AOC’s R058 Designed for Carbon Reinforced Composites
AOC Announces Price Increase for Europe
AOC’s Corrosion-Resistant Resins Critical to HCL Tanks
AOC Unveils New Vinyl Ester Reactor in Lakeland Florida Facility
Firepel® K120-MTA Halogen-Free/ Fire Retardant Resins Produce Lighter Weight Composites
AOC Named 2012 BMCI Supplier of the Year
Pipe Dreams: An Odor Control System Built to Last
AOC & Hawkeye Manufacturing Innovate Spa Production
Enhanced Oil Recovery in Southeast Asia includes Vipel® Technology
AOC Launches Chroma-Tek Website
New AOC Operations Organization Sharpens Customer Focus
AOC Research and Development Team Promotions Enhance Innovation
AOC Leadership Structure Ensures Continued Growth
Wesson Strengthens AOC Commitment to Composites Growth
New Cobalt-Free AOC Resin Has Earned Certification by NSF International
Vipel® protects Indonesian power plant structure
Brunswick Award recognizes AOC quality and service
Architectural masterpiece takes shape in composite forms
Record-breaking composite CIPP made with Vipel®
AOC expands its Corrosion Team
New FR Resin Guide covers 18 different standards
Leslie Ann Beck joins AOC as Director for Global Communication
New AOC resin makes smoother, lower cost tooling
Canada’s largest city takes its greenness underground
Composites play critical role in 320 million-gallon water plant
Global resin supplier AOC has developed a line of resins to meet the increased demand for high-performance composites in aerospace, automotive, wind energy, military, marine and other markets. The R058 series of epoxy vinyl ester resins is specifically designed for carbon fiber reinforcements and creates lightweight composite parts with exceptional strength-to-weight ratios.
The R058 series packs a double punch, combining the performance of epoxy resins with the processing speed of unsaturated polyester resins. Designed for vacuum infusion and resin transfer molding (RTM), R058 has excellent mechanical properties and chemical resistance. Other benefits of the epoxy vinyl ester resins include:
- Room temperature cure for laminates as thin as two millimeters.
- Low viscosity for shorter mold fill times and complete fiber wet-out.
- Low laminate exotherm for improved surface aesthetics.
- Superb strength, toughness and chemical resistance over a broad range of temperatures.
“The R058 series is an excellent choice for applications requiring lightweight and high-performance laminate,” says Mike Dettre, AOC’s Business Manager. “They don’t require post-curing or autoclaving, which makes them faster to process than most pure epoxy resins. And that’s critical for high-volume applications.”
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC develops technology, lives quality and delivers service better than any other resin supplier. For more information, phone Leslie Beck at (901) 854-2318 or e-mail LBeck@AOC-Resins.com.
AOC, LLC announces a price increase in the amount of €90 per metric ton for all products sold in Europe. The implementation date for the increase is July 15, 2014.
This increase is necessary as AOC continues to see higher prices for raw materials due to tight supply in Europe. AOC’s global purchasing resources continue to work with their network of suppliers to manage costs and continue to meet customers’ needs.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. For more information on AOC technology, quality and service, phone Leslie Beck at (901) 854-2318 or e-mail LBeck@AOC-Resins.com.
Next month, oil and gas distributor Panther Industries Inc. will open a new 10-acre transload facility in Fort Saskatchewan, Alberta, Canada, to move shipments of hydrochloric acid (HCL) from trains to trucks for transport to oil fields. A critical part of the facility are four fiberglass surge capacity tanks that ensure the company has enough product on hand for shipments.
Chemposite®, based in Delta, British Columbia, Canada, designed and manufactured the HCL tanks and liners, which feature AOC’s Vipel® F010 and F085 corrosion-resistant resins. “Hydrochloric acid is a corrosive liquid and there are a lot of concerns,” says Jamie Dewar, Fort Saskatchewan project manager for Panther Industries. “We had to ensure the tank was designed to handle both vacuum and pressure. And the choice of resin had to be compatible with the product as well.”
The surge capacity tanks control pressure differences caused by the flow of HCL during the unloading process. They are designed to handle seismic loads, winds and frigid temperatures in Alberta. The tanks incorporate a dual resin system: Vipel® F010, which is used in the structural layer, is a premium epoxy vinyl ester, bisphenol-A and offers a good balance of corrosion resistance and processability. The liner utilizes Vipel® F085, which is an epoxy novolac vinyl ester resin that has an exceptional organic solvent resistance with improved high-temperature properties.
AOC was a perfect partner for this project, says Marvin Hlynka, P.Eng., the engineer with Chemposite who designed the tanks. “AOC offers a good working relationship, great technical support with user friendly resin systems and they were very competitive in pricing and delivery.”
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC develops technology, lives quality and delivers service better than any other resin supplier. For more information, phone Leslie Beck at (901) 854-2318, e-mail LBeck@AOC-Resins.com, or go to www.AOC-Resins.com.
Chemposite is an industry leader in the design, engineering, manufacturing and supply of corrosion-resistant fiberglass reinforced plastic (FRP) and advanced composite products for a wide range of industrial applications. Its products include pipe and fittings, ducting and stacks, tanks and vessels, pressure vessels, scrubbers and internals, carbon absorbers, hoods and covers, dampers, pump basins and stations, pultruded structural shapes and custom fabrication.
Global resin supplier AOC, LLC recently announced the installation of a new high-performance reactor for the production of vinyl ester resins at its manufacturing plant in Lakeland, Florida. This investment underscores AOC’s commitment to the growing corrosion-resistant composite market which relies on the unique properties of vinyl ester resins.
Driven by unparalleled customer support, technical expertise and product quality, AOC’s comprehensive line of vinyl ester resins has become the preferred choice for corrosion-resistant markets. AOC’s vinyl ester resins meet customer specifications for a range of applications, including water and wastewater treatment, marine, industrial tanks and pipes, and chemical processing.
“This new reactor is a major investment and exemplifies our continued focus on technology and growth,” said Fletcher Lindberg, AOC’s Vice President of Marketing. “The new equipment greatly expands our capacity, which allows us to serve more customers and meet their needs for larger jobs.”
The Florida manufacturing plant was the chosen location to maximize AOC’s global logistics network. Installation of the new state-of-the-art reactor started more than a year ago with actual resin production beginning in March. The reactor utilizes AOC’s proprietary manufacturing and control systems that set the world standard for producing resins of exacting consistency.
AOC is a leading global supplier of resins, gel coats, colorants, dispersions and synergistic material systems for composites and cast polymers. AOC develops technology, lives quality and delivers service better than any other resin supplier. For more information, visit www.aoc-resins.com or contact Leslie Beck at (901) 854-2318 or LBeck@aoc-resins.com.
