GRATING

FIELD OF THE INVENTION

This invention relates to a grating and a method of forming a grating.

BACKGROUND OF THE INVENTION

Grating is used for a number of end uses including walkways, concrete reinforcement, security fencing, drainage, and other similar uses. In the livestock or cattle industry, grating is often used to provide drainage for the livestock or cattle to stand or walk on.

One type of grating used in the cattle industry is formed from a fibreglass material. The fibreglass grating can be formed by attaching a plurality of pultruded bars together, or integrally moulding the grating. Fibreglass grating is typically provided with a textured surface to provide a non-slip surface. However, the textured surface often wears away after use.

Another type of grating used in the livestock or cattle industry is formed from high tensile steel. In use, the weight of the livestock or cattle causes the grating to deflect downwards. The grating returns to it original shape when the weight is removed. However, high tensile steel grating has a poor shape memory compared to fibreglass gratings. After years of use, with corrosion breaking down the grating, it becomes permanently deformed with failure and breakage in high load areas. As a result, this type of high tensile steel grating has a life expectancy of three to four years.

An object of at least preferred embodiments of the invention is to provide a grating and a method of forming a grating that is cost effective to manufacture from existing available materials, and/or to at least provide the public with a useful choice.

SUMMARY OF THE INVENTION

In a first aspect, the invention broadly consists in a grating comprising:

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a first plurality of elongate polymeric components extending generally in a first direction; a second plurality of transverse elongate polymeric components extending generally in a second direction transverse to the first direction;

5. a first plurality of elongate sinuous metallic components extending generally in the first direction; a second plurality of transverse elongate sinuous metallic components extending generally in the second direction;

^■ wherein the first plurality of elongate sinuous metallic components extend over at 0 least a majority of the second plurality of elongate polymeric components and extend under at least a majority of the second plurality of elongate sinuous metallic components, and the second plurality of elongate sinuous metallic components extend under at least a majority of the first plurality of elongate polymeric components and over at least a majority of the first plurality of elongate sinuous metallic components. 5

It will be appreciated that "over" and "under" are relative terms, and the product could be inverted or supported in a vertical configuration or at a different angle for example. Such configurations are encompassed by the present invention.

The term "comprising" as used in this specification means "consisting at least .in part of; that is to say -when interpreting statements in this specification which include "comprising", the features prefaced by this term in each statement all need to be present but other features can also be present. Related terms such as "comprise" and "comprised" are to be interpreted in a similar manner.

The first plurality of elongate polymeric components may be discrete components.

Alternatively, two or more of the first plurality of elongate polymeric components may be integrally formed.

The second plurality of transverse elongate polymeric components may be discrete components. Alternatively, two or more of the second plurality of transverse elongate polymeric components may be integrally formed.

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The Sist plurality of elongate sinuous metallic components may be discrete components. Alternatively, tvvo or mone of the first plurality of elongate sinuous metallic components may be integrally formed.

The second plurality of transverse elongate sinuous metallic components may be discrete components. Alternatively, two or more of the second plurality of 'transverse elongate sinuous metallic components may be integrally formed.

Preferably, the first plurality of elongate polymeric components extend substantially parallel to each other.

Preferably, the second plurality of elongate polymeric components extend substantially parallel to each other.

Preferably, the first plurality of elongate sinuous metallic components extends substantially parallel to each other.

Preferably, the second plurality of elongate sinuous metallic components extends substantially parallel to each other.

Preferably, the second plurality of transverse elongate-polymeric components extends substantially perpendicularly to the first plurality of elongate polymeric components.

Preferably, the second plurality of transverse elongate sinuous metallic components extends substantially perpendicularly to the first plurality of elongate sinuous metallic components.

Preferably the first plurality of elongate polymeric components extends substantially parallel to the first plurality of elongate sinuous metallic components.

Preferably, the second plurality of transverse elongate polymeric components extends substantially parallel to the second plurality of transverse elongate sinuous metallic components.

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The first plurality of elongate polymeric components may extend at any suitable angle to the transverse elongate polymeric components, such as between about 30 degrees to about 60 degrees, for example.

The first plurality of elongate sinuous metallic components may extend at any suitable angle to the transverse elongate sinuous metallic components, such as between about 30 degrees to about 60 degrees, for example.

The first plurality of elongate polymeric components may extend at any suitable angle to the first plurality of elongate sinuous metallic components, such as between about 30 degrees to about 60 degrees, for example.

The second plurality of transverse elongate sinuous metallic components may extend at any suitable angle to the transverse polymeric components, such as between about 30 degrees to about 60 degrees, for example.

Preferably, the first plurality of elongate polymeric components and the first plurality of elongate sinuous metallic components alternate along the length or width of the grating.

Preferably, the second plurality of elongate polymeric components and the second plurality of elongate sinuous metallic components alternate along the length or width of the grating.

Preferably, the elongate polymeric components are substantially straight.

Preferably, the elongate polymeric components are formed from a fibreglass material. Alternatively, the elongate polymeric components may be formed from other suitable materials such as a carbon fibre or aramid fibre material, for example.

Preferably, the elongate polymeric components have a substantially circular cross section. Alternatively, the elongate polymeric components may have an alternative cross section shape.

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Preferably, the elongate sinuous metallic components are formed from a steel alloy. The steel alloy may be a stainless steel, mild steel, carbon steel, or any other suitable steel. Alternatively, the elongate sinuous metallic components may be a different metallic material such as aluminium, or brass for example. 5.

Preferably, each elongate sinuous metallic component has a plurality of convex portions alternating with a plurality of concave portions with intermediate portions extending between the convex and concave portions. In a preferred embodiment, the intermediate portions extend tangentially and in a substantially straight line between the convex and 0 concave portions. In a preferred embodiment, each of the concave portions of each transverse elongate sinuous metallic component has an internal radius generally corresponding to the radius of the polymeric component and each of the convex portions has an internal radius generally corresponding to the radius of the metallic component. In a preferred embodiment, each of the concave portions of each of the first plurality of 5 elongate sinuous metallic component has an internal radius generally corresponding to the radius of the elongate sinuous metallic component and each of the convex portions .has an internal radius generally corresponding to the radius of the elongate polymeric component. ^• Preferably, generally square spaces are formed between the polymeric and metallic components. In a preferred embodiment, the spaces between the polymeric and metallic components are substantially square and have a width and length of about 19 mm.

