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First Flovac Project in Denmark, Hages Badehotel (Beach Hotel)

Flovac’s first project in Denmark is linked wih Denmark’s largest infrastructure project and the world’s longest immersed tunnel. The Fehmarnbelt. The land used for the Hotel and housing project has come from the earth excavated from the tunnel project.

The project is located on the island of Lolland and the tunnel will connect Lolland with the German island of Fehmarn. It was vitally important for the developer Lidsøparken A/S and the architect Miami Ark to create a project that would fit in with the natural beauty of the area, looking after the birdlife and unique plant life. It was decided at an early stage that a vacuum sewerage system would be the only collection system suitable to meet all environmental criteria with low energy use and low impact.

STEEL ApS, who had some previous experience with vacuum systems decided in 2021 to enter a long-term relationship with Flovac, to use Flovac’s vacuum valves and equipment throughout Denmark.

The project’s first stage is a vacuum station and several collection pits servicing a restaurant and 72 houses with 124 apartments. The area is covered with reeds, small lakes with a clay soil and a high ground water table. The second and third stages will include a further 134 holiday houses and a luxury glamping area.

The Hages Badehotel and housing is built on stilts with the idea that this would create the least amount of impact on the land. And that in 100 years the development could be closed and there would be no sign of any impact on the area. This is another reason why a Flovac system was chosen.

EPA demands that vacuum technology to be used at Eco Resort

The Couran Cove Eco Resort in Queensland Australia is an award winning environmental success story for Flovac and for our client.

Designing to best environmental practices which included refunds to staying guests if they used less than average electricity and water during their stay.  A vacuum collection system was a natural choice, chosen for its ease of installation and environmental credentials.

2,000 visitors plus staff with a swimming pool, function center, laundry facility, restaurant and marina.

The system at a glance

  • 1 Vacuum Pump Station
  • 2,000 Guests plus Staff
  • Villa’s, apartments and cabins along with a conference facility, restaurants, sporting areas, offices and marina pump out facility
  • 215 Collection Pits
  • Fibre Optic Monitoring System

System Benefits

The developer showed a strong preference for a vacuum sewerage system as he saw it offering significant benefits in this development over each of the alternatives. These benefits were identified as:-

  • Ability to handle low flush toilets thus reducing the ultimate treated water disposal problem
  • Minimal impact on the landscape during construction with shallow trenches
  • Maximum water recovery for reuse in the re-vegetation irrigation system
  • Construction route flexibility thus minimizing the damage to vegetation
  • Ability to transport grey and black water in the one small bore pipe
  • Ability to safely lay all services in the one trench with minimal spacing
  • Zero infiltration and exfiltration
  • Ability of the system to service the entire site with one centralized pump station
  • Ability of the scheme to service the Boardwalk accommodation and even the boat sullage

Couran Cove Web Page

If you would like more information about this project or would like a free concept and budget for your next project please contact Flovac Engineering by clicking here

Vacuum Valve and Collection Sumps were located under the walkways in stainless steel vessels.

 

 

Award winning project for Flovac as a Commerce by Design award in the annual Gold Coast Urban Design Awards

 

Able to handle seasonal flows from different areas within the resort. The remote beach restaurant is 3 km from the main resort

 

Flovac Protecting the Environment in Barcelona

Flovac was in charge of the design and installation of a Flovac vacuum sewerage system at the MB92 Port of Barcelona expansion project to collect wastewater and ensure that no environmental damage could occur in the area.

MB92 expands its installations at Barcelona’s port

Marina Barcelona 92 (MB92), a company dedicated to the maintenance and repair of superyachts, was in charge of carrying out the ambitious project to expand the port coastline of Barcelona, in the Port Vell area. The project, started in 2015 and completed in 2019, consisted of the construction of a large surface area in which a new boat lifting system (known as shiplift) would be located, with the aim of grounding yachts of up to 4,000 tons for repair and maintenance. Currently, it is the largest shiplift in the world dedicated exclusively to yachts.

The Project

The project, which involved a total investment of 50 million euros, was completed in August 2019 after 4 years of work. Thanks to the shiplift, customers have more ability than ever to work out of the water, which offers more flexibility, capacity and opportunities when it comes to maintaining and repairing yachts. Since its launch, the shiplift has already carried 22 superyachts with an average of over 75m LOA. It is a feat of world-class civil engineering in the heart of the port of Barcelona.

