Lightweight Anti-Slip Grating Design and Testing

Paper No. SPE-188686-MS
Creation of a
New Light Weight Grating
Bugs Tan PhD,
Malaysia University of Science and Technology
Mastek Oil Tools Sdn Bhd
MALAYSIA
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THE NEW LIGHT WEIGHT ANTI-SLIP GRATING
Creation of a light weight
anti-slip steel grating
Paper # SPE-188686-MS • Creation of a New Light Weight Grating • Bugs Tan PhD, Mastek Oil Tools MALAYSIA
LIGHT IN WEIGHT
BETTER INTEGRITY
COST BENEFIT
Slide 3 of 24

TURNING IDEAS INTO INNOVATIONS
Common Steel Grating Innovative Litewalk steel grating
Paper # SPE-188686-MS • Creation of a New Light Weight Grating • Bugs Tan PhD, Mastek Oil Tools MALAYSIASlide 4 of 24

PROJECT FLOW CHART
Description of activities Purpose
1 Development of conceptual design Creation of the profile and new design of the
components and grating panel
2 Finite Element Analysis (FEA) Optimization of the new design
3 Development of Prototype Load test to comply to industry standard
4 Corrosion Test Corrosion test to comply to industry standard
5 Filling of patent and trademark Protection of ideas
6 Commercialization Penetration into the marketplace
Slide 5 of 24

CONCEPTUALIZATION
Profile of common grating Profile of the Load Bearing Bar for Litewalk

The Finite Element Analysis on the design of Litewalk grating
SIMULATION
No. Description of the Test Computer Software Test carried-out
1.
A workstation to simulate the
Finite Element Analysis of
the Litewalk grating design
ABAQCUS/CAE 6.6
 Uniform distributed test
(UDL Test)
 Concentrated Load Test
(CL Test)
Slide 7 of 24

Purpose of the test is to:-
• Determine the deflection of the grating panel
• Deflection should not exceed 1/200 times (5mm) of the effective span or
10mm whichever is lesser
Standard complied to:-
• British Standard BS 4592 Part 1 : 1995
• Uniform distributed load (UDL) of 5kN/m²
• Concentrated load (CL) of 1 kN
OBJECTIVE OF THE SIMULATION TEST
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The performance of the simulation test on the load bearing bar
PARAMETER
Model 885-3515 920-3520
Width of grating panel (mm) 885 920
Height of load bearing bar 35
Width of load bearing bar 15 20
Thickness of load bearing bar 1.0, 1.2, 1.5, 1.8, and 2.0
Diameter of holes drilled at bar 6 mm NA
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DISPLACEMENT TEST RESULT OF FEA
FEA UDL t1.5 x w15 x h35mm load bearing FEA CL t1.5 x w15 x h35mm load bearing

DEVELOPMENT OF PROTOTYPE
Fabrication of the prototype Prototype model of the Litewalk grating panel

LOAD TEST CONDUCTED AT SIRIM
Concentrated load test of 1kN Uniform distributed load test of 5kN/m²

Results from 3 different exercise
SUMMARY OF THE LOAD TEST RESULTS
Load Manual
Calculation
FEA
Simulation
Test on
Prototype
Concentrated Load
(CL) 1kN
2.05mm 2.228mm 0.63mm
Uniform Distributed Load
(UDL) 5kN/m²
0.194mm 0.087mm 1.54mm
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SIGNIFICANT OF STUDY
• Although the result is within the deflection range allowable
• However, the result from the 3 exercises seems to be inconsistence.
• Recommendation
• More research work and load test
• Investigate and examine what could possible went wrong.
• It would bring benefit to the academia and the industry players,
• So people could fully understand the mechanical challenges for this type of project

