Best References: Fiberglass

Fiberglass products are manufactured through a process of open molding or laminating of thermosetting plastics to produce what are known as fiberglass reinforced and composite plastics. The most common products are fiberglass boats, but other products include furniture, corrosion resistant equipment, cultured marble bath fixtures, bathtubs, heat exchanger components, floating pier modules, large storage tanks, truck body components, and machinery housings. This sector includes information on several fiberglass production methods, including open mold laminating using spraying or rolling techniques, closed molding, rotational molding, infusion, vacuum bag molding, and UV curing, among others. Specifically addressed are the issues of handling hazardous materials and contaminated solvents, and controlling air and particulate emissions.
Date Last Updated: 11/16/2007

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Case Studies | Fact Sheets | Articles and Reports | Manuals | Sector Notebook | Web sites |

Case Studies |

Section Title: Boat Builder, VOCs
Full Title: Case Studies of the Rhode Island On-Site Technical Assistance Program
URL: /32/31014.pdf
Length: 3 pages
Full Work Author: The Rhode Island Port Authority (RIPA)
Abstract: The Rhode Island Port Authority Trade Pollution Prevention Research Project case study describes how using infusion molding or the Seeman Composite Infusion Molding Process (SCIMP) on a 30-foot sailboat hull cut laminating and resin usage and volatile organic compound (VOC) production.
Section Title: Fountain Powerboats Incorporated - On-Site Recovery and Reuse
Full Title: Case Summaries of Waste Reduction by Industries in the Southeast
URL: /01/0034350.pdf
Length: 1 page
Date: July 1998
Full Work Author: Waste Reduction Resource Center
Abstract: This fiberglass fabricator installed a batch still to recover acetone.
Section Title: Fountain Powerboats Incorporated - Process Modification: Equipment Change
Full Title: Case Summaries of Waste Reduction by Industries in the Southeast
URL: /01/0034351.pdf
Length: 2 pages
Date: July 1998
Full Work Author: Waste Reduction Resource Center
Abstract: This fiberglass fabricator switched from spray guns to vacuum bags to deliver resin to the mold.
Section Title: Grady White Boats
Full Title: Case Summaries of Waste Reduction by Industries in the Southeast
URL: /01/0034352.pdf
Length: 1 page
Date: July 1998
Full Work Author: Waste Reduction Resource Center
Abstract: This fiberglass fabricator switched to air assisted airless spray guns for applying the gel coating.
Full Title: Fiberglass Manufacturer Substitutes Acetone With a Water-Based Emulsifier
URL: /03/02100.pdf
Length: 1 page
Date: May 1991
Full Work Author: NC Office of Waste Reduction
Abstract: This case study discusses how a manufacturer of fiberglass plumbing fixtures and other items (Eljer Industries) substituted acetone with a water-based resin emulsifier to clean equipment and hand tools used in production. Only a small quantity of acetone was used for final cleaning and drying, reducing acetone use by 50% and hazardous wastes by 70%
Full Title: Ford - Molded Fiberglass Headliner Offal Reduction Project
URL: /03/02499.pdf
Length: 2 pages
Full Work Author: US Auto Pollution Prevention Project
Abstract: In September 1995, under the auspices of the Company Pollution Prevention Program, a materials management consulting firm was contracted to help the Utica Plant perform a full cost pollution prevention evaluation. The primary purpose of the project was to provide a full cost analysis of waste by each major manufacturing process. A detailed material balance flow chart for the top five processes selected for future investigation by the Plant was included in the project. As a result of the investigation it was determined that part offal accounted for over 57% of the total waste while scrap contributed 25% of the waste generated at the facility
Section Title: Chem-Pruf Door Company - Fiberglass Plastics
Full Title: Pollution Prevention Ideas from Texas Industries
URL: /02/01494.pdf
Length: 1 page
Date: March 1996
Full Work Author: Texas Natural Resource Conservation Commission
Abstract: Waste fiberglass dust from floors and vacuum systems is reused by this building products manufacturer. Solid waste disposal has decreased by 74%.

