The main difference between the Polycast 600 and Polycast 700 series products is a frame.  Both systems utilize the same polymer concrete pre-sloped channels, the same end caps and installation hardware.  However, when a 700 frame (cast iron or HDPE) is used with a 600 series channel, the system is instantly transformed into a 700 series channel which is capable of much higher load ratings when using a cast iron grate.  For instance, a standard Polycast 600 channel with a ductile iron grate (DG0641D) is capable of class D loading, which should be able to withstand an eighteen-wheeled tractor with trailer.  When that same channel/grate combination utilizes the DG0700aa cast iron frame, the system is able to withstand the 747 jumbo jet at your local international airport, which requires a class F loading.  If you use the high density polyethylene frame (DG0700PE) in this scenario, the load class changes to class E, which is appropriate for fork truck traffic.

A recent addition to Polycast’s grating options is the DG0675HD ductile iron grate.  This product, shown above, is ADA compliant and heavy duty enough to be used in heavy load applications.  Though it is a slotted grate, it doesn’t look as industrial as standard slotted grates.  And, while not technically heel-proof, the narrow openings of this grate make it very “heel-friendly”.  The longitudinal slots help define this grate as ADA or wheelchair compliant, I feel that this grates slots give it a sleeker look which make it a more attractive option for residential drainage applications.  When used with one of the 700 series frames, the system gains both strength and aesthetics which make it an ideal selection for commercial and streetscape applications.

For applications which require a higher degree of aesthetics, ADA compliancy and higher load ratings, Polycast has their new decorative cast iron product line.  They have joined the ranks of manufacturers such as, NDS, Iron Age Designs, Zurn and Polydrain (ABT) that have decorative cast iron grating offerings.  Finally!!!  In the world of pre-sloped, commercial grate trench drain products, Iron Age is the leader in ornamental trench grating (who, by the way, make most of ABT’s decorative grates).  Zurn has a small, and somewhat boring collection of decorative grates that they sell at a premium.  NDS developed a handful of economically priced products which have not really been promoted as well as I feel they should be.  Now, “better late than never”, Polycast has developed four grates which are appealing to the eye and handsomely priced.  Let’s take a look-see.

The photo above shows the Abbott (DG0693) and the Spiral (DG0694).  The Abbott is geometrically floral and harkens to an earlier time when mosaics and repeating geometric patterns dominated architecture.  It is a solid bodied grate that will stand the tests of time.  The Spiral pattern is a more eloquent pattern that is reminiscent of ancient Greece.  The thin top webbing is supported underneath with a structural mesh.

Above are two more Polycast decorative grating options:  Patriot and Cobblestone.  The Patriot (DG0692) is my favorite of all the Polycast patterns.  It displays the “stars and stripes” theme which is a common revolutionary war era design.  I expect to see this used in the historic districts of Boston and Philadelphia.  Likewise, the Cobblestone design (DG0695) is an old style pattern suitable for a stone driveway or fieldstone house.  Both grates are rugged and offer an added component of grace to the streetscape or estate where they are used.

There is another important point to bring up about these grates.  They fit exclusively in the Polycast 600 and 700 series trench drains.  This is important because I feel that the Polycast system is the best polymer concrete, pre-sloped channel drain on the market.  There are plenty of other commercial grade drain products in the same class.  But, in my humble opinion, the patented installation hardware and longer channel lengths of Polycast make it the easiest to install while offering the best value for the money.

For cut sheets and literature on the grating product discussed here, download the available drawings embedded throughout the article.  If you’d like a quote on a Polycast trench drain system, contact Trench Drain Systems (TDS) at 866-570-2333 or visit them on the web at www.trenchdrain.biz.

Ultimately, we decided to custom paint the grate and use it as a decorative planter stand for our office plant life.  It really came out beautifully…  I’ve included details on the process with photos below:

The first stage was to create a base coat that would be the natural color of the grate.  The paint I used was gray enamel designed to protect metals against rust.  After spraying an initial layer, I returned to coat the corners and crevices – just to ensure that there would be no rust-vulnerable area on the grates.

The grate dried in the sun for several hours until the paint was no longer soft.  Then we baked it at low heat (150 F) in an electric oven for 15 minutes so that the paint hardened.  Because paint is simply pigment suspended in a bonding agent, paint relies on a long evaporation process to become dry. The theory in baking the grate was to reinforce that process.

