JEC Asia: Construction the future for composites in Malaysia

Perhaps surprisingly, Malaysia is highly dependent on migrant labor in its construction industry. Composite technology has been touted as one solution in reducing this dependence.

Speaking at the recent JEC Asia Show in Singapore, DK Composites (Melaka, Malaysia) Director Habibur Rahman Ibrahim stated that industrialized building systems were a solution that could solve at least some of Malaysia’s labor woes, particularly given the government’s willingness to offer incentives for adoption. However he did note that their were several hurdles to overcome, not least architects who may be adverse to modular designs given that they make money out of designing highly customized, creative structures.

“Architects are increasingly aware of composites, but they’re not moving quickly enough,” he claimed. Ibrahim highlighted the success of Japan, South Korea, and Taiwan in incorporating modular designs into bathrooms in particular to accommodate small installation spaces, while at the same time reducing installation effort.

Ibrahim also called on thermoset resin suppliers to offer better technical service in the Asian region. “Sending agents with briefcases full of brochures and thumb drives is no longer enough,” he said.

DK Composites is one of the leading suppliers of composite domes to the Muslim world. “Shipping costs to the Middle East and overcoming the region’s sweltering heat are key challenges in serving this market,” notes Ibrahim. DK Composites supplied 120 composite domes to the Kempinski Hotel in Dubai lined with 22-carat gold. The company is also supplying composite cladding for a major resort project in Southeast Asia.

Outside of construction, DK Composites manufactures carbon-fiber and glass-fiber composite hulls and decks for the Damen Interceptor patrol vessel designed by The Netherlands’ Damen Shipyards Gorinchem, and it also fully fits out the vessel, which can travel at up to 60 knots. The vessel was a joint winner in the Transportation category of the JEC Asia Awards.

Fireproof prepregs reach highest rating
Australian Composites Pty Ltd. (Moorabbin, VIC) has successfully developed a range of UV-curing, flame-resistant polyester and vinyl ester prepregs called Auspreg 986T, which have just achieved the highest possible ratings for fire testing on building materials and structures.

Independent testing by Exova Warringtonfire (Warrington, UK) saw the materials meet BS 476 Parts 6 (Class 0) & Parts 7 (index 1) standards, which are widely used for manufacturing interior parts for commuter mass transit that are designed to resist lateral spread of flame and propagation of flame when in contact with radiant heat or actual fire.

Manufacturers of fire-resistant parts for train, tram, and buses have up until now only had the option of using epoxy or phenolic resin systems which have short shelf lives, require refrigeration in shipping and storage, and must be cured under heat and pressure for up to eight hours in autoclaves, according to Australian Composites CEO Daniel Leipnik. “Auspreg 986t does not need any refrigeration, can remain useable at room temperature for over 12 months, and cures in a matter of minutes per layer under standard factory lighting or natural sunlight.” The materials can also be cured in multiple layers in a one-step process for thicker (up to 90 mm) or stronger parts.

Leipnik believes that several large business opportunities that have specified this standard will now proceed with contractualizing their orders. “The global demand for flame-resistant composite parts is substantial and growing as billions of people turn to public transport as their daily travel means. Just think of all the structures such as internal walls, paneling, bulkheads, luggage compartments, and seating in trains, buses, trams, ferries, and even unusual items such as mosque domes themselves that all use composites and must be resistant to flame to protect the public in case of fire.”

“By utilizing our rapid light-curing prepreg technology with flame-resistant properties, we have succeeded in producing a more economical, easier-to-handle, and time-saving option that will likely be of great interest to the global composites industry.” Leipnik adds. Auspreg 986t is available in most glass types (E, C & S), various fiberglass weaves (Uni, Biax, CSM, Triax, DB, Combimat, etc) and in finished weights ranging from 300 gsm to 3500 gsm. —Stephen Moore