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64-511: The Anziel Nova was meant to be New Zealand's first domestically produced car. A prototype of the fibre-glass bodied car was unveiled in September 1967, however never reached production. In 1965 Alan Gibbs , then an economist, had returned from England with the idea of creating a New Zealand made car. However, he initially worked for the Government's Department of Prime Minister and Cabinet on

128-424: A glass with no true melting point, can be used as a glass fiber for fiberglass but has the drawback that it must be worked at very high temperatures. In order to lower the necessary work temperature, other materials are introduced as "fluxing agents" (i.e., components to lower the melting point). Ordinary A-glass ("A" for "alkali-lime") or soda lime glass, crushed and ready to be remelted, as so-called cullet glass,

192-539: A 5 mg/m total limit. As of 2001, the Hazardous Substances Ordinance in Germany dictates a maximum occupational exposure limit of 86 mg/m . In certain concentrations, a potentially explosive mixture may occur. Further manufacture of GRP components (grinding, cutting, sawing) creates fine dust and chips containing glass filaments, as well as tacky dust, in quantities high enough to affect health and

256-602: A November, 2011 modification to its Proposition 65 listing to include only "Glass wool fibers (inhalable and biopersistent)." Therefore a cancer warning label for biosoluble fiber glass home and building insulation is no longer required under federal or California law. As of 2012, the North American Insulation Manufacturers Association stated that fiberglass is safe to manufacture, install and use when recommended work practices are followed to reduce temporary mechanical irritation. As of 2012,

320-439: A binder. It is typically processed using the hand lay-up technique, where sheets of material are placed on a mold and brushed with resin. Because the binder dissolves in resin, the material easily conforms to different shapes when wetted out. After the resin cures, the hardened product can be taken from the mold and finished. Using chopped strand mat gives the fiberglass isotropic in-plane material properties. A coating or primer

384-417: A chemical solution. The individual filaments are now bundled in large numbers to provide a roving . The diameter of the filaments, and the number of filaments in the roving, determine its weight , typically expressed in one of two measurement systems: These rovings are then either used directly in a composite application such as pultrusion , filament winding (pipe), gun roving (where an automated gun chops

448-444: A chopped strand mat, or woven into glass cloth . The plastic matrix may be a thermoset polymer matrix —most often based on thermosetting polymers such as epoxy , polyester resin , or vinyl ester resin —or a thermoplastic . Cheaper and more flexible than carbon fiber , it is stronger than many metals by weight, non- magnetic , non- conductive , transparent to electromagnetic radiation , can be molded into complex shapes, and

512-401: A combined stream from a chopper gun. Workers roll out the spray-up to compact the laminate. Wood, foam or other core material may then be added, and a secondary spray-up layer imbeds the core between the laminates. The part is then cured, cooled, and removed from the reusable mold. Pultrusion is a manufacturing method used to make strong, lightweight composite materials. In pultrusion, material

576-430: A liner to prevent gas leakage or as a barrier to protect the composite from the fluid to be stored. Filament winding is well suited to automation, and there are many applications, such as pipe and small pressure vessels that are wound and cured without any human intervention. The controlled variables for winding are fiber type, resin content, wind angle, tow or bandwidth and thickness of the fiber bundle. The angle at which

640-625: A new record for crossing the English Channel in an amphibious vehicle. Branson cut 4 hours 20 minutes off the previous record of 6 hours, which had stood since the late 1960s. The officially recorded time was 1 hour 40 minutes, 6 seconds. For the August 2004 edition of Top Gear magazine, journalist Paul Walton drove an Aquada into and around the Monaco harbour during the Grand Prix of Monaco to watch

704-913: A post-exposure recovery period." Historic reviews of the epidemiology studies had been conducted by Harvard's Medical and Public Health Schools in 1995, the National Academy of Sciences in 2000, the Agency for Toxic Substances and Disease Registry ("ATSDR") in 2004, and the National Toxicology Program in 2011. which reached the same conclusion as IARC that there is no evidence of increased risk from occupational exposure to glass wool fibers. Genetic and toxic effects are exerted through production of reactive oxygen species , which can damage DNA, and cause chromosomal aberrations , nuclear abnormalities, mutations, gene amplification in proto-oncogenes , and cell transformation in mammalian cells. There

