POLYETHYLENE TANK CHAMBER/SUMP

INSTALLATION GUIDE
The information in this publication is provided for reference only. While every effort has been made to ensure the
reliability and accuracy of the information contained in this manual at the time of printing, we recommend that
you refer to “franklinfueling.com” for the most current version of this manual. All product specifications, as well as
the information contained in this publication, are subject to change without notice. Franklin Fueling Systems does
not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of, or in any way
connected with, installation, operation, use, or maintenance by using this manual. Franklin Fueling Systems assumes
no responsibility for any infringement of patents or other rights of third parties that may result from use of this
manual or the products. We make no warranty of any kind with regard to this material, including, but not limited to,
the implied warranties of merchantability and fitness for a particular purpose.

Copyright © 2017 Franklin Fueling Systems, Madison, WI 53718. All world rights reserved. No part of this publication
may be stored in a retrieval system, transmitted, or reproduced in any way, including, but not limited to, photocopy,
photograph, magnetic, or other record, without the prior written permission of Franklin Fueling Systems.

For technical assistance, please contact:

Franklin Fueling Systems

3760 Marsh Rd.
Madison, WI 53718
USA

Web: franklinfueling.com
Telephone:
USA and Canada: +1.608.838.8786, +1.800.225.9787
USA and Canada Technical Support: +1.800.984.6266
UK: +44 (0) 1473.243300
Mexico: 001.800.738.7610
France: +33 (0) 1.69.21.41.41
China: +86.10.8565.4566

UPP is a registered trademark of Franklin Electric Company, Inc.

408001028 r6
Contents
Introduction.......................................................................................................................................1
Conventions used in this manual...................................................................................................1
Questions and concerns.................................................................................................................1
Operating precautions....................................................................................................................2
Installing the Tank Chamber/Sump...................................................................................................3
Installing a fusion polyethylene tank chamber/sump base...........................................................3
Installing an electrofusion tank chamber/sump riser....................................................................8
Height adjustment to suit final grade..........................................................................................12
Trim the riser.............................................................................................................................12
Installing the lid gasket.............................................................................................................13
Final backfilling............................................................................................................................14
Site investigation.......................................................................................................................14
Rounded gravel backfill specifications.....................................................................................14
Crushed stone backfill specifications.......................................................................................15
Sand backfill specifications.......................................................................................................15
Compacting backfill..................................................................................................................15
Installing a mechanical tank sump/chambers riser.....................................................................17
Installing a composite access cover with skirt...............................................................................19
Parts and materials required.......................................................................................................19
Composite access covers:............................................................................................................19
Prepare the product....................................................................................................................20
Prepare the area..........................................................................................................................20
Prepare the forecourt surface.....................................................................................................20
Crown the cover.......................................................................................................................20
Apply a two-part, cold-pour sealing compound.........................................................................21
Maintenance................................................................................................................................21
Installation overview illustrations...................................................................................................22
Installation overview................................................................................................................22
Lid installation overview...........................................................................................................22
Installing a dip riser entry seal........................................................................................................23
Parts and materials required.......................................................................................................23
Procedure....................................................................................................................................23
Intentionally Blank
Introduction
Conventions used in this manual
This manual includes safety precautions and other important information presented in the
following format:
NOTE: This provides helpful supplementary information.
IMPORTANT: This provides instructions to avoid damaging hardware or a potential hazard to the
environment, for example: fuel leakage from equipment that could harm the environment.
CAUTION: This indicates a potentially hazardous situation that could result in minor or
moderate injury if not avoided. This may also be used to alert against unsafe practices.
WARNING: This indicates a potentially hazardous situation that could result in severe injury or
death if not avoided.
DANGER: This indicates an imminently hazardous situation that will result in death if not
avoided.

