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Complete Blue Thumb 40-inch Cascading Falls Kit showing the waterfall spillway box, Pump Canyon, Basin Matrix, pump, liner, plumbing, and installation components.

Elite X-Large 40" Cascading Falls Kit

SKU:
PB40CFK
$3,499.99
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  • 40" Waterfall Spillway – Wide, natural-looking cascading waterfall
  • Max Stream Size: 18' L x 6'-7' W
  • 7,800 GPH IllumiFlow Pump Included
  • Complete Pond-Less Waterfall Kit – Includes pump, liner, underground reservoir, and plumbing
  • Low-Maintenance Design – Recirculating water feature with a hidden reservoir
  • Rocks & Gravel Sold Separately
Current Stock:
Description
 
Blue Thumb Elite Series | Complete Pond-Less Waterfall Kit

Create a Wide, Natural-Looking Waterfall Without Building a Traditional Pond

Make a statement in your landscape with our Elite X-Large 40" Cascading Falls Kit. Designed for larger backyard water features and professionally installed landscapes, this complete pond-less waterfall system combines a 40-inch cascading spillway with a high-flow pump, underground water reservoir, liner, and plumbing.

Water travels over your arranged rockwork before disappearing into a hidden basin, creating the movement and sound of a natural stream without an exposed pond. The extra-large configuration provides room for dramatic waterfall drops and a generously sized streambed.

40" Waterfall Spillway Width
18 ft. Published Maximum Stream Length
7,800 GPH Included Pump's Maximum Rated Flow
8 Basin Matrix Units Included

Why Choose Our Elite X-Large Cascading Falls Kit?

A Wider Waterfall

The 40-inch Elite Cascade Box distributes water across a wide spillway, making it suitable for larger rock waterfalls, broad cascades, and landscaped streams.

Hidden Water Storage

Eight Basin Matrix units create storage space beneath the decorative stone, allowing water to recirculate without a traditional open pond.

Complete System Components

We include the primary waterfall equipment, pump, reservoir components, liners, plumbing, and installation materials needed to build your pond-less water feature.

Is the 40" Cascading Falls Kit Right for Your Landscape?

Our Extra-Large Cascading Falls Kit is designed for projects where a smaller waterfall would get lost in the surrounding landscape.

The current product specifications describe a maximum stream approximately 18 feet long and 6–7 feet wide. Actual dimensions depend on elevation changes, the shape of the stream, rock placement, liner overlap, and site conditions.

Planning Your Stream and Underground Basin

The 40-inch measurement refers to the waterfall spillway opening, not the overall width of the Cascade Box. The box itself measures approximately 51 inches wide.

Our published installation layout for the PB40CFK shows an underground basin approximately 46" long × 58" wide × 34" deep. This is a planning reference, not a substitute for measuring your actual site and components.

The older installation layout illustrates a stream approximately 17 feet long and 5–7 feet wide. The current product listing publishes an 18-foot maximum. If your design needs the full published length, we recommend confirming the layout with our Sales/Tech Team before excavation.

This kit is especially useful for broad landscape slopes, larger residential properties, and commercial water-feature installations where a wide, natural-looking cascade is desired.

For a slightly smaller project, compare our Elite Large 30" Cascading Falls Kit . It includes a 30-inch spillway and a 6,000 GPH pump for a narrower waterfall design.

What's Included in the 40" Pond-Less Waterfall Kit?

We package the main components of the recirculating waterfall system together. The following parts are included with the PB40CFK kit and do not need to be purchased separately.

40" Elite Cascade Falls Box

  • 40" Elite Cascade Falls Box (PB1182)
  • 40-inch waterfall spillway
  • Attached landscape lid
  • Black Matala diffuser mat
  • Detachable weir
  • Two factory-installed 3-inch inlets
  • Installation fittings and hardware

Pump and Plumbing

Underground Water Reservoir

Installation and Startup Materials

  • Illustrated installation instructions
  • PVC glue
  • Black expanding waterfall foam
  • 8 oz. Pond Cleaner
  • Muck Buster® starter treatment
  • Included installation fittings and materials

What You'll Need to Supply

Rocks, boulders, and gravel are not included. These materials are selected locally to create the waterfall drops, streambed, and finished landscape appearance.

You'll also need water to fill the reservoir, excavation and site-preparation materials, and a suitable GFCI-protected electrical connection. Labor and landscape finishing materials are not part of the kit.

