Mall environmental systems - For the protection of water ... · projects. With the aid of this certificate trading, Mall offsets the unavoidable CO2 emissions from the print production,

Separating plants Wastewater treatment plantsRainwater

managementRenewable energy sources

Pump and plant engineering

Mall environmental systemsfor the protection of water and soil

2 / Company profile and products

Mall – the specialists in rainwater, wastewater and renewable energies

For over ten years, Mall has been promoting renewable energies, producing various sizes of pellet storage units, woodchip containers and buffer storage tanks.

In addition, the Mall Group has established itself as a skilled manufacturer and supplier of special-ist products for street and road design and burial chamber systems. The Mall Group has six production sites. These are in Donaueschingen, Ettlingen-Oberweier, Coswig/Anhalt, Haslach in the Black Forest, Nottuln in the Münsterland and Szentendre near Budapest.

For many years, Mall GmbH has been using renewable energy to fully meet the needs of all its production sites in Germany. This way, Mall avoids emitting around 800 tonnes of harmful carbon dioxide per year and also makes a contri-bution to environmental protection in this field.

Furthermore, all printed documents are printed in an environmentally neutral way, preventing an increase of carbon dioxide in the atmosphere. The CO2 output of the printed products is calcu-lated precisely and the emissions which result are compensated at First Climate by purchasing certificates which finance regenerative energy projects. With the aid of this certificate trading, Mall offsets the unavoidable CO2 emissions from the print production, making it climate neutral.

Over six decades, the Mall Group has become one of the most important specialist providers, with process-engineering expertise for rainwater management, separating plants, wastewater treatment plants, pump and plant engineering and rainwater management with its comprehen-sive range of environmental systems.

Table of contents

Topic Page

Company 2 – 4

Services 5

Rainwater management 6 – 9

Separating plants 10 – 12

Retention and separation 13

Treatment of washing water 14

Wastewater treatment plants 15 – 17

Pump and plant engineering 18 – 19

Renewable energy sources 20 – 22

Reinforced concrete tanks 23

Company profile and products / 3

Highest quality concrete technology

Working as a team, we at Mall continuously develop new solutions, and are involved in projects from site analysis, laboratory tests and manufacturing right through to installation and final inspection. Thanks to consultants who are renowned in their fields and development work in partnership with universities and colleges, Mall technology is always state of the art.

DIN-tested quality Reinforced concrete containers and concrete components from Mall are not subject to quality fluctuations. Additives, reinforcement steels and binding agents are selected in accordance with the exacting requirements of the latest genera-tion of standards – DIN EN 206 and DIN 1045, parts 1 to 4. Concrete production is subject to systematic factory production monitoring in Mall's concrete laboratory and continuous quality control by the recognised testing and certification body PÜZ BAU.

Delivery and installation using Mall's special-purpose vehiclesMall has a fleet of special crane vehicles with a lifting capacity of up to 12 tonnes for lifting con-tainers into place on site. The reinforced-concrete containers and complete systems are delivered and installed all over Germany.

Concrete has many advantages

+ Made of natural, local raw materials

+ 50 years operating life in conformance with DIN or EN

+ Easy to dispose of and recycle

+ Can be driven over by passenger cars and trucks (weighing up to 60 tonnes) thanks to its stability and robustness

+ Filling with existing excavation material and mechanical compression possible

+ Easy to position in the prepared con-struction pit

+ High earth cover possible

+ Can even be used in high groundwater and in flood areas

Internal testing and development centre At its location in Donaueschingen, Mall has a testing and development centre for separating plants, rainwater and wastewater treatment plants, which is one of the most cutting-edge in Europe. It features a test course for separat-ing plants, wastewater treatment plants and test systems, a modern workshop and a testing laboratory equipped with automated control and measurement technology. Here, products can, for example, be quickly adjusted or converted to meet changed environmental protection regula-tions or the amended German water resources law (Wasserhaushaltsgesetz, WHG). These test results are verified by the testing company LGA in Würzburg and, if necessary, they are submitted to the German Institute of Construction Engineering (DIBt) in Berlin for approval.

Washing facility with drainage

Pellet storageRetention basin

Separator systemRainwater utilisationRainwater treatmentRainwater infiltration

Reservoir

Control and testing medium dosing device

Equipment shaft

Pump station

Domestic water stationBurner

Separator system

Workshop


Support around the clock – www.mall.info

Online Mall forums and communities

You can find more information on the products online.

To get started quickly, simply enter the web code printed on the product on the home page of www.mall.info in the box provided.

Web code M5561

At www.mall.info, you will find everything you need to help you during the different phases of your project.

Technical dataFor every product, we have compiled an overview of technical data along with all relevant informa-tion.

Tender textsYou can have the product-related tender texts compiled for your convenience or you can down-load them yourself.

Measuring programsMall has developed sizing programmes for rain-water management and separating plants. This makes it easier to calculate the optimum size of your rainwater storage tank or determine the nominal size of a separating plant.

Installation and operating instructionsYou can download detailed installation instructions in advance from our website. Answers to all ques-tions relating to the functioning of the system, installation, maintenance or possible faults are given in the operating and installation instructions.

Project reportsReports on completed Mall projects offer you a high level of experience and help with orientation.

Project consultantsMall has developed online planning sheets for various product fields in order to make it easier for you to plan your system. Simply fill it in online and send it to our experts. You will be sent a personalised product recommendation after we assess your data.

