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Moulded vs Pultruded FRP Grating for Access Platforms
Overview
This Tech Talk Tuesday session explains the key differences between moulded FRP grating and pultruded FRP grating, with a practical focus on how each product type behaves in real access platform and walkway applications. The session compares GratEX moulded grating with GridEX pultruded grating, including their reinforcement direction, span capacity, load performance, support requirements, penetration detailing and common use cases.
The webinar highlights that moulded grating is a versatile bi-directional product, making it useful for platforms with regular direction changes, pipe penetrations and services passing through the deck. Pultruded grating, by contrast, has most of its glass reinforcement running in one direction, giving it higher span capacity and better performance for applications where the load bar direction can be controlled.
Treadwell’s FRP grating range includes GratEX moulded grating and GridEX pultruded grating. Treadwell describes GratEX moulded grating as having bi-directional strength characteristics, while GridEX pultruded grating provides uni-directional strength and higher point loading capability.
Key Benefits
Clear product selection guidance
The session helps engineers, contractors and asset owners understand when to choose moulded FRP grating and when pultruded FRP grating may be the better solution. This is important because both products are corrosion-resistant FRP grating systems, but they behave differently under load and require different design considerations.
Bi-directional performance with moulded grating
GratEX moulded grating has glass reinforcement running in both directions, allowing the panel to span north-south or east-west. This makes it useful where platforms change direction, where grating sheets may need to be oriented differently, or where pipe penetrations and services interrupt the deck layout.
Useful around penetrations and irregular layouts
Moulded FRP grating can self-support around penetrations to approximately 300 mm, according to the webinar. This makes it practical for industrial platforms with pipework, ductwork, ventilation, services and other interruptions that would otherwise require careful load bar coordination.
Higher span capacity with pultruded grating
GridEX pultruded grating has a higher glass content, and most of the glass reinforcement runs in one direction. This gives the product a larger span capacity than moulded grating, making it useful where existing steel, stainless steel or aluminium grating is being replaced, and support spacing is already fixed.
Suitable replacement for metallic grating in selected applications
The presenter introduces a new 32 mm thick GridEX product with approximately 11 mm openings, designed as a strong replacement option for common 32 mm steel grating. Matching the 32 mm depth helps avoid changes to stair risers, handrail compliance and floor level transitions when only part of an existing deck is replaced.
Dropped object compliance options
The new 32 mm GridEX product discussed in the session has an opening of approximately 11 mm between bars and is described as complying with the dropped object clause of AS 1657. This supports applications where smaller apertures are required to reduce the risk of objects falling through elevated access flooring.
Broad GridEX product range for different loads
The GridEX range includes I-type, T-type, and bar-type pultruded grating profiles. The webinar explains that these options provide different levels of span and load performance, including very high span and heavy loading capability through the bar-type product.
Lightweight and easier to install than traditional metals
Treadwell states that GridEX pultruded FRP grating is approximately 35 per cent lighter than aluminium and 75 per cent of the weight of steel, which can make handling and installation easier. Treadwell also notes that GridEX can be cut onsite using simple hand tools, without hot work tools such as grinders or torches.
Product support for fixings, pricing and project selection
The Q&A section explains that fixing details are not identical across every grating type and depend on the support structure, support frequency, uplift forces and whether the fixing is simply restraining the grating. Treadwell encourages project-specific discussion to confirm the correct product and fixing arrangement.
Applications
Industrial platforms with pipe penetrations
GratEX moulded FRP grating is suitable for industrial platforms where services, pipework, ventilation, ductwork or other penetrations regularly pass through the deck. Its bi-directional span behaviour makes it easier to manage direction changes and small interruptions in the grating layout.
Boardwalks and access routes with changing directions
Where walkways move around trees, services, equipment or irregular site geometry, moulded grating can be easier to use because it does not rely on a single load bar direction in the same way as pultruded grating.
Replacement of existing steel, stainless steel or aluminium grating
Pultruded GridEX grating is useful where existing metallic grating is being replaced, and the support spacing is larger than the moulded grating can accommodate. This can reduce the need to add extra steelwork, site welding, blasting, painting or additional support members.
Applications with larger span requirements
GridEX pultruded grating is better suited to applications where longer spans are required, provided the grating is installed with the correct load bar direction. Treadwell’s GridEX I-type system is described as offering strong resistance to deflection and the ability to support maximum loads because of the engineered load bar shape.
