GB2576181A

GB2576181A - Chamber system

Info

Publication number: GB2576181A
Application number: GB1812868.6A
Authority: GB
Inventors: Alpin David
Original assignee: In Depth Chamber Solutions Ltd
Current assignee: In Depth Chamber Solutions Ltd
Priority date: 2018-08-08
Filing date: 2018-08-08
Publication date: 2020-02-12
Anticipated expiration: 2038-08-08
Also published as: GB2576181B; GB201812868D0

Abstract

An inspection chamber system 10 for an access chamber, comprising a base 14, an upper frame 24 or lip for supporting an access cover 26, and a chamber body 20 positioned between the base 14 and the upper frame 24. The base may be a split base 14a,14b formed of two complementary shaped sections that each include an opening or cut-out such that when the two sections are placed in abutment, form a mating pair which defines an aperture 16 through which an underground asset can be received. The chamber may have ribs 22 on the outer surface. The chamber system 10 may have a RFID tag for audit purposes or tracking. The access chamber may be manufactured by supplying polymer into moulding tools.

Description

CHAMBER SYSTEM

Technical Field Of The Invention

This invention relates to a chamber system and its method of manufacture. In particular, this invention relates to a chamber system that can be used to quickly and easily form an access or inspection chamber for underground and/or buried utilities or other services including water, sewers, telephone, electricity, storm drains and gas.

Background

Access chambers are covered openings to underground utilities or assets, and provide an access point for making connections, inspection, adjustment and/or maintenance of underground and buried assets, and other equipment. For many years, access chambers were constructed from courses of engineering brick. Custom-made segmented concrete sleeves were then developed which, in use, can be arranged in a stacking, interlocking manner around the underground asset. Segmented precast concrete structures of this type are however brittle, and it is estimated that up to one third of these segmented concrete structures or sleeves are damaged either in transportation or during installation. In addition, these products are heavy and bulky, which increases the costs in terms of warehousing and transportation to site, and still requiring skilled workers and equipment to excavate, install and reinstate the ground around the access chamber.

In order to address this problem, various modular prefabricated plastic access chamber systems are now available in the marketplace. These can be arranged, or stacked, around the underground asset to form an access or inspection chamber.

However, these modular systems are not watertight, and do not protect against the ingress of water and other solids. They can also be expensive to manufacture and install, needing perhaps ten or more individual stackable units to form an assembled access chamber. As such, these plastic modular systems, are expensive to purchase, transport and install, have not found complete acceptance in the industry.

It is an object of the present invention to provide a chamber system for an access chamber and its method of manufacture which overcomes or reduces the drawbacks associated with known products of this type. It is an object of the present invention to provide a quick and convenient means of constructing an access chamber using a chamber system. Such a chamber system is lightweight and environmentally friendly, and can be entirely recyclable. It is a further object of the present invention to provide a chamber system which minimises the ingress of underground water or solids into the assembled access chamber. It is a further object of the present invention to provide a chamber system that is very easy to install by a single person, if required, and which complies with the necessary manual handling regulations and reduces the risks of short and long term injury due to the much reduced weight. It is a further object of the present invention to provide a system that is virtually indestructible, being thirty times lighter than an equivalent precast concrete access chamber, and which leads to substantial savings in terms of both transportation and installation. The use of the present invention leading to significant reductions in installation time, and the resultant excavation and reinstatement works are generally more straightforward.

Summary Of The Invention

The present invention is described herein and in the claims.

According to the present invention there is provided a chamber system for an access chamber, comprising:

a base;

an upper frame or lip for supporting an access cover; and a chamber body positioned between the base and the upper frame.

An advantage of the present invention is that it can be used to quickly and conveniently form an access or inspection chamber for the underground asset, and which minimises both installation time and resources.

The base may be a split base being assemblable around an underground asset.

Preferably, the split base is formed from two complementary shaped sections.

Further preferably, the two complementary sections each include an opening or cut-out, such that when the two complementary sections are placed in abutment they form a mating pair which defines an aperture through which an underground asset can be received.

In use, the opening may be pre-formed or includes a series of cut-out panels of different sizes and shapes defined by lines of weakness which can be snapped out.

Preferably, around the periphery of the base is a peripheral lip into which the chamber body can be received.