Raising Capacity

  • Capacity to lift vessels up to 115m LOA.
  • 30,000m2 hard standing area to host up to 9 vessels of up to 115m LOA on dry land
  • Hard standing area includes integrated keel pit with dimensions of 8m depth, 5m width and 14.5m length.
  • Bidirectional rail system to facilitate flexible and more efficient maneuverability of vessels once hauled out.
  • Supply of all essential services such as fresh water and shore power connections.

Flovac Looking after the Environment

Flovac was commissioned to install a vacuum sewerage system in this project in order to collect the wastewater generated by MB92’s activity. The goal of Flovac and the products it offers is to reduce the human footprint. Therefore, one of the main priorities was to guarantee the environmental protection of the area. The installation is made up of 2 independent vacuum networks; one for the wastewater from buildings and yachts, and the other one for industrial wastewater produced from yacht repair. The industrial wastewater is transported to a new treatment plant, at MB92’s own facilities. The facility has 4 tanks with 2 vacuum valves each. Flovac has finished the commissioning this July.

To find out more about Flovac’s port and marina projects you can click here

Flovac’s First Project in Botswana

A Flovac vacuum sewerage system has been installed at the site of one of Africa’s most important infrastructure projects, funded by the African Development Fund.

Kazungula Bridge Connecting Countries

The Kazungula Bridge project which is connecting Zambia and Botswana over the Zambezi River will be a 40{1deaea03afbf3f3fb2d45caffee157f5a0ec73dd837732cad8f5061c47eb75db} boost to the GDP of the countries involved as it opens up the regions for trade all the way to the port at Durban.

The Kazungula Bridge is located at the only area in the world where 4 countries meet together. Zambia, Botswana, Namibia and Zimbabwe. One of the Seven Natural Wonders of the World, the Victoria Falls is located a short 1 hour drive from the project.

As the new Bridge opens up trade and tourism between the four countries it was necessary to set up a new border customs and immigration complex. Zhong Gan, an experienced International engineering and construction company based in Botswana, has done numerous projects for the World Bank and Botswana Government and decided to use a Flovac vacuum sewerage system on this project which services this complex.

Justin Peng the project director of Zhong Gan chose a vacuum sewer as a value engineering proposal to the client as there was a high water table which prevented deep excavations required by the original gravity system proposed. Ensuring that no sewage could overflow to the Zambezi River was also important as the area is home to elephants and others in Africas Big 5.

Installing a Flovac Collection Pit and Valve

Smart Vacuum Sewer System

The Flovac system is the first smart sewer system installed in Botswana which allows the operator to have a complete system overview. The smart system allows the operator to look at the performance of each vacuum valve in the system and independently alert operators to any potential problems.

Mr Peng chose Flovac due to the operator friendly nature of the design and equipment and the overwhelming positive feedback from prior installations that his team visited. The Water Utilities Corporation approved the system who were extremely pleased by the advancement in technology and ease of maintenance compared to other systems that had been installed in Botswana and Southern Africa.

The Flovac Team worked very closely with our local representatives Multi Waste Pty Limited headed by Andrew Davies. Multi Waste are a large domestic company , experts in water, wastewater and energy in Botswana and Southern Africa. Multi waste set up a fabrication plant for the Flovac pits and handled all assembly of the system at their head office in Gaborone prior to delivery to site.

The Multi Waste team will operate and maintain the system for the time being with support from the Flovac International Operations Group via the monitoring system.

 

The Flovac and Multi Waste Design and Install team

 

 

 

 

First Flovac Project in Vietnam – The Ana Marina in Nha Trang

The Riviera of the South China Sea

Vietnam’s first marina is nearing completion, and will include Flovac’s first vacuum system in the country. Upon completion it will contain berths for over two hundred yachts and Super-yachts. Ana Marina in Nha Trang on the south east coast of Vietnam will be the country’s first world class marina, initially offering 60 berths for vessels of 20-40m and extra wide berths for catamarans

Future phases will include a super yacht dock for six yachts up to 70m in length and an additional 100m berth is under consideration. The remaining berths, to bring the overall total to 220, will accommodate yachts of 10 to 20m and will be operational by 2021.