Elite X-Large 40" Cascading Falls Kit Specifications

Kit SKU: PB40CFK
Product type: Complete pond-less waterfall kit
Spillway width: 40 inches
Published max stream: 18' L × 6'–7' W
Cascade Box model: PB1182
Cascade Box size: 19.5" × 51" × 14.25"
Cascade Box max flow: 10,000 GPH
Cascade Box inlets: Two 3" spinweld fittings
Included pump: IllumiFlow® 7800 — PB1755
Pump maximum flow: 7,800 GPH
Pump flow at 5 ft.: 6,480 GPH
Pump flow at 10 ft.: 5,725 GPH
Pump max head: 27.5 feet
Pump power: 607 W / 5.28 A published model figures
Pump cord: 25 feet
Pump Canyon: Large Elite — PB1175
Pump Canyon size: 24" × 27.75" × 31.5"
Pump Canyon capacity: 57 gallons nominal
Large matrix: 4 × WMLG34; 32 gallons each
Small matrix: 4 × WMSM17; 17 gallons each
Basin liner: 15' × 15' PondGard Rubber Liner
Stream liner: 15' × 20' PondGard Rubber Liner
Flex hose: 3" diameter × 25 feet
Basin layout guide: Approx. 46" L × 58" W × 34" D

Technical note: Pump GPH ratings are model performance figures, not guaranteed flow at the finished waterfall. Actual output depends on vertical lift, plumbing resistance, and installation conditions. The Cascade Box's 10,000 GPH maximum is its component rating, not the flow of the included pump. Matrix and Pump Canyon capacities are individual component figures and should not be added together as a guaranteed usable reservoir volume.

How Our Pond-Less Waterfall System Works

A pond-less waterfall uses an underground water reservoir instead of a traditional exposed pond. The liner creates a waterproof basin beneath the finished rockwork.

The Basin Matrix units maintain open water-storage space below the surface. The included IllumiFlow® pump sits inside the Large Pump Canyon®, where it can be accessed for inspection and maintenance.

Water travels from the pump through the 3-inch PVC flex hose to the 40-inch Cascade Box. The box distributes water over the spillway, sending it across the arranged rocks and down the stream.

At the bottom, the water passes through the decorative stone into the concealed reservoir and circulates back to the waterfall.

Planning and Installing Your 40" Pond-Less Waterfall

This is a substantial landscape installation. The kit supplies the primary mechanical and waterproofing components, but excavation, rockwork, plumbing connections, and site preparation are still required.

Plan the Waterfall Layout

Choose the waterfall location, stream path, underground basin position, and intended elevation changes. Confirm access to water and electricity.

Excavate the Reservoir

Position the Pump Canyon and Matrix units to establish the basin footprint. Excavate according to the installation guide and remove sharp roots and stones.

Install the Liner and Reservoir

Place the protective underliner and rubber liner. Assemble the Basin Matrix units and position them with the Pump Canyon inside the excavated basin.

Position the Cascade Box

Prepare a compacted base at the top of the stream. Install the Cascade Box level from side to side with the slight forward pitch described in the manual.

Connect the Pump and Plumbing

Install the IllumiFlow pump and check valve assembly in the Pump Canyon. Route and connect the 3-inch flex hose to the Cascade Box using the supplied components.

Finish, Fill, and Test

Build the waterfall with decorative stone, conceal the basin, and fill with water. Start the pump only after confirming adequate water coverage. Test for leaks and adjust the rockwork as needed.

Important Installation Considerations

The two liner sections must overlap correctly to return water to the underground reservoir. Follow the installation manual for liner attachment, overlap, and edge construction.

Keep enough extra liner along the stream edges to make adjustments after testing. Plan the rockwork and elevation changes before trimming any excess material.

Always locate underground utilities before excavation. Use the electrical protection specified in the pump instructions.

Water-Level Management and Maintenance

Pond-less waterfalls generally require less maintenance than traditional ponds, but they are not maintenance-free.

Monitor the underground reservoir water level regularly. Evaporation and splashing gradually reduce the available water, and the pump must not be allowed to run dry.

Remove leaves and debris that could redirect stream flow. Periodically inspect the pump, tubing, and connections. The Cascade Box's filter media should be cleaned according to the maintenance guide.

To reduce manual refilling, the Large Pump Canyon includes a fitting for an optional Hudson Automatic Water Fill Kit (PB1342) . The auto-fill kit is sold separately.

Winter Care

In freezing climates, winter operation requires monitoring for ice dams that can redirect water outside the stream. Low water levels and ice formation can damage the pump.

If you shut the waterfall down for winter, follow our maintenance guide for removing and storing the pump, cleaning the Cascade Box, and maintaining the reservoir. Our guide recommends leaving the basin at least half full during winter shutdown.

