How to Design and Install a Wheel Wash

By:

Mark Kestner, Ph.D.

National Environmental Service Co., Inc.
7 Hampshire Drive, Mendham, NJ 07945
Tel: 973-543-4586

Presented at: California

www.drdust.com

Mining Association Annual Meeting 2005, Squaw Valley, CA May 24-27

Introduction
Quarries, ready-mix plants, construction sites and other industrial facilities have become the
targets of new regulations designed to prevent track-out of mud, dust and dirt on to public roads. These
regulations have been developed primarily in response to Federal EPA actions that have designated many
metropolitan areas as non-attainment for their failure to comply with air quality standards for fine
particulate. Fine particulate, known as PM10 and fine respirable particulate, PM2.5, are now regarded as
the number one health hazard in urban environments. These particles are so small that they become
lodged in the aveoli of the lungs where they can cause or aggravate a variety of respiratory diseases
including asthma, emphysema and lung cancer.
Local governments in non-attainment areas are forced to take draconian measures to comply with
fine particulate standards or face the loss of federal highway funds. As a result, cities like Los Angeles
and Phoenix, have or are in the process of adopting rules that require affected facilities to install wheel
washes. The South Coast Air Quality Management District (SCAQMD) in California, for example, has
recently passed Rule 1157 that will mandate the use of rumble grates and tire washes.
In other areas of the country, encroaching residential and commercial development around
industrial sites has led to an increased demand for wheel washes. Many companies, particularly stone
quarries, have installed wheel washes in order to get out in front of regulation and demonstrate their
willingness to be good neighbors. Other facilities are forced into compliance through fines and litigation.
Faced with state and local governments under the threat of federal action and a public unwilling
to tolerate any pollution, companies need to take a hard look at how best to respond. Because the costs of
pollution control equipment are difficult to recover, affected facilities have a real incentive to develop
affordable and effective technology to prevent carryout.
Wheel Wash Design
There are basically four types of wheel washes. These are:
1.
2.
3.
4.

Flooded basins
Countercurrent channel
Low pressure inundation, and
High pressure cleaning.

All of these will do an effective job of

cleaning tires if they are properly designed,
operated and maintained.
1. Flooded Basins
Basin style washes are the simplest in
design. They consist of a shallow basin long
enough to permit at least one tire rotation
through it. Typical basin washes are 20 to 60
ft. in length. The bottom of the basin may be

equipped with rumble strips to improve tire agitation. For best performance, fresh make-up water should
be supplied to flush dirty water from the basin for collection and treatment. The main advantages of a
basin style wash are:
a.
b.
c.
d.

Low cost
No nozzles required
Continuous operation, no automation required
Trucks do not get wet

Their disadvantages include:

a. Basin requires daily cleaning for optimum performance
b. Do not wash mud flaps or wheel wells where dirt can accumulate
c. Require large land area (>1000 sq. ft.)
2. Countercurrent Channel Washes
The countercurrent channel design consists of
long, shallow inclined channels for left and right side
tires.
Water continuously flushes the channel
countercurrent to the direction of traffic. Dirty water
drains to a sump where it is collected for disposal or
treatment. Channel washes require a great deal of
space. A typical channel wash may be 100-300 ft.
long requiring 1500 to 4500 sq. ft. of space.
Channels can include rumble strips or other texture to
agitate or open tire treads.
The advantages of a channel wash are:
a.
b.
c.
d.

Low cost
No nozzles required
Continuous operation, no automation required
Trucks do not get wet

Their disadvantages include:

a. Requires daily cleaning for optimum performance
b. Do not wash mud flaps or wheel wells where dirt can accumulate
c. Require large land areas (>1500 sq. ft.)
3. Low Pressure Inundation Washes
Inundation washes are designed to clean the
tires, mudflaps, and undercarriage using large amounts
of low pressure water. Water consumption may range
from 1000 to 3000 gallons per truck depending on the
size of the trucks and duration of the spray cycle. These
washes generally use multiple pumps capable of
handling dirty water and, because of the high water
consumption rate, require a large reservoir.
A typical inundation wash uses sprays directed
at the truck from the sides and bottom and may be

combined with a rumble grate. Inundation washes operate intermittently and use one or more sensors to
detect when trucks enter and exit the wash zone. The wash zone is located over a catch basin that directs
dirty water into a reservoir where it can be collected and treated.
The main advantages of an inundation wash are:
a. Wash tires, mud flaps and undercarriage
b. Require small area (<800 sq. ft. excluding reservoir)
Their disadvantages include:
a.
b.
c.
d.