Questions and concerns

In case of emergency, follow the procedures established by your facility. If you have questions or
concerns about safety or need assistance, use the information below to contact Franklin Fueling
Systems:
Web: franklinfueling.com
Telephone:
USA and Canada: +1.608.838.8786, +1.800.225.9787
USA Technical Support: 1.800.984.6266
UK: +44 (0) 1473.243300
Mexico: 001.800.738.7610
France: +33 (0) 1.69.21.41.41
China: +86.10.8565.4566

1
 Operating precautions
Franklin Fueling Systems (FFS) equipment is designed to be installed in areas where volatile
liquids such as gasoline and diesel fuel are present. Working in such a hazardous environment
presents a risk of severe injury or death if you do not follow standard industry practices and the
instructions in this manual. Before you work with or install the equipment covered in this manual,
or any related equipment, read this entire manual, particularly the following precautions:
IMPORTANT: To help prevent spillage from an underground storage tank, make sure the delivery
equipment is well-maintained, that there is a proper connection, and that the fill adaptor is tight.
Delivery personnel should inspect delivery elbows and hoses for damage and missing parts.
IMPORTANT: When you use sand as a backfill material, make sure you maintain the desired
compaction (90% of standard proctor density) and prevent backfill migration. In areas with a high
water table, you must take additional measures (such as using geotextile membranes or filter
fabrics) to maintain the desired compaction.
IMPORTANT: Make sure all excavation, piling, and backfilling conforms to local geotechnical
engineer requirements.
CAUTION: Use only original FFS parts. Substituting non-FFS parts could cause the device to
fail, which could create a hazardous condition and/or harm the environment.
WARNING: Follow all codes that govern how you install and service this product and the
entire system. Always lock out and tag electrical circuit breakers while installing or servicing
this equipment and related equipment. A potentially lethal electrical shock hazard and the
possibility of an explosion or fire from a spark can result if the electrical circuit breakers are
accidentally turned on while you are installing or servicing this product. Refer to this manual (and
documentation for related equipment) for complete installation and safety information.
WARNING: Before you enter a containment sump, check for the presence of hydrocarbon
vapors. Inhaling these vapors can make you dizzy or unconscious, and if ignited, they can explode
and cause serious injury or death. Containment sumps are designed to trap hazardous liquid
spills and prevent environmental contamination, so they can accumulate dangerous amounts
of hydrocarbon vapors. Check the atmosphere in the sump regularly while you are working in
it. If vapors reach unsafe levels, exit the sump and ventilate it with fresh air before you resume
working. Always have another person standing by for assistance.
WARNING: Follow all federal, state, and local laws governing the installation of this product
and its associated systems. When no other regulations apply, follow NFPA codes 30, 30A, and 70
from the National Fire Protection Association. Failure to follow these codes could result in severe
injury, death, serious property damage, and/or environmental contamination.
WARNING: Always secure the work area from moving vehicles. The equipment in this manual
is usually mounted underground, so reduced visibility puts service personnel working on it in
danger from moving vehicles that enter the work area. To help prevent this safety hazard, secure
the area by using a service truck (or some other vehicle) to block access to the work area.
WARNING: Make sure you check the installation location for potential ignition sources such as
radio waves, ionizing radiation, and ultrasound sonic waves. If you identify any potential ignition
sources, you must make sure safety measure are implemented.

2
Installing the Tank Chamber/Sump

Installing a fusion polyethylene tank chamber/sump base

NOTE: All FFS UPP® fittings must be secured to the chamber using the Electrofusion welding
process. Do not use additional sealant or screws.
1. Mark the base for the access shaft opening and bolt holes to suit the access shaft.

3
 2. Cut base opening using jig saw or hand saw only.

NOTE: For square collars, use a hole saw to cut all 4 corners of the opening. The opening’s
corners must have rounded corners and NOT have square-cut corners.
3. Drill bolt holes.

4
4. Clean the tank chamber base and tank access shaft flange with acetone.

5. Apply adhesive backed gasket to access shaft flange ensuring there are no gaps. Use a sharp
knife to create slits through the gasket at the location of the bolt holes.

5
 6. Mount the sump / chamber base onto tank. Fit backing plates and bolt together using M12
(½") bolt sets (not supplied). Ensure all bolts are tightened equally. Recommended torque:
20 Nm (14.75 lbft). (See "Final backfilling" on page 14 for more information.)

7. Backfill up to the top of the tank collar. Ensure backfill is well compacted and is fully into
the area under the tank sump.

IMPORTANT: Make sure the temperature of tank sump/chamber is below 40˚C  (104 ˚F) during
the vacuum test.
IMPORTANT: To reduce the effect of heat radiation from the sun, use a shelter such as a Gazebo
to provide shade when testing in direct sunlight.

