Corrosion resistant grating protects Abu Dhabi depot

APPLICATION

Battery Storage Sump Flooring

LOAD CAPACITY

Up to 17.5 kN/m²

PROJECT DURATION

5 Days

Company background

Etihad Rail is the national railway network of the United Arab Emirates. Designed to help diversify the country’s economy in line with the UAE Vision 2021 and Abu Dhabi Economic Vision 2030 plans, Etihad Rail is responsible for linking major population centres in the UAE, both with each other and with other major cities in the Gulf region.

Construction of Stage One of the network was undertaken in conjunction with Deutsche Bahn, and completed in 2016. Construction of Stage Two is currently underway, involving 605 km of lines and a number of freight facilities. The project involves numerous partners across Europe and Asia, with construction having started in April 2020.

Project Challenges

Invicta was asked to design a corrosion-resistant, load-bearing solution for two battery storage areas in hazmat stores for the Etihad Rail Stage 2 project. As batteries would be stored in these areas for long periods, it was important that in the event of a battery acid leak, the acid would be freely able to flow and drain into the sump pit below, rather than allowed to build up on the batteries.

Technical Constraints

Due to the potential for damage inhibiting the performance of the solution, the gratings and profiles would need to be corrosion resistant against battery acid. They would also need to be load bearing (up to 17.5 kN/m²), and be designed in a way that allowed the battery acid to drain into the sump below. A traditional solution with steel grating and channels would be subject to corrosion from the battery acid, and require regular painting and maintenance.

Installed Solution

Invicta opted to install Dura Composites’ unique GRP (glass reinforced polymer) profiles and 38mm deep d2 grating to be able to meet both the corrosion resistance and load-bearing requirements. We were able to cut the profiles according to the different slopes of the sump/pit without compromising the strength of the system. Drainage holes were drilled into the profiles to allow any battery acid to drain through and into the sump, again without compromising the strength of the material.

Key Benefits

GRP profiles and gratings do not need to be painted for corrosion protection, reducing the need for regular maintenance. They are also lighter than equivalent steel profiles and gratings, making them easier to install and remove later for maintenance, relocation or recycling.