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–DRAINAGE SOLUTIONS

SINCE 1908

SURFACE DRAINAGE Installation Guide

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RECYFIX® PRODUCTS

RECYFIX® trench drain systems are available in a wide range of load class ratings and grate options. They are constructed from high grade PP (polypropylene) making them extremely durable, lightweight and virtually unbreakable. These pre-assembled, lightweight trench drain units are easy to handle and simple to install with pre-molded lateral and vertical connections, as well as tongue and groove ends to ensure perfect alignment. They withstand frost, de-icing salt and UV radiation and are highly chemical resistant. Their torsion resistant rib design ensures stability and secure anchoring to concrete.

RECYFIX® products are made from recycled material and certified to the International Standard EN 1433.

TOOLS AND EQUIPMENT

Potential hazards include• Cuts to hands or abrasive damage• Dust inhalation from grinding or cutting activities• Potential for small fragment propulsion during grinding and cutting activities• Potential for generation of sparks during cutting of grates (flammable materials should be kept away from work area)

The following personal protection equipment is recommended when handling polypropylene products:• Gloves• Eye protection, dust mask/respirator, hard hat • Protective clothing.

The following tools and equipment may be required for a typical installation:Levelling and Alignment• String-line• Pipe laser and spirit level• Theodolite

Cutting and Drilling• Drill and drill bits (core, steel, hole saw)• Hand saw, jig-saw, angle grinder/disc cutter (cutting disks for plastic material)• Cutting/trimming knife

Excavation and Installation• Excavator (required for longer runs)• Shovel• Compactor (vibratory plate compactor)• Ready-mixed concrete• Concrete vibrating rod• Rubber mallet and wooden block• Trowel• Wrench and screw drivers• Flexible sealant

HEALTH AND SAFETY

EN 1433 C E R T I F I E D

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INSTALLATION SEQUENCE –

BEDDING METHOD

The following procedures relate to a ‘continuous trench’ installation. Before starting the installation, the contractor shall have in hand the correct Installation Drawing according to the model and size of the trench drain, the loading requirement and the surface finish.

1.1 Excavate the trench to accommodate the RECYFIX® modular catch basin and trench drain units. Remove all loose material. Take account of the following dimensions and requirements:

• Catch basin and trench drain dimensions• Depth of concrete base• Width of concrete encasement• Dimensions of trench or form-work/shuttering system (if any) • Working room• Invert levels of underground pipework• Finished surface level

1.2 A ‘blinding’ layer of concrete may be placed within the trench base to provide a level and clean environment. The trench drain concrete base will be installed on top of the ‘blinding’ layer.

1.3 Prepare the string-line or survey equipment to establish correct alignment and level. Ensure the catch basin and trench drain top edge will sit 3 to 5 mm beneath the finished surface level.

1.4 Level the ground and compact well. Ground compaction should be in accordance with ‘structural engineering static calculations’ and local standards/regulations.

Trench ExcavationSTEP 1

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The modular catch basin and trench drain units can be bedded directly on semi-dry concrete.

If a wet-mix concrete base is applied, this should be given adequate time to cure fully. The modular catch basin and trench drain units will be bedded on mortar.

Semi-Dry Base (Low Slump)

Wet-Mix Base (High Slump)

2.1 Install the concrete base (depth dimension according to load class). Refer to HAURATON Installation Drawing for dimensions.

2.2 The concrete encasement width and concrete base depth dimensions for the RECYFIX® modular catch basin are generally the same as for the trench drain installation. They are dependent on the project application and load class requirement for the specific location on site.

2.3 The concrete base can be applied as semi-dry (low-slump) or wet-mix (high-slump) concrete, depending on project requirements and load class.

Concrete Base InstallationSTEP 2

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6.1 If not already secured in place (with concrete haunch) the RECYFIX® modular catch basin can be adjusted at this stage.

6.2 Make finite adjustments to make sure the catch basin is in the proper position with the string line. Adjust if necessary with a rubber mallet or by adding more concrete/mortar beneath the modular catch basin.

Modular Catch Basin Installation: Finite AdjustmentSTEP 6

5.1 Apply sealing grease/flexible sealant to the selected pipe spigot on the RECYFIX® modular catch basin.

5.2 Connect pipe-work to the spigot (push-fit/flexible adapter, other).

Modular Catch Basin Installation: Fit the Pipe-WorkSTEP 5

4.1 Embed the RECYFIX® modular catch basin onto the concrete base (semi-dry concrete or mortar bed).

4.2 Adjust catch basin in position with the string line using a rubber mallet.

4.3 Once the correct height and position is achieved, secure the RECYFIX® modular catch basin with a concrete haunch around the base of the unit.

Modular Catch Basin Installation: Bedding and AdjustmentSTEP 4

3.1 Install the modular catch basin first and trench drain units afterwards. Lay units back (upstream) from the modular catch basin (downstream) position.

3.2 Select the correct pipe diameter. The RECYFIX® modular catch basin includes a series of pre-formed pipe connectors (with pre-formed spigots in various diameters) integral within the body of the box (at various locations).

3.3 Remove knock-out sections of plastic material from the modular catch basin by core drill.

Modular Catch Basin Installation: Prepare Pipe ConnectionSTEP 3

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7.1 Apply the concrete haunch around the base of the modular catch basin and connected pipe-work to secure these firmly in position.

7.2 Install trench drain units once the RECYFIX® modular catch basin is secured in its correct position and the concrete haunch is dry (cured).

8.1 Lay trench drain units ‘up-stream’ using the outlet position as the starting point and working backwards.

8.2 Lay trench drains with arrow (direction of flow) pointing towards the outlet.

8.3 Connect trench drain units using the ‘vertical sliding’ action with male-female ‘tongue-and-groove’ joints.

8.4 Bed units on a semi-dry concrete (or mortar) base and adjusted to the correct line and level. Finite adjustment to suit line and level can be made with a rubber mallet or by adding more concrete/mortar beneath the trench drain unit.

8.5 Apply the concrete haunch (semi-dry/low-slump concrete) to fix trench drain units securely in place once installed in the correct position.

Trench Drain Unit InstallationSTEP 8

STEP 7 Secure the Modular Catch Basin and Pipe-Work: Apply the Concrete Haunch

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Paving Units Asphalt Surface

10.1 Install the adjacent sub-base material beside the trench drain installation as per the HAURATON Installation Drawing. Ensure sub-base material is well compacted to avoid settlement.

10.2 Compact ground to achieve the project’s structural engineering static calculations and to meet local standards/regulations.

10.3 Ensure the finish grade of the trench drain top edge sits 3 to 5 mm beneath the finished surface level.

System Installation: Install Sub-Base Material and Surface FinishingSTEP 10

Paving Units Asphalt Surface

9.1 Allow the concrete haunch around the modular catch basin and trench drain installation to dry (cure) adequately before final backfilling and surface finishing occurs.

Modular Catch Basin and Trench Drain Installation: Back FillSTEP 9

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The Patty method involves the installation of concrete pads (patties) along the ground/trench base on which RECYFIX® trench drain units are supported. This method allows concrete to be poured under and around the trench drain body in one operation during the main concrete pour.

INSTALLATION SEQUENCE –

PATTY METHOD

1.1 Prepare the ground or trench base along which the trench drain will be installed.

1.2 Prepare the string-line or survey equipment to establish correct alignment and level. Ensure the modular catch basin and trench drain top edge will sit 3 to 5 mm beneath the finished surface level.

1.3 Install the outlet point first.

1.4 Set the RECYFIX® modular catch basin or trench drain with vertical/horizontal outlet on concrete bed at the correct height. Refer to previous section ‘Install modular catch basin’ Steps 3 to 6.

1.5 Connect and seal pipe-work within the outlet/trench drain unit.

2.1 Install concrete pads (patties) of semi-dry (low slump) concrete at intervals along the ground/trench base. Pads (patties) should be positioned at both ends of each trench drain unit.

2.2 Use pads (patties) to support and raise trench drain units above the ground/ trench base at the appropriate height (at the trench drain concrete base depth dimension). Refer to the HAURATON Installation Drawings.

2.3 Clean trench drain joints to ensure they are free of dirt or concrete slurry.

2.4 Apply flexible sealant within trench drain joint sealant groove if required.

Prepare Ground and Install OutletSTEP 1

Install Concrete Pads (Patties)STEP 2

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3.3 Trench drain units can be adjusted by adding or removing semi-dry concrete and/or by gently tapping with a rubber mallet.

3.4 When trench drain units are correctly positioned, additional concrete should be ‘haunched’ around the trench drain units at the location of the concrete pads (patties). Ensure that trench drain concrete anchors (within the trench drain body) are covered with concrete to secure the trench drain installation.

Final Position

3.1 Lower trench drain unit into position on concrete pads (patties).

3.2 Connect (join) trench drain units using a ‘vertical sliding action’. Lower successive trench drain units into place (downwards) along the jointing-groove of the trench drain unit that is already installed. Male/female end profiles have a ‘tongue-and-groove’ joint design.

Male End Lowered

Install Trench Drain UnitsSTEP 3

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4.1 The contractor should work back from the outlet position until the next outlet/access point is reached, using the same method.

4.2 Allow haunched concrete pads (patties) to cure sufficiently before the main pour of concrete takes place.

4.3 Pour concrete under and around the trench drain units using a vibrating rod to ensure concrete fills all voids.

4.4 Refer to the HAURATON Installation Drawings for concrete encasement dimensions and installation detail in relation to the finished surface material.

