About fiberglass grating, how it is made, and its uses with a list of manufacturers
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Fiberglass grating is a lightweight, easy to install construction material that is versatile and used in a variety of ways. It was developed as an alternative to metal grating due to its lightweight, resistance to corrosion, ease of installation, and lower cost. Fiberglass grating is fire retardant, non-conductive, and a popular option for fire escapes, platforms, drain covers, stair treads, and walkways.
The two types of methods for producing fiberglass grating are molded and pultruded with molded fiberglass grating being created using a molding process while pultruded is a process that combines fiberglass components. The difference between the two methods of manufacturing is in regard to the strength of the final grating product with pultruded grating being stronger and capable of supporting heavy loads for a longer amount of time. Molded fiberglass grating has a long service life due to its unique mixture of resin to glass.
The material used to manufacture fiberglass grating is fiberglass reinforced plastic (FRP), which is a composite material made of glass fiber reinforcement and cured resin. The resins used are polyester, vinylester, and phenolic, each of which has unique characteristics and properties. They are selected based on the application for which the grating will be used and the likelihood of exposure to chemicals, UV rays, extreme temperatures, and climatic and environmental factors. In addition to the selection of resin, the performance of fiberglass grating is impacted by the quality of the raw materials and manufacturing method. Of paramount importance is choosing a manufacturer with the expertise, knowhow, and skills to match a fiberglass grating material to an application.
The use of fiberglass reinforced plastics has become a booming business as their use has rapidly grown into every sector of society. The key to the manufacture of fiberglass materials is the ratio of resin to glass, which significantly impacts the capabilities, properties, and performance of fiberglass grating. The blending of glass with resin is to enhance the polymer material and give it greater strength. How this is completed is dependent on the percentage of each material, a factor that determines the use and quality of fiberglass grating.
The common methods for producing fiberglass grating are pultrusion and molding, manufacturing methods that are radically different. With molding, fiberglass grates are constructed in layers, which allows the manufacturer to control the thickness of the grating. Pultrusion involves joining load bars and cross bars, a production method that produces fiberglass grating that is exceptionally strong and durable.
The mesh types or patterns of fiberglass are the appearance or shape of the openings in the grating with square and rectangular being the most common. Each of the mesh types has positive characteristics that make them ideal for a particular application. Square mesh has strength that is comparable to steel. Micro mesh is composed of very small squares that makes the fiberglass grating highly durable with a high strength to weight ratio.
Aside from the use of the term mesh, and due to the shape of the openings, fiberglass grating openings are also referred to as grid, since they bear a strong resemblance to a graphic grid. Molded and pultruded fiberglass manufacturing produces grid or mesh patterns of varying opening sizes and shapes.
Molded fiberglass grating is manufactured by combining thermoset resin with continuous fiberglass rovings in molds. Each panel consists of 65% resin and 35% fiberglass rovings. Although the molding process is standard, there are variations in the types of openings in the grating, which can be square, rectangular, and micro.
The resins and fiberglass chosen for the manufacture of fiberglass grating are selected in accordance with the desired properties of the grating. The types of resins are polyester, vinyl ester, and epoxy. The factors that determine the choice are strength, corrosion resistance, and the cost of the grating. The fiberglass reinforcements are in the form of chopped strands, mats, or fabric.
In the mold process for the manufacture of fiberglass grating, a meticulously designed mold is used to shape and form the grating. A specially designed molding technique is used to form molded fiberglass grating. Molds are made of steel or composite materials and have the strength and endurance to withstand the hot resin placed on the mold. The shapes of the openings take different forms with rectangular and square being the most common. The design and shape of the mold is dependent on the properties required for the final product. Size, shape, and grid pattern are determined by the mold.
The mechanism that contains the mold is a long flat piece that supports the mold and has various components that make the molding process efficient and accurate. Prior to applying the resin, the mold is cleaned and treated with a release agent, which prevents the completed grating from sticking to the mold. The release agent ensures that the grate is smooth and enhances the appearance by reducing imperfections. The application and use of a release agent adds additional time to the process but guarantees the quality of the fiberglass grating.
