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FRP Cutting, Drilling and Installation Best Practices
Overview
This Tech Talk Tuesday session covers practical best practices for working with FRP on site, including cutting, drilling, bolted connections, resealing and handling safety. The guidance is presented as general advice based on Treadwell’s experience, rather than site-specific instruction, with the recommendation that project teams contact Treadwell for detailed advice on specific applications.
The session explains why correct fabrication methods are important for maintaining the performance, appearance and long-term durability of FRP products. It covers preferred cutting tools, recommended drilling methods, why FRP should not be punched or sheared, how bolted connections should be approached, and why every cut, drilled or sanded surface should be resealed.
Treadwell’s own FRP best practice resources also highlight that correct cutting, drilling, bolting, resealing and handling help FRP platforms, walkways, handrails and structural members perform as intended throughout their design life.
Key Benefits
Cleaner cuts and better finished appearance
Diamond blades are recommended for cutting FRP because they produce cleaner cuts, reduce fraying, minimise heat generation and provide a better finished appearance. The session recommends continuous rim diamond blades, similar to tile blades, rather than segmented concrete blades that may chip edges or create rougher cuts.
Reduced risk of resin damage during cutting
Excessive heat from unsuitable cutting discs can soften or char the resin system. Using the correct blade type helps protect both the appearance and the material integrity of the FRP component.
Better drilling performance with suitable drill bits
Tungsten carbide drill bits are recommended for drilling FRP. High-speed steel drill bits can be used, but they tend to blunt more quickly because of the embedded glass fibres. Moderate drilling speed, similar to working with hardwood, is recommended, along with avoiding excessive force.
Protection of glass fibres and structural performance
The webinar specifically advises against punching or shearing FRP because these methods can damage the embedded glass fibres and may negatively affect structural performance. Cutting and drilling should be done with proper tools instead.
Reliable connections through bolting
FRP cannot be welded, so bolted connections are the standard approach. The session recommends appropriate fasteners, flat washers under bolt heads and nuts, Nylock nuts or lock nuts, and thread lockers such as Loctite where vibration is a concern.
Reduced risk of crushing hollow sections
Anti-crush tubes are recommended where SHS or RHS FRP sections are bolted. These inserts help prevent deformation during tightening, maintain load-bearing capacity and allow proper snug tightening without damaging the profile.
Longer service life through resealing
Whenever FRP is cut, drilled, sanded or altered, the exposed surface should be resealed. This helps protect exposed glass fibres from moisture ingress, water absorption, blistering and loss of long-term durability.
Improved chemical resistance and appearance
Treadwell’s fabrication guidance explains that resealing cut edges and drilled holes with a compatible resin sealer helps prevent moisture ingress, chemical attack at exposed glass fibres and visual lightening of cut surfaces.
Safer on-site fabrication
The session reinforces that safety glasses, hearing protection and breathing protection should be used when cutting FRP. FRP dust is not described as being like asbestos, but inhaling fine particulate matter is still a health risk, so suitable dust control and PPE are required.
Support for pre-cutting and pre-drilling
Treadwell notes that products can often be pre-cut and pre-drilled before delivery, reducing site work. However, the session also recognises that site modifications are sometimes unavoidable, especially on public infrastructure and other projects where final adjustments may be needed.
Applications
On-site cutting of FRP grating and profiles
The best practices covered in this session are relevant when FRP grating, platforms, profiles or access components need to be cut to size on site. Suitable tools include circular saws, angle grinders, reciprocating saws, jigsaws and other equipment that can be fitted with diamond tooling.
Site drilling for bolted installations
Where holes need to be drilled for fixings, brackets, handrails, grating clips or structural connections, tungsten carbide drill bits and moderate drilling speeds help maintain clean holes and reduce tool wear.
Bolted FRP connections
Since FRP cannot be welded, bolting is the standard method of connection. This applies to FRP platforms, walkways, handrails, structural members and other fabricated assemblies where mechanical connections are required.
Hollow FRP section connections
Anti-crush tubes are especially relevant for SHS and RHS profiles, where overtightening can deform hollow sections. These inserts help maintain profile shape and connection reliability during installation.
Applications involving vibration
Where vibration is expected, Nylock nuts, lock nuts, or thread locking products can be used to help prevent loosening. This is relevant for industrial platforms, access structures, plant areas and locations near operating equipment.
