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PTT Exploration and Production Public Company Limited

PTTEP Engineering General Specification

PEGS

Pultruded Fire Resistant Fibre Reinforced Plastic


Floor Grating

Document No: PEGS-0710-OSS-010

Revision No: 0-0

Revision Date: October 2014


PTT Exploration and Production Public Company Limited

Revision History

Rev Description of Revision Authorised by Date


0-0 New Document

October 2014 Rev.0-0 History


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TABLE OF CONTENTS

1.0 Purpose................................................................................................................... 1
2.0 Scope ...................................................................................................................... 1
3.0 Definitions .............................................................................................................. 2
3.1 Language .............................................................................................................................2
3.2 Terminology .........................................................................................................................2
3.3 Common Acronyms ..............................................................................................................3
4.0 References.............................................................................................................. 4
4.1 PTTEP Internal References ..................................................................................................5
4.2 International Standards ........................................................................................................5
4.3 Industry Codes and Standards .............................................................................................5
5.0 Requirements for Pultruded Fire Resistant Fibre Reinforced Plastic Floor
Grating .................................................................................................................... 7
5.1 Application ...........................................................................................................................7
5.2 Performance Requirements ..................................................................................................7
5.3 Type Approval ....................................................................................................................12
5.4 Quality Assurance Requirements........................................................................................ 12
5.5 Component Marking ...........................................................................................................16
5.6 Handling, Storage and Transportation ................................................................................ 16
5.7 Documentation ...................................................................................................................17
5.8 Spares ...............................................................................................................................18
6.0 APPENDICES ........................................................................................................ 19
Appendix 1. Extract from USCG Fire Test Requirements.............................................................. 19

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1.0 PURPOSE

The purpose of the PTTEP Engineering General Specification, PEGS-0710-OSS-010


Pultruded fire resistant fibre reinforced plastic floor grating, is to specify general and
fundamental specification for basic of design of the system; assuring technical integrity and
fitness of purpose with optimum life cycle cost.

2.0 SCOPE

This document defines the requirements for pultruded fire resistant fibre reinforced phenolic
floor grating for use in external parts of an offshore installation (fixed or floating).

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3.0 DEFINITIONS

A number of different terms are commonly used to describe the work stages, processes, and
approvals which take place during the early stages of a development. This can often be a
source of confusion so the following section is intended to show the PTTEP preferred
terminology as used in this document.

3.1 LANGUAGE

In this document, the words should and shall have the following meanings:

Should Indicates a preferred course of action. Should is a non-mandatory word and


is not forbidden, but use in the body of the text should be the exception.
Where none mandatory terms are used, each paragraph within these clauses
shall also have an associated commentary paragraph that provides the
rationale for why the stated choices and modifications are appropriate and
circumstance under which the stated choices and modifications might be
different.
Shall Indicates a course of action with a mandatory status. The term “shall” shall
be used if a requirement is considered to be necessary to claim compliance
with a PEGS document.

3.2 TERMINOLOGY

Terminology Description

Approval The authorization in writing given by the COMPANY to the Contractor on a procedure
or to proceed with the performance of a specific part of the work without releasing in
any way the Contractor from any of his obligations to conform with the technical
specifications, requisitions, etc. The words “Approve”, “Approved” and “Approval” shall
be construed accordingly
COMPANY PTT Exploration and Production Public Company Limited
Contractor Per contract: Contractor – ‘The contractor who is a PARTY to this CONTRACT and
where the context so requires, any and all SUBCONTRACTORS utilised by
CONTRACTOR for the performance of the WORK’.

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3.3 COMMON ACRONYMS

Set out below in alphabetical order are common acronyms as found within this document:

DVT Design Validation Test

ESD Emergency and Shutdown

ETR Electrical Technical Room

EWS Engineering Work Station

F&GS Fire and Gas system

FAT Factory Acceptance Test

FCW Full Control of Wells

HIPS High Integrity Protection System

I/O Input / Output

ICSS Integrated Control and Safety System

IFAT Integrated Factory Acceptance Test

ITR Instrument Technical Room

OCWR Overall Control of Wells and Risers

OTS Operator Training Simulator

OWS Operator Work Station

PCS Process and Control System

PDS Process Data Server

PLC Programmable Logic controller

PSS Process Safety System

SIL Safety Integrity Level

SOR Statement of requirements

WHCP Well Head Control Panel

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4.0 REFERENCES

The reference documents listed below, including Industry Codes and Standards and
COMPANY specifications, form an integral part of this Engineering General Specification.
Unless otherwise stipulated, the applicable version of these documents, including relevant
appendices and supplements, is the latest revision published on the effective date of a
contract.