High water consumption (>1000 gallons per truck)

Spray nozzles can plug or wear out if water is dirty.
Requires sensor and controls for auto operation.
May remove lube oils and greases from undercarriage

4. High Pressure Cleaning Washes

High pressure cleaning washes use water at
pressures in excess of 150 psi to promote cleaning
efficiency and reduce water consumption. Water
consumption may range from 40 to 100 gallons per
truck depending on the speed of the truck through the
wash zone. They are designed to wash tires and mud
flaps and are usually not used to wash the
undercarriage because sprays designed to shoot up
under the truck may obscure the drivers vision.
A typical high pressure system consists of a
150 to 200 gpm pump, surge tank and two or more
vertical spray nozzle manifolds that are sufficiently
separated to permit at least one full tire revolution.
High pressure systems require cleaner water because
the abrasive effects of sediment wear pumps and
nozzles out more quickly.
The main advantages of a high pressure cleaning wash are:
a. Washes tires and mud flaps
b. Require small area (<500 sq. ft.)
c. Low water consumption
Their disadvantages include:
a. Spray nozzles can plug or wear out if water is dirty.
b. Requires sensor and controls for auto operation.
Sensors for Automatic Operation
Basin and channel type washes are designed to operate continuously and require no automation.
Low pressure inundation and high pressure cleaning washes are designed to operate intermittently in
order to conserve water and reduce wear and tear on equipment.

For stationary wheel washes, an in-ground magnetic induction loop is preferred. This is the same
type of sensor used to activate traffic signals. It consists of an approximate 4 x 8 loop of braided wire
that establishes a magnetic field at the entrance of the wash zone. When this field is perturbed by a large
metal object, like a truck, the sensor activates the spray nozzles. A second sensor at the exit can be used
to turn nozzles off but it is more common to use a single loop in conjunction with an adjustable time
delay to control the duration of the wash cycle.
The main advantage of the magnetic loop is that it
requires no maintenance and is extremely reliable. Because it is placed in the pavement it cannot be
damaged or vandalized.

Sensor for automatic operation

For portable washes, there are two basic types of electronic

sensors, electric eyes and proximity switches. Electric
eyes use a transmitter and receiver to establish a beam of
light. Spray nozzles are activated when the beam is broken by a
passing truck. When the beam is re-established after the truck
exits the wash zone, nozzles are switched off. While these
detectors are highly reliable, they require periodic cleaning and
maintenance.
The receiver and transmitter also need
adjustment to keep the beam targeted. And, like any above
ground sensor, they are susceptible to accidental damage or
vandalism.

Proximity switches, the kind of switch that opens your supermarket door, also use focused beams
of light but combine the transmitter and receiver into a single unit which substantially reduces the
requirement for cleaning and maintenance. They are very reliable but can also be damaged or vandalized.
Either type can work well but care should be taken when locating the detector. If it is installed
too close to the wash zone, mist from the spray nozzles may interfere with the beam and cause the system
to run on. Sensors should be located in protected positions and armored or set in concrete to protect them.
Locating a Wheel Wash
The two most important considerations when deciding where to install a wheel wash are:
1. Distance from the exit of the plant and
2. Proximity to water and drainage
Locating the wheel wash as far a possible from the plant
exit will help tires to dry before trucks leave the plant. If
possible, the wheel wash should be set back at least 1500 feet.
Although tires may appear clean, trucks track water out of the
wash and onto the pavement. When this water evaporates, a
residue of very fine dust is left on the road surface that can be reentrained by passing traffic. Because the finest particles are the
best light-scatterers, the haze over the road appears out of all
proportion to the tiny amount of the dust that is actually in the air
especially at sunrise and sunset.
Many plants have scales located at the exit with less than
100 ft. of paved surface before trucks go on the road. At
construction sites, there is often no paved surface and trucks
often exit over a bed of rip rap at the curb. In either case, the
residue left by clean trucks has to be swept or flushed from the
road. A wet vacuum sweeper is the preferred method of

