FRP Grating Installation Guide for Industrial Walkways and Platforms
The correct installation of FRP grating is not only about laying the panels on a metal framework. The proper spacing of supports, orientation of the panels, trimming, fixing and loads all influence the quality of an industrial walkway or platform.
FRP grating can be installed wherever protection against corrosion and maintenance-free flooring is needed: in chemical plants, water treatment plants, cooling towers, industrial platforms, walkways, tank farms, etc.
This guide describes how to install FRP grating correctly and what should be considered before using the panels.
What Is Required Before FRP Grating Installation?
Before installation, make sure of the following:
- Type of grating: moulded or pultruded
- Panel lengths and widths
- Panel thickness
- Load on the grating
- Clear span between supports
- Support spacings
- Method of fixing
- Surface finish requirement
- Pipe holes, column holes, and equipment holes
The choice of the grating should be based on the load, span, support spacings, and applications, and not only on the thickness.
Step-by-Step FRP Grating Installation
1. Inspect the Supporting Structure
Before installing the grating, make sure to check the steel or concrete support system.
Make sure that:
- The supports are properly aligned
- The framework is leveled
- The spacing of the supports corresponds to the design
- Bearing surfaces are sufficient
- Obstructions do not exist
- Openings and access points are properly positioned
The grating panel relies on the underlying support system. A panel that can handle more weight will not necessarily make up for insufficient or widely-spaced supports.
2. Confirm the Panel Orientation
In pultruded FRP gratings, the primary supporting I-beams need to be directly spanning the structural supports.
The incorrect placement of the panel would greatly alter the load transfer mechanism.
According to Plastic Fabricators, the following should be considered before the installation of the panel: bearing direction, support spacing, and frame arrangement.
3. Measure the Opening
Measure the real area of installation prior to cutting.
Check:
Length x Width x Number of supports
Also consider piping, columns, drains, hatches and other things which might require cut-outs.
Site measurement must be checked prior to cutting as an oversized or undersized panel will cause problems.
4. Cut the FRP Grating Where Required
FRP grating may be trimmed, bored and notched for site-specific installation.
For straight cuts:
- Measure and mark the size needed.
- Position the grating appropriately.
- Select the right tooling to cut composite.
- Cut the grating smoothly.
- Clean the loose fibers and sharp edges.
For large openings for pipes or equipment, consider whether there is enough support left in the grating. Large cutouts can alter the grating’s load characteristics.
5. Position the Panels
Position the panels on the support structure that has been prepared.
Ensure that each panel is:
- Properly positioned on the support structure
- Providing sufficient support
- Properly aligned
- Not rocking or moving
- Not interfering with other panels and/or equipment
Panels should never be rammed into the opening by forceful impact.
6. Install the Fixings
FRP Grating must be fixed to ensure that there is no motion during normal usage and other loads.
Depending on the application, proper FRP Grating clips, clamps or mechanical fasteners may be utilized.
The fixation system must be chosen based on the type of grating, support system, and project requirements.
Over-tightening must be avoided since composite material will be damaged due to excessive fastening force.
7. Check Joints and Cut-Outs
After the correction of panels, joint and openings inspection should be done.
The following need special consideration:
- Joint between panels
- Penetrations through pipes
- Drain openings
- Column openings
- Hatch openings
- Openings at platforms
- Opening at stairs
Any unsupported edge or large openings must be checked before use of walkway.
FRP Grating Installation for Industrial Walkways
The design of industrial grating needs to take into account the reality of use.
Prior to installation, one must think about:
Foot traffic: The likely foot traffic and loading of the surface.
Traffic by Equipment: Wheeled equipment (carts, etc.) moving across the surface.
Chemical exposure: The right resin system for the chemicals present.
Wet or Oily conditions: An anti-slip finish may be needed.
UV or Weathering conditions: For outdoor applications, this is a consideration.
Plastic Fabricators supplies grating with an anti-slip surface from a grit finish for areas where wet, oily, or process residue might create slip hazards.
FRP Grating Installation on Factory Platforms
The basic process for a factory platform is:
Inspection of existing platform
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Confirmation of support spacing
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Grating type verification
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Measurement of panels
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Cutting/notching if needed
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Installation of panels
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Fitting of clips/nails
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Checking of joints and cut-outs
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Stability testing
If the platforms have to accommodate equipment, then they should not be used only based on foot-traffic rating.
Moulded vs Pultruded FRP Grating Installation
Installation will vary depending on the type of grating.
Moulded FRP Grating
Moulded grating is made in one piece as an interlocked mesh panel and can be used for walkway, platform, floor and trench covers.
Pultruded FRP Grating
Pultruded grating involves combining structural FRP profiles to form a grating panel. Care should be taken about the load direction and bearing bar orientation.
The right choice will depend on several factors.
Common FRP Grating Installation Mistakes
Installation without considering the support spacing
The performance of the grating relies not only on the specification of the panel but also on the support structure.
Opening cut outs too large without thinking of reinforcement
Taking out of the load bearing parts can affect the performance of the panel.
Wrong installation of pultruded panels
The bearing bars need to be in line with the load bearing direction of the structure.
Use of incorrect fixings
Inadequate fixation will cause movement of the panels.
Failure to consider chemical compatibility
The resin system needs to be right for the chemicals and the environmental conditions.
Selection of grating only based on thickness
Thickness alone does not determine suitability of a panel.
Can FRP Grating Be Factory-Cut?
Yes. Panel production from a factory is effective for projects where there are multiple panels or unusual openings and exact dimensions.
Plastic Fabricators’ services include:
- Precise panel cutting
- Edge banding
- Trim finish
- Notching pipes and structures
- Resin selection
- Colour selection
Factory-produced panels minimize on-site cutting and facilitate easier installations.
In large-scale industrial projects, submitting drawings or measurements from the site or a marked photograph to the manufacturer can aid in panel production.
What Information Should You Give an FRP Grating Manufacturer?
In order to obtain the proper quotation and installation specifications, please provide:
- Grating type
- Panel size
- Thickness required
- Clear span
- Support spacing
- Expected load
- Type of traffic
- Chemical exposure
- Indoor or outdoor use
- Surface finish
- Openings required
- Quantity
FRP Grating, according to Plastic Fabricators, requires the customer to provide this information for specification purposes.
Final Takeaway
Proper FRP Grating Installation begins even before the first panel installation.
Verify the support structure, span, load, bearing direction, panel size, fixing system and environmental conditions before installing. Proper measurements should be taken, proper cut-outs planned and the panels installed using a suitable fixing system.
In case of complicated industrial walkways and platforms, factory cut FRP grating can help you save on site works and mistakes in installation.
Are you in need of FRP grating for industrial walkways, platforms, trenches or factories? Provide us your panel sizes, support spacing, load considerations and applications for a custom-made quotation and recommendation.