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THE MOST BASIC TYPES OF FRP GRATINGS In our last post, we told you 5 things you need to know about FRP Grating. For those of you that are not familiar with Fibre Reinforced plastic/polymer grating, this article will give you a simplified summary and helpful background on FRP before you dive into reading this post. For those of you that ARE familiar with FRP, read on and learn more about factors to consider when selecting your grating in addition to how FRP gratings are commonly categorised in the industry. FACTORS TO CONSIDER WHEN SELECTING YOUR FRP GRATING Choosing the right grating and correct resin for your application areas depends on two factors: Environment Factors or Application area Chemical exposure level Temperature Humidity factors UV exposure Desired Fire rating Loading Requirements Load Rating Structural Support Span THE TWO MOST BASIC METHODS OF CATEGORISING FRP The two most basic methods of categorising FRP (Fibre Reinforced plastic/polymer) gratings are by: Method of manufacturing/ production Type of resin (thermosetting) used There are other sub-categories within this broad classification that are based on application areas. These include: Type of surface finish Load rating requirements Other special requirements such as UV exposure, Fire rating, Colour etc. 1. METHOD OF MANUFACTURING/PRODUCTION Moulded FRP Gratings Moulded FRP gratings are manufactured using the following process: Laying or Weaving glass fibres This step involves laying continuous glass fibres in the mould in vertical & horizontal directions. These are thoroughly wetted by the chosen resin (layer by layer). Heating & Curing After the completion of the weaving process, the mould is heated for curing the panel. Ejecting the Panel After the curing process is completed, the panel is ejected from the mould. Standard panels would have a meniscus (concave) top surface finish. Based on requirements we bond grit to the surface or finish the surface to have a plain finish. These are called secondary operations. The most important feature of the Moulded FRP grating is that they are an integral, one piece panel offering bidirectional strength. This is a standout feature compared to Pultruded FRP grating. Pultruded FRP Gratings Pultrusion is a continuous moulding process that produces products of the uniform cross section such as I beams, Channels, Flat bars, Rods, & other FRP profiles. Pultruded FRP gratings are manufactured using the following process: Resin Impregnation Preselected reinforcement materials such as fibreglass roving, mat, woven or stitched fabrics are drawn through a resin bath or resin impregnation zone where the glass substrate is thoroughly impregnated with the resin mixture (liquid thermosetting resin). Preforming & Forming This wetted out fibre is formed to a desired geometric shape as it initially gets pulled through the Preformer (Preforming Die) & then through to the Heated Die. Inside the die, the resin curing process is initiated by precisely controlling the temperature. The laminate then solidifies to the exact shape of the cavity in the die (Forming Process), as the pultrusion machine continuously pulls it. Cutting: An Automatic Cutter is deployed at the end of the machine to cut this Pultruded FRP section to desired lengths. FRP GRATING MOULDED FRP MANUFACTURING PROCESS Liquid resin and continuous fiberglass rovings are sytematically laid in a mould, layer after layer to produce the desired thickness and panel dimensions. The finished moulds are then set aside to cure. The one-piece interwoven mesh construction of moulded fiberglass grating produces a product with optimal corrosion resistance and bi-directional strength. Since the fiberglass grating is "cast" in one piece, there is no mechanical joint between bearing bars. The high percentage of resin (65%) in moulded fiberglass grating offers superior corrosion resistance and optimal impact resistance. Moulded fiberglass gratings with a square mesh pattern offer increased load capacity and panel utilization due to its bi-directional trait. Being of one-piece construction, the fiberglass grating distributes loads throughout the fiberglass grating section. ADVANTAGES OF FRP MOULDED GRATING Light weight Chemical corrosion resistance Non sparking Non electrically conductive Non magnetic Tapered bars all debris to easily fall through Standard mesh has a 70% open area Mini Mesh has a 45% open area FRP GRATING PATTERNS FRP Grating is available in two pattern types (stocked) STANDARD MESH