The emergence of new technologies and markets warrants a reappraisal of the reinforced plastics market, often called “composites.” Nanocomposites and long-fiber reinforced thermoplastics are the two most prominent and potentially commercially important examples that have begun to impact this market.
 
In addition, a review of reinforced plastics is needed with a view towards appropriately segmenting the major components of this market into its resin, technology, and applications components. Fillers and reinforcements need to be carefully defined when it comes to their principal functions and effects on properties of substrate resins since many terms and market estimates used within this industry are not clear cut.
 
Another important reason for undertaking this report is to assess the current and future scenario of this market in terms of the current financial recession, which has had an enormous impact on two of the largest applications of reinforced plastics, namely construction and automotive.
 
This report covers usage of both thermosets and thermoplastics that use fillers and reinforcements to increase their respective property profiles. Fillers will be differentiated from reinforcements, which in turn, will include both fibrous and non-fibrous variants.
 
The term “fillers/reinforcements” will be used when generally referring to these materials as in most literature references, mainly because many nontechnical sources often do not distinguish fillers from reinforcements. For the purposes of this report, the following are defined as fillers and not reinforcements: aluminum trihydrate (ATH), barium sulfate, calcium carbonate, and kaolins. Talcs, mica, silicas, and wollastonite are treated as non-fibrous reinforcements. Fibrous reinforcements will include all glass fiber variants, carbon, boron, ceramic, aramid, and stainless steel fibers, and so forth. The major exception will be nanocomposites, which are based on fillers and will be included in the study. There have been quite a few lengthy reports based solely on composites.
 
A basic premise in distinguishing between a “filler” and a “reinforcement” is whether the primary function of the material is used to enhance property profiles of substrate resins. If the answer is “yes,” then it can be considered a “reinforcement.” This definition is, of course, arbitrary, especially since in many cases mineral “fillers” are used in conjunction with fibrous materials, most notably glass.
 
Another source of confusion is the constant overlapping of the terms “reinforced plastics” and “composites.” One distinction between these two terms, cited by some within the industry, is that the latter refers to those reinforced resins that can “support a load” or are “structurally reinforced.” This definition is also arbitrary.
 
Therefore, in this report, the terms “reinforced plastics” and “composites” will be used interchangeably unless specifically designated by suppliers or in the trade literature as one or the other. In other instances, the term “reinforced plastics/composites” will be used.
 
Current and forecasted quantitative market estimates will be provided for all appropriate thermoset and thermoplastic fiber-reinforced resins by application, along with detailed descriptions of the major types of reinforcements. Fillers will be discussed in detail as well, but will not be considered in the quantitative analysis of reinforced plastics/composites. It should also be pointed out that many compounded resin formulations contain both fillers and reinforcements and many glass fiber reinforced resins contain other fibrous and non-fibrous minerals.
 
Furthermore, the volumes of product shown in the tables refer only to the estimated weight of the resins and exclude weights of reinforcements. The quantitative information contained in all data tables refers to the North American market, although there will be a great deal of information provided for the global market.
 
Applications covered will include: automotive; construction/infrastructure including anti-corrosion and panel products; marine markets; aerospace; electronic parts/components; appliances; consumer products (sport and leisure, lawn/garden products, etc.); and a miscellaneous category including the power market, wind energy products, medical, and others.

Highlights of the Report

•The North American fiber-reinforced plastic/composite market is estimated at 2.7 billion pounds in 2010 and is expected to increase to about 3.1 billion by 2015, reflecting a 2.8% compound annual growth rate (CAGR).

•Construction/infrastructure and automotive products are the key applications of this market since they comprise about 60% of total volume. This sector is valued at 836 million pounds in 2010 and is expected to reach 963 million pounds in 2015, a 2.9% compound annual growth rate (CAGR). 

•The largest growth will be experienced by the very low volume aerospace market led by the introduction of composite commercial aircraft exterior parts such as fuselages and wings. This sector is estimated at 20 million pounds in 2010 and should increase at a 7% compound annual growth rate (CAGR) to reach 28 million pounds in 2015.

TABLE OF CONTENTS

CHAPTER ONE: INTRODUCTION
REASONS FOR DOING THE STUDY  1
SCOPE OF THE STUDY  1
METHODOLOGY . 2
ABOUT THE AUTHOR  3
RELATED BCC REPORTS  3
BCC ONLINE SERVICES  3
DISCLAIMER . 3

CHAPTER TWO: SUMMARY
SUMMARY TABLE NORTH AMERICAN FIBER REINFORCED
PLASTIC MARKET BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) . 4
SUMMARY FIGURE NORTH AMERICAN FIBER REINFORCED
PLASTIC MARKET BY APPLICATION, 2009-2015 (MILLION
POUNDS) . 5
SUMMARY (CONTINUED) . 6