The laying up process is the application of fiberglass resin in layers onto the surface of the mold. This can be completed slowly by hand or automatically but is completed very carefully to ensure bonding. The process is repeated multiple times in order to achieve the designed thickness of the grating and ensure its durability.
Hand layup methods are convenient and include positioning woven, knitted, stitched, or bonded fabrics inside the mold. A catalyzed resin is applied, manually, using a brush or roller to create the fiberglass laminate. A topcoat or flow coat is applied for aesthetic purposes for enhanced protection of the surface of the grating. The manual or hand layup process is slow and dependent on the skill of the craftsmen performing the process.
Spray layup methods are used for large industrial grating projects. With the spray layup method, a spray gun is filled with the fiber and resin mixture and directed at the grating mold until the surface area is saturated with a thin layer of the mixture. At the completion of the spraying, the mold is allowed to cure for several hours. To avoid the potential of air bubbles, the ratio of fiber to resin is carefully proportioned.
Although spray layup is fast and efficient, it is used for large projects. The process accurately controls the ratio of catalyst to resin. Spray guns are limited to the use of short fibers, which limits the strength of the grating that is produced. An obvious downside of using the spray layup method is the dispersal of the spray into the atmosphere, which further restricts its use to large enclosed projects.
The conclusion of the layup process is dictated by the number of layers required to be laid up. At its completion, the molded fiberglass grating is compressed under hundreds of pounds of pressure. As the force is applied, the glass in the fiber is forced deeper into the resin to create a strong, durable, and compact grating shape. During the process, air is pushed out forming a dense and less porous grating. During the compression, heat is added to enhance the compression force and facilitate uniformity.
The temperature of the curing process determines the length of the process since heating accelerates the curing. Temperatures are determined by the type of resin used and the curing requirements of that resin. In general, polyester fiberglass cures at 80°C (176°F) for three or four hours while epoxy fiberglass cures at 150°C (302°F). As with all forms of plastics and resins, the curing process for fiberglass grating is used to harden and solidify the fiberglass material.
Different heating methods are used during curing, which vary between curing ovens and in-mold or infrared heating methods. The use of curing ovens is for small grating projects while in-mold and infrared are used for large gratings. The length of the curing process is influenced by the temperature of the environment, humidity, and the thickness of the resin.
Resin Type – The chemical composition of the resin determines the length of time of the curing process
During the curing process, pieces of grating may feel dry to the touch. For some, this may indicate that a piece is fully cured. For fiberglass grating to be fully cured, it must be hard and solid to the touch and be exceptionally durable.
Demolding is the simple process of removing the cured fiberglass grating from the mold. The mold is carefully opened, and the completed grating is removed. Although the process lacks complexity, it has to be performed in such a way that the grating is not damaged.
Once the completed grating is removed from the mold, it may necessitate additional finishing to achieve a certain surface finish. Surface types include smooth, gritted, and meniscus, a cup shaped or concave surface. Top covers may be added to enhance the appearance of the grating and provide protection.
Pultruded fiberglass grating is a series of parallel bars, T shaped or I shaped, that are kept in place by perpendicular fiberglass cross rods. As the distance between the bars decreases, the stronger and more durable is a grating panel. The design of pultruded fiberglass grating enables it to support heavier loads over longer spans. The continuous glass rovings help resist tension, compression, and bending, which provides longitudinal strength. The manufacture of pultruded fiberglass grating, like molded fiberglass grating, involves a series of steps that are used to ensure the appropriate final form is achieved.
The fiber reinforcement are continuous filament mats (CFM) creels in rolls that have been split into required widths. The creels stage the reinforcement before it is fed into the guide plates that position the rovings and unrolled mats before they are placed in the resin bath. Included in the resin bath is resin, a catalyst, fillers, wetting agents, and pigments. The bath is designed to optimize the reinforcement wet out that keeps the reinforcements separated in the bath. After the reinforcements are fully saturated, they exit the bath and are shaped into flat sheets in preparation for being placed in the performer.
