FIBERGLASS REINFORCED PLASTICS (FRP) FABRICATIONS
STRUCTURAL SHAPES, HANDRAILS, LADDERS, GRATING, AND TREADS
PART 1: General
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this section.
B. The Fiberglass Grating Manual, ACMA, latest edition
C. The publications listed below (latest revision applicable) form a part of this specification to the extent referenced herein. The publications are referred to within the text by the designation only.
AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) Test Methods:
ASTM D-635 Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Plastics in a Horizontal Position
ASTM D-638 Tensile Properties of Plastics
ASTM D-790 Flexural Properties of Unreinforced and Reinforced Plastics
ASTM D-2344 Apparent Interlaminar Shear Strength of Parallel Fiber Composites by Short Beam Method
ASTM D-495 High Voltage, Low-Current, Dry Arc Resistance of Solid Electrical Insulation
ASTM D-696 Coe cient of Linear Thermal Expansion for Plastics
ASTM E-84 Surface Burning Characteristics of Building Materials
THE OCCUPATIONAL HEALTH AND SAFETY ADMINISTRATION (OSHA) Code of Federal Regulations (CFR), Volume 29
1.02 SCOPE OF WORK
A. This section includes shop fabricated fiberglass reinforced plastic (FRP) pultruded and molded gratings and treads, structures, handrails and ladders where noted on the drawings.
1.03 SCOPE OF WORK
A. The CONTRACTOR shall furnish, fabricate (where necessary), and install all fiberglass reinforced plastic (FRP) items, with all appurtenances, accessories and incidentals necessary to produce a complete, operable and serviceable installation as shown on the Contract Drawings and as specified herein, and in accordance with the requirements of the Contract Documents.
1.04 CONTRACTOR SUBMITTALS
A. The CONTRACTOR shall furnish shop drawings of all fabricated systems and accessories in accordance with the provisions of this Section.
B. The CONTRACTOR shall furnish manufacturer's shop drawings clearly showing material sizes, types, styles, part or catalog numbers, complete details for the fabrication and erection of components including, but not limited to, location, lengths, type and sizes of fasteners, clip angles, member sizes, and connection details.
C. The CONTRACTOR shall submit the manufacturer’s published literature including structural design data, structural properties data, grating load/deflection tables, corrosion resistance tables, certificates of compliance, test reports as applicable, concrete anchor systems and their allowable load tables, and design calculations for systems not sized or designed in the contract documents.
D. The CONTRACTOR may be requested to submit sample pieces of each item specified herein for acceptance by the ENGINEER as to quality and color. Sample pieces shall be manufactured by the method to be used in the WORK.
E. The CONTRACTOR shall provide calculations and drawings sealed by a Registered Professional Engineer.
1.05 QUALITY ASSURANCE
A. All items to be provided under this Section shall be furnished only by manufacturers having experience in the design and manufacture of similar products and systems. If requested, experience shall be demonstrated by a record of at least five (5) previous, separate, similar successful installations in the last five (5) years.
B. Substitution of any component or modification of system shall be allowed when approved by the Architect or Engineer.
C. Fabricator Qualifications: Firm experienced in successfully producing FRP fabrications similar to that indicated for this project, with su cient production capacity to produce required units without causing delay in the work.
D. In addition to requirements of these specifications, comply with manufacturer’s instructions and recommendations for work.
1.06 DESIGN CRITERIA
A. The design criteria of the FRP products including connections shall be in accordance with governing building codes and generally accepted standards in the FRP industry.
B. Gratings: Design live loads of the FRP gratings for walkway applications shall be 65 psf uniformly distributed load (or as required by the governing building code) with a maximum deflection of 3/8” or L/120 at the center of a simple span OR a concentrated load of 250 pounds with a maximum deflection of ¼” at the center of a simple span.
C. Structures: Structures shall be designed for 65 psf live load wit ha maximum deflection of L/180 for the structural member being considered.
D. Stair Treads: Stair treads shall be designed for a uniform live load of 100 psf on the simple span of the tread OR a 300 pound line load at the center of the tread, whichever produces the greater stress.
1.7 PRODUCT DELIVERY AND STORAGE
A. All gratings and components shall be shop fabricated, piece match marked to assembly or erection drawings.
B. Delivery of Materials: Manufactured materials shall be delivered in original, unbroken pallets, packages, containers, or bundles bearing the label of the manufacturer. Adhesives, resins and their catalysts and hardeners shall be crated or boxed separately and noted as such to facilitate their movement to a dry indoor storage facility.
C. Storage of Products: All materials shall be carefully handled to prevent them from abrasion, cracking, chipping, twisting, other deformations, and other types of damage. Store items in an enclosed area and free from contact with soil and water. Store adhesives, resins and their catalysts and hardeners in dry indoor storage facilities between 70 and 85 degrees Fahrenheit (21 to 29 degrees Celsius) until they are required.
