ACO Construction & Building Products

Transcription

1 ACO Construction & Building Products Custom Trench Drains Custom Trench Drain Introduction and Overview Catalog Custom Sizes Special Materials Double Containment

2 The ACO Group Founded in 1946, the ACO Group is the world leader and pioneer of modular trench drain systems. ACO drainage systems are used in a variety of applications from domestic environments to airports, and have been used at many prestigious locations. ACO USA was founded in 1978 and is America s foremost manufacturer of trench drainage products. Aquaduct - Custom Drainage Solutions ACO recognizes that in some applications an off-the-shelf product will not solve the user s drainage 2 problem. For these situations, ACO has a separate division - Aquaduct. Aquaduct solves drainage problems on a project-by-project basis using FRP (fiber reinforced plastic), stainless steel and other materials. Aquaduct engineers are involved from the outset providing industry knowledge and experience, designing a solution that meets specific site requirements within the project budget. Aquaduct also provides on-site technical service to advise on installation of these custom products. V Aquaduct solutions are used extensively by industries such as: chemical manufacturers, food processing plants, auto manufacturers, shipyards and airports. Sales support for Aquaduct custom drainage systems is available from ACO Polymer Products area sales managers.

3 Aquaduct offers a custom design and manufacturing service that provides a quality drainage solution for applications where a standard ACO Drain product is not appropriate. Common requirements for a custom trench system include: 1. Custom sizing Page 4 Aquaduct will design and manufacture trenches to virtually any width, depth, slope or shape. The invert slope can be varied to account for an uneven finished grade, or other site-specific requirements. Custom catch basins with inlet/outlet pipe connections are also available. isual access port 2. Special materials Page 6 Aquaduct will manufacture the trench system from different materials, depending on the liquid medium being handled. Aquaduct works with many different resins, as well as various grades of stainless steel and other metals dependent upon site requirements. Aquaduct will provide suitable gratings in appropriate material for the application requirements. Primary trench Installation anchor 3 3. Double containment Page 8 Aquaduct will design and manufacture custom double contained surface drainage systems for areas with high sensitivity to ground contamination. Environmental problems can create substantial cost implications for any industry. Double contained trenches provide an extra measure of security required by many industries conscious of EPA regulations. nular space for leaks

4 Custom sized trenches On occasion off-the-shelf products do not meet the design requirements of a project. The common response is to try to adapt a standard product to suit, or ignore certain project requirements. The Aquaduct solution removes the need for compromise. To enable budgetary as well as design requirements to be met, Aquaduct utilizes over fifteen years experience in the design, manufacture and installation of trench drainage systems. Common design requirements that necessitate the use of a custom solution include: Hydraulic capacity Design layout Custom profiles - depth - width - length - shape Installation restrictions Hydraulic capacity When draining large, impervious paved areas, the hydraulic requirements of a trench system can go beyond the capacity of standard off-the-shelf products. Aquaduct can vary many dimensional factors to meet the required hydraulic performance of a project. Factors that can affect hydraulic performance include: Slope - the % of built-in slope to the trench unit can be altered to create a short and steep run, or a long run with a small grade. Slope can also be altered along the run. Design layout In many industrial applications, machinery is discharging liquids that need to be removed. Complex layouts may be necessary to fit around equipment, accept unusual inlet or outlet pipes, and deal with changes in floor elevation. Trench layout designed for fit around machinery 4 Length of continuous slope - Aquaduct can produce as long a continuously sloping run as required. Width of channel - wider channels usually offer greater hydraulic capacity, but wide grates can add significantly to project costs - particularly if heavy loadings are involved. Depth of channel - the depth of the channel allows more liquid to flow before flooding and is often a more economical solution as narrower, industry standard grates can be used. Changes in floor elevation without discontinuing the trench Custom inlet/outlet pipes Where possible, all Aquaduct parts are shipped assembled with angles and junctions manufactured in the factory. This saves valuable time assembling and producing complex fabrications on site. Finish is also of a higher, consistent quality.

5 Custom profiles Custom profiles are available to meet unusual project requirements. Regardless how strange the circumstances, Aquaduct can custom design a system to meet specific needs. Site-specific requirements - when a project has unusual floor levels, or the trench system has to work around already existing structures or utilities, Aquaduct can produce a site-specific solution to overcome these obstacles and produce a trench drain with the correct performance criteria. Installation restrictions A large proportion of construction projects are refurbishment or retrofit work. In these instances, if the facility is still operating, there is a vital requirement to minimize downtime required for the installation of a new trench drain system. A custom engineered trench system will help reduce this downtime, and Aquaduct can manufacture units up to 20 feet in length. By reducing the number of pieces to be placed, and joints to be sealed, an Aquaduct system can reduce downtime considerably. This reduces the costly expense of idle machinery. PROJECT CASE STUDY Wide-body deicing facility Pittsburgh Airport Wide trench opening with narrow base for optimum catchment Modular systems have no forms to strip and concrete trench walls to finish or coat, thus reducing installation time further and adding to the cost savings. Due to large volume of liquids at the Pittsburgh Airport deicing facility, the hydraulic performance of the trench system was critical. In order to meet the hydraulic requirements, a high capacity trench and grate were needed with a continuous slope up to 350ft. In addition to the hydraulic requirements, the grate also needed to be aircraft rated and bolted. 20 foot Aquaduct units being installed A custom solution from Aquaduct proved to be ideal. The 12 wide trench was installed in a single pour; sections were supplied in 20ft lengths to match expansion joints. 5 Existing post tension rods run through the trench in protective sleeves Uneven floor grade from previous installation of area drains Aquaduct trench compensates for floor grade and provides a continuous invert slope KEY POINT Significant installation cost and time savings

6 Special materials When dealing with aggressive chemicals and unusual fluids, isophthalic polyester and standard vinyl ester resins are not always the ideal material for the trench drain system. Aquaduct custom manufactures every order and can, therefore, easily tailor the resins, and even the glass reinforcement, to suit a particular requirement. There are many different resins and additives available that can be used to increase the durability of the trench system. Common requirements that necessitate the use of custom resins, additives and reinforcements include: Chemical resistance Heat resistance Abrasion resistance Fire retardance UV resistance Chemical resistance FRP is produced from glass fibers bonded together using resins and hardeners. The most commonly varied component is resin; however, in special situations, carbon fiber may be used in lieu of glass for the veil (a thin layer of material used to form a resin rich, corrosion resistant surface on the inside of the trench drain) and reinforcing layers. This substitution also produces a conductive form of FRP that will dissipate static electricity, which is especially useful when dealing with potentially explosive environments. Carbon fiber veil and reinforcing can be incorporated to handle special situations. The grate, locking devices and frame should also be resistant to any chemicals present. Aquaduct offers a variety of metals, or composite grates and rails to suit. When specifying a trench for a chemically aggressive environment, it is important to consider the following: Type(s) & mixture of chemical(s) Temperature resistance Temperature is a commonly neglected issue when specifying a trench system. Liquids at extremely high temperatures can alter trench material and grate properties, leading to failure. Aquaduct offers a number of resins that provide a much higher temperature resistance than those typically used for dirty water trench drain applications. In extreme cases, a stainless steel trench body may be necessary. Temperature issues include: Ambient temperature of the installation - both hot and cold Temperature of liquids discharged into trench drain - and duration Other temperature considerations such as steam cleaning 6 Concentration percentages Contact time with trench system Temperatures of chemicals flowing in the trench drain Flushing system employed to clear chemicals from the system Cleaning agents used on surrounding floors should also be compatible with trench materials Test coupons are offered for final determination of chemical resistance Grates, locking devices, frame and trash bucket materials should also be checked for chemical resistance Many food processing facilities have boiling liquids discharging into the trench Check sealants for compatibility Where certain chemicals are used, a stainless steel trench body may be necessary, as resin based trench bodies cannot handle some aggressive environments.