I wanted my final background to be bright and have a clean surface to show through, so I painted the grate white.  It took a few touch-ups here, too, to make sure that I had an even coating.  I baked the grate again and let it cool before continuing.

Early on the grate’s design, I’d decided on a blue-to-green gradient background that had a separation at the locust branch.  The effect suggests shadows underneath the branches and a blue sky.  The background shown below is different from the final product because it lacks the gradient dynamic of the blue paint (I forgot to photograph the final background before I began detailing).

With the background complete, I was able to begin detailing the leaves and stems.  This was the most was the most time consuming aspect of the project.  I worked with oil-based paints (bright yellow and red) to create a highlighting which gives the grate a Japanese anime effect.  You can see me at work in the photos below.  (Note:  Cleaning the brushes from this oil-based paint was a chore until I learned to use acetone.  It works like a charm but gives off a lot of fumes, so be careful!)

Once my artwork was complete, I gave it one final bake in the oven just to make certain it was dry and hard.  At this point, I could have given it a coating of clear enamel, but I was too anxious to put my new creation to use.

The final phase of my project was attaching felt pads to the bottom of the stand.  This is important in protecting the wood table from the heavy plant stand.  The grate used to make the stand is cast iron and weighs a hefty 18 pounds.  I used six ½ inch diameter pads that I purchased from the local hardware store.  They also had rubber bumpers that I considered using.  I felt that the “felt” would work better for this application.

Just take a look at the finished product below!  Wowzer!!  This was a fun project.  This locust grate is available in a 20” x 40” size, as well.  I’ve seen a coffee table made from this larger locust grate.  And, I have my eye on a sun grate that looks like it would make a nice wall hanging.  It makes me wonder about how many uses there are for these ornamental grates.  Email me, Hannah@trenchdrain.biz, with your ideas if you can think of other uses for any of the Iron Age ornamental grating products.  If you have photos of something special you have done, send those, too.  I’d love to see your work.

One of MEA’s trench drain product lines is called “Meadrain”. Meadrain’s polymer concrete channel drains are available in 1 and ½ meter lengths, are of varying widths and are made with an assortment of integral metal edging. There is also a broad assortment of grating options available for each of the Meadrain channels. The photo to the left is the Meadrain Z1000 with a galvanized steel channel edging.

The EN2000 channel (shown right) is another example of integral metal edging. This is a popular product in the US and Canada. Neutral sloped channels are 8” wide and are available in three depths: 11”, 13” and 15”. The polymer concrete channels have “male-female” butt jointing features that make installation easier.

A typical 11” deep, one meter channel is 82 pounds in weight. Each channel has a knock-out for a 6” bottom outlet. Two sloped sections are available which are used for making “stepped fall” runs. Stepped fall sections make a transition between 11”-13” and 13”-15” deep channels.

The ductile iron channel edging is a distinctive feature of the EN2000. It helps protect the polymer concrete from deterioration during use. The edging is designed to accept standard bolt-down grates or MEA’s patented ProFix grate locking mechanism. ProFix grates have a pre-attached spring steel locking mechanism that snaps into recesses in the ductile iron channel edge.

Likewise, the solid polymer concrete end caps and end outlets have ductile iron edging. This is a feature not available in similar ACO trench drain products. MEA is one of the few manufacturers that still make end caps and outlet out of polymer concrete with the integral metal edging, as opposed to plastic.

The EN2000 is used in applications where heavy wheel loads will be frequent and where occasional large volumes of run-off water can occur. Food processing plants, maintenance facilities and fire stations are a few of the locations where a slotted ductile iron grate is commonly used as a trench cover in these conditions.

Decorative Options for the EN2000

The EN2000 can also be used in residential and commercial driveways where heavy wheel loads may occur or where the owner wants to create a vision of elegance and style. The ductile iron edging of the channel provides a nice border that accents the drain and separates it from the remainder of the driveway entrance. To help in adding the desired aesthetic, Iron Age Designs has developed two decorative grates that fit the EN2000 channel: Oblio and Greek Key.

