This article takes an in-depth look at metal grating.
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Metal grating is a type of grid made from metal sheets that are either perforated or combined to form a lattice structure. It's commonly utilized in various sectors for stairs, platforms, scaffolding, and protective barriers. The production techniques for metal gratings include processes like expansion, perforation, shaping, and welding.
The inception of metal grating was intended for improving ventilation in underground areas to prevent overheating and maintain hygiene. In World War II, it gained prominence as a rapid solution for constructing runways and emergency surfaces, often termed as "magic carpets."
When creating metal gratings, factors such as thickness, bar dimensions, opening patterns, load capacity, and the specific environment of installation are considered. Its adaptability allows for both standard sizes and tailored designs to accommodate the specific requirements of different applications. Often, custom designs are necessary to meet the unique demands of each installation.
Nearly any metal can be used to make metal gratings. The most common types are iron, carbon steel, aluminum, and stainless steel. Metal gratings are commonly used as a non-slip safe surface for applications that require a secure work platform.
Metal gratings come in a wide variety of patterns, designs, and configurations, some of which integrate steel grating with steel plates. These gratings can be produced through methods such as welding, press-locking, or combining with metal plates, and they are designed to withstand demanding and harsh conditions.
Engineers and designers focus on creating metal grating solutions tailored to the specific requirements of a structure. They take into account factors such as thickness, dimensions of the metal bars, and the arrangement or pattern of the openings, which can vary in shapes like oval, square, and diamond.
When designing metal gratings, considerations include the amount of light, air, and sound that needs to pass through, as well as the visual impact of the grating. Heavier gratings are typically constructed from welded steel or pressure-locked bars to ensure durability.
Expanded metal grating is named for its production method, which involves creating slits in a metal sheet and then stretching and expanding the sheet to form a diamond-shaped pattern. The finished sheets can be cut to meet specific application requirements. Various metals can be used to produce expanded metal gratings.
Standard expanded metal grating provides a slip-resistant surface, while flattened expanded metal grating is processed through cold rolling to achieve a smooth finish. Non-flattened expanded metal grating retains a raised surface to enhance traction.
Bar metal grating is the most familiar type of metal grating, typically visualized in discussions about this material. It features parallel bars joined by perpendicular bars through various methods, with welding being among the most prevalent. Other joining techniques include riveting, close meshing, and press locking.
The joining method used depends on the metals involved. Bar metal grating, often made from aluminum or steel, boasts a high strength-to-weight ratio and is commonly used in industrial flooring. Its robustness and durability also make it suitable for applications like fire escapes, street drains, and bridges.
The many names for wire mesh metal grating include wire fabric and wire cloth. It is a form of grating that has rows and columns of intersecting wires. It is very easy to install, exceptionally durable, and has applications in many industries. The flexibility, versatility, and variations of wire mesh metal grating have made it extremely popular.
Wire mesh metal grating can be either welded or woven, based on the manufacturer's process. In welded wire grating, intersections of columns and rows are fused together. Woven wire grating, on the other hand, is interlaced like fabric, with columns and rows crossing over and under at their junctions.
Perforated metal grating is produced by stamping, punching, or deforming metal sheets by placing holes in them of a specific size, pattern, and shape. The metal sheets are made of exceptionally sturdy metals, including stainless steel, carbon steel, and aluminum. The perforations are placed in the metals by rotary pinning, die punching, and laser cutting.
Perforated metal grating serves a diverse range of applications, such as reducing noise, facilitating ventilation, and providing screening solutions.
Safety grating is designed to offer a stable, skid-resistant surface to enhance traction and reduce the risk of slips and falls. It typically features diamond-shaped protrusions to improve grip. To further enhance safety and allow for effective drainage and airflow, safety metal grating includes large openings. The improved traction is achieved through serrated edges on the diamond patterns, which are formed using cold stamping techniques.
Compound metal grating integrates two types of grating, such as bar grating and steel plate grating. It features a checkered plate bonded to the surface of steel bar grating, with steel plates ranging from 0.12 inch to 0.24 inch (3 mm to 6 mm) in thickness.
Available in various sizes and materials, compound metal grating can include wire mesh, multiple layers of bar grating, or perforated grating. Heavy gauge steel is used to prevent deformation during the zinc coating process.