Alternatively, the spaces formed between the polymeric and metallic components could be any other shape such as rectangular, for example.

Preferably, the grating is formed as one or more panels. Two or more panels may be joined together to form a larger grating.

In one embodiment, the ends of at least some of the elongate sinuous metallic components are shaped to receive an elongate joining component. In a preferred embodiment, the ends of at least some of the metallic components are curved to define an aperture to receive the joining component. More preferably ^' each ends is formed as a loop defining.an aperture to receive the joining component.

Preferably, the joining component comprises a bar or rod.

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Preferably, the joining component is formed from a polymeric material.

In a second aspect, the invention broadly consists in a grating comprising: a first plurality of elongate components extending generally in a first direction; a second plurality of transverse elongate components extending generally in a second direction transverse to the first direction; a first plurality of elongate sinuous components extending generally in the first direction; a second plurality of transverse elongate sinuous components extending generally in the second direction; wherein the first plurality of sinuous components extend over at least a majority of the second plurality of transverse elongate components and extend under at least a majority of the second plurality of transverse elongate sinuous components, and the second plurality of transverse elongate sinuous components extend under at least a majority of the first plurality of elongate components and over at least a majority of the first plurality of elongate sinuous components.

The first plurality of elongate components may be discrete components. Alternatively, two or more of the first plurality of elongate components may be integrally formed.

The second plurality of transverse elongate components may be discrete components. Alternatively, two or more of the second plurality of transverse elongate components may be integrally formed.

The first plurality of elongate sinuous components may be discrete components. Alternatively, two or more of the second first plurality of elongate sinuous components may be integrally formed.

The second plurality of transverse elongate sinuous components may be discrete components. Alternatively, two or more of the second plurality of transverse elongate sinuous components may be integrally formed.

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The grating may be polymeric and/or metallic.

Preferably, the first plurality of elongate components comprises a plurality of elongate polymeric components. Alternatively, the first plurality of elongate components comprises a plurality of elongate metallic components.

Preferably, the second plurality of transverse elongate components comprises a plurality of elongate polymeric components. Alternatively, the second plurality of transverse elongate components comprises a plurality of elongate metallic components.

Preferably, the first plurality of elongate sinuous components comprises a plurality of transverse elongate sinuous metallic components. Alternatively, the first plurality of elongate sinuous components comprises a plurality of transverse elongate sinuous polymeric components.

Preferably, the second plurality of transverse elongate sinuous components comprises a plurality of transverse elongate sinuous metallic components. Alternatively, the second plurality of transverse elongate sinuous components comprises a plurality of transverse elongate sinuous polymeric components.

In a preferred embodiment, the first plurality of elongate components and the second plurality of transverse elongate components, comprise polymeric components and the first plurality of elongate sinuous components and the second plurality of transverse elongate sinuous components comprise metallic components.

In an alternative embodiment, the first plurality of elongate components, the second plurality of transverse elongate components, the first plurality of elongate sinuous components, and the second plurality of transverse elongate sinuous components ^' comprise polymeric components.

In an alternative embodiment, the first plurality of elongate components, the second plurality of transverse elongate components, the first plurality of elongate sinuous

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components, and the second plurality of transverse elongate sinuous components comprise metallic components.

Preferably, the first plurality of elongate components extend substantially parallel to each other.

Preferably, the second plurality of transverse elongate components extend substantially parallel to each other.

Preferably, the first plurality of elongate sinuous components extends substantially parallel to each other.

Preferably, the second plurality of transverse elongate sinuous components extends substantially parallel to each other.

Preferably, the second plurality of transverse elongate components extends substantially perpendicularly to the first plurality of elongate components.

Preferably, the second plurality of transverse elongate sinuous components extends substantially perpendicularly to the first plurality of elongate sinuous components.

Preferably, the first plurality of elongate components extends substantially parallel to the first plurality of elongate sinuous components.

Preferably, the second plurality of transverse elongate components extends substantially parallel to the second plurality of transverse elongate sinuous components.

The first plurality of elongate components may extend at any suitable angle to the transverse elongate components, such as between about 30 degrees to about 60 degrees, for example.

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The first plurality of elongate sinuous components may extend at any suitable angle to the transverse elongate sinuous components, such as between about 30 degrees to about 60 degrees, for example.

The first plurality of elongate components may extend at any suitable angle to the first plurality of elongate sinuous components, such as between about 30 degrees to about 60 • degrees, for example.

The second plurality of transverse elongate sinuous components may extend at any suitable angle to the transverse components, such as between about 30 degrees to about 60 degrees, for example.

Preferably, the first plurality of elongate components and the first plurality of elongate sinuous components alternate along the length or width of the grating.

Preferably, the second plurality of transverse elongate components and the second plurality of transverse elongate sinuous components alternate along the length or width of the grating.

Preferably, the elongate components are substantially straight.

Preferably, the elongate components are formed from a fibreglass material.

Preferably, the elongate components have a substantially circular cross section.

Preferably, the grating is formed as one or more panels.

Preferably, the ends of at least some of the elongate sinuous components are shaped to receive an elongate joining component. Preferably, the ends of at least some of the elongate sinuous components are curved to define an aperture to receive the joining component. More preferably each ends is formed as a loop defining an aperture to receive the joining component.

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Preferably, the joining component comprises a bar or rod.

Preferably, the joining component is formed from a polymeric material.

In a third aspect, the invention broadly consists in a method for manufacturing a grating comprising:

(a) providing a first plurality of elongate polymeric components, a first plurality of elongate sinuous metallic components, a second plurality of transverse elongate polymeric components, a second plurality of transverse elongate sinuous metallic components;

(b) assembling the components so that the first plurality of elongate polymeric components extend generally in a first direction, the second plurality of transverse elongate polymeric components extend generally in a second direction and transverse to the first direction, the first plurality of elongate sinuous metallic components extend generally in the first direction and extend over at least a majority of the second plurality of elongate polymeric components and under at least a majority of the second plurality of elongate sinuous metallic components, the second plurality of transverse elongate sinuous metallic components extend generally in the second direction and extend under at least a majority of the first plurality of elongate polymeric components and over at least a majority of the first plurality of elongate sinuous metallic components.

