Clarifier Installation
Clarifier Installation
Clarifier Installation
Clarifier
Installation
6 [1.83 m] - 24 [7.31 m] Diameters
CONSTRUCTION AND OWNERS MANUAL
P/N 80010036
Be Alert!
A copy of this manual should be available at all times to the owner/operator. Additional
copies may be requested from the company at the address shown on the back cover.
Please reference part number #80010036 when requesting additional copies.
Please Contact Global Treatment Systems or Your
Dealer if You Have Any Questions Concerning This Manual
Keep This Manual In A Safe Place Available For Future Reference
A GENUINE
PREFACE
You have purchased the finest Clarifier manufactured today. This manual includes the
following instructions for your Clarifier: pre-construction guidelines, directions for proper
construction, and methods for proper use once constructed. Read and understand this
manual before building and use of your Clarifier.
Contents
General Safety Statement ...........................3
Warranty........................................................4
Maintenance .................................................8
Safety ............................................................9
Sign Identification and Placement .............................. 9
General Safety Requirements .................................. 11
Specifications .............................................14
General Specifications .............................................. 14
Other Specifications.................................................. 18
Bolt Identification and Torque Values ........................ 19
Pre-Assembly .............................................22
Parts Identification .................................................... 23
Connection Details.................................................... 24
Assembly ....................................................25
Clarifier Sidewall Construction .................................. 26
Cone Construction .................................................... 30
Completed Clarifier, Example Drawings ................... 37
Backfilling.................................................................. 42
Contents
Maintenance
An ounce of prevention is worth a pound of cure, an old adage that still rings true. Your
GLOBAL Wastewater Treatment System / Global System has been designed for many years of
dependable service, but as with any system, proper inspection and maintenance is essential.
Corrosion is the primary concern in regard to the long-term structural integrity of the clarifiers.
GLOBAL utilizes galvanized sheet good, cathodic protection and an epoxy coating as a
standard three-level protection against corrosion. Inspection, detection and repair are the keys
to long service life. We suggest implementing the following as part of the a regularly scheduled
maintenance program for corrosion and overall clarifier integrity:
1. Keep exterior surfaces free of debris and foreign materials. Maintain a clean plant site.
2. Accumulated organic material, clinging to the interior walls, should be removed by scrubbing
or power washing.
3. Inspect the integrity of the basin coating for scratches, abrasion or peeling. Promptly remove
loosened paint, clean and re-coat.
4. The anodes should be checked annually to verify proper working condition. Refer to
manufactures testing procedures.
5. Inspect for any obvious foundation settlement. Major settlement may cause structural failure
of clarifier(s).
6. Inspect for any deterioration or looseness of bolts or fasteners.
7. GLOBAL strongly suggests that any mechanical, electrical or auxiliary equipment installed in
or on the clarifier be checked on a yearly basis by a qualified service technician.
Safety
CAUTION
2 Safety
10
2 Safety
!
It Points Out Important Safety Precautions. It Means
ATTENTION - Become Alert! Your Safety Is Involved.
OPERATOR QUALIFICATIONS
Operation of this unit shall be limited to competent and experienced persons. In order to be
qualified, he must also know and meet all other requirements, such as, but not limited to, the
following:
1. Some laws and regulations specify that no one under the age of 16 years may operate
power machinery. It is your responsibility to know what these requirements are in your own area
or situation.
2. Current OSHA regulations state in part: At the time of initial assignment and at least
annually thereafter, the employer shall instruct every employee in the safe operation and
servicing of all equipment with which the employee is, or will be involved*
11
2 Safety
OSHA
OCCUPATIONAL SAFETY AND HEALTH ACT OF 1970
Certain purchasers of our products may be subject to the requirements and standards of the
William-Steiger Occupational Safety and Health Act of 1970, which prescribes standards for use
of appurtenances of our manufacture, such as handrails, platforms, stairways, fixed ladders,
ladder cages, and guard rails. (Occupational Safety and Health Standards Section 1910.21
through 1910.32). Before installing these devices, familiarize yourself with the above Federal
Standards.
