Exploring the Cement Casting Process for Grease Interceptors

Exploring the Cement Casting Process for Grease Interceptors: A Guide for Commercial Plumbers

When it comes to commercial plumbing, there’s one essential component often overlooked but critical to the functionality of large kitchens, restaurants, and food processing facilities — grease interceptors. These devices, made primarily from cement, are pivotal in preventing fats, oils, and grease (FOG) from entering and clogging the sewer system. Recently, Foster Plumbing had the opportunity to visit, Copeland Precast, a cement casting company that specializes in manufacturing high-quality grease interceptors and many commercial concrete products. The experience gave us a new appreciation for the engineering and craftsmanship that go into these heavy-duty plumbing solutions.

Here’s a breakdown of my visit and what we learned about the process, benefits, and importance of these cement grease interceptors in commercial plumbing.

The Role of Grease Interceptors in Commercial Plumbing

Before diving into the cement casting process, it’s important to understand why grease interceptors are a vital component in the commercial plumbing industry. In restaurants, hotels, and other facilities where food is prepared, waste from cooking can send grease, oils, and fats down the drain. If left unchecked, this grease can solidify in the plumbing system, leading to blockages, backups, and potentially expensive repairs.

A well-designed grease interceptor traps these potentially harmful substances before they enter the sewer system, ensuring smooth operation and reducing the risk of plumbing issues. For commercial plumbers, recommending and installing durable interceptors is crucial to maintaining long-term efficiency and compliance with local regulations.

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Visiting Copeland Precast: The Manufacturing Process

Upon arriving at the cement casting facility we were greeted by Bart Copeland (President), and immediately impressed by the scale of the operation. The production of cement-based grease interceptors involves several key steps, each meticulously executed to ensure quality and durability.

• Molding the Interceptor

The first step in creating a cement grease interceptor is designing and preparing the mold. These molds are carefully crafted to meet specific size requirements, depending on the facility’s plumbing needs. For commercial plumbing, the interceptors typically come in large sizes, capable of handling significant volumes of grease-laden wastewater.

During the tour, we saw both standardized molds and custom ones tailored for unique plumbing setups.

• Pouring the Cement

Once the molds are ready, it’s time to pour the cement. Copeland Precast uses a special high-strength concrete mixture to ensure the interceptor is robust enough to withstand the harsh conditions of commercial kitchens and the outdoors. Cement is poured evenly into the molds and left to cure, a process that will take 5-7 days to ensure the structure is solid and durable.

The use of heavy-duty concrete is essential for the longevity of grease interceptors, particularly in commercial plumbing applications where they must endure constant pressure from high wastewater volumes. This strength also ensures the interceptor remains leak-proof and structurally sound for years to come.

• Finishing Touches and Quality Control

After the curing process, the grease interceptors undergo a series of finishing steps. Each interceptor is checked for proper dimensions, structural integrity, and the ability to handle varying wastewater flows without failure. This attention to detail is particularly important in commercial plumbing, where the reliability of grease interceptors can make or break a facility’s drainage system.

Why Cement Grease Interceptors Are the Best Choice for Commercial Plumbing

There are various materials available for grease interceptors, including plastic, steel, and fiberglass. However, cement grease interceptors have distinct advantages, especially for large-scale commercial plumbing applications.

• Durability

Cement grease interceptors are far more durable than their plastic or steel counterparts. They are built to last for decades, even under harsh conditions. In commercial kitchens, where the wastewater temperature can fluctuate, and the volume of grease is significant, cement interceptors maintain their structural integrity.

• Capacity

Commercial facilities often produce vast amounts of FOG (fats, oils, and grease). Cement grease interceptors can handle much larger volumes than plastic units, making them the ideal choice for restaurants, hotels, and other high-traffic establishments. These large units ensure that grease is effectively separated from wastewater, reducing the likelihood of sewer backups.

• Environmental Resistance

Unlike steel interceptors, which can corrode over time, cement interceptors are resistant to corrosion. This makes them particularly suited for outdoor installation, where exposure to the elements is inevitable. For commercial plumbers, this means fewer repairs and these can last up to 30 plus years.

Installing a Cement Grease Interceptor: Key Considerations for Commercial Plumbers

For commercial plumbers, recommending the right grease interceptor is only half the battle. Proper installation is equally important to ensure that the unit functions effectively and complies with local commercial plumbing codes.

• Sizing the Interceptor

One of the most critical aspects of installation is choosing the correct size of the interceptor. This is determined by the flow rate of the facility’s wastewater system. Oversizing the interceptor can lead to inefficient separation of grease, while an undersized unit will quickly overflow, leading to blockages.

• Positioning

Another important factor is the placement of the grease interceptor. Typically, it should be installed underground and as close to the source of grease-laden wastewater as possible. This ensures that the interceptor captures the grease before it has a chance to cool and solidify within the plumbing system.

• Regular Maintenance

Even the most robust grease interceptors require routine maintenance to function properly. Commercial plumbers should advise clients on the importance of cleaning the unit regularly to remove accumulated grease and prevent blockages. Most municipalities have strict regulations regarding grease trap maintenance, so staying compliant is a must.

Conclusion

Visiting the Copeland Precast company provided Foster Plumbing with valuable insight into the production of grease interceptors, specifically designed for commercial plumbing applications. From the meticulous crafting of molds to the precise pouring and finishing of the cement, it’s clear that these units are built to withstand the demands of high-volume commercial environments.

For commercial plumbers, recommending cement grease interceptors offers clients a reliable, long-lasting solution to protect their plumbing systems from the damaging effects of grease buildup. By choosing the right size, ensuring proper installation, and conducting regular maintenance, commercial plumbers can help businesses avoid costly repairs and keep their kitchens running smoothly.

Whether you’re installing a grease interceptor in a new restaurant or replacing an old unit, understanding the benefits of commercial cement grease interceptors will ensure you make the best choice for your clients.

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