The overall order of precedence of the applicable documents shall be:

1. Applicable Laws, Rules and Regulations of the country in which the system/equipment
will be operated (if any);

2. Purchase Order/ Service Order/ Contract Documents (Only applicable for direct
purchase by COMPANY);

3. Project Particular Specification (PPS), and relevant data sheet(s) if any;

4. COMPANY General Specification;

5. Codes and Standards in reference.

Any conflict between any of the Contract Documents, or between this specification and any
other Contract Document, shall be reported to COMPANY for decision. In such a case, and
unless otherwise agreed or decided by COMPANY, it is understood that the more stringent
requirement shall apply.

Exceptions to, or deviations from this specification are not permitted unless previously
accepted in writing by COMPANY. For this purpose, requests for substitutions or changes of
any kind shall be complete with all pertinent information required for COMPANY assessment.
COMPANY’s approval, nevertheless, will not, in any way, relieve the responsibility of the
Contractor to meet the requirements of the industry Codes and Standards referred to and
amended herein, in the event of conflict.

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4.1 PTTEP INTERNAL REFERENCES

Internal documents applicable to this document are indicated in the table below.

Document Number Document Title


PEGS-0710-OSS-017 (TBA) Design of offshore topside structure

PEGS-1015-SAF-005 Escape, evacuation and rescue from fixed installations

4.2 INTERNATIONAL STANDARDS

International standards applicable to this document are indicated in the table below
i.e. ISO, IEC or ITU.

Document Number Document Title


Safety of machinery - Permanent means of access to
ISO 14122-2
machines - Part 2: Working platforms and walkways
Safety of machinery - Permanent means of access to
ISO 14122-3 machines - Part 3: Stairways, stepladders and guard-
rails
Quality Systems - Model for Quality Assurance in
ISO 9001 Design, Development, Production, Installation, and
Servicing

4.3 INDUSTRY CODES AND STANDARDS

Industry codes, standards and regional legislation applicable to this document are indicated in
the table below.

Document Number Document Title


Recommended Practice for Planning, Designing and
API RP2A-WSD Constructing Fixed Offshore Platforms - Working Stress
Design
Standard Specification for Chromium and Chromium-
ASTM C 177 Nickel Stainless Steel Plate, Sheet, and Strip for
Pressure Vessels and for General Applications
Test for tensile properties of glass fiber strands, yarns
ASTM D 2343
and rovings used in reinforced plastics
Test for gel time and peak exothermic temperature of
ASTM D 2471
reacting thermosetting resins
Standard Test Methods for Determining the Izod
ASTM D 256
Pendulum Impact Resistance of Plastics
Standard Practice for Classifying Visual Defects in Glass
ASTM D 2563
Reinforced Plastic Laminate Parts
Standard Test Methods for Ignition Loss of Cured
ASTM D 2584
Reinforced Resins
Standard Test Methods for Measuring the Minimum
ASTM D 2863 Oxygen Concentration to Support Candle-Like
Combustion of Plastics (Oxygen Index)
Standard Test Methods for Measuring Adhesion by
ASTM D 3359
Tape Test

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Document Number Document Title


Standard Test Method for Abrasion Resistance of
ASTM D 4060
Organic Coatings by the Taber Abraser
Standard Test Methods for Curing Properties of
ASTM D 5028
Pultrusion Resins by Thermal Analysis
Standard Test Methods for Rate of Burning and/or
ASTM D 635 Extent and Time of Burning of Plastics in a Horizontal
Position
ASTM D 638 Standard Test Methods for Tensile Properties of Plastics
Standard Test Methods for Compressive Properties of
ASTM D 695
rigid Plastics
Standard Test Methods for Flexural Properties of Un-
ASTM D 790
reinforced and Reinforced Plastics
Test Method for Static Coefficient of Friction of Polish-
ASTM D2047 Coated Floor Surfaces as Measured by the James
Machine
Standard Practice for Xenon Arc Exposure of Plastics
ASTM D2565
Intended for Outdoor Applications
Standard Test Methods of Fire Tests of Building
ASTM E 119
Construction and Materials
Standard Test Methods for Surface Burning
ASTM E 84
Characteristics of Building Materials
Industrial type flooring, walkways and stair treads - Part
BS 4592-4 4: Specification for glass reinforced plastic open bar
gratings
Recommendation on Improved Fire Test Procedures for
IMO A653 (16) Surface Flammability of Bulkhead, Ceiling and Deck
Finish Materials
Standard Safety Test for Flammability of Plastic
Underwriters Laboratory, UL-94
Materials for Parts in Devices and Appliances
United States Coast Guard Use of Fiber Reinforced Plastic (FRP) Grating and
(USCG) Policy File Memorandum Cable Trays
PFM 2-98
University of Houston's
Composites Engineering and Fiber Reinforced Plastic (FRP) Grating – Procurement
Applications Center, CEAC-GL- Specification
2003-0102
US Department of Transportation Para. 5.C.6, Fiber Reinforced Plastic (FRP) grating
Marine Safety Manual Vol. II

