IJSTE - International Journal of Science Technology & Engineering | Volume 3 | Issue 06 | December 2016

ISSN (online): 2349-784X

Design and Experimental Analysis of Composite

Grating
Mr. Akash H. Barhe Prof. Bhamre V.G.
PG Student (Design Engineering) Head of Dept.
Department of Mechanical Engineering Department of Mechanical Engineering
S.N.D. College of Engineering & Research Center, Yeola S.N.D. College of Engineering & Research Center, Yeola
(Nasik), India (Nasik), India

Abstract
Steel grating has been the standard industrial foot walk products and has been a popular grating choice for many years. The steel
grating is widely used in refineries on landing and operating platforms. These industries has great interest in a cheaper, but
quality alternative for steel grating since it offers great techno-commercial advantage to them. In this paper the design and
experimental analysis of composite grating is carried out. The numerical design of composite grating is conducted as per IS
guidelines used in industrial practices for grating design. The model prepared for composite grating is evaluated in finite element
analysis. For experimental testing, Composite grating plate is fabricated from hand lay-up process. This grating plate is analyzed
experimentally against predefined load test. Finally the results are discussed to conclude the paper.
Keywords: Grating Platform, Gratings
________________________________________________________________________________________________________

I. INTRODUCTION

The gratings are widely used in factories, workshops, mining, ports of various platforms, refineries, power plants and
petrochemical industries on landing and operating platforms. Gratings are used at different walkways, access zones in to take live
and/or dead loads depending on application. These industries has great interest in a cheaper, but quality alternative for steel
grating since it offers great techno-commercial advantage to them.

Fig. 1: Typical Grating Platform Made of Carbon Steel

Typically manufactured from mild carbon steel, aluminum and stainless steels, bar gratings are also available in specialty
metal alloys to suit nearly any application. The metallic gratings used in industrial applications are having certain limitations as
listed below.
1) The metallic gratings are made from stainless steel, aluminum, carbon steel which have high density and hence the grating
is heavy. This directly effect on the design of supporting structure and civil foundation of the plant.
2) The carbon steel grating is corrosion prone. Therefore they cannot be used in corrosive atmosphere without galvanizing
treatment.
The introduction of composite gratings will help in designing structural platform with same strength at lesser cost and equal
quality and reliability. Being corrosion resistant, the grating will not require additional galvanizing or painting. This will further
save the cost of project.

II. DESIGN CALCULATIONS

Following sections will provide the design and sizing of composite grating.

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Loading on Grating Platform

As the composite grating is being designed as an alternative to steel grating, the composite grating shall be suitable to withstand
the equal load which is applicable for carbon steel grating. Therefore imposed loads in this case will remain same as that of steel
grating.
Table – 1
IS 875 Parts 2, 1987, Imposed Floor Loads for Different Occupancies
Sr. No. Occupancy Classification Uniformly Distributed Load (UDL), kN/nm3 Concentrated Load, kN
1 Industrial Building
a. Work area without machinery / equipment 2.5 4.5
b. Work area with machinery / equipment
Light Duty 5.0 4.5
Medium Duty 7.0 4.5
Heavy Duty 10.0 4.5
c. Boiler rooms and plant rooms 5.0 6.7
Accordingly,
Total imposed load on the grating [10] = 𝑊𝑖𝑚𝑝𝑜𝑠𝑒𝑑 = 5.0 𝑘𝑁 = 5000 𝑁
Total dead load on the grating = 𝑊𝑑𝑒𝑎𝑑 = 400 𝑁
𝑊𝑡𝑜𝑡𝑎𝑙 = 5400 𝑁
Total number of flats in 1m X 1m grating platform is given by,
𝐺𝑟𝑎𝑡𝑖𝑛𝑔 𝑆𝑝𝑎𝑛 1000
𝑁𝑓𝑙𝑎𝑡 = =
𝑆𝑝𝑎𝑐𝑖𝑛𝑔𝑓𝑙𝑎𝑡 40
𝑁𝑓𝑙𝑎𝑡 = 25
Total load taken by single flat is given by,
𝑊𝑡𝑜𝑡𝑎𝑙 5400
𝑊𝑓𝑙𝑎𝑡 = =
𝑁𝑓𝑙𝑎𝑡 25
𝑊𝑓𝑙𝑎𝑡 = 216 𝑁
Each bearing bar will carry equal load of 216 N. This load will be uniformly distributed on the complete span. The bearing
bars are simply supported on side plates.
Now,
Total length of each flat = Lflat = 1000 mm or 1 m.
Uniform Distributed Load (UDL) on each flat is given by,
𝑊𝑓𝑙𝑎𝑡 216
𝑈𝐷𝐿𝑓𝑙𝑎𝑡 = =
𝐿𝑓𝑙𝑎𝑡 1000
𝑈𝐷𝐿𝑓𝑙𝑎𝑡 = 0.216 𝑁/𝑚𝑚

