Water

A tractor trailer is more than just a large piece of on-road equipment. It’s a major investment, foundation to a livelihood and a home away from home. Collectively, big rigs are the engine that keep industries and economies in motion.

But none of that comes cheap. A new truck and trailer can cost well over a quarter-million dollars, and that’s not including a lot of chrome and aftermarket equipment so often added to personalize vehicles. After all, plenty of truckers find ways to make their million-mile rolling office as comfortable as possible.

The miles are a given, so long as the truck is properly maintained, and clean. The challenge of removing snow, ice, mud and salt gave rise to the modern, roadside truck wash.

Washing big rigs – from over-the-highway trucks to off-road energy industry trucks – is infinitely more involved than washing cars. They’re bigger, sure, but they also come in a wide variety of sizes and shapes.

 

Water, the lifeblood of everything

“Whether you’re washing an oil field truck covered in 5,000 pounds of mud or you’re cleaning a chromed-out road truck, water is a huge consideration,” said Jyrki Koro, president of Truck Wash Technologies, Inc., in Sault Ste. Marie, Ontario. “It takes a lot of water, and it needs to be processed accordingly.”

With 21 years in the truck wash industry, Koro started the company in 1999, with a vision to develop the commercial, for-profit truck wash that has eluded other manufacturers to date. Designing superior automation and water treatment technology that can adapt to a very diverse trucking industry was key, but equally important is minimizing capital costs related to building and land, and developing a service and operational standard which allows the business model to work.

“Until recently, little has changed in the truck wash industry in the past 40 years or so,” said Koro. “We aim to provide a fast and affordable public wash that offers value and consistency while delivering what every owner wants: a clean and shiny truck.”

Their unique, innovative wash system provides an automated cleaning rivalled only by a long, labor-intensive manual wash, but utilizing advanced technology that delivers high wash quality with minimal labor costs.

For the portion of the wash when cleaning chemicals are used and also on the final, spot-free rinse, conditioned fresh water is used. For all other facets of the washing process, large amounts of recycled water are used. The fresh water portion of the system includes filtration, scale prevention and reverse osmosis for uncompromising purity.

“During the design of our truck wash systems, we researched the trucking industry to determine the needs of the end user and tailored a system using innovative designs and vendors to complement the application with quality components,” said Koro. Though he’s been designing truck wash systems for 16 years, the current model has been seven years in the making.

 

Two types of fresh water

As fresh water comes into the facility from a well or municipal supplies, it’s treated for scale prevention either by TAC (template-assisted crystallization) technology or traditional water softener with brine tank. Using both technologies provides a more cost effective approach to treating all incoming water to a degree that suits its application in the wash process.

If used for high-pressure rinsing applications, water first goes through a 100 GPM Watts OneFlow anti-scale system to treat water before entering a large storage tank for use. This chemical-free, TAC anti-scale technology bonds calcium ions together so that they’re inert, and won’t build up on surfaces downstream. It’s used chiefly to reduce the negative effects of water hardness (calcium carbonate) in plumbing systems, appliances, valves and other components.

After TAC treatment, water is used in the high-pressure, fresh water rinsing of the vehicle. For fresh water used during the chemical application process, a different anti-scale approach is used.

“Because calcium and magnesium rapidly absorb the cleaning chemicals and render them less effective, we need to be absolutely sure that all minerals are removed from the water stream for chemical application. TAC reduces scale buildup, but the ions are still in the water. So, a commercial Watts water softener conditions the water used in the chemical application. This amounts to roughly 30 gallons per truck wash.”

Fresh water supplied to the softener passes first through a large Watts carbon filter that features automatic backwashing. The activated carbon media in the large tank is generally used for dechlorination, removal of tastes, odors and as pretreatment for reverse osmosis systems. Chlorine causes destruction of reverse osmosis membranes and polymer based ion exchange resins used in water softeners.

A spot-free, final rinse is the very last phase of a truck wash. For this, water is treated by a large reverse osmosis system. A 4,400 GPD (gallon per day) reverse osmosis system provides ample water volume. The RO removes any remnant of minerals that could otherwise create powdery looking spots on the vehicle surface after drying.

 

Sediment removal

The freshwater purification components of the truck wash system insure we minimize chemical costs and produce a clean truck with no streaks or spotting. Nonetheless, recycled water does the heavy lifting.

Each Truck Wash Technologies system uses recycled water for the bulk of the washing process. Heavily-soiled trucks can require as much as 12,000 gallons of recycled water, but never less than 2,000.

“We have off-road trucks come in with so much mud that it actually reduces the amount of cargo they can legally haul,” said Koro. “Needless to say, this cuts into their paycheck.”

As the system’s moving gantry makes pass after pass over the vehicle, tons of sediment drains into an in-floor catchment system. A series of screens and settlement tanks strain solids from the liquid.