The elongate polymeric components may be preformed as a grid, by moulding for example. However, it is preferred that the polymeric components are initially provided as discrete elongate members.

In a fourth aspect, the invention broadly consists in a method for manufacturing a grating comprising:

(a) providing a first plurality of elongate p'olymeric components extending generally in a first direction;

(b) providing a first plurality of sinuous elongate metallic components extending generally in the first direction;

(c) providing a transverse elongate polymeric component;

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(d) inserting the transverse elongate polymeric component between the first plurality of elongate polymeric components and the first plurality of elongate sinuous metallic components so that the transverse elongate polymeric component extends in a direction transverse to the direction of the first plurality of elongate polymeric components such that at least a majority of the first plurality of sinuous elongate metallic components extend one of over or under the transverse elongate polymeric component and at least a majority of the first plurality of elongate polymeric components extend the other of over or under the transverse elongate polymeric component; (e) providing a transverse elongate sinuous metallic component;

(f) inserting the transverse elongate sinuous metallic component between the first plurality of elongate polymeric components and the first plurality of elongate sinuous metallic components so that the transverse elongate sinuous metallic component extends in a direction transverse to the direction of the first plurality of elongate sinuous metallic components such that if said majority of the first plurality of elongate sinuous metallic components extend over the transverse elongate polymeric component then at least a majority of the first plurality of elongate sinuous metallic components extend under the transverse metallic component and at least a majority of the first plurality of elongate polymeric components extend over the transverse metallic component, and if said majority of the first plurality of elongate sinuous metallic components extend under the transverse elongate polymeric component, then at least a majority of the first plurality of elongate sinuous metallic components extend over the transverse metallic component and at least a majority of the first plurality of elongate polymeric components extend under the transverse metallic component; and

(g) repeating steps (c) to (f) to form a grating having a first plurality of elongate polymeric components extending generally in a first direction, a second plurality of transverse elongate polymeric components extending generally in a second direction transverse to the first direction, a first plurality of elongate sinuous metallic components extending generally in the first direction, and a second plurality of transverse elongate sinuous metallic components extending generally in the second direction.

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Preferably, the sinuous metallic components are preformed by bending a metallic rod or bar into a sinuous shape. Preferably, the metallic rod or bar has a substantially circular cross section.

Preferably, each elongate polymeric component is pre-notched, before step (a). The notches are spaced substantially evenly along the length of the elongate polymeric component.

Preferably, the method comprises assembling the components so that the first plurality of elongate polymeric components extend substantially parallel to each other.

Preferably, the method comprises assembling the components so that the second plurality of elongate polymeric components extend substantially parallel to each other.

Preferably, the method comprises assembling the components so that the first plurality of elongate sinuous metallic components extend substantially parallel to each other.

Preferably, the method comprises assembling the components so that the second plurality of elongate sinuous metallic components extend substantially parallel to each other.

Preferably, the method comprises assembling the components so that the second plurality of transverse elongate polymeric components extends substantially perpendicularly to the first plurality of elongate polymeric components.

Preferably, the method comprises assembling the components so that the second plurality of transverse elongate sinuous metallic components extends substantially perpendicularly to the first plurality of elongate sinuous metallic components.

Preferably, the method comprises assembling the components so that the first plurality of elongate polymeric components extends substantially parallel to the first plurality of elongate sinuous metallic components.

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Preferably, the method comprises assembling the components so that the second plurality of transverse elongate polymeric components extends substantially parallel to the second plurality of transverse elongate sinuous metallic components.

Alternatively, the method may comprise assembling the components so that the first plurality of elongate polymeric components may extend at any suitable angle to the transverse elongate polymeric components, such as between about 30 degrees to about 60 degrees, for example.

Alternatively, the method may comprise assembling the components so that the first plurality of elongate sinuous metallic components may extend at any suitable angle to the transverse elongate sinuous metallic components, such as between about 30 degrees to about 60 degrees, for example.

Alternatively, the method may comprise assembling the components so that the first plurality of elongate polymeric components may extend at any suitable angle to the first plurality of elongate sinuous metallic components, such as between about 30 degrees to about 60 degrees, for example.

Alternatively, the method may comprise assembling the components so that the second plurality of transverse elongate sinuous metallic components may extend at any suitable angle to the transverse polymeric components, such as between about 30 degrees to about 60 degrees, for example.

Preferably, the method comprises assembling the components so that the first plurality of elongate polymeric components and the first plurality of elongate sinuous metallic components alternate along the length or width of the grating.

Preferably, the method comprises assembling the components so that the second plurality of elongate polymeric components and the second plurality of elongate sinuous metallic components alternate along the length or width of the grating.

Preferably, the elongate polymeric components are substantially straight.

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Preferably, the elongate polymeric components are formed from a fibreglass material.

Preferably, the method further comprises forming the grating as one or more panels.

Preferably, the ends of at least some of the elongate sinuous metallic components are shaped to receive an elongate joining component. Preferably, the ends of at least some of the metallic components are curved to define an aperture to receive the joining component.

In a fifth aspect, the invention broadly consists in a method for manufacturing a grating comprising:

(a) providing a plurality of elongate components;

(b) assembling the components to form a grating comprising: a first plurality of elongate components extending generally in a first direction; a second plurality of transverse elongate components extending generally in a second direction transverse to the first direction; a first plurality of elongate sinuous components extending generally in the first direction; a second plurality of transverse elongate sinuous components extending generally in the second direction; wherein the first plurality of sinuous components extend over at least a majority of the second plurality of transverse elongate components and extend ^• Tinder at least a majority of the second plurality of transverse elongate sinuous components, and the second plurality, of transverse elongate sinuous components extend under at least a majority of the first plurality of transverse elongate components and over at least a majority of the first plurality of elongate sinuous components.

Preferably, step (a) comprises providing the first plurality of preformed elongate sinuous components.

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Preferably, step (a) comprises providing the second plurality of preformed transverse elongate sinuous components.

Alternatively, at least some of the elongate components are shaped to form the first plurality of elongate sinuous components during the step of assembling the elongate components.

