FRP Composite 101

Fiber-reinforced plastic (FRP) composites have revolutionized the manufacturing sector. In many commercial, industrial, and municipal applications, FRP composites offer high-end performance at a fraction of the weight and cost of comparable metal materials. Construction, energy, aerospace, and other critical sectors are realizing the benefits of FRP for producing reliable parts and components.

The Basics of FRP Composites

A composite is any material made from more than one constituent material with significantly differing properties. The union of these constituent materials often yields a product that is stronger, more versatile, and more durable than any of the input materials alone. An FRP composite consists of a plastic resin or polymer matrix and a fiber.

The fiber may be anything from glass to recycled carpet flooring, depending on target properties of the material. The resin provides superior support and transfer of force between fibers and insulates them from exposure to environmental conditions such as rain, insects, heat, and wind. In turn, the fibers provide stiffness and structural support for the flexible plastic, granting the composite material an incredibly high strength-to-weight ratio.

Fiber-reinforced plastic composites also go by other names, such as fiber-reinforced polymer composites, fiber reinforcement composites, and fiber composites—though they all generally refer to the same type of material.

Material Benefits

There are thousands of composites being used in the market for purposes ranging from structural components in construction to spacecraft components in aerospace. Designers and manufacturers across industry sectors turn to FRP for the expansive range of benefits it offers. Here are some of the beneficial features of FRP composites:

Applications of FRP Composites

Some of the common applications for FRP materials include:

Choosing Miura Board™ — A 100% Recycled FRP Composite

Miura Board is an environmentally friendly and weatherproof FRP composite made entirely from recycled plastic and the following: post-consumer carpet fibers, or rice hulls, peanut shells, coconut shells, soybean hulls and any man made or natural fiber. To make this versatile material, we first take in commingled recycled plastics. We then use a patented process to blend these recycled thermoplastics with non-melting fibers—usually nylon or polyester—drawn mostly from carpet backing. The composite is then shaped, cooled, and cut to meet design specifications. The result is usually gray or slate in color, but at customer request, we may add a colorant the fiber-reinforced plastic to obtain a different pigmentation.

Why Miura Board?

Currently one of the most eco-friendly and durable wood replacements on the market, Miura Board boasts low weight, high strength, impact resistance, and invulnerability to the elements. Like other FRP composites, Miura Board does not sustain fungus, bacteria, or termites, and has a long useful lifetime that surpasses that of treated wood. This makes our product a valuable solution for decks, siding, gangways, and just about anywhere a strong, durable material is needed.

Our customers are constantly finding new uses for our product and cutting global demand for lumber in the process. Miura Board is pressure washable, weldable, able to be sanded, and may be left without maintenance for years. Miura Board material is also itself recyclable.

If you share our passion for reducing waste and logging or have a need for a material with far fewer maintenance requirements than wood, please contact our team or request your quote today.

Miura Board. Cut waste, not trees™.

Recycled Plastic Composite vs. HDPE Lumber

As we become more aware of our impact on the environment, it has grown increasingly critical to use environmentally friendly construction materials. Wood and wood-plastic composites (WPC) have long been popular materials for decking, but today’s market is replacing them with even more durable and eco-friendly recycled plastic “lumber” or wood alternatives. High-density polyethylene (HDPE) and fiber-reinforced plastic (FRP) composites are two of the most common types of plastic lumber that are available today.

The following guide summarizes the characteristics of HDPE and FRP composite lumber to help you select the ideal material for your deck.

Recycled Plastic Lumber

Wood-based materials have fallen out of favor with consumers for a variety of reasons:

• Wood and WPC composites are often produced using materials procured through unsustainable logging practices.
• They also degrade and decay when exposed to the sun, wind, moisture, and foot traffic.
• They are expensive to maintain and replace.
• Chemicals that are used to weatherproof wood can leach into the ground and water, polluting the environment.

Between the short life span, expense, and ecological impact of wood-based lumber, it is no surprise companies are developing more durable and sustainable materials.

Recycled plastic “lumber” offers a low-maintenance, sturdy, and environmentally friendly wood alternative for construction. Manufacturers repurpose post-consumer plastics (e.g. HDPE milk jugs) into a material that can withstand exposure to outdoor environments. These materials are commonly used in marine and consumer-focused applications instead of wood.

HDPE Lumber vs. Fiber-Reinforced Plastic (FRP) Composite Lumber

High-density polyethylene (HDPE) and fiber-reinforced plastic (FRP) composites are two of the most common plastic-based lumber alternatives available today. Both materials are manufactured using recycled plastics, which makes them more sustainable and less expensive than wood. HDPE and FRP also feature enhanced durability compared to traditional lumber.

However, even though HDPE and FRP have many similarities, they also exhibit a few significant differences.

What Is HDPE?

HDPE is one of the most popular plastic materials in the world. It is a thermoplastic polymer made of ethylene, which is derived from petroleum. The ethylene monomers in HDPE are strictly aligned with very little branching, which means the material is strong and rigid, hence the “HD” which stands for “high density”. HDPE is opaque, resistant to chemicals, and capable of withstanding temperatures as high as 120 °C/248 °F.

. Pros and Cons of Using HDPE

HDPE is valued for its lightweight strength and hardness. It is an excellent barrier against moisture, corrosion, rot, and insects, and it won’t leach chemicals into the surrounding environment. The HDPE manufacturing process does not produce harmful emissions.

Although HDPE is strong, it has a tendency to expand or contract with changing temperatures. It also will degrade when exposed to UV radiation for long periods of time, resulting in unsightly cracks and splitting that could make the surface unsafe for walking. Since there are no fibers incorporated in the HDPE structure, it lacks the structural stability of FRP composites like Miura Board™. The surface of HDPE board is also impervious to paint, coatings, and adhesives, so it is difficult to brand or customize HDPE lumber to meet certain functional and aesthetic needs. This is a significant factor for businesses and homeowners who want to attach abrasive safety strips to their outdoor decking or deviate from standard color options.

. Common HDPE Applications

HDPE is commonly used for containers such as plastic bottles, milk jugs, and (rarely) plastic bags. Recycled HDPE is also used for consumer goods such as crates and buckets, plastic furniture, HDPE playground equipment, office supplies, and, of course, construction decking. Overall, HDPE is an adequate choice for many applications that occur indoors or in shaded areas that don’t need to be painted or customized.

What Is FRP Composite Lumber?

Fiber-reinforced plastic (FRP) is a polymer matrix made up of resin and various strengthening fibers, such as basalt, carbon, glass, aramid, and/or asbestos. Miura Board™ is a type of FRP that uses commingled recycled plastics combined with natural (e.g. rice hulls) or synthetic fibers (e.g. carpet backing). The synthetic fibers used to strengthen the thermoplastic resin include nylon and polyester (PET) from recycled carpet. As a result, Miura Board™ is composed entirely of recycled materials. The resultant composite lumber is fully recyclable once it has reached the end of its service life.

. Pros and Cons of Using FRP Composite Miura Board™

FRP composites such as Miura Board™ feature all the benefits of HDPE without the disadvantages. Miura Board™ can be painted, coated, power washed, and even welded, and adhesives stick easily to the surface. Although the Miura Board™ standard is slate-gray, the color can be customized pre- and post-production.

Because of its resistance to UV exposure, FRP typically has a longer service life and requires less maintenance than HDPE, which also makes it more cost-effective long-term.

. Common FRP Composite and Miura Board™ Applications

FRP composites such as Miura Board™ are valued for their strength, structural integrity, and corrosion-resistance, all of which make them ideal for marine, industrial, farming, and commercial applications. FRP can be used to build decks, platforms, siding, stalls, coops, kennels, roofing, and ground protection mats, just to name a few examples.

Contact Miura Board™ for Your Recycled Plastic Composite Needs!

