Case at a glance: In a chemical processing facility, an elevated access platform originally built with steel grating had reached the point where corrosion was creating regular maintenance and safety concerns. HotFRP supplied molded fiberglass grating as a replacement, matched to the platform’s load and span requirements. The new grating continues to perform under constant exposure to acid fumes and occasional chemical spills.

Project Background

The platform sits above a process area where mild acid vapors are 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.

Replacing the steel panels with the same material would have meant accepting the same maintenance cycle. The project team looked for a material that could handle the environment without relying on surface coatings, and that could be installed with the same support structure already in place.

Material Selection

After reviewing the platform dimensions and typical foot traffic, HotFRP recommended molded FRP grating with a vinyl ester resin system. This resin type is commonly used in corrosive industrial environments where acid resistance is a priority. The open mesh design also allowed liquid to drain through rather than pool on the surface, which helped reduce slip risk in wet areas.

For areas where workers regularly walked with tools or carts, a grit-top surface was selected to improve traction under damp conditions. The grating panels were supplied in standard sizes, and the existing steel support beams were retained after a visual inspection confirmed they were still structurally sound.

Installation Notes

The installation crew cut several panels on site to fit around pipe penetrations and a small equipment skid. Field cutting does alter the factory-sealed edges, so all cut edges were re-sealed with a compatible resin topcoat before final placement. This step is important to keep exposed glass fibers from wicking moisture and to maintain long-term corrosion resistance.

Panels were fixed using standard FRP grating clips, and the spacing between supports was checked against the supplier’s span tables. Because the platform had existing cross members at regular intervals, the replacement panels did not require additional steelwork.

Outcome and Observations

After installation, the platform went back into daily service. The maintenance team reported that the new grating did not require the same coating touch-ups as before, and the surface remained stable under normal chemical exposure. No special cleaning routine was introduced beyond routine washing with water.

This project shows how a material change, without redesigning the whole support structure, can address a persistent corrosion problem in a chemical plant environment. The choice of resin and surface finish matters as much as the grating profile itself.