General Manager of the project, Ruurd Van Putten, gave us his insight. “It’s a unique project in Vietnam that will ignite a whole new industry. Yachting is generally known for its high standard, quality and innovation. Marinas have proven to be a catalyst for economic growth, development of tourism and overall improvement of leisure services and facilities.

With environmental concerns a high priority in coastal developments, Ana Marina is heavily focused on the key concepts of Sustainability, Durability and Responsibility. “A marina means less pollution, cleaner water, and protection to vulnerable marine life. It will have special systems to prevent spillage of oil, fuel and waste of boats.

This will result in better water quality allowing plants, coral and fish to grow un-threatened, and also a safe and clean area to swim and play. We are dedicated to raising awareness that the sea is the beating heart and lifeline of Nha Trang, and must be preserved and protected at all costs”, Ruurd concluded.

A Flovac Vacuum Marina system was chosen as it has been demonstrated that it can provide certainty around the environmental benefits that the client has determined to be of absolute importance. Flovac marina systems have been installed in a number of high profile areas including in Barcelona, Greece, Italy and the Caribbean.

The Flovac systems look after boats of all sizes and can include the handling of bilge water and oil separation.  The larger Superyachts pump their wastewater or bilgewater into a Flovac collection chamber which can be sized and designed to fit into the marina area.

For smaller boats a pillar that often houses water and power will have a connection point for a hose that will suck the wastewater from the boats. This is often done by the marina operator or can also be via a key card or code-pad operation by the boat owner. Flovac has initially supplied 9 pillars to the project and all are connected to a single vacuum pump station. All of the pillars will be located on floating pontoons.

The main benefits of the Flovac vacuum sewerage system is that it will not leak into the water and is very easy to install. All points of the system are fully monitored from the central command center as so easily managed. To see more details of our marina systems please go to this page.

How to Sewer The Water Villages of Kampong Ayer

Kampong Ayer in Brunei’s capital city of Bandar Seri Begawan is a cluster of around 40 small villages connected by a 38-kilometer (23-mile) boardwalk. It dates back more than 600 years. Today, around 13,000 people live in the water village, about 3{f2ac4d1e1d40dc2e2d9280a1dfa90d854b2d8c80eba743affa37fc4ce2e16def} of the country’s population.

These Water Villages are very common throughout South East Asia down as far as PNG which has a large water village just outside of Port Moresby at Hanuabada.

Many of these villages have enormous cultural and historic value to the countries and communities that live in them. They are also major drawcards for tourists with the Kampong Ayer townships in Brunei known as the “venice of the east”

Although some of the houses are now on vacuum sewer networks, many have still not been connected. Historically having raw sewerage drop into the water below only really affected the health of the local population as many of the water people swam or fished in the same water. With the wealth of those living in the villages increasing, more problems have surfaced with detergents entering the waterways, killing off the fish and other local seafood. None of this is good for tourism, especially the odour.

The government has big plans to increase many of the houses serviced but are also finding the structural integrity of many of the houses to be a problem. Imagine laying a length of pipework between houses to pick up the sewage when the house in the middle collapses due to age.

How these houses get serviced is a very complex problem. At one of the water villages in Labuan Malaysia a gravity system was installed but proved to be a failure within a short amount of time.

The pipework sloping to a gravity main below the houses close to the surface of the water was cut many times by local residents as it was impeding the way that many residents got around the area in their boats. For hundreds of years the residents drove their small boats under their houses and around the village. All of a sudden plastic pipes were in the way. A simple solution – cut them.

In 1995 our firm was hired by the Brunei and Australian governments to design and then supply a vacuum sewerage system for two main sections of Kampong Ayer at Bolkiah A and B. The sewerage was collected into sumps pinioned below the walkways to the houses and on average 4 houses was connected to each sump. Vacuum valves were housed in small stainless steel valve boxes attached to the side of the walkways to allow for easy operator access. All of the vacuum mains were laid under the walkways back to land where the vacuum pump station and treatment plant were located.

As the pipework was laid directly under the walkways it was not visible and did not impact on the passage of the residents. The number one lesson for residents was to learn not to use their toilet as a rubbish bin. Initially blockages were common and operators grew frustrated by the number of items thrown into the system. The problem residents were easily found as with only 4 houses connected to a sump, the process of elimination was easy and the residents were educated as to proper use. Modern valve monitoring systems will make this even easier.

