ZeAllgrate FRP Ladder & Stair Systems — Complete Specifications
Corrosion-proof, non-conductive access systems
ZeAllgrate ladders and stairs are built from pultruded FRP profiles — light to install, non-sparking and immune to rust in chemical, offshore and wastewater service.
Ladder types
Vertical fixed ladder, caged ladder, ship / alternating-tread ladder, and stairway with grating treads.
Standards
Designed to OSHA 1910.23, ISO 14122-4, EN ISO 14122-4 and ANSI A14.3.
Non-conductive & light
FRP is dielectric — no grounding; ≈ 1/4 the weight of steel for easy single-person installation.
Components, dimensions and standard references
| Component | Dimensions / Specification | Material | Standard Reference |
|---|---|---|---|
| Rungs | Ø25 mm or Ø32 mm round; 300 mm clear width; 300 mm (12 in) spacing c/c | ZeAll VE / ISO pultruded tube, fluted/gritted | OSHA 1910.23(d); ANSI A14.3 |
| Stiles (side rails) | 50×50×4 mm square tube or 75×6 mm flat bar | ZeAll VE / ISO / FR pultruded | OSHA 1910.23(d) |
| Stand-off brackets | 150 mm clearance from wall; every 1500 mm c/c | FRP / SS316 bracket + M10 anchor | OSHA 1910.23(d)(4) |
| Top extension | 1100 mm (42 in) above landing / platform surface | — | OSHA 1910.23(d) |
| Safety cage | Required above 2.4 m; cage hoop Ø750 mm; hoops every 1500 mm; 5 × 50 mm vertical bars | FRP flat bar + hoops | OSHA 1910.23(d)(1) |
| Ladder width | 300 mm clear inside stiles (typical 16 in / 400 mm overall) | — | OSHA 1910.23(d) |
When a safety cage is required by height
Cages required above 2.4 m; rest platforms required every 6 m for tall ladders.
| Ladder Height | Cage Required (OSHA) | Cage Type / Notes |
|---|---|---|
| < 2.4 m (8 ft) | No cage required | Straight vertical ladder, no fall protection beyond grab |
| 2.4 – 6.0 m (8 – 20 ft) | Cage from 2.4 m to top | Standard cage; rest landing not mandatory |
| > 6.0 m (20 ft) | Full cage + rest platforms every 6 m | Rest / landing platform every ≤ 6 m; consider ladder safety system > 7.3 m (24 ft) |
Basis: OSHA 29 CFR 1910.23(d) — fixed ladder cages and rest platforms. For ladders > 7.3 m (24 ft), a personal fall-arrest or ladder-safety system is additionally required per OSHA 1910.28(b)(9).
Steep-angle access where space is limited
| Item | Specification |
|---|---|
| Angle from horizontal | 50 – 70° (steep ship / alternating-tread ladder) |
| Tread depth | 150 – 200 mm (alternating treads) |
| Width | 400 – 500 mm |
| Handrail | Both sides, Ø38 mm round tube |
| Load rating | Pedestrian 3.5 kN/m² + 1.3 kN concentrated; designed per OSHA 1910.23(e) |
FRP grating treads on pultruded stringers
| Component | Specification |
|---|---|
| Stair angle | 30 – 45° typical (OSHA 1910.25 range) |
| Tread | 38 mm molded or pultruded grating panel, grit-top, 250 – 300 mm deep, reinforced gritted nosing |
| Riser | 150 – 200 mm |
| Stringer | Pultruded channel (C-200×100 typical) or I-beam, flanges outward |
| Handrail | Both sides; top rail 1070 mm above nosing; mid rail; toe board ≥ 100 mm |
| Load | Pedestrian 3.5 kN/m² + concentrated 1.3 kN; moving load 4.4 kN (1000 lb) per stair |
| Tread deflection | ≤ L/150 (typical) |
OSHA / ANSI requirements vs. FRP capacity
| Component | Load Requirement | FRP Capacity (typical) | Reference |
|---|---|---|---|
| Rung — concentrated load | 1.36 kN (300 lbf) at rung midpoint | FRP rung ≈ 2.0 – 2.7 kN capacity | OSHA 1910.23(d) / ANSI A14.3 |
| Stile — between attachments | Two 1.11 kN (250 lbf) loads between any two brackets | FRP stile exceeds | ANSI A14.3 |
| Stair tread | 1.3 kN (300 lbf) point load over 100×150 mm plate at nosing | FRP tread panel exceeds | OSHA 1910.25 / ZeAllgrate |
| Handrail | 890 N (200 lbf) concentrated | FRP rail system exceeds | OSHA 1910.29(b) |
| Cage hoop | Per OSHA 1910.23(d)(1)(ii) | FRP cage meets | OSHA 1910.23(d) |
Basis: OSHA 1910.23(b)(d)(e) and ANSI A14.3 — Fixed Ladders. Rung concentrated load 1.36 kN (300 lbf) at midpoint; installed ladder supports two 1.11 kN (250 lbf) loads between consecutive brackets.