Test procedure was carried-out in accordance to:-
• Alternative immersion ASTM G44-99 (2005)
Description of the corrosion test:-
• The purpose of the test to identify the form of corrosion
• Sample is dipped in 3.5% sodium chloride (NaCI) for 10 minutes
• then allowed it to dry for 50 minutes.
• Sample are visually examine at 200, 500 and 1,000 cycle interval
• Temperature at 27C ± 1 C and relative humidity of 45% ± 6%
CORROSION TEST
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The set-up of the corrosion test in a controlled environment
CORROSION TEST SET-UP
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BEFORE CORROSION TEST BEGINS
Data of the sample before the test commences
1 Temperature = room 27.3ºC and water was 26.5ºC
2 Humidity = 46.8%
3 pH value = 7.18 for both coated and uncoated
4 Weight of sample (dry) as follows:-
Sample before corrosion test commence
Specimens Coated /
Uncoated
Weight of sample
before test
Sample A Coated 2,758.88 gram
Sample B Coated 2,771.55 gram
Sample C Uncoated 2,794.79 gram
Sample D Uncoated 2,793.67 gram
Slide 16 of 24

AFTER THE TEST COMPLETED
Results after 1,000 cycles
1 Temperature = room 27.8ºC and water was 26.2ºC
2 Humidity = 45.5%
3 pH value = Coated 7.39 and uncoated 9.62
4 Weight of sample (dry) as follows:-
Sample after corrosion test completed
Specimens Coated /
Uncoated
Weight of sample
after test
Sample A Coated 2,762.07 gram
Sample B Coated 2,774.71 gram
Sample C Uncoated 2,880.05 gram
Sample D Uncoated 2,883.18 gram
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Conclusion
• After 1,000 cycles (about 42 days) of alternative immersions , the coated
Litewalk grating sample are found to be resistant to corrosion.
• However, the uncoated Litewalk grating samples are physically corroded
CONCLUSION OF THE CORROSION TEST
Specimens Coated /
Uncoated
Weight before test Weight after test Weight different
Sample A Coated 2,758.88g 2,762.07g -3.19g
Sample B Coated 2,771.55g 2,774.71g -0.16g
Sample C Uncoated 2,794.79g 2,880.05g -85.26g
Sample D Uncoated 2,793.67g 2,883.18g -89.51g
Slide 18 of 24

SUMMARY OF THE FINISHED PRODUCT
• This new product has significant advantages
over the traditional (common) steel grating.
• The 4 major advantages are:-
• A lot lighter in weight
• Grating panel is stronger
• Cost benefit
• It has a true anti-slip feature
Litewalk grating used on process facility

1) A grating panel that is light in weight
• The load bearing bar is hollow section
• It enables the overall grating panel to reduce in
weight significantly.
• Litewalk steel grating is lighter than common
steel grating of the same grade by up to 35%
• This lightness in weight will benefit the overall
structure
Litewalk being used on oil platforms

2) A grating panel that can take more load
• Design of the load bearing bar is hollow
• Yet, the integrity on the grating panel remained
intact.
• Litewalk grating can take 12% more load than
common steel grating of a same grade
Litewalk grating use at chemical plant

3) Cost benefit
• It consumes approximately 35% less raw
material to manufacture
• Cost of manufacturing is lower
• This cost saving is passed down to the
consumer…
• making Litewalk grating panel competitive in
price
Litewalk being used on walkways

4) A grating panel that is safer to walk-on
• The design of a hollow section bar allows the
creation of the embossed ring on the upper part
of the load bearing bar.
• These round rings provides a good anti-slip
traction on the foot wear.
• A person’s body mass weight is transferred to his
footwear
• thus naturally giving him a good grip when he
walks on the Litewalk grating panels.
Embossed rings that gives you a good grip

We would like to thank our research collaborator
UNIVERSITY of MALAYA, Kuala Lumpur
Thank You!
I’m pleased to take your questions
Bugs Tan PhD, Mastek Oil Tools MALAYSIA
bugs@mastek-ot.com.my
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Lightweight Anti-Slip Grating Design and Testing

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