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5.0 REQUIREMENTS FOR PULTRUDED FIRE RESISTANT FIBRE REINFORCED


PLASTIC FLOOR GRATING

5.1 APPLICATION

Fire-integrity pultruded fibre-reinforced floor grating may be used for the following applications:

• All internal platforms that are solely used for elevated access to equipment, valves,
etc., and which are not for heavy maintenance or handling use

• Boat access landings

• Deck areas in utility modules, particularly those in water treatment modules subject to
heavy external condensation in warm environments, but excluding areas which are for
heavy maintenance or handling use

• Inspection access ways within crude oil tanks and ballast tanks of an FPSO or FPU.
Steel flooring systems shall be used in the following applications:

• Muster areas and platforms for lifeboats

• All primary escape routes

• All areas which are for heavy maintenance or handling use (such areas include all
unobstructed open deck areas which are accessible to crane use, or which are served
by overhead runway beams or similar handling facilities)

• All lower deck areas of process modules (used for fired heaters, separation,
compression, produced water treatment, etc.)

• All floors requiring a plate surface for protection against fire or to retain fluids

• All parts of flare towers, and adjacent structure influenced by flare radiation.

Within any given area of deck grating, the selected grating shall be uniformly steel or FRP.
FRP grating is not permitted within accommodations, service or control spaces.

For other applications, the CONTRACTOR may select either steel or fire-integrity pultruded
fibre-reinforced floor grating, subject to prior approval by COMPANY.

5.2 PERFORMANCE REQUIREMENTS

The manufacturer shall supply data demonstrating that the proposed product satisfies each of
the general performance requirements which are set out in the following paragraphs. If the
manufacturer has obtained Type Approval certificates by an accepted Classifying Society
these certificates may be submitted to document performance of the product.

Submission of the qualification data, a Certificate of Conformance or Type Approval is an


essential part of the procurement process and shall be included in the Contractor’s
documentation requesting COMPANY’s approval to use the Manufacturer’s product.

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5.2.1 GRATING PATTERN


Grating panels shall be made of pultruded I bars. The bearing bars of the grating panels
located above a working area shall be spaced so as to comply with ISO 14122-2: they shall
not permit a ball of 20 mm diameter to penetrate the grating. In other areas which are not
located above working areas (like spider decks or boat landing) the bearing bars shall be
spaced so as to comply with ISO 14122-2: they shall not permit a ball of 35 mm diameter to
penetrate the grating.

The bearing bar composite shall be manufactured by the pultrusion process using phenolic
resin, and continuous glass fibres wrapped by a continuous strand glass mat. Panels shall be
assembled into the sizes ordered using pultruded phenolic transverse bars. The transverse
bars shall be configured so that they are fixed at each point of intersection or contact wit the
load- bearing bars by means of a suitable resin adhesive so as to provide lateral restraint to
the load- bearing bars. The transverse bars shall be spaced at no more than 150 mm on
centre in the panel.

Grating panels shall not be less than 300 mm in width.

Channel section binding bars shall be adhesively bonded at panel edges where the
unsupported starting edge dimension to the first transverse bar is greater than 75 mm (or less
if required to achieve the manufacturer’s performance guarantee).

Stair treads and the edging of deck grating at the top of stairs and other step-off points shall
be fitted with a slip-resistant nosing bar of a pattern to be approved by COMPANY.

5.2.2 DESIGN LIFE

The grating will be exposed to direct sunlight in an offshore salt-laden atmosphere in a tropical
location. The design operating life of the grating panels shall be the platform operating life,

20 years.

5.2.3 LOADING AND DEFLECTION LIMITS

Load and deflection criteria shall be achieved on the basis that support structure will
be provided with a span not exceeding 1050 mm between web centres.

