL/r = 30,
the ultimate stress of the I-section column from test results is less than the bearing strength of 30 ksi
of the composites; therefore, the prediction curve in short I-section column regions becomes an
inclined straight line.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Columns with Angle Sections

Columns with angle sections were axially loaded at the centroid of the section. The ultimate load
capacity is a function of the slenderness ratio KL/r. The column strength decreases with an increase
in the slenderness ratio. For columns with angle sections, the dividing line at the slenderness ratio for
short and long columns appears to be in the range of 45 to 60. For columns with KL/r greater than
60, the Euler characteristics of the column with angle section is close to that of the column with Wide
Flange Sections; however, for the angle-section columns with KL/r less than 45, the ultimate stress is
significantly lower than that of the Wide Flange Section columns due to a larger bf/tf ratio and
localized instability. The crippling of the flange in the testing of angle-section columns was observed
for all specimens; the local buckling instigated a torsion and global buckling of the column. In the
short angle section column region, the ultimate column strength is sensitive to the bf/tf ratio. For a
bf/tf greater than 8, the ultimate strength of the column with angle section decreases significantly.
Column Load Design Equations
The Column Load Design Equations for E-glass reinforced polymer columns are based on a large group
of data points from full section tests of composite columns. The observed column failure can be
categorized into two modes: bearing failure and local/global instability. Figure 5-3 depicts a general
behavior for all fiber reinforced polymer columns. The curve can be divided into two groups: short
column and long column, as the plotted compressive stress versus slenderness ratio. The short columns
generally fail in bearing deformation or local buckling mode; the long columns generally fail in the global
buckling mode.

Compressive Stress vs. Slenderness Ratio

Figure 5-3
35

Compressive Stress, ksi

30
25
20
15
10
5
0
0

100

120

140

160

180

200

Slenderness Ratio, KL/r

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Design Equations for Box Sections

For short columns with box sections, a bearing failure due to axial compressive loading governs the
design equation as follows:

ult =
=
=
=

Where Pult
A

ult

Pult
A

Ultimate axial load (lbs.)

Cross-sectional area (in2)
Bearing strength of the composite (psi)

Columns with Round- and I-Sections

For short columns with round- and I-sections, the columns fail due to a combination of axial load and
bending moment. The design equations consider the interaction of bearing and flexural buckling
failure. A linear equation is developed from the test results for the transition behavior as follows:

ult = 30

1 KL
7 r

ult = 25

Where

(ksi) for short Pultex FRP Round Section columns (2)

5 KL
38 r

ult
K
L
r

=
=
=
=

(ksi) for short Pultex FRP I Section columns (3)

Ultimate compressive stress (ksi)

Effective length coefficient
Column length (in) when used in above equation
Radius of gyration of the section (in)

Columns with Wide Flange Sections

For short columns with Wide Flange Sections, local buckling or crippling occurs on the flanges.
According to the test results, the ultimate local buckling stress, ult,l of the Pultex FRP composite
Wide Flange Section column can be predicted by the modified buckling equation of thin plate for
isotropic materials as follows:

2 E t f
ult = k
12(1 2 ) b f
Where:

tf
bf

=
=
=
=
=
=

(psi) for short Pultex FRP W ide Flange Section columns (4)

Modulus of elasticity in the loading direction (psi)

Poissons ratio
Thickness of the local flange element (in)
Width of the local flange element (in)
0.8, a coefficient to account for the orthotropic material of the composite
0.5 is recommended for the non-stiffened outstanding flanges of the Wide Flange
Section
4.0 is recommended for the stiffened outstanding webs of the Wide Flange
Section
The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

It should be noted that the ultimate local buckling strength needs to be checked against bearing
strength. The lower value will be used for the ultimate strength of the short composite column with
the Wide Flange Section. Then, the ultimate strength of the short column is compared with the
flexural buckling strength to determine the dividing point for short and long columns.
Columns with Angle Sections
For short columns with angle sections, the local buckling of the flange occurs, as in the column with
the Wide Flange Section. Thus, the design Equation (4) can also be applied to predict the ultimate
strength of the short columns with angle sections.
Design Equations for Long Columns
The flexural buckling, known as Euler buckling, is the general behavior of long, slender Pultex FRP
columns under axial compression loads. According to the test results, the ultimate buckling strength of
the composite columns was in agreement with the Euler buckling equation:
(psi) for all long Pultex FRP columns (5)

ult , Euler =

2E
KL

The equation can be applied to the long Pultex FRP composite columns with square-, round-, I-, W-, and
angle- sections; however, for columns with angle-sections, flexural-torsional buckling governs the
ultimate strength. In the test, the coupling of the flexural and torsional buckling was observed in a form
of lateral deflection and global twisting for the angle-section columns. The ultimate flexural-torsional
buckling stress can be approximated by the lower value from equation (5) for flexural buckling strength
about the weak axis, or from the torsional buckling equation as follows:
ult , ft

t
f
=
2 (1 + ) b f
E

(psi) for short Pultex FRP Angle columns (6)

According to the test results, the coefficient = 0.8 is recommended for Equation (6) to account for the
orthotropic material of the composite, where bf is the width of the local flange element (in); one-half the
width for Wide Flange Sections; whole leg width for angle sections.
The effective length coefficient, K-value, in the equation, accounts for the different end conditions.
The K-value is recommended in Table 1. for Pultex FRP composite columns with various end
supports.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Table 5-1 Effective Length Coefficient, K-Value

End Conditions
Recommended K-Value
1. Pinned-Pinned
1.00
2. Fixed-Fixed
0.65
3. Pinned-Fixed
0.80
4. Fixed-Translation Fixed
1.20
5. Fixed-Translation Free
2.10
6. Pinned-Translation Fixed
2.00

Note: Buckled Shape of Column Displayed by Dashed Line

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Nomenclature
A
bf

=
=

E
Fa
Ix,Iy
k

=
=
=
=

K
L
Pa
r
S
tf

ult
ult,l
ult,Euler
ult,ft

=
=
=
=
=
=
=
=
=
=
=
=

Cross-sectional area (in2)

Width of local flange element; width of angle leg or width of a Wide Flange
Beam (in)
Modulus of elasticity in the loading direction (psi)
Allowable compressive stress (psi)
Moment of Inertia (in4)
Flange stiffness factor 0.5 for non-stiffened outstanding flanges of the Wide
Flange Section; 4.0 for stiffened
Effective length coefficient
Length of column (ft); (in) when used in KL/r equation
Allowable axial load (lbs.)
Radius of gyration of the section (in)
Section Modulus (in3)
Thickness of local flange element (in)
Poissons Ratio (.36 in/in)
0.8, a coefficient to account for the orthotrophic material of the composite
Ultimate compressive or bearing stress of the composite (psi)
Ultimate local buckling stress (psi)
Ultimate Euler buckling stress (psi)
Ultimate flexural-torsional buckling stress (psi)

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Tables for Allowable Compressive Stresses and Loads

The following tables provide information for the allowable stresses (Fa) and the allowable loads (Pa) for
columns with square tube sections, round sections, Wide Flange Sections, I-sections and angle-sections.
The tables represent sections used as compressive members (columns). The tables were developed based
on the following criteria:
1.
2.
3.
4.
5.
6.
7.
8.

Experimental test results

Room temperature (73 F)
A safety factor of S.F. = 3.0
A value of K = 1.0
A value of E = 3x106 psi
= .36 in/in
No damages on the composite columns
Tables display KL/r values to 200 for reference. It is recommended that KL/r be limited to 120.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Tables for Allowable Compressive Stresses and Loads

Pultex Standard Structural Profiles
Equal Leg Angles
2" x 2" x 1/4" (Part# AE 240)
Pultex1500/1525/1625 Series
A = .92 in2, rz = .38 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0

KL/r
31.5
47.2
63.0
78.7
94.4
110.2
125.9
141.7
157.4
173.1
188.9
204.6
220.4
236.1
251.8

Fa (psi)
4596
4427
2490
1594
1107
813
622
492
398
329
277
236
203
177
156

Pa (lbs.)
4237
4081
2296
1469
1020
750
574
453
367
304
255
217
187
163
143

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Short Column
Short Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column

Pultex Standard Structural Profiles

Equal Leg Angles

3" x 3" x 1/4" (Part# AE 340)

Pultex 1500/1525/1625 Series
A = 1.42 in2, rz = .58 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0

KL/r
20.6
30.8
41.1
51.4
61.7
72.0
82.2
92.5
102.8
113.1
123.4
133.7
143.9
154.2
164.5
174.8
185.1
195.3
205.6

Fa (psi)
2042
2042
2042
2042
2042
1906
1459
1153
934
772
648
553
476
415
365
323
288
259
233

Pa (lbs.)
2904
2904
2904
2904
2904
2710
2075
1639
1328
1097
922
786
677
590
519
459
410
368
332

Chapter 5

Pa (lbs.)
7334
7334
7334
7334
7334
7334
7334
5835
4726
3906
3282
2797
2411
2101
1846
1635
1459
1309
1182
976
821
699
603

Short Column
Short Column
Short Column
Short Column
Short Column
Short Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column

Pultex Standard Structural Profiles

Equal Leg Angles
4" x 4" x 1/2" (Part# AE 480)
Pultex 1500/1525/1625 Series
A = 3.72 in2, rz = .78 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
11.0
12.0
13.0
14.0
15.0
16.0

KL/r
15.5
23.3
31.0
38.8
46.5
54.3
62.0
69.8
77.6
85.3
93.1
100.8
108.6
116.3
124.1
131.9
139.6
147.4
155.1
170.6
186.1
201.7
217.2
232.7
248.2

Fa (psi)
4596
4596
4596
4596
4558
3348
2564
2026
1641
1356
1139
971
837
729
641
568
506
454
410
339
285
243
209
182
160

Chapter 5

Pa (lbs.)
22400
22400
22400
20882
14501
10654
8157
6445
5220
4314
3625
3089
2664
2320
2039
1806
1611
1446
1305
1184
1079
987
906

Pultex Standard Structural Profiles

Square Tubes
3" x 3" x 1/4" (Part# TQ 340)
Pultex 1500/1525/1625 Series
A = 2.74 in2, r = 1.12 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
10.5
11.0
11.5
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0

KL/r
Fa (psi)
10.7
10000
16.0
10000
21.3
10000
26.7
10000
32.0
9638
37.3
7081
42.7
5422
48.0
4284
53.3
3470
58.7
2868
64.0
2410
69.3
2053
74.7
1770
80.0
1542
85.3
1355
90.7
1201
96.0
1071
101.3
961
106.7
867
112.0
787
117.3
717
122.7
656
128.0
602
138.7
513
149.3
443
160.0
386
170.7
339
181.3
300
192.0
268
202.7
240
213.3
217

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Pa (lbs.)
27400
27400
27400
27400
26409
19403
14855
11737
9507
7857
6602
5626
4851
4225
3714
3290
2934
2634
2377
2156
1964
1797
1651
1406
1213
1056
928
822
734
658
594

Short Column
Short Column
Short Column
Short Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column

Pultex Standard Structural Profiles

Square Tubes
3-1/2" x 3-1/2" x 3/8" (Part# TQ 360)
Pultex 1500/1525/1625 Series
A = 7.70 in2, r = 1.28 in3
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
10.5
11.0
11.5
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0

KL/r

Fa (psi)

Pa (lbs.)

9.3
14.0
18.7
23.4
28.0
32.7
37.4
42.1
46.7
51.4
56.1
60.7
65.4
70.1
74.8
79.4
84.1
88.8
93.5
98.1
102.8
107.5
112.1
121.5
130.8
140.2
149.5
158.9
168.2
177.6
186.9

10000
10000
10000
10000
10000
9224
7062
5580
4520
3735
3139
2675
2306
2009
1766
1564
1395
1252
1130
1025
934
854
785
669
577
502
441
391
349
313
282

77060
77060
77060
77060
77060
71082
54422
43000
34830
28785
24188
20610
17771
15480
13606
12052
10750
9648
8708
7898
7196
6584
6047
5152
4443
3870
3401
3013
2688
2412
2177

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Pultex Standard Structural Profiles

Square Tubes
4" x 4" x 1/4" (Part# TQ 440)
Pultex 1500/1525/1625 Series
A = 3.73 in2, r = 1.53 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
10.5
11.0
11.5
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0

KL/r
7.8
11.8
15.7
19.6
23.5
27.5
31.4
35.3
39.2
43.1
47.1
51.0
54.9
58.8
62.7
66.7
70.6
74.5
78.4
82.4
86.3
90.2
94.1
102.0
109.8
117.6
125.5
133.3
141.2
149.0
156.9

Fa (psi)
10000
10000
10000
10000
10000
10000
10000
7923
6418
5304
4457
3797
3274
2852
2507
2221
1981
1778
1604
1455
1326
1213
1114
949
819
713
627
555
495
444
401

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Pa (lbs.)
37300
37300
37300
37300
37300
37300
37300
29553
23938
19784
16624
14165
12213
10639
9351
8283
7388
6631
5985
5428
4946
4525
4156
3541
3053
2660
2338
2071
1847
1658
1496

Pultex Standard Structural Profiles

Square Tubes
6" x 6" x 3/8" (Part# TQ 660)
Pultex 1500/1525/1625 Series
A = 8.48 in2, r = 2.3 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
22.0
24.0

KL/r

Fa (psi)

Pa (lbs.)

5.2
10.4
15.7
20.9
26.1
31.3
36.5
41.7
47.0
52.2
57.4
62.6
67.8
73.0
78.3
83.5
88.7
93.9
99.1
104.3
114.8
125.2

10000
10000
10000
10000
10000
10000
7399
5665
4476
3626
2996
2518
2145
1850
1611
1416
1255
1119
1004
906
749
629

84800
84800
84800
84800
84800
84800
62747
48041
37958
30746
25410
21351
18193
15687
13665
12010
10639
9490
8517
7687
6353
5338

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Pultex Standard Structural Profiles

Round Tubes
1-3/4" x 1/4" (Part# TU 142)
Pultex 1500/1525/1625 Series
A = 1.18 in2, r = .54 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0

KL/r
Fa (psi)
22.3
8937
33.5
8406
44.6
4952
55.8
3169
67.0
2201
78.1
1617
89.3
1238
100.4
978
111.6
792
122.8
655
133.9
550
145.1
469
156.3
404
167.4
352
178.6
310

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Pa (lbs.)
10546
9919
5844
3740
2597
1908
1461
1154
935
773
649
553
477
416
365

Short Column
Short Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column

Pultex Standard Structural Profiles

Round Tubes
2" x 1/4" (Part# TU 240)
Pultex 1500/1525/1625 Series
A = 1.37 in2, r = .62 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0

KL/r
Fa (psi)
19.2
9086
28.8
8629
38.4
6693
48.0
4284
57.6
2975
67.2
2186
76.8
1673
86.4
1322
96.0
1071
105.6
885
115.2
744
124.8
634
134.4
546
144.0
476
153.6
418
163.2
371
172.8
331
182.4
297
192.0
268

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Pa (lbs.)
12487
11859
9199
5888
4089
3004
2300
1817
1472
1216
1022
871
751
654
575
509
454
408
368

Pultex Standard Structural Profiles

Round Tubes
2-1/2" x 1/4" (Part# TU 242)
Pultex 1500/1525/1625 Series
A = 1.77 in2, r = .80 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
10.5
11.0
11.5
12.0

KL/r
Fa (psi)
15.0
9286
22.5
8929
30.0
8571
37.5
7018
45.0
4874
52.5
3581
60.0
2742
67.5
2166
75.0
1755
82.5
1450
90.0
1218
97.5
1038
105.0
895
112.5
780
120.0
685
127.5
607
135.0
542
142.5
486
150.0
439
157.5
398
165.0
363
172.5
332
180.0
305

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Pa (lbs.)
16408
15777
15146
12402
8612
6327
4844
3828
3100
2562
2153
1835
1582
1378
1211
1073
957
859
775
703
641
586
538

Pultex Standard Structural Profiles

Round Tubes
3" x 1/4" (Part# TU 340)
Pultex 1500/1525/1625 Series
A = 2.16 in2, r = .98 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
10.5
11.0
11.5
12.0
13.0
14.0
15.0
16.0

