installguidests

Installation Guidelines for
Brentwood Tube Settler Systems

These Installation Guidelines were written by Brentwood Industries, Inc. with the expressed purpose of providing helpful hints and examples for contractors and others of the varied methods of installing tube settler media.

These Guidelines are not to be construed as the only Brentwood approved methods for tube settler media installation or the final installation authority.

The text and pictures are for illustrative purposes only, check with the tube settler owner/ project engineer for their contract/specification requirements.

Examples of Tube Settler Media Support Structures

Pictured below are different width and material type support beams that have been used in other tube settler projects and are typical for many tanks:

Delivered Media

Our tube settler media modules will arrive palletized onsite in closed 48’ or 53’ trailers. The media will be delivered at the normal rate of 2 to 4 truckloads per day or as per a mutually acceptable schedule. Typically there are 12 or 16 modules on a pallet, resulting in a full pallet that has a 3 or 4 ft. width; 6, 8, 10, or 12 ft. length; and an 8 ft. height.

Media Rigging Methods

The pallets must be moved in some fashion to the back of the truck. A pallet jack or a skid puller and chain have been the most successful methods. From the back of the truck the pallets must be lifted by forklift or crane and lowered to ground level. The media must then be conveyed to the tank and lifted into the basin, usually by hand or by crane. There is no correct method or only one way to rig media into a tube settler basin/tank.

Pictured below are tube settlers being off-loaded and moved to a tank for later installation.

Media Placement

The final placement of the media must be placed/installed by hand. The starting point for tube placement is determined by whether the installation is for a round or square/rectangle basin. Normally, the tubes will be first placed at the center column of a round tank and at one end of a square/rectangle basin. The tube settler media modules shall be placed in the tank to provide the closest possible fit with adjacent modules without damaging the modules. The tube settler module packing arrangement shall be as recommended by the media manufacturer and shown on the engineer-approved installation drawings.

The following installation pictures illustrate proper media placement and module orientation.

Manpower Needs

For estimating purposes, a crew consisting of one crane operator, one forklift operator, one other worker to unload trucks and rig media pallets, plus two to three inside tank workers, installing/cutting should be able to install from 200 to 300 or more modules per day.

Tube Settler Media Cutting, Debris Containment, and Protection

Onsite cutting of tube settler modules is done with a chain saw with a 24" or 28" bar because that length bar is long enough to make most of the cuts in one pass, yet small enough to be safely handled. The media modules should be carefully measured and then cut or trimmed to fit within 1/2 inch (or less, if so specified by the project engineer) of the center column and/or the tank perimeter wall.

Normally, the shaping, cutting, and trimming of the media modules is done outside the tank to keep debris out of the basin.

To prevent damage to the tube settler modules, walking on the installed tube settlers should be limited and only allowed after the Contractor has placed 4’ x 4’ x 3/4" plywood or other suitable temporary planking on top of the modules.

The following photos are examples of a cutting area and methods used to protect the tube settlers during installations.

All of the information, observations and recommendations provided in these guidelines are being furnished as a matter of general information and are not in any way intended as a guarantee on the part of Brentwood Industries, Inc., Reading, PA.

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