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Plastics EngineeringMAY 2015

■ NPE & ANTEC® Orlando: FromPellet to Part

■ Resin Market Focus: Where ArePE Prices Going?

■ Lean & “Green” Compounding■ Testing Tackles New Challenges

Composites 2015Reinforced plastics build bridges – and more

CONTENTSVOLUME 71 ■ NUMBER 5 ■ MAY 2015

2 From SPESPI & SPE Announce Joint Membership Option for Students

6 From Pellet to Part in FloridaBy Michael TolinskiNPE & ANTEC® Orlando 2015: Innovations, from 3-D printing to part assembly

COVER STORY14 Reinforced Plastics Move into Non-Traditional Markets

By Peggy MalnatiComposites are being brought into more medical and construction applications

22 Plastics Testing: Tackling New ChallengesBy Nancy D. LamontagneEquipment options and regulations are influencing testing practices

PLANT VISIT

26 Lean & “Green” CompoundingBy Jennifer MarkarianThis New Jersey compounder strives for sustainability

CONSULTANT’S CORNER30 Cold Runner Design: It’s All About the Details

By David A. HoffmanCommon mold features can create flow variations

34 Effect of Polypropylene Contamination on Weld Strength of Recycled Polyamide 6By Hesam Ghasemi, Philip J. Bates, Amin Mirzadeh, Ying Zhang, and Musa R. KamalContamination can be a big factor when dealing with materials likewaste carpet fiber

GLOBAL LOOK40 High-Barrier Packaging in China Enjoys Steady Rise

From China Plastic & Rubber JournalA packaging CTO talks about the direction of packaging in China

42 Too Valuable to Waste: Rethinking PlasticsBy Steve RussellRealizing the full value of plastics with “the 4 R’s”

INSIDE SPI46 Plastics Machinery Shipments Escalated Sharply in Q4

…and other news about the state of the plastics industry, from SPI: The Plastics Industry Trade Association

DEPARTMENTSNEW! Resin Market Focus ................4By IHS Chemicals

Industry News ................................50

Industry Patents ............................54By Dr. Roger Corneliussen

Energy-Saving Tip ............................57By Dr. Robin Kent

Upcoming Industry Events ............58

Market Place....................................60

Editorial Index ................................62

Advertiser Index..............................64

About the cover:“Inflatable arches” are composites-basedstructures aiding in the construction ofconcrete bridges; learn more in ourcover story. (Original photo courtesy ofUniv. of Maine.)

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Plastics EngineeringMAY 2015

■ NPE & ANTEC® Orlando: FromPellet to Part

■ Resin Market Focus: WhereAre PE Prices Going?

■ Lean & “Green”Compounding

■ Testing Tackles NewChallenges

Composites 2015Reinforced plastics build bridges – and more

0

www.4spe.org

www.plasticsengineering.org | www.4spe.org | MAY 2015 | PLASTICS ENGINEERING | 1

By Peggy Malnati

Reinforced Plastics Move intoNon-Traditional Markets Composites improve performance, reduce mass andcosts, increase design versatility, and extend use life

COVER STORY

14 | Plastics EnginEEring | MaY 2015 | www.4spe.org | www.plasticsengineering.org

Composites are helping speed up bridge construction (see the second section of this article).

Hyperbaric OxygenTherapy ChambersHyperbaric (above atmospheric pres-sure) oxygen therapy (HBOt) is bestknown for saving divers with “the bends”(decompression sickness), but it’s also awell-documented medical treatmentfor many chronic and acute conditions(i.e., altitude sickness, severe anemia,brain abscesses, carbon-monoxide poi-soning, arterial embolism, radiationinjuries, and sudden vision or hearingloss). Because HBOt temporarilyenables blood to carry more oxygen, italso helps fight infection, reducesinflammation, and speeds healing incases of crushing injuries, skin/boneinfections, skin grafts, and burns.

traditionally HBOt sessions wereadministered in rigid single- or multi-person chambers capable of pressuresup to 3 ata (atmosphere absolute, i.e.,pressure above normal atmosphericpressure). these heavy glass and met-al units were permanent installationsthat were costly to install and maintain,so treatment costs were high and cham-bers were only available at largehospitals or naval/diving and recom-pression centers.

