Aquatec Fluid Systems Pty Ltd · AS 3735:2001 - Concrete structures for retaining liquids AS 4100:1998 - Steel Structures AS 3600:20012 - Concrete Structures Published: 20 July 2017

WSAA Product Appraisal 1011 Issue 3 1

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Aquatec Fluid Systems Pty Ltd PRODUCT APPRAISAL REPORT 1011 Issue 3

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: 20 July 2017


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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

20/7/2017 Publication Issue 3

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2010\PA 1011 Issue 3 Aquatec Environmental Group Pty Ltd

Packaged Pumping Stations\WSAA PA 1011 Issue 3 Aquatec.docx

1st Draft Peer Reviewers

Name/Title Organisation Date

Andy Krumins, Manager Infrastructure Planning Queensland Urban Utilities 25/7/2011

Don McAdie, Wastew ater Conveyance Standards Water Corporation 5/8/2011

Geoff Reynolds, Manager Asset Quality South East w ater. 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 w ater. 3/10/2012

Frank Scheele, Civil Design Engineer Queensland Urban Utilities 28/9/2012

Carl Radford, Product Appraisal Manager WSAA 4/9/2012




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Overview of WSAA

The Water Services Association of Australia (WSAA) is the peak industry body

representing the urban water industry. Our members provide water and sewerage services to over 20 million customers in Australia and New Zealand and many of Australia's largest industrial and commercial enterprises.

Based around our vision of 'customer driven, enriching life', WSAA facilitates collaboration,

knowledge sharing, networking and cooperation within the urban water industry. We are proud of the collegiate attitude of our members which has led to industry-wide approaches

to national water issues.

WSAA can demonstrate success in the standardisation of industry performance monitoring and benchmarking, as well as many research outcomes of national significance. The

WSAA Executive retains strong links with policy makers and legislative bodies and their influencers, to monitor emerging issues of importance to the urban water industry.

WSAA was formed in 1995 as a non-profit organisation to foster the exchange of

information between industry, government and the community, and to promote sustainable water resource management.

The urban water industry is committed to anchoring its services to customers' values, and

to enrich communities where water services have broad economic, environmental and social values. In line with this our main activities focus on four areas:

1. influencing national and state policies on the provision of urban water services and

sustainable water resource management

2. promoting debate on environmentally sustainable development and management of water resources and the community health requirements of public water supplies

3. improving industry performance and establishing benchmarks and industry leading

practices for water service processes; and

4. fostering the exchange of information on education, training, research, water and

wastewater management and treatment and other matters of common interest.

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 Water Services Association of Australia Limited.

© Copyright 2017 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



6.2.2.5 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 Intellectual Property and other rights .......................................................................................................................25

17.2.3 Need for independent assessment...........................................................................................................................25

17.3 No Updating .........................................................................................................................................................................25

17.4 No Warranty.........................................................................................................................................................................26

APPENDIX A – TECHNICAL MANUAL .......................................................................................................................................27

APPENDIX B - QUALITY CERTIFICATIONS .............................................................................................................................33

APPENDIX C - WSA PRODUCT SPECIFICATION ..................................................................................................................39 APPENDIX D - SUPPLIER CONTACTS .....................................................................................................................................40

APPENDIX E –PACKAGING AND TRANSPORTATION .........................................................................................................41


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1 EXECUTIVE SUMMARY

Issue 3 of this report addresses the outstanding future work item relating to performance

testing of Bostik 5240 sealing strip. Aquatec has advised that Bostik 5240 is no longer manufactured and JointGard Round Butyl Strip is now the recommended sealant. The report has been amended accordingly. Quality assurance documentation has also been

updated.

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 specifies 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


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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 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).


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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.

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.


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The range of Aquatec Precast Concrete Packaged Sewage Pumping Stations listing the

model numbers and specifications is shown in Table 1.

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 nonstandard 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 APPRAIS AL

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 reflect 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 specific 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.


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Until such time as an appropriate Industry Standard, Australian or International Standard is

developed which specifies the

(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.


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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')

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

Petro Coating Systems Pty Ltd, an operating unit of Denso Australia Ltd, is a Quality Endorsed Company accredited by Lloyds Register Quality Assurance Limited to ISO

9001:2008, License No. MEL0927759 (Refer to Appendix 'B'). The recommended sealant supplied by PCS is JointGard Round Butyl Strip which is a blend of synthetic rubbers formed from isobutylene and isoprene. Adhesion is enhanced with appropriate tackifiers.

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)


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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

Water Cement Ratio Not to exceed 0.5 Complies

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 Linw ood

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.as px

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 a Technical Data Sheet for JointGard Round Butyl Strip. This product is custom designed for the sealing of segmented concrete pipes and maintenance hole units. (Refer to Appendix A).

https://www.wsaa.asn.au/Publications/NationalCodes/Pages/WaterIndustryStandards.aspx


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Aquatec recommends JointGard round butyl strip be used as the sealant between the

concrete riser segments and the cover slab, particularly in homogenous sandy soils of uniform moisture. The use of butyl 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.

