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FRP Modular Composite Sandwich Panels

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FRP Modular Composite Sandwich Panel Kits is produced with German Technology and Machines,it is the best ideal to build overland Expedition bodies. It allows for maximum diversity of cabin size choices and provides the option to adjust strength requirements through additional plys or wall thickness. The Finished box has superior insulating performance with an approximate thermal K-value of 0.29 w/㎡*k. Typical panels are a solid core 3-ply and all edges sealed by Solid FRP panel that is ultra-high strength, low weight, self-supporting. The plys are hydraulic Press Machine bonded with FRP rude material and Resin with no thermal conduction paths. This panels hold up to the mechanical stresses and dynamic forces, such as flexing, wind, & extreme hot or cold encountered in Overland Travel.

1: All Closed Modular Structure provides the best insulation of U value to less than 0.1.
2: Light in weight:40% lighter than metal.
3: Better insulation: K value of the box less than 0.29w/sqm*k.
4: High in strength : Tensile strength>180MPa Flexural strength>220MPa Barcol hardness 24.6MPa
5: Non-corrosion, non-pollution, anti-brine, acid and soda-resisting.
6: Floor and roof Max. bearing capacity up to 0.5 tons / m.
7: Modular Design Easy to assembly and repair at site.
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FRP Modular Composite Sandwich Panel Kits
1. Instruction of the FRP Modular Composite Sandwich Panel Kits

FRP Modular Composite Sandwich Panel Kits is produced with German Technology and Machines,it is the best ideal to build overland Expedition bodies. It allows for maximum diversity of cabin size choices and provides the option to adjust strength requirements through additional plys or wall thickness.  The Finished box has superior insulating performance with an approximate thermal K-value of 0.29 w/㎡*k. Typical panels are a solid core 3-ply and all edges sealed by Solid FRP panel that is ultra-high strength, low weight, self-supporting.  The plys are hydraulic Press Machine bonded with FRP rude material and Resin with no thermal conduction paths. This panels hold up to the mechanical stresses and dynamic forces, such as flexing, wind, & extreme hot or cold encountered in Overland Travel.


1: All Closed Modular Structure provides the best insulation of U value to less than 0.1.

2: Light in weight:40% lighter than metal.

3: Better insulation: K value of the box less than 0.29w/sqm*k.

4: High in strength : Tensile strength>180MPa Flexural strength>220MPa Barcol hardness 24.6MPa

5: Non-corrosion, non-pollution, anti-brine, acid and soda-resisting.

6: Floor and roof Max. bearing capacity up to 0.5 tons / m.

7: Modular Design Easy to assembly and repair at site.

FRP Modular Panel
As this box is Original German Technology , with wet-in wet process made, all the surface FRP are made with the rude Fibre glass material with an chemical process, so all the panels is sealed wtih the FRP, and made the panel as an whole like a pie. so we called FRP-Pie Modular Panel. 
2. General Of the Modular FRP Modular Composite Sandwich Panel Kits
Max. Length of the Panel Kits 14750mm 
Max Wideth of the panel Kits 3200mm
Thickness of the Panel Kits  60,80,82,105,mm120mm
K Value of   the FRP-Pie Truck Body
Tensile strength >180MPa
Flexural strength >220MPa
Barcol hardness 24.6MPa



 FRP-Pie

3. Super Structure 

Self-supporting Panel, FRP Bone And Skin Structure without cross bars , inside and outside skin made of glassfibre reinforced polyester, reinforced with FRP Z-Straps as the bone, the Core of hard foam with best insulation properties, which are all sealed in the FRP Skin Covers and Vacummed. 
Without metal carrier elements = without direct heat conductivity
Without Opening Edage (Panel insde Vacummed )= without heat conductivity
PANEL TYPE THICKNESS Application
Standard Panel Kits Length 0-14750mm
Width 0-3200mm
Thickness 27-135mm
1. Insulated & refrigerated truck body side and roof wall.
2. RV and Expedition side and Roof Wall.
3. Mobile Cold Room Side Walls
Floor Panel Kits Length 0-14750mm
Width 0-3200mm
Thickness 27-135mm
1. Insulated & refrigerated truck body Floor.
2. RV and Expedition Floor Wall.
3. Mobile Cold Room Floor Wall
Super Strong Roof Length 0-14750mm
Width 0-3200mm
Thickness 27-135mm
1. Refrigerated Meat hanger truck body roof wall.
2. Mobile Meat hanger Cold Room roof wall
Side Door / Windows Embedded Reinforcement Length 0-3000mm
Width 0-3200mm
Thickness 27-135mm
1. Insulated & refrigerated truck body side Door
2. RV and Expedition box Windows and Entry Doors
3. Mobile Cold Room entry Door.

