FABRICATION OF FRP GRATING

A PROJECT REPORT
Submitted by

BHARAT KUMAR(1021320273)
SAJU JOSE(1021320243)
RAHUL VERMA(1021320272)
PRUDHVI(1021320300)
in partial fulfillment for the award of the degree
of

B.Tech.
in

Mechanical Engineering

SRM UNIVERSITY
RAMAPURAM

MAY 2016

SRM UNIVERSITY
RAMAPURAM

BONAFIDE CERTIFICATE

Certified that this project report

FABRICATION

OF

FRP

GRATING is the bonafide work of BHARAT KUMAR, SAJU

JOSE,

RAHUL

VERMA

AND

PRUDHVI

who carried out the project work under my supervision.

SIGNATURE

GUIDE
DEPARTMENT

INTERNAL EXAMINER

SIGNATURE

HEAD OF THE

EXTERNAL EXAMINER

SNo:

Title

Page

Materials Properites

10

Chemical resistant test

22

Load Bearing Capacity

24

LIST OF TABLES

LIST OF FIGURES

Sno:

Title

Page no:

Walkway and Scaffold

Pultruded grating

13

Pultrusion System

16

Fabrication Cad Design

18

Tensile test specimen

19

Load Vs Displacement graph

20

Flexural Test

21

Chemical reagent Vs Change in weight graph

23

Load Vs deflection graph

24

Abstract
Our team is planning to develop FRP gratings using high beam sections
to support dynamic and static load for platforms and protecting fencing.
We are also developing checkered plates for anti skidding platform for
industrial purposes. This is a prototype of mega fencing and platform
grating used in heavy industries. Fiberglass reinforced plastic (FRP)
grating is manufactured by combining a resin and fiberglass. That makes
it a composite material. Fiberglass grating does not corrode like steel
gratings. They are used in corrosive environments. Fiber glass grating is
formed using continuous interwoven glass fibers as reinforcement
material and resin as the matrix with continuous solidification through a
mould system. The uniform construction provides excellent bidirectional mechanical properties. It is beneficial to all industries
whether it be chemical, pharmaceutical, offshore or leisure to name just
a few with many applications like platforms, floorings, walkways, trench
covers, ramps and cable trough covers. Fiberglass grating is
exceptionally slip resistant and the gritted and concave anti-slip grating
offers excellent traction in wet and icy conditions. In this work, molded
fiber glass gratings are manufactured and subjected to tensile test,
chemical resistance, water absorption, flexural test, load bearing test.

TABLE OF CONTENTS

CHAPTER No.

TITLE

PAGE No.

I.

LIST OF TABLES

II.

LIST OF FIGURES

ii

III.

ABSTRACT

iii

1.

INTRODUCTION

2.

MATERIAL CHARACTERISTICS

3.

MANUFACTURING METHOD

4.

CADD DESIGN AND FABRICATION

11

5.

TESTS AND RESULTS

12

6.

CONCLUSION

25

7.