Alternatively, at least some of the elongate components are shaped to form the second plurality of transverse elongate sinuous components during the step of assembling the elongate components.

The first plurality of elongate components may be discrete components. Alternatively, two or more of the first plurality of elongate components may be integrally formed.

The second plurality of transverse elongate components may be discrete components.

Alternatively, two or more of the second plurality of transverse elongate components may be integrally formed.

The first plurality of elongate sinuous components may be discrete components. Alternatively, two or more of the first plurality of elongate sinuous components may be integrally formed.

The second plurality of transverse elongate sinuous components may be discrete components. Alternatively, two or more of the second plurality of transverse elongate sinuous components may be integrally formed.

Preferably, the first plurality of elongate components comprises a plurality of elongate polymeric components. Alternatively, the first plurality of elongate components comprises a plurality of elongate metallic components.

Preferably, the second plurality of transverse elongate components comprises a plurality of elongate polymeric components. Alternatively, the second plurality of transverse elongate components comprises a plurality of elongate metallic components.

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Preferably, the first plurality of elongate sinuous components comprises a plurality of transverse elongate sinuous metallic components. Alternatively, the first plurality of elongate sinuous components comprises a plurality of transverse elongate sinuous polymeric components.

Preferably, the second plurality of transverse elongate sinuous components comprises a plurality of transverse elongate sinuous metallic components. Alternatively, the second plurality of transverse elongate sinuous components comprises a plurality of transverse elongate sinuous polymeric components.

Preferably, the first plurality of elongate components, the second plurality of transverse elongate components, the first plurality of sinuous elongate components, and the second plurality of transverse sinuous elongate components comprise polymeric components.

Preferably, the first plurality of elongate components, the second plurality of transverse elongate components, the first plurality o'f sinuous elongate components, and the second plurality of transverse sinuous elongate components comprise metallic components.

Preferably, the method comprises assembling the components so that the first plurality of elongate components extend substantially parallel to each other.

Preferably, the method comprises assembling the components so that the second plurality of transverse elongate components extend substantially parallel to each other.

Preferably, the method comprises assembling the components so that the first plurality of elongate sinuous components extend substantially parallel to each other.

Preferably, the method comprises assembling the components so that the second plurality of transverse elongate sinuous components extend substantially parallel to each other.

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Preferably, the method comprises assembling the components so that the second plurality of transverse elongate components extends substantially perpendicularly to the first plurality of elongate components.

Preferably, the method comprises assembling the components so that the second plurality of transverse elongate sinuous components extends substantially perpendicularly to the first plurality of elongate sinuous components.

Preferably, the method comprises assembling the components so that the first plurality of elongate components extends substantially parallel to the first plurality of elongate sinuous components.

Preferably, the method comprises assembling the components so that the second plurality of transverse elongate components extends substantially parallel to the second plurality of transverse elongate sinuous components.

Alternatively, the method may comprise assembling the components so that the first plurality of elongate components may extend at any suitable angle to the transverse elongate components, such as between about 30 degrees to about 60 degrees, for example.

Alternatively, the method may comprise assembling the components so that the first plurality of elongate sinuous components may extend at any suitable angle to the transverse elongate sinuous components, such as between about 30 degrees to about 60 degrees, for example.

Alternatively, the method may comprise assembling the components so that the first plurality of elongate components may extend at any suitable angle to the first plurality of elongate sinuous components, such as between about 30 degrees to about 60 degrees, for example.

Alternatively, the method may comprise assembling the components so that the second plurality of transverse elongate sinuous components may extend at any suitable angle to the

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transverse components, such as between about 30 degrees to about 60 degrees, for example.

Preferably, the method comprises assembling the components so that the first plurality of elongate components and the first plurality of elongate sinuous components alternate along the length or width of the grating.

Preferably, the method comprises assembling the components so that the second plurality of transverse elongate components and the second plurality of transverse elongate sinuous components alternate along the length or width of the grating.

Preferably, the elongate components are substantially straight.

Preferably, the method further comprises forming the grating as one or more panels.

Preferably, the ends of at least some of the elongate sinuous components are shaped to receive an elongate joining component. Preferably, the ends of at least some of the components are curved to define an aperture to receive the joining component.

It is intended that reference to a range of numbers disclosed herein (for example, 1 to 10) also incorporates reference to all rational numbers within that range (for example, 1, 1.1, 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9 and 10) and also any range of rational numbers within that range (for example, 2 to 8, 1.5 to 5.5 and 3.1 to 4.7) and, therefore, all sub-ranges of all ranges expressly disclosed herein are hereby expressly disclosed. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

^■ As used herein the term "and/ or" means "and" or "or", or both.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The

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disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting. Where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

The invention consists in the foregoing and also envisages constructions of which the following gives examples only.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present invention will now be described with reference to the accompanying drawings in which:

Figure 1 is a perspective view of a preferred embodiment of a grating of the invention; Figure 2 is a side view of the grating shown in Figure 1 ;

Figure 3 is a top view of the grating shown in Figure 1 ; Figure 4 is perspective view of a plurality of fibreglass bars; Figure 5 is a side view of a sinuous steel component; Figure 6 is perspective view of a plurality of sinuous steel components; Figure 7 is perspective view of a plurality of fibreglass bars and a plurality of sinuous steel components;

Figure 8 is a perspective view of a transverse fibreglass bar inserted between the fibreglass bars and steel components of Figure 7;

Figure 9 is a perspective view of a transverse sinuous steel component inserted between the fibreglass bars and steel components and adjacent the transverse fibreglass bar of Figure 8;

Figure 10 is a perspective view of a further transverse fibreglass bar inserted between the fibreglass bars and steel components of Figure 10;

Figure 11 is a perspective view of a further transverse steel component inserted between the fibreglass bars and steel components of Figure 10;

Figure 12 is a perspective view of two panels of the grating of Figure 1 , with two panels joined together;

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Figure 13 is a top view of two panels of the grating of Figure 1 being joined together by a joining component;

Figure 14 is a side view of the panels of Figure 12;

Figure 15 is an end view of the panels of Figure 12; Figure 16 is a perspective view of the grating of Figure 1 attached to I-beams by brackets;

