ZeAll Pultruded FRP Grating — Complete Specifications & Load Data
ZeAll Pultruded FRP Grating
Continuous glass roving is pulled through a resin bath and heated die to a precise bearing-bar profile, then mechanically assembled with tie rods into rigid panels.
Pultrusion process
Glass roving and continuous mat are impregnated and pulled through a heated die, producing a repeatable, high-quality bar cross-section with unidirectional strength along the bearing bar.
≈ 70% glass, uni-directional
Longitudinal roving gives high tensile and flexural stiffness along the bearing bar; pultruded panels are roughly twice as stiff as molded panels of the same depth.
Long spans up to ≈ 3 m
Because load follows the bearing bars, pultruded grating spans further than molded grating and suits long platforms, heavy live loads and mechanical equipment decks.
| Standard panel size | 1200 × 3660 mm (≈ 4 ft × 12 ft) — most stocked |
| Other standard panels | 915 × 3050 mm · 1200 × 2440 mm · 1500 × 6000 mm (custom) · cut-to-size |
| Standard meshes | 1" × 4" (25 mm) · 1.5" × 4" (38 mm) · 2" × 4" (50 mm) bar centers |
| Standard depths | 33 mm · 40 mm · 50 mm · 60 mm (I-bar and T-bar bearing profiles) |
Assembled-panel designations, weights, open area and spans
Spans are indicative clear spans at the listed deflection limits (L/100, L/150, L/200) for pedestrian live load; Max UDL @ 1.5 m is the allowable uniform load at a 1.5 m simply-supported span at L/150.
| Grating Designation | Bearing Bar | Bar Spacing (mm) | Tie Bar | Panel Thickness (mm) | Weight (kg/m²) | Open Area | Max Span @ L/100 (mm) | Max Span @ L/150 (mm) | Max Span @ L/200 (mm) | Max UDL @ 1.5 m span (kN/m²) |
|---|---|---|---|---|---|---|---|---|---|---|
| 1.5" × 4" mesh (38 mm bar centers) | I-4010 | 38 | Ø6 cross rod @ 100 mm | 40 | 11.5 | ≈ 65% | ≈ 1100 | ≈ 1400 | ≈ 1650 | ≈ 3.8 |
| 1.5" × 4" mesh (38 mm bar centers) | I-5010 | 38 | Ø6 cross rod @ 100 mm | 50 | 12.5 | ≈ 65% | ≈ 1300 | ≈ 1650 | ≈ 1950 | ≈ 5.5 |
| 1.5" × 4" mesh (38 mm bar centers) | I-6010 | 38 | Ø8 cross rod @ 100 mm | 60 | 13.5 | ≈ 63% | ≈ 1500 | ≈ 1900 | ≈ 2250 | ≈ 7.5 |
| 1" × 4" mesh (25 mm bar centers) | I-4010 | 25 | Ø6 cross rod @ 100 mm | 40 | 16.5 | ≈ 55% | ≈ 950 | ≈ 1200 | ≈ 1450 | ≈ 6.0 |
| 1" × 4" mesh (25 mm bar centers) | I-6015 | 25 | Ø8 cross rod @ 100 mm | 60 | 20.0 | ≈ 52% | ≈ 1350 | ≈ 1750 | ≈ 2050 | ≈ 11.0 |
| 2" × 4" mesh (50 mm bar centers) | T-5020 | 50 | Ø8 cross rod @ 100 mm | 50 | 13.0 | ≈ 70% | ≈ 1400 | ≈ 1800 | ≈ 2100 | ≈ 7.0 |
| 2" × 4" mesh (50 mm bar centers) | T-6020 | 50 | Ø8 cross rod @ 100 mm | 60 | 16.0 | ≈ 70% | ≈ 1650 | ≈ 2100 | ≈ 2450 | ≈ 9.5 |
| 1.5" × 4" mesh (38 mm bar centers) | T-3320 | 38 | Ø6 cross rod @ 100 mm | 33 | 13.5 | ≈ 62% | ≈ 900 | ≈ 1150 | ≈ 1350 | ≈ 2.8 |
Weights include bearing bars + tie rods. Spans and uniform loads are indicative and consistent with industry pultruded load-table practice (manufacturer data); confirm against certified charts for your exact resin, surface and live-load case.
Typical unidirectional pultruded laminate values
Longitudinal = along pultrusion / bearing bars. Transverse values are significantly lower and are not a design basis. Use characteristic (minimum) values per ASTM D7290.
| 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 |
| Dielectric strength | ASTM D149 | > 10 kV/mm (inherent insulation) |
Pultruded coupon values are ~300–400 MPa tensile and ~350–450 MPa flexural longitudinal, well above molded grating due to ~70% unidirectional glass. Exact values supplied on the batch COA.
