Installation Guide
Pedestrian Walkway Minimum Design
Minimum design loads and deflection for molded FRP grating walkways. [ZeAllgrate p.3, §7.1]
| Parameter | Value |
|---|---|
| Uniform live load | 50–65 lb/ft² (psf) |
| Concentrated load | 250 lb |
| Dead load (grating self-weight) | 3.75 lb/ft² (psf) |
| Maximum deflection | Span L/120 OR 3/8" (9.5 mm) — whichever is the smaller value |
Recommended Molded Grating Spans
Support spacing and the maximum clear span each panel depth will carry for pedestrian service. [ZeAllgrate p.3, §7.2]
| Grating Depth | Acceptable Clear Span |
|---|---|
| 1" deep | Up to 3′-0" (914 mm) |
| 1-1/2" deep | 3′-0" to 3′-6" (914–1067 mm) |
| 2" deep | 4′-0" to 4′-6" (1219–1372 mm) |
Keep support beams at 36" or 48" on center. Always confirm the exact panel against the certified load/span chart for your deflection criterion.
Cantilever (Overhang) Limits
Maximum projection beyond the last support centerline. [ZeAllgrate p.3, §7.3]
| Grating Depth | Max Overhang from Last Support CL |
|---|---|
| 1" deep | 6" (152 mm) |
| 1-1/2" deep / 2" deep | 12" (305 mm) |
Hold-Down Requirement
Each cantilevered panel must be held down to at least 2 supports.
Clip Count
Use at least 3 hold-down clips per interior support to restrain the overhanging section.
Never Free-Overhang
An unrestricted cantilever beyond these limits violates ZeAllgrate guidance.
Hold-Down Clip Schedule
Molded grating clip and splicing hardware. [ZeAllgrate p.3–4, §7.4/§7.5; FGRAT p.16]
| Item | Specification |
|---|---|
| M hold-down clips | Minimum 2 per support beam; max spacing 4′-0" (1219 mm) o.c. per beam |
| Clips per panel | Minimum 4 hold-down clips per grating panel |
| F end-abutment (splice) clips | Maximum 24" (610 mm) o.c. where panel edges abut without a support |
| Unsupported cut holes | Up to 1/3 of panel width without added support |
| Edge banding | Not required structurally — FRP cannot be welded; applied only to prevent stub-bar injury |
Pultruded Grating Fastening (MI-60 / FC Clips)
Mechanical fastening of pultruded ZeAll Pultruded grating. [ZeAllgrate p.4, §7.5; drawings G & H]
| Clip | Drill / Fastener |
|---|---|
| MI-60 clip | Field-drill 5/16" hole; fix with 1/4" × 2-1/4" bolt |
| FC clip | Mounting hole 9/32" (0.281"); fix with 1/4"-20 × 1-1/2" truss-head bolt |
| General rule | ≥2 clips at max 4′-0" (1219 mm) o.c. per support beam; minimum 4 clips per panel |
Cutting Tools & Edge Sealing
Field cutting and sealing of cut edges. [FGRAT p.15–17, §7.7/§7.8; DURA p.4]
Cutting Tools
Carbide-tipped saw blade, abrasive cutter, or masonry blade. Wood-working tools may be used with abrasive blades.
PPE / Safety
Wear dust mask, eye protection and gloves — FRP dust is abrasive. Wet cutting reduces airborne dust.
Seal All Cut Edges
Spray-can epoxy clear coat ≈ 100 lin.ft / can; half-pint kit covers 20–40 lin.ft. Seal every cut edge and hole.
On concrete: masonry bit + concrete anchor bolts. On steel/wood/FRP: drill + truss-head bolt. Space fasteners 12"–24" apart. [FGRAT p.16]
ZeAllgrate FRP Guardrail & Handrail
FRP guardrail system geometry and OSHA loading. [ZeAllgrate p.5, §7.9]
| Component | Specification |
|---|---|
| Post | 2-1/8" × 3/16" square tube |
| Two intermediate rails | 1-3/4" × 1/8" flat |
| Top rail height | 42" above walking surface |
| Handrail height | 34" |
| Post spacing | ≤ 6′-0" (1829 mm) o.c. |
| Corners | No post at the corner itself — use two posts within 12" each side |
| Loading | OSHA 1910.29(b): 200 lb concentrated down/out OR 50 lb/ft uniform on the top rail (not concurrent) |
ZeAllgrate FRP Fixed Ladder System
Fixed ladder dimensions and code loading. [ZeAllgrate p.6–7, §7.10]
| Item | Specification |
|---|---|
| Side rails | 1-3/4" × 1/4" square tube |
| Rungs | 1-1/4" diameter × 1/4" fluted |
| Clear inside width | 18" |
| Rung spacing | 12" o.c. |
| Wall support | ≤ 6′-0" (1829 mm) |
| Loading | OSHA 1910.23; rung 250 lb at midspan; two 250 lb loads between attachments (ANSI 14.3) |
| Tall ladders | ≥24 ft require personal fall-arrest / ladder-safety system per OSHA 1910.28(b)(9); drop test 18" / 500 lb per 1910.29(i) |
ZeAllgrate FRP Stair System
FRP stair treads and stringer design. [ZeAllgrate p.11–13, §7.11; FGRAT p.14–15]
| Item | Specification |
|---|---|
| Tread | ZeAllgrate FRP stair tread, 1-1/2" deep, 1-1/2" × 6" mesh; panels 22-1/4"×120" and 25-1/4"×144" |
| Tread deflection limit | L/150 |
| Stair live load | 1000 lb (500 lb per stringer) |
| Slope | OSHA 30–50°; IBC 20–32.5°; IBC 100 psf uniform, L/D ≥ 180 |
| Landings | Every 12′ rise |
| Stringers | C8 (8" × 2-3/16" × 3/8") or C10 (10" × 2-3/4" × 1/2") |
Installation Sequence Overview
| Step | Practice |
|---|---|
| 1. Layout | Orient bearing bars along the span across the supports; mark cut positions |
| 2. Cutting | Carbide blade or abrasive saw; clean square cuts; deburr edges |
| 3. Openings | Fabricated or field cut-outs edge-sealed; reinforce per the cutting guide |
| 4. Seating | Full bearing on supports; minimum seating width per design |
| 5. Clipping | Clip pattern per the drawing (corners + mid-span); torque snug, not tight |
| 6. Gaps | Thermal movement gaps; one fixed end per run |
| 7. Acceptance | Walk the deck; verify orientation, bearing, clips and gaps; retorque after first week |
Common Installation Errors
- Rotated panels — bearing bars must run along the span; a rotated panel loses capacity.
- Over-torqued clips — crushes the laminate; use a torque wrench, snug not tight.
- Missing mid-span clips — the pattern is corners plus mid-span, not corners only.
- Free overhang beyond the last support — never cantilever past the hold-down limit.
- Hard butting with no gap — thermal movement needs a nominal 10 mm gap.
Need a Full Installation Drawing Package?
ZeAllgrate supplies clip schedules, support layouts and accessory lists (angle clips, adjustable pedestals) with every order, plus remote on-site guidance.
Source: ZeAllgrate Guidelines for the Engineer & Designer, Part No. 884305-9/18 ©Industry reference 2018 [ZeAllgrate] §7.1–§7.11; clip hardware and sealing [FGRAT p.15–17]. All spacing, bolt and load values transcribed verbatim.