In copper electrowinning facilities, walkway safety and corrosion resistance are non-negotiable. Traditional steel grating succumbs to electrolyte splashes, leading to costly replacements and safety hazards. At PRS, we engineer integrated FRP (Fiberglass Reinforced Polymer) grating systems that outlast steel by 10+ years while enhancing operational safety. Discover how our design-first approach transforms platform infrastructure.
1. The PRS Advantage: Turnkey FRP Grating Solutions
Unlike component suppliers, PRS delivers end-to-end structural systems:
- Custom-Engineered Grating: Cut-to-fit FRP panels for complex layouts.
- Hybrid Support Structures: FRP beams + steel columns for optimal strength/corrosion balance.
- Bolt-On Assembly: Pre-fabricated nodes with angled galvanized carbon steel or stainless steelconnectors for rapid installation.
Caption: FRP grating walkways (yellow) with FRP beams spanning steel columns.
2. Material Selection: Why FRP Dominates
Core Specifications
|
Component |
Material |
Key Property |
|
Grating Panels |
Pultruded FRP |
1.5x stronger than steel per weight |
|
Support Beams |
FRP I-beams (ISO 9001) |
Zero corrosion, 20-year lifespan |
|
Columns |
Galvanized steel |
Cost-effective vertical support |
|
Connectors |
SS316 bolts + angle iron |
Quick maintenance/replacement |
Critical Benefits
- Zero Electrolyte Corrosion: Immune to H₂SO₄splashes (pH 0.5–2).
- Non-Conductive: Eliminates electrical hazards near bus bars.
- Weight Savings: 75% lighter than steel, reducing structural load.
3. Precision Engineering: From 3D Model to Field Reality
PRS’s integrated design process ensures perfect fit:
- Making 3D Model by SolidWorks: Maps existing plant layout (columns, pipe routes).
- Load Simulation: Validates grating/beam specs for:
- Point Load: 1,500 lbs (maintenance tools).
- Uniform Load: 300 lbs/ft² (personnel + equipment).
-
Panel Optimization:
Custom-cut FRP panels avoiding beams below (Zambia plant example)
4. Beyond Grating: The PRS System Approach
We supply every structural element:
- Pre-Drilled Beams: FRP I-beams with pre-set bolt holes (tolerance: ±2mm).
- Adaptive Columns: It is equipped with leveling shims of different specifications, which can compensate for uneven ground..
- Safety Add-Ons:Non-slip grating surface (Ra >30 PN).
5. Case Study: Eliminating Shutdowns in a Chilean Copper Plant
Challenge: Steel grating corrosion caused 3 annual shutdowns for replacements ($180k loss/year).
PRS Solution:
- Hybrid FRP/steel structure with SS316 connectors.
- 140 custom-cut grating panels (1,200m² total).
Result:
✅Zero grating replacements in 4 years.
✅ 40% faster installation vs. traditional systems.
✅ ROI achieved in 14 months.
Conclusion
In copper electrowinning – where every acid droplet is a cost and every shutdown a revenue loss – PRS’s system-engineered FRP solutions deliver infrastructure that works harder, lasts longer, and thinks smarter. From 3D models to the last bolt, we ensure certainty.
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