One-Step System for Mass Transit Applications
AOC introduces its latest technology, Firepel® K120-MTA, a high-performance resin system ideal for mass transit applications. The unique one-part system is halogen-free and does not require antimony or aluminum trihydrate (ATH) to achieve its fire-retardant properties.
Unlike conventional low smoke resins, K120-MTA achieves its fire performance through a proprietary intumescent mechanism. As a result, K120-MTA offers excellent wet out and spray characteristics, crack resistance, and low density. This unique combination of properties produces fire-retardant and low-smoke composites that are lighter weight, stronger and easier to fabricate than those made from mineral-filled resins.
The increasing need to reduce the weight of vehicles will continue to drive the demand for composites’ use in buses, trains and other mass transit vehicles. Parts using K120-MTA have a potential weight savings of up to 30% compared to standard composites using antimony or ATH.
“K120-MTA is a unique product and outperforms every other resin on the market,” says Fletcher Lindberg, Vice President of Marketing for AOC. “It utilizes proprietary halogen-free technologies to achieve the highest fire-retardant and low-smoke characteristics possible. And because its excellent performance is achieved without ATH, K120-MTA has a much lower specific gravity, which makes it easier to process than traditional systems.”
Low Fire, Smoke and Toxicity
Firepel K120-MTA exceeds the requirements of mass transit applications in North America and demonstrates low flame spread, low smoke and excellent smoke toxicity data when tested according to:
- ASTM E162, Standard Test Method for Surface Flammability of Materials Using a Radiant Heat Energy Source,
- ASTM E662, Standard Test Method for Specific Optical Density of Smoke Generated by Solid Materials,
- SMP 800-C, Toxic Gas Generation
Firepel K120-MTA is engineered for the hand lay-up and spray-up composite manufacturing processes. AOC’s technical support team will help manufacturers maximize results through personalized consultation. For additional information or to order samples, contact Scott Lane at email@example.com or 901-861-8362.
AOC is a leading global supplier of resins, gel coats, colorants, dispersions and synergistic material systems for composites and cast polymers. AOC develops technology, lives quality and delivers service better than any other resin supplier. For more information, visit www.aoc-resins.com or contact Leslie Beck at (901) 854-2318 or firstname.lastname@example.org.
AOC Mexicana has been named the first annual Supplier of the Year by the Mexico Division of Bulk Molding Compounds, Inc., the primary producer of thermoset compounds in Mexico. AOC Mexicana is a wholly-owned subsidiary of global resin supplier AOC, LLC. The award is the premier recognition for supply chain partners who demonstrate distinguished performance in quality, customer support and technical expertise.
Chad Nunnery, President of BMCI Mexico, said AOC has both global relationships and a local presence that allows BMCI to maintain a more consistent product internationally. “The BMCI Mexico team is very appreciative of the effort and performance by the AOC operation and staff,” said Nunnery. “We selected AOC Mexicana as our first Supplier of the Year not only based on their excellent service and product, but also their partnering efforts to support the growth of thermoset composites in Mexico.” The AOC team has achieved 4 years of outstanding service to the company without any late deliveries or major quality issues.
AOC Mexicana, the leading supplier of composite resins in Mexico, operates a major resin manufacturing facility in Ciudad Nezahualcóyotl inside the Mexico City Metropolitan Area. The central location helps to facilitate BMCI Mexico’s localized, world-class supply base as well as maintain reduced freight and importation costs over other providers. BMCI’s primary markets are automotive and electrical industries producing applications such as headlamps, valve covers, and circuit breaker switch gears.
Our industry-leading franchise is positioned to create customer value and ensure their continued success,” said Brian Parker, AOC’s Vice President, Global Business. "This award recognizes AOC’s quality of service, its cutting-edge technology, and the synergy of both companies.” The Supplier of the Year award winner is chosen by BMCI Mexico’s team of quality, manufacturing and logistics executives.
About Bulk Molding Compounds Inc.
Founded in 1979, BMCI is the leading global supplier of high-quality glass reinforced, polyester thermoset compounds. Serving a broad range of industries, BMCI has successfully grown both organically and through acquisition to become the world leader in Bulk Molding Compounds. For more information, visit www.bulkmolding.com.
AOC is a leading global supplier of resins, gel coats, colorants, dispersions and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other resin supplier. For more information, visit www.aoc-resins.com or contact Leslie Beck at (901) 854-2318 or email@example.com.
AOC and ECS Environmental Solutions worked together to create an integral part of the city of Austin’s complex wastewater infrastructure project. The new 3.9-mile wastewater tunnel increases capacity for the downtown district and facilitates residential and business growth in the area. An important part of the project is an odor control system.
ECS provided the odor control equipment and relied on AOC’s Vipel® resin for more than 1,000 feet of fiberglass ductwork and additional accessories. The ductwork ranges in size from 12 inches to 72 inches in diameter. Approximately half of the ductwork is buried below ground and had to be able to withstand thousands of pounds of high-density traffic driving over the site. Additional elements of the project include field joint kits, flexible connectors, control and back-draft dampers, bolt gaskets and two fiberglass exhaust fans rated at 40,000 cubic feet per minute (CFM).
Long Life Cycle
ECS manufactured all of the fiberglass ductwork using a state-of-the-art computerized filament winder. The fiber was impregnated with AOC’s Vipel® K022 corrosion-resistant vinyl ester resin, which is ideally suited for filament winding. “The K022 resin was the best choice for this project,” says Jeff Jones, president of ECS. “Some of the gases in the air stream are corrosive – hydrogen sulfide and ammonia. There’s also sulfuric acid. Pipes built with this resin are very resistant to what goes in them: They will not easily corrode.”
To help ease installation, ECS prefabricated and sub-assembled the duct system at its facility, then shipped it to Austin about an hour away. A field crew of five from ECS traveled to the construction site and handled all the field layup. That’s when AOC’s service became invaluable, says Jones.
“We work in a controlled environment in the shop, but in the field you are open to the elements,” says Jones. “Some of the days we were in Austin were cold and others were really hot. We had to adjust promotion levels and add inhibitors to work with the resin long enough to do a quality job under tough conditions.” AOC’s Scott Lane, product leader, offered technical assistance that helped ECS re-formulate the resin. Eric Stuck, AOC sales representative, also assisted ECS in meeting the demands of this material-intensive project. “With the long runs and thick pipes, we went through material much faster than normal, and AOC was very good at meeting this fluctuation in demand,” says Jones. “If we ran out of resin on this job, it would have put the project to a halt. AOC got materials here when we needed them. They were fantastic to work with!”
About ECS Environmental Solutions
ECS, Belton, Texas, is the nation’s leading supplier of odor control equipment and accessories. A division of family-owned TexGlass Industries, ECS designs and manufactures products at its 100,000-square-foot facility in central Texas. Its odor control systems have been installed across North America. For more information, visit www. ecs-env.com for environmental solutions or www.ecs-frp.com for manufactured offerings.