6
 8. Vacuum test using UPP® Vacuum Test Unit to prove joint between tank collar and tank sump
base. Recommended test setting: 1 ft: -30 mbar.

NOTE: Make sure plugs in tank manway are in position and sealed.
9. Install Pipework per customer specification.

10. Repeat vacuum test (step 8) to prove all entry seals are tight.
NOTE: Never use sealant or screws on an entry seal. If an entry seal leaks, contact FFS.

7
 Installing an electrofusion tank chamber/sump riser
1. Use a black marker to draw hash marks over the entire weld area.

2. Scrape weld area on base with hand scraper. Clean weld area with acetone.

IMPORTANT: Make sure the surfaces you clean with acetone remain dry and
uncontaminated before you weld them.
3. Clean weld area on the riser with acetone.

8
4. Place riser on base and ensure it is mounted squarely.

5. Attach the harness assembly:

For Deep Burial, pass the harness over the riser and position the top strap above the lower
rib.

For Shallow Burial, pass the harness over the riser and position top strap below top rib.

9
 6. Pull the top strap tight with cam buckle.

7. Position 4 drop-straps in line with base corners.

8. Loop harness rings over corners. For the OCH-1450-1400 chamber (shown below to the
right), position the loop harness rings onto the posts on the chamber base.

10
 9. Center riser on the base, ensuring it sits squarely with an even gap all round. Pull the strap
in tension, and ratchet until webbing has wound itself and is locked in place. Add two full
ratchets. DO NOT OVER-TIGHTEN.

10. Repeat for opposite corner and two remaining corners, ensuring riser is still sitting squarely.

11. Connect the white welding lead to the terminals. Begin weld. EF1 orange units will
stop automatically after 6 minutes. Mark the time near the weld terminals. See manual
408001007 for Electrofusion Instructions.

11
 12. After a minimum of 20 minutes cooling time, release harness by pulling and holding release
tabs on top assembly to override ratcheting function.

13. Repeat the vacuum test procedure to prove the welded joint. (See step 8 of "Installing a
fusion polyethylene tank chamber/sump base" in this manual for the test procedure.)

Height adjustment to suit final grade

Trim the riser.
1. Select the trim mark closest to the desired height. Make sure the trim height is above the
bottom of the access cover skirt and is high enough to allow a seal between riser and access
cover skirt below the toggle height.

Trim Mark on Moulding

30 mm

Riser

Trim Mark on Moulding

2. Highlight Trim mark on riser with a marker pen.

12
IMPORTANT: Use only a handsaw or jig saw to trim the riser.
IMPORTANT: Make sure the cut edge is square and flat. Otherwise, there will not be a
watertight seal with the lid gasket.
3. Trim the riser using highlighted trim mark as a guide and ensure cut edge is square and flat.
4. Remove any burrs using hand scraper. Maintain 30 mm (1.2") clear vertical rise to ensure
water tight lid location is correct.

Installing the lid gasket

IMPORTANT: To help ensure that the chamber is water-tight, make sure the lid gasket is
undamaged and properly fitted. Also, make sure you install the toggle latches properly.
1. Clean the gasket seat with acetone or isopropyl alcohol.
2. Attach the gasket to the gasket seat on the underside of the lid.

3. Position ends of gasket together first and work the gasket around the channel.
4. Place the lid on the riser and attach the latches

13
 5. After welding the riser to the tank sump base, vacuum test to verify the tightness of the
complete sump. Recommended Test Setting: 1ft: (-30 mbar).
IMPORTANT: When you finish the vacuum test, make sure you reinstall the plugs in the test
ports and position the lid correctly, with all toggles fitted, to keep the system liquid tight.

Final backfilling
Site investigation
The following are ways you can get information about the soil conditions you will encounter:
• Do a full geo-technical investigation of the site.
• Drill or dig a test pit in the vicinity of the excavation.
• Research site files for any details from previous work.
• Interview local contractors or consultants familiar with area.
• Determine the groundwater conditions.
When you prepare the tank pit area, refer to “Recommended Practices for Installation of
Underground Liquid Storage Systems" (PEI/RP100-17).
IMPORTANT: Make sure all excavation, piling, and backfilling conforms to local geotechnical
engineer requirements.

