Welcome to Team One Composites

The company was founded by a team of multinational experienced professionals in the world of composites. The group having expertise in the areas, Mechanical Design, Civil Design, Analysis, Material selection, Process, Project management, commissioning etc., with the intension of serving the needs of Production units and End user customers. The company provides high quality Engineering and design solutions to all types of Composite needs.

The group has extensive experience in composite solutions from major industrial sectors like Railway, Wind energy, renewable energy, defense, Aerospace, chemical processing, oil and gas, water and waste water management, construction, infrastructure, electrical and electronics, marine, telecommunications, navel and more.

Each area of composite solution needs is attended with specific experts dedicated to customer oriented approach and serving with best quality services to customers.

About Composites

A composite material (also called a composition material or shortened to composite) is a material made from two or more constituent materials with significantly different physical or chemical properties that, when combined, produce a material with characteristics different from the individual components.


COMPOSITES

Manufacturers, designers and engineers recognize the ability of composite materials to produce high quality, durable, cost-effective products. Composites solve problems, raise performance levels and enable the development of new innovations.

Composites, also known as Fiber-Reinforced Polymer (FRP) composites, are made from a polymer matrix that is reinforced with an engineered, man-made or natural fiber (like glass, carbon or aramid) or other reinforcing material. The matrix protects the fibers from environmental and external damage and transfers the load between the fibers. The fibers, in turn, provide strength and stiffness to reinforce the matrix—and help it resist cracks and fractures.

Consumer Composites

The composites industry has been producing consumer goods since the 1950s. Typically, consumer composites include products (that require a cosmetic finish) like boats, recreational vehicles, bathroom fixtures and sporting goods. In many cases, the cosmetic finish is an in-mold coating. Consumer products make up a significant portion of the composites market.

Industrial Composites

Composites are used in industrial applications where corrosion resistance and performance (in adverse environments) are critical. Generally, premium resins such as isophthalic or vinyl ester are required to meet corrosion-resistance specifications. Other specialty resins may be used depending on the chemical resistance properties required. Fiberglass is almost always used as the reinforcing fiber. In this segment of the industry, performance trumps cosmetic finishes. Industrial composite products include underground storage tanks, scrubbers, piping, fume hoods, water treatment components, and pressure vessels.

Advanced Composites

This sector of the composites industry is characterized by the use of high-performance resin systems and high-strength, ultra-stiff fiber reinforcement. The aerospace industry, including military and commercial aircraft, is the major customer for advanced composites. Stealth aircraft and Unmanned Aerial Vehicles (drones) take advantage of composites’ radar transparency. Advanced composites are also used for blast and ballistic protection. Additionally, they have been adapted to use in sports equipment to make it lighter and stronger. A number of exotic resins and fibers are used in advanced composites, but epoxy resin and aramid or carbon fibers are most common.

Natural and synthetic composites

Composites can be natural or synthetic. Wood, a natural composite, is a combination of cellulose or wood fibers and a substance called lignin. The fibers give wood its strength; lignin is the matrix or natural glue that binds and stabilizes them. Other composites are synthetic (man-made).

Plywood is a man-made composite that combines natural and synthetic materials. Thin layers of wood veneer are bonded together with adhesive to form flat sheets of laminated wood that are stronger than natural wood.

Are plastics composites?

Not all plastics are composites. In fact, most plastics—the ones used in toys, water bottles and other familiar items—are not composites. They’re pure plastics. But many types of plastic can be reinforced to make them stronger. This combination of plastic and reinforcement can produce some of the strongest, most versatile materials (for their weight) ever developed by technology.

Polymer resins (such as polyester, vinyl ester, epoxy or phenolic) are sometimes referred to as plastic.

By any other name

Many terms are used to define FRP composites. Modifiers have been used to identify a specific fiber such as Glass Fiber Reinforced Polymer (GFRP), Carbon Fiber Reinforced Polymer (CFRP), and Aramid Fiber Reinforced Polymer (AFRP). Another familiar term used is Fiber Reinforced Plastics. In addition, other acronyms have been developed over the years and their use depended on geographical location or market use. For example, Fiber Reinforced Composites (FRC), Glass Reinforced Plastics (GRP), and Polymer Matrix Composites (PMC) can be found in many references. Each of the aforementioned terms means the same thing: FRP composites.

COMPOSITE MATERIALS

Composites are composed of fiber reinforcements and a resin matrix that bonds the fibers. They can also include core materials, fillers, additives and surface finishes to provide unique performance attributes.


Resins

The primary functions of the resin are to transfer stress between the reinforcing fibers, act as a glue to hold the fibers together, and protect the fibers from mechanical and environmental damage. Resins used in reinforced polymer composites are either thermoplastic or thermoset.