Part 2: Products
2.1 MANUFACTURER
A. Molded gratings and treads shall be Gridwalk®
B. Pultruded gratings shall be AmeriSpan
C. Structural shapes shall be AmeriShapes
D. Handrail system shall be AmeriRail
E. Ladder system shall be AmeriRail
All (A, B, C, D, E) above as manufactured by:
American Grating, LLC. 1191 Center Point Dr.
Henderson, NV 89074
(702) 567-0303
(702) 567-0323 FAX
2.2 GENERAL
A. All FRP items under this Section shall be composed of fiberglass reinforcements and resins in qualities, quantities, properties, arrangements and dimensions as necessary to meet the design requirements and dimensions as specified in the Contract Documents.
B. Fiberglass reinforcement shall be a combination of continuous roving, continuous strand mats (pultruded structural shapes, hand layup products) and/or surfacing veils
(pultruded shapes and gratings) in sufficient quantities as needed by the application and/or physical properties required.
C. Resin shall {VINYL ESTER or POLYESTER - choose one} for all systems. Gratings used in chemical storage or containment areas shall only be MOLDED which shall be vinyl ester resin system, with chemical formulations as necessary to provide the corrosion
resistance, strength and other physical properties as required.
D. All finished surfaces of FRP items and fabrications shall be smooth, resin-rich, free of voids and without dry spots, cracks, crazes or unreinforced areas. All glass fibers shall be well covered with resin to protect against their exposure due to wear or weathering.
E. All FRP gratings and systems shall have a tested flame spread rating of 25 or less when tested in accordance with the ASTM E-84 Tunnel Test. Gratings shall also have a tested burn time of less than 30 seconds and an extent of burn rate of less than or equal to 10 millimeters per ASTM D635. Manufacturer may be required to provide certification of ASTM E84 test on grating panels from an independent testing laboratory. Test data shall be from full scale testing of actual production grating of the same type of material supplied on the project. Test data performed only on the base resin shall not be accept able.
F. All grating clips and hardware shall be manufactured of Type 316SS.
G. After fabrication, all cut ends, holes and abrasions of FRP grating shall be sealed with a resin comparable to the grating panel or structural system.
2.3 STRUCTURAL SHAPES
{Note to Specifier: This section will be required for projects requiring structural shapes systems including ladders and handrails}
A. All structural shapes are to be manufactured by the pultrusion process with a glass content minimum of 45%, maximum of 55% by weight for maximum sunlight and
chemical resistance. The structural shapes shall be composed of fiberglass reinforcement and resin in qualities, quantities, properties, arrangements and dimensions as necessary to meet the design requirements and dimensions as specified in the Contract Documents.
B. Pultruded structural shapes are to have the minimum longitudinal mechanical properties listed below:
| Property |
ASTM Test Method |
Value |
Units |
| Tensile Strength |
D-638 |
30,000 (206) |
psi (MPa) |
| Tensile Modulus |
D-638 |
2.5 x 106 (17.2) |
psi (GPa) |
| Flexural Strength |
D-790 |
30,000 (206) |
psi (MPa) |
| Flexural Modulus |
D-790 |
1.8 x 106 (12.4) |
psi (GPa) |
| Flexural Modulus (Full Section) |
N/A |
2.8 x 106 (19.3) |
psi (GPa) |
| Short Beam Shear (Transverse) |
D-2344 |
4,500 (31) |
psi (MPa) |
| Shear Modulus (Transverse) |
N/A |
4.5 x 106 (3.1) |
psi (GPa) |
| Coefficient Of Thermal Expansion |
D-696 |
8.0 x 10-6 (1.4 x 10-6) |
in/in/°F (cm/cm/°C) |
| Flame Spread |
E-84 |
25 or LESS |
N/A |
2.4 HANDRAIL
A. All handrail systems shall be compliant to OSHA 1910.23
B. All posts, rails and toeplates are to be AmeriRail. FRP structural shapes shall be manufactured by the pultrusion process.
C. Top rails and posts shall be 2 x 1/4 wall (50.8 mm x 6.4 mm) square tube, the midrail shall be 1-1/2” diameter x 1/8” round tube (38.1 mm x 3.2 mm). Kickplate is to be ½" deep x 4" high (12.7 mm x 201.6 mm) with two reinforcing ribs. The base of the posts are to be reinforced to a height of 10" (254 mm) using a high strength epoxy compound or solid bar.
D. The top rail-to-post connection is to be fabricated such that the top rail is unbroken and continuous over the post with the use of internal splice. The mid rail is to be installed through the post at a prepared hole made to fit the outside dimensions of the rail. The rails are to be joined to the post through a combination of bonding and riveting. No
sharp, protruding edges are to remain after assembly of the handrail. Spacing of the posts shall not exceed 6'-0" (1.83 m).