REFERENCE

26

Introduction
A grating is any regularly spaced collection of essentially identical, parallel,
elongated elements. Gratings usually consist of a single set of elongated elements,
but can consist of two sets, in which case the second set is usually perpendicular to
the first (as illustrated). When the two sets are perpendicular, this is also known as
a grid or a mesh. Fiberglass grating is an integral construction single piece
fiberglass roving reinforced with Isopthalic resin typically composed of 60-65%
resin by weight and immensely strong continuous glass fibers manufactured by a
specially designed process that provides a property of good mechanical and
corrosion resistance. These are safe & ideal for chemically corrosive environment
having long maintenance free life.
The EPP gratings and treads are high strength pultruded bar type gratings that can
be designed and used like traditional metal grates but have the inherent benefits of
fibreglass. These problem solving products are ideal replacements for steel or
aluminium gratings in corrosive environments or anywhere frequent grating and
walkway replacement costs are unacceptable.
The EPP fibreglass gratings are a composite of fibreglass reinforcements (fibres
and mat) and a thermosetting resin system, produced by the pultrusion process. The
pultrusion manufacturing process produces many of the outstanding characteristics
of the product.
The bearing bars use both longitudinal (glass roving) and multidirectional (glass
mat) reinforcements as well as a synthetic surfacing veil to provide unequalled
strength and corrosion resistance. The densely packed core of continuous glass
rovings gives the bar strength and stiffness in the longitudinal direction while the
continuous glass mat provides strength in the transverse direction and prevents
chipping, cracking and lineal fracturing. The synthetic surfacing veil provides a
100% pure resin surface for added corrosion resistance and UV protection.
The 3-piece cross-rod assembly used in grating forms a strong, unified panel that
can be cut and fabricated like a solid sheet. This unique system consists of two
continuous, pultruded spacer bars and a centre core wedge. The spacers are
notched at each bearing bar so that the bars are both mechanically locked and
chemically bonded to the web of each bearing bar. This separates and affixes
bearing bars firmly in position and distributes concentrated loads to adjacent bars.
7

The pultruded gratings are

Highly Corrosion Resistant

Structurally Strong
having High Impact and Fatigue Strength
Lightweight
Easy to Fabricate and Install
Low in Maintenance
Low in Electrical Conductivity
Resistant to Chipping and Cracking
Having Aesthetically Pleasing Appearance
Skid Resistant
Rigid
Low Thermal Conductivity
Non-Sparking

Electric insulation
Durability therefore economical and available in anti skid
Fire retardant and ultraviolet protection types.
Demerits
Only straight sections are possible by Pultrusion
Cannot be welded, only can be moulded

Applications

Chemical & Petrochemical plants

Oil & Gas, Offshore rig & power plants
Architecture and Construction industry
Water treatment plants & pools
Operating platforms & Trench covers
Walkways, Footbridges & Staircases
Ramp, Scaffolds etc

Material Charecteristics
Two main components produce composite FRP: polyester resin and glass fibres.
There are several types of resin systems depending on the application: Isopthalic,
rthopthalic, Vinylester and Phenolic. Isopthalic & Orthopthalic polyesters are the
most widely used resin types and are suitable for most industrial applications.
Phenolic & Vinylester are available by special order.
Typical Material Properties
Density kg/m (Specific Gravity)
Hardness (Barcol)
Tensile Strength MPa
Modulus of ElasticityGPa / (Tensile Strength)
Compressive Strength MPa
Flexural Strength MPa
Interlaminate Shear Strength MPa
Water Absorption %
Voltage breakdown (k volts/mm)
Thermal Conductivity W/m C
Max Operating Temp (deg. C)
Specific Heat (kJ/kg C

Resin
1200
38
55
3.5
140
78
n/a
0.15
0.21
140
2.3

Glassfibre
2100
45
207
16
18
182
9
0
18
0.29
200
n/a

FRP Grating grid flooring is durable, lightweight and chemical and corrosion
resistant which makes it ideal for the industrial, chemical, construction and
shipping industries.
Pultruded Gratings Provide:

Corrosion resistance This type of grating has the strength of steel, and it
wont corrode and break down like steel can.

Safety Our grating features an epoxy anti-skid coating for enhanced

traction. It also meets the specifications set forth by the Virginia Graeme Baker Act
for use in VGBA compliant drain systems.

Extended life Our grating has the ability to withstand the elements of
nature. Resin provides the resistance to the environment, (i.e., the corrosion
resistance, the UV resistance, the impact resistance, etc.) and the glass provides
strength, in addition to safety from fire.

10

Easy fabrication A major advantage of pultruded fiberglass gratings is

that the panels are lightweight. Therefore, they are easy to transport and work with,
and you can easily cut and fabricate them by using standard tools.

During the pultrusion process, a caterpillar-like machine grips the raw materials
and pulls them through a series of steps until the finished profiles reach the cutoff saw.

