POLYCAST Product Lines
(Manufactured by Hubbell)
Polycast 400 Series
The Polycast 400 Series is a 4" wide, neutral slope polymer concrete system designed for use in a variety of residential applications. Consider using this product in your driveway, sidewalk, patio, or tennis court to help quickly drain storm water away. It can be used with both light vehicle and pedestrian traffic. Its galvanized steel grates have narrow openings that won’t catch on wheelchair or bicycle tires.
Polycast 400 Series features include solid and open end caps and installation chairs that prevent the system from "floating" during installation. Channels are available in two and four foot lengths. Each 4 foot long channel has a 4" bottom cutout in the event your project requires a bottom outlet.
The polymer concrete channel construction of the Polycast 400 ensures that it is three times stronger than ordinary concrete and is resistant to salts, acids and alkalis. The smooth interior surface prevents debris from clogging, making water drainage more efficient.
Additional product information on the Polycast 400 is available for your viewing. Follow one of the following links to view a Polycast 400 Bulletin, Polycast 400 Cut Sheet, or an article comparing Polycast 400 with a similar commercial grade Polycast product.
Polycast 500 Series
The Polycast 500 Series is a neutral sloped, low profile polymer concrete trench system that was designed specifically for applications which had depth restrictions. With an overall height of 2.5" and a channel depth of 1.75”, it is designed for above shallow grade applications like parking decks and roofs where deep excavation is prohibited.
Polycast 500 channels have a 4 inch wide channel made in four foot lengths, and each channel offers a bottom knock-out to connect with piping. The channel end caps are all solid. Grating is available in fiberglass, galvanized and stainless steels. Reinforced and cast iron grating can be used if accompanied by a Hardnose® framing system. Otherwise, the system is meant for pedestrian and light vehicle traffic. Polyguard channel edge protectors can be used with the 500 series and are available in stainless and galvanized steel.
Polycast 500 channels are made with the same high quality polymer concrete that has helped make Polycast a leading trench drain manufacturer. Polymer concrete is three times stronger than ordinary concrete, is resistant to salts, acids and alkalis, and is available in polyester and vinyl ester compositions.
Polycast 600 Series
Polycast 600 Series is the workhorse of the Polycast Product line. This pre-sloped polymer concrete system has a 4.25” wide interior width and a sturdy wall construction designed for high compressive loads commonly seem in commercial and industrial uses.
Grating options for this system are extensive, ranging from perforated galvanized or stainless steel for pedestrian traffic to slotted ductile iron for semi truck traffic. All grates are 5.25” in width. Most grating is in 2 foot and 4 foot lengths. Locking mechanisms are available for each grate type.
The 600 Series features include an optional steel rail to protect the concrete edges of the channel from the chipping caused by heavy traffic. Channel sections are sloped, but half channels and neutral channels are available. Special bottom cutouts come in some four foot channels and all half channels. Flow rates of up to 470 GPM are possible with the Polycast 600 product line.
The polymer concrete channel construction ensures high compressive strengths and resistance to salts, acids and alkalis. The smooth interior surface prevents debris from clogging, making water drainage more efficient. For high temperature or extra corrosive applications, channels can be made from vinyl ester based polymer concrete.
Polycast 700 Series
POLYCAST 700 is an impact and wear resistant trench drain system that builds on the success of the POLYCAST 600. Using the same pre-sloped polymer concrete channel, POLYCAST 700 reinforces the channel edges with a Duraguard® or Hardnose framing system. The Duraguard® frame is used with the POLYCAST 700PE system and is made from durable high density polyethylene, which provides extreme chemical and impact resistance. The Hardnose framing system is used with the POLYCAST 700AA system and is made from cast iron. This heavy duty frame increases the effective strength of the channels when using a grey or ductile iron slotted grate. With either framing systems, heavy fork truck traffic can be achieved (Class E loads). With the Hardnose cast iron frame and a ductile iron grate, FAA and Class F loadings can be achieved.
Polycast 800 Series
POLYCAST 800 is a high volume system that has an interior width of 8" and an exterior width of 12", making it double the width of the POLYCAST® 600 Series. The 800 series is designed for applications where high water flows and heavy traffic are expected, such as loading docks and driveway entrances. Bolt down cast iron grates are available in either slotted or solid covers. These channels can be fitted with fiberglass grating that is capable of handling loads experienced with semi-trucks.
800 Series channels are made in four foot lengths with interlocking butt jointing. All channels are neutral, but a grade can be built into the concrete slab during installation to create a sloped effect in the system. The system has three end cap options: closed, 6" outlet or 8" outlet.
POLYCAST 800 is made from polymer concrete. You can choose from either polyester (standard) or vinyl ester (high temperature) channel compositions, which ensures that it is three times stronger than ordinary concrete and is resistant to salts, acids and alkalis. The smooth interior surface prevents debris from clogging, making water drainage more efficient.
Polycast 900 Series
POLYCAST® 900 is a 6" pre-sloped polymer concrete trench drain build specifically for transportation applications. Like the 700 series, POLYCAST® 900 uses the channel body of the 600 series and a specially designed frame and grate. In this case, however, the frame is made with a more rugged design and the ductile iron grate has a high open area specifically made to handle large water volumes. The polymer channels still have the same 4.25” interior width and 470 GPM maximum flow capabilities, but the special features are in the frame and grate design, which make it approved for use in DOT applications.