Pultruded stile / rung laminate
| Property | Test Method | Typical Value |
|---|---|---|
| Glass content | Ignition loss | 70% ± 5% by weight |
| Flexural strength, longitudinal | ASTM D790 | ≈ 350 – 450 MPa |
| Flexural modulus, longitudinal | ASTM D790 | ≈ 22,000 – 26,000 MPa |
| Impact resistance (Charpy) | ASTM D6110 | ≈ 150 – 250 kJ/m² |
| Density | ASTM D792 | 1.7 – 1.9 g/cm³ |
| Dielectric strength | ASTM D149 | > 10 kV/mm |
ZeAll ISO
Standard — general industrial, water/wastewater, mild corrosion.
ZeAll VE
Vinyl ester — offshore, coastal, chemical and pulp & paper; superior pitting resistance.
ZeAll FR
Fire-retardant — E84 Class A / low smoke; metro, tunnels, enclosed access.
Vertical caged FRP ladder — stiles, rungs, cage, stand-off, top extension
Schematic, not to scale.
Mounting, cage assembly and inspection
Ladder mounting
Wall stand-off brackets every 1500 mm c/c; base supported to structure; top connected to platform; never cantilever unsupported beyond 1800 mm.
Cage assembly
Hoops Ø750 mm every 1500 mm; 5 × 50 mm vertical bars; cage starts 2.4 m above base and continues to top extension.
Stair stringer mounting
Channel/I-beam stringers flanges outward; tread angles bolted with 2 × M10 bolts; support at both ends and intermediate columns for long runs.
Safety gate & inspection
Self-closing safety gate at top platform; inspect rungs, brackets and cage annually; replace damaged stiles/rungs.
| Standard | Scope | Requirement Covered |
|---|---|---|
| OSHA 29 CFR 1910.23(b)(d)(e) | Walking-Working Surfaces; fixed ladders | Rung spacing 300 mm, cage > 2.4 m, rest platforms, 300 lbf rung load |
| ISO 14122-4 | Permanent access machinery; fixed ladders | Ladder geometry, cage, rest landings |
| EN ISO 14122-4 (EU) | Permanent access to machinery | Harmonised European ladder requirements |
| ANSI A14.3 | Fixed Ladders — Safety Requirements | 250 lbf rung load; two-load stile criterion |
Ladder and stair designs must be verified against OSHA 1910.23 / ISO 14122-4 / ANSI A14.3 and local code. Contact [email protected] for a ladder/stair arrangement and BOM.
OSHA 29 CFR 1910.23 Key Parameters
| Parameter | Requirement (Fixed Ladders) | ZeAllgrate Provision |
|---|---|---|
| Rung spacing | 10–14 in (254–356 mm) uniform | 12 in (305 mm) standard, uniform |
| Side rail clearance | ≥ 7 in (178 mm) behind rungs | Pultruded side rails with backing clearance |
| Rung load | 250 lbf (1.11 kN) concentrated | Load-tested FRP rungs per design |
| Cage (where required) | From 7–8 ft above landing, 27 in deep, 42 in wide | FRP cage hoops and verticals, corrosion-proof |
| Ladder safety system | Personal fall arrest or ladder safety device on fixed ladders > 24 ft | Compatible attachment points; system advice provided |
Material and Corrosion Detail
Ladder and stair components are pultruded FRP — side rails, rungs, stringers, tread pans and handrail members — with SS316 hardware throughout. The pultruded section carries the same ~70% glass content as pultruded grating, giving the stiffness needed for rung spans and stair stringer lengths without steel's rust cycle. In chemical, offshore and wastewater service this removes the failure modes that plague steel ladders: corrosion at welds, seized fixings and painting programmes.
Installation and Accessory Package
- Base fixing — SS316 base plates and anchor bolts; chemical anchoring where concrete condition requires it.
- Landing integration — ladders land onto ZeAllgrate grating decks or FRP platforms; supplied with matching handrail.
- Treads — stair treads with grit-top surface in wet service; nosing detail to prevent slip at the step edge.
- Custom elevations — dimensioned to site drawings with cage, fall-arrest and handrail options specified at order.
- Base fixing — SS316 base plates and anchor bolts; chemical anchoring where concrete condition requires it.
- Landing integration — ladders land onto ZeAllgrate grating decks or FRP platforms; supplied with matching handrail.
- Treads — stair treads with grit-top surface in wet service; nosing detail to prevent slip at the step edge.
- Custom elevations — dimensioned to site drawings with cage, fall-arrest and handrail options specified at order.
Approved by Industry Bodies, Tested to International Standards
Every ZeAllgrate shipment is backed by documented quality systems, marine approvals and independent third-party verification.
ISO 9001:2015
Certified quality management system — since 2004.
DNV & ABS Marine
Marine-grade grating for offshore platforms and vessel decks.
SGS & Intertek
Independent third-party inspection and load testing on request.
OSHA 1910.23
Handrail systems load-tested to US federal requirements.
Material certificates, COA, ASTM test reports and compliance documentation supplied with every order. View certifications →
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