One of the Iron Age patterns, named Oblio, is shown above in a Meadrain EN2000 channel. These custom grates measure 9” x 19.75” and weight 28 lbs each. The Oblio comes with holes that line up with the threading portion of the channel edging so the grates can be bolted into place. Typically, Iron Age grating is sold in the raw cast iron state. But, shown above, is a special finish call a “baked on oil finish” (or BooF). The baked on oil finish is an added cost that is growing in popularity, especially because it is both less expensive and longer lasting than a painted or powder coating.

The Greek Key pattern is the other Iron Age Grating that fits the MEA EN2000 channel. This version of the Greek Key pattern has a very tastefully designed border of what could be called “spears and shields”. Regrettably, this border does not appear in Iron Age’s 5” wide version of the pattern and, I believe, makes a big impact on the style and elegance of the grate. The Greek Key grate is shown here in its raw cast iron state. You can compare uncoated cast iron surface to the baked on oil finish of the adjacent Oblio grate.

In this article, I’m not going to discuss grate pricing.  Contact www.trenchdrain.biz  for product pricing.  I am going to show you 10 ductile iron ornamental grating products manufactured by Ironage Designs.  The designs are unique and creative.  All the grates are ADA (American Disability Act) compliant and are strong enough to be used with vehicular traffic.  Each grate displays a casting quality and detail that could someday be architecturally significant in identifying a style used in the early third millennium.  More importantly, each grate is made to fit a trench drain channel size that has become the industry standard.  And, to this point, I will briefly discuss trench drain channel standardization in the United States market. 

Let me begin by sharing a little history.  ACO was the first prefabricated, pre-sloped polymer concrete trench drain manufactured in the United States and, possibly, in Europe.  When  the ACO Group (of Germany) first introduced their trench drain product line to the US market, they kept the metric dimensions used in Europe, having a standard channel length of 1 meter (approx. 40 inches) and the standard interior channel width of 100 millimeters (or about 4 inches).  A cast iron grate to fit this channel is about 4.8” x 19.6” (or 122mm x 498mm).

ACO was very successful in the US market and quickly became the company to emulate.  For instance, ABT developed a 1000mm x 100mm polymer channel to compete with ACO called PolyDrain.  Plumbing giant Josam began distributing MEA products (also from Europe), which we currently know as the Mea-Josam product line.  Even plumbing fixture company J.R. Smith licensed ACO technology to develop their Smith/ACO polymer concrete channel and EnviroFlo HDPE channel product lines.  Other manufactures followed suit.  All of these products have a 1000 mm (1 meter) polymer concrete channel with a 100 mm interior width.  In essence, this channel sizing has become the industry standard in the US, although there are other trench drain manufacturers, such as Zurn and Polycast, that have ignored the “me too” mindset and gone their separate way with the dimensions of the products they developed.

All this market imitation has led to a “standardization” of trench drain channel sizing, at least in the smaller products.  All of the 1 meter x 100mm channels will support, essentially, the same grates between brands.  Companies like ACO have tried to devise quick grate locking technology to separate themselves from the other manufacturers.  But, in the final analysis, all these channels can accept grating from competing manufacturers. 

This grating interchangeability and the “coming of age” of surface water control in the United States have allowed IronAge Designs to develop a niche product line.  IronAge has developed a number of attractive ornamental grates that measure 5” x 20” and fit the ACO, MEA, Polydrain and JR Smith 100mm wide channels.  

IronAge is constantly adding to their product line.  In fact, the Riverrock pattern shown at the beginning of this article was added to the IronAge product line after all my photographs were taken.  It is difficult to keep up with their complete product offering because they are always working on new projects.  Their growing product line is an indication of their respected designs and their affordable pricing structure.

I’m not going to give specific pricing on these grates, but I will say they are roughly twice the price of a standard slotted ductile iron grate.  Every grate you see in this article is the same price, though.  There is not one grate more or less expensive than another in this product grouping.

 As mentioned previously, these grates are made of ductile iron. Manganese bronze or brass grating can be made in one of these patterns if you want, but be prepared to pay 5 times the price of a standard iron grate.

Of the 10 grate patterns shown above, the Interlaken is the most versatile.  I’m saying this because IronAge uses this pattern in a number of catch basins and other size trench grating.  So, if you wanted to build a drainage system in your hardscape with more options than a single width trench drain, you will have more drainage structure options available if you use the Interlaken pattern.  The Locust leaf pattern and Oblio are two other patterns that come in different sizes.