Compare Blue Thumb Pond-Less Waterfall Kits

Our Cascading Falls collection includes smaller DIY systems and larger Elite Series kits. Compare the spillway width, pump, liner, reservoir components, and published stream dimensions to find the right configuration.

View the Complete 8-Kit Specification Comparison
Specification DIY Mini 10" DIY Small 20" Elite 14" Elite Spillway 16" Elite 22" Elite Spillway 28" Elite 30" Elite 40"
THIS KIT
SKU PB1373 PB1854 PB1229 PB16KIT PB1236 PB28KIT PB30CFK PB40CFK
Max Stream 4' × 1'–2' 8' × 2'–4' 6' × 1'–2' 6' × 1'–2' 16' × 2'–4' 16' × 2'–4' 17' × 4'–6' 18' × 6'–7'
Liner 6' × 10' 8' × 15' 10' × 15' 10' × 15' 10' × 10' + 10' × 20' 10' × 10' + 10' × 20' 15' × 15' + 10' × 20' 15' × 15' + 15' × 20'
Spillway 10" 20" 14" 16" 22" 28" 30" 40"
Pump GPH 1,495 1,980 2,100 2,100 4,500 6,000 6,000 7,800
Flex Hose 1" × 7' 1.5" × 10' 2" × 25' 2" × 25' 2" × 25' 2" × 25' 3" × 25' 3" × 25'
Matrix Canyon Matrix Canyon Matrix 1 Large 1 Large 3 Large 3 Large 3 Large + 3 Small 4 Large + 4 Small
Pump Access Integrated Integrated Small Canyon Small Canyon Small Canyon Small Canyon Large Canyon Large Canyon

DIY Mini 10" — PB1373

Stream: 4' × 1'–2'

Liner: 6' × 10'

Spillway: 10"

Pump: 1,495 GPH

Hose: 1" × 7'

Reservoir: Canyon Matrix

Pump access: Integrated

DIY Small 20" — PB1854

Stream: 8' × 2'–4'

Liner: 8' × 15'

Spillway: 20"

Pump: 1,980 GPH

Hose: 1.5" × 10'

Reservoir: Canyon Matrix

Pump access: Integrated

Elite Small 14" — PB1229

Stream: 6' × 1'–2'

Liner: 10' × 15'

Spillway: 14"

Pump: 2,100 GPH

Hose: 2" × 25'

Matrix: 1 Large

Pump access: Small Canyon

Elite Spillway 16" — PB16KIT

Stream: 6' × 1'–2'

Liner: 10' × 15'

Spillway: 16"

Pump: 2,100 GPH

Hose: 2" × 25'

Matrix: 1 Large

Pump access: Small Canyon

Elite Medium 22" — PB1236

Stream: 16' × 2'–4'

Liner: 10' × 10' + 10' × 20'

Spillway: 22"

Pump: 4,500 GPH

Hose: 2" × 25'

Matrix: 3 Large

Pump access: Small Canyon

Elite Spillway 28" — PB28KIT

Stream: 16' × 2'–4'

Liner: 10' × 10' + 10' × 20'

Spillway: 28"

Pump: 6,000 GPH

Hose: 2" × 25'

Matrix: 3 Large

Pump access: Small Canyon

Elite Large 30" — PB30CFK

Stream: 17' × 4'–6'

Liner: 15' × 15' + 10' × 20'

Spillway: 30"

Pump: 6,000 GPH

Hose: 3" × 25'

Matrix: 3 Large + 3 Small

Pump access: Large Canyon

Elite X-Large 40" — THIS KIT

SKU: PB40CFK

Stream: 18' × 6'–7'

Liner: 15' × 15' + 15' × 20'

Spillway: 40"

Pump: 7,800 GPH

Hose: 3" × 25'

Matrix: 4 Large + 4 Small

Pump access: Large Canyon

Published maximum stream dimensions are estimates. Actual installations depend on the landscape, elevation, liner configuration, and rockwork. Older installation documents may show different stream-length recommendations.

Installation Guides and Product Resources

We recommend reviewing these official Blue Thumb resources before beginning excavation or installation. The guides cover component assembly, waterproofing, plumbing, and seasonal maintenance.

