SPEL Vortceptor User manual

SPEL Vortceptor®
spel.com.au
Installation Manual

CONTENTS
Installation Checklist 3
A. Handling and Preparation 5
B. Site Preparation 5
C. Anti Floatation Ballast FRP Wetwell 5
D. Bed and Backfill 6
E. Wetwell Installation with a 7
Fibreglass Underground Tank
F. Piping Penetrations / Fittings 7
G. Invert 7
H. Top Pad 8
Tracable Manhole Installation 9
J. Wet Hole Installation 11
Table 1 12
2Installation Manual Vortceptor
SAFETY
These instructions should not be interpreted in any way
to put one’s health at risk, or to harm property and/or
the environment. The following definitions will serve as
a guide when reading this manual:
WARNING
Indicates a potentially hazardous situation, which
if not avoided could result in death or serious
injury.
CAUTION
• Indicates a potentially hazardous situation,
which if not avoided may result in minor or
moderate injury.
• A caution without the safety alert symbol
indicates a potentially hazardous situation,
which if not avoided may result in property
damage.
IMPORTANT INFORMATION
Proper installation of each wetwell is essential:
• To ensure the safety of all the individuals involved
in the installation.
• To prevent wetwell damage and/or failure, which
could lead to product loss and environmental
contamination.
• To validate the wetwell warranty.
GENERAL INFORMATION
WARNING
Wetwells are a confined space per OHS
guidelines. Follow proper confined space safety
procedures.
SPEL fibreglass wetwells are designed for
installation with concrete top pad and bottom
slabs. The following instructions reflect the
approved methods for installing wetwells. Follow
all OHS, Federal, State or Local, safety and
environmental codes and regulations
WETWELL WARRANTY ACTIVATION
• These instructions must be followed.
• The Wetwell Installation Checklist must be
properly completed and signed by the owner’s
representative and the installing contractor.
• The Wetwell Installation Checklist, these
instructions, and any correspondence related to
the wetwell installation must be retained by the
owner and provided to GA to validate any future
warranty claim. The warranty in eect at the time
of delivery will apply and is available from SPEL
Environmental.
SAFETY
!
!
INTRODUCTION
These instructions, while using the word “wetwell”, will
pertain to all wetwells, lift stations, vertical pump vaults
and basins.
INTRODUCTION
!

spel.com.au 3
GETTING STARTED
BEFORE YOU BEGIN
• Read, understand and follow these instructions.
• Barricade the work area.
• Review and prepare to complete the installation checklist as the installation progresses.
If you have questions on other wetwell installation details, call Technical Support at [phone]
Site
Preparation
It is best practice to prepare the excavation for the Vortceptor separation
chamber first. The Vortceptor separation chamber is the blue fibreglass
vertical tank, which we will refer to as ‘the Vortceptor’. The excavation for
the Diversion Chamber (the rectangular precast concrete chamber) follows
afterwards.
YES / NO
Prior to installation, the inlet pipe run would typically be installed, within one
or two pipe lengths prior to the diversion chamber. YES / NO
Vortceptor
Installation
Always physically check measurements on the Vortceptor prior to installation. YES / NO
The Vortceptor excavation should be no greater than required, this would
be 1000mm oversized or to suit shield sizing. This is with due regard to the
amount of backfill to be used under and around the tank.
YES / NO
Install a 150mm thick, compacted base. This can be either a concrete blinding
or compacted crushed rock layer. YES / NO
Lower the Vortceptor into the excavation, ensure no rocks or sharp objects fall
into the hole and damage the tank. YES / NO
Level and adjust the Vortceptor to suit the main drain pipework and the
Diversion Chamber inlet void. The invert levels of the inlet and outlet
pipework is to match the invert of the inlet and outlet chute of the Vortceptor.
(The inlet and outlet chute is the rectangular flanged opening on the side of
the Vortceptor)
YES / NO
Fill the tank with water up to the invert of the inlet - the volume will depend on
the specific Vortceptor. YES / NO
Encase & backfill the outside of Vortceptor with an engineer specified material
– such as graded gravel aggregate, or crushed recycled concrete, or cement
stabilised sand.
YES / NO
In installations when the tank is located in an area subject to high water
table or trapped ground water, the tank must be completely encased in
unreinforced concrete, up to the specified height above the Vortceptor base,
and at the minimum specified width beyond the perimeter of the Vortceptor
base. Refer to SPEL Stormwater for recommended concrete dimensions and
volumes to withstand buoyancy forces.
YES / NO
INSTALLATION CHECKLIST

4Installation Manual Vortceptor
Diversion
Chamber
Installation
Always physically check measurements on the diversion chamber prior to
installation. YES / NO
Prepare the diversion chamber excavation, this is to be benched or battered
to suit the site constraints. YES / NO
Ensure sucient room is left to install inlet pipe (Remember you will need to
angle the pipe to feed it in). YES / NO
Lift the Diversion Chamber into the excavation - ensure site specific safety
requirements are adhered to. YES / NO
Adjust the Diversion Chamber to a correct level so the rectangular opening
matches the Vortceptor. The inlet and outlet block outs are to match the
drainage line.
YES / NO
Use the template provided with the Vortceptor to drill the bolt holes into the
diversion chamber rectangular void. YES / NO
Use Sikaflex or silicone (by others) to seal the Vortceptor to the Diversion
Chamber, use 8.5mm 4 cutter SDS bit to drill the bolt holes. YES / NO
Use M8 x 100mm Galvanised screw bolts to fix the Vortceptor to the Diversion
Chamber. YES / NO
Associated
Drainage
& Finishing
Works
Install upstream and downstream drainage pipework. YES / NO
Connect the pipework (by others) to the Diversion Chamber, concrete
bandage the inlet and outlet pipes to the Diversion Chamber. YES / NO
Internally render the inlet and outlet pipework with C-Crete or similar render. YES / NO
Use low slump concrete to mass infill and bench the base of the diversion
chamber and weir. This is to direct the flow and remove any dead zones in the
diversion chamber.
YES / NO
Cover Slab
Installation
Use a Sikaflex bead around the rebate on the top of the Diversion Chamber
to ensure a satisfactory seal between cover slab (Lid) and chamber. YES / NO
Lift and install cover slab, ensure manhole void / cover is on Vortceptor side of
the chamber. YES / NO
Use Sikaflex and screw bolts to secure fibreglass manhole riser to cover slab. YES / NO
Tie in the manhole covers as per lid manufacturers installation guidelines, to
achieve Finished Surface level. YES / NO

spel.com.au 5
WARNING
Collapsing excavation walls can cause injury
or death. Do not enter the wetwell excavation
unless necessary and in compliance with
OHS regulations. Follow OHS guidelines for
excavations.
WETWELLS
• Lower Wetwell onto Compacted Base then place
Wet concrete around the Unit covers 2 x Ribs plus
meets the Ballast Quantity in (table 1 and figure 1).
Cold concrete joints are not allowed. Fibreglass solid
bot- tom wetwells with external reinforcing ribs must
be installed in a continuous and monolithic concrete
pour. Concrete must extend 75mm above the second
rib from the wetwell bottom, and around the entire
circumference of the wetwell. (Refer to figure 1.)
• Concrete slab must fill all gaps and voids in and
around the external tank reinforcing ribs.
• It may be necessary to add ballast (water) inside
the wetwell to counteract buoyancy until the
concrete is cured.
ANTI FLOATATION RING CONCRETE SLAB
Use minimum 20 mpa concrete for anti floatation
and ballast Final concrete depth, size, thickness and
reinforcements shall meet the minimum requirements
in these instructions and applicable tables. Anti
floatation ring should extend a minimum of (refer to
table 1) in all directions from the wetwell outer diameter.
CAUTION
Voids in the concrete slab around external
structural anchors will result in product damage
and environmental contamination.
A. HANDLING &
PREPARATION
WARNING
Do not stand on or under wetwell while it is being
lifted. This could result in personal injury or death.
• Do not drop or impact the wetwell.
• Wetwells should be stored horizontally and
chocked, using only appropriate materials such as
sandbags, tires, or other soft or pliable materials.
• Upon wetwell delivery and when lifting wetwell,
visually inspect entire exterior surface of the
wetwell for shipping or handling damage.
• If the wetwell must be moved by rolling, ensure
that ground to be traversed is smooth and free of
rocks, debris, or other hard objects.
• Do not roll or set the wetwell on any pipe stubout,
accessory or appurtenance installed on the
wetwell.
• The contractor is responsible for rigging, unloading
and securing the wetwell.
• When lifting the wetwell in the horizontal position,
use two slings with a spreader bar.
• Use a minimum of two lift lugs when pivoting the
wetwell from horizontal to vertical.
• Utilize all lift lugs provided at the wetwell top for
vertical lifting.
• Only a pliable strap or rope should contact the
wetwell, do not use chains, steel cables or hard
metallic slings.
!
B. SITE
PREPARATION
Dimensions of the excavation should be wide enough
to provide sucient working room around the wetwell.
Minimum anti floatation ring and ballast dimensions are
speci- fied in (table 1).
Anti floatation ring and ballast designs in (Table 1) meet
Australian Standard Code S3600A.
(Dead load resisting floatation have a factor of safety of
0.9 applied.)
C. ANTI
FLOTATION
BALLAST FRP
WETWELLS
!
!

6Installation Manual Vortceptor
D. BED AND
BACKFILL
Proper backfill selection and compaction is required for
a proper installation. The allowed backfills are shown
in Table D-1 along with the degree of compaction
required.
TABLE D-1
BED AND BACKFILL COMPACTION
Soil type-pipe bedding
material (Unified Soil
Classification System -
see Table D-2)
Minimum Degree of
Compaction Required*
Fine - grained soils
(Liquid Limit < 50) with
medium to no plasticity
with less than 25% coarse
grained particles.
CL, ML, ML - CL
High
Fine grained soils (Liquid
Limit < 50) with medium
to no plasticity with more
than 25% coarse grained
particles.
CL, ML, ML - CL
Moderate
Coarse grained soils
containing more than 12%
fines.
GM, GC, SM, SC
Moderate
Coarse grained soils with
less than 12% fines.
GW, GP, SW, SP
Slight
Coarse grained soils with
less than 12% fines.
GW, GP, SW, SP
Dumped
* Degree of compaction:
• Dumped - No compaction eort.
• Slight - Some compactive eort. In-place density
<85% standard compaction. Or < 40% modified
compaction.
• Moderate - Intermediate level of compactive
eort, In-place density >/=85% and < 95% standard
compaction, or >/=40% and <70% modified
compaction.
• High - Considerable compactive eort. In-place
density >/= 95% standard compaction, or >/= 70%
modified compaction
• The dierence in the “dumped” and “slight” degree
of compaction values are significant and are based
on the method of construction, not the measured
densities.
• “Dumped” means that there is absolutely no
compaction of the embedment soil.“Slight” means
there was something done that increased the soil
density, even if minor, such as water settling, jet-
ting, flooding, equipment travel, and in some cases,
foot trac.
• For stable soils (cohesion ≥ 36 kpa and / or a
bearing capacity ≥ 170 kpa a minimum 300mm of
backfill must be placed around the wetwell.
• For unstable soils (cohesion ≤ 36kpa and ultimate
bearing capacity ≤ 170 kpa).
• Wetwells 1200mm diameter or smaller require
a minimum 600mm of backfill around the entire
circumference of the wetwell.
• Wetwells larger than 1200mm diameter require
a minimum backfill of ½ the wetwell diameter
around the entire circumference of the wetwell.
• If muck, bog or peat are present, consult with a
Geotechnical Engineer for backfill and excavation
requirements.
• For permafrost conditions, consult with a Geotech-
nical Engineer for backfill and excavation require-
ments.
Keep backfill dry and free of ice in freezing conditions.
Ensure that no foreign objects such as large stones,
concrete clumps, tree roots/limbs, or debris is in the
backfill surrounding the wetwell.
Prevent large surges of backfill from displacing the
wetwell.
TABLE D-2
LETTER AND
DEFINITION
SECOND LETTER
AND DEFINITION
G Gravel
S Sand
M Silt
C Clay
O Organic
P Poorly Graded
(uniform particle sizes)
W Well Graded
(diversified particle sizes)
H High Plasticity
L Low Plasticity

spel.com.au 7
E. WETWELL
INSTALLATION
WITH A
FIBREGLASS
UNDERGROUND
TANK
Do not backfill around the wetwell until the
concrete slab has hardened.
Add backfill in maximum 900mm lifts evenly
around the wetwell to avoid uneven backfill loads.
• A flexible joint on each connecting pipe is required
to relieve stresses from dierential backfill
movement or soil consolidation. Backfill should be
added to the invert elevation of each connecting
pipe, the connection made and sealed, before
continuing to backfill.
WARNING
To prevent fire or explosion hazard, GA
recommends air driven tools whenever possible.
DO NOT use power tools where flammable vapors
or liquids exist. Also, when electric hand tools are
used, be aware of potential shock hazards.Wear
protective clothing and eye protection.
Wetwells may be a confined space. Follow proper
safety procedures.
CAUTION
Not using approved backfill material may result in
tank failure and environmental contamination.
If the wetwell is installed in the same excavation as an
underground fibreglass tank, the backfill around the
wetwell must also meet the tank backfill requirements
so as to not compromise the tank installation. Tank
backfill requirements are more restricted and strict
conformance to the tank backfill requirments in MAN
600 must be met for both the wetwell and tank.
F. PIPING
PENETRATIONS/
FITTINGS
CAUTION
Always wear safety glasses and protective
clothing when cutting on the wetwell, failure to do
so can result in personal injury.
• Pipe penetration cutouts should be round holes
and should be no larger than the pipe diameter
plus 25mm.
• Make cuts using a saw with a masonry or
diamond grit blade.
• Do not use an axe or other impact type tools.
• Accessories must be installed and used in strict
accordance with the manufacturer’s instructions.
• All piping must have a flexible connector installed
directly on the fitting or accessory to allow for a
minimum 15mm dierential settlement between the
wetwell and the pipe.
If more than 15mm dierential settlement is
expected, choose a flexible connector designed
for the expected settlement.
!
!
!
G. INVERT
Invert specified by Certified Engineer. The invert may
be at any angle and may project up the wetwell any
distance.

8Installation Manual Vortceptor
H. TOP PAD
The wetwell is designed to support the dead weight
of an 200mm thick square pad 600mm larger than
the diameter of the wetwell (centered on the wetwell)
along with a dynamic T-44 trac load as long as the
pad is designed to distribute the loads on the wetwell
perimeter and not on the interior of the lid.
If the static load will exceed the 200mm pad weight
or the trac load will exceed T-44, the pad must be
1200mm larger than the wetwell diameter (centred on
the wetwell) and all of the pad and / or trac loads
must be supported by the soil around the wetwell and
not by the wetwell itself.
Fibreglass flat tops 1000mm through 2500mm
diameter are designed to support 200mm concrete
pads without internal supports while the concrete
cures.
The concrete pad must be designed to be self
supporting after cured.
The pad shall be specified by the Certified Engineer.
FIBREGLASS FLAT TOPS WITHOUT TRAFFIC
LOAD (See Figure H-1)
• The pad must be larger than the wetwell a
minimum of 300mm in all directions.
• Maximum 200mm concrete pad thickness.
FIBREGLASS FLAT TOPS WITH TRAFFIC LOAD
(See Figure H-2)
• The pad must be larger than the wetwell a
minimum of 600mm in all directions.
• The Certified Engineer shall specify the pad
strength and reinforcement so that the static
weight of an 200mm thick square pad (no more
than 600mm larger than the diameter of the
wetwell centred on the wetwell) along with a
dynamic T-44 trac load must be distributed on
the wetwell perimeter and not on the interior of the
lid.
• If either the static pad load or the dynamic trac
load is ex- ceeded, all of the pad and / or trac
loads must be supported by the soil around the
wetwell and not by the wetwell itself.
TRAFFICABLE MANHOLE
Ensure cover is installed to manufacturers instructions.
SPEL drawing is a guide (page 9).

spel.com.au 9

10 Installation Manual Vortceptor

spel.com.au 11
J. WET HOLE
INSTALLATION
CAUTION
Never allow an empty tank to remain in a wet
hole, or a dry hole that may become wet unless
anchoring and backfilling have been completed.
Failure to anchor and backfill may damage the
tank or surrounding property.
Firstly make site preparation as per section B.
Pump the water from the hole to maintain minimum
water level. Add a minimum of 300mm of well-placed
backfill material (MUST be crushed gravel) to the hole,
and level the bed to assure uniform bottom support for
the tank. Position the tank in the hole.
Partially ballast tank using water until it settles firmly
on the prepared bed. Ballast level in a tank must never
exceed water level in hole during installation. Use only
enough ballast to sink the tank.
One tank is level and ballasted, carefully place
concrete ballast as per section C then processed to
sections D, E (if applicable), F, G and H.
!

12 Installation Manual Vortceptor
TABLE 1
External Anti Floatation Ribs:
The wetwell bottom is designed to BS4994 to any
resist buckling of the wetwell bottom from external
water pressure and internal pressure, in the installed
condition with a compacted base to (Figure 1, below)
and the perimeter of the wetwell including the anti-
floatation Ribs embedded in concrete.
This table must be followed for the concrete slab
design for all wetwalls with fibreglass external ribs.
COLUMN 1 COLUMN 2 COLUMN 3 COLUMN 4 COLUMN 5
Wetwell
Dia.
mm
Reinforcement REO BAR
(In Center of
Slab, Ref-Figure 1.)
Required Slab
Extension
Around
Wetwell (mm)
Slab Thickness
(mm)
Required Ballast
Extension
Around
Wetwell (mm)
Ballast Height
(mm)
1200 1 @ 1800mm Dia. N12 400 200 300 400
1520 1 @ 1920mm Dia. N12 500 200 350 500
1850 1 @ 2250mm Dia. N12 &
1 @ 2650mm Dia. N12
550 200 400 600
2200 1 @ 2600mm Dia. N12 &
1 @ 3000mm Dia. FN12
700 200 500 700
2470 1 @ 2900mm Dia. N16 &
1 @ 3300mm Dia. N16
800 250 500 800
3000 1 @ 3400mm Dia. N16 &
1 @ 3800mm Dia. N16
900 300 700 1000
3500 1 @ 3900mm Dia. N20 &
1 @ 4800mm Dia. N20
1000 300 700 1200
4000 1 @ 4400mm Dia. N20 &
1 @ 4900mm Dia. N20
1100 350 750 1400
• These slabs are designed to AS3600.
• In some cases the slab and/or reinforcing design
is controlled by temperature requirements and in
other cases by flexure.
• Use minimum 20Mpa concrete.
• Since some of the slab designs are controlled
by temperature, the slab thickness should not
be increased without the approval of a Design
Engineer.
FIGURE 1

spel.com.au 13

100 Silverwater Rd, Silverwater NSW 2128 Australia
Phone: [phone]
Email: [email protected]
spel.com.au
SPEL Stormwater accepts no responsibility for any loss or damage resulting from any
person acting on this information. The details and dimensions contained in this document
may change, please check with SPEL Stormwater for confirmation of current specifications.
NSW HEAD OFFICE
100 Silverwater Rd, Silverwater NSW 2128
PO Box 7138, Silverwater NSW 1811
P: [phone]
P: 1300 773 500 E: nsw[email protected]
QLD MAIN OFFICE
130 Sandstone Pl, Parkinson QLD 4115
P: [phone]
P: 1300 773 500 | E: [email protected]
QLD SUNSHINE COAST BRANCH
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P: 1300 773 500 | E: [email protected]
VIC & TAS OFFICE
897 Wellington Rd Rowville VIC 3178
P: [phone]
P: 1800 810 139 | E: [email protected]
VIC GEELONG BRANCH
70 Technology Close, Corio,
P: [phone]
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SA OFFICE
9 Hampden Road, Mount Barker SA 5251
P: 1300 773 500 E: [email protected]
WA OFFICE
2 Modal Crescent Canning Vale WA 6155
P: [phone]
P: 1800 335 550 E: [email protected]
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100 Montgomerie Road Airport Oaks
P: [phone]
E: [email protected]
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Unit 2210 Lumiere Residences
Pasig Boulevard, Pasig City
P: [phone]
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Industrial Estate, Singapore 469028
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Lancaster Rd Shrewsbury SY1 3NQ UK
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Ohio 44135
P: [phone]
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We believe clean water is a
right not a privilege and we
work to ensure a joy in water
experience for you with your
children and grandchildren.
SPEL Vortceptor®
Installation Manual
0522