Fact Sheets |

Full Title: Best Practices in Glass Recycling - Cullet Specifications for Fiberglass Insulation Manufacturing
URL: /13/12079.pdf
Length: 2 pages
Date: 11/96
Full Work Author: Clean Washington Center
Full Title: Fiberglass & Composite Manufacturing
URL: /32/31015.htm
Full Work Author: Spokane County Air Pollution Control Authority (SCAPCA)
Abstract: SCAPCA in Washington State provides information on fiberglass and composite manufacturing techniques to reduce emissions, increase efficiency and improve environmental management.
Full Title: Fiberglass Operations
URL: /32/31022.htm
Full Work Author: University of Missouri Outreach & Extension
Abstract: The Missouri Outreach & Extension service provides common pollution prevention techniques as well as fiberglass operation specific tips on purchase and inventory, materials and waste storage, basic operations, equipment and process changes, materials substitution and recycling.
Full Title: Pollution Prevention Fact Sheet - Fiberglass Fabrication
URL: /31/30002.pdf
Length: 3 pages
Full Work Author: Utah Department of Environmental Quality
Abstract: The Utah Department of Environmental Quality compiled this pollution prevention fact sheet for fiberglass fabrication that includes opportunities for use of spray guns, catalysts, engineering controls, alternative resins and other alternative processes as pollution prevention opportunities.
Section Title: Fiberglass-Reinforced Plastics/Composites "Top 10" Pollution Prevention Opportunities
Full Title: Pollution Prevention Resources
URL: /26/25937.htm
Full Work Author: Washington Department of Ecology
Section Author: Pollution Prevention in Washington
Abstract: "Top 10" Pollution Prevention Opportunities
Full Title: Reducing Volatile Emissions in the Fiber Reinforced Plastics (FRP) Industry
URL: /02/01991.htm
Length: 8 pages
Date: December 1997
Full Work Author: Minnesota Technical Assistance Program
Abstract: This fact sheet describes some of the options available to reduce acetone and styrene emissions from FRP operations. Includes a list of suppliers with additional information.

Articles and Reports |

Full Title: Establishing Waste Reduction Benchmarks and Good Manufacturing Practice for Open Mold Laminating
URL: /01/00372.pdf
Length: 20 pages
Date: 1997
Full Work Author: Hillis, David R.
Abstract: Report illustrates how to use planned experimentation to establish benchmarks and Good Manufacturing Practice in a fiberglass lamination facility. The variables studied were the styrene-content of the resin, the spraying method, and operator technique.
Full Title: Evaluation of Direct Resin Applicator and HVLP Gelcoat Equipment in Large Fiberglass Boat Construction
URL: /23/22253.pdf
Length: 12 pages
Date: 6/94
Full Work Author: Arthur, Robert C.
Abstract: This project’s goals were to evaluate an HVLP (high volume low pressure) gelcoat gun and a direct application resin roller.
Full Title: Pollution Prevention Assistance Tools for the Fiber Reinforced Plastics and Boat Manufacturing Industries
URL: /26/25282.htm
Full Work Author: The Minnesota Technical Assistance Program (MnTAP) and the Minnesota Pollution Control Agency (MPCA) Small Business Assistance Program (SBAP)
Abstract: The Minnesota Technical Assistance Program (MnTAP), in partnership with the Minnesota Pollution Control Agency (MPCA) Small Business Assistance Program (SBAP), assisted fiberglass shops with implementation of pollution prevention strategies that will help the industry meet or go beyond regulatory thresholds for compliance with OSHA and the CAA. Many shops have implemented pollution prevention practices and technologies and are benefiting from reduced styrene emissions, reduced regulatory requirements, and cost savings.
Full Title: Project Summary - Evaluation of Pollution Prevention Techniques to Reduce Styrene Emissions from Open Contact Molding Processes
URL: /07/06390.pdf
Length: 6 pages
Date: September 1997
Full Work Author: Kong, Emery; Bahner, Mark; Wright, Robert; Clayton, Andrew
Abstract: This study evaluated various pollution prevention techniques for styrene emission reduction from open molding processes in fiberglass-reinforced plastics/composites and fiberglass boat building industries. The study concluded that using controlled spraying, low-styrene and styrene-suppressed materials and non-atomizing application equipment can reduce styrene emissions from 11 to 52 percent.
Full Title: Solvent Substitution to Reduce Air Emissions for the FRP Industry
URL: /01/00904.pdf
Length: 70 pages
Date: 1990
Full Work Author: Hoffman, Douglas J.
Abstract: This report is an evaluation of alternatives to acetone for cleaning tools & equipment during fiberglass manufacturing. While this report is based on one boat builder's experience, the methods are broadly applicable. Alternatives evaluated include dibasic esters (DBE), N-methyl pyrolidone, and propylene carbonate. The best cleaner depends on the application but payback for many of the alternative cleaners is under 3 years.

