P

EX G
EN

ACO DRAIN
Site Installation Manual
Polymer Concrete Drain Systems

Re-order DL016
 Getting Started
ACO Drain consists of a full range of
POLYMER CONCRETE

modular channels with captive grates;

Systems include catch basins, end caps,
and other accessories.

When installed correctly, ACO Drain

products are designed to withstand a
variety of loadings as classified by
EN 1433 (The only standards specifically
for trench drain systems).

Polymer concrete products should be

Contents handled with care as they can be
damaged by impact from other products,
Getting Started 2 or machinery.
Health and Safety 3
Typical equipment necessary for
Installation Sections 4
installation may include:
1. Excavation 6
2. On-site Fabrications Excavating equipment
- Cutting channels & Tee junctions 7
- Miters, Corners, Bends & Radius 8 String-line and laser level
3. Pipe Connections 9
Measuring tools
4. Connection with
Underground Piping 10 Masonry drill, grinder and/or saw
2
5. Positioning of Channels
- Patty Method 11 Rubber mallet
- Hanging Methods 12
- Installation Devices 14 Concrete - 4,000 psi recommended
compressive strength
6. Catch basin blanking plates 15
7. Pouring Concrete 16 Gloves, respirator and eye protection
8. Pavement Finishing
- Concrete 17
- Asphalt 18
- Brick Pavers 18
9. Fit / Remove Grates 19
10. Final Inspections & Maintenance 22

(800) 543-4764 www.ACODrain.us

 Commercial Trench Drains

Health and Safety

Polymer concrete Metal grates

POLYMER CONCRETE
Products are manufactured using Grates are typically made from either cast
synthetic resin, mineral aggregates and or fabricated metals.
curing agents.
Main hazards include:
Main hazards include: Abrasive damage/cuts to hands.
Abrasive damage to hands. Inhalation of dust from grinding
Inhalation of dust from grinding, cutting, or cutting.
or drilling. Grinding, cutting, etc. may generate
Grinding, cutting, etc. may project small sparks; flammable items should be
fragments. removed from area.

Gloves, eye protection and a respirator Gloves, eye protection, and respirator
should be worn to avoid these hazards. should be worn to avoid these hazards.
Operations should be conducted away
Female Male from areas of fire or explosion hazard.

Only required for

QuickLok grates

female end
(up stream)

3
male end
(down stream)

Supplied
by others Channel sequence
number

Flow direction
indicator arrow
Make sure arrows molded on sides
of channel all point in the intended
direction of flow (outlet point).

(800) 543-4764 www.ACODrain.us

 Installation Sections
These illustrations are a guide
POLYMER CONCRETE

for typical ground conditions

only. Engineering advice
should be taken.

Refer to www.ACODrain.us for

further information.

An installed ACO Drain System

should incorporate the following:
Correct grate type.
Correct channel type and size.
Recommended grade 4,000 psi
compressive strength cement
concrete surround. Pavers - EN 1433 Class A - C only
Concrete surround dimensions
Pavers
are minimum dimensions and
engineering advice should be
taken to confirm appropriate for
the specific project.
Concrete surround should
typically be the same thickness See table
pg 6
as the concrete slab.
Subgrade
Poor site conditions and low load
bearing pavement will require
See table pg 6 See table pg 6
an increase in these dimensions
4 to meet both vertical and lateral
loads. Pavers - EN 1433 Class A - F
Reinforcing steel may be required Pavers
within the slab and around the
trench drain - engineering advice
should be sought to determine
bar size and configuration.
See table
For Load class F applications, pg 6
ACO recommends using the
Subgrade
concrete anchors offered with
PowerDrain.
See table pg 6 See table pg 6

(800) 543-4764 www.ACODrain.us

 Commercial Trench Drains

Asphalt - EN 1433 Class A - C only

POLYMER CONCRETE
Asphalt

Concrete

See table
pg 6

Subgrade

See table pg 6 See table pg 6

Asphalt - EN 1433 Class A - F

Asphalt

Concrete

See table
pg 6

Subgrade

See table pg 6 See table pg 6

5

Concrete - EN 1433 Class A - F

Expansion
joint to
engineer’s
details

Concrete

See table
pg 6

Subgrade

See table pg 6 See table pg 6

(800) 543-4764 www.ACODrain.us

 1 Excavation

Excavate trench to accommodate drain

POLYMER CONCRETE

system. Excavations must be made about

the center line of proposed drainage run
and catch basin.

