US20180087283A1 - System and method for making polymer concrete - Google Patents
System and method for making polymer concrete Download PDFInfo
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- US20180087283A1 US20180087283A1 US15/723,000 US201715723000A US2018087283A1 US 20180087283 A1 US20180087283 A1 US 20180087283A1 US 201715723000 A US201715723000 A US 201715723000A US 2018087283 A1 US2018087283 A1 US 2018087283A1
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- Prior art keywords
- aggregate
- resin
- sidewall
- manhole apparatus
- mold
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
- E04G21/14—Conveying or assembling building elements
- E04G21/142—Means in or on the elements for connecting same to handling apparatus
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/16—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
- B28B7/168—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes for holders or similar hollow articles, e.g. vaults, sewer pits
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/22—Component parts, details or accessories; Auxiliary operations
- B29C39/42—Casting under special conditions, e.g. vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
- B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
- B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D29/00—Independent underground or underwater structures; Retaining walls
- E02D29/12—Manhole shafts; Other inspection or access chambers; Accessories therefor
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D29/00—Independent underground or underwater structures; Retaining walls
- E02D29/12—Manhole shafts; Other inspection or access chambers; Accessories therefor
- E02D29/124—Shaft entirely made of synthetic material
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- E—FIXED CONSTRUCTIONS
- E03—WATER SUPPLY; SEWERAGE
- E03B—INSTALLATIONS OR METHODS FOR OBTAINING, COLLECTING, OR DISTRIBUTING WATER
- E03B7/00—Water main or service pipe systems
- E03B7/09—Component parts or accessories
-
- E—FIXED CONSTRUCTIONS
- E03—WATER SUPPLY; SEWERAGE
- E03F—SEWERS; CESSPOOLS
- E03F5/00—Sewerage structures
- E03F5/02—Manhole shafts or other inspection chambers; Snow-filling openings; accessories
-
- E—FIXED CONSTRUCTIONS
- E03—WATER SUPPLY; SEWERAGE
- E03F—SEWERS; CESSPOOLS
- E03F5/00—Sewerage structures
- E03F5/02—Manhole shafts or other inspection chambers; Snow-filling openings; accessories
- E03F5/024—Manhole shafts or other inspection chambers; Snow-filling openings; accessories made of plastic material
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L1/00—Laying or reclaiming pipes; Repairing or joining pipes on or under water
- F16L1/024—Laying or reclaiming pipes on land, e.g. above the ground
- F16L1/028—Laying or reclaiming pipes on land, e.g. above the ground in the ground
- F16L1/038—Laying or reclaiming pipes on land, e.g. above the ground in the ground the pipes being made in situ
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- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Mechanical Engineering (AREA)
- Structural Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Hydrology & Water Resources (AREA)
- Water Supply & Treatment (AREA)
- Public Health (AREA)
- Health & Medical Sciences (AREA)
- Paleontology (AREA)
- Mining & Mineral Resources (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Environmental & Geological Engineering (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Sewage (AREA)
Abstract
Resin-based structures for use in corrosive environments. The resin-based structures may include a mixture of resin and aggregate. The resin-based structures may be formed in a mold by placing aggregate and resin into the mold. The resin-based structures may have thin wall design with high compression and tension strength.
Description
- This application is a continuation of U.S. patent application Ser. No. 15/632,068, filed Jun. 23, 2017, which is a continuation of U.S. patent application Ser. No. 15/431,667, filed Feb. 13, 2017, which is a continuation of U.S. patent application Ser. No. 14/029,573, filed Sep. 17, 2013, now U.S. Pat. No. 9,567,760, issued Feb. 14, 2017, which is a continuation of U.S. patent application Ser. No. 13/861,316, filed Apr. 11, 2013, which claims the benefit of U.S. Provisional Patent Application No. 61/747,190, filed Dec. 28, 2012, and application Ser. No. 13/861,316 is also a continuation-in-part of U.S. patent application Ser. No. 13/676,084, filed Nov. 13, 2012, which is a continuation of U.S. patent application Ser. No. 13/537,027, filed Jun. 28, 2012, which is a continuation of U.S. patent application Ser. No. 13/372,393, filed Feb. 13, 2012, which is a continuation of U.S. patent application Ser. No. 13/245,821, filed Sep. 26, 2011, which claimed the benefit of U.S. Provisional Application No. 61/386,439, filed on Sep. 24, 2010, which are hereby incorporated by reference herein in their entirety, including but not limited to those portions that specifically appear hereinafter, the incorporation by reference being made with the following exception: In the event that any portion of the above-referenced applications are inconsistent with this application, this application supercedes said above-referenced applications.