The addition of the surface veil to the reinforcement material is to smooth its surface and provide chemical and environmental resistance. It does not add strength to the reinforcement and is added prior to the reinforcement material entering the heated die. The essence of the surface veil is a lightweight material containing polyester fabric. The veil plays a critical role in pultrusion in that it enhances the performance and properties of the pultruded grating. As the reinforcement material exits the resin bath, and prior to entering the die, the surface veil is applied.
Pultrusion dies are an essential part of the pultrusion process. They are used to shape the fiberglass grating reinforcement in order to meet design parameters. Dies are made of various materials including steel, nitride steel, high carbon steel, medium carbon steel, and H13 tool steel with a hardness rating of HRC55 up to HRC65 on the Rockwell Hardness Scale.
Dies for the pultrusion process are designed to meet the requirements of the type of resin being used since different resins have different curing times and viscosities that influence flow through the die. Although the fibers are the structural factor in pultruded fiberglass grating, the orientation of the fibers influences how the fiberglass material passes through the die. In addition, the speed of the process has to match the other factors. Faster processing creates cost savings but may be detrimental to the quality of the fiberglass grating.
After the application of the surface veil, the reinforcement is pulled through a heated die that has an I shape or T shape. The movement of the material through the die initiates the curing process that hardens the material. The temperatures and curing times vary in accordance with the type of resin system, which can vary between hours and days. Once the formed bars are cured, they are cut to the desired length for assembling the grating.
Unlike molded grating that is formed in a mold, pultruded grating requires assembly where fiberglass support rods are inserted through holes drilled through the reinforcement weight bearing bars. The cross bars are placed perpendicular to the reinforcement bars. To ensure a tight, secure fit, the cross bars are secured with epoxy or a form of mechanical locking system. Prior to assembly, the bars are cut to the appropriate lengths for the width of the fiberglass grating. This aspect of the process is defined by the specifications outlined in the design schematic.
Like the reinforcement bars, the cross bars are manufactured using the pultrusion process. This aspect of pultrusion grating is what distinguishes it from molded fiberglass grating in that pultruded fiberglass grating has 60% or greater of fiberglass reinforcement. The increase in fiberglass enhances the strength, durability, resilience, and longevity of pultrusion fiberglass grating.
A mechanical method for securing cross bars takes various forms. A common form is the three piece cross bar assembly method. It gets its name from the three sections of the cross bar, which are two spacer bars and a center wedge. Each spacer bar is notched where it intersects with the bearing bar such that they mechanically lock. After the spacer bars are inserted, the center core is wedged between forcing the notches on the spacer bars to securely connect with the bearing bars. The cross bars are placed perpendicular to the bearing bars to make a tight and secure connection.
Of the two methods used to produce fiberglass grating, pultrusion produces the strongest and sturdiest of the two due to the concentration of fibers created by the pultrusion process. In most cases, pultruded fiberglass grating is used for heavy duty applications while molded fiberglass grating is used for lower stress and decorative applications. In both cases, the lasting longevity of fiberglass grating has proven it to be a valuable asset for construction and industrial purposes.
The use of fiberglass grating has steadily grown since the introduction of fiberglass during World War II. Unlike metal grating, fiberglass grating has several variations and comes in colors that give it an aesthetically appealing appearance. In addition to the many colors of fiberglass grating, it is available with different surfaces that enhances its use as a safety measure for environments containing moisture, chemicals, and lubricants.
Fiberglass grating is a low maintenance material that can be easily cleaned using traditional cleaning methods. The protected surface of fiberglass grating resists the adherence of chemicals, liquids, and viscous materials. It can be cleaned with soap and water and is designed to drain off any moisture, which keeps cleaners from accumulating on it. The easy cleaning aspect of fiberglass grating makes it ideal for indoor and outdoor use, especially in harsh, hostile conditions where resilience and strength are required. Unlike wood or metal, fiberglass does not rot, corrode, or rust, regardless of environmental factors.
