Enhancing Durability with 15% Weight Reduction Made Possible
A major player in the steel construction industry frequently operates in environments that expose structural components to harsh weather conditions. Among the critical elements used in their projects, steel guardrails presented recurring challenges related to weight, corrosion, and long-term maintenance. These issues were negatively impacting project timelines, safety, and overall operational costs.
Problem Statement
The steel guardrails used in various projects were found to be excessively heavy, increasing logistical complexity during transportation and installation. Moreover, due to constant exposure to environmental factors such as moisture and UV radiation, the steel components suffered from accelerated corrosion, leading to frequent repainting and premature replacement. The cumulative effect of these drawbacks led to increased project costs, extended downtimes, and compromised structural aesthetics and safety.
Arihant Composite’s Solution
To address these challenges, Arihant Composite provided a custom-engineered Fiber Reinforced Polymer (FRP) guardrail system. The solution involved the selection of a high-strength polyester resin with excellent mechanical properties and environmental resistance. The guardrail surfaces were designed with textured elements to enhance both tactile grip and visual appeal. Additionally, a water-resistant gelcoat skin was applied to protect against moisture ingress, UV exposure, and weathering. The entire system was tailored using project-specific FRP configurations to meet structural load requirements while ensuring long- term performance in harsh environments.
Cost and Performance Benefits
The introduction of FRP guardrails led to a 15% reduction in system weight, significantly easing transport and installation. The corrosion resistance of FRP completely eliminated rust-related degradation, resulting in an estimated threefold increase in service life. Maintenance costs were substantially lowered due to the elimination of repainting and reduced frequency of replacements. Overall, the customer achieved notable long-term cost savings and operational efficiencies.
Non-Financial Benefits
Beyond measurable cost reductions, the FRP guardrails offered several qualitative improvements. The anti-slip surface enhanced workplace safety, particularly in wet or high-risk environments. The clean, modern aesthetic of the gel-coated finish contributed positively to the visual quality of the final structure, improving both brand perception and user experience.
Conclusion
Arihant Composite’s custom FRP guardrail solution successfully addressed the client’s key operational challenges. The outcome demonstrated the potential of advanced composites to replace conventional materials, offering superior durability, reduced maintenance, and improved structural efficiency across steel construction projects.