- Not Applicable.
- The present disclosure relates generally to polymer concrete structures, and systems and methods for making the same.
- Traditional concrete is a material composed of two main materials, namely, common cement and aggregate, that are mixed together in a mixer and then poured into a form. Common cement is traditionally made by heating limestone, with small quantities of other materials, in a kiln. The resulting hard substance removed from the kiln is then ground with a small amount of gypsum into a powder to make the cement. The aggregate mixed with the cement may comprise coarse particulate material, that including sand and gravel. One drawback to the use of common cement in concrete is that it tends to breakdown over time. For example, common cement used in concrete may breakdown due to microorganisms that actually may feed on the cement itself.
- Recent advancements in concrete technology have resulted in the common cement traditionally used in concrete being replaced with a synthetic resin, such as polymer resin. For example, in the past, polymer concrete was formed by mixing a polymer with an aggregate in a mixer. One significant drawback to the use of a polymer in a mixer is that due to the polymer's relatively short cure time, the mixer may be ruined, or rendered unusable for a significant period of time, unless the polymer and aggregate mixture is quickly removed from the mixer. One object of the present invention is to eliminate the need for mixing the polymer and aggregate in a mixer.
- The features and advantages of the present disclosure will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the present disclosure without undue experimentation. The features and advantages of the present disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.
- The features and advantages of the disclosure will become apparent from a consideration of the subsequent detailed description presented in connection with the accompanying drawings in which:
-
FIG. 1 is a side view of a mold pursuant to an embodiment of the present disclosure; -
FIG. 2 is a cross-sectional view of the mold depicted inFIG. 1 with a layer of aggregate deposited therein; -
FIG. 3 is a cross-sectional view of the mold depicted inFIG. 1 with a layer of aggregate deposited therein further showing resin being deposited on the top of the layer of aggregate; -
FIG. 4 is a cross-sectional view of the mold depicted inFIG. 1 with stacked layers of aggregate deposited therein further showing resin being deposited on the top of the uppermost layer of aggregate; -
FIG. 5 is a cross-sectional view of the mold depicted inFIG. 1 with stacked layers of aggregate filled to the top of the mold; -
FIG. 6 is a perspective view of a resin-based structure formed by the mold depicted inFIG. 1 ; -
FIG. 7 depicts a process for forming a resin-based structure in a mold pursuant to an embodiment of the present disclosure; -
FIG. 8 is a perspective and fragmentary view of a resin-based structure formed pursuant to an embodiment of the present disclosure; -
FIG. 9 is a perspective and fragmentary view of a resin-based structure formed pursuant to an embodiment of the present disclosure; -
FIG. 10 is a perspective and fragmentary view of a resin-based structure formed pursuant to an embodiment of the present disclosure; -
FIG. 11 is a perspective and fragmentary view of a resin-based structure formed pursuant to an embodiment of the present disclosure; -
FIG. 12 is a perspective and fragmentary view of a resin-based structure formed pursuant to an embodiment of the present disclosure; -
FIG. 13 is a perspective and fragmentary view of a resin-based structure formed pursuant to an embodiment of the present disclosure; -
FIG. 14 is a perspective of a resin-based structure formed pursuant to an embodiment of the present disclosure; -
FIG. 15 is a cross-sectional view of a resin-based structure formed pursuant to an embodiment of the present disclosure; -
FIG. 16 is a cross-sectional view of a resin-based structure formed pursuant to an embodiment of the present disclosure; -
FIG. 17 is a cross-sectional view of the mold depicted inFIG. 1 with resin deposited therein; -
FIG. 18 is a cross-sectional view of the mold depicted inFIG. 17 with aggregate deposited therein; -
FIG. 19 is a diagram of a system for casting polymer concrete structure; -
FIG. 20 is a cross-sectional view of a polymer concrete structure having projections extending from an inner surface; -
FIG. 21 is an exploded view of a manhole assembly according to an embodiment of the present disclosure; and -
FIG. 22 is a diagram of a vibrator pursuant to an embodiment of the present disclosure. - For the purposes of promoting an understanding of the principles in accordance with the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the disclosure as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the disclosure claimed.