For deck areas where FRP grating is permitted the minimum design uniform load for the
grating is 7.5 kN/m2. It is to be noted that this loading requirement has been set at a higher
level than specified for steel flooring in order to extend the load-bearing capacity in the event
of accidental conditions. The underlying steel structure for such deck areas shall be
designed for a uniform loading of 5 kN/m2 in accordance with PEGS-0710-OSS-017 (TBA).
FRP grating shall be designed with the above blanket live loads. An additional point load of
5 kN distributed on a 0.3 m by 0.3 m area shall be also considered.

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For walkways (which do not form part of a larger deck area), gangways, stairways, access
and inspection platforms on equipment the design uniform load for the FRP grating is 2.5
kN/m2.

For stair treads, the design loads shall be 5 kN/m2 applied over the whole area of the
tread. Treads must be adequately stiffened under the nosings to carry a point load of not
less than 1.5 kN over an area of 150 x 150 mm located at the most onerous position.

The grating shall have sufficient flexural stiffness to limit the mid-span deflection to no
more than 6 mm for the specified loads and support span.

The ultimate flexural strength for qualified grating products shall be five (5.0) times the
specified design loads, or greater. All testing of mechanical strength and deflection
characteristics shall be in compliance with ASTM D 256, ASTM D 638, ASTM D 695, ASTM
D 790 as applicable.

The manufacturer shall document that the pultruded bearing bars have sufficient strength
under local loading, particularly in respect to web-to-flange connection strength.
Manufacturer shall document compliance in accordance with the standard defined for
repeated wheel loading given by CEAC-GL-2003-0102 or a COMPANY-approved equivalent
standard:

• A 36” X 48” panel shall be supported on two steel beams with a minimum clear span
of 43”.
• A hard rubber wheel 6” in diameter by 2” wide shall be cycled over the panel on a 24”
long pass 20° from perpendicular to the bearing bars. The wheel load shall be 400
pounds and the loading shall be cycled for 1000 times. There shall be no splitting
of the top flange or the webs of the bearing bars resulting from the cyclic loading.
In addition, the residual flexural stiffness shall be 90% of the original flexural
stiffness, or greater.

The manufacturer shall document that the grating panels have an impact resistance as
measured by the impact test given by CEAC-GL-2003-0102 or a COMPANY-approved
equivalent standard:

• A 48” X 48” panel shall be supported on 2 steel beams with a minimum clear span of
43 inches and held down by clips, one at each corner. The panel shall be impacted
with a 10-inch flange weighing 152 pounds. The flange shall be dropped from a
height of 5.3 feet producing impact energy of 1100 joules (806 ft.-lbf.). The panel
shall then be impacted with a steel ball weighing 26 pounds dropped from a height of
5.6 feet producing impact energy of 200 joules (146 ft.-lbf.) The test assembly shall
incorporate a cylinder to guide the impact weight to the target. After the two impact
tests, the panel shall meet the design load deflection requirements.

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5.2.4 SKID RESISTANCE AND DURABILITY


The grating panels shall have an anti-slip surface made from uniform grit and a heat
cured epoxy coating with the following characteristics:
• The “static coefficient of friction” of the anti-slip surface shall be measured in
accordance with ASTM D 2047 and shall be greater than 0.75
• The durability of the anti-slip grit/adhesion system shall measure in accordance
with ASTM D 4060-01, and shall be greater than 800 revolutions.

5.2.5 ULTRA-VIOLET (UV) RESISTANCE

A UV resistant coating shall be applied to all grating surfaces of phenolic pultruded grating.
The manufacturer shall provide data demonstrating the UV resistance of the proposed FRP
grating in accordance with ASTM D 2565.

5.2.6 RESISTANCE TO CHEMICALS

Contractor shall identify to the manufacturer any chemicals used in production to which the
gratings may be exposed. To qualify for areas requiring chemical resistance, the manufacturer
shall supply data showing that the proposed grating is resistant to chemical attack when
subjected to spills, splashes or fumes of the specified chemicals.

5.2.7 FIRE PERFORMANCE REQUIREMENTS

All FRP grating shall be fire resistant phenolic type for use in fire integrity locations, and
shall meet Level 2 structural fire integrity requirements as defined in the US Coast Guard’s
requirements as stated in Policy File Memorandum 2-98, 9078, Enclosure (1), Paragraph
5.C.6, or shall comply with an equivalent standard to be accepted by COMPANY.

All FRP grating shall meet fire retardant characteristics as demonstrated by testing to
ASTM D 635 with a flame spread rating not exceeding 10 mm/min.

All FRP grating shall have low flame spread characteristics as demonstrated by testing
to ASTM E 84 with a flame spread rating not exceeding 10.