The JointGard round butyl strip is a blend of synthetic rubbers formed from isobutylene and

isoprene. Adhesion is enhanced with appropriate tackifiers.

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 a performance standard for the jointing material.

PCS advises that JointGard Round Butyl Strip conforms fully with the requirements of ASTM C990M-09.

Aquatec comments relating to a trial of JointGard Round Butyl Strip concludes that:

The butyl strip performed well and was easy to apply

The strip was trialled over a range of pump station sizes including 1800mm diameter,

2250mm diameter, and 3200mm diameter where it performed very well with no leakages even under ground water situations

It bonded well with the concrete and behaved well under pressure when increments were

applied

Aquatec are confident using the JointGard Round Butyl Strip

A copy of the JointGard Round Butyl Strip Technical Data Sheet is attached to Appendix A and can also be downloaded from the following web site:

http://petrocoating.com.au/products/round-butyl-strip/

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.

http://petrocoating.com.au/products/round-butyl-strip/


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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 20mm 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 3200mm 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 3200mm 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 500mm 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 3200mm 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 3200mm 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.


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 350mm 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.


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

JointGard Butyl 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 products, 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 mastic joints in clay soil, particularly in saturated conditions.

Answer 7: Aquatec uses and has had success using soft synthetic rubber based sealing

strips that can withstand extreme heat and cold conditions and still retain its sealing, adhesive properties and resilience. However, the use of butyl 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.

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,


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(d) Watertight structures easily achieved,

(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 electrofusion welding.

8 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION

Aquatec provide customers with pro-forma 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


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manufacture and specification is normally well documented in records held by the water agency.

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

mailto:[email protected]



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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.

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

There are no future works items.


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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 Intellectual Property and other rights

The Water Services Association of Australia Limited does not undertake any assessment of whether the importation, manufacture, sale or use of the Product the subject of this

Report infringes the intellectual property rights or proprietary rights of any person. Recipients of the report should undertake their own assessment of whether (as relevant) the importation, manufacture, sale or use of the relevant Products infringe the intellectual

property rights or other proprietary rights of any person. If the Product infringes intellectual property rights or other proprietary rights there is potential for the supply of the Products to be interrupted.

From time to time the Water Services Association of Australia Limited and the other

Publishers may receive notice of allegations that the importation, manufacture, sale or use of the Product infringes intellectual property rights or other proprietary rights. The Water

Services Association of Australia Limited's policy is to not refer to such allegations in its reports or take any other steps to put Recipients on notice of such allegations, unless and until it is aware that the allegations have been admitted or proved in Court. As such,

Recipients acknowledge, agree and accept that the Water Services Association of Australia Limited may have information in its possession about intellectual property rights infringement allegations or other infringement allegations in relation to the Product which

are not referred to or disclosed in this Report and which are not otherwise communicated to Recipients.

17.2.3 Need for independent assessment

The information and any recommendation contained (expressly or by implication) in this Report are provided in good faith (and subject to the limitations noted in this Report). 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 material 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.


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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.

JointGard Round Butyl 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 its peer reviewers

during this appraisal.

These documents are considered commercial-in-confidence. If you wish to obtain a copy please contact 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 Member’s Website.

TABLE B1 AQUATEC FLUID SYSTEMS PTY LTD – MANAGEMENT SYSTEMS

Business Address: 2 Provincial Crescent Shepparton VIC 3630

Quality Systems Standard ISO 9001:2008

Certificate No. 100326

Certifying agency Qual-Safe Management Systems1

First date of certification 14 December 2012

Current date of certification 23 February 2015

Expiry date of certification 23 February 2018

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


Certificate No. QEC24389

Certifying agency SAI Global

First date of certification 31 October 2007

Current date of certification 7 September 2016

Expiry date of certification 14 September 2018

TABLE B3 BORAL RESOURCES (SA) LIMITED – MANAGEMENT SYSTEMS

Address of Premix Concrete Plant: Wingfield Road Wingfield, South Australia


Certificate No. FS 603749

Certifying agency BSI

First date of certification 24 April 1992

Current date of certification 31 May 2017

Expiry date of certification 31 May 2020


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TABLE B5 PETRO COATING SYSTEMS PTY LTD – MANAGEMENT SYSTEMS


Certificate No. MEL0927759

Certifying agency Lloyds Register Quality Assurance

First date of certification 4 November 1993

Current date of certification 13 July 2015

Expiry date of certification 31 August 2017


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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

http://www.wsaa.asn.au/

Documents

Aquatec Fluid Systems Pty Ltd · AS 3735:2001 - Concrete structures for retaining liquids AS 4100:1998 - Steel Structures AS 3600:20012 - Concrete Structures Published: 20 July 2017