Rounded gravel backfill specifications

The following table shows the standard size of rounded gravel coarse aggregates that meet FFS
backfill requirements for containment sumps, according to ASTMD-448, ASTM C-33, and AASHTO
M 43. (The amount of material passing through each laboratory sieve is given as a percentage of
the total weight.)

Size # Sieve nominal size square 3/4" 1/2" 3/8" #4 #8

openings (19.1mm) (12.7mm) (9.5mm) (4.8mm) (2.4mm)
6 3/4" (19.1 mm) - 3/8" (9.5 mm) 90-100% 20-55% 0-15% 0-5%
67 3/8" (9.5 mm) - #4 (4.8 mm) 90-100% 20-55% 0-10% 0-5%
7 1/2" (12.7 mm) - #4 (4.8 mm) 100% 90-100% 40-70% 0-15% 0-5%

14
Crushed stone backfill specifications
The following table shows the standard size of crushed stone coarse aggregates that meet FFS backfill
requirements for containment sumps, according to ASTMD-448, ASTM C-33, and
AASHTO M 43. (The amount of material passing through each laboratory sieve is given as a percentage of
the total weight.)
Size # Sieve nominal size square openings 1/2" 3/8" #4 #8
7 1/2" (12.7 mm) - #4 (4.8 mm) 90-100% 40-70% 0-15% 0-5%
8 3/4" (19.1 mm) - 3/8" (9.5 mm) 100% 85-100% 10-30% 0-10%

Sand backfill specifications

IMPORTANT: Use only coarse or medium graded sand to backfill around polyethylene tank
chambers.
IMPORTANT: Sand that is used for backfill must be free of salt, clay, fines, and native excavation
soil. If you use sand for backfill in a cold weather installation, it must be free of ice.
Sand can be divided into the following categories based on particle size:
• Coarse Sand: This type of sand passes a No. 4 (4.75mm) sieve and is retained on a No. 10
(2.0mm) sieve.
• Medium Sand: This type of sand passes a No. 10 (2.0mm) sieve and is retained on a No. 40
(0.425mm) sieve.
• Fine Sand: This type of sand passes a No. 40 (0.425mm) sieve and is retained on a No. 200
(0.075mm) sieve.

Compacting backfill
It is important to compact backfill correctly in order to provide shear strength, stability, and
increased stiffness to support underground chambers adequately.
IMPORTANT: Make sure backfill is clean, well-granulated, free-flowing, and inert.
IMPORTANT: Do not use mechanical compactors around tank chambers and dispenser sumps
within 12" (30 cm) of the chamber or sump’s wall. This helps prevent local deformation.
Place the backfill evenly in layers (or lifts). Compact each lift thoroughly before you place the next
layer. In general, you should make each layer approximately 12" (30 cm) deep. Check for voids
underneath the chambers while you are backfilling. If the backfill material appears loose in these
areas, continue compacting the backfill, but keep the following in mind:
• Sand: When you use sand for backfill, make sure you achieve and maintain the desired
compaction (90% of standard proctor density) and prevent backfill migration. In areas
with a high water table, you must take additional measures (such as using filter fabrics) to
maintain the proper compaction. You must do mechanical compaction to properly compact
sand backfill after each lift, and you should compact sand at, or near, the optimum moisture
content.

15
 • Rounded gravel and crushed stone: These are self-compacting materials that you can use
for backfill in all ground water conditions. Vibration compaction or shovel slicing works best
with these granular materials
IMPORTANT: For installations in areas with a high water table, FFS recommends using
self-compacting round gravel or crushed stone, which simplifies maintaining proper compaction.
NOTES:
• Prior to backfilling, the chamber lid must be in position to prevent any deflection of the
riser.
• Before an installation, add a 6" (15 cm) bed of backfill under the pipes. Make sure the
backfill is not contaminated and that there are no voids under or around the pipe.
• If the tank chamber overhangs the tank containment collar, add enough backfill around the
underside of the chamber so that it is fully supported.
• If the UPP® pipe exceeds 39' (12 m), lay it in a series of large curves not straight lines.
(Uncoiled pipe will settle into a natural curve.)
• Make sure pipes are separated from each other by at least the diameter of the largest pipe.
• If pipes cross each other, make sure they are separated by at least as much backfill material
as the diameter of the largest pipe or are protected by at least 1" (25 mm) of expanded
polystyrene.