E. All rails, posts, and kick plates are to be integrally pigmented yellow.
F. Handrails to be located outdoors in direct UV shall be shop coated with a two-part polyurethane coating, 2 mils thick minimum, for improved durability and UV resistance.
G. All fasteners used in the railing system are to be 316 SS. Rivets will be 18-8 SS.
2.5 LADDERS AND CAGES
A. All ladder and cage systems shall be compliant to OSHA 1910.27
B. All ladder side rails, rungs and cage straps shall be AmeriShapes structural shapes, manufactured by the pultrusion process. Cage hoops and ladder mounting brackets shall be produced by the open molded hand lay-up method.
C. All pultruded ladder components shall be further protected from ultraviolet (UV) attack with 1) integral UV inhibitors in the resin and 2) a synthetic surfacing veil to help produce a resin rich surface
D. All FRP products shall have a tested flame spread rating of 25 or less per ASTM E-84 Tunnel Test.
E. All ladder and cage components are to be integrally pigmented safety yellow. All wall and floor mount brackets shall be hand layup and pigmented safety yellow.
F. Ladders and cages to be located outdoors in direct UV shall additionally be shop coated with a two-part polyurethane coating, 2 mils thick minimum, for improved durability and
UV resistance.
2.6 DETAILS
A. The ladder side rail shall be 2" square tube with a wall thickness of 1/4" (50 mm x 6 mm) or greater. The rungs shall be 1" (25 mm) diameter solid round bar, gritted to provide a
non-slip surface. Rungs shall be both mechanically attached to the ladder with FRP dowels and chemically bonded with epoxy.
B. Ladder wall and floor mount shall be 3/8" (9.5 mm) minimum thickness.
C. Cage hoops shall be hand layup FRP and have integral mounting loops to provide a free and clear hand path so that climbers do not have to use rungs for climbing. The ladder cage vertical bars shall be 2" wide by ¼” thick (50.8 mm x 6.4 mm) flat bars. Top, intermediate, and bottom hoops shall be 3" wide by 1/4" thick minimum (76.2 mm x 6.4 mm).
D. Type 316SS round head bolts shall be provided for attaching ladder cage vertical bars to hoops and ladder cage hoops to ladder rails to eliminate a point of catch or snag to
worker clothes and hands. Ladder standof and base brackets shall be connected by 316SS bolts.
2.7 MOLDED GRATING – SQUARE MESH
A. Manufacture: Grating shall be Gridwalk®, a one piece molded construction with tops and bottoms of bearing bars and cross bars in the same plane. Grating shall have a square mesh pattern providing bidirectional strength. Gratings shall be reinforced with rovings of equal number of layers in each direction. The top layer of reinforcement shall be no more than 3/16" below the top surface of the grating so as to provide maximum stifness and prevent resin chipping of unreinforced surfaces. Percentage of glass (by weight) shall not exceed 40% so as to achieve maximum corrosion resistance, and as required to maintain the structural requirements of the CONTRACT.
After molding, no dry glass fibers shall be visible on any surface of bearing bars or cross bars. All bars shall be smooth and uniform with no evidence of fiber orientation irregulari
ties, interlaminar voids, porosity, resin rich or resin starved areas.
B. Non-slip surfacing: Grating shall be manufactured with a secondarily applied grit on the top of each bar providing excellent slip resistance.
C. Fire rating: Grating shall be fire retardant with a tested flame spread rating of 25 or less when tested in accordance with ASTM E 84. Certifications shall be dated within the past two years and test data performed only on the resin shall not be acceptable.
D. Resin system: The resin system used in the manufacture of the grating shall be {OTHRO,
ISO or VFR – choose one}. Manufacturer may be required to submit corrosion data from tests performed on actual grating products in standard chemical environments.
Corrosion resistance data of the base resin from the manufacturer is not a true indicator of grating product corrosion resistance and shall not be accepted.
E. Color: {Green, Yellow or Dark Gray – choose one}
F. Depth: 1-1/2" with a tolerance of plus or minus 1/16".
G. Mesh Configuration: 1-1/2” x 1-1/2” with a tolerance of plus or minus 1/16" mesh centerline to centerline.
H. Substitutions: Other products of equal strength, stifness, corrosion resistance and overall quality may be submitted with the proper supporting data to the engineer for approval.
2.8 PULTRUDED GRATING
A. Manufacture: Grating components shall be high strength and high stifness pultruded elements having a maximum of 70% and a minimum of 60% glass content (by weight)
of continuous roving and continuous strand mat fiberglass reinforcements. The finished surface of the product shall be provided with a surfacing veil to provide a resin rich surface which improves corrosion resistance and resistance to ultraviolet degradation. Bearing bars shall be interlocked and epoxied in place with a two piece cross rod system to provide both a mechanical and chemical lock.