KL/r
Fa (psi)
12.3
9415
18.4
9122
24.6
8829
30.7
8537
36.9
7259
43.0
5333
49.2
4083
55.3
3226
61.5
2613
67.6
2160
73.7
1815
79.9
1546
86.0
1333
92.2
1161
98.3
1021
104.5
904
110.6
807
116.8
724
122.9
653
129.1
593
135.2
540
141.3
494
147.5
454
159.8
387
172.1
333
184.4
290
196.7
255

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Pa (lbs.)
20334
19702
19070
18438
15678
11518
8819
6968
5644
4664
3919
3340
2880
2508
2205
1953
1742
1563
1411
1280
1166
1067
980
835
720
627
551

Pultex Standard Structural Profiles

KL/r
Fa (psi)
38.2
6657
57.3
3003
76.4
1689
95.5
1081
114.6
751
133.8
552
152.9
422
172.0
334

Pa (lbs.)
9439
4258
2395
1533
1065
782
599
473

Short Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column

Pa (lbs.)
13561
10039
5647
3614
2510
1844
1412
1115
904
747
627
146

Short Column
Short Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column
Long Column

Pultex Standard Structural Profiles

I-Sections
4" x 2" x 1/4" (Part# IB 440)
Pultex 1500/1525/1625 Series
A = 1.92 in2, r = .41 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5

KL/r
Fa (psi)
29.0
7063
43.4
5229
57.9
2941
72.4
1882
86.9
1307
101.4
960
115.9
735
130.3
581
144.8
471
159.3
389
173.8
327
188.3
76

Chapter 5

Pa (lbs.)
57210
55335
53460
51585
49710
43151
33038
26104
21144
17475
14683
12511
10788
9397
8259
7316
6526
5857
5286
4369
3671
3128
2697
2349
966

Pultex Standard Structural Profiles

I-Sections
10" x 5" x 1/2" (Part# IB 980)
Pultex 1500/1525/1625 Series
A = 9.67 in2, r = 1.03 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
11.0
12.0
13.0
14.0
15.0
16.0

KL/r
11.6
17.5
23.3
29.1
34.9
40.7
46.6
52.4
58.2
64.0
69.9
75.7
81.5
87.3
93.1
99.0
104.8
110.6
116.4
128.1
139.7
151.4
163.0
174.6
186.3

Fa (psi)
7823
7567
7312
7057
6801
5944
4551
3596
2912
2407
2023
1723
1486
1294
1138
1008
899
807
728
602
506
431
371
324
163

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Pa (lbs.)
75655
73186
70716
68247
65778
57484
44011
34774
28167
23279
19561
16667
14371
12519
11003
9746
8694
7803
7042
5820
4890
4167
3593
3130
1577

Pultex Standard Structural Profiles

I-Sections
12" x 6" x 1/2" (Part# IB 982)
Pultex 1500/1525/1625 Series
A = 11.67 in2, r = 1.23 in
Allowable Axial Stresses and Loads
Effective Column Length (KL) (ft.)
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0

KL/r
9.7
14.6
19.5
24.3
29.2
34.0
38.9
43.8
48.6
53.5
58.4
63.2
68.1
73.0
77.8
82.7
87.6
92.4
97.3
107.0
116.7
126.5
136.2
145.9
155.7
165.4
175.1
184.8

Fa (psi)
7907
7693
7480
7267
7053
6840
6518
5150
4171
3447
2897
2468
2128
1854
1629
1443
1287
1156
1043
862
724
617
532
463
407
361
322
226

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Pa (lbs.)
92280
89790
87300
84810
82320
79830
76070
60105
48685
40235
33809
28808
24839
21638
19017
16846
15026
13486
12171
10059
8452
7202
6210
5409
4754
4211
3757
2641

Biography
Dr. Robert Yuan
Dr. Robert Yuan has been a faculty member with the University of Texas at Arlington (UTA), Arlington,
Texas, since 1970. He is a professor in the Department of Civil and Environmental Engineering and has
been teaching courses in the area of structural design and analysis, structural mechanics, and structural
materials. Dr. Robert L. Yuan received his Ph.D. degree in theoretical and applied mechanics from the
University of Illinois in 1968, and his M.S. and B.S. degrees in Structural Engineering in 1964 and 1960,
respectively. His research specialties include (1) properties and behavior of reinforced concrete and
prestressed concrete; (2) fiber-reinforced polymer composites for civil engineering structure applications;
and (3) experimental mechanics.
Dr. Yuan has published over 40 refereed papers and 60 technical reports. He has spoken at more than 50
national and international conferences. Dr. Yuan has supervised 19 master theses and 10 doctoral
dissertations. He is the faculty advisor of the Chi Epsilon student chapter, a national honor society for
civil engineers.
Dr. Yuan received the Outstanding Engineering Teacher Award in 1976, and the Haliburton Research in
Excellence Award in 1986 at UTA.
Publications Technical Papers
The Effect of Environmental Exposure on the Behavior of Pultruded Mechanical Connections,
Proceedings of ICE '97, Vol. 1, pp. 14F1 14F6 (with Shane E. Weyant).
Hydrothermal Effects on the Bearing Strength of FRP Composite Joints, Proceedings of ASCE/MEC
'96, Vol. 1, pp. 243-250 (with Stephanie Hurd).
Study of Mechanical Connections for GFRP Laminated Structures, Proceedings of ACMBS '96, Vol. 1,
pp. 951-958 (with C.J. Lui and T. Daley).
Vibration Analysis of GFRP Composite Box Beams, Proceedings of ICCE '96, Vol. 1, pp. 965-966
(with S. Seangatith).
Optimization of GFRP Composite Bridge Railing Systems, Proceedings of Fourth National Bridge
Research Conference, pp. 345-348, 1996 (with S. Seangatith).
The Effects of End Support Conditions on the Behavior of GFRP Composite Columns, Proceedings of
ICCI '96, Vol. 1, pp. 621-627 (with Z. Hashcm).
Presentations at National & International Meetings
The Effect of Environmental Exposure on the Behavior of Pultruded Mechanical Connections, SPI/ICE
Conference, Nashville, Tennessee, January 27, 1997.
Hydrothermal Effects on the Bearing Strength of FRP Composite Joint, ASCE/MEC Conference,
Washington, D.C., November 11, 1996.
Study of Mechanical Connection for GFRP Laminated Structures, ACMBS Conference, Montreal,
Canada, August 14, 1996.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Presentations at National & International Meetings (contd)

Vibration Analysis of GFRP Composite Box Beams, ICCE/3 Conference, New Orleans, Louisiana, July
23, 1996.
Optimization of GFRP Composite Bridge Railing Systems, Fourth National Bridge Research
Conference, June 19, 1996.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 5

Chapter 6

Environmental Considerations

Pultrusions are used in many varied applications. Through experience and laboratory testing, Pultex
Profiles have been evaluated in a variety of environments. The resulting guidelines should be considered
if the pultrusion is to be exposed to environmental attack.
Temperature
Pultrusion experiences some property loss from continuous exposure to high temperatures. It is, therefore,
recommended that property loss be taken into consideration during design using the following guidelines
for Pultex 1500/1525 Series and 1625 Series.
Table 6-1 Property Retention at Varying Temperatures
Temperature

Pultex 1500/1525 Series

Pultex 1625 Series

100 F
125 F
150 F
175 F
200 F

85%
70%
50%
Not Recommended
Not Recommended

90%
80%
80%
75%
50%

100 F (37 C)
125 F (51 C)
150 F (65 C)
175 F (79 C)
200 F (93 C)

100%
90%
85%
Not Recommended
Not Recommended

100%
95%
90%
88%
85%

Ultimate Stress

Modulus of Elasticity

In applications requiring greater strength retention, it is possible to select a higher performance resin
system specifically designed for elevated temperatures. An example is Pultex 1625 Series Vinyl Ester,
which has better strength retention of properties at elevated temperatures. Creative Pultrusions can
design additional resin systems to achieve higher temperature ratings. Contact Creative Pultrusions early
in the design stages so that confirmation testing can be performed for various temperatures and
environments to verify suitability.
Weathering
Most plastic materials undergo some decay and change in appearance during prolonged exposure to
outdoor weathering. In order to minimize this effect with pultruded profiles, various options are
available.
UV Stabilizers
Pultex 1500/1525 Series and 1600/1625 Series contain a UV inhibitor for protection against sunlight.
It will retard the effect of outdoor weathering, but eventually the profile surface will degrade. A
condition, fiber blooming, will occur on the surface of the profile with subsequent slight deterioration
in physical properties.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 6

Surfacing Veils
To enhance the weathering characteristics further, a synthetic veil is applied to the composite surface
during processing. The veil enhances weatherability and corrosion resistance by adding resin
thickness to the surface of the product. It provides a smooth glass-free surface, eliminating any
possibility of exposing glass fiber.
Coatings
The optimum method of maintaining surface appearance during outdoor exposure is to apply a
coating to the surface. Two-component, UV stabilized, urethane coatings work very well with this
application. A 0.38 mm dry coating will provide protection for many years with minimal change in
appearance. A coatings manufacturer should be contacted in order to determine the best coating for
the application.
Resistance To Chemicals And Reagents
Pultex is resistant to a wide range of organic and inorganic substances. 1500/1525 Series is based on
isophthalic polyester. 1600/1625 Series is based on vinyl ester.
Concentration Of Solution
The percentage of the reagent in the solution or environment will affect the overall performance of
the pultruded profile.
Time Of Chemical Exposure
Time of chemical exposure must be identified whether the application involves intermittent
exposures, exposure to fumes, complete submersion or only an occasional splash.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 6

Chemical Compatibility Guide

The Chemical Compatibility Guide describes various resin series and presents a detailed chemical
resistance guide to assist engineers in recommending the type of resin to be used in each application.
Pultex Selection Guide
Pultex 1500 Series Polyester Resin
Pultex 1525 Series Flame Retardant Polyester Resin
Pultex 1625 Series Flame Retardant Vinyl Ester Resin
Thermosetting resins are used in a wide range of fiberglass reinforced profiles. Conventional fabrication
methods are used, coupled with sealing all cut holes and ends, to enhance the corrosion resistance.
The general guidelines in selection of resin types depend on the following:
the corrosion environment
normal operating concentration, including minimum and maximum concentration
normal operating temperature, including minimum and maximum temperature
The Chemical Compatibility Guide provides up-to-date information regarding the chemical resistance for
Pultex Profiles.
The data presented in the Chemical Compatibility Guide on the following pages covers the effect of
chemicals on pultruded fiber reinforced profiles. This chart is provided as a guide only. Evaluate these
recommendations in a laboratory or actual field trial prior to use.
Temperatures are not the minimum or maximum, but represent standard test conditions. Some products
may be suitable at higher temperatures. Individual testing would be required. Contact Creative
Pultrusions for chemicals, temperatures, or both, for any special application. Resin systems can be
designed for special needs.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 6

Chemical Compatibility Guide

Acetic Acid Calcium Bisultite

Chemical Environment

ACETIC ACID
ACETIC ANYDRIDE
ACETONE
ACRYLONITRILE
ALCOHOL, BUTYL
ALCOHOL, ETHYL
ALCOHOL, ETHYL
ALCOHOL, ISOPROPYL
ALCOHOL, ISOPROPYL
ALCOHOL, METHYL
ALCOHOL, METHYL
ALCOHOL, METHYL ISOBUTYL
ALCOHOL, SECONDARY BUTYL
ALUM
ALUM POTASSIUM
ALUMINUM CHLORIDE
ALUMINUM HYDROXIDE
ALUMINUM POTASSIUM SULFATE
AMMONIA, AQUEOUS
AMMONIA, GAS
AMMONIUM ACETATE
AMMONIUM BICARBONATE
AMMONIUM BISULFITE
AMMONIUM CARBONATE
AMMONIUM CITRATE
AMMONIUM FLUORIDE
AMMONIUM HYDROXIDE
AMMONIUM HYDROXIDE
AMMONIUM HYDROXIDE
AMMONIUM NITRATE
AMMONIUM PERSULFATE
AMMONIUM PHOSPHATE
AMMONIUM SULFATE
ARESENIOUS ACID
BARIUM ACETATE
BARIUM CARBONATE
BARIUM CHLORIDE
BARIUM HYDROXIDE
BARIUM SULFATE
BARIUM SULFIDE
BEER
BENZENE
BENZENE IN KEROSENE
BENZENE SULFURIC ACID
BENZOIC ACID
O-BENZOYL BENZOIC ACID
BENZYL ALCOHOL
BENZYL CHLORIDE
BORAX
BRASS PLATING SOLUTION
BUTYL ACETATE
BUTYRIC ACID
BUTYLENE GLYCOL
CADMIUM CHLORIDE
CADMIUM CYANIDE PLATING
CALCIUM BISULTITE

Flowgrip
Polyester
Vinyl ester
Temp
Temp
Concentratio Max.
Max.
n
Percentage F/C
F/C
0-50
NR
100/38
-NR
NR
100
NR
NR
100
NR
NR
-NR
NR
10
NR
150/65
100
NR
NR
10
NR
150/65
100
NR
NR
10
NR
150/65
100
NR
NR
-NR
150/65
-NR
150/65
100
150/65
150/65
-100/38
100/38
10
NR
150/65
5 - 20
NR
150/65
100
150/65
150/65
0-10
NR
100/38
-NR
100/38
25
NR
100/38
15
NR
120/49
-NR
120/49
25
NR
100/38
10
NR
120/49
-NR
120/49
5
NR
120/49
10
NR
120/49
20
NR
120/49
15
120/49
150/65
5 - 20
NR
150/65
-NR
120/49
15
120/49
150/65
-NR
160/71
100
NR
NR
100
NR
NR
100
NR
100/38
10
NR
NR
100
NR
100/38
10
NR
NR
-NR
120/49
100
NR
NR
5
NR
160/71
5 - 20
100/38
150/65
5 - 20
NR
100/38
-NR
160/71
100
NR
NR
100
NR
NR
5 - 20
100/38
150/65
-NR
160/71
-NR
NR
5 - 30
NR
120/49
100
150/65
150/65
-NR
160/71
-NR
120/49
-150/65
160/71

Supergrate
Pultruded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

Supergrate
Molded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

Pultex Structural Profiles

1500/1525 Srs.
1625 Srs.
Temp
Temp
Max.
Max.

F/C
100/38
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
150/65
100/38
NR
NR
150/65
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
120/49
NR
NR
120/49
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
100/38
NR
NR
NR
NR
100/38
NR
NR
NR
150/65
NR
NR
150/65

F/C
100/38
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
150/65
120/49
100/38
100/38
150/65
NR
100/38
120/49
120/49
NR
120/49
120/49
NR
NR
NR
NR
150/65
150/65
NR
150/65
NR
100/38
100/38
100/38
100/38
120/49
100/38
NR
100/38
NR
150/65
120/49
NR
NR
NR
100/38
NR
NR
100/38
150/65
NR
NR
150/65

F/C
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
150/65
100/38
NR
NR
150/65
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
120/49
NR
NR
120/49
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
100/38
NR
NR
NR
NR
100/38
NR
NR
NR
150/65
NR
NR
150/65

F/C
100/38
NR
NR
NR
NR
150/65
NR
150/65
NR
150/65
NR
150/65
150/65
150/65
100/38
150/65
150/65
150/65
100/38
100/38
100/38
120/49
120/49
100/38
120/49
120/49
120/49
120/49
120/49
150/65
150/65
120/49
150/65
160/71
NR
NR
100/38
NR
100/38
NR
120/49
NR
160/71
150/65
100/38
160/71
NR
NR
150/65
160/71
NR
120/49
150/65
160/71
120/49
160/71

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 6

F/C
150/65
NR
NR
NR
NR
150/65
NR
150/65
NR
150/65
NR
150/65
150/65
180/82
150/65
180/82
180/82
150/65
100/38
NR
150/65
150/65
120/49
150/65
180/82
120/49
120/49
120/49
120/49
180/82
180/82
120/49
180/82
160/71
150/65
150/65
150/65
150/65
150/65
150/65
120/49
150/65
160/71
180/82
150/65
160/71
100/38
100/38
150/65
160/71
NR
150/65
150/65
160/71
120/49
160/71

Chemical Compatibility Guide (contd)

Supergrate
Pultruded Grating

Flowgrip

Calcium Carbonate - Dichloroethylene

Supergrate
Molded Grating

Pultex Structural Profiles

Vinyl ester
Temp
Max.

Polyester
Temp
Max.