A cluster of high-volume hydro cyclones manufactured by Bailey-Parks Urethane provides a second level of water filtration, spinning fine dirt out of the stream in a centrifuge. Finally, a liquid polymer is injected into the water. This substance binds any remaining fine solids together so that they settle out more quickly. All sediment is continuously removed from the wash water and dewatered for ease of disposal.

 

On down the road

A Truck Wash Technologies installation will service upwards of 1,000 trucks each month. As drivers wait 15 or 20 minutes for their rig to come out sparkling clean, they’re oblivious to the hi-tech processes going on in the background.

Truck Wash Technologies currently has two truck washes in Canada, and a third under construction in Tacoma, WA. The company is slowly watching trends in the industry shift favorably.

“We have the potential to change the truck washing landscape in North America,” said Koro. “But being the first mover in a large, untapped market, it’s imperative we remain involved in all facets of the truck wash business to maximize the potential for our customers’ success. The superior technologies we’ve developed and assembled speak for themselves.”

 

 

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(Uponor) announced it has purchased a minority position in Upstream Technologies, a New Brighton, Minn.-based company.

Upstream Technologies is involved in the stormwater management market and has introduced innovative products that significantly improve process and efficiency in these areas. The opportunity came to Uponor through its recently launched subsidiary Uponor Innovations LLC.

“We are excited about this opportunity and although it is outside Uponor’s core strategic focus, Upstream Technologies’ products align with our sustainability goals and our vision of enriching people’s way of life,” says Bill Gray, president, Uponor North America. “Uponor believes companies play a special role in leading sustainability initiatives by producing products and services that make it convenient, affordable and effective to do the right things for the environment.”

One of Upstream Technologies’ products to make waterways clean in an affordable way is the SAFL Baffle. Developed out of the University of Minnesota College of Science and Engineering’s St. Anthony Falls Laboratory (SAFL), this product keeps sediment pollution out of lakes, rivers and oceans.

“Urban runoff hits the road, goes into the storm sewers and ends up in receiving water bodies such as lakes and rivers,” says John Gulliver, a professor in the Department of Civil, Environmental and Geo-Engineering and co-inventor of the SAFL Baffle. “Cities are required to treat urban runoff and are trying to figure out how to deal with this in times of limited funding.”

Jay Schrankler, director of the University of Minnesota Office for Technology Commercialization, says, “Uponor’s commitment to University of Minnesota start-up licensee Upstream Technologies further cements the SAFL Baffle’s place as an affordable tool to keep our waterways clean.”

A.J. Schwidder, CEO of Upstream Technologies, is very excited with Uponor’s investment in the company. “Uponor has a reputation of creating innovative and green products to save energy and ensure safe water — with a focus on reducing our carbon and water footprint locally and globally,” he says. “Their investment is an endorsement of our products, our company and our vision of improving the quality of our water in an affordable way.

The Upstream Technologies story has been an outstanding example of the good that can come from government, academic and corporate collaboration. “Uponor’s commitment to Upstream, along with the Minnesota Department of Transportation and the University of Minnesota’s St. Anthony Falls Laboratory, makes them a member of a group dedicated to improving our waterways,” Schrankler says. “With Upstream and Uponor behind the SAFL Baffle technology, we believe adoption will be accelerated for the good of our environment.”

 

Cast Iron Piping Benefits

By Francesca Dunbar

We have to make choices every day. Personal preference seems to dominate over objective reasoning and we get complacent in our decision making. When it comes to drain, waste and vent (DWV) plumbing systems there is an ongoing debate over which is a better solution, iron or plastic.  Both products have their advantages and disadvantages. Designers and contractors are experiencing tremendous pressure to value engineer projects. Most builders are not willing to give up features in their design to bring the project costs down and look to cut corners on building materials to help reduce the overall project cost. These value engineered tradeoffs are typically not seen until a building is occupied.

Life Safety – Making the Right Choice

The superiority of cast iron (CI) over polyvinyl chloride (PVC) piping in fire safety cannot be overstated. Many people who die in fires do not perish from flame or heat, but rather from the gases released during the heating and combustion of typical building materials or furnishings. Slowing or stopping the spread of these gases through aggressive firestopping is a proven life saver. Contractor and building owners today are concerned about liability.

Most experts agree that CI provides unsurpassed fire resistance. Cast iron does not burn, does not off-gas when heated to temperatures normally encountered in structure fires, it is easy to install, and has superior durability often out lasting the life of a building. This resistance to burning has the added benefit of requiring simple, low-cost firestopping between the annular space between the pipe and wall penetration. That is not the case with PVC piping where the initial cost savings are frequently offset by the added perfunctory material costs. Cast iron pipe and fittings are joined together with no-hub couplings consisting of neoprene gaskets and stainless steel shields and bands. These can be assembled or disassembled very easily.

