FRP

About non-combustible FRP (next-generation FRP)

20 L can of next-generation FRP (Product name: BOTH) Kyowa Inc. version
20 L can of next-generation FRP (Product name: BOTH-Lam) Kyowa Inc. version
※As we have a distributor for our product, the package is designed for the distributing company.

Each DreaM Inc. non-combustible FRP actually an FRC (Fiber Reinforced Ceramics). It is developed based on water-soluble fiber-reinforced ceramics and reinforced with basalt cloth.

This product is resin-free, and its component is all non-flammable; thus, it is wholly non-combustible and poison gas-free.

Since this new material has the same nature and characteristics as the pre-existing FRP (fiber reinforced plastic) and could be used in the same manner, we call this new material next-generation FRP (tentative name) for convenience.

Mr. Hamamura, developer and chairman of the board, is a specialist who has worked with FRP for over 40 years. He has simulated various situations for its development and possesses the knowledge and experience to overcome needed criteria and challenging problems. The quality of the next-generation FRP (tentative name) progresses every day.

 

 

A simple video that shows the ability of the world’s first “non-combustible FRP.”

Video verifying that it is possible to build a fire-resistant house in preparation for a major earthquake (April 2021)

Developing non-combustible FRP was the most extended dream in the FRP industry.
Each DreaM Inc. has succeeded in creating the world’s first non-combustible FRP that has passed the ISO 1182 test.

As seen in the video, it can withstand a 1200 ℃ (2192 °F) burner fire even being 0.8 mm (ca. 0.031 in.) thin. The melting point of aluminum is 660℃ (1220 °F), but our product will bear against 1200 ℃ (2192 °F) fire without deformation. Depending on its use, it can replace aluminum. Its potential is limitless as you can modify them into any shape,

Demonstration video that clearly shows the performance of next-generation FRP, which is truly flame-proof.

Video verifying the reinforcement of rebar and its use in oil complexes (April 2021)

Video verifying that ship fires can be prevented (March 2021)

Promotional Video for Each DreaM Inc (October 2020)

Demonstration video conducted in Akiruno City, Tokyo (October 2020)

Apart from the pre-existing FRP, it is easily pulverized and recycled in 3 ways.

The ext-generation FRP pulverized for recycling.The powder on the top is baked. The powder on the bottom is before being baked.
The ext-generation FRP pulverized for recycling.
The powder on the top is baked. The powder on the bottom is before being baked.

Non-combustible FRP (next-generation FRP) is easy to pulverize and recycle, another different feature from the pre-existing FRP (fiber reinforced plastic).

The left image shows a 1 mm (ca. 0.039 in.) and 6 mm (ca. 0.236 in.) powder for recycling. The bottom is the pulverized form. The top is pulverized and baked.

There are 3 ways to recycle.
1.Dispose of by mixing the powdered form with dirt (it is harmless).
2.Reuse by pulverizing and mixing into base material for another next-generation FRP.
3.Add to cement to reinforce concrete strength.

Pre-existing FRP (fiber reinforced plastic) is usually hard to separate and difficult to recycle, dispose of, and bad for the environment.
Non-combustible FRP (next-generation FRP), as mentioned above, is not only non-flammable but can be recycled in 3 easy ways, adding eco-friendly merit.

Passed the test for world-class standardization ISO 1182

Reults of the next-generation FRP in ISO 1182/ Fire prevention, Fireproof Performance Test Reports (non-combustion material)
Reults of the next-generation FRP in ISO 1182/ Fire prevention, Fireproof Performance Test Reports (non-combustion material)
Reults of the next-generation FRP in ISO 1182/ Temperature measurement curve
Reults of the next-generation FRP in ISO 1182/ Temperature measurement curve

The above video shows our next-generation FRP (tentative name) going through the ISO 1182 test on July 22, 2020.

ISO 1182 is the world-class standardization for non-combustible material, and no other FRP in the world has passed this test.