Further preferably, the chamber body is formed as a single elongate piece.

In use, disposed around the outer faces of the chamber body may be a series of external transverse ribs.

Preferably, the chamber body has a length of around Im.

Further preferably, the transverse ribs project outwardly at around 5mm in height and around 5mm in width from the outer faces of the chamber body.

In use, the spacing between successive ribs may be around 100mm.

Preferably, the lowermost surface of the frame includes a peripheral lip into which the chamber body can be received.

Further preferably, the uppermost surface of the frame is situated overground when in use.

In use, the access cover may be removable or can be attached to frame via a push-fit, hinge or any other attachment means.

Preferably, the assembled chamber can be retained by a close or interference fit between the base, chamber body, upper frame and access cover, and/or by the use of threaded fasteners and/or a suitable adhesive and/or any suitable fixing means.

Further preferably, the system further comprising:

a coupler for receiving abutting chamber bodies by a push-fit arrangement.

The base may be separate and, in use, the base may be formed as a sealed unit with the chamber body.

Alternatively, the base is integrally formed with the chamber body and preferably as one piece of material.

Preferably, the chamber system has rectangular or square cross-section when in plan view from above and/or any number of circular and/or ellipsoid and/or curved geometric shapes, including pentagonal, hexagonal, octagonal or any suitable polygonal shape when in plan view from above.

Further preferably, the base, chamber body, upper frame and access cover have a wall thickness between around 6mm to around 8mm.

The chamber body may be formed having an integral upper frame or lip for receiving the access cover.

The chamber body may be a retrofittable chamfered internal liner that can be received inside an access chamber.

The system may further comprise a retrofittable RFID tag which can be received within at least on part of the chamber system for audit purposes and/or to allow asset tracking and location.

The system may further comprise an upper sealing platform operable to cooperate with the upper end of the chamber body to provide a fluid seal therewith.

The system may further comprise a lower sealing platform operable to cooperate with the lower end of the chamber body to provide a fluid seal therewith.

At least one of the lower and upper sealing platforms may comprise central opening.

At least one of the lower and upper sealing platforms advantageously comprises a seating groove for receiving an end of the chamber body to form a fluid seal between the sealing platform and the chamber body.

The seating groove advantageously comprises an inner seating groove and an outer seating groove.

The lower sealing platform may be the base.

In an alternative embodiment the base is integrally formed with the chamber body.

Also according to the present invention there is provided a method of manufacturing a access chamber, comprising the steps of:

supplying a polymer into one or more moulding tools which define a base, an upper frame or lip for supporting an access cover, and a chamber body; and ejecting the moulded base, upper frame, access cover and chamber body from the moulding tool.

In one embodiment, the base may be a split base being assemblable around an underground asset.

In another embodiment, the base may be a sealing platform operable to cooperate with the chamber body to provide a fluid, or liquid, seal between the sealing platform and the chamber body.

In a further embodiment, the base is integrally formed with the chamber body in a suitable tool, which provides a combined chamber body and base. This is advantageous as it is relatively inexpensive to manufacture and easy to install whilst providing improved prevention of ingress of fluid or liquid into the chamber system.

Preferably, the polymer includes a blend of recycled polymers from both post-industrial and domestic waste streams.

Further preferably, the method further comprising the step of:

admixing a masterbatch or coloured pigment additive with the polymer.

It is believed that a chamber system and its method of manufacture in accordance with the present invention at least addresses the problems outlined above.

It will be obvious to those skilled in the art that variations of the present invention are possible and it is intended that the present invention may be used other than as specifically described herein.

Brief Description Of The Dra wings

The present invention will now be described by way of example only, and with reference to the accompanying drawings, in which:

Figure 1 shows an exploded perspective view from the front and above of a chamber system in accordance with the present invention and which forms an access or inspection chamber for underground utilities or assets;

Figure 2 is an exploded perspective view from the front and above of a chamber system which forms a completely watertight access chamber in accordance with the present invention;

Figure 3 illustrates a perspective view from the front and above of an assembled access chamber for a fire hydrant;

Figure 4 shows a side plan view of a second embodiment of the present invention, and shows that the chamber body can be formed having an integral upper frame or lip;

Figure 5 is an exploded perspective view from the front and above of a third embodiment of the present invention, and which illustrates a retrofittable chamfered chamber body which can be received inside an existing concrete access chamber.