Technical approvalsGeneral technical approvals (allgemeine bau-aufsichtliche Zulassungen, abZ) are granted by the German Institute of Construction Engineering (Deutsches Institut für Bautechnik, DIBt) for prod-ucts and processes that have proven themselves in practical tests in terms of performance and environmental sustainability. In many cases, lim-its are considered as kept if an approval has been granted. Mall products are technically approved where it is possible or necessary.

Mall-Aktuell – subscribe now for free!We can send you a regular email newsletter on request, with information on new products, current market developments and interesting projects involving the entire Mall product range. Register now at www.mall.info/mall-aktuell

The Mall project consultant – personalised project advice with prod-uct recommendations tailored to your requirements.

New website from May 2014 – www.mall.info


You have to plan before you decideThe mall specialists will assess the conditions on site and will then prepare a concept design for an optimised system configuration. Mall will supply the technical documentation for construction as well as all necessary official documentation and approvals.

Everything you need for installationMall has its own special crane vehicles to coordi-nate the delivery, unloading and placement of the system, and offers professional installation using pipe connections ready for push-fit connection right through to the general inspections.

The Mall maintenance contractWe generally conduct maintenance and inspec-tion work once a year. The system operator is given a maintenance contract and a protocol each time maintenance work is completed. Any related and required maintenance works are listed therein. The data provided by the manufac-turer should also be taken into account, since the contract with Mall can also include products from other manufacturers.

Repairs and refurbishmentMall not only maintains and inspects, but also rectifies any faults found. If required, one of our experienced service teams can conduct the necessary repairs or full refurbishment of the system, even if it is not a Mall product.

RetrofittingThe retrofit kits at Mall meet the necessary standards and are easy to integrate into exist-ing systems. The prescribed warning system for light liquid separating plants can be retrofitted. Likewise, retrofit systems are available for fully biological small wastewater treatment plants and filtration systems for rainwater use.

ReplacementNaturally, you will also receive a replacement for all Mall products. In the separating plant area, we additionally provide you with original replacement parts for the Buderus brand. Our replacement parts pages are accessible via the Internet at all times. Here, you’ll find all the individual parts available.

Dismantling and disposalEverything comes to an end — including build-ings, wastewater treatment and rainwater utilisa-tion systems. This is why our systems are made of environmentally friendly materials that can be reused or disposed of at the end of the plant’s operational life. This holds true both for building materials such as concrete, steel or recyclable plastics as well as for the equipment used by our company. A quick look into the future helps cut costs here.

Our comprehensive service for youServices

All services from a single source – Mall is your reliable partner for the entire life cycle of your Mall system.

Separating plant servicesEven after the system has been running for a long time, Mall will still be your expert partner for regular maintenance, inspections, repairs and refurbishments. Order our service brochure now from [email protected].

Dienstleistungen AbscheiderService, Zubehör und Ersatzteile

Pumpen- und Anlagentechnik

Abscheider Kläranlagen Neue EnergienRegenwasser-

bewirtschaftung


Sensible products and solutions for rainwater and wastewater Rainwater management

In recent years, floods and growing problems in connection with drinking water abstraction have led to a change in the way we look at water. The natural water supply is either to be disturbed as little as possible or reproduced as well as possible. Rainwater management is now of high significance in urban water management. As a result, the requirements on products and system technology have increased. Universal, decentralised solu-tions are in demand.

Mall provides technologically sophisticated systems which reliably meet the official requirements for all fields of rainwater management. The instruments of rainwater management are as follows:

Utilisation

Infiltration

Evaporation

TreatmentRetention Throttled discharge

For this reason, decentralised systems for retain-ing and treating rainwater are increasingly being installed as part of the construction of industrial parks, traffic areas and residential buildings. This water is treated before being discharged in a controlled manner into a body of water or allowed to percolate into the ground – an economical and also environmentally friendly alternative to treating the water in municipal wastewater treat-ment systems together with other waste. How contaminated rainwater is depends on where the water landed.

Because: The rainwater run-off from sealed areas can pose problems because of its volume and contents. The possible consequences include overloading of wastewater systems and a build-up of suspended matter in receiving bodies of water. Falling rainwater will pick up a range of difference substances depending on the state of roof areas and what has built up on traffic sur-faces. In order to discharge the rainwater into a body of water or into the ground after treating it, a range of treatment methods must be used.


Treatment of rainwater

ViaSedi sedimentation system For groundwater and infiltration system protec-tion. Sedimentation systems from Mall protect surface water against contamination and ensure that rainwater infiltration systems remain func-tional in the long term. Sedimentation systems filter out solids, thus ensuring that water and groundwater is considerably cleaner. At the same time, there is space for the retention of light flu-ids. This provides protection, for example, during oil accidents.

The guide baffle directs the incoming water to form a circular stream flowing tangentially to the container. Dirt particles settle at the bottom and light fluids are retained in the upper area. An additional containment area is provided for light liquids if accidents occur.

The system can be used wherever rainwater from traffic areas is discharged into bodies of water and where there are legal require-ments on the properties of that rainwater. This is always the case when water is dis-chargedn straight into the groundwater n in water catchment areasn in waters with valuable fish stocks n in waters containing protected aquatic

species

ViaTub lamella separatorFor the treatment of rainwater from sealed surfaces before discharge into water bodies / ground water. Thanks to the disc packs, large connected areas can be treated in relatively small plants; this helps meet the current water protection criteria. Compact system for underground precipitation water treatment with a smaller size than a sedimentation system. Plastic pipes in the disc packs enhance the settling effect, particularly for small particles; this increases the effective area of the basin. The inclination of the lamellas causes particles to slide to the bottom of the container (sludge settlement).