CHAPTER THREE: FILLERS AND REINFORCEMENTS
BACKGROUND  7
PROPERTY PROFILES . 7
CHARACTERISTICS OF FILLERS/REINFORCEMENTS 8
TABLE 1 PROFILE OF CHARACTERISTICS OF
FILLERS/REINFORCEMENTS  8
TABLE 2 OVERVIEW OF CHARACTERISTICS AND APPLICATIONS
OF FILLERS/REINFORCEMENTS  9
FILLER/REINFORCEMENT USAGE WITH SPECIFIC RESINS  10
TABLE 3 FILLER/REINFRORCEMENT USAGE WITH SPECIFIC
RESINS  10
FILLERS . 11
OVERVIEW  11
ALUMINA TRIHYDRATE (ATH) . 11
Background  11
Properties . 11
Grades  12
A Recent Development  12
BARIUM SULFATE . 12
CALCIUM CARBONATE  12
Background  12
Grades  13
As Plastic Fillers  13
Automotive Applications . 13
CALCIUM SULFATE  13
Background  13
Applications . 14
KAOLINS  14
Background  14
Grades  14
Automotive Applications . 15
REINFORCEMENTS . 15
OVERVIEW  15
NON-FIBROUS  16
Talcs . 16
Background . 16
Grades . 16
Applications . 17
Mica  17
Background . 17
Properties  17
Applications . 18
Thermosets . 18
Thermoplastics . 18
Wollastonite . 18
Background . 18
Applications . 19
Silicas . 20
FIBROUS  20
Background  20
Reinforcement Types . 20
Overview  20
Mats . 20
Woven Fabrics . 21
Knitted Fabrics . 21
Braids  21
Preforms  21
Glass-Fiber Reinforcements  21
Production . 21
Types of Fiberglass . 22
Background . 22
Types of Glass Fibers  22
Sizing . 23
Microspheres . 23
Background. 23
Solid Microspheres . 23
Hollow Microspheres . 23
TABLE 4 ADVANTAGES OF SOLID GLASS MICROSPHERES . 24
Applications . 24
New Development . 24
Glass Fiber Suppliers . 24
TABLE 5 GLASS FIBER SUPPLIERS  25
Carbon Fibers  25
Background . 25
Manufacture  26
Product Types . 26
Applications . 27
Largest Users of Carbon Fiber Reinforced Plastics  27
The Military  27
Commercial Aircraft  28
Producers . 28
Recent Developments 28
Usage in Non-Sports Cars . 28
BMG Developments . 28
Metallized Carbon Fibers . 29
End-of-Life Recycling  29
Aramid Fibers  29
Background . 29
Production . 30
Properties  30
Usage . 30
Ceramic Fibers . 30
Background . 30
Applications . 31
Suppliers . 31
Boron Fibers  31
Stainless Steel Fibers  32
Natural Fibers . 32
Background . 32
Background (Continued) . 33
Types of Natural Fibers  34
Overview . 34
Flax Fibers  34
Jute Fibers  34
Kenaf Fibers . 34
Hemp Fibers . 35
Global Cultivation of Selected Natural Fibers  35
TABLE 6 GLOBAL PRODUCTION OF SELECTED NATURAL FIBERS . 35
Source: Trade literature . 35
Processing  35
Comparison with Glass Fibers . 36
Pricing . 37
Review of Possible Stumbling Blocks to Natural
Fiber Reinforcements  37
Suppliers of Natural Fibers  37
Composite Products . 37
Flexform Technologies . 37
Quadrant Plastic Composites . 38
Automotive Applications  38
Overview . 38
Recent Developments  39
Other Potential Applications  39
New Advances . 39
Sabic IP . 39
In-Line Compounding and Molding of
Biocomposites . 39
Use of Sunflower Hull Fibers  40
Bamboo Fiber Reinforcement Usage  40
RheTech Introduces Biocomposite 40
Market Estimates and Forecasts . 40
NANOCOMPOSITES . 41
BACKGROUND . 41
CHARACTERISTICS . 42
BENEFITS  42
MECHANICAL ASPECTS . 42
PROCESSES  43
EARLY WORK WITH PLASTICS . 43
APPLICATIONS . 43
CARBON NANOTUBES  44
NANOCOMPOSITE SUPPLIERS . 45
TABLE 7 SELECTED NANOCOMPOSITE SUPPLIERS  46
RECENT NANOCOMPOSITE CONFERENCE . 46