Figure 6 is an exploded perspective view of a fourth embodiment of the present invention, illustrating upper and lower sealing platforms;

Figure 7 is a close up view of a comer portion of the upper and lower sealing platforms, illustrating inner and outer seating grooves;

Figure 8 is an exploded perspective view of a fifth embodiment of the present invention, illustrating a chamber body and an upper sealing platform operable for use with an existing or new concrete chamber; and

Figure 9 is an exploded perspective view of a sixth embodiment of the present invention, illustrating a chamber body having an integral base and an upper sealing platform.

Detailed Description Of The Preferred Embodiments

The present invention has adopted the approach of using a chamber system to quickly and easily construct an access or inspection chamber for an underground asset. Such a chamber system is lightweight and environmentally friendly, and can be entirely recyclable. Advantageously, the present invention provides a chamber system which minimises the ingress of underground water or solids into the assembled access chamber. Further advantageously, the present invention also provides a chamber system that is very easy to install by a single person, if required, and which complies with the necessary manual handling regulations and reduces the risks of short and long term injury due to the much reduced weight. Further advantageously, the present invention also provides a system that is virtually indestructible, being thirty times lighter than an equivalent precast concrete access chamber, and which leads to substantial savings in terms of both transportation and installation. The use of the present invention leading to significant reductions in installation time, and the resultant excavation and reinstatement works are generally more straightforward.

Referring now to the drawings, a chamber system 10 according to the present invention is illustrated in Figures 1 to 9. Specifically, the chamber system 10, when assembled, forms an access or inspection chamber for an underground asset 12.

The chamber system 10 comprises a base 14. In the embodiment shown in Figure 1, the base 14 is a split base that is formed from two complementary shaped sections 14a, 14b. The two complementary sections 14a, 14b each include a generally semi-circular opening or cut-out 15 such that when the two complementary sections 14a, 14b are placed in abutment they form a mating pair which defines an aperture 16 through which the fire hydrant or asset 12 can pass. The skilled person will appreciate that the openings 15 can be pre-formed, or can include a series of cut-out panels of different sizes and shapes defined by lines of weakness formed in the sections 14a, 14b of the base 14 and which can be snapped out for ease of installation. The most appropriate-sized opening 15 can then be selected for asset 12.

Around the periphery of the base 14 is a peripheral lip 18 into which an elongate unitary chamber body 20 is received. The chamber body 20 is formed as a single piece, and is formed in a preferred embodiment as a box section. Disposed around the outer faces of the chamber body 20 are a series of external transverse ribs or reinforcement sections 22 which provide structural rigidity for the chamber body 20 when in use. The chamber body 20 is supplied in around Im lengths, and which means that the vast majority of access chambers can be formed using only a single chamber body 20. Since existing underground fire hydrant and valve chambers are presently constructed using ten or more separate concrete, composite or rubber segments, assembly of the present invention can therefore be achieved very rapidly, and construction difficulties are minimised since resultant excavation and reinstatement works are generally more straightforward. The skilled person will appreciate that length of the chamber body 20 can be easily cut to size using hand tools or power-operated tools (not shown).

Figure 1 also shows that, at the upper section of the chamber body 20, there is a separate moulded upper frame or lip 24. Although not shown in Figure 1, the lowermost part of the frame 24 includes a peripheral lip into which the chamber body 20 is received. The skilled person will appreciate that the uppermost surface of the upper frame 24 is situated overground, and is capable of receiving within it a removable access cover 26 which can be a push-fit, hinged or indeed any other form of attachment that is known to those skilled in the art. The assembly of the base 14, chamber body 20, upper frame 24 and access cover 26 thereby forms an access chamber for the asset 12, as shown in Figure 3. Once the assembly of the access chamber has been completed, aggregate and/or other building materials are backfilled and which surrounds the assembled access chamber. The assembled access chamber can be retained by a close or interference fit between the base 14, chamber body 20, upper frame 24 and access cover 26, and/or by the use of threaded fasteners, a suitable adhesive or any suitable fixing means.

Should an excavation be needed which requires a greater depth than Im, then couplers are available (not shown) which are capable of receiving abutting chamber bodies 20 by a simple push-fit arrangement.