At the time of manufacture, these optional items conform to applicable standards. GLOBAL
assumes no liability with respect to proper constructed, inspection, assembly, or use of its
products under applicable laws, all of which is the sole responsibility of the purchaser and those
doing the assembly work.
PROPER PERSONNEL
To insure the safe operation of your clarifier be sure that only trained personnel install, maintain,
and operate your clarifier!
12
2 Safety
13
Specifications
General Specifications
Clarifier(s) are designed along guidelines which allow years of effective service if it is not used
for purposes for which it was not intended. The sidewall gage specifications for your clarifier(s)
appear on clarifier sidewall layout page(s) (provided to you by Global Wastewater Treatment
Systems with your unit). The general material specifications for your clarifier(s) are as follows:
WALLS
All wall sheets are of corrugated, galvanized steel with 2.66 corrugation.
Wall sheets have .90 oz. per square foot zinc coating (G-90 designation).
2.66 corrugation sheets have 32 vertical coverage.
Horizontal coverage of wall sheets is 112 1/2.
All 5/16 bolts are electro-galvanized grade 8.2 with self-sealing injection molded washers.
Anchor Bolts are standard with all clarifiers.
14
3 Specifications
DESIGN CRITERIA
Clarifiers are designed for contact with water or waste water only.
Have your builder make all non-clarifier equipment in excess of GLOBAL recommendations,
like and WALK - WAYS self supporting.
SAND FILL
GLOBAL recommends that a sand base of 4 be used as fill on the excavated site. Following
this and prior to the pouring of the concrete foundation an optional vapor barrier (usually
polyethylene) could be laid down upon the sand base. The foundation should be a minimum of
six (6) inches and should include wire mesh of 6 X 6, 10/10 or better as required by a Site
Engineer.
15
3 Specifications
Inlet Pipe
Clarifier
Diameter
D
Cone
Height
H
Cone
Inlet
I.P.D.
Wier
Outlet
O.P.D.
7 - 0
12
15
18
14 - 2
21
12
12
24
12
12
Number of
Sidewall
Rings
Tank
Gallons
Tank
Height
Liquid
Height
Surface
Area
(U.S. gallons)
(ft)
(ft)
(ft2)
1,733
11.40
9.90
28
2,297
14.07
12.57
28
3,036
11.28
9.78
64
4,304
13.95
12.45
64
12
6,116
13.83
12.33
113
15
7,156
13.72
12.22
177
15
10,679
16.38
14.88
177
18
11,922
16.27
14.77
254
18
16,995
18.93
17.43
254
21
18,428
18.82
17.43
346
21
25,334
21.48
19.98
346
24
26,945
21.37
19.87
452
24
35,964
24.03
22.53
452
NOTE: All volumes are calculated on 32 per sidewall ring and 18 down from the top of the tank.
16
3 Specifications
Clarifier basins have been designed to be located on the interior of aeration basins in certain
installations. Depending on the size of clarifier and aeration tank, many of the clarifier cone
bottoms will be placed below the aeration tank floor elevations. Plans will specify construction
details for tank installation. The table on the previous page illustrates the volume of the clarifiers
and related cone bottom elevation location in regard to the aeration tank floor elevation.
17
3 Specifications
Other Specifications
CHECK DELIVERY
Your clarifier has been carefully checked before shipment. However, you should check your
shipment upon arrival using the Packing List provided to insure it is complete.
Should you discover that a shortage exists or find that some material is damaged you should
note on the freight bill that a shortage or damage exists. This should be done before you sign
the freight bill since your signature indicates an acceptance of the shipment as it is received.
Claims of any shortages must be made within ten (10) days from receipt of the shipment. Parts
that are short or damaged are the responsibility of the delivering carrier. If there is damaged or
missing equipment it must be reordered immediately so the installation of the equipment is not
delayed.
CAUTION
All galvanized steel is subject to oxidation, sometimes called white rust when exposed to
moisture from any source. Care should be taken to protect sidewall sheets and roof sheets as
much as possible. INSIDE STORAGE IS ADVISABLE. When on the job site, sheets should be
placed on edge far enough apart to allow air to circulate freely.
18
3 Specifications
Bolt Head
Torque
1/4 grade 2
1/2 grade 5
Have your contractor demonstrate that he/she is giving you the correct torque.