Reinforcements

The mechanical properties of FRP composites are dependent on the type, amount, and orientation of fiber that is selected for a particular service. Fiber reinforcements carry load along the length of the fiber to provide strength and stiffness in one direction.

Additives & Fillers

Additives are used in composites to modify materials’ properties and tailor the laminate’s performance. When added to the resin, fillers can improve properties including water resistance, weathering, surface smoothness, stiffness, dimensional stability and temperature resistance.


Core

Core materials are used extensively throughout the composites industry to fabricate stiff and yet lightweight composites products. Core material is “sandwiched” between fiber reinforced laminate skins to significantly increase stiffness and flexural strength while reducing warpage of flat surfaces.

Surface Finishes

Surface finishes are mainly used for UV protection, corrosion resistance and aesthetics. They can be molded in process or secondarily applied coatings and support the long term appearance of composite products.

COMPOSITE ADVANTAGES

Composites have permeated our everyday lives: They are used in the cars we drive, golf clubs we swing, pipes that remove wastewater from our neighborhoods and much more. Some applications, such as rocket ships, probably wouldn’t get off the ground without composite materials. Composites offer many benefits.


CORROSION RESISTANT

FRP Products are known for their ability to provide corrosion resistance in the harshest environments and chemical exposures.Will not rust like metal or rot like wood. Resistant to a broad range of chemicals including fresh water and salt water.

Corrosion resistance is determined by the choice of resin and reinforcement used within the composite application. There are various resin systems available which provide long-term resistance to nearly every chemical and temperature environment. The choice of reinforcements is much more limited but crucial for certain chemical environments. Properly designed composites have a long service life and minimum maintenance.

One of the primary functions of resins in composites is to protect the fibers they surround. There are dozens of resins designed to provide corrosion resistance. Each unique formulation offers protection against specific conditions, such as caustic solutions, acidic environments, alkaline environments, oxidizing chemicals and high temperatures.

The first corrosion resins employed bisphenol fumurate and chlorendic anhydride resin chemistries. Subsequently, isophthalic resins were developed and became the mainstay of corrosion-resistant resins. Isophthalic resins – along with epoxy vinyl ester resins – are commonly used today.



FIRE RETARDANT

Most FRP products are engineered to have a flame spread of 25 or less as tested in accordance with ASTM E-84. They also meet the self-extinguishing requirements of ASTM D-635.



LOW MAINTENANCE

Tough, durable and impact resistant. Will not dent and deform like metal. Resists rot and corrosion eliminating the need for constant maintenance. Provides long term, cost effective solutions in many applications. TOC FRP Products reduce or eliminate the need for sandblasting,scraping and painting.



SLIP RESISTANT

TOC FRP grating and stairway products provide superior, slip resistant footing in wet and oily environments. Steel becomes slippery when oily or wet, but TOC FRP gratings have a higher friction factor and remain safe even when wet. TOC’s slip resistant products increase safety for workers which will lead to fewer workplace accidents and a reduction of injury-associated costs.



LIGHT WEIGHT

Pultruded fiberglass shapes generally weigh 75-80% less than similar steel shapes and 30% less than similar aluminum shapes.The lightweight properties of FRP result in products that weigh considerably less than steel. The density of steel is 4 times higher than that of FRP, and steel gratings are 2 to 2-1/2 times heavier that FRP gratings. This allows for easy removal for access below floor level. The reduction in weight that TOC FRP products provide can save on material transit costs and installation costs.



LOW INSTALLATION COST

TOC FRP products can be easily and quickly cut with ordinary hand tools. Welding or hot work is not necessary with FRP. FRP products are lightweight and can be installed easily with bolts and clips. Installation of material can be done without using heavy equipment and machinery and requires less manpower. Can be field fabricated using simple carpenter's tools and easily installed with less equipment than most traditional installations.



HIGH STRENGTH: WEIGHT RATIO

FRP products has a high strength-to-weight ratio when compared to traditional materials like metal, concrete and wood. FRP products are strong enough to carry vehicular loads while still being less than one-half the weight of steel products.



ELECTRICALLY AND THERMALLY NON-CONDUCTIVE

Fiberglass is electrically non-conductive leading to increased safety compared to conductive materials (i.e. metal). FRP also has low thermal conductivity (heat transfer occurs at a lower rate) resulting in a more comfortable product surface when physical contact occurs. Low electrical and thermal conductivity properties and high dielectric capability.



LONG SERVICE LIFE

TOC products provide outstanding durability and corrosion resistance in demanding applications providing improved product life over traditional materials. The longevity of TOC products provide cost savings over the product’s life cycle. Installed costs are less because of the ease of installation. Maintenance expenses are reduced because downtime in work areas requiring maintenance is not necessary.