The skilled person will appreciate that the speed of installation of such an access chamber using the chamber system 10 of the present invention is significantly faster than known segmented products available in the art.

The skilled person will also appreciate that an additional advantage of the present invention is that should a connection be needed through the side wall of the chamber body 20, then a simple tank cutter (not shown) can be used to cut through the side walls thereof to receive such connections. Hitherto known concrete and segmented plastic products have to be damaged to allow such connections to occur.

The skilled person will appreciate that the chamber system 10 can be formed from any number of synthetic plastics material, such as a thermoplastic or thermoset material, or any other suitable first or second generation plastics material. The above list is in no way intended to be limiting and exhaustive.

In a preferred embodiment, the chamber system 10 is injection-moulded using Polypropylene (PP), High-Density Polyethylene (HDPE), Polyethylene Terephthalate (PET), Polyvinyl Chloride (PVC) or Acrylonitrile Butadiene Styrene (ABS) or blends thereof.

The skilled person will appreciate that different variations or densities of materials could also be provided. Manufacturing the chamber system 10 using injection moulding will allow for a generally low product weight which provides a good structural rigidity and durability. The chamber system 10 can be supplied in a number of different colours.

The chamber system 10 can be further manufactured using other techniques such as blow moulding, vacuum forming, rotational moulding, compression moulding, rim moulding, powder impression moulding or any other form of plastics manufacture. The chamber system 10 can also be manufactured from a blend of recycled polymers from both postindustrial and domestic waste teams. In a preferred embodiment, the chamber system 10 can be manufactured having up to 50% by weight recycled polymer relative to the total polymer content. The amount of recycled polymer can be as high as 75% by weight relative to the total polymer content, or even 100% by weight recycled polymer relative to the total polymer content.

In a preferred embodiment, the wall thickness of the base 14, chamber body 20, upper frame 24 and access cover 26 is between around 6mm to around 8mm.

The transverse ribs 22 on the chamber body 20 project outwardly at around 5mm in height and around 5mm in width from the surface of the chamber body 20. The spacing between successive ribs 22 is around 100mm.

Figure 2 is illustrative of an embodiment of the invention which is used as a completely sealed watertight access chamber for underground data loggers and the like. In this embodiment, the base 28 is formed as a sealed unit into which electrical equipment can be placed, and which totally prevents the ingress of soil and water.

Figure 3 is illustrative of an underground asset 12 inside the chamber system 10 of the present invention. Instead of a rectangular cross-section, the chamber system 10, including the base 14, chamber body 20 and upper frame 24 of Figure 3, has a square cross-section when in plan view from above and the cover 26 is shown having a circular cross-section. The skilled person will appreciate that any size or geometrical configuration of chamber system 10 is entirely possible, including any number of circular and/or ellipsoid and/or rectangular and/or curved geometric shapes, including pentagonal, hexagonal, octagonal or any suitable polygonal shape when in plan view, and this is not intended to be limiting.

Figure 4 shows a second embodiment of the chamber system 10. The construction of the second embodiment is very similar to that of the first embodiment and corresponding features have been given the same reference numerals. The second embodiment differs from the first embodiment in that instead of a straight elongate chamber body 20, the unitary chamber body 20 can be formed having an integral upper frame or lip 32 for receiving the access cover 26.

Figure 5 shows a third embodiment of the chamber system 10. The construction of the third embodiment is very similar to that of the first and second embodiments and corresponding features have been given the same reference numerals. The third embodiment of the invention comprises a retrofittable chamfered internal liner 34 that can be received inside existing concrete chambers 36. In this way, there is no need to remove or repair the damaged existing concrete chamber 36, and a chamfered liner 34 can instead be placed around the asset 12 to effect a useful repair. The internal liner 34 does not include ant external ribs.

Figure 6 shows a fourth embodiment of the chamber system 10. The construction of the fourth embodiment is very similar to that of the first and second embodiments and corresponding features have been given the same reference numerals. The fourth embodiment of the invention comprises a lower and upper sealing platform, 28A and 28B respectively, wherein the lower sealing platform 28A replaces the base 28 in the first and second embodiments.