CHAPTER FOUR: REINFORCED PLASTICS 
BACKGROUND  47
THERMOSETS . 48
OVERVIEW  48
TABLE 8 SELECTED PROPERTIES AND MANUFACTURING
PROCESSES OF REINFORCED THERMOSETS  48
PROCESSING  49
Background  49
Hand Lay-Up . 49
Spray-Up  49
Pultrusion  49
Filament Winding  50
Reinforced Reaction Molding (RRIM) . 50
SHEET MOLDING COMPOUNDS (SMC) . 51
Background  51
Advantages  51
SMC Process Choices . 51
SMC Formulations  52
TABLE 9 TYPICAL SMC FORMULATION (WEIGHT PERCENT)  52
Technology . 52
Advantages  53
SMC Compounders  53
TABLE 10 SELECTED KEY SMC PRODUCERS  53
Markets  54
Other Process Challenges . 54
Use of Nanoparticles . 54
Applications . 54
TABLE 11 SPECIFIC SMC AUTOMOTIVE EXTERIOR APPLICATIONS  54
New Developments  55
SMC Products for Mass Transit . 55
Other IDI SMCs  55
Direct Process for Mixing and Molding SMC  55
A New SMC Center . 55
BULK MOLDING COMPOUNDS (BMC) . 55
Overview  55
Background  56
Technology . 56
Advantages  56
Applications . 57
BMC Compounders  57
New Developments  57
Bulk Molding Compounds, Inc.  57
New Starfire Products  58
THERMOPLASTICS  58
BACKGROUND . 58
REINFORCEMENT DETAILS  59
COMMODITY THERMOPLASTICS . 59
Background  59
Polypropylene  59
Background . 59
Upgraded Polypropylene  60
Polypropylene Producers  60
TABLE 12 U.S. MARKET SHARES OF LEADING GLOBAL
POLYPROPYLENE PRODUCERS . 61
Fiber-Reinforced Polypropylene Products . 61
TABLE 13 KEY FIBER-REINFORCED POLYPROPYLENE PRODUCTS . 61
Examples of Reinforced Polypropylene Product
Lines . 62
New Products and Developments . 62
Ticona  62
Use of Banana/Glass Fibers  63
Bamboo Fiber Reinforced Polypropylene . 63
Use of Wheat Straw Fibers with
Polypropylene . 63
RTP New Long-Glass Polypropylene for Automotive
Products . 63
Quadrant’s GMT  63
Ferro’s New Products. 64
PolyOne’s New Reinforced Polypropylenes  64
Asahi Plastics Short Glass Polypropylene . 64
Lower Density Reinforced Polypropylenes
from Borealis . 64
Sabic Europe Adds Stamax Products . 64
Polyethylenes . 65
Background . 65
Need for Additives  65
Polyethylene Producers  65
TABLE 14 SELECTED MAJOR GLOBAL HDPE PRODUCERS AND
CAPACITIES  66
High Density Polyethylene (HDPE) . 66
Reinforced Polyethylenes  67
Some Details on Commercial Reinforced HDPEs  67
Spartech  67
Ticona’s Celstran Additions  67
Flax-Fiber Reinforced Polyethylenes . 68
Cellulose Fiber HDPE Composites . 68
Polyvinyl Chloride . 68
Overview  68
Forms of PVC  68
Processing  69
Background. 69
Extrusion  69
Calendering  69
Consumption Patterns  69
Producers . 69
Reinforced PVC . 70
Market Estimates and Forecasts . 70
TABLE 15 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
COMMODITY THERMOPLASTICS, THROUGH 2015 (MILLION
POUNDS) . 70
TABLE 16 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
POLYETHYLENE BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) . 71
TABLE 17 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
POLYPROPYLENE BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) . 71
TABLE 18 NORTH AMERICAN AUTOMOTIVE MARKET FOR FIBERREINFORCED
POLYPROPYLENE, THROUGH 2015 (MILLION
POUNDS) . 72
POLYSTYRENE . 72
General Purpose Polystyrene  72
High Impact Polystyrene (HIPS)  72
Background . 72
Properties  73
Applications . 73
Styrenic Polymer Producers  73
The New Domestic Styrenic Scenario . 74
Processing  75
Overview  75
TABLE 19 FABRICATION METHODS AND USES FOR
POLYSTYRENE  75
Injection Molding . 75
Extrusion  75
Reinforced Polystyrene Products  76
Market Estimates and Forecasts  76
TABLE 20 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
POLYSTYRENE MARKET BY APPLICATION, THROUGH 2015
(MILLION POUNDS)  76
ACRYLONITRILE-BUTADIENE-STYRENE (ABS)  77
Background  77
Properties . 77
Processing  77
Grades  78
Producers . 78
Overview  78
Capacities  78
TABLE 21 ESTIMATES OF SELECTED ABS PRODUCERS AND
CAPACITIES (MILLIION POUNDS) . 78
Applications . 79
Reinforced ABS Products  79
Examples of Reinforced ABS Products . 79
Market Estimates and Forecasts  80
TABLE 22 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
ABS BY APPLICATION, (MILLION POUNDS)  80
STYRENE MALEIC ANHYDRIDE (SMA) . 80
Background  80
Fiber-Reinforced SMA . 81
Market Estimates and Forecasts  81
TABLE 23 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
SMA BY APPLICATION, THROUGH 2015 (MILLION POUNDS) . 82
ENGINEERING THERMOPLASTICS (ETPS)  82
Background  82
Nylon  82
Background . 82
Properties  83
Major Types . 83
Nylon 66  83
Nylon 6  83
Producers and Capacities . 84
TABLE 24 NYLON PRODUCERS AND CAPACITIES (MILLION
POUNDS PER YEAR) . 84
Fiber-Reinforced Nylons . 84
Examples of Commercial Reinforced Nylons . 85
TABLE 25 SELECTED EXAMPLES OF COMMERCIALLY
IMPORTANT FIBER REINFORCED NYLONS . 85
New Developments . 85
Filament Wound Nylon . 85
Lanxess New Product  86