ViaPlus substrate filterFor draining traffic areas with a high traffic volume, e.g. car parks in shopping centres. Areas measuring up to 3,000 m2 can be connected. The substrate filter cleans in 3 stages: Stage 1: Retention of settling substances Stage 2: Separation of filterable substances Stage 3: Removal of detached and emulsified

substances

The advantages at a glance

+ Monolithic reinforced concrete tank

+ Corrosion-resistant fitted components

+ Simple, low-maintenance technology

+ Prefabricated system components of consistent quality

+ Reliable adherence to the specified outlet limits

+ Short installation time

Rainwater treatment systems protect infiltration systems from being contaminated and blocked by settling materials when rainwater drains away from road surfaces. How contaminated rain-water is depends on where the water landed.


Retention and infiltration of rainwater

Reto rainwater tankRainwater tanks not only store water for use, they also retain rainwater which would otherwise burden the sewage system with undesirable peak volumes. Not enough attention is generally paid to this retention effect in private use. This behav-iour is altered with the Reto rainwater storage tank, an ingenious system which combines usage with retention. In the same manner as public rainwater retention basins, this tank repeatedly provides free retention capacity for the next instance of precipitation. Its function in providing for rainwater use is unaffected.

Cavi infiltration chamberThis shallow rainwater infiltration and retention system is suitable for all infiltration and retention volumes in private, commercial and public applications. It stands out for its high load capacity and easy installation, can be used flex-ibly, and has a storage coefficient of up to 85 %. The infiltration chambers can be used as ditches or basin-ditches for rainwater infiltration.

Retention The amended Water Management Act 2009 (WHG), which obliges communal planners and deci-sion-makers to simulate the natural water supply when planning new development areas, poses the question of how decentralised rainwater retention can be implemented.

Infiltration Rainwater utilisation and retention systems are not dependent on the local wastewater disposal and sewage systems, or the costs associated with these. The run-off rainwater is filtered and collected in a rainwater storage tank. The stored rainwater is used as service water in the house or for watering the garden. Excess rainwater is discharged and percolates into the ground.


+ Sample

+ Conventionally equipped rainwater stor-age tank, equals approx. 30 % of the costs of a rainwater utilisation system.

+ The ideal time to relocate is when new development areas are being planned

+ Drainage is available even after the shell and roof are finished

+ Flexible to use, construction length can be adjusted based on the available space


+ Highly robust; can be driven over by vehicles weighing up to 60 tonnes

+ Flexible modular system

+ For shallow installation where there is, for example, a high level of groundwater

+ All sorts of volume are possible

+ Storage capacity of up to 85 %


Proven units and systems forrainwater utilisation

Rainwater storage tanks for every application As early as 1979, we began carrying out pioneer-ing environmental and commercial work with the monolithic Mall rainwater storage tank made of concrete. Since then we have been working hard on decentralised solutions for rainwater use, infiltration, treatment and retention. Mall rainwater storage tanks are available with capacities of 1,000 to 22,400 litres.

Product rangen Reinforce concrete rainwater storage tanks

ranging from 1 – 1,000 m3

n Rainwater use for businesses, sports facilities and industry

n Tano rainwater centre for domestic water usen Fontana draw-off unit for watering gardens

The use of rainwater has become an established element in building services for houses, especially since the publication of the DIN 1989 series of standards, parts 1 to 4. The fact that groundwater reserves are permanently under threat and that wastewater treatment plants and sewage systems can't keep up with precipitation levels has lead to increased recognition of the importance of rainwater management.

Rainwater use for engineering, commercial and industrial premisesCommercial and industrial companies generally have large water needs and large roof surfaces too. If this is the case, the prerequisites are in place to use rainwater in the company. Alongside use in production, rainwater can also be used as service water in other areas. This leads to significant savings on drinking water and wastewater rates, which are rising all the time. This is particularly true where additional precipi-tation charges are applied based on the amount of paved or sealed surface area.

Individual sizing and manufactureMall rainwater storage tanks and large-scale containers can be made into tailored systems by adapting them to suit local conditions and spe-cific water requirements. Individual construction heights for various types of containers can be easily implemented. Reinforced concrete contain-ers are manufactured in accordance with EN 206 / DIN 1045, parts 1-4.


+ High robustness and density

+ Robustness (60 t HGV)

+ Optimally adjustable tank heights

+ Buoyancy prevention

+ Quick to assemble, up to 300 m3 in one day

+ Pre-installed components

+ Volumes up to 1,000 m3


Certification system

Separating plants(mineral oil separa-

tors)

Retention and separa-tion facilities

Washing water treat-ment systems

CE marking n n n

Ü markMonitoring by an external body

n n n

General technical approval n n n

RAL quality certificate n n n

RAL quality control association Certifies manufacturers that have the criteria tested by an independent institute.