Trench must be big enough to

accommodate each of the following:

A. Channel/catch basin width and C. For sloped systems, excavate base

depth dimensions. of trench to roughly follow fall of
trench run.
B. Concrete surround dimensions*.
Sloped
system 3
See table below ACO Drain channel 5, 4,
6,
for recommended Finished surface 8, 7,
dimensions 10, 9,

Constant
depth
x x system 010, 010, 010, 010, 010, 010, 010, 010

NOTE: Check product literature for

x overall product depth. Add additional
measurement for concrete surround
from table at left.
Trench profile Form board if required
Ensure loose material is removed from
trench and base is well compacted.
6 Concrete Surround Dimensions* (x)
Run string line, or laser, at finished
Load Cl A B C D E F
surface level along full length of proposed
4” trench run to ensure trench is installed to
4” 4” 6” 6” 8” 12”
channel grade.
8”
4” 4” 6” 8” 8” 12”
channel In concrete pavements ensure an
12” allowance is made for expansion/isolation
4” 6” 6” 12” 12” 12” joints, if necessary, to allow movement
channel
due to thermal expansion/contraction.
* These dimensions are recommended
minimums only, based on recommended
4,000psi concrete. Ground conditions
will affect actual dimension required;
engineering advice should be sought.
Concrete surround should be same
thickness as surrounding slab depth.

(800) 543-4764 www.ACODrain.us

 Commercial Trench Drains

2 On-Site Fabrications

When cutting channels and/or grates, Tee Junctions

POLYMER CONCRETE
gloves, protective eye wear and respirator Tee junctions are when an opening is cut
or mask are recommended. into the side of one channel and another
channel is butted up to this opening.
Cutting channels
Required to form miters, tee junctions All half meter channels provide molded
and non-standard lengths. Most guide for side removal. Other channels;
fabrications can be completed on site. mark area in channel wall to be removed
ACO offers a custom fabrication service by butting channels together and marking
for more complex fabrications. Contact profile of interior of channel.
ACO Technical Department for further
information. NOTE: Edge rail should be left intact
to provide additional strength and
Channels should be cut with a masonry or seating for grate.
diamond disc saw. Grates should be cut with
band saw, or similar, with suitable blade.

Side wall cut-out

A 2 - part rigid resin glue (ACO Bond) can

be used to bond cut surfaces together, if Cut opening
on the side
required. of the channel

If corrosive liquids are transported in

trench, joints should be properly sealed.

Ensure the sealant/adhesive used is

chemically resistant.

(800) 543-4764 www.ACODrain.us

 2 On-Site Fabrications

Miters
POLYMER CONCRETE

Corners Channels mitered

Formed by cutting channels to required at 45° angle
angle and butting together.

For heavy duty applications (D-F), mitered

grates are not recommended. A tee joint is
suggested to give grate maximum support. Channels are mitered;
grates are shown as tee joint.

Tight curves/bends
For tight curves or bends, miter cut end of
each channel and grate to required angle.
Results in a neat finish at joint

Miter each
channel end

Radius
Channels can be installed to slight curves
by leaving an acceptable gap at the
channel joints (acceptable gap to be
approved by client).
8

Acceptable gap

Using half meter non-sloping channels, allows more ’segments’ to be added to the radius;
the gap between channels is reduced, or alternatively a tighter radius can be achieved.

(800) 543-4764 www.ACODrain.us

 Commercial Trench Drains

3 Pipe Connections

Removal of knockout, or cut hole:

POLYMER CONCRETE
1. Identify and mark area to be removed.
(Bracing may be necessary).

2. Material removal:
Catch Basin - cut-out Channel - knockout
Use cut-off tool, reciprocating saw Stand channel upright holding outlet
or band saw to cut opening for end in hand to absorb impact
required pipe size and location. and prevent cracking. Using
hammer, from inside of channel,
carefully tap out required area
following around inside of symbol.