FRP-Pie Modular Panels

4.Description of material

FRP-Pie All Plastic assembly kit elements are manufactured in accordance with the "wet-in wet" method , with integral polyester reinforcement, however without any metallic carrier elements whatsover , in a homogenous construction method.

the foam core consists of polyurethane resp.prepolymer-foam with optimum insulating properties, the inner and outer skin of glassfibre reinforced polyester. The individual elements are hermetically sealed on all sides
Core Thermal Polyrethane Foam
All panels, Floor & Roof of the box will be insulated with POLYURETHANE foam (PU) of density 40KG~45/M3, which can carry the Thermal Conductivity value 0.3kcal/M3. 
KOMMERLING Two component reaction adhesive
Base Polyurethane, 2-components, solvent-free
Hardener Colour Consistency Köracur TH 650
Beige
Highly fluid, easily brushable
Density


Körapur 672 1.66 (resin)

Köracur TH 650 1.23 (hardener)

mixture  1.41 g/cm³ DIN 53 479
Viscosity


resin : hardener 30

hardener 200

mixture Mixing ratio 8000 MPa•s Brookfield RVT
resin : hardener 05:01 units by weight
resin : hardener 3.7 : 1  units by volume




Pot life 60 min
Hardness Shore D 60
DIN 53 505

-20°C: ca. 24 N/mm² DIN 53 283

+20°C: ca. 18,5 N/mm²
Shear strength +80°C: ca. 5,2 N/mm²
Tensile strength 18 N/mm² DIN 53 404
Consumption 250-300 g/m² depending on substrate

20130926_120106

German Origin PRessur Machine

PU

Insulation PU Material


FRP Modular Composite Sandwich Panel Finished Box



GET.EXP.6.KGL46-MAN-8

Driver Side Elevation

GET.EXP.6.KGL46-MAN-9

Front Side Elevation

GET.EXP.6.KGL46-MAN-7

Rear Side Elevation

GET.EXP.6.KGL46-MAN-5

Entry Door Side Elecation

5. The main characters

Advantages
1) Light in weight:40% lighter than metal.
2) Better insulation: K value less than 0.3w/sqm*k.
3) High in strength and long life: 5 times longer than metal.
4) Non-corrosion, non-pollution, anti-brine, acid and soda-resisting.
5) Floor Can meet forklift’s operation, Ceiling can let the Meat hooks fix without special enforcement, bearing capacity up to 2 tons / m.
6) Easy to assembly and repair at site.
Fault:
1) The FRP chemical with Glues cannot guaranty the Smoothness of the Skin, so it need paint after assembled.
2) More FRP Chemical Harden inside as Bone of the panel, so it is 10% Heavier than the Composite Sandwich Panels
3) Too Strong, Long life than the Chassis, you may Change the Chassis during its life.



6. Box Installation Process 

Requirements for installation:
Crane or alternative lifting equipment
Standard assembly tools, i.e. pneumatic screwdriver, wrenches, etc.

FRP-Pie Panel KIT:
Prepare the Floor Panels
Mount the Walls from front , side,   roof to the floors and Clamp with C-Clamps
Mout the Portal and Clamp the Assembly box with C-Clamp, Wait a Setting Time of 8 Hours .
Paint the setted box with the color you like
Mount the box to the Chassis Prepared .
Install the required options like Proficles and lights
Finishin

Expedition Box Installation -1

1. Floor-Front Wall

Expedition Box Installation -5

2. Side Walls adhesive

Individual-Box 70

3. Roof Adhesive

Expedition Box Installation -4

4. Amount to Truck

Brief Instruction


China MAN EXPEDITION TRUCK 3

GET.6EXP.
LIGHT AND STRONGER MODULAR BOX
BY TRAILERBULL

TRAILERBULL engineered expedition box types are available to accommodate your ideas about Expedition Vehicles. Though the basic needs of globetrotters are much the same, their demands on the vehicle itself differ lone traveler, twosome, family, class of driving license, destination, infrastructure, terrain, duration of the journey … All these criteria ultimately determine the optimum vehicle and the suitable chassis.


GET.6EXP can translates these criteria into 3 Expedition box models geared to these different requirements thanks to our durable GRP Sandwich panel composite technology offers top performing strength.

TRAILERBULL With different wall panels (FRP-Pie Modular Panel, FRP-Plast Sandwich Panel) to meet all the popular chassis and requirements in the world and already have proven themselves on the actual journeys of many satisfied customers.


FAQ

-Can you pre-cut openings for windows and doors?

We can offer this service with cost as we have embeded strengthen parts inside, but that will be confirmed before producing. your own Openings can easily be cut with a jigsaw and plastic rated blade, but the embeded strengthen parts can not make . So if it willl work in really bad expedition, you'd better let us pre-cut opennings for windows and doors.

Can you do departure angles?

Yes, we have two size of the box shape, one is the standard square shape , the other is the departure angle design. Please mark the desired angle (including dimensions) in the quoting template if you need.

-Can you design subframes?

We have the service of this, but you need supply the full chassis layout to us in advance.

-Can I use different windows and doors than what’s listed on your specification?

Yes. However, we highly recommend our windows and doors as they work in perfect balance with our camper bodies.

–Can I order a camper body with an alcove?

Yes. Please ask us for our alcove quoting template.

–What’s included in the shipment?

1. CKD type with All panels cut to size (other than departure angle),
2. CBU type with assembled box per your requirements.

–Can you help with the interior layout?

No. We are  solely a camper body supplier, not a full scale outfitter/design office.


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