Approximate torque levels for the fasteners that bolt your bin together are listed here. For all
these bearing type sidewall sheet connections, a snug tight condition is sufficient to ensure
structural soundness, where snug-tight is defined as the tightness attained by several impacts
on an impact wrench, or the full effort of a worker with an ordinary spud wrench that brings the
connected sheets into firm contact. A properly tightened bolt must have its seal washer fully
seated in the hole and the sheets fully drawn together to produce a water-tight seal.
19
* NOTE:
final
clarifier
20
111 11/16
[2,836 mm]
147 1/2
[3,747 mm]
55 27/32
[1,418 mm]
13
[330 mm]
10
[254 mm]
11 0
[3,352 mm]
56 7/16
[1,434 mm]
14 0
[4,267 mm]
FOUNDATION NOTES:
1. The foundation site should be well drained and free of vegetation and/or debris.
2. Foundation(s) should be on undisturbed soil or engineered compacted backfill.
3. Foundation Design is based on an allowable soil bearing capacity of 3500 psf.
4. The concrete shall have a minumum compressive strength of 3000 psi. at 28 days.
5. Concrete should be allowed to cure 7 days before beginning the clarifier assembly
and 28 days before filling the clarifier.
6. Welded Wire Fabric (WWF) shall conform to specifications for welded steel wire
fabric for concrete reinforcement (ASTM A 185)
7. Concrete should be kept level to 1/8 between two adjacent columns, and 1/4 between
any two other columns. High spots or debris should be removed prior to setting the bin.
8. Foundation details in this manual are to be considered general in nature
and are intended only as a guide. It is the owners responsibility to provide
an appropriate site and foundation design for the adequate support of
clarifier(s) / basin(s). GLOBAL assumes no responsibility for results arising from
these suggestions.
21
Pre-Assembly
14 Gage
To determine the number of sheets per ring, divide the bin diameter by three:
(IE: 12 diameter clarifier divided by 3 = 4 sheets per ring.)
22
5 Pre-Assembly
Parts Identification
top angle,
inverted base angle
sidewall sheets
column
cone sheets
column bracing
(on certain
installations)
base plate
clarifier cap
23
5 Pre-Assembly
Connection Details
5/16 nut
5/16 x 1
5/16 x 1
inside
of bin
inside
of bin
5/16 nut
5/16 x 1
inside
of bin
5/16
flange
nut
5/16 x 1 1/4
sealer
tape
inside
of bin
inside
of bin
sealer
tape
5/16 nut
5/16
flange
nut
5/16 x 1
truss bolt
inside
of bin
sealer tape
24
flange
nut
Assembly
25
6 Assembly
sidewall sheet
outside of tank
5/16
hex nut
inside of tank
lower sidewall sheet
sealer tape
6 - 12
EXAMPLE
26
6 Assembly
2
assemble the top sidewall ring
Assemble the topmost sidewall ring on the upper part of the sidewall sheet
(example d). Note the sheets on the for installing the top angle.
topmost ring have special hole punching
overlap
sidewall sheet
overlap
different
hole punching
on the top
sidewall sheets
27
6 Assembly
Note: Make certain that the sidewall sheets are correctly positioned so that
the I.D. COLOR CODES are at the BOTTOM CORNERS of the sidewall sheets!
Note: In many cases it may be preferable to initially rest the tank on its side
for assembly. Determine if this will work best for your situation. We suggest
using 4 x 4 [100 mm x 100 mm] pieces of wood to keep it from rolling.
3
install the next sidewall ring
Install the next sidewall ring staggering
the sheets (example a).
hole
punching
for roof
connection
28
6 Assembly
Note: Position the roof cap and peak ring so that the roof cap will open
away from the roof ladder.
Note: The way sidewall sheets are punched varies according to the clarifier
model.
column hole
punching
cone
punching
29
6 Assembly
Cone Construction
1
install the cone sheets
SECTION AA
sidewall
sheet
NOTE: On 15 60 cones
flange nuts are used to
assemble the cone.
