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FRP Structures for Mining and Mineral Processing
Overview
This Tech Talk Tuesday session focuses on the use of FRP in mining and mineral processing applications, especially where corrosion, conductivity, installation access, downtime and whole of life cost need to be considered. The session explains why FRP can be a strong alternative to steel, timber and coated structures in mining environments where saline process water, reagents, slurry build-up, abrasion, limited access and hot works restrictions can affect material performance and installation cost.
The webinar discusses several mining and industrial project examples, including a salt facility in Western Australia, a corrosive channel access structure, a gold processing plant, nickel sites, an ammonium nitrate facility and a cooling tower support structure. Across these examples, the focus is not only on FRP material supply, but also on engineering, fabrication, prefabrication, delivery, reduced installation effort and longer service life.
Treadwell positions itself as an established FRP solutions provider in Australia, offering durable FRP products supported by practical calculations, data and application-specific advice. Its FRP product range includes grating, structural profiles, handrail systems, cable ladder, platforms and other composite access solutions used across demanding industrial sectors.
Key Benefits
Corrosion resistance in mining process environments
Mining and mineral processing sites often expose structures to saline process water, reagents, slurry build-up and aggressive operating conditions. FRP does not oxidise like steel when exposed to moisture and many corrosive environments, making it useful in areas where steel coatings may degrade or require frequent maintenance.
Reduced coating maintenance
The webinar highlights situations where steel structures with hot-dip galvanising and heavy coating systems still had limited service life in corrosive mining environments. FRP can reduce dependence on blast and paint regimes, coating repairs and corrosion maintenance, especially where slurry or salt exposure accelerates steel deterioration.
Non-conductive material properties
FRP is non-conductive, which can be beneficial around substations, high voltage areas, electrical equipment, cable tray, cable ladder and service routing. This makes it useful where electrical isolation and corrosion resistance are both important project considerations.
Lightweight installation advantages
FRP’s lower weight can reduce crane requirements, scaffolding needs, access constraints and manual handling challenges. In the channel structure example, the FRP modules were able to be installed using a smaller crane, with reduced need for bank stabilisation or heavy lifting equipment.
No hot works required for site modification
FRP systems typically use bolted or mechanical connections. If trimming, cutting, or drilling is required on site, it does not generate sparks in the same way as steel modification. This can reduce hot work requirements and improve practicality in sensitive environments such as processing plants and ammonium nitrate facilities.
Potential installation cost and time savings
Although FRP may carry a higher initial material cost than steel in some cases, the webinar explains that installation savings can offset this. Reduced crane size, easier handling, prefabrication, fewer site activities and less coating remediation can all contribute to better overall project economics.
Longer service life in harsh environments
One case study compares a steel structure that lasted approximately five years with an FRP structure supplied around the end of 2014 that had already exceeded the steel structure’s life by more than twice at the time of the presentation. The FRP structure was designed with a longer life expectancy, supported by Treadwell’s material and design methodology.
Integrated design, engineering and fabrication
For the cooling tower structure example, Treadwell’s scope included in-house design, engineering and fabrication. This reduced the number of separate parties involved compared with a steel structure that may require separate engineering, fabrication, blasting, painting and coating coordination.
Reduced risk of coating damage during transport and site work
Coated steel structures can be damaged during transport, lifting, handling or final site modification. FRP avoids many of these concerns because there is no steel coating system to scratch, scrape or remediate after trimming or installation.
Broad mining infrastructure suitability
The examples in the webinar include FRP staircases, handrails, grating, cable ladder, conveyor guarding, access structures, platforms, solid surface flooring, treads, hatches and cooling tower support structures. This shows how FRP can be applied across multiple mining and mineral processing access requirements.
Applications
Mining process plant access structures
FRP can be used for access platforms, walkways, handrails, stairs and grating in process plants where corrosion is a constant maintenance concern. The gold processing plant example shows FRP handrails, staircases and access systems used in a processing environment where internal corrosion of traditional handrails could create hidden safety risks.
Salt and evaporation facilities
The WA salt facility example highlights FRP’s suitability for highly corrosive salt environments, where cyclones, high winds and salt blasting can damage protective coatings on steel. Treadwell supplied a full FRP staircase and conveyor access structure, including handrail, stair treads, grating, structural profiles and suspended FRP cable ladder.
Conveyor access and guarding
FRP can be used for conveyor access structures, handrails, stair systems, cable ladder and non-metallic conveyor guarding. The webinar discusses FRP guarding around a conveyor drive end, where corrosion durability and lightweight installation were important considerations.
