Dramatically improve wastewater treatment lagoon efficiency with the Director I Floating Baffle System.
Flow diversion curtains increase hydraulic retention time (HTR) and can increase the effective treatment area of a lagoon from less than 20% to over 95%. Floating baffles create hydraulic flow patterns that guide wastewater through a serpentine route from the inlet to the outlet, improving aeration and allowing contaminants and solids to settle. The extended treatment time significantly reduces Biological Oxygen Demand (BOD) and Total Suspended Solids (TSS).
Floating baffle curtains separate reactor cells from settling cells to create a dual-power, multicellular (DPMC) aerated lagoon system, allowing aerators to operate more efficiently to dramatically reduce energy costs. The DPMC system consists of four cells separated by baffles. In the first reactor cell, intense aeration generates enough oxygen to convert the influent CBOD to carbon dioxide and biomass while maintaining solids in suspension. The following three settling cells provide sedimentation, solids stabilization, and sludge storage. The settling cells use less aeration to allow solids to settle while supporting a thin aerobic layer at the top of the solids deposit to inhibit algal growth. A properly designed dual-power, multicellular (DPMC) aerated lagoon system using floating baffle curtains uses 50% less power than a comparable Activated Sludge system.
Every Director I Floating Baffle is manufactured to fit your specific lagoon profile. Our exclusive fully encapsulated bottom anchor creates an undivided seal along the bottom of the lagoon to prevent short-circuiting and protect your liner.
Environetics, Inc. is not limited to fabricating from one material but uses a variety of materials including the X-R 5® or PVC. We will assist you in choosing the best fabric for your site and the length of service desired. The selection of a geomembrane fabric resistant to the chemical composition of the wastewater is of critical importance.
The Director I Floating Baffle System is a cost-effective upgrade for new and existing lagoons. Floating Baffles install quickly and easily and require little or no maintenance throughout their 20-year life cycle. Installation can be completed in less than a day without costly equipment or expensive labor.
Environetics uses Seaman Corporation 30 Mil XR-5 material which is designed specifically for
flow diversion baffle applications. XR-5 is the highest-strength and most chemically resistant
geomembrane on the market. Seaman Corporation claims 30 years of proven performance and they offer a 10-year weathering and chemical resistance warranty. Environetics supports the manufacturer’s performance claim. We have had XR-5 material in service in outdoor wastewater applications for 35 years without any material failures under normal operational conditions.
Environetics has manufactured many floating baffles that have been installed in cold climates.
See attached project reference list.
Environetics uses Seaman Corporation 30 Mil XR-5 material which is designed specifically for flow
diversion baffle applications. Seaman also makes an XR ULT material rated for -50° which is designed specifically for arctic applications (see attached specification). XR-5 is the highest-strength and most chemically resistant geomembrane on the market. Seaman Corporation claims 30 years of proven performance and they offer a 10-year weathering and chemical resistance warranty. Environetics supports the manufacturer’s performance claim. We have had XR-5 material in service in outdoor wastewater applications for 35 years without any material failures under normal operational conditions, including extremely cold climates.
Floating baffles are not affected by ice and it is common for baffles to remain in freezing conditionsthroughout the winter (see the attached photo).
The baffle flotation collar floats above the ice and the baffle material is not affected by freezing.
Floating baffles made from standard XR-5 8130 have been installed in nearby locations, such as nearby Lloydminster, AB, and Maskwacis, AB.
Baffles have also been installed in arctic locations as far north as North Pole, Alaska, without incurring any damage from winter freezing.
Seaman Corporation offers an Ultra Low Temperature version of XR-5 8130 rated to -50F for extremeapplications compared to the standard -30F rating.
Please see the attached 8130 XR-5 ULT material specification and let me know if I can provide further assistance.
The floatation collar of the floating baffle is exposed to wind on the surface of the water. The wind will cause the floatation collar to move down-wind along the surface of the water, but the baffle curtain will remain anchored to the bottom of the lagoon.
Environetics pioneered the design of lateral wind anchors to minimize the movement of the baffle collar on the surface of the water. Cables are installed on both sides of the under-collar cable at 100-foot intervals. The cables extend perpendicular to the baffle on both sides, then a concrete anchor is deployed at the end of each cable. The lateral wind anchors limit the distance the baffle can move down-wind along the surface of the water, but the anchors still allow the baffle to rise and fall with changes in the water level.
The load force on the berm anchor has many variables and each application is different. There
is the hydraulic force based on the peak flow rate against the baffle curtain area and the wind load
against the baffle collar along the surface of the water. The breaking strength of the cable is 6,400 lbs and they never break, so that is the maximum force. Soil conditions are site specific and they vary greatly, so berm anchor posts are typically designed based on the soil conditions present at the site.
The bottom of the floating baffle incorporates a hem at the bottom of the curtain that
contains a continuous hot dip galvanized ballast chain that extends from shore to shore.
Our floating baffles using hot dip galvanized chain have remained in continuous service in wastewater lagoon applications for 35 years without corrosion issues. We have never received a report of the bottom ballast chain failing due to corrosion.
Rectangular baffle windows are oriented with the longer dimension on the horizontal axis and
the shorter dimension on the vertical axis to maintain baffle curtain stability. The baffle window size is calculated for the peak flow rate. The flow through window area should equal a minimum of one (1) square foot per 30 GPM of peak flow.
It is common for lagoon bottom profiles to vary. Dimensional variances within a one-foot
range are typically addressed by manufacturing the baffle to the deepest depth. Dimensional variances exceeding a one-foot range are typically addressed by manufacturing the baffle to the exact survey profile of the lagoon bottom. Silting at the toe of the slope is also typical. The ballast chain in the hem at the bottom of the baffle curtain is sufficient to seal the baffle curtain to the existing toe of slope profile.
It is not recommended to install a floating baffle in an empty lagoon due to potential damage
caused by exposure to wind. It is much better to install a floating baffle in a full lagoon and it is typically easier because the baffle can be floated across the lagoon, reducing the effort required to move it into place.
Manufacturing lead time is typically 6 to 8 weeks from receipt of approved submittals and verified field dimensions.
Seaman Corporation claims 30 years of proven performance and they offer a 10-year
weathering and chemical resistance warranty for floating baffle applications. Environetics supports the manufacturer’s performance claim. We have used XR-5® material for floating baffles that have been in service in outdoor wastewater lagoon applications for 40 years without any material failures due to UV or weather exposure.
Steel posts set in concrete footings are used to anchor the ends of the floating baffle to the
shore of the lagoon. Local contractors supply and install the steel posts into the concrete footings in advance of the floating baffle installation. The concrete must set, or hydrate, prior to placing a load on the post. Air temperature, ground temperature and weather conditions all play major roles in the rate with which cement hydrates. After the concrete has hydrated properly and load can be place on the steel post, the floating baffle can be installed in the lagoon and attached to the anchor posts.
Directional surface aerators can cause displacement of the baffle curtain if they are placed too close to the baffle. We recommend separating directional surface aerators from the baffle curtain by no less than 1 foot per horsepower.
The baffles are custom made to fit the profile of the lagoon. The lagoon profile typically varies
from the plan drawings due to the dynamic hydraulic effects of the wastewater in the lagoon. The
project engineer is not responsible for variations from the plan drawings to the actual dimensions of the existing lagoon. The field verified dimensions are required to ensure that the baffle fits the existing lagoon profile so it can perform the intended task of diverting flow.
The task of altering the baffle in the field can vary from challenging to impossible. Baffles can be
shortened in length in the field. Adding length to a baffle or altering the depth is typically done in the factory which requires shipping the baffle back to Environetics. Alterations in the field and shipping are costly and cause delays. Verified dimensions will be required prior to altering the baffle anyway, so this problem will be avoided by taking field dimensions prior to production.
Flow through windows should be located near the top of the baffle curtain to allow clarified
liquid to pass through the window and solids to settle beneath the window. Windows are typically
located in the top 1/2 of the baffle curtain and at least 12 inches below the water level to capture scum at the surface.
Rectangular flow through windows in a horizontal orientation improve settling of solids and maintain the integrity of the baffle curtain. Flow through windows should not be located near the bottom of the baffle curtain because sludge and silt buildup will reduce the open area and will eventually collapse the baffle window.
The baffle window size is calculated for the peak flow rate. The flow through window area should equal a minimum of one (1) square foot per 30 GPM of peak flow.
Length measurement: Measure the distance from shore to shore at the high-water level.
1. Depth measurements are to be taken at the high-water level.
2. The depth measurement can be taken from a boat.
3. The operator follows the line where the baffle will be installed and uses a rod to gauge the
depth of the lagoon at ten-foot intervals.
4. The length and depth measurements are sent to Environetics and they are used to create a
profile for the baffle that will fit the lagoon profile.
Environetics manufactures the baffles but we seldom provide installation services. Local installation contractors are significantly less expensive due to the high cost of remote mobilization. If installation certification is required by the contract, then a certified Installation Technician can review the installation, but this service is usually unnecessary because the installation procedure is simple. Environetics can certify a floating baffle installation by reviewing photos of the baffle.
1201 COMMERCE STREET
LOCKPORT, IL 60441