AOC is a leading global supplier of resins, gel coats, colorants, dispersions and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other resin supplier. For more information, contact Leslie Beck at (901) 854-2318 or firstname.lastname@example.org.
Resin supplier AOC and spa producer Hawkeye Manufacturing collaborated to produce one of the largest, most complex single-piece spa liners on the market. The Bossetti combination spa and hot tub from Barefoot Fitness Spas is a 2,000-gallon tub with seating for up to five adults. Features include 37 stainless-steel spa jets, six adjustable-flow swim jets, flow fountains and a waterfall. Named after an exotic Argentine waterfall, the spa offers a variety of options—from a family relaxation session to resistance exercises.
Hawkeye Manufacturing’s workforce uses AOC materials technology and technical support to ensure the quality and durability of this product. “With a unit this large, we had to be right the first time,” declared Casey Murray, Vice President for Hawkeye Manufacturing. “The unit’s size makes it difficult—and more expensive—to transport and install. Any issues in the field would create an enormous cost.”
Hawkeye Manufacturing starts with a sheet of acrylic that is heated and vacuum-formed into the shape of the spa’s smooth, seamless uni-liner. After mastering the technique for forming the large, complex Bossetti liner, the next challenge was developing a protocol for the fiber-reinforced polymer (FRP) structural composite back-up.
According to Murray, the major concerns for the composite manufacturing step were:
• Precisely controlling the composite thickness variations that are needed for the complex liner,
• Controlling the exothermic heat generated during composite cure to prevent temperature spikes that could distort the liner shape, and
• Ensuring an extremely strong adhesion between the composite and liner.
Murray said Hawkeye Manufacturing found the right solutions with help from AOC Sales Representative Berk Pleasants. “Berk has been our ‘go-to’ person for composites technology for about twenty years. We ran AOC’s recommendations by the acrylic supplier and received confirmation that the composite and acrylic liner were compatible.”
The first step for the back-up composite is the application of a skin coat consisting of chopped glass fibers and high performance Altek® H100 vinyl ester. This technique is similar to that used in boat building and serves the same purpose, to prevent moisture from reaching and affecting the integrity of the thicker composite structure. The vinyl ester also provides excellent adhesion between the composite and acrylic. To finish the back-up laminate, Hawkeye technicians apply chopped fiber in Altek C949 polyester.
“This spa is larger than anything we have ever produced before,” Murray stated. “The consistency of AOC resins and outstanding AOC technical support were essential to helping us reach this milestone.”
About Hawkeye Manufacturing
With corporate offices in Richmond, Virginia, USA, Hawkeye Manufacturing Inc. is the largest spa producer in the Eastern United States. Hawkeye Manufacturing’s waste reduction and recycling policies earned recognition from the State of Virginia Department of Environment Quality. The company’s product development and quality control standards earned a Five-Star “Best of Class” rating for industry media leader PoolandSpa.com. For more information about Hawkeye Manufacturing products, phone 804-231-7727 e-mail email@example.com or go to manufacturing.com or www.hawkeyemfg.com.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other resin supplier. For more information, phone Leslie Beck at (901) 854-2318 or e-mail Lbeck@AOC-Resins.com.
One of Southeast Asia’s largest oil fields benefitted from the chemical resistance of Vipel® vinyl ester from AOC to improve oil recovery.
Vipel technology played a critical role in one step of enhanced recovery at the Minas Oil Field in Province Riau, Indonesia. This field has been serving the world’s energy needs since the middle of the 20th Century and still has significant oil reserves for owner Chevron Corporation. However, the oil in older wells is becoming more difficult to reach.
To increase production, Chevron turned to global engineering resource Technip to design a recovery system that uses cutting-edge technology. Technip provided engineering services, project management, and construction of an advanced system that maximizes oil recovery. The system injects a special, low-cost, “surfactant” fluid into designated wells. As fluid from the “injector” wells floods the underground reservoir, oil is pushed towards a “producer” well where pressure is increased to more easily extract the remaining oil.
A by-product of this “flooding” is a highly corrosive brine solution that is extracted along with the oil. Technip’s system separates and stores the brine in a special tank until it is ready for the next step in the process.
Because of the high heat and corrosive nature of the brine, it was necessary to construct the storage tank from a high-performance material. PT Graha Adhi Jaya Abadi FRP Engineering & Manufacturing, called GAJAFIBERGLASS, made the cylindrical vessel on-site using filament winding manufacturing. The operation required precise control of the resin temperature, prior to winding, to prevent ambient heat from initiating a resin cure.
The process started with the application of an anti-corrosion liner made up of a resin-saturated surfacing veil onto a horizontal, cylindrical mandrel. The liner was backed with a structural laminate of resin-impregnated continuous fiberglass that was applied as the mandrel rotated. The finished tank is 25 feet in diameter by 16 feet high (7.6 by 4.9 meters) and has a capacity of 1,400 barrels (167,000 liters).
Corrosion and Heat Resistance
Gunawan Karim of GAJAFIBERGLASS said an effective presentation by Jason Triggs, technical consultant for Nuplex Composites, and a professional and quick response from AOC Corrosion Resin Product Leader, Scott Lane, secured the resin specification for Vipel technology.
“We verified that Vipel F080 epoxy vinyl ester was suitable for containing brine solution at temperatures up to 210° Fahrenheit (99° Celsius), which is a critical requirement for the tank,” Karim said. “Additionally, delivery of the AOC resin was excellent because we benefited from the tracking and follow-up service of Lany Aldrich, AOC Sales Manager – Asia,” he added.
Technip is a world leader in project management, engineering and construction for the energy industry. The company offers the most innovative technologies for meeting the world’s energy challenges. With world headquarters in Paris, Technip is present in 48 countries and all continents. For more information, go to www.technip.com.
About Nuplex Composites
Nuplex Composites is a full-service distributor of materials, supplies and technical support for composite manufacturers in the Asia-Pacific region. For more information, go to http://www.nuplex.co.nz.
With headquarters in Jakarta, Indonesia, PT. Graha Adhi Jaya Abadi FRP Engineering & Manufacturing, or GAJAFIBERGLASS, has been making engineered fiber-reinforced composites to world-class standards since 1990. End-use application expertise includes tanks, linings, coatings, pipes, fittings, roofs and gutters. For more information, e-mail firstname.lastname@example.org or go to www.gajafiberglass.com .
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other resin supplier. To discover more, phone Leslie Beck at (901) 854-2318 or e-mail LBeck@AOC-Resins.com.
Collierville, TN—Global leader in resin manufacturing, AOC, LLC, announced today its launch of AOC-Colorants.com. The website is devoted to the company’s Chroma-Tek line of colorants, pigment dispersions and other resin additives. It serves as a resource for wide variety of plastic manufacturing clients in the automotive, bath, marine and other industries.
