Catwalks and walkways are often essential for performing daily operations, allowing easy access for maintenance duties, and helping to maximize the space. Our team recently replaced two deteriorating wooden catwalks that became a hazard at a fertilizer plant. We created a custom fiberglass solution that replaced the catwalks with a corrosion-resistant FRP walkway.
FRP Walkway Project Details
Because the project was located in a fertilizer plant and corrosion had taken its toll on the existing structure, safety was the biggest risk. The other concern was the maintenance required for upkeep on the catwalks. The FRP walkway we designed spanned the 20-foot preexisting support system and was an OSHA-compliant solution. FRP 12” x 3” x ½” channel and an 8” x 3/8” FRP channel were used for the framing, and FRP pultruded grating was used for the decking. The sidemounted 2-rail handrails were constructed with 2’ x ¼” square tubes and a kickplate.
Why FRP is Right for the Job
Non-Corrosive – Chemicals and byproducts, such as ammonia and nitric acid, are often found in fertilizer plants. The chemicals, plus the fact that fertilizer plants are often exposed to humidity, dust, and high moisture levels, make them a highly corrosive environment. Metals like steel corrode and rust under these conditions, and the levels of humidity and moisture can cause wood to rot. FRP is resistant to corrosion, even in extreme circumstances, like a fertilizer plant. FRP is made of fibers and resin and does not contain any metal, so it doesn’t have the same reactions as steel or aluminum. This also significantly reduces maintenance costs and downtime that would be used on repairs.
Added Safety – Because FRP is inherently slip-resistant, the FRP walkway will boost safety and not have to be recoated or retaped to maintain its slip-resistant qualities. FRP is also non-conductive, reducing the risk of shock or electrocution.
Lightweight but Strong – The FRP walkway was being installed on the support system that was already there. It was important to install a walkway that was safe, strong, and sturdy, but didn’t add stress or too much weight to the structure. Fiberglass has a higher strength-to-weight ratio than steel, making it perfect for the job.
FRP Pultruded Grating
Designed to handle longer spans, pultruded grating was the perfect choice for the 20-foot FRP walkway crossing the plant. Pultruded grating features parallel bars that are connected by smaller crossbars for maximum unidirectional strength.
Our team can create customized fiberglass structures to fit your exact specifications. Contact us today to discuss your project and whether FRP is the right material for the job.
Learn more about our other featured projects here.
Check out our resources page here.
Follow us on LinkedIn!
