Case at a glance: In a mining operation, elevated walkways and access platforms around processing equipment had been built with steel grating. Years of moisture, chemical contact, and heavy foot traffic had caused significant corrosion, especially at cut edges and support points. HotFRP supplied heavy-duty molded FRP grating as a replacement, matched to the existing support spacing and the loads imposed by workers and maintenance equipment.

Project Background

The walkways serve as daily access routes for operators and maintenance crews, and they occasionally support tool carts and small equipment during servicing. The original steel grating had been coated, but the coating system did not hold up well against the combination of dampness, spilled process water, and chemical residues typical of the site. Several panels had become loose at the edges, and rust flakes were a regular problem around the fasteners.

The maintenance team wanted a replacement that could handle the same loads without requiring frequent recoating or panel replacement. Because the support structure was already regularly spaced and in serviceable condition, the project focused on swapping the grating panels only.

Material Selection

After reviewing the span distances and the types of loads expected, HotFRP recommended heavy-duty molded FRP grating. This type of grating is designed for applications where higher load capacity or longer spans are required compared with standard open mesh panels. The heavier construction provides additional stiffness and strength while keeping the benefits of fiberglass: no rust, light weight relative to steel, and resistance to moisture and many chemicals found in mining environments.

The open mesh design allowed water and debris to fall through rather than collect on the walking surface, which reduced slip risk and helped keep the walkway clear. For areas with frequent foot traffic and occasional rolling loads, the panels were selected based on the supplier’s span tables to ensure they matched the existing support spacing without overloading the structure.

Installation Notes

Installation took place during a scheduled maintenance window, with sections of walkway closed one at a time. The FRP panels were lighter than the steel panels they replaced, so the crew could handle and position them without cranes or lifting gear. A small number of panels required field cutting to fit around pipe penetrations and equipment bases. All field-cut edges were sealed with a compatible resin topcoat before installation to protect the exposed glass fibers from moisture and chemical wicking, which is especially important in a mine environment where dampness is common.

The panels were fastened with standard FRP grating clips. Before finalizing the layout, the crew checked the support spacing against the supplier’s recommendations for the selected heavy-duty panel type. No additional steel supports were needed because the existing framework was already within the required span limits.

Outcome and Observations

Since installation, the walkways have remained in service without the recurring rust and panel loosening that marked the previous steel grating. The maintenance team reported that the new surface feels secure underfoot, even when wet, and that debris no longer collects in the same way it did with the old panels. The heavy-duty construction has held up well under regular traffic and occasional wheeled loads.

This case demonstrates that heavy-duty FRP grating can serve as a practical replacement for steel in mining walkways where corrosion and moisture are ongoing concerns. Matching the panel type to the existing support spacing and sealing all field cuts were key steps in ensuring a straightforward installation and long service life.