INSTALLATION INSTRUCTIONS B407-PP SERIES SINGLEWALL TANK SUMP Tank Sump Body Tongue and Groove Joint (pour in place) Base Lamination Joint S. Bravo Systems, Inc. 2929 Vail Ave. - Commerce, CA 90040 (323) 888-4133 - FAX: (323) 888-4123 www.sbravo.com ii-b407-pp-10c
The B-407-PP Series Singlewall Sump from S. Bravo Systems, Inc. MUST be installed by a Bravo Certified Installer. Get Certified at www.sbravo.com/cert READ THESE INSTRUCTIONS - KEEP FOR FUTURE REFERENCE TABLE OF CONTENTS REQUIRED TOOLS and INCLUDED TOOLS... p. 3 A) Preparing Tank Sump Base Lamination...p. 3 B) Fiberglassing Tank Sump Base to Collar or Tank...p. 4 C) Installing Penetration Fittings... p. 5 D) Preparing Tank Sump Body...p. 5 E) Sealing Tank Sump to Base - Mix & Pour Step... p. 6-8 Testing your Sump Optional Overseal Step - FACTORY RECOMMENDED F) Repairing Tank Sumps...p. 8 G) Installing Tank Sump Covers... p. 8 H) Backfill and Concrete Guidelines... p. 9 - Closely adhere to all directions and warnings indicated on the product or contained in these instructions. This includes following the OTHER manufacturers recommendations and Installation guidelines including -but not limited to- equipment associated or in contact with, Bravo Systems Products. - Warranty is void if there is any evidence of modification, abuse, negligence or improper installation. - For assistance please call Bravo for technical support at (800) 28-BRAVO. Outside the U.S.A. please call (323) 888-4133. SAFETY FIRST! S. Bravo Systems, Inc. urges you to carefully adhere to the normal safety procedures and precautions followed by your company. Please follow the mandates and compliances decreed by OSHA, local, State and federal regulations regarding the use of this product. WARRANTY All containment systems sold by S. Bravo Systems, Inc. are warranted to be free from defects in material and workmanship for a period of one year from date of purchase. This warranty will be limited to the repair and replacement of Bravo parts only and will exclude all claims for labor or consequential damage. No other express warranties given and no affirmation of S. Bravo Systems, Inc., or its agents and/or representatives, by words or action, will constitute a warranty. IT IS EXPRESSLY AGREED THAT THIS WARRANTY WILL BE IN LIEU OF ALL WARRANTIES OF FITNESS AND IN LIEU OF THE WARRANTY OF MERCHANTABILITY. This warranty is void if there is any evidence of modification, abuse, negligence, or improper installation. If any fittings or components, other than S. Bravo Systems approved fittings or components, are used in conjunction with any S. Bravo Systems product, the warranty pertaining to these products is immediately void. 2 ii-b407-pp-10c
INSTALLATION COMPONENTS PROVIDED 1 SLURRY KIT (FRP-KIT-407-RB) 1 Gal slurry mix. 1 bottle catalyst. 2 pairs of gloves. 1 LAMINATION KIT (FRP-KIT-400) 2 Gal resin. 3 bottles catalyst. 1 90-ft roll of 2oz fiberglass mat. 4 pairs of gloves. 1 sheet sandpaper. NOT PROVIDED REQUIRED TOOLS Air Sanders and cutters. Acetone. Hole saws. Drills. Manual caulk gun. SITE TOOL KIT 4.5 paint covers, 4 paint roller, mixing buckets, mixing sticks and 3 metal chamfer roller. EQUIPMENT DRY-FIT BEFORE INSTALLING PENETRATION FITTINGS DO NOT PLACE FIBERGLASS SUMP ON THE BASE AND ATTEMPT TO SEAL THE CHANNEL. READ STEP-BY-STEP INSTRUCTIONS FIRST. If using electric powered-tools move piping sump a safe distance from piping, tank and any other source of flammable liquids or vapors before trimming. Failure to do so may result in serious injury or death. When installing on existing tank(s), use a Vapor Detector around tank(s) before installation. A - PREPARING BASE LAMINATION A.1 - Abrade the fiberglass walls of the bottom of the Tank Sump Base with air-driven sander up the wall - Inside and Outside - until fiberglass surface can be seen clearly and all gloss or coatings are removed. (Fig. B.4). Abrade more area than will be laminated. Dust off with shop brush and keep clean. 3 ii-b407-pp-10c
