Composite material processing dust filtration.

A composite material is a combination of two materials with different physical and chemical properties. When combined, they form a material that is specialised to do a specific job, for example to be stronger, lighter or resistant to electricity. They can also increase strength and stiffness. They are used in comparison to conventional materials because they improve the properties of their base material and are applicable in many situations.

Composite dusts

Some types of composite materials:

- Ceramic matrix composite: Ceramic dispersed in a ceramic matrix. These are better than regular ceramics as they are resistant to thermal shock and fracture.

- Glass fibre reinforced concrete: Concrete cast in a glass-fibre structure with a high zirconia content.

- Composite honeycomb: A selection of composites in many hexagons to form the honeycomb shape.

- Treated wood: Manufactured wood combined with other inexpensive materials. An example would be particleboard. A specialised material such as veneer can also be found in this composite.

- Sandwich panel: Various composites layered on top of each other.

- Fibreglass: Glass fibre combined with a relatively cheap and flexible plastic.

- Carbon fibre reinforced polymer: Carbon fibre embedded in a plastic with a high strength-to-weight ratio.

- Syntactic foams: Lightweight materials formed by filling metals, ceramics or plastics with micro-balloons. These balloons are made using glass, carbon or plastic.

- Carbon-carbon (C/C) composites: These composites are a family of materials consisting of a carbon (or graphite) matrix reinforced with carbon (or graphite) fibres.

What are the Advantages of Composite Materials?

- Low cost compared to metals

- Design flexibility

- Resistance to a wide range of chemicals

- Low weight

- Resilience

- Electrical insulation

- High impact resistance

Composite materials such as carbon, glass fibre and resins are widely used in the manufacture of products and components in every industrial sector.

The processing of composite materials, such as cutting, milling or polishing, often releases dust, particles and fibres fine enough to affect the respiratory system of operators or sometimes create skin problems. Under certain conditions, such dusts can also be potentially explosive.

Effects on human health:

Various composite materials in industry can cause health problems. A polymer matrix (a resin) is a vital component of composite structures. The most common resins are vinyl esters and polyester epoxies.

Anyone working with resins should be aware of the health risks associated with exposure to such materials. The main risk areas are the lungs, skin and eyes. When working with any resin system, it is imperative that appropriate PPE is worn at all times and that these contaminants are removed from the work area.

Working with epoxy, vinyl esters, polyester and phenolic materials can pose health risks to the central nervous system as well as to the skin, lungs and eyes. It can lead to respiratory sensitisation, dermatitis, conjunctivitis and potential carcinogenic effects on DNA. 

The most effective way to reduce risks is to capture waste contaminants from the processing of composite materials at source.

Dust extraction and filtration equipment that can be used:

- Work tables with downdraft extraction

- Dust extraction at source with acrobat extraction arms (mobile or centralised system)

- Dust extraction from the source with high vacuum systems (mobile or centralised system)

- Special working cabins with air extraction system

- Mobile or fixed extraction walls

Dust extraction system

Contact the HiVent team for professional support with dust extraction systems and the extraction and filtration of composite dust.