SECTION BB
Z stiffener
cone
sheet
b, page 34
EXAMPLE a1
30
6 Assembly
18 60 cone shown below
sidewall
sheet
clarifier column
SECTION AA
standard nuts
(other cones)
upper
cone
sheet
SECTION BB
NOTE: On 15 60 cones
flange nuts are used to
assemble the cone.
lower
cone
sheet
Z stiffener
SECTION CC
e,
page
page
37 25
EXAMPLE a2
31
6 Assembly
SECTION AA
5/16 x 1 1/4
bin bolt
SECTION BB,
15 DIAMETER CONES ONLY
inside of
cone
5/16 nut
sealer tape
2"
5/16 nut
3"
inside of
cone
5/16 x 1
bin bolt
Z stiffener
sealer
1/2"
3/4
AA
BB
SECTION BB,
ALL OTHER CONES
inside of
cone
SECTION CC,
15 DIAMETER CONES ONLY
gasket strip
inside of
cone
2"
3"
1/2 nut
3/16 x 3/8
sealer tape
1/2 x 1
truss bolt
5/16 x 1
bin bolt
Z stiffener
5/16 nut
1/2"
3/4
CC
SECTION CC,
ALL OTHER CONES
DETAIL d
count down
(5) holes to
install the
stiffener
inside of
cone
9 5/8
19/32"
BB
1/8 x 1 1/4
gasket strip
1/2 x 1
truss bolt
CC
upper
cone
sheet
1/2 nut
Z stiffener
32
6 Assembly
DETAIL b
Z stiffener
77 1/2
Z stiffener
a1
33
6 Assembly
DETAIL b
Z stiffener
Installed 5
holes down
to provide
clearance for
the column.
a
b
Z stiffener
a2
34
6 Assembly
cone sheet
1 1/4
[381 mm]
gasket
strip
(038819)
cone sheet
9
8
2
7
3
b1
35
6 Assembly
11
9
12
10
8
7
2
5
b2
36
6 Assembly
NOTE: Continue installing
bolts so bolt heads are on
the inside of the clarifier.
cone
sheets
cone
sheets
(1)
a
collar
(2)
b
collar
3
install cone braces if required
Bolt the cone braces into place
between the columns and the cone if
required on your installation (example
c, on the next page). See the following
pages to find the appropriate brace
layout for your clarifier.
37
6 Assembly
cone brace
column
cone
38
6 Assembly
pump box
outlet pipe
sidewall
sheet
inlet pipe
column
Not all
details shown
in this
illustration
cone sheet
foundation,
ring type
shown
39
6 Assembly
inlet pipe
sidewall
sheet
pump box
outlet pipe
column
Not all
details shown
in this
illustration
cone sheet
foundation,
ring type
shown
40
6 Assembly
outlet pipe
inlet pipe
cone sheet
column
Not all
details shown
in this
illustration
foundation,
ring type
shown
41
6 Assembly
Backfilling
Note: Before backfilling, you must apply exterior coating to the outside
of the Clarifier. Refer now to the instructions for applying Clarifier exterior
coating on pages 44 - 48.
Backfilling Procedure
1. Install the Drain Tile.
2. Backfill in uniform lifts of approximately 1 (using granular fill 3-10 mm) completely
around the tank. However, you must backfill at least up to the level of the Top of Cone
before starting to fill the clarifier with water. After backfill is level to the top of the cone,
backfilling must occur as the tank fills.
3. Start Filling the Tank - Check for leaks and make repairs as needed.
4. Grade backfill to provide slope away from the tank. The top 6 to 12 inches of the fill
may be non-granular soil to support vegetation (if desired).
42
6 Assembly
Note: By starting construction of the project immediately after placing the order
for the GLOBAL Clarifier the excavation can be completed in advance so that the
concrete work can be completed and ready for the clarifier(s) / basin(s) construction
as soon as the plant arrives.
clarifier
slope
Top of Cone
clarifier
column
granular fill
soil
43
Note: The coating applied to the Exterior Clarifier is for corrosion protection
only. The Exterior Clarifier coating is applied differently from the Interior
Clarifier Liner!!! For Interior Clarifier Liner application, you must follow the
instructions on pages 45 - 52!