As seen in the video, the temperature change is slow, creating a parabolic graph, apart from the standard charts. It is completely non-flammable, as well as retaining its shape. It has passed the test with unprecedented results.

Each DreaM Inc.’s next-generation FRP (tentative name) has become the world’s first FRP to pass the ISO 1182.

【A rough details of the non-combustion test】
A 44 mmΦ x 50 mm cylindrical test body was placed in a 750 ℃ (1382 °F) furnace and measured for 30 minutes. During that time, if the furnace’s rising inner temperature is under 20 ℃ (68 °F), and the test body’s decreased weight is under 30 %, it is considered cleared.

【Non-combustion test evaluation point】
1.Does not burn under 750 ℃ (1382 °F) for 30 minutes.
2.70 % or more of the test body’s weight is left.
3.The furnace’s rising inner temperature (ΔT), calculated from the difference of the furnace’s average inner final temperatures, is under 20 ℃ (68 °F).

Certificate of analysis: 第20-1100号 No. 20-1100 issue
Test name: non-combustion test (fire prevention, fireproof performance test)
Test date: July 22, 2020
Test body: Next-generation FRP (tentative name)

 

Why we aimed for the ISO1182

It is not easy to pass the ISO 1182, and you can’t find much of its details.

If you were to use it only for building materials, you would only need to pass the ISO 5660 test, receive accreditation from the Ministry, and you can sell it as non-combustible material.

The reason why we aimed for the demanding ISO 1182 is for the IMO certification. We could not even qualify to take the IMO test without the ISO 1182. The IMO certification will allow our product to be used in all kinds of boats.

Mr. Hamamura, our chairman of the board, has worked in designing foreign luxury cruise ships in the past and has expert knowledge in ship construction. We have assumed that our product would also be applied to boats

Passed the non-combustion ISO 5660 test for railways

Reults of the next-generation FRP in ISO 5660/ Exothermic Test Reports
Reults of the next-generation FRP in ISO 5660/ Exothermic Test Reports

The General Building Research Corporation Of Japan conducted the ISO 5660 test for our next-generation FRP (tentative name) on July 3, 2020, and it has passed with overwhelming results.

“ISO 5660” also called the railway non-combustible test, is used as criteria for railway materials. Soon, FRP that passes this standard has been called non-combustible FRP.

【Details of exothermic testing】
Exothermic testing of “ISO 5660” is as below.
The test body is exposed to an external ignitor and radiant heat ( 10~100 kW/㎡ range )  under an air environment. It is then ignited and burned. Oxygen concentration in the exhausted combustion gas and the flow rate of the exhaust gas is then measured. The heat generation rate is determined by the oxygen-consuming method.



【Exothermic testing evaluation point】
1.The gross heating value is under 8 MJ/㎡ after 20 minutes of heating.
2.No fatal cracks or holes for fire protection both inside and out after 20 minutes of heating.
3.Heat generation rate is under 200 kW/㎡ for 10 continuous seconds or more.

When you look at the numbers, the gross heating value is a mere 0.01 MJ/㎡, and the maximum heat generation rate is 0.33 kW/㎡, which on the graph is nearly a zero. It is completely non-flammable, and its shape unchanged. These numbers confirm the material’s unprecedented performance.

Test number: III C-20-0046
Test name: Exothermic test (cone calorimeter test)
Test date: July 3, 2020
Test body: Next-generation FRP (tentative name)

Determined as “non-combustible” for combustion test for railway vehicle material

Determined as “non-combustible” for combustion test for railway vehicle materials
Determined as “non-combustible” for combustion test for railway vehicle materials

Our next-generation FRP (tentative name) receives non-combustible evaluation.
【Test Method】

Combustion test for non-metal railway vehicle materials is as below.
A 182 mm x 257 mm sample material is kept at a 45-degree angle on a low heat-conducting material like a cork to keep the bottom center of the combustion vessel 25.4 mm vertically below the center of the sample’s burning side (bottom face). 0.5 cc of pure ethyl alcohol is poured in and ignited, then left until it is completely burnt.
Combustion evaluation is sectioned in during alcohol combustion and after combustion. In the former, an observation was made on the sample ignition, catch flame, and the state of the fumes and flames. In the latter were examined the after-flame, after-glow, carbonization, and deformation.
 

