Technical Guide · Quality
Eight QC Gates
Before you accept a shipment, these are the documents and checks that separate a certified panel from a promissory one.
| Test / Check | Frequency | Method | Typical Target |
|---|---|---|---|
| Resin / gel coat inspection | Incoming raw material | Batch certificate, gel time, viscosity | Reject off-spec batches |
| Glass content | Per batch | Burn-off / ignition test | Molded ~33%, pultruded ~70% (± tolerance) |
| Barcol hardness | Per panel | Barcol impressor | ≥ 40 polyester / ≥ 35 VE (cure check) |
| Dimensional check | Per panel | Calliper, tape | Thickness, flatness, opening, length ± |
| Visual / void check | Per panel | Visual, tap test | No surface voids, delamination or bloom |
| Load / deflection test | Per type, periodic | Test rig at certified span | Uniform + concentrated load vs. table |
| Fire test (E84) | Per resin grade | Steiner tunnel report | FSI/SDI for Class A claim |
| Chemical resistance | Per resin grade | ASTM C581 immersion | Flexural retention after immersion |
Per ISO 9001 quality system and manufacturer QC practice. Require the batch QC record, not just a certificate of conformance.
Documents to Require
- Batch test report (COA): resin type, glass content, Barcol, dimensions, batch number.
- Load test certificate: traceable to actual test panels at your span, not extrapolated resin data.
- Fire report: current ASTM E84 report (FSI/SDI) for the exact resin grade, if Class A is specified.
- C581 data: if chemical service is critical, require immersion-retention data for the exact resin.
On-Arrival Checks
Visual
No cracks, delamination, uneven color or exposed glass on the surface. Tap panels; a dull, dead sound indicates delamination.
Dimensional
Check thickness with a caliper and panel flatness. Bowing beyond spec can make installation hard and clips uneven.
Marking
Each panel should carry a batch number, resin grade and manufacturer mark for traceability back to the QC record.
Damage in transit
FRP corners chip; inspect edges and reject panels with cracked bars or crushed ends before installation.
What to Test Against What Lot
Factory QC should be sample-based, not purely visual.
| Check | Sample rate | Reject if |
|---|---|---|
| Dimensions | First & last of a run | Beyond tolerance |
| Barcol hardness | 1 per 50 panels / per batch | Below grade minimum |
| Visual / void | 100% of panel faces | Any exposed glass or delamination |
| Load test | Per type, periodic / by agreement | Below table value at span |
| Fire (E84) | Per resin grade, lab report | FSI/SDI above Class A |
Sample rates indicative; align with the project inspection plan and ISO 9001.
What Arrives With the Shipment
- Certificate of analysis (COA): resin, glass content, Barcol, dimensions, batch.
- Load test certificate traceable to test panels at the design span.
- E84 fire report (if Class A specified) for the exact resin.
- Packing list and batch marking matching each panel.
- Installation and clip-up note.
What Actually Fails QC
Most QC rejections are not dramatic structural failures; they are recurring surface and cure defects. Watch for:
- Low Barcol - under-cured resin that will chalk and degrade early; re-cure or reject.
- Surface voids or exposed glass on the face - missing veil or poor wet-out; the chemical barrier is gone.
- Thickness outside tolerance - usually a mold-parting issue; affects span and load.
- Warped or twisted panels - poor stack during curing; hard to clip up flat.
- Missing batch marking - cannot trace back to the COA; reject or require re-labeling.
A factory that can show you batch QC records - Barcol, glass content, dimensions - for the panel you are buying is a different partner from one that offers only a certificate of conformance.
One Panel, One Record
FRP properties vary with the resin batch, glass batch, cure cycle and operator - far more than a steel mill product varies. A panel from one press run is not identical to one from another. That is why each panel should carry a batch number, and why the COA, load certificate and E84 report should all reference that batch. If a panel fails in service, traceability lets you compare it against the exact cure and resin record rather than arguing from a generic datasheet. When you compare suppliers, ask to see the QC record for the last shipment of the same grade - not a promotional certificate, but the actual batch sheet.
References
- Industry molded grating engineering guide (manufacturer PDF) — QC and test methods. Manufacturer technical data available upon request.
- Industry pultruded grating metric design manual (manufacturer PDF) — Barcol and load-test practice. Manufacturer technical data available upon request.
- ASTM D2584 (glass content burn-off), D2583 (Barcol), E84 (fire), C581 (chemical); ISO 9001 quality system.
Test Standards Behind the Gates
| Property | Typical Standard | What It Verifies |
|---|---|---|
| Glass content | Ignition / burn-off (ASTM D2584) | Fibre fraction of the laminate — molded ~33%, pultruded ~70%. |
| Flexural strength / modulus | ASTM D790 | Bending capacity of the section used in load tables. |
| Barcol hardness | ASTM D2583 | Surface cure state; quick production-line check. |
| Flame spread / smoke | ASTM E84 | Fire classification for code compliance. |
| COF (slip resistance) | ASTM C1028 / pendulum | Wet and dry slip performance of the walking surface. |
| Chemical resistance | ASTM C581 / D3681 | Retained strength after immersion in the service chemical. |
Sampling and Documentation
Factory QC follows a sampling plan: incoming resin and glass are checked batch-by-batch; cure, dimensions and visual condition are checked panel-by-panel; and load/deflection tests are run per type at a certified span on a periodic schedule, with the results tied to the production lot. Every shipment carries material certificates, load test reports and batch traceability records. For projects that require independent assurance, third-party inspection (SGS, Intertek, or a nominated lab) can witness testing and review documentation before dispatch — arrange this at order stage so the inspection points are written into the production schedule.
What a Buyer Should Request
- Material certificate covering resin type, glass content and production lot.
- Load/deflection test report for the exact panel type and span in the specification.
- E84 test report where fire class is specified.
- Wet COF data where slip resistance is specified.
- Batch traceability records tying panels to raw materials and testing.
- Material certificate covering resin type, glass content and production lot.
- Load/deflection test report for the exact panel type and span in the specification.
- E84 test report where fire class is specified.
- Wet COF data where slip resistance is specified.
- Batch traceability records tying panels to raw materials and testing.
Request a Batch QC Record
Ask ZeAllgrate for the COA, load certificate and E84 report for your exact grade — supplied with every order.