GET quality characteristics n External monitoring of production processesn Specific proof of stability n Quality characteristics as defined by quality

guidelines n Regular update of the products’ technical

standardsn External monitoring of the type approval and of

national approvalsn Internal and external production monitoring n Tested type structure SLW 60n Bears RAL quality mark RAL-GZ 693

The solution: Wastewater treatment with Neutra separating plants from MallRainwater and wastewater that might contain hydrocarbons must be drained via a light liq-uid separating plant as per DIN EN 858 and DIN 1999-100 / -101. They must have both a CE marking and a German national technical approval. In addition, con-sistent quality is guaranteed and thus reliable operation of the structures when dealing with water-polluting liquids in conjunction with the RAL quality mark RAL-GZ 693. Businesses in which commercial wastewater with animal and vegetable fats and oils are produced must treat their wastewater with a grease separating plant. Grease separating plants are manufactured and operated in accordance with DIN EN 1825 and DIN 4040-100. They are also subject to the CE marking obligation, they must have a German national technical usability certification and are provided by Mall with the RAL quality mark.Both types of separating plant are available for underground and free-standing installation in buildings. Large plants can be conceptualised in a building-specific way.

Separating plants are an ecological must-have

According to legislation, water that is contaminated by light mineral liquids, lubricants and ani-mal and vegetable fats must be subjected to pre-treatment. This pre-treatment must take place in an approved separating plant. This may be either a light liquid or a grease separating plant.


For light mineral liquids –Neutra separating plants

The components of a separating plant system Sludge trapA sludge trap sediments settling solids. This is necessary especially for large amounts of sludge produced. An effective sludge trap is of great importance for the subsequent treatment. The design of the sludge trap depends on the nominal size of the separating plant and the sludge quan-tity produced.

Class II separating plantA class II separating plant must exhibit a maxi-mum discharge value of 100 mg/l hydrocarbons in test conditions. All principle guidelines are tested and certified as is the case with the coa-lescence separating plant.

Class 1 separating plantFor the class I separating plant, a variety of prin-ciple guidelines and functional requirements are tested and certified both during the initial inspec-tion of the product and in recurring production monitoring and certification steps. One of the requirements of the class I separating plant is the discharge value with a maximum of 5 mg/l of mineral hydrocarbons under prescribed test con-ditions. In effect, a class I separating plant has even greater purification capabilities than a class II separating plant.

Sampling manholeAll separating plant systems feature a sampling manhole that allows for sampling of the dis-charged wastewater stream. To ensure this, the sampling manhole is subject to strict geometrical requirements as per DIN 1999-100. There are in-tegrated sampling manholes in separating plants or downstream sampling shafts.

Neutra oil, coalescence and gasoline separat-ing plants (classes I and II) These separation systems are used in all appli-cations where light mineral liquids are filled, vehicles are washed, or where light liquids may escape during the operation, servicing and repair of vehicles. They consist of the following functional areas: sludge trap, petrol separator, coalescence separator, sample-removal manhole and warning system.Method

Depending on requirements, the functional com-ponents are housed in one or several structures made of seamless reinforced concrete. Solid particles such as sand and sludge are separated in the sludge trap. Light mineral components are separated from water and rise to the surface in the oil and petrol separating plant. This light liq-uid layer must be properly removed and disposed of. The sample-removal manhole is used for tak-ing monitoring samples of the discharged water.


+ Monolithic reinforced concrete tank

+ Quality-controlled prefabrication using water permeable jointless reinforced concrete C 35 / 45 (B45) as per DIN 4281 and DIN 1045, reinforced to ensure protection against cracking.

+ With type-tested structural calculation.

+ Certified under the RAL quality mark 693


For animal and vegetable fats —Neutra grease separating plant

Grease separators are part of the wastewater treatment process necessary for certain commer-cial operations. The animal or vegetable fats and oils contained in wastewater must be treated before they are discharged into the sewage system. This is the only way that deposits on pipe walls, which lead to reductions in available cross-sectional area of the pipe and to blockages of sewage pipes, can be prevented in the long term.

Prevention of blockages and deposits in pipelinesSeparation systems for animal and vegetable substances consist of several functional compo-nents: sludge trap, grease separator and sample-removal manhole. Depending on the requirements, these functional components can be installed in one or several structures.

4Heavier matter will settle in the sludge trap, while fats and oils rise to the surface. The layer of fat must be removed and disposed of. The sample-removal manhole is used in monitoring the discharged wastewater.

Grease separating plant for underground installationn Covers suitable for traffic – installation location

remains available for usen Excellent access for maintenance and disposaln Long-lasting seals and flexible pipe connec-

tionsn The separating plant is available with internal

coating to the relevant standards or with a plastic lining (PE)

Free-standing, frost-protectedn The system remains mobilen Narrow shape, low weight, can fit through

narrow doorsn No earthworks required for installationn Viewing glass for monitoring the layer of fatn Tested, guaranteed quality


+ Made from high-quality, robust reinforced concrete

+ Certified under the RAL quality mark 693

+ Corrosion-proof, high-quality stainless steel components

+ Standard-compliant internal coating.

+ Type-tested structural calculations

PE concrete protection plate for special anti-corrosion applications For special anti-corrosion requirements made necessary by waste water inside containers, Mall provides a model with an HDPE inner lining. This way, the reinforced concrete grease separating plants can be lined with PE concrete protection

plates in the factory. The high level of mechani-cal stress is combined with improved resilience against wastewater with varying temperatures.One side of the artificial plates feature a certain number of conical anchor nubs which provide for a permanent bond with the concrete. Stress caused by various instances of heat expansion of concrete and plastic is suppressed by this force-locked connection.For 30 years the combination of concrete and plastic has proven itself to be a highly acid-proof lining under the toughest conditions around the world. Hydraulically smooth, non-porous surfaces prevent encrustation and support the self-cleaning process, allowing the system to be low-maintenance and therefore highly economi-cal in the long term.