Trench drain units installed from outlet position

Install Successive Trench Drain UnitsSTEP 4

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SURFACE FINISHING

For most project applications the finished surface level (concrete encasement/ asphalt/block paving) should finish 3 to 5 mm above the top-edge of the trench drain to achieve efficient drainage and to provide protection to the trench drain system and grate.

It is recommended that strong construction tape is fitted to trench drain grates to prevent concrete slurry, asphalt or site debris from entering the system during installation.

Concrete Pavement Installation (A15 – F900; EN 1433; 2002)

Refer to the HAURATON Installation Drawings for further information regarding concrete encasement dimensions, expansion joints and steel reinforcement (if required).

Longitudinal Expansion Joint as specified by Design Engineer

Crack Control Joints as Specified by Design Engineer. Crack Control Joints need to be located where trenches are joined together.

Concrete PavementConcrete Wearing Course

Base Course Material

Frost Resistant Sub Base

Trench Drain Concrete Encasement:Refer to HAURATON Installation Drawings for specification and dimensions relative to load class

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Asphalt Surface Installation (A15 – C250; EN 1433; 2002)

Block Paving Installation (A15 – B125; EN 1433; 2002)

Cold bituminous joint compound applied at interface between trench drain edge and asphalt surface

Longitudinal Expansion Joint will be required if joints between paving units are mortar filled

Paving UnitsSand Filled Joints

Paving Unit Bedding

Base Course Material

Frost Resistant Sub Base

Asphalt Wearing CourseTack coat applied on concrete surfaces at interface between asphalt and trench drain concrete encasement

Trench Drain Concrete Encasement: Refer to HAURATON installation Drawings for specification and dimensions relative to load class

Asphalt Binder Course and Bituminous Base Course

Trench Drain Concrete Encasement (haunched): Refer to HAURATON Installation Drawings for specification and dimensions relative to load class Frost Resistant Sub Base

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FLUSHING PROCEDURE

INSPECTION AND MAINTENANCE

Regular inspections and maintenance of trench drain systems are necessary for proper functioning. The frequency depends on the local environment and operating conditions but the system should be inspected and maintained at least every 12 months.

FrequencyRefer to HAURATON for a detailed Inspection and Maintenance document.

InspectionSystems should be checked for damage, blockage or settlement. Inspection of the system should include:

• Trench drain and edge-frame housings• Concrete encasement and adjacent surfaces• Modular catch basin and sediment buckets• Grates and locking mechanisms

1. Remove grates at the start of the trench drain run and at the RECYFIX® modular catch basin (1). In most cases it will only be necessary to remove single grates at intervals along the trench drain run to allow access for flushing the system clean.

2. Remove sediment bucket from outlet box (2). The sediment bucket can remain in place during the first power-wash flushing in order to collect additional solid matter and prevent it from entering underground pipe-work.

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3. Visually inspect the trench drain system.

4. Direct a high pressure water hose with reverse jetters into the trench drain system from the RECYFIX® modular catch basin or downstream end (1) up to the upstream end of the system.

5. Pull back the hose down the line flushing the debris and sediments towards the catch basin. Water pressure to be set between 90 to 120 bar (1300 to 1750 psi).

6. Remove the sediments and debris using a vactor truck. Larger items can be removed by hand.

7. Clean sediment buckets and pipe-connections.

8. Remove debris in grate slots/openings using a screwdriver or pressure washer.

9. Remove dirt from trench drain angle-frame housings and locking mechanisms.

10. Perform necessary repairs. Worn and/or broken components should be replaced.

11. Remove cleaning equipment.

12. Replace sediment buckets.

13. Perform final flush of the trench drain system with clean water to ensure free flow.

14. Apply light oil to metal locking bolts/bars.

15. Lock grates securely into position with bolt heads secured beneath the top of the grate surface.

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DISCLAIMER:09/2017

Armtec takes reasonable and due care when compiling product information for use within marketing and technical documents. Any guidance, recommendations or advice provided regarding HAURATON products and systems is given without guarantees, as conditions relating to the use and installation of products and systems is beyond the control and influence of the company. The customer has the final responsibility to ensure the suitability of the system regarding its use and application for their project.

Armtec reserves the right to make changes to products, system designs and company information without notice. This document has been issued subject to withdrawal without prior notice. Images, photos, illustrations and specification details are not binding regarding their detail.

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–Drawings and product details are for information and/or illustrative purposes only, and may vary. Please contact your local Armtec representative for the most current product information.

–SURFACE DRAINAGE / INSTALLATION GUIDE | 2017-10PROD-C02-G15_OTH-2017-10-E