Knock-out symbol
x
x x
x x
x x
3. Attach outlet pipe using coupler, Tap here x x

if required seal using appropriate

sealant/adhesive. If corrosive liquids
are transported in trench, ensure
sealant or adhesive is chemically
resistant.
9

3. Use a grinder to dress or enlarge hole

for proper pipe insertion.

4. A pipe may be fitted into hole

using appropriate sealant/adhesive.
If corrosive liquids are transported
in trench, ensure sealant or adhesive
is chemically resistant.

(800) 543-4764 www.ACODrain.us

 4 Connection with Underground Piping

Channels may be connected directly to

POLYMER CONCRETE

underground piping via:

1. End cap outlets (horizontal outlet). 4. Catch basin.

2. Vertical knockouts (penetrations Connecting channels to catch basins

on underside of channel). Catch basins have guides for channel
connection at depths corresponding to
invert level of designated channel units
(10, 20, 30, 40).

In-line catch basins - cut out black end

material at required channel height. Seal
joint with flexible sealant. See page 15 for
end blanking plate details, if required.

600 Series catch basins - stitch drill out

10
polymer concrete panel (100 systems) or
cut out black end material (200 systems)
at required height. See page 15 for end
3. In-line catch basin.
blanking plate details, if required.

(800) 543-4764 www.ACODrain.us

 Commercial Trench Drains

5 Positioning of Channels

Start with outlet. Ensure string-line, or laser

POLYMER CONCRETE
Male
is set at top edge of required channel height.
Female

Common methods of positioning channels:

include:
1. Patty Method
2. Hanging Method
3. Installation Device
As per table (pg. 6)

1. Patty Method d) Lower channel vertically onto ‘patties’

a) Set catch basin (or outlet channel) on and position to correct height and
bed of concrete to required height alignment ensuring ‘tight’ connection
(see page 6 for concrete dimensions). to previous channel.
Connect and seal outlet pipe. Concrete key

b) Using low slump concrete, create

‘patties’ at intervals to support channels.
Allow two patties per channel, spaced
such that no concrete material is
trapped in joint, creating gaps.
Note: Patties should be sized to Avoid concrete/dirt at joint
provide required concrete surround e) Add concrete on top of ‘patty’ to cover
(see page 6). concrete ‘keys’ on side of channel - this
prevents movement, or floating, during
c) If channels are to be sealed, roughen concrete pour.
ends and use a flexible sealant -
check chemical compatibility, if f) Continue to lay channels until end of
11
required. run or next catch basin is reached.

IN
RA
OD
AC

Work away from outlet

(800) 543-4764 www.ACODrain.us

 5 Positioning of Channels - Hanging Methods

Retrofit installations - use existing slab to

POLYMER CONCRETE

anchor supports. Alternatively, form boards 1.25”

can also be used.

H
2.i Bolting Method - DrainLok/
L
QuickLok
K100, K200, K300, H100, H100K, H200K, 100 - L=4.64” H=0.50”
200 - L=8.58” H=0.75”
H300K will require a long threaded rod and
300 - L=12.52” H=0.75”
cross bar to fit in the locking bar recesses.
Threaded rod and bar

a) Cut 2 x 4’s to length to span excavated 2x4

trench or form boards (minimum 2 per supports
channel - K200 & K300 will require 3 - 4).
Cut ‘spacers’ to ‘lift’ supports above
Spacer
finished level. Cut bracing to fit into
grate rebate. Saw cut
Anchoring
fasteners
b) Drill 5/8” diameter holes in the center to prevent floating
of each 2 x 4 and spacer. Drill holes in
Retrofit installation
center of bracing at 19.69” (500mm)
centers to match locking positions.
Use shims to position
c) Tighten 5/16” x 18 threaded rod channel correctly
relative to slab
through center of each cross bar. Fit
cross bars into channel recesses.
Plywood
bracing
d) Slide bracing, spacers and 2 x 4’s over
12 threaded rods.
Threaded rod
Spacers allow 2 x 4’s (anchoring
e) Lower channels into excavated trench, concrete surface fasteners should be
adjust to required position and height. finishing at used to prevent floating)
supports
Shims may be required beneath 2 x 4’s
to achieve required height and ensure
channels are level.
Finished height
f) If channels are to be sealed, roughen Plywood bracing
ends and use a flexible sealant - check Cross Threaded rod
chemical compatibility, if required. bar

g) Nail or anchor 2 x 4 supports securely to

slab/form boards. This ensures channels
are held securely during concrete pour. New installation

(800) 543-4764 www.ACODrain.us

 Commercial Trench Drains

5 Positioning of Channels - Hanging Methods

Retrofit installations - use existing slab

POLYMER CONCRETE
to anchor supports. Alternatively, form
boards can also be used.