Water tracked from the wash can dry and

leave fine silt behind that becomes airborne

removing silt and uses spray nozzles in front of the brooms to prevent emissions. An alternative to a wet
vacuum is flushing where men with hoses or mobile tankers with spray nozzles are used to wash silt off
the road.
Proximity to water and drainage is another important factor. At large quarries with more than
500 trucks per day, for example, an inundation wash that uses 1000 gallons per truck is going to require
500,000 gallons daily. Even a pressure wash at 100 gallons per truck is going to need 50,000 gallons a
day. Whether large plant or small, the wheel wash has to drain somewhere. Since it is easier to pump
fresh water to the wheel wash than it is to drain dirty water from it, try to locate the wash close to a
retention pond. If no pond exists, the wheel wash will
require the construction of a 3-5,000 cu. ft. settlement pit.
Portable plants and construction sites rarely have access to
a pond or pit and have to use a temporary collection basin.
This could be as simple as a precast concrete sump or as
sophisticated as a dewatering bin that uses a liner and
filter.
Another important factor to consider in locating a
wheel wash is traffic pattern. One of the biggest problems
are truckers who try to bypass the wash. Consequently,
truck traffic must be funneled into the wheel wash using
concrete blocks or other barricades. Likewise, traffic
from unpaved areas on the site must be prevented from
entering
the
paved
road
Truckers are reluctant to use washes that
obscure their vision or wet their windows
leading
from
the wash to the
exit. Moreover, truckers should not be allowed to trim their
loads on clean paved surface when it can aggravate trackout.
Try to take advantage of the topography. If there is a
long incline up to a scale, for example, this might be an ideal
location for a channel wash where wash water flows
countercurrent to the direction of traffic. Locating the wash
where there is natural drainage to a sump or pond can save a
great deal of money.

Tankers equipped with flushing nozzles

are used to clean silt from pavement

Recycling Water
Stormwater regulations in most parts of the country
require that no water be discharged without collection and
treatment. Recycling dirty water can easily triple the cost of
a wheel wash. Large stationary quarries are fortunate in that
they generally have large retention ponds they can use to
recirculate water to the wheel wash. However, construction
sites, recycling plants and other smaller facilities do not.

Water drains into a settlement pit where it is

collected for treatment and re-circulation to
the wheel wash

In the absence of a retention pond, stationary plants have

to construct and install a sump or settlement pit to collect
dirty water. Their size depends primarily on the number of
trucks washed in a day and they are often equipped with one
or more wiers that allow clean water to overflow into a
sump where it can be recirculated. Many washes employ

pumps that can handle this muddy water but using it to wash tires can aggravate silt carryout.
If the water requires filtration, there are two basic options - bag and sand filters. Bag filters are
relatively inexpensive and are available in configurations that use two or more bags so that they can be
changed while the filter is on line. Bag filters, however, require periodic replacement and can
significantly increase maintenance costs. Sand filters are also high capacity filters but they can be backflushed to keep them clean. While more expensive than bag filters, maintenance requirements are much
lower.
Portable plants and construction sites can
use dewatering bins to collect and filter water.
These are usually 30 or 40 cu. yd. roll-off containers
fitted with a mesh liner and filter. The liner is used
to keep the filter away from the walls and promote
flow through it. The filter should be porous enough
to allow a sufficiently high water flow but fine
enough to capture the bulk of the dirt. A typical
filter of this type will generally remove any particles
over 130 150 microns in diameter. Dewatering
bins are suitable for sites handling less than 50
trucks a day unless they are used in parallel so that
one can be cleaned while another is in service.
There are several companies that sell or rent
dewatering bins and can also be contracted to
provide regular maintenance.
Factors Affecting Cleaning Efficiency

