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West Palm Beach, FL 33409, USA
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How Pultrusion GFRP Material Manufacturing Technology Works

Our glass fiber reinforced polymer processing systems run a continuous pultrusion cycle that converts glass rovings into finished composite rebar. GFRP processing equipment feeds rovings into the line, impregnates them with resin, shapes the bundle in heated dies, cures the material and then cuts it to adjustable lengths, ensuring consistent quality and high production efficiency across every stage.​
Preparation and feeding of fibers
The glass roving is placed on racks, and the threads are fed through guide combs and rollers.
​The number and layout of the fibers determine the future diameter and strength of the reinforcement, so the number of threads and tension are controlled at this stage.
Polymer impregnation
A bundle of dry fibers enters a bath of binder polymer. The bath ensures complete wetting of the fibers and the removal of bubbles; excess resin is partially removed by guides/calibrators after exiting the bath.
Forming and hardening in a die
The impregnated "wet" bundle passes through preformers - a set of holes and guides that assemble it into a compact round bundle matching the diameter of the required reinforcement. It enters a heated steel die (matrix), where the channel has the shape and diameter of the future rod
Forming and hardening in a die
The impregnated "wet" bundle passes through preformers - a set of holes and guides that assemble it into a compact round bundle matching the diameter of the required reinforcement. It enters a heated steel die (matrix), where the channel has the shape and diameter of the future rod
Cooling
After exiting the hot zone, the rebar passes through an air or water cooling section (bath/tunnel) to stabilize the mold and relieve thermal stress. The already-cured rebar is then gripped by a crawler or roller puller, which pulls the entire object through the line at a constant speed.
Cutting
Adjustable‑length cutting of composite rebar is performed by a cutting unit at the end of the line, where the desired product length is set via the control panel and maintained automatically to ensure a perpendicular rod end without noticeable deformation.

Configurable FRP Production Technology

Composite Group's FRP production line is designed for uniqueness and customizable parameters, allowing us to tailor our FRP production equipment to meet the specific requirements of your project. Customizable parameters for production include various rebar diameters, mesh cell sizes, and the ability to design unique bending shapes.
Configurable parameters:
  • Selectable GFRP rebar diameters from 0.08" to 1.57"
  • Customizable mesh cell sizes and various rebar diameters within the mesh
  • Ability to produce any shape for non-standard types of bent rebar
  • Ability to select the appropriate operating speed for any diameter
Custom-bent GFRP elements help reduce the risk of errors on-site, as each element is pre-manufactured to a specific contour and marked according to the design.
The equipment configuration is tailored to specific structures: you can specify the required rebar diameters, angles, geometry, and bending radii, as well as create tooling of virtually any shape for the serial production of custom GFRP elements.
Design a custom GFRP bent element line to suit your needs.
Request a custom configuration
Produce custom FRP bent elements
Quality Standards & Testing
FRP Products manufactured by the lines of the Composite Group meet the required quality standards for composite reinforcement in the USA and around the world.
Our production lines are engineered so that GFRP rebar and mesh manufactured on this equipment can be qualified to all relevant U.S. and international reinforcement standards when customers follow specified materials and process parameters. Products made on our lines have undergone mechanical and durability testing, with all test results documented and available for technical review, confirming compliance with industry requirements.
We also implement structured quality control procedures along the entire process chain and provide a formal quality guarantee for equipment‑produced output, ensuring repeatable properties from batch to batch.
440.1R-06 - Guide for the Design and Construction of Structural Concrete Reinforced with FRP Bars.
440.2R-08 - Guide for the Design and Construction of Externally Bonded FRP Systems for Strengthening Concrete Structures.
440.3R-04 - Guide for Test Methods for Fiber-Reinforced Polymers (FRPs) for Reinforcing or Strengthening Concrete Structures.
The company holds the following certifications:
TÜV SUD Germany 2017,
TÜV SUD Germany 2020,
TÜV Austria 2021,
TÜV SUD Germany 2024
Constantly developing
The company has produced three generations of equipment and six types of machine lines, successfully supplying customers in nine countries.​
Patents & Intellectual Property
The company holds 20 PCT patents for inventions, 6 patents in India, and 4 patents in China, while actively registering intellectual property at the national level in 14 countries.

Requirements for GFRP Rebar Production Line

Electricity consumption
12 kW/h – average

24 kW/h – peak

380 V, 50 ±1 Hz – power supply
Minimal staffing
Only 2 operators per shift required — full cycle automation reduces labor costs
Plant space needed
500 yd² required for installation and operation
Caring for the environment
Water consumption up to 528.4 US gallons per production cycle
(closed-loop system recommended)
Budget to Start
The cost of the production line starts from $140.000
Small dimensions
Length: 41.5 yd
Width: 6 yd
Height: 4 yd

FRP Production Line Capacity & Specifications

(recommended speed)
Request a quote
Share a few details about your project, and our team will prepare an indicative budget quotation for the
Composite Rebar and Mesh Production Lines, tailored to your target capacity and timeline.
This request is for budgetary estimation of equipment and machinery only and does not constitute a binding sales agreement. Final terms and configurations will be defined in a formal contract.

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