F1 Factory FRP Access Staircase — Built With Our Own Profiles

The Challenge

F1 Composite's Chongqing production base required a multi-level access staircase and intermediate platform linking the pultrusion line mezzanine to the fiber-creel area. The installation sits above the resin impregnation zone, where ambient humidity, resin vapor, and occasional chemical splash rule out painted carbon steel — historical galvanized steel stairs on this site needed re-coating every 18 months and still developed surface rust. The replacement had to be non-corroding, electrically isolating (live electrical cabinets are within 2 meters), fire-retardant to the factory's class, and installable over a 3-day shutdown window without hot work permits.

Our Solution

The entire stair system was engineered and built from F1 Composite's own pultruded FRP profiles — making this an end-to-end showcase of the product line our customers buy. Stringers and landing beams use pultruded FRP I-beams and square tubes in vinyl ester resin for chemical resistance; intermediate platforms use molded FRP gratings with anti-slip gritted top surface (AS 4586 R11 rating); handrails and kick-plates are built from pultruded FRP round tube and flat bar in safety-orange UV-stabilized polyester resin for maximum visibility. All connections use 316L stainless-steel bolts through pre-drilled FRP profiles — no welding, no hot work, no cranes. The modular design allowed 4 workers to complete assembly using hand tools within the 3-day window.

Results

The staircase and elevated platform have been in continuous service for 18 months with zero maintenance — no repainting, no tightening, no corrosion inspection required. Total installed weight is approximately 68% lower than the steel structure it replaced, which allowed reuse of the existing concrete pad without reinforcement. Because this is F1's own facility, we use this installation as a live reference for visiting customers — walk it, load it, inspect the connections, and see 18 months of real-world wear on profiles identical to what ships to your project.