Press locked metal grating is a type of bar grating characterized by its joining technique, where the perpendicular and parallel bars are notched and pressed together, resulting in a smooth, uniform surface.
This joining method provides an attractive finish that complements architectural designs. Press locked metal grating is offered in steel and aluminum, with a range of sizes and bar openings available.
The term "grating" refers to any covering or frame designed to cover openings, provide support, serve as a platform, or offer protection. Grating can be made from a diverse range of materials, including various robust plastics and durable metals like steel and stainless steel. When selecting a grating material, key considerations include its intended use, required strength, and whether it needs to enhance the aesthetic of a structure.
Metal gratings are utilized in various settings for safety and protection. They are especially common in airports, industrial sites, and manufacturing facilities due to their exceptional strength and durability.
Aluminum metal gratings are known for their malleability, corrosion resistance, and ductility, as well as their thermal and electrical conductivity. They are lightweight, non-toxic, non-magnetic, and resistant to bacterial growth. Aluminum gratings maintain their toughness even in extreme cold. Their appealing appearance contributes to their popularity in both industrial and decorative applications.
Light-duty steel metal grating is designed for pedestrian use and light rolling traffic, including carts and hand trucks. It typically comes as bar metal grating, which can be produced through methods such as swaging, riveting, dovetailing, or welding. Often made from carbon steel, it features load-bearing bars with perpendicular crossbars and an open grid structure. Its cost-effectiveness and low maintenance requirements make it a popular choice for highway platforms, safety barriers, and machinery floors.
Several grades of stainless steel are used for producing metal grating, which include grades 304, 304L, 316, and 316L. Stainless steel metal grating is exceptionally strong, long-lasting, and capable of withstanding corrosive, humid, and high moisture conditions. It is produced using a wide variety of bar sizes using swage or welding methods.
Stainless steel grating is particularly well-suited for use in water treatment facilities, chemical processing plants, and oil and gas production due to its exceptional durability. Its resistance to harsh weather conditions and extreme temperature fluctuations makes it an ideal choice for these demanding environments.
Galvanized steel is carbon steel coated with zinc to prevent rust and corrosion. Similar to stainless steel, it is well-suited for outdoor use or in highly damp environments. The zinc coating wears away gradually, prolonging the lifespan of galvanized steel gratings.
Most galvanized steel gratings fall under the B load class, capable of supporting up to 28,000 lbs or 125 kilonewtons (kN), according to Deutsches Institut für Normung (DIN) standards.
Heavy-duty carbon steel metal gratings feature deeper and thicker bars joined at high temperatures to create a robust and secure connection. Designed to support substantial loads, this type of grating provides excellent performance and durability over many years.
The production of grating varies based on the materials and manufacturing techniques used. Common methods include welding, dovetailing, stretching, and swaging, with welding being the most frequently employed. The choice of method depends on factors such as material thickness, weight, and the intended use of the grating.
Regardless of the chosen manufacturing process, selecting the appropriate metal is the initial step. This decision is guided by the environmental conditions and the required strength and durability of the grating.
Expanded metal grating starts with metal sheets that have diamond-shaped cuts. This process involves cutting diamond-shaped slits into the metal while stretching the sheets in a single operation.
During the piercing and stretching process, expanded metal grating develops a raised surface with consistent bonds and strands angled relative to the plane of the metal sheet. This results in a grate with notable strength and rigidity. For applications needing a smooth surface, the metal sheets can be flattened between rollers.
Non-flattened expanded metal grating, also known as raised metal grating, features a three-dimensional appearance due to its angled or bumpy texture. This design enhances its strength and rigidity. It is used in various applications, including platforms, walkways, protective panels, speaker grills, and fluid or air filters. The key advantage of non-flattened grating is its contribution to structural strength and stability.
Swaging is a cold metalworking technique that deforms metal to fit precisely into another metal component through applied force. In the production of metal gratings, the process starts with load-bearing metal bars spaced evenly for structural integrity and design. Tubular bars are then placed across these load-bearing bars at regular intervals and are joined using electrode welding. The depth and spacing of the bars can be adjusted based on the intended application of the grating.