Design of Grating for Bending Stresses

Maximum bending moment for simply supported beam having uniform load distribution is given by,
𝑤𝑙 2
𝑀𝑏𝑒𝑛𝑑𝑖𝑛𝑔 =
8
Therefore,
𝑈𝐷𝐿𝑓𝑙𝑎𝑡 × 𝐿2𝑓𝑙𝑎𝑡
𝑀𝑏𝑒𝑛𝑑𝑖𝑛𝑔 =
8
0.216×10002
𝑀𝑏𝑒𝑛𝑑𝑖𝑛𝑔 =
8
𝑀𝑏𝑒𝑛𝑑𝑖𝑛𝑔 = 27000 𝑁. 𝑚𝑚
The material of construction for composite grating is Fibre Reinforced Plastic (FRP). It has ultimate tensile strength in the
range of 480 to 1650 MPa depending upon the properties of parent materials.
Table – 2
Mechanical Design Properties of FRP
Sr. No. Reinforcing Material Yield Strength ksi (MPA) Tensile Strength ksi (MPA) Elastic Modulus ksi (MPA)
1 Steel 40-75 (276-517) N/A 29,000 (200)
2 Glass FRP N/A 70-230 (480-1,600) 5,100-7,400 (35-51)
3 Basalt FRP N/A 150-240 (1,035-1,650) 6,500-8,500 (45-59)
Therefore we will take the lowest UTS for glass FRP i.e. 480 MPa to design the grating bearing bars. The maximum allowable
stress in bending is given as below:
𝜎𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 = 0.66 ×𝑓𝑈𝑇𝑆
𝜎𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 = 0.66 ×480
𝜎𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 = 316.8 𝑁/𝑚𝑚2

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 Design and Experimental Analysis of Composite Grating
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The section modulus of the beam is given by,

𝑀𝑏𝑒𝑛𝑑𝑖𝑛𝑔
𝑍𝑓𝑙𝑎𝑡 =
𝜎𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒
27000
𝑍𝑓𝑙𝑎𝑡 =
316.8
𝑍𝑓𝑙𝑎𝑡 = 85𝑚𝑚3
Since the bearing bars for composite grating will be rectangular shaped, it will have section modulus which is given by,
𝑏ℎ2
𝑍𝑓𝑙𝑎𝑡 =
6
Therefore,
𝑏ℎ2
0.085 =
6
Here we can select either height or width and then the remaining dimension can be derived. Let’s consider the thickness of flat
as 5mm for ease of manufacturing and higher strength.
Therefore,
5 × ℎ2
0.085 =
6
ℎ = 10 𝑚𝑚
Since the height of the bearing bar is derived from the opted thickness, will select 20.0 mm height for bearing bar for
composite grating.

Design of Grating for Deflection due to Loading

Maximum deflection for simply supported beam having uniformly distributed load across the span is given by,
𝑤𝑙 4 5
𝛿𝑚𝑎𝑥 = ×
𝐸𝐼𝑋𝑋 384
Where,
w = Uniformly Distributed Load (UDL)on beam, N/mm
l = Total length of beam over which load is distributed, mm
E = Modulus of Elasticity for glass FRP = 35 N/mm2
bh3
IXX = Moment of Inertia, mm4 =
12
Therefore,
bh3
IXX =
12
5×203
IXX =
12
IXX = 3334 mm4
Maximum deflection can be obtained as,
0.216 ×10004 5
δmax = 3
×
35 ×10 ×3334 384
δmax = 24 mm
Allowable deflection for any load carrying member is given by,
Lflat
δallowable =
400
1000
δallowable =
400
δallowable = 2.5 mm
Comparing the deflections,
𝛿𝑚𝑎𝑥 ≥ 𝛿𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒
Hence the bearing bar is failing for deflection which is the most commonly observed failures in composites. In order to
overcome this failure, we will increase the flat height to 50mm.
Rechecking the deflection,
5×503
𝐼𝑋𝑋 =
12
𝐼𝑋𝑋 = 52083 𝑚𝑚4
Maximum deflection can be obtained as,
0.216 ×10004 5
𝛿𝑚𝑎𝑥 = 3
×
35 ×10 ×52083 384