- It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. In describing and claiming the present disclosure, the following terminology will be used in accordance with the definitions set out below. As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps.
- Referring now to
FIG. 1 , there is depicted amold 100 for forming a resin-based structure pursuant to an embodiment of the present disclosure. Themold 100 may include an outer mold orwall 102 and in inner mold orwall 104. It will be appreciated that themold 100 may take virtually any size or shape. Themold 100 may be manufactured to any shape and size to meet any specification required. In an embodiment of the present disclosure, themold 100 may be utilized to form a structure with an opening and detachable cover that gives access to an enclosed area, such as a sewer, drain or tank. In an embodiment of the present disclosure, themold 100 may be utilized to form a manhole for use in accessing a sewer, drain, or tank. In an embodiment of the present disclosure, themold 100 may be utilized to form a pipe for use in an underground system for carrying sewage or water. In an embodiment of the present disclosure, themold 100 may be utilized to form a vault structure. In an embodiment of the present disclosure, themold 100 may be utilized to form a raceway for use in a sewage treatment plant. - The
outer mold 102 may be formed from twopieces pieces FIG. 1 ). Lockingdevices 112 may secure the twopieces outer mold 102 together. In an embodiment of the present disclosure, theouter mold 102 may be of unitary construction. Theinner mold 104 may be sized to fit inside of theouter mold 102. - Referring now to
FIG. 2 , there is depicted a cross-sectional view of themold 100 taken along the section A-A shown inFIG. 1 mounted on abase member 120. Aninner surface 114 of theouter mold 102 and anouter surface 116 of theinner mold 104 may be separated by a distance, W, sometimes referred to herein as a wall thickness. In an embodiment of the present disclosure, the wall thickness, W, may be between about two and ten inches. Theinner surface 114 of theouter mold 102 and anouter surface 116 of theinner mold 104 and anupper surface 122 of thebase member 120 may define acavity 118. Thecavity 118 may take the form of the desired resin-based structure as is known to one having ordinary skill in the art. An diameter inner diameter, D, of the mold may be between about ten inches and one hundred inches. - As can be observed in
FIG. 2 , a first step of forming a resin-based structure using themold 100 may be to place a first layer ofaggregate 124 in thecavity 118 and on top of theupper surface 122 of thebase member 120. The first layer ofaggregate 124 may extend upwardly from theupper surface 122 of thebase member 120 to a predetermined height, H. The first layer ofaggregate 124 may have a width, W. A total volume, V, of the first layer ofaggregate 124 in thecavity 118 may be determined from its height, H, its width, W, as well as a radius R2 of theinner surface 114 of theouter mold 102 and a radius R1 of theouter surface 116 of theinner mold 104. The first layer ofaggregate 124 may be placed into themold 100 by hand or by an automated process. - Once the first layer of
aggregate 124 is in place in themold 100, aresin 150 may be directed from asupply 154 through aguide 156 and then onto atop surface 152 of the first layer ofaggregate 124 as shown inFIG. 3 . It will be appreciated that theresin 150 may briefly accumulate on thetop surface 152 of theaggregate 124. The application of theresin 150 may be accomplished by hand or by an automated process. Theresin 150 may be applied to the entiretop surface 152 of the first layer ofaggregate 124. Once in place, theresin 150 may be allowed to gravity feed from thetop surface 152 of the first layer ofaggregate 124 to theupper surface 122 of thebase member 120. - As shown in
FIG. 4 , theresin 150 applied to thetop surface 152 of the first layer ofaggregate 124 may gravity feed to theupper surface 122 of thebase member 120. A second layer of aggregate 124A may then be placed onto thetop surface 152 of the first layer ofaggregate 124.Resin 150 from thesupply 154 may be directed by theguide 156 onto atop surface 158 of the second layer ofaggregate 124A. It will be appreciated that theresin 150 may briefly accumulate on thetop surface 158 of the aggregate 124A. Theresin 150 may be applied to the entiretop surface 158 of the second layer ofaggregate 124A. - Once in place, the