AOC-Colorants.com provides information about the company’s many product sectors, including polyester pigment dispersions, chemical thickeners and additives, pultrusion specialty colors, urethane and epoxy dispersions, marble dispersions and colorants for gel coats. Visitors can also learn about AOC’s advanced color science division and its experience in developing colorant solutions for clients worldwide.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. Sustainability is at the core of AOC’s culture through green ideas and actions in product technology, manufacturing, facility design, operations and corporate attitude. To learn more, phone Leslie Beck at (901) 854-2318 or e-mail LBeck@AOC-Resins.com.
New leadership positions and the consolidation of several strategically-aligned departments within a new Operations organization, sharpen AOC’s focus on exceeding customer expectations.
“AOC measures success by how well we help our customers succeed,” said Chief Executive Officer Fred Norman in announcing the new Operations team. “These changes keep AOC on the forefront of leading-edge processes and technologies that deliver the highest quality and most consistent products.”
New Operations Leadership Team
Matt Watkins is promoted to Senior Vice President, Operations. Watkins is responsible for manufacturing, engineering, safety and regulatory affairs, purchasing, and information technology. During his 22 years of service to AOC, Watkins has held several leadership positions, each focusing on continuously improving product quality and service. Watkins has a Bachelor of Mechanical Engineering degree from Auburn University.
Chris Lenegar is promoted to Vice President, Global Purchasing. He is responsible for global procurement of all raw materials used to manufacture AOC products. His focus is on securing the most reliable and lowest cost sources. With 27 years of expertise in the buying, selling and distribution of petrochemicals, Lenegar joined AOC in 2007. He earned his Bachelor’s Degree in Chemical Engineering from Ohio University.
Allen Brown is promoted to Director, Information Technology (IT). Brown is responsible for all information systems and technology. Brown has held several IT positions since joining AOC in 1996. He leads a team of IT professionals focused on technology and business strategy alignment. Brown has earned two degrees from the University of Memphis – a Bachelor’s in Information Systems and an MBA in Management.
Dan Cox is promoted Director, Operations, responsible for manufacturing, engineering, safety and regulatory affairs. Since joining AOC ten years ago, he has led the development of technologies and procedures that improve product quality, increase manufacturing productivity, and make AOC a more sustainable enterprise. He has a Bachelor of Science degree in Mechanical Engineering from the University of Memphis.
AOC announces promotions in its Research & Development department, strengthening its commitment to the creation of innovative new technologies.
“These promotions effectively use the proven experience that our technology team members offer,” said Fred Norman, Chief Executive Officer. “Delivering new products that improve performance and quality has helped AOC and our customers succeed – even through difficult economic times. Our commitment to future creativity for the composites industry is stronger than ever.”
Research and Development Promotions
Dr. Tom Folda is promoted to Senior Vice President, Technology. Folda is responsible for all aspects of AOC’s product technology and research development. He has served AOC for 15 years and earned his Doctorate in Polymer Chemistry from the University of Mainz, Germany.
Mike Beebe is promoted to Director, Research and Development (R&D), Open Mold Synthesis/Analytical. Beebe is responsible for synthesis and analytical projects that support open mold activities. He also manages AOC’s laboratories in Tennessee and Indiana and is responsible for AOC’s polymer technologies in Europe. Beebe has 35 years in the industry and has a Master’s Degree in Chemistry from Case Western University.
Dr. John McAlvin is promoted to R&D Director, Open Mold. McAlvin is responsible for new and improved material technologies for open mold customers. He has been with AOC 12 years, during which he led the creation of EcoTek® Green Technologies and authored patents for styrene-free and UV-stable resins. McAlvin received his Doctorate in Chemistry from the University of Virginia and a Bachelor of Science in Chemistry from Stony Brook University.
Dr. Thomas Steinhausler is promoted to R&D Director, Closed Mold. Steinhausler is responsible for developing new resins and low profile additives for the closed mold sector, including sheet and bulk molding compounds, resin transfer molding, infusion and pultrusion. Steinhausler has been with AOC for 13 years. He has a Doctorate in Chemistry from Technical University Graz, Austria, and has completed post-doctoral research at the University of Texas at Austin.
About AOC Research & Development
The AOC Technology Team develops chemistries that help customers improve quality, boost performance and reduce costs. Their work is dedicated to improving the competitiveness of fiber-reinforced polymer composites and cast polymers versus alternative materials. AOC knows technology, lives quality and delivers service better than any other resin supplier. For more information, phone Leslie Beck at (901) 854-2318 or e-mail LBeck@AOC-Resins.com.
AOC announces key executive positions within a new leadership structure that will ensure continued future growth for the company and its customers.
“These promotions and new structure effectively use the proven experience that our executive team members offer,” said Fred Norman, Chief Executive Officer. “The exceptional quality of leadership that has helped AOC succeed – even through difficult economic times – is stronger than ever. To stay on the path of success, this team is taking AOC’s already high standards for innovation, quality and service to new levels.”
AOC Executive Leadership Team
Dr. Tom Folda is promoted to Senior Vice President, Technology. Formerly Vice President, Technology, Folda is responsible for all aspects of AOC’s product technology and research development.
Jim Griffith is promoted to Senior Vice President after serving as Vice President, Global Purchasing. He will assist in the transition of purchasing responsibilities prior to his planned retirement on June 30, 2013.
Matt Watkins, formerly Vice President, Operations, is promoted to Senior Vice President, Operations. Watkins will be responsible for manufacturing, engineering, safety and regulatory affairs, purchasing, and all information technology.
John Griggs, Vice President, Finance and CFO will continue to manage accounting, finance and human resources.
Chris Lenegar is promoted to Vice President, Global Purchasing. Formerly Manager, Sourcing and Procurement, Lenegar will be responsible for procurement of all raw materials.
Fletcher Lindberg, formerly Business Manager, Open Mold Reinforced Products, is now Vice President, Marketing. Lindberg will be responsible for global marketing programs.
Emilio Oramas is promoted to Vice President, U.S. and Canada Sales from Director, Domestic Sales. Oramas is responsible for sales in the United States and Canada.
Brian Parker is promoted to Vice President, Global Business from Global Managing Director. Parker is responsible for sales, technical service and contract manufacturing relationships outside the U.S. and Canada.
Mike Beebe is promoted to Director, Research and Development (R&D), Open Mold Synthesis/Analytical from Manager for the same area. Beebe is responsible for synthesis and analytical projects that support open mold activities.
Allen Brown, formerly Director, Information Technology Operations, is promoted to Director, Information Technology. Brown is responsible for all information systems and technology.
Dan Cox is promoted to Director, Operations from Director, Engineering. Cox will be in charge of manufacturing, engineering, safety and regulatory affairs.
