FRP Grating Case Study | Passenger Ferry Terminal Decking — ZeAllgrate
Marine & Coastal — Project Background
A busy passenger ferry terminal on a coastal route needed durable, slip-resistant decking for its boarding gangway and waiting area. The existing wooden decking rotted within 4 years in salt spray and became dangerously slippery when wet. Steel was rejected by the terminal operator because of saltwater corrosion and because bare steel decks burned passengers' feet in summer sun — a recurring complaint on a terminal where passengers often board in sandals or barefoot. The operator needed a surface that would not rot, not rust, not overheat, and not become a slip trap.
Engineering specified a high live load for crowd comfort, a tight deflection limit to avoid a bouncy feel under dense foot traffic, and a UV-stabilized resin for direct sun exposure. Client identity is kept confidential; the project is described as Confidential Client, a busy passenger ferry terminal operator.
Engineering Specification
Working values agreed with the client's engineering team during design review.
| Parameter | Selected Value | Standard / Reference |
|---|---|---|
| Pedestrian live load | 5.0 kN/m² (high crowd) | Local code / EN 1991-1-1 crowded areas |
| Clear span | 1.0 m between supports | ZeAllgrate molded grating design guide |
| Deflection limit | L/200 (crowd comfort) | ZeAllgrate / terminal engineering basis |
| Resin system | ZeAll VE (vinyl ester, UV-stabilized) | Saltwater + UV resistance |
| Panel thickness | 38 mm molded, gray color | Heat-reflecting color for summer comfort |
| Surface | Grit-top, bonded quartz aggregate | Maximum wet slip resistance |
| Mesh | Standard 38×38 mm | ZeAllgrate standard molded grating |
| Fixings | SS316 clips | ASTM A276 316, marine grade |
| Edge banding | FRP flat bar | Finished edge, corrosion-free |
| Wet slip performance | Wet COF > 0.7 | ASTM F1679 |
What Was Supplied and How It Went In
ZeAllgrate supplied 320 m² of 38 mm ZeAll VE UV-stabilized molded grating in gray (heat-reflecting) color, with bonded grit-top surface across the gangway and waiting deck. Custom curved panels were fabricated for the angled sides of the gangway transition. Because FRP is roughly 75% lighter than the equivalent steel deck, the installation crew was able to lay panels by hand, without a crane on the busy terminal pier.
Wet coefficient of friction was tested on a sample batch at > 0.7 per ASTM F1679, comfortably above the terminal's acceptance threshold. The gray vinyl ester surface stays cool under direct sun compared with dark steel or concrete, addressing the bare-foot comfort complaint from the previous summer season.
Grit-top FRP grating on passenger ferry terminal gangway
Marine-grade molded grating panels with FRP edge banding
FRP stair treads and walkways at coastal terminal
Outcomes and Inspection Findings
In the first two years of operation, the terminal reported zero slip-and-fall claims on the gangway and waiting deck, compared with roughly 12 incidents per year under the previous wooden decking. The surface also does not heat up to the point of discomfort in summer, and has shown no saltwater corrosion or UV chalking.
- Safety: wet COF > 0.7 measured; slip-and-fall claims dropped from ~12/year to zero.
- Comfort: gray vinyl ester surface stays cool in direct sun; comfortable for barefoot and sandal-wearing passengers.
- Corrosion: immune to saltwater; SS316 clips and FRP edge banding show no rust.
- Installation: lightweight panels allowed hand-laying without a crane on an active pier.
- Service life: expected 25+ years vs. 4 years for the previous wooden decking.
Engineering Notes
Ferry terminal decking is specified against salt, UV and wet traffic: vinyl ester for splash-zone panels, UV-stabilised resin for the exposed surfaces, and grit-top where the deck stays wet from rain and sea spray. SS316 hardware is used throughout — never mixed with galvanized, which fails in the marine atmosphere — and the lightweight panels install over existing steel without cranes or hot work. Loads are checked at the actual berth deck span, with the concentrated case verified alongside the uniform case.
What to Specify
- Vinyl ester for splash-zone panels; UV-stabilised resin for exposed areas.
- Grit-top surfaces on the passenger and vehicle traffic lines.
- SS316 clips, fasteners and base hardware.
- Load table at the actual span; uniform and concentrated cases both checked.
- Vinyl ester for splash-zone panels; UV-stabilised resin for exposed areas.
- Grit-top surfaces on the passenger and vehicle traffic lines.
- SS316 clips, fasteners and base hardware.
- Load table at the actual span; uniform and concentrated cases both checked.
Planning a Similar FRP Grating Project?
Send us your layout drawings, service chemicals and span requirements — ZeAllgrate will return a design proposal, load calculation and reference pricing within 48 hours.
- ZeAllgrate molded grating design guide, load and deflection tables.
- ASTM F1679 — Standard Test Method for Measuring the Dynamic Coefficient of Friction on Walking Surfaces.
- EN 1991-1-1 — Eurocode 1: actions on structures, imposed loads for crowded areas.
- Marine / coastal engineering guidance on saltwater-resistant deck materials.
- Project inspection records supplied by Confidential Client; values quoted as-reported.