If you have questions on any of these products, or want to have your own pattern developed, please contact a drainage specialist at TrenchDrain.Biz by calling 610-638-1221.  You can email us at sales@trenchdrain.biz.  Product cut sheets are available at www.ironagegrate.com.

Dura Slope™ is the brand name for a pre-sloped plastic trench drain system manufactured by National Diversified Systems (NDS). The channels have a 5” interior width and come in 4 foot lengths. The grates that fit this system are 6” wide and 24” long. The system has a built-in 0.7% channel slope that helps keep water flowing out of the drain. Catch basins and heavy duty frames are available for this system. Grating options are also available that will rugged enough for fork truck traffic or tender enough for bare feet on a pool deck.
Plastic grating is a popular option for the Duraslope™ system. Two styles are shown below. The slotted plastic grates are available in seven (7) different colors. Perforated plastic grates are only available in light gray. Slotted galvanized steel and perforated stainless steel grates are also available, as are ductile and grey iron slotted grates (cast iron).

A few years ago, cast iron grates for the Dura Slope™ channels only came in a standard black slotted style. However, this has changed with their introduction of the DecoGrate line of powder coated decorative grates. Five (5) new ductile iron grate styles are now available and can be purchased in any of 10 different color options. All grates are rated for class C loading and are ADA compliant. No other grate manufacturer offers the broad selection of grate style and color. Congratulations NDS!!!

Below are the photos of the new grate styles with an example of the bold colors they offer. I’ve also put a standard black slotted grate in here for comparative purposes.

Now let’s look at another manufacturer of decorative grating for the Dura Slope™ channel. Ironage Designs has built a respectable product line of ornamental grates that fit existing trench drain systems. For NDS’s Dura Slope™, they have two products: Interlaken and Locust.

You can get these grates in your choice of color powder coatings. However, Ironage Designs doesn’t stock any pre-coated grates. You may be better off purchasing the grates yourself and have a coating applied by a local paint shop prior to installation. Nevertheless, I really like the quality of the grates produced by Ironage. They are a sturdy, 15-16 lbs. in weight. The detail of the design and the quality of the relief are remarkable.

No matter, with the Dura Slope™ trench drain channels you have both decorative grating options and color selection. The Dura Slope™ product line is technically solid and will go toe-to-toe with other pre-sloped plastic channel systems, such as Zurn’s Perma-Trench Z886. These products are available at your local NDS distributor and the trench drain supplier Trench Drain Systems.

I have to be honest. My interest in decorative trench drain grating is for material gain. I am looking for products to sell that give my customers selection and quality. The standard slotted and perforated grating, though functional, can get boring. I have had customers looking for products that give them a “look” that is in keeping with the theme of the house or community. Sometimes, galvanized steel slotted grating just doesn’t cut the mustard. Let’s discuss three manufacturers of ornamental or decorative grating.

Ironsmith— I’m starting with them for a purpose. This is a foundry in Palm Desert California with an additional manufacturing point in Mexico. They have a number of ornamental trench drain grating products. They advertise that they used 100% recycled materials to make their castings. I counted 8 different grating styles. However, only 3 of these had any “curviness” in the design (I like curviness). Most grate styles were some variation of a standard slotted or perforated ADA grate.

The Ironsmith products are available in 4, 6, 8, and 12 inch wide grates. In addition, you are able to purchase grates in iron, aluminum or bronze. So the variety is good. They also have 12” x 12” catch basin grates and tree grates. And, if that was not enough, you can purchase the frame and trench to use when forming a trench drain system.

The folks at Ironsmith are nice people to work with. They are eager to help. Their prices are affordable for the west coast. I had difficulty getting an affordable product from them to sell on the east coast. Nevertheless, they seem to have a good product. For more information, go to www.ironsmith.biz.

Urban Accessories — I think these guys are the oldest of all the existing ornamental grate foundries in the US. Urban Accessories was founded in 1972 by an architect who was inspired by the vision of Louis Sullivan to enhance the urban environment. This is the Tacoma, Washington foundry that I promoted in my “Black Hill Trench Drain” blog entry. I also saw products of theirs in the Epcott Center in Orlando, Florida.