More recently, single-person, soft-sided portable systems capable of

pressures to 1.4 ata were introduced.these polymer-coated fabric chambersdon’t provide the same efficacy as thehigher-pressure rigid systems, but theyare less costly to purchase and maintain,making them affordable for small clin-ics and individuals. they also weigh farless so are portable/transportable andcan be stowed until needed.

now, a new composites-intensivehyperbaric chamber bridges the gapbetween costly/high-pressure units andportable units operating at less thanhalf the pressures. the Hematocaresystem from groupe Médical gaumond(gMg; Montréal, Quebec, canada) tooka decade to develop, and later this yearwill become the first HBOt system to

composites have a long history of use in industries such as automotive, avi-ation/aerospace, and sporting goods, but their use is now expanding intoless-traditional markets like medical, infrastructure, power transmission, and

building & construction, where they are displacing metals, wood and wood prod-ucts, and even concrete. composites are moving into non-traditional segments fora variety of reasons: they improve part performance, reduce mass and costs,increase design flexibility through parts consolidation, reduce or eliminate sec-ondary operations, don’t corrode or rot, extend durability and use life, increaseproduction speeds, and produce more consistent products. some interesting exam-ples of recent applications in non-traditional markets are below.

Hyperbaric oxygen therapy (HBOT) is a medicaltreatment for a variety of chronic and acuteconditions. A new type of composites-intensivehyperbaric chamber has a cone-shaped hollowchamber that’s filament wound using high-performance aramid fiber impregnated withurethane. Rigid composite end caps (infused withgel-coated, fiberglass-reinforced epoxy and fittedwith curved acrylic windows) are held snuggly in place on either end of the flexiblechamber by pressure alone and provide patient egress. All standard systemcomponents pack into a tough two-piece HDPE rotomolded case with casters(insets). (Photos courtesy of Groupe Médical Gaumond.)

www.plasticsengineering.org | www.4spe.org | MaY 2015 | Plastics EnginEEring | 15

achieve global agency approvals. Work-ing with national research councilcanada’s industrial research assistanceProgram (iraP; Ottawa, Ontario, cana-da), cytec industries inc. (WoodlandPark, new Jersey, Usa), and compositesatlantic ltd. (lunenburg, nova scotia,canada), the team’s goal was to devel-op a lightweight chamber capable ofmaintaining 3 ata without leaking ortearing, but still affordable for smallclinics and individuals. (certification at3 ata operating pressures means cham-bers are tested at pressures six-timeshigher, so mechanical requirements aredemanding and flame-retardancy stan-dards stringent, owing to oxygen’scombustibility.)

Years of testing and evaluation ledto development of a filament-woundcone-shaped hollow chamber producedby composites atlantic using high-per-formance aramid fiber from teijin ltd.(Osaka, Japan) impregnated with cus-tom-formulated urethane.

rather than make ill patients enterthrough a double-zippered opening atthe top, like with most soft-sided units,gMg eases patient access by creating

door- and window-equipped rigid com-posite end caps that fit snuggly into theflexible chamber yet aren’t permanentlyattached. gMg infuses the parts in gel-coated, fiberglass-reinforced epoxy.after post-mold trimming, an aluminumsupport ring is bonded into each endcap followed by insertion of a rubber O-ring, a curved acrylic window, and afinal aluminum locking ring. cleverdesign inside the end caps allowsoptional rails to be added to supportpatients entering on stretchers.

all standard system components packinto a tough, two-piece case with castersthat’s rotomolded from unreinforcedhigh-density polyethylene. When thechamber is deployed, carrying-case halvesopen to form a base that supports thechamber, while foam blocks prevent itfrom rolling. With experience, two peoplecan deploy the system in 15 minutes andrepack it in half that time. the system iswarranted for ten years/4,000 cycles and,with a 125-kg packed weight, is said to bethe lightest, least-expensive HBOt cham-ber certified to 3 ata working pressures,making it adaptable for home, clinic, orhospital use.