Fiberglass rovings and mats are pulled through guides on an automated and
continuous cycle. Next, the profile receives a resin bath. Then, it is wrapped with a
synthetic veil before being pulled through a heated die. The final task is to
assemble the bearing bars, groove and notch rod. The bearing bars are drilled on
centers along the length and the cross rods are inserted and secured with epoxy
perpendicularly to the bearing bar to form panels.

11

A high glass-to-resin ratio (65% glass to 35% resin), increases the stiffness along
the length of the bearing bar (and panel) allowing for longer spans or higher loads
in one direction.

This type of FRP grating offers builders a wide variety of panel sizes, and
flexibility because it is assembled and not molded. This helps to reduce waste, or
scraps of FRP in comparison to the molded fiberglass grating process.

12

Material Safety
This section provides data for protection against substances hazardous to health.
Material Identification and Use
Chemical Name: Fibreglass Reinforced Polyester
Common Name: FRP (Fibreglass Reinforced Plastics, Fibreglass)
Product Identification: Permastruct FRP Grating
Uses: Industrial flooring, walkways, platforms
Composition
Glass fibres, thermosetting plastic resin, catalysts, styrene, aluminium oxide,
pigments.
Components are chemically and thermally cured and bonded together.
Hazard Identification
None by contact. Dust produced by cutting or grinding can penetrate pores and
skin causing itching. Avoid breathing dust.
First Aid procedure:
Skin shower with water and soap.
Eyes flush with sterile eye wash solution.
Product Appearance
Open mesh or solid, flat panels. Sharp edges, grit applied to top surface. Zero
odours. Not soluble in water. Standard colour Grey RAL 7047, Green RAL 6010
and Sand RAL 001. Others on request.
Fire Fighting Measures
Standard extinguishing equipment, water, foam, A, B or C fire extinguishers.
Produces black smoke while burning, carbon particles. Use air respirator.
Waste Disposal
Product is not considered a hazardous waste. Abide by local laws and procedures.
Handling/Cutting
Wear masks and goggles when cutting or grinding. Cover exposed parts of the
body. Wear gloves when moving or lifting. Use diamond tipped tools for cutting.
Avoid direct fire source.
13

Manufacturing Method
The glass fiber rovings used for manufacturing of the gratings was supplied by
ERP India Ltd. The matrix material was Isopthalic resin Polyester based on
Isopthalic / superior mixed glycol is a high quality, medium viscosity, medium
reactive specially formulated for processes like Filament winding, spray up/hand
layup. It exhibits good chemical resistance and possess superior mechanical and
thermal properties. The resin has exceptionally good hydraulic resistance making it
an ideal choice for coating / laminating applications. The ISO resin forms strong
bond with fiber glass rovings and depicts good wet out characteristics due to good
weathering properties and retention of glass it is suitable for corrosion resistant
applications.
Manufacturing of FRP Gratings
FRP gratings are processed in two different manufacturing methods. Generally
gratings are classified according to type of manufacturing process. They are:
1. Molded FRP grating
2. Pultruded FRP grating
Our team will be going for the Pultruded FRP gratings.