Projects requiring stainless, galvanised, duplex or super duplex fasteners
The session explains that 316 stainless steel is commonly used, galvanised steel may be used where required, and duplex or super duplex stainless steel can be considered for more demanding applications, with cost implications.
FRP fastener applications
FRP threaded rods, bolts and nuts are available, but their capacity is generally lower than that of conventional steel fasteners. This means upsizing and revised spacing or edge distances may be required.
Resealing after cutting, drilling or sanding
Any exposed FRP surface created by cutting, drilling, sanding or alteration should be resealed. Treadwell’s EX-Series sealer kit is described as a two-part resin and catalyst system that can be brushed onto exposed areas to help maintain product longevity.
Wet cutting and dust control
Wet cutting may be used for dust control and cleaner work conditions, provided the cutting equipment is rated for wet operation to avoid electrical risk. Other dust control measures include appropriate PPE and extraction where suitable.
FRP repair and maintenance discussions
The Q&A notes that some minor defects or impacts may be repairable on a case-by-case basis, but incorrectly cut components cannot simply be joined back together if the issue is dimensional. This makes correct cutting, checking and fabrication planning important before site modification begins.
Key Moments
- 00:32 🔧 FRP best practices cover cutting, drilling, bolted connections, resealing, and handling safety as general recommendations.
- 01:45 💎 Use diamond blades for clean FRP cuts with minimal fraying, heat, and better aesthetics.
- 02:12 ⚙️ Prefer continuous rim diamond blades over segmented ones to avoid chipping and resin charring.
- 02:38 🛠️ Suitable tools include circular saws, angle grinders, reciprocating saws, and jigsaws with diamond tooling.
- 02:52 ⚠️ Timber or aluminium blades blunt quickly due to glass fibres, requiring frequent replacement.
- 03:18 💧 Wet cutting is recommended for dust control if equipment is rated for it.
- 03:44 🏭 Factory pre-cuts and pre-drills FRP; site modifications possible with proper tools.
- 04:15 🪛 Use tungsten carbide drill bits at moderate speed, like cutting hardwood; avoid excessive force.
- 04:42 🚫 Never punch or shear FRP to prevent glass fibre damage and structural issues.
- 05:22 🔩 FRP uses bolted connections, not welding; opt for stainless steel or galvanized fasteners.
- 06:01 📏 FRP bolts have lower strength than steel, requiring upsizing and adjusted spacing.
- 06:18 🛡️ Use flat washers, Nylock nuts, and thread lockers like Loctite for vibration-prone areas.
- 06:46 🔧 Tighten bolts snug tight with quarter turns; avoid overtightening, especially in hollow sections.
- 07:01 🛠️ Anti-crush tubes recommended for SHS/RHS sections to prevent deformation during tightening.
- 07:29 🔄 Reseal cut, drilled, or sanded FRP surfaces to prevent moisture ingress and blistering.
- 08:10 🖌️ Apply two-part resin sealer kit to exposed areas for longevity and chemical resistance.
- 08:50 🥽 Wear PPE, including safety glasses, ear protection, and breathing masks when cutting FRP.
- 09:20 📚 Structural guides and installation manuals available on website or via request.
Why Treadwell?
Treadwell does more than supply FRP products. It also provides practical installation knowledge, fabrication guidance and technical support to help customers work with FRP correctly. Its best practice resources cover cutting, drilling, bolted connections, resealing and dust management, giving installers and project teams a clear framework for maintaining product performance on site.
The session also highlights Treadwell’s ability to support projects through pre-cutting, pre-drilling, sealer kits, anti-crush tubes, installation manuals, material safety data sheets and project-specific discussions. This helps reduce avoidable site errors and supports safer, more durable installations.
Treadwell’s Structural Fabrication and Repair Guide reinforces the importance of proper bolting practices. It states that bearing-type FRP connections should generally be tightened to a snug-tight condition, with torque limited to avoid crushing pultruded FRP laminates, especially where larger structural bolts and oversized washers are used.
With FRP products used across mining, oil and gas, rail, utilities, water and wastewater treatment, food and beverage, and public infrastructure, Treadwell brings practical project experience to the fabrication and installation process. That combination of product supply, technical documentation and application support helps designers, fabricators and site crews achieve the durability and low maintenance performance expected from FRP systems.
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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.