Referring also to Figure 7, each of the lower and upper sealing platforms, 28A and 28B, have a central opening 38. An inner seating groove 42 and an outer seating groove 44 extend at least partially, and preferably completely, around the central opening 38.

The lower and upper sealing platforms, 28A and 28B, are formed from a material comprising polyvinyl chloride (PVC) and are approximately 50mm thick. The width and length of each sealing platform, 28A and 28B, is dimensioned to fit specific dimensions of the chamber and may be, for example, approximately: 200x200mm; 400x250mm; 450x450mm; 600x600mm and 900x600mm

The lower and upper sealing platforms, 28A and 28B, are advantageously identical elements which, in use, are disposed such that the inner and outer grooves, 42 and 44, of the lower sealing platform 28A face the inner and outer grooves, 42 and 44, of the upper sealing platform. The chamber body 20 is disposed between the lower and upper platforms, 28A and 28B, such that each end of the chamber body 20 is seated in either the inner or outer groove, 42 or 44, of the respective sealing platform, 28A and 28B to provide a fluid, or at least a liquid, seal between the sealing platforms, 28a and 28B, and the chamber body 20 and thereby, in use, at least substantially mitigate ingress of water into the chamber.

The lower and upper sealing platforms, 28A and 28B, being identical elements enables savings on tooling and manufacturing the system.

The provision of an inner groove 42 and an outer groove 44, allows for accommodation of end of the chamber body 20 where the length of the chamber body 20 terminates on a narrower chamber body dimension, in the inner groove 42, or on a wider dimension of a rib 22, in the outer groove 44.

During installation, where a concrete base is required, only a small quantity of concrete is required to self-level a base under the lower sealing platform 28A. This is particularly advantageous because known methods and systems generally require excavation around and removal of a damaged concrete chamber before rebuilding the chamber. This requires a significant quantity of concrete. Therefore, the system 10, according to the present invention, is easier and requires less time to install, is less expensive to purchase and install and is more environmentally friendly compares to using concrete.

Referring to Figure 8, an upper sealing platform 28B can also used to seal an existing or new concrete chamber 36 and is operable to provide a seal between the chamber body 20 and the upper sealing platform 28B in the same manner as described above with reference to Figures 6 and 7, with the peripheral outer portions of the upper sealing platform 28B also extending to overlie the upper surface of the chamber 36.

Figure 9 shows a fifth embodiment of a chamber system 10 which comprises a chamber body 20 having an integral base 46 and an upper sealing platform 28B for providing an inspection chamber. Having an integral base 46 is advantageous because it enables the inspection chamber to be sealed against the ingress of fluid, or at least liquid. The upper sealing platform 28B is operable to cooperate with the chamber body 22 to provide a sealed upper portion of the chamber body, as described with reference to Figures 6-8 above, on which the upper frame 24 and cover 26 can be disposed.

In use, the chamber system 10 is positioned and backfilled with aggregate and/or other building materials to surround the chamber system 10.

The invention is not intended to be limited to the details of the embodiments described herein, which are described by way of example only. It is contemplated by the inventor that various substitutions, alterations and modifications may be made to the invention without departing from the spirit and scope of the invention as defined by the claims. It will be understood that features described in relation to any particular embodiment can be featured in combination with other embodiments.

As an example, although particular embodiments refer to utilising the chamber system 10 formed from virgin polymer materials, this is no way intended to be limited as any number of different types of polymer, including recycled polymers from both postindustrial and domestic waste streams, can be used.

In addition, the present invention can be used with a retrofittable RFID tag (not shown) which can be received within at least on part of the chamber system 10 for audit purposes, and to allow asset 12 tracking and location.

The chamber body 20 and liner 34 can be supplied in a range of lengths. The choice of length would be dependent on the size required to bring the uppermost surface of the upper frame or lip 24, 32 to the level of the surrounding road or ground surface. The chamber body 20 and liner 34 of the present invention is supplied in Im lengths as standard. The skilled person will understand that many other sizes are possible, and the above is in no way intended to be limiting and exhaustive.

Claims

1. A chamber system for an access chamber, comprising:

a base;

2. The system as claimed in claim 1, wherein the base is a split base being assemblable around an underground asset.

3. The system as claimed in claim 2, wherein the split base is formed from two complementary shaped sections that each include an opening or cut-out, such that when the two complementary sections are placed in abutment they form a mating pair which defines an aperture through which an underground asset can be received.