Composites for RapidBridge ReplacementWith increasingly unpredictable weath-er, natural disasters, and civil unrestplaguing many regions, it’s increasinglyimportant to be able to replace dam-aged or destroyed bridges rapidly. Evenin settled areas, aging infrastructure onbridges that are over their limit andbeyond their service life means localand regional governments need ways toreplace bridges quickly and cost effec-tively, preferably with materials offeringlonger use life.

traditional precast and cast-in-placeconcrete bridges have issues. Precastcomponents are very heavy and costlyto move, while extensive formworkmust be built before casting-in-place,followed by long waits as the concretecures, adding weeks or months to jobs,particularly in cold and wet conditions.although fully cured concrete isdurable—withstanding broad temper-ature fluctuations, high winds, heavyloads, and abrasion—it can be affectedby cold-weather salt deicers used onroads and bridges (causing concrete

16 | Plastics EnginEEring | MaY 2015 | www.4spe.org | www.plasticsengineering.org

Reinforced Plastics ____________________________________________________

A composites-intensive bridge technology developed by the University of Maine is said to provide a better and faster way toreplace a wide variety of concrete and other bridges. The composite bridge uses “inflatable arches”―Portland cement-filledresin-infused textile sleeves that provide a permanent form for concrete—creating an exoskeleton that eliminates the needfor rebar and protects concrete from water and environmental damage. (Photos courtesy of University of Maine.)

spalling and rebar corrosion) and waterintrusion (necessitating installation andmaintenance of expansion joints to pre-vent freezing water from splittingcomponents). Both situations eventuallycan compromise bridge integrity.

additionally, concrete’s high specificgravity adds significant “dead weight,”reducing a bridge’s true carrying capac-ity. the shear mass of precastcomponents and the high labor require-ments of cast concrete require the useof heavy equipment and large workcrews. this increase risks for negativeenvironmental impacts and oftenrequires environmental-impact studiesbe conducted prior to permitting, slow-ing projects and adding cost.Furthermore, shutting down busybridges for repair/rebuilding increasestraffic delays and commute times, frus-trates commuters, and can harm localcommerce, all of which mean munici-palities want bridges fixed and back inservice as soon as possible.

a composites-intensive bridge tech-nology developed by University ofMaine’s advanced structures & com-posites center and commercialized byadvanced infrastructure technologies(both in Orono, Maine, Usa) is said toprovide a better, faster way to replacea wide variety of concrete bridges, free-way underpasses/overpasses, andrailroad bridges. the project began withthree ambitious goals: replace concreteformwork and rebar, use efficientarched structures, and produce com-ponents at the worksite.

researchers reviewed and rejectedmany design options before decidingto produce formworks using inflatablefabric sleeves. Ultimately a proprietaryfabric blending glass, carbon, and otherfibers and infused with epoxy-vinyl esterresin (selected for its durability, ductili-ty, and favorable adhesion to concrete)was developed. in use, the custom-

designed sleeves are cut to length andwidth, joined to form a tube, and mount-ed to custom fixtures. tube ends arethen sealed and sleeves are inflatedwith air prior to resin impregnation.cure occurs at room temperature andnormal pressures.

arches are then moved to a job site,positioned, and concrete footings arepoured. next, holes are cut at the top ofeach arch and a proprietary grade ofPortland cement (which is slightly expan-sive and bonds well to the compositesleeve) is poured into each arch andallowed to cure. then decking (conven-tional or composite) is installed over thearches, sand backfill is used, and a finalwear surface (asphalt or polymer con-crete) is applied.

Functionally, inflatable arches providea permanent form for concrete, createan exoskeleton that eliminates the needfor rebar, and protect concrete fromwater intrusion and other environmen-tal damage. installed costs can be 20%lower than conventional materials, yetthese joint- and rebar-free bridges aredesigned to last at least twice the typical50- to 70-year lifespan of conventionalbridges. Eliminating expansion jointsand rebar means the new technology isless prone to fatigue, corrosion, andwater infiltration, reducing maintenancecosts and time. smart sensors can beinstalled for active bridge monitoring. asmall bridge can be completely replacedin as little as one week, versus monthswith conventional construction.

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A pultruded 3-D composite technology called Transonite developed by EbertComposites Corp. is used for a wide variety of lightweight panels, providingreinforcement in all three orthogonal directions. A variety of fibers, fabrics, andthermoset or thermoplastic resins can be used, making it easy to tailorperformance, cost, and mass to meet application needs. An internal “wave”pattern of reinforcement is said to withstand deflection and high shear forces.(Photo courtesy of Creative Pultrusions, Inc.)

