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GRP Step-Over Crossover System

Pre-fabricated crossover systems for hazardous and industrial environments.

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The Engineered Composites GRP Step-Over is a fully pre-fabricated crossover access system that allows personnel to safely pass over pipework, cable trays, conveyors, and low-level barriers without temporary scaffolding or metal fabrication. Every component, including the platform, stair sections, and tubular handrails, is manufactured from Glass Reinforced Plastic.

This makes the system suitable for chemical, coastal, rail, nuclear, and utilities environments where steel corrodes, requires repainting, or introduces electrical conductivity risks. The system arrives on site in bolted sub-assemblies, fully factory-assembled and inspected. Installation requires no welding, grinding, or specialist lifting. Two people can position, level, and fix the unit using standard anchor bolts.

GRP Step-Over

Why GRP Step-Over?

Corrosion-Free and Long-Lasting Body

GRP is inherently resistant to corrosion, chemicals, de-icing fluids, and salt air. Unlike steel, it requires no galvanising, no protective coating, and no repainting cycle throughout its service life.

Non-Conductive by Nature Body

GRP has zero electrical conductivity. In rail environments, substations, and cable-dense facilities, a steel step-over must be earthed or bonded. A GRP system requires no earthing and eliminates electrocution risk under fault conditions.

Pre-Fabricated and Ready to Install Body

All units are factory-assembled and inspected before dispatch. No welding, hot work permits, or specialist tools are needed on site. Two people can install the system in a short timeframe using the supplied stainless steel fixings.
  • Platform height range: 360 mm to 1,560 mm
  • Standard span: 1,000 mm or 1,500 mm
  • Inside width: 800 mm across all models
  • 100% GRP construction throughout
  • 14 standard sizes available, custom sizes on request
  • Handrail: pultruded GRP round tube, 50 mm nominal diameter
  • Grating: moulded GRP, bi-directional, 38 mm panel depth
  • Fixings: A4 stainless steel throughout
  • Standard colours: Safety Yellow handrail, Light Grey structure
  • Weight: approximately 75% lighter than equivalent steel
  • EN 13501-1 Class B-s1,d0 fire classification, independently certified
  • BS EN 13706 pultruded GRP profiles, structural grade
  • A4 stainless steel fixings, Grade 304 throughout, no galvanic corrosion
  • RISQS accredited supplier for the rail sector
  • ISO 9001:2015 quality management system certified
  • JOSCAR registered for defence sector procurement
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Non-Conductive and Entirely Free

No earthing required. Zero electrical conductivity throughout, safe for rail, substation, and cable-dense environments.

EN 13501-1
Class B-s1,d0

Independently certified fire classification for industrial, rail, and public infrastructure environments.

Up to 75% Lighter Than Steel

Allows two-person installation with no crane, reducing transport costs and structural loading concerns.

24 Year Design
Service Life

No corrosion, no repainting. Periodic visual inspection only, at significantly lower whole-life cost than steel.

Why Choose the GRP Step-Over?

Safe to Use in Electrically Hazardous Environments

Zero electrical conductivity throughout. No earthing, no bonding, and no additional electrical safety measures required.

Corrosion Resistance Without Protective Coatings

Inherently resistant to corrosion and most industrial chemicals. No galvanising, no recoating, and no surface treatment required.

Lightweight for Simple, Fast Installation

Up to 75% lighter than steel. A two-person team can install without a crane, specialist equipment, or heavy plant.

Pre-Assembled, Bolt-Together System

Factory-assembled before dispatch. No welding, grinding, or hot work permits required on site.

Zero Maintenance in Service

No repainting, no rust treatment, and no inspection of protective coatings. Visual inspection only throughout the service life.

Compatible With Detection Systems

Fully compatible with perimeter detection and monitoring systems. Lower sections can be buried for wildlife exclusion without specialist equipment.

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Technical Specifications

Parameter Specification
Profile material Pultruded GRP, E-glass fibre with isophthalic polyester or vinyl ester resin
Grating type Moulded GRP, bi-directional, 38 mm panel depth
Handrail tube Pultruded GRP round tube, 50 mm nominal diameter
Fittings Moulded GRP elbows, tees, and base feet
Fixings A4 stainless steel throughout: bolts, washers, and nuts
Fire rating EN 13501-1 Class B-s1,d0, independently certified
UV resistance Integral UV-stabilised polyester surface veil
Electrical conductivity Non-conductive, no earthing required
Corrosion resistance Inherently corrosion resistant, no protective coating required
Handrail colour Safety Yellow RAL 1023 (standard), alternatives on request
Structure colour Light Grey (standard), alternatives on request
Weight vs steel Approximately 75% lighter than equivalent steel system
Platform height range 360 mm to 1,560 mm
Standard spans 1,000 mm and 1,500 mm
Inside width 800 mm across all models
Standard sizes 14 models in standard range

Need a GRP Step-Over for Your Project?

Speak to our technical team for product selection, sizing advice, and compliance guidance. Custom spans, heights, widths, inclined approaches, and alternative colours are available on request.