Figure 16b is a detail view of one of the brackets of Figure 16;

Figure 17 is an end view of die grating being formed by a preferred method for manufacturing the grating, showing lower fingers of a grating forming machine in a raised position;

Figure 18 is an end view of the grating being formed by the preferred method for manufacturing ^' the grating, showing a transverse sinuous metallic component inserted;

Figure 19 is an end view of the grating being formed by the preferred method for manufacturing the grating showing rollers raising the first plurality of metallic components; Figure 20 is an end view of the grating being formed by the preferred method for manufacturing the grating showing a transverse polymeric component being inserted; and

Figure 21 is an end view of the grating the preferred method for manufacturing the grating showing the rollers in a central position.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

With reference to Figures 1 to 3 a preferred embodiment grating of the invention is shown, indicated generally by reference numeral 1. The grating 1 is suitable for a number of end uses such as walkways, platforms, bridges, stairs or stair treads, ramps, livestock pens, concrete reinforcement, security fencing, drainage, fishing boats, food processing, gates, suspended ceilings, safety barriers, scaffolding, screens and filters, marine uses, architectural or decorative applications, and other similar uses.

The grating 1 has a first plurality of polymeric components 3, 3', 3", and a second plurality of transverse polymeric components 5, 5', 5". In the embodiment shown, the polymeric components are elongate straight components having a substantially circular cross section in the form of fibreglass (polymeric material reinforced with glass fibres or particles) rods or fibreglass extrusions.

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The first plurality of polymeric components 3, 3', 3" extend generally in a first direction and preferably parallel to each other. The second plurality of polymeric components 5, 5', 5" extends generally in a second direction and preferably parallel to each other and transverse to die first plurality of polymeric components 3, 3', 3". In the embodiment shown, the second plurality of polymeric components extends perpendicularly to the first plurality of polymeric components.

The grating also has a first plurality of sinuous metallic components 7, 7', 7", and a second plurality of transverse, sinuous metallic components 9, 9' 9". In the embodiment shown, the metallic components are in the form of zigzag rods or wires.

In the embodiment shown, the first plurality of elongate sinuous metallic components 7, T ', 7" extend parallel to each other and substantially parallel to the first plurality of polymeric components 3, 3', 3".

The second plurality of elongate sinuous metallic components 9, 9' 9" extends parallel to each other and transverse to the first plurality of elongate sinuous metallic components 7, 7', 7". In the embodiment shown, die second plurality of elongate sinuous metallic components extends perpendicularly to the first plurality of metallic components.

With reference to Figure 1, the first plurality of elongate sinuous metallic components 7, 7', 7" extends over the second plurality of polymeric components 5, 5', 5" and extends under the second plurality of elongate sinuous metallic components 9, 9' 9". The second plurality of elongate sinuous metallic components 9, 9' 9" extend under the first plurality of polymeric components 3, 3', 3" and extends over the first plurality of elongate sinuous metallic components 7, 7', 7". That forms a grating having a woven or interlaced configuration of polymeric and metallic components as shown.

The metallic components may be steel components. With reference to Figures 5 and 6, the steel components 7, T, 7" and 9, 9' 9" may be preformed into a sinuous or zigzag shape. The steel component may be a suitable steel wire, rod, or bar that is formed into the

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sinuous or zigzag shape. In the embodiment shown, the steel components are of substantially equal length to the fibreglass bars when bent to their final shape.

In the embodiment shown, each steel component 7, T, 7" and 9, 9' 9" has a plurality of convex portions 11 alternating with a plurality of concave portions 13. Intermediate portions 15 extend between the convex and concave portions. In the preferred embodiment, the intermediate portions extend tangentially and in a substantially straight line between the convex and concave portions. Alternatively, the intermediate portions 15 may have a curved shape.

The internal radius of the convex portion 11 is formed on one side of the steel component and generally corresponds to the radius of the fibreglass bar. The internal radius of the convex portion is formed on the other side of the steel component and generally corresponds to the radius of the steel component.

In the assembled product, a mechanical grip or non skid surface is provided by the preformed zigzag steel wires, due to their prominence as they loop over the polymeric components in both top and bottom faces of the finished grating or grate.

In the embodiment shown, generally square spaces are formed between adjacent polymeric and metallic components. It will be appreciated that the shape and size between the polymeric and metallic components will be chosen or designed depending on the intended final use of the grating and the configuration of the polymeric and metallic components. For example, the embodiment shown is useful for grating that livestock can stand or walk on. In particular, the spacing between the components is chosen so that cattle or other animals with cloven hooves can stand or walk on the grating without their toes falling through or being caught in the spaces. In the preferred embodiment, the open spaces between the polymeric and metallic components are substantially square and have a width and length of between about 10 mm and about 80 mm, more preferably about 19 mm.

With reference to Figures 12 and 13, the grating is formed as panels that can be joined together to form a larger grating. In the embodiment shown, the ends 19 of the first plurality of elongate sinuous metallic components 7, 7', 7" are shaped to receive an

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elongate joining component 21. Each end 19 is curved into a loop 23 that defines an aperture 25 to receive the joining component 21. A portion 23 of each metallic component 7, 7', 7" near the curved ends 19 extends at an angle to the longitudinal direction of the metallic component, forming a step in each metallic component (seen most clearly in Figure 13). This allows panels of grating to be joined together so that the metallic components 7, 7', 7" in adjacent panels are aligned.

In the embodiment shown, the joining component 21 is an elongate component in the form of a fϊbreglass rod or bar. The joining component has a substantially circular cross section with a flat portion. The flat portion allows the joining component to slide over the notches of the first plurality of polymeric components 3, 3', 3" during assembly. The joining component joins the ends of at least some of the metallic components and provides support to the bottom layer of rods where the ends of the rods meet.

With reference to Figures 12 to 14, the grating can be mounted to an I-beam or other structural component to support the panels. Alternatively, when used as a fencing material, the grating can be attached to a fence post 26. The joining component is attached to the fence post by one or more brackets 27.