Our engineers received an award from the Institute of Engineers Australia for this project. Our operations group still goes to site whenever requested the the government to ensure that the system continues to work well.

The lessons which both our engineers and operators learnt from these projects has enabled us to offer clients great insights in to how best design systems for water villages, resorts and marina’s. If you would like to learn more about other Flovac projects you can read about them here.  FLOVAC PROJECTS

Growing Pains or Growing Old Pains – What best describes your old gravity sewer?

What happens when your sewerage network gets too old? Your old clay pipes have cracked or are filled with roots, every time it rains it seems like its a direct line from the clouds to the Treatment Plant. People in the community start asking why you are spending a load of money on treating rainwater instead of just sewerage.

If you are part of a coastal community it could be worse, your old broken  pipes could be letting seawater into the system every time there is a high tide or major storm. Salt water can cause major problems at the Treatment Plant. For communities like Miami Beach who get storm surges flooding their sewers and closing their beach on an increasingly regular basis it can cause major economic and health risks. Santa Pola in the Alicante area of Spain found that the impact of global warming and rising sea levels caused a complete failure of their old sewer system.

The town of Santa Pola with over 10,000 homes replaced their whole gravity sewer system with a Flovac vacuum sewerage system. As vacuum mains are laid in shallow trenches it was possible to skirt around, above and below exiting infrastructure and eventually replace the network. You can read more about that project here.

It could be that the old gravity sewer system with large heavy pipes just wasn’t suited to the ground conditions that are often found near the coast or in swampy area’s and that over time they no longer have the correct grade to remove the sewage or have pipes that continually break allowing ground water into the system as well as blockages. This occurred at Hope Island on Queensland’s famous Gold Coast.  Gold Coast Council have developed a Master Plan and slowly replaced a number of area’s with vacuum sewers. When the original gravity sewer was laid, there was no choice, developers were racing to put up houses and council at that stage had no experience with vacuum sewers and so deep gravity mains were installed. Almost immediately problems were noticed as the ground subsided in different area’s. Sewage backed up in pipes and was unable to flow as the grades first allowed for in the networks were no longer the same.

When looking at upgrading a gravity sewer, pipe relining can be an option, but in many cases this becomes an ongoing expensive option and be too difficult in a large network. Some utilities just look to replace the old pipework, but in most communities this is just not practical. This could mean uprooted gardens, roads out of use for a number of months, noise, dust and a huge cost.

For many communities it is the size of the town that has changed dramatically over the years. In most cases this has meant an increase in the population as people move from the city to the coast. Developers move into the fringes of the town. Planning regulations change allowing for sub dividing of the old large land blocks or height and density changes. This puts pressure on existing sewers that are already not coping due to age and lack of maintenance. This has happened, not only in small coastal towns but in larger developed cities like Abu Dhabi and New Delhi. Vacuum sewers can be used to supplement the towns aging sewer system, loads can be taken off the main system by a series of collection pits and shallow pipework.

Flovac vacuum sewers have shown time and again, their versatility. This means either their ability to handle density changes or climate changes. It might even mean changes in ground conditions as happened in Christchurch New Zealand when they suffered from a terrible earthquake. The old gravity sewers in the city and surrounding suburbs broke and left residents with no service for months. Vacuum sewers have now replaced a large portion of the gravity sewers in Christchurch and although difficult has proved to be a better long term  solution for the residents and operators. Christchurch systems

Vacuum sewers should not be looked at as the only solution in many of these towns. In some cases a combination of grinder pumps, gravity and vacuum is going to be the better result for the community. Whether the problem is growing pains, or growing old pains a vacuum solution might offer the versatility that you need.

Glossy Bay Resort and Marina Project opens in the Caribbean

Flovac’s latest project in the Caribbean has opened in Canouan at Glossy Bay Resort and Marina with Flovac providing a plug and play containerized vacuum system and treatment plant.

The system at the Glossy Bay Marina and Resort will support a luxury marina which will accommodate mega yachts in excess of 100 meters in length. There will also be hotels villa’s, restaurants and other facilities. The island of Canouan is a two hour ferry ride to the main island of St Vincent of the St Vincent and the Grenadines group of islands in the Southern part of the Caribbean.