There are two grating options for the POLYCAST® 900 series.
DG0900 Non-removable Grating
The bulk of gratings designed for highway strip drains are non-removable. That is to say, the grate and frame are one piece which is set firmly into concrete during installation. This is important for safety. A removable grate could potentially come loose and leave the channel exposed to high speed traffic. The DG0900 grate is 16” in length, 14 pounds, and has 41 sq. inches per linear foot of open area (60%). The anchor tabs of this grate are part of the ductile iron casting construction and contribute to the high ultimate strength. The heavy duty grate is designed to support dynamic wheel loads in excess to AASHTO H-20 and federal specification AA-60005E. Because of the 16” length of these grates, 3 units are needed per each 4 foot POLYCAST® channel.
Removable Grating (DG0970 and DG0941D)
Removable grating is used in highway strip drainage in areas where access is required for cleanout. This cleanout area may be over a catch basin or over a channel earmarked as an access point for a particular section of drain. The DG0970 Frame and DG0941D grate are made for this application. Each part is 24” in length and is made from ductile iron. The frame is designed with 4 long anchors which keep it firmly set in the concrete. The grating is made with a high open area (60%) and a sturdy bolt down locking mechanism. Together, the frame and grate weigh 22 pounds. They also exceed the AASHTO-H20 and AA-60005E specifications.
Polycast 3000 Series
The 3000 Series is a high volume system with a unique bulb shape that, in combination with the system's 1% slope, creates more efficient water flow rates that can remain constant for 120 feet. Flow rates of 3000 GPM are achievable with proper installation and slope, making the system a great choice for applications with open areas that gather large amounts of water and need quick drainage.
POLYCAST® 3000 channels are 8 feet long and come with a galvanized or stainless steel frame to add durability. Channel couplers lock channels together and restrict movement during the pour. The system channels do not need extender panels, as other products would, because it is designed to maintain a continuous slope for up to 120 feet. The system has end caps with cutout options and bottom outlet adapters to channel water runoff into PVC piping.
The pultruded fiberglass channel construction is reinforced with polyester resin, ensuring that the system is heavy duty and has a water absorption rate of less than 1%. The fiberglass channels create strong walls which will not collapse from pressure during installation.
The new POLYCAST FP800 Series is a heavy duty 8" fiberglass trench drain built for high volume, commercial-industrial applications. Featuring thick fiberglass channel walls and an integral iron frame, the FP800 Series handles load classes C-F. The non-removable frame is built to reinforce the surrounding concrete slab's strength by preventing air pockets from forming in the cement during installation. Durable grating, built to meet airport and roadway criteria without decreasing the open area of the grate, increases the utility of the drainage system.
Designed with convenient installation in mind, the FP800 Series offers 120' of continual slope. Ninety degree elbows as well as t-sections following the system's slope add a level of flexibility to any designed layout. With 6"-10" end and bottom outlets, the drain is ready to handle high volume water runoff efficiently.
The chemical resistant fiberglass channels of the 12" FP1200 Series are thicker than competition, making them more durable and longer lasting than other fiberglass drains on the market. With a non-removable iron frame and heavy duty grates meeting government criteria for airports and roadways, the system if further reinforced to handle the demanding environments found in transport and industrial areas.
The FP1200 Series gives you durability and flexibility in one drainage system. Pre-sloped channels can run for a continuous 120' at 1% slope at a rate of over 6,500 GPM. Ninety degree elbows and t-sections enable the installer to create complex layouts to accommodate any project specifications. To evacuate large water flows, outlets ranging from 6"-10" are available as either bottom or end adapters.
The POLYCAST Trench Drain product line has a number of accessories. Catch basins, installation chairs, extender panels, edge protection, channel adapter, end caps and locking devices are all components that may be needed in your trench drain system.
POLYCAST® catch basins are manufactured with high strength corrosion resistant polyester or vinyl ester polymer concrete. They are designed to be used as collection points, drain run transitions and interceptors to collect solid debris. They are designed to accommodate all drain channel sizes and have cutouts designed specifically for channels with catalog numbers ending in 5,0,N and H. POLYCAST® catch basins can be used with a drain system or can be used as an individual point drain. They are available in 3 sizes, 11 gallons (6.25” wide), 17 gallons (12” wide) and 46 gallons (24” wide). Debris baskets are available for the 6.25” and 12” wide basins.
Installation Chairs are a patented feature of the POLYCAST® product line that contributes to ease of channel installation. Each chair is used to help secure the butt-joint of the channels during installation. However, it also aids in leveling the channel (on rebar) and allows adjustments to level channels laterally for straightness. By using the installation chairs, double pour installations are eliminated, resulting in quick turn-around times.
POLYGUARD edge protectors
POLYGUARD edge protectors are galvanized or stainless steel strips that cover and protect the exposed channel edges of the 600 series. Not only do they give the channel a cleaner look, but they help keep the channel from damage from impact or freeze thaw exposure. POLYGUARD is not required, but will help your POLYCAST® 500 and 600 series last longer.
For more information on these and other POLYCAST® accessories, download the complete POLYCAST® catalog or contact one of the sales professionals at Trenchdrain.biz by calling 610-638-1221.