Industrial Re-Use of Composites

The amount of obsolete composites is increasing on a global scale, for example yacht hulls from a growing leisure industry and large rotor blades from wind energy production. Until now it has not been possible to recycle or disassemble thermoset composites into their original constituent parts of fibre reinforcement and resins. Subsequently a new method of re-use has been developed. This method involves machining the obsolete composite product into strips or flakes for re-use as reinforcing elements which, when combined with fresh resin and fibre, enable the production of a brand new component. This, in effect, preserves and re-uses the mechanical properties of the original obsolete composite. This method has been proven in manufacturing retaining walls, also guide beams for canals, crane mats and bridge decking, all using the strips or flakes from end of life composite products. For use on an industrial scale, a positive business case is imperative. In order to prove the industrial technology, new products have to contain a sufficiently high percentage of re-used composites in combination with automated processing. This has been achieved with “push-pultrusion” which is in essence a further development of the long established pultrusion process.