All FRP grating shall have low smoke characteristics as demonstrated by testing to
ASTM E 84 with smoke developed rating not to exceed 10.

The vendor shall provide USCG certificate of approval for the product. The vendor shall also
provide a test report from a third party laboratory demonstrating that the proposed grating
product meets Level 2 fire integrity requirements.

5.2.8 SUPPLEMENTARY PERFORMANCE REQUIREMENTS

CONTRACTOR shall specify additional performance requirements as needed to comply with


the Contract.

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5.2.9 FIXINGS
All phenolic grating shall be attached to the supporting beams by means of marine grade
stainless steel clips profiled to suite the grating pattern. These clips shall be secured to the
supporting structure. A minimum number of four clips shall be provided for each panel, and
additional clips shall be provided for shaped gratings to prevent uplift under non-uniform load.

The minimum bearing length at support points shall be 25 mm, or more if required by the
manufacturer.

Fixings shall be made from the upper surface.

The maximum clearance between grating panels shall be 3 mm.

5.2.10 PENETRATIONS AND CUT-OUTS

The manufacturer shall provide guidance on the detailing and cutting of penetrations, and
shall supply documentation to confirm that all characteristics required by this specification
are achieved when such penetrations exist. As a minimum, grating shall satisfy the
performance standard specified in this document when cut to accommodate a hole of 320
mm in diameter:
• At any location fully within a 1 m wide panel
• At any point in the span centred on the junction between two 1 m wide panels.

All cut ends shall be sealed with an appropriate resin after cutting.

Suitable trimmer steel shall be incorporated into the support structure to ensure that the
grating retains its load-bearing capacity where there are larger penetrations or a greater
number of penetrations than guaranteed within the manufacturer’s performance data.

Locking bars shall be bolted into position between adjacent grating panels to provide
continuity of transverse bars where these are needed to achieve grating capacity in the
case of penetrations close to a panel edge.

Penetrations for piping shall provide a nominal 50 mm clearance all round the pipe and
any insulation/coating. Penetrations for piping shall provide a similar clearance over the
dimensions of any flanges that are to be withdrawn through the grating for maintenance.
Piping penetrations shall be edged with marine grade stainless steel toe plates with collars
which enable them to be bolted into position.

Cut-outs for structural steelwork shall closely follow the profile of the steel leaving a
clearance of 10 mm. Where re-entrant form makes it not possible to achieve this clearance,
the edge of the grating shall be finished by means of a toe plate. Alternatively, such cut-outs
may be edged with a suitably shaped fire resistant, non-slip FRP plate bonded to the grating.

Toe plates at penetrations shall be 100 to 150 mm high.

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5.2.11 EQUIPMENT SUPPORT


No items of permanent equipment shall be supported on grating without provision of
underlying load-bearing trimmer steel.

5.3 TYPE APPROVAL

Where compliance with this specification is documented by means of Type Approval


certificates, these may be accepted from the following Classifying Agencies:

• American Bureau of Shipping (ABS)

• Bureau Veritas (BV)

• Det Norske Veritas (DNV)

• Lloyds Register (LR).

5.4 QUALITY ASSURANCE REQUIREMENTS

The FRP grating manufacturer shall be registered by an accredited agency as meeting the
requirements of ISO 9001. For the purpose of this specification, the manufacture of FRP
grating shall be considered a “Special Process” as defined in ISO 9001, Paragraph 4.9.

The supplier shall identify manufacturing processes and activities that affect component
performance and shall ensure that these processes and activities are adequately controlled in
accordance with ISO 9001, Paragraph 4.9. Critical processes or activities for which
procedures must be developed and maintained or where pre-qualifications are necessary,
shall include, but are not limited to, the following:

• Raw material acceptance

• Resin mixing

• Grating fabrication

• Curing (including time and temperature monitoring)

• Marking, packing, handling and transportation.

The Manufacturer shall maintain a quality manual. The quality manual and all quality records
shall be made available to COMPANY inspectors upon request. It shall be the responsibility of
the Manufacturer to maintain copies of records, documents and procedures for a minimum of
two years from the date of product delivery. COMPANY reserves the right to witness any or all
tests, and shall be given sufficient advance notice of them.

5.4.1 QUALITY CONTROL EQUIPMENT

Equipment used to inspect, test or examine shall be identified, controlled, calibrated and
adjusted at special intervals in accordance with the documented quality program, and
consistent with industry standards to maintain the accuracy required by this specification.

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5.4.2 QUALITY CONTROL TESTS


The Manufacturer is required to test the raw materials he uses and to check during and at the
end of fabrication that his product performs as required.

Quality control of the glass fibre - The certificates of origin of the glass fibres used in
fabrication, identified by batch number, must be presented to the COMPANY on request.
These documents must, in particular, state the results of the tensile tests called for in the
ASTM D 2343.

Checks of resin quality - at the time of acceptance of a batch of resin, the Manufacturer is
required to check the quality of the batch by carrying out the following tests on reactivity and
viscocity of the batch:

• The reactivity - measured in accordance with ASTM D 2471 - of the resin here means
the rate and intensity of curing under specified conditions. This test is important,
because the resin, most often delivered with its accelerator, may be altered if stored for
a too long time, especially if the storage temperature is high. The Manufacturer shall
assure that the storage time does not exceed approximately six months, and that the
temperature of the storage area is less than 20°C.

• The measurement of the viscosity of the resin and of the mix of resin plus hardener,
gives an idea of the application conditions that will result in proper impregnation of the
reinforcing materials. The frequency of the shop quality checks is variable; the
Manufacturer may test each batch or each drum in each batch. A certificate stating the
results of these checks shall be submitted to the COMPANY.

Lot Size - production lots for pultruded grating shall consist of a production run of bearing bars
from each production line, or the production accomplished in a time period of one week,
whichever is smaller. Multiple lots of bearing bars may be used in a given order for pultruded
grating.

Glass Content - The glass content (mass fraction expressed as percentage) of at least one
sample per production lot shall be determined in accordance with ASTM D 2584. If the
measured glass content is not within 5% of the value in the manufacturer’s specification, the
lot shall be rejected or subject to retest.

Modulus of Elasticity - the modulus of elasticity shall be verified by testing the pultruded
bearing bars. One sample from each production line (die) shall be subjected to bending test
with vertical end supports and concentrated loading at the centre of the span. The resulting
deflection value must meet or exceed the manufacturer’s minimum standard value.

5.4.3 VISUAL INSPECTION

Each grating panel shall be visually inspected for compliance with the requirements stated in

Table 1, and either accepted, rejected, or repaired in accordance with these guidelines.

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5.4.4 SIZES AND TOLERANCES


Dimensional inspection shall be carried out to confirm overall length, breadth, squareness,
depth and flatness.

Overall dimensions shall comply with BS 4592-4:

The maximum permissible deviations from work sizes of gratings shall be as follows:

• Length of grating +0 mm

− 5mm

• Width of grating +0 mm

- 5 mm

• Centres of transverse bars ± 0.5 mm

• Difference between diagonals 5 mm

• Depth of load-bearing bar: +1 mm


• Up to 25 mm - 0 mm
• 25 mm up to 50 mm
+1.5 mm.

-0 mm

Flatness shall be measured with the panel resting on two end beams and comparing against a
straight gauge over each diagonal. Departure from the straight edge shall be no more than

3mm, and no single corner shall be more than 3mm off the supporting beams when the other
corners are in contact.

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Table 1 - Visual Inspection Acceptance-Rejection Criteria (Based on ASTM D 2563)

Defect Description Acceptance Criteria Corrective


Type Action

Burn Thermal decomposition evidenced by None permitted Reject


distortion or discoloration of the FRP
product surface.

Chip Small piece broken from edge or If there are undamaged, fibres exposed Minor repair
surface. If reinforcement fibres are over any area; or no fibres are exposed
broken, the damage is considered a but an area greater than 10 mm x 10
crack. mm lacks resin

If there are no fibres exposed, and the Accept


area lacking resin is less than 10 mm x
10 mm

Crack Actual separation of the component, None permitted Reject


visible on opposite surfaces, and often
extending through the component.
Reinforcement fibres are often
visible/broken.

Crazing Fine hairline cracks at or under the Crack lengths greater than 25.0 mm Minor repair
surface of the component.

Crack lengths less than 25.0 mm Accept

Dry spot Area of incomplete surface film where None permitted Reject
the reinforcement has not been wetted
by resin.

Fracture Rupture of the component with None permitted Reject


complete penetration of the laminate.
Majority of fibres broken. Visible as
lighter coloured area of inter-laminar
separation.

Inclusion Foreign matter moulded into the None permitted Reject


component.

Wear Shallow mark caused by improper If there are undamaged, fibres exposed Minor repair
scratch handling, storage and/or transportation. over any area; or no fibres are exposed
If reinforcement fibres are broken, the but an area greater than 10 mm x 10
damage is considered a crack. mm lacks resin

If there are no fibres exposed, and the Accept


area lacking resin is less than

10 mm x 10 mm

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5.4.5 RETEST
If any specimen fails to conform to any of the specified requirements, the production lot shall
be rejected. Nevertheless,

Manufacturer may elect to make retests on three additional replicate samples selected at
random from the same production lot.