As the project was quite remote Flovac supplied a containerized plug and play vacuum pump station and treatment plant. All water on the island is supplied by a desalination plant, so water is precious and spared as much as possible. Treatment quality is very important so that this pristine area is not polluted in any way.

The containerized system has been used in deployable situations on a number of projects and is a great way to transport and set up a project. You can read more about Flovac’s deployable solutions HERE

Flovac vacuum sewerage and marine systems have become very well respected among the boating community. Flovac has completed many world class marina facilities around the world, including Italy, Australia, Greece and Spain. It was the completion of the latest super yacht facility at Marina Vela in Barcelona that caught the attention of the owners in Canouan.

You can read more about Flovac’s experience with Marina’s and why a Flovac solution is often chosen in this interview with Flovac’s expert Mr Francisco Rodríguez

There are many positive reasons for using a vacuum system in this type of project. Fast, easy and cheap installation are some of the key attributes, but importantly for this client was the reduced risk of any overflows of sewage into the water area’s. This is a first class resort and the beach and marina areas need to be pristine. The system can also easily be monitored and maintained by the resorts utility personnel as no specialist equipment is required to handle the vacuum system.

 

 

Interview with Marina Expert for Flovac, Francisco Rodríguez

Francisco Rodríguez

At the end of 2017, aguasresiduales.info, Spain’s leading journal on wastewater and sanitation interviewed Flovac Spain’s Technical Director to understand the massive growth in the vacuum sewerage industry in Spain and elsewhere, particularly for Marina and Port infrastructure.

This is a translation from the original article which can be found here.

We speak with Francisco Rodríguez, Technical Manager of FLOVAC Spain, about vacuum sanitation in Ports and Marinas

The company FLOVAC Vacuum Sewerage Systems, is the world’s largest designer, manufacturer and supplier of complete vacuum sewerage systems Among its solutions, one of the fastest growing solutions is the complete sanitation of marinas and commercial ports, where a vacuum sewerage network allows the operator to manage the port’s own sanitation network and at the same time service the collection of wastewater from the boats.

Francisco, in general terms, how does a vacuum sanitation system installed in ports and marinas work?  

A Flovac valve connected to the vacuum network is installed at each connection point. When it detects that there is about 20 cm of water in the sump, the valve opens, sucks in the water, sucks in air and closes again in a matter of 2 or 3 seconds. All this without electricity, only with the force of the vacuum.

The only point that needs electricity is the vacuum station. The vacuum pumps located in the station maintain a constant vacuum level in the vacuum network that covers the entire port or marina. A tank collects the wastewater before being driven or pumped to the municipal collector or sewage treatment plant.

What advantages does this vacuum sanitation offer compared to traditional sanitation in this type of site? In marinas and ports, the water table is very high and has often been filled with breakwater, so deep ditches are extremely expensive and technically complicated. Thanks to the force of the vacuum, the pipes can be installed at a shallow depth and serve the entire port or marina with a single vacuum station. The wells where buildings and megayachts are poured can also be shallow, since the valve only needs 20 cm of water to act.

The vacuum station itself can be buried (for space or aesthetics) or it can be on the surface, without the need for excavation. Another advantage would be the absence of odors, since when emptying the well each time there is 20 cm of water (about 50 liters), the residence time is minimal and avoids the appearance of the smell characteristic of pumping. In addition, the valve remains open a couple of seconds after emptying the well, so it renews its air. The network of pipes is watertight, since any leakage is detected in the vacuum station and an alarm occurs. In addition, in case of leakage, air will be sucked through the fissure and no residual water will be spilled. Therefore, it is the only system that ensures correct environmental protection of the port or marina.

