Composites is the name given to polymer resins reinforced with glass, Kevlar or carbon fibres. They are very strong, flexible, lightweight, non-conductive, insulating and weather-proof. These features make composites an attractive alternative to traditional wood or metals for many applications.

Composite Applications

Composites are versatile – they can be moulded into complex shapes, colours and textures. This means they can suit thousands of applications. Below are some of the fields we typically work in.

Industrial Operations

We have experience providing custom fibreglass and composite solutions to a wide range of industries, including food processing, aluminium smelting and fertiliser plants. This includes:

Custom composite industrial products

• Machinery guards
• Insulated personnel cages/buckets for forklifts and cranes
• Non-conductive ladders
• Pipes, ducts and covers
• Tanks and troughs
• Silos

Containment solutions to protect people, places and the environment

• Sumps
• Bunding
• Easy-clean fibreglass wall linings

Transport

We have the capability to make, repair, restore, modify and protect all kinds of high-performance fibreglass transport products, vehicles and automotive parts. Some of the work we do includes:

• Repairs and modifications
• Large fibreglass flat panels
• Deck linings and coatings
• Spray-on protective coatings
• Campervan and caravan repairs
• Showers for campers and RVs
• Tractor and machine guards
• Horse float production and repairs
• Truck bodies

Pools and Recreation

We specialise in maintaining, restoring and enhancing fibreglass swimming pools. Our services include:

• Diagnose and fix leaks
• Re-line or re-coat existing fibreglass pools
• Design and manufacture pool accessories – slides, starting blocks and placegetter podiums.

Pleasure Boats

As marine specialists, fi innovations can custom make, repair, modify and protect anything nautical. We deal with all manner of recreational powerboats and yachts, commercial vessels, jet-skis, dinghies, kayaks, canoes and stand-up paddleboards, plus we can source the necessary marine parts and accessories.

Whether it’s customising a new boat to meet your needs or breathing new life into an older model, we offer a wide range of solutions. We cater for individual boat owners, manufacturers such as Stabicraft Marine, and tourism fleet owners like Shotover Jet.

A selection of our services:

Modifications

• Hardtops
• Boat lengthening
• Inboard-to-outboard conversions
• Refits

Hull and keel protection

• Carborundum keel strips
• Anti-fouling paint

Repairs

• Transom replacements
• Colour-matched Gelcoat repair
• Re-spray hulls and decks
• Osmosis treatment and repair
• Replace rotten floors and bearers

Manufacture

• Battery boxes
• Bait tanks
• Fish chillers
• King/queen seat pedestal

We also have a dedicated foam-filling machine that can inject expanding polyurethane foam into the pontoons and underfloor compartments of boats. This provides greater safety from the increased emergency buoyancy and a quieter ride due to its sound-deadening qualities. Learn more about our Foam services

Civil Infrastructure

The durability and flexibility of composites allow us to provide ideal infrastructure solutions that will stand the test of time.

We have experience working with councils and private entities to on projects including water reticulation and sewerage, providing bunds, repairs and in-line patching to existing pipework.

Agriculture

Modern composites are used for a range of practical applications in agriculture, benefitting the farmer and rural support services. These include:

• Tractor guards
• Machine guards
• Storage tanks
• Water troughs
• Custom vehicle canopies
• Water reticulation
• Bunds

Architecture and Building

Fibreglass and composites are ideal materials for building use. Their high strength-to-weight ratio, fire and weather resistance, non-corrosive and non-conductive properties make them a durable, versatile alternative to masonry and other products. With infinite options for colour and finish, composites really are the perfect architectural and design tool.

We use composite technology to make earthquake-safe chimneys, columns and facades that look just as solid as traditional brick and stone masonry.

We can custom craft from concept, or replicate and manufacture almost any complex shape, structure, pattern or decorative piece.

Some of the common applications for composites in architecture and building include:

• Pillars and columns
• Replica-patterned architraves
• Replica stonework and facades
• Chimneys

Custom Manufacturing

Our experienced composite team can work with you from a prototype onwards to create a custom product that meets your needs, using techniques that maximise the advantages of composites.

There are several steps in the custom manufacturing process.

1. Make an exact replica of your item, called a plug.

2. Take a mould off the plug. For a one-off product, a temporary mould is acceptable. But if a high number of parts are required, then a more durable mould is made.

3. The finished part is made for you, using the most appropriate technique and composite product for your application.

Composite Processes

fi innovations is the expert in resin infusion, also known as vacuum infusion – a state-of-the-art technology producing lightweight products with maximum strength and a precision finish.

The benefits of resin infusion, compared to traditional laminating methods, include:

• Optimal resin-to-fibre ratio
• Stronger laminate
• Minimum weight
• Lower number of voids
• Reduced operator exposure to harmful chemicals
• Reduced resin usage with cost savings
• Easier lay-up of reinforcement layers
• High quality exposed carbon finish if desired

We use a range of composite processes, including hand lay, laminating gun and vacuum bagging.