A Modular Precast Approach to Sumps
Sumps are used in Industrial settings for a variety of applications ranging from critical chemical containment to drainage and collection. In Industrial settings, sumps are often required coatings to resist the impact of harsh chemicals.
A modular approach to sumps, such as precast, has many advantages. Contractors and owners appreciate the efficiency and risk aversion that precast can offer. Pieces arrive “just-in-time” and greatly reduce onsite construction manhours.
Precast Sumps can be produced as one monolithic piece and can be cast in pieces utilizing emulative engineering design techniques. Casting in pieces can be a great alternative on construction sites that have lifting limitations. The modular pieces are easily pieced and grouted together in the field.
Sumps are lined with coatings to resist the impacts of being exposed to various hard chemicals. Field lining requires very specific craft skills sets that can sometimes be hard to find on remote job sites. This work too is often susceptible to weather delays as coatings cannot be applied in damp weather conditions. It is for these reasons that utilizing precast that is shop lined is a tremendous advantage to owners and contractors.
THE PRECAST ADVANTAGE!
Labor
Casting sumps “in place” requires significant man hours, the readiness of raw materials and puts the project in schedule risk.
Forming and pouring concrete on site can take up to five times longer than utilizing precast elements. Utilizing precast reduces man hours and decreases the need for onsite craftsmen and more importantly reduces the owner and contractor’s exposure to safety incidents. The growing demand for craft labor coupled with the dwindling supply is also a reason for the recent increased utilization of modular elements such as sumps.
Raw Materials
Sump construction is often located in remote locations or within the security fence of an industrial facility. Transporting raw materials to site can be difficult and often results in schedule slippage due to logistical challenges.
Schedule Risk
Casting sumps in place often requires multiple contractors to excavate, form, pour and finish concrete. This can be a schedule challenge coordinating each pour. Because the sump area remains open throughout the process, projects are greatly susceptible to weather related delays as the open trenches require dewatering after rain events. Precast elements can be delivered “Just in Time” and installed immediately to greatly reduce these risks.
#THEWASKEYWAY of installing trenches – a case study
For this project in SE Nebraska, our client faced a strict onsite lift capacity limit of 30,000 lbs. To overcome this constraint, Waskey designed and engineered the sump as a modular, multi-piece system, allowing each section to be safely handled, positioned, and installed with the available equipment. This approach ensured a smooth, predictable installation with no compromise to structural performance.
Waskey often partners with its sister company, Satco, to coat custom sumps and other products for a wide range of industrial applications. This particular sump was shipped 880 miles north to a power plant in southeast Nebraska. It’s coated to withstand exposure to Sodium Hydroxide, Sulfuric Acid, Sodium Bisulfite, and Sodium Hypochlorite.
Having coating expertise in-house saves clients countless field man-hours, reduces weather-related schedule risks, and eliminates the challenges of sourcing skilled craftsmen for remote job sites. Satco, a wholly owned subsidiary of Waskey, has delivered Specialty Industrial Services for over 40 years. Their expertise spans refractory lining repair, concrete restoration and protection, coatings, crack injection, fireproofing, and cathodic protection. Satco’s reputation is built on consistently providing creative, efficient, and cost-effective solutions to the toughest industrial challenges.
The combined modular design and shop-applied coating created significant project value. The client realized major savings in field man-hours, crane time, and onsite prep work. The modular configuration also greatly reduced weather-related risks, allowing the installation to proceed quickly, safely, and with minimal disruption to the surrounding operations.
From engineering through installation, this project highlights the advantages of offsite precast fabrication, modular construction, and coating application—all delivered efficiently and reliably. Another great example of innovative precast solutions done!
Conclusion
Given today’s high demand for craft labor, modular precast solutions such as sumps offer an efficient alternative to cast-in-place construction. Precast greatly mitigates safety and schedule risk for contractors and owners. It is for these reasons that contractors and EPCs continue to demand more modular solutions on projects.