If all the retest samples conform to the requirements then the remainder of the production lot
shall be accepted.

If any retest specimen fails to conform then the production lot shall be rejected without option
for further retest.

5.5 COMPONENT MARKING

All grating panels shall be marked by the Manufacturer with the following information:

• Manufacturer’s name

• Product series and resin type

• Panel size

• Lot number traceable to the date of manufacture

• Reference number as required by the Buyer to assist assembly on site.

Markings shall be applied by paint or ink stencil, sticker, or both. Markings shall be permanent,
shall not overlap, and shall be applied in such a manner as not to damage the product.

The Inspection Agency must also affix its mark on the parts it has inspected in conformity with
this specification and which it has accordingly accepted. An indelible "Rejected" mark must be
applied to defective parts.

5.6 HANDLING, STORAGE AND TRANSPORTATION

FRP product is susceptible to mechanical damage from impact, sharp edges, or scratching.
Special consideration must therefore be given to protecting FRP grating during handling. All
personnel involved shall be trained in appropriate procedures for handling FRP products.

Lifting, loading, unloading, and shipping shall be performed in accordance with the
Manufacturer’s recommendations. FRP grating shall be shipped from the manufacturer in
bundles secured by banding, protected and secured to prevent damage in shipment.

All materials and equipment necessary for the on-site fabrication shall be stored before,
during, and after shipment in a manner to prevent cracking, twisting, bending, breaking,
chipping, or damage of any kind to the products or equipment.

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5.7 DOCUMENTATION

5.7.1 MANUFACTURER PRE-QUALIFICATION


The manufacturing facility and the quality system are subject to audit. The audit shall inspect
for compliance with the details of ISO 9001, special provisions, the requirements of this
specification and pre-qualification testing. A manufacturing procedure shall be available for
each grating product. The manufacturing procedure shall be provided, if requested, prior to the
start of manufacture.

5.7.2 PRODUCTION QUALITY CONTROL DOCUMENTATION

The Manufacturer shall maintain a Compliance File to document all quality assurance
provisions and providing evidence of compliance with all the requirements of this specification.
The Compliance file shall contain material certificates for the raw materials of all components
and all production quality control records for the components to be supplied The Manufacturer
shall provide access to the compliance file on request.

The manufacturer shall provide “certificates of conformance” to this specification with each
shipment of product.

5.7.3 INSTALLATION DOCUMENTATION, SAFETY AND TRAINING

The Manufacturer shall provide detailed installation instructions and training in Contractor’s
facilities of operators and supervisors and COMPANY inspectors. These instructions shall
clearly and fully cover handling, cutting, repair, and fixing.

Manufacturer’s instructions shall in particular address the tools to be used for cutting, and
specific measures to be taken in respect to the handling of dust generated by the cutting
process.

Manufacturer’s instructions shall in particular explain how to apply resin sealers, used after
cutting, and repairs, and adhesives. Requirements for health and safety protection for such
applications shall be fully defined.

Manufacturer shall provide an initial period of supervision to monitor storage and handling
during installation, and may be requested to return to the installation site to inspect the
completed grating work.

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5.8 SPARES

CONTRACTOR shall supply spare grating panels, stair treads, fixing clips and tie-bars for an
area equal to 3% of the installed FRP grating area, and 5% for stair treads. Spare floor panels
shall be supplied in as rectangular panels with span equal to the largest installed span. Panel
widths shall be not less than 1 m.

Contractor shall supply two sets of cutting tools, with spare blades and dust-handling devices,
and supplies of end-sealing chemicals as required to trim grating panels for any of the areas in
which they are used.

Unless otherwise specified by COMPANY, the spares shall be loaded into the installation’s
stores on departure.

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6.0 APPENDICES

Appendix 1. Extract from USCG Fire Test Requirements

This extract is provided for reference. The original source document shall be the basis for
qualification and approval.

Structural Fire Integrity Test Procedures

The structural fire integrity tests required to qualify grating products are defined as follows:

2.1 Level 1: To be qualified as level 1 (L1), the FRP grating shall meet the requirements
for qualification as level 3 and leel 2, and in addition shall be subjected to the following test
procedures:

2.1.1 Three (3) FRP grating specimens, after being subjected to the level 2 testing, shall be
unloaded and prepared for impact testing in the manner specified for horizontal specimens in
ASTM E 695, Standard Method of Measuring Resistance of Wall, Floor, and Roof
Construction to Impact Loading. The test specimens shall be secured as required in
paragraph 8.3 of ASTM E 695 except that the span shall be 200 mm less than the specimen
length. A lead shot bag of 40 kg mass shall be dropped once from a height of 2 m such that
the point of impact is in the center of the span. The specimens shall then be uniformly loaded
as required by the level 2 test procedures.

