Case at a glance: In a chemical processing facility, an elevated access platform originally built with steel grating had developed corrosion at the edges and cut ends, increasing maintenance requirements. HotFRP supplied molded FRP grating as the replacement, based on the platform dimensions and existing support arrangement. The case focuses on material selection, field cutting, edge sealing, and installation observations.

Project Background

The platform was located above a process area where mild acid vapors were present during normal operation. The original steel grating had been in service for several years, and despite periodic recoating, the edges and cut ends showed heavy rust. Walkway sections near pipe flanges were particularly affected, where small drips and condensation kept the surface damp.

The project team therefore looked for a grating material suited to the operating environment and compatible with the existing support structure. The objective was to replace the corroded panels without redesigning the platform support system.

Material Selection

After reviewing the platform dimensions and typical foot traffic, the project used molded FRP grating with a vinyl ester resin system. Vinyl ester resin systems are commonly used in corrosive industrial environments where chemical resistance is an important material-selection factor. The open mesh construction also allows liquids to drain through the grating rather than remain on the walking surface.

For areas where workers regularly walked with tools or carts, a grit-top surface was selected to provide a higher-friction walking surface in damp conditions. The grating panels were supplied in standard sizes, and the existing steel support beams were retained after a visual inspection confirmed that they remained suitable for the replacement panels.

Installation Notes

Several panels were cut on site to fit around pipe penetrations and a small equipment skid. Field cutting removes the factory-finished edge treatment, so the cut edges were re-sealed with a resin topcoat before final placement. The purpose of this step was to protect the exposed glass fibers at the cut edges and limit moisture ingress at those locations.

The panels were fixed using FRP grating clips, and the support spacing was checked against the supplier's span tables. Because the platform already had cross members at regular intervals, the replacement panels did not require additional steelwork.

Outcome and Observations

After installation, the platform returned to daily service. The maintenance team reported that the new grating did not require the coating touch-ups that had been used on the previous steel panels. No special cleaning routine was introduced beyond routine washing with water.

The case illustrates how a grating replacement can address corrosion-related maintenance on an existing platform while retaining the support structure. It also shows why resin selection, surface finish, and treatment of field-cut edges need to be considered together when selecting FRP grating for a chemical processing environment.

The observations described here are specific to this installation. They provide a project example rather than a universal service-life or chemical-exposure rating for FRP grating.