first time1stfabricationGrating Catalogue
SpecialiSt FabricationFTF ManuFacTuring
1
• Extensive product knowledge – We have over 20 years
involvement in the structural/grating fabrication industry
• Large Stock Inventory Levels – We carry an extensive
stock range in grating, stanchions and stair treads, all
available from our Perth Factory.
• Fast Project Turnaround Times – When you are on a tight
project schedule FTF is able to deliver a prompt production
service which consistently out performs our competitors.
• Personalized Service – At FTF your initial contact oversees
the whole project, from the quotation through to fabrication,
delivery and documentation.
• General Fabrication – FTF can also provide light to
medium General fabrication works and processing involving
highly repetitive type works.
• Rolling & Bending – Talk to your FTF Rep about our rolling
& bending capabilities to see if we can be of service to you.
“SpecialiST FabricaTion ServiceS To induSTry”
FTF can assist you in your next engineering project with our:
SpecialiSt Fabrication
conTenTS
2
Contents Page
How to order 3
Top treatment & finishes 4
Load/deflection tables 5 - 6
Stair treads 7
GrateShield & GrateMesh 8
Fastening Methods 9
Install Tolerances 10
Manufacturing Tolerances 11
Terminology/Glossary 12
Other Services 13
Capabilities 14
3
Example order code:
a 325 -1 M p g
Cro
ss b
ar p
itch
Fin
ish
Load
bar
siz
e
Load
bar
pitc
h
Mat
eria
l
Load
bar
trea
tmen
t
Choose the dimensions of the load bar in terms of height and width.
325
Select between a 50 and 100mm cross bar pitch (the distance between cross bars).
A B
Select between a 30, 40 or 60mm load bar pitch.
M SSelect between mild steel or stainless steel.
Mild Steel Stainless Steel
100mm 50mm
Indicates a height of 32mm and width of 5mm
SerieS 1 30mm
Use the information below to determine your order code.Specify whether the grating is to be banded or cut to size only, by referring to the terminology on page 12Nominate the number of panels required and provide dimensions for width and span of each panel. Span is always the last dimension.Where large floor areas are required provide a drawing of the area to be covered showing:
• grating type • dimensions • span • section size, location, and toe direction of the support steel • location and size of cut outs and removable areas • location of kick plate and nosings • indicate if penetrations are to be split
Span Direction• Grating and metal needs to be supported in a specific way. The direction that the load bar runs, or the span, is important for this. Refer to (page 12).• Span is always the last dimension given when referencing a panel size.• Grating has to be supported 90˚ to the span direction and does not require support on the other sides.
Select between plain or serrated load bars.
P S
Select between galvanised, bitumen dipped or untreated finishes.
G BGalvanised Bitumen Dipped U Untreated
Plain Serated
how To order
ordering guide
SerieS 2 SerieS 3 60mm40mm
load bar TreaTMenT
FiniSh
MaTerial
load bar piTch
load bar Size
croSS bar piTch
4
Top TreaTMenT & FiniSheS
FiniSheS
PlainOur standard grating comprises plain square edge flat load bars, with a 6mm square twisted bar, forge welded on top
of load bars. Although not required under AS 1657 the use of 10mm square bar cleats, every 300 - 400mm will provide for better slip resistance.
Steel grating can improve its slip resistance by placing them in such a way that you have to walk over the load bars.In steel grating there is a better slip resistance in patterns with 100mm cross rod centres.
SerratedAnother method for improving slip resistance is the use of serrated grating. The serrations are made up of small
notches cut into the load bar during the slitting of the material as one process, providing a low cost solution for improving slip resistance.
Top TreaTMenTS
Hot Dipped GalvanisedHot dip galvanising produces durable, abrasion resistant coating of metallic zinc alloy layers metalurgically bonded to
the steel base at a temperature of over 450˚
All hot dip galvanising conforms to equivalent following standardsAustralian/New Zealand Standard AS/NZS 4680:1999
British Standard BS729-1971American Standard ASTM-A123-73
Black Bitumen DippedAn economical paint finish which is best suited for indoor installations, or mining applications in a dry climate.
