Pultruded Grating — Full Profile Catalog & Section Properties
Pultruded FRP Grating
Continuous glass roving is pulled through a resin bath and die, producing bearing bars with unidirectional strength and high stiffness.
Pultrusion process
Continuous glass roving and mat are impregnated and pulled through a heated die to a precise, repeatable bar cross-section — consistent lengthwise properties every metre.
≈ 70% glass content
Unidirectional bearing bars carry load along their length; roughly 70% glass by weight gives high longitudinal stiffness and strength.
2× stiffness of molded
For the same depth, pultruded bars are roughly twice as stiff and span up to ≈ 3 m — ideal for long platforms and heavy loads.
Section properties per individual bar (nominal cross-section)
Ix / Zx about the strong (bending) axis; Iy / Zy about the weak axis. Weight per linear metre of bar. Values computed from nominal cross-sections (web/flange ≈ 3 mm) at ≈ 1.85 g/cm³.
| Profile | Type | Height (mm) | Width (mm) | Weight (kg/m) | Area (cm²) | Ix (cm⁴) | Zx (cm³) | Iy (cm⁴) | Zy (cm³) |
|---|---|---|---|---|---|---|---|---|---|
| I-4010 | I-bar | 40 | 10 | 0.30 | 1.62 | 3.04 | 1.52 | 0.06 | 0.12 |
| I-5010 | I-bar | 50 | 10 | 0.36 | 1.92 | 5.45 | 2.18 | 0.06 | 0.12 |
| I-6010 | I-bar | 60 | 10 | 0.41 | 2.22 | 8.81 | 2.94 | 0.06 | 0.12 |
| I-4015 | I-bar | 40 | 15 | 0.36 | 1.92 | 4.07 | 2.03 | 0.18 | 0.24 |
| I-6015 | I-bar | 60 | 15 | 0.47 | 2.52 | 11.25 | 3.75 | 0.18 | 0.24 |
| T-3320 | T-bar | 33 | 20 | 0.50 | 2.68 | 2.83 | 1.40 | 0.38 | 0.38 |
| T-5020 | T-bar | 50 | 20 | 0.68 | 3.70 | 9.14 | 3.12 | 0.41 | 0.41 |
| T-6020 | T-bar | 60 | 20 | 0.80 | 4.30 | 15.25 | 4.42 | 0.43 | 0.43 |
Dimensional check: Zx = Ix / (h/2) holds for every row (e.g. I-6015: 11.25 cm⁴ ÷ 3.0 cm = 3.75 cm³). For design, use certified EI/section data for the exact resin and glass loading; pultruded values are typical and should be confirmed per ASTM D7290 characteristic method.
Standard mesh weights, open area and spans
Bearing bars run across the clear span. Weight includes bars + tie bars; spans are indicative at L/200 for pedestrian live load.
| Configuration | Bearing Bar | Bar Centers (mm) | Tie Bar | Thickness (mm) | Weight (kg/m²) | Open Area | Max Span @ L/200 (mm) | Max Uniform Load @ 2 m span (kN/m²) |
|---|---|---|---|---|---|---|---|---|
| 1" × 4" mesh (25 mm bar centers) | I-4010 | 25 | Ø6 cross rod @ 100 mm | 40 | 16.5 | ≈ 55% | ≈ 1300 | ≈ 3.5 |
| 1.5" × 4" mesh (38 mm bar centers) | I-4010 | 38 | Ø6 cross rod @ 100 mm | 40 | 11.5 | ≈ 65% | ≈ 1500 | ≈ 2.8 |
| 2" × 4" mesh (50 mm bar centers) | I-4010 | 50 | Ø6 cross rod @ 100 mm | 40 | 9.0 | ≈ 72% | ≈ 1600 | ≈ 2.2 |
| 1.5" × 4" mesh (38 mm bar centers) | I-6015 | 38 | Ø8 cross rod @ 100 mm | 60 | 15.0 | ≈ 62% | ≈ 2200 | ≈ 7.0 |
| 2" × 4" mesh (50 mm bar centers) | T-5020 | 50 | Ø8 cross rod @ 100 mm | 50 | 13.0 | ≈ 70% | ≈ 2000 | ≈ 6.0 |
| 2" × 4" mesh (50 mm bar centers) | T-6020 | 50 | Ø8 cross rod @ 100 mm | 60 | 16.0 | ≈ 70% | ≈ 2500 | ≈ 9.0 |
Spans and loads are indicative and consistent with industry pultruded load-table practice; confirm against certified charts for your configuration. Source: Industry pultruded-grating technical brochures (manufacturer data); ZeAllgrate (ACMA) design guidelines.