Note: Read and understand the instructions that came with your
PermaDriTM products and equipment before applying any PermaDriTM
products! Read and understand all PermaDriTM instructions pertaining to
safety, operation, equipment, product familiarization, rubber spray, mixing,
identifying product contamination, product maintenance, part B accelerator,
pump, cleaning, and all other instructions pertaining to your installation.
44
Note: Mine Spray and Mine Coat application differs from painting. If your
Exterior Coating is not applied properly, THIS WILL VOID YOUR WARRANTY! If
your Exterior Coating is not applied correctly, as indicated in these instructions,
THIS WILL VOID YOUR WARRANTY! See pages 44 - 47 before applying.
1
start applying coating at clarifier base
Follow the Spray Technique instructions.
Spray exterior starting from bottom (with
4015 TIP A Nozzle). Cover the exterior
of the clarifier with Exterior Coating to
protect against corrosion.
45
Exterior
Coating Application
GLOBAL
INDUSTRIES, INC.
Make each coating strip approximately 18 inches wide X 10 feet long (when applicable).
Use 4008 spray gun Tip for detail work,
and 4015 spray gun Tip when applying to larger areas.
N95
~18
approximately
10 - 12
long
<A>
When applying a coating strip, make each strip approximately 18 wide and 10 - 12 long.
2
N95
PART A nozzle
<B>
When applying a liner strip, make a double pass (2 passes) with coating spray for each strip
of coating applied, left and then right. ON THE FIRST PASS OF EACH STRIP,
ALWAYS LEAD WITH PART A MINE SPRAY PRODUCT.
46
10 - 12
nozzle path
travels
across center
of strip
STRIP 1
Apply
strip 2.
Overlap
first strip
by 50%
Always DOUBLE
<C>
<D>
STRIP 1
STRIP 1
STRIP 2
STRIP 2
After
completing
STRIP 3,
COATING
LAYER 1
is now
complete.
Apply
strip 3.
Overlap
first strip
by 50%
<E>
STRIP 3
<F>
<G>
STRIP 2
47
STRIP 3
by completing strip 3.
48
Note: Read and understand the instructions that came with your
PermaDriTM products and equipment before applying any PermaDriTM
products! Read and understand all PermaDriTM instructions pertaining to
safety, operation, equipment, product familiarization, rubber spray, mixing,
identifying product contamination, product maintenance, part B accelerator,
pump, cleaning, and all other instructions pertaining to your installation.
49
Note: Spray Liner and Mine Coat application differs from painting. If your
Rubber Liner is not applied properly, THIS WILL VOID YOUR WARRANTY! If
your Rubber Liner is not applied correctly, as indicated in these instructions,
THIS WILL VOID YOUR WARRANTY! Read pages 49 - 57 before applying.
50
1
brush on Mine Coat, work-in fabric
<A> Start the Prep-work. Brush on Mine around the clarifier with gloves until
Coat approximately 4 up the sidewall saturated with coating. (Cut and apply
and 4 down the cone.
fabric in manageable lengths (5 - 10.)
< B > W o r k - I n F a b r i c ( 6 - w i d e <C> Brush on thin layer of Mine Coat
Tietex T272) in sections all the way over fabric.
sidewall
sidewall
Tietex T272
fabric
column
cone
<A>
<B>
Work-in Fabric
51
sidewall
Tietex T272
fabric
cone
<B>
Work-in Fabric
sidewall
fabric
<C>
52
Prep-work: COAT ALL SEAMS AND BOLTS WITH MINE COAT AND
SPRAY ALL PREP-WORK WITH 1 PASS OF LINER
coat / dab Mine Coat on seams/bolts apply 1 pass of part A and B liner
A. Continue Prep-work. Coat / dab Mine
Coat over all bolt heads and coat all
sheet seams. Make certain bolts are
completely coated. Use a stiff brush.
4
start applying liner at clarifier base
5
continue applying liner up interior
Follow the Spray Technique instructions. Following the same method, continue
Spray walls starting from bottom (with up the interior. Apply liner, (1) sidewall
ring at a time, from the bottom sidewall
4015 TIP A Nozzle).
ring to the top sidewall ring. Apply liner
A. ALWAYS KEEP NOZZLE
until a 96 Wet Mils / 60 Dry Mils liner
PERPENDICULAR to work surface.
thickness is achieved over the entire
B. Start at the base of the clarifier. clarifier interior.
First, spray the bottom of the clarifier
and then work up.
