RAUSIKKO BOX INSTALLATION INSTRUCTION. Construction Automotive Industry

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Annabel Mathews
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1 RAUSIKKO BOX INSTALLATION INSTRUCTION Construction Automotive Industry

2 RAUSIKKO BOX INSTALLATION INSTRUCTIONS GENERAL... 3 TRANSPORT AND STORAGE EXCAVATION AND SETTING BED INSTALLATION OF THE GEOTEXTILE / SEALING DEVICE INSTALLATION OF THE RAUSIKKO BOXES SHAFTS AND CONNECTIONS BACKFILLING OPERATION Definition of pictograms Safety information Legal information Important information The advantages for you 2

GENERAL The RAUSIKKO Box is used for building

The following basic types of the RAUSIKKO Box

project-related assembly of such systems:

3 GENERAL The RAUSIKKO Box is used for building systems for rainwater management. The following basic types of the RAUSIKKO Box are available to ensure an optimum, project-related assembly of such systems: RAUSIKKO Box C Side / front grid RAUSIKKO Box C RAUSIKKO Box 8.6 SC RAUSIKKO Box 8.6 S Front grid RAUSIKKO Box 8.6 S/SC Front connection spigot RAUSIKKO Box 8.6 S/SC 3

6 H Various module combinations are possible, all of which have a stable structure the modules can be placed on top of each

4 For special installation cases where a particularly high load capacity is required, two heavy duty variants are available in addition to this. RAUSIKKO Box 8.6 HC RAUSIKKO Box 8.6 H Various module combinations are possible, all of which have a stable structure the modules can be placed on top of each other or side by side. The installer is responsible for carrying out the work in accordance with the Specific Technical Clauses, the specifications of our technical documents and the general regulations in force. 4

Assembly of two RAUSIKKO Box C units Stacking layers When assembling multi-layer

socket connections. When installing a RAUSIKKO Box system with a height of 1.

construction as shown below, using the RAUSIKKO Box C 2-3 elements.

could be used to reinforce the structure s stability.

It is essential that the modules are installed in accordance with the sizing

5 Assembly of two RAUSIKKO Box C units Stacking layers When assembling multi-layer Box systems the Boxes are fixed on top of each other using integrated push-fit socket connections. When installing a RAUSIKKO Box system with a height of 1.32 m or more and using the RAUSIKKO Box C, the modules must be laid as a brick-wall construction as shown below, using the RAUSIKKO Box C 2-3 elements. Socket connections RAUSIKKO Box C RAUSIKKO Box C 2-3 A brick wall construction could be used to reinforce the structure s stability. This option would require pre-cut modules. It is essential that the modules are installed in accordance with the sizing guidelines. Socket connections RAUSIKKO Box 8.6 If a RAUSIKKO Box C is placed on top of a RAUSIKKO Box 8.6, the Socket connections of the Box 8.6 can be adjusted to the notches of the Box C. 5

The brick wall construction has to be made like this: installing the lower layer of the

afterwards installing the upper layer of the RAUSIKKO C units in orthogonal direction also

Edge situation: Starting with a pre-cut unit (here: consisting of 2 pillar rows) Edge

Box C elements is starting with another pre-cut unit (here: consisting of 3 pillar rows),

installation with un-cut Box C elements Other rows with brick wall construction: Above a

6 The brick wall construction has to be made like this: installing the lower layer of the RAUSIKKO C units in one direction using a pre-cut unit at the beginning and the end, afterwards installing the upper layer of the RAUSIKKO C units in orthogonal direction also starting and ending with a pre-cut unit. Edge situation: Starting with a pre-cut unit (here: consisting of 2 pillar rows) Edge situation: Continuing the installation with non-cut units Edge situation: The next layer of Box C elements is starting with another pre-cut unit (here: consisting of 3 pillar rows), placed in orthogonal direction to the pre-cut unit below Edge situation: Carrying on the installation with un-cut Box C elements Other rows with brick wall construction: Above a layer with un-cut elements starting with a pre-cut unit (here: consisting of 2 pillar rows Other rows with brick wall construction: Carrying on the installation with un-cut Box C elements 6

7 pre-cut unit with 2 rows of pillars pre-cut unit with 3 rows of pillars un-cut unit Lower layer of the brick wall construction: at least every fourth row is starting and ending with a pre-cut unit 7