Dr. John McAlvin, formerly R&D Manager, Open Mold, is promoted to R&D Director, Open Mold. McAlvin is responsible for R&D development work for open mold products.
Dr. Thomas Steinhausler is promoted from R& D Manager, Closed Mold to Director, Closed Mold. Steinhausler is responsible for R&D development work for closed mold products.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other resin supplier. For more information, phone Leslie Beck at (901) 854-2318 or e-mail LBeck@AOC-Resins.com.
Ed Wesson, a leading expert in corrosion-resistant and structural composites, joins AOC as a Corrosion and Infrastructure Specialist.
“Bringing Ed onboard further strengthens the industry’s best technical support,” said Jim Ness, Corrosion Market Specialist. “Ed has extensive experience in composite manufacturing processes, including vacuum infusion for very large parts. His expertise will help the composites industry grow by showcasing the benefits of composites as compared to other materials,” Ness added.
Prior to joining the AOC, Wesson was Manager for RPS Composites Alabama Inc. (formerly Non Metallic Resources), in Mobile, Alabama. He led the development and expansion of RPS into new processes and applications.
Wesson will be based in Mobile, Alabama, and will be responsible for supporting AOC’s corrosion-resistant sector in the Gulf of Mexico region and Southeastern states.
Wesson is a graduate of the University of South Alabama where he earned a Bachelor of Science in Mechanical Engineering.
AOC is a leading global supplier of resins, gel coats, colorants, dispersions and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other resin supplier. For more information, phone Leslie Beck at (901) 854-2318, e-mail LBeck@AOC-Resins.com, or go to www.aoc-resins.com.
New Vipel® F010-H2O-00 vinyl ester from AOC is Certified to NSF/ANSI 61: Drinking Water System Components-Health Effects by NSF International, making it easier for customers to manufacture products for potable water applications. The resin’s cobalt-free formulation also gives it superior corrosion resistance for applications that contain sodium hypochlorite, or bleach.
Benefits of NSF Certification
The NSF/ANSI 61 standard establishes health effects requirements for products, components, and materials used in drinking water systems. “Customers that fabricate products for drinking water use can be assured that this resin conforms to the health effects requirements for NSF 61,” said Fletcher Lindberg, Business Manager for Open Mold, Reinforced Resins. “This makes it faster and easier for those companies to obtain NSF Certification for their products,” said Lindberg. “The Vipel F010-H2O data sheet describes the protocols for customers to follow to meet the requirements,” Lindberg added.
Benefits of Cobalt-Free
Vipel F010-H2O uses a special catalyst that does not require a cobalt promoter. This feature makes the coating suitable for sodium hypochlorite containment. In contrast, composite materials that use cobalt-based promotion weaken over time when exposed to bleach or sodium hypochlorite.
“Since F010-H2O is formulated for sodium hypochlorite resistance, the composite equipment lasts longer and saves customers the cost of replacement,” explains Scott Lane, Corrosion Product Leader. “This is a tremendous benefit for customers in the municipal water treatment sector where the use of sodium hypochlorite as a sanitizer is increasing,” Lane added.
How the new resin is used
Vipel F010-H2O is used as a coating system in tanks that hold at least 4,000 gallons (15,142 liters) and piping at least 6 inches (152 millimeters) in diameter. When the resin is formulated and processed according to specifications, the coating system is suitable for both potable water (as demonstrated by the NSF 61 certification), as well as sodium hypochlorite containment used in potable water systems. For more information on the new technology and AOC expertise, contact Scott Lane at SLane@AOC-Resins.com or (901) 861-8362. Or, go to www.CorrosionResins.com.
About NSF International
NSF International is an independent organization that writes standards, tests and certifies products for the food, water and consumer goods industries to minimize adverse health effects and protect the environment (nsf.org). Founded in 1944, NSF is committed to protecting human health and safety worldwide. NSF is a World Health Organization Collaborating Centre for Food and Water Safety and Indoor Environment.
NSF International’s Water Programs require extensive product testing and unannounced audits of production facilities to verify that water treatment products meet the design, material and performance requirements. NSF International is accredited by the American National Standards Institute (ANSI).
NSF led the development of the American National Standards for all chemicals used to treat drinking water and materials/products coming into contact with drinking water. In 1990, the U.S. EPA replaced its own drinking water product advisory program with these NSF standards.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other resin supplier. To discover more, phone Leslie Beck at (901) 854-2318, e-mail LBeck@AOC-Resins.com, or go to www.AOC-Resins.com
When a power company expansion in Indonesia needed a new concrete aeration pit, its surface was protected with Vipel® F010 vinyl ester from AOC. The versatile resin technology was supplied through Nuplex Composites.
The new power plant will add 815 megawatts of capacity to PT Paiton Energy’s complex in Paiton, East Java, Indonesia. The site has an existing 1,230-megawatt facility. General contractor for the expansion project is TOA Corporation, headquartered in Tokyo, Japan.
The new unit will use the aeration pit for seawater that is circulated through the cooling water system and for water used to scrub sulphates from stack emissions. Temperatures as high as 122°F (50°C) increase the aggressive nature of the liquid environment.
Technology for the criteria
“We worked closely with the civil contractors to demonstrate that the AOC technology meets the demanding criteria for the application,” said Jason Triggs, technical sales consultant for Nuplex Composites. “The Vipel F010 resin series is based on a versatile bisphenol-A epoxy chemistry that allows for a range of formulations. Nuplex Composites was able to tailor the resin to balance process, cost and performance requirements.”
PT Samudera Indoraya Perkasa, of Surabaya, Indonesia, applied the protective composite liner. After preparing the concrete surface, workers manually applied a laminate of Vipel F010 resin-impregnated fiberglass chopped strand mat. In a final step, a topcoat of Vipel F010 resin with synthetic surfacing veil established a resin-intensive layer with superior corrosion resistance.
Teaming up with AOC
Triggs said AOC’s technical service team helped Nuplex Composites support the project from quotation to application. The resin was promoted to process well at high temperatures and meets the need for a long pot life. The formulation also addressed thixotropic needs for vertical application to 16.4-feet (5-meter) high walls without running.
In addition to the resin, Nuplex Composites supplied the veil and mat used to protect the concrete substrate of two aeration pit sections and its beams. A total of 40,709 square feet (3,782 square meters) of surface received the corrosion-resistant protection.
About Nuplex Composites
Nuplex Composites (formerly “FGI”) is a full-service distributor of materials, supplies and technical support for composite manufacturers in the Asia-Pacific region. From large ocean-going vessels to small “one-off” components, Nuplex Composites helps customers achieve the optimum composite solution. For more information, go to http://www.nuplex.co.nz.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other resin supplier. To discover more, contact Corrosion and Infrastructure Market Development Specialist Jim Ness by e-mailing email@example.com or phoning (503) 694-1264.
For helping to improve bowling ball quality and providing exceptional delivery and service, AOC has been awarded the 2011 Supplier of the Year Award from Brunswick Bowling and Billiards Corporation.
Unsaturated polyesters help Brunswick offer an almost endless variation in bowling ball cover designs. But before the ball leaves the manufacturing plant, the surface must meet Brunswick’s extremely high standards for quality. Brunswick and AOC research teams worked together to develop a resin formulation that dramatically improves surface quality.
Higher quality = lower costs
“AOC’s ‘No Crack’ cover and core resin improved our Reynosa facility’s ball quality and substantially reduced total costs,” said Andrew Logg, Director of Supply Chain, Brunswick Bowling and Billiards. “In 2010 and 2011, AOC had 100% Quality and 100% On-time Delivery metrics. The relationship between the two companies is maintained more than effectively at all levels of management, and AOC constantly evaluates and makes changes were necessary throughout all aspects of the business.”
The materials for Brunswick were developed at the AOC World Headquarters R&D Center and manufactured in the AOC Mexico facility. The Brunswick-AOC partnership is managed by Jeff Holshevnikoff, Managing Director, South America, under the leadership of Brian Parker, Global Managing Director.
“The entire AOC organization should be proud of this accomplishment,” said Fred Norman, AOC President and COO. “To achieve the top award over 500 other suppliers is a testament to our commitment to quality and customer service.”
About Brunswick Bowling and Billiards
Brunswick is the bowling industry’s premier full-line, full-service provider. Brunswick has always been dedicated to improving both the tenpin game and the experience around it. For more than a century, Brunswick has continually worked to grow bowling on a global scale and has helped to create the $10 billion industry that it is today. For more information, go to www.BrunswickBowling.com.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC knows technology, live quality and delivers service better than any other resin supplier. To discover more, e-mail Leslie Beck at LBeck@AOC-Resins.com or phone her at (901) 854-2381.
The architectural centerpiece inside the Texas A&M University Health Science Center is a dramatic spiral staircase made possible by the artistic collaboration of two highly divergent material systems. One of the materials is the steel bar-reinforced concrete that forms the stairway’s sweeping treads and connecting platform landings. The other material is the fiber-reinforced polymer (FRP) composite that MFG Construction Products (MFG-CP) made into forms that gave the concrete its structure and aesthetics.
MFG-CP’s experience as a premier manufacturer of FRP forms for architectural concrete was useful in meeting the engineering and design challenges of the project. The architectural design required three forms, one for each floor. At the job site, concrete was poured into the forms which remained in place until the concrete cured.
A design feature was engineered into the form so that the top riser could accommodate an overlaid marble cover that matched the surface of the floor at the top. In addition, MFG-CP engineered a solution on site that allowed one form to be modified so it could form the staircase around an already-installed large column.
The architectural firm was GS&C Group, and structural engineering was handled by Structure + Haynes Whaley. Both are headquartered in Austin, TX.
How the forms were made
Before the composite forms could be made, MFG-CP used engineering drawings to create pre-construction replicas of finished stairway sections out of wood and masonite. The replicas served as precise dimensional models for building the FRP forms that would give the poured concrete its final shape.
To keep the FRP forms from adhering when removed from the model, the surface of the model is coated with a special wax. Workers then apply the first layer of the form itself – a sandable gel coat that will create the finished surface of the concrete. Next comes the critical structural laminate that keeps the form rigid for shipping, on-site handling, and the pour and cure cycles. The laminate is formed by lay-up of resin-impregnated glass fiber mat and woven roving.
To achieve the required rigidity, select areas of the laminate are internally cored with balsa wood and externally braced with hardwood pieces. The coring and braces are encapsulated into the laminate to result in a monolithic unit when the resin reactively cures into a crosslinked solid.
The resin MFG-CP used to mold the forms was Altek® H864, a low-shrink unsaturated polyester from AOC. MFG-CP Sales Manager Jim Williams pointed out characteristics of the resin that contributed to the laminate’s strength and physical integrity. “This is a very good all around resin that wets the glass fibers well and rolls out easily,” Williams said. “And by showing very little entrapment of air, Altek H864 also ensures a more solid laminate construction.”
About MFG Construction Products
MFG Construction Products Company (MFG-CP), Independence, Kansas, USA, has more than four decades of experience and expertise in the technology, engineering and manufacture of FRP composite forms for concrete. The company offers a complete range of forms for columns, domes, pans, floors and custom architectural shapes. For more information, phone (800) 225-5634 or email firstname.lastname@example.org.
AOC is a leading global supplier of resins, gel coats, colorants and synergistic systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other supplier. For more information, phone Leslie Beck at (901) 854-2318 or e-mail LBeck@AOC-Resins.com.
A record-breaking application of higher strength iPlus® Composite cured-in-place pipe (CIPP) technology significantly reduced the time and cost of expanding San Diego International Airport. Insituform Technologies®, Inc., completed the work using Vipel® resin from AOC.
Expansion plans by the San Diego Airport Authority put a new terminal over a 96-inch (2,438-millimeter) diameter concrete sewer pipeline. The pipe was 25 feet (7.6 meters) underground and not designed for the structural loads the new project would add. Because pipe excavation and replacement would have created headaches for taxpayers and air travelers alike, engineers explored trenchless technologies.
Keeping the wall thickness of the new liner under 1.26 inches (32 millimeters) became a critical design factor for ensuring that the upgraded pipe’s flow rate could handle current and projected volumes. To make the liner strong enough, slip-lining would have added approximately 12 inches (305 millimeters) of wall thickness; and conventional CIPP would have added 2.07 inches (51 millimeters).
For a solution, general contractor Charles King Co. brought in Insituform Technologies® to install a custom, 1,700-foot (518-meter) long fiber-reinforced iPlus® Composite liner. Carbon fibers in the iPlus Composite for the airport project resulted in a pipe strong enough to withstand the new structural loads at a wall thickness that is 40 percent less than conventional CIPP.
The Vipel 102NA resin is specially designed to efficiently wet out the reinforced liner,” said Bill Moore, AOC Product Leader for CIPP. “The resin technology optimizes the performance and superior mechanical properties of the carbon fiber-reinforced composite structure.”
With no appropriate manhole available for the installation, site workers created a single access point for two inversions in opposite directions. The job established a new benchmark for iPlus® Composite technology, which to date had not been used for a water inversion greater than 200 feet nor in a host pipe larger than 60 inches in diameter.
Insituform Technologies® Inc. is a leading worldwide provider of proprietary technologies and services for rehabilitating sewer, water and other underground piping systems without digging and disruption. To learn more, visit www.insituform.com.
