Hubbell, the makers of the Polycast trench drain product line, has been busy at improving its product lines.  The manufacturer recently introduced four new ornamental cast iron grating products which fit their Polycast 500 deck drains and Polycast 600 pre-sloped trench drains.  In addition to these, they have also begun offering a heavy duty ADA compliant ductile iron grate that can be used with their 700 Series product line to achieve a class F load rating.  These new grates are a welcomed addition to their current full selection of standard commercial grating options.

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.

Fiberglass has become a popular grating option for trench drain.  As the price of stainless steel increases, fiberglass is filling the material gap because of its resistance to corrosion, its high strength, and its easy fabrication.  Also, more people are turning to fiberglass as a alternative grating because it has little secondary scrap value and is less likely than is cast iron to be stolen for recycling.

In general, there are two methods used to form fiberglass grating:  molded and pultruded.  The molded fiberglass forming method is usually used for making mesh grating and involves a jig that is the size of the desired final product.  Fiberglass thread is arranged and stretched within the mesh shaped wall recesses of the jig before adding a polymer bonding material.  If desired, an abrasive sand-sized material can be applied to the surface at this time to form a non-slip surface.

Molded fiberglass is made in large sheets (4′ x 8′) that are cut to size to make trench grating.  The load capabilities of mesh grating will be a function of the grate’s thickness and the open area that the grate will span.  Generally speaking, molded fiberglass is used for pedestrian and some light traffic applications.  It doesn’t have properties that would allow it to be a drop-in replacement for heavy duty cast iron.  However, a 12″ wide grate of 1.5″ thick molded fiberglass mesh (1.5″ x 1.5″) has the strength to hold a 2830 pound/sq. ft. load.  (See above.)

Fiberglass grating made from the “pultrusion” method (pulling + extrusion) is strong enough to be used in structural applications.  This forming method involves pulling fiberglass reinforcing through an extrusion die, which simultaneously applies binders, heat and protective coatings to the bar or rod-shaped component.  When this method is used for making I-beams, it can rival the functionality of conventional steel.   In the case of grating, pultruded bar grating has potential to replace cast iron grating of the same dimension, though not at the same price.  To manufacture pultruded grating, fiberglass bar stock is cut to size and fabricated into large sheets with a frequent cross-member supports.  The cross members impart a weakness to the grating.  While the grate is strong on its own merits, and the cross members help to concentrate that strength, if a vehicle’s wheels turn too abruptly while on the grating the cross members can be weakened and compromise the grate’s overall strength This can be an issue in some high traffic applications.

For most common trench drain applications, fiberglass grating isn’t required.  Galvanized steel and cast iron grating are the materials of choice when load capabilities are the main grating requirement.  When corrosion resistance becomes the most important design criteria, the materials of choice are stainless steel, high density polyethylene and fiberglass.  Thereafter, the cost and specific details of the application will dictate which material is best to specify.

Polymer concrete trench drain systems are one of the most common pre-fabricated trench drain systems available in the marketplace.  Each manufacturer offers a fiberglass grating option for their channels.  Hubbell, the manufacturer of the Polycast brand, offers two fiberglass grates that fit their Polycast 500 and 600 polymer concrete channels.  Both grates are bar grating made in the “pultrusion” method and have an added slip resistant top coating.  The difference between these two grates is only in the bar spacing.  The standard fiberglass bar grate, DG0644, has bar spacing on 3/4″ centers which allows it to be used in light automotive applications (Class B).  A heavy duty version of this grate, DG0644SP, uses the same fiberglass bar sections at a 3/8″ spacing.  This tighter bar spacing provides added strength which enables this grating to handle heavier loads (Class C).

For all fiberglass grating, a special locking mechanism is required to keep it secure in the trench drain channel.  This locking device, shown below, is made of stainless steel.  It works by strapping the cross-members of the grate to a center toggle attached to the channel.  Attachment to the cross member keeps the locking device below the surface of the grate and out of the way of traffic above.