As for the installation costs of this technology and maintenance costs, replacement of equipment, etc., what can you tell us? The reduction of excavation in such difficult conditions as a port, means a reduction of important costs, and the reason why sewage collection by vacuum is the most economical solution. The maintenance costs of a system with a single vacuum station, compared to an alternative that would require multiple pumping, are also clearly lower. The valve is specifically designed to work with wastewater. They are manufactured in glass filled polypropylene, with a stainless steel shaft. The result is that the first valves installed in Spain, specifically in Empuriabrava, 15 years ago, continue to operate with a minimum consumption of spare parts

Currently FLOVAC is the benchmark in the installation of vacuum sewerage systems, both in residential areas and in ports and marinas, what are your main references and projects at this time in Spain? The first installations in ports that we carried out in Spain, more than 10 years ago, were sewerage projects for the existing buildings in the marinas or ports. Later, we added sewage suction points for small boats that had to move to that point. In the most recent marinas, a single vacuum station serves buildings, suction points for yachts located at the gas station, megayachts on their own mooring and even a network of bilge water suction points that are treated before they are sent to the public sewage system.

The result is that among our projects in Spain there are all kinds of facilities: large commercial ports, such as the Port of Barcelona or small ones such as Arenys de Mar, marinas for yachts or mega yachts such as the Royal Marina Juan Carlos I (Valencia), Port Vell and Marina Vela (Barcelona) or industrial facilities such as Marina Barcelona 92 ​​for megayacht repair.

To empty wastewater from small boats, suction points are available, usually next to the gas station. Likewise, Flovac valves open and allow the emptying of yacht deposits. The megayachts, on the other hand, have their own sewage pumps, which drive the water to small wells located on the same dock where Flovac valves evacuate the water to the vacuum station. Finally, to evacuate the bilge water from the gas stations, a second vacuum network is required, so that these waters end up in a different reservoir that allows their treatment before being sent to the public sewage system. But the equipment at the vacuum station is the same for both networks.

Finally, Francisco, are marina and port projects being installed in other countries?

Flovac is leading the world in providing sewerage solutions at Marina’s and many countries are now following Spain’s lead which we feel is a world leader in using best environmental practices. Greece has always been another leading country for marinas and we have done a number of projects as far away as Australia and more recently in the Caribbean, Italy is also a very good market for us.

For more information please visit www.flovac.es or www.flovac.com

Prestons Residential Development Vacuum Sewer

The Flovac Vacuum Pump Station was installed in 2015 to service the Prestons residential development in Marshlands Christchurch and has continued to grow with house sales in the area ahead of schedule.

Every effort has been made by the developer Ngai Tahu to ensure that this medium priced housing development for 8,000 residents is world class.

Environmentally Sensitive Development at Prestons

 

Right next to the vacuum pump station, the Marshland School for children aged 5-13 has been completed. When Master Planning a vacuum sewer system it is always important to consider that any flows from schools will be interrupted during school holidays and weekends. So to ensure that plenty of air is entering

Marshlands School

the system, especially close to the station the system needs to be tuned correctly or have an automatic air inlet system that can be programmed to take the change into account.

 

The vacuum sewerage system is the ideal technology for a development like this as it can be very flexible with new additions over time and is resilient to damage from earthquakes. Unlike low pressure pump systems, the only power requirement is at the vacuum pump station, so if an earthquake interrupts power supply the vacuum sewerage network at Prestons will continue to work as there is a back up generator located at the station.

Another resilient feature of the Flovac system is that if any of the vacuum mains break or rupture during an earthquake, the negative pressure in the pipe ensures that no sewage will leak out. A low pressure pump system operates on positive pressure, so if a pipeline breaks sewage will surcharge from the pipe into the surrounding area. In an environmentally sensitive area like Prestons, that could be a disaster.

Another benefit of the vacuum sewer system is its ability to handle high flows into the collection system. A large supermarket complex is being planned in the neighborhood complete with a Foodstuffs supermarket, cafe’s and restaurants. Already built is a large BP service station which houses a cafe and a Jetwash. The Flovac system handles the commercial premises and can handle any flows from the car washing facility.

On the right side of the BP Jetwash you can see three of the Flovac pillars that house the air vents that are required to admit air into the vacuum sewer. These are connected to three separate valve pits which are served via a splitter to handle the high flows. The pillars will also house the wireless monitoring system that is being rolled out. The monitoring system will alert operators to any valve faults or potential overflows from the pit.

The operators looking after the system have been very happy with the operational benefits and have had very few callouts. As the operators have little to no contact with sewage and have no requirements to enter the property of the residents they see real benefits relative to how the low pressure pumps have performed. Many low pressure pumps are located on the property of the resident and any maintenance often leaves residual sewage on the lawns of the residents.