What Are the Key Benefits of Using FRP Gratings in Industrial Flooring?
A lot of different factors contribute to the durability of an industrial flooring system. Each industrial floor is subject to heavy shifting loads (weight), hazardous chemicals (acid/base resistant), moisture erosion from the ground or areas with high water content, accelerated heating from a machine while operating, and for all employees, regardless of where they may be working (for retail, etc.). Due to these complex requirements, many companies have selected Fiber Reinforced Plastics (FRPs) asa flooring material since this material provides an incredibly wide range of beneficial properties compared with traditional metal or timber-based flooring systems. This blog post will focus on how companies are increasingly using FRP for more than just its aesthetics; it has also emerged as an effective option for continued safety, increased durability, and long-term cost savings!
1. What Are FRP Gratings? A Quick Overview
FRP or Fiber Reinforced Plastic is generally produced through the use of glass fibers in combination with a plastic (polymer) resin matrix (i.e., polyester or epoxy resin). The composite formed has an extremely high strength-to-weight ratio and is highly resistant to moisture, corrosion, and chemicals.
There are two primary ways of making FRP Gratings:
Molded FRP Gratings – The process involves making the gratings in a mold, producing a flat, rigid panel that has very high load-carrying and impact-resisting capabilities.
Pultruded FRP Gratings – Manufactured via pultrusion, these gratings are manufactured to be stronger and more rigid; they are used for applications with heavier load requirements.
Both types are advantageous over conventional materials, which may not last.
2. Exceptional Corrosion Resistance
Corrosion resistance is one of the key advantages of using FRP gratings as an industrial flooring material.
The Importance of Corrosion Resistance to Industrial Flooring
Industrial flooring in many applications encounters corrosive materials that are damaging; therefore, FRP gratings should be utilized in the following types of industries because those environments contain high amounts of corrosive materials that will cause damage to flooring over time:
- Chemical Processing Facilities
- Wastewater Treatment Facilities
- Marine & Offshore Facilities
- Food Processing Facilities
Metal Gratings such as Steel and Galvanized Steel – While metal gratings are often used to provide structural support, they will eventually corrode, which will reduce the strength of the grating and require repair or replacement.
Benefits of Using FRP Gratings as an Industrial Grating Material
Because the chemical attack of the polymer matrix protects the glass fibres, FRP Gratings have a unique quality of corrosion resistance. This means:
- A longer service lifetime,
- Lower maintenance costs than metal gratings, and
- No corrosion or deterioration in conditions where there is moisture or a highly acidic environment.
For industrial facilities that encounter corrosive chemicals on a continual basis, the ability of FRP Gratings to provide long-term corrosion protection results in significant cost savings over an extended period of time.
3. Superior Strength and Load-Bearing Capacity
FRP gratings are very lightweight and offer exceptional strength, making them capable of withstanding some of the heaviest industrial loads.
The “lightweight” of an FRP composite comes from the hundreds of thousands of miles of extremely high-strength glass fibre contained within it. As a result, FRP composites offer superior:
- Superior tensile strength (pulling force)
- Superior flexural strength (bending force)
- Superior impact resistance (resistant to sudden loads)
These characteristics of strength enable FRP gratings to be used in:
- Heavy loading (such as truck traffic) areas
- Forkliftable areas
- As platforms and supporting mezzanines
- As trench covers for vehicular loads
Steel Compared to FRP
Steel has extremely high strength but is also very heavy and prone to corrosion. FRP gratings, on the other hand, provide the same structural ability as steel without the burdensome weight.
4. Lightweight and Easy Installation
Compared to Steel, Aluminum, or Concrete Grating, FRP is a much lighter-weight option, providing many practical benefits for industrial floor applications:
Faster Installations
FRP panels are lightweight:
- Fewer people (labour hours are significantly reduced)
- No need for heavy lifting equipment
- Installations can be completed much more quickly.
As such, FRP allows for faster completion of projects with less disruption and increased productivity.
Reduced Labour Costs
FRP panels are a cost-effective option because of the reduced amount of energy and time that is required to install them, and the smaller crews needed.
Design Flexibility
Since FRP would be slightly weightier if installed as an integral part of a building structure, extreme caution must be given to the installation of new FRP products into complex geometric shapes or retrofits.
5. Slip Resistance and Worker Safety
Safety should always come first in an industrial setting. Walkways and Floors should be designed to ensure that slip and fall accidents do not occur on them when there are wet or moist spills.
Excellent Slip Resistance
FRP grating is designed with:
- Textured surfaces
- Grit Coated Surfaces
- Non-Skid Surface Finishing
The above-listed features will ensure there is a secure grip on these surfaces in both wet/oily conditions and secure grips at all times.