8 Upper layer of the brick wall construction: at least every fifth row is starting and ending with a pre-cut unit When installing a RAUSIKKO Box system which is accessible to vehicles a minimum covering of 0.80m and a maximum installation depth of 3.0m must be observed. The height of the box system must not exceed 2.64m. The ground underneath the boxes must have sufficient load bearing capacity. If necessary, measures are to be taken to increase the load bearing capacity. The systems must not be installed in permanent or occasionally occurring ground, stratum or impounded water. In the case of percolation systems the relevant recommendations of the national guidelines (e.g. DWA worksheet A 138) are to be considered. According to DWA A-138 the distance between the bottom of the percolation system and the highest average groundwater level should generally be at least 1.0m. Under the conditions described above and considering the following specifications for installation, the ground surface above and to the side of the Boxes can be loaded with a maximum traffic load equivalent with SLW 60 according to DIN 1072 (heavy trucks with a total weight of 60 t and a wheel load of 100 kn or an area load of 33.3 kn/m²). These conditions are also to be maintained throughout the whole construction period. The construction site has to be organized accordingly. In particular it is to be ensured that no cranes, silos, containers, construction or excavated materials, which could lead to a larger single or area load than described above, are placed above the box system. 8

9 RAUSIKKO Box standard installation condition* Installation conditions which deviate from this in particular deeper installation depths require an individual assessment and are to be clarified with the REHAU technical applications department. The approval of these alternative installation conditions is ultimately given by the company commissioned with the installation and/or the building supervisor or specifier. * grown ground appropriate soil group G1 up to G3 according to standard DWA A 127 (non-cohesive soils (sand, gravel), little cohesive soils, silt, silty sand or silty gravel 9

TRANSPORT AND STORAGE RAUSIKKO Boxes are delivered stacked up and strapped down. Stacks of RAUSIKKO Boxes must be unloaded using a forklift truck.

They must be placed on a flat and stable surface. The stacks must not be taller than 2.64 m or stored outside for longer than one year.

10 TRANSPORT AND STORAGE RAUSIKKO Boxes are delivered stacked up and strapped down. Stacks of RAUSIKKO Boxes must be unloaded using a forklift truck. Unloading must be done carefully. Stacks of RAUSIKKO Boxes must not be thrown, knocked over or dropped. RAUSIKKO Box units can be stored outside. They must be placed on a flat and stable surface. The stacks must not be taller than 2.64 m or stored outside for longer than one year. Where possible, RAUSIKKO Boxes should be stored out of direct sunlight (stored in the shade, covered with a bright geotextile to avoid heat build-up). Storage units must be checked for damage before being installed. Damaged units must never be used. 10

11 EXCAVATION AND SETTING BED The appropriate regulations on accident prevention for excavation and also the applicable standards for digging excavation pits and trenches are to be observed. The earth removal work for the bottom of the trench should be carried out using a dredger bucket with cutters to limit bulking. At the compacting stage it is advisable to resume decompression of the grown ground and the filling material which could cause differential settlement. The general excavation dimensions must be at least 50 cm larger on each side compared to the dimensions of the basin and take the natural soil s characteristics into account. Any imbalances in the regulating layers will be amplified when the modules are stacked and could jeopardise the structure s stability. The base of the trench must be stable, free of stones, even and without any gradients. The load bearing capacity and permeability of the base must be equal to the grown ground. The load bearing capacity E v2 (measured in the static plate load bearing test) must be but at least 35 MPa and consistent across the entire base area. If necessary, suitable measures are to be taken (soil replacement, compacting, etc.). The setting bed must be made on a thickness of at least 10 cm with gravel or crushed material with granulometry of 2/8 mm. The setting bed must be levelled out to ensure that it is totally even (it is advisable to check this with a ruler) and without any gradients. It is essential to ensure that the setting bed is made carefully. The degree of compaction D pr (measured by the Proctor test) beneath retention basins must be at least 95 % and beneath infiltration basins - depending on the granulometry and permeability of the material - at least 92 %. 11