Vinyl ester
Temp
Max.

Polyester
Temp
Max.

Vinyl ester
Temp
Max.

Chemical Environment

Polyester
Temp
Concentratio Max.
n
Percentage F/C

F/C

CALCIUM CARBONATE
CALCIUM CHLORIDE
CALCIUM CHLORATE
CALCIUM HYDROXIDE
CALCIUM HYPOCHLORITE
CALCIUM NITRATE
CALCIUM SULFATE
CALCIUM SULFITE
CAPRYLIC ACID
CARBON DIOXIDE
CARBON DISULFIDE
CARBON MONOXIDE GAS
CARBON TETRACHLORIDE
CARBONIC ACID
CARBON METHYL CELLULOSE
CASTOR OIL
CHLORINATED WAX
CHLORINE DIOXIDE/AIR
CHLORINE DIOXIDE,WET GAS
CHLORINE DRY GAS
CHLORINE WET GAS
CHLORINE LIQUID
CHLORINE WATER
CHLOROACETIC ACID
CHLOROBENZENE
CHLOROFORM
CHLOROSULFONIC ACID
CHROMIC ACID
CHROMIC ACID
CHROMIC ACID
CHROMIUM SULFATE
CITRIC ACID
COCONUT OIL
COPPER CHLORIDE
COPPER CYANIDE
COPPER FLUORIDE
COPPER NITRATE
COPPER BRITE PLATING
COPPER PLATING SOLUTION
COPPER MATTE DIPPING BATH
COPPER PICKLING BATH
COPPER SULFATE
CORN OIL
CORN STARCH-SLURRY
CORN SUGAR
COTTONSEED OIL
CRUDE OIL
CYCLOHEXENE
CYCLOHEXENE VAPOR
DEIONIZED WATER
DETERGENTS SULFONATED
DI-AMMONIUM PHOSPHATE
DIBROMOPHENOL
DIBUTYL ETHER
DICHLORO BENZENE
DICHLOROETHYLENE

10
10
10
5 - 20
10
5
10
---100
-100
10
-100
10
-----10
0-50
-100
-5
20
30
-5 - 30
-5
5
-------100
-100
-100
----------

100/38
100/38
100/38
100/38
120/49
150/65
150/65
160/71
160/71
160/71
NR
150/65
100/38
120/49
120/49
150/65
120/49
160/71
160/71
160/71
160/71
NR
120/49
100/38
NR
NR
NR
100/38
120/49
NR
160/71
150/65
160/71
180/82
180/82
160/71
NR
120/49
160/71
160/71
160/71
160/71
100/38
160/71
150/65
160/71
150/65
120/49
NR
150/65
160/71
160/71
NR
120/49
NR
NR

NR
NR
NR
NR
NR
120/49
120/49
150/65
NR
150/65
NR
100/38
NR
100/38
NR
150/65
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
150/65
120/49
NR
150/65
150/65
NR
150/65
NR
NR
NR
NR
150/65
NR
NR
NR
NR
NR
NR
NR
150/65
NR
NR
NR
NR
NR
NR

120/49
120/49
120/49
100/38
100/38
120/49
120/49
150/65
NR
150/65
NR
150/65
NR
120/49
NR
150/65
120/49
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
100/38
NR
NR
150/65
120/49
NR
150/65
150/65
NR
150/65
NR
NR
NR
NR
150/65
120/49
NR
150/65
NR
150/65
NR
100/38
150/65
NR
NR
NR
NR
NR
NR

150/65
150/65
150/65
150/65
150/65
150/65
150/65
160/71
160/71
160/71
NR
150/65
120/49
150/65
120/49
150/65
150/65
160/71
160/71
160/71
160/71
NR
120/49
100/38
NR
NR
NR
150/65
120/49
NR
160/71
150/65
160/71
180/82
180/82
160/71
NR
120/49
160/71
160/71
160/71
160/71
150/65
160/71
180/82
160/71
180/82
120/49
150/65
150/65
160/71
160/71
NR
120/49
NR
NR

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 6

1500/1525 Srs.
Temp
Max.

1625 Srs.
Temp
Max.

Chemical Compatibility Guide (contd)

Diethylene Glycol Hydrogen Sulfide Aqueous
Supergrate

Supergrate

Pultruded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

Chemical Environment

F/C

DIETHYLENE GLYCOL
DIETHYL ETHER
DIMENTHYL PHTHALATE
DIOCTYL PHTHALATE
DIPROPYLENE GLYCOL
DODECYL ALCOHOL
ESTER, FATTY ACIDS
ETHYL ACETATE
ETHYL BENZENE
ETHYL ETHER
ETHYLENE GLYCOL
ETHYLENE DICHLORIDE
FATTY ACIDS
FERRIC CHLORIDE
FERRIC NITRATE
FERRIC SULFATE
FERROUS CHLORIDE
FERROUS NITRATE
FERROUS SULFATE
8-8-8 FERTILIZER
FLUOBORIC ACID
FLUOSILICIC ACID
FORMALDEHYDE
FORMIC ACID
FUEL GAS
FUEL OIL
GAS NATURAL
GASOLINE AUTO
GASOLINE AVIATION
GASOLINE ETHYL
GASOLINE SOUR
GLUCONIC ACID
GLUCOSE
GLYCERIN
GLYCOL ETHYLENE
GLYCOL PROPYLENE
GLYCOLIC ACID
GOLD PLATING SOLUTION
HEPTANE
HEXANE
HEXALENE GLYCOL
HYDRAULIC FLUID
HYDROBROMIC ACID
HYDROCHLORIC ACID
HYDROCYANIC ACID
HYDROFLUORIC ACID
HYDROFLOUSILICIC ACID
HYDROZINE
HYDROGEN BROMIDE ,DRY
HYDROGEN BROMIDE , WET GAS
HYDROGEN CHLORIDE , DRY GAS
HYDROGEN CHLORIDE, WET GAS
HYDROGEN PEROXIDE
HYDROGEN SULFIDE DRY
HYDROGEN SULFIDE AQUEOUS

-100
--100
--100
--100
-10
10
10
10
------5 - 30
25
-100
------100
100
----100
100
-100
5 - 50
10 - 30
--10
100
--------

NR
NR
NR
NR
NR
NR
150/65
NR
NR
NR
100/38
NR
120/49
120/49
120/49
120/49
150/65
150/65
150/65
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
150/65
150/65
150/65
150/65
NR
NR
100/38
100/38
150/65
NR
100/38
NR
150/65
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR

160/71
NR
160/71
160/71
120/49
160/71
160/71
NR
NR
NR
150/65
NR
150/65
150/65
150/65
150/65
160/71
160/71
160/71
120/49
120/49
160/71
100/38
100/38
160/71
100/38
160/71
160/71
160/71
160/71
160/71
160/71
180/82
180/82
160/71
160/71
160/71
160/71
150/65
150/65
160/71
120/49
150/65
120/49
160/71
NR
160/71
NR
NR
160/71
160/71
160/71
120/49
160/71
160/71

NR
NR
NR
NR
100/38
NR
150/65
NR
NR
NR
150/65
NR
150/65
150/65
150/65
150/65
150/65
150/65
150/65
NR
NR
NR
120/49
NR
NR
100/38
NR
NR
NR
NR
NR
NR
150/65
150/65
150/65
150/65
NR
NR
120/49
120/49
150/65
120/49
120/49
100/38
150/65
NR
NR
NR
100/38
NR
NR
NR
NR
NR
NR

160/71
NR
160/71
160/71
150/65
160/71
160/71
NR
NR
NR
180/82
NR
180/82
180/82
180/82
180/82
160/71
160/71
160/71
120/49
120/49
160/71
150/65
120/49
160/71
120/49
160/71
160/71
160/71
160/71
160/71
160/71
180/82
180/82
160/71
160/71
160/71
160/71
180/82
180/82
160/71
150/65
180/82
150/65
160/71
NR
160/71
NR
150/65
160/71
160/71
160/71
120/49
160/71
160/71

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 6

Molded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

Pultex Structural Profiles

1500/1525 Srs.
1625 Srs.
Temp
Temp
Max.
Max.

Flowgrip
Polyester
Vinyl ester
Temp
Temp
Concentratio Max.
Max.
n
Percentage F/C
F/C

Chemical Compatibility Guide (contd)

Hydrogen Fluoride Vapors Nitric Acid

Chemical Environment
HYDROGEN FLUORIDE VAPORS
HYDROSULFITE BLEACH
HYPOCHLORUS ACID
IRON PLATING SOLUTION
IRON AND STEEL CLEANING BATH
ISOPROPYL AMINE
ISOPROPYL PALMITATE
JET FUEL
KEROSENE
LACTIC ACID
LAUROYL CHLORIDE
LAURIC ACID
LEAD ACETATE
LEAD CHLORIDE
LEAD NITRATE
LEAD PLATING SOLUTION
LEVULINIC ACID
LINSEED OIL
LITHIUM BROMIDE
LITHIUM CHLORIDE
LITHIUM SULFATE
LITHIUM HYDROXIDE
MAGNESIUM BISULFITE
MAGNESIUM CARBONATE
MAGNESIUM CHLORIDE
MAGNESIUM HYDROXIDE
MAGNESIUM NITRATE
MAGNESIUM SULFATE
MALEIC ACID
MERCURIC CHLORIDE
MERCUROUS CHLORIDE
METHANOL
METHYLENE CHLORIDE
METYL ETHYL KETONE @ 120F
METHYL ISOBUTYL CARBITOL
METHYL ISOBUTYL KETONE
METHYL STYRENE
MINERAL OIL
MOLYBDENUM DISULFIDE
MONOCHLORIC ACETIC ACID
MONOETHANOLAMINE
MOTOR OIL
MYRISTIC ACID
NAPTHA
NICKEL CHLORIDE
NICKEL NITRATE
NICKEL PLATING:
.4% Boric Acid)
NICKEL PLATING:
(11% Nickel Sulfate, 2% Nickle
Chloride, 1% Boric Acid)
NICKEL PLATING:
(44% Nickel Sulfate, 4% Ammonium
Chloride, 4% Boric Acid)
NICKEL SULFATE
NITRIC ACID

Flowgrip
Polyester
Vinyl ester
Temp
Temp
Concentratio Max.
Max.
n
Percentage F/C
F/C

Supergrate
Pultruded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

Supergrate
Molded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

Pultex Structural Profiles

1500/1525 Srs.
1625 Srs.
Temp
Temp
Max.
Max.

F/C

------------100
10
10
----25
-10
-10
10
10
10
10
100
10
10
------100
---100
-100
10
10
--

NR
NR
NR
NR
NR
NR
150/65
NR
NR
NR
NR
NR
NR
120/49
NR
NR
NR
150/65
150/65
NR
150/65
NR
NR
100/38
100/38
NR
NR
100/38
150/65
120/49
120/49
NR
NR
NR
NR
NR
NR
150/65
NR
NR
NR
150/65
150/65
120/49
120/49
NR

NR
120/49
160/71
160/71
160/71
100/38
160/71
160/71
160/71
160/71
160/71
160/71
120/49
150/65
100/38
160/71
160/71
160/71
160/71
120/49
160/71
120/49
160/71
150/65
150/65
120/49
120/49
120/49
150/65
150/65
150/65
160/71
NR
NR
NR
NR
NR
150/65
160/71
NR
NR
150/65
160/71
150/65
150/65
150/65
160/71

NR
NR
NR
NR
NR
NR
150/65
NR
NR
NR
NR
NR
100/38
120/49
100/38
NR
NR
150/65
150/65
100/38
150/65
100/38
NR
100/38
120/49
100/38
100/38
100/38
150/65
100/38
120/49
NR
NR
NR
NR
NR
NR
150/65
NR
NR
NR
150/65
150/65
150/65
150/65
NR

NR
120/49
160/71
160/71
160/71
100/38
160/71
160/71
160/71
160/71
160/71
160/71
150/65
150/65
150/65
160/71
160/71
160/71
160/71
150/65
160/71
150/65
160/71
180/82
180/82
150/65
150/65
150/65
150/65
180/82
180/82
160/71
NR
NR
NR
NR
NR
150/65
160/71
NR
NR
150/65
160/71
150/65
180/82
180/82
160/71

160/71

10
5 - 30

120/49
NR

150/65
100/38

120/49
NR

150/65
100/38

150/65
120/49

180/82
150/65

120/49
NR

150/65
100/38

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 6

Chemical Compatibility Guide (contd)

Nitric Acid Fumes Silver Plating Solution

Chemical Environment
NITRIC ACID FUMES
NIBROBEBZENE
OCTONOIC ACID
OIL, SOUR CRUDE
OIL, SWEET CRUDE
OLEIC ACID
OLEUM (FUMING SULFURIC)
OLIVE OIL
OXALIC ACID
PEROXIDE BLEACH:
(2% Sodium Peroxide-96%
.025% Epsom Salts,
5% Sodium Silicate 42Be,
1.4% Sulfuric Acid 66Be)
PHENOL
PHENOL SULFONIC ACID
PHOSPHORIC ACID
PHOSPHORIC ACID FUMES
PHOSPHOROUS
PENTOXIDE
PHOSPHOROUS TRICHLORIDE
PHTHALIC ACID
PICKLING ACIDS:
(Sulfuric And Hydrochloric)
PICRIC ACID ALCOHOLIC
POLYVINYL ACETATE LATEX
POLYVINYL ALCOHOL
POLYVINYL CHLORIDE LATEX
With 35 (Parts Dop)
POTASSIUM ALUMINUM SULFATE
POTASSIUM BICARBONATE
POTASSIUM BROMIDE
POTASSIUM CARBONATE
POTASSIUM CHLORIDE
POTASSIUM DICHROMATE
POTASSIUM FERRICYANIDE
POTASSIUM FERROCYANIDE
POTASSIUM HYDROXIDE
POTASSIUM NITRATE
POTASSIUM PERMANGANTE
POTASSIUM PERSULFATE
POTASSIUM SULFATE
PROPIONIC ACID
PROPIONIC ACID
PROPYLENE GLYCOL
PULP PAPER MILL EFFLUENT
PYRIDINE
SALICYLIC ACID
SEA WATER
SEWAGE TREATMENT
SEBACIC ACID
SELENIOUS ACID
SILVER NITRATE
SILVER PLATING SOLUTION:
(4% Silver Cyanide, 7% Potassium
Cyanide,5% Sodium Cyanide,
2% Potassium Carbonate)

Flowgrip
Polyester
Vinyl ester
Temp
Temp
Concentratio Max.
Max.
n
Percentage F/C
F/C

Supergrate
Pultruded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

Supergrate
Molded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

Pultex Structural Profiles

1500/1525 Srs.
1625 Srs.
Temp
Temp
Max.
Max.

F/C

---100
100
100
-----

NR
NR
NR
NR
NR
120/49
NR
150/65
150/65
150/65

NR
NR
160/71
120/49
120/49
150/65
NR
160/71
160/71
160/71

NR
NR
NR
NR
NR
120/49
NR
150/65
150/65
150/65

NR
NR
160/71
120/49
120/49
150/65
NR
160/71
160/71
160/71

NR
NR
NR
120/49
120/49
120/49
NR
150/65
150/65
150/65

NR
NR
160/71
150/65
150/65
180/82
NR
160/71
160/71
160/71

NR
NR
NR
NR
NR
120/49
NR
150/65
150/65
150/65

NR
NR
160/71
120/49
120/49
150/65
NR
160/71
160/71
160/71

10
-5 - 50
---100
100
--

NR
NR
100/38
150/65

NR
NR
150/65
160/71

NR
NR
100/38
150/65

NR
NR
150/65
160/71

NR
NR
120/49
150/65

120/49
NR
180/82
160/71

NR
NR
100/38
150/65

NR
NR
150/65
160/71

150/65
NR
NR
150/65

160/71
NR
120/49
160/71

150/65
NR
NR
150/65

160/71
NR
120/49
160/71

150/65
NR
100/38
150/65

160/71
120/49
150/65
160/71

150/65
NR
NR
150/65

160/71
NR
120/49
160/71

--100
--

150/65
NR
NR
NR

160/71
160/71
100/38
120/49

150/65
NR
NR
NR

160/71
160/71
100/38
120/49

150/65
NR
NR
NR

160/71
160/71
120/49
120/49

150/65
NR
NR
NR

160/71
160/71
100/38
120/49

10
-10
10
100
100
--10
10
100
-10
1 - 50
50 - 100
100
----------

120/49
NR
NR
NR
NR
NR
150/65
150/65
NR
120/49
100/38
NR
120/49
NR
NR
150/65
NR
NR
NR
150/65
NR
NR
NR
150/65
NR

150/65
120/49
120/49
120/49
120/49
120/49
160/71
160/71
150/65
150/65
150/65
160/71
150/65
120/49
NR
150/65
160/71
NR
140/60
150/65
100/38
160/71
160/71
160/71
160/71

120/49
NR
NR
NR
NR
NR
150/65
150/65
NR
120/49
100/38
NR
120/49
NR
NR
150/65
NR
NR
NR
150/65
NR
NR
NR
150/65
NR

150/65
120/49
120/49
120/49
120/49
120/49
160/71
160/71
150/65
150/65
150/65
160/71
150/65
120/49
NR
150/65
160/71
NR
140/60
150/65
100/38
160/71
160/71
160/71
160/71

150/65
100/38
100/38
150/65
100/38
100/38
150/65
150/65
120/49
120/49
120/49
NR
150/65
NR
NR
150/65
NR
NR
NR
150/65
NR
NR
NR
150/65
NR

180/82
150/65
150/65
180/82
150/65
150/65
160/71
160/71
180/82
180/82
180/82
160/71
180/82
120/49
NR
180/82
160/71
NR
140/60
150/65
100/38
160/71
160/71
160/71
160/71

120/49
NR
NR
NR
NR
NR
150/65
150/65
NR
120/49
100/38
NR
120/49
NR
NR
150/65
NR
NR
NR
150/65
NR
NR
NR
150/65
NR

150/65
120/49
120/49
120/49
120/49
120/49
160/71
160/71
150/65
150/65
150/65
160/71
150/65
120/49
NR
150/65
160/71
NR
140/60
150/65
100/38
160/71
160/71
160/71
160/71

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 6

Chemical Compatibility Guide (contd)

Supergrate

Soaps Superphosphoric Acid

Chemical Environment
SOAPS
SODIUM ACETATE
SODIUM BENZOATE
SODIUM BICARBONATE
SODIUM BIFLUORIDE
SODIUM BISULFATE
SODIUM BISULFITE
SODIUM BROMATE
SODIUM BROMIDE
SODIUM CARBONATE
SODIUM CHLORATE
SODIUM CHLORIDE
SODIUM CHLORITE
SODIUM CHROMATE
SODIUM CYANIDE
SODIUM DICHROMATE
SODIUM DI-PHOSPHATE
SODIUM FERRICYANIDE
SODIUM FLUORIDE
SODIUM FLOURO SILICATE
SODIUM HEXAMETAPHOSPHATES
SODIUM HYDROXIDE
SODIUM HYDROXIDE
SODIUM HYDROXIDE
SODIUM HYDROSULFATE
SODIUM HYPOCHLORITE
SODIUM LAURYL SULFATE
SODIUM MONO-PHOSPHATE
SODIUM NITRATE
SODIUM SILICATE
SODIUM SULFATE
SODIUM SULFIDE
SODIUM SULFITE
SODIUM TETRA BORATE
SODIUM THIOCYANATE
SODIUM THIOSULFATE
SODIUM TRIPOLYOPHOSPHATE
SODIUM XYLENE SULFONATE
SODIUM SOLUTIONS
SODIUM CRUDE OIL
SOVA OIL
STANNIC CHLORIDE
STANNOUS CHLORIDE
STEARIC ACID
STYRENE
SUGAR, BEET AND CANE LIQUOR
SUGAR, SUCROSE
SULFAMIC ACID
SULFANILIC ACID
SULFATED DETERGENTS
SULFUR DIOXIDE, WET OR DRY
SULFUR, TRIOXIDE/AIR
SULFURIC ACID
SULFURIC ACID
SULFURIC ACID
SULFUROUS ACID
SUPERPHOSPHORIC ACID
(76% P2O5)

Supergrate
Pultex Structural Profiles
1500/1525 Srs.
1625 Srs.
Temp
Temp
Max.
Max.

Flowgrip
Polyester
Vinyl ester
Temp
Temp
Concentratio Max.
Max.
n
Percentage F/C
F/C

Pultruded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

Molded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

F/C

---------0 - 25
--25
--------0-5
5 - 25
50
-10
--------------------------0 - 30
30 - 50
50 - 70
10
--

NR
NR
NR
150/65
NR
150/65
150/65
150/65
150/65
NR
NR
150/65
NR
150/65
NR
150/65
150/65
150/65
NR
NR
NR
NR
NR
NR
NR
NR
150/65
150/65
150/65
NR
150/65
NR
NR
150/65
NR
NR
NR
NR
NR
150/65
150/65
150/65
150/65
150/65
NR
NR
150/65
NR
NR
NR
NR
NR
150/65
NR
NR
NR
NR

160/71
160/71
160/71
160/71
160/71
160/71
160/71
140/60
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
120/49
120/49
100/38
150/65
150/65
150/65
160/71
120/49
160/71
160/71
160/71
120/49
160/71
120/49
120/49
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
NR
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
120/49
100/38
160/71

NR
NR
NR
150/65
NR
150/65
150/65
150/65
150/65
NR
NR
150/65
NR
150/65
NR
150/65
150/65
150/65
NR
NR
NR
NR
NR
NR
NR
120/49
150/65
150/65
150/65
120/49
150/65
120/49
120/49
150/65
NR
NR
NR
NR
NR
150/65
150/65
150/65
150/65
150/65
NR
NR
150/65
NR
NR
NR
NR
NR
150/65
NR
NR
NR
NR

160/71
160/71
160/71
160/71
160/71
160/71
160/71
140/60
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
120/49
120/49
100/38
150/65
150/65
150/65
160/71
150/65
160/71
160/71
160/71
150/65
160/71
150/65
150/65
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
NR
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
160/71
120/49
100/38
160/71

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 6

Chemical Compatibility Guide (contd)

Tall Oil Zinc Sulfate

Chemical Environment
TALL OIL
TANNIC ACID
TARTARIC ACID
THIONYL CHLORIDE
TIN PLATING SOLUTION:
(18%Stannous Fluoroborate,
7% Tin, 9% Fluoroboric Acid,
2% Boric Acid)
TOLUENE
TOLUENE SOLFONIC ACID
TRANSFORMER OILS:
(Mineral Oil Types,
Chloro-phenyl Types)
TRICHLOR ACETIC ACID
TRICHLORETHYLENE
TRICHLOROPENOL
TRICRESYL PHOSPHATE +A618
TRIDECYLBENZENE SULFONATE
TRISODIUM PHOSPHATE
TURPENTINE
UREA
VEGETABLE OILS
VINEGAR
VINYL ACETATE
WATER:
DEIONIZED
DEMINERALIZED
DISTILLED
FRESH
SALT
SEA
WHITE LIQUOR (Pulp Mill)
XYLENE
ZINC CHLORATE
ZINC NITRATE
ZINC PLATING SOLUTION:
(9% Zinc Cyanide, 4% Sodium
Cyanide, 9% Sodium Hydroxide)
ZINC PLATING SOLUTION:
(49% Zinc, Fluoroborate,
5% Ammonium Chloride,
6% Ammonium Fluoroborate)
ZINC SULFATE

Flowgrip
Polyester
Vinyl ester
Temp
Temp
Concentratio Max.
Max.
n
Percentage F/C
F/C

Supergrate
Pultruded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

Supergrate
Molded Grating
Polyester
Vinyl ester
Temp
Temp
Max.
Max.

Pultex Structural Profiles

1500/1525 Srs.
1625 Srs.
Temp
Temp
Max.
Max.

F/C

------

NR
NR
150/65
NR
NR

150/65
120/49
160/71
NR
160/71

NR
NR
150/65
NR
NR

150/65
120/49
160/71
NR
160/71

NR
120/49
150/65
NR
NR

150/65
150/65
160/71
NR
160/71

NR
NR
150/65
NR
NR

150/65
120/49
160/71
NR
160/71

----

NR
NR
NR

NR
160/71
NR

NR
NR
NR

NR
160/71
NR

NR
NR
NR

NR
160/71
NR

NR
NR
NR

NR
160/71
NR

50
-----------

NR
NR
NR
NR
NR
NR
NR
NR
150/65
150/65
NR

160/71
NR
NR
120/49
160/71
160/71
100/38
140/60
160/71
160/71
NR

NR
NR
NR
NR
NR
NR
NR
NR
150/65
150/65
NR

160/71
NR
NR
120/49
160/71
160/71
100/38
140/60
160/71
160/71
NR

NR
NR
NR
NR
NR
NR
NR
NR
150/65
150/65
NR

160/71
NR
NR
120/49
160/71
160/71
100/38
140/60
160/71
160/71
NR

NR
NR
NR
NR
NR
NR
NR
NR
150/65
150/65
NR

160/71
NR
NR
120/49
160/71
160/71
100/38
140/60
160/71
160/71
NR

------------

150/65
150/65
150/65
150/65
150/65
150/65
NR
NR
150/65
150/65
NR

160/71
160/71
160/71
160/71
160/71
160/71
160/71
NR
160/71
160/71
120/49

150/65
150/65
150/65
150/65
150/65
150/65
NR
NR
150/65
150/65
NR

160/71
160/71
160/71
160/71
160/71
160/71
160/71
NR
160/71
160/71
120/49

150/65
150/65
150/65
150/65
150/65
150/65
NR
NR
150/65
150/65
NR

160/71
160/71
160/71
160/71
160/71
160/71
160/71
NR
160/71
160/71
120/49

150/65
150/65
150/65
150/65
150/65
150/65
NR
NR
150/65
150/65
NR

160/71
160/71
160/71
160/71
160/71
160/71
160/71
NR
160/71
160/71
120/49

160/71

150/65

160/71

150/65

160/71

150/65

160/71

150/65

160/71

Chemical Compatibility Guide information is based on full immersion laboratory tests and resin manufacturers data. In some
environments, splashing may lead to further corrosion than indicated due to the evaporation of water. Regular washdown is
recommended in these situations. All data represents the best available information, is believed to be correct, and is not a warranty of
product performance. User tests are recommended to determine actual suitability of service, for which CP will gladly supply samples.
CP does not take responsibility for design or suitability of materials for service intended, nor will CP be held liable for consequential
or special damages due to defective material or workmanship including, without limitation, labor charge and/or other expense of
damage to properties resulting from loss of materials or profits, or increased expenses of operation.
They are expected typical values. Depending on the individual resin formulation/fiber volume of the composite, additional testing
may be needed.
- - = All Concentrations
NR = Not Recommended

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 6

Chapter 7

Custom Profile Design

Custom profiles are created from a wide variety of resin systems and an array of colors.
Several items need to be considered in the cross-sectional design of a custom pultruded profile. The
following elements are conducive to efficient profile production. Although not absolutes, there are
important considerations that can affect the economics of the system from tooling costs to price per piece.
Wall-Section Thickness
The rate at which a profile is produced is determined by the curing time required for the thickest section:
the thicker the section, the slower the cure rate. For example, a 1/8-inch thick profile can be produced at
3 4 feet per minute. In comparison, a 3/4-inch thick profile section has a production rate of
approximately 6-inches per minute. Whenever possible, it is advantageous to design a section with
uniform cross-sectional wall thickness.
Pultruded profiles exhibit a 0% to 4% cross-sectional shrinkage during production. A uniform wall
thickness aids in limiting the warpage of the end product, because shrinkage will be uniform.
Symmetrical design, although not necessarily of uniform thickness, also helps in controlling warpage.
Pultruded sections of .032 to 2 inch thickness, with solid rounds up to 3-inch diameters, are currently
produced, but typical structural laminates range from .080 inches to 1 inch in thickness. Again, the
thickness determines the pull rate; therefore, when rigidity is an important consideration, it is preferred to
design deeper sections with a thinner wall.
Radius Design
Radius in pultruded profiles is the curved connection of two intersecting sections. With pultrusion, the
best practice is to maintain uniformity of cross-section through the radius. It helps to prevent resin-rich
areas that can crack or flake. Uniformity also aids in a more even distribution of glass reinforcement and
helps to maintain consistent properties throughout the profile.
While square corners are obtainable, generous radii aid in processing and in-feed guiding systems.
Generous radii also help to distribute stress in corners or cross-sectional changes, resulting in stronger
profiles.
Although profile cross-section is the determining factor when calculating radii, a minimum of 1/16 inch is
recommended for interior or exterior surfaces. The minimum radius is especially important on profiles
The New and Improved Pultex Pultrusion Global Design Manual

Chapter 7

where surface appearance is critical, particularly where reinforcing ribs are necessary on the opposite
side. A radius that is too generous can cause shrink marks and off-color areas in the profile.
On dead-end sections, it is particularly helpful to maintain a radius of half the thickness.
Shrinkage
Pultruded profiles typically shrink 2% to 3% during processing. Since the shrinkage is caused by the
resin, changes in the type of resin or resin content will affect the final profile shrinkage. Proper die
design will allow for this shrinkage.
Shrinkage, though a small percentage of the profile thickness, must be taken into consideration when
establishing tolerances.
Shrinkage can be controlled with low-shrink resin systems. These systems typically contain
thermoplastics that lessen shrinkage. Some problems that may be experienced in the final product are:
decreased weatherability; lower peak temperature usage; reduced corrosion resistance; and lessened paint
and bonding agent adhesion.
Shrinkage can also affect the angular relation of one section to another. Again, proper design of the die
can lessen this problem, but variances do occur, and must be considered when establishing tolerances.
Surface Appearance And Performance
Pultrusions manufactured by a low-pressure process typically display a glass-rich surface. The surface can
create several problems, such as pattern-through of reinforcing materials and exposure of glass fibers due
to excessive wear or weathering.
When pattern-through is a problem, there are several methods for surface improvement. Low-shrink resin
systems can dramatically lessen this occurrence. By lowering resin shrinkage, the surface of the profile
remains smooth and uniform. Finer fiber mats and surfacing veils also improve surfaces by creating a
smooth backing and attract more resin to the surface, masking the coarser fibers beneath.
Where pattern-through and exposed fibers are both a problem, a polymeric surface veil is available and
used to create a resin-rich surface of up to .020 inches thick without detracting from the profile's
performance. The surface improves the weatherability, ultraviolet resistance and corrosion resistance of
the laminate. It will effectively coat the material with the base resin in-line and eliminate the need for
secondary coating operations on areas other than end-cut or fabricated holes.
Since pultrusion is a low-pressure process, fiberglass reinforcements normally appear close to the surface
of the profile. The reinforcements can affect the appearance, corrosion resistance or handling of the
product. Fiberglass and polymeric veils can be added to the laminate construction to depress the
reinforcement from the surface. This is done to enhance the surface by adding a resin-rich finish to the
profile. The two most commonly used products are A-glass and polymeric veils.
To extend long life during outdoor exposure, urethane coatings are employed. In this secondary
operation, a typical application is 25 to 40 microns. These coatings protect the profiles from UV
degradation and are generally recommended when they will be exposed to a variety of weather
conditions. They are also beneficial for profiles in which uniformity of color or variety of color is
required in a low volume application.
To determine the proper surface treatment, artificial weathering or accelerated corrosion tests can be
employed.
2

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 7

Parting Lines
Pultruded dies are typically segmented to aid in machining and facilitate chrome plating of the die
surface. Where these segments join in the assembled die, surface marks are created on the profile. These
marks are referred to as parting lines. A parting line will appear as a straight, slightly raised area on the
profile. On structural profiles, these lines are unimportant, as most of them are incorporated into ends or
corners where they are fairly well concealed. On profiles where surface appearance is critical, these
parting lines must be taken into consideration. It is best for the designer to consult with Creative
Pultrusions to establish the part configuration and die segmentation to produce the best profile without
dramatically affecting the tooling and price per piece due to difficulties.
Localized Stiffening
Although this section may seem contradictory to some earlier statements, localized strength and stiffening
are obtainable by various methods. Distribution of glass loadings or changes in reinforcement types can
provide localized strength. By replacing materials of lesser strength with higher strength, the end product
physical properties can be altered to meet necessary requirements.
Additional ribs or added thickness can also be used for reinforcing a profile as necessary. Creative
Pultrusions can greatly aid the designer in cross-sectional development to best meet the end requirements.
Undercuts
Unlike some other processes, undercuts are obtainable with pultruded profiles. The main consideration
when working with undercuts is the machining and plating of the tool.
Dimensional Tolerances
Standard tolerances for pultruded profiles have been established by the industry and ASTM committees.
Workable tolerances are best established as a joint effort between the designer and the pultruder. As with
most other processes, tight tolerances affect the costs of the end product. It is important to take this into
consideration when establishing tolerances. Tolerances of particular segments of a cross-section are also
an effective method of meeting the needs of both the designer and the pultruder.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 7

CREATIVE PULTRUSIONS, INC

214 Industrial Lane Alum Bank, PA 15521 USA

PHONE: 814-839-4186 FAX: 814-839-4276
Web Site: http://www.creativepultrusions.com e-mail: [email protected]

Designer Checklist
1.

