Extra Large 40" Elite Cascade Falls Box
$620.99
PROUDLY MADE IN THE USA!
• Maximum Flow: 10,000 GPH
• Waterfall Width: 40" Spillway
• Dimensions: 19.5" x 51" x 14.25"
• Inlet Connections: Two 3" Spinwelds
• Pump & Reservoir: Sold Separately
• Lifetime Warranty on Cascade Box
• Maximum Flow: 10,000 GPH
• Waterfall Width: 40" Spillway
• Dimensions: 19.5" x 51" x 14.25"
• Inlet Connections: Two 3" Spinwelds
• Pump & Reservoir: Sold Separately
• Lifetime Warranty on Cascade Box
Blue Thumb Elite Cascade Series
Extra Large 40" Elite Cascade Falls Box
Create a wide, natural-looking waterfall with our Extra Large 40" Elite Cascade Falls Box. Designed for pond-less waterfall systems, this heavy-duty engineered plastic waterfall box distributes incoming water across a 40-inch spillway to create a broad cascade over your chosen rockwork. Its internal Matala diffuser helps create an even flow, while the integrated landscape lid makes it easier to conceal the box within the surrounding landscape.
40" Waterfall Spillway
10,000 GPH Maximum Pump Flow
Two 3" Spinweld Inlets
Lifetime Plastic Component Warranty
Built for Wide Pond-Less Waterfalls
Our Elite Cascade Falls Boxes are designed to serve as the starting point of a recirculating pond-less waterfall. Water enters through the plumbing connections, passes through the black Matala diffuser, and flows over the detachable weir into the streambed below.
The 40-inch model is ideal when you want a wider waterfall opening and greater flow capacity than our smaller Elite Cascade models. Two factory-installed 3-inch spinweld connections provide flexibility when planning the incoming plumbing. The box can also be positioned alongside additional Cascade Falls Boxes for custom waterfall configurations.
Important: This listing is for the 40-inch Elite Cascade Falls Box and its included installation components. It is not a complete pond-less waterfall kit. A functioning waterfall also requires a properly sized pump, water reservoir, liner, plumbing run, and other installation materials.
What's Included & What You'll Need
Included With the Cascade Box
- Extra Large 40" Elite Cascade Falls Box
- Attached landscape lid for concealment
- Black Matala diffuser mat
- Two factory-installed 3" spinweld fittings
- Detachable waterfall weir
- Self-tapping stainless steel screws
- Black silicone for the weir and liner connection
- Box plumbing connection fittings and installation hardware
- Installation instructions
Replacement diffuser: Replacement Matala for Elite Cascade Falls . Select the 40" size, model MT40BK.
Additional System Components
For a complete pond-less waterfall installation, plan for the appropriate:
- Submersible waterfall pump
- Pump Canyon or compatible pump vault
- Underground water reservoir and matrix system
- Rubber liner and protective underlayment
- 3" flexible PVC feed line and related system plumbing
- Stone, gravel, and landscape finishing materials
- Electrical supply and site preparation
Prefer a coordinated system? Explore our Elite X-Large 40" Cascading Falls Kit .
Technical Specifications
Product: Extra Large 40" Elite Cascade Falls Box
Item number: PB1182
Spillway width: 40 inches
Maximum flow: 10,000 GPH
Dimensions: 19.5" × 51" × 14.25" (as listed)
Inlet connections: Two 3" spinweld fittings
Feed plumbing: 3" flexible PVC
Diffuser: Black Matala mat
Replacement mat: MT40BK
Application: Pond-less waterfalls and recirculating cascades
Country of origin: USA
Warranty: Lifetime manufacturer warranty on the qualifying Blue Thumb plastic component
Compare Blue Thumb Spillway & Cascade Models
Compare spillway widths, maximum flow ratings, connection sizes, and dimensions across our Cascade and Elite Spillway models. The highlighted row identifies the Extra Large 40" Elite Cascade Falls Box.
| Model | Item | Spillway | Max Flow | Inlet | Dimensions |
|---|---|---|---|---|---|
| Mini Cascade | PB1359 | 10" | 1,800 GPH | 2 × 1" | 8.5" × 10" × 8" |
| DIY Cascade 20" | PB1762 | 20" | 2,500 GPH | 2 × 1.5" | 20" × 8" × 7" |
| Corner Falls | PB1861 | 12" | 2,500 GPH | 2 × 1.5" | 12" × 12" × 10" |
| Elite Spillway 28" | PB2866 | 28" | 7,500 GPH | 2" | 32.25" × 15.5" × 5" |
| Small Elite | PB1106 | 14" | 2,500 GPH | 2 × 2" | 19" × 24" × 14.25" |
| Medium Elite | PB1113 | 22" | 5,500 GPH | 2 × 2" | 20" × 33" × 14.25" |
| Large Elite | PB1120 | 30" | 7,500 GPH | 2 × 3" | 20" × 41" × 14.25" |
| Extra Large Elite 40" — This Model | PB1182 | 40" | 10,000 GPH | 2 × 3" | 19.5" × 51" × 14.25" |
| Elite Spillway 16" | PB16ES | 16" | 4,500 GPH | 2" | 20.25" × 15.5" × 5" |
Planning Your Waterfall Installation
The 40-inch Elite Cascade Falls Box is designed to work with an appropriately sized recirculating water system. Because this is a waterfall component rather than a complete kit, the pump, plumbing run, reservoir, and surrounding construction must be planned for your specific installation.
