The Machinery Behind Cost-Effective FRP Rebar

  1. FRP Rebar by Pultrex Krauss Maffei

The efficiency of the iPul Rebar Pultrusion Line, a Pultrex and Krauss Maffei Rebar Pultrusion Machine, is making FRP rebar an affordable option for the construction industry. Until now composite rebar has been a more costly option compared to steel alternatives, but the higher efficiency of the unique iPul Rebar Pultrusion Line means the benefits of using composite rebar over steel comes with an appealing price tag too.

  • Lower costs
  • Lower material consumption
  • 10 metres per minute
  • From as little as €0.42 per metre

Rebar made from glass fibre and carbon fibre composite materials are used for buildings in corrosive environments, non-magnetic applications, or where lightweight construction is an advantage.

This is because by it’s very nature composite rebar is highly durable, corrosion resistant, stronger than steel, non-magnetisable, non-conductive, easily machinable, and it is four times lighter than steel!

To find out more about the advantages of composite rebar and which types of construction they are most suited to check out Looking To Leave an Architectural Legacy? Incorporate FRP Rebar…Looking To Leave an Architectural Legacy? Incorporate FRP Rebar…

The array of properties also makes it a far more eco-friendly option for construction – not only does it last longer, but it uses less concrete and has a faster installation time.


Injection Box Pultrusion vs Open Bath Production 

Composite rebar is not a new product, but the way it can be produced thanks to the cutting edge expertise of Pultrex and Krauss Maffei is. The iPul Rebar Pultrusion Line uses an injection box method of manufacture which has many distinct advantages over open-bath pultrusion.

  • With Injection Box Pultrusion, quality is determined by tight tolerance control, whereas with an open bath the quality varies depending on a range of factors that are hard to control such as age and quantity of resin, ambient temperature and humidity.
  • The Injection box is a very clean automated process with very little smell nuisance for the operatives. Open bath production has a reputation for being a manual process that is quite dirty with a strong smell.
  • Much faster line speeds are achievable with injection box pultrusion, and a wider variety of resins can be used compared to an open bath where resin choice is limited due to reaction time.


How the iPul Rebar Pultrusion Machine Works

Reinforcements from glass fibre rovings are pulled out from a spool and funnelled together to the required shape through a guide system into the injection box.

Simultaneously, a low pressure metering machine mixes the Epoxy resin under appropriate conditions inside the mixing head. The blended medium is fed into the properly tempered injection box.

Inside the injection box the fibres are impregnated with the highly reactive resin.

After passing through the heated die, the winder will wrap twisted glass fibre yarn around the profile.

Different heating and cooling zones harden the profile to the final Rebar shape.

A caterpillar pulling mechanism grips and hauls the profile with constant speed and clamping force out of the die.

The profiles can be cut to length by a traveling cut-off saw and afterwards be stacked, coiled or packed.

The operator panel is monitoring the process parameters for the whole pultrusion line.

As an option, an automatic refilling station can be integrated to the production line for continuous high-speed 24/7 output.


For more detailed information about rebar pultrusion machines, such as the fibre racks, handling, tension and guidance; the mixing head, injection box, winder unit and other components contact Pultrex for a Rebar brochure.


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