Trench Drain Systems (TDS) manufactures a molded fiberglass grate to fit the Polycast and Dura Slope trench drain product lines.  This grating, 4 foot long and 3/4″ thick, has a slip resistant top surface.  And, while it is strong enough to handle light automobile traffic, it is meant for residential use only.  Since it is made from a molded fiberglass, it isn’t designed to be locked down to the channel.  Its uses are best in corrosive or frequent clean-out applications that see only foot traffic, such as kennels or small maintenance facilities.

There are many manufacturers of trench drain.  Trench Drain Systems handles most of them.  Custom fiberglass grating is also available through Trench Drain Systems.  For further information on fiberglass grating and how it can be used in your trench drain application, contact Trench Drain Systems at 866-570-2333.  Or, email us at sales@trenchdrain.biz.

There are a number of trench drain manufacturers that sell 4 inch wide (100 mm) polymer concrete channels. In general, each manufacturer offers two grades of channel – “ residential and commercial.”  Hubbell, the maker of Polycast Trench Drain, is one of these companies. In this article, their residential product, 400 series, is compared to their commercial grade product, 600 series.

The photo to the left compares a 2 foot long section of a  Polycast 400 series (left) and 600 series channel (right). Both products are made from the same polymer concrete composition, which is a mixture of silica sand and epoxy resin. This material, while taking on some of the polymaic properties of the resin, displays the compressive strength of a concrete due to the high amount of silica sand. And though the material has the compressive strength which allows it to withstand heavy traffic while in service, it behaves as a ceramic and will crack upon impact or if dropped prior to installation.
Both channels have a similar 4” interior width and are available in 2 foot and 4 foot lengths. And from a functionality point of view, in low flow, low load applications both products perform equally. Most residential driveway applications would fall into this category.

Some of the differences between the 400 and 600 series are apparent in the above photo. Wall thickness of the 600 series is greater, which allows for heavier load bearing capabilities. Also, the channel end of the 600 series has a more integral male-female connection than does the 400 series product. Additionally, the grate used on the 400 series rests on top of the channel, while the 600 series channel actually has a recess within the channel for the grate to lie. However, a major difference between the two products is that the 400 channels are all non-sloped, while the 600 series channel are pre-sloped. The pre-sloped character of the 600 channel insures that water flows more quickly, thus allowing for higher overall flow rates. 600 Series channels can still be purchased without slope and are needed when designing complex drainage systems.

The 400 series product comes with a Class B galvanized steel slotted grate and is capable of withstanding loads from most automobiles. This is the only grating option. With the 600 series, you get a wider selection of grating options. You can get a Class B galvanized steel slotted grate, shown below. Or, you can upgrade to a cast iron or ductile iron grate for heavier loads. Stainless steel grates are even available for applications in a corrosive environment. In fact, there are 19 different grates options and four frame option for the 600 series channels.

The frames available with the 600 Series include a galvanized steel channel protector (shown above). This is a steel edge covering that keeps the channel from deteriorating while in use and helps increase the load capabilities of the system. The channel protector is also available in stainless steel. For heavy load capabilities (fork truck or airline) a cast iron or high density poly ethylene (HDPE) frame is used to cover the channel prior to inserting a ductile iron grate.

A final comparison between these two products is price. The 400 series product is manufactured for economy. It is a light duty product that is easily manufactured due to its uncomplicated dimensioning. It has only one grate option. Because of this, it sells for approximately 30% less expensive than the comparable 600 series product.
With the 600 series, you get flexibility and value. Though more expensive than the 400 series, the 600 series allow for higher load capabilities which can be further improved by changing your frame or grate. The 600 channels are more expensive due to the sturdier and pre-sloped design. And, of course, your choice of grating will directly influence your final $/foot price, especially if your application requires a stainless steel grate.
For a quotation on the Polycast 400 or 600 series products, email michael@trenchdrain.biz or call Trench Drain Systems at 610-638-1221.