BASF Enters Long-Glass Fiber Reinforced
Nylon Market  86
Cold Weather Reinforced Nylon . 86
Ube Industries’ New Reinforced Nylons  86
Reinforced Nylon Cell Phone Housings . 86
Market Estimates and Forecasts . 86
TABLE 26 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
NYLON BY APPLICATION, THROUGH 2015 (MILLION POUNDS) . 87
TABLE 27 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
NYLON IN THE AUTOMOTIVE MARKET, THROUGH 2015
(MILLION POUNDS)  87
Polybutylene Terephthalate (PBT) . 87
Background . 87
Properties  88
Applications . 88
Producers . 89
TABLE 28 GLOBAL PBT PRODUCERS AND CAPACITIES (MILLION
POUNDS) . 89
Fiber-Reinforced PBT Products  89
TABLE 29 EXAMPLES OF REINFORCED PBT PRODUCTS . 90
Polyethylene Terephthalate (PET) . 90
Overview  90
Engineering-Grade PET  91
Producers and Capacities . 91
Reinforced PET . 91
Examples of Reinforced PET Products  92
TABLE 30 REINFORCED PET PRODUCTS  92
Market Estimates and Forecasts . 93
TABLE 31 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
THERMOPLASTIC POLYESTER BY APPLICATION, THROUGH
2015 (MILLION POUNDS)  93
TABLE 32 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
THERMOPLASTIC POLYESTER IN THE AUTOMOTIVE MARKET,
THROUGH 2015 (MILLION POUNDS)  93
Polycarbonates . 94
Background . 94
General Grades . 94
Impact of Bisphenol A on Polycarbonate Usage  94
Processing  94
Properties  95
Producers and Capacities . 95
TABLE 33 NORTH AMERICAN POLYCARBONATE PRODUCERS AND
CAPACITIES (MILLION POUNDS/YEAR) . 96
Fiber-Reinforced Polycarbonates . 96
TABLE 34 SELECTED EXAMPLES OF COMMERICALLY
IMPORTANT REINFORCED POLYCARBONATES  96
Source: Trade literature . 96
A New Development . 96
Market Estimates and Forecasts . 97
TABLE 35 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
POLYCARBONATE BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) . 97
Polyacetals . 97
Background . 97
Grades  98
Properties  98
Processing  99
Producers . 99
Examples of Polyacetal Reinforced Products . 99
A New Development . 100
Market Estimates and Forecasts . 100
Polyphenylene Sulfides (PPS) . 100
Background . 100
Properties  100
Advantages and Disadvantages . 101
Producers . 101
Applications . 101
PPS Fiber-Reinforced Products  102
TABLE 36 SELECTED REINFORCED POLYPHENYLENE SULFIDE
PRODUCTS AND SUPPLIERS  102
Source: Trade literature . 102
New Developments . 102
Ticona’s New Fortron Reinforced Grades  102
Celanese Expands Production  102
Market Estimates and Forecasts . 103
TABLE 37 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
POLYPHENYLENE SULFIDE, BY APPLICATION, THROUGH 2015
(MILLION POUNDS)  103
Polyimides/PEI/PAI . 103
Background . 103
Properties  103
Polyetherimides (PEIs) . 104
Polyamideimides (PAIs)  104
New Products  104
PAI Grades Show Wear-Resistant Properties . 104
Overall Polyimide Fiber-Reinforced Products . 105
Market Estimates and Forecasts . 105
TABLE 38 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
POLYIMIDE, BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) . 105
Liquid Crystal Polymers (LCPs) . 105
Background . 105
Properties  105
Applications . 106
LCP Fiber-Reinforced Products  106
A New Development . 106
Market Estimates and Forecasts . 107
Polysulfones . 107
Background . 107
Types of Polysulfones  107
Grades . 108
Properties  108
Applications . 108
Producer Scenario . 109
Recent Developments 109
BASF . 109
Solvay  109
Sumitomo Chemical . 110
Polysulfone Fiber-Reinforced Products  110
Market Estimates and Forecasts . 110
Polymer Alloys/Blends . 110
Background . 110
PC/ABS  111
Background. 111
Grades and Properties . 111
Applications  111
Reinforced Grades  112
New Developments  112
PPO/HIPS  112
Background. 112
Grades . 112
Applications  113
PPO/Nylon . 113
Background and Properties . 113
Grades and Applications . 114
PC/PBT  114
Background. 114
Properties 114
Applications  115
PC/PET  115
Fiber-Reinforced Polymer Alloy/Blend Grades . 115
Market Estimates and Forecasts . 116
TABLE 39 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
POLYMER ALLOYS/BLENDS, BY APPLICATION, THROUGH 2015
(MILLION POUNDS)  116
Other Engineering Thermoplastics  116
Styrene-Acrylonitrile (SAN) . 116
Background. 116
Producers  117
Fiber-Reinforced SAN Products  117
Polyketones . 118
Background. 118
Properties  118
Applications  118
Polyketone Composites  119
New Products . 119
Vertec Polymers  119
Fiber-Reinforced PEEK Sheet Products . 119
RTP Advances . 119
Market Estimates and Forecasts . 119
TABLE 40 NORTH AMERICAN MARKET FOR MISCELLANEOUS
FIBER-REINFORCED THERMOPLASTICS, BY APPLICATION,
THROUGH 2015 (MILLION POUNDS)  120
MARKET SUMMARY FOR FIBER-REINFORCED
THERMOPLASTICS  120
TABLE 41 NORTH AMERICAN MARKET FOR TOTAL FIBERREINFORCED
THERMOPLASTIC, THROUGH 2015 (MILLION
POUNDS) . 121