Manuals |

Full Title: Guides to Pollution Prevention - The Fiberglass-Reinforced and Composite Plastics Industry
URL: /02/01058.pdf
Length: 64 pages
Date: October 1991
Full Work Author: US Environmental Protection Agency
Abstract: The fiberglass reinforced and composite plastic industries generate wastes (including air emissions) during fabrication processes and from the use of solvents for clean-up tools, molds and spraying equipment. The wastes generated are: partially solidified resins, contaminated solvent from equipment clean up, scrap coated fiber, solvated resin streams, and volatile organic emissions. The guide manual presents source reduction and recycling opportunities for reducing these wastes. Suggestions include using substitutes for solvent cleaners, making changes to mixing and application equipment, recovering and recycling solvent, and implementing good materials management and housekeeping practices. To help companies in the industry identify opportunities for waste reduction at their own facilities, the guide includes a set of worksheets, which take the user step-by-step through an analysis of the on-site waste generating operations.
Full Title: Waste Reduction Assistance for the Fiberglass Fabrication Industry
URL: /32/31811.pdf
Length: 30 pages
Date: June 2003
Full Work Author: Pinellas Country Department of Environmental Management
Abstract: The manual outlines best management practices (BMP’s) for reducing air emissions and hazardous waste generation in fiberglass fabrication processes that can increase regulatory compliance.
Full Title: Waste Reduction Strategies for Fiberglass Fabricators
URL: /01/00368.pdf
Length: 134 pages
Date: 1995
Full Work Author: Hillis, David R.; Davis, A. Darryl
Abstract: This excellent manual approaches waste reduction in fiberglass operations from the perspective of the whole facility including the effect of process control and plant layout on emissions. Written at a level of technical detail that is easily understandable and sufficiently detailed.

Sector Notebook |

Full Title: EPA Office of Compliance Sector Notebook Project - Profile of the Plastic Resin and Manmade Fiber Industries
URL: /01/00501.pdf
Length: 190 pages
Date: September 1997
Full Work Author: US Environmental Protection Agency
Abstract: This comprehensive document is one of a series of specific industry sector notebooks complied by the EPA to address environment issues. This document covers introductory material, pollution prevention opportunities, and an overview of relevant federal statutes and regulations for the plastic resin and manmade fiber industries.

Web sites |

URL: http://www.acmanet.org/
Full Work Author: American Composite Manufacturers Association
Section Author: ACMANET
Full Title: Fiberglass Fabrication
URL: http://www.pprc.org/hubs/toc.cfm?hub=10&subsec=7&nav=7
Full Work Author: Pollution Prevention Resource Exchange (P2RX)
Section Author: Pacific Northwest Pollution Prevention Resource Center

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Content provided by N.C. Division of Pollution Prevention and Environmental Assistance and Waste Reduction Resource Center through a grant from the EPA.