Safety Functions
- Reducing workplace injury caused by accidents
- Allowing all employees who enter wet/hazardous areas to be more confident and comfortable in their jobs.
- Making all industrial workplaces meet the required federal and state safety guidelines that allow for compliance with industry regulations.
Slip-resistant floors make compliance with the applicable Federal and State Safety Guidelines possible for all facility types and prevent lost time due to employee injuries.
6. Resistance to Moisture, UV, and Extreme Weather
FRP Grating isn’t affected like many other products or materials regarding moisture, sunlight, or temperature extremes.
Moisture Resistance
FRP won’t rot or warp like wood or grow mildew because it:
- Will not take in moisture
- Will not swell or deform
- Will maintain its structural properties over time
The structural integrity of FRP is essential in Wastewater Treatment Plants, Marine Applications, and other outdoor uses.
UV Stability
When manufactured using the proper resin formulations, with the use of various UV inhibitors added, FRP Grating resists sun degradation and is an excellent candidate for industrial or outdoor use.
Temperature Tolerance
FRP can withstand significant temperature fluctuations while retaining its structural properties, making FRP ideal for use in:
- Cold Storage Facilities
- High Temp Processing Areas
- Uncovered Outdoor Walkways
7. Customization for Exact Requirements
FRP Grating’s versatility is its key advantage.
FRP Grating provides an almost infinite number of possible configurations. These include thickness, depth and width of the gratings, type of mesh pattern used, colour of grating, and edge finish. All these factors are considered when developing FRP Grating to meet the requirements of:
- Load Capacity
- Environmental Conditions
- Aesthetic and safety requirements
When using FRP Grating, an industrial customer can create flooring solutions to meet both the equipment and architectural needs of the customer.
Another important characteristic of FRP Grating is the fact that it can be easily integrated with other systems. This means that designers can make use of existing support structures, hand railings, stairs treads, and cable trays to create a cohesive industrial solution.
The ability to adapt to and integrate within these various support systems is what makes FRP a great choice for many different industrial design applications.
8. Low Maintenance and Long-Term Cost Savings
Conventional wisdom states that ongoing maintenance costs will significantly exceed initial investment. With regard to maintenance, FRP Grating significantly decreases cost.
Reduces Frequency of Maintenance
When compared to steel, FRP Grating requires far less frequent maintenance:
- Repainting Steel
- Corrosion Prevention Measures for Steel
- Replacement of Steel Surfaces
In contrast, FRP Grating requires only an occasional cleaning with a mild detergent and water.
Elimination of Expenses Related to Corrosion
Because of excellent corrosion-resistance, FRP Grating does not incur any costs associated with:
- Replacing Corroded Components
- Repairing Damaged Walkways
- Interruption of Operations Due to Maintenance
Long-Range Economic Benefits of FRP Grating
Because of the difference in the cost of maintenance, replacement, and compliance, FRP Grating generally has a greater economic value than traditional materials over the entire life of the product.
9. Electrical Non-Conductivity
In locations where electrical safety is critical, such as at power stations, switch yards, or electronic manufacturing facilities, non-conductivity presents a real benefit.
FRP is Not an Electrical Conductor
Since the composite materials utilized in FRP do not allow for the conduction of electricity, FRP gratings provide:
- a significant decrease in electrocution hazards
- increased overall safety levels within the workplace.
In addition, FRP is the best option for use in electrical or industrial areas, in comparison to steel and aluminum, which must be grounded and used with caution due to the possibility of creating electrical hazards.
10. Fire Retardant and Heat Resistant Options
Industrial applications require that FRP gratings be manufactured with the necessary fire-safety ratings established by FM and ASTM standards.
By utilizing a properly-engineered resin system combined with specific additive formulations, FRP gratings can be manufactured to meet the following fire safety requirements:
- Fire-retardant
- Low Flame Spread
- Low Smoke Emission
FRP gratings, meeting the above standards, can be used in:
- Chemical Plant Operations
- Process Facilities
- Industrial Facilities with Fire-Safety Codes.
Conclusion
Fiber Reinforced Polymer (FRP) gratings are not simply an updated version of traditional flooring materials. FRP gratings represent a transformation in the development of smarter, safer and more sustainable industrial infrastructure. The combination of outstanding corrosion resistance, lightweight strength, slip resistance, electrical safety, long service life and low maintenance makes FRP gratings suitable for all types of industrial environments.
FRP gratings can perform and provide a level of safety and cost-effectiveness that is unmatched by many other materials. From wastewater treatment plants to offshore drilling and production rigs to manufacturing facilities and energy generation and transmission, FRP gratings provide the same performance and safety as most other materials.
As industries enshrine the critical importance of safety, sustainability, and the potential for long-term operational savings, FRP gratings will continue to be a go-to solution for industrial flooring and access systems.