What is FRP Pultrusion? – The Complete Guide to Fiberglass Pultrusion Machines and Applications

Aug / 22 / 2025

Learn how the FRP pultrusion process works, what equipment you need, where pultruded profiles are used, and why fiberglass pultrusion machines are the preferred choice for modern composite manufacturing.

Introduction

FRP pultrusion is a continuous, automated process that produces fiber reinforced polymer profiles with constant cross-sections—such as FRP rebar, rods, tubes, beams, channels, and gratings. Compared with traditional molding, pultrusion offers stable quality, high throughput, and excellent control of fiber alignment, resulting in outstanding strength-to-weight performance.

What is FRP Pultrusion?

The word “pultrusion” combines pull and extrusion. Unlike extrusion which pushes material through a die, pultrusion pulls fiber reinforcements through resin and a heated die to form cured composite profiles.

Fibers: E-glass fiberglass (common), carbon, or basalt.
Resins: Unsaturated polyester, vinyl ester, epoxy, or polyurethane—selected based on mechanical, chemical, and thermal performance.
Outputs: Continuous profiles with consistent quality and precise dimensions.

Step-by-Step Workflow

Fiber Feeding: Rovings/mats are guided from creels into pre-formers.
Resin Impregnation: Fibers pass through a resin bath or injection box for complete wet-out.
Forming & Curing: The bundle enters a heated steel die for shaping and polymerization.
Continuous Pulling: Hydraulic or crawler pulling maintains stable speed and pressure.
Cutting: A flying saw cuts profiles to required lengths with clean edges.

Step	Description	Output
1. Fiber Feeding	Rovings/mats guided through pre-formers	Aligned reinforcement
2. Resin Wet-Out	Resin bath or injection chamber	Impregnated fiber bundle
3. Heated Die	Forming, shaping, and curing	Solid composite profile
4. Pulling	Hydraulic/crawler traction	Continuous product
5. Cutting	Flying saw to fixed/custom length	Finished profiles

For a deeper dive into parameters (speed, temperature, pressure), see our Pultrusion Technical Parameters.

Types of FRP Pultrusion Machines

Hydraulic Pultrusion Machine: High pulling force for large/structural profiles (I-beams, channels, heavy tubes).
Crawler Type Pultrusion Machine: Smooth, uniform traction ideal for thinner or delicate profiles.
Multi-line Pultrusion Machine: Simultaneous production of multiple rods/rebars/small profiles to boost throughput.
Double Station Pultrusion Machine: Parallel operations for higher productivity and reduced downtime.
Custom Pultrusion Solutions: Tailored lines for specific profiles and industries; compatible with bespoke steel dies and resin systems.

Explore our equipment range: FRP Rebar Line · Fiberglass Tube Line · Profile Pultrusion Equipment

Applications of Pultruded FRP Products

Construction & Infrastructure

FRP rebars for concrete reinforcement
Structural beams, columns, handrails
Walkways, platforms, and gratings

Electrical & Energy

Non-conductive cable trays and ladder rails
Utility poles and composite insulators
Support structures with electrical insulation

Marine & Offshore

Corrosion-resistant docks and walkways
Deck gratings and safety railings
Ship ladders and platforms

Transportation

Lightweight beams and components
Bridge decks and reinforcement elements
Rail and truck interior supports

Industrial & Chemical

Chemical-resistant gratings and platforms
Tanks, covers, guards, and structural frames
Non-sparking and low-maintenance solutions

Advantages of FRP Pultrusion vs. Traditional Materials

Feature	Steel	Aluminum	FRP Pultrusion
Corrosion Resistance	Poor	Moderate	Excellent
Strength-to-Weight	High weight	Light	Very high
Electrical Insulation	Conductive	Conductive	Non-conductive
Thermal Conductivity	High	Medium	Very low
Maintenance	High	Medium	Low
Lifespan	Medium	Long	Very long

Result: FRP profiles provide durable, lightweight, and cost-effective performance—especially in corrosive and electrically sensitive environments.

Why Choose Pultrusion Machines from China

Advanced hydraulic and crawler traction technology
Competitive pricing with proven reliability
Custom dies, multi-line options, and process integration
Spare parts supply and remote/on-site commissioning

With turnkey solutions covering equipment, molds, process tuning, and operator training, Chinese suppliers help new plants start production quickly and confidently.

Case Study: FRP Rebar Pultrusion Line for Construction

A Middle East contractor invested in a multi-line FRP rebar pultrusion system. Within six months, capacity reached ~2,000 tons/year. FRP rebars replaced steel in infrastructure projects, reducing corrosion-related maintenance while improving lifecycle economics.

Outcome: Stable output, consistent diameter and rib geometry
Benefit: Lower total cost of ownership vs. steel rebar in corrosive environments
ROI: Strong demand from local contractors accelerated payback

Frequently Asked Questions (FAQ)

What is the typical lifespan of a pultrusion machine?

With regular maintenance and proper alignment, high-quality pultrusion machines typically operate for 10–15 years or more.

How much does a pultrusion machine cost?

Depending on size, configuration, and customization, typical ranges are USD 20,000–120,000+. Multi-line and special profiles may require higher budgets.

Which resins are used in FRP pultrusion?

Common choices are polyester (cost-effective), vinyl ester (chemical resistance), and epoxy (high mechanical/thermal performance).

Can one line produce multiple profiles?

Yes. Multi-line systems can produce several small profiles simultaneously; tool/die changes allow different cross-sections on the same base line.

What speeds are typical?

Typical production speeds are 0.3–1.5 m/min, depending on profile size, resin reactivity, and die temperature.