7 Abrasion resistance Certain industrial processes create wash down or slurry that has particles, such as glass or metal, suspended within it. Constant abrasion from such particles may, over time, wear through the trench drain body. Aquaduct can incorporate a special gelcoat onto the surface of the FRP that significantly increases abrasion resistance of the drainage system. Fire retardance Some applications and regulatory bodies require all building materials to be fire retardant, such that if a fire occurs they should not act as fuel and increase or prolong the fire. Aquaduct can include a special additive into the resin during the manufacture of the FRP trench that will give the product an NFPA Class 1 Flame Retardant rating. PROJECT CASE STUDY Bush Brothers & Company Dandridge, TN This is of particular importance around aircraft fueling ramps, petrochemical plants and anywhere else large volumes of flammable liquids may be present. Standard FRP trench drain systems such as ACO Drain FlowDrain offer a Barcol hardness of 30-40, while the addition of this special gelcoat increases that to about 55. The new Bush Brothers & Company plant required chemically resistant trench drains. Hygiene regulations imposed on food processing plants required floors to be washed down regularly, and the washing agents needed to be drained. To comply with these requirements, Aquaduct custom manufactured over 2,000 feet of 8 wide trench drains with a chemically resistant vinyl ester body and stainless steel frames. 7 With much of the project needing strong grates to carry forklift traffic (Class E), custom stainless steel bar grates were required. Class C, medium duty grates were used for areas of pedestrian traffic. KEY POINT Hygiene requirements necessitate frequent wash down with cleaning agents

8 Double containment trench drains Increasing governmental regulations, insurance providers and industry developments (LEED) are demanding tighter pollution controls in the area of groundwater quality. In areas of environmental concern and/or when handling particularly hazardous chemicals, a fail-safe double containment drainage system may be necessary. While there are several double contained pipe systems and small catch basins available, these do not offer the collection and catchment performance benefits of using a trench drain. Primary trench - acts as the main trench drain to collect and transfer spills. Aquaduct s double containment trench system is two FRP trench drains, assembled one inside the other with an annular space between where any leaks will collect. Aquaduct will produce double containment trenches in sections up to 40 feet, as joints are easier to seal in the factory. However, field joints are almost always required and Aquaduct s field service technician will be available on site to seal these joints to guarantee a fail-safe system. 8 The entire trench system is water tested prior to concrete being poured to ensure joints for both primary and secondary trenches are sound. Once the trench is in use, should the primary trench fail or leak, a full repair is usually possible because the entire trench is accessible from ground level. Aquaduct offers a double contained trench system with several leak detection options: Leak detection ports - allows visual detection, positioned at various low points around the system. Secondary trench - fits around the primary trench and acts as a backup to contain liquids should the primary trench fail. Leak sensors - the trench can be adapted to incorporate an electronic sensor system. Removal of inspection covers provides visability into the secondary trench to check for any leaks. Sensors can be installed within the secondary trench to identify and pinpoint any leaks.

9 PROJECT CASE STUDY Visual access unit - solid, sealed cover that can be removed to inspect for leaks in primary trench. DuPont Chemical Plant Rochester, NY Leak detection port - allows periodic visual inspection into secondary trench. All channels and outlets are double contained and joints are guaranteed not to leak. Leak detection ports are positioned at strategic points throughout the system to aid the location of any leakage. In response to increasing governmental regulations concerning groundwater pollution, DuPont established worldwide design regulations for their facilities handling certain chemicals. These facilities utilize double containment drainage systems. Aquaduct designed and manufactured a system with a primary FRP trench that would drain surface runoff, encased in a secondary FRP trench that would act as a backup should the primary trench fail. This system would prevent harmful chemicals leaking into and contaminating the surrounding ground. DuPont installed leak sensor cables that would identify the occurrence and location of any penetration of liquid into the secondary channel. 9 To create a double contained trench drain Aquaduct requires: Chemicals present - see page 6 Dimensional requirements Hydraulic (flow) requirement of trench Loadings - see Type of sensor equipment (visual or electronic) Other project specific factors Aquaduct s field technician is available on-site to assist in installation and to fabricate any field joints to ensure the integrity of the system. KEY POINT Engineering requirement was for high integrity, sealed joints and minimal downtime The trench system runs all the way around the chemical vats to contain any spills or leaks

10 The Aquaduct service The Aquaduct division has over 20 years experience in the design and manufacture of FRP trench drain systems. Aquaduct provides a total solution from design to product, and from manufacturing process through installation. With any custom designed product, the optimum result comes from both parties understanding the needs and limitations of each other. Aquaduct has in-house engineers and ACMA Certified Composites Technicians who work with clients at all phases in the construction process to provide a product that meets project requirements. Design phase When involved from the initial design phase, Aquaduct s engineers can work with you to design a custom trench drain system that meets your exact requirements, and advise on implications for other design issues. Manufacturing process The process of combining glass fibers, resins and hardeners can be achieved through a number of techniques: filament winding, hand lay-up, spray-up, pultrusion or closed molding. The technology used depends upon the size and type of product to be produced and the anticipated usage. If involved early enough, Aquaduct can offer a number of options that may give significant cost and/or time savings. Our in-house engineers have extensive experience in the design and manufacture of custom trench drains. They can advise on the various resins and additives available and commonly faced installation issues. This dialogue of ideas generates the ideal solution. 10

11 PROJECT CASE STUDY The Boeing Company San Antonio, TX Installation Any product will fail, or provide a short service life, if installed incorrectly. To reduce installation time and complexity, Aquaduct delivers products assembled and in as few pieces as possible. All projects are delivered with parts clearly identified and marked on a layout print. The Boeing Company was opening a new facility in an old aircraft hanger in San Antonio, TX and during the refit of the hanger, planned to install a custom trench drainage system from Aquaduct. Engineers specified where the drainage was required on the site drawings and the system was fabricated and sent to site. For projects that are complex or unusual in nature, Aquaduct has a CCT certified field service technician who is available to go to site to help ensure a good installation. Pre-delivery product advice is available to ensure that the correct excavation and other details are carried out, which speeds installation once products arrive. This on-site service provides hands-on guidance and training to ensure the contractor is capable of: While saw-cutting the concrete floor the contractor discovered two 2 diameter post tension rods running through the floor, perpendicular to where the drainage was to be installed. As the rods could not be removed, an Aquaduct field service technician went to site to evaluate the situation. Correct assembly, layout, bracing and alignment of product - this ensures trench system is correctly positioned and setup prior to pouring concrete. Concrete placement - this ensures correct amount of concrete surrounds the trench drain, and that concrete is poured in a manner that does not disturb the setup and alignment. On-site fabrications - should on-site fabrications or changes be required, training can be provided to ensure these are done in the correct manner. Follow-up Aquaduct s involvement doesn t end once the product is installed. Support is available to answer future questions, and advise on maintenance issues. In the unlikely event that a problem arises, a certified field technician will visit the site to address any issues. After determining that the rods were not in the main flow area of the trench drain, it was decided that two 4 pipe sleeves could run through the trench drain which would allow the tension rods to be reconnected without having to redesign the drainage system. 11 KEY POINT On-site customization of the trench drain prevented construction delays and additional expenses

12 Other ACO product lines ACO DRAIN ACO Drain is the world s leading modular trench drain system for commercial, industrial and landscape applications. ACO SPORT ACO Sport is the most advanced product range for all track & field drainage, used at Olympic sites since ACO Road ACO Road is a range of surface drainage products engineered for the unique design and performance demands of highways, urban roads and bridges. ACO Environment ACO Environment is a range of separator and spill containment systems manufactured in corrosion resistant polymer concrete. QuARTz by aco QuARTz by ACO linear shower channel solutions inspire creative bathroom planning while maintaining quality and functionality. Markant by aco Markant by ACO is a range of building products designed for the residential builder and DIY enthusiast. ACO Polymer Products, Inc. East Sales Office P.O. Box 245 Chardon, OH Tel: (440) Toll free: (800) Fax: (440) West Sales Office PO Box Casa Grande, AZ Tel: (520) Toll Free: (888) Fax: (520) Electronic Contact: info@acousa.com Aquaduct Support Office Tel: (800) Fax: (704) aquaduct@acousa.com Follow us on February 2011 ACO Polymer Products, Inc. All reasonable care has been taken in compiling the information in this document. All recommendations and suggestions on the use of ACO products are made without guarantee since the conditions of use are beyond the control of the Company. It is the customer s responsibility to ensure that each product is fit for its intended purpose and that the actual conditions of use are suitable. ACO Polymer Products, Inc. reserves the right to change products and specifications without notice. Re-order Part # AQ001