Fiber reinforced polymers (FRP) are 70% lighter than steel but have exceptional strength. It is stronger, lighter, and highly resistant to a long list of chemicals and various other materials. The factors that differentiate each of the various types of fiberglass are the kinds of glass fibers and the resin. Load bearing rebar has higher longitudinal tensile strength and lower module of elasticity and density compared to steel, with fiberglass having a megapascal (MPa) rating of 1000 and gigapascals (GPa) rating of 50 compared to steels ratings of 550 MPa and 200 GPa.
Unlike other materials, the strength and durability of FPR remains unchanged for over 15 years, which removes the need to replace it. The long useful life of fiberglass grating is one of the reasons that it is used in extreme and hostile environments where dependability and durability are essential.
Thermal resistance is a method for comparing materials and relates to a materials ability to resist the flow of heat. A material has thermal resistance if it resists the transfer of heat, the ratio of temperature different to heat transfer rate. Materials that should have high thermal resistance include insulators, which are designed to slow the speed of heat transfer. Thermal management involves the selection of construction materials that will not over heat, a factor that makes fiberglass grating so important in construction projects.
The resistance of fiberglass grating in regard to the transfer of heat is one of the reasons it is chosen as a grating material over steel and other metals. It is a safer choice in conditions where thermal conductivity can be a safety factor and pose a threat. The resistance of fiberglass grating to transfer heat is the reason that it is used where there is the potential of fire emergencies. Fiberglass grating tests at 25 or less under the American Society for Testing and Materials (ASTM) rating system, which is in accordance with ASTM E-84. It also meets the requirements of ASTM D-635 for self-extinguishing.
The two types of conductivity are thermal and electrical, which refers to the passage of heat or electricity through a material. All forms of materials have some form of thermal conductivity. Of the many materials, fiberglass has one of the lowest thermal conductivity ratings as determined by ASTM International. In regard to electricity, fiberglass is non-conductive and is used as an insulator. The non-conductivity of fiberglass gives it a distinct advantage over metals in cases where conductivity is prohibited or restricted.
In the modern era, where electromagnetic waves are necessary for wireless communication, concrete, steel, and aluminum significantly inhibit the passage of electromagnetic waves. On the other hand, fiberglass allows radio waves, cellular frequencies, and other electromagnetic signals to easily pass through. It is for this reason that it is widely used in the telecommunications industry.
Of all the aspects of business, cost is a motivating factor since it determines profitability and influences the bottom line. There are many alternatives available for the installation of grating. They include steel, aluminum, and concrete. Each of these materials is expensive, heavy, and difficult to install and maintain. In contrast, fiberglass grating is lightweight, flexible, and easy to install. While it may take days to install other materials, fiberglass can be installed in a few hours and be easily altered and adjusted during installation.
Once fiberglass grating is installed, it can be cleaned and maintained using traditional cleaning methods without the need to scrape or sandblast the surface. The wide range of resins makes it possible to choose a material that perfectly fits the application for which the grating will be used.
The many advantages of fiberglass grating have led to its increasing use in a wide range of applications and industries. From stairways to platforms, fiberglass grating has become a staple of multiple businesses and construction projects.
The wide use of fiberglass (FRP) grating is due to its resilience, strength, and ability to endure years of impact and stress. Its exceptional strength to weight ratio, which is less than half the weight of steel, makes it easier to handle, less expensive to transport, and easier to install. All of these factors have led to FRP grating replacing other forms of grating as a more practical and useful alternative.
Molded and pultruded FRP grating is commonly used as floor grating. Which of the two is chosen depends on the types of loads that the flooring will have to bear with pultruded FRP grating being able to endure more robust and heavier loads. In cases where appearance is important, the versatility of molded FRP grating makes it easy to adapt a grating to the surrounding environment while maintaining strength and durability.
FRP flooring grating can have various features added to enhance the grating, such as an anti-skid surface to minimize workplace accidents. Since FRP grating has multi-directional strength, it can be fitted into any location regardless of the surroundings. Low maintenance, significant impact resistance, and high load capacity makes FRP floor grating an ideal choice.