Our 100% recycled Miura Board™ products have been widely used across Brazil, Argentina, and Chile for decades and are perfectly suited for outdoor decking. At Miura Board™, we are dedicated to providing top-quality, environmentally friendly products for customers around the world to suit every type of construction project. To learn more about recycled wood alternatives, contact us today or request a quote.

What Is the Best Composite Decking Material?

Composite decking is a popular option among many homeowners today. Unlike wood decking, it is cheaper and easier to maintain, yet still more durable and sustainable. And as a new concept to many homeowners, people often cannot tell the difference between wood and composite deck boards.

Composite Decking Selection Considerations

This guide goes through the basics of composite decking, including what composite decking is, reasons why it serves as a popular alternative to wood decking, and factors to consider when shopping for the best composite decking.

• Composite Decking Materials
• Benefits of Composite Decking
• Cost-Effectiveness
• Key Factors to Consider When Choosing Composite Decking
• Industrial Applications
• Miura Board – The Ideal Composite Decking Brand

. Composite Decking Materials – What is it Made of?

Composite decking uses a variety of materials instead of wood:

• Wood composite. A blend of sawdust and recycled plastic, wood composite serves as the most popular composite decking material. With appearance and feel like wood decking, wood composite also comes in an array of colors and can be styled to look like laminate flooring.
• Plastic. Plastic composite decking uses a variety of plastic materials, including polyethylene, polypropylene, and vinyl. It is lightweight and durable. Additionally, many of the high-end brands can be styled to look like authentic wood decking.
• PVC/vinyl. PVC and vinyl composite decking material is made of 100% polyvinyl chloride. Easily customizable, vinyl offers an abundance of color selections.

Other common materials used for composite decking include:

• Poly
• Rubber
• Other recycled materials

. Benefits of Composite Decking

Due to its many benefits, composite decking’s popularity keeps growing. Most notably, using it eases the global dependence on wood. For every home to afford a wooden deck, it would require a lot of this finite resource, and over-harvesting will likely devastate the forests.

Other significant benefits of composite decking include:

• Great value for money. The installation cost runs higher than that of wood decking. In the long term, however, the choice for composite decking saves a lot of money and time, as covered below.

• Durable. That characteristic sleek and elegant look and feel of wood decking does not always last. Instead, it wears and tears over time, develops splinters and stains, and generally degrades overall as a material. However, durable composite decking retains its structure and look over time.

• Easy to maintain. Because of its short-term resilience, wood decking needs proper maintenance. This care includes cleaning, sheltering from extreme weather, and making all necessary repairs. Low-maintenance composite decking does not need this type of attention over time.

. Cost-Effectiveness

The initial cost of composite decking surpasses that of wood decking. Yet in the end, choosing to build with composite decking material still proves more cost-effective.  Durability and easy maintenance over time help keep long-term cost low.

Composite decking lasts longer than wood decking. Not prone to the degradation associated with wood, it does not splinter or rot away over time. That means that less money will be spent on repairs and replacements, saving the consumer more than the margin difference of wood decking.

Maintenance can also be costly. With wood decking, handyman help may be needed to fix small problems, increasing overall cost over time. Composite decking does not degrade as much as wood decking, which means lower maintenance expenses.

Key Factors to Consider When Choosing Composite Decking

So, what makes the ideal composite decking? That depends on personal preferences. However, there are several factors that every shopper should take into consideration:

• Material. Different materials used to make composite decking have varying strengths and shortcomings. Some materials provide more durability while others look more visually appealing. For wood composite decking, benefits in both design and strength position it as the most popular or best composite decking material.

• Aesthetic appeal. Wood decking remains popular for the elegant wooden appearance. However, some of the more versatile composite decking materials can be styled to look realistically like wood. Compared against one another, many people cannot tell the difference between wood and composite decking.

• Color and texture. In addition to a wooden appearance, some composite decking materials can also imitate the texture and feel of genuine wood. But, unlike wood decking, composite deck boards can offer a variety of colors and designs.