B. Non-slip surfacing: Grating shall be provided with a quartz grit bonded and baked to the top surface of the finished grating product.
C. Fire rating: Grating shall be fire retardant with a tested flame spread rating of 15 or less when tested in accordance with ASTM E 84. Manufacturer may be required to provide certification of ASTM E84 test on grating panels from an independent testing laboratory. Test data shall be from full scale testing of actual production grating, of the same type and material supplied on the project. Test data performed only on the base resin shall not be acceptable.
D. Resin system: The resin system used in the manufacture of the grating shall be ISOFR, a fire retardant polyester resin matrix. Manufacturer may be required to submit corrosion data from tests performed on actual grating products in standard chemical environments.
Corrosion resistance data of the base resin from the manufacturer is not a true indicator of grating corrosion resistance and shall not be accepted.
E. Color: Gray or Yellow {choose one}.
F. Depth: 1-1/2" deep “I” shaped load bars with a tolerance of plus or minus 1/32". The width of the top and bottom of the “I” shape shall be 0.60”.
G. Mesh Configuration: 1 1/2" load bar spacing, 6" tie bar spacing on centers. Grating shall be AmeriSpan, PI-1560.
H. Substitutions: Other products of equal strength, stifness, corrosion resistance and overall quality may be submitted with the proper supporting data to the engineer for approval.
2.9 STAIR TREADS
A. Stair treads shall be Gridwalk®. Stair treads shall be of a one piece molded construction and shall have a 1" x 6" rectangular mesh pattern providing unidirectional strength in the tread span direction. Treads shall be reinforced with continuous rovings in each direction. The top layer of reinforcement shall be no more than 3/16" below the top surface of the tread so as to provide maximum stifness and prevent resin chipping of unreinforced surfaces. Percentage of glass (by weight) shall not exceed 35% so as to achieve maximum corrosion resistance, and as required to maintain the structural requirements of the CONTRACT.
After molding, no dry glass fibers shall be visible on any surface of bearing bars or cross bars. All bars shall be smooth and uniform with no evidence of fiber orientation irregularities, interlaminar voids, porosity, resin rich or resin starved areas.
B. Non-slip surfacing: Stair treads shall be manufactured with a concave profile on the top of each bar providing maximum slip resistance. For additional safety, and to meet OSHA requirements, stair treads shall be manufactured with a 1-1/2" solid, molded nosing. Nosing shall be gritted with an angular quartz grit, integrally molded into the top surface of the nosing area only.
3.1 EXECUTION
A. GENERAL
1) Measurements - FRP Structures and systems supplied shall meet the dimensional requirements and tolerances as shown or specified. The Contractor shall provide and/or verify measurements in field for work fabricated to fit field conditions as required by manufacturer to complete the work. When field dimensions are not required, contractor shall determine correct size and locations of required holes or cutouts from field dimensions before grating fabrication.
2) Sealing - All shop fabricated cuts, drilled holes, etc. shall be coated with resin to provide maximum corrosion resistance. All field fabricated cuts, drilled holes, etc. shall be coated similarly by the contractor in accordance with the manufacturer's instructions.
3) Hardware - Type 316 stainless steel hold-down clips shall be provided and spaced at a maximum of four feet apart with a minimum of four per piece of grating, or as recommended by the manufacturer.
B. GRATING
1) Layout - Each grating section shall be readily removable, except where indicated on drawings. Manufacturer to provide openings and holes where located on the contract drawings. Grating openings which fit around protrusions (pipes, cables, machinery, etc.) shall be discontinuous at approximately the centerline of opening so each section of grating is readily removable. Gratings shall be fabricated free from warps, twists, or other defects which afect appearance and serviceability.
3.2 INSPECTION
A. Shop inspection is authorized as required by the Owner and shall be at Owner's expense. The fabricator shall give ample notice to Contractor prior to the beginning of any fabrication work so that inspection may be provided.
B. The grating shall be as free, as commercially possible, from visual defects such as foreign inclusions, delamination, blisters, resin burns, air bubbles and pits. The surface shall have a smooth finish (except for grit top surfaces).
3.3 INSTALLATION
A. Contractor shall install FRP structures in accordance with manufacturer’s assembly drawings.
B. Lock grating panels securely in place with hold-down fasteners as specified herein.
C. Field cut and drill fiberglass reinforced plastic products with carbide or diamond tipped bits and blades. Seal cut or drilled surfaces in accordance with manufacturer's instructions. Follow manufacturer's instructions when cutting or drilling fiberglass products or using resin products; provide adequate ventilation.