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WSAA Product Appraisal 10/11 Issue 2 1
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Aquatec Fluid Systems Pty Ltd PRODUCT APPRAISAL REPORT 10/11 Issue 2
Precast Concrete Sewage Pumping Stations DN 1800, 2250 and 3200
AS/NZS 1170 .0 :2002 - Structural design action General principles. AS 3735-2001 – Concrete structures for retaining liquids AS 4100:1998 -Steel Structures AS 3600 :20012 - Concrete Structures
Published: 12 June 2014
WSAA Product Appraisal 10/11 Issue 2 2
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Document History
The following information indicates the changes made to this document.
Date Version File Location
18/7/2011 Peer Review
U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2012\PA
1011 Aquatec\WSAA PA 10_11 Aquatec Revision 04092012.docx
11/10/2012 Publication
U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2012\PA
1011 Aquatec\WSAA PA 10_11 Aquatec Revision 08102012.docx
20/5/2014 Publication Issue 2
U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2012\PA 1011 Aquatec\Issue 2\WSAA PA 10_11 Aquatec Issue 2.docx
1st Draft Peer Reviewers
Name/Title Organisation Date
Andy Krumins, Manager Infrastructure Planning Queensland Urban Utilities 25/7/2011
Don McAdie, Wastewater Conveyance Standards Water Corporation 5/8/2011
Geoff Reynolds, Manager Asset Quality South East water. 22/7/2011
Steven Nash, Senior Engineer Asset Performance Goulburn Valley Water 9/6/2011
Pre-publication Peer Reviewers
Name/Title Organisation Date
David Moore, Manager, Design City West Water 28/9/2012
Colin Paxman - Manager Products & Standards South East water. 3/10/2012
Frank Scheele, Civil Design Engineer Queensland Urban Utilities 28/9/2012
Carl Radford, Product Appraisal Manager WSAA 4/9/2012
Carl Radford, Product Appraisal Manager WSAA 20/05/2014
Approvals
Name/Title Signature Date
Carl Radford, Product Appraisal Manager Carl Radford 11/10/2012
Carl Radford, Product Appraisal Manager Carl Radford 12/06/2014
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Overview of WSAA
The Water Services Association of Australia (WSAA) is the peak body of the Australian
urban water industry. Its members and associate members provide water and wastewater
services to approximately 16 million Australians and to many of our largest industrial and
commercial enterprises.
Urban water service providers have a critical role in ensuring that Australians have access
to adequate and high quality water services. As Australia’s population continues to grow,
with most of this growth occurring in cities, that role becomes increasingly important.
WSAA’s vision is for Australian urban water utilities to be valued as leaders in the
innovative, sustainable and cost effective delivery of water services. WSAA strives to
achieve this vision by promoting knowledge sharing, networking and cooperation amongst
members. WSAA identifies emerging issues and develops industry-wide responses. WSAA
is the national voice of the urban water industry, speaking to government, the broader
water sector and the Australian community.
Copyright
This document is copyrighted. Apart from any use as permitted under the Copyright Act
1968, no part of this document may be reproduced or transmitted in any form or by any
means, electronically or mechanical, for any purpose, without the express written
permission of the Water Services Association of Australia Limited.
© Copyright 2014 by WATER SERVICES ASSOCIATION of Australia Limited All rights
reserved.
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CONTENTS
1 EXECUTIVE SUMMARY ............................................................................................................................................. 6
1.1 Report Recommendations ..................................................................................................................................... 7
2 MANUFACTURER AND DISTRIBUTION OVERVIEW ................................................................................................ 7
2.1 Precast Concrete Manufacturers ........................................................................................................................... 7
2.2 Distributor/Supplier ................................................................................................................................................ 8
3 THE PRODUCT ........................................................................................................................................................... 8
4 SCOPE OF THE APPRAISAL ..................................................................................................................................... 9
5 APPRAISAL CRITERIA ............................................................................................................................................... 9
5.1 Quality Assurance Requirements .......................................................................................................................... 9
5.2 Performance Requirements................................................................................................................................... 9
5.2.1 Product Manufacturing Standards .................................................................................................................. 9
6 COMPLIANCE WITH APPRAISAL CRITERIA........................................................................................................... 10
6.1 Compliance with Quality Assurance Requirements ............................................................................................. 10
6.1.1 Premix concrete plant suppliers .................................................................................................................... 10
6.1.2 Precast concrete manufacturers ................................................................................................................... 10
6.1.3 Supplier ......................................................................................................................................................... 11
6.1.4 Sub suppliers ................................................................................................................................................ 11
6.1.4.1 Flexible Sealant Supplier ........................................................................................................................ 11
6.1.5 Access covers suppliers ............................................................................................................................... 11
6.2 Compliance with Performance Requirements ..................................................................................................... 11
6.2.1 Component materials .................................................................................................................................... 11
6.2.1.1 Concrete ................................................................................................................................................. 11
6.2.1.2 Concrete testing ..................................................................................................................................... 12
6.2.1.3 Reinforcement ........................................................................................................................................ 12
6.2.1.4 Jointing material for riser segments and cover slab ............................................................................... 12
6.2.1.5 Attachments ........................................................................................................................................... 13
6.2.1.6 Concrete specials, lining and coatings availability .................................................................................. 13
6.2.1.7 Wet-well and value pit access covers ..................................................................................................... 13
6.2.2 General design requirements ........................................................................................................................ 14
6.2.2.1 Structural integrity .................................................................................................................................. 15
6.2.2.2 3200 mm diameter pump wet-well and valve chamber .......................................................................... 15
6.2.2.3 2250 mm diameter pump wet-well and valve chamber .......................................................................... 16
6.2.2.4 1800 mm diameter pump wet-well and valve chamber .......................................................................... 16
6.2.2.5 Precast concrete cover slabs ................................................................................................................. 17
6.2.2.6 Cover to reinforcement for corrosion protection ..................................................................................... 17
6.2.3 Product type testing ...................................................................................................................................... 17
6.2.4 Review of the documentation and guidance for designers, installers and operatives ................................... 18
7 WSAA NETWORK REQUESTS ................................................................................................................................ 18
8 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION ................................................................................... 21
8.1 Backfill Requirements .......................................................................................................................................... 21
9 PRODUCT MARKING ............................................................................................................................................... 21
10 PACKAGING AND TRANSPORTATION ................................................................................................................. 22
11 PRODUCT WARRANTY .......................................................................................................................................... 22
12 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT ..................................... 22
13 DISCUSSION ........................................................................................................................................................... 22
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14 LIFE EXPECTANCY ................................................................................................................................................ 23
15 FUTURE WORKS .................................................................................................................................................... 23
16 REPORT RECOMMENDATIONS ............................................................................................................................ 24
17 DISCLAIMER ........................................................................................................................................................... 24
17.1 Issue of Report .................................................................................................................................................. 24
17.2 Limits on Reliance on Information and Recommendations................................................................................ 24
17.2.1 Disclaimer of liability ................................................................................................................................... 24
17.2.2 Need for independent assessment ............................................................................................................. 25
17.3 No Updating ...................................................................................................................................................... 25
17.4 No Warranty ...................................................................................................................................................... 25
APPENDIX A – TECHNICAL MANUAL ........................................................................................................................ 26
APPENDIX B - QUALITY CERTIFICATIONS ............................................................................................................... 33
APPENDIX C - WSA PRODUCT SPECIFICATION ...................................................................................................... 37
APPENDIX D - SUPPLIER CONTACTS ....................................................................................................................... 38
APPENDIX E –PACKAGING AND TRANSPORTATION .............................................................................................. 39
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1 EXECUTIVE SUMMARY
Issue 2 of this Report includes amendments which recognize that Aquatec Environmental
Group Pty Ltd, trading as Aquatec Fluid Systems Pty Ltd, has appointed a new pre-mixed
concrete supplier and precast concrete manufacturer for their range of mould formed
Precast Concrete Sewage Pumping Stations with integral valve chamber.
Aquatec Fluid Systems specialises in the supply of packaged pumping stations and
services for individual council or Water Agency requirements across Australia.
Aquatec Fluid Systems Pty Ltd (Aquatec) has submitted for WSAA appraisal their range of
mould formed Precast Concrete Sewage Pumping Stations with integral valve chamber.
The Aquatec Precast Concrete Packaged Sewage Pumping Stations are available in three
sizes - 1800 mm, 2250 mm and 3200 mm diameters up to a maximum depth of 15 metres.
However for the purposes of this appraisal WSAA has elected to assess the performance
of this product up to a maximum depth range of 10 metres.