12 INSTALLATION OF THE GEOTEXTILE / SEALING DEVICE The RAUSIKKO Box system must be fully covered with the appropriate geotextile to prevent the permeation of fine soil particles. The geotextile should be placed perpendicular to the longitudinal axis of the excavation. Construction: Length of the panels = basin perimeter m of overlap. Overlap in the longitudinal axis and at the edges must also be approx. 0.5 m. The two edges of the panels must be provisionally fixed to the edges of the trench. The geotextile must be cut for passing the pipes through. Once the RAUSIKKO Box modules have been installed and all the shaft-connections are complete the geotextile has to be removed from the edges of the trench and laid on top of the RAUSIKKO Box modules with an overlap of 0.5 m at the joints. It is to be ensured that the textile fits tightly to the contour of the modules and that no earth gets between the RAUSIKKO Box modules and the textile cover. The front and back side of the box system must be covered with a patch corresponding to the surface area of the face and an overlap of around 0.5 m. If the modules are used solely for collecting rainwater, a geomembrane sealing device must be used to prevent any infiltration of rainwater into the earth and, conversely, any penetration of inflow water into the structure. The geomembrane is to be protected on both sides against mechanical damage with a protective geotextile (e. g. RAUMAT 500). Great care must be taken when putting the corners in place and the connections on the structure s inputs and outputs. The geomembrane panels must be welded or glued to ensure that they are tight. The welding torches used must not damage the geomembrane. 12

13 RAUSIKKO Box soakaway system covered with a geotextile RAUSIKKO Box retention tank with a geomembrane 13

INSTALLATION OF THE RAUSIKKO BOXES The modules must be installed in accordance with the layout plan drawn up in advance

In particular, it must detail the width, length and height of the structure, the number of layers of modules and the

These grids (dimensions l h = 0.8 m 0.33 m) have a saw cutting die for connecting pipes DN110 to DN250. RAUSIKKO modules 8.

The grids are also equipped with clips and are interlocked onto the front faces of the modules.

14 INSTALLATION OF THE RAUSIKKO BOXES The modules must be installed in accordance with the layout plan drawn up in advance during the construction site preparation phase. In particular, it must detail the width, length and height of the structure, the number of layers of modules and the direction that they are to face when installed. The basin edges must be closed using front/side grids. These grids (dimensions l h = 0.8 m 0.33 m) have a saw cutting die for connecting pipes DN110 to DN250. RAUSIKKO modules 8.6 S and 8.6 SC have front grids or PLUS front connection spigot. The grids are also equipped with clips and are interlocked onto the front faces of the modules. Additional assembly units are not needed. Installation of the RAUSIKKO Box modules Assembling the front/side grids of the Box C Mounted front/side grids The ventilation plate (with a PP socket for a smooth pipe DN/OD160) is to be screwed onto the top of a RAUSIKKO Box with 4 woodscrews (not supplied). 14

The spigot end of the smooth pipe is then inserted.

15 For the connection of a smooth pipe (e.g. AWADUKT PP) DN 110, 160 or 200 the appropriate saw matrix on the front/side grids has to be sawed out with the aid of a jig saw. The spigot end of the smooth pipe is then inserted. Due to the wall thickness of the smooth pipe a slight bed drop occurs between the base of the cleaning channel and the base of the pipe. Front connection sockets with moulded-on smooth pipe spigot ends DN 200 or DN 250 are available for an exactly level connection. Raccordement direct sur façade latérale/frontale Raccordement sans rupture de fil d'eau 15

SHAFTS AND CONNECTIONS The AWASCHACHT and RAUSIKKO C3 systems can be used as an inlet, inspection or cleaning shaft. RAUSIKKO fabrication shafts or AWASCHACHT systems are used as throttling units.

Connection with a RAUSIKKO C3 shaft For this purpose a ventilation plate with a smooth pipe half socket DN 160 is fitted to the cover of a RAUSIKKO Box. A smooth pipe (e.g.

16 SHAFTS AND CONNECTIONS The AWASCHACHT and RAUSIKKO C3 systems can be used as an inlet, inspection or cleaning shaft. RAUSIKKO fabrication shafts or AWASCHACHT systems are used as throttling units. Details about installing the shafts can be found in the corresponding installation instructions. A vent is to be provided so that the air displaced when filling the Box system can escape. Connection with a RAUSIKKO C3 shaft For this purpose a ventilation plate with a smooth pipe half socket DN 160 is fitted to the cover of a RAUSIKKO Box. A smooth pipe (e.g. AWADUKT PP) DN 160 is connected to the plate, routed to the extension pipe of the RAUSIKKO C3 shaft and fastened there with the aid of the AWADOCK CP connecting branch. Alternatively a ventilation can be build using the ventilation plate with spigot DN 350, the unperforated RAUSIKKO pipe DN 350 fitted to it, and a cast cover DN 400 with ventilation holes. RAUSIKKO C3 shaft extension with AWADOCK CP 16