Urban Accessories has a wonderful product line. Besides trench drain grates, they have a rich assortment of tree grates, bollards, building buttons, drain covers, manhole covers and more. You can purchase trench drain frames to go with their grates, as well. They have a nice catalog and good coverage with the architects who deal with hardscapes.

Too good to be true? Maybe so!!! I never had a very good experience trying to purchase product from these people. They were reluctant to work with me on requests for special items. I had a difficult time getting information from them or my phone calls returned. And, once I had made contact with my area sales representative, I didn’t feel confident that he really had all the knowledge required for this product line. In addition to all this, the prices for their products are very expensive. A reason for all of this is out there. Check out the next company.

Ironage — This is a new company that is making some waves in the industry. I think they are part of the reason that Urban Accessories seems “disorientated”. Apparently, a few of the top (and best?) Urban Accessories managers left and formed the new company – Ironage.

Compared to UA, Ironage’s product line is small. Don’t let this fool you. Their product line is growing, the design quality is great, and the marketing is the “missing link” in the industry. Listen to this…Where all other foundries have promoted a cast-in-place philosophy for trench drain marketing, Ironage has decided to make ornamental grating that fits the vast number of preformed or pre-sloped trench drain products that are currently on the market. If you want ACO, Mea-Josam, Polycast, Polydrain or NDS trench drain, you can still buy it and use the Ironage decorative grate. It is a wonderful idea!!
Affordable??? The answer is YES! Of all the companies I have mentioned in this article, Ironage is the most affordable. They have inventory on the east coast which makes the shipping of small orders even less costly. I’m excited about their future. Look them up on-line!

This summer, I had the opportunity to view more trench drain at various National Monuments. This time, I visited the Black Hills and viewed the trench drain marvels of Devil’s Tower and Mount Rushmore.

MOUNT RUSHMORE

I went to Mount Rushmore 25 years ago on my way to Field Camp (to study field Geology). At that time, it was foggy and I was unable to view the mount or see the faces of the four Presidents. If I recall, I was also driving with a friend from Panama (Juan Villanueva) in his brown 1976 Dodge Charger and camping under the stars. Ahh, to be 20 again… It didn’t matter that I was unable to see the monument. What I know now is that I wouldn’t have seen any trench drain!!!Since that time, the monument has undergone remodeling and has seen some wonderful improvements…..such as trench drain.

I have two photos……

The above photo is of a custom Stainless Steel Grate that was found in the lobby to the ampitheatre. Beautiful!! The square grate openings are either laser cut or stamp pressed. (My guess is laser cut) Big Buck Stuff!!! Kudos to the park. If anyone knows the maker, I’d like to find this out.

The drain shown below is from a company out of Washington State:  Urban Accessories. They have nice patterns of trench drain grates, which may be made in China. They have a good product line. I’ve quoted custom trench to jobs that had specified their grating. They seem to be good folk and have a nice niche in the industry. Their trench grating sure added a charming touch to the amphitheater stairs at Rushmore.

DEVIL’S TOWER

The first time I came to Devil’s Tower was shortly after the movie “Close Encounters”. Because of this, my first visit here was a pseudo-religious experience. I saw no little green men (at least from interstellar encounters) on this first visit. And, I don’t recall having as much fun then as I did this time hiking with my children and nieces. We took lots of photos and journeyed farther than we were allowed without being registered climbers. We even even had a mid-day lunch on the side of the sacred tower.

One of my favorite photos is of the “primitive” perforated steel grating found in front of the ranger station at the base of the tower. Again, this had to be a special made item (US tax $$$). And, though the holes are small and spaced far apart, they must allow enough water flow to make themselves useful. Besides, this is an arid region. I have no idea of the age of these grates, but I’m guessing that they were made before the age of pre-sloped, pre-formed polymer trench drain systems. Look at the imperfect hole pattern. Maybe the Park Department made these grates itself.

Many “Thanks” to the National Park System for preserving and maintaining the parks for all of us. If you haven’t gone to the Black Hills, I urge you to go. There are many, many more things to see than these two monuments. My children and I had a wonderful time……probably the best vacation of our life. And we only spent 4 days!