If you've ever had a custom Mcnichols grating order arrive with the wrong bar spacing (ugh) or a fiberglass panel that doesn't quite fit the saddle, you know the drill: phone calls, rush fees, and a deadline that's suddenly a lot closer. I coordinate these orders for a living, and I've seen that gut-punch more times than I'd like. What most people don't realize is that the fix isn't better shipping—it's a better check. The 12-point checklist I created after my third mistake has saved us an estimated $8,000 in potential rework. Here are the 10 checkpoints I run on every Mcnichols order.
Before You Even Open the Catalog
1. Load Rating—Seriously, Double-Check the Spec
This sounds obvious, but (note to self: especially on aluminum grating). The load rating determines the bar size, spacing, and overall depth. I had an order in April 2023 where the engineer specified a "light-duty" walkway—meant for pedestrian traffic only. The client was using it for light equipment carts. The spec called for 1-1/4" x 3/16" bars, but they needed 1-1/2" x 3/16". Missed it during the quote. Caught it during the pre-order check. The cost to swap? About $0.15 per linear foot extra on the metal itself, plus a two-day delay. The cost if we hadn't caught it? A collapsed walkway. I don't want to think about that phone call.
2. Material Match—Aluminum vs. Steel vs. Fiberglass (Obvious, Right?)
Here's something vendors won't tell you: a plain steel quote can look almost identical to an aluminum quote in the catalog listing if you're not reading the material column carefully. Mcnichols' catalog is excellent, but it shows everything. During a rush order in Q3 2024, our spec writer accidentally selected "steel" for a corrosive environment that required "aluminum." The price was close enough that no one flagged it. The difference? About a 6-month lifespan in that chemical plant. We caught it in step two. Now it's a non-negotiable checkpoint—before we even look at pricing, we verify the material. Aluminum grating for wet/corrosive, fiberglass for electrical/chemical, steel for heavy industrial. Period.
Inside the Catalog Order
3. Bar Spacing—The Most Common Gotcha
People think the bar spacing is set once you pick the series. Actually, you can get custom spacing in most product lines. The assumption is that "standard" spacing fits every application. The reality is that a nurse's heel can get caught in a 1-1/2" spacing, and a warehouse pallet jack will skip right over 1/4" bars. I always verify: what is the smallest object that will be on this grating? For pedestrian areas with women's heels (common in architectural applications), I push for 3/8" or tighter. For industrial forklift traffic, 1-1/2" is fine. For a project in March 2024 (36 hours before the deadline), the client realized they'd specified 1-1/2" spacing for an elevated catwalk used by maintenance staff. They switched to 3/4" (which was still in stock). The lesson: ask about the traffic, not just the load.
4. Overall Panel Dimensions—Measure Twice, Or Better, Thrice
This is where the tape measure comes in (and seriously, learn to read it in 16ths if you haven't). I've seen orders where the width was correct but the length was off by 1/2". That's enough to make a panel not sit right in a saddle. Mcnichols' standard tolerance is +/- 1/8" on length and width up to 60", which is tight enough for most structural work. But if you're fitting into an existing frame, that 1/8" can be the difference between a seamless fit and needing grinding. My rule: provide the exact opening dimension, not the nominal dimension. A 48" clear opening might need a panel at 47-7/8" to allow for installation tolerance. We lost a $1,500 contract in 2022 because we tried to cut corners on the measurement process. Now we have a policy: the dimensions must be verified on-site by two people before the order is placed.
5. Surface Finish—It Matters More Than You Think
The catalog shows "mill finish" and "anodized" and "PVC coated." They're not just aesthetics. On aluminum grating, the mill finish will oxidize and become dull gray within weeks if exposed to weather. If you need it to stay bright (architectural railing, front entrance), you need anodized—unless you're in a coastal environment, where anodizing can actually fail faster. (Fun fact I learned the hard way: salt spray penetrates the anodized layer on some alloys. Check with Mcnichols for the specific alloy recommendation for your region.) PVC coating is for electrical or chemical contact, but it can crack in UV. I always ask: will this live indoors or out? What's the environment? That five-minute conversation has prevented three re-orders in the last year alone.