For cured-in-place pipe (CIPP), Vipel® resins from AOC process smoothly and perform impeccably time after time. AOC knows technology, lives quality and delivers service better than any other resin supplier. To find out more, e-mail Bill Moore at email@example.com, phone him at (901) 854-7291, or go to www.cippresins.com.
Jim Ness has joined the AOC team as Corrosion & Infrastructure Market Development Specialist, announced Fletcher Lindberg, Business Manager for Reinforced Resins.
“Jim brings valuable experience and relationships from many levels within the industry,” said Lindberg. “He will work with engineers, specifiers, and fabricators to expand the awareness of AOC’s Vipel® corrosion and fire retardant resins on a global basis,” Lindberg added.
Ness will be based in Portland, Oregon, and can be reached via email at firstname.lastname@example.org.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other resin supplier. For more information contact Steve Martin at email@example.com.
“AOC’s fire-retardant and smoke-suppressant technologies cover a wide range of cost-performance options, including halogen-free and synergist-free systems,” said Fletcher Lindberg, Business Manager for Reinforced Resins. “Innovative new technologies are incubating in our laboratories to underscore our commitment to serving this important performance sector.”
Ease of use
The new Guide simplifies fire-retardant resin selection into two basic steps:
- Choose the unsaturated polyester, methacrylate modified or vinyl ester resin that most cost-effectively meets end-use performance requirements for such properties as strength, elongation, corrosion resistance and heat distortion temperature.
- Within the selected resin category, match the fire and/or smoke standard that is written in the specification with the AOC product or products that have been tested to that standard.
“With comprehensive tables and extensive notes, the guide is designed to help users navigate through the maze of different fire and smoke standards that are written into specifications,” said Scott Lane, AOC Product Leader and architect of the guide’s technical data. “To further direct the selection process, there are several examples of how Firepel and Vipel FR technologies have been put into action.”
For a copy of the Fire Retardant Resin Guide, contact an AOC sales representative or distributor. Or go to www.firepel.com, AOC’s Internet-based resource about fire-retardant and smoke-suppressant composites.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than other resin supplier. For more information, contact Steve at firstname.lastname@example.org, or by phone (901) 854-2847.
Leslie Ann Beck has joined AOC, LLC as Director for Global Communication, announced Jack Roesle, Senior Vice President Global Sales & Marketing.
“AOC is very fortunate to have Ms. Beck join our Sales and Marketing team,” Roesle said. “Her more than 20 years of broad communication, public relations, marketing and brand-building successes with Hilton Worldwide/Promus Hotels will be an asset as we continue to provide our customers with value-added products and services.”
Beck is a graduate of the University of Tennessee at Knoxville with a Bachelor of Science in Public Relations and earned a Master’s of Business Administration in Marketing from the University of Memphis.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other resin supplier. For more information, contact Steve Martin at email@example.com, or by phone (901) 854-2847.
New MoldTru™ LPT-68000 low-profile tooling resin from AOC can reduce the cost and time to make Class A surface composite tools by up to 70%. The new resin is designed to make tools for open molding, resin transfer molding and resin infusion.
“Because MoldTru LPT-68000 resin’s unique chemistry produces very low exotherm heat, up to five layers of tooling laminate can be built simultaneously without causing surface distortion,” explained AOC Business Manager Fletcher Lindberg.
“Making the same mold with conventional tooling resin takes five individual steps, each followed by an overnight cure,” he continued. “With MoldTru LPT-68000 technology, all that extra labor is eliminated, and finished parts are going out the door much sooner.”
Replicating the master model
AOC chemists leveraged the company’s leadership in automotive Class A resins to engineer a special additive technology that gives the new tooling resin a near-zero shrink feature. Ultralow shrinkage combines with excellent fiber and filler wetting to ensure that the mold surface is essentially a precise replica of the master model’s surface. For some applications, vacuum can be used to produce high glass content tooling with technical fabrics.
Data and guide
A new brochure has more information, including properties data and detailed guidelines on how to make smoother, lower cost molds in less time. For a copy of the new MoldTru LPT-68000 literature, ask an AOC sales representative or distributor, or download a PDF from www.aoc-resins.com.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other resin supplier. To learn more, phone Fletcher Lindberg at (901) 854-7277, e-mail firstname.lastname@example.org, or go to www.aoc-resins.com.
Nationally recognized in Canada for environmental leadership, the City of Toronto has taken its greenness underground by specifying a more Earth-friendly material for storm sewer rehabilitation.
Under the direction of Toronto Water’s Senior Engineer Kamran Sarrami, P. Eng., a sensitive rehabilitation project with respect to timing and location had new cured-in-place pipe (CIPP) installed inside old corrugated steel pipe. By eliminating the need to excavate, CIPP was the lowest cost, much less disruptive to the public and businesses in the area, and much friendlier to the environment.
The environmental advantage increased when installer Capital Sewer Services Inc. used new EcoTek® L040-TNVG-33 vinyl ester resin from AOC. Unlike conventional CIPP resins, EcoTek L040-TNVG-33 uses proprietary, styrene-free monomer chemistry with ultra-low volatile organic compound (VOC) content.
“We continually seek leading-edge technologies to turn problems into solutions,” said Capital Sewer Vice President Brian Ratchford. “The EcoTek resin was part of a pilot program with the City of Toronto to reduce VOC emissions. New Canadian regulations for lower VOC limits are on the horizon. This experience puts the City and Capital Sewer ahead of the game for tomorrow’s mandate while providing an environmental benefit today.”
The project rehabilitated approximately 700 feet (200 meters) of sewer line and culverts that carry storm water through a golf course into Don River. The river drains into Lake Ontario, Toronto’s only source of drinking water. Host pipe diameters were 30, 36 and 48 inches (762, 914 and 1,219 millimeters). A pipe failure in the 30-inch section led to flooding of an apartment building and the golf course. A spot dig and further CCTV inspection revealed that all pipe sections were showing signs of rust and decay that caused leaking and threatened pipe integrity.
The CIPP Process
Capital Sewer used the EcoTek resin to impregnate non-woven polyester felt tubes supplied by National Liner LLC, Houston TX, USA. The felt products were impregnated at Capital Sewer’s facility where the resin’s styrene-free technology resulted in lower VOC workplace emissions. The impregnated tubes were shipped to job sites in refrigerated trucks to prevent premature resin cure.
During installation, interior water pressure advanced the tubing forwarded as it was inverted through the host pipe. When an insertion of predetermined length was achieved, hot water or steam was introduced. The heat initiated the chemical reaction that cured the liquid resin into a molecularly crosslinked solid polymer. The result inside the host pipe was a new, seamless, conforming liner with excellent durability and corrosion resistance.
Natural transition to EcoTek
To facilitate the transition to styrene-free technology, AOC scientists developed EcoTek L040 resin to process like conventional materials, which use styrene as a diluent to optimize resin viscosity. “The handling and processing characteristics of EcoTek L040 resin are identical to those of resins we have always used,” Ratchford pointed out. “We get the same workability, the same wetting, the same pot life, and the same or better physical properties.