2.ii Bolting Method - PowerLok

S100K, S200K, S300K, H100SK,
H200SK, H300SK will require M10 - 1.5
x 120mm bolts to screw into widgets in
edge rail of channel. This allows the bolt
to pass through the spacers, 2 x 4’s and Widgets in edge rail
into widget nut.

a) Cut 2 x 4’s to length to span excavated

trench or form boards (minimum 2 per 2x4
channel - S200K & S300K will require supports
3 - 4 per channel). Cut ‘spacers’ to
‘lift’ supports above finished level. Spacer

b) Drill two 5/8” diameter holes in the Saw cut

Anchoring
2 x 4’s and spacers - width to match fasteners
widgets in channel rail. to prevent floating

Retrofit installation
c) Using M10 - 1.5 x 120mm bolts with
washers, bolt 2 x 4 and spacer to
channel - do not overtighten. If using
torque wrench do not set higher than
15ft. lbs. 2 x 4 (anchoring fasteners
Spacers allow to prevent floating) 13
concrete surface
d) Lower channels into excavated trench, finishing
adjust to required position and height.
Packing material may be required
beneath 2 x 4’s to achieve required Finished height
height and to ensure channels are level.

e) If channels are to be sealed, roughen

ends and use a flexible sealant - check
chemical compatibility, if required.

f) Nail or bolt 2 x 4 supports securely

New installation
to slab/form boards. This ensures
channels are held securely during
concrete pour.

(800) 543-4764 www.ACODrain.us

 5 Positioning of Channels - Installation Devices

A clamping system that fits around the

POLYMER CONCRETE

profiled end details is available to support

the channel in place and allow a single
pour if required.

Rebar is used to achieved correct height.

One device per joint is required, including
start and end of the run.

100, 200 & 300 wide versions available.

Parts are supplied with a full detailed
instruction sheet
4. Move template and set rebar in place
- always allow two sets of rebar to be
installed before placing channels to
enable template to be moved to next
position.

5. When ready to lock channels in place,

Adjustable clamp fits Rebar allows ensure channel is positioned such
into recesses on easy height that the fixed clamp fits into recess in
side of channels adjustments channel end.

1. Create required width template using

6. Push adjustable clamp tight onto
timber sheet or similarly suitable rigid
other side of channel.
material. Diagrams can be printed
from the ACO website.
7. Tap metal wedge into slot to lock
14 www.ACODrain.us/technical.html
adjustable clamp in place, locking
channel joint closed.
2. Start at outlet. Drive #4 or #5 rebar
into ground to hold three installation
5. Repeat for additional channels.
devices spaced using ACO template.
Screw installation device to rebar at
6. Check channels are at required level -
required height.
adjust using screws on rebar.

3. Set channels in position but do not

lock into position until next channel is
in place as his allows some flexibility
and movement.

(800) 543-4764 www.ACODrain.us

 Commercial Trench Drains

6 Catch Basin Blanking Plates

All in-line catch basin tops and the 200mm

POLYMER CONCRETE
and 300mm wide 600 Series catch
basin tops have open end rails to allow
connection of channels both ends.

Blanking plates are supplied to prevent

concrete ingress during the concrete
pour when channel connection does not
close end rail openings. Blanking plates
match catch basin edge rail - galvanized,
stainless, or coated black steel to match
color of iron rails.

To close off the entire opening where no Where a channel is connecting into a
channel is connecting, simply push down Series 600 catch basin the blanking plate
over the polymer concrete bridge. can be cut, removing the center where the
channel connects.

Push blanking plate down over Blanking plate cut down to

the polymer concrete bridge fit channel opening.

