GRP on Site: Simplifying Installation and Handling for Construction Teams
Introduction
Material choice on a construction site is not just about long-term performance — it is about how quickly, safely, and efficiently it can be delivered, positioned, and fixed in place. For many construction teams, handling heavy steel components or awkward timber sections comes with logistical and safety challenges that affect both programme and cost. Glass Reinforced Plastic (GRP) is increasingly recognised for its ability to simplify installation processes, reduce manual handling risks, and allow rapid assembly without specialist tools or heavy machinery.
While often evaluated for its corrosion resistance and long service life, GRP’s benefits during the construction phase are just as significant. This article examines how its light weight, pre-fabrication potential, and ease of cutting and fixing can support contractors on site — with real project examples showing how GRP can improve build efficiency.
Lightweight, High-Strength Advantage
Pultruded GRP profiles can be up to 75% lighter than steel and around 30% lighter than aluminium, while still delivering tensile strengths up to 240 MPa. This strength-to-weight ratio means structural elements can often be lifted into position manually, reducing reliance on cranes or telehandlers. For site teams, this translates into:
● Fewer lifting plans and reduced need for specialist lifting equipment
● Lower risk of injury during handling
● Greater flexibility in sequencing installation, as smaller teams can move components without waiting for plant availability
In the refurbishment of Poole’s Wharf pedestrian bridge, GRP Deck 500 panels were carried by hand to the installation point without plant hire. This allowed the works to progress without lane closures for lifting equipment, keeping both the programme and costs under control.
Pre-Fabrication for Faster Assembly
GRP components are often supplied cut-to-size or pre-drilled, reducing the need for on-site modification. When changes are required, GRP can be cut using standard hand tools fitted with diamond-tipped blades, avoiding the need for hot works permits or specialist metal fabrication equipment.
This flexibility proved valuable during the installation of GRP mesh fencing for Network Rail, where pre-fabricated panels were delivered to exact measurements. When minor adjustments were required on site, they were completed in minutes with portable tools, avoiding delays to the possession schedule.
Fixings and Jointing Without Complexity
GRP can be joined using mechanical fixings or bonded connections, with no need for welding, galvanising, or corrosion protection treatments post-installation. Mechanical fixings can often be installed with battery-powered tools, which is particularly beneficial in remote or difficult-to-access locations.
For example, in coastal infrastructure projects, such as the installation of GRP structural profiles for the Copenhagen Kastrup Airport blast wall, components were bolted into place quickly, avoiding prolonged exposure of site teams to harsh weather.
Reduced Site Disruption and Programme Time
Shorter installation times can have a knock-on effect on safety, cost, and client satisfaction. In live environments such as rail stations, substations, and busy pedestrian areas, the ability to install without heavy plant and within limited working windows is critical.
GRP’s combination of light weight, pre-fabrication, and ease of fixing has enabled overnight or weekend works to be completed within short possessions, reducing the impact on operational activities. This can be a deciding factor for clients where downtime or public access disruption is costly.
Compliance and Standards for Site Use
GRP used on construction sites must still meet structural and safety standards, including BS EN 13706 for pultruded profiles, BS EN 4592 for industrial flooring, and BS 476 Part 7 Class 2 for fire performance where relevant. Anti-slip surfaces should comply with BS 7976 to ensure safe working areas during installation and in the final application.
By sourcing GRP from manufacturers that can provide this certification, contractors can demonstrate compliance during handover, reducing the risk of remedial work or disputes.
Conclusion
GRP’s advantages extend well beyond its in-service performance. On site, its lightweight nature, ease of handling, rapid assembly, and compatibility with standard tools can reduce programme time, improve safety, and simplify logistics. For construction teams under pressure to deliver on time and on budget, these benefits can make a measurable difference to project outcomes.
By considering GRP early in the design and procurement process, contractors can select systems that not only perform for decades but also support a safer, faster, and more cost-effective build.