Dovetailing is a traditional manufacturing technique used for centuries to join different materials. In metal grating, this process starts with precision slotting of the load-bearing and cross bars. The slots are meticulously cut to ensure a snug fit for the cross bars within the load-bearing bars.
Once the bars are correctly aligned, a hydraulic press is used to apply pressure, forcing the metal pieces into a permanent, secure lock. This creates a tightly connected, flat surface with enhanced rigidity. The dovetail design provides lateral stability and effective distribution of axial loads. Metal gratings with quarter-inch clean openings manufactured using dovetailing are often preferred in public areas where drainage and high-heeled traffic are considerations.
Welded metal grating is created through an electro-forging process, where rectangular load-bearing bars are welded to cross bars. This welding method results in a strong, durable connection between the bars. The thickness of the load-bearing bars in welded metal grating ranges from 0.125 inches to 0.5 inches (0.3175 cm to 1.27 cm).
Welded metal grating is one of the most widely used types, suitable for various applications. It can be left in its raw metal state or finished with options such as paint, hot-dipped galvanizing, enamel, epoxy coatings, or powder coatings for added protection and aesthetics.
Riveted metal grating is made using materials such as carbon steel, 6000 series aluminum, and 300 series stainless steel. The production involves riveting crimped flat bars in a reticulated pattern onto load-bearing bars. This method produces gratings with enhanced resistance to impact, fatigue, and heavy loads. The reticulated cross bars offer excellent strength and durability, making them suitable for applications requiring high stress and pressure endurance.
Metal gratings typically come with open ends but can be enhanced with banding—flat metal bars welded to the edges of grating panels. Banding improves the stiffness of the gratings and provides a finished, architectural look. It is essential for removable metal gratings to ensure safety during installation and removal.
For areas with motor traffic, banding is crucial to minimize impact loads on adjacent load-bearing bars and prevent deformation. Trench banding is an additional option where the band bar is positioned above the load-bearing bars in drainage applications, allowing for effective drainage while maintaining structural integrity.
Standard banding offers a uniform finish and aligns with the depth of the grating bars, welded centrally. Load banding features welds at each load-bearing bar to evenly distribute the load across the grating panel and provide a consistent end finish.
Various types of mechanical fasteners are used to securely connect metal gratings through friction. These fasteners come in different sizes and styles to accommodate the specific requirements of different metal grating forms.
Weld Lugs – Weld lugs are welded between the load-bearing bars such that the metal grating can be bolted to the supporting structure.
Industrial products, including metal gratings, are produced according to established standards. The two most widely recognized standards are those from the American National Standards Institute (ANSI) and the Deutsches Institut für Normung (DIN), also known as the German Institute for Standardization.
DIN uses a classification system from A to F, while ANSI provides classifications based on the specific applications and performance requirements of the metal grating.
ANSI standards categorize metal gratings into five groups based on their load-bearing capacity:
Light Duty – Suitable for loads under 2,000 lbs (900 kg), these gratings are designed for pedestrian traffic only.
Medium Duty – Capable of supporting loads ranging from 2,000 lbs to 5,000 lbs (900 kg to 2,250 kg), this grating is appropriate for light pneumatic traffic, sidewalks, and residential parking areas.
Heavy Duty – These gratings support loads between 5,000 lbs and 7,500 lbs (2,250 kg to 3,375 kg) and are used for commercial traffic and tractor trailers.
Extra Heavy Duty – Designed for use on roads, highways, and bridges, this grating has an H-20 load rating, supporting up to 10,000 lbs (4,500 kg).
Special Duty – Built to withstand airport traffic and loads of 10,000 lbs (4,500 kg) or more, these gratings are engineered for high-demand applications.
Load Class A – Designed for pedestrian traffic, Load Class A can support up to 3,370 lbs or 15 kilonewtons (kN).
Load Class B – Suitable for parking lots, sidewalks, and light vehicular traffic, this class supports up to 28,000 lbs or 125 kN.
Load Class C – For commercial use, Load Class C handles loads of up to 56,000 lbs or 250 kN.
Load Class D – This class is intended for very heavy-duty applications with an H-20 rating, supporting up to 90,000 lbs or 400 kN. It is suitable for use with forklifts, roads, bridges, and highways.