15

(800) 543-4764 www.ACODrain.us

 7 Pouring Concrete

Channel Anchors
POLYMER CONCRETE

For Load class F applications, ACO Screw

Anchor
recommends using the concrete anchors
offered with PowerDrain. Metal anchors are
attached through punched out hole in edge
rail - see Technical Bulletin for details.

Channel Bracing
To prevent channel wall and joints from
distortion by weight of concrete, grates
or 3/4” plywood sections (cut to create
a snug fit) should be placed in the grate
rebate of channel.

If grates are used, they should be suitably

protected from concrete contamination
during concreting (wrapped in plastic Shim
or masking tape) and should be laid to
bridge channel joints to aid alignment.
Shims (or washers) should be placed
along one side to maintain a clearance
gap.

Concrete Pour
If using closing/outlet end caps with
channels 1-15 remove unused spigot to Second lift
ensure sufficient concrete coverage.
16
First
To prevent concrete from filling channel lift
body, cover open areas with plywood or
similar. (Bracing should suffice).

Recommended that concrete have

compressive strength of 4,000 psi. Concrete should be poured evenly (both
sides of channel) and carefully to avoid
If using hanging method, and channels dislodging channels. A wand type concrete
are securely in position, first concrete vibrator should be used to ensure concrete
lift should come approximately 2 inches distributes evenly around channels.
(50mm) up sides of channels.
If ‘cold joints’ are a concern, engineering
Once first lift has hardened, remaining advice should be sought to determine
concrete surround can be poured. single pour procedure.

(800) 543-4764 www.ACODrain.us

 Commercial Trench Drains

8 Pavement Finishing - Concrete

To finish installation, trowel concrete flat

POLYMER CONCRETE
Approx. Finished concrete
and taper down to channel edge. The 45° to have slight
1/8” slope down to
top of adjacent pavement must be above
channel
the grate level (approximately 1/8”), this Grating
ensures all liquids drain into the channel.

Once concrete has cured 24 hours,

remove bracing and/or grate protection.
Fit grates - see page 19/21.

Concrete

Expansion joints Align with channel joint

Transverse joints (perpendicular to the Transverse
channel) are required to prevent surface joint
cracking in the slab. Such joints should
be positioned at channel joints to prevent
channels from cracking. If such spacing is
not possible, a cut must be made at the 17
appropriate location through the channel
Original slab
Expansion
and sealed with flexible sealant. joint

Longitudinal expansion/isolation joints

should be continuous and flexible. They
must be provided between the concrete
surround and surrounding slab and may
be varied to suit concrete surround width
by up to a meter (3 feet) from the channel.

If the joint is dowelled, debonding should

be provided. ACO recommends seeking
engineering advice.

(800) 543-4764 www.ACODrain.us

 8 Pavement Finishing - Asphalt
POLYMER CONCRETE

For applications where asphalt can be

applied directly up to channel edge, see
appropriate channel/installation detail. Approx. Finished asphalt
ACO recommends for applications over 45° to have slight
1/8” slope down to
Class C a full concrete surround be used.
channel
See page 6 for concrete haunch details. Grating

CAUTION: To prevent damage to

channels and grates, protect channel
between concrete pour and application of
Base
asphalt and when rolling asphalt.
Course

Asphalt must be above grate level by

approximately 1/8”, this ensures all liquids
drain into channel. Concrete

Once pavement is finished, remove

bracing and/or grate protection. Fit grates
- see pages 19/21.

Pavement Finishing - Brick Pavers

For applications where brick pavers can

be installed directly up to channel edge,
see appropriate channel/installation detail.
ACO recommends for applications over
Class C a full concrete surround be used.
18 See page 6 for concrete haunch details.

Brick pavers adjacent to channel MUST

First course bonded
be fully bonded to concrete haunch. This 1/8” to concrete haunch
prevents movement of bricks and possible
Grating
damage to channel. Subsequent pavers
can be bedded on compacted sand.

Bricks must be above grate level by

approximately 1/8”, this ensures all liquids
drain into channel.

