FRP Grating Case Study | Livestock Farm Walkways & Slat Floor — ZeAllgrate

A 12,000-head integrated livestock farm in East Asia operated concrete slatted floors and steel service walkways across its gestation barns, farrowing rooms and manure handling areas. The concrete slats wore and spalled under hoof traffic and acidic manure liquors, producing hoof injuries in sows and recurring concrete repair costs. The steel service walkways corroded rapidly under continuous ammonia and hydrogen sulfide atmosphere, and had to be painted every 18 months to maintain structural integrity. Farm management wanted a flooring system that would not absorb manure odor, would not harbor bacteria, and would require zero painting for the life of the barn.

Engineering specified molded FRP grating over the existing concrete support beams, using a mesh small enough that hooves could not fall through but open enough for manure to pass through to the slurry pit below. Client identity is kept confidential; the project is described as Confidential Client, a large integrated livestock producer.

ZeAllgrate supplied 480 m² of 38 mm ZeAll ISO molded grating in mini-mesh 19×19 mm panels, custom-cut to fit over the existing concrete slat support beams. All panels were pre-cut in the factory to the barn bay dimensions, with rounded cut-outs around waterers and feeder stations. The concave surface allows manure and washdown water to drain through to the slurry pit below without standing on the walking surface.

Installation was carried out by the farm's own maintenance team over two routine barn cleaning windows, using SS304 clips. No hot work, no welding, and no need to empty the adjacent pens during installation because panels were light enough to carry through the barn aisles by hand. The non-porous surface hoses clean with the farm's existing high-pressure washdown system, and does not absorb manure odor like concrete or wood does.