Load Class E – Capable of withstanding diverse manufacturing and transportation conditions, including high-impact steel struts and metal wheels, Load Class E supports up to 134,000 lbs or 600 kN.
Load Class F – Designed for airport traffic, Load Class F has a load-bearing capacity exceeding 200,000 lbs or 900 kN.
Metal grating is frequently used as a safety feature to offer a stable, secure, and firm work surface with excellent traction. Additionally, it can be utilized as a barrier to help prevent accidents in hazardous or unsafe conditions.
The choice of metal grating depends on the material used. Aluminum and stainless steel are ideal for corrosive and moist environments, while carbon steel provides the strength and durability needed for heavy-duty applications.
Metal gratings enhance the aesthetic appeal of various structures, including flooring, walkways, platforms, and mezzanines. Their safe, robust, and durable characteristics make them an excellent choice for adding both functionality and visual interest to any construction. The cohesive quality of metal gratings contributes to a sense of continuity while also serving as a protective barrier.
Metal gratings are utilized in water filtration systems due to their corrosion resistance and remarkable strength. Their efficiency is highlighted by their ability to process large volumes with minimal material usage and a long service life. Pressed metal gratings are particularly effective in capturing large debris, such as plastic bags and boxes, from water before further processing.
Metal grating is commonly used for flooring and can be crafted from various alloys to meet specific application requirements. Aluminum floor grates are ideal for marine and wastewater environments due to aluminum's lightweight nature, which makes them easy to handle and position in tight spaces.
Steel metal floor grating is typically employed in heavy-duty settings where strength and a rugged surface are essential. Production facilities rely on steel grating for its superior performance and safety in demanding environments.
Metal grating fencing combines an attractive appearance with the strength and rigidity needed for high-security applications. The secure connections between grating panels make it ideal for areas requiring protection from intruders. Metal grating fencing can be customized and fabricated to fit any site, ensuring a precise match to the location's dimensions.
Wire mesh is fabricated by the intertwining, weaving, or welding of wires of various thicknesses to create proportionally equal parallel rows and intersecting columns. Also known as wire fabric, wire cloth, or...
Expanded metal is a sheet metal mesh. It is made by stretching a slitted sheet of malleable metal. The orientation of the slits is perpendicular to the direction of the stretch. The result of such stretching is an array of holes on the slits - to give a mesh form...
Hardware cloth is a woven mesh made by interlacing various sizes of wire to form a metal fabric that can be used for animal cages, fence material, strainers, and filtering screens. The differences between the various types of hardware cloth...
The phrase "wire mesh" describes two- or three-dimensional structures constructed of two or more metallic wires connected by various techniques. In a wide range of settings, wire mesh products are...
Perforated aluminum consists of an aluminum sheet which has been manually or mechanically pierced or punched using CNC (computerized numerical control) technology in order to produce shapes and patterns of various sizes...
Perforated metals are sheets of metal that have had decorative shapes, and holes punched or stamped into their surface for practical or aesthetic purposes. The perforation of metal sheets takes several forms and includes a variety of geometrical patterns and designs...
A perforated metal is a piece of sheet metal that has been stamped, fabricated, or punched to create a pattern of holes, slots, and various aesthetic shapes. A wide range of metals are used in the perforating metal process, which include steel, aluminum, stainless steel, copper, and titanium...
Perforated stainless steel is cut, punched, or stamped to produce a precise pattern of holes or apertures. It is used for functional reasons, such as filtration or ventilation, and aesthetic ones, such as architectural accents...
Perforated metals are sheets of metal that have had decorative shapes, and holes punched or stamped into their surface for practical or aesthetic purposes. The perforation of metal sheets takes several forms and includes a variety of geometrical patterns and designs...
Welded wire mesh is a series of wires that are welded where the individual wires cross. The openings of the mesh varies depending on the type of wire used and the function of the mesh. Regardless of size and wire, welded wire mesh is permanent and...
Wire cloth is a woven (or nonwoven) sheet or web material with a series of openings across the surface. Wire cloth is also known as: Metal Fabric or Metal Cloth; Wire Mesh, Metal Mesh, or Alloy Mesh...