How to Cut and Install FRP Grating Without Damaging It
The FRP grating is commonly employed in many industrial applications, such as walkway systems, platforms, floorings, trench coverings, cooling towers, water treatment plants, and chemical plants as a replacement for metal gratings that may be vulnerable to corrosion. But the wrong cutting or installation can compromise the performance of the panel and result in poor edges or bad fitting.
Knowledge on how to cut and install FRP grating properly ensures proper performance of the panel and professional installation.
Here are the essentials you need to know about cutting and installing the FRP grating.
Can FRP Grating Be Cut on Site?
| Feature | FRP Cable Tray | GI Cable Tray |
|---|---|---|
| Material | Fiberglass-reinforced polymer | Galvanized steel |
| Corrosion resistance | High | Good, but coating can deteriorate |
| Electrical conductivity | Non-conductive | Conductive |
| Weight | Relatively lightweight | Heavier |
| Rusting | Does not rust like steel | Can rust if galvanizing is damaged/exposed |
| Maintenance | Generally low | Coating and corrosion may require attention |
| Chemical environments | Suitable for many applications | Suitability depends on galvanizing and exposure |
| Installation handling | Easier to handle in many cases | Generally heavier |
| Outdoor use | Application dependent; UV-stabilised grades available | Suitable, but corrosion protection must be maintained |
| Magnetic properties | Non-metallic | Metallic |
| Custom fabrication | Available | Available |
| Typical applications | Chemical, water treatment, corrosive and electrical environments | General industrial and commercial applications |
Yes. FRP gratings can be trimmed and drilled with appropriate workshop tools.
But trimming needs careful planning as it results in altering the original design of the grating sheet by removing a portion of it. Additional reinforcement or engineering considerations may be necessary for larger openings, penetrations, and unsupported edges. In addition to this, Plastic Fabricators can offer factory fabrication services such as cutting, notching and edge finishing to minimize on-site fabrication.
Tools Required for Cutting FRP Grating
In the normal manufacture of FRP grating, you might require:
- Measuring tape
- Marker pen or chalk
- Ruler or square
- Clamps
- Circular saw with an appropriate carbide tipped blade
- Saw or jigsaw for making smaller cuts
- Drill with appropriate bits
- Finishing tools
Depending on the thickness, shape and amount of material to be cut, the appropriate cutting equipment will vary.
Step 1: Measure the Opening Carefully
Measure the actual dimensions of the opening before cutting the grating.
Measurement should include:
Length x Width x Position of support
Never base dimensions only from drawings since site conditions can change, especially at:
- Pipes
- Columns
- Structural members
- Tanks
- Machinery
- Existing platforms
Always mark the cut line before cutting the grating.
Install with tolerance in mind
Never use an exact dimension for opening as dimension for the panel.
This can give some room for installation.
Step 2: Mark the Cutting Line
Put the grating on a firm and flat surface.
With the use of a straight edge, make marks along the cut line.
In case of large panels, measure it once again before cutting it.
Measure → Mark → Re-measure → Cut
Sometimes, after cutting a wrong line, it is very difficult to make any changes in it.
Step 3: Support the Grating Before Cutting
One of the main factors responsible for rough or damaged cuts is vibrations during the cutting process.
The cut should be supported from both sides and the panel held down with suitable clamps.
This will prevent:
- Vibrations
- Chips
- Splinters
- Uneven cuts
Good support is especially important while cutting long panels.
Step 4: Use the Correct Blade
Utilize a suitable carbide-tipped blade for cutting or any other blade that is used to cut FRP or composite material.
Using an inappropriate blade for cutting FRP can cause unnecessary wear, rough cuts, and damage to the material.
Cut the material smoothly without trying to force the tool into it.
If you want to fabricate repeatedly, use tooling that is specially designed for composites.
Step 5: Handle FRP Dust Carefully
FRP cutting gives rise to fine dust and particles.
Wear suitable protective eyewear, face masks, and protective clothing.
Do not create any unnecessary dust from the FRP material at the work site.
Clear the work place after cutting and follow the site’s occupational health requirements for composite dust.
Step 6: Finish the Cut Edge
The next step is to examine the edges after cutting.
Loose fibres and any sharp projections should be taken care of by the right finishing process.
Based on the specific application, cut edges can either need resin coating or some edge treatment.
Edge treatment becomes necessary when the cut part will be coming in contact with moisture, chemicals or any other substance.
Plastic Fabricators offers edge banding and trimming for FRP moulded grating products.
Cutting FRP Grating Around Pipes and Columns
Notches and cut-outs are usually necessary for complicated industrial assemblies.
For instance:
Pipe penetration → Label position → Perform cut-out → Check edge reinforcement → Provide reinforcement where needed
It is not advisable to have a cut-out without taking into consideration its impact on the supporting structure.
This is because cut-outs can decrease the section area of the sheet, thus requiring additional reinforcement of the structure. The technical advice by Plastic Fabricators makes it clear that cut-outs of gratings for pipes, hatches and penetrations impact the load bearing capacity.
In the case of complicated cut-outs, provision of drawings and measurements or even site photographs to the fabricator could be helpful.
How to Install FRP Grating
Once the panels have been cut, installation should be completed on a properly prepared supporting structure.
1. Check the Support Structure
Prior to installing the grating, check the following:
- Spacing of supports
- Leveling of frame
- Bearing points
- Panel orientation
- Size of opening
- Fixing point requirement
Grating cannot span unsupported spans beyond its designed span distance.
For pultruded gratings, the bearing bars should run along the primary span direction.
2. Position the Panels
Mount each of the panels to the supporting structure, making sure they fit properly on all bearing surfaces.
Avoid forcing the panel into place through excessive impacts.
If there are any sections which are irregular, ensure they fit before drilling and fixing holes.
3. Drill the Fixing Holes
Drill using the right drill bit and avoid applying too much pressure during the drilling process.
The area surrounding the drilling point must be supported, where necessary, to minimize the breakout.
4. Secure the Grating
FRP Grating may be fixed using appropriate clips, clamps or mechanical fixings depending on the design of the project.
The fixing system should avoid any movement or provide proper restraint for the fixing.
Over tightening of fasteners should be avoided since it can damage the composite material.
5. Check the Finished Installation
Post-installation verification includes:
- Panel Alignment
- Joint Gaps
- Fixity of Securing
- Stability
- Edge Condition
- Contact with Support
- Penetration Clearance
- Final installation must be stable with no unintended movement or swaying.
6 Common Mistakes to Avoid
Cutting without measuring the real opening of the site
Small mistakes while measuring could cause a gap or a useless panel.
Cutting without supporting the panel
That could cause vibrations, irregular cuts, and damages to the fibers.
Wrong blade choice
The use of the wrong tool could cause low quality of cutting and tool wear.
Neglecting reinforcement for cut-outs
Large cut-outs may influence the load-carrying ability of the panel.
Installation without verifying the support distance
Gratings perform depending on their support pattern, not only on their thickness and aesthetics.
Over-tightened fastening
Tightening too much the fastener could damage the FRP where the fixings are made.
When Should You Order Pre-Cut FRP Grating?
Factory-cut grating may be a good choice where there are many complex cut-outs or where uniform sizing is required.
Pre-fabricated panels are good to consider if you have:
- Specified panel dimensions
- Pipe notches
- Column cut-outs
- Hatch cut-outs
- Edge banding
- Trim finishing
- Same panels repeated multiple times
At Plastic Fabricators we will cut, notch, edge finish, and fabricate your FRP Grating exactly as per your needs.
Sending a drawing or photo of your site to the manufacturer can minimize mistakes on-site.
What Information Should You Give an FRP Grating Manufacturer?
For an exact quote, include the following information:
- Moulded or pultruded grating specification
- Length and width of panels
- Specified thickness
- Requirement for loading
- Support span
- Number of panels
- Chemical or environmental exposure
- Specification for surface finish
- Cut-outs or notches
- Point of delivery
Plastic Fabricators suggest that you provide information including application, size of panels, spacing of supports, required load, environmental exposure, surface finish and cut-outs when ordering pultruded grating.
Final Takeaway
Proper installation of FRP grating begins with precise measurements and good support.
Ensure you have the right cutting equipment; secure the grating prior to cutting, manage FRP dust, finish all cuts and mechanically fixate in the correct manner. Above all, keep in mind support spacing and structural demands before making any large openings.
Where projects have irregular shapes or multiple penetrations, pre-fabricated FRP grating may be the answer.
FRP Grating Custom Cut to Your Specifications. Please provide the dimensions of your grating panel, support spacing and any other relevant details when requesting a quote from Plastic Fabricators.