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. [blockquote] 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. [/blockquote] 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 38X38MM centre to centre FRP GRATING FIXING CLIPS Stainless steel "M" Clips: Clips for FRP grating, such as M clips are designed to clamp two of the FRP grating load bars to the supporting member. This provides excellent holding capacity as it restrains movement in both directions. "M" clips are available for both Standard and Minimesh grating. Stainless steel "C" Clips C Clips are designed to hold two grating panels together to minimise differential deflections when their joints fall between supports. The low nut is secured to the bottom of the clips so these can be installed from the top side of the grating. C Clips are available for standard mesh grating only and are designed for 25mm and 38mm thick FRP grating. CUTTING & INSTALLATION Cutting: FRP grating can be cut with a variety of different cutting tools. For best results we recommend a heavy duty rotary saw with a masonry, carbide or diamond tip blade. Make sure that the grating is on a steady and even surface to help prevent shifting or moving of the grating that can cause chipping of the grating surface. Please ensure you wear gloves, full length overalls, a face shield and a dust mask when cutting FRP grating. Always cut FRP grating in a well ventilated area or where mechanical extraction of the dust particles is available. Finishing: All cut surfaces should be coated with resin to prevent corrosion of the glass fibres, A coating of a two part resin or comparable to the resin used to manufacture the grating should be used. APPEARANCE OF FRP GRATING: Unlike traditional Steel and Aluminium grating when FRP grates are cut they do not have a banding bar welded to the cut edges (the cut edge becomes the finished edge). Where possilble to make FRP grating look neat and presentable we recommend that any sheets cut to size along with cut outs or penetrations be made to the nearest whole square dimension. This prevents any grates with open ends or fingers as we call them. This is not always practical but with enough forward planning this can be achieved. STANDARD SHEET SIZES FRP grating comes in one standard sheet size 1220x3660mm ex stock. Other sheet sizes are available but are manufactured to order, For non standard panel sizes please call Steel Grating Ltd to discuss what options are availalbe to suit your requirements. CUTTING TO SIZE In addition to supplying stock sheets we can also cut FRP grating to the shapes and sizes you require along with any cut outs or penetrations. TOP SURFACE FRP grating comes standard with two different surfaces for slip resistance. Grit top surface Concave top surface RESIN SELECTION Isophthalic Polyester (Type I) - Industrial grade resin great for environments where fiberglass grating may occasionally be in contact with harsh chemicals due to splashes or spills. Vinyl Ester (Type V) - Developed to withstand frequent and direct contact in the harshest of chemical environments. Type V is ideal for use in acidic and caustic environments. FRP pultrusion profiles technology is a manufacturing process which produces uniform cross-sectionally shaped glass-fiber reinforced polymer composite profiles. These profiles are designed to compete with the strength properties of traditional metal grating structures, but offer the inherent environmental benefits that come with using fiberglass. The fiberglass reinforced polymer matrix is ideal for corrosive environments and greatly reduces the maintenance required over the life-time of the grating. FRP roof tile is standard-sized FRP roofing sheets having a roofing tile-like appearance over the surface. These sheets mimic the ceramic or other types of tiles to provide a traditional look to the buildings. What is Tile Roofing? Tile roofing has been around since as early as 10000 B.C when clay tiles were used for roofing in China. The practice later spread to the Middle East and throughout the other parts of the world. Roof tiles are made from different materials, including fired clay or terra cotta products, ceramic, and slate. Still, technology advancements have allowed manufacturers to produce tile roofing from various materials such as metal, tinted concrete, bitumen, and polymer sand. A tile roofing system is a specific type of roof installation that requires a specific skill set and significant experience. Tile roofs are installed by starting at the bottom part of the roof, securing a row of tiles to the roof deck, and overlapping the next row of tiles over the first until the roof is fully covered. How Long Does a Tile Roof Last? Perhaps the most significant upside of tile roofing is its lifespan. It exceeds all other roof materials when it comes to its durability and longevity. Some buildings in Europe have tile roofs that lasted for centuries. To be more conservative in our approach, a well-cared-for and well-maintained modern tile roofing can last an average of 50 years. Regardless of the type of tile roofing used, whether it's cement, terra cotta, concrete, slate, or fiber-reinforced tiles, this type of roofing material can withstand the test of time. The key is to keep it well-maintained and ensure it is properly installed.