Company Information
Company Name _____________________________________________________________________________
Name _____________________________________________________________________________________
Department or Position ________________________________

Phone _______________________________

Profile Application Information

A. Profile Name ___________________________________________
New Design R

Profile Modification R

Number ______________________
Existing Design R

Profile Application________________________________________________________________________
Present Material Used _____________________________________________________________________
Current Material Cost __________

Annual Volume __________

B. Profile Dimensions Height __________

Actual Print Attached R
Is sample available?
Have you used FRP before?
Were the results satisfactory?

Width __________

Release Quantity ______________

Length __________

Conceptual Sketch Attached R

Yes R
Yes R
Yes R

No R
No R
No R

If no, please explain ______________________________________________________________________

Color __________________________________________________________________________________
Surface Appearance/Cosmetic Requirements ___________________________________________________

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 7

Designer Checklist (contd)

C. Properties

Standard R

Custom R

Primary loads on part ______________________________________________________________________

Critical properties required _________________________________________________________________
Electrical requirements ____________________________________________________________________
Resin Fire Retardant _____ Polyester ______
ASTM R

NBS R

UL R

Vinyl ester _____

Fed. Spec R

Other (please specify) ______

Other R

D. Fabrication
Drilling R

Punching R

Grinding R

Assembly _______________________________________________________________________________
Finishing _______________________________________________________________________________
Painting ________________________________________________________________________________
Bonding ________________________________________________________________________________
E. Environmental Considerations
Chemical Exposure Type (s) ________________________________________________________________
Service Temperatures _____________________________________________________________________
Intermittent R

Continuous R

Degree of Exposure
Immersion R

Vapors R

Splash R

Concentration % by weight _________________________________________________________________

Indoor __________

Outdoor __________

F. Other Requirements/Comments ___________________________________________________________

___________________________________________________________________________________

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 7

Notes

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 7

Chapter 8

Quality Assurance and Standard Tolerances

Profiles are subjected to

rigorous testing,
insuring customer
specifications are met.

Full section bending test is conducted to

assure product performance.

Coupon testing is conducted to

verify mechanical properties.
Quality Assurance System

To provide consistency in the production of Pultex Profiles, a Quality Assurance System is

followed. Inspection points have been established to cover incoming raw materials, various stages of
production, and follow-up to production before shipment. In addition, routine quality audits are
performed internally, and by large-contract customers, to assure adherence to our quality assurance
system.
Standard Tolerances
A better understanding of the dimensional and physical property capabilities of the material can assist
the designer in determining the performance limitations of the product before it is produced.
In addition to those tolerances provided on the following pages, the designer should consult with the
reference standards for background information and as a guideline in determining dimensional
performance.
ASTM 3647

Standard Practice for Classifying Reinforced Plastic

Pultruded Products According to Composition

ASTM D3917

Standard Specifications for Dimensional Tolerances

of Thermosetting Glass Reinforced Plastic
Pultruded Products

ASTM D3918

Standard Definitions of Terms Relating to Reinforced

Plastic Pultruded Products

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 8

Standard Tolerances Index

Cross Sectional Dimensions

A.
B.
C.
D.

II.

Straightness
A.
B.
C.
D.
E.

III.

Pultex Structural Profiles

Pultex Round and Square Tubes
Pultex Round and Square Bars
Pultex Flat Sheets

Pultex Profiles
Pultex Rods and Bars
Pultex Structural Profiles
Pultex Round, Square and Rectangular Tubes
Pultex Camber (Lateral Bow), Sheets and Plates

Flatness
A. Pultex Rods, Bars, and Structural Profiles
B. Pultex Sheets and Plates
C. Pultex Hollow Profiles

IV.

Twist
A. Pultex Bars, Tubes and Structural Profiles

V.
VI.
VII.

Angularity
Length
Squareness of End Cut
A. Pultex Structural Profiles
B. Pultex Sheets and Plates

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Standard Tolerances of Pultex Standard Structural Profiles

I. Cross Sectional Dimensions
A.

Pultex Structural Profiles

Allowable deviation from nominal dimensions

Angles
I-Beams
Tolerance
Deviation
Tolerance
Deviation
Dimensions

Thickness (T)
10%
.010" Minimum
10%
.010" Minimum
Flange (B)
5%
.094" Maximum
5%
.094" Maximum
Depth (H)
5%
.094" Maximum
5%
.094" Maximum

Pultex Round and Square Tubes

Allowable deviation of depth at

corners or diameter from specified
.020"
.040"
1.5%
Tolerance
20%
15%

Dimensions (D) or (B)

Under 2"
2" 4"
Over 4"
Dimensions (T)
Under .100"
.100" and Over

Channels
Tolerance
Deviation

10%
.010" Minimum
5%
.094" Maximum
5%
.094" Maximum

Pultex Round and Square Bars

Dimensions (D) or (B)

Under 3"

Allowable deviation from nominal dimensions

.020"

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Pultex Flat Sheets

Dimensions
Width (D)
Thickness (T) .125" and under
Over .125"

II.

Tolerances
3%
15%
10%

Allowable Deviation
.125" Maximum
.010" Minimum
.050" Maximum

Straightness
A.

Pultex Structural Profiles*

Width of Profile
Up to 1.5"
Up to 1.5"
Over 1.5"

Allowable deviation from straight (D)

Wall thickness
Deviation
Up to .094"
.050"/ft
Over .094"
.040"/ft
All
.050"/ft

Deviation per part

.050" x length (L)
.040" x length (L)
.050" x length (L)

Note: length of part (L) in feet/meters

Pultex Rods and Bars*

Outside Dimensions
Up to 1"
Over 1"

Allowable deviation from straight (D)

Deviation
.020"/ft
.030"/ft

Deviation per part

.020" x length (L)
.030" x length (L)

Note: length of part (L) in feet/meters

*Note: Straightness is measured when weight of pultrusion minimizes the deviation by contact with
flat surface.

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Pultex Structural Profiles, i.e., Channels, I-beams, Angles, etc.*

Allowable deviation from straight (D)

Length
Up to 5 feet
5 feet and Over

Deviation
.025"/ft
.050"/ft

Deviation per part

.025" x length (L)
.050" x length (L)

* Note: length of part (L) in feet/meters

D. Pultex Round, Square and Rectangular Tubes*

Diameter/Depth
Up to 2"
2" and Over

Allowable deviation from straight (D)

Deviation
.020"/ft
.030"/ft

Deviation per part

.020" x length (L)
.030" x length (L)

Note: length of part (L) in feet/meters

*Note: Straightness is measured when weight of pultrusion minimizes the deviation by contact with
flat surface.

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Pultex Camber (Lateral Bow), Sheets and Plates*

Allowable deviation from straight (D)

All Thicknesses
Length in feet x .025"

III. Flatness
A.

Pultex Rods, Bars, Profiles and Structural Profiles

Allowable deviation from flat (D)

Width (B)
Deviation per part width
Up to 1"
0.008"
1" and Over
0.008 in/in

*Note: Straightness is measured when weight of pultrusion minimizes the deviation by contact with
flat surface.

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Pultex Sheets and Plates

Allowable deviation from flat (D)

.25" up to 78" in width

All Thicknesses

Pultex Hollow Profiles

Thickness
Up to .187"
.187" and over

Allowable deviation from flat (D)

Dimensions up to 1" width (B)
.012"
.008"

Dimensions over 1" width (B)

0.012 in/in of width
0.008 in/in of width

IV. Twist
A.

Pultex Bars, Tubes and Structural Profiles

Width/Diameter
Up to 1.5"
1.5" to 3"
3" & over

Allowable deviation from straight in degrees

Thickness of profile Twist per foot/meter Twist per part length (ft)(m)
.100" and up
1
1 x length (ft), 7 Max.
.100" and up
.5
.5 x length (ft), 5 Max.
.100" and up
.33
.33 x length (ft), 3 Max.
Note: length of part (L) in feet/meters

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Angularity

All Pultex Structural Profiles

Thickness
Up to .75"

Allowable deviation from specific angle

Angles less than 90
1 1/2

Angles more than 90

1 1/2

VI. Length
All Pultex Structural Profiles
Allowable deviation from specific length
20' to 30'
30' to 40'
+ .250", -.250"
+ .500", -.500"

Length up to 20'
+ .125", - .125"

on-site installation easy.
Almost all fabricating methods currently used for wood, aluminum, steel or other materials are available
for fabrication of fiber reinforced polymer pultrusions.
To fabricate Pultex Profiles with complete success, the following techniques should be followed:

Punches work better with a slight shear edge.

Router bits should be diamond-coated.

Drilling speeds should take hole size and thickness into consideration.

Cutting speeds should be moderately fast (3,450 rpm).

Solvents, such as methylene chloride or acetone, should be used to prepare surface for bonding
or coating.

Lag screws are not recommended for fastening FRP to metal.

Counter support is necessary when drilling hollow profiles.

A medium coarse grinding wheel is preferable to the finer grades.

Each operation requires some change in technique or some modifications of equipment.

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When fabricating, the most important characteristics of pultrusion are: it is a fibrous material with a grain
(very much like wood); it is quite abrasive; it will bend. Although working with a fiberglass profile is
similar to working with wood, it is uniquely a pultrusion and has its own characteristics. Explaining the
nature of pultrusion fabrication is the purpose of this section of the manual.
Fabrication Of Pultex Structural Profiles
Before fabricating Pultex Profiles, several characteristics of the product itself should be recognized.
These considerations apply to every phase of each operation.
1. Fiberglass is extremely abrasive. Tools, such as saw blades, router bits or punches, will wear
quickly. Production problems will occur unless this problem is anticipated.

Frequent tool sharpening is common.

Diamond-coated edges and blades are the best.

Some re-tooling is common for heavy production.

Maintaining an at-hand inventory of saw blades, punches and other cutting tools is
recommended.

2. Fiberglass is dusty during fabrication.

Minor health problems, such as skin irritation, may be experienced by some workers.

Wear dusk masks or respirators, long-sleeved shirts or coats.

Machines, such as saws, should have totally enclosed dustproof motors or better.

Machines, their supports and their general vicinities should be cleaned frequently. Dust and
glass particles will build and become abrasive; and the machine will become damaged.

Vacuum hoses or vents should be placed near fabricating areas for dust collection.

3. Fiberglass, though strong, is also elastic. Pultex is typically produced in 20-foot

lengths. Because of its greater length, increase in elasticity, warpage or twist may be experienced.

Rigid support is needed for all fabrication procedures.

Clamps, tie-downs, and vices should be incorporated before and after a section is to be cut.

Process designers should individualize clamp and support systems for each profile for each
fabrication procedure. What is typical for aluminum is not necessarily appropriate for
pultruded profiles. Rigidity is mandatory.

4. Fiberglass will degrade if exposed to friction. Ragged edges and material splits could result.

Always use appropriate machine speeds in each operation.

The greater the thickness, the slower the cutting or drilling speed.

5. Exposed fibers will absorb more moisture or other contaminants than resin-coated fibers. When
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fabricating, the surface coating of resin is broken and fibers are exposed; therefore, it is always a
good practice to coat fabricated areas with resin to prevent attack from the elements, whether it be
corrosive agents or simple weathering.
6. All fastening procedures should be carefully appraised. Prototype testing should be included in
the decision process.

Experience has demonstrated that mechanical fasteners and a good adhesive bond are the
best procedures.

Choosing the correct adhesive is mandatory; bonding surfaces should be carefully prepared.

Process engineering should know the final product application and environment when
considering fastening systems.

Fiberglass is a composite in which many variables are operating, such as ultra-violet

exposure, chemical and temperature factors, and mechanical requirements. All fastening
systems should take these variables into account.

Never assume that what works with aluminum, bronze, or wood will suffice for FRP.
Concurrently, never assume that it won't. It is best to check first.

7. Pultex Profiles are composites that are engineered into laminate sections. Do not rigidly
impose the fabrication requirements of homogenous materials, such as aluminum or cold rolled
steel, on FRP, without first considering the composite characteristics of Pultex.

Properly understood, FRP will fabricate as well as any other material.

Tolerances, punch clearances and hole sizing should be gauged to the fibrous characteristics
of FRP.

Adhesives/Bonding
Consult Creative Pultrusions for adhesive recommendations for your needs. Adhesives are an integral
factor in fastening Pultex Profiles. As has been detailed, adhesives should be used in combination with
other fastening devices whenever possible.
Thousands of formula for adhesives exist; the basic ones used with Pultex are:
1. Epoxies
2. Acrylics
3. Polyesters
Advantages Of Adhesives

Distribute stress more uniformly.

Permit fabrication at a lower cost and weight for structures that are mechanically equivalent to or
stronger than conventional assemblies.

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Advantages of Adhesives (contd)

Bond thin sections to thick sections; thus, make use of the full strength of each section.

Produce smooth surfaces.

Eliminate defacing of exposed surfaces.

Reduce weight.

Join dissimilar materials.

Accommodate differences in thermal expansion.

Permit profile movement with flexible adhesives.

Seal surfaces and joints.

Accommodate thin or fragile profiles.

Bonded Shear Joint Concepts

The behavior of bonded joints is further challenged by several significant variables which requires an
understanding of the mechanics of configuration necessary for efficient and successful design.
Four basic stresses are associated with joint behavior: tensile, shear, cleavage and peel. Cleavage and
peel stresses are both special cases of tensile stresses involving large stress gradients through the joint.
Joints developing direct tension or shear stresses are stronger and more reliable than joints subjected to
cleavage and peel stresses.
Joint Stresses

Cleavage

Tensile

Shear

Peel

Symmetry of load transfer through a joint is to be held in highest esteem. (This axiom is also true for any
material and connectors, such as bolts or welds.) Non-symmetrical joints induce couples, which must be
resisted by cleavage or peel stresses.
With adhesive joints, flexibility of either the adhesive or the joined components is an advantage because it
permits the connecting elements to rotate into alignment with the applied forces, thereby reducing the
couple effect in the glue line. The geometric design of the joint can be used to improve strength and
efficiency; for example, where a single lap joint is a very inefficient joint, it can be improved by using a
low-modulus adhesive or beveling the joined elements to introduce some flexibility. The eccentricity of
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the joint may also be reduced by using a scarf type lap. (CAUTION: The desired stiffness of the joint
must be observed if a joint is designed to maximize flexibility. Both cannot be achieved at the same time.)
The strength of a single lap (or any other nonsymmetrical joint) is not proportional to its size due to the
stress concentration at the edges. The usual mechanism of failure in an adhesive joint is a crack
propagation process initiating at points of high tensile stress; thus, failure is progressive and limited to a
very small localized region at any given time, indicating that the overall size of the joint may be irrelevant
to the total strength of the joint. Anything done to avoid the stress concentration will improve the integrity
of the joint. The use of mechanical fasteners in cleavage stress regions, and void or crack-free glue lines,
are methods in which joints can be strengthened.
Surface Preparations
The bond strength of an adhesive can be no better than the lap sheer strength of the interlaminate
material itself; in other words, surface is bonded to surface, resin to resin. The fiberglass reinforcement
has little to do with achieving the bond strength.
The major fact in bonding Pultex Profiles is this: because the profiles have been manufactured with a
formulated mold-release, many adhesives will not react properly.
Mold release agents rise to the surface of the profile during the manufacturing process. By removing this
outer layer through proper surface preparation, the overly smooth surface can be abraded. Also, the
majority of mold release agents will be removed. The procedures for surface preparation in painting can
also apply.
Guidelines For Surface Preparations
1. Wipe contaminated surfaces with a solvent---styrene, toluene or methyl alcohol.
2. Wipe surface dry.
3. Remove surface film by sanding or light sand-blasting. Surface gloss should be removed.
4. Air blast the surface to remove any remaining dust. (Avoid recontamination by re-handling!)
5. Mix and apply adhesive 3 to 5 mils thick. Be certain that all surfaces and any glass fibers have
been covered.
6. Clamp, screw and/or fasten the bonded surface.
7. Allow for proper cure time:

Ovens will shorten the cure time.

A minimum of 20 to 24 hours is an average length of time for many adhesives to bond.

A structure should not be exposed to its designed load limit until 48 hours have
passed.

8. Always follow the adhesive manufacturer's recommendations.

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Table 9-1 Adhesive Comparison Guide Used With Pultex Standard Structural and
Pultex SuperStructural Profiles
Important Details
Product Advantages

Substrates
Resistant to
Dispensing Methods
Strength

Cure time
Formula available
Upper temperature range
Cost relative to other
adhesives

Epoxies
Strongest average lap shear can
be approximately
1200 psi
Adheres to many surfaces
Many use clean surfaces
Moisture, acids, bases, salts
Meter mixing
Hand mixing
Strength to
6000 psi
Average 1200 psi
Varies
Thousands
Service Range
-40F and +160F

Acrylics
Lower cost
Impurity tolerant
Metals, glass, plastics,
ceramics
Moisture, solvents, acids
Meter mixing
Hand mixing
Strength to
4000 psi
Average 700 psi
Varies
Many
250F Maximum

Moderate

Table 9-2 Comparison of Joining Techniques

Seal (water tightness)

Thermal insulation
Electrical insulation
Stress concentration at joint
Strength/weight ratio
Aesthetics (smooth joints)
Fatigue endurance
Inspection
Skill required of fabricator
Sensitivity to peel loading
Time to develop strength
Disassembly

Mechanical Bonds

Adhesive Bonds

No
No
No
High
Low
Poor
Poor
Easy
Low
No
Immediate
Possible

Yes
Yes
Yes
Medium
Medium
Good
Good
Difficult
High
Yes
Varies
Impossible

Cutting/Sawing
The most common cuts are: (1) straight lines, (2) 20-80 angles, (3) ripping, and (4) concentric cuts.
Different saws are not required for cutting profiles of different resin systems; however, adequate support
is necessary for all cutting procedures. Clamps are the preferred method for the hold-down function.
These clamps can be either air cylinder hold-downs or the wide range of welding clamps such as the
De-Sta-Co type. Precise cuts can be made if the profile is fastened on each side of the cut-line. Because
dust will obscure the cutting marks and the heat of the saw may burn the material, it is advisable to use
water-cooled blades for heavy production cutting. Parameter for cutting: Anything can be cut; thickness
is not an issue, shape is.

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Table 9-3 Machining Operations

Type of Saw
Circular Power Saw

Radial Arm Saw

Application
Straight cuts
and ripping

Saber Saw/Band Saw

Straight cuts
and ripping
Curved cuts

Hand Router

Curved cuts

Radial Arm Saw with Swivel Head

Hack Saw

20-80 angle cuts

Cutting rod stock

Comments
The hand model is good for on-site fabrication with
small to moderate numbers of cuts.

b) The table saw is a better model for accuracy and

support use, and is recommended for volume slitting or
cutting when equipped with the proper blade.
a) Good for large or thick sections. Water-cooled for
large production. Blade sizes can be varied.
a) Adequate for very small quantities. Diamond-coated
blades will increase production.
a) Better for large production. Often the slot cut by the
router bit will be wider or deeper than needed. It is a
good practice to try the bit before designing fixtures;
however, if properly done, this will yield precise
results.
a) Can be used for mitering; 3,450 rpm recommended.
a) Hand variety good for limited cuts ---.94 1.25 teeth
per mm.
Power hack saw is better for large production.
Tungsten carbide or diamond abrasive blades
recommended. Keep plenty on hand as breakage is a
problem.

Cutting Procedures
1. Blades should always be diamond or carbide-coated for large production; diamond blades
should be 30 to 40 mesh.
2. Tolerances should be no less than 1/16 inches for large productions.
3. Very often another more precise cutting is needed as a secondary procedure.
4. Precision cuts are also made with a (diamond-tipped) jig saw.
5. When mitering an end-cut, permit 1/2 to 1 inch waste area.
6. Infrequent circular cuts could use a metal cutting blade, although it will be dull after one cut.
7. Carbide-coated masonry blades are recommended for on-site fabrication.
8. For large section cuts, use the following:
a) begin with a power band saw for multiple cuts
b) use a circular saw and then invert material to finish the cuts
Operating Tips
1. When the edges begin to fray, reduce the saw speed.
2. If pultruded profiles are covered with nico or veil material, cut the visible side face-up.

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Operating Tips (contd)

3. Use a light, even touch!
4. The thicker the profile, the slower the cut. Time must be taken and a saw with adequate
horsepower used.
5. Excessively high speed will make the edges ragged and the diamonds will peel off the saw
blade.
Design Note
For hollow sections with thin walls (.080 inches and under), counter supports may have to be designed to
fit into the cavity. Or, you may need to purposely schedule a second-cut procedure. Unique custom
profiles often require unique cut-off operations and equipment.
Drilling
Drilling Pultex Profiles is an easy, routine operation. Re-design of equipment is generally unnecessary.
Standard twist drills are more than adequate for low production, but cobalt-bits are best for high
production. Carbide-tipped bits are not required.
Parameters for Drilling
Drilling of Pultex Profiles is standard for sections with thicknesses of .187 inches or
thicker.
Holes drilled in Pultex Profiles are generally undersized by .002 inches to .005 inches. A 1/8-inch
drill bit will not make a hole large enough for a 1/8-inch rivet. A No. 30 bit is necessary. Oversize
the drill bit in order to compensate for any shrinkage variation in fastener dimensions.
1. Drill Pultex Profiles as you would drill hard wood.
2. Feed drills slowly, even with higher speeds.
3. For profiles with surfacing veils, drill from the visible side to the non-visible side.
4. Off-centering can be a problem in mass production; use bushings for this procedure.
5. For riveting holes, use supplier's recommended clearance.
6. For larger holes, a back-up plate of wood or receiving bushing will prohibit fracturing or
breakouts on the backside of the material.
Design Note
For round, hollow profiles and custom, hollow profiles, use sturdy counter-supports from within the
hollow sections.

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Grinding
Grinding of Pultex Profiles is not generally recommended; however, it is necessary for the following
operations:
1. Notching
2. Recessing an internal wall in order to accommodate a flush fitting with another surface
3. Mounting secondary accessories or parts
4. Correcting inaccuracies in primary or secondary cuts (fragments, splinters)
5. Touching up edges
Parameters for Grinding
Grinding may be used for any thickness; results may vary.
Grinding Equipment

Use any standard grinder. Air-powered equipment is preferred.

Use carbide grinding wheels---especially for medium and coarse grit surfaces. (Fine surfaces
will quickly clog.)

Provide constant attention to the wheel surface. Grinding wheels need to be "dressed" or
cleaned regularly.

Operate at fairly high speeds. (1500 rpm plus)

Centerless grinding for tubes and rods is very accurate.

Use light pressure.

Turning
Pultex Profiles can be turned with standard metal working equipment on either a limited or a largeproduction basis.
Parameters For Turning
Dimensional tolerance for turning Pultex Profiles should be equated with cold rolled steel
tolerances. Operation feed and speed limits should be geared as if for brass or aluminum.
Equipment
For short production, steel tool cutters, with a single or multiple point, are satisfactory.
For large or multiple production, carbide tool bits are a necessity.
Round-nose lathe tools are best for good finishes.

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Turning (contd)

Use water coolants.

Use climb cutting, not under cutting.

For round-nose lathe tools, observe these pointers:

The tool should display tight tolerance.

Single points may tear the material, with sharp corners being rounded instead.

The surface speeds must be regulated according to the desired finish.

The speed must be geared to the hardness of the material and the type of cutting.

The material should be fed continuously and steadily.

Stopping and starting will noticeably mark the fiberglass.

The cutters should be set slightly above the center of the material when lathing.

Design Note
Fiberglass is a composite material; turning it should be executed only after ample experimentation. Get to
know the tolerances and the degree of hardness of each profile. Gauge the turning procedures to a
medium range derived from that experiment.
Routing
A router can cut a straight line or any angle. With a special bit, routers can be used for cutting radii,
keyways and milling profiles. The router cuts tend to be smooth and even which makes this an excellent
choice. Frayed edges may then be avoided.
Thickness
Routing is done on parts that are 1/8 to 1/2 inches thick.
Equipment
Two types of routing machines are used:

A hand-held air-powered model of 0 - 4,500 rpms

A medium-sized table model of 4500 - 10,000 rpms

Tungsten-carbide coated rotary file bits are adequate for moderate production; however, the selfcleaning diamond-tipped, channeled or fluted bits serve even better for a routing operation.

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Routing (contd)
Procedures
1. A coarser bit (36 mesh) will generally cut faster. Routing greatly improves when performed
at a higher speed; however, with a 1/2-inch-thick profile, the pultrusion material will cause a
great deal of friction. Caution should be exercised to avoid over-heating.
2. Use very light pressure when making router cuts. Forcing the bit could damage the material.
Design Note
A wide variety of router bits is available. As pultrusion gains the design flexibility of aluminum
extrusions, routing will take on great significance. The versatility of the process adapts quite well to
profile customization.
Punching
Fiberglass punches better than metal because it will spring back rather than bend. The amount of tonnage
for punching is also somewhat less than aluminum, especially on a thinner profile.
Punching is one of the most common fabrication methods. It is very important for a number of secondary
processes, such as fastening. If the inherent qualities of fiberglass are taken into account, punching can be
effortless. If not taken into account, problems may arise.
It is also important to note that many basic rules applicable to metal are not applied when punching
Pultex Profiles. Some differences to keep in mind are:

The clearances between the punch and the die are not as generous with pultrusion.

Hole sizing in pultrusion is typically "oversized" by as much as .002 to .030 inches.

The standard 15% rule regarding die clearance and material thickness of metal does not apply to
fiberglass.

Standard metal punching equipment is often inadequate for pultrusion punching. The equipment
must be realigned and/or fitted.
Procedure
1. The abrasiveness of pultrusion must be compensated for in the method of punching:

The punches need to be sharpened often.

The dies will need to be replaced or sharpened.

The overall tooling life may be shorter than the equivalent for metal punching.

It is common for punched holes to be drilled again in a secondary procedure when

dictated by tight tolerances.

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Punching (contd)
2. The fiberglass material will make dust and chips.

A clearance of .001 inches is not adequate. Dust will clog the female die almost instantly;
thus, a punch would quickly be off-center.

The minimum clearance should always begin at .005 inches. For high-production lines or
thicker sections of 3/16 inch or more, there is often a clearance of .010 to .020 inches.

3. All plastics are not the same.

Extremely close tolerances can be maintained for some thermoplastics.

Polyester, vinyl ester and epoxy thermosets are not as predictably tight; tolerances
often have to be generous.

Mat-reinforced pultrusion (thermoset) can be punched to closer tolerances than those

containing high roving.

4. Reinforced fiberglass is resilient.

The hold-down systems should be designed very carefully to compensate for this
resiliency.

Strippers are mandatory.

Lubrication will gather the fiber and dust particles, thus quickly jamming the punch.
A clean machine and work area at all times should eliminate this problem.

5. Pultex Profiles can deviate from specified tolerances regarding thickness, warpage, twist and
straightness. Though the deviation may not extend beyond acceptable limits, punching
accuracy and alignment may be affected.

System designers must take into account the degree of variance from specified
tolerances.

System flexibility should be designed into the punching system.

Due to the flexibility of a pultruded profile, proper clamp-down systems can alleviate
most of the problems associated with profile deviations.

Press Tonnage Requirements

Test results illustrate the shear strength values for Pultex Profiles.
The samples below were taken from one production run. The sample dimensions were circular coupons.
Thickness

0.130 inches

Circumference

3.132 inches

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Results
Sample #1 Break

=
=

7,400 lbs.
18,175 psi

Sample #2 Break

=
=

6,800 lbs.
16,701 psi

Sample #3 Break

=
=

7,200 lbs.
17,683 psi

The average shear value for Pultex Profiles is 17,520 psi. Converted to pounds,
the total is7,133 lbs.

The press tonnage required to punch fiberglass: .130 inches thick = 3.56 tons.

Punching a 15/16-inch diameter hole in 10-gauge half-hard 1/4-inch

thick aluminum requires 3.80 tons.

To determine the press tonnage values to punch Pultex Profiles, follow this procedure:
Multiply the profile material thickness by the hole circumference to be punched by the shear value.
Example: a 13/16-inch hole in a pultruded profile .077 inches thick is .077 inches (thickness) x 2.553
inches (circumference) x 17,000 psi (punch shear) = 3,342 lbs. pressure.
If 15 holes were going to be simultaneously punched, the number of holes would be multiplied by 3,342
pounds. In the above example, 50,130 pounds, or 25 tons of pressure, would be necessary for the
multiple punch machine.
Always use the 17,520 psi (120.8 MPa) shear value in the calculation.
Equipment
The following punching equipment is used routinely at Creative Pultrusions:
Equipment

Application

(1) 3 Ton Press

1 to 6,000 pounds

(1) 5 1/2 Ton Press

Punching profiles of 1/8-inch

thickness or smaller
profiles from 1/8-3/16 inch
thickness

(1) 13 Ton Brake Press

Punching profiles from 3/16 - 1/2 inch

thickness

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Design Note
Most fabrication shops are already equipped to punch aluminum sheet metal and cold rolled steel. Their
machinery can be used for punching Pultex Profiles, if the punches are appropriate for fiberglass. Holddown and support equipment should be evaluated for appropriateness, i.e., extra support.
Shear Angle in Punching
Rule: Optimum benefits for punching will be achieved when the punch is specially designed. Only a
small portion of the cutting edge should penetrate the material at any given time.
During the punching cycle, the goal is to subject the minimum amount of fiberglass to the smallest
fraction of cutting edge on an even basis. The punch should function as much like a scissor edge as
possible.
To design shear angle into a punch, the following criteria can be observed:

Shear strength of material

Thickness

Degree of resiliency

Production needs

Amount of hole clearance for fasteners

Type of fasteners (if any)

Round, flat-headed punches without shear edges are routinely used in punching small round holes on an
industry-wide basis with success.
Shear angle should be incorporated, if optimum benefits are desired. A shear angle that is equal to the
material thickness will reduce the required tonnage by one-third.
Providing a slighter shear angle is the most effective method. Shear angles are used, not only to reduce
tonnage, but to obtain a cleaner punch hole.
Doubling the shear angle to twice the material thickness of the profile is the recommended maximum
angle. Shear angle should not exceed that limit.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 9

Routing is one of many techniques used in fabrication.

Other Useful Guidelines for Punching
1. Some useful parameters are:

Oversize all holes by .020 to .030 inches.

The punched holes will range from .010 to .020 inches smaller than
the punching die.

The larger the hole, the cleaner the punch.

Material thickness to be punched will range from .070 to .187 inches.

2. For riveting, punched holes occasionally have to be redrilled especially in parts with thickness
of 1/8 inch or thicker.
3. Material Differences:

Mat-reinforced materials can be punched with exactness, especially when bushings are used.

Profiles with surfacing veils are punched from the non-visible to visible side.

4. A laminate .070 inches thick by 43 feet long, with a hole punched every 2 inches, has been
punched successfully.
5. For materials 3/16-inch thick, rivet holes can be placed every 6-8 inches; for bolting, the holes
should be 8-12 inches (203.2 mm 304.8 mm).
6. The depth of a punch should be twice the thickness of the laminate.
7. When punching hollow profiles, use strong counter supports, such as mandrels or bottom
carriage rests.