With reference to Figures 12, the bracket 27 has a body 29 with an aperture 31 extending through the body to receive the joining component 21. The body 29 also has a slot 33 perpendicular to the longitudinal axis of the aperture 31 for receiving the ends 19 of the metallic components. The angle of the slot relative to the aperture may be altered,, depending on the angle between the first plurality of polymeric components and the second plurality of metallic components.

Flanges 35 extend from either side of the body 29 for attaching the bracket 27 to the I- beam 26. In the embodiment shown, each flange has a slot 37 for receiving a flange 38 of the I-beam. Alternatively, the bracket may be attached to the I-beam or other structural component using fasteners, such as screws or rivets.

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The joining component and bracket allow a number of panels to be joined together to provide an uninterrupted length of grating. The uninterrupted length of grating can be used for a fence or walkway, for example.

The bracket described above may also be used along the length of the grating for support and to attach the grating to structural components. An alternative second bracket 39 for joining a panel of grating to a I-beam is shown in Figures 14 to 16, with a detail view of the second bracket 39 shown in Figure 16b.

The second bracket 39 has a body 41 with an aperture 43 extending through the body to receive a polymeric component. The body 41 also has a groove or slot 45 perpendicular to the longitudinal axis of the aperture 43 for receiving a portion of the metallic components. The angle of the groove 45 relative to the aperture 43 may be altered, depending on the angle between the first plurality of polymeric components and the second plurality of metallic components. Flanges 47 extend from either side of the body 41 for attaching the bracket 39 to the I-beam 26. In the embodiment shown, each flange has a slot 49 for ^• receiving a flange 38 of the I-beam. Alternatively, the bracket-may be attached to the I- beam or other structural component using fasteners, such as screws or rivets extending through the flanges 47.

The angle of the groove relative to the aperture may be altered, depending on the angle between the first plurality of polymeric components and the second plurality of metallic components.

METHOD OF MANUFACTURE

A suitable method of manufacturing the product will now be described, with reference to Figures 3 to 11. Unless otherwise specified, it should be appreciated that references to directions in the following description such as upward, downward, vertical, horizontal, behind, or hang or angles such as 0 degree or 90 degree are for reference only, and should not be considered limiting.

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Step 1: With reference to Figure 4, a first oϊ bottom layer of flbreglass bars 3, 3', 3" are substantially evenly spaced and aligned generally in parallel to each other. The fibreglass bars 3, 3', 3" are positioned at 0 degrees. The number of bars and the spacing between the bars will be chosen depending on the desired size of the final grating product. Each bar has preformed notches 17 that are cut evenly at a repeat distance. The distance between notches substantially corresponds to the desired spacing of the second layer of fibreglass bars that is formed in step 3 described under. In the embodiment shown, the spacing between adjacent fibreglass bars 3, 3', 3" in the first or bottom layer is the same as the spacing between adjacent fibreglass bars in the second or top layer.

Step 2: With reference to Figures 5 to 7, a number of pre-bent sinuous steel components 7, T ', 7" are positioned between the previously laid fibreglass bars. The steel components 7, 1\ 7" are positioned at 0 degrees. Each steel component is held in an upright or vertical state, as shown in Figure 7. In the embodiment shown, the steel components 7, 7', 7" are positioned so that the distance between each steel component and the two adjacent fibreglass bars is generally equal.

Step 3: With reference to Figure 8, a single perpendicular fibreglass bar 5 is inserted between the fibreglass bars 3, 3', 3" and the metallic components 7, 7', 7" provided in steps 1 and 2. The bar 5 is similar to those shown Figure 7 with notches. The notches are spaced at distances mat generally correspond to the distance between the fibreglass bars in the bottom layer. The fibreglass bar 5 is pre-glued with promoted uncured adhesive gel then clamped at 90 degrees on top of the bottom layer of fibreglass bars 3, 3', 3". The adhesive is allowed to set. Both upper and lower layer notches 17 interlock in a snug fit (Figure 5). The fibreglass bars 3, 3', 3" and 5, 5", 5" are glued during assembly at the contact points to inhibit lateral movement or slip due to tension from the steel components.

The single transverse fibreglass bar 5 crosses the fibreglass bars 3, 3', 3" in the bottom layer. In the embodiment shown, the transverse fibreglass bars 5 extend slightly beyond the width of the bottom layer of fibreglass bars.

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Step 4: With reference to Figure 9, the 0 degree zigzag steel components 7, T, 7" are allowed to hang or hinge downward off the 90 degree fibreglass component 5 at least far enough to insert one transverse zigzag steel component 9 at 90 degrees. The steel component 9 is positioned beneath the 0 degree pultruded fibreglass extrusions 3, 3', 3" and over the 0 degree zigzag steel components 7, T, 7". In the preferred embodiment, the transverse zigzag steel component 9 is laid flat on its side for insertion. Once in place, the transverse zigzag steel component 9 is turned to an upright or vertical position. The transverse zigzag steel component 9 is turned so that the radiuses of the transverse degree steel components correspond with the radiuses of the first plurality of steel components and the first plurality of fibreglass components. The zigzag steel component 9 is then allowed to 'hang" on the 0 degree upright zigzag steel components 7, T, 7". The 0 degree steel components 7, T, 7" are lifted back up to a central position (Figure 6).

Step 5: The 0 degree zigzag steel components 7, 7', 7" are lifted upward under tension from behind the previously installed 90 degree components at least high enough to insert or slide in from the side another 90 degree fibreglass rod 5' beneath them and over the lower 0 degree fibreglass rods 3, 3% 3". In the preferred embodiment, the fibreglass rod is inserted on its side to avoid collision of the notches 17 and adhesive while inserting, then rotated to align opposing notches once the 90 degree fibreglass rod 5' is in place. The tension is released off the 0 degree zigzag steel 7, 7', 7" to apply tight clamping of the newly glued fibreglass extrusion notched junctions (Figure 10).