Clean water overflow wier and oil skimmer

Of all the factors that affect the performance of a wheel wash, the speed of the truck through the
wash zone is by far the most important. The slower the truck speed, the better the cleaning. A speed of 5
mph through the wash is generally considered the slowest practical rate. Unfortunately, most truckers are
in a rush to get out on the road and tire washes often incorporate speed bumps or rumble strips to slow
them down.
Secondly, the volume and pressure of water are important
determinants of cleaning efficiency. The performance of basin
and channel washes that do not use spray to wash tires are
directly proportional to the volume of water used per truck the
more the better. The performance of low pressure inundation
washes is also highly dependent on the volume of water used per
truck
since
spray pressures
are usually low
enough
that
Speed bumps help to slow trucks down
sprayed water
is used to rinse
rather than blast dirt from tires. In contrast, the
efficiency of high pressure wheel washes is less
dependent on water flow rates and rely more on targeted
sprays to dislodge material from the tire.
Finally, the amount and type of mud and dirt on
the truck affects performance. Most stationary plants,
like stone quarries, generally have a stable unpaved

Rumble grates help dislodge stones from tire treads

but require frequent cleaning

route through the plant, while trucks at construction sites are more likely to have wheel wells and mud
flaps fouled with dirt. Mud and dirt that contains a lot of clay or reactive material like lime or cement can
solidify into very hard deposits that are extremely difficult to remove.
Rumble grates can significantly improve cleaning efficiencies by agitating the tires and flexing
their treads to help dislodge material. Concrete or asphalt rumble strips can improve agitation but do not
possess a sharp edge that causes treads to deform and flex. While rumble grates can be effective they
become quickly fouled with compacted debris and require frequent cleaning or flushing to keep them in
good operating condition.
Portable Wheel Washes
Many wheel wash installations are temporary and require portable equipment. While there are
several styles all feature one or more skid mounted pumps and portable spray manifolds. Only low
pressure inundation and high pressure cleaning washes are suitable for portable applications. Some sites
may permit use of a basin that can be demolished or abandoned in lieu of a temporary wash.
High pressure washes using vertical spray manifolds are quite compact and can be housed in a
trailer along with a surge tank that can be towed from site to site. Low pressure inundation washes utilize
a portable spray frame that is placed onto the ground. The spray frame may or may not use a catch basin
depending upon its design and application. Because a retention pond or settlement pit is often not
available or feasible, some portable washes include a dewatering box or concrete basin to collect and
recirculate dirty water. At sites where silt carryout is a problem or when pumps need to be protected
from abrasive solids, a portable filter and other solids handling equipment may be required.
Costs
To keep costs down, determine how clean trucks have to be. If mud flaps and undercarriages do
not contribute to the problem, there is no reason to clean them. Setting the wheel wash as far from the
exit of the plant as possible can go a long way to simplifying its design and maintenance. To avoid the
high costs of collecting and recirculating clean water, it may be more cost-effective to use dirty water to
wash tires and operate a vacuum sweeper to clean silt from the road. In climates where water is scarce or
in cities where it is expensive, the lower water consumption of a high pressure wash can help control
costs over the longer term. Some states, like Texas, provide tax exemptions or rebates for the installation
of control measures.
The costs of a basin or channel wash can range from a low of about $10,000 up to as much as
$150,000 depending primarily on the volume of truck traffic and cleaning efficiency required. Small
facilities with less than 50 trucks a day may be able to get by with a simple basin that is cleaned and
flushed daily. Larger plants handling 500 trucks a day located adjacent to residential or commercial
property will require a substantially higher investment.
Commercial tire washes range in price from about $20,000 to $60,000 for an automated pump
system with spray manifolds and frame. These costs, however, do not include any site preparation or
water treatment. Inundation washes may require the construction of a large settlement pit as a reservoir in
addition to a concrete pad to support the spray frame and basin. This can add another $70,000 to
$100,000 to the project. High pressure washes have a smaller footprint but still require a level concrete
pad and some means of water collection and treatment that can add significantly to its cost.
Finally and most importantly, institute control measures that will insure that truckers use the wash
properly. Erecting concrete barricades to funnel traffic into the wash zone and using speed bumps or
rumble grates to slow them down will help you to get your moneys worth from your investment.