Custom Fabrication
Built to your site's specs
Standard catalog sizes cover most municipal and commercial drainage projects. But sometimes your site demands something different — a non-standard grate width, a specialized erosion control geometry, materials suited to aggressive water chemistry, or flow handling tailored to your site's unique slope and debris load.
Spillway Grates
Custom spacing, grating patterns, and frame dimensions engineered to fit your site's exact footprint and flow requirements. We work from your civil engineer's specs and collaborate on geometry to optimize debris handling and water passage.
Erosion Control Hardware
Bespoke liners, retention grilles, and flow-dispersal systems fabricated to match your site's slope, soil conditions, and stormwater volume. Every piece is welded and finished to withstand years of seasonal water exposure.
Material Selection
Choose from carbon steel with protective coatings, weathering steel for natural patina, or stainless for aggressive chemical environments. We'll spec the finish that keeps your hardware performing in your climate.
Materials and process
Every piece we fabricate starts with material selection matched to your site's water chemistry and climate, then moves through precise cutting, welding, and finishing — all with the same durability standard that backs our catalog hardware.
Steel selection
We source material matched to your site's exposure — salt spray near coastal areas, acidic groundwater in industrial sites, or standard municipal stormwater. Each material choice carries implications for fabrication and long-term performance.
Precision cutting
CNC cutting and plasma techniques hold tight tolerances for grate spacing, frame dimensions, and mounting points. Accuracy at this stage means field fit and flow performance are predictable on site.
Welding and assembly
Full-penetration welds are spec'd and inspected for structural integrity and water-tightness where required. We build for load-bearing capacity and corrosion resistance, not just assembly.
Finishing
Paint, powder coating, hot-dip galvanizing, or natural weathering — your finish is chosen for the environment and your maintenance tolerance. We apply it with the rigor of a finished product, not an afterthought.
Designed with erosion control in mind
Custom fabrication isn't just about fitting your site's footprint — it's about tailoring grate geometry and placement to reduce erosion and manage debris responsibly. We design for water flow, not just against it.
Debris management
Custom grate spacing and bar orientation are engineered to capture sediment and flotsam at the right flow velocity — reducing the risk of clogging downstream and keeping erosion sediment from washing into the channel.
Flow optimization
Non-standard grate geometries can be tailored to your site's slope and approach velocity, ensuring water dispersal that protects the channel bed and banks from scour damage.
Site-specific placement
We work with your civil engineer to position custom hardware where it will be most effective — at the right elevation relative to the spillway, with frame anchoring suited to your soil and hydrologic conditions.
Material durability
Custom coatings and material selections keep your hardware performing through freeze-thaw cycles, chemical exposure, and years of seasonal flow — erosion control that doesn't degrade with time.
Working with engineers and contractors
Custom fabrication begins with your civil engineer's specifications and your contractor's field knowledge. We collaborate from design through delivery, ensuring the finished hardware meets both the blueprints and the site's real-world demands.
Specification review
We read your engineer's drawings and collaborate on fabrication approaches, material choices, and tolerances to ensure the finished piece performs as designed.
Design consultation
If your specs need adjustment for fabrication efficiency or durability, we flag it early and propose alternatives backed by our experience on similar sites.
Lead time planning
Custom work has different timelines than catalog orders. We'll commit to a delivery date that fits your project schedule and give you updates as fabrication progresses.
Documentation
You'll receive fabrication drawings, material certifications, and inspection records — the documentation civil engineers and contractors need to sign off on the finished work.
Shipping coordination
Large custom pieces need logistics planning. We coordinate timing and delivery method to fit your site access and schedule constraints.
Field support
Questions on site? Our team is available to discuss fit, installation approaches, or any issues that come up during construction.
Start your custom project
If your spillway or erosion control project needs custom fabrication, get in touch. Bring your site plans, flow specs, or just a description of what you're trying to accomplish — we'll work out the rest with you and your engineer.
Questions before you reach out? See our standard product line or read more about Millbach's experience in waterway infrastructure.