2.1.2 The test will be considered successful if all three (3) specimens remain intact after being
subjected to the impact test and the level-2 loading test. Failure will be indicated by collapse of
one or more of the grating.

2.2 Level 2: To be qualified as level 2 (L2), the FRP grating shall meet the requirements for
qualification as level 3, and in addition shall be subjected to the following test procedures:

2.2.1 On the FPP grating specimen and the steel-grating specimen subjected to the level 3
post-loaded testing, the specimen shall be gradually loaded in increments not to exceed 20
kg, placed in such a manner as to represent a uniformly distributed load across the span.

2.2.2 The test will be considered successful if the FRP grating remains intact at a load greater
than or equal to a uniform 4.5 kN/m2 (94 lbf/ft2) or greater than or equal to the steel grating
failure loading, whichever is less. Failure will be indicated by collapse of the grating.

2.3 Level 3: To be qualified as level 3 (L3), the FPP grating should be subjected to the
following fire test procedures for both the post-loaded and pre-loaded tests and conditions:

2.3.1 A fire test will be conducted in accordance with ASTM E 119, Standard Test Method for
Tests of Building Construction and Materials. Two tests shall be conducted in the ASTM E 119
furnace for each FRP grating design. The first fire test shall be conducted with the specimens
under the specified load (pre-loaded) and the second fire test will be conducted on unloaded
specimens (post-loaded). The time-temperature curve shall be the standard for E 119 or the
ISO equivalent. The duration of the tests shall be as specified below.

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2.3.2 Each test specimen shall be 300-350 mm wide to allow for the differences in the spacing
of longitudinal supporting members. The length of each test specimen shall be the length of
the maximum span to be seen in service plus 200 mm. Four test specimens shall be prepared
as described above; two of the proposed FRP grating and two of similar steel grating that
would be used in the same location constructed to the applicable

regulations and standards (steel grating rated at a minimum of 4.5 kN/m2 (94 lbf/ft2) uniform
loading with a 1.67 factor of safety are acceptable).

2.3.3 The pre-loaded test shall consist of the following:

a) One steel grating specimen and one FRP grating specimen shall be placed adjacent to
one another in the furnace simply supported on two I-beams with a minimum flange
width of 100 mm at an elevation of at least one half of the furnace height or a minimum
of 300 mm above the burners

b) The specimens shall be placed on the I-beams such that 100 mm of each side of the
specimen rests on each of the two I-beams

c) A static load represented by a 40 kg mass shall be placed in the center span of the test
specimens

d) The 40 kg mass load shall consist of a steel container filled with sand, the base of
which shall be square with an area of 0.9 m2

e) Arrangements shall be made to measure the deflection at the center of the span of
each of the loaded specimens during the test with a degree of accuracy of ± 5 mm

f) The two specimens shall be subjected to the time-temperature curve specified in the
ASTM E 119

g) Deflection of the two loaded test specimens shall be measured throughout the duration
of the fire test and the average furnace temperature shall be recorded when each of
the two specimens has deflected a distance of L/10 (failure point) from the horizontal,
where L is equal to the maximum unsupported span of the specimens; and

h) The test will be considered successful if the difference between the average furnace
temperature at the time of failure of the steel grating and the average furnace
temperature at the time of failure of the FPP grating is less than 100oC (180°F).

2.3.4 The post-loaded test shall consist of the following:

a) One steel grating specimen and one FRP grating specimen shall be placed adjacent to
one another in the furnace simply supported on two I-beams with a minimum flange
width of 100 mm at an elevation of at least one half of the furnace height or a minimum
of 300 mm above the burners height

b) The specimens shall be placed on the I-beams such that 100 mm of each side of the
specimen rests on each of the two I-beams

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c) The two specimens shall be subjected to the time-temperature curve specified in the
ASTM E 119 for a duration of 60 minutes

d) At the end of the 60 minutes the specimens will be allowed to cool and shall then be
subjected to a static load represented by the 40 kg mass specified in the pre-loaded test
above, placed in the center span of the test specimens, and

e) The test will be considered successful if the FRP grating specimen is intact at the end of
the test and does not collapse under the 40 kg mass load.

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