Retention and separationof liquids hazardous to water

The safety collecting tank NeutraSab was developed to retain liquids hazardous to water on fuel filling and transfer areas in the event of an accident.

Areas of applicationn Siphoning and transfer points for liquids

hazardous to watern Petrol stations for alternative fuelsn Marinas, airfieldsn Printersn Chemical or processing industries n Vehicle industryn Extinguishing water retention

Resistance against n Light mineral liquidsn Diluted organic and inorganic acids and basesn Large quantity of solventsn AdBlue (36% urea solution)n Contaminated extinguishing watern Alternative fuelsn Other liquids (see the list of the DiBt media

group)

Other products related to liquids hazardous to water:

NeutraBlocThe shut-off shaft is used to retain liquids hazardous to water by shutting off the pipeline.

NeutraSwitchThe diversion shaft is used for the separate discharge of wastewater with different types of pollution into two different wastewater treatment systems or discharge points.

NeutraHavThe overflow basin is used to collect liquids hazardous to water which are created within buildings or in roofed outdoor areas, e.g. effluent-free workshops.


+ General technical approval Z-74.1-80 NeutraSab

+ Inner coating or inliner selected based on the liquid in question

+ Long-lasting shut-off flap

+ Cable duct sealing with elastic, fuel-resistant squeeze gaskets for electric wires


Treatment of washing water

Annex 49 of the German wastewater ordinance stipulates the recycling of wash water. This not only eases the burden on the environment, but also helps to lower the operating costs signifi-cantly. The treatment process provided by Mall functions entirely without chemical additives.

MethodThe circulation water treatment plant NeutraClear treats the contaminated wash water using a me-chanical/biological treatment system. A filter that is supplied with compressed air treats the waste-water using a complex combination of bio-film processes, filtration, adsorption and flotation. The added oxygen reliably prevents the development of odours.

System design and flow pathThe system consists of an optimised pre-treat-ment basin which retains settling and floating solids, a biological cleaning stage with adsorption filter and counter-current aeration, and a reser-voir for service water. The components are designed to match each other and are operated as a continuous system. The wash water flows under gravity through the whole system, ending with the discharge of the excess water into the sewage system. Evaporation and other water losses maybe balanced out using rainwater or fresh water.


+ Particularly low-maintenance and reliable operation

+ No chemical additives necessary

+ No odour nuisance

+ Saves space as all treatment basins are installed underground

+ Reduction of surfactants, phosphates and hydrocarbons

+ Reduction of COD and BOD

+ Simple control system

+ Options such as conductivity measure-ment, flow meter and sludge dewatering

+ Additional savings possible by using rainwater

+ General technical approval in Germany for NeutraClear Z-83.4-6

Areas of application n Drive-through washing facilitiesn Washing facilities for commer-

cial vehiclesn Continuous washing facilities

Z-83.4-6


Mall wastewater treatment plants at a glance

System type SanoClean SanoFix SanoKomeasyline

SanoKom VarioKom

Sizes 4 – 200 PE 4 – 200 PE 200 – 500 PE 100 – 3000 PE 100 – 500 PE

Modern, aerated SBR wastewater treatment plants

Aerated SBRplus wastewater treat-ment plant

SBR plants for commercial premises, hotels and restaurants

Small, municipal wastewater treatment plants

Tried and tested trickling filter system for small communities

Centralised and decentralised wastewater purification –treatment plants and methods

Centralised or decentralised? Planning officers and local authorities are confronted with this question regularly. The answer can only be provided by considering the overall situation, taking financial, technical, organisational and ecological considerations into account. If the costs for sewage connections and cleaning are analysed together with wastewater charges, connection to a centralised sewage treatment plant becomes the most expensive solution in rural areas with lower population densities.

Nature as a role modelSmaller, decentralised water treatment units made from pre-cast concrete are generally a more economic alternative. Natural, ecological treatment processes which, after a short start-up phase, are almost self-regulating and purify the wastewater biologically are particularly economi-cal and environmentally friendly.

Mall treatment systems provide a perfect treat-ment result. The SanoClean Sequencing Batch Reactor (SBR) treatment system is especially effective; it uses modern treatment technology as a basic module to meet the minimum statutory requirements and, with additional components, can also be used in particularly demanding applications.


SBRplus small wastewater treatment plant SanoFixThe SBR Plus method in the form of the SanoFix product range helps you with special purification tasks with strongly varying loads. In addition to

the tried and tested portion-by-portion treatment of wastewater, SanoFix offers the combination with biofilm technology. The freely moving carrier elements are particularly well suited to underload operation, where they still achieve excellent puri-fication results.

SanoClean – SanoFixDelivered fully assembled and ready to be plugged in, the Mall small wastewater treatment plants are available in four equipment packages: n SanoClean easyline – the low cost solutionn SanoClean classicline – the elegant solutionn SanoClean activeline – energy-optimised and

environmentally friendly right from the beginning n SanoFix with fixed biomass – best suited to

varying loads and underload operations

Wastewater treatment can be this easy –Small wastewater treatment plants from Mall

SanoClean small SBR wastewater treatment plantThe modern SanoClean SBR plant works in two stages. One stage is the mechanical pre-treat-ment. At the same time, this chamber collects the wastewater from your house. This buffer function means that the system can adjust itself to your behaviour over the course of the day. The bacte-ria in the second chamber, the activated sludge chamber, receive a predefined amount of water from the buffer. Since we are able to estimate accurately the amount of contamination, we can also adjust the aeration to achieve the desired purification result. This will also optimise your domestic running costs.