Note: there is no pre-treatment of steel before dipping. This finish is not recommended in corrosive environments.
Untreated (No surface treatment/protection)Normally supplied on stock mats or panels to customers who wish to perform their own fabrication on grating.
Example: 4475 x 1500 Platform
Shown here is a 4475mm (span) x 1500LBmm platform. The platform is made up of four 1500LB panels with a standard width of 995mm, with one make up panel cut to the nearest
load bar (455mm width). The balance allows for gaps of up to 10mm between panels.
SaMple order1500 m
m
995 455995995 995
load bar direcTion
IMPORTANT
When designing and ordering your grating panels check the direction of the load
bars. As their name suggests load bars take all the weight placed on the grating panel. The cross bars are only intended
to hold the load bars together and to help provide traction. It is the resposability of
the designer/client to ensure that the load bar span is running in the correct
direction.CORRECT DESIGNLoad bar direction is across the span.
WRONG DESIGNThis panel will collapse due to lack ofsupport at the ends of the load bars.
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Load bar code Load bar size (mm) Serrated edge conversion factor
203 20x3 NOT RECOMENDED205 20x5 NOT RECOMENDED253 25x3 0.876255 25x5 0.876 323 32x3 0.902325 32x5 0.902403 40x3 0.922405 40x5 0.922455 45x5 0.930505 50x5 0.937555 55x5 0.943655 65x5 0.951
Load bar code
Load bar size (mm) Series
Maximum span for various loads (with 5 mm deflection)
2.5kPa 4.0kPa 5.0kPa 7.5kPa
203 20x3Series 1 1190 1055 1010 905Series 2 1120 1000 945 860Series 3 1140 1020 965 875
205 20x5Series 1 1355 1210 1155 1040Series 2 1290 1140 1065 975Series 3 1185 1050 1005 895
253 25x3Series 1 1430 1265 1195 1060Series 2 1320 1180 1125 1010Series 3 1375 1195 1140 1030
255 25x5Series 1 1610 1435 1350 1225Series 2 1490 1335 1265 1150Series 3 1375 1195 1140 1030
323 32x3Series 1 1740 1616 1440 1306Series 2 1600 1420 1340 1200Series 3 1420 1275 1195 1085
325 32x5Series 1 1940 1720 1630 1480Series 2 1790 1600 1510 1375Series 3 1640 1445 1355 1230
403 40x3Series 1 2020 1790 1695 1530Series 2 1880 1685 1580 1435Series 3 1700 1495 1420 1285
405 40x5Series 1 2290 2035 1936 1746Series 2 2115 1900 1790 1620Series 3 1925 1700 1615 1460
455 45x5Series 1 2450 2226 2100 1905Series 2 2315 2070 1950 1770Series 3 2070 1860 1760 1590
505 50x5Series 1 2700 2400 2280 2060Series 2 2610 2230 2110 1920Series 3 2220 1860 1760 1590
555 55x5Series 1 2900 2680 2440 2210Series 2 2690 2400 2250 2060Series 3 2420 2130 2040 1845
655 65x5Series 1 3255 2930 2770 2605Series 2 3045 2720 2560 2315Series 3 2745 2445 2330 2090
Conveyer walkways / Light access platforms 2.5kPa
Standard Australian pedestrian platform loading 4.0kPa
Brittish Standard pedestrian platform loading 5.0kPa
Boiler house platform loading, esp. Power Stations 7.5kPa
Maximum loads for various standards.
Maximum span in mm for to allow for various loads with a 5.00 mm deflec-tion.
Multiply span by the appropriate conversion factors to determine maximum span for various loads (with 5mm deflection).