Something else to consider if choosing PVC as it relates to fire wall penetrations. PVC is combustible and requires complex firestopping systems – each penetration between the pipe and wall infiltration must be sealed with an intumescent material. In the case of fire due to heat, PVC piping will melt away. Therefore, firestopping with intumescent product is needed to fill each and every void and penetration. This intumescent firestopping system is significantly more expensive than the simple and low-cost measures required for cast iron.

Sound Attenuation

Cast iron is often referred to as the “quiet pipe^tm” because of its superior noise suppression unlike PVC piping. Studies have shown CI to be a superior product in controlling noise due to its density. This makes cast iron ideal for condominiums, hotels, healthcare facilities and educational institutions. Unlike PVC, cast iron soil pipe effectively suppresses the sound of swooshing water cascading down from upstairs fixtures. This sound attenuation feature can be a major benefit in quality residential and commercial construction, where building owners and tenants understand the advantage of iron by the very first flush.

On the other hand, PVC used in drain and waste systems is noisy and annoying and often the cause of tenant frustration. If you’ve ever stayed in a hotel plumbed with PVC, you can often hear others showering and flushing toilets depriving guests from the well needed rest they desire. While plastic piping is an inexpensive material, it may not be the right product for every application. The problem with PVC pipe in drain and waste systems is that it produces a lot of noise due to the innate properties of low density plastic and the cementing of pipe and fittings together. To combat the noisy PVC piping system one solution is to wrap the PVC pipes with a good insulating material such as fiberglass or neoprene foam jacketing. The intrinsic properties of cast iron pipe along with the separation of the pipe and fittings by the use of a gasket or coupling is highly effective in reducing the likelihood of sound traveling through the system. Don’t get me wrong, there are special applications for PVC piping, but not in drain and waste applications.

 

Noise Level Chart

A noise level chart showing examples of sounds with dB levels ranging from 0 to 100 decibels.

0 = Healthy hearing threshold

30 = A voice whisper

25 = Cast iron vertical enclosed pipes (average)

33 = PVC vertical enclosed pipes (average)

50 = Light traffic or sound of a refrigerator

70 = A shower or dishwasher running

75 = A toilet flushing or vacuum cleaner

100 = Riding a motorcycle or operating a hand held drill

 

Summary of overall noise levels in dBA emitted by cast iron and PVC pipes while evacuating a 1.6 gallon water flush test. Significant findings that cast iron pipes are quieter than PVC whether or not the pipes are enclosed. This information is based on an independent research study by MJM Acoustical Consultants, Inc.

Listen Up – Noise Pollution is a Problem

Commercial building designers and engineers need to take note of the acoustical performance of the building project and be very cautious of the potentially negative effects of value engineering. Excessive noise from plumbing systems is typically unnoticed until the building is occupied, creating ongoing problems for the occupants. Sound attenuation is regularly value engineered out of jobs, often the result of product substitutions and misguided cost cutting measures. Beware of the unexpected consequences of value engineering.

The World Health Organization (WHO) has done extensive studies in healthcare facilities and has identified noise levels around rooms at night as disruptive to patients. This is especially true in hospitals with multiple levels. These types of structures also have additional noise pollution from waste water evacuation from toilets flushing, showers and storm drains. Excessive noise can lead to sleep disruption and increased levels of stress thus hindering the healing process sought in a hospital setting.

Studies have also concluded classroom noise interferes with the ability for a teacher to educate students effectively, and students to learn. Raising the voice level provides little compensation. ANSI Standard S 12.60-2002 Design Requirements and Guidelines for Schools recommend a maximum of 35 decibels for background noise. There is a direct link between the classroom acoustic environment and the scholastic achievement of students. The result of a US Government Accounting Office survey found that 28% of the nation’s schools reported “acoustics for noise control” as their top environmental problem. This suggests that the 28% figure from this survey may be a substantial understatement of the problem of acoustic barriers in schools since a background noise level of 50 db is 15 dB above the recommended limit included in a US standard for classroom acoustics.

The attributes of cast iron when it comes to sound attenuation cannot be overlooked. Due to its sound-deadening properties, cast iron inherently has a dense molecular structure and a natural heavy mass making it the quieter solution. According to a study by Polysonics Acoustical Engineers, cast iron is 750% more effective in silencing plumbing noise when compared to PVC. With CI, sound is effectively muffled rather than transmitted, as it is with PVC pipe. Noisy PVC piping can be masked by utilizing sound-deadening insulation that is carefully installed with neoprene foam jacketing or other insulation processes but there are again added costs to even come close to the quiet CI piping.

Friend, Foe or Both?