Temperature 25 ℃, humidity 61 %, duration of alcohol combustion 1 h 42 sec.

During alcohol combustionAfter alcohol combustion
ignition:_none after-flame: ― 
catch flame:_none after-glow: ― 
smoke:_few carbonization:_90mm discoloration
the force of the flame: ― surface deformation: 90mm

Evaluation: Non-combustible
 

Certification Authority: Japan Railway Rolling Stock & Machinery Association
Test number: vehicle material combustion test 2020-450K
Test name: Combustion test for railway vehicle material
Test date: August 31, 2020
Test body: Next-generation FRP (tentative name)

Passed the cone calorie meter exothermic test of the combustion test for railway vehicle material

Cone calorie meter Exothermic Test Results
Cone calorie meter Exothermic Test Results

Our next-generation FRP has cleared the cone calorie meter exothermic test of the combustion test for railway vehicle material.
Only materials evaluated as non-combustible in the railway vehicle material combustion test can qualify for this test.

You can see the overwhelming results on the left.

【Test method】
Test method is as below, based on those of ISO 5660-1: 2002.
An approx. 100 mm square sample with a maximum thickness of 50mm and a smooth surface is put under heat radiation of 50 kW/㎡for 10 minutes. Gross heat value (MJ/㎡), maximum heat generation rate (kW/㎡), and the time to ignition (seconds) are measured in this test to evaluate combustion.


【Pass verdict】
Below are the criteria

1)Gross heat value is under 8 MJ/㎡, and the maximum heat generation rate is under 300 kW/㎡.
2)If gross heat value is over 8 MJ/㎡ and under 30 NJ/㎡, ignition time is over 60 seconds, the maximum heat generation rate is under 300 kW/㎡.


Certification Authority: Japan Railway Rolling Stock & Machinery Association
Test number: Vehicle material combustion test 2020-27K
Test name: Corn calorimeter combustion thermic test
Test date: September 14, 2020
Test body: Next-generation FRP (tentative name)

Non-combustible FRP (next-generation FRP) Safety Data Sheet (SDS)

Next-generation FRP Safety Data Sheet (SDS) Kyowa Inc. version
Next-generation FRP Safety Data Sheet (SDS) Kyowa Inc. version

[Hazard Information]
・Harmful when swallowed.
・Severe chemical burn on skin and damage to the eye.

[Safety Precautions]
・Wear protective gloves/ gears/ glass/ face shield.
・Do not inhale dust or mist.
・Do not eat, drink, or smoke while using this product.
・Wash hands thoroughly after use.

[First Aid]
・If in eyes: Rinse carefully in clean water for few minutes. Remove contact lenses if present and continue rinsing eyes. If irritation persists, call a doctor.
・If on skin: Rinse immediately with running water or shower.
・If on clothes: Immediately take off all contaminated clothing and remove product. Wash clothing if reusing.
・If swallowed: Rinse mouth. Do not force vomiting. Consult a doctor if feeling nauseous.
・If inhaled: Move person to a fresh air environment and rest in an easy to breathe position.

[Storage]
・Make sure the container is sealed and kept in a ventilated area.


*The product label contains our selling agent company and our company’s name. Image is the version of Kyowa Inc.

Components of the non-combustible FRP (next-generation FRP)

Details coming soon!

 

Nature and characteristics of the non-combustible FRP (next-generation FRP)

Details such as tensile strength, tensile elasticity, density.
Coming soon!

 

Sales of non-combustible FRP (next-generation FRP)

Our company does not directly sell the next-generation FRP, but they are available through our distributing agencies. Once we are ready, we will provide information about the distributors according to the individual industry.