load/deFlecTion TableS
Typical applicaTion loading
MaxiMuM Span To load
SerraTed edge converSion
6
ProductLoadBar Size
Masskg/m2
U - kPa
D
Span (mm) 4kPa 5mm
Defl span450 600 750 900 1050 1200 1500 1800 2100 2400 2700 3000 3300 3600
A203/2 20x3 14.3U 34 19 12 8 6 5 3 2
980D 1.8 3.2 5 7.2 9.8 12.9 20.1 29
B205/3 20x5 18.2U 36 20 13 9 6 5 3 2
1010D 1.8 3.2 5 7.2 9.8 12.9 20.1 29
A203/1 20X3 18.2U 45 25 16 11 8 6 4 3 2
1060D 1.8 3.2 5 7.2 9.8 12.9 20.1 29 39.4
A205/2 20X5 22.2U 56 32 20 14 10 8 5 3 2
1120D 1.8 3.2 5 7.2 9.8 12.8 20.1 28.9 39.4
A253/2 25X3 17.3U 53 30 19 13 10 7 5 3 2
1170D 1.4 2.6 4 5.8 7.9 10.3 16.1 23.2 31.5
A205/1 20X5 28.7U 74 42 27 18 13 10 6 4 3
1200D 1.8 3.2 5 7.2 9.8 12.8 20.1 28.9 39.4
B255/3 25X5 21.5U 56 32 20 14 10 8 5 3 2
1200D 1.4 2.6 4 5.8 7.8 10.2 16.0 23.1 31.5
A253/1 25x3 22.2U 70 39 25 17 13 10 6 4 3 2
1250D 1.4 2.6 4 5.8 7.8 10.3 16.0 23.1 31.5 41.5
A255/2 25X5 27.1U 88 49 31 22 16 12 8 5 4 3
1320D 1.4 2.6 4 5.8 7.8 10.2 16.0 23.1 31.5 41.2
A323/2 32X3 21.4U 87 49 31 21 16 12 8 5 4 3 2
1400D 1.1 2 3.1 4.5 6.1 8.0 12.5 18.1 24.6 32.1 40.7
A255/1 25X5 35.2U 115 65 42 29 21 16 10 7 5 4 3
1420D 1.4 2.6 4 5.8 7.8 10.3 16.0 23.1 31.5 41.1 49.6
B325/3 32X5 21.4U 92 52 33 23 17 13 8 6 4 3 2
1440D 1.1 2 3.1 4.5 6.1 8.0 12.5 18.0 24.6 32.1 40.7
A323/1 32X3 27.7U 114 64 41 28 21 16 10 7 5 4 3
1510D 1.1 2 3.1 4.5 6.1 8.0 12.5 18.0 24.6 32.1 40.7
A325/2 32X5 34.0U 144 81 52 36 26 20 13 9 6 5 4
1590D 1.1 2 3.1 4.5 6.1 8.0 12.5 18.0 24.6 32.1 40.7
A403/2 40X5 26.1U 135 76 49 34 25 19 12 8 6 4 3
1660D 0.9 1.6 2.5 3.6 4.9 6.4 10 14.5 19.7 25.7 32.6
B405/3 40X5 31.1U 144 81 52 36 26 20 13 9 6 5 4 3
1700D 0.9 1.6 2.5 3.6 4.9 6.4 10 14.5 19.7 25.7 32.6 40.2
A325/1 32X5 44.4U 190 107 68 47 35 26 17 11 8 6 5
1710D 1.1 2 3.1 4.5 6.1 8.0 12.5 18 24.6 32.1 40.7
A403/1 40X3 33.9U 179 100 64 44 33 25 16 11 8 6 5 4
1780D 0.9 1.6 2.5 3.6 4.9 6.4 10 14.5 19.7 25.7 32.6 40.2
A404/2 40X5 41.8U 226 127 81 56 41 31 20 14 10 8 6 5
1890D 0.9 1.6 2.5 3.6 4.9 6.4 10 14.4 19.7 25.7 32.5 40.2
A405/1 40X5 54.8U 298 167 107 74 52 41 26 18 13 10 8 6
2030D 0.9 1.6 2.5 3.6 4.9 6.4 10 14.5 19.7 25.7 32.6 40.2
A455/2 45X5 46.7U 286 160 102 71 52 40 25 17 13 10 7 6 5
2030D 0.8 1.4 2.2 3.2 4.3 5.7 8.9 12.9 17.5 22.9 29.0 35.8 43.2
A455/1 45X5 61.4U 377 212 135 94 67 52 33 23 17 13 10 8 6
2175D 0.8 1.4 2.2 3.2 4.3 5.7 8.9 12.8 17.5 22.8 28.9 35.8 43.2
A505/2 50X5 51.5U 353 198 127 88 64 49 31 22 16 12 9 7 6 5
2200D 0.7 1.3 2 2.9 3.9 5.1 8.0 11.5 15.7 20.5 26.0 32.1 38.9 46.3
A505/1 50X5 67.9U 465 261 167 116 85 65 41 28 21 16 12 10 8 7
2350D 0.7 1.3 2 2.9 3.9 5.1 8.0 11.5 15.7 20.5 26.0 32.1 38.9 46.3
A655/1 65X5 87.5U 787 442 283 196 144 110 70 48 35 27 21 17 14 11
2825D 0.5 1 1.6 2.2 3.0 4 6.1 8.9 12.1 15.8 20.0 24.8 29.9 35.6
A755/1 75X6 120.2U 1049 500 387 262 193 147 94 66 48 37 29 24 20 16
3250D 0.46 1 1.3 1.8 2.5 3.2 5.1 7.3 10.0 13.0 16.5 20.4 24.7 29.4
U = Safe uniformly distributed load in kPa D = Deflection in mm at mid span due to USpans to the left of the red line have a deflection of less than 5mm for a 4kPa uniformly distributed load.