16
Installing a mechanical tank sump/chambers riser
1. Cut riser to required height using ribs as a guide.

2. Clean gasket surfaces of chamber base and riser using cleaning solvent (Acetone).

3. Apply the quarter circle gasket pieces one by one to top of chamber base - ensure holes in
gasket line up with holes in chamber for best fit and make sure all joints between gasket
quarter circles are butted together to make a water-tight seal.

17
 4. Place riser on base and line up bolt holes.

5. Tighten all bolts (supplied M 12 x 60) around chamber initially before repeating to make sure
all bolts are fully tightened.

18
Installing a composite access cover with skirt
Parts and materials required
Composite access covers:
Part number Description
PCR090 35" (900mm) composite access cover, C250 rating
PDR090 35" (900mm) composite access cover, D400 rating
PCR090-DIP 35" (900mm) composite access cover with integrated dip
inspection port, C250 rating
PCR106 42" (1,060mm) composite access cover, C250 rating
PCR106-DIP 42" (1,060mm) composite access cover with integrated
dip inspection port, C250 rating
PCR-DIPCAP Replacement dip cap for composite access covers
PCR-LIFT Lifting handle tool for composite access covers
PCR-LOCK Locking mechanism for composite access covers
SDFLX40FC Sealant (to seal access cover frame to skirt)

35" (900mm) composite access cover accessories:

Part number Description
PDR090-S Replacement gasket for 35” (900mm) composite access
covers (between lid and frame)
PXR090-OCH-SK 35" (900mm) fiberglass skirt, for use with OCH tank
cambers

42" (1,060mm) composite access cover accessories:

Part number Description
PCR106-S Replacement gasket for 42” (1,060mm) composite access
covers (between lid and frame)
PCR106-OCH1400-SK 42” (1,060mm) fiberglass skirt, for use with OCH tank
cambers
PCR106-TSM4542-SK 42” (1,060mm) fiberglass skirt, for use with TSM tank
cambers

19
 Prepare the product
PCR106 PCR106
Composite Cover Watertight Seal Frame

Bonding Surface:
Frame to Skirt (Step 5)

77 mm
Skirt (3 inches) Bearing Surface:
Frame to Concrete

IMPORTANT: Make sure the frame and cover are not damaged before you begin the installation.
1. Remove the protective packaging from the cover, and place the cover on a clean, level
surface.
2. Remove the cover from the frame.
3. Abrade and clean the areas that will be bonded with Acetone.
4. Use SoudaFlex 40FC bonding agent to attach the frame to the skirt. Make sure the skirt
®

fully engages the inner lip of the frame.

5. Allow the skirt and frame to bond fully before continuing. (Refer to the MSDS for the
bonding agent).

Prepare the area

1. Place the skirt on top of the backfill, and take account of how deep the frame is buried and
the desired finished surface level.
2. Allow a minimum of 56 mm (2 ¼ inches) clearance between the bottom of the skirt and the
wider extending section of the tank sump/chamber to allow for tank movement.
3. Allow a minimum of 56 mm (2 ¼ inches) clearance between the bottom face of the access
cover and the top face of the tank sump/chamber lid.
4. Backfill around the area of the skirt to secure its position.

Prepare the forecourt surface

FFS recommends a minimum finished base thickness of 200 mm (7 ⅞ inches) in C 30-35 concrete
to achieve maximum load capabilities of EN124 D400 covers.

Crown the cover

To improve the dispersion of water away from the cover, crown the cover slightly above the
finished surface level. Typically, a crown of 5–10 mm over a distance of 300 mm (0.2–0.4 inches
over 12 inches) around the perimeter of the cover is effective.