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768-469: A project, but would continue to consider it. Discussions continued in the following year with no real change. By the end of 1968 the government offered a licence for 600 units, but this was insufficient. Through 1969 there were ongoing battles with the government but no progress. Even obtaining funds for paying a fee for Reliant's technical assistance was declined. The project was finally doomed in March 1970, due to

832-608: A prototype from Reliant. On 16 December 1966, Otosan had begun production of the FW5, naming it the Anadol A1 . Whether it was an FW5 or an A1 that the Gibbs brothers obtained as their prototype is unknown, as either source could have been used. Given the probable higher import duties on non-United Kingdom sourced vehicles it is more likely that it was a Reliant FW5. The car arrived in New Zealand in

896-557: A station wagon, commercial van, and a light truck. The prototype is still in existence and owned by Alan Gibbs. The Gibbs brothers brought in Sir Laurence Hartnett , who was considered the father of the Australian car industry , to promote the car at an official announcement on 17 September 1967. The car was said to be going to sell for NZ$ 2,400. This would have placed the car in a price range in New Zealand with cars that included

960-415: A thermoplastic inner tank which acts as a preform during construction. Much more reliable tanks are made using woven mat or filament wound fiber, with the fiber orientation at right angles to the hoop stress imposed in the sidewall by the contents. Such tanks tend to be used for chemical storage because the plastic liner (often polypropylene ) is resistant to a wide range of corrosive chemicals. Fiberglass

1024-427: Is a fabrication technique mainly used for manufacturing open (cylinders) or closed-end structures (pressure vessels or tanks). The process involves winding filaments under tension over a male mandrel. The mandrel rotates while a wind eye on a carriage moves horizontally, laying down fibers in the desired pattern. The most common filaments are carbon or glass fiber and are coated with synthetic resin as they are wound. Once

1088-545: Is also indirect, inflammation-driven genotoxicity through reactive oxygen species by inflammatory cells . The longer and thinner as well as the more durable (biopersistent) fibers were, the more potent they were in damage. In the US, fine mineral fiber emissions have been regulated by the EPA , but respirable fibers (“particulates not otherwise regulated”) are regulated by Occupational Safety and Health Administration (OSHA); OSHA has set

1152-432: Is also used for septic tanks . Glass-reinforced plastics are also used to produce house building components such as roofing laminate, door surrounds, over-door canopies, window canopies and dormers, chimneys, coping systems, and heads with keystones and sills. The material's reduced weight and easier handling, compared to wood or metal, allows faster installation. Mass-produced fiberglass brick-effect panels can be used in

1216-401: Is applied to the chosen mold to allow the finished product to be cleanly removed from the mold. Resin—typically a 2-part thermoset polyester, vinyl, or epoxy—is mixed with its hardener and applied to the surface. Sheets of fiberglass matting are laid into the mold, then more resin mixture is added using a brush or roller. The material must conform to the mold, and air must not be trapped between

1280-479: Is applied to the roving to help protect the glass filaments for processing and manipulation and to ensure proper bonding to the resin matrix, thus allowing for the transfer of shear loads from the glass fibers to the thermoset plastic. Without this bonding, the fibers can 'slip' in the matrix causing localized failure. An individual structural glass fiber is both stiff and strong in tension and compression —that is, along its axis. Although it might be assumed that

1344-483: Is called pultrusion . The manufacturing process for glass fibers suitable for reinforcement uses large furnaces to gradually melt the silica sand, limestone , kaolin clay , fluorspar , colemanite , dolomite and other minerals until a liquid forms. It is then extruded through bushings ( spinneret ), which are bundles of very small orifices (typically 5–25 micrometres in diameter for E-Glass, 9 micrometres for S-Glass). These filaments are then sized (coated) with

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1408-478: Is chemically inert under many circumstances. Applications include aircraft, boats, automobiles, bath tubs and enclosures, swimming pools , hot tubs , septic tanks , water tanks , roofing, pipes, cladding, orthopedic casts , surfboards , and external door skins. Other common names for fiberglass are glass-reinforced plastic ( GRP ), glass-fiber reinforced plastic ( GFRP ) or GFK (from German : Glasfaserverstärkter Kunststoff ). Because glass fiber itself

