Chemical Processing
Why Chemical Processing Needs FRP
Chemical plants combine aggressive process atmospheres — acids, caustics, solvents and chlorides — with constant moisture. Carbon steel corrodes within months; painted structures demand endless maintenance. FRP is the material engineered to survive.- Acid & alkali vapor attack on steel structures
- Solvent splash and chemical spill exposure
- Secondary containment and trench systems that must not corrode
- Walkways over process equipment requiring spark resistance
ZeAllgrate Solutions for Chemical Processing
ZeAllgrate supplies molded and pultruded grating, covers and handrail systems with 3+ resin formulations matched to your specific chemical environment — from isophthalic polyester for general service to vinyl ester and phenolic for aggressive oxidizers.
Typical Applications
Process unit platforms
Pipe rack walkways
Drain trenches & covers
Secondary containment
Loading & unloading platforms
Tank farm access
Project Gallery
Real ZeAllgrate FRP grating products and installations in service across this industry.
Vinyl ester molded grating platform over chemical process units
Long-span pultruded walkway over chemical storage tanks
FRP grating platform over chemical process pipework
Solutions for Every Process Area
Engineered FRP solutions mapped to each stage of your facility — from corrosive process zones to high-traffic access routes.
Secondary containment, dike crossings and tank access platforms resisting acid and alkali atmospheres.
Long-span pultruded walkways over process lines with fire-retardant options.
Non-conductive, chlorine-resistant platforms and cell-room walkways.
Truck and rail loading platforms built from molded grating and covers.
Scrubber platforms and chemical treatment trenches that must not corrode.
Technical Specifications & Compliance
Application-specific engineering reference for Chemical Processing — corrosion rating, load criteria, governing codes and the recommended ZeAllgrate configuration. Use this as the specification starting point; final design must be verified against certified load/span charts and the project's governing codes.
| Parameter | Specification for Chemical Processing |
|---|---|
| Corrosion Level | Severe Aggressive acid/alkali/solvent vapors, splashes and secondary containment duty. |
| Typical Load Requirements | Pedestrian 50–75 psf (2.4–3.6 kN/m²); equipment & loading platforms to 100 psf (4.8 kN/m²); occasional forklift service on designated routes. |
| Applicable Standards & Regulations | OSHA 1910.23 (ladders), OSHA 1910.29 (guardrails), ISO 14122-1/-2/-3/-4 (fixed machinery platforms), ASTM E84 (surface burning, Class A ≤25), ASTM D635 (self-extinguishing), NFPA 1 (flammable liquids), local fire code. |
| Recommended Resin System | ZeAll VE (vinyl ester) as primary; ZeAll ISO (isophthalic) for milder process atmospheres; ZeAll FR grade where fire code requires low flame spread. |
| Recommended Grating Type | Molded 38.1 mm (70% open) for process platforms & secondary containment; Mini-Mesh where chemical splash or small-part fall-through is a concern; Pultruded I4015/I6015 for long-span pipe-rack walkways. |
Resin systems: ZeAll VE (vinyl ester — severe corrosion), ZeAll ISO (isophthalic polyester — general service), ZeAll FDA (food/potable grade), ZeAll FR (extra flame-retardant), Phenolic (fire/smoke-critical). Grating types: Molded (bi-directional), Pultruded (long-span), Mini-Mesh (fine openings), HLC (high-load capacity).
Typical System Configuration
A complete vinyl-ester FRP access package for a chemical process unit — molded grating deck, handrail, stair treads, solid covers and corrosion-proof fasteners, specified for acid and alkali vapour duty. This is the reference starting configuration; verify spans and loads against certified load charts for your specific geometry.
Component List
| Component | Product / Model | Material / Resin | Key Spec | Quantity / Ratio |
|---|---|---|---|---|
| Grating panels | ZeAllgrate Molded 38mm | ZeAll VE (vinyl ester), grit-top | 38.1 mm thick, ~70% open, grit anti-slip surface | Main process platform deck |
| Handrail system | ZeAll VE tube handrail | ZeAll VE tubes, SS316 fittings | 42.4 mm posts, mid-rail, toeboard | Perimeter and open edges |
| Stair treads | Molded 38mm stair treads | ZeAll VE, grit-top | Grit nosing, anti-slip | Stair flights and landings |
| Solid covers | 38mm solid covers | ZeAll VE | Chemical dosing areas | Dosing / secondary-containment zones |
| Clips & fasteners | G-type panel clips | SS316 (A4-70) | Through-bolted, corrosion-proof | 2 clips per panel |
| Edge banding | FRP edge banding | ZeAll VE | 3 mm protective trim | Panel perimeter |
Design Parameters Summary
| Design Parameter | Value for Chemical Processing |
|---|---|
| Load rating | Pedestrian 3.5 kN/m² (~73 psf) |
| Span | 0.9 m panel span |
| Deflection limit | L/150 under design load |
| Resin selection rationale | Vinyl ester (ZeAll VE) for HCl / H₂SO₄ and acid vapour resistance |
| Surface type | Grit-top for wet and acid-spill walking surfaces |
| Fastener material | SS316 (A4) stainless steel |
Applicable Standards & Codes
- OSHA 1910.23 (ladders & walking-working surfaces)
- OSHA 1910.29 (guardrail systems)
- ISO 14122-1/-2/-3/-4 (machinery access by permanent means)
- ASTM C581 (chemical resistance of thermoset corrosion equipment)
- NFPA 30 (flammable and combustible liquids code)
This all-vinyl-ester, SS316-fastened configuration is selected because chemical processing environments combine acid vapour, splash and secondary-containment duty in a single footprint. Vinyl ester outperforms isophthalic polyester against aggressive oxidising acids, the grit top keeps walking safe during spills, and SS316 clips eliminate the one point where galvanic corrosion normally starts. It is a cost-balanced package: no over-specification on mild zones, no weak link where chemistry is worst.
Chemical Service Selection
| Exposure | Resin Guidance |
|---|---|
| Acids / alkalis (dilute, ambient) | Isophthalic polyester |
| Strong acids / oxidizers | Vinyl ester |
| Hot strong acid / chlorine service | Novolac vinyl ester |
| Solvents | Vinyl ester (check chemical list) |
Specification Guidance
In chemical plants the resin list decides the panel life: confirm every chemical at its concentration and temperature against the compatibility chart, and specify the worst exposure on each deck zone rather than the plant average. Grit-top surfaces handle the wet, corrosive walkways; pultruded framing and SS316 clips complete the access package; E84 fire class is confirmed for the rated areas. The result is a deck that removes the paint and replacement cycle that steel cannot escape in the same service.
In chemical plants the resin list decides the panel life: confirm every chemical at its concentration and temperature against the compatibility chart, and specify the worst exposure on each deck zone rather than the plant average. Grit-top surfaces handle the wet, corrosive walkways; pultruded framing and SS316 clips complete the access package; E84 fire class is confirmed for the rated areas. The result is a deck that removes the paint and replacement cycle that steel cannot escape in the same service.Go Deeper with the ZeAllgrate Knowledge Base
Corrosion Engineering & Resin Selection
Choosing ISO/VE/phenolic resins for acid and alkali service.
Read article →Chlorine & Bleach Environments
Resin behavior under chlorine dioxide and caustic exposure.
Read article →Have a Chemical Processing Project?
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