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Chapter 9

Shearing
Similar to punching, shearing is possible with Pultex Profiles. Profiles of 3/16-inch or thinner have
been sheared successfully in production.
Shearing is very useful for large production, particularly in very thin laminates (.070 to .090 inches).
Thicker profiles (.125 to .187 inches) can be sheared on flat sections, but shearing of profiles with
multiple contours are best cut with a saw.
The rules for punching also apply to shearing, especially those rules referring to angles.
All shearing should be done perpendicular to any continuous fibers in the laminate.
Shearing should be perpendicular to the longitudinal reinforcements. Cuts must be clean.
Consideration of the shear angle should be of primary importance before specifying this procedure.
Small profiles with a thickness not exceeding 3/16 inches can be sheared if the punch and profile are
designed together.
Painting
For most applications, internal coloration and a variety of surface treatments eliminate the need for
secondary coating operations. Situations exist, however, when paints are used to improve the weathering
properties or the appearance of a pultruded profile.
For improved weathering, urethane coatings are recommended as they have superior ultraviolet resistance
and adhere well to the pultruded substrate. Urethane-coated Pultex Profiles have been exposed to
advanced weathering, equivalent to 30 years of exposure, with no loss in insulation properties and only a
slight loss in mechanical properties. Non-skid coatings are available for slip resistant surfaces. These
coatings are available from several suppliers and in a wide range of colors.
Surface Preparation
Due to the fact that the pultrusion process requires internal mold releases, it is essential that, prior to any
painting or coating, the surface be properly prepared. The mold releases are a form of wax that creates a
film on the surface of the profile to be removed. It can be accomplished with several methods:

Solvent-wiping is the simplest method of surface preparation. Several solvents will attack
the mold release films. Some of these are toluene, xylene, acetone, or styrene.

Sanding will also adequately prepare the surface; however, when you break the surface at times,
you will expose minor imperfections that become quite visible when paint is applied. A sand and
fill primer can be applied to help this situation.

Sand-blasting can be used as a surface preparation technique, but exhibits the same problems as sanding.
It is best to follow the paint manufacturer's recommendations for the application of any type of coating.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 9

Joining Pultex Structural Profiles

Engaged

SCREW
Used for fastening Pultex profiles to metal.
Use metal as backup to fiberglass.

BOLT AND NUT

Used for fastening profiles together. Best to use
washers to distribute load whenever possible.
Steel, galvanized, silicon, bronze, nylon,
polyester and other materials available for a
wide range of applications. Check with your
supplier.

SUPERSTUD!/NUTS!
Threaded fiberglass rods with molded fiberglass
nuts. Good for highly corrosion applications.
Good shear values.

BOLTS AND THREADED HOLE

Possible assembly technique; however,
special construction of Pultex Profile required.
Fiberglass nuts above are made by this
technique. Epoxies or other adhesives greatly
improve joint strength.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 9

Mechanical Fastenings (contd)

Application

Fastener

Engaged

LAG SCREW
Can be used to attach profiles to wood. Washer
should be used to distribute load. Not recommended
for attaching fiberglass to fiberglass.

TUBULAR RIVET
Used in conjunction with washer or metal
backup plate. Stronger than pop-rivets
because of solid shank. Requires accessibility
from both sides of profile.

SOLID RIVET
Use with backup plate or washer. Must have
accessibility to both sides of profile.

Part 1 General
1.01

Related Documents
A. Drawings and general provisions of Contract, including General and Supplementary
Condition Specifications apply to the Writing Specification Section.

1.02

Summary
A. The following Fiber Reinforced Polymer Composites
Flowgrip Flooring Panel
Pultex Structural Profiles

Pultex SuperStructural Profiles

Tuf-Dek Flooring Panel
Stair Treads
Supergrate Pultruded Grating
Supergrate Molded Grating

1.03

Scope of Work
A. Furnish all labor, material and equipment to install the fiber reinforced polymer products
as displayed on the drawings and as specified herein.

1.04

Quality Assurance
A. The material specified will be furnished by a reputable and qualified manufacturer of
demonstrated ability who has routinely engaged in the manufacture of Fiber Reinforced
Polymer Composites.
B. Substitution of any component or modification of system will be made only when
approved by the Architect or Engineer.
C. Qualifications are limited to experienced manufacturers and fabricators producing fiber
reinforced polymer composite products similar to that indicated for this project, with
adequate production capacity, so as to not delay the work.
D. In addition to requirements of these specifications, comply with manufacturers
instructions and recommendations for work.

1.05

Design Criteria
A. The design of fiber reinforced polymer composite products, including connections, will
be in accordance with the governing building codes and standards, as applicable.

1.06

Submittals
A. Drawings of all fiber reinforced polymer composite products will be submitted to the
Engineer for approval in accordance with the necessary requirements of each specific
project.
B. Manufacturers catalog of data displaying

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 10

Submittals (contd)
1. Dimensions, spacings and construction of products
2. Design tables, with span length and deflection limits, under various
uniform and concentrated loads
3. Construction materials
C. Detail drawings displaying
1. Dimensions of fiber reinforced polymer composite products
2. Sectional assembly
3. Location and identification mark
1.07

Shipping and Storage Instructions

A. All systems, sub-systems and structures will be factory-fabricated and assembled to the
best practical sizes for transportation.
B. All material and equipment necessary for the fabrication and installation of the fiber
reinforced polymer composite products will be stored before, during, and after shipment
in a manner to prevent cracking, twisting, bending, breaking, chipping or damage of any
kind to the material, or equipment, including ultraviolet damage. Any material, which in
the opinion of the Engineer, becomes damaged as to be unfit for use, will be promptly
removed from work site, and the Contractor will receive no compensation for the
damaged material or its removal.
C. Identify all materials, items, and fabrications for installation and field assembly.

Part 2 Products
2.01

General
A. Material used in the manufacturing of fiber reinforced polymer composite products of the
best quality and free from defects and imperfections that may affect the performance of
the finished product.
B. All material will be of the type and quality specified; where quality is not specified, it
will be the best of the respective types and applicable for the intended purpose.
C. All standard 1525 and 1625 fiber reinforced polymer composite products noted in the
Summary Section will be manufactured using the pultrusion manufacturing process, with
either thermoset polyester or thermoset vinyl ester resins, including flammability and
ultraviolet (UV) inhibitor additives. A synthetic surface veil will be the outermost layer
of the exterior surface. The fiber reinforced polymer composite profiles will achieve a
class 1 flammability rating (< 25) per ASTM E84 test method. (Thermoset polyester
resin and vinyl ester resins are available without flame retardant and UV inhibitor
additives.)
D. After fabrication, all cut ends, holes and abrasions of fiber reinforced polymer composite
products will be sealed with a compatible resin coating to prevent intrusion of moisture
where applicable.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 10

General (contd)
E. Fiber reinforced polymer composite products, exposed to weather, will contain an
ultraviolet inhibitor.
F. All exposed surfaces will be smooth and true-to-form.
G. Manufacturers:
1. Creative Pultrusions, Inc., Pultex Standard Structural Profiles, Pultex
SuperStructural Profiles, Superstud!/Nuts!, Flowgrip, Supergrate
and Tuf-dek.
2. or approved equal
2.02

Gratings and Treads

General
A. Grating will be transported from the manufacturer, palletized and banded with
exposed edges protected by cardboard to prevent damage.
B. Each product will be clearly identified with the applicable drawing number.
C. Grating will be Supergrate, Flowgrip or Tuf-dek, as manufactured by Creative
Pultrusions, Inc., Alum Bank, Pennsylvania.
D. Grating will be specified by loading requirements. Specify grating type by using
Solutions that Work---The Most Complete Line of Grating and Access Structure
Products in the Industry, page #11 18 and 20c and 20d.
Design
A. The panels will be ______inches deep and sustain a deflection of no more than_____
inches under a uniform distributed load or point load over a span length of
_____inches. Reference Solutions that Work---The Most Complete Line of Grating
and Access Structure Products in the Industry.
B. The top surface of all panels will have a nonskid grit affixed to the surface. Reference
Solutions that Work---The Most Complete Line of Grating and Access Structure
Products in the Industry.
C. Panels will be fabricated to the sizes shown on the drawings.
Hold down clamps will be type 316L stainless steel. A minimum of four each per
panel.
(Select One)
Option 1: Color will be high visibility safety yellow. (OSHA safety yellow)
Option 2: Color will be gray. (OSHA safety gray)

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 10

Products
A. The fiber reinforced polymer composite grating and stair treads will be fabricated
from bearing bars and cross rods manufactured by the pultrusion process. The
glass fiber reinforcement for the bearing bars will be a core of continuous glass
strand rovings wrapped with continuous glass strand mat. A synthetic surface
veil will be the outermost layer of covering for the exterior surfaces. Reference
Solutions that Work---The Most Complete Line of Grating and Access Structure
Products in the Industry.
2.03

Fiberglass Grating and Stair Treads

A. Fiberglass grating and stair treads will be manufactured with a premium grade chemical
resistant, fire retardant thermoset polyester or fire retardant thermoset vinyl ester resin
system, with antimony trioxide included to meet the flame rating of 25 or less in
accordance with ASTM E84 testing and the self-extinguishing requirements of ASTM
D635. UV inhibitors are added to the resin.

2.04

Flowgrip Flooring Panel or Supergrate Grating with Plate

A. Grating will be the same as described above in this section.
B. Plate will be Pultex flat sheet as manufactured by Creative Pultrusions, Inc., Alum
Bank, Pennsylvania.
C. Grating with plate will be manufactured with a premium grade polyester or vinyl ester
resin with fire retardant additive to meet Class I flame rating of 25 or less as tested by
ASTM E84 and the self extinguishing requirements of ASTM D635. All plate will
contain a UV inhibitor.
D. Grating with plate will be bonded to the grating, and non-skid grit will be affixed to the
top surface.
E. All cut and machined edges, holes and abrasions will be sealed with a resin equal to the
resin used in manufacturing the product.
F. All panels will be fabricated to the sizes displayed on the approved drawings.
G. Grating with plate can be substituted with Flowgrip; for additional information
Reference Solutions that Work---The Most Complete Line of Grating and Access
Structure Products in the Industry.

2.05

Pultex Structural Profiles

A. Structural profiles will be manufactured with a premium grade polyester or vinyl ester
resin with fire retardant additives to meet Class I flame rating of ASTM E84 and the selfextinguishing requirements of ASTM D635. All structural profiles will contain a UV
inhibitor.
B. Manufactured by the pultrusion process.
C. Structural fiber reinforced polymer composite member composition will consist of a glass
fiber reinforced polyester or vinyl ester resin matrix, approximately 50% resin-to-glass
ratio. A synthetic surface veil will be the outermost layer of the exterior surfaces.

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 10

Continuous glass strand rovings will be internally used for the longitudinal strength.
Continuous strand glass mats or stitched fabrics will be internally used for transverse
strength.
For properties, reference the Pultex Fiber Reinforced Polymer Structural Profile Materials
Properties Sheet, Superstud!/Nuts! Fiber Reinforced Polymer Fastener System Materials
Properties Sheet, Pultex Fiber Reinforced Polymer Rod and Bar Materials Properties Sheet and
Pultex Fiber Reinforced Polymer Flat Sheet Materials Properties Sheet. Reference Solutions
that Work---The Most Complete Line of Grating and Access Structure Products in the Industry.

Part 3 Execution
3.01

Installation All Fiber Reinforced Polymer Composite Profiles

A. All field cut and drilled edges, holes and abrasions will be sealed with a catalyzed resin
compatible with the original resin as recommended by the manufacturer. The sealing of
the edges will prevent premature fraying at the field cut edges.
B. Install items specified as indicated and in accordance with manufacturers instructions.

Part 4 Inspection and Testing

A. The Engineer will have the right to inspect and test all to-be-furnished materials under
these specifications prior to transportation from the point of manufacture.
B. All labor, power, materials, equipment and appurtenances required for testing will be
furnished by the Contractor at no cost to the Owner.
Part 5 Subsection
Part 1 General
1.01
1.02
1.03
1.04
1.05
1.06
1.07

Related Documents
Summary
Scope of Work
Quality Assurance
Design Criteria
Submittals
Shipping and Storage Instructions

Part 2 Products
2.01
2.02
2.03
2.04
2.05

General
Gratings and Treads
Fiberglass Grating and Stair Treads
Flowgrip Flooring Panel or Supergrate Grating With Plate
Pultex Structural Profiles

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 10

Part 3 Execution
3.01

Installation All Fiber Reinforced Polymer Composite Profiles

Part 4 Inspection and Testing

The New and Improved Pultex Pultrusion Global Design Manual

Chapter 10

Appendix A
Clip Connection Test Procedures

Double Cantilever Test

The objective of the double cantilever test is to develop full section data to be used by engineers, for the
design of structural systems using Pultex SuperStructural Angles.
Test Set-Up
A double cantilever test setup was designed as displayed below. The design was implemented to
maximize the effects of shear and minimize the eccentricity in the connection. Two hinge supports were
placed directly below the bolts in the web of the beams; and an identical support was placed at the top of
the column beneath the load cell. The steel Wide Flange Section 8 x 31 column used in the connection
was loaded in the main stiffness direction.

The New and Improved Pultex Pultrusion Global Design Manual

Appendices

Test Procedure
All hinges were made of steel plates and rollers. The bottom hinges were placed in the line of
action of the beam-web bolts to eliminate eccentricity. After the connection was centered on the
testing machine a small load of 100 lbs. was applied. The load was applied in increasing
increments of 5,000 lbs. at a constant rate of 2,000 lbs. per minute. At every 5,000 lbs., the
deflection was recorded. The tests were halted when the load would no longer increase.
Experimental Results
The tests were conducted using 4" x 4" x 3/8" Pultex SuperStructural Angles, pultruded in
polyester and vinyl ester resins. The angles were clipped into steel beams and columns. The
load value recorded from the load cell was divided by 2 to calculate the force transferred to each
connection. This computation provided a conservative load estimate because the side that failed
first supported more than half the load. The failure mechanism observed was interlaminar
peeling and shear through the heel of the angle. The design loads were calculated by dividing
the heel area of the angles by half of the total load.
Tests were conducted at the University of Maine by Dr. Roberto Lopez-Anido and Creative
Pultrusions full section testing laboratory.

The New and Improved Pultex Pultrusion Global Design Manual

Appendices

Appendix B
Computing Modulus (E) and Shear Modulus (G)

(ASTM D198)
Objective
The Elastic Modulus and the Shear Modulus of a beam can be estimated by using a linear regression
analysis of the three-point bending deflection equation and a deflection test as pictured above.
Analysis
The deflection of a simply supported beam with a concentrated center load can be modeled by the
following equation:

1
1
P L3
=
+

48 E I 4 K G A

(1)

where

A
Aw
E
G
Ixory
k
L
P

=
=
=
=
=
=
=
=
=

Deflection of the beam at its center

kAw (Ref. Table 2)
Cross sectional area of web (in2)(Ref. Table 2)
Modulus of elasticity (psi)
Modulus of rigidity (shear modulus) psi
Moment of inertia about axis being tested (in4)
Shear coefficient (Ref. Table 2)
Span of beam (inches)
Applied load (lbs.)

This equation can be rearranged into the following slope-intercept form:

1
1
1
1
=

L2 +
P L 48 E I
4 G A
The New and Improved Pultex Pultrusion Global Design Manual

Appendices

(2)
3

where

1 1

48 E I

SLOPE =

(3)

and

INTERCEPT =

1
1

4 G A

(4)

By the method of super position, equation (2) can be split into separate terms and rearranged into the
following equations:

EI =

G A =

1
1

48 SLOPE

(5)

1
1

4 INTERCEPT

(6)

Test the beam at a minimum of three different spans and gather load, span, and deflection data. The
graph of

, versus

as displayed, can be produced.

/(P*L)

/(P*L) vs. L

1 1

4 GA

1 1

48 E I
2

The Apparent Modulus can be calculated by finding the slope of the regression line and plugging it into
equation (5). At least three points need to be used in order that test results can be checked for error by
calculating the variance of the line. The Shear Modulus can be calculated from the y-intercept of the line
and equation (6).