Durable 3-D CompositePanel Structures

a unique pultruded 3-D compositedeveloped by Ebert composites corp.(chula Vista, califorinia, Usa) andlicensed by creative Pultrusions, inc.(alum Bank, Pennsylvania, Usa) pro-vides x, y, and z-axis reinforcement(structural fibers in all three orthogonaldirections). this increases panel dura-bility by greatly improving peel strengthand delamination resistance and boost-ing torsional rigidity. Other benefitsinclude extremely high strength/weightratios, thermal and acoustical insula-tion, and elimination of corrosion.

called transonite, the technology(now in its third generation) is coveredunder nine U.s. patents and is producedon unique equipment via an automatedprocess (both developed by Ebert) capa-ble of supporting high-volumemanufacturing at low costs. Functioninglike i-beams, z-axis fibers are precutrovings (e.g., glass, carbon, aramid,basalt) that are pushed through topand bottom skins with or without a corein place. the “clinched/riveted” rovingsin one discrete fiber bundle aren’t con-nected to fibers in adjacent bundles(fibers are not stitched together), yetthe unbroken fibers form regular“columns” in the through-thicknessdirection. cores may be solid or foamedresins or even balsa wood.

special tooling keeps skins and fibercolumns from collapsing prior to infu-sion/impregnation, which ties fibers,cores, and skins. additional skin layersare added to lock rovings into originalskins and improve surface finish. Final-ly, the pultruded sandwich is pulledthrough a heated die to catalyze andcure the resin, which typically is a ther-moset (unsaturated polyester, vinylester, or polyurethane) but also can bethermoplastic.

thanks to process versatility, a widevariety of fibers, fabrics, and resins canbe used, making it easy to tailor per-formance, cost, and mass to meetapplication needs. Performance can bechanged by manipulating panel thick-ness (13-102 mm), skin thickness(1.27-10.2 mm), skin/core ratio, panelwidth (15-259 cm), and density of z-axisfibers (0.08-2.48/cm2). since it’s a con-tinuous process, panels can be cut tonearly any length greater than 2.5 cm,yielding large, clean surfaces free ofseams, which is important in situationswhere moisture intrusion is a concernand/or aesthetics are important.

the angle of z-axis fiber placement isanother interesting variable. While 90°degrees to the skins is most common,recent developments permit addition ofvery-high-shear layers of fibers posi-tioned nearly 45° to the z-axis prior toresin impregnation, creating an internal“wave” pattern that withstands deflec-tion and high shear forces.

Post-mold trimming is done via water-jet or diamond tools. Bare panels can befinished with a variety of surfaces forinterior or exterior use, including carpet,antiskid aggregate, wallpaper, andpolyurea.

transonite technology is currentlyused for floors and sidewalls on recre-ational vehicles and truck trailers andwas demonstrated on a small buildingin a chinese solar competition. Otheruses include panels for ballistic protec-tion, air-cargo containers, marine uses,furniture, rails, bridge decks, industrialmats, and automotive uses.

Composites for PowerTransmissionin an industry long dominated by met-als, uses of composites in high-voltageoverhead electrical conductors areincreasing power-transmission capa-

bilities and capacities. as populationsincrease and nations consume morepower, much of the planet’s electrical-transmission infrastructure is outdatedand exceeding its capacity limits. loadgrowth aside, utilities in many coun-tries legally are required to connect toincreasing amounts of solar and windenergy generated by public and privatesources, which expands and furtherstresses aging electrical infrastructure.

to meet projected demand andaccommodate alternative power gen-eration, electric utilities have three waysto increase system capacity: • build new lines (a costly approach

requiring difficult-to-secure publicconsent and rights-of-way for land,and even longer waits for permittingand construction);

• “reconductoring” (restringing) exist-ing lines with conductor of the sametype (which may necessitate strength-ening or replacing existing towersand poles, and still involves waits forpermitting and construction); or

• reconductoring existing lines withmore efficient conductor (the fastestand least costly approach).Overhead transmission lines must

meet many challenging standards,including minimum clearance toground, ice and wind loads, and ther-mal-operating limits to prevent damage.lines are designed to maintain a safedistance from the ground at a ratedelectrical load under specific environ-mental conditions. line sag andtherefore ground clearance are affect-ed by both thermal and mechanicalissues.