1472-579: Is credited with producing the first composite boat in 1937 but did not proceed further at the time because of the brittle nature of the plastic used. In 1939 Russia was reported to have constructed a passenger boat of plastic materials, and the United States a fuselage and wings of an aircraft. The first car to have a fiberglass body was a 1946 prototype of the Stout Scarab , but the model did not enter production. Unlike glass fibers used for insulation, for

1536-401: Is essentially an entire two-dimensional plane; with woven fabrics or unidirectional layers, directionality of stiffness and strength can be more precisely controlled within the plane. A fiberglass component is typically of a thin "shell" construction, sometimes filled on the inside with structural foam, as in the case of surfboards. The component may be of nearly arbitrary shape, limited only by

1600-513: Is pulled through forming machinery using either a hand-over-hand method or a continuous-roller method (as opposed to extrusion , where the material is pushed through dies). In fiberglass pultrusion, fibers (the glass material) are pulled from spools through a device that coats them with a resin. They are then typically heat-treated and cut to length. Fiberglass produced this way can be made in a variety of shapes and cross-sections, such as W or S cross-sections. People can be exposed to fiberglass in

1664-639: Is required, such as equipment cabinets and steel support structures, due to the ease with which it can be molded and painted to blend with existing structures and surfaces. Other uses include sheet-form electrical insulators and structural components commonly found in power-industry products. Because of fiberglass's lightweight and durability, it is often used in protective equipment such as helmets. Many sports use fiberglass protective gear, such as goaltenders' and catchers' masks. Storage tanks can be made of fiberglass with capacities up to about 300 tonnes . Smaller tanks can be made with chopped strand mat cast over

1728-505: Is sometimes referred to as "fiberglass", the composite is also called fiberglass-reinforced plastic ( FRP ). This article uses "fiberglass" to refer to the complete fiber-reinforced composite material, rather than only to the glass fiber within it. Glass fibers have been produced for centuries, but the earliest patent was awarded to the Prussian inventor Hermann Hammesfahr (1845–1914) in the U.S. in 1880. Mass production of glass strands

1792-402: Is that the resins used are subject to contraction during the curing process. For polyester this contraction is often 5–6%; for epoxy, about 2%. Because the fibers do not contract, this differential can create changes in the shape of the part during curing. Distortions can appear hours, days, or weeks after the resin has set. While this distortion can be minimized by symmetric use of the fibers in

1856-460: Is used when tensile strength (high modulus) is important and is thus an important building and aircraft epoxy composite (it is called R-glass, "R" for "reinforcement" in Europe). C-glass ("C" for "chemical resistance") and T-glass ("T" is for "thermal insulator"—a North American variant of C-glass) are resistant to chemical attack; both are often found in insulation-grades of blown fiberglass. Fiberglass

1920-433: Is versatile because it is lightweight, strong, weather-resistant, and can have a variety of surface textures. During World War II, fiberglass was developed as a replacement for the molded plywood used in aircraft radomes (fiberglass being transparent to microwaves ). Its first main civilian application was for the building of boats and sports car bodies, where it gained acceptance in the 1950s. Its use has broadened to

1984-467: The Hillman Hunter (NZ$ 2,232), Toyota Corona (NZ$ 2,296), and Isuzu Bellett 1500 (NZ$ 2,398). Its advantage over these models was that its higher local content meant a reduced need for overseas funds. Jack Marshall and Norman Shelton , Minister of Customs , were less than enthusiastic about the project. They considered that the country at that time could ill afford to spend its overseas funds on such

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2048-564: The International Agency for Research on Cancer (IARC) as "not classifiable as to carcinogenicity to humans" ( IARC group 3 ). "Epidemiologic studies published during the 15 years since the previous IARC monographs review of these fibers in 1988 provide no evidence of increased risks of lung cancer or mesothelioma (cancer of the lining of the body cavities) from occupational exposures during the manufacture of these materials, and inadequate evidence overall of any cancer risk." In June 2011,

2112-539: The European Union and Germany have classified synthetic glass fibers as possibly or probably carcinogenic, but fibers can be exempt from this classification if they pass specific tests. A 2012 health hazard review for the European Commission stated that inhalation of fiberglass at concentrations of 3, 16 and 30 mg/m3 "did not induce fibrosis nor tumours except transient lung inflammation that disappeared after

