Products

FRP Gutters

F.R.P. Gutters are used in industrial sheds & commercial buildings to help collect & drain rain water from over the roof top. 

F.R.P. Gutters outperform ordinary gutters made out of conventional material (such as ACC, steel & ordinary plastics such as P.V.C.), especially in terms of mechanical strength & resistance to rust & U.V. Rays of sun.  

 

SALIENT FEATURES:

1. Mechanically strong & impact resistant

2. Light weight & therefore easy to handle & install

3. Weatherable - resistant to rust & harmful U.V. Rays

4. Maintenance free

5. Easy to repair & that too at a nominal charge in case of an accidental damage

6. Easy to wash & clean & therefore hygienic 

7. Can be made anti-corrosive & fire resistant, if required 

8. Unsurpassed designing freedom- can be designed in any shape & size as per customer requirement

9. Can be reinforced with steel for added mechanical strength

10. A wide range of colours to choose from

11. Highly durable

12. Value for money 

 

APPLICATIONS: 

1. Production sheds

2. Warehouses

3. Production utility areas

 

COMPARISON WITH OTHER MATERIAL:     

FEATURE

F.R.P.

GALVALUME

G.I.

Aluminium

U.P.V.C.

Weatherability (resistance to rust & UV)

Good

Excellent

Poor

Excellent

Poor

Corrosion Resistance

Excellent

Poor

Poor

Poor

Poor

Strength

Excellent

Good

Good

Poor

Average

Designing Freedom

Excellent

Good

Good

Good

Poor

Colour Options

Excellent

Good

Good

Poor

Good

Ease of installation

Good

Excellent

Excellent

Excellent

Average

Reparability

Excellent

Poor

Good

Poor

Poor

Durability

Good

Excellent

Poor

Excellent

Average

Value for money

Good

Good

Poor

Average

Poor

 

SHAPES & DESIGNS: 

1. Valley (‘V’ shaped)

2. Eaves or Box type (‘U’ shaped)  

3. Half round

4. Any other customized shape

 

SIZES:

The Gutters can be manufactured in any size (length & width) as per customer requirement. 

The maximum length of F.R.P. Gutter can be up to 5.20 Mtr. The width of the Gutter (also referred to as its girth / span) is generally 1.0 Mtr., but can be more or less.  

The size of the Gutter depends on the maximum volume of water, which is expected to flow into the Gutter. In case the inflow of rain water is more than what the Gutter can hold and drain, there would be a problem of an overflow of rain water.  

The size of the Gutter is generally confirmed by the end user. Generally, the buyer is requested for a formal drawing or sketch. The size of the Gutter should be such that it easily fits inside the M.S. support frame fabricated for holding the Gutter. 

The side walls of the Gutter can be perpendicular or at an angle with relation to the base. Similarly, the collars can be perpendicular to the side arms or at any angle.   

 

THICKNESS: 

2.0 MM, 3.0 MM, 4.0 MM, 5.0 MM, 8.0 MM & any other as required. 

 

WEIGHT:

S. NO.

THICKNESS

PER. SQ. MTR. WT.

1.

2.0 MM

4.00 Kgs

2.

3.0 MM

5.50 Kgs

3.

4.0 MM

6.50 Kgs

4.

5.0 MM

7.50 Kgs

5.

8.0 MM

9.75 Kgs

 

COLOURS:

Any RAL colour. Common colours are White, Blue, Green and Grey.     

 

FINISH:

Generally, the F.R.P. Gutters are provided with a smooth glass like laminated finish on the inside & a rough textured fibre finish on the outside. A smooth inside finish is necessary to minimize frictional losses & deposits of mud & to ensure that the Gutter can easily be washed and cleaned as and when necessary.

Alternately, the F.R.P. Gutters can be provided with a smooth glass like laminated outer finish and a rough textured fibre inside finish. A coat of Resin can be applied on the Gutter’s inside surface to smoothen it.    

The production process is such that a smooth laminated finish can be provided on only one side. 

 

CALCULATION OF SURFACE AREA:

The surface area of one Gutter (in terms or Sq. Mtr. or Sq. Ft.) is calculated by multiplying its girth & length, where the girth is the total of all sides of the Gutter. The total surface area of all Gutters is calculated by multiplying the surface area of one Gutter by the total no of Gutters. 

 

ILLUSTRATION: 

·         Length (F)                                                                                            - 5.0 Mtrs.

·         Girth (G=A+B+C+D+E)                                                                      - 1.0 Mtr.