The Aquatec range of Precast Concrete Sewage Pumping Stations comprises modular
segments known as a base casting, standard increments, cantilevered valve chamber and
cover slab. To affect a water tight joint between joint segments Aquatec specify a flexible
mastic joint sealant. The manufacture of these components is carried out at an accredited
concrete precast plant with JAS-ANZ third party Quality Management System,
accreditation to ISO 9001:2008
Unless otherwise nominated in the project specification, a minimum 50 MPa concrete shall
be used in the pre-cast concrete base casting standard increments, cantilevered valve
chamber and cover slab segment application. The minimum internal cover to reinforcement
shall be 45 mm and calcareous aggregate shall be used.
The project consultant and/or Water Agency is responsible for determining the suitability of
the station design for the local ground conditions.
A range of options and accessories (offered at fit out) are outlined in this Appraisal to
demonstrate product versatility but are not intended to be included in the appraisal. The
project constructor will need to ensure that the specifications for covers, pumping
equipment, electrical controls and cubicle comply with relevant project documentation
based upon the individual council or Water Agency standards. Each station can be
designed to accommodate multi-part cast iron Class D covers or aluminium covers.
Aquatec is affiliated with another Australian owned company called Global Pumps (formally
All Pumps Supplies). Global Pumps also specialises in packaged pumping products and
services. All Pumps Supplies was the Report Holder of WSAA Product Appraisal Report No
99/26 until it lapsed in March 2008. The Product Appraisal Report No 99/26 issued to All
Pumps Supplies covered their range of 1800 mm diameter and 2250 mm diameter
packaged pumping stations.
Global Pumps and Aquatec share dedicated steel moulds for their respective range of
mould formed precast concrete sewage pumping stations.
A new 3200 mm diameter Precast Concrete Sewage Pumping Station has been added to
Aquatec product range. The range of packaged pumping station sizes covered is 1800 mm
to 3200 mm in diameter.
The Aquatec range of Precast Concrete Sewage Pumping Stations is designed in
accordance with AS 3735 – Concrete structures for retaining liquids which also
supplements and takes precedence over the requirements of AS 3600 – Concrete
structures for strength.
MLEI Consulting Engineers incorporating the practice of Pocius & Associates Pty Ltd has
provided revised structural calculations and associated drawings for the Aquatec range of
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Precast Concrete Sewage Pumping Stations comprises modular segments known as a
base casting, standard increments, cantilevered valve chamber and cover slab.
The original calculations and associated drawings, compiled by Pocius & Associates Pty
Ltd have been amended to address the following additional requirements identified by the
WSAA Infrastructure Products and Material (IPAM) Network.
Exposure Classification “D” has been used for all wall surfaces;
80kN vehicle loading has been assumed;
Groundwater level has been assumed to be at the top of the precast concrete sewage pumping station;
Floatation calculations have been amended; and
The capacity of the cantilever cover slab extension has been recalculated.
The requirements of this appraisal have now been met with respect to general design
requirements, product type testing, auditing of production quality control systems, review of
documentation and guidance for designers, installers and operatives and the products are
seen as 'fit for purpose'.
1.1 Report Recommendations
It is recommended that WSAA Members and Associates, subject to any specific
requirements of the Member or Associate, accept or authorise the Aquatec range of
Precast Concrete Sewage Pumping Stations, as detailed in this report for use in sewerage
networks provided pipeline design, installation, acceptance testing and commissioning are
in accordance with relevant WSAA Codes, WSAA Member Integrated Codes, and the
manufacturer's requirements.
Water Agencies considering installing an Aquatec Precast Concrete Sewage Pumping
Stations at depths greater than 8.0m are advised to consult with Aquatec representatives.
2 MANUFACTURER AND DISTRIBUTION OVERVIEW
2.1 Precast Concrete Manufacturers
Bianco Walling Pty Ltd Trading as Bianco Precast manufactures the precast concrete
products for the Aquatec range of Precast Concrete Sewage Pumping Stations, using
dedicated steel moulds supplied and owned by Aquatec. Bianco Precast has third party
accreditation to IS O9001:2008 Certificate No: QEC24389
Bianco Walling Pty Ltd Trading as Bianco Precast commenced operations in 1994 and is a
manufacturer of a range of precast concrete products serving new infrastructure, defense,
commercial and industrial projects throughout Australia. The range of products includes:
Structural building products such as Architectural and Grey panels, columns and beam
Drainage Products such as Junction Boxes, Side Entry Pits, Grated Inlet Pits, Other Pits, Inspection Openings, Trench Grating ,Trade Waste Arrestors, Culverts,
Sewer and Stormwater Products such as precast sewer MH’s, Maintenance shaft and Inspection Shaft concrete access covers, Meter boxes covers and frames.
Boral Resources (SA) Limited supplies batched premixed concrete to Bianco Walling Pty
Ltd Trading as Bianco Precast for manufacturing the Aquatec range of concrete packaged
pump stations. The Boral Resources (SA) Limited Premix Concrete Batching Plant is
located at Wingfield in South Australia. Boral Resources (SA) Limited has third party
accreditation to ISO 9001:2008 (Certificate No. QEC6063000-SQ-002).
Boral Resources (SA) Limited also supplies pre-mixed concrete to domestic, commercial
and industrial markets in South Australia and has been servicing Australia’s market with
pre-mixed concrete since 1972.
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2.2 Distributor/Supplier
Aquatec Environmental Group Pty Ltd (trading as Aquatec Fluid Systems Pty Ltd) was
founded in Shepparton in 1993 and since that time, has expanded its facilities and services
and carries out all works under ISO 9001 quality assurance accreditation. Aquatec is a
supplier of pumping equipment to government and municipal authorities, hydraulic and
mechanical services, civil engineers, contractors and the mining and general industry.
Aquatec is a privately owned company with a sister company, Global Pumps (formally All
Pumps Supplies) located in Edwardstown, South Australia.
As well as the range of packaged pumping systems, Aquatec has also developed a range
of water and wastewater treatment packages, pollution control systems, potable water
treatment packages, oil-water separators, trade waste treatment plants, storm water
diversion equipment, and chemical dosing systems. All of these systems are individually
tailored using standardised designs to meet specific customer requirements and assure
compliance with relevant standards and statutory requirements.
Aquatec facilities include a 1000 m2 warehouse and a 2400 m2 fully equipped service and
fabrication workshop with gantry crane, including a dedicated pump test bay complying
with AS 2417-2001 Rotodynamic pumps - Hydraulic performance acceptance tests -
Grades 1 and 2.
Aquatec has a technical service division supported by qualified personnel and fully
equipped site service vehicles, having the capacity to handle complete turn-key projects
including mechanical and electrical installations, total refurbishments, site repairs and
maintenance programs.
Aquatec is currently a Melbourne Retail Water Agency accredited Consultant/Contractor to
provide design engineering, auditing and construction services to the Land Development
industry for Sewage Pumping Stations.
3 THE PRODUCT
Aquatec Fluid Systems Pty Ltd markets a range of precast concrete sewage pumping
stations. Bianco Walling Pty Ltd Trading as Bianco Precast manufactures the concrete
segments using dedicated steel molds owned and supplied by Aquatec and premixed
concrete supplied by Boral Resources (SA) Limited. The concrete segments are jointed
with a butyl mastic rubber composite material which is specifically designed for the sealing
of segmented concrete pipes and maintenance hole units.
Aquatec Precast Concrete Sewage Pumping Stations sizes include 1800 mm diameter,
2250 mm diameter and 3200 mm diameter with an attached integral/cantilevered valve
chamber. A separate precast concrete valve chamber can be supplied, when specified.
Aquatec Precast Concrete Sewage Pumping Stations consist of the following components:
precast concrete base section;
standard increment;
attached integral/cantilevered valve chamber or separate precast concrete valve chamber engineered to be self-supporting as an unsupported cantilevered structure.
valve chamber increments and
cover slab.
Each station can be designed to accommodate a multipart cast iron, Class B or D solid-top
or concrete infill cover or a fabricated aluminium cover.
Aquatec Precast Concrete Sewage Pumping Stations components are illustrated in
Appendix A.
The range of Aquatec Precast Concrete Packaged Sewage Pumping Stations listing the
model numbers and specifications is shown in Table 1.
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Table 1 Precast Model Numbers and Specifications
Model Internal
Diameter (mm)
Min Depth (mm)
Integral valve
Incremental Size (Min-
Max)
Max Depth
Nominal Pit Capacity (I)
Capacity per
Extra m/l
Max Pipe work size
Cast Iron or Alum Cover
Twin or
single Pump
PPM-1 1800 2000 1200 x 1200 300 x 1000 10000 4500 2600 150 ● ●
PPM-2 2250 2000 1500 x 1500 300 x 1510 10000 7000 3980 200 ● ●
PPM-3 3200 2000 2200*1800 500 x 1500 10000 14300 8000 450 ● ●
Aquatec Precast Concrete Sewage Pumping Stations are usually supplied to include fit -out
with a range of optional accessories including pumps and valves installed with either
polyethylene or ductile iron pipe work, well washers, ladders, platforms and stainless steel
adjustable brackets. Adaptors to suit non standard pumps can also be provided. Electrical
controls including main switchboard and level controls, can be supplied by Aquatec, to
Water Agency specification, if specified.
