Installation Guide. MEA-JOSAM 300 Size Pro-Plus Trench Drain

Transcription

1 Installation Guide for MEA-JOSAM 300 Size Pro-Plus Trench Drain Josam Company 525 W. U.S. Hwy 20 Michigan City, IN WARNING: Cancer and Reproductive Harm - REV A 08/29/11

2 GUARANTEE: All MEA-JOSAM products are guaranteed against defective materials and workmanship or errors in shipping, and any material or part proving defective will be replaced free of charge provided that MEA-JOSAM is notified within a reasonable time for inspection after delivery, and the equipment, material, or part claimed to be defective has been properly maintained and used in accordance with instructions and is delivered prepaid to Seller at Michigan City, Indiana. Under no circumstances will MEA-JOSAM assume any liability for damages or labor charges resulting there from. EXPRESS LIMITED WARRANTY: All recommendations on the use of MEA-JOSAM products are made without any warranties or guarantees. The products described in our literature are sold with an Express Limited Warranty which is in lieu of all other express or implied warranties. It is the responsibility of the customers of MEA-JOSAM to ensure that each particular product is fit for its intended purpose and that the conditions in which it will be used are suitable. Any products supplied by MEA-JOSAM will be done solely upon the standard Conditions of Sale, incorporated into all contracts. MEA-JOSAM develops and improves its products on a regular basis and information provided in this document is subject to change without prior notification. DELAYS: MEA-JOSAM will not assume any liability for delays or defaults occasioned by strikes, fires, or exercised by governmental authorities, failure to obtain material, or by any cause unavoidable beyond its control. RETURNED GOODS: Material may be returned subject to the following conditions. 1. Must first be referred to your local MEA-JOSAM Representative for prompt handling; 2. Minimum value of $ net; 3. Replacement parts will not be accepted for return; 4. Buyer must identify original shipment of material by invoice number and invoice date; 5. Buyer must obtain prior written authorization; 6. 25% restocking charge; 7. Less any charges necessary to put the material into saleable condition; 8. Credit will be issued to apply only against future purchases; 9. Outgoing freight will be deducted from the credit; 10. Material must be returned freight prepaid; 11. Products designated non-stock or special are not subject to cancellation nor are they acceptable for return; 12. Discontinued or obsolete material is not returnable. ILLUSTRATIONS AND DESCRIPTIONS: All illustrations, detail drawings, and accompanying descriptions refer to standard features of each product and do not necessarily show or describe the variations available. All designs are subject to change without notice, and unless specifically stated on order, material will be furnished of design in effect at the time the order is filled. All weights are approximate. RISKS: Our responsibility ceases after product has been delivered to the carrier in good order. It is the responsibility of the consignee to inspect each shipment carefully and file a claim with the carrier for any damage or shortages. Content shortages must be reported within 15 days after receipt of material. Any claim received after this time will be disallowed. ***Please contact Josam Company for a full list of Terms & Conditions. Page 2

3 Table of Contents 1.0 Tools Installation Figures Page 3

4 1.0 Tools Some or all of the following tools may be required during installation: Sledge or large hammer Stringline Chalkline Level Square Drill ¼ or similar size drill bits Core drill Ø5/8 threaded rod Duct tape Vibrator (finger type) Rubber mallet Concrete saw Cold chisel Caulking gun Shovel or spade Grinder Acetone if using sealants Standard socket set Visqueen or plastic wrap Safety glasses or goggles Gloves Respirator mask Phillips screwdriver Utility knife Page 4

5 2.0 Installation ***IMPORTANT: READ ALL INSTALLATION INSTRUCTIONS PRIOR TO STARTING THE JOB. THIS WILL AVOID COSTLY MISTAKES*** 1) Excavate soil or saw cut existing concrete to a sufficient width and depth to create a trench. Ensure that at least 3 inches (class A15) of bedding concrete can be placed under and alongside the channel. For higher loadings see the chart in figure A. The carrying capacity of the subsoil must also be taken into account, or respectively, the carrying capacity of the trench floor must be established. When sawing concrete always wear gloves, protective eyewear and a respirator mask! Avoid breathing the dust. 2) The direction of flow is marked on the inside of every channel element by directional arrows on both sides of the channel body. The arrows point downstream or in the direction of the outlet. In rare cases, a channel section may be reversed from normal flow direction (usually a neutral section) to facilitate easier run assembly. See layout. 3) Visible numbers on the inside ends of the channel mate with like numbers on the downstream channel. For example, a 1 on the downstream end of the first channel will mate with a 1 on the upstream end of the second channel. A 2 on the downstream end of the second channel will mate with a 2 on the upstream end of the third channel and so on. Page 5