• For galvanised fabrication add 14% to the mass shown. See page 4 for more details.• Stainless Steel will be provided in either 30x5 or 32x5 depending on availability.
• Other combinations of pattern and bar size avilable to order.
load/deFlecTion TableS
STeel graTing load/deFlecTion Table
7
Type T5Welded fixing Banded ends
Abrasive nosing
STair TreadS
Stair treads can be supplied in any load bar/pitch configuration required. The treads shown here are for illustrative purposes only. Overall tread length can be made to any dimension. We suggest that tread width be selected from the table below with its recommended widths.
Wear rates are higher on stair treads than on general flooring due to concentrated impacts resulting in bowed treads. FTF recommends that stair treads never have less than a 25 x 5 Load Bar size, regardless of main flooring depth.
For safety and strength reasons, Nosing Bars should be specified. To the eye, when walking on grating stairways, grating patterns tend to merge with the result that tread edges become ill defined causing over or under stepping by users. Strength at the front of the tread is increased with Nosing Bars. Also deflection resistance of the tread from impact loads is improved.
Recommended Widths
Series 1 125 155 185 215 245 275 305Series 2 125 165 205 245 285 325Series 3 185 245 305
Bolted Connections‘A’ 45 75 75 100 100 125 125
STair TreadS
RecommendedWidth
Fron
t
25
50
‘A’
End plate 65 x 5mm flat with 14mm diam holes
Note: Special end plate hole centres available on request.
Standard end plate for bolted threads.
Load bar size (mm)Recommended max length (mm)
Series 1 Series 2 Series 3
25 x 5 900 750 50032 x 5 1300 1200 80040 x 5 1600 1500 1300
When ordering treads nominate type of grating required.Example – T3 – 750 x 275 (Made from A325/1 Grating)
Type T3Welded fixing Banded ends
Floor Plate nosing
Type T1Welded fixing Banded ends
No nosing
Type T4Bolted Fixing
Holed end platesFloor Plate
nosing
Type T6Bolted Fixing
Holed end platesAbrasive nosing
Type T2Bolted Fixing
Holed end platesNo nosing
graTeShield & graTeMeSh
8
graTeShield
how To order
how To order
GrateShield is a merged floor grating with Chequer plate welded on top of the grating. Designed for high impact floor areas it is an economical alter-native to using traditional floorplate systems while keeping weight down to a minimum. Series 1 grating is recommended but other configurations can be supplied
GrateMesh is a merged floor grating with a light gauge expanded mesh welded on the underside on top of the grating depending on require-ments. Designed to stop small objects or tools from falling through the grating. If welded on top it is ideal for mezzanine floors with wheeled trol-leys and also stops rubbish collecting between load bars.
Product Floor Grating Weight untreated kg/sqm Span at 4kPa UDL 5mm deflection
GS3-255/1MP 3mm 255/1MP 44.49 1390mmGS5-325/1MP 5mm 325/1MP 64.78 1625mm
graTeMeSh
1. Choose the product type required by reference to the recommen-dations shown above.
Or choose a grating by using the pattern choices on page 3 and choose an appropriate Load Bar from the Load/Deflection Table on page 5 & 6.