Calm after the stormOnce main purification is complete, an idling phase follows where the bacteria settle on the base of the activated sludge chamber. Only treated water is allowed to leave the system. Mall do not use rotating or electrical parts in their small wastewater treatment plants. Wastewater and sludge transport are carried out by wear-free lifting systems driven by compressed air. All mechanical and electrical components are located outside of the system in a switch cabinet.

Easy to operate – low follow-on costsThe control system with d-pac automatically controls the fully biological wastewater treatment process. If necessary, it switches your system to holiday or economy mode, monitors it for faults and documents the operation – with SanoWeb, the intelligent remote monitoring system, if de-sired. SanoClean knows when it is needed.

Today, small wastewater treatment plants can be permanently used for wastewater disposal in areas where up until recently, expensive and ecologically less prudent solutions were required.

The approvals at a glance

SanoClean S SanoClean M SanoClean L SanoFix S

Run-off class C Run-off class N Run-off class D Run-off class C

Treatment goal: minimum statutory requirementabZ Concrete Z-55.31-233abZ PE Z-55.31-287 abZ Retrofit Z-55.3-285

Treatment goal: nitrificationabZ Concrete Z-55.31-232abZ PE Z-55.31-286 abZ Retrofit Z-55.3-284

Treatment goal: denitrificationabZ Concrete Z-55.31-231–abZ Retrofit Z-55.3-283

Treatment goal: minimum statutory requirementabZ Concrete Z-55.61-328 –abZ Retrofit Z-55.62-395


+ The reinforced concrete tank can be driven over and is robust, seamless and water-tight; it is even ideal for high levels of groundwater

+ High-quality currentless technology in the reinforced concrete tank

+ Particularly quiet and energy-saving

+ Maintenance can be carried out dur-ing operation


For 100 to 3000 residents –Municipal wastewater treatment plants

SanoKom – the processIn the SBR process, all the treatment steps that are carried out in physically separate locations in a conventional activated sludge system are combined in one tank. The purification stages operate in succession with a cycle of filling, mix-ing and aeration phases. After sedimentation of the biomass and removal of the purified water and excess sludge, the SBR basin is available for the next cycle. A special program controls the gradual build-up of contaminants in the water. The reactor serves as a nitrification basin, denitri-fication basin and post-treatment basin in turn.

SanoKom S easyline, up to 200 PEn For commercial premises, hotels, holiday

camps and restaurantsn Standardised system componentsn Easy to handle and installn Low investment costs

VarioKom – the process After pre-treatment, the wastewater is subjected to biological purification in the trickling filter. The trickling filter consists of a filling of open-pored ash (substrate for aerobic micro-organisms). On its surface, aerobic bacteria and micro-organisms form a "biological lawn" in the case of uniform wastewater and oxygen addition ("counter-current principle"). Using the oxygen in the air, this "lawn" converts the contaminants in the wastewater into water, carbon dioxide and miner-als that settle out. The wastewater that is freed of materials that consume oxygen is fed through a recirculation shaft into the post-treatment basin. The pump in the recirculation shaft compensates for load fluctuations and also flushes the trickling filter. The wastewater settles in the post-treat-ment basin and the sludge falls to the bottom. A pump at the point of the funnel pumps the excess sludge back to the sludge storage tank or buffer. This closes the wastewater cycle.

SanoKom up to 3000 PEn For municipalitiesn Special features of the wastewater can be

taken into account separately (infiltration water, inflow of separation and mixed water)

n Adaptable technologyn Professional equipmentn Custom sizes


+ Very low operating costs

+ Easy installation

+ Single or parallel layout

+ Gradual commissioning and extensions are easy to carry out

+ High purification performance

+ Robust operation, even with fluctuating loads


If there is an insufficient slope, if the groundwater level is high or if there are other unfavourable topographical conditions, the discharge of wastewater with faecal matter and rainwater using gravity drainage becomes either impossible or too expensive. An economic solution is offered by the Mall pump station.

For domestic and municipal applications –pump stations for pressure draining

Variable sizesThe pump manholes are monolithic round containers made from high-quality reinforced concrete, and have a height of up to 3.25 m. For various shaft depths there are shaft attachments measuring up to 3 metres in height. In addition to our standard range, Mall also provides large rec-tangular reinforced concrete structures with wet and dry chamber walls.

Pre-assembled and ready for installationAll pump stations are dimensioned individually. All system components of the pump stations are supplied ready for installation, including the elec-tric control system, and are generally delivered pre-assembled.

Ready-to-connect compact pump stationsAlternatively, Mall also provides fully pre-assem-bled compact pump stations. Models are avail-able for wastewater with or without faecal content. As all the parts are in stock and in sufficient quantities, we can guarantee quick delivery times at all times. For areas beneath the backflow level, the system can be expanded with a backflow loop that prevents the basement from being flooded when the water level in the sewage system rises.