“And because the resin is from AOC, we get the same excellent delivery, service and technical support,” he added. “Sales Representative Steve Maybee and CIPP Product Leader Bill Moore helped us reach this milestone and were on site for our first styrene-free resin installation.”
About Capital Sewer Services Inc.
Formed in 1998, Capital Sewer Services Inc. has become recognized as a major force in the field of pipeline maintenance, inspection and reconstruction. Headquartered in Hamilton, Ontario, is one of the largest municipal, commercial and industrial service providers in Canada. For more information, phone (905) 522-0522, e-mail email@example.com or go to www.capitalsewer.com.
For cured-in-place pipe (CIPP), AOC offers resins that process smoothly and perform impeccably time after time. AOC knows technology, lives quality and delivers service better than any other resin supplier. For more information, phone CIPP Product Leader Bill Moore at (901) 854-7291, e-mail firstname.lastname@example.org, or go to www.cippresins.com.
A new water filtration plant under construction in The Bronx is the centerpiece of the largest single construction project in the history of New York City.
The filtration plant is designed to ensure that water from the Croton System watershed is aesthetically pleasing and meets or exceeds all drinking water quality standards. When completed in 2012, the plant will provide roughly 10 percent of New York City’s 1.4 billion gallon average daily demand for water. During drought or other conditions affecting other watersheds servicing New York, the new plant can deliver up to 30 percent of in-City water needs.
To achieve a design capacity of 320 million gallons (1.2 million cubic meters) per day, each link in the filtration process chain has been engineered for the optimum in reliability and performance. That is why An-Cor Industrial Plastics made 38 fiberglass-reinforced polymer (FRP) composite tanks for the filtration plant to standards set by the American Society of Mechanical Engineers (ASME) and the Fiberglass Reinforced Plastics Institute (FRPI).
The following table summarizes the An-Cor products, functions and dimensions:
Capacity gallons (liters)
Bulk storage of aluminum sulfate or polyaluminum chloride coagulant
Bulk storage of cationic coagulant aid polymer
Bulk storage of
Day tanks for
Day tanks for
UV cleaning system
How the tanks were made
To achieve performance requirements, An-Cor used Vipel® vinyl ester resins from AOC. The inner corrosion barriers of each vessel were made withVipel F010 bisphenol-A epoxy vinyl ester because of its excellent corrosion resistance and U.S. Food and Drug Administration (FDA) compliant properties. The barrier liners were formed using hand lay-up of the resin with veils and fiberglass mats. In addition to the standard barrier, each tank designed to hold sodium hypochlorite added a 116 mil (2.95 millimeter) thick corrosion allowance for extending the equipment life.
Structural laminates were manufactured with Vipel K022 bisphenol-A epoxy vinyl ester. The high performance resin meets project specifications for high strength, excellent chemical resistance and, with synergist addition, Class I fire-retardant properties per ASTM E84.
“The Vipel resins were selected for their ability to meet critical end-use performance specifications,” said Rob Merrill, An-Cor (Vice President-Operations). “The technical support that AOC provided with the resins was excellent. AOC Corrosion Specialist Bill Holtzclaw’s knowledge of FRP processing and quality standards was very helpful. Both Bill and AOC Product Leader Scott Lane were quick to respond when we needed to optimize processing.”
The corrosion barriers of the cylinders were made using the hand lay-up method utilizing fiberglass taped goods. Depending upon the diameter of the tank, the structural portion of the cylinders were built using mechanical applications of chop strand mat, woven roving, and/or winding glass.
The top and bottom heads of the 10- and 12 -foot (3- and 3.7-meter) tanks were resin-infused using Vipel K022-EBB resin. Balsa wood cores were encapsulated into the glass fiber-reinforced laminate to achieve higher stiffness. The heads of the smaller tanks were made by hand lay-up of fiberglass and resin. All tanks were post-cured in a convection oven prior to shipment.
The tanks that An-Cor delivered to the Croton Project were backed by certification from two prestigious industry associations — the American Society of Mechanical Engineers (ASME) and the Fiberglass Reinforced Plastics Institute (FRPI). An-Cor is the first composite manufacturer to be certified by both organizations.
ASME is a not-for-profit professional organization whose mission includes the establishment and maintenance of engineering codes and standards. An-Cor is among the elite group of composite fabricators that meets certification requirements for ASME RTP-1 “Reinforced Thermoset Plastic Corrosion Resistant Equipment.”
ASME certification ensures design rules, fabrication methods, testing procedures and quality control programs are followed. Each tank was successfully hydro tested after installation at 5 psi (0.3 bar) to validate designs in accordance with the standard.
FRPI is a non-profit membership organization that audits and tests laminates of corrosion-resistant equipment on a job-by-job basis. “The versatility of FRP composites allows corrosion-resistant equipment to be custom-designed to meet specific project needs,” said Gary Arthur, Executive Director and President of FRPI.
“FRPI certification tells specifiers and buyers that the FRP equipment materials for their project meet their specification,” Arthur said. “This provides confidence that the equipment will meet objectives for quality, consistency, reliability and performance.”
In addition to meeting manufacturing standards, tanks, subassemblies and components that come into contact with stored products or the process stream meet FRPI food-grade standards.
Engineer and Construction
The project sponsor was the New York City Department of Environmental Protection, who will ultimately be responsible for running the plant. The main contractor is a Skanska/Tully Construction joint venture. Haley & Aldrich was geo-technical consultants, digital automation architecture was provided by Emerson, and a Hazen & Sawyer/Metcalf & Eddy joint venture acted as client consultant. URS provided support in construction management, cost estimating plus resident engineering, geotechnical engineering and tunneling inspection.
Based in North Tonawanda, NY, USA, An-Cor Industrial Plastics specializes in the design, engineering, manufacturing, installation and maintenance of custom fiberglass-reinforced polymer (FRP) composite industrial equipment. Applications include tanks, scrubbers, pipe and fittings, ductwork, stacks and chimney liners. An-Cor is part of Group DKG. For more information, phone (716) 695-3141, e-mail email@example.com or go to www.an-cor.com.
Established in 2003, FRPI is the industry’s only fiberglass reinforced plastic materials certification non-profit organization, In providing certification, FRPI educates FRP manufacturers and specifiers and buyers of FRP equipment through seminars and publications. For more information, phone (508) 380-2232, e-mail firstname.lastname@example.org, or go to www.frpi.org.
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic material systems for composites and cast polymers. AOC knows technology, lives quality and delivers service better than any other composites resin supplier. For more information, go to www.corrosionresins.com, the Internet’s comprehensive and user-friendly resource on corrosion-resistant composites.