B - FIBERGLASSING BASE SUMP TO COLLAR OR TANK ENSURE THAT THE SUMPS ARE COMPLETELY DRY, FREE OF DEBRIS, ICE AND/OR SNOW. DO NOT HANDLE ANY FIBERGLASS SUMP WITH YOUR BARE HANDS. B.1 - Pre-cut several dozen pieces of 6 wide fiberglass mat to lengths of 20-24. You will need 3 layers of these fiberglass mat strips for the INSIDE and OUTSIDE joints of each piping sump. B.2 - Mix together resin and catalyst with mix stick thoroughly. For SUMMER!! 1/4 bottle per 1/4 Gallon of resin. For WINTER!! 1/2 bottle per 1/4 Gallon of resin. B.3 - Use paint roller to apply resin generously to a smooth surface. Spread the resin so it wets out an area larger than the strip of fiberglass mat. (Fig. B.3) B.4 - Apply one layer of fiberglass mat to the resin and use the paint roller to add more resin to fully saturate it. (Fig.B.4) B.5 - Lay down another strip of fiberglass mat, staggering the new layer ONE INCH. This means to offset the next fiberglass strip horizontally (lengthwise) 1 to the right. Roll more resin into the new strip to saturate it. (Fig. B.5) B.6 - Repeat Step B.5, offsetting another strip of fiberglass mat and using the paint roller to add more resin to it until it is fully saturated. (Fig. B.6) B.7 - Use a Chamfer roller to completely roll over the pre-soaked fiberglass strip while it is on the cardboard, horizontally and vertically, to run out any air bubbles. (Fig. B.6) CARDBOARD Fig. B.3 Fig. B.4 PAINT ROLLER RESIN LAYER 1 Fig. B.5 Fig. B.6 LAYER 3 LAYER 2 CHAMFER ROLLER LAYER 1 LAYER 2 LAYER 1 4 ii-b407-pp-10c
C - PENETRATION FITTING INSTALL C.1 - Install any penetration fittings and piping to the Tank Sump Base after the Base has been laminated in place. If any penetration fittings must be installed to the top half, wait until the top is sealed to the base before penetrating. D - PREPARING TANK SUMP BODY D.3 - Determine where your planned grade is. Following the illustration shown on Page 9, allow for 1 to 1-1/2 space between the top of your dry-fit sump cover and the lowest point of the installed manhole lid. After these measurements have been verified, cut the required material from the BOTTOM edge of the Tank Sump Body using a carbide tipped blade or masonry saw (Fig. D.3). Material must be cut square with a 1/4" +/- tolerance 360 around sump. D.4 - Abrade the fiberglass walls with air-driven sander (Fig. D.4) 3 inches up from the bottom edge on Tank Sump Body that will sit in the Retrofit Base - Inside and Outside - until fiberglass surface can be seen clearly and all gloss or coatings are removed. (Fig. D.4). Dust off with shop brush and keep clean. Reducer Double Check all calculations according to site plans and verify with team members or overseers. Fig. D.3 Tank Sump Body Fig. D.4 Fig. D.3 5 ii-b407-pp-10c
E - SEALING TANK SUMP TO BASE SUMP MUST BE CLEAN & DRY E.1 - Get your Slurry Kit and tools together. Ensure surfaces inside and outside of the channel and surrounding walls are clean of debris and COMPLETELY DRY! Also ensure that the bottom edge of the Tank Sump Body has been abraded 3 up inside and outside and that it is uncontaminated and dry. Wear protective goggles and a mask when mixing and applying resin or paste. RB SLURRY CATALYST DIRECTIONS TEMPERATURE SPECIAL DIRECTIONS CATALYST AMOUNT FULL CURE TIME Winter Months Ideal: 45-70 F Warm Slurry mixture to ~80 F before installation 1 Bottle (Winter) 70 F+ = 4 hours 45-70 F = 8 hours UNDISTURBED Extreme Winter 44 F or lower Warm Interior of Sump and Slurry mixture to ~80 F before installation 1 Bottle (Winter) 8 Full Hours UNDISTURBED Summer Months Ideal: 71-100 F N/A Half Bottle (Summer) 4 Full Hours UNDISTURBED Extreme Heat 101 F or higher Refrigerate Slurry mixture until installation Half Bottle (Summer) 4 Full Hours UNDISTURBED DO NOT DISTURB THE SUMP OR IT S PIPING UNTIL AFTER THE FULL SPECIFIED CURE TIME CATALYST (HARDENER) BOTTLES ARE LABELED FOR BOTH WINTER AND SUMMER. THE LABELS WILL READ: WINTER SLURRY CATALYST or SUMMER SLURRY CATALYST 6 ii-b407-tg-10b