2176-538: The Import Licensing schedule. This experience gave him a good understanding of the problems a start-up venture would face. The project commenced in Autumn 1966 when Alan moved to Auckland to join with his brother Ian, owner of Anziel Limited, in the venture. The Gibbs brothers also needed an import licence for the assembly plant, parts, and materials. Because of its use of fibreglass bodywork Reliant Motor Co of England

2240-553: The US National Toxicology Program (NTP) removed from its Report on Carcinogens all biosoluble glass wool used in home and building insulation and for non-insulation products. However, NTP still considers fibrous glass dust to be "reasonably anticipated [as] a human carcinogen (Certain Glass Wool Fibers (Inhalable))". Similarly, California's Office of Environmental Health Hazard Assessment (OEHHA) published

2304-458: The air near manufacturing facilities or when they are near building fires or implosions . The American Lung Association advises that fiberglass insulation should never be left exposed in an occupied area. Since work practices are not always followed, and fiberglass is often left exposed in basements that later become occupied, people can get exposed. No readily usable biological or clinical indices of exposure exist. Fiberglass will irritate

2368-599: The automotive and sport equipment sectors. In the production of some products, such as aircraft, carbon fiber is now used instead of fiberglass, which is stronger by volume and weight. Advanced manufacturing techniques such as pre-pregs and fiber rovings extend fiberglass's applications and the tensile strength possible with fiber-reinforced plastics. Fiberglass is also used in the telecommunications industry for shrouding antennas , due to its RF permeability and low signal attenuation properties. It may also be used to conceal other equipment where no signal permeability

2432-463: The changes made by the government on import rules for cheaper, fully built cars. Alan Gibbs retained his interest in cars and went on to develop the Gibbs Aquada in 2003. Fibre-glass Fiberglass ( American English ) or fibreglass ( Commonwealth English ) is a common type of fiber-reinforced plastic using glass fiber . The fibers may be randomly arranged, flattened into a sheet called

2496-550: The complexity and tolerances of the mold used for manufacturing the shell. The mechanical functionality of materials is heavily reliant on the combined performances of both the resin (AKA matrix) and fibers. For example, in severe temperature conditions (over 180 °C), the resin component of the composite may lose its functionality, partially due to bond deterioration of resin and fiber. However, GFRPs can still show significant residual strength after experiencing high temperatures (200 °C). One notable feature of fiberglass

2560-412: The construction of composite housing, and can include insulation to reduce heat loss. In rod pumping applications, fiberglass rods are often used for their high tensile strength to weight ratio. Fiberglass rods provide an advantage over steel rods because they stretch more elastically (lower Young's modulus ) than steel for a given weight, meaning more oil can be lifted from the hydrocarbon reservoir to

2624-973: The design, a certain amount of internal stress is created; and if it becomes too great, cracks form. The most common types of glass fiber used in fiberglass is E-glass , which is alumino-borosilicate glass with less than 1% w/w alkali oxides, mainly used for glass-reinforced plastics. Other types of glass used are A-glass ( A lkali-lime glass with little or no boron oxide), E-CR-glass ( E lectrical/ C hemical R esistance; alumino-lime silicate with less than 1% w/w alkali oxides, with high acid resistance), C-glass (alkali-lime glass with high boron oxide content, used for glass staple fibers and insulation), D-glass (borosilicate glass, named for its low D ielectric constant), R-glass (alumino silicate glass without MgO and CaO with high mechanical requirements as R einforcement), and S-glass (alumino silicate glass without CaO but with high MgO content with high tensile strength). Pure silica (silicon dioxide), when cooled as fused quartz into

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2688-433: The early 1940s, and many sailing vessels made after 1950 were built using the fiberglass lay-up process . As of 2022, boats continue to be made with fiberglass, though more advanced techniques such as vacuum bag moulding are used in the construction process. Though most bullet-resistant armours are made using different textiles, fiberglass composites have been shown to be effective as ballistic armor. Filament winding

2752-459: The ease of manufacture. This car was deemed suitable to meet the Gibbs' requirements. In August 1966, the Gibbs brothers sought government consent to obtain an import licence for their proposal. They proposed to build 3,000 cars per annum, with production commencing in mid-1968. However, Jack Marshall , who was the Minister of Trade in that period, declined the request on the grounds that New Zealand

2816-562: The eyes, skin, and the respiratory system. Hence, symptoms can include itchy eyes, skin, nose, sore throat, hoarseness, dyspnea (breathing difficulty) and cough. Peak alveolar deposition was observed in rodents and humans for fibers with diameters of 1 to 2 μm. In animal experiments, adverse lung effects such as lung inflammation and lung fibrosis have occurred, and increased incidences of mesothelioma , pleural sarcoma , and lung carcinoma had been found with intrapleural or intratracheal instillations in rats. As of 2001, in humans only

2880-563: The fiber has an effect on the properties of the final product. A high angle "hoop" will provide circumferential or "burst" strength, while lower angle patterns (polar or helical) will provide greater longitudinal tensile strength. Products currently being produced using this technique range from pipes, golf clubs, Reverse Osmosis Membrane Housings, oars, bicycle forks, bicycle rims, power and transmission poles, pressure vessels to missile casings, aircraft fuselages and lamp posts and yacht masts. A release agent, usually in either wax or liquid form,

2944-434: The fiber is weak in compression, it is actually only the long aspect ratio of the fiber which makes it seem so; i.e., because a typical fiber is long and narrow, it buckles easily. On the other hand, the glass fiber is weak in shear—that is, across its axis. Therefore, if a collection of fibers can be arranged permanently in a preferred direction within a material, and if they can be prevented from buckling in compression,

3008-415: The fiberglass and the mold. Additional resin is applied and possibly additional sheets of fiberglass. Hand pressure, vacuum or rollers are used to be sure the resin saturates and fully wets all layers, and that any air pockets are removed. The work must be done quickly before the resin starts to cure unless high-temperature resins are used which will not cure until the part is warmed in an oven. In some cases,

3072-420: The final structure to be strong, the fiber's surfaces must be almost entirely free of defects, as this permits the fibers to reach gigapascal tensile strengths . If a bulk piece of glass were defect-free, it would be as strong as glass fibers; however, it is generally impractical to produce and maintain bulk material in a defect-free state outside of laboratory conditions. The process of manufacturing fiberglass

3136-468: The functionality of machines and equipment. The installation of effective extraction and filtration equipment is required to ensure safety and efficiency. Gibbs Aquada The Gibbs Aquada was a limited production concept car produced in 2003 and 2004. The Gibbs Aquada is powered by a 2.5 L Rover V6 engine . In 2004 Richard Branson , owner of the Virgin Group , used a Gibbs Aquada to set

3200-459: The gas content of the material was replaced by plastic. This reduced the insulation properties to values typical of the plastic, but now for the first time, the composite showed great strength and promise as a structural and building material. Many glass fiber composites continued to be called "fiberglass" (as a generic name) and the name was also used for the low-density glass wool product containing gas instead of plastic. Ray Greene of Owens Corning

3264-473: The glass into short lengths and drops it into a jet of resin, projected onto the surface of a mold), or in an intermediary step, to manufacture fabrics such as chopped strand mat (CSM) (made of randomly oriented small cut lengths of fiber all bonded together), woven fabrics, knit fabrics or unidirectional fabrics. Chopped strand mat (CSM) is a form of reinforcement used in fiberglass. It consists of glass fibers laid randomly across each other and held together by

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3328-441: The legal limit ( permissible exposure limit ) for fiberglass exposure in the workplace as 15 mg/m total and 5 mg/m in respiratory exposure over an 8-hour workday. The National Institute for Occupational Safety and Health (NIOSH) has set a recommended exposure limit (REL) of 3 fibers/cm (less than 3.5 micrometers in diameter and greater than 10 micrometers in length) as a time-weighted average over an 8-hour workday, and

3392-413: The mandrel is completely covered to the desired thickness, the resin is cured; often the mandrel is placed in an oven to achieve this, though sometimes radiant heaters are used with the mandrel still turning in the machine. Once the resin has cured, the mandrel is removed, leaving the hollow final product. For some products such as gas bottles, the 'mandrel' is a permanent part of the finished product forming

3456-449: The material will be preferentially strong in that direction. Furthermore, by laying multiple layers of fiber on top of one another, with each layer oriented in various preferred directions, the material's overall stiffness and strength can be efficiently controlled. In fiberglass, it is the plastic matrix which permanently constrains the structural glass fibers to directions chosen by the designer. With chopped strand mat, this directionality

3520-586: The more biopersistent materials like ceramic fibres, which are used industrially as insulation in high-temperature environments such as blast furnaces , and certain special-purpose glass wools not used as insulating materials remain classified as possible carcinogens ( IARC Group 2B ). The more commonly used glass fibre wools including insulation glass wool , rock wool and slag wool are considered not classifiable as to carcinogenicity to humans ( IARC Group 3 ). In October 2001, all fiberglass wools commonly used for thermal and acoustical insulation were reclassified by

3584-628: The surface with each stroke, all while reducing the load on the pumping unit. Fiberglass rods must be kept in tension, however, as they frequently part if placed in even a small amount of compression. The buoyancy of the rods within a fluid amplifies this tendency. GRP and GRE pipe can be used in a variety of above- and below-ground systems, including those for desalination, water treatment, water distribution networks, chemical process plants, water used for firefighting, hot and cold drinking water, wastewater/sewage, municipal waste and liquified petroleum gas . Fiberglass composite boats have been made since

3648-488: The winter of 1967. As the Anziel Nova, the two-door car was to be powered by a 1498cc pre-crossflow Ford Kent engine with a 4-speed gearbox. It had an expected top speed of 90 mph (140 km/h). Alterations were made to its trim and the car was re-badged by the Gibbs brothers prior to its unveiling. In the publicity documents the company said that it was going to produce a four-door version, as well as planning to make

3712-482: The work is covered with plastic sheets and vacuum is drawn on the work to remove air bubbles and press the fiberglass to the shape of the mold. The fiberglass spray lay-up process is similar to the hand lay-up process but differs in the application of the fiber and resin to the mold. Spray-up is an open-molding composites fabrication process where resin and reinforcements are sprayed onto a mold. The resin and glass may be applied separately or simultaneously "chopped" in

3776-415: The workplace during its fabrication, installation or removal, by breathing it in, by skin contact, or by eye contact. Furthermore, in the manufacturing process of fiberglass, styrene vapors are released while the resins are cured. These are also irritating to mucous membranes and respiratory tract. The general population can get exposed to fibreglass from insulation and building materials or from fibers in

3840-490: Was accidentally discovered in 1932 when Games Slayter , a researcher at Owens-Illinois , directed a jet of compressed air at a stream of molten glass and produced fibers. A patent for this method of producing glass wool was first applied for in 1933. Owens joined with the Corning company in 1935 and the method was adapted by Owens Corning to produce its patented "Fiberglas" (spelled with one "s") in 1936. Originally, Fiberglas

3904-425: Was a glass wool with fibers entrapping a great deal of gas, making it useful as an insulator, especially at high temperatures. A suitable resin for combining the fiberglass with a plastic to produce a composite material was developed in 1936 by DuPont . The first ancestor of modern polyester resins is Cyanamid 's resin of 1942. Peroxide curing systems were used by then. With the combination of fiberglass and resin

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3968-453: Was approached for a suitable design. This was to maximise the quantity of local product in the manufacture. At the time Reliant was developing the FW5, a mid-range family saloon, for Otosan of Turkey. The FW5 was aimed at relatively low production numbers without the need for expensive plant and tooling. It was designed by Tom Karen of Ogle Design . Reliant considered the model suitable for construction in less developed countries because of

4032-417: Was suffering from falling export revenues at the time, which was causing a balance of trade problem for the government. Other established car manufacturers were having their import licences reduced and the granting of a licence to another manufacturer was seen as counter-productive. Despite this setback, the Gibbs brothers continued to lobby Marshall, who eventually relented and allowed them a licence to import

4096-443: Was the first type of glass used for fiberglass. E-glass ("E" because of initial Electrical application), is alkali-free and was the first glass formulation used for continuous filament formation. It now makes up most of the fiberglass production in the world, and also is the single largest consumer of boron minerals globally. It is susceptible to chloride ion attack and is a poor choice for marine applications. S-glass ("S" for "stiff")

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