To maximize the use of space, many companies are adding mezzanines and platform work stations that require durable and sturdy decking that is lightweight. Fiberglass deck grating has been found to be the perfect choice due to its structure and adaptability. FRP grating can match the size, shape, and configuration of any form of platform, deck, or mezzanine. Unlike wood, metal, or concrete, it is easy to install and long lasting.
Trench grating requires exceptionally strong and durable material due to the stress and weight that it has to endure. Commonly, steel is used due to its ability to withstand high loads. Recently, FRP grating has been improved and perfected such that it has the same capabilities as steel without the weight of steel. This has made trench grating more flexible, capable of enduring harsh weather, and easier to handle.
FRP grating is used to cover trenches for foot traffic and vehicles in the forms of standard grating and carefully designed heavy duty grating for high loads. The factor that separates FRP grating from standard metal gratings is its resistance to rust and corrosion that shortens the life of metal gratings. The strength of FRP grating ensures durability and long lasting trench protection.
Catwalks tend to be another part of companies using mezzanines. Unlike mezzanines, catwalks have use above and beyond being work spaces and are used to move easily between large equipment, containers, storage units, and other such industrial equipment. There are certain factors that have to be adhered to in regard to catwalks due to the nature of their use. In many cases, catwalks are a part of a worker’s daily routine. They need to be sufficiently strong to support workers and equipment but light enough to be placed a distance off the floor and have a pleasant appearance.
FRP catwalks meet every criterion regarding the requirements of catwalks. The multi-colors of FRP catwalks makes them easily visible and aesthetically pleasing while offering exceptional support and durability to support workers and equipment. Metal catwalks present several dangers, which include deterioration, heavy weight, and instability, a factor that has made fiberglass catwalks so successful.
An area of grating use that requires the greatest amount of care and safety is offshore oil rigs that experience extreme weather conditions, a tremendous amount of moisture, and constant stress that endangers workers. The use of FRP grating is necessary due to the corrosive effects of saltwater where offshore rigs are placed. Although specially treated metals are used to build the structure of offshore rigs, the lightweight of platforms requires the use of fiberglass that will not deteriorate under such conditions compared to metals.
The use of FRP platforms ensures the safety of workers by adding materials to the surfaces of FRP panels that are designed to be non-sticking or slippery. This is necessary because offshore platforms are constantly battered with waves of saltwater that would saturate and make other materials unsafe.
The five examples of the use of FRP grating are a small picture of the grating’s many uses. FRP grating can be found in storage units, warehouses as shelving, retail stores, shipping docks, and complies with the standards established by the Americans with Disabilities Act. It is a versatile and strong material that is changing how people view industrial and commercial surfaces.
When preparing for a construction project, the choice of grating falls into two categories, metal or fiberglass. Both types of grating have positive characteristics that make them ideal for a particular application. Determining which of the two is the best is the question that vexes many designers and engineers. Although both types serve the same purpose, there is a great deal of variation in their characteristics and properties.
FRP can be used indoors or outdoors and is able to withstand all forms of climatic conditions including salty air, saltwater, UV exposure, and extreme variations in temperature. For industrial applications, FRP can endure chemical environments, help with health and safety issues, and is designed to endure heavy loads under all conditions. It is easy to clean and maintain. Dirt and all forms of industrial substances can easily be removed with soap and water.
Made of non-conductive fiberglass, FRP grating is fire retardant and corrosion resistant, important considerations for industrial environments. It is easy to install and lasts for many years without the need for support or maintenance. During installation, FRP can be cut and shaped using power saws to ensure the right fit.
The characteristic that stands out for metal grating is its strength, durability, and ability to withstand heavy loads and high traffic areas. The factors that diminish metal grating is its susceptibility to corrosion and rust. When stainless steel and galvanized steel are used to produce metal grating, they are able to endure the effects of the elements but require ongoing maintenance and have several other issues that can be dangerous to workers.
