Corrosion-Proof Infrastructure: GRP in Pump Stations and Treatment Plants
Introduction
Pump stations and water treatment plants operate in some of the most aggressive service environments in the utilities sector. High humidity, constant water exposure, and the presence of chlorinated or chemically treated water accelerate the deterioration of conventional construction materials.
For decades, steel and timber have been the standard choice for platforms, walkways, and safety systems in these facilities. However, these materials are prone to corrosion, rot, and ongoing maintenance requirements that increase operational costs. Glass Reinforced Plastic (GRP) is emerging as a preferred alternative, delivering corrosion-proof performance, long service life, and compliance with key safety standards.
The Corrosion Challenge in Water Infrastructure
Steel corrodes rapidly in damp or submerged conditions, even when galvanised or coated. The combination of constant moisture, chemical exposure, and temperature variation can break down protective coatings within a few years, exposing the metal beneath and compromising structural integrity.
Timber performs poorly in these environments without frequent application of preservatives, which adds cost and introduces chemical agents that can be undesirable in potable water facilities.
In contrast, GRP is chemically inert, meaning it will not rust, rot, or degrade when exposed to water or common treatment chemicals. This allows it to maintain structural performance and appearance without the need for regular coating or treatment cycles.
Case Study — Coastal Pump Station Upgrade
In a coastal pump station project, GRP gratings and handrails replaced corroded steel structures. The installation team was able to remove the old components and fit the new GRP sections in days rather than weeks, thanks to the material’s lighter weight and prefabricated sections. Since installation, the GRP components have required only routine cleaning, with no signs of corrosion despite constant exposure to saltwater spray and chlorinated water.
Safety and Compliance
Pump stations and treatment plants require materials that support both operational safety and regulatory compliance. GRP platforms and walkways can be manufactured with anti-slip surfaces to BS 7976 standards, reducing slip hazards in wet environments. Fire-retardant resin systems can achieve BS 476 Part 7 Class 2 performance where fire spread control is necessary.
Non-conductivity is another advantage in sites with electrical pumps, control panels, and lighting systems, eliminating the risk of stray electrical currents travelling through structural components.
Installation Efficiency
Many pump stations and treatment plants are located in confined or hard-to-reach areas, making the delivery and installation of heavy materials difficult. GRP’s weight advantage allows for manual handling in many cases, reducing or eliminating the need for cranes or lifting equipment. Prefabricated sections mean installation can be completed quickly, minimising site downtime.
Long-Term Cost Performance
Over the lifespan of a pump station or treatment plant, maintenance and replacement of corroded steel structures can be a significant recurring expense. Each maintenance cycle not only costs money but can also require partial shutdowns that impact service delivery.
GRP’s corrosion-proof nature eliminates the need for repainting, recoating, or replacing components due to rust or rot. Routine cleaning and periodic inspections are typically all that is required to keep the structure in service for its full design life, often exceeding 50 years.
For operators, this means predictable budgets, reduced unplanned outages, and improved overall efficiency.
Conclusion
GRP’s corrosion resistance, safety performance, and installation efficiency make it a natural fit for pump stations and treatment plants. By eliminating the ongoing battle against rust and rot, GRP enables water utilities to focus resources on service delivery rather than maintenance.
With proven performance in both inland and coastal installations, GRP is set to become a standard material choice for water infrastructure in the years ahead.