17 BACKFILLING The quality of the side backfilling is essential for the stability of the structure. During the backfilling and compacting phase, care must be taken to ensure that the structure is not subjected to any asymmetrical pressure. To do this, the backfilling and then the compacting are done in successive and alternating layers on both sides of the structure. The workspace next to the basin is to be filled with non-cohesive, stone-free soil which can be compacted (sand or gravel, soil group G1 according to DWA work sheet A 127) in 0.3m thick layers. The filling material must be compacted in layers with a light to medium-weight vibration plate with a maximum compaction force of 3 t. The Proctor density and permeability of the filler should be at least equal to that of the grown ground. The soil on top of the modules must be filled in layer by layer through distribution ahead of a light excavator or a loader (maximum overall weight of 15 tonnes). These vehicles must drive only on G1 type soil which is sufficiently compacted and at least 50 cm thick on top of the basin. When compacting the excavated soil of the first layers, only the vibrating plate described above should be used (not a vibrating tamper). From a backfilling height of 0.3 m upwards, heavier vibrating plates can also be used for compacting (maximum compacting strength of 6 tonnes). The use of heavy construction site vehicles with a maximum wheel load of 50 kn (lorries with a gross vehicle weight of 30 tonnes and a surface load equivalent to 16.7 kn/m 2 ) is permitted only when the backfilling is compacted at a height of at least 0.8 m. For constructions with an infiltration ditch and a module-based infiltration basin underneath, the ditch overflow must be located on top of the modules once the filtration geotextile has been folded back. The basin must then be covered with a layer of sand 0.10 m thick followed by a layer of topsoil 0.30 m thick. The gradient of the bank of the ditch is thus formed and the ditch, if necessary, is covered with a planting mat. Ensure that no construction site vehicles drive over the infiltration ditch. In the ditch overflow area, the layer of sand and topsoil must be cleared to form a funnel shape. The funnel must then be filled with course gravel with with a grain size of 8/32 so as to cover the ditch overflow. Compactage de l espace de travail à côté du bassin. 17

18 OPERATION If possible the percolation system is not to be made operational until the catchment area has settled and is green again. Drainage during the construction period is to be ensured. As rooting of the percolation system is to be avoided, only shallow-rooted plants should be planted in the vicinity of the percolation system. If possible, the infiltration system should be put into operation only after consolidation and turfing of the service area. Drainage must be carried out during construction. Since the infiltration installation must not be rooted down, only plants which do not have deep roots should be used near the system. If there are already trees or when new trees have to be planted, the distance between the trunk and the edge of the basin must be equal to at least half of the diameter of the crown of the tree. If this minimum distance is not possible, the top of the basin and the side part facing the tree must be covered with a root-repellent geosynthetic material. The joints of the protective root-repellent geosynthetic material must overlap by at least 0.5 m. The inspection holes and feed units, as well as the outputs of the cleaning ducts must be inspected twice a year and after heavy rainfall or accidents and, if necessary, jet washed. If necessary the RAUSIKKO Box cleaning and distribution channels can be high pressure cleaned with up to 120 bar. Any contaminants washed out into the sand trap of the connection shaft are to be extracted. 18

Conditions that are beyond our control or applications other than those specified release us from any obligations in regard to claims made in respect of the products.

19 Infiltration trench RAUSIKKO Box 8.6 SC Our verbal and written advice relating to technical applications is based on experience and is correct to the best of our knowledge but is given without obligation. Conditions that are beyond our control or applications other than those specified release us from any obligations in regard to claims made in respect of the products. We recommend that the suitability of any REHAU product for the intended application is checked. Application, use and processing of our products are beyond our control and are therefore exclusively your responsibility. In the event that a liability is nevertheless considered, then this will be based exclusively on our delivery and payment terms, which can be found at This also applies to any warranty claims, where the warranty assumes consistent qualityof our products in accordance with our specification. If you have not understood the safety instructions and the individual assembly, operating and maintenance instructions or find them unclear, please contact your local REHAU Sales Office. Our written and verbal technical advice, based on our experience and knowledge, are provided, however, without any obligation on our part. Any working conditions that we cannot control and any other application conditions relinquish us from all liability. We advise you to ensure that the REHAU product is appropriate for the intended use. Since the application, use and installation of our products are out of our control, you are solely responsible for them. If, however, our liability is called into question, it shall be limited to the value of the goods that we have delivered and that you have used. Our guarantee covers the consistent quality of our products in accordance with our specifications and our general delivery and payment terms and conditions 19

20 REHAU SOLUTIONS FOR ENERGY EFFICIENT BUILDING AND WATER MANAGEMENT Please scan for further informations REHAU - S /2016

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