Before Hitting 'Order'
6. The Accessories Checklist—You Will Forget One
The grating is the star, but the show is the whole assembly. I guarantee you will forget the toe plate (kicker plate) on your first staircase grating order. Or the stair treads themselves (yes, someone ordered grating for a staircase and forgot the nosings—true story). Or the hold-down clips to secure the panel to the frame. Mcnichols' catalog lists all the accessories: toe plates, banding, cutouts, fasteners. My pre-order checklist looks like this: 1) Grating panels. 2) Stair treads (if applicable). 3) Banding/toe plate for edges. 4) Fasteners—are they included? (Often not.) 5) Cutouts—for pipe penetrations, drains, etc. 6) Lifting devices (if panels are heavy). That's six items on top of the grating itself. Every time I skip this list, I pay a rush fee later.
7. Cutouts and Notches—Draw a Picture
Don't just say "cutout for 4" pipe." Mcnichols can do cutouts, but the tolerance is about 1/4" on the location. If that pipe needs to go exactly in the center of a panel section between two bearing bars, and the cutout ends up hitting a bar, you're in trouble. I learned this after a $3,000 order came back with a cutout that was perfect in size but the wrong location relative to the bar pattern. Now we always provide a sketch showing the bar direction and the cutout location relative to the bars, not just the panel edges. The vendor can do a lot with a clear drawing; they can't read your mind.
8. Quantity—Are You Really Sure?
You'd think this is the easiest part. It's actually where most of our order errors have come from. The spec says "12 panels." But is that 12 for the whole job, or 12 for this delivery, with a second delivery later? Are they all the same? I've had two orders in the past year where the quantity was correct for the job but split across two purchase orders, and we ordered 12 for the first PO and 12 again for the second, not realizing the first had already been fulfilled and the total needed was 12. (Should mention: the second order was for a different series. That was a fun conversation with the client.) Verify the PO matches the delivery schedule. Every. Single. Time.
After You Order (But Before Delivery)
9. The Lead Time Reality Check
The catalog says "standard lead time is 2-3 weeks." Mcnichols, like everyone in the industry, will ship most standard items quickly. But anything with a custom size, cutout, or finish can push that out. I always add a week to whatever the sales rep says. (I really should start being more honest with myself about this.) In March 2023, I took a verbal commitment of "2 weeks" on a custom aluminum grating order with six cutouts. It took 3.5 weeks. We had a partial delivery of standard items in 10 days, but the custom stuff held up the job. The client had to work around it. Now I ask: what's the longest this has ever taken? What's the typical for this specific combination of features? That question has saved me from three false promises in the last quarter alone.
10. The Unboxing—Catch It Before the Installer Does
This is the cheapest insurance you can buy. When the truck arrives, don't just count the pallets. Pull one panel from each bundle—yes, open the wrapping—and check it against the spec. The bar spacing. The finish. The overall length. The cutout locations (if you can see them without removing the whole bundle). I've caught two incorrect orders in the last year at the receiving dock. One had the wrong bar spacing (it was 1-1/2" vs the spec of 3/4"). Another had a 1/8" bow in the panel that would have made it impossible to install. The cost to return and replace at that point is just the freight—way cheaper than the cost of having an installation crew wait on site. Mental note: tell the warehouse team to do this for every grating order from now on.
A Few Things to Avoid
Don't assume the catalog is always right. The product listing is for a standard item. Your custom configurations might have different tolerances or lead times. Always confirm for non-standard spec.
Don't skip the material spec sheet. Mcnichols provides them for a reason. The load tables on the sheet are what the engineer uses; make sure your order matches the sheet exactly.
And seriously, have a second person look at the order before it goes out. 5 minutes of verification today beats 5 days of correction next week. I promise you that.