Once pavement is finished, remove

bracing and/or grate protection. Fit grates
- see pages 19/21. Concrete

(800) 543-4764 www.ACODrain.us

 Commercial Trench Drains

9 Fitting/Removing Grates

DrainLok Grates

POLYMER CONCRETE
1. DrainLok does not require a locking
bar - clips in the grate fit into recesses
in the steel edge rail to hold grates
securely in place.

2. To install grate, align clips in underside

of grate with recesses in edge rail. Push
down/stand on grate until clicks into
position.

19
3. To remove first grate, insert removal
tool under grate bar, pull up sharply.
Subsequent grates can be removed by
hand - Grip end of grate and lift sharply.

(800) 543-4764 www.ACODrain.us

 9 Fitting/Removing Grates

QuickLok Grates
POLYMER CONCRETE

1. Fit QuickLok bar in channel wall

recesses by rotating clockwise.
K100 - Use hammer to tap into place,
so that serrated ends grip in recess.
K200/K300 - Use plastic safety clip
to hold bar in place.

2. To install grate, align stud directly over

locking bar. Push down/stand on grate
until clicks into position.

3. To remove first grate, insert removal

tool under grate bar, pull up sharply.
Subsequent grates can be removed by
hand - Grip end of grate and lift sharply.

4. To remove K100 bar, insert screwdriver

20 into hole at end of bar - lever back
serrated section to loosen. K200/K300
- remove plastic clip to remove bar.

(800) 543-4764 www.ACODrain.us

 Commercial Trench Drains

9 Fit/Remove Grates

PowerLok Grates PowerDrain Bolted Grates

POLYMER CONCRETE
1. To unlock: Slip flat end of grate removal 1. To lock: Fit one side of grate under
tool into the slot between PowerLok lugs in rail and lower into position. Align
mechanism and edge rail as shown. bolt into hole and use wrench or socket
set to tighten. If using torque wrench,
do not set to more than 15ft lbs.

2. Rotate through 90˚ until lock mechanism

slides across and clicks open.

2. To unlock: use wrench or socket set to

loosen/remove bolts. Use grate
removal tool to lift first grate, sliding
from beneath anti-shunt lugs. Once
unbolted, other grates can be removed
3. To remove grates, insert removal tool by hand (use gloves).
under grate bar and lift first grate out,
sliding from beneath anti-shunt lugs.
Once unlocked, other grates can be 21
removed by hand (use gloves).

4. To lock: Fit one side of grate under

lugs in rail and lower into position. Use
hook on removal tool to push clip back
to closed position, and click is heard.

(800) 543-4764 www.ACODrain.us

 10 Final Inspections & Maintenance

Final Inspections
POLYMER CONCRETE

1. Remove any debris in system and grate

rebate. Ensure outlet pipes are clear. Maintenance

2. Install trash buckets in catch basins, if Regular inspections of trench drain system
required. are recommended. Frequency will depend
on local conditions and environment, but
3. Flush trench run to check for pipe work should be at least annually.
blockages, unblock if necessary.
Inspections should cover:
4. Empty trash buckets and clean out Grates and locking devices
pipe connections, if necessary. Replace
Catch basins and trash buckets
trash buckets.
Concrete surround and adjacent paving
5. Install grates in proper position
ensuring they are securely locked down All items should be inspected for damage,
blockage or movement. Compare with site
(page 19/21).
drawings if necessary.
Drainage system is now ready for use.
1. Remove grates - see page 19/21.
2. Remove debris from channel.
Grate oxidation
3. Flush channels with water or high
pressure washer.
Grates are supplied with a temporary
protective coating that will eventually wear 4. Repair damaged surfaces, if necessary,
off. with an appropriate ACO repair kit.
22
5. Renew joint seals as required.
Regular traffic will buff iron grate surfaces
6. Empty trash buckets and clean out
to a smooth, dark finish.
pipe connections.
Grates that are not regularly trafficked 7. Re- install trash buckets.
will oxidize unless regularly painted. 8. Re- install grates, ensuring they are
This oxidization is only on the surface locked in place.
and only affect the aesthetics, not the
performance, of the grates. Systems with grates that have wide slots
may be cleaned with the use of pressured
water applied through the grate - debris
will be washed to catch basin for removal.
(Empty and replace trash bucket).

(800) 543-4764 www.ACODrain.us