C. Work in lengths of 10 - 12.
D. Now, apply Liner following the
Spraying Technique instructions.
Uniformly apply 96 Wet Mils of Spray
Liner parts A and B to the first full
sidewall ring up to the level of the
first sidewall seam. (Make certain all
4-sides of bolts are covered to avoid
bolt shadowing.)
53
Note: The third liner layer of overlapping double passes (LINER LAYER 3)
of Spray Liner should yield 96 Wet Mils or 60 Dry Mils. If the liner is applied too
thick, it will take too long to cure. If the liner is applied to thin, you will not have an
adequate liner! If you do not achieve the correct consistent Liner thickness or
Mine Coat thickness everywhere the liner is applied, THIS WILL VOID YOUR
WARRANTY!
Note: Spray Liner and Mine Coat application differs from painting. If your
Rubber Liner is not applied properly, THIS WILL VOID YOUR WARRANTY! If
your Rubber Liner is not applied correctly, as indicated in these instructions,
THIS WILL VOID YOUR WARRANTY! Read pages 49 - 57 before applying.
54
55
Make each coating strip approximately 18 inches wide X 10 feet long (when applicable).
Use 4008 spray gun Tip for detail work,
and 4015 spray gun Tip when applying to larger areas.
N95
~18
approximately
10 - 12
long
<A>
When applying a liner strip, make each strip approximately 18 wide and 10 - 12 long.
2
N95
PART A nozzle
<B>
When applying a liner strip, make a double pass (2 passes) with liner spray for each strip
of liner applied, left and then right. ON THE FIRST PASS OF EACH STRIP, ALWAYS LEAD
WITH PART A LINER PRODUCT.
56
10 - 12
nozzle path
travels
across center
of strip
STRIP 1
Apply
strip 2.
Overlap
first strip
by 50%
Always DOUBLE
<C>
STRIP 2
<D>
STRIP 1
STRIP 1
STRIP 2
STRIP 2
After
completing
STRIP 3,
LINER
LAYER 1
is now
complete.
Apply
strip 3.
Overlap
first strip
by 50%
<E>
STRIP 3
<F>
<G>
by completing strip 3.
STRIP 3
Always DOUBLE
<H>
57
8. UNLEADED GAS
9. NON-DETERGENT 10/30WT OIL
10. DISPOSABLE GLOVES
11. 9 SHORT NAP PAINT ROLLERS
12. HANDLES FOR THE PAINT ROLLERS
13. 3 or 4 CHIP BRUSHES
14. ELECTRICAL EXTENTION CORD
15. SHOP TOWELS
16. DRINKING WATER
17. SUN SCREEN
18. SHADE COVERING
19. PLASTIC OR TARP FOR UNDER MACHINE (SPILLS)
20. SMOOTH SOLE SHOES (STEEL TOE)
58
PUMP:
A) ---- Check Oil
B) ---- Check Oil
----Fluid Flow
----Fluid Flow
PACKING LIST:
----Pump Package
----200 Pressure Hose w/ Caps
----A Side Suction Tube & Hose
----B Side Suction Tube & Hose
----Return Hoses (2)
----Dual Gun W/Wands 8
----Spray Tips (2 @ 4001, 2 @ 4008, 2 @ 4015)
----Spare Parts Kit 5026-080
----Magic Tape
----Manuals (Honda & comet)
----Air Pressure/ Inflator Tool
----Gun Repair Kit Plus additional Brass Seat
----1 ea. Metric Allen Wrench set
----1 ea. Dentist Tool to remove Check Valves
----1 ea. Crescent Wrench 8 & 10
----Small wire Brush
----Small Bottle Cleaning Brush
----Hose Clamps (4)
----Tie-Wraps
----13/16 Spark Plug Wrench w/ a 4 Extension
----1Quart of SAE 30 Non-Detergent Oil
----1 Roll of Aluminum Window Screen
----Duct Tape
59
----Pressure
----Pressure
Notes:
60
61
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