Fibre Reinforced Plastic (FRP) has become an increasingly important material across industrial, commercial and
infrastructure projects, particularly where corrosion, weight, electrical conductivity or ongoing maintenance present
challenges for traditional materials.
From floor grating and structural profiles to access platforms, handrails, ladders and complete fabricated structures,
FRP can provide a durable and practical alternative to materials such as steel, aluminium and timber.
But what exactly is FRP, how is it made, and where is it best used?
What is Fibre Reinforced Plastic?
Fibre Reinforced Plastic, commonly referred to as FRP, is a composite material manufactured using reinforcing fibres combined with a polymer resin.
The glass fibre reinforcement provides strength and structural performance, while the resin binds the fibres together and helps protect the material from its surrounding environment.
Different combinations of reinforcement, resin systems and manufacturing methods can be used to produce FRP products with characteristics suited to different applications.
At FRP Engineering, FRP is used across products including:
- Floor and walkway grating
- Structural profiles
- Handrails
- Ladders
- Access platforms and walkways
- Cable management systems
- Safety structures
- Custom-fabricated FRP solutions
This versatility means FRP can be used as an individual component or as part of a complete engineered access or structural solution.
Why is FRP Used in Industrial and Infrastructure Applications?
One key advantage of FRP is the combination of properties it provides.
Corrosion Resistance
Unlike steel, FRP does not rust.
This makes it particularly useful in environments where infrastructure is regularly exposed to moisture, saltwater, chemicals or other corrosive conditions.
For industries such as water and wastewater treatment, chemical processing, mining, marine infrastructure and food processing, corrosion resistance can significantly reduce the maintenance associated with conventional materials.
Selecting the correct resin system remains important, particularly where chemical exposure or elevated temperatures are involved.
Lightweight Construction
FRP products are considerably lighter than comparable metallic components.
Lower component weight can make materials easier to transport, handle and install and can also be advantageous where access is restricted or additional loading on an existing structure needs to be considered.
FRP Engineering regularly uses offsite fabrication to take advantage of these characteristics. Components and structures can be measured, fabricated and prepared in our Canning Vale workshop before being transported to site for installation.
This approach can reduce the amount of fabrication required onsite and assist with efficient project delivery.
Electrically Non-Conductive
FRP is electrically non-conductive, making it particularly useful in environments where electrical conductivity needs to be considered.
This characteristic can make FRP suitable for infrastructure around electrical equipment, utilities and other applications where the conductive nature of steel or aluminium may be undesirable.
Low Maintenance
The corrosion resistance of FRP means it does not require the same ongoing corrosion protection commonly associated with steel infrastructure.
Depending on the application and environment, this can reduce requirements for activities such as painting and corrosion treatment throughout the service life of the structure.
When assessing materials for infrastructure, it is therefore important to consider not only the initial material cost, but also installation, maintenance and replacement requirements over the life of the asset.
Slip-Resistant Options
For walkways, platforms, stairs and other pedestrian access areas, FRP grating is available with surfaces designed to provide slip resistance.
This makes FRP particularly well suited to wet, industrial and outdoor environments where safe access is a key consideration.
Moulded vs Pultruded FRP
Not all FRP products are manufactured in the same way.
Two of the most common forms used by FRP Engineering are moulded FRP and pultruded FRP.
Moulded FRP Grating
Moulded grating is manufactured as an integral panel, with glass fibre reinforcement distributed through the resin matrix.
Its grid construction provides strength in both directions, while its relatively high resin content provides strong corrosion resistance.
Moulded grating is commonly considered where chemical resistance, wet service conditions and bi-directional support are important.
FRP Engineering supplies moulded grating in a range of configurations, resin systems and thicknesses to suit different operating environments and project requirements.
Pultruded FRP
Pultruded FRP is produced by drawing continuous glass fibre reinforcement through resin and then through a heated die to form a consistent structural shape.
The continuous fibres are predominantly aligned in the load-bearing direction, producing high strength and stiffness in that direction.
This process is used to manufacture structural profiles such as channels, beams, angles, tubes and box sections, as well as pultruded grating.
Pultruded grating is particularly useful where longer spans, increased stiffness or reduced deflection are required.
The choice between moulded and pultruded products should therefore be based on the structural, environmental and operational requirements of the individual project.
Choosing the Right Resin System
The resin is a critical part of an FRP product and should be selected according to its intended operating environment.
FRP Engineering supplies products using resin systems including Isophthalic Polyester, Vinyl Ester and Phenolic, with other resin systems available for specific requirements.
Each offers different performance characteristics.
For example, polyester resin can be appropriate for many general industrial applications, while vinyl ester may be selected where enhanced chemical and corrosion resistance is required. Phenolic systems may be considered where specific fire and low-smoke performance requirements apply.
Chemical exposure, operating temperature, fire requirements and environmental conditions should all be considered before specifying a resin system.
There is no single FRP specification that is right for every application.
Where Can FRP Be Used?
The properties of FRP make it suitable for a broad range of industrial and commercial environments.
FRP Engineering supplies and fabricates composite solutions for industries including:
- Mining
- Oil and gas
- Water and wastewater treatment
- Chemical processing
- Food and beverage
- Marine and coastal infrastructure
- Transport
- Commercial and public infrastructure
Typical applications include access walkways, platforms, stairs, ladders, handrails, floor grating, pipe crossovers, rooftop access systems and custom structures.
FRP can also be particularly useful when upgrading existing infrastructure where corrosion, difficult access, installation weight or ongoing maintenance have become an issue.
FRP as a Complete Structural Solution
FRP does not have to be limited to replacing an individual piece of grating or a single handrail.
Structural profiles, grating, handrails and other components can be combined to create complete FRP structures.
FRP Engineering provides a design-to-install service, with capabilities extending from initial site requirements and CAD drawings through engineering, fabrication and installation.
Where appropriate, structures can be prefabricated offsite before being transported to site for final installation.
For a recent rooftop HVAC access project at a major medical facility in Murdoch, for example, FRP Engineering used pedestal supports, structural profiles, grating and handrails to create a continuous access system around existing rooftop infrastructure. Following detailed site measurement and offsite prefabrication, the complete system was installed onsite in three days.
It demonstrates how FRP can be considered not simply as a material substitute, but as part of the overall design and delivery methodology.
Is FRP Right for Every Project?
FRP offers significant advantages, but material selection should always be based on the specific requirements of the project.
Factors such as:
- Required loads
- Support spans
- Deflection limits
- Chemical exposure
- Operating temperatures
- Fire requirements
- Electrical environment
- Slip resistance
- UV and weather exposure
- Installation conditions
should all be considered when determining the appropriate product.
Understanding these requirements at the beginning of a project helps determine whether moulded grating, pultruded grating, structural profiles or a combination of FRP products is the most appropriate solution.
Talk to FRP Engineering
Founded in 2003 and based in Canning Vale, Western Australia, FRP Engineering supplies, fabricates and installs composite solutions for projects across Australia and New Zealand.
From individual FRP components through to custom-engineered structures, our team works with clients to determine a solution suited to the structural, environmental and operational requirements of each project.
Considering FRP for an upcoming project? Talk to the FRP Engineering team about your application and project requirements.