resin 150 may gravity feed from thetop surface 158 of the second layer of aggregate 124A to thetop surface 152 of the first layer ofaggregate 124. It will be appreciated that the above described process may then be repeated as many times as necessary until the layers of aggregate reach the top of themold 100 as shown inFIG. 5 . Once themold 100 is filled to a desired level, theresin 150 and aggregate mixture may then be allowed to cure for a period of time before removal of themold 100. - Referring now to
FIG. 6 , there is depicted a resin-basedstructure 200 that may be formed by themold 100. In an embodiment, the resin-basedstructure 200 may be used as a riser in a manhole assembly. Thestructure 200 may have a height, H1. As can be observed, thestructure 200 may have a generally cylindrical shape having an outer diameter, D2. Thestructure 200 may comprise anouter surface 202 and aninner surface 204. Theouter surface 202 and theinner surface 204 may be separated by asurface 206. Theinner surface 204 may form ahollow passageway 208 in thestructure 200 having an inner diameter, D1. A distance between theouter surface 202 and theinner surface 204 may be a wall thickness, T.Multiple structures 200 may be joined end-to-end to form a fluid pathway. A lap joint (not explicitly shown) may be utilized to interconnectmultiple structures 200 end-to-end. - Referring now to
FIG. 7 , there is depicted asystem 300 for forming a resin-based structure. Thesystem 300 may comprise amold 302. Themold 302 may comprise anouter mold 304 and aninner mold 306. It will be appreciated that themold 302 may take virtually any size or shape. Themold 302 may be manufactured to any shape and size to meet any specification required. In an embodiment of the present disclosure, themold 302 may be utilized to form a structure with an opening and detachable cover that gives access to an enclosed area, such as a sewer, drain or tank. In an embodiment of the present disclosure, themold 302 may be utilized to form a manhole for use in accessing a sewer, drain, or tank. In an embodiment of the present disclosure, themold 302 may be utilized to form a pipe for use in an underground system for carrying sewage or water. In an embodiment of the present disclosure, themold 302 may be utilized to form a vault structure. In an embodiment of the present disclosure, themold 302 may be utilized to form a raceway for use in a sewage treatment plant. For purposes of convenience, acutaway portion 305 of theouter mold 304 shows a cavity orspace 316 between theouter mold 304 and theinner mold 306. (During operation, thecutaway portion 305 would not be present.) - In an embodiment of the present disclosure, the
mold 302 may be mounted on arotatable base member 308. Thebase member 308 may rotate around a central axis of themold 302. For example, thebase member 308 may be connected to ashaft 340 of amotor 342 that may rotate thebase member 308 and themold 302 in the direction indicated by an arrow marked with thereference numeral 320. In an embodiment of the present disclosure, the rate of revolution of themold 302 may be controlled by controlling the speed of themotor 342. Themotor 342 may be electric or hydraulic. - A
hopper 310 may contain a supply ofaggregate 312. Anaggregate guide member 314 may extend from thehopper 310 to aterminal end 318 positioned in thecavity 316 between theouter mold 304 and theinner mold 306 of themold 302. Theaggregate guide member 314 may take the form of a chute, tube, channel, walls or any other structure for guiding aggregate into themold 302. In an embodiment of the present disclosure, theaggregate guide member 314 may include a mechanized apparatus for moving aggregate. The mechanized apparatus may include a conveyor belt or auger. In an embodiment of the present disclosure, the flow of aggregate through theaggregate guide member 314 may be controlled such that the aggregate is deposited into themold 302 at a predetermined rate. For example, an aperture (not shown) may control the flow of aggregate from thehopper 310. - The
aggregate guide member 314 may allow aggregate 312 to be directed into thecavity 316. The flow ofaggregate 312 through theaggregate guide member 314 may be constant or varied. In an embodiment of the present disclosure, the flow ofaggregate 312 through theaggregate guide member 314 may be controllable. Areservoir 322 may contain a supply ofresin 324. Aresin guide member 326 may extend from thereservoir 322 to aterminal end 328 positioned in thecavity 316 between theouter mold 304 and theinner mold 306. In an embodiment of the present disclosure, theresin guide member 326 may comprise a tube, channel, passage way, walls or a spout. - The
resin guide member 326 may allowresin 324 to be directed into thecavity 316. The flow ofresin 324 through theresin guide member 326 may constant or varied. In an embodiment of the present disclosure, the flow ofresin 324 through theresin guide member 326 may be controllable. