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Documentation - Pultruded Shapes - Overview

Pultruded Shapes Product Overview

Pultruded FRP Structural Shapes

Pultruded fiberglass-reinforced plastic shapes are high-strength, lightweight structural profiles manufactured through a continuous production process. Continuous fiberglass reinforcement is pulled through a resin system and heated forming die to create a finished profile with a consistent cross-section, controlled dimensions, and repeatable material performance.

Fiberr pultruded shapes provide a corrosion-resistant alternative to steel, aluminum, and wood in industrial, commercial, infrastructure, marine, wastewater, utility, transportation, and cooling-tower applications. Products are available as standard structural profiles or custom profiles designed for specific dimensional, mechanical, assembly, or installation requirements.

View Pultruded Shapes Technical Data Review representative mechanical, physical, electrical, thermal, and fire-performance properties. View the Pultruded Shapes Catalogue Browse available standard profiles and dimensional configurations.
Selection of Fiberr pultruded FRP structural shapes
Pultruded FRP shapes are available in standard and custom cross-sections.
Fiberr pultrusion manufacturing line
Continuous pultrusion production supports consistent dimensions and high-volume manufacturing.
Pultrusion forming die used to manufacture an FRP profile
The heated die shapes and cures the resin-impregnated fiberglass into the final profile.

Benefits

Corrosion Resistance Pultruded FRP does not rust and can provide long-term service in wet, chemical, marine, wastewater, and other corrosive environments.
High Strength-to-Weight Ratio Structural fiberglass reinforcement provides useful load capacity at a fraction of the weight of conventional steel profiles.
Lightweight Installation Reduced profile weight can simplify transportation, handling, field cutting, lifting, and installation while reducing structural dead load.
Electrical Insulation Standard FRP formulations are nonconductive and suitable for many electrical, utility, rail, and industrial applications where metallic conductivity is undesirable.
Low Maintenance FRP does not require routine painting for corrosion protection and can reduce inspection, coating, repair, and replacement requirements.
Dimensional Consistency The continuous manufacturing process produces a repeatable cross-section with controlled dimensions throughout the profile length.
Custom Profile Capability New dies can be developed for project-specific shapes, wall thicknesses, channels, tubes, connectors, stiffeners, and functional features.
Color Throughout the Material Pigment is incorporated into the resin system, avoiding dependence on a separately applied decorative paint layer.
Weathering and Fire Options UV-protective and fire-retardant formulations are available for exterior, code-sensitive, and industrial applications.

Production Process

Pultrusion is a continuous manufacturing process in which fiberglass reinforcement is pulled through resin, shaped, cured, and cut to the required length. Unlike extrusion, which pushes material through a die, pultrusion pulls the reinforcement and resin system through the forming process.

Diagram showing the Fiberr pultrusion production process
Pultrusion production process from fiberglass feeding through final cutting.
  1. Fiber Feeding: Continuous fiberglass rovings, woven reinforcement, mats, or surface materials are supplied from creels and rolls.
  2. Guiding: The reinforcement passes through guides that align and organize each fiberglass component within the intended profile cross-section.
  3. Resin Impregnation: The fiberglass is thoroughly saturated with the selected thermosetting resin formulation and applicable pigments, fillers, fire-retardant additives, and UV stabilizers.
  4. Preforming: The wet reinforcement is gradually shaped and consolidated near the final profile geometry before entering the heated die.
  5. Heating and Curing: The resin-impregnated reinforcement enters the heated steel die, where the profile reaches its final cross-section and the resin cures into a rigid composite.
  6. Pulling: A continuous pulling system draws the cured profile through the die at a controlled rate.
  7. Cutting: The finished pultruded profile is cut to the required production or customer-specified length.

Product Options

Fiberr pultruded shapes can be configured to balance structural performance, chemical resistance, fire performance, appearance, weathering, weight, and cost for the intended application.

Resin System

Available in isophthalic polyester (ISO) for general industrial and structural service, or vinyl ester (VE) for more aggressive chemical, moisture, and corrosion environments.

Fiberglass Configuration

Reinforcement can include continuous rovings, woven fiberglass, chopped strand mat (CSM), and multiple reinforcement layers. The number, location, orientation, and type of layers can be configured for axial strength, transverse strength, impact resistance, surface quality, and profile geometry.

Surface Veil

An optional synthetic or fiberglass surface veil can create a resin-rich exterior layer that improves surface finish, weathering, corrosion resistance, fiber coverage, and UV durability.

Color

Profiles are available in standard RAL colors or customer-specific color matches. Pigment is incorporated into the resin system during manufacture.

View Available Color Options
Profile

Standard profiles include angles, channels, beams, tubes, rods, bars, plates, structural members, and additional functional cross-sections. Cross-sectional dimensions, wall thicknesses, corner radii, internal webs, reinforcement placement, and overall geometry can be selected from existing profiles or developed as a custom configuration through dedicated tooling.

View the Pultruded Shapes Catalogue
Fire-Retardant Construction

Available without a fire-retardant formulation or with fire-retardant constructions intended to meet ASTM E84 Class A or Class C requirements, subject to the selected resin system, profile, reinforcement, and certified product configuration.

UV Protection

UV stabilizers, pigments, and surface veils can be incorporated to improve color retention, fiber protection, and long-term performance in exterior and sun-exposed applications.

Cut Length

Profiles can be cut to standard stock lengths or customer-specified production lengths, subject to profile geometry, handling, transportation, packaging, and project requirements.

Secondary Fabrication

Profiles may be cut, drilled, slotted, notched, machined, assembled, or otherwise fabricated to support project-specific installation and component requirements.

Configuration review: Final profile construction should be selected based on structural loads, span, support conditions, chemical exposure, temperature, UV exposure, fire requirements, electrical requirements, fastening method, dimensional tolerances, fabrication, and installation conditions.
View Technical Data View Shapes Catalogue

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