The New and Improved Pultex Pultrusion Global Design Manual

Appendices

Works Cited
Bank, L.C. Flexural and Shear Moduli of Full-Section Fiber Reinforced Plastic (FRP) Pultruded
Beams, Journal of Testing and Evaluation. ITEVA, Vol. 17, No. 1. Philadelphia: 1989.
Bank, L.C. Bolted Connections for Pultruded Frame Structures. Diss. The Catholic
University of America, 1996.
Beer, Ferdinan P., E. Russell Johnston, Jr. Mechanics of Materials. 2nd ed. New York:
McGraw-Hill, Inc., 1992.
Cowper, G.R. The Shear Coefficient in Timoshenkos Beam Theory. National Aeronautical
Establishment, National Research Council, Ottawa, Canada, 1966.
Hibbeler, R.C. Engineering Mechanics Statics and Dynamics. 5th ed. New York: R.C.
Hibbeler, 1989.
Mallick, P.K. Fiber Reinforced Composites Materials, Manufacturing, and Design. 2nd ed.
New York: Marcel Dekker, Inc., 1993.
Salmon, Charles G. and John E. Johnson. Steel Structures Design and Behavior Emphasizing Load
and Resistance Factor Design. 3rd ed. New York: Harper & Row, Publishers, Inc.,
1990.
Task Committee on Design of the Structural Plastics Research Council of the Technical Council
on Research of the American Society of Civil Engineers. Structural Plastics Design Manual
Vol. 1. New York: American Society of Civil Engineers, 1984.
Task Committee on Design of the Structural Plastics Research Council of the Technical Council
on Research of the American Society of Civil Engineers. Structural Plastics Design Manual
Vol. 2. New York: American Society of Civil Engineers, 1984.
Davalos, Julio F., PhD., Barbero, Ever, J., Ph.D., Qiao, Pizhong, Ph.D., P.E. Step-by-Step Engineering
Design Equations for Fiber-reinforced Plastic Beams for Transportation Structures. Diss. West
Virginia Department of Transportation, 1999.

The New and Improved Pultex Pultrusion Global Design Manual

Works Cited

Pultex Fiberglass Standard Structural Profiles and Superstud!/Nuts!

Product Availability List
All Items are available upon request in standard resin series:

Delivery:

Series 1500 = Isophthalic Polyester (I) - Olive Green

Stocked Items: 1-3 days

Series 1525 = Isophthalic Fire Retardant (IFR) - Slate Gray (Dark Gray)

Items Out of Stock: 2 weeks

Series 1625 = Vinyl Ester Fire Retardant (VFR) - Beige

x = Stocked Items (All items stocked in 20' lengths unless otherwise noted.)

Unequal Leg
Angle

Equal Leg Angle

Size (inches)
1 x 1/8
1 x 1/4
1-1/2 x 1/8
1-1/2 x 3/16
1-1/2 x 1/4
2 x 1/8
2 x 3/16
2 x 1/4
3 x 1/8
3 x 3/16
3 x 1/4
3 x 3/8
4 x 1/4
4 x 3/8
4 x 1/2
6 x 1/4
6 x 3/8

I
x

I V
Mill
F F
R R Run (ft) Wt. Ft. Size (inches)

3,000
2,500
2,700
x

x
x
x
x
x

x
x
x
x

x
x

6 x 1/2
*

2,200
2,000

0.17 4 x 6 x 3/8
0.31 4 x 6 x 1/2
0.25 5 x 10 x 3/8
0.38
0.51 Channel

2,500
2,000
1,800
2,000
1,500
1,500

0.35
0.56
0.68
0.53
0.78
1.06

1,200
1,300

1.74
1.59

900
1,300
900
800
700

2.28
3.01
2.29
3.57
4.66

Stocked in NSF 61 Olive Green.

Unequal Leg Angle

Size (inches)
1 x 1-1/2 x 1/8

Non-Stocked Items: 2-4 weeks

= SuperStructural Items

I V
Mill
F F
R R Run (ft) Wt. Ft.
2,500
0.21

1 x 2 x 1/8
1 x 2 x 3/16
1 x 2 x 1/4
1 x 3 x 1/8
1-1/4 x 2 x 1/4
1-1/2 x 2 x 1/8
1-1/2 x 2 x 1/4
1-1/2 x 3 x 1/8
1-1/2 x 3 x 3/16
1-5/8 x 2-5/8 x 1/8
2 x 3 x 3/16
2 x 3 x 1/4
2 x 3 x 3/8

2 x 4 x 1/4
2 x 4 x 3/8
3 x 4 x 1/4
3 x 4 x 3/8
3-1/2 x 5 x 1/2

2,500
2,000
2,000
2,000
1,500
2,500
1,500
2,000
1,500
2,500
1,000
1,500
1,500
1,500
1,000
1,200
1,000
1,000

0.27
0.46
0.50

Size (inches)
1-1/2 x 1 x 3/16
2 x 9/16 x 1/8
2-3/4 x 1 x 1/8
3 x 7/8 x 1/4
3 x 1 x 3/16
3 x 1-1/2 x 1/4
4 x 1-1/16 x 1/8
4 x 1/8 x 1-3/4 x 3/16
4 x 1-1/8 x 1/4
5 x 1-3/8 x 1/4
6 x 1-5/8 x 1/4
6 x 1-11/16 x 3/8
7 x 2 x 1/4
8 x 2-3/16 x 1/4
8 x 2-3/16 x 3/8
10 x 2-3/4 x 1/8
10 x 2-3/4 x 1/2
11-1/2 x 2-3/4 x 1/2
14 x 6 x 1/2
18 x 2-1/2 x 1/4
24 x 3 x 1/4
24 x 4 x 1/2

I-Beam

I
F
R

V
F Mill Run
R
(ft)
Wt. Ft. Size (inches)

700
700
700

I
F
R

x
x****

V
F Mill Run
R
(ft)
Wt. Ft.
2,200
0.48
2,800
0.27
5,000
0.42

1,700
1,800
x

x
x**

x***

x
x

x** x**
x
x

2.93 3 x 1-1/2 x 1/4

3.75 4 x 2 x 1/4
4.50 6 x 3 x 1/4
6 x 3 x 3/8
8 x 4 x 3/8

1,300
1,900
1,500
1,200
1,300
1,200
1,000
1,200
1,000
800
1,500
600
600
500
700
600

500
0.35 **Stocked in 20'1", 30'1" and 40'1" lengths only.
0.55 *** Stocked in 20'1", 25'1" and 30'1" lengths only.
0.37 ****Stocked in 20'1" lengths only.
0.55 ** Stocked in 1525 Light Gray and 1625 Beige Only. Call for
0.39 Availability.
0.57 Also available in SU PUR TUF Polyurethane Resin. Consult
0.38 factory.
0.66
0.91
1.28
1.07
1.99
1.25
1.85
2.98

8 x 4 x 1/2
10 x 5 x 3/8
10 x 5 x 1/2
12 x 6 x 1/2

I V
Mill
F F
R R Run (ft) Wt. Ft.

x
x x
x
x
x

1,400
1,300
800

1.01
1.63
2.39

800
600

3.78
4.74

700
700
600
400

6.45
6.06
7.93
9.83

*Stocked in 25' lengths only.

0.78
Wide Flange Beam
0.63
0.98
I V
0.54
Mill
F F
I R R Run (ft) Wt. Ft.
0.87 Size (inches)
1.02 3 x 1/4
x x
1,000
1.84
1.37 4 x 1/4
800
2.44
x x* x
1.67 6 x 1/4
700
3.64
x*
2.51 6 x 3/8
x x
600
5.53
2.06 8 x 3/8
400
7.26
x
2.22 8 x 1/2
400
9.99
x*
3.28 10 x 3/8
400
9.07
1.44 10 x 1/2
400
12.03
x*
300
14.92
5.77 12 x 1/2
x**
6.46 * Stocked in 20' and 25' lengths only.
10.44 ** Stocked in 25' lengths only.
4.86
5.61 Round Tube
11.21
Size (inches)
3/4 x 3/32
1 x 1/8
1-1/4 x 3/32
1-1/4 x 1/8
1-1/2 x 1/8
1-1/2 x 1/4
1-3/4 x 1/8
1-3/4 x 1/4
2 x 1/8
2 x 1/4
2-1/2 x 1/8
2-1/2 x 1/4
3 x 1/4
4.02 x 0.28
**

I V
Mill
F F
R R Run (ft) Wt. Ft.

x
x

x
x**

2,000
2,000
1,900
1,900
1,900
1,500
1,600
1,500
1,500
1,400
1,500
1,000
900
900

Stocked in Dark Gray and Yellow Only.

Reference Part Drawings for Actual Dimensions.

Part Construction is Special. Consult Factory for
Special Properties.

Creative Pultrusions, Inc. reserves the right to edit and modify literature, please consult the web site for the most current version of this document.

Product Availability List

Imperial Version

CPSALI-0111.1C
DLR:05.30.13

0.17
0.28
0.27
0.34
0.42
0.77
0.50
0.91
0.64
1.08
0.62
1.32
1.66
1.66

Square Tube

Size (inches)
1 x 1/8
1-1/4 x 1/4
1-1/2 x 1/8
1-1/2 x 1/4
1-3/4 x 1/8
1-3/4 x 1/4
2 x 1/8
2 x 1/4
2-1/8 x 3/16
2-1/2 x 1/4
3 x 1/4
3-1/2 x 3/8
4 x 1/4
5.2 x 3/8
6 x 3/8

CPM059m-0601.1C

Solid Round Rod

I
x
x

x
x****

I V
Mill
F F
R R Run (ft) Wt. Ft.
0.33
x x*** 1,800
1,000
0.76
1,800
0.48
x
0.92
x** 2,500
2,500
0.54
1.12
x* x* 1,600
0.69
x* x* 1,600
1.40
x* x* 1,200
1,500
1.08
1,000
1.79
800
2.16
x
700
3.70
700
2.96
x
700
5.82
700
7.81

*Stocked in Yellow Only.

**Stocked in Dark Gray and Yellow Only.
***Stocked in Dark Gray, Yellow and Beige.
****Stocked in 20 1Lengths Only.
Reference Part Drawings for Actual Dimensions.

Size (inches)
1/4
3/8
1/2
5/8
3/4
1
1-1/4
1-1/2
2

Special Shapes

DLR: 07.02.13

I
F
R

I
x
x
x
x
x
x
x

V
F Mill Run
R
(ft)
Wt. Ft.
10,000
0.04
5,000
0.10
3,500
0.17
2,400
0.28
2,000
0.40
1,500
0.69
1,200
1.10
900
1.54
600
2.56

Size (inches)
Toe Plate
4 x 1/2 x 1/8
6 x 1/2 x 1/8

I V
Mill
F F
R R Run (ft) Wt. Ft.
x* x*

2,500
2,500

0.53
0.72

x**
x**
x**

1,400
1,300
1,200

0.90
1.02
1.10

2,500

1.21

Curb Angle
1 x 1-1/2 x 1/4
1-1/2 x 1-1/2 x 1/4
2 x 1-1/2 x 1/4
Gate Guide

All Rods Stocked in Natural Color

2-1/2 x 2-1/4 x 1/4

x***

Sludge Flight
6 x 1/8 x 2-1/2 x 3/16
8 x 1/8 x 2-1/2 x 3/16

x*
x*

Solid Square Bar

Size (inches)
1/4
1
1-1/4(1.234" Actual)
1-1/2 (1.460" Actual)

I
F
R

x**

x
x*
x*

V
F Mill Run
R
(ft)
Wt. Ft.
0.05
10,000
0.81
1,400
1.27
1,000
1.84
800

U-Trough
8-1/2 x 9-1/4 x 1/4
12 x 12 x 1/4

1,000
1,000

1.52
1.67

1,000
1,000

4.95
6.32

5,000

0.47
1.72

1,500

1.64

2,000

0.32

*Stocked in Yellow Only.

**Stocked in Yellow and Olive Green Only.
Reference Part Drawings for Actual Dimensions.

Square Tube with

Round Hole

**Stocked in Light Gray and Slate Gray.

I V
Mill
F F
R R Run (ft) Wt. Ft.

1-1/4 x 3/4 x 1/8

4x1/8 x1-3/4 x 1/4
4-7/16 x 1-7/16 x 1/8
4-3/4 x 1-3/4 x 1/8
5 x 2 x 1/8
6 x 2 x 1/8
8 x 1 x 3/32

1,700
2,000
2,500
2,500
2,500
2,000
1,000

Shapes contain internal webs.

Reference Part Drawings for Actual Dimensions.

x**
x*

V
F Mill Run
R
(ft)
10,000
6,000
6,000
3,000
2,000
1,500
3,000
1,500
3,000

Wt. Ft.
0.24
0.39
0.37
0.76
1.10
1.90
0.87
1.62
0.75

*Stocked in Yellow 21 Lengths Only.

**Stocked in Yellow 22 4-1/2
Lengths
Only.
Superstud!/Nuts!
Fasteners

0.26 Isoplast Hex Nuts

1.37
1.03
1.17
1.44
2.00 Size (inches)
1.84 3/8 - 16 UNC
1/2 - 13 UNC

Rectangular Box
Beams

Size (inches)
6 x 4 x 1/4
7 x 4 x 1/4
7 x 4 x 3/8
8 x 4 x 1/4
8 x 4 x 3/8

Size (inches)
1/8 x 2-1/2
1/8 x 4
3/16 x 2-1/2
1/4 x 4
1/4 x 6
1/4 x 9
3/8 x 3
3/8 x 6
1/2 x 2

1 x 3/4 dia.
I
F
R

Note: Many other Flat Strips are available. Consult factory for other
sizes. other sizes.

Rectangular Tube

Size (inches)

Flat Strip

I V
Mill
F F
R R Run (ft) Wt. Ft.
1,000
3.85
1,000
4.08
800
5.99
1,000
4.48
800
6.52

5/8 - 11 UNC
3/4 - 10 UNC
1 - 8 UNC

x** x**

Door Frame
6"
Fluted Ladder Rung
1.24 x .125

Note: T-Sections are cut from I-Sections and can be

quoted upon request.
*Stocked in Yellow Only.
**Stocked in Dark Gray Only.
***Stocked in NSF 61 White Only.
*

Stocked in NSF Light Gray Only.

Stocked in 1525 Light Gray and 1625 Beige Only:

25' Lengths. Call for Availability.

Adhesive Epoxy Kit

and
1/2 Gallon Kit

Wt.
Ft.

Nuts/Hexnuts

Size (inches)
1/8 x 48 x 96
3/16 x 48 x 96
1/4 x 48 x 96
3/8 x 48 x 96
1/2 x 48 x 96
5/8 x 48 x 96
3/4 x 48 x 96
1 x 48 x 96

Mill
Run
I V
F F (sheets
I R R
)
Wt. Ft.2
x x x
188
1.17
x
140
1.69
x x** x
94
2.27
x x
63
3.46
x x
47
4.64
40
5.77
30
6.57
20
9.45

Superstud!

Flat Sheet

x
x

0.08
0.13

x
x
x

(includes 1 quart base

and 1 quart hardner)

Stocked
x

Wt. Ft
(Nuts)

Wt. Ft.
(Hex
nuts)

x
x

0.55
1.10

0.45
0.90

0.21
0.32

x
x

1.00
1.25

0.59

1.35

0.90 Flowgrip and Pultex are registered trademarks of Creative

1.25 Pultrusions, Inc. Creative Pultrusions, Shaping the Future,
1.30 Superstud!, Superstud!/Nuts!, Superstik, SU PUR TUF,

Superstud! is stocked in 48 and 96 Lengths and is made with

Series 1625 VFR resin.
Isoplast Flanged Hex Nuts are also stocked in all sizes. Please
specify square or hex nuts when ordering.

Superplank, Superdeck, Supergrate, Tuf-dek,

SuperLoc, SuperWale, SuperCap, SuperRod,
Pultrusion Dynamics, DYNAPUL, Pulshaping,
TOPSCAN and TOPDIE are trademarks of Creative
Pultrusions, Inc.

Creative Pultrusions, Inc. reserves the right to edit and modify literature, please consult the web site for the most current version of this document.

Product Availability List

Imperial Version

CPSALI-0111.1C
DLR:05.30.13

The Pultex Pultrusion

Design Manual

of Standard and Custom Fiber Reinforced Polymer Structural Profiles

Imperial Version
Volume 4 Revision 8

Flowgrip and Pultex are registered trademarks of Creative Pultrusions, Inc. Creative Pultrusions, Shaping the Future, Superstud!,
Superstud!/Nuts!, Superstik, SUPURTUF, Superplank, Superdeck, Supergrate, Tuf-dek, SuperLoc, SuperWale, SuperCap,
SuperRod, Pultrusion Dynamics, DYNAPUL, Pulshaping, TOPSCAN and TOPDIE are trademarks of Creative Pultrusions, Inc.

CPS034IMP-0404.5C
DLR: 08.23.12

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