Pultruded Grating

14

Pultrusion
Pultrusion is a type of continuous automated closed molding, composite processing
method. The basic mechanism of putrusion system is same as that of the metal
extrusion process. The only difference is that in extrusion process, material is
pushed through the dies whereas in pultrusion, material is pulled through the dies.
Reinforcement in terms of continuous rovings or fiber mats is unrolled from creel
holding rolls and passes through a resin tank. In resin tank, fibers are dipped
thoroughly to get completely wetted fibers. Now, these resin saturated
fibers are guided to the hot die where the desired profile is given to these resin
impregnated fibers with the help of dies. Curing of the composite also takes place
in this section due to heating. Now, the cured composite profile is pulled with the
help of gripper coming from the hot dies. Finally, putruded profiles are cut with the
help of a cutter which is inbuilt after the pulling mechanism in the putrusion
system. The schematic of pultrusion system is shown in figure. Sometimes, in the
resin tank, some filler materials are added which also go with the fiber roving.
Though, excess resin is removed in the hot die portion due to pressure, but in
some pultrusion systems, a pre-former is used in between the resin tank and hot
die. In the pre-former, excess polymer is squeezed out and uncured composite is
generated which is then passed through hot die section. The pultrusion process is
generally used and is suitable for thermoset polymer composites and a constant
cross section profile of the composite product is produced on a continuous basis.
As the cross section of product is uniform, the fiber distribution and alignment and
resin impregnation is good in this process. Though rate of production is high but a
large variation in area of cross-section is difficult to achieve. The expenditure
requirement to start pultrusion process is low as compared to other costly and
complex molding processes.
Important components of putrusion process:
There are mainly six components in the pultrusion system which govern the
processing of composites. These components are:
1. Fiber Creels
2. Preformer
3. Resin impregnation systems
4. Hot dies
5. Pulling mechanism
6. Cut off saws

15

The creel should be located in such a way that it should provide uniform and
controlled tension to roving while transferring to the pultrusion system. For
continuous and uninterrupted supply of the roving strand, a second back-up roving
package is also provided besides running package. The shape and size of creel is
decided on the basis of number of roving packages to be handled and its dimension
and the distance to be maintained in between the strands. Preform plates are critical
component of pultrusion system as it properly aligns and feeds the reinforcement
to the heated die. If pre-forming system is not properly functioning, it may lead to
bad quality output and failure of pultrusion system. Resin impregnation system has
a resin bath tank. The size of the tank depends upon the volume of resin to be
handled. Resin impregnation system may have a heating arrangement for the resin
to enhance fiber wetting but the working life of bath is decreased due to heating
system. The commonly used resin impregnation system is dip bath system which is
also known as open bath. It allows the reinforcement travelling from the creels
down into the bath and the resin coated fibers comes out through a guided bar
located into the bath. Heating dies are the main component of any pultrusion
system where part to be produced is given shape and is cured. Pulling system pulls
the product from the heated dies on a continuous basis. Generally, a
caterpillar belt is used in the pulling system. The last unit of pultrusion system is
cut off saw which cut the pultruded product in desired size. Most commonly, a
flying type of cut off saws are used in the pultrusion system. A flying cut off is
movable unit which moves with the same speed as the pultruded product moves.
The advantage of this movement is that the cutting edge of the component is
square and straight. Sometimes, water is used as coolant and lubricant for cutting
blades during cutting which is known as a wet saw. It also flushes the dust and
debris generated during cutting to the filter. A dry-cut saw uses a continuous rim
diamond blade which does not require any coolant or lubrication during cutting
and it gives clean cut of the product.

Pultrusion system

16

Raw materials used in the pultrusion system:

A wide variety of reinforcement and resin systems are used to fabricate composite
materials with exceptional properties. The reinforcing materials used are: glass (Eglass and S-glass), carbon, aramid fibers in the form of roving strands, mat
(continuous filament mat, chopped strand mat) and fabrics. Specific properties can
be achieved by altering the design of the fabric reinforcement. Sometimes veils are
also used in pultrusion system to achieve high quality surface layer of the
pultruded component. These veils may have pre-printed designs and logos that
appear in the final product. Generally, unsaturated polyester, epoxy, vinyl ester
resin and phenolic resins are used as matrix materials. The fillers and additives are
also incorporated during composite fabrication as per the design requirement.
Manufacturing Process:
The pultrusion process utilized in the manufacturing of pultruded fiberglass grating
and structural shapes is a continuous and automated process where continuous
fiberglass rovings and mat are pulled through guides, a resin bath and pre-formers,
then wrapped with a synthetic veil before being pulled through a heated die. The
individual components of pultruded fiberglass grating load bars and each piece of
the two piece tie-bar are pultruded separately. Load bars are then cut to specified
lengths as they exit the machine. They are drilled at centers for tie-bar insertion.
Once the bars have been drilled they are spaced proportionately for the width of
the panel. The two piece locking tie bar assemblies are then inserted creating
multiple bonded intersections of load bars and tie bars, thus providing the security
of both a mechanically locked and bonded connection. The final step in the process
is to seal the cross bars and holes with corrosion resistant epoxy resin. Pultruded
fibre glass grating is unidirectional in strength and provides increased load capacity
and very good levels of corrosion resistance. The components (bearing bars and
cross bars) which are pulled by machine provide a higher glass to resin ratio
content (65% glass to 35% resin) which gives it superior load capacity, yet reduces
the corrosion resistance when compared to molded fiberglass grating. Assembled
from components, pultruded fiberglass grating can offer a wide variety of panel
sizes and substantially reduce "scrap loss" not always possible from molded
fiberglass grating panels. In addition, since the pultrusion process is automated, it
produces a consistent, high quality finished product.
Application:

17

1. Products like solid rods, tubing, and long flat sheets are easily fabricated with
pultrusion process.
2. Simple and constant cross sectional structural sections such as channels, angled
and flanged beams.
3. Tool handles for high voltage work, and third rail covers for subways.
Advantages of pultrusion system:
1. This is a low cost automated system where human involvement is least which
produces high quality products.
2. The surface finish of the product is high as compared to other composite
processing methods.
3. The production rate is high as it is a continuous production process.
4. It is a straight forward and simple process which does not require specific labour
skills.
5. Easy handling and low maintenance.
Disadvantages of pultrusion system:
1. The process is mainly suitable for constant cross sectional areas. Tapered and
complex shapes can not be produced with this method.
2. Control of fiber orientation is not possible in the pultrusion system.
3. Thin wall parts can not be produced with this system.

18

Fabrication - CAD Design

19

Tests and Results

Tests are carried out on a molded fibre glass grating are:
1. Tensile test
2. Flexural test
3. Chemical resistance test
4. Load bearing capacity.
Tensile Test:
Tensile test is carried out on molded fibre glass grating to know the ultimate tensile
strength and cross breaking strength. The mechanical properties of materials are
determined by performing carefully designed laboratory experiments that replicate
as nearly as possible the service conditions. In real life, there are many factors
involved in the nature in which loads are applied on a material. The following are
some common examples of modes in which loads might be applied: tensile,
compressive, and shear. These properties are important in materials selections for
mechanical design. Other factors that often complicate the design process include
temperature and time factors. The topic of this lab is confined to the tensile
property of polymers. The above figure shows a tensile testing machine similar to
the one used in this lab. This test is a destructive method, in which a specimen of a
standard shape and dimensions (prepared according to ASTM D 638: standard test
method for tensile properties of plastics) is subjected to an axial load. During a
typical tensile experiment, a dog-bone shaped specimen is gripped at its two ends
and is pulled to elongate at a determined rate to its breakpoint; a highly ductile
polymer may not reach its breakpoint. The setup of the experiment could be
changed to accommodate different types of mechanical testing, according to the
ASTM standard (e.g. compression test, etc).

Tensile test specimen

20

Results:
Width of the specimen = 18.94mm
Thickness of specimen = 12.09mm
Cross sectional area = 228.985 mm2
Ultimate load = 53.120 KN
Ultimate tensile strength = 231.985 MPa

21

Flexural Test:
These test methods cover the determination of flexural properties of unreinforced
and reinforced plastics, including high-modulus composites and electrical
insulating materials in the form of rectangular bars molded directly or cut from
sheets, plates, or molded shapes. These test methods are generally applicable to
both rigid and semi rigid materials. However, flexural strength cannot be
determined for those materials that do not break or that do not fail in the outer
surface of the test specimen within the 5.0 % strain limit of these test methods.
This test is a destructive method, in which a specimen of a standard shape and
dimensions (prepared according to ASTM D 790-03: standard test method for
Flexural strength of plastics) is subjected to a simply supported load. These test
methods utilize a three-point loading system applied to a simply supported beam. A
four-point loading system method can be found in Test Method D 6272. Flexural
test is carried out on molded fibre glass grating to know the cross breaking
strength. Flexural test is carried out as per ASTM D790-03 standard. Their
dimensions were determined according to the ASTM D790-03 standard mentioned
earlier in the introduction.