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Standard Range Dimensions

Inside width is 800 mm across all models. Custom sizes are available for non-standard spans, heights, widths, inclined approaches, and wider platforms of 1,000 mm or greater.
Model Reference Span L (mm) Platform Height H (mm) Overall Height H1 (mm)
Stepover 1000 x 360 1000 360 590
Stepover 1500 x 360 1500 360 590
Stepover 1000 x 560 1000 560 790
Stepover 1500 x 560 1500 560 790
Stepover 1000 x 760 1000 760 990
Stepover 1500 x 760 1500 760 990
Stepover 1000 x 960 1000 960 1190
Stepover 1500 x 960 1500 960 1190
Stepover 1000 x 1160 1000 1160 1390
Stepover 1500 x 1160 1500 1160 1390
Stepover 1000 x 1360 1000 1360 1590
Stepover 1500 x 1360 1500 1360 1590
Stepover 1000 x 1560 1000 1560 1790
Stepover 1500 x 1560 1500 1560 1790
Note: Custom sizes available: Non-standard spans, heights, widths, inclined approaches, and wider platforms (1,000 mm or greater). Contact the ECL technical team with your project requirements.

Typical Applications for the GRP Step-Over

The GRP Step-Over is designed for any environment where personnel need to cross over low-level obstacles safely and where steel would corrode, conduct electricity, or require ongoing maintenance.

Rail & Trackside

Safe, non-conductive crossing over cable trays and trackside infrastructure.

Utilities & Water Treatment

Corrosion-resistant access over pipework, valve manifolds, and duct runs.

Chemical & Pharmaceutical

Resistant to aggressive chemicals where steel coatings would fail in service.

Electrical Substations

Non-conductive throughout, with no earthing required near live equipment.

Nuclear & Defence

Non-sparking and non-magnetic for sensitive and high-security installations.

Marine & Offshore

Withstands salt spray, UV, and constant moisture with no maintenance.

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Which Variant Do I Need?

The standard range is split into two assembly variants based on platform height. Both variants use the same GRP materials and stainless steel fixings. The difference is in the number of components and the assembly sequence.

Lower Height Models

or platform heights up to a certain level where a straightforward two-step build is sufficient. The kit includes two guardrail sets, two staircase sets, and one platform. Step 1 connects the platform and staircases. Step 2 assembles the guardrails. No support feet required.

Best for: compact crossings in constrained spaces, lower pipework, and cable trays close to floor level.

Mid to Tall Height Models

For taller platform heights where additional structural support and extended guardrail coverage are needed. The kit adds two support feet and two mid guardrail sections to the assembly. Builds in four steps, with anchor bolts strongly recommended for all permanent installations.

Best for: taller obstacles, mezzanine-level crossings, and permanent installations requiring maximum stability.

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FAQs About GRP Step-Over

What is a GRP step-over and what is it used for?

A GRP step-over is a pre-fabricated crossover access system that allows personnel to safely pass over obstacles such as pipework, cable trays, conveyors, and low-level barriers at floor or ground level. It is constructed entirely from Glass Reinforced Plastic, which makes it non-conductive, corrosion resistant, and lightweight. The system is used across rail, utilities, chemical, water treatment, nuclear, defence, marine, and construction environments where steel would corrode, require repainting, or introduce electrical conductivity risks.

Why should I use a GRP step-over rather than a steel option?

Steel step-overs corrode in wet, coastal, and chemically active environments and require galvanising, periodic repainting, and ongoing inspection to remain serviceable. In electrical environments such as substations and rail trackside locations, a steel unit must be earthed or bonded to manage fault current risk. A GRP step-over requires no earthing, no protective coating, and no repainting. It is up to 75% lighter than an equivalent steel fabrication, which simplifies installation and reduces transport costs. Over its service life, the whole-life cost of a GRP step-over is significantly lower than steel.

How many people does it take to install a GRP step-over?

Two people can install the system using standard hand tools. No welding, grinding, crane, or specialist lifting equipment is required. The Stepover 01 (lower height models) assembles in two steps: connect the platform and staircases, then assemble the guardrails. The Stepover 02 (mid to tall height models) assembles in four steps, adding support feet and mid-rail guardrail extensions. All connections use M8 stainless steel hex bolts, washers, and nuts supplied with the unit. Anchor bolts are strongly recommended for all permanent installations.

Are custom sizes and configurations available?

Yes. The standard range covers 14 models with spans of 1,000 mm or 1,500 mm and platform heights from 360 mm to 1,560 mm, with an inside width of 800 mm across all models. Custom options include non-standard spans and heights, wider platforms of 1,000 mm or greater, inclined stair approaches for uneven or ramped surfaces, and alternative colours such as safety orange, safety green, or a corporate RAL colour. The system is also compatible with ECL GRP walkway, grating, and handrail systems for integrated access solutions. Contact our technical team with your project dimensions.

What standards does the GRP step-over comply with?

The system complies with EN 13501-1 Class B-s1,d0 for fire performance, independently certified. Structural GRP profiles meet BS EN 13706. All fixings are A4 Grade 304 stainless steel throughout, with no galvanic corrosion between components. Engineered Composites is RISQS accredited for the rail sector, ISO 9001:2015 certified for quality management, and JOSCAR registered for defence and aerospace procurement.