When lines are strung over areas withmountains, bodies of water, or prone tosevere weather, higher performancehigh-temperature low-sag (Htls) con-ductor is typically required instead ofconventional aluminum conductor steel-reinforced (acsr) or other alloy-based

18 | Plastics EnginEEring | MaY 2015 | www.4spe.org | www.plasticsengineering.org

Reinforced Plastics ____________________________________________________

products. conductors using lighter,stronger core materials with broaderthermal performance can transmitmore power during both normal andcontingency operations while main-taining required line clearance.

recent developments in high-strength, low-sag lightweight compositecores to replace stranded steel coreshave changed how transmission linesare designed. carbon fiber-reinforcedepoxy cores typically use a single (mono-lithic) rod rather than multiple strandstraditionally used with steel cores toeliminate a single point of failure. Mono-lithic cores require a larger bendingradius than traditional stranded coresand must be handled carefully bytrained technicians using special con-nectors and terminations.

another composite product featuresaluminum metal-matrix composites(MMcs, aluminum oxide fibers in a high-purity aluminum matrix). themulti-strand MMc products use tradi-tional fittings but also have a higherbend radius than traditional acsr con-ductor. they are rated for highoperating temperatures (to 240°c).However, their high cost means theyare typically used for only the mostrestrictive installation environments.

given the limitations of current Htlscomposite conductors, southwire com-pany, llc (carrollton, georgia, Usa, oneof the world’s largest wire and cableproducers), and celanese corp. (Dal-las, texas, Usa) have jointly developeda new type of Htls product called c7™Overhead conductor. the multi-strand

pultruded thermoplastic-compositecore combines carbon fiber-reinforcedpolyphenylene sulfide (PPs) with a poly-etheretherketone (PEEK) capping layerfor very-high resistance to chemicals,heat, galvanic corrosion, and abrasion.

the new conductor carries approxi-mately twice the current as conventionalascr conductor and provides a highcontinuous-use (180°c) and even high-er emergency-use (225°c) rating,helping utilities maximize energythroughput. the installation-friendlyconductor provides greater flexibilityand bending radius than monolithicthermoset and MMc composites andworks with conventional fittings, reduc-ing crew training time and increasingfamiliarity. a multi-strand core meansgreater reliability and redundancy dur-

www.plasticsengineering.org | www.4spe.org | MaY 2015 | Plastics EnginEEring | 19

_____________________________________________________________________

Visit us atNPE 2015

West Hall, Booth W-1329Orlando, FL�/�USAMarch 23-27, 2015

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ing installation and long-term use com-pared with monolithic-core conductor.

the new product combines high per-formance, excellent value, and thetoughness and durability to deliver atleast a 40-year service-life expectancy,helping utilities increase capacity withoutthe cost of installing new infrastructure.By reducing power losses, transmissionis more efficient, and utilities delivermore billable power to customers whileavoiding infrastructure upgrades, whichalso benefit power consumers andreduce environmental impact of thepower-transmission grid.

Composite FoundationWalls for Homesa new composite-based foundation-wall system introduced last year by

composite Panel systems, llc (Eagleriver, Wisconsin, Usa) with supportfrom panel fabricator Fiber-tech indus-tries, inc. (spokane, Washington, Usa)and resin supplier ashland Perform-ance Materials (a commercial unit ofashland inc., Dublin, Ohio, Usa) is set tooverturn the century-old trend of usingpoured concrete to form vertical foun-dation walls on residential homes, atcomparable costs, faster installation,and far-better performance.

concrete has very-high compressionstrength but poor tensile strength,which is why it’s so often reinforcedwith rebar. in the case of below-gradefoundation walls, concrete’s brittlenesstends to make it crack under the con-stant pressure of soil backfill within afew years of installation, leading to leakybasements. Further, because concrete

is porous and a poor thermal insula-tor, moisture and cold can easily passthrough walls, making below-groundspaces damp and cool (the perfectbreeding ground for mold and mildew)unless further improvements are made.

composites, in contrast, can be engi-neered for both high tensile andcompressive strength, plus are inher-ently moisture and corrosion resistant,making them interesting materials forfoundation walls. since composites arenaturally thermally insulating and thatproperty can be improved via polymerfoams, composite foundation walls canbe insulating, helping transform cold,damp, smelly basements into warm,dry spaces and creating an airtight tran-sition between the foundation andupper floors.