4 SCOPE OF THE APPRAISAL
The scope of this appraisal is limited to the range of Aquatec Precast Concrete Sewage
Pumping Stations referenced in Section 3, and the flexible joint sealant supplied.
The range of optional accessories (fit-out) are discussed in Clause 6.2.1.5 and 13 to
demonstrate product versatility but not intended to be included in the appraisal as they are
usually supplied to individual agency specification.
5 APPRAISAL CRITERIA
Appraisal criteria is determined by the WSAA Infrastructure Products and Materials
Network and regularly reviewed to ensure that the criteria reflects the requirements of
WSAA members.
5.1 Quality Assurance Requirements
The WSAA Infrastructure Product and Materials Network accept pre-cast concrete
components manufactured and supplied under cover of a certified ISO 9001 management
system. The scope of the certification shall include “Manufacture and supply of pre -mixed
concrete to AS 1379” (or similar).
5.2 Performance Requirements
5.2.1 Product Manufacturing Standards
There is no specific Australian or International product standard that provides
manufacturers, designers and installers with a document that outlines the specifi c criteria
for the manufacture of pre-cast concrete chambers for sewerage applications, applicable to
the scope of products covered by this appraisal.
In Australia and New Zealand Precast Concrete Access Chamber for Sewerage
Applications are manufactured in accordance with AS 4198 Precast concrete access
chambers for sewerage applications, however this standard is limited to precast concrete
access chambers intended for use with buried sewer pipes to a depth of 6 m and for pipes
not greater than 300 mm in diameter.
AS/NZS 1546.1 specifies the performance requirements and performance criteria for septic
tanks, but is limited to domestic wastewater flows of 14,000 litres per week. This flow limit
represents a maximum daily flow of 2000 litre. Applying this standard to a ‘small’ pumping
station (<90L/s) is not recommended by WSAA.
Until such time as an appropriate Industry Standard, Australian or International Standard is
developed which specifies the
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(a) requirements of precast concrete access chambers;
(b) the minimum requirements for the materials to be used in, and the manufacture of;
and controlled quality precast concrete access chambers components; and
(c) includes descriptions of methods of sampling and testing of components.
the performance criteria defined in Section 6.2 shall be applied.
For the purposes of this appraisal the manufacture and supply of premixed concrete used
to produce the base casting, standard increments, cantilevered valve chamber and cover
slab has been assessed for compliance against WSA 114 Concrete Special Class.
The requirements for special class pre-mixed concrete have been developed for
specification in the construction of principally sewerage infrastructure assets where
concrete durability is critical to the life expectancy of such assets. Concrete provided shall
be the class specified in the purchase order and/or referenced design plans, Specifications
or Drawings based upon the individual council or Water Agency standards.
Table 2 in Section 6.2.1.1 provides a comparative assessment with concrete mix design
produced by Boral Resources (SA) Limited and WSA 114 Concrete Special Class
The concrete structure design has been appraised for compliance with AS 3735 - Concrete
structures for retaining liquids for serviceability and other relevant parts of WSA 04:2005
Sewage Pumping Code of Australia.
A geotechnical report, prepared with information determined from soil samples taken at the
Sewage Pumping Station site, is requested by Aquatec in order to verify the structural
integrity of the design of the Precast Concrete Sewage Pumping Stations. As a minimum
the geotechnical report shall contain soil classification, information on the water table
location, the soil bearing capacity and the lateral earth pressure coefficients.
6 COMPLIANCE WITH APPRAISAL CRITERIA
6.1 Compliance with Quality Assurance Requirements
6.1.1 Premix concrete plant suppliers
The Industry Standard WSA 114 Concrete Special Class, Section 2.1 requires special
class concrete to be manufactured by quality endorsed companies to AS/NZS: 9001. The
scope of ISO 9001 certification should also include reference to “Manufacture and supply
of premixed concrete to AS 1379 - Specification and supply of concrete” (or similar).
Bianco Walling Pty Ltd Trading as Bianco Precast uses premixed concrete supplied by
Boral Resources (SA) Limited to manufacture Aquatec’s range of precast concrete modular
base, standard increments, cantilevered valve chamber and cover slabs. Boral Resources
(SA) Limited is a Quality Endorsed Company and holds ISO 9001 Certificate of
Registration No 6063000-SQ-002, for the manufacture and supply of premixed concrete.
(Refer to Appendix 'B').
6.1.2 Precast concrete manufacturers
Bianco Walling Pty Ltd Trading as Bianco Precast manufacturers the complete range of
precast concrete base casting, standard increments, attached cantilevered valve chambers
and cover slabs for the Aquatec Precast Concrete Sewage Pumping Stations.
Bianco Walling Pty Ltd Trading as Bianco Precast is a Quality Endorsed Company and
holds AS/NZS ISO 9001:2008 Certificate of Registration No QEC 24389 for the
manufacture of precast concrete products in concrete and glass reinforced concrete.
Aquatec has submitted a copy of the Bianco Walling Pty Ltd Trading as Bianco Precast SAl
Global Surveillance Audit Report dated 2 July 2013 - 17 July 2013 indicating no major
NCR's and no opportunities for improvement. (Refer to Appendix 'B')
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6.1.3 Supplier
Aquatec’s quality management system has been audited to AS/NZS ISO 9001:2008 by
Qual-Safe Management Systems 'Certificate of Compliance' No 100326 The scope of the
quality management system covers the Supply of packaged pumping products and
services to the water and wastewater industries. (Refer Appendix 'B').
6.1.4 Sub suppliers
6.1.4.1 Flexible Sealant Supplier
Bostik Australia Pty Ltd is a Quality Endorsed Company accredited by SAI Global to ISO
9001:2008, License No. QEC22260. Bostik Australia Pty Ltd states that their quality
system has also been formulated around the stringent requirements of the automotive
industry. Bostik is a butyl rubber sealant widely used in the sewerage industry in pipe
jointing to ensure integrity of joints. (Refer to Appendix 'B').
Petro Coating Systems Pty Ltd is a Quality Endorsed Company accredited by Bureau
Veritas to ISO 9001:2008, License No. 11000132 (Refer to Appendix 'B')
6.1.5 Access covers suppliers
Multipart covers and frames both infill and solid top are supplied to comply with AS 3996 -
2006 Access covers and grates.
NOTE:1 It is recommended that access covers and frames be supplied under cover of an ISO Type 5
Product Certification scheme administered by a JAS-ANZ accredited conformity assessment body.
6.2 Compliance with Performance Requirements
6.2.1 Component materials
6.2.1.1 Concrete
The Water Industry Standard WSA 114 Concrete Special Class, Section 2.1 requires
special class concrete to be manufactured by quality endorsed companies to AS/NZS:
9001. The scope of ISO 9001 certification should also include reference to “Manufacture
and supply of premixed concrete to AS 1379 - Specification and supply of concrete” (or
similar). (Refer to Appendix 'B')
Boral Resources (SA) Limited supplies pre-mixed concrete to Bianco Walling Pty Ltd
Trading as Bianco Precast for manufacturing the Aquatec range of Precast Concrete
Sewage Pumping Stations.
Aquatec has provided a special concrete mix design for concrete supplied by Boral
Resources (SA) Limited for the production of the base casting, standard increments,
attached cantilevered valve chambers and cover slabs. Boral Resources (SA) Limited can
also vary the concrete mix design details or proportions to achieve specification criteria.
The special concrete mix design details for concrete supplied by Boral Resources (SA)
Limited for the production of the Aquatec Precast Concrete Sewage Pumping Stations
complies with Section 4 of the WSAA Water Industry Standard WSA 114 Concrete Special
Class.
Table 2 Concrete Special Class Specification as per Water Industry Standard WSA
114-2002
Specification Details as Water Industry Standard WSA 114-2002 Concrete Special Class versus Boral Resources (SA) Limited concrete mix design detail
WSA 114-2002 Boral Resources (SA) Limited
Strength Grade Minimum 40 MPa Minimum 50MPa
Compressive Strength at 28 days (MPa) – minimum.
S40 (MPa) (S = Special Concrete) S50 (MPa) (S = Special Concrete)
Water Cement Ratio Not to exceed 0.5 Complies
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Specification Details as Water Industry Standard WSA 114-2002 Concrete Special Class versus Boral Resources (SA) Limited concrete mix design detail
Minimum Cementitious content 350 Kg/m3 Complies
Maximum Aggregate size Calcareous aggregate 10mm See Note 1 Complies
Fine Aggregate size Refer to WSA 114 Rolca Golden Grove and Boral Linwood
Admixtures Refer to WSA 114 Sika Australia Water reducing Admix ( See Note 3)
Max Dry Shrinkage 700 x 10-6. @ 56 days Complies
Alkali Content (Na2O equiv) Maximum 3Kg/m3 Complies
NOTE:1 Calcareous aggregate supplied to Boral Resources (SA) Limited is sourced from Penrice Quarry,
Angaston, South Australia. The maximum size of aggregate used is 20 mm.