Metal was the original grating material and has been used for many years as a stable and reliable material. Since its inception, the price of the various metals has risen to the point that users have to carefully consider the use of metal grating due to its very high cost. The viability of metal grating can be enhanced with slip resistant coatings and serrated surfaces.
Unlike FRP grating, the connections between the elements of metal grating are securely welded to meet the load bearing requirements of metal grating. This makes metal gratings stronger and gives them the ability to endure heavy loads.
Although metal grating is highly durable and strong, its downside is its ability to endure the environmental factors. Moisture, chemicals, and other materials can cause metal grating to deteriorate, things that do not affect FRP grating due to the chemical mixture of the resins used to manufacture FRP grating. Regardless of the investment in FRP grating, the cost can be amortized over several years due to the longevity of FRP grating. This is not true of metal grating that begins to deteriorate the day that it is installed, regardless of any protective measures used to prevent its deterioration.
Resins for fiberglass grating are available in a wide selection of resin systems. The choice of a resin is dependent on many factors, which involve cost, application, and type of processing. The structure of all forms of fiberglass is made up of several forms of resins and glass that are blended together during the manufacturing process to form a solid and strong material capable of enduring a wide range of conditions.
When making the decision to purchase grating for a project, it is important to understand the different types of resins used to produce fiberglass. Manufacturers work with their clients to explain the advantages of each type and the importance a resin plays in the manufacture of FRP grating.
Orthophthalic polyester is a very common resin produced by reacting orthophthalic acid with idols. It is used to produce grating with moderate mechanical properties and chemical resistance. Gratings made of orthophthalic polyester are used for marine applications, the automotive industry, and electrical manufacturing. It is a less expensive resin, which is one of the reasons for its popularity. To enhance orthophthalic polyesters mechanical features, fillers and reinforcements can be added to the resulting fiberglass.
Isophthalic polyester, like orthophthalic polyester, is produced by reacting isophthalic acid with diols. ISO polytester has exceptional mechanical properties and chemical resistance due to the isophthalic acid in the polymer. The high tensile strength of ISO makes it ideal for the production of FRP grating. Its thermal stability makes it suitable for harsh, stressful environments. During manufacturing, unlike other resins, ISO cures at room temperature.
Vinylester is known for its strength and exceptional resistance to corrosion, fatigue and impacts. It is very common for vinylester to be used in conjunction with glass to produce fiberglass due its exceptional positive properties and characteristics. Like ISO, vinylester can be cured at room temperature but can also be cured with the addition of heat. Due to its high resistance to the effects of UV rays, vinylester is used to manufacture FRP gratings for outdoor use. As with all forms of resins, vinylester is used in a range of colors and finishes, which makes it suitable for aesthetic applications.
Epoxy resins are thermoset resins made from the reaction of epoxide monomers with curing agents, such as amines, anhydrides, and phenols. The result of the chemical process is a cross linked polymer with exceptional mechanical properties and resistance to chemicals that bonds well. The use of epoxy resin to produce fiberglass is due to epoxy resins strength, stiffness, and toughness as well as its excellent adhesive properties. In the case of FRP grating, epoxy is ideal for producing gratings that are lightweight with high strength and resistance to fatigue and impacts.
Phenolic resin is a synthetic polymer made by reacting phenol with formaldehyde. It was first introduced in 1907 and has a complex structure due to phenol’s ability to react with ortho and para positions that leads to multiple positioned isomers for any given chain. Acidic or basic catalysts are used during the polycondensation of phenol and formaldehyde. Additives are included, such as oil, silicon, rubber, and boron phosphorus, to enhance the resin’s impact resistance and dielectric performance. The two types of phenolic resin are novolac and resole, which are thermal stable, have exceptional mechanical strength, and are chemical and fire resistant.
Resin and glass are the primary components of fiberglass. The combination of the two produces strong, durable and long lasting reinforcements that give fiberglass its positive characteristics and properties. Additives are used to enhance FRP or help in the manufacturing process. They include a long list of substances that add to the effectiveness and quality of fiberglass.
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