Step 6: The 0 degree zigzag steel components 7, T, 7" are pulled in a downward direction from behind the previously installed 90 degree components low enough to insert one zigzag steel component 9\ In the preferred method, the steel component 9' is slid in from the side. With reference to Figure 11, the steel component 9' is positioned beneath the 0 degree fibreglass components 3, 3', 3" and over the 0 degree zigzag components 7, 7', 7". In the preferred embodiment, the zigzag steel component 9' is laid fiat on its side for insertion. Once in place, the zigzag steel component 9' is turned to an upright position then allowed to hang on the 0 degree upright zigzag steel components 7, 7', 7". The zigzag steel component 9' is turned so that the radiuses of the 90 degree steel component 9 ¹ correspond with the radiuses of the 0 degree steel components 7, 7', 7" and the 0 degree

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fibreglass components 3, 3',3". The 0 degree zigzag steel components 7, 7', 7" are raised back up to a central position (Figure 11).

In the embodiment shown, the transverse or 90 degree steel components 9, 9",9" are generally the same as the 0 degree steel components 7, 7', 7". The transverse steel components are of substantially equal length when in the bent form to the transverse fibreglass components. The transverse or 90 degree fibreglass bars are generally the same as the 0 degree fibreglass bars.

Step 7: Steps 5 and 6 are continued in sequence to complete the desired length of grating required. One form of the final product is shown in Figure 1.

The profile view of the finished grating product is shown in Figure 2. The plan view of the finished grating product is shown in Figure 3.

The grating may be formed manually and/ or using a suitable machine.

In one preferred embodiment, the grating is formed in panels following the method described above. An alternative method for manufacturing the grating will now be described with reference to Figures 17 to 21. Unless described below, the method should be considered to be the same as that described above and like numerals are used to indicate Eke parts. In the alternative embodiment, at least some of the steel components may be provided in a substantially straight form, which are then bent into a sinuous or zigzag shape during assembly of the grating.

Figures 17 to 21 show a machine for manufacturing the grating. The machine has an upper roller 101a, a lower roller 101b, a lower support plate with a plurality of fingers 103, and two upper support plates 104 with a plurality of fingers 105.

Steps 1 and 2: With reference to Figure 17, in the alternative method, a first or bottom layer of 0 degree fibreglass bars 3, 3', 3" are substantially evenly spaced and aligned generally in parallel to each other. A number of 0 degree steel components 7, 7', 7" are positioned between the previously laid fibreglass bars. The 0 degree steel components and

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the 0 degree fibreglass components extend between the fingers of the support plates. The 0 degree steel components are substantially straight components, which are fed or bent under tension around the 90 degree fibreglass components 5, 5', 5" and the 90 degree steel components 9, 9', 9" during subsequent steps of the method to form sinuous components. 5. The steel components may be provided in continuous lengths that are held on spools. The spools may provide tension to the steel components.

Step 3: With reference to Figure 17, the lower fingers 103 are raised. The steel components extend between the fingers 103 of the lower support plate. With reference to 0 Figure 18, the 0 degree steel components 7, T, 7" are held by the rollers 101a, 101b. The 0 degree steel components are pulled .under tension in the downward direction by the rollers 101a, 101b. This bends the steel components around the 90 degree fibreglass components 5, 5', 5". The steel components are supported by the lower support plate during bending and bend around the around the 90 degree fibreglass components 5, 5', 5". This creates a curve in each of the steel components around the 90 degree fibreglass components 5, 5', 5".

Step 4: A preformed 90 degree steel component ψ is inserted beneath the 0 degree fibreglass components 3, 3', 3" and over the 0 degree steel components 7, 7', 7". The two upper support plates 104. support the transverse steel component 9' as it is inserted. In the alternative method, the steel component 9' is inserted in an upright position. With reference to Figure 19, the 0 degree steel components 7, T, 7" are then raised by the rollers 101a, 101b under tension to bend the steel components around the 90 degree steel component 9\ The steel components are guided by the upper support plate during bending and bend around the around the 90 degree steel component 9'. This creates a curve in each of the steel components around the 90 degree steel components 9'.

Step 5: With reference to Figure 20, a single perpendicular fibreglass bar 5 is inserted above the fibreglass bars 3, 3', 3" and below the metallic components 7, T, 7". The 0 degree steel components 7, 7', 7" are then lowered to a central position by the rollers (Figure 21).

Step 6: The lower and upper fingers are lowered and raised. The rollers 101, lower fingers 103, and upper fingers 105 are supported by a frame. The frame moves in steps across the

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width of the machine after the lower and upper fingers have been lowered and raised. The frame moves by the required spacing between the transverse components. The above steps are continued in sequence to complete the desired length of grating required. One form of the final product is shown in Figure 1.

In a further alternative method for manufacturing the grating, the transverse steel component 9' may be bent or fed around the 0 degree steel components 7, 1\ 7" and the fibreglass bars 3, 3', 3".

The grating may be formed in panels following either method described above. With reference to Figures 12 to 16, the panels of grating are joined together to form a larger grating. The panels can be joined together as part of the manufacturing process or joined together on site.

In the embodiment shown, the ends 19 of .the first plurality of elongate sinuous metallic components 7, 7', 7" are joined together by an elongate joining component 21. The panels of grating are joined together so that the metallic components 7, 7', 7" in adjacent panels are aligned. The joining component is attached to an I-beam 26 or similar structural component by one or more brackets.

The bracket is positioned so that the ends 19 of the metallic components are positioned in the slot of the bracket. The joining component is inserted through the apertures 25 formed in the end of each, metallic component and the aperture 31 of the bracket. The flat portion of the joining component allows the joining component to slide over the notches of the first plurality of polymeric components 3, 3', 3" during assembly.

The bracket is attached to an I-beam by sliding the bracket over the I-beam, or clipping the bracket onto the I-beam. The bracket may be attached to the I-beam either before or after the bracket is assembled -with the joining component and grating. The second bracket is attached to the grating and I-beam in a similar manner.

Preferred embodiments of the invention have been described by way of example only and modifications may be made thereto without departing from the scope of the invention.

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For example, the fibreglass bars of the top layer have been described as being substantially perpendicular or at 90 degree to the bottom layer of fibreglass bars. In alternative embodiments, the fibreglass bars of the top layer may extend at any other suitable angle to the bottom layer of fibreglass bars, such as between about 30 degrees to about 60 degrees, for example. In a similar manner, the steel components of the top layer may extend at angles other than 90 degree to the steel components of the bottom layer such as between about 30 degrees to about 60 degrees, for example.

