GFRP Rebar Manufacturing: Continuous Composite Reinforcement
PGFRB GFRP Rebars are manufactured using a continuous composite reinforcement process in which glass-fiber rovings are combined with a polymer resin system and formed into a continuous reinforcement profile.
Materials
Material & Manufacturing Configuration
Our current manufacturing configuration uses 4800 Tex glass-fiber roving together with an epoxy resin system consisting of DY-128 epoxy resin and MTHPA curing agent.
The manufacturing process is designed around controlled fiber placement, resin impregnation, forming, curing and surface profiling to produce consistent composite reinforcement.
| Component | Current configuration |
|---|---|
| Reinforcement | Continuous glass-fiber roving |
| Roving specification | 4800 Tex |
| Epoxy resin | DY-128 |
| Curing agent | Methyl Tetrahydrophthalic Anhydride (MTHPA), DY-013 |
Final formulation ratios and finished-product fiber/resin fractions will be confirmed by PGFRB production records and laboratory testing before publication as certified data.
Manufacturing Process
From Fiber to Finished Rebar
Seven controlled stages turn continuous glass-fiber rovings into finished, inspected GFRP reinforcement bars.
- 01
Glass Fiber Preparation
High-strength glass-fiber rovings are prepared according to the required bar diameter.
- 02
Resin Impregnation
The continuous fibers are impregnated with the polymer resin system.
- 03
Composite Forming
The impregnated fibers are consolidated and formed into the required bar profile.
- 04
Curing
The resin system undergoes controlled curing to develop the composite matrix.
- 05
Surface Profiling
The bar surface is configured to provide the required bond characteristics with concrete.
- 06
Cutting & Finishing
Finished bars are cut to the required lengths and inspected before packaging.
- 07
Quality Inspection
Finished products are checked for dimensional consistency and applicable quality requirements.
Production Facility
Our Production Line
PGFRB GFRP Rebars are manufactured at our production facility in Karachi, Pakistan.
Quality
Quality You Can Build On
At PGFRB, quality begins with raw materials and continues throughout the manufacturing process. Our quality system focuses on maintaining consistency across:
- 01Raw Materials
- 02Production
- 03Profiling
- 04Testing
- 05Inspection
- 06Packaging
- 07Delivery
Quality-Control Framework
PGFRB is establishing a quality-control framework covering incoming materials, production parameters, dimensional checks, finished-product inspection and laboratory testing.
| Stage | Control focus |
|---|---|
| Incoming materials | Supplier identification, batch records and material documentation. |
| Roving | Roving specification, batch identification and production quantity. |
| Resin system | Material identification, batch control and process records. |
| Production | Process parameters, line operation and visual consistency. |
| Finished bar | Diameter, weight per meter, surface/profile and appearance. |
| Mechanical testing | Tensile and related performance properties after laboratory verification. |
| Durability testing | Environmental and long-term performance testing as applicable. |
| Traceability | Batch/lot identification linking raw materials and finished product. |
Certification
Certification Status
Our certifications are currently under process. We will publish verified certificates and applicable standards documentation as they become available.
Our Commitment
We will never use certification logos or make compliance claims without appropriate documentation.
Testing in progress
Mechanical, physical and durability testing of finished PGFRB GFRP rebar is in progress. Verified values will be published once test reports are issued and approved.
Engineering References
Standards & Engineering References
PGFRB is developing its testing and technical documentation with internationally recognized FRP reinforcement practices in view.
- ISO 10406-1:2025
Fibre-reinforced polymer (FRP) reinforcement of concrete — Test methods — Part 1: FRP bars
Specifies test methods for physical, mechanical, durability and long-term properties of FRP bars.
- ACI CODE-440.11-22
Building Code Requirements for Structural Concrete Reinforced with GFRP Bars
Covers materials, design and detailing for structural concrete reinforced with GFRP bars, and references ASTM D7957-22 for conforming GFRP bars.
These references are included as engineering frameworks and test-method references. Their inclusion does not mean that PGFRB currently claims certification or compliance with them.
Request Technical Information
Get product specifications, testing information and technical documentation.