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.

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.

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.

The job was located in the Pocono Mountains of Pennsylvania, earshot from the Pocono Raceway. The trench drain was to be installed in a new equipment storage facility. The floor of the facility was being pour at the same time as the drain in order to pitch the floor toward the drain.

Initially, the excavator roughed out a trench in which to install the drain. The site was already installed with gravel, but was not compacted.

(This will probably cause a problem in the future. The gravel base for trench drain and all concrete floor projects need to be compacted. This floor has an excellent chance of developing voids underneath the concrete in the future.)

The position of the drain was determined and a level line was set. Then, the trench was cleaned of debris to assure that the channels could be set without obstructions.

Next, the channels were set along side the trench in order that they would be installed. The highest number channel (deepest) was set at the discharge invert. The smallest channel number was set at the beginning of the drain flow path. For this particular installation, the channel protector and grates were both left in place. The grates were later protected with plastic sheeting prior to pouring concrete.

The discharge water was designed to exit the end of the drain through 4” PVC pipe. A hole was drilled through the foundation of the building for this pipe to exit. It was later tied into a drain pipe that took the water to a sewer.

Installation started with the deepest channel first, then proceeding upstream. The channels were connected to each other with an installation bracket and connected to ½” rebar (#4). This particular installation bracket is patented and used exclusively with the Polycast system. It makes installation easy. However, in this case, the installation would have been easier if the excavator hadn’t used so many large stones in the base. At times, large boulders have to be removed in order to hammer the rebar in the ground. No matter, the bracket was adjustable enough to line the channel up perfectly, even if the rebar stakes didn’t install perfectly.

From the photo to your left, you can get a better idea on how the Polycast installation chair works. Bolts from the installation chair fit into the “dimples” of adjoining channels to hold the channel tight. The bolts can adjust in our out to help align the channels left or right.  The chair can also be adjusted up or down on the rebar to keep the top of the drain (grate) on level.

Once the first few channels were put into place, the remainder of the installation went smoothly. The channels seemed to fall into the proper place when the installation chair was properly used. In the end, we had a 40 foot length of polymer concrete trench drain, suspended in air, and ready to be set in concrete.

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!

While checking out the monuments (and getting a little sentimental), I was able to look at some trench drain. Let me show you two that were interesting to me.

Trench Drain at the Lincoln Memorial Steps – These drains must have looked beautiful when they were originally installed at the base of the granite steps leading up to the Lincoln Memorial. Now they sport a handsome green oxidation coat, which means the original finish must have been a brilliant bronze or brass. These 4″ wide drains are filled with dirt and sediment, an indication that they probably are not pre-sloped. (Maybe, also, an indication of the maintenance budget.) I’m not certain they are really needed here, anyway.

The monument would probably look nicer if these drains were put into service again. Any volunteers to help clean these out?

Trench Drain at the Native American Museum – If you like Native American culture and artifacts, this museum has something for you. I was impressed with a number of aspects of the building’s architecture. The granite trench drain grates running through the courtyard and water sculpture areas, in particular, caught my eye.

These grates are probably the most expensive pedestrian grates I’ve ever seen. Let’s not even talk about the percent open space for efficient water drainage…… You can see they are ADA approved, but I’m not certain if they are heel proof. Are those holes 3/8″ diameter or smaller ???

No matter, the weekend was beautiful and educational. Maybe you have a unusual trench drain system or grate you want to share. Let me know. Thanks……………….  Michael