2. Add the required finish from page 4.
3. Nominate the required thickness of the floorplate.
Examples:GS3-325/3MP32 x 5mm load bar, 60mm pitch mild steel(1 piece A x B span)
1. Select a grating from the pattern choices on page 3 and choose an appropriate Load Bar from the Load/Deflection Table on page 5 & 6.
2. Add the required finish from page 4.
3. Prefix your choice
GM Examples:GM-A255/1MPGAll as per drawing supplied.The standard mesh supplied is a flattened Expanded MetalSWM 12mm x LWM 30mm.
9
Illustration 3 - Series 3 grating
Illustration 2 - Series 2 grating
Illustration 1 - Series 1 grating
The most effective and economical way for fastening grating is to weld it to the support steelwork. Recommended weld is 5mm fillet at 1000mm centres.
If panels are required to be removable or grating damage may regularly occur then fixing clips are recommended. Our clips come in galvanised finish. A minimum of 4 clips per panel or per sqm.
Once placed down grating panels should immediately be fixed as they will often move or drift unknowingly off supporting steelwork.
Illustrations 1-3Illustrations 1, 2 and 3 show the FTF Universal Clip (comprising of a double saddle clip, 8mm diameter cheese head screw and bottom clamping bracket) in use on Series 1, 2 and 3 gratings respectively.
FaSTening MeThodS
FaSTening MeThodS
IMPORTANTTo avoid any risk of accident it is recommended that panels used for temporary access during construction or mainenance of a site are lightly tack-welded to supporting steelwork before use. Unfixed panels are likely to shift gradually as a result of constant traffic and may fall or tip.
Illustrations 4The FTF Universal Clip is suitable for joining grating panels as well as fixing them down.
Illustrations 5FTF universal top clip used with self drilling or thread cutting screws. Can also be used in locations where there is no open flange on the supporting steelwork to clamp to.
inSTallaTion ToleranceS
Fabrication Welding
Banding bars and attachments are welded
with a minimum 3mm fillet to one side of:
every 5th load bar on Series 1 gratings
every 4th load bar on Series 2 gratings
every 3th load bar on Series 3 gratings
Other welding is applied to cut-outs, splays
or circles as appropriate or as requested.
10
inSTallaTion clearanceS
10mm nom.10mm nom. 10mm nom.
15mmMin clearance equal to rebate angle thickness
Span Span
Support
Actu
al c
utou
t will
be
to n
eare
st lo
ad b
ar
Wid
th
10mm Nominal
10mm Nominal
25mm Bearing minimum (Typical)
Load Bar(Typical)
10mm Nominal
Load Bar(Typical)
Cut-outs around pipes and circular ducts to have minimum clearance of 25mm all round and will be opened out to nearest standard pipe size
NOTE:clearance can vary relative to rebate angle straightness
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diMenSionS & SquareneSS
croSS bar locaTion load bar lean
A and A1 are the overalldiagonal dimensions
1mm in 10mm
3mm
1.5m
m
Load bars1/10
0 of
wid
thW
idth
+/-
3m
m
Length + 0 - 3mm1mm in 25mm
TranSverSe bow
Span +/- 6mm
Wid
th (W
)+/-
6m
m
A
A1 = A +/- 6mmW
1 =
W +
/- 6
mm
W and W1 are thedimensions across Load Bars at oppositeend of panel
croSS bar alignMenT & Spacing
longiTudinal bow
STair Tread STair Tread end FlaT lean
Edge Bars and attachments are welded witha minimum 3mm fillet weld to one side of:Every 5th Load Bar on Series 1 GratingEvery 4th Load Bar on Series 2 GratingEvery 3rd Load Bar on Series 3 Grating
FabricaTion welding
ManuFacTuring ToleranceS
1000
mm
nom
inal
5mm
± 6mm centre to centre of crossrods measured randomly across 1500mm in length
1/20
0 of
leng
th
Load bars
1/10
0 of
wid
th
TerMinology/gloSSary
Cut OutGrating areas removed from panel to permit passage for installa-tion of pipes, plant and structural and handrail items.