·         Surface Area of One Gutter (H= Length (F) x Girth (G))                 - 5 x 1 = 5 Sq. Mtr.

·         No. of Gutters                                                                                     - 50

 

·         Total Surface Area                                                                             - 250 Sq. Mtrs.  

Note: Both length & width have to be in the same unit of measurement, which can be either Feet or Meter.  

 

TOOLING REQUIRED:

For customized designs & sizes, a separate set of tooling would have to be developed. The tooling comprises of a wooden pattern manufactured by a specialized pattern maker and a mould in F.R.P.

The cost of developing a complete set of tooling for a 5.2 Mtr. long customized Gutter is approx. Rs. 15,000/-. The cost of developing the tooling can either be passed on to the customer by building it into the supply price or is amortized depending on the order quantity.  

 

BILLING CRITERIA: 

Rates are quoted in terms of Sq. Mtr. or Sq. Ft. & billing is done accordingly. 

The running meter rates can also be worked out by multiplying the Sq. Mtr. rates with the girth of the Gutter. 

 

ILLUSTRATION:

Basic Rate (A) - Rs. 1000/ Sq. Mtr. 

Girth (B) - 1.5 Mtr.

Running Meter rate (C) - 1000 (A) x 1.5 (B) = Rs. 1500/-   

 

SIDE COLLARS: 

The Gutters can be provided with side collars running along the entire length of the Gutter on one or both sides. The collars lend strength and dimensional stability to the Gutter and help keep their side arms stiff, straight and upright.

Owing to their benefits, customers generally incorporate collars in their design. Even if not requested, small collars (about 15 MM) wide are provided by us at no additional charges.   

With relation to the side arms, the collars could be perpendicular or at an angle.

 

STEEL REINFORCEMENT: 

The Fibre Gutter can be reinforced with steel for added mechanical strength & dimensional stability. Welded steel brackets (made of M.S. Flats, generally in the size of 25 MM x 3.0 MM thick) are sandwiched between layers of glass fibre during the production process. The brackets cover the entire girth of the Gutter.   

The welded joints of the frame are neatly finished before being used. The brackets are placed at a uniform centre to centre distance of appx. 1.0 Mtr. unless specified otherwise.

Charges for metal reinforcement shall be extra.  

 

RAW MATERIAL:

The raw materials used for manufacture of F.R.P. Gutter are:

1. Gel-Coat  

2. Glass Fibre (in the form of Chopped Strand Mat & Woven Roving) 

3. Resin (Grade - U.V. stabilized G.P. Resin) 

Gel-Coat is a protective coating, which guards the Fibreglass Gutter against damage due to harmful U.V. Rays & also provides the Gutter with a smooth glass like inner finish.

Glass Fibre imparts mechanical strength, where as Resin acts as a binding agent and protects the Gutter against environmental damage due to rust & harmful U.V. Rays.

 

U.V. STABILITY:

The F.R.P. Gutters are manufactured using U.V. stable Resins and Gel-Coats to resist the harmful effects of the ultra violet radiation of sun. Gutter moulded using non-U.V. Resins tend to degenerate rapidly & become brittle over a short period of time.  

 

PRODUCTION PROCESS:       

Step 1 Cleaning & preparing the surface of the mould

Step 2 Application of standard release agents

Step 3 Gel-Coat is applied over the mould using a hand brush after the release agents have dried up

Step 4 Gel-Coat is allowed to gel (dry up) for 10-15 minutes

Step 5 A number of layers of CSM & WR are applied. The total no. of layers depends on the required thickness. Each layer is impregnated (wetted) with Resin using a hand brush, before laying the next one. Due care is taken to ensure that the Glass Fibre is properly wetted with Resin so that there are no air pockets left in the course of moulding

Step 6 Once the moulding is over, the laminate is allowed to dry & harden for a period for a period of 40 – 45 minutes

Step 7 Cutting & finishing

Step 8 Packing  

 

CORROSION RESISTANCE & FLAME RETARDANCY: 

The F.R.P. Gutter can also be made anti-corrosive & fire retardant, if need be. 

Anti-Corrosive Resins (such as ISO, Bisphenol, Vinyl Ester or Epoxy Resin) are used for manufacture of F.R.P. Gutter.

The Anti - Corrosive F.R.P. Gutters commonly find use where there is a problem of chemical corrosion. Anti-Corrosive Gutters resist high temperature & can be made flame retardant as well. These speciality Gutters are also U.V. stabilized. 