Further, the steel components of the top layer have been described as being substantially parallel to the fibreglass bars of the top layer. In alternative embodiments, the steel components may extend at any suitable angle to the fibreglass bars, such as between about 30 degrees to about 60 degrees, for example. In a similar manner, the steel components need not be parallel to the fibreglass bars of the bottom layer. The steel components of the bottom layer may extend at any suitable angle to the fibreglass bars, such as between about 30 degrees to about 60 degrees, for example.

Additionally, the fibreglass bars extending in each general direction need not be parallel to each other. Alternatively, they could be provided at desired angles relative to each other such as those suggested above. The steel components extending in each general direction need not be parallel to each other. Alternatively, they could be provided at desired angles relative to each other such as those suggested above.

The transverse or 90 degree steel components and fibreglass bars have been described as being generally the same as the 0 degree steel components and fibreglass bars respectively. However, it will be appreciated that the 90 degree components may differ from the 0 degree components. For example, to provide improved mechanical properties of the grating in one direction compared to another direction.

The polymeric components have been describes as being a fibreglass material. However, it will be appreciated that the polymeric components may be formed from other suitable materials. For example, other suitable composite materials include carbon fibre or aramid fibre composites.

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The properties of the polymeric components or fibreglass bars will be chosen depending on the final use and expected load requirements of the grating. For example, the type of fibre, the type of resin, the fibre content, and the diameter or width will be chosen or designed depending on the final use and expected load requirements of the grating.

The polymeric components may be formed from any suitable manufacturing process such as extrusion, pultrusion, or moulding. In the preferred embodiment, the polymeric components are pultruded fibreglass rods. The polymeric components could be preformed as a grid prior to insertion of the metallic components. In that configuration, the method of manufacture would differ as at least some of the metallic components would have to be fed or bent around the polymeric components.

In a preferred embodiment, the polymeric components are pultruded and the notches are machined or cut out. In an alternative embodiment, the notches may be integrally formed in the polymeric component, for example, during moulding of the polymeric component. In another alternative embodiment, instead of having notches, the polymeric component may be formed with a flat surface extending substantially along the length of the component, for example during extrusion or pultrusion. In a further alternative embodiment, the polymeric components may not have any notches.

In the preferred embodiment, each polymeric component has a diameter of about 10 mm. This diameter is suitable when the grating is intended to be used as a grating that livestock can stand or walk on. It will be appreciated that the dimensions of the polymeric components or the type of polymeric material used will be chosen depending on the final use and expected load requirements of the grating. For example, the diameter of each polymeric component may be from about 5 mm to 40 mm.

The polymeric components have been described as elongate components having a substantially circular cross section. However, it will be appreciated that the polymeric components may have any other suitable cross section such as square, rectangular, or oval, for example.

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In the preferred embodiment, each metallic component is formed from stainless steel bar having a diameter of about 5 mm. This diameter is suitable when the grating is intended to be used as a grating that livestock can stand or walk on. It will be appreciated that the dimensions of the metallic components or the type of metal used will be chosen depending on the final use and expected load requirements of the grating. For example, the diameter of the bar or wire may be from about 2 mm to 20 mm.

In the embodiment described, the metallic components are formed from a stainless steel material to inhibit corrosion of the grating. Alternatively, other suitable metals or metal alloy may be used, for example mild steel, carbon steel, aluminium, or brass. The metallic components may be galvanised and/or painted to prevent corrosion and for aesthetic purposes.

The metallic components are preferably formed by bending a steel rod or wire into the desired sinuous or zigzag shape. . In a preferred embodiment, the metallic components are bent in such a manner to substantially inhibit any stretching or deformation of the component through the curved portions. Alternatively, the metallic components may be cast into the desired sinuous or zigzag shape.

The grating and method of manufacturing the grating have been described as having each metallic component extending under one transverse component, then extending over the next transverse component, then under the next transverse component, and continuing to alternate along the length or width of the product. Alternatively, each metallic component may extend over or under more than one adjacent component.

The grating and method of manufacturing the grating have been described as having the polymeric and metallic components alternating along the length or width of the product. It will be appreciated that there could be variants in that pattern.

The polymeric components may have notches or grooves where the metallic components extend over or under the polymeric components.

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The preferred embodiment of the grating has been described as having a first plurality of fibreglass bars, a second plurality of transverse fibreglass bars, a first plurality of elongate sinuous metallic components, and a second plurality of transverse elongate sinuous metallic components extending generally in the second direction. This embodiment is preferred because the fibreglass bars will flex under load and return to its original shape after the load is removed. Further, the sinuous shape of the steel components allows a spring-like movement and does not inhibit the nature of the fibreglass bars to flex and return to its original shape.

In alternative embodiments, the first plurality of elongate components may be a plurality of elongate metallic components, the second pluraKty of transverse elongate components may be a plurality of elongate metallic components, the first plurality of elongate sinuous components may be a plurality of transverse elongate sinuous polymeric components, and/or the second plurality of transverse elongate sinuous components may be a plurality of transverse elongate sinuous polymeric components. All of the components may be polymeric components or all of the components may be metallic components.

In the alternative embodiment in which the elongate sinuous components may be polymeric components, the first plurality of sinuous components may be preformed and cured. For example, the sinuous components may be preformed from fibreglass rope as continuous strands bundled with braiding. The sinuous polymeric components may be inserted in a similar manner to the metallic components of the preferred embodiment.

The sinuous polymeric components may have a similar diameter or cross section to the polymeric components of the preferred embodiment.

The transverse elongate sinuous components may be formed wet with uncured resin. During assembly, the second plurality of transverse elongate sinuous components may be held with light tension then lifted under and over the second plurality of transverse elongate components and the first plurality of elongate sinuous components.

The transverse elongate sinuous components may be held until the resin cures, preferably in an oven.

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This method may be set to run as a continuous production line with a wet saw cutting off sheets to any desired length at the finish.

5. The grating may be formed with or with out adhesive. When adhesive is used, the adhesive substantially inhibits moisture entering the cut and/ or notched end or grain of the polymeric components.

The first plurality of elongate components, the second plurality of transverse elongate 0 components, the first plurality of elongate sinuous components, and/or the second _. plurality of transverse elongate sinuous components may be hollow components or solid components.

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