Typical unidirectional laminate values
Longitudinal = along pultrusion / bearing bars; transverse values are significantly lower and are not a design basis.
| Property | Test Method | Typical Value |
|---|---|---|
| Density | ASTM D792 | 1.7 – 1.9 g/cm³ |
| Glass content | Ignition loss | 70% ± 5% by weight |
| Tensile strength, longitudinal | ASTM D638 | ≈ 300 – 400 MPa (typical) |
| Flexural strength, longitudinal | ASTM D790 | ≈ 350 – 450 MPa (typical) |
| Flexural modulus, longitudinal | ASTM D790 | ≈ 20,000 – 25,000 MPa (typical) |
| Compressive strength, longitudinal | ASTM D695 | ≈ 250 – 300 MPa (typical) |
| Water absorption (24 h) | ASTM D570 | < 0.2% |
| Barcol hardness | ASTM D2583 | > 45 |
| CTE, longitudinal | ASTM D696 | ≈ 5 × 10⁻⁶ /°C |
| CTE, transverse | ASTM D696 | ≈ 25 × 10⁻⁶ /°C |
Pultruded coupon values are typically ~300–400 MPa tensile and ~350–450 MPa flexural longitudinal — far above molded grating due to ~70% unidirectional glass. Source: Industry pultruded-grating technical brochures (manufacturer data); ZeAllgrate (ACMA) design guidelines.
Lateral connection between bearing bars
| Tie Type | Size | Top-Surface Finish | Material / Note |
|---|---|---|---|
| Round cross rod (fiberglass core) | Ø6 mm / Ø8 mm | Flushed or below top surface | Standard tie for I-bar gratings; pultruded with resin over-wrap |
| Round cross rod (stainless steel) | Ø6 mm / Ø8 mm | Full depth / flush | Higher lateral rigidity; specify SS304/SS316 by environment |
| T-tie bar | Matching bar depth | Flush-top | Integral look; used with T-bar decks for long spans |
| Flush-top tie bar | Matching profile | Top surface flat | Smooth walking surface; ADA-friendly where required |
Grit-top (standard)
Embedded silica grit on the bearing-bar top surface — standard for pultruded grating in wet/chemical service.
Smooth / covered
Smooth natural finish for light pedestrian use; covered (integral) panels available for drip-free decks.
| ZeAll ISO (isophthalic, ISOFR) | General corrosion grade, self-extinguishing, E84 ≤ 25. |
| ZeAll VE (vinyl ester, VEFR) | Harsh chemical resistance, self-extinguishing; preferred for offshore / process. |
| ZeAll FR (fire-retardant) | Low-flame / low-smoke pultruded formulations with marine (USCG/ABS) options. |
Indicative maximum clear spans at deflection limits
Pedestrian live load basis. Lower deflection limit (L/100) gives shorter spans for firmer walking; L/200 is the comfort limit.
| Configuration | Max Clear Span @ L/100 (mm) | Max Clear Span @ L/150 (mm) | Max Clear Span @ L/200 (mm) |
|---|---|---|---|
| I-4010, 1.5" mesh | ≈ 1900 | ≈ 1600 | ≈ 1400 |
| I-6015, 1.5" mesh | ≈ 2800 | ≈ 2400 | ≈ 2100 |
| T-5020, 2" mesh | ≈ 2600 | ≈ 2200 | ≈ 1900 |
| T-6020, 2" mesh | ≈ 3200 | ≈ 2700 | ≈ 2400 |
Indicative only. Final design must use certified load/span charts; apply appropriate safety factor (pultruded typically 2:1 F.S. per manufacturer practice). Source: Industry pultruded-grating technical brochures (manufacturer data); ZeAllgrate (ACMA) design guidelines.
- Industry pultruded-grating technical brochures (manufacturer data) — profiles, mesh configurations and load/span practice.
- ZeAllgrate (ACMA) Guidelines for the Engineer / Designer — deflection limits, ASTM D7290 characteristic values.
- Industry molded-grating technical catalogs (manufacturer data) — resin and fire system cross-reference.
Section properties above are computed from nominal cross-sections and are intended for specification-level sizing. ZeAllgrate supplies certified section data and load test reports for each resin and configuration. Contact [email protected].
Combining Profiles with Grating
Pultruded grating is usually supplied as part of a wider framing package: pultruded I-beams and channels support the panels, angles and flats form borders and stiffeners, and tubes carry handrail posts. Ordering the grating and its framing together from one supplier removes the interface risk — spans, bearing details and clip patterns are coordinated on one drawing set, and the laminate, resin and hardware choices stay consistent across the whole access system.
Mesh, Open Area and Drainage
Pultruded panels are produced in the standard mesh openings — 38 × 38 mm, 25 × 100 mm, and variants — and the open area determines drainage and debris behaviour: larger openings drain faster and carry less wind load on open decks, smaller openings stop tools and feet. For walkways above process equipment, check the mesh against the smallest object the deck must retain; for splash decks, confirm the open area drains the spill volume quickly.
Tolerance and Site Acceptance
- Panel width, length and flatness verified on arrival against the order tolerance (± 3 mm typical length).
- Grit-top surface checked for even aggregate coverage; edge chips rejected before installation.
- Batch marking and certificates matched to the delivery; load test report for the ordered span requested at order stage.
- Bearing bars oriented along the span at installation; clips placed per the clip schedule.
- Panel width, length and flatness verified on arrival against the order tolerance (± 3 mm typical length).
- Grit-top surface checked for even aggregate coverage; edge chips rejected before installation.
- Batch marking and certificates matched to the delivery; load test report for the ordered span requested at order stage.
- Bearing bars oriented along the span at installation; clips placed per the clip schedule.
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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