1
24-016
Challenges of Design and Fabrication of Fiber Reinforced
Polymer (FRP) Flanges—A Review
Shahin Shadlou
RPS Composites, Maple, ON
Bruce D Hebb
RPS Composites, Mahone Bay, NS
ABSTRACT
Fiber Reinforced Polymer (FRP) is an excellent material
choice for a broad spectrum of corrosive fluids and, in many
cases, offers the best value per dollar. FRP Flanges present
the greatest design challenge of all standard piping compo-
nents. The theory underlying the design of flanges is very
complex. In addition, due to the nature of FRP material,
proper fabrication of the flanges is as critical as the design.
In this review, the challenges of making FRP flanges along
with the design techniques and best practices of fabrication
that will lead to a high-quality flange will be discussed.
RPS COMPOSITES
With over 45 years of experience, RPS Composites is a
leading provider of composite pipe and vessel solutions for
a wide range of industries, including mineral processing,
chemical processing, power generation, and marine appli-
cations. Their expertise is underpinned by three flagship
FRP manufacturing plants, strategically located to optimize
production and delivery schedules. Committed to safety
and service excellence, they deploy Field Service teams
across the US, serving Fortune 100 industrial manufactur-
ers and processors. RPS also plays a significant role in the
energy transition, supporting projects related to hydrogen
production, EV battery recycling, and carbon capture and
storage, aligning with the growing demand for critical min-
erals. With a strong presence in North and South America,
they have earned a reputation for the superior performance
of their FRP piping, tanks, and vessels, securing major
projects and offering both supply and installation services
to their clients.
FIBER-REINFORCED MATERIAL VS. STEEL
In the dynamic worlds of mining and chemical indus-
tries, the choice of materials for pipes and tanks plays a
key role in the success of operations. Traditionally, steel
has been the go-to material for these critical components.
However, in recent years, FRP has emerged as a formidable
alternative. This section explores the advantages of using
FRP pipes and tanks compared to steel counterparts:
1. Corrosion Resistance
One of the most significant advantages of FRP pipes and
tanks in mining and chemical industries is their excellent
resistance to corrosion. Chemical processes, aggressive
chemicals, and high humidity levels in mines can rapidly
degrade steel, leading to maintenance headaches and safety
concerns. FRP, on the other hand, is resistant to corrosion,
offering a longer service life.1,2
2. Lightweight
FRP pipes and tanks are notably lighter than their steel
counterparts. This weight advantage could be beneficial,
particularly in the mining industry, where the ease of trans-
portation, installation, and reconfiguration is vital. Lighter
FRP components could simplify logistics, and make han-
dling in remote or challenging locations more manageable.3
24-016
Challenges of Design and Fabrication of Fiber Reinforced
Polymer (FRP) Flanges—A Review
Shahin Shadlou
RPS Composites, Maple, ON
Bruce D Hebb
RPS Composites, Mahone Bay, NS
ABSTRACT
Fiber Reinforced Polymer (FRP) is an excellent material
choice for a broad spectrum of corrosive fluids and, in many
cases, offers the best value per dollar. FRP Flanges present
the greatest design challenge of all standard piping compo-
nents. The theory underlying the design of flanges is very
complex. In addition, due to the nature of FRP material,
proper fabrication of the flanges is as critical as the design.
In this review, the challenges of making FRP flanges along
with the design techniques and best practices of fabrication
that will lead to a high-quality flange will be discussed.
RPS COMPOSITES
With over 45 years of experience, RPS Composites is a
leading provider of composite pipe and vessel solutions for
a wide range of industries, including mineral processing,
chemical processing, power generation, and marine appli-
cations. Their expertise is underpinned by three flagship
FRP manufacturing plants, strategically located to optimize
production and delivery schedules. Committed to safety
and service excellence, they deploy Field Service teams
across the US, serving Fortune 100 industrial manufactur-
ers and processors. RPS also plays a significant role in the
energy transition, supporting projects related to hydrogen
production, EV battery recycling, and carbon capture and
storage, aligning with the growing demand for critical min-
erals. With a strong presence in North and South America,
they have earned a reputation for the superior performance
of their FRP piping, tanks, and vessels, securing major
projects and offering both supply and installation services
to their clients.
FIBER-REINFORCED MATERIAL VS. STEEL
In the dynamic worlds of mining and chemical indus-
tries, the choice of materials for pipes and tanks plays a
key role in the success of operations. Traditionally, steel
has been the go-to material for these critical components.
However, in recent years, FRP has emerged as a formidable
alternative. This section explores the advantages of using
FRP pipes and tanks compared to steel counterparts:
1. Corrosion Resistance
One of the most significant advantages of FRP pipes and
tanks in mining and chemical industries is their excellent
resistance to corrosion. Chemical processes, aggressive
chemicals, and high humidity levels in mines can rapidly
degrade steel, leading to maintenance headaches and safety
concerns. FRP, on the other hand, is resistant to corrosion,
offering a longer service life.1,2
2. Lightweight
FRP pipes and tanks are notably lighter than their steel
counterparts. This weight advantage could be beneficial,
particularly in the mining industry, where the ease of trans-
portation, installation, and reconfiguration is vital. Lighter
FRP components could simplify logistics, and make han-
dling in remote or challenging locations more manageable.3