Results:
Load at fracture W = 9600N
Distance between supports L = 100.21mm
Width of the specimen B = 21.49mm
Thickness of the specimen D = 12.24mm
Calculated cross breaking strength = 448.20 N/mm2

22

Chemical Resistance Test:

ASTM D543 - 95, Standard Test Methods for Evaluating Resistance of Plastics to
Chemical Reagents, outlines test procedures for determining resistance of the
grating to various chemical reagents by means of reporting weight, dimensions,
appearance, and strength properties, after a set duration period of immersion.
ASTM D543 does not specify the types or concentrations of reagents, duration of
the test, or properties to be reported. The test method consisted of soaking test
laminated coupons cut from the glass fibre laminate in the following chemical
reagents for a seven day period. For a 100ml of solution, the % of chemicals taken
was 5% Caustic Soda, 10% Sulphuric Acid. The intial weights of the specimens
must be recorded before placing the specimen into the chemical reagents. After
seven days period the pieces were taken out from the beakers and rubbed with the
soft cloth in order to make the pieces dry. The final weights also recorded. The
difference of the two weights can be caluclated to know the performance of the
material. The test equipment is as shown below.
Formula for calculating % of weight loss or gain
Where Wf = Finalweight of the specimen; Wi = Intial weight of the specimen
Chemicals
Used

Initial weight

Final weight

% Change in
weight

10% Sulphuric Acid

9.555

9.565

0.18

5% Caustic Soda

9.232

9.243

0.119

23

24

Load Bearing Capacity:

Molded high load capacity (HLC) grating is yet another product in the arsenal of
engineered fiberglass reinforced plastic (FRP) solutions by fiber grate. While
capitalizing on most of the traditional benefits of the molded grating products
high strength, corrosion resistance, fire retardancy, non conductivity and low
maintence this is specially manufactured by molded as well as pultruded process in
FRP composite materials. There are different types of standard panel sizes with
respect to depth, mesh, clear span, and % of open area will available under ASTM
E-84 standard.
Fiber grate/Chemgrate Uniform Load Table - Deflection in mm
Clear
Span
(mm)

300

Style

Dept
h
(mm)
38

Mesh
(mm)

Load = KN/m2

2.50

3.00

5.00

10.00

25.00

50.00

100.0
0

38x38 0.10

0.20

0.33

0.60

0.80

1.50

2.50

Maximu
m Load
(KN/m2)

Ultimate
Capacit
y
(KN/m2)

103.07

824.55

25

Conclusion
The Grating is manufactured by combination of resin and fiber glass. It is
subjected to Tensile, Flexural, Chemical resistance test and Load bearing test. In
chemical resistance test the composite grating is subjected to 10% sulphuric acid,
5% caustic soda and can also be tested with another acids and bases. The cost of
grating is lowered compared to metal/metal alloy system. Though, the tensile test
result is close to mild steel yield strength GFRP grating will be used, because of
rust free, durability and maintenance factors.

26

References
[1] R.M. Jones, Mechanics of Composite materials, Mc Graw Hill Company.
[2] L. R. Calcote, Analysis of Laminated Composite Structures, Van Nostrand
Rainfold.
[3] P. K. Mallik, Fiber Reinforced Composites, 2nd Edition, Marcel Dekker Inc.
[4] Jones, R.M. Mechanics of Composite Materials (2nd edition) Phidelphia:
Taylor & Francis.

27

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