LevaPur compact pump stationn For wastewater with no faecal content (grey

water)n For use as backwater protection downstream

of separating plants

LevaPol compact pump stationn For wastewater containing faeces (black water)n For use in detached and semi-detached houses


+ Individual solutions thanks to flexible components and sizes

+ Ready for installation or pre-assembled at the factory, resulting in quick installation and low costs

+ Mall takes care of planning, manufacture, delivery and installation

+ Fixed price means no cost uncertainty

+ Reliable operation with proven, brand-name pumps

+ Tough, high-quality and waterproof rein-forced concrete with seamless construction


Valve manholes

Wastewater applicationsn Aeration and deaeration manholes for pressure

pipes with gravity-flow sectionsn Sliding gate shaft with manual gate or electri-

cal driven Cleaning manhole for pressure pipesn Valve manhole downstream from pump stationn Compressor manholen Measurement manhole – e.g. for flow rate

measurement devices

Drinking water applicationsn Water meter manholen Cleaning manhole for pressure pipesn Distribution manhole for main and branch

pipes

Only high-quality fittings are used in the installation of our systemsn Shut-off flapsn Slidern Hydraulic gatesn Drivesn Waste weirsn Change-over flaps with stem and locking levern Tooth profiles with clamp straps as per

DIN 19558 in aluminium or stainless steel n Submerged bafflesn Dam sluicesn Backflow gatesn Tipping troughsn Manhole ladders as per DIN 18799 made of

stainless steel, galvanised steel or reinforced plastics

n Climbing systems with fall protection for climb-ing heights of over 5 m (stipulated by German accident prevention regulations, UVV)

n Entry aids for increased safetyn Manhole covers made of stainless steel /

moulded concrete / mouldings as per required load class

Other equipment and installation partsA large proportion of the equipment and instal-lation parts for Mall products is produced in our own manufacturing facilities.

Mall valve manholes are the right choice wherever pressure pipes are equipped with fittings. The shafts are delivered ready to install, and factory assembly ensures fast installation and high quality. Mall only uses high-quality, corrosion-free materials for piping and fittings, working in close cooperation with the project planner.


+ Precise reinforced concrete tanks with smooth surfaces

+ Seamless and water-tight, can also be driven over by vehicles larger than a 60 t HGV

+ Quick to install – delivered ready to install

+ Fittings made from corrosion-free materials


Pellet storage unit for deep earth storage Renewable energy sources

Pneumatic, flexible and visible – the ideal removal systemThe suction 'mole' is a pneumatic removal sys-tem – i.e. the pellets are sucked out to the heat-ing system in the basement. The system stays on top of the pile of pellets, and can thus be seen when the cover is opened. It can be pulled up slightly when the storage unit is being filled. The mole moves over the pellets during the removal process. This avoids the formation of funnel shapes, gaps or bridges.

Pellet storage unit with mole 2500n Storage capacities from 6.5 m3 up to 12 m3 n Heating capacity of up to approx. 25 kW

Pellet storage unit with mole 3000n Storage capacities from 12.5 m3 up to 22 m3 n Heating capacity of up to approx. 70 kWn Pneumatic system with integrated PLC control

unitn Also available with fill level indicator

Pellet storage with mole 6000 removal system n Storage capacities from 45 m3 up to 60 m3 n Heating capacity of up to approx. 250 kWn Mole 6000 removal systemn Pneumatic system with integrated PLC control

unitn Also available with fill level indicatorn Also available without a removal system,

removal takes place via worm conveyors on site by the customer or the boiler manufac-turer (heating capacity up to approx. 400 kW)


+ Dry storage

+ More cost-effective than basement storage

+ The basement room can be used for other purposes

+ Prevents dust and odours forming in the building

+ Optionally with a cover that can be driven over or walked on

+ High-quality reinforced concrete C 35/45

+ Concrete is chemically neutral in the ground, sturdy in demanding construction applica-tions, and is not affected by buoyancy effects if the groundwater is high

Mall also provides reinforced concrete tanks for the underground storage of pellets, heat and bi-omass. Wood pellets are stored securely and dry, out of sight, in the water-tight and frost-proof ThermoPel earth storage units. External storage provides the best fire prevention and saves valuable basement space.



+ Concrete can be driven over by all vehicles

+ Long service life

+ Standard 3 bar operating pressure, more pressure levels are available

+ For diverse applications, e.g. in large solar thermal plants, in biomass heating plants, for waste heat recovery, cooling and in combined heat and power plants

Buffer storage tank for the underground storage of heat Renewable energy sources

Mall buffer storage tank ThermoSol The buffer storage tank ThermoSol consists of a reinforced concrete tank and an inner steel tank that is directly connected to the heating circuit. The pressurised buffer storage tank is primarily suited for high heat outputs and flow rates and it is available with a storage capacity ranging from 2,050 to 13,400 litres.

Ready-to-connect deliveryThe Mall buffer storage tank is assembled in the factory and unloaded on site directly from the Mall lorry crane; only larger storage tanks will also need an additional mobile crane. Under-ground installation usually takes less than an hour.

Customised configurationEvery heating system is different. Accordingly, the Mall buffer storage tank is designed in consulta-tion with the planning authority and trimmed and configured to meet the specific requirements. Possible options include solar heat exchangers and stratified feed-in devices.

Insulation The new buffer storage tank from Mall can be easily installed in the ground and connected to the heating system using insulated pipe con-nections. The insulation between the inner tank and the storage tank (that can be driven upon) is comprised of cellular glass particles fully made of recycled glass, a material that has proven itself as a heat-insulating material.

Keeping heat losses under controlThe favourable ratio of volume to surface area of the Mall buffer storage tank is the most important factor in minimising heat losses. In addition, heat insulation which is 25 cm thick prevents the tank from losing heat.