Industrial Applications

Composite decking works for more than just residential backyards. Other applications expand beyond the home, reaching such industries as construction, transportation, and public works or governmental projects. On a smaller scale, it can be used in industrial projects such as:

• Assembling ramps
• Constructing stadiums and bleachers
• Paving boardwalks
• Building marinas

Miura Board – The Ideal Composite Decking Brand

Miura Board pushes the limits of composite decking. It takes recycling to the next level by making use of plastic waste and natural fibers such as rice hulls, or synthetic fibers such as post-consumer carpet. Stronger and more durable, Miura Board products pack an original aesthetic appeal. Get in touch with Miura Board to learn more about the best composite deck boards on the market.

Composite vs Wood Fence Guide: Benefits, Costs

Miura Board™is one of many plastic composites on the market. Like other composite fencing materials, Miura Board™ allows users to create strong and reliable fences that stand the test of time. However, Miura Board™ is a superior alternative to both wood and wood composites for a variety of reasons.

This blog post will compare Miura Board™ to competitive solutions to help you determine if our proprietary product is right for your fencing project.

Composite vs. Wood Fence

Wood composite fencing and wood fencing differ from one another in several ways. Wood fencing had few market competitors until fairly recently, but wood composites have offered an appealing alternative. Composite fences are made of a mixture of plastic and real wood to create an eco-friendly alternative to standard fencing.

Here are some factors to consider when deciding between wood and wood composites.

Installation Costs

One of the most notable differences between wood and wood composites is their upfront cost. Cost plays a central role in most projects and standard wood fences are cheaper to purchase than their composite counterparts. Wood fences tend to cost around $15 per foot, while composite wood fences may run $25 per foot or more.

While increased upfront costs may be a deterrent, it’s important to consider the overall lifespan of the product. The significantly longer service life of wood composites makes them much more affordable over time by delivering a lower cost of ownership. With a minimum service lifespan of 15–20 years, composite wood is ultimately much more cost-effective.

Maintaining Composites

When comparing maintenance requirements, wood and wood composite fences vary considerably. While wood fences require frequent repainting and/or repair, composite wood fencing simply requires occasional wash downs with water. Composite holds up better than wood when exposed to weather, UV rays, and other environmental factors such as insects and mold.

The natural decomposing process of wood can only be delayed through frequent treatments and coatings. Wood must frequently be repainted, repaired, or replaced. In climates with significant moisture, inclement weather, or insect problems, a wood fence may only last a few years.

Miura Board™: The Ideal Composite Fencing Solution

Fiber-reinforced composites present several advantages over conventional FRP counterparts. They last longer, require much less maintenance and tend to be cheaper in the long-term. Miura Board™ fiber-reinforced composites are not simple blends of plastics and fibers like other FRPs, but rather a molecular scaffolding of fibers that enable commingled plastics to be used instead of a single type of plastic (typically just HDPE).  The resulting strength and durability make it suitable for use in a variety of private and municipal projects for:

• Boardwalks
• Stadiums
• Parks
• Ramps
• Bleachers
• Fences

Miura Board™ is the highest-quality fiber-reinforced, composite solution on the market. Compared to other (wood-plastic) composites, Miura Board™ offers comparable or superior performance while remaining a sustainable solution. We use 100% recycled materials only, to help divert plastic waste and carpet from landfills.

The below photo illustrates how regular wood fences require regular maintenance and repair, and when a new wood board is added, it creates this “eye-sore” contrast between the new and old pieces. Miura Board™ doesn’t have this “weathered” look and can seamlessly be replaced for a more consistently cohesive look.

             Common contrast seen between the new and old wood boards

Advantages of Miura Board™ Composite Fencing

Compared to common conventional wood and wood-plastic composite fencing, Miura Board™ offers a broad range of benefits, including:

• Longer service life
• Low maintenance requirements
• Better weather resistance
• Pest-immunity
• Higher strength and durability
• Easy installation
• Can be pressure washed
• Solvent resistant
• Graffitti can be removed
• UV resistant
• Can be painted

If you’d like to learn more about the advantages of Miura Board™ composite fencing, contact our team today.