Dropped object prevention in access areas
The new 32 mm GridEX product discussed in the webinar has approximately 11 mm spacing between bars, making it suitable for access areas where smaller openings are required to reduce dropped object risk. This may include elevated platforms, maintenance decks and process areas where people or equipment are located below.
Pedestrian bridge and waterproof deck discussions
During the Q&A, the presenter notes that Treadwell has used a variety of products for pedestrian bridges and that waterproof deck requirements may be better served by an interlocking deck board profile rather than a standard grating product. This reinforces the need to match the FRP system to the required surface performance.
High heel safe or smaller aperture requirements
The Q&A explains that there is no specific Australian standard for high heel safe grating, but that openings below approximately 10 mm are generally accepted as suitable in the industry. Treadwell offers grating products with smaller openings, including 7 mm, 6 mm and solid top surface options, as well as 13 mm opening products that may be applied to AS 1428.1 requirements.
Marine and high load environments
The Mandurah Jetty example in Western Australia used GridEX bar-type grating, where higher wave uplift and larger span requirements made pultruded grating the most suitable product for the application.
Chemical and industrial facilities
The webinar references a fluoride plant in Victoria using a 38 mm thick, 38 by 38 square mesh moulded grating product. This reflects the common use of FRP grating in corrosive or chemically exposed environments where traditional metallic grating may require more maintenance.
Fire performance and project-specific compliance reviews
The Q&A notes that fire performance depends on the specific standard or compliance pathway being considered, such as AS 1530 Part 3, ISO tests, the National Construction Code or practical fit for purpose testing. Treadwell can review these requirements on a project-specific basis.
Key Moments
- 00:20 👋 Welcome to Tech Talk Tuesday on FRP grating types at Treadwell.
- 01:44 🧱 Moulded grating is the most common FRP type with various thicknesses, mesh sizes, and options like green, mini, or solid tops.
- 03:08 ↔️ Moulded grating offers bi-directional spanning for flexible installation around penetrations or direction changes, self-supporting up to 300mm.
- 04:31 📏 Moulded grating spans are limited to about 1,200mm at 2.5 kPa UDL, often requiring extra steelwork for larger replacements.
- 05:14 🏗️ Pultruded GridEX grating uses more glass fibres in one primary direction for higher load and span capacity than moulded.
- 05:58 ➡️ Pultruded grating is uni-directional, requiring specific orientation like steel grating and extra support planning around pipes.
- 06:54 📊 New 32mm pultruded product spans 1,200mm at 4 kPa UDL with 4.5mm deflection and meets AS 1657 dropped objects rules.
- 08:05 🔧 GridEX pultruded range includes I-type, T-type, and solid bar-type for varying span and heavy-load needs.
- 08:36 🏭 Real-world examples: moulded square mesh in fluoride plant and jetty; pultruded bar-type for high wave uplift and large spans.
- 10:13 🔥 Fire ratings vary by test standard; specific compliance details available on request via email.
- 12:21 🔩 Fixings differ by grating type, support material, and loads like wave uplift—case-by-case advice offered.
- 13:19 📐 Minimum bearing area is generally 40mm or equal to product thickness if thicker than 40mm.
- 14:32 👟 Heel-proof options available with openings under 10mm (e.g., 6-7mm) or solid tops per industry guidelines
Why Treadwell?
Treadwell provides both GratEX moulded FRP grating and GridEX pultruded FRP grating, allowing project teams to choose between bi-directional versatility and higher uni-directional span performance based on the specific application. Its FRP grating range also includes moulded, pultruded and heavy-duty options, giving consultants and contractors a broader selection than a single grating type.
The value of Treadwell’s approach is in practical specification support. This webinar does not treat FRP grating as one generic product. It explains how glass direction, product thickness, aperture size, bearing width, support spacing, fixings, penetrations, uplift, fire testing and public access requirements all affect product selection.
Treadwell can also support project teams with samples, budget pricing, project-specific quotations, fixing discussions, site visits and product guidance. Whether the requirement is a corrosion-resistant replacement for steel grating, a smaller aperture dropped object solution, a public walkway surface, or a high-span pultruded grating system, Treadwell can help match the FRP grating type to the structural, safety and maintenance needs of the project.
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*Disclaimer
The information on this page is derived from webinar content and AI-assisted transcription and summarisation. While every effort has been made to ensure accuracy, minor inaccuracies may occur. We recommend viewing the original webinar recording for context.