Heaters of large systems can only be operated efficiently with a sufficient buffer tank volume. In cellars, however, large buffer tank volumes can only be realised by cascade solutions with several successively connected storage tanks. The resulting large surface area leads to signifi-cant heat loss.


Drainage of silage Renewable energy sources

Liquid manure, dung, slurry and fermented silage are valuable farm fertilisers for agriculture, but if stored or used improperly they can poison our water. The discharge of these substances into sewage systems, surface water and ditches and their percolation into the ground and entry into the groundwater are therefore prohibited. Liquid manure, slurry, slurry and liquid silage must be collected and properly used in collecting basins.

ThermoSil reinforced concrete tanks for fermented silageThe reinforced concrete tanks are available with diameters of 2, 2.5 or 3 m. These allow for volumes ranging from 3.6 to 19 m³. The reinforced concrete tanks are reinforced to meet a crack width limit of under 0.2 mm and therefore they meet the usage parameters of the approved coating ThermoSave.

ComponentsThe ThermoSil main tank is a monolithic reinforced concrete tank produced using the overhead method. As a result, there are no construction seams between the wall and the base. The interior of the walls and base is lined with the ThermoSave coating in accord-ance with the conditions of application.

ThermoSave epoxy resin coating Z-59.15-365Fermentation processes produce organic acids and other substances that can attack any container material. The German Institute of Construction Engineering (DIBt) has there-fore drawn up approval criteria for coatings that are designed to protect such materials and that come into long-term contact with fermented silage, silage effluent, slurry or liquid manure.

ThermoDuo drainage element The drainage element ThermoDuo, with a dual pipe connection, is ideal for regulating waste-water and rainwater discharge for silage areas. It is easy to operate manually by means of the inte-grated pipeline closing mechanism. It is installed using the recommended assembly instructions from Mall.

n Covering grate (that can be driven over), optionally with inserted perforated plate

n Collection recessn Discharge 1 for highly polluted inlets,

e.g. into the silage tankn Discharge 2 for only slightly polluted inlets,

e.g. into a rainwater treatment plant with closing mechanism


+ Reliable adherence to the statutory, ad-ministrative and normative requirements

+ Prefabricated and tested components

+ Easy to install thanks to sophisticated, patented and normative connection technology

+ Secure pipe connections thanks to prefabricated elastic connections

+ The tanks are water-tight and robust thanks to the approved crack-bridging coating

+ Usability certification thanks to approval in connection with a proven type structure

Economical solutions for the drainage and wastewater treatment of biogas plants


For a range of applications Reinforced concrete tanks from Mall

Reinforced concrete tanks from Mall are used wherever liquids are collected, stored or treated.

Tailor-made systemsIndividual construction heights for various types of containers can be easily implemented. Inlets and outlets in the form of core drillings, unfinished recesses or ready-to-connect seals can be integrated during production. Reinforced concrete tanks are manufactured in accordance with DIN EN 206 and the new series of standards for concrete DIN 1045-1, parts 1 to 4.

Made from high-quality concrete, tailored, robust and watertightReinforced concrete tanks from are made from high-quality reinforced concrete, are seamless and have a smooth surface. To increase the vol-ume, it is also possible to connect several tanks together, extend them by using U-shaped connec-tor pieces, or to install them on top of each other.

Areas of applicationn Waste water collection pits n Decentralised and municipal wastewater

treatment plantsn Pump stationsn Rainwater management n Separating plantsn Stormwater settling basinsn Service water storage for commercial and

industrial premisesn Extinguishing water tanks n Cooling water storage

Reinforced concrete tanks at a glance

Reinforced concrete tanks

InnerØ

Total height Length Width Content

Type mm mm mm mm m3

Round structure 800 – 3000 750 – 3250 – – 1 – 23

Rectangular structure – Max 3400 Max 6000 Max 3300 20 – 50

Rectangular profile – 2850 From 6000 4050 24 – 100

Multi-component structure

4000 or 5600 1500 – 3250 From 6000 – 25 – 1000


+ Can even be driven over by vehicles larger than a 60 t HGV

+ Lower costs thanks to the quick installation, as well as due to potentially necessary water retention

+ No loss of useful area thanks to installation underground

+ Buoyancy prevention if necessary

Germany

Italy

SpainPortugal

France Switzerland

Hungary

Poland

Belgium

Netherlands

Luxembourg

Denmark

Sweden

Croatia

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Separating plantsPump and

plant engineeringNew energy sourcesWastewater treatment plants

Rainwatermanagement

Mall GmbHHüfinger Straße 39-4578166 DonaueschingenGermanyPhone +49 771 8005-0Fax +49 771 8005-100

Mall GmbHGrünweg 377716 Haslach i. K. GermanyPhone +49 7832 9757-0Fax +49 7832 9757-290

Mall GmbHIndustriestrasse 276275 EttlingenGermanyPhone +49 7243 5923-0Fax +49 7243 5923-500

Mall GmbHRosslauer Strasse 7006869 Coswig (Anhalt)GermanyPhone +49 34903 500-0Fax +49 34903 500-600

Mall GmbHOststrasse 748301 NottulnGermanyPhone +49 2502 22890-0Fax +49 2502 22890-800

www.mall.info

Documents

Mall environmental systems - For the protection of water ... · projects. With the aid of this certificate trading, Mall offsets the unavoidable CO2 emissions from the print production,