20
Apply a two-part, cold-pour sealing compound
Ø 1246 mm (49 inches)
Ø 1060 mm (41.7 inches)
Clear Opening
1060mm Cover Concrete 10 mm
Frame (0.4 ")

200 mm
(7.9")

.
50mm (2")

90 mm
425mm (16.7")

(3.6")

Polyurethane Sealant

Backfill

44mm (1.7")

Foam packer
1426 to 986mm (56 to 39")
Height Adjustment

IMPORTANT: In areas with a high water table, use a foam blocker to stop water from coming in
before you apply a two-part, cold-pour sealing compound.
IMPORTANT: Make sure both the access cover skirt and the chamber riser are clean and dry
before you apply the two-part, cold-pour sealing compound.
IMPORTANT: Make sure you apply the two-part, cold-pour sealing compound below the toggles.
This allows you to replace the toggles, if necessary, without disrupting the seal.
1. Do one of the following:
• Fit a packing piece between the skirt and chamber riser on top of the backfill.
• Cover the backfill with a layer of well compacted sand.
2. Apply a two-part, cold-pour sealing compound. Allow the compound to cure for the
recommended time. (See the compound's MSDS.)
3. Clean the cover and frame thoroughly to remove excess concrete. Give special care to the
area around the seal and the corresponding sealing face of the cover.

Maintenance
Composite access cover seals are replaceable and are considered a service spare:
1. Remove the existing seal.
2. Clean all of the silicon mastic out of the sealing channel.
3. Apply a continuous bead of silicone mastic in the channel as bedding.
4. Install the new seal.

21
 Installation overview illustrations
IMPORTANT: When you install access covers at or above ground level, make sure no load
from the access cover or supporting structure is transferred to the top face of the tank access
chamber. To do this:
• Position supporting structures outside the footprint of the tank chamber.
• Make sure the supporting structure is attached to the surrounding forecourt structure.
• Make sure the supporting structure has a foundation that spreads the load through the
backfill material and not onto the tank chamber.
• Make sure that the separation distance between the supporting structure foundation and
tank chamber shoulder exceeds 300.0 mm (11.8").
Installation overview

Lid installation overview

22
Installing a dip riser entry seal
Parts and materials required
• 305- Entry seal with rubber reducer and band clamps
• Paint scraper
• Hole saw-HS5/ Drill
• 305-Clamp-1 (green)
• Acetone
• Lint-free rags
• Nitrile gloves
• Black marker
• OCH Chamber lid
• UPP EF1 Welder with red leads
• UPP Piping Systems Electrofusion Welding Instructions (FFS part number 408001007)

Procedure
1. Measure from the sump rim to the edge of the dip riser from 4 axis points at 90 degree
angles.

2. Translate the measurements to the sump lid to mark the location the dip riser will pass
though the lid.

23
 3. Make sure you measure from the inside of each point where the latches attach to sump
lid. This provides accurate measurements based on the distance from the sump rim to the
sump lid.

4. Place the sump lid on a clean surface and mark it where you will drill the hole for the dip
riser.

5. Use the drill and HS5 hole saw to drill a hole in the lid at the mark.

24
 6. Deburr the hole and place the entry seal in it. Trace around outside of entry seal with the
black marker. Remove the entry seal and shade inside of outline with the black maker.

CAUTION: Wear cut-resistant gloves when you use a scraper. Wear nitrile gloves when you
use acetone, and refer to the acetone MSDS for additional safety precautions.
7. Use the hand scraper to scrape off the shaded area, and then clean the area with acetone.
8. Trim the internal spigot from the 305 entry seal.

Trim off this section

Do not trim this section

CAUTION: Wear nitrile gloves when you use acetone, and refer to the acetone MSDS for
additional safety precautions.
9. Clean the 305 entry seal weld face with acetone.

25
 10. Secure the 305 entry seal to the sump lid with a 305-Clamp-1.

a. Slide the front of the clamp (with the hole for the screw) onto the bottom side of the
sump lid.

b. Insert the 305 entry seal, and then finish installing the 305-Clamp-1.
11. Tighten the clamp, and then try to slide a business card between the 305 entry seal and the
sump lid. If you can, use pieces of wood or cardboard to offset any warping or gaps.
WARNING: Before you perform an electrofusion weld, you must read and follow all
instructions and safety precautions in the UPP Piping Systems Electrofusion Welding Instructions
manual (FFS part number 408001007). You must wear all required personal protective equipment
indicated in that manual.
12. Use the EF1 electrofusion welder with red leads to do the weld.
IMPORTANT: To help ensure that the chamber is water-tight, make sure you install the dip riser
entry seal boot correctly and fit the band clamps properly.
13. The correctly installed dip riser feeds through the entry fitting and is secured with a reducer
and band clamps.

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A Franklin Fueling Systems Brand

408001028 r6