Pump and plumbing selection: The box accepts 3" flexible PVC feed plumbing and has a maximum flow rating of 10,000 GPH. This is the box's maximum flow capacity, not a required pump size. Actual delivered flow depends on the selected pump, elevation change, plumbing length, and system restrictions.
We recommend confirming your complete pump and plumbing configuration before installation.
Prepare the Location
Choose the waterfall's starting point and prepare a compacted, stable base. Allow sufficient room for the box, plumbing, liner connections, and surrounding rockwork.
Connect the Incoming Plumbing
Use the supplied connection fittings according to the installation guide. One spinweld can receive the feed line while the other is plugged, or the second connection may be used for another pump line. Follow the guide's thread-sealing and PVC assembly instructions.
Level the Box and Secure the Liner
Position the box level from side to side with the slight forward tilt specified in our instructions. Bring the liner up to the waterfall opening, then attach and seal it using the detachable weir, silicone, and stainless steel hardware as directed.
Finish the Landscape and Test Water Flow
Install the Matala diffuser and landscape lid as instructed. Complete the surrounding rockwork, fill the connected reservoir, and test the system. Check that water travels through the intended stream channel and returns to the reservoir without escaping over the edges.
Installation tip: The landscape lid can be concealed with suitable gravel, mulch, or planting arrangements as described in our official guide. Keep future access to the box and diffuser in mind when finishing the surrounding area.
Routine Care & Seasonal Maintenance
Inspect the Cascade Falls Box periodically for leaves, sediment, and other debris that may interfere with the diffuser or spillway. Our maintenance guide recommends removing and thoroughly cleaning the filter media at least once per year. Also inspect the connected pump, plumbing, and reservoir water level as part of routine system maintenance.
In freezing climates, follow our pond-less waterfall winterization instructions. If shutting the system down, clean the spillway and diffuser, service the pump according to its manual, and prepare the reservoir for winter. If operating through freezing weather, monitor for ice dams that could redirect water outside the lined stream.
Installation Guides & Product Resources
Use our official instructions when planning and installing your waterfall. These resources cover Cascade Box connections, liner attachment, Pump Canyon and reservoir installation, and seasonal maintenance.
Pond-Less Waterfall Installation Videos
See how pond-less waterfall systems come together with our waterfall video series. These videos provide additional installation context and demonstrate how the different components work together to create a recirculating waterfall.
Pond-Less Waterfall Video 1
Pond-Less Waterfall Video 2
Pond-Less Waterfall Video 3
Pond-Less Waterfall Video 4
Good to know: These videos demonstrate pond-less waterfall systems and related installation techniques. The Extra Large 40" Elite Cascade Falls Box is sold as a standalone component. Pumps, reservoirs, liner, plumbing, and other materials shown in the videos are not included unless specifically listed with the product being purchased. Video demonstrations may feature different Cascade Box sizes or configurations.
Need Help Planning Your Waterfall?
Not sure which Cascade Falls Box, pump, or reservoir configuration is right for your project? Our Sales/Tech Team can help you review the system requirements before ordering.
Frequently Asked Questions
Does this Cascade Falls Box include a pump and water reservoir?
No. This product is the 40-inch Cascade Falls Box component with its supplied box installation hardware. The pump, underground reservoir, liner, and other complete-system components are purchased separately. For a coordinated system, consider our Elite X-Large 40" Cascading Falls Kit.
Do I need a 10,000 GPH pump?
No. The 10,000 GPH specification is the maximum flow rating of the Cascade Falls Box. The appropriate pump depends on your desired waterfall appearance, elevation change, plumbing configuration, and other system requirements. Select a pump based on the flow delivered at your actual operating conditions.
Can I connect plumbing to either side of the box?
Yes. The box has two factory-installed 3-inch spinweld connections. You can connect the incoming feed line to either side and plug the unused connection. The installation guide also describes using the second connection for an additional pump line.
Can I install multiple Cascade Falls Boxes together?
Yes. Elite Cascade Falls Boxes can be installed side by side for wider or custom waterfall configurations. Each box requires appropriate support, plumbing, and liner integration. The combined system must be planned around the total desired flow and available reservoir capacity.
Can I replace the black Matala diffuser mat?
Yes. Replacement Matala diffuser mats are available separately. For the 40-inch Elite Cascade Falls Box, select the 40-inch replacement mat, model MT40BK. The black Matala material helps distribute water across the spillway.
Is this a biological waterfall filter?
This Cascade Falls Box is designed primarily for pond-less waterfall applications as an alternative to a large biological waterfall box. Its Matala diffuser helps distribute water and capture debris, but the unit should not be treated as a complete biological filtration system for a fish pond.
What does the lifetime warranty cover?
Our lifetime plastics warranty covers qualifying Blue Thumb-branded engineered plastic components, including Cascade Boxes, against manufacturing defects for the original purchaser. Proper installation is required, and modifications may void coverage. Labor and freight are not included. Pumps and other separately purchased components have their own applicable warranties.
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