4. The system as claimed in claim 3, wherein the opening is pre-formed or includes a series of cut-out panels of different sizes and shapes defined by lines of weakness which can be snapped out.

5. The system as claimed in any of the preceding claims, wherein around the periphery of the base is a peripheral lip into which the chamber body can be received.

6. The system as claimed in any of the preceding claims, wherein the chamber body is formed as a single elongate piece.

7. The system as claimed in any of the preceding claims, wherein disposed around the outer faces of the chamber body are a series of external transverse ribs.

8. The system as claimed in any of the preceding claims, wherein the chamber body has a length of around Im, and/or optionally wherein the transverse ribs project outwardly at around 5mm in height and around 5mm in width from the outer faces of the chamber body, and/or optionally wherein the spacing between successive ribs is around 100mm.

08 08 19

9. The system as claimed in claim 1, wherein the lowermost surface of the frame includes a peripheral lip into which the chamber body can be received, and wherein the uppermost surface of the frame is situated overground when in use.

10. The system as claimed in any of the preceding claims, wherein the access cover is removable or can be attached to frame via a push-fit, hinge or any other attachment means.

10

11. The system as claimed in any of the preceding claims, wherein the assembled chamber can be retained by a close or interference fit between the base, chamber body upper frame and access cover, and/or by the use of threaded fasteners and/or a suitable adhesive and/or any suitable fixing means.

15

12. The system as claimed in any of the preceding claims, further comprising:

a coupler for receiving abutting chamber bodies by a push-fit arrangement.

13. The system as claimed in any of the preceding claims, wherein the base is formed as a sealed unit with the chamber body, or wherein the base is integrally formed in one

20 piece of material with the chamber body.

14. The system as claimed in any of the preceding claims, wherein the chamber system has rectangular or square cross-section when in plan view from above and/or any number of circular and/or ellipsoid and/or curved geometric shapes, including

25 pentagonal, hexagonal, octagonal or any suitable polygonal shape when in plan view from above.

15. The system as claimed in any of the preceding claims, wherein the base, chamber body, upper frame and access cover have a wall thickness between around 6mm to

30 around 8mm.

16. The system as claimed in any of the preceding claims, wherein the chamber body is formed having an integral upper frame or lip for receiving the access cover, and/or optionally

08 08 19 wherein the chamber body is a retrofittable chamfered internal liner that can be received inside an access chamber.

5

17. The system as claimed in any of the preceding claims, further comprising:

a retrofittable RFID tag which can be received within at least on part of the chamber system for audit purposes and/or to allow asset tracking and location.

18. The system as claimed in any of the preceding claims, further comprising:

10 an upper sealing platform operable to cooperate with the upper end of the chamber body to provide a fluid seal therewith; and a lower sealing platform operable to cooperate with the lower end of the chamber body to provide a fluid seal therewith.

15

19. The system as claimed in claim 18, wherein at least one of the lower and upper sealing platforms comprises a central opening.

20. The system as claimed in claim 19, wherein at least one of the lower and upper sealing platforms comprises a seating groove for receiving an end of the chamber body to

20 form a fluid seal between the sealing platform and the chamber body.

21. The system as claimed in claim 20, wherein the seating groove comprises an inner seating groove and an outer seating groove, and wherein the lower sealing platform is the base.

22. A method of manufacturing an access chamber, comprising the steps of: supplying a polymer into one or more moulding tools which define base, an upper frame or lip for supporting an access cover, and a chamber body; and ejecting the moulded split base, upper frame, access cover and chamber body 30 from the moulding tool.

23. A method as claimed in claim 22, wherein the moulding tools define a split base being assemblable around an underground asset, and wherein the base may be a sealing platform operable to cooperate with the chamber body to provide a fluid, or liquid, seal between the sealing platform and the chamber body.

24. A method as claimed in claims 22 or 23, wherein the base is integrally formed 5 with the chamber body in a suitable tool, which provides a combined chamber body and base.

25. The method as claimed in claims 22 to 24, wherein the polymer includes a blend of recycled polymers from both post-industrial and domestic waste streams, and/or

10 optionally further comprises the step of admixing a masterbatch or coloured pigment additive with the polymer.

CO