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𝛿𝑚𝑎𝑥 = 1.54 𝑚𝑚
Comparing the deflections,
𝛿𝑚𝑎𝑥 ≤ 𝛿𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒
Now, the deflection of bearing bar is within the permissible limit under given loading conditions.

Fig. 2: Composite Grating Drawing

III. FABRICATION OF GRATING

For fabrication of composite grating, combination of fibers and matrix shall be used. Glass fiber reinforcement with Epoxy resin
is used as major constituents. Continuous Fibre Reinforced Plastic (FRP) strings are used as reinforcement. In preparation of
matrix two solution are used namely resin and hardener.
First the sufficiently thin layer of gelcoat is applied on the mould. The FRP strings are arranged in two handles from opposite
ends. Two operators lay down the strings in zig-zag manner overlapping each other inside the square mesh grooves provided on
the mould surface. Matrix is then applied on this reinforcement by hand brush. Then air is removed by pressing the laminate b y
metal plate.

Fig. 3: Mould for Composite Grating

Same process is repeated several times until the desired thickness of grating plate is achieved. After applying matrix the
arrangement is kept to dry at least for next 24 hours as the curing time of this matrix is 24 hrs. After this curing, the grating plate
is removed from mould by manual hammering. The grating plate is then deburred by portable electric operated grinding
machine. The ends of grating plates are trimmed by portable cutting machine to obtain desired outer dimensions.

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 Design and Experimental Analysis of Composite Grating
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Fig. 4: Measurement of Composite Grating

IV. EXPERIMENTAL VALIDATION AND RESULTS

Composite grating plate is analysed against pre-defined load conditions by using Universal Testing machine.

Experimental Procedure
1) Arrange grating with help of fixture on the base of machine.
2) Adjust the actuator on the center of grating with loading plate.
3) Arrange the strain gauges on both side of grating.
4) Start the machine & apply the load of 5400 N on center of grating.
5) Record the reading of load, deflection & stress.
6) Store the data in computer to generate the graph of load Vs deflection & stress.
7) Release the load, so that actuator moves in original position.
Table – 3
Observation Table for UTM Readings
Sr. No. Description Min Max Set 1 Set 2
1 Flat Thickness, mm - - 5 5
2 Span Length, mm - - 1000 1000
3 Span Width, mm - - 1000 1000
4 Grating Area, m2 - - 1 1
5 Applied Load, kN - - 5.4 5.5
6 Shear Stress, kN/m2 - 192 X 10^3 538 537
7 Deflection, mm - 2.5 2.3 2.7

Results from Experimental Analysis

The results obtained in analytical design calculations and experimental testing for composite grating are summarized below.
Table - 4
Test Results for Composite Grating
Sr. No. Result Description Analytical Calculations Experimental Testing
1 Total Load Applied on Grating, N 5400 5400
2 Deflection due to loading, mm 1.54 2.3
3 Induced shear force, kN/m2 432 538
1) The weight of the composite grating for equivalent area and strength is 13.8 kg as compared to 24.5 kg of metallic grating.
This will have a significant impact on the supporting structural design.
2) The composite grating is limited to use for ambient temperature conditions only. Use of grating at elevated temperatures i.e.
above 60 degree has direct impact on the strength of the plates.
3) Since the composite grating is completely made of non-corrosive substances, it is purely corrosion resistance. This gives
advantage over metallic grating which needs galvanizing treatment before using in saline atmosphere.
4) The grating is giving 2.3 mm deflection when loaded with 5400 N. However this deflection is within acceptable limit of 2.5
mm.
5) The flexibility of composite grating absorbs the shock or impact loads which metallic grating cannot absorb and will bend
permanently.
6) FRP Composite is purely non-conductive in nature and hence the grating can be used for electrical machinery platforms
where metallic grating cannot be used for safety reasons.

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