CHAPTER FIVE: OTHER IMPORTANT GROUPINGS OF REINFORCED PLASTICS 
OVERVIEW . 122
GLASS MAT THERMOPLASTICS (GMTS)  122
OVERVIEW  122
BACKGROUND . 122
TECHNOLOGY  123
SUPPLIER SCENARIO . 123
APPLICATIONS . 123
LONG-FIBER REINFORCED THERMOPLASTICS (LFRTS)  124
BACKGROUND . 124
OVERVIEW  124
PROPERTIES . 124
TECHNOLOGY  125
TWINTEX PRODUCTS . 125
ADVANTAGES OF LFRTS  126
LIMITATIONS . 126
RESIN MATRICES  126
SUPPLIERS . 127
StaMax . 127
Ticona Developments  127
APPLICATIONS . 128
OTHER NEWS . 128
Celanese Buys a LFRT Producer  128
EXAMPLES OF COMPANY PRODUCTS  128
RTP . 128
Ticona’s Celstran . 128
A Key Borealis LFRT . 129
LNP LFTPs  129
PolyOne Corporation . 129
LFRTs for Thermoforming  129
BASF Becomes a Nylon LFRT Supplier . 130
DEMAND  130
TABLE 42 GLOBAL LFTP DEMAND (AS PERCENT OF TOTAL) . 130
MARKET ESTIMATES AND FORECASTS . 130
THERMOSET RESINS  131
OVERVIEW  131
FIBER-REINFORCED GRADES  131
GENERAL PROPERTIES . 132
TABLE 43 FIBER-REINFORCED THERMOSET PROPERTIES AND
MANUFACTURING PROCESSES  132
UNSATURATED POLYESTERS  132
Background  132
Ingredients of Unsaturated Polyester Formulations . 133
TABLE 44 INGREDIENTS OF UNSATURATED POLYESTER RESIN
FORMULATIONS IN DESCENDING ORDER OF COMMERCIAL
USE . 133
Types of Unsaturated Polyesters  133
Applications . 134
Overview  134
Construction/Infrastructure . 134
Bathroom Products . 134
Corrosion-Resistant Products . 134
Marine Products  135
Transportation  135
Other Applications  135
Non-Reinforced Unsaturated Polyesters  135
Examples of Commercial Reinforced Unsaturated
Polyesters 135
TABLE 45 KEY COMMERCIAL REINFORCED UNSATURATED
POLYESTERS . 136
New Developments  136
Soybean Unsaturated Polyesters . 136
Biobased Unsaturated Polyesters  136
Market Estimates and Forecasts  136
TABLE 46 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
UNSATURATED POLYESTERS BY APPLICATION, THROUGH 2015
(MILLION POUNDS)  137
TABLE 47 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
UNSATURATED POLYESTER IN THE CONSTRUCTION MARKET,
THROUGH 2015 (MILLION POUNDS)  137
TABLE 48 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
UNSATURATED POLYESTER AUTOMOTIVE MARKET, THROUGH
2015 (MILLION POUNDS)  138
VINYL ESTERS . 138
Background  138
Technologies . 138
Properties . 139
Characteristics . 139
Applications . 139
Differences between Unsaturated Polyesters and Vinyl
Esters  140
Commercially Important Reinforced Vinyl Esters . 140
TABLE 49 KEY COMMERCIAL REINFORCED VINYL ESTERS . 140
New Developments/Products  141
Market Estimates and Forecasts  141
TABLE 50 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
VINYL ESTERS, BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) . 141
EPOXY RESINS . 141
Background  141
Chemistry . 142
Chemical Epoxy Types  142
Technology . 143
Epoxy Systems . 143
Background . 143
Non-Molded . 143
Laminating Systems . 143
Molded Epoxies . 144
Advanced Epoxy Composites  144
Other Applications . 144
Fiber-Reinforced Epoxy Grades  145
New Developments/Products  145
High-Heat Epoxies  145
Wind Blade Epoxies  145
Market Estimates and Forecasts  145
TABLE 51 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
EPOXIES BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) . 146
PHENOLICS  146
Background  146
Technology . 146
Grades  147
Molding Compounds  147
Applications . 148
Fiber-Reinforced Phenolic Grades  148
TABLE 52 KEY COMMERCIAL FIBER-REINFORCED PHENOLIC
RESINS  148
Market Estimates and Forecasts  148
TABLE 53 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
PHENOLIC RESINS BY APPLICATIONS, THROUGH 2015
(MILLION POUNDS)  149
POLYURETHANES . 149
Background  149
Polyureas  149
RIM Products . 150
RRIM Products  150
SRIM Products . 150
Competing Products  151
Advantages  152
Fiber-Reinforced Polyurethane Products . 152
Recent Developments  152
Polyurethane Long Fiber Injection  152
Extended Use of Pultrusion  153
BASF Promoting Sprayed Polyurethane
Composites . 153
Polyurethane Composites via Filament Winding on
the Upswing . 153
Bayer Looking at Polyurethane Composites for
Large Turbine Blades  153
Bayer Promoting Polyurethane Composites for
Automotive Parts . 154
Reichhold Develops Polyurethane for Pultrusion  154
Market Estimates and Forecasts  154
TABLE 54 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
POLYURETHANES, BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) . 154
TABLE 55 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
POLYURETHANE IN THE AUTOMOTIVE MARKET, THROUGH
2015 (MILLION POUNDS)  155
MISCELLANEOUS FIBER-REINFORCED THERMOSETS  155
Diallyl Phthalate (DAP)  155
Background and Applications  155
Thermoplastic Elastomers (TPEs)  156
Overview  156
Cyanate Esters  156
Polybutadiene Resins  157
Market Estimates and Forecasts  157
TABLE 56 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
MISCELLANEOUS THERMOSETS BY APPLICATION, THROUGH
2015 (MILLION POUNDS)  157
MARKET SUMMARY OF FIBER-REINFORCED
THERMOSETS . 157
TABLE 57 MARKET SUMMARY OF FIBER-REINFORCED
THERMOSETS, THROUGH 2015 (MILLION POUNDS)  158

CHAPTER SIX: APPLICATIONS 
OVERVIEW . 159
AUTOMOTIVE  159
OVERVIEW  159
TABLE 58 HISTORICAL, CURRENT, AND PROJECTED U.S.
AUTOMOTIVE SALES, THROUGH 2015 (MILLION UNITS)  160
TABLE 59 ESTIMATED HYBRID AUTO SALES FOR THE U.S.,
THROUGH 2015 (THOUSAND UNITS)  160
CAFE ISSUES  160
RECENT EXAMPLES OF INCREASED USE OF
REINFORCED PLASTICS WITHIN THE AUTO INDUSTRY  161
Overview  161
Coolant Systems  161
Air-Intake Manifolds . 162
Rear-Seat Carrier  162
Plastic Radio Housings  162
Powertrain Parts . 162
Reinforced Plastic Tailgates  162
Underbody Heat Shield . 163
Truck Trailer Panels . 163
Seats Made from Reinforced Plastics . 163
Reinforced Plastic Air-Intake Manifold Systems . 163
Reinforced Nylon Cylinder-Head Covers  163
LyondellBasell Products  164
Example of Natural Fiber Composites for the Auto
Market  164
Carbon Fiber Reinforced Plastic Cars  164
What about Chinese Cars and Use of Reinforced Plastics? . 164
AUTOMOTIVE UNDER-THE-HOOD  164
Overview  164
Key Factors of UTH Resin Market . 165
TABLE 60 SELECTED AUTOMOTIVE UNDER-THE-HOOD FIBERREINFORCED
RESINS BY PART . 166
Recent Developments in Auto UTH Reinforced Plastic
Parts  166
DuPont’s New Zytel Nylon . 166
Potential Replacement of Steel in Fuel Systems . 167
Plastic Oil Pans . 167
Engine Valve Cover  167
Market Estimates and Forecasts  167
TABLE 61 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
PLASTIC AUTOMOTIVE UNDER-THE-HOOD MARKET BY RESIN,
THROUGH 2015 (MILLION POUNDS)  168
AUTOMOTIVE INTERIORS . 168
Background  168
Overview of Specific Fiber-Reinforced Plastic Auto
Interior Applications  169
Seat Structures  169
Background . 169
Front Seat Bases . 169
Front Seat Shells  169
Seat Backs . 169
Rear Seats . 170
Child Safety Seats . 170
Instrument Panel Structures (IPs) . 171
Overview  171
ABS  171
PC/ABS  171
Polycarbonates  171
Polypropylene  172
Polyurethanes . 172
PPO/HIPS  172
SMA . 173
Door Panels and Trim . 173
Consoles . 173
Overview  173
Resin Usage . 174
Flooring  174
Package Shelves/Trays  175
Headliners  175
Background . 175
Resin Usage . 175
Recent Developments in Auto Interiors . 176
Celstran Products Being Promoted for Auto
Interiors . 176
Sabic IP Products  176
Glass Bubbles Replace Talc Fillers  176
Market Estimates and Forecasts  176
TABLE 62 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
PLASTICS IN AUTOMOTIVE INTERIORS, THROUGH 2015
(MILLION POUNDS)  177
AUTOMOTIVE EXTERIORS  177
Background  177
Use of Reinforced Plastics/Composites . 177
Fuel Efficiency Scenario  178
Bumper Systems  178
Background . 178
Products . 178
Bumper Beams  179
Doors  180
Body Panels . 180
Overview  180
Horizontal vs. Vertical Body Panels (Steel vs. SMC)  180
Specific Thermoplastics  181
General Decision Factors for Body Panels . 181
Overview . 181
Carbon Fiber SMC . 181
Need for Class A Finishes . 182
Other SMC Competition  182
Other Considerations . 183
Paint-Free SMCs?  183
New Developments of Reinforced Plastics in Automotive
Exteriors . 184
Magna International Developments  184
Quadrant Plastic Composites’ New Bumper Beams . 184
SMC for Body Panel Applications  184
Sabic IP and Azdel Combine to Produce Lighter
Body Panels . 184
Molded-in-Color Panels  184
Market Estimates and Forecasts  185
TABLE 63 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
PLASTICS AUTOMOTIVE EXTERIOR MARKET, THROUGH 2015
(MILLION POUNDS)  185
THE FUTURE FOR REINFORCED PLASTICS/COMPOSITES
SEEMS BRIGHT IN THE AUTOMOTIVE MARKET  186
WHAT ABOUT FUEL CELLS IN AUTOS?  187
Background  187
Possible Future Scenario . 187
Types of Fuel Cells and Components  187
Materials and Processes  188
Other Items of Interest  188
Companies Involved  189
What Does the Future Hold? . 189

CHAPTER SEVEN: CONSTRUCTION/INFRASTRUCTURE
BACKGROUND  190
CONSTRUCTION MARKET OVERVIEW  190
U.S HOUSING STARTS  190
TABLE 64 U.S. HOUSING STARTS FOR SINGLE-FAMILY HOMES,
1982-2009 (THOUSAND UNITS)  191
RECENT COMMENTS ON THE HOUSING MARKET  191
ADVANTAGES OF REINFORCED PLASTICS/COMPOSITES . 191
SOME BARRIERS TO REINFORCED PLASTICS/COMPOSITE
USAGE  192
INFRASTRUCTURE APPLICATIONS  192
Background  192
Advantages of Composites . 193
Roadblocks . 193
Infrastructure Repair  194
Jacketing . 194
Concrete Reinforcement . 194
Background. 194
Rebars/PlateBonding . 195
Concrete Highway Pavement  195
New Developments  195
Wave Power Converters . 195
Fiberglass Towers . 195
BRIDGES  195
Background  195
Bridge Cables from Composites  196
Recent Developments  197
PIPE  197
Background  197
Fiberglass Reinforced Thermoset Plastic Pipe . 197
Background . 197
Allyl Resins . 198
Bismaleimides and Furan Resins  198
Phenolic Resins . 198
Epoxy Resins . 199
Unsaturated Polyester Resins  199
Water-Pipe Systems  199
Overview  199
Composites Used in Offshore Drain Pipe Repair  200
Recent Developments 200
BATHROOM FIXTURES AND COMPONENTS . 201
PANELS  201
Overview  201
Natural Fibers for Panels  202
ANTI-CORROSION MARKETS  202
Background  202
Types of Corrosion-Resistant Resins  203
Markets  203
Resurgence in Corrosion-Resistant Composites . 204
Examples of an Industry Impacted by Corrosion:
Underground Storage Tanks . 204
Return of the Corrosion Market for Composites? . 205
New Developments  205
Market Estimates and Forecasts  205
TABLE 65 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
PLASTIC CONSTRUCTION/INFRASTRUCTURE BY RESIN,
THROUGH 2015 (MILLION POUNDS)  206
TABLE 66 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
PLASTIC CONSTRUCTION/INFRASTRUCTURE BY SEGMENT
THROUGH 2015 (MILLION POUNDS)  206
TABLE 67 NORTH AMERICAN
CONSTRUCTION/INFRASTRUCTURE MARKET FOR FIBERREINFORCED
UNSATURATED POLYESTER BY SEGMENT,
THROUGH 2015 (MILLION POUNDS)  207
TABLE 68 NORTH AMERICAN
CONSTRUCTION/INFRASTRUCTURE MARKET FOR FIBERREINFORCED
EPOXY BY SEGMENT, THROUGH 2015 (MILLION
POUNDS) . 207
MARINE MARKETS  207
OVERVIEW  207
MATERIALS. 208
Glass . 208
Carbon  209
Aramid . 209
Epoxy/Vinyl Ester . 209
TRENDS IN MARINE COMPOSITES  209
MARINE REINFORCED PLASTICS/COMPOSITES PLUSES
AND MINUSES  209
MARKET ESTIMATES AND FORECASTS . 210
TABLE 69 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
PLASTIC MARINE PRODUCTS, THROUGH 2015 (MILLION
POUNDS) . 210
ELECTRONICS  211
OVERVIEW  211
MARKETS  211
GROWTH  211
TECHNOLOGIES  211
REINFORCED PLASTICS MOVE AHEAD IN ELECTRONICS  212
PRINTED CIRCUITBOARDS (PCBS)  212
Background  212
Definitions  213
Physical Composition  213
Types of Rigid Boards  213
Assembly Technologies  213
E-Glass Suppliers  214
Issues Facing Plastics Usage  214
PCB Substrates  214
TABLE 70 IMPORTANT TECHNICAL FACTORS TO CONSIDER
WHEN SELECTING PCB SUBSTRATE MATERIALS . 214
Rigid PCBs . 215
Background . 215
Standard FR-4 Epoxy Resin . 215
Higher-Performance Epoxies  215
Other Materials  216
Types of Reinforcements . 216
New Developments  217
Impact of Lead-Free Soldering . 217
Aramid Fibers . 217
CONNECTORS  217
Background  217
Function of Connectors  218
Trends  218
Resin Selection . 218
Market Estimates and Forecasts  219
TABLE 71 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
PLASTIC ELECTRONICS, THROUGH 2015 (MILLION POUNDS) . 220
CONSUMER PRODUCTS  220
BACKGROUND . 220
SPORTS/RECREATION EQUIPMENT  220
Background  220
General Resin Usage . 221
Skis and Other Winter Sports Equipment . 221
Recreation Boards  222
Bicycles . 222
Specific Reinforced Plastics Products Used in Sports &
Recreation Products . 223
LAWN/GARDEN EQUIPMENT  223
Overview  223
Resin Usage . 223
Market Estimates and Forecasts  224
TABLE 72 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
PLASTIC CONSUMER PRODUCTS MARKET, THROUGH 2015
(MILLION POUNDS)  225
APPLIANCES . 225
OVERVIEW  225
APPLIANCE USAGE IN U.S. HOUSEHOLDS  226
KEY APPLICATIONS FOR PLASTICS IN APPLIANCES . 226
FIBER-REINFORCED PLASTIC USAGE  226
Market Estimates and Forecasts  227
TABLE 73 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
PLASTIC APPLIANCE MARKET, THROUGH 2015 (MILLION
POUNDS) . 227
AEROSPACE  227
OVERVIEW  227
BACKGROUND . 228
MILITARY AIRCRAFT  228
INTERIOR PARTS . 229
COMPOSITION OF REINFORCED PLASTIC PARTS . 229
MATERIAL USAGE . 229
POTENTIAL PROBLEMS . 229
SUPPLIERS . 230
NEW DEVELOPMENTS . 230
Bis-Maleamide Resins (BMIs) . 230
New Cook Composite Products . 230
The Drive for Composite Tooling  230
Production Has Begun for Airbus A350 XWB  230
Epoxy Usage  231
MARKET ESTIMATES AND FORECASTS . 231
TABLE 74 NORTH AMERICAN AEROSPACE MARKET FOR FIBERREINFORCED
PLASTIC, THROUGH 2015 (MILLION POUNDS)  231
MISCELLANEOUS APPLICATIONS . 232
BACKGROUND . 232
MEDICAL . 232
Overview  232
Orthopedic Implants and Prostheses  232
Overview  232
Composites May Move Into Orthopedics/Prosthesis . 233
POWER MARKET  233
Overview  233
Distribution/Utility Poles  233
A Recent Development  234
Cross Arms . 234
Summary of Benefits that can be Derived from
Composites in the Power Market  235
OTHER TRANSPORTATION MARKETS  235
Overview  235
Rail Applications . 235
Background . 235
Monorails . 236
Phenolic Composite Usage in Mass Transit  236
Recreational Vehicle Market (RVs)  236
WIND ENERGY PRODUCTS . 237
Background  237
Technology . 237
Recent Developments  237
Ashland Chemical . 237
TPI Composites . 238
Owens Corning  238
PPG’s New Product . 238
Ahlstrom Corporation . 238
LM Glasfiber, Inc. . 238
Vestas Wind Systems 238
Three-Company Partnership  239
Other Noteworthy Developments in Wind Blade
Production  239
OILFIELD RELATED APPLICATIONS  239
WATER DESALINATION . 240
REINFORCED PLASTIC IN-GROUND TANKS . 240
MARKET ESTIMATES AND FORECASTS . 240
TABLE 75 NORTH AMERICAN MISCELLANEOUS MARKET FOR
FIBER-REINFORCED PLASTICS, THROUGH 2015 (MILLION
POUNDS) . 241
SUMMARY OF FIBER-REINFORCED PLASTICS APPLICATIONS
MARKET  241
TABLE 76 NORTH AMERICAN MARKET FOR FIBER-REINFORCED
PLASTICS APPLICATIONS, THROUGH 2015 (MILLION POUNDS) . 242

CHAPTER EIGHT: COMPOSITE MARKET GROWTH IN ASIA MOVES FORWARD 
OVERVIEW . 243
AUTOMOTIVE PRODUCTS  243
OTHER NOTEWORTHY NEWS . 243

CHAPTER NINE: ENVIRONMENTAL ISSUES
BACKGROUND  244
STYRENE EMISSION PROBLEM  244
OVERVIEW  244
CHANGES IN MACT DIRECT FINAL RULE . 245
METHODS TO LOWER STYRENE EMISSIONS 245
SUMMARY OF OPTIONS TO REDUCE STYRENE
EMISSIONS AND MAINTAIN PRODUCT QUALITY . 246

CHAPTER TEN: RECYCLING 
OVERVIEW . 247
SPECIAL CONCERNS . 248
DO COMPOSITES REQUIRE A BETTER SOLUTION FOR THEIR
END-LIFE?  248
EFFORTS IN THERMOSET RECYCLING  248
BACKGROUND . 248
PYROLYSIS  248
GLASS SEPARATION . 248
GRINDING . 249
CARBON FIBER RECYCLING . 249
NEW EURPOEAN EFFORTS  249
USING RECYCLED SMC  249
RECOVERING CARBON FIBERS . 250
RECYCLING LONG-FIBER REINFORCED
POLYPROPYLENE (LFPP) . 250

CHAPTER ELEVEN: RECENT CORPORATE DEVELOPMENTS/PRODUCTS WITHIN THE REINFORCED PLASTIC/COMPOSITE MARKET 
AZDEL SOLD TO KOREAN FIRM  251
SABIC IP PURCHASES RHE MAX LINE  251
DUPONT MOVING AHEAD WITH LONG FIBER AND
NANOCOMPOSITES  251
NEW VINYL ESTERS  252
SIKA’S NEW EPOXY RESIN FOR AVIATION USES . 252
VICTREX ST POLYMERS . 252
TICONA ACQUIRES LFT BUSINESS IN GERMANY  252
ACY DEVELOPS FIBERS FOR IMPLANTS  252
DECOMA INTERNATIONAL PURCHASED MERIDIAN
COMPOSITE PLANTS  253
FERRO ADDS NEW FIBERGLAS-REINFORCED COMPOUNDS  253
A NEW REINFORCING AGENT FROM MILLIKEN CHEMICAL . 253
RTP DEVELOPS LFTPS WITH HIGH PERFORMANCE RESINS  253
HEXION TO MERGE ITS OPERATIONS  253
COMPANY PROFILES  254
ASHLAND SPECIALTY CHEMICAL COMPOSITE
POLYMERS  254
AZDEL, INC.  254
AOC LLC  255
BULK MOLDING COMPOUNDS, INC. . 255
COOK COMPOSITES AND POLYMERS (CPP)  256
DSM ENGINEERING PLASTICS NORTH AMERICA . 256
FERRO CORPORATION . 257
GEORGIA-PACIFIC CHEMICALS LLC  257
HAYSITE REINFORCED PLASTICS  258
HEXION SPECIALTY CHEMICALS  258
IDI COMPOSITES INTERNATIONAL  259
INTERPLASTIC CORPORATION  259
LNP ENGINEERING PLASTICS . 259
OWENS CORNING  260
PREMIX, INC.  261
QUADRANT PLASTIC COMPOSITES  261
REICHHOLD CHEMICAL  262
RTP COMPANY . 262
TICONA  263
APPENDIX ONE: ACRONYMS . 264
ACRONYMS (CONTINUED) . 265
ACRONYMS (CONTINUED) . 266
APPENDIX TWO: GLOSSARY OF TERMS  267
GLOSSARY OF TERMS (CONTINUED)  268
GLOSSARY OF TERMS (CONTINUED)  269