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Manufacturing of SPiRe®+

Advanced Pultruded FRP Panels for Structural Repair

SPiRe®+ panels are manufactured using a highly controlled pultrusion process, producing precision-engineered Fiber Reinforced Polymer (FRP) panels for structural repair and strengthening. This advanced manufacturing method ensures consistent quality and high performance for infrastructure rehabilitation projects.

manufacturing-structural-frp-panels-by-pultrusion
SPiRe+ panels are manufactured using the pultrusion process

Pultrusion Process & Materials

At the core of SPiRe®+ is a continuous pultrusion manufacturing process, where high-strength glass fibers are saturated with vinyl ester resin and formed into rigid structural panels.

These pultruded FRP panels offer:

  • Uniform geometry and thickness
  • High strength-to-weight ratio
  • Long-term durability in harsh environments

The use of vinyl ester resin FRP provides exceptional resistance to:

  • Corrosion and moisture
  • Marine and coastal exposure
  • Chemicals, chlorides, and industrial environments

This makes SPiRe®+ an ideal solution for:

  • marine infrastructure repair
  • seawall and bulkhead rehabilitation
  • wastewater and chemical plant structures
Pultruded FRP SPiRe+ panels being manufactured at QuakeWrap facility
Pultruded FRP SPiRe+ panels being manufactured at QuakeWrap facility

Engineered Surface for Improved Bonding

A defining feature of SPiRe®+ is its grit-coated FRP surface, designed to improve bonding with grout or concrete.

This grit-coated backing:

  • Enhances FRP-to-concrete bond strength
  • Creates mechanical interlock with grout
  • Improves composite structural behavior
  • Reduces field surface preparation

As a result, SPiRe®+ functions as both:

  • A stay-in-place formwork system
  • A structural reinforcement solution

Versatile Structural Applications

SPiRe®+ is a multi-purpose FRP panel system used in a wide range of infrastructure repair applications.

Common applications include:

  • Concrete wall repair and strengthening
  • Seawall and sheet pile repair systems
  • Slab and soffit rehabilitation in industrial facilities
  • Beam and girder strengthening
  • Marine pile and waterfront structure repair

Its lightweight nature allows installation in:

  • Confined spaces
  • Underwater conditions
  • Areas with limited access

This significantly reduces construction time and eliminates the need for cofferdams or heavy formwork.

SPiRe+ panels repairing seawalls, piles and pilasters in Fort Lauderdale, Florida
SPiRe+ panels repairing seawalls, piles and pilasters in Fort Lauderdale, Florida

Standard Sizes & Custom Fabrication

SPiRe®+ panels are available in:

  • 3 ft wide FRP panels
  • Standard lengths of 12 ft and 18 ft

Custom manufacturing allows:

  • Virtually any panel length
  • Reduced joints and faster installation
  • Project-specific solutions for complex geometries

A Manufacturing Advantage

By combining pultruded FRP technology, vinyl ester resin durability, and a grit-coated bonding surface, SPiRe®+ delivers:

  • Long-lasting corrosion-resistant infrastructure repair
  • High-performance structural strengthening system
  • Fast and efficient installation
  • Reduced lifecycle costs

SPiRe®+ is a proven solution for extending the life of critical infrastructure in harsh environments, including marine, industrial, and transportation applications.

Case Studies

Below are few published papers and videos of projects that have used the new SPiRe®+ system: