Site Installation Manual Grated Trench Drains ACO DRAIN
Contents
1. Specific site conditions may require an increase in these dimensions or reinforcement Pavers AS 3996 Class A B 100mm 100mm Pavers It is the customer s responsibility to ensure the concrete Paving sand encasement is designed for the Bedding layer application Concrete If in doubt seek further engineering 100mm advice Soil Grated Trench Drains Concrete ki xpansion AS 3996 Class C D ae engineer s details Concrete Bedding layer Asphalt AS 3996 Class D Asphalt tL Epi menen A tm ZZ Bedding layer 150mm Soil 5 Pavers mi AS 3996 Class C D Pavers Paving sand Bedding layer Concrete 150mm Soil AA Concrete Expansion AS 3996 Class E G joint to engineer s details Concrete Bedding layer Asphalt Asphalt AS 3996 Class E G Base course Concrete Road course Bedding layer MM Wi 200mm la MN io M Do Jee ON soi a ix Sa oe S a Ti 200mm mi Pavers Pavers AS 3996 Class E G Paving sand Bedding layer Concrete Grated Trench Drains Excavation Excavate trench to accommodate drain system Excavations must be made about the centre line of proposed drainage run and pit Trench must be big enough to accommodate eac2. 7 M T CACY ON MU Positioning of Channels Start with outlet point Ensure string line or laser is set at top edge of required channel height For KlassikDrain K100 System K31 to K60 channels are supplied in two pieces a base channel and an extension piece Install base channel at 180mm below the required height then position the extension piece on top of the base channel Common methods of positioning channels include Patty Method Hanging Method Patty Method Set pit or outlet channel on bed of concrete to required height see page 7 for concrete dimensions Connect and seal outlet pipe Using stiffAvet mix concrete create patties at intervals to support channels Allow two patties per channel spaced such that no concrete material is trapped in the joint creating gaps Note Patties should be sized to provide required concrete surround see page 7 If channels are to be sealed roughen ends and use a flexible sealant check chemical compatability if required Grated Trench Drains Male Female ACO DRAIN As per table pg 7 Lower channel vertically onto patties and position to correct height and alignment ensuring tight connection to previous channel Concrete key ACO DRAIN 7 D Avoid concrete dirt at joint Add concrete on top of patty to cover concrete keys on side of channel this prevents movement
3. or floating during concrete pour Continue to lay channels until end of run or next pit is reached Work away from outlet 12 Positioning of Channels Hanging Method Hanging is often used in retrofit installations as existing slab provides good anchor for supports Alternatively formwork can be used for support Hanging Method PowerDrain Only S100K S200K S300K will require M10 1 5 x 120mm bolts to screw into widgets in edge rail of channel This allows the bolt to pass through the spacers 2 x 4 s and into widget nut Cut 2 x 4 s of appropriate width to span excavated trench or formwork minimum 2 per channel S200K S300K will require 3 4 per channel Cut spacers to lift supports above finished level one per hanging 2 x 4 Drill two 16mm diameter holes aligned with the widgets in the 2 x 4 s and spacers Using M10 1 5 x 120mm bolts with washers bolt 2 x 4 and spacer to channel do not overtighten If using torque wrench do not set higher than 20 Nm Lower channels into excavated trench adjust to required position and height Packing material may be required beneath 2 x 4 s to achieve required height and to ensure channels are level If channels are to be sealed roughen ends and use a flexible sealant check chemical compatability if required Nail or bolt 2 x 4 supports securely to slab formwork This ensures channels are held securely during concrete pou
4. the preformed dril out or marked hole slot Bracing may be required Remove the remaining fins using a hammer and a sharp cold chisel Grated Trench Drains Holesaw Holesaws are available to assist with pipe connections To Suit Pipe Sizes Part Number 90mm 99095 100mm 99120 125mm 99150 150mm 99170 SDS Plus Arbour 99200 Using correct size diamond holesaw remove channel pit wall base to fit pipe Bracing may be required 9 00 A grinder may be used to dress or enlarge hole for proper pipe or channel insertion A pipe may be fitted into hole using proprietary sealant adhesive If corrosive liquids are transported in trench ensure sealant or adhesive is chemically resistant CAUTION Do not hammer directly on material to make penetration or remove drill out This may cause severe cracking of material surrounding hole Connection with Underground Piping Channels may be connected directly to underground piping via End cap outlets horizontal outlet Universal Junction Pit UMM N RN IN Vertical drill outs penetrations Cut out guides are featured on sides of on underside of channel in line pits and the universal junction pit for channel connection at depths and widths corresponding to different channel systems Using a masonry or diamond disc saw cut at required channel depth and remove wall Smooth edges with grinder and seal joint with flexible sealant 10 7 7 Milf
5. Grated Trench Drains A yan 7 bak sa L A ft A lt 5 di AN a on S r a TE eae ire i 2 er j ma Ze d y Pigs AS aN ACO DRAIN Site Installation Manual Polymer Concrete Drain Systems 2 m Getting Started ACO Drain consists of a full range of modular channels with lockable grates Systems include pits end caps and other accessories When installed correctly ACO Drain products are designed to withstand a variety of loadings as classified by AS 3996 standard for access covers and grates Polymer concrete products should be handled with care as they can be damaged by impact from other products or machinery Typical equipment necessary for installation may include Excavating equipment String line and laser level Measuring tools Masonry drill diamond holesaw grinder and or saw Rubber mallet Concrete 25 MPa minimum compressive strength Gloves respirator and eye protection www acoaus com au Health and Safety Polymer concrete products are manufactured using synthetic resin mineral aggregates and curing agents Main hazards include Abrasive damage to hands Inhalation of dust from grinding cutting or drilling Grinding cutting etc may project small fragments Gloves eye protection and a respirator should be worn to avoid these hazards Male Female downstream Grated Trench Drains Grates made fr
6. h of the following Channel pit width and For sloped and stepped systems depth dimensions excavate base of trench to roughly follow fall of trench run Concrete surround dimensions Sloped e fo See table below ACO Drain channel system 5 4 3 for recommended ee surface g 7 amp dimensions 10 gt A k pise Stepped system 030 030 030 020 020 020 010 010 Neutral gt fe eee fa f system 010 010 010 010 010 010 010 010 Trench profile Formwork if required Concrete Surround Dimensions x 7 FEN Load Class X a Ensure loose material is removed from trench A B 100mm and base is compacted C D 150mm Run string line or laser at finished surface E G 200mm level along full length of proposed trench run Specific site conditions may require an to ensure the drainage run is installed at the increase in these dimensions or correct grade reinforcement It is the customer s responsibility to ensure the concrete encasement is designed for the In concrete pavements ensure an allowance application Engineering advice may is made for expansion isolation joints be required if necessary to allow movement due to expansion contraction 8 m On Site Fabrications When cutting channels and or grates gloves pro
7. harply use gloves forward to lock bar into position K100 To remove bar insert screwdriver into holes at ends of bar and lever back To install QuickLok grate align stud serrated end which should then come free directly over locking bar Push down or K200 K300 Push plastic clips back to stand on grate until it clicks into position unlock rotate bar free y M Fit Grates Used on PowerDrain S100K S200K S300K PowerLok provides secure locking using the ACO grate removal tool To open slip flat end of grate removal tool into the slot between PowerLok mechanism and edge rail as shown Grated Trench Drains Grate removal tool yan Slide grate removal tool into grate and lift first grate out subsequent grates can be removed by hand Rotate the tool through 90 until lock mechanism slides across and clicks open Repeat for each lock 2 per grate To close Fit one side of grate under lugs in channel rail and lower grate into position Use hook on grate removal tool to push the clip back towards closed position until a click is heard Repeat for all locks 17 18 Final Inspections Remove any debris in system and grate rebate Ensure outlet pipes are clear Install rubbish baskets in pits if required Flush trench run to check for pipe work blockages unblock if necessary Empty rubbish baskets and clean out pipe connections if necessary Replace rubbish baskets I
8. iron galvanised steel and composite loadings access covers in a wide range of sizes and configurations from single to large multi part units ACO STAINLESS A range of high performance stainless steel drainage channels grates floor drains and pipes for hygiene and aesthetic applications ACO SPORT A complete range of surface drainage systems and ancillary products for sport fields running tracks and stadiums ACO HOME An range of economical domestic drainage products ideal for homes gardens and landscaped areas ACO Polycrete Pty Ltd ABN 65 050 102 942 www acoaus com au Sales Hotline Telephone 1 300 765 226 Facsimile 61 2 4747 4040 Email sales acoaus com au NSW and Head Office 134 140 Old Bathurst Rd Emu Plains NSW 2750 Australia Telephone 61 2 4747 4000 Facsimile 61 2 4747 4060 South Australia Telephone 1300 765 226 acosa acoaus com au March 2008 ACO Polycrete Pty Ltd Technical Services Hotline Email technical acoaus com au QLD Office VIC Office 467 Tufnell Road 9 Overseas Drive Banyo QLD 4014 Noble Park VIC 3174 Telephone 07 3267 8700 Telephone 03 9795 3666 Facsimile 07 3267 8711 Facsimile 03 9795 6444 acoqld acoaus com au acovic acoaus com au Western Australia Northern Territory Telephone 1300 765 226 Telephone 1300 765 226 acowa acoaus com au acont acoaus com au All reasonable care has been taken in compiling the information in this document All recommendati
9. nstall grates in proper position ensuring they are securely locked down pages 16 8 17 Drainage system is now ready for use Grated Trench Drains Maintenance Regular inspections of trench drain system are recommended Frequency will depend on local conditions and environment but should be at least annually Inspections should cover Grates and locking devices Pits and rubbish baskets Concrete surround and adjacent paving All items should be inspected for damage blockage or movement Compare with site drawings if necessary Remove grates see pages 16 8 17 Remove debris from channel Flush channels with water or high pressure washer Repair damaged surfaces if necessary with an appropriate ACO repair kit Renew joint seals as required Empty rubbish baskets and clean out pipe connections Re install rubbish baskets Re install grates ensuring they are locked in place 19 Systems with grates that have wide slots may be cleaned with the use Hm of pressured water applied through the grate debris will be washed to pits for removal Empty and replace rubbish basket Cc ACO DRAIN A range of grated trench drainage systems and pits made from Polycrete polymer concrete Grates are available in various materials and finishes for all Other ACO Product Lines ACO CABLEMATE A range of electrical and communication cable jointing pits and surface ducting systems ACO ACCESS A range of ductile
10. om metals are either cast or fabricated Main hazards include Abrasive damage cuts to hands Inhalation of dust from grinding or cutting Grinding cutting etc may generate sparks flammable items should be removed from area Gloves eye protection and respirator should be worn to avoid these hazards Operations should be conducted away from areas of fire or explosion hazard female end upstream male end Flow direction Channel sequence number Make sure arrows moulded on sides of channel all point in the intended direction of flow outlet point 4 FET Installation Sections An installed ACO Drai Concrete n insta ed ACO Drain System A AS 3996 Class A B should incorporate the following joint to Correct grate type engineer s F Correct channel type and size details Minimum grade 25 MPa Concrete compressive strength cement i Bedding layer concrete surround It is recommended that the cement 100mm concrete surround be durable and conform to minimum strength Soil requirements shown in the illustrations 100mm 100mm These illustrations are a guide for Asphalt average ground conditions only Asphalt AS 3996 Class A B l P ent If more than one pour is cast for the LI E EVA concrete surround they must be do n Li a le VOL adequately bonded to each other Road course This is for structural continuity Bedding layer Refer to 100mm for other installation scenarios
11. ons 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 Polycrete Pty Ltd reserves the right to amend products and specifications without notice
12. r Anchoring fasteners to prevent floating 2 x 4 anchoring fasteners Spacers allow to prevent floating concrete surface finishing Finished height Pouring Concrete To prevent channel wall and joints from distortion by weight of concrete grates or plywood sections cut to create a snug fit should be placed in the grate rebate of channel If grates are used they should be suitably protected from concrete contamination during concreting wrapped in plastic or masking tape and should be laid to bridge channel joints to aid alignment Shims or washers should be placed along one side to maintain a clearance gap To prevent concrete from filling channel body cover open areas with plywood or similar Bracing should suffice Concrete should have compressive strength of minimum 25 MPa If using hanging method once channels are securely in position first concrete pour should come approx 50mm up sides of channels Once concrete patties or first pour has set remaining concrete surround can be poured Concrete should be poured evenly both sides of channel and carefully to avoid dislodging channels A wand type vibrator should be used to ensure concrete distributes evenly underneath and around channels Grated Trench Drains If cold joints are a concern engineering advice should be sought to determine alternative details 13 14 7 Pavement Finishing Concrete To finish in
13. stallation trowel concrete flat Approx Finished concrete and taper down to channel edge The 45 to have slight top of adjacent pavement must be above Sppe lk to the grate level approximately 3mm this ensures all liquids drain into the channel Once concrete has set remove bracing and or grate protection Fit grates see pages 16 8 17 Expansion joints ve n r Flexible material Transverse joints cutting across channel J at channel joint Expansion haunch and base to prevent surface joint cracking in the slab may be required Ideally such joints should be positioned at channel joints Alternatively a cut may be made at the appropriate location along the channel and sealed with flexible sealant Longitudinal expansion isolation joints should be continuous and flexible They must be provided between the concrete surround and surrounding slab and may be varied to suit concrete surround width Transverse Joint by up to a metre from the channel If the joint is dowelled debonding should be provided ACO recommends seeking engineering advice Grated Trench Drains Pavement Finishing Asphalt For applications up to Load Class D asphalt can be applied directly up to channel edge See page 7 for concrete haunch details Area should be protected between concrete pour and application of asphalt as channel edge could be damaged CAUTION When rolling asphalt care should be taken not to damage channel edge or gra
14. te Asphalt must be above grate level by approximately 3mm this ensures all liquids drain into channel Once pavement is finished remove bracing and or grate protection Fit grates see pages 16 8 17 Pavement Finishing Pavers For applications up to Load Class D pavers can be installed up to channel edge See page 7 for concrete haunch details Pavers adjacent to channel MUST be fully bonded to concrete haunch This prevents movement of pavers and possible damage to channel Subsequent pavers can be bedded on compacted sand Pavers must be above grate level by approximately 3mm this ensures all liquids drain into channel Once pavement is finished remove bracing and or grate protection Fit grates see pages 16 8 17 Approx Finished asphalt 45 to have slight slope down to channel Base Course Concrete 15 ii First course bonded to concrete haunch Fit Grates Grate removal tool Used on KlassikDrain grates QuickLok provides secure boltless locking which is quick to remove replace for maintenance and cleaning Locate locking bar in the channel wall recesses by rotating clockwise To remove grate insert grate removal tool under grate bar and pull up li sharply Once first grate is removed K100 Use hammer to tap bar into remaining grates can be removed place so that the serrated ends grip in by hand Grip end of grate and lift recess K200 K300 Push plastic clips s
15. tective eye wear and respirator or mask are recommended Cutting channels is required to form mitres tee junctions and non standard lengths Fabrications can be completed on site Channels should be cut with a masonry or diamond disc saw Grates should be cut with band saw or similar with suitable blade A 2 part polymer concrete repair kit ACO Tuffstick or a suitable proprietary sealant adhesive can be used to bond cut surfaces together if required If corrosive liquids are transported in trench joints should be properly sealed Ensure the sealant adhesive used is chemically resistant Mitred joints are formed by cutting channels to required angle and butting together For heavy duty applications mitred grates are not recommended A tee joint is suggested to give grate maximum support Channels mitred Pa at 45 angle Channels are mitred grates are shown as tee joint Tee junctions are when an opening is cut into the side of one channel and another channel is butted up to this opening Mark area in channel wall to be removed by butting channels together and marking profile of interior of channel Edge rail should be left intact to provide additional strength and seating for grate A Pipe Connections Removal of preformed dril outs or cut hole Identify and mark area to be removed Remove drill out Stitch Drill Using approximately an 8mm masonry drill bit stitch drill around
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