 The choice of Resin depends upon the following two factors: 

1. The operating inside temperature

2. The corrosiveness of the gases, fumes & vapour- type & nature (acidic or alkaline) and its pH value

3. Level & extent of exposure to corrosive & obnoxious gases, fumes and vapour

4. Amount of forced and natural ventilation in the building     

FRP Anti-Corrosive Gutters are relatively more expensive as compared to the ordinary ones.    

 

JOINTING ARRANGEMENT: 

The Gutter can be provided with collars or a male-female arrangement for fixing & linear extension of the Gutter. The most commonly used method is the male-female method.

 

MALE - FEMALE: 

The Gutter is provided with a groove at one end, which is about 4’’ wide and covers the entire girth of the Gutter 

The depth of the groove depends upon the wall thickness of the Gutter. For example, if the thickness of the Gutter is 4.0 MM so the depth of the groove should be close to 6.0 MM so that the joints are levelled (after fixing) so that rain water flows through the Gutters and does not stagnate.

 

JOINTING COLLARS: 

Under this method, the F.R.P. Gutters are provided with collars at both ends for joining purpose. Both the collars carry holes of an appropriate diameter size for fastening of nuts & bolts. The collar is about 4.0’’ wide and is perpendicular to each of the Gutter’s sides. 

It is necessary to ensure that the collars on all three sides are perpendicular to the Gutter’s sides.

 

DOWN PIPES & PIPE FITTINGS: 

We also manufacture F.R.P. Down Pipes & Pipe Fittings (also referred to as down take pipes & down spouts) in various diameter sizes for use with our FRP Gutter. 

 

Standard sizes are:

A. 10’’ (250 MM) dia x 3.0 MM thick x 3.0 Mtr. long 

B. 08’’ (200 MM) dia x 3.0 MM thick x 3.0 Mtr. long

C. 06’’ (150 MM) dia x 3.0 MM thick x 3.0 Mtr. long

The Down Pipes can be made available in other diameter sizes as well, if need be. 

The Pipe fittings used with Pipes are as follows: 

1. Flanged Tail Piece (F.T.P.)

2. Sockets / Couplers

3. FRP Short & Long Bends & Elbows 

4. End Plates (also called End Caps) for blinding the ends of Gutter

P.V.C. Pipes & Pipe Fittings, which are cheaper than their FRP counterparts can also be used with our F.R.P. Gutter   

 

INSTALLATION OF FRP GUTTER USING MALE-FEMALE METHOD: 

Step 1 The F.R.P. Gutter are moved to the roof and are made to rest within the Steel Frame (Brackets) manually. 

Step 2 The Gutters are brought together for jointing. The method of jointing depends on the fixing arrangement provided in the Gutters.   

 MALE - FEMALE METHOD:

The Gutters are overlapped to the extent of the groove’s width. The plain end of one Gutter is made to rest over the groove of the Gutter adjoining it & self tapping screws are applied on the joint along the entire girth of the Gutter.

COLLARS:    

The collars of two adjoining gutters are brought together for fastening and are fastened using fasteners (nuts, bolts & washers)    

Step 3 The Gutters joints are then sealed using any of the methods given below:

 

OPTION A (USING RUBBER GASKETS & SILICON): 

The joint is fastened using fasteners (screws in case of male-female gutters & nuts & bolts in case of collared gutters). A thin layer of rubber gasket is placed between both the Gutters before fastening them. The fastened joints are then sealed from the top & on the inside using silicon sealants.

 

OPTION B (USING F.R.P. MTRL.): 

The other method of joining the Gutters is through F.R.P. Lining. The surface of the joint is properly prepared using abrasives & / or a hand grinder. 

The joints are then sealed using F.R.P. raw material- Resins & Fibre. Generally, two layers of Fibre (Chopped Strand Mat, both of which are both about 8’’ wide) are applied over the joints (along their entire girth) one after the other and both layers are properly impregnated & wetted using U.V. stable G.P. Resin. This is done using a hand brush.  

FRP Sealing is carried out at sites by a of team skilled technicians (moulders) only. The material required for sealing work is dispatched to sites by road.

There is a possibility of the joint opening up, if the surface of the joint is not prepared properly.  

STEP 4 The pipes are connected to the Gutter using flanged tail pieces (F.T.P.s). A hole of an appropriate diameter size is cut in the Gutter where the down pipe has to be installed. The tail of the F.T.P. is first pushed through the hole, where as its flange rests over the Gutter. 

The flange of the FTP is fastened over the Gutter’s surface using self tapping screws. The joint is sealed with silicon sealants. Alternately, the sealing can also be done with F.R.P. Material.   