6 4) There are three types of brackets available. A standard bracket 300-BS (bracket support) supports a male-to-female connection. See illustration below. 5) For male-to-male connections, middle outlets and low points, a 300-BSC (bracket support center) bracket is used. See illustration below. Page 6

7 6) For 20 x24 GRP catch basin connections, a 300-BSCB (bracket support catch basin) is used. See illustration below. 7) Unlike 100 and 200 Pro-Plus, a 300-BS is also used on male and female ends where it is necessary to hold an endcap or endcap outlet. See illustration below. Page 7

8 8) Lay out and orient the channel elements in the proper sequence in the excavated trench (as per installation plan, if available) to ensure correct layout. Remove all channel elements. Starting at the downstream or outlet end, place the first bracket in the desired location on the ground. If this is the end of a run, use a 300-BS (shown). If it is a low point in the middle of a sloped run or where two male ends meet, use a 300-BSC. 9) Insert one threaded rod into one of the holes. Drive the rod into the soil until it is firm. All rods must be at least 2 below the top of the trench, yet high enough to support the bracket. If the rod is too long, cut it down. If the rod is too short, longer rod must be substituted. Page 8

9 10) Insert another threaded rod into other hole and drive into soil until it is firm. 11) Remove the bracket and thread one nut onto each rod so that the bracket is at approximately the correct elevation. Place bracket back onto rods. Page 9

10 12) Insert another nut onto each threaded rod. Adjust nuts so bracket is at correct elevation and is level. Tighten all nuts to the bracket. 13) If the layout has a T connection or right angles, you must use -T channels as explained in the appendix. 14) If required, remove preformed knockouts from the channel or silt box for the discharge outlet. Knockouts must be removed with the aid of suitable tools (drill, grinder, chisel, etc.). Always use protective equipment while drilling, grinding, or chiseling. Assemble bottom outlets or corner connectors to channel. Page 10

11 15) Embed silt boxes and gullies similar to the installation of channels so that the thickness of concrete surround is identical. 16) Stretch a stringline for use as a straight edge. Set the channel into the first bracket. Ensure that directional arrows point towards the outlet or reference the layout drawing. Place next bracket into opposite end of channel. This will set the location of the second bracket. Remove the channel. Repeat process with next bracket using steps Page 11

12 17) Trim height of endcaps to match trench height. When using endcaps and endcap outlets, remove 1 long thumbscrews from brackets and replace with 4 long thumbscrews (supplied with bracket). 18) Install the gratings (do not unwrap protective plastic) in the channel upside down. This may slightly expand the channels and prevent lateral compression to maintain channel dimensions and protect the trench interior from any concrete spillage. Place the grates across section joints. This will aid in channel alignment at the top surface. Page 12

13 19) Ensure the concrete surround is equal on both sides of the channel. If installing in concrete slabs, provide for expansion/contraction joints and do not let the drainage line interrupt existing expansion/contraction joints. If possible, locate the expansion/contraction joints near the channel joint. Maximum distance between expansion joints is 25 feet. 20) Lay the upper channel surface about 1/8 lower than the ground surface to provide slope for the water to run into drain. 21) Pour concrete. Do not chute concrete directly against channels! This will disturb the alignment. Allow concrete to cure fully. 22) If the drain system requires sealant in the joints to prevent leakage, apply this now. Make sure the sealant is compatible with any corrosive fluids that may be in use. Insert 300-RI, if ordered. Page 13

14 23) Clean any spilled concrete from gratings, channels, and outlet points. Remove plastic wrap from gratings. Insert and secure gratings to channel body using the grating locking system. 3.0 Figures Figure A: Concrete dimensions (inches) Page 14

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16 APPENDIX Page 16

17 Josam Company 525 W. U.S. Hwy 20 Michigan City, IN Page 17