NOTE:2 The WSAA Water Industry Standard WSA 114 for Concrete Special Class is available on their web
site at https://www.wsaa.asn.au/Publications/NationalCodes/Pages/WaterIndustryStandards.aspx
NOTE:3 The water reducing accelerator is a non-chloride accelerator admixture based on modified co-
polymer technology.
Boral Resources (SA) Limited has 2 mix designs. The first mix design is the “Summer Mix”
and the second is the “Winter Mix”. They are basically both the same except the second
mix has Silca Fume added which they may use during the winter months. Both mixes
comply with WSAA Water Industry Standard WSA 114.
The following Product Specification is also relevant to this application WSA PS 358
Concrete. Pre-mixed Special Class.
A copy of the above Specification is attached to Appendix C or can be downloaded from
the WSAA website.
6.2.1.2 Concrete testing
In accordance with WSA 114 - 2002 Special class concrete shall be sampled, tested and
assessed for compliance in accordance with AS 1379, Section 5.
Boral Resources (SA) Limited operates under a Quality Management System which
complies with the requirements of ISO 9001:2008. The registration covers the quality
management system for the manufacture and supply of pre-mixed concrete.
Boral Resources (SA) Limited carries out routine quality testing on all grades on concrete
produced. All testing is carried out by NATA registered laboratories accredited for
compliance with ISO/IEC 17025. Boral Resources (SA) Limited use both Hanson Testing
and Lab SA Pty Ltd.
6.2.1.3 Reinforcement
The Aquatec pump station utilises S50 (50 MPa) Special mix concrete and therefore under
AS 3735 requires a minimum of 45mm cover over reinforcing. Pocius & Associates Pty Ltd
directions on reinforcement for the 1800 mm diameter, 2250 mm and 3200 mm diameter
components states:
All steel reinforcement shall comply with AS 1302, AS 1303 and AS 1304.
It should be pointed out that AS/NZS 4671:2001 Steel reinforcing materials supersedes AS
1302, AS 1303 and AS 1304. Aquatec advise that their drawings are being revised to
reflect the new Australian Standards reference to steel reinforcement.
6.2.1.4 Jointing material for riser segments and cover slab
Aquatec has supplied Technical Data Sheets for the Bostik 5240 and JointGuard butyl
mastic sealing strip. These two products are designed for the sealing of segmented
concrete pipes and maintenance hole units. (Refer to Appendix A).
Aquatec recommends the Bostik 5240 product be used as the sealant between the
concrete riser segments and the cover slab, particularly in homogenous sandy soils of
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uniform moisture. The use of mastic sealing strip joints in clay soil, particularly in saturated
conditions, should be investigated on a project-by-project basis, in conjunction with the
geotechnical report and advice from suitably qualified structural engineer.
Aquatec is currently trialing the JointGuard Sealing Strip, supplied by Petro Coating
Systems Pty Ltd, for the sealing of precast concrete riser segments and the cover slab.
The Bostik 5240 and JointGuard butyl mastic sealing strips are a blend of synthetic rubber
compounds.
The Network recommended ASTM C990M-09: Standard Specification for Joints for
Concrete Pipe, Manholes, and Precast Box Sections Using Preformed Flexible Joint
Sealants (Metric), be used as performance standard for the jointing material.
At the time of preparing this report no comparative performance data for the Bostik 5240
butyl mastic sealing strip was available and this item has been referred to Future Working
Items in Section 14 of this appraisal report.
The Technical Data Sheets for the JointGuard butyl mastic sealing strip claims this product
conforms fully with the requirements of ASTM C990M-09 and offers a service life of 30
years plus.
The Bostik 5240 butyl mastic sealing strip has been successfully used in the above
applications for over 30.
The Bostik 5240 Technical Data Sheet is attached to Appendix A and can also be
downloaded from the following web site www.bostikfindley.com.au.
The JointGuard Round Section Butyl Mastic Strip Technical Data Sheet is attached to
Appendix A and can also be downloaded from the following web site
http://www.petrocoating.com.au
6.2.1.5 Attachments
Aquatec design, manufactures and supplies either own stainless steel (SS) 316 ladders
and brackets. Other attachments such as platforms, handrails or fiber reinforced plastic
ladders can be fitted to suit Water Agency Specifications.
NOTE: The above items are not included in this appraisal.
6.2.1.6 Concrete specials, lining and coatings availability
Standard components are unlined and uncoated, however a corrosion protection lining
and/or coating as specified in the Water Specification can be applied to the interior of the
components.
Aquatec can supply mechanically anchored polyethylene lining to all their Aquatec precast
modular pumping stations.
6.2.1.7 Wet-well and value pit access covers
Aquatec supply single and multi-part solid-top or recessed (with concrete infill) cast ductile
iron access covers and frames, sourced from Havestock for their range of Precast
Concrete Sewage Pumping Stations.
Single and multi-part solid top access covers and frames have been appraised for
compliance with AS 3996:2006 Access covers and grates.
In trafficable area, Class D covers and frames shall be provided to access points. In non-
trafficable areas, Class A access covers hinged to frames can be provided to access
points.
The aluminium access covers for the wet-well and valve chambers are designed and
fabricated by Aquatec. Aluminium is commercial grade 5052 in H32 temper with triple grip
finish. The aluminium access covers are not designed for vehicle loads.
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Aquatec has advised that in line with current trends, pumping stations are rarely located in
trafficable areas and ductile iron covers are therefore not normally fitted. Aquatec advise
that some ductile iron covers exceed OH&S maximum lifting limits and pose other safety
risks to service personnel..
Aquatec has submitted detailed drawings covering the design and fabrication of the
lockage aluminium hinged lids, including the galvanised swing up safety grate. The cover
is manufactured from 6 mm (min) aluminium checker plate with recessed hinges and lifting
handles. Hinged safety grates are mounted below the cover to prevent operators
accidentally falling into the wet-well. The individual covers are opened only during pump
removal. The covers are sized to suit the pump and valve access requirements and the
hinge assemblies and step down frame is cast into the cover slab.
Aquatec assemble a EPDM rubber odour seal to the frame edging under the cover.
Aquatec advise that their aluminium covers are not water or gas tight. The cover slab is set
above ground level if rainwater surface infiltration is likely. The height of the cover slab
above ground level is specified on the Project Drawings to conform to the Water Agency
requirements.
Aquatec have indicated that aluminium post inserts for corner posts for rail safe telescopic
guardrail system can be cast into the cover slab or mounted underneath the cover.
Aquatec aluminium covers, when subjected to centrally placed load of 120 kg, did not
exceed the 20 mm deflection of the cover, as specified in Clause 5.8 of the Sewage
Pumping Station Code of Australia, WSA-04-2005.
Aquatec safety grates can be made to order with a suitably located lockable access point
and cover of minimum size 300 mm x 300 mm to allow easy access for maintenance of all
level sensing equipment. Safety grates are provided as standard on all Aquatec pump
stations.
The aluminium cover design allows the cover to be opened fully and laid flat.
For valve chamber depths greater than 1.5 m, Aquatec recommend safety grates.
6.2.2 General design requirements
Aquatec has supplied structural calculations and drawings by a suitably qualified engineer,
using appropriate design methodology and relevant standards for the standard precast
concrete components, in the size ranges offered by Aquatec up to a maximum depth of 15
metres. Accompanying the structural calculations and drawings is a design verification
statement, signed by a Registered Professional Engineer from Pocius & Associates Pty
Ltd, verifying the following item of concrete plant has been verified in respect to design and
construction details by Pocius & Associates Pty Ltd by calculation.
The original calculations and associated drawings, compiled by Pocius & Associates Pty
Ltd have been amended to address the following additional requirements identified by the
WSAA Infrastructure Products and Material (IPAM) Network.
Exposure Classification “D” has been used for all wall surfaces;
80kN vehicle loading has been assumed;
Groundwater level has been assumed to be at the top of the precast concrete sewage pumping station;
Floatation calculations have been amended; and
The capacity of the cantilever cover slab extension has been recalculated.
The MLEI Consulting Engineers incorporating the practice of Pocius & Associates Pty Ltd
has provided revised structural calculations and associated drawings for the Aquatec range
of Precast Concrete Sewage Pumping Stations comprises modular segments known as a
base casting, standard increments, cantilevered valve chamber and cover slab.
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The requirements of this appraisal have now been met with respect to general design
requirements, product type testing, auditing of production quality control systems, review of
documentation and guidance for designers, installers and operatives and the products are
seen as 'fit for purpose'.
6.2.2.1 Structural integrity
The Aquatec pump station utilises a S50 (50 MPa) Special mix concrete. In accordance
with AS 3735 the minimum requirement for cover over reinforcement is 45 mm.
Pocius & Associates Pty Ltd, Structural Engineers, has prepared computations and
construction notes for the 1800 mm diameter, 2250 mm diameter and 3200 mm diameter
concrete components. The design criteria include the following:
For the 1800 mm, 2250 and 3200 diameter assembly:
(a) Minimum internal depth of 2 m + 1 m top segment. (Overall depth)
(b) Maximum depth – 15 m. (Overall depth)
(c) Liquid depth – 2 m in normal operating range Calculations for full immersion have
been taken into consideration.
(d) An exposure classification of D (Severe/extreme)
Pocius & Associates Pty Ltd specifications include:
(a) All concrete elements are to be precast in steel forms using intense vibration.
(b) The maximum wheel loading on the cover slab is 80 kN (8 Tonne). Cover Slabs
designed for higher loadings are available to suit heavy duty covers
(c) Ground water level to 2 m below surface level and calculations for full immersion
have been taken into consideration.
Pocius & Associates Pty Ltd computations have been submitted to verify the design of the
concrete components. Using calcareous aggregate, 10 mm loss of material has been
allowed for the structural design. The computations include:
For the 1800, 2250 and 3200 mm diameter wet-well - structural strength to 15 m deep and an exposure classification of D (Severe/extreme).
The integral valve chamber structural strength computations are based on the protruding
structure being cantilevered and not relying on backfill for support.
The design drawings for the 1830, 2250 and 3200 mm diameter pump wet-well and valve
chamber, up to in 15m depth, have been amended to reflect changes to ballast
configuration.
6.2.2.2 3200 mm diameter pump wet-well and valve chamber
The 3200 mm diameter pump wet-well and valve chamber are certified for up to 15 m
deep, based on the certified design drawings and Pocius & Associates Pty Ltd
computations.
Aquatec has supplied design drawings and Pocius & Associates Pty Ltd computations for
the 3200 mm diameter precast sections show the base section has a reinforced under-slab
thickness of 250 mm and a footprint diameter of 3750 mm. There are two flat sides to the
base giving an overall width of 3500 mm which is within the limit for non-over width
transport. The inside has a 500 mm high non-symmetrical benching or batter to prevent
solids build-up in the 'dead area' behind the pump stands. Aquatec advise that the mould
formed method of manufacture provides a steeper and more efficient sludge batter than is
possible with separate pouring and being part of the reinforced base there are no
shrinkage cracks that require post-cast sealing. The overall height of the base section is
1990 mm. The reinforced wall is tapered and has a minimum thickness of 120 mm at the
top with a rebate key formed to accept the riser section and sealant.
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The 3200 mm internal diameter riser sections are available up to 1500 mm high and have a
minimum wall thickness of 120 mm as S50, 50MPa concrete is used requiring minimum 45
mm cover over reinforcing. Riser increments can be supplied in almost any combination to
give the exact finished depth required but would normally be supplied in multiples of 250
mm. The upper and lower edges have rebate key forms to match the base and accept
additional riser sections or cover slab.
The 3200 mm diameter integral valve chamber increment has the valve chamber
reinforcement interlocking with the riser section reinforcement and in a cantilevered
formation. The riser and valve chamber has an overall height of 1000 mm (available
deeper on request) and a minimum wall thickness of 120 mm. The floor of the valve
chamber is also 120 mm thick with a 15 mm fall towards the floor drain. Reinforcement in
the valve chamber is centrally placed to maintain a minimum 45mm cover in accordance
with AS 3735 when utilizing S50, 50 MPa concrete. The underside has a rebate key formed
to accept the riser section. The valve chamber is 2200 mm x 1800 mm inside. The inside
wall height of the valve chamber is set down 10 mm to provide a clearance for the cover
slab and not act as a load bearing surface.
6.2.2.3 2250 mm diameter pump wet-well and valve chamber
The 2250 mm diameter pump wet-well and valve chamber are certified for up to 15 m
deep, based on the certified design drawings and Pocius & Associates Pty Ltd
computations.
Aquatec has supplied design drawings and Pocius & Associates Pty Ltd computations for
the 2250 mm diameter precast sections show the base section has a reinforced under-slab
thickness of 200 mm and a footprint diameter of 2780 mm. There are two flat sides to the
base giving an overall width of 2500 mm which is within the limit for non-over width
transport. The inside has a 350 mm high non-symmetrical benching or batter to prevent
solids build-up in the 'dead area' behind the pump stands. Aquatec advise that the mould
formed method of manufacture provides a steeper and more efficient sludge batter than is
possible with separate pouring and being part of the reinforced base there are no
shrinkage cracks that require post-cast sealing. The overall height of the base section is
1980 mm. The reinforced wall is tapered and has a minimum thickness of 115 mm at the
top with a rebate key formed to accept the riser section and sealant.
The 2250 mm internal diameter riser sections are available from 300 mm up to 1500 mm
high and have a wall thickness of 115 mm. (due to the use of S50 concrete minimum of 45
mm cover required) Riser increments can be supplied in almost any combination to give
the exact finished depth required but would normally be supplied in multiples of 250 mm.
The upper and lower edges have rebate key forms to match the base and accept additional
riser sections or cover slab.
The 2250 mm diameter integral valve chamber increment has the valve chamber
reinforcement interlocking with the riser section reinforcement and in a cantilevered
formation. The riser and valve chamber has an overall height of 1000 mm (available
deeper on request) and a minimum wall thickness of 115 mm. The floor of the valve
chamber is also 115 mm thick with a 15 mm fall towards the floor drain. Reinforcement in
the valve chamber is centrally placed except the wet-well area dividing wall, where it is
offset to maintain a 60 mm cover internally. The underside has a rebate key formed to
accept the riser section. The valve chamber is 1500 mm square inside. The inside wall
height of the valve chamber is set down 10 mm to provide a clearance for the cover slab
and not act as a load bearing surface.
6.2.2.4 1800 mm diameter pump wet-well and valve chamber
The 1800 mm diameter pump wet-well and valve chamber are certified for up to 15 m
deep, based on the certified design drawings and Pocius & Associates Pty Ltd
computations.
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Aquatec has supplied design drawings and Pocius & Associates Pty Ltd computations for
the 1800 mm diameter precast sections show the base section has a reinforced under-slab
thickness of 200 mm and a footprint diameter of 2400 mm. The inside has a 350 mm high x
250 mm wide benching or batter and 500 mm wide section at the area behind the pump
location to prevent solids build up in the 'dead area' behind the pump stands. Aquatec
advise that the mould formed method of manufacture provides a steeper and more efficient
sludge batter than is possible with separate pouring and being part of the reinforced base
there are no shrinkage cracks that require post-cast sealing. The overall height of the base
section is 2000 mm. The reinforced wall is tapered and has a minimum thickness of 100
mm (due to S50, 50MPa concrete minimum of 45mm over reinforcement required) at the
top with a rebate key formed to accept the riser section and sealant.
The 1800 mm internal diameter riser sections are up to 1000 mm high and have a
minimum wall thickness of 100 mm (as above).The floor of the valve chamber is also 100
mm thick with a 15 mm fall towards the floor drain. The upper and lower edges have rebate
key forms to match the base and accept additional riser sections or cover slab.
The 1800 mm diameter riser section with integral valve chamber increment has the valve
chamber reinforcement interlocking with the riser section reinforcement and in a
cantilevered formation. The valve chamber riser has an overall height, as standard, of
1000 mm (available deeper on request) and a minimum wall thickness of 100 mm. The
floor of the valve chamber is also 100 mm thick and graded towards the floor drain.
Reinforcement in the valve chamber is centrally placed to maintain a minimum 45mm cover
in accordance with AS 3735 when utilizing S50 concrete. The underside has a rebate key
formed to accept the riser section. The valve chamber is 1200 mm square inside. The
inside wall height of the valve chamber is set down 10 mm to provide a clearance for the
cover slab and not act as a load bearing surface.
6.2.2.5 Precast concrete cover slabs
The cover slab has been designed for a vehicle loading based on W80 wheel load as
defined in AS 5100.2—2004 Bridge Design, Part 2:Design Loads.
The precast reinforced concrete cover slab is 250 mm thick on the 1800, 2250 and 3200
mm diameter pits, with various size clear openings (to suit the required access) for access
to the wetwell and to the valve chamber. The cover slab is 3500 mm wide for the 3200 mm
diameter wet-well, 2500 mm wide for the 2250 mm diameter wet-well and 2040 mm wide
for the 1800 mm diameter wet-well. The cover slab is 4600 mm long for the 3200 mm
diameter wet-well and valve chamber, 3300 mm long for the 2250 mm diameter wet-well
and valve chamber, and 2800 mm long for the 1800 mm wet-well and valve chamber. The
underside is flat and there is no rebated joint. The cover slab has locator blocks to key with
the riser section and prevent any lateral dislocation or movement. The cover slabs are also
available without the valve chamber extension for use when the external valve chamber is
adopted. There is also an optional 300 mm to 2000 mm extension at the opposite side to
the valve chamber for mounting of a control panel, educt vent and water supply
connection.
6.2.2.6 Cover to reinforcement for corrosion protection
Based on a minimum concrete strength of 50 MPa and exposure classification D Pocius &
Associates Pty Ltd directions on cover to reinforcement shall be a minimum of 45 mm to all
internal surfaces of the main chamber.
6.2.3 Product type testing
There is no specific Australian or international standard that provides manufacturers,
designers and installers with a document that outlines the specific criteria required to
produce modular pre-cast concrete chambers for packaged pump stations for sewerage
applications.
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In Australia and New Zealand Precast Concrete Access Chamber for Sewerage
Applications are manufactured in accordance with AS 4198. However AS 4198 is limited to
precast concrete access chambers intended for use with buried sewer pipes to a depth of 6
m and for pipes not greater than 300 mm in diameter.
AS/NZS 1546.1 specifies performance requirements and performance criteria for septic
tanks, technical means of compliance and provides test specifications that enable septic
tanks to be manufactured to comply with the performance requirements and performance
criteria. The scope of the standard is limited to domestic wastewater of up to 14000 litres
per week; well below the quantum of flows that will be seen in a sewage pump station.
Inspection and testing for serviceability and durability should be carried out on completion
of construction. The Constructor is required to undertake acceptance testing of all sewers,
pressure mains, wet wells and structures in accordance with the requirements in the
Design Specifications.
At an appropriate time after completion the wet-well should be tested for liquid–tightness.
The purpose of this test is to verify the leak tightness of the joints and penetrations.
Aquatec state that final testing for liquid retention is a responsibility of the Constructor. If
units are installed correctly and in accordance with Aquatec’s installation requirements
then Aquatec take responsibility.
6.2.4 Review of the documentation and guidance for designers, installers and
operatives
Aquatec provides customers with documents for submission of their pump station
requirements, plus diagrams for customers/designers to nominate pipe positions for factory
cored apertures. Also provided to customers is a list of items required to be completed
prior to installation and/or commissioning of the pump station.
For further information Refer to Section 8.
7 WSAA NETWORK REQUESTS
The network raised the following questions:
Question 1: Agencies had various requirements for cover to reinforcement and asked if
they could be accommodated.
Answer 1: Aquatec has advised that they are aware that cover to reinforcement is not an
accepted constant because agencies have different requirements relative to sewage and
ground water conditions. Aquatec standard is 45 mm minimum internal cover for the 1800
mm, 2250 mm and 3200 mm diameter wet-well. Aquatec are also able to manufacture wet-
wells to individual agency cover requirements, although obviously there is a limit to which
the internal cover to reinforcement can be extended when the wall thickness is fixed.
It should also be noted that the Aquatec base unit (no segment joints), which extends to
1740 mm high from pit invert and covers the normal pump operation levels (i.e. alternate
wet and dry zone), has a greater cover over reinforcement because the mould is tapered.
In the case of the DN 1800 wet-well, the standard cover of 50 mm increases to 83 mm at
the top of the sludge batter. For the DN 2250 wet-well the standard cover of 60 mm
increases to 95 mm at the top of the sludge batter. For the DN 3200 wet-well the standard
cover of 60 mm increases to 110 mm at the top of the sludge batter.
Question 2: Several concerns have been raised about resistance to flotation when
installed in water charged ground. The concerns include wet-well de-segmentation at the
joints and also the joint integrity of the valve pit wet-well when the wet-well is flooded.
Answer 2: Aquatec has provided computations from Pocius & Associates Pty Ltd,
Structural Engineers to demonstrate resistance to flotation for each of the three sizes to
nominated levels. My understanding is that the new computations supplied cover all this.
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In order to design for the more conservative case the groundwater level has now been
assumed to exist at the surface of the pumping station. Based on the revised flotation
calculations, the base casting details for the DN 1800, DN 2250 and DN 3200 units have
been amended to incorporate an option for extended base design, which provides
additional resistance to buoyant forces.
Included on the alternative base configuration drawings is a note specifying the
requirement to provide a concrete ring beam cast in situ. The concrete ring beam is
designed to increase the base casting further beyond the outer face of the shaft wall.
De-segmentation of increments is unlikely because of the demonstrated strength of the
Bostik and / or Jointguard Sealing Strip.
Aquatec advise there are no special requirements needed to avoid flotation.
Where specified Aquatec can supply a jointing system designed to hold the base and
concrete segments together to maintain water tightness where precast concrete
components could be subjected to lateral forces. This system uses 316 stainless steel
plates 12 mm thick fitted across the joints after placement of the sealing compound and
generally after assembly of the segments. The SS plates can be fitted to the outside or
inside of the concrete segments.
One of the benefits of the integral valve chamber design is that the valve chamber is not
jointed to the wet-well, but is mould formed with the top increment as a single piece with
continuous reinforcing, and thus joint failure is not a factor. The top of the valve chamber
dividing wall is sealed to the underside of the cover slab.
Question 3: Which parts of the package does Aquatec take responsibility for?
Answer 3: The Aquatec packaged pumping station is a turn-key product. The civil
contractor's main responsibilities are to installation of precast segments provide
excavation, trenching and backfill works, craneage, water supply, and site restoration.
Aquatec Environmental Group Pty Ltd scope of works usually includes the mechanical and
electrical fit-out. Aquatec will also attend site during installation to make sure joint sealant
in applied correctly etc.
Question 4: How many concrete packaged pumping stations have Aquatec supplied?
Answer 4: Aquatec currently supplies packaged pumping stations to more than 50 water
authorities and councils and has successfully carried out more than 1500 installations.
Question 5: Is it possible for liquid to leak out of the pumping station, or for groundwater to
ingress?
Answer 5: No. The Aquatec packaged pumping station chamber is mould formed with the
base and walls poured as one unit, therefore there is no possibility for leakage in or out of
the chamber. Pump chamber increments are keyed, rebated and sealed with special
pressure-sensitive epoxy which chemically bonds to the concrete, ensuring no leakage can
occur.
Question 6: Is a cored hole in a reinforced component likely to expose any steel? If so
what assurance is there that the steel will be adequately covered by epoxy or mortar and
prevent corrosion?
Answer 6: Aquatec ensures that all core hole penetrations are completely sealed with
Megapoxy part 1 and part 2 product, prior to commissioning of the pump station. Due to
the additional reinforcing placed around the areas of coring prior to concrete pour, no steel
reinforcing will be exposed.
Question 7: Mastic joints are rated as water resistant but can they withstand differential
soil movements or are they only suitable for homogeneous sandy soils of uniform
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moisture?. Does Aquatec recommend the use of flexible joint mastic joints in clay soil,
particularly in saturated conditions.
Answer 7: Yes. Aquatec uses and has had a lot of success with a Bostik product (5240
sealing strips). Bostik 5240 is a soft synthetic rubber based sealing strip that can withstand
extreme heat and cold conditions and still retain its sealing, adhesive properties and
resilience. Bostik 5240 will maintain a flexible seal after many years of exposure to the
elements.
Question 8: Does the aluminium plate used to fabricate the covers comply with AS 1734
Grade 5251 and is the design and fabrication in accordance with AS 1664?
Answer 8: Aluminium Grade 5251 is an American grade of aluminium not really available
in Australia, we have used Grade 5052 in the past. This is considered the European/Asian
equivalent and complies with AS 1734. Alternative aluminium grade such as 6061 T6 and
or Grade 5083 H116 to AS 1734 are also available. .
Question 9: Does the welding and inspection of aluminium fabrication comply with the
requirements of AS 1664?
Answer 9: This can be achieved on request. There is an increase in costs to achieve this
standard and will be passed on to the customer.
Question 10: Does Aquatec offer a pump station design and drafting service?
Answer 10: Yes. Aquatec offers full pump station designs and drafting services of project
specific drawings hydraulic calculations. All designs and drawings are in line with the
Water Authorities’ specifications.
Question 11. Can a fibre reinforced plastic ladder system be installed.
Answer 11: Yes. Aquatec can supply Water Agency approved fibre reinforced plastic
ladder system.
Question 12. With reference to Section 7, answer 2 and answer 5. I would like to see more
information on the mastic. Does it have the suggested tensile strength to resist “de-
segmentation”? Is there evidence of the “Chemical Bond” that ensures no leakage?
Answer 12. Aquatec have sent through all the information we have on this product. After
using this product over the past 20 years it has stood the test of time.
Where the ground conditions warrant, Aquatec can supply a jointing system designed to
hold the base and concrete segments together to maintain water tightness where precast
concrete components could be subjected to lateral forces. This system uses 316 stainless
steel plates 12 mm thick fitted across the joints after placement of the sealing compound
and generally after assembly of the segments. The SS plates can be fitted to the outside or
inside of the concrete segments.
Question 13: How does Aquatec address vapor attack on the underside of the cover slab.
Answer 13: Where specified the Constructor can apply a protection from vapor attack by
applying an approved epoxy resin. The epoxy resin is not supplied by Aquatec and it is the
responsibility of the contractor or Water Agency to procure and apply to ensure an
adequate seal.
Question 14: What are the advantages of precast Concrete Sewerage Pumping Station?
Answer 14: Precast concrete MH’s are
(a) readily available,
(b) modular, and therefore offer a more flexible design,
(c) Produced in a quality controlled plant environment,
(d) Watertight structures easily achieved,
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(e) Resists Buoyant Forces and
(f) Offer superior strength.
(g) Question 15: Can block-outs instead of core penetrations be used and is it possible
to specify an integrally cast embedded pipe connector into a precast concrete
segment.
(h) Answer 15: Block-outs for inlet/outlet pipework can be provided by Aquatec. Aquatec
are trialing the AGRULINE concrete connection socket. This fitting enables a water-
tight and secure anchoring of PE pipes in the wall of the concrete segments. The
concrete connection socket is made from PE100 material. It is mounted aligned to the
formwork and cast into the concrete. A prefabricated groove ensures anchoring.
Connecting PE pipework can be connection to the socket by eletrofusion welding.
8 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION
Aquatec provide customers with proforma documents for submission of their pumping
station requirements plus diagrams for customers/designers to nominate pipeline positions
for location factory cored apertures. There are also documents for the customer to
complete advising Aquatec of the required delivery dates and programmed commissioning
dates. Aquatec also provide a checklist of items required to be completed prior to
commissioning of the pumping station.
Aquatec advise that installation is usually carried out by experienced civil contractors but
the modular design provides a simple and trouble free assembly. However, an Aquatec
representative will be made available to provide specialised assistance or to oversee the
installation. The pumping station is delivered in numbered segments fully precored in
accordance with design requirements and with general assembly instructions for the civil
contractor. The pumping station concrete components are fitted with spherical head lifters
'cast in' for ease and security of slinging, lifting and placement. Location keys moulded in
each joint ensure no rotational misalignment can occur.
Aquatec provide a general installation guideline to enable agencies to follow the assembly
and ensure the installation proceeds in accordance with the manufacturer’s expectations.
These guidelines are for use with the specific instructions provided with each pumping
station. If required, Aquatec can also supply on-site supervision and technical assistance
through to complete pumping station installation and commissioning contracts in most
regional areas via their network of affiliated companies and authorised distributors.
At the completion of commissioning Aquatec provide the Asset Owners with Operation and
Maintenance Manuals in accordance with the specified requirements. Refer to Appendix B
for further information.
8.1 Backfill Requirements
Aquatec recommends the consulting engineer conducts a site investigation to establish
indicative subsurface conditions prior to the commencement of construction.
Aquatec has submitted backfill requirements and construction notes for correct installation
procedures, as detailed in Appendix A. The Construction Notes are based on normal site
conditions which are free of groundwater and apply to installations in cohesive and non-
cohesive soils. Sites which have ground water will need dewatering for construction
purposes.
9 PRODUCT MARKING
Aquatec, or their distributor's nameplate is attached to the safety grate as part of the safety
sign under the metal cover. Some distributors stencil their name and contact details on the
cover slab. Aquatec suggest that traceability is not an issue with pumping stations as their
manufacture and specification is normally well documented in records held by the water
agency.
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10 PACKAGING AND TRANSPORTATION
Aquatec are responsible for delivery of the precast concrete components to site. The
precast components are loaded onto the truck using timber chocks between and beneath
each component. Transportation follows an agreed procedure that includes re-tensioning
chains after the first 20 kilometres. Bianco Walling Pty Ltd Trading as Bianco Precast
provides the transport driver with a checklist for each item to be signed off as inspected by
the driver, loader and receiver at the construction site. The checklist also carries a diagram
of the slinging procedure to ensure no damage occurs at the rebate joint. Refer to
Appendix E.
11 PRODUCT WARRANTY
This product is covered by the normal commercial and legal requirements of the
Competition and Consumer Act 2010, which covers manufacture to the relevant standard,
which in this case for concrete is AS 3972:2010 Additional warranties may be negotiated
on a project specific basis.
12 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING
REPORT
The approval of Aquatec Precast Concrete Sewage Pumping Stations range by the
individual Water Authorities will enable any issues associated with quality and performance
to be reported and addressed.
TABLE 2 LIST OF WATER AGENCIES EXPERIENCED WITH THE PRODUCT
COMPANY CONTACT PHONE EMAIL
South East Water Colin Paxman 03 9552 3651 [email protected]
Yarra Valley Water Kevin Dawson 03 9872 1474 [email protected]
City West Water Mohamed Yoosuf 03 9313 8435 [email protected]
SA Water Ivor Ebdell 1300 650 950 [email protected]
Barwon Water Ian Sanderson 03 52269286 [email protected]
Goulburn Valley Water Steve Nash 03 58320400 [email protected]
NOTE:The above list comprises major Water Utilities of Australia only. A more comprehensive list is
available on request.
The following advice was received from South East Water:
‘South East Water has audited the design; installation and commissioning of numerous
2250mm diameter precast concrete packaged pump station units within its licensed district
over the last decade. This process has been carried out in conjunction with the technical
services division of the Aquatec on each project. Wet well depths have been generally
restricted to 8.0 metres in accordance with the report recommendations set out in WSAA
Product Appraisal Report 99/26. (Now lapsed) All pump station installations were
successfully completed and fully operational as intended. ’
Since April 2014, Bianco Precast has supplied for Aquatec precast concrete sewage
pumping stations for Water Agencies and Councils projects. For further information contact
Aquatec. Refer to Appendix D for information.
13 DISCUSSION
Aquatec has advised that requests for packaged pumping stations with separate valve
chambers are now rare for the 1800 mm and 2250 mm diameter sizes and whilst they are
still available they are considered a special order. Aquatec designs with the integral valve
chamber is compact and provides a fully sealed yet drained valve space with no differential
settlement or interconnecting pipework and a short one-way drain line.
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The mould formed concrete components of the pumping station are intensely vibrated to
create an "off steel" finish to AS 3610 Class 2X without laitance. Aquatec guarantee the
cover to reinforcement and no separation of concrete and reinforcement. The base is one
piece forma single mould, therefore has no shrinkage and provides maximum strength. The
single mould base section provides a watertight enclosure to the normal maximum height
of sewage during pumping, eliminating the possibility of head pressure leakage through the
floor slab.
Whilst computations have been provided for nominated depths for each size of wet-well,
Aquatec has advised that site specific calculations can be done if there is a requirement for
a deeper chamber or a chamber location in specified severe adverse conditions.
The Aquatec range of Modular Precast Concrete Pumping Stations incorporates a range of
optional items beyond the reasonable scope of this appraisal. The many variations result in
an adaptable product designed to satisfying the requirements of water agencies for
Sewage Pumping Stations in this size range. The optional items available but not included
in this appraisal are:
(a) PE and DI pipe work and 'Y' piece variations;
(b) All valves;
(c) Pumps, rails, mounting and bracing brackets, baffle plate and lifting chains;
(d) Level controls;
(e) Auto well washer;
(f) Ladders and Platforms
(g) Vent piping;
(h) Odour Filter;
(i) Control panel and electrical wiring.
(j) Agru concrete connection socket
(k) HDPE concrete protective liners,
(l) SS 316 plates for connecting segments
14 LIFE EXPECTANCY
The life expectancy of unprotected concrete sewer structures is impossible to nominate in
general terms. Sewer conditions vary widely in Australia and levels of septicity that
generate concrete corrosion are many and varied. The factors include sewage type,
sewage age, sewage temperature, and ventilated or sealed sewers. In highly corrosive
installations it is recommended that additional measures are adopted to protect or reduce
the corrosive effect on the exposed concrete surfaces. To assess the life expectancy of the
Aquatec precast pumping chambers it is recommended that agencies draw on their local
knowledge and look for advice from Aquatec. To provide a basis for life expectancy
estimation the following is recommended:
"Based on the documented product conformance to the nominated standards and
installation in compliance with the manufacturer’s instructions in locations subject to
'normal domestic' sewage in a fully ventilated sewer, at temperatures below 20° C, this
product range has been rated 'B' - Life expectancy in excess of 50 years before major
rehabilitation. This rating is only a general guide to life expectancy and may increase or
decrease as a result of the quality of installation, system operating conditions, operating
environment and other geographical and site specific factors".