Elite Cascading Falls Kit Installation Manual (PDF) Elite Cascade Box, Pump Canyon & Matrix Guide (PDF) Basin Matrix Assembly Instructions (PDF) Pond-Less Waterfall Maintenance & Winter Care (PDF)

Pond-Less Waterfall Installation & IllumiFlow Pump Videos

Learn more about installing a pond-less waterfall and the IllumiFlow pump included with your kit. These videos offer helpful guidance on how a pond-less waterfall system works, what to expect during installation, and the equipment responsible for keeping water circulating through your feature.

Pond-Less Waterfall Installation
Learn about the general installation process for a pond-less waterfall system, including the underground reservoir and recirculating water feature. Components and installation details may vary by kit size.
Blue Thumb IllumiFlow Pump Overview
Learn about our IllumiFlow pump family and the features of these recirculating water pumps. This 40-inch Cascading Falls Kit includes the 7,800 GPH IllumiFlow pump, model PB1755.

Component Warranty Coverage

Different components in this complete pond-less waterfall kit have different warranty coverage.

  • 40" Elite Cascade Falls Box: Lifetime manufacturer's warranty against qualifying manufacturing defects.
  • Large Elite Pump Canyon®: Lifetime manufacturer's warranty against qualifying manufacturing defects.
  • Basin Matrix: Lifetime manufacturer's warranty under Blue Thumb's engineered-plastics coverage.
  • IllumiFlow® 7,800 GPH Pump: 24-month limited pump warranty.

Warranty coverage is subject to the applicable manufacturer's conditions, installation requirements, and exclusions. Lifetime coverage on qualifying plastic components does not mean the entire waterfall kit has a lifetime warranty.

Read Our Complete Warranty Information

Have Questions About Your Waterfall Project?

Planning a larger pond-less waterfall can involve several important decisions, including stream length, elevation changes, reservoir placement, and installation requirements.

Our Sales and Technical Team can help you determine whether the 40" Cascading Falls Kit is the right size for your landscape before you order.

Call 888-619-3474 Email Our Sales/Tech Team

Frequently Asked Questions

What is a pond-less waterfall?

A pond-less waterfall is a recirculating water feature that stores its water in an underground reservoir instead of an exposed pond. Water flows over decorative stone before returning through gravel to the hidden basin.

How long can the stream be with the 40" Cascading Falls Kit?

The current product listing publishes a maximum stream approximately 18 feet long and 6–7 feet wide. An older installation layout illustrates approximately 17 feet long and 5–7 feet wide.

Actual dimensions depend on the slope, rockwork, liner overlap, and stream layout. We recommend confirming projects that require the full published maximum before excavation.

Does this waterfall kit include rocks and gravel?

No. Decorative rocks, boulders, and gravel are purchased separately. This allows you to select materials that match your landscape and create the waterfall appearance you want.

What is the difference between the 30" and 40" Cascading Falls Kits?

The 40" kit includes a wider spillway, a 7,800 GPH pump, eight Basin Matrix units, and larger stream-liner coverage.

The 30" kit includes a 30-inch spillway, a 6,000 GPH pump, and six Basin Matrix units. Both use a Large Elite Pump Canyon and 3-inch PVC flex hose.

Choose based on the desired waterfall width, stream dimensions, site conditions, and available installation space.

Can the 40" Cascading Falls Kit be installed on a slope?

Yes. Sloped landscapes can be well suited to cascading waterfalls. The elevation change helps create visible waterfall drops, while rockwork directs water toward the underground basin.

The final slope and waterfall height must be considered when planning the stream length, liner coverage, and pump performance.

Can I add an automatic water-fill system?

Yes. The included Large Elite Pump Canyon provides a fitting for an optional automatic water-fill system.

Our Hudson Automatic Water Fill Kit, item PB1342, can replace water lost through evaporation. It is sold separately and requires a suitable water-supply connection.

How much maintenance does a pond-less waterfall require?

Routine care includes monitoring the reservoir water level, removing leaves and debris, inspecting the pump and plumbing, and periodically cleaning the Cascade Box filter media.

Pond-less waterfalls generally require less ongoing care than traditional fish ponds, but regular inspection is still important for dependable operation.

Can I leave my pond-less waterfall running during winter?

Winter operation is possible in some installations, but freezing conditions can create ice dams that redirect water out of the stream and lower the reservoir level.

In colder climates, we recommend reviewing our seasonal maintenance guide and winterizing the pump when freezing conditions could damage the system.

Does the entire waterfall kit have a lifetime warranty?

No. The Cascade Box, Pump Canyon, and qualifying Basin Matrix components have lifetime manufacturer's coverage against qualifying manufacturing defects.

The included IllumiFlow® pump has a separate 24-month limited warranty. Other components are subject to their applicable warranty terms.