Wear protective goggles and a mask when mixing and applying resin or paste. DO NOT USE POWER TOOLS ONLY MIX YOUR SLURRY BY HAND E.2 - DO NOT CATALYZE UNTIL SLURRY IS THOROUGHLY MIXED. Pour your entire Gallon of slurry mix into your blue bucket and mix thoroughly for one minute. THEN add the catalyst and mix thoroughly again for one minute (Fig. E.2a). Then pour half the mixture evenly into the groove channel of the base (Fig. E.2b). Use your stir stick to spread it around until it is even and level. E.3 - Slowly and evenly lower your Tank Sump into the channel (Fig. E.3). DO NOT SPILL ANY SLURRY FROM MOVING THE SUMP OR DROPPING IT INTO THE CHANNEL. Fig. E.2a Add the rest of the slurry mixture to the channel on the inside and outside. Spread or spackle the slurry inside the channel from the interior of the sump. Visually check to make sure the slurry has not overflowerd over the lip of the channel, either inside or outside. Pay particular attention to the quality of seal at the corners. DO NOT DISTURB THE SUMP OR IT S PIPING UNTIL AFTER THE FULL SPECIFIED CURE TIME Half the Slurry Mixture Fig. E.2b Fig. E.3 With Tank Sump in place, pour the rest of the slurry into the Channel Tank Sump Channel Tank Sump Base 7 ii-b407-pp-10c
E.4 - Install any additional penetration fittings and equipment in the Tank Sump. Install all necessary equipment per local code & regulations. You must NOT disturb the penetration fittings while the sealant/adhesive is drying. Allow for the minimum cure time for the slurry, 4 Hours at or above 75 F. E.5 - TESTING YOUR SUMP - Conduct a water test only after all joints/penetration fittings are fully installed and all adhesives/epoxies/resins have fully cured. WATER LEVEL MUST NOT EXCEED 2 ABOVE THE HIGHEST PENETRATION OR FIBER- GLASS JOINT. E.6 - OPTIONAL OVERSEAL - It is highly recommended that as a redundant seal for your Tank Sump Joint, you cover and coat the top of the slurry installation with Vulkem 116 polyurethane sealant on the outside only. If you choose to excercise this additional seal, you must thoroughly coat the top of the slurry within the channel so that the Vulkem smoothly seals to both the outside edge of the channel and the Tank Sump wall, just above the fully cured slurry. You can NOT use any other sealant type. NOTE: Vulkem 116 Sealant must cure Overnight. F - REPAIRING SUMPS Look at edges and penetrations for pinhole leaks. For large leaks, consult factory. A: Locate leak point(s) and mark with marker so you can locate it / monitor it. B: Repair or reinstall penetration fittings according to your penetration fitting manufacturers Installation / Maintenance Instructions. C: Abrade a 2 diameter area centered on the leak point until natural resin/fiberglass material can be seen. Ensure repair area is completely dry. Then apply a 3-layer strip of 2 x 2 resin-saturated fiberglass mat squarely on the abraded area. Let cure. E: After cure, knock down fiberglass hairs with a light sand, and apply another flow coat of resin only. Apply any extra resin to repaired leak point(s) while still wet. ALLOW ANY REPAIRS TO FULLY CURE BEFORE TESTING SUMP AGAIN VULKEM 116 G - Sump Covers G.1 - Install Sump Covers and/or any components required to secure or fasten them to the Tank Sump reducer. Trash Can style cover for the B407 series (Model # C32) seats on reducer without preparation, modification or tools Top Hat Reducer of B407-PP Sump 8 ii-b407-pp-10c
H - Concrete and Backfill Guidelines. To ensure that no immediate or future damage is done to your Bravo Tank Sump Reducer components, make sure that your manhole skirt DOES NOT TOUCH OR REST ON THE TANK SUMP SHOULDER. The Manhole Skirt should be kept at minimum of 4 away from the tank sump shoulder. Follow the manhole manufacturers instructions for installing the manhole. Also follow other details provided by tank and/or engineering firm for tank driveway pad installation. Backfill your peagravel around the sump maintaining a minimum of 1 foot all the way around (if your site backfill is not entirely peagravel) and 4 minimum distance from the top edge of sump reducer. When peagravel is in place, use a 3mil or thicker plastic sheet to cover the surface of the peagravel no less than 2 feet away from the sump reducer wall. Secure this plastic barrier to the EXTERIOR OF THE MANHOLE SKIRT using duct tape. This prevents concrete from seeping too far down into the peagravel. Minimum 4 inches between top of sump reducer and peagravel 1 to 1-1/2 Distance 3mil+ Plastic Barrier taped to manhole skirt Manhole Cover Manhole skirt CONCRETE SLAB SAND OR SOIL Min 1 foot peagravel all around sump Sump Cover Manhole skirt min. 4 away from Tank sump shoulder 9 ii-b407-pp-10c