IMPACT RESISTANT

FRP Gratings can withstand major impacts with negligible damage. TOC offers extremely durable gratings to satisfy even the most stringent impact requirements.

COMPOSITES COMPARED

Composites are gaining traction in lots of industries, from architecture to infrastructure and automotive. They offer clear advantages that make them an ideal replacement for a variety of materials, including steel, aluminum, wood. Composites are fast becoming the material of choice.

COMPOSITES COMPARISON

COMPOSITES VS. STEEL

Composites offer several advantages over steel, which has intrinsic design limitations, is heavy and costly to transport and is susceptible to corrosion, which leads to high maintenance costs.

The advantages are clear cut. That’s why companies are making the steel-to-composites conversion for everything from manhole covers to valve covers. Now that you know the benefits, take a closer look at specific applications within architecture, automotive, infrastructure and other markets.

Consider these attributes:
  • Composites are lighter than steel – A cubic foot of cast steel weighs approximately 490 pounds. Depending on the material formulation, composites can be up to 70 percent lighter.
  • Composites are incredibly strong – They can be custom-tailored to add strength in critical areas, such as spots that may bend or wear out. With steel, if greater strength is needed in any area then more metal must be added, which in turn increases weight.
  • Composites are corrosion resistant – In outdoor applications, composites stand up to severe weather and wide temperature changes. Steel rusts easily unless it is painted or coated with zinc. And corrosion is expensive, with annual direct costs hitting $2.2 trillion.
  • Composites are nonconductive – By their very nature, metals like steel conduct electricity. Composites are superior insulators: They don’t respond to an electric field and resist the flow of an electric charge.
  • Composites allow for parts consolidation – A single piece made of composites can replace an entire assembly of metal parts, streamlining the production process and reducing lifetime maintenance.

COMPOSITES VS. ALUMINUM

By using composites to manufacture 50% of the Boeing 787’s airframe, the aerospace leader knocked 20% of the weight off the aircraft compared to conventional aluminum designs.

The benefits of composites are easy to see, but if you’re curious about what makes them so strong, light and flexible then delve into the materials behind these mighty products – resins, reinforcements, fillers/additives and core materials.

Composites offer other advantages over aluminum, too:​
  • Composites are excellent at handling tension – In highly tension-loaded applications, such as the fuselage of airplanes; this helps decrease fatigue and maintenance. Aluminum is sensitive to tension loads.
  • Composites can create one-piece designs – Fabricating a product in one piece, whether it’s an airplane wing or a wind blade, reduces maintenance because there aren’t any fasteners or joints.
  • Composites allow for precise weight distribution – In an application such as baseball bats, this allows for either balanced loading that contributes to an effortless, fast swing or end loading, which helps power hitters gain more distance. Aluminum alloy bats have less precise weight distribution.
  • Composites are strong, yet flexible – Composites ski poles, for instance, usually offer more flexibility and durability than standard aluminum ones: They can bend significantly without snapping.
  • Composites absorb vibrations – Because they are non-elastic, composites dissipate the energy of vibrations, making them well-suited for applications ranging from equipment mounts to athletic shoe insoles. Aluminum doesn’t absorb vibrations as well as composites.

COMPOSITES VS. WOOD

Wood has a long history of use, from tools in the Stone Age to carts in the Middle Ages and modern-day furniture. It remains a primary material today in applications ranging from wood-frame houses to utility poles.

But wood has distinct disadvantages, including susceptibility to pests, moisture and warping.
  • Wood is actually a natural composite – a combination of cellulose fiber and lignin. Some composite applications, including fishing poles and golf club shafts, copy the natural design of woods such as bamboo. But manmade composites have clear-cut advantages over wood.
  • Composites are long lasting – Wood eventually rots, but composites are durable. Think about the marine industry: Wooden boats require considerable care to last an owner’s lifetime, while many composite boats remain afloat for 50-plus years with routine maintenance.​
  • Composites are dimensionally stable – They retain their shape and size when they are hot or cool, wet or dry. Wood, on the other hand, swells and shrinks as the humidity changes.
  • Composites are low maintenance – In an application such as a residential deck, this is critical. Composite decks can be cleaned with soap and water, while wood decks need to be regularly power washed, inspected for rot, sanded and stained.
  • Composites are easy to transport and install – Because they are lightweight, composites are an ideal replacement for wood in applications such as utility poles: They cost less to transport and are simpler to install in remote locations than their wooden counterparts.
  • Composites are resistant to pests – Termites, carpenter ants, beetles and other pests eat away at wood, causing extensive damage. Composites are pest-free, making them ideal for everything from window frames to retaining walls.