Match the resin to media, concentration and service temperature
Tg = glass-transition temperature; max service temperature is the long-term design limit.
| Resin System | Tg (typical) | Max Service Temp. | Chemical Resistance Summary | Fire Performance | Typical Application |
|---|---|---|---|---|---|
| ZeAll ISO (isophthalic) | ≈ 110 – 120 °C Tg | ≈ 80 °C | Good general/corrosion; water, mild acids & bases | Self-extinguishing (ASTM D635); E84 ≤ 25 typical | General walkways, water treatment, plating areas |
| ZeAll VE (vinyl ester) | ≈ 130 – 150 °C Tg | ≈ 90 °C | Excellent — acids, solvents, oxidisers, bleach | Self-extinguishing; E84 ≤ 25 | Harsh process areas, pulp & paper, offshore |
| ZeAll Novolac VE (novolac vinyl ester) | ≈ 160 – 180 °C Tg | ≈ 110 °C | Best — strong oxidisers, high-temperature acids, chlorine | Self-extinguishing; E84 ≤ 25 | Chlorine/dry-bleach plants, scrubbers, high-temp service |
| ZeAll FR (fire-retardant VE) | ≈ 130 – 150 °C Tg | ≈ 90 °C | Excellent corrosion + low flame spread / low smoke | E84 Class A (≤ 25, low smoke); USCG / ABS options | Marine, metro, enclosed & ventilated buildings |
| ZeAll FDA (food-contact grade) | ≈ 110 – 130 °C Tg | ≈ 80 °C | Compliant resin for incidental food contact (FDA 21 CFR) | Self-extinguishing; E84 ≤ 25 | Food & beverage, dairy, cleanroom processing |
Coefficient of friction (COF) — wet and dry
Grit-top is the standard pultruded surface; COF values are indicative.
| Surface | COF (dry / wet) | Note |
|---|---|---|
| Grit-top (standard) | 0.75 – 0.85 dry / 0.55 – 0.70 wet | Embedded silica grit on bearing-bar top — standard for wet/chemical service |
| Smooth (natural pultrusion finish) | 0.30 – 0.40 dry / 0.15 – 0.25 wet | Light pedestrian / aesthetic; not for wet or oily service |
| Concave / serrated top | 0.55 – 0.65 dry / 0.40 – 0.50 wet | Molded anti-slip profile on bar crest; good drainage |
Allowable uniform load (kN/m²) at L/150 by span
Three common configurations. Values are indicative allowable UDL at a simply-supported span; short-span rows are stress-limited, long-span rows are deflection-limited.
| Configuration | 0.6 m | 0.9 m | 1.2 m | 1.5 m | 1.8 m |
|---|---|---|---|---|---|
| I-4010, 1.5" × 4" mesh (40 mm deep) | 25 | 11 | 6.0 | 3.8 | 2.5 |
| I-6015, 1.5" × 4" mesh (60 mm deep) | 55 | 24 | 13.5 | 8.5 | 5.8 |
| T-5020, 2" × 4" mesh (50 mm deep) | 45 | 20 | 11 | 7.0 | 4.7 |
Indicative only. Final design must use certified load/span charts with an appropriate safety factor (pultruded typically ≈ 2.5 : 1 long-term, including creep).
Typical pultruded bearing-bar cross-section with tie bar
Schematic, not to scale. Bearing bars run across the clear span; tie rods cross the bars laterally to maintain mesh spacing.
Orientation, bearing, clips and thermal movement
Correct installation is essential to realise the rated span and load.
Bearing bar orientation (critical)
Bearing bars MUST span across the supports — load follows the bars. Installing bars parallel to the span reduces capacity by an order of magnitude.
Minimum bearing
Minimum 75 mm bearing on support (recommended 100 mm); support on structural steel angle or concrete beam, never on bare masonry edges.
Clip spacing
Fasten at every bearing-bar / support intersection; minimum 4 clips per panel; clips ≤ 1200 mm c/c along each support.
Thermal expansion
FRP moves with temperature (longitudinal CTE ≈ 5 × 10⁻⁶/°C). Maintain 3–5 mm edge gaps; use slotted holes / expansion clips on runs > 6 m or ΔT > 40 °C.
Clip material
Galvanized for dry interior; SS304 for general outdoor; SS316 for coastal / chemical / chloride service. Avoid galvanic coupling of dissimilar metals.
Cut edges
Seal cut edges with matching resin + chopped strand to prevent wicking of chemicals into exposed glass ends.
Engineers should specify from certified load/span charts for the exact resin, thickness and surface. ZeAllgrate supplies load test reports and material certificates (COA) with every shipment. Contact [email protected] for project-specific data.
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 →
Need a Certified Pultruded Grating Specification?
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