the Epitome foundation-wall system

20 | Plastics EnginEEring | MaY 2015 | www.4spe.org | www.plasticsengineering.org

Reinforced Plastics ____________________________________________________

Composites are helping electrical utilities increase system capacity without the time and cost of building new conductor lines.Southwire Co. and Celanese have jointly developed a new type of high performance high-temperature low-sag conductor called theC7™ Overhead Conductor. The multi-strand thermoplastic-composite core combines carbon fiber-reinforced PPS with a PEEK cappinglayer, providing very-high resistance to chemicals, heat, galvanic corrosion, and abrasion. (Image courtesy of Southwire Co., LLC.)

consists of foam-cored fiberglass pan-els using ashland’s Modar fire-retardant,non-halogenated modified (thermoset)acrylic polymer and produced in a pro-prietary process. Panels are 18 cm thick,7.4 m long, and 2.8 m tall and carry anr-16.5 insulation value. thermal insu-lation (provided by urethane foam) andvapor barrier are integral to the panels,allowing them to last the life of the foun-dation. Pultruded flanges attached topanel ends facilitate attachment to adja-cent panels. Panels also featureintegrally molded nominally sized studs(41 cm on center) and stud cavities,which act as pilasters and make it easyfor contractors to install mechanicalsor additional insulation (boosting r-val-ues to 30+).

Unlike poured-concrete foundationwalls, which can take up to two weeks tocure depending on weather, the newsystem’s custom-fabricated panelsarrive in a single delivery ready to install.On a standard-size dwelling, founda-tion walls can be erected in less thantwo hours by crews with standard tradeskills and minimal training. this not onlygives builders more control (reducingweather and subcontractor constraints)but also means contractors can installmore homes per season with the samecrew, and that a given home can bemade weather-tight much faster.

the structurally robust compositepanels are designed to withstand six-times greater pressures than a standardsand backfill load, and each 7.4 m pan-el can withstand 272 tonnes of downforce, resulting in a maximum allow-able house load of 13,245 kg/linearmeter. Usable on any soil suitable forbackfilling, this wall system is said tobe cost-competitive anywhere concretefoundations are installed.

consumers benefit too with warmer,drier, more energy-efficient founda-tions that are structurally dependable

for the life of the home. the sanitizablepanels are highly fire retardant (havingpassed demanding U.s. national FireProtection association 286 room cornerburn testing), so no thermal barrierslike gypsum drywall are needed beforeoccupancy. this lets homeowners finishbasements at their convenience. sincepanels are 18-cm deep, not 31-cm deeplike most insulated, stud-framed castfoundation walls, the system actuallyoffers more usable living space insidethe basement―adding an average of9.3 m2 (roughly the size of a small bed-room). Finally, panel construction andinstallation use fewer natural resourcesand less energy for a smaller carbonfootprint than concrete.

the new panel system has met strictguidelines for in-plant quality and hassuccessfully completed rigorous test-ing and building code requirements setby nta inc., accredited by the interna-

tional accreditation service (ias), a sub-sidiary of the international code council(icc), which grants Epitome foundationwalls national code compliance for res-idential foundations. the technologyalso won several awards for industry-changing technology at the compositesand advanced Materials Exposition(caMX) last fall.

Acknowledgements information in this article was largelydrawn from interviews with claude gau-mond, groupe Médical gaumond, andclaude Baril, composites atlantic ltd.;Habib Dagher, University of Maine-Orono; ted Harris and Dustin troutman,creative Pultrusions, inc., and David W.Johnson, Ebert composites corp.;Michael ruby, celanese corp., and Marklancaster, southwire company, llc;and thom Johnson, ashland, inc.

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A new foundation-wall system of foam-cored fiberglass panels replaces poured concreteto create warmer, drier, more energy-efficient foundations that reportedly arestructurally dependable for the life of the home. On a standard-size dwelling,foundation walls can be erected in less than two hours by crews with standard tradeskills and minimal training. The wall system is said to be cost competitive anywhereconcrete foundations are installed. (Photo courtesy of Composite Panel Systems, LLC.)