Cable ladder and cable tray near electrical assets
Because FRP is non-conductive, it can be useful for cable ladder, cable tray and service routing around substations, high voltage areas and other electrical infrastructure. This is especially relevant where the site also faces corrosion or chemical exposure.
Channel and limited access structures
The channel access structure case study demonstrates how FRP can reduce installation complexity where crane access is difficult. By supplying prefabricated sections and a preassembled bridge span, Treadwell helped reduce the need for large cranes, bank stabilisation and extended installation time.
Cooling tower access and support structures
The cooling tower example shows a full FRP structure with columns, beams, bracing, handrail and floor grating. Treadwell worked with the cooling tower manufacturer to integrate the FRP support structure with maintenance access, pipework support and continuous handrail requirements.
Ammonium nitrate and hot works sensitive facilities
In the ammonium nitrate facility example, FRP was used for solid surface floor grating, handrail, stair treads and intermediate structural elements. The webinar notes that hot works can be a problem in this environment, making FRP’s mechanical fixing and non-spark modification advantages valuable.
Nickel and mineral processing sites
The webinar references FRP use on nickel sites, including cable ladder, cable tray, grating and walkways. These are typical applications where corrosion resistance, reduced weight and easier installation can provide value in mineral processing environments.
Odour extraction and covered process areas
The Jameson cell example includes a solid surface FRP grating with integrated hatches to support odour extraction and regular inspection or sampling. The hatches can be lockable and allow quick access where operational checks are required.
Prefabricated modular structures
FRP structures can be prefabricated and delivered to the site for faster installation. In several examples, Treadwell’s scope included design, supply and fabrication, with modules assembled or partially assembled before site delivery.
Lifecycle cost comparison against steel
The session discusses both initial material cost and total project cost. In one example, the FRP structure carried only a modest material premium compared with steel, while offering installation savings and longer life. In another example, FRP had a higher material cost than coated steel, but provided benefits through in-house engineering, lower self-weight, easier prefabrication, reduced footing and crane costs, and fewer coating damage concerns.
Key Moments
- 01:01 🎤 Welcome to Tech Talk Tuesday webinar on FRP applications in mining, including cost comparisons and project case studies.
- 03:12 🛡️ FRP delivers three key mining benefits: corrosion resistance in saline/process environments, nonconductive properties for electrical safety, and a lightweight design reducing crane/scaffolding needs.
- 04:35 🚫 No hot work required with FRP bolting/fixings, eliminating sparks, permits, and safety risks during installation or modifications.
- 05:31 🧂 Salt facility case study shows full FRP staircases, handrails, gratings, and cable ladders withstand cyclones, saline corrosion, and outperform coated steel.
- 07:20 💰 FRP material costs ~10-20% higher than steel but yield major install savings via smaller cranes, no shoring, and pre-assembled modules in limited-access sites.
- 09:15 ⏳ FRP structure installed in 2014 remains fully serviceable after nearly 11 years—more than double the 5-year lifespan of prior coated steel.
- 10:39 🏭 Gold processing plant uses FRP handrails and stairs for worry-free, low-maintenance access in highly corrosive environments.
- 13:53 🏗️ Cooling tower project highlights FRP’s 25-year design life, in-house engineering, no coating damage issues, reduced footings/cranes, and easier prefab vs. steel or timber.
Why Treadwell?
Treadwell’s value in mining applications lies in combining FRP materials with engineering, fabrication, project-specific design thinking and installation practicality. The webinar shows that Treadwell is not only supplying grating or handrail components, but also complete FRP structures, conveyor access systems, cooling tower support structures, cable ladder, guarding, hatches and prefabricated modules.
The company has operated in the FRP industry since 1994 and has grown from an Adelaide-based business into an established FRP solutions provider with installations across Australia and New Zealand. This experience is relevant for mining clients who need systems that can perform in corrosive, remote, high-access-cost and operationally sensitive environments.
Treadwell’s approach also helps clients assess FRP from a whole-of-life perspective rather than only the purchase price. The mining case studies show how reduced corrosion maintenance, less coating dependence, lower crane requirements, easier prefabrication, reduced hot works, faster installation and longer service life can make FRP a practical and cost-effective option even where the initial material cost is higher than steel.
For mining and mineral processing projects, Treadwell can support site visits, project discussions, samples, structural design, fabrication, access system optimisation and product selection. Whether the challenge is corrosion, non-conductivity, limited access, safety, downtime or lifecycle cost, Treadwell can help engineers and asset owners assess where FRP provides the strongest technical and commercial value.
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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.
