Projects

Kaldnes K1 conversion


Many koi-keepers are changing one of their chambers to use Kaldnes as the media, and this is the details of how this was done.

The chamber to be converted to Kaldnes K1, and one of four in total, is kind of “octagonal" in shape, made of GRP, and is about 105cm “square” and about 93 cm in depth.

It has been in operation for many years on a 5600 (UK) gallon pond.

Chamber before conversion

As you can see, the chamber to be converted was filled with a Japanese Matting cartridge supported on a perforated PVC sheet and heavily aerated from underneath.

The overflow skimmer can be seen on the right of the picture.
The old transfer port

The chamber had 2 “letter box” style outlet transfer ports.

These two upper, outlet “letter box” transfer ports were converted to 2 “centralised” 4” strainer outlets, and the following article details how this was achieved.

Important note: If these conversions had not been done this way, and alternatively say, mesh grids were fixed across the existing transfer ports, the K1 would be pulled against the transfer port mesh and would not be properly fluidised. This is a crucial design detail.
Conversion plate

2 X 316 stainless steel conversion plates to fit over the existing transfer ports were custom fabricated by a specialist for me.

These were fixed in place using stainless steel bolts and sealed with silicone sealant.

4

Special 4” tank connectors (from East Riding Koi) were used to facilitate the connection of 4” pipe to the conversion plates.

All pipe work connections were glued.

Conversion plate in place

The 2 conversion plates and the 4” tank connectors were fixed in place.

4” pipe could now be glued into these, to which would be fixed the 2 stainless steel mesh (5mm) strainers.

The stainless steel filter

This is of one of the 2, 300 mm long, stainless steel strainers (5mm) prior to it being fixed to the 4” transfer pipe work with a couple of stainless steel self tapping screws.

Note that one end is open and the other closed.

These strainers prevent the K1 being transferred to the next chamber.They had been fabricated so that they would be a tight push fit onto the 4” pipe that would be used.
Ready for the Kaldnes

Here is the final conversion. You can see the modified transfer pipe work (black) and the 2 stainless steel strainers which feed the next chamber.

Note. Depending upon the situation, a small air-bleed hole/ tube may be needed at the top of each of the 90 degree elbows in order to prevent air locks.

The perforated sheet was been left in place as this will prevent any K1 being lost when the chamber's bottom drain is opened (a strainer could have been fitted over the drain as an alternative).

The air ring made of 12mm dia. compressed air pipe can be seen sitting on top of the perforated sheet. (It could have been made of clear plastic hose). It‘s diameter (500 mm) was half of the width of the chamber (this ratio is important) and had 1.5 mm dia. holes drilled at 1” centres all the way around.
The air ring is secured in place with some electrical ties (otherwise it would float). The perforated sheet was well secured too for the same reason.The air ring is fed with air at a flow rate of 40 litres per minute from an Airtech pump.
12mm pressure fittings

The 12 mm compressed air “Speedfit” fittings used for the air ring are made by John Guest, and can be obtained from a specialist supplier. They have the advantage that they are push–fit and can be easily disconnected too.
The 12mm airline is made of Nylon and is quite stiff, but sufficiently flexible, and can be easily cut with a utility knife.

Also pictured on the left of the above photo is a small needle valve (from a different supplier) and can be used for regulation of the air supply to the air ring.
The completed filter

Here is the finished conversion, and the chamber filled with 200 litres (4 X 50 litre bags) of “semi-mature” Kaldnes K1.
The K1 here was helped to “mature” by placing it in mesh filter media bags (available from many Koi dealers) and floated in the other chambers of the filter. This would help give it a bit of a kick start, and was done 6 weeks prior to the conversion.
The 200 litres of K1 is adequately “fluidised” here with 40 litres/ min of air.

Note: New K1, straight out of the bag, will float for several days, before becoming semi-buoyant and fluidising / rolling correctly.

The overflow pipe work (seen temporarily capped off on the left) was subsequently removed and sealed off, as it was not required. If it had been left in place a strainer would have had to have been fitted to prevent loss of K1

So, how much K1 do you use for a given size chamber?
The ratio of the volume of K1 in relation to the chamber volume is quite important. You need to calculate the volume of your chamber in litres. To calculate the volume of your chamber in square inches multiply the length by the breadth by the depth (L x B x D). Then multiply by 0.0164 to give the number of litres. Centimeters are easier, simply divide total volume by 1000 to give litres.
It is possible to use no less than 30% to a maximum of 67% of this volume with K1. An average of 50% is recommended.

Examples:
1. Tank 24" x 24" x 24" = 13,824 square inches.
Multiply by 0.0164 to give 227 litres volume of the chamber. Then multiply this by 50% to give 113.5 litres of media (recommended).

2. For a 24" vortex with a straight side 24" depth to the cone of this would be 12 (half its diameter) x 12 x 3.14 (pi) x 24 (height) = 10,581 square inches. 10,581sq" x 0.0164 = 178 litres. = 89 litres of media at 50%

 

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This website started with a booklet which I made up originally for the help of those members of the BKKS - South Wales Section who were intending to start building a koi pond, and as the website has expanded more information and articles from other people have been included. This is for general guidance only, and we do not take any responsibility for problems that might occur by following these ideas. It is important that you check out everything in your area, and check on local laws and rules that may apply.
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