PenetrationsAs for cut out but typically within the grating panel and not on the edge.
SerrationsSmall notches made in the top edge of the load bar to assist in slip resistance.
Kick PlateHeavy section flat bar welded to ends or sides of panels and around cut outs, etc. when specified. Top edge to be 100mm above grating generally and is typically 130 x 6.
NosingA member attached to or on the leading edge of a stair tread or at the top of a flight of stairs to assist slip resistance and to give a clear visual indication of the start of the flight.Can be• Floor Plate• Yellow Abrasive
12
graTing parTS
BandedRefers to the process of welding a flat bar (normally 5mm) to the loadbars after they have been cut to size to provide a uniform appearance around all sides of a grating panel. This process also helps prevent injury from laceration during installation and assists in keeping the panels flat.
Cut to Size OnlyRefers to the process of leaving the panels with a raw cut edge and not banded as described above.
Exact SizeRefers to the requirement to make the panels to an exact dimen-sion and not to be adjusted to the nearest width across the standard pattern of the load bars.
Gross AreaThe total area of a panel based on its width and span (regard-less of cut outs) as shown above. This area is always used when calculating invoices.
WidthOverall dimension of a panel measured at right angles to the load bars. Always called “Width” even if greater than the length.
SpanSpan refers to the lenght of a panel along the load bar, as shown above.
Load BarLoad bars are the flat metal bars which are the basis of grating
Cross BarA square bar twisted to form
This is a twisted square bar forged into the top of the load bar.
proceSSeS
opTional FeaTureS
MeaSureMenTS
13
oTher ServiceS
FTF provides a variety of services catering to the metal services industry including;
Stanchions & HandrailingFirst Time Fabrications handrail and balustrade system with its wide range of standard components forms an economical, strong and simple form of handrail and balustrade. FTF can supply stanchions either loose or in prefabricated panels to your specific needs, providing you with safe access to all areas. We can provide stanchion/prefabricated panels in galvanised steel, aluminium or stainless steel to suit your requirements.
General FabricationFTF can also provide light to medium General fabrication works and processing involving highly repetitive type works.
Conveyor/Safety GuardsFrom fully enclosed units to simple side guards with mesh FTF has expertise in the manufacture of conveyor/safety guards, providing a cost effective alternative to manufacturing them in house, leaving you to focus on your core business manufacturing.
Pipe BendingFTF has extensive experience in pipe bending, we can provide most types of bends required and can cope with high volume bending projects.
Pipe/Plate RollingFTF can provide rolling services for both mild steel plate and pipe, contact your FTF rep for more information on our capabilities.
FTF ManuFacTuring“caTering To all The MeTal ServiceS induSTry”
14
FTF capabiliTieS
capabiliTieS
Bandsaw
Bandsaw
Dual Head Pipe Bender
4 Head Stanchion Drill
Cropper
Pipe Rollers
Presses
Semi Auto Hydraulic Cold Saws
Pipe Bender
Dot Peen
Cosen 300NC Bandsaw Pipe Dream
First Time Fabrication
Ph (08) 9452 7806Fax (08) 9459 9956
Unit 3, 2 Baltic CourtMaddington 6109 WA
FRPFibre Reinforced Plastic (FRP) grating is a moulded, one-piece fibreglass reinforced plastic grating, available in standard panels or fabricated into panels of the shape you require to fit your floor.
HandrailingFirst Time Fabrications handrailing system is an economical, strong and simple form of handrailing. Specifically manufactured to suit Australian Standards and conditions, it is equally at home in industrial, commercial, municipal and general applications.
iTreadiTread is a tough walkway system designed for aggressive environments. Use it to safely access rooftops, access platforms, factory environments: all those hard to reach destinations it might otherwise be too dangerous to venture.
Designed to be lightweight and easy to handle, iTread is simple and quick to install. Manufactured from robust aluminium alloy this walkway system is strong, and best of all, the system is corrosion and maintenance free. Versatile, resilient, and built to last, iTread is the single solution to your walkway needs.