15 FUTURE WORKS
Within 12 months from the date of publication of the report Aquatec are required to provide
comparative performance data for the Bostik 5240 sealing strip against ASTM C990-09.
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16 REPORT RECOMMENDATIONS
It is recommended that WSAA Members and Associates, subject to any specific
requirements of the Member or Associate, accept or authorise the Aquatec range of
Precast Concrete Sewage Pumping Stations, as detailed in this report for use in sewerage
networks provided pipeline design, installation, acceptance testing and commissioning are
in accordance with relevant WSAA Codes, WSAA Member Integrated Codes, and the
manufacturer's requirements.
Water Agencies considering installing an Aquatec Precast Concrete Sewage Pumping
Stations at depths greater than 8.0m are advised to consult with Aquatec representatives.
17 DISCLAIMER
This Product Appraisal Report (Report) is issued by the Water Services Association of
Australia Limited on the understanding that:
This Report applies to the product(s) as submitted. Any changes to the product(s) either
minor or major shall void this Report.
To maintain the recommendations of this Report any such changes shall be detailed and
notified to the Product Appraisal Manager for consideration and review of the Report and
appropriate action. Appraisals and their recommendations will be the subject of continuous
review dependent upon the satisfactory performance of products.
WSAA reserves the right to undertake random audits of product manufacture and
installation. Where products fail to maintain appraised performance requirements the
appraisal and its recommendations may be modified and reissued. Appraisal reports will be
reviewed and reissued at regular intervals not exceeding five (5) years.
The following information explains a number of very important limits on your ability to rely
on the information in this Report. Please read it carefully and take it into account when
considering the contents of this Report.
Any enquiries regarding this report should be directed to the Program Manager, Carl
Radford, Phone: 03 8605 7601 email [email protected].
17.1 Issue of Report
This Report has been published and/or prepared by the Water Services Association of
Australia Limited and nominated Project Manager and peer group of technical specialists
(the Publishers).
The Report has been prepared for use within Australia only by technical specialists that
have expertise in the function of products such as those appraised in the Report (the
Recipients).
By accepting this Report, the Recipient acknowledges and represents to the Publisher(s)
and each person involved in the preparation of the Report that the Recipient has
understood and accepted the terms of this Disclaimer.
17.2 Limits on Reliance on Information and Recommendations
17.2.1 Disclaimer of liability
Neither the Publisher(s) nor any person involved in the preparation of the Report accept(s)
any liability for any loss or damage suffered by any person however caused (including
negligence or the omission by any person to do anything) relating in any way to the Report
or the product appraisal criteria underlying it. This includes (without limitation) any liability
for any recommendation or information in the Report or any errors or omissions.
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17.2.2 Need for independent assessment
The information and any recommendation contained (expressly or by implication) in this
Report are provided in good faith. However, you should treat the information as indicative
only. You should not rely on that information or any such recommendation except to the
extent that you reach an agreement to the contrary with the Publisher(s).
This Report does not contain all information that a person might require for the purposes of
assessing any product discussed or appraised within it (Product). The product appraisal
criteria used in preparing this Report may not address all relevant aspects of the Product.
Recipients should seek independent evidence of any matter which is mater ial to their
decisions in connection with an assessment of the Product and consult their own advisers
for any technical information required. Any decision to use the Product should take into
account the reliability of that independent evidence obtained by the Recipient regarding the
Product.
Recipients should also independently verify and assess the appropriateness of any
recommendation in the Report, especially given that any recommendation will not take into
account a Recipient’s particular needs or circumstances.
WSAA has not evaluated the extent of the product liability and professional indemnify
insurance that the provider of the product maintains. Recipients should ensure that they
evaluate the allocation of liability for product defects and any professional advice obtained
in relation to the product or its specification including the requirements for product liability
and professional indemnity insurance.
17.3 No Updating
Neither the Publisher(s) nor any person involved in the preparation of this Report [has]
[have] any obligation to notify you of any change in the information contained in this Report
or of any new information concerning the Publisher(s) or the Product or any other matter.
17.4 No Warranty
The Publisher(s) do[es] not, in any way, warrant that steps have been taken to verify or
audit the accuracy or completeness of the information in this Report, or the accuracy,
completeness or reasonableness of any recommendation in this Report.
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APPENDIX A – TECHNICAL MANUAL
Refer to Aquatec for a copy of their Technical Manual/Brochure.
Refer to Aquatec for a copy of their Operations and Maintenance Manual.
The following extracts are included in this Appendix:
Aquatec Precast Concrete Sewage Pumping Stations components
Typical diagrams of the Aquatec Precast Concrete Sewage Pumping Stations with
integral valve chamber.
Jointguard butyl mastic sealing strip
Please note that copies of the full set of drawings and structural calculations for the various
models covered by the scope of this appraisal, including the Design Verification Statement
from the Structural Engineer have been made available to WSAA and it’s Peer reviewers
during this appraisal.
These documents are considered commercial-in-confidence. If your wish to obtain a copy
please conduct the Applicant. Refer to Appendix D for their contact details.
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APPENDIX B - QUALITY CERTIFICATIONS
Copies of the following Quality Certification Certificates are available for downloading from
the WSAA ‘Members Only’ IPAM Portal Website.
TABLE B1 AQUATEC FLUID SYSTEMS PTY LTD – MANAGEMENT SYSTEMS
Business Address: 2 Provincial Crescent Shepparton VIC 3630
Quality Systems Standard 9001:2008
Certificate No. 100326
Certifying agency Qual-Safe Management Systems1
First date of certification
Current date of certification 26/3/2010
Expiry date of certification 26/3/2013
NOTE: 1 Qual-Safe Management Systems is not accredited to JAS-ANZ and Aquatec Fluid Systems Pty
Ltd General Manager, Kevin Seeley, has stated that Aquatec Fluid Systems Pty is not the manufacturer
and operates only as the marketing agency and does not require the higher level of quality certification.
TABLE B2 BIANCO WALLING PTY LTD TRADING AS BIANCO PRECAST –
MANAGEMENT SYSTEMS
Precast Concrete Manufacturing Facility: 535 Grand Junction Road, Gepps Cross, SA5094, Australia 183 South Terrace, Wingfield, SA5013, Australia
Quality Systems Standard ISO 9001:2008
Certificate No. QEC24389
Certifying agency SAI Global
First date of certification 31 October 2007
Current date of certification 18 July 2013
Expiry date of certification 31 October 2016
TABLE B3 BORAL RESOURCES (SA) LIMITED – MANAGEMENT SYSTEMS
Address of Premix concrete Plant: Wingfield in South Australia
Quality Systems Standard 9001:2008
Certificate No. 6063000-SQ-002
Certifying agency SAI Global
First date of certification
Current date of certification 28 June 2012
Expiry date of certification 31 May 2015
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TABLE B4 BOSTIK AUSTRALIA PTY LTD – MANAGEMENT SYSTEMS
Quality Systems Standard 9001:2008
Certificate No. QEC22260
Certifying agency SAI Global
First date of certification 16/6/1997
Current date of certification 9/2/2010
Expiry date of certification 11/4/ 2013
TABLE B5 PETRO COATING SYSTEMS PTY LTD – MANAGEMENT SYSTEMS
Quality Systems Standard 9001:2008
Certificate No. 11000132
Certifying agency Bureau Veritas
First date of certification 13/7/2011
Current date of certification 13/7/2011
Expiry date of certification 12/7/2014
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APPENDIX C - WSA PRODUCT SPECIFICATION
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APPENDIX D - SUPPLIER CONTACTS
Aquatec Fluid Systems Pty Ltd
PO Box 841
Shepparton VIC 3632
Telephone 1300 088 555
Global Pumps (formerly All Pumps Supplies)
PO Box 135
Melrose Park SA 5039
08 8275 8000
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APPENDIX E –PACKAGING AND TRANSPORTATION
Figure 1 Transportation Figure 2 Transportation
Figure 3 cover slab Figure 4 cover slab
Figure 5 base lining on the mould Figure 6 DN2250 *1000 HDPE Liner
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Melbourne Office
Suite 8.02 Level 8,
401 Docklands Drive Docklands VIC 3008
Phone: (03) 8605 7601 Fax: (03) 8605 7612 Sydney Office
Suite 1, Level 30, 9 Castlereagh Street Sydney NSW 2000
GPO Box 915 Sydney NSW 2001
Phone: (02) 9221 5966 Fax: (02 9221 5977
www.wsaa.asn.au