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Environmental benefits of Fibre ReinforcedPlastics (FRP)

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Environmental benefits of weight reductionProducts made from composite FRP materials offersignificant environmental benefits because of theircharacteristically low weight, good mechanicalproperties and excellent resistance to corrosion. Forexample, composites used in cars can substantiallyreduce overall weight by as much as 40% comparedto steel. Over the lifetime of the car, this means manythousands of litres of fuel saved and consequent

reductions in harmful exhaust emissions. Manyautomotive manufacturers therefore use compositebody parts not just in lower series vehicles such asMPVs (minivans), estate cars and sports / utilityvehicles (4x4s) - but also in higher series models.

Life Cycle Analysis comparison puts FRP abovesteel and aluminiumIn 2003, the European Alliance for SMC together withBASF undertook a comprehensive eco-efficiencyanalysis on a composite part (a boot lid for Mercedes),versus the equivalent part in steel and aluminium. Thestudy considered the entire ecological fingerprint frommanufacture of the raw material to recycling of thefinished part. Economy and ecology were ranked asequally important in this sustainability study. Thecomposite part came out as most favourable overall.

Truck producers harness FRP benefitsCommercial vehicle producers were the first group inthe automotive sector to fully exploit the benefits ofFRP as a structural material for building truck cabs andair deflectors. Every kilogram saved in the weight of acab means a kilogram increase in payload carryingcapacity.

Greener engines thanks to compositesWhen it comes to under the bonnet applications, FRPcomposites are also an environmentally attractivealternative to metals. For engine oil sumps and valvecovers, for example, FRP fulfils all the mechanicalstrength requirements (e.g. a sump must be able tosupport the weight of the engine), but also deliversadded-value environmental benefits. These include areduction in noise and harshness levels and improvedengine efficiency, since the engine warms up fasterand reaches operational efficiency sooner. The resultis less fuel wasted during cold starting and also duringoperation, due to the lower weight of the engine.

A Mercedes boot lid was used as a reference part in an extensive LifeCycle Analysis study.

The Renault Espace is a vehicle that has made extensive use of FRPcomposite body parts throughout its long history. (continued)

Many engine manufacturers use SMC (sheet moulding compound) foroil sumps and valve covers. The SMC components have a similarcoefficient of expansion to metals, so a gas-tight seal is ensured at theinterface with other mechanical parts.

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INFORMATION SHEET (continued)

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PlasticsEuropeAvenue E. van Nieuwenhuyse 4B-1160 Brussels, BelgiumTelephone + 32 2 676 1732Fax +32 2 675 3935Email info@plasticseurope.orgwww.plasticseurope.org

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This publication is intended for guidance only and while the information is providedin good faith and has been based on the best information currently available, is tobe relied upon at the users own risk. The information contained in this documentis provided in good faith and, while it is accurate as far as the authors are aware,no representations or warranties are made with regards to its completeness andno liability will be accepted for damages of any nature whatsoever resulting fromthe use of or reliance on the information contained in the publication.

Alternative energyWind farms are becoming a prominent feature on landand off-shore throughout the world. Windmills the sizeof those that we see today with blades of around 60metres would have been almost impossible to buildwithout FRP. Steel blades of this size would be soheavy they would require hurricane force winds tomove them.

Helping to conserve tropical hardwoods with FRPFRP doors are becoming increasingly popular for newbuildings and home renovations. They faithfullyreproduce the look and solid feel of tropicalhardwoods, such as mahogany, without the need for asingle ancient tree to be felled. FRP doors also bringadded security as they are extremely strong andresistant to break-in. Composite doors are also highlydurable, they will not rot, warp or splinter - and, whatsmore, they never need painting.

Is FRP an environmentally sustainable solution?The environmental benefits of FRP composite, in itsmany applications, is proven. However questions areoften asked about the material itself and theenvironmental impact of manufacturing and workingwith the constituent materials.

Issues that affect the industry include; health & safety;the emission of volatile organic compounds (VOCs);

energy consumption & toxicity from the manufacturingprocess; and the recycling of production waste andend-of-life parts. Compliance with strict environmentallegislation and codes of practice, combined with theadoption of alternative materials and technologies(such as closed mould processes, natural fibres andlow-styrene resins) have largely addressed theseenvironmental issues.

As far as recycling is concerned, The EuropeanComposite Recycling Services Company (ECRC), aEuropean-wide consortium, is actively developingcomposites recycling initiatives and solutions that meetEuropean Union directives. Solutions include energyrecovery through incineration, and recycling end-of-life

composite parts via collection, shredding and millingdown into fractions. The resulting recyclate can bereused as a filler in new FRP formulations and hasother industrial uses, as does the grate ash residuefrom incineration.

Recycling FRP waste

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