FRP shapes
Pultruded FRP does not corrode, does not conduct, and does not rot. In a cooling tower that makes it the obvious material for the components that keep failing.
Understanding the component
Pultruded fiberglass structural shapes are made by drawing glass reinforcement through a resin bath and a heated die, producing a constant-section profile with very high strength along its length. The result is a structural member that is roughly a quarter the weight of steel, entirely corrosion-proof and electrically non-conductive.
In cooling towers FRP shapes do two distinct jobs. As structure they replace steel or timber framing, fill supports, partition framing and mechanical equipment supports in water chemistry that has already destroyed the original. As safe access they provide grating, decking, walkways, stair treads, ladders, handrails and kneerails, which is where most of the demand comes from, because access steelwork corrodes faster than the tower around it.
Grating is the common case. FRP grating is slip-resistant when wet, non-conductive, corrosion-proof and light enough to be carried into a tower and installed by hand without a lift. It is normally supplied in a high-visibility yellow, which is a genuine safety benefit inside a dark plenum.
New FRP walkway grating. Safe access is a repair scope in its own right.
We supply components for cooling towers from every manufacturer, including towers whose original makers no longer exist. If it is on your tower, we can identify it.
What actually goes wrong
These are the failures we find in the field, roughly in order of how often we find them. If you recognize one, we can usually tell you what to check next over the phone.
| Failure | What it means |
|---|---|
| UV surface degradation | Fiber blooming on exposed surfaces after years of sunlight. Largely cosmetic if the shape is coated, but worth watching on unprotected material. |
| Impact damage | FRP is strong but not ductile. A dropped tool or a heavy impact produces local cracking rather than a dent. |
| Deflection under load | FRP is less stiff than steel of the same section, so span tables have to be respected. Grating that feels springy was under-specified. |
| Fastener issues | Over-torqued or wrongly located fixings crushing or splitting the profile. FRP wants correctly sized holes and controlled torque. |
Manufacturers and product lines
We are independent, so the recommendation follows your tower, your water and your duty rather than a single manufacturer's catalog.
Angle and channel
Structural profiles for framing, supports and bracing.
Tube and box section
Where a closed section is preferred.
Decking
Fan deck and walkway decking.
Grating
Molded and pultruded grating, slip-resistant and non-conductive, in high-visibility yellow and other colors.
Walkways and stair treads
Complete walkway sections, stair treads and landings.
Handrail systems
Handrails, kneerails, toe boards, ladders and cages.
Profiles and sections we supply
FRP shapes are specified by profile and section rather than by make, so there is rarely a name on them to look up. If you know the profile you need, ask for it by name. If you do not, send a photograph of what is there now along with the span it has to cover and the load it carries.
- pultruded angle
- pultruded channel
- FRP tube and box section
- FRP decking
- FRP grating
- FRP walkway and stair tread
- handrail and kneerail
- ladder and cage
What we would tell you on the phone
This is what safe-access remediation is built from.
Corroded handrails, kneerails, walkways and grating are the most frequent safety findings on a cooling tower and the easiest to close out. See safe-access remediation.
Respect the span tables.
FRP is not a drop-in substitute for steel of the same section. Deflection governs, and support spacing usually has to reduce. We will work that out rather than assume it.
Cutting FRP needs the right precautions.
Cutting and drilling produces glass dust requiring respiratory protection and it exposes fibers that should be sealed. Where possible we supply material cut and sealed to size.
Usually replaced or inspected at the same time
Lumber & hardware
CTI-grade treated Douglas fir and redwood, plywood, and fasteners in 304/316 stainless, silicon bronze, monel and hot-dip galvanized.
View componentCasing & louvers
FRP casing in 4.2 corrugated and 5.33 V-Beam profiles, and inlet louvers. Fire rated panels available with UL flame spread of 25 or less.
View componentFan stacks
FRP fan cylinders and velocity-recovery stacks in Class I, II and III fire ratings: Midwest, Polymer Fabrication and BAC · Baltimore Aircoil.
View componentDistribution systems
Counterflow header and lateral systems and crossflow distribution basins, including redesign to correct uneven water loading.
View componentSend us the nameplate and we will identify it
The fastest route to a correct quote is a photograph of the nameplate and of the component in place. Model numbers get superseded and drawings go missing; photographs do not lie.
- Phone
- (713) 643-0691
- Shop & office
-
3811 Cedar Blvd Ste A
Baytown, TX 77523