In conclusion, so do you know which product is better, cast iron or plastic? Both products have their advantages and disadvantages, though cast iron is more environmentally friendly than plastic as it is made from ~100% post-consumer scrap iron while on the other hand, thermoplastic piping is produced using petroleum derived materials. So we go back to which product is better. Well, the answer may be to consider using both together.  Plastic pipe is a great choice for the vent system since air doesn’t create vibrations and will be whisper quiet. While on the other hand using cast iron is an ideal solution for underground piping and vertical stacking of indoor pipes. This amalgamated method will benefit the occupants seeking a quiet and durable plumbing system that is a cost effective solution.

Word to the wise, consider the added costs if you choose PVC as it will require more hangers, screws, fasteners, primer, glue, additional labor costs, inspections, neoprene foam jackets to deaden sound, or insulation to muffle the noisy pipes. These supplementary costs are often overlooked when value engineering a project and can cost just as much if not more than a cast iron DWV system.

 

About the Author:

Francesca Dunbar is the Director of Marketing for the McWane Plumbing Group Division. She can be reached by email at Francesca.Dunbar@McWanePlbGrp.com.

 

Quiet Pipe is a trademark of Cast Iron Soil Pipe Institute “CISPI”.

REFERENCES

1.      The Impact of Classroom Acoustics on Scholastic Achievement by Louis C. Sutherland and David Lubman, 17th Meeting of the International Commission for Acoustics, Rome, Italy, Sept. 2-7, 2001

2.      Plumbing Engineer – Features: June 2012: Sound design in drain, waste and vent lines http://www.plumbingengineer.com/june_12/piping_feature.php

3.      Acoustic Control LLC http://www.acousticontrol.com/hospital-acoustics.html

 

by plumbing expert Rich Grimes

What is the best domestic water piping system? Great question with no easy answer! It is truly a matter of preference and each system has its own inherent benefits. Let’s look at some of the more common materials that are used. Most products up to 2″ size are Copper Tube Size (CTS) but alternative methods can be Iron Pipe Size (IPS). The key is that products must be NSF-61 listed for potable water.

COPPER is one of the oldest and most reliable methods for domestic water supplies. It has become an expensive metal over time so that opens the door for alternative piping systems. It has various benefits such as strength, corrosion and temperature resistance, longevity and its natural ability to inhibit bacterial growth. It uses full-flow fittings (tube fits inside of fitting) that are typically soldered connections.

CPVC is another CTS piping material that is often used for domestic water. It is a harder version of PVC that can withstand temperatures up to 180F. It employs a full-flow fitting that is usually socket-welded with solvent-cement. It is non-metallic so it can answer some issues that may arise with copper (dielectric corrosion, etc.) but it is a polymer that can degrade when exposed to petroleum and other chemical products. While it is mostly sold up to 2″ size in CTS, it also is sold as a Schedule 40 or 80 IPS potable water distribution system.

PEX is another polymer that is rated for domestic potable water. It is also CTS size tubing with an internal fitting. It uses a crimp-ring or clamp around the tubing and fitting to create a joint. Crimp and clamp tools are an integral part of the system for making a watertight connection. PEX is a flexible, labor-saving product that is produced in long coils. Long runs can be accomplished with fewer fittings or no fittings under slab.

There are several other polymers that have a NSF-61 rating, typically in IPS and used on domestic water lines over 2″ size. These are competing with large diameter metal piping systems for CW and HW mains of copper or SS.

One variable that must considered is the fittings to be used and the joining method. Today there are a variety of specialty fittings that can greatly reduce installation time and labor. While these fittings and joining methods may have a higher fitting cost, they can ultimately save money when considering the total installed cost. Press fittings have become popular because they greatly reduce labor and allow for a viable copper joint. Solvent welded CPVC can save labor over a soldered copper connection but there are solvent cement costs and joint curing times that must be considered. PEX fittings cost more that CPVC fittings but their clamping methods reduce labor and there is no waiting for curing. A mechanically-extracted tee on copper can eliminate most fitting costs and greatly reduce labor, but they require brazed joints and the cost of the tool system comes into play. Push-joint fittings eliminate tool costs, soldering or solvent-welding, down time, and labor but the fitting cost is higher…

It is probably best to look at items like project location, type of service, local environment, operating temperatures, ambient temperatures, tubing heat transfer, etc. to select the right piping or tubing for a project. Most contractors will utilize several if not all of these methods in their business, but typically standardize on a preferred pipe and fitting method. There is no single piping system that can meet every need and each system has its own benefits and best application. As well, each system is not bulletproof and can be susceptible to the surrounding environment, chemicals or various stresses that can cause a failure. Most products today have very high pressure ratings and it is proven that most piping failures are due to improper preparation and installation. If the manufacturer’s instructions are followed, any of these piping methods can provide a good domestic water distribution system that will last for years and years.