A Bend (short / long) then covers the Tail of the F.T.P. from outside (The inner diameter (I.D.) of the Bend is slightly more than the Outer Diameter of the F.T.P.s. The Down pipe then covers the Bend (s) from outside (The I.D. of the Pipe is slightly more than the O.D. of the Bend). The Down Pipe is then clamped with the wall cladding sheets using clamps of an appropriate diameter size.   

Two or more down pipes can be connected using sockets, if need be. Bends or Elbows can be used along with the pipes to bend the pipeline .The water is drained into a drain or can be channelized for harvesting.

The down pipes are provided at a uniform distance (generally 15-25 ft.). The total number of pipes required would depend on the slope of the Gutters and the volume of water that is expected to flow through them.

STEP 5 The ends of the Gutter are blinded using F.R.P. End Plates. 

PLS. NOTE: The Gutters should always be laid within the M.S. Brackets before the roof sheets are installed. If in case, the sheets have already installed before the gutters are laid, the roof sheets would have to be dismantled and slid back to allow the gutters to be laid inside the steel support. 

 

FASTENING VS F.R.P. SEALING:  

The work of sealing of joints with F.R.P. Material is prone to errors in workmanship & can only be carried out by specialists. The F.R.P. sealed joints may break open or dislodge over a short span of time due to constant thermal expansion & contraction and due to vibrations in the shed due to movement of heavy overhead cranes (especially in case weak bonding / adhesion of the F.R.P. Lining with the Gutters due to factors such as improper surface preparation). F.R.P. Sealing is also tedious, cumbersome and expensive.  

The easies, quicker & more reliable method of fixing the F.R.P. Gutter is by using fasteners, rubber gaskets and silicon. This option also offers the flexibility and advantage of dismantling & opening the Gutter joints later for any purpose including replacement.      

WHAT IF OLD GUTTER ALREADY EXISTS? 

In case old Gutter exists, there are two options:

Option 1 The new F.R.P. Gutter can be fixed inside the old Gutter after cleaning them

Option 2 The new FRP Gutter can be fixed after removing the old existing worn out Gutter

For removing the old Gutter or for fixing the new F.R.P. Gutter inside the old ones, a few of the existing roofing sheets would have to be dismantled and slid backwards. In such a case, the sheets can be brought forward and screwed after the new F.R.P. Gutters have been successfully laid.

The decision to remove the Gutter or not depends on the condition of the old Gutter. It would be advisable to remove the old Gutter, if it badly damaged. 

The size of the FRP Gutter should be such that it easily & snugly fits within the steel frame or the old Gutter, as the case may be. More importantly, the decision to retain or replace the old Gutter should be made before manufacturing the new FRP Gutter. 

M.S. SUPPORT BRACKETS:

The Gutters are fixed within M.S. Brackets, which are generally fabricated using M.S. angles. The M.S. brackets are supported on to the eave strut, which is a part of the PEB structure.  

For proper support, the brackets should be at a maximum centre to centre distance of 1.0 Mtr. & should cover the entire girth of the Gutter. 

The Gutter themselves are quite heavy and also carry the weight of water & foreign matter such as leaves, twigs, ash & silt, which get deposited inside the Gutter over a period of time. It is therefore necessary that the support is adequate. The level & extent of external support determines the Gutter’s overall performance & durability.         

The outer dimensions of the Gutter (especially its base) should be less than the inner dimensions of the M.S. brackets by at least 10 MM to ensure easy and hassle free installation. 

In case, the outer dimensions of the Gutter is equal to or more than the inner dimensions of the M.S. Frames, there would be difficulty in fixing the FRP Gutter. In such a case, either the size of the Gutter would have to be reduced or the size of M.S. Frame would have to be increased. Both of these options would be difficult and expensive to execute at far away sites. It is therefore necessary to exercise due care, diligence & caution while carrying out measurements at sites. Further, the size of frames and or the existing Gutter may not be uniform & consistent along the length of the shed.    

 

M.S. SUPPORT BRACKETS

Commonly, the support frame has a slope to ensure rapid drainage of rain water from inside the Gutter & to avoid stagnation.

 

GUTTER SLOPE

Fabrication work is outside our scope of work. Our job is limited to lifting the Gutter to the roof, laying them inside the frame and to joining them. The Gutter are lifted manually by tying them with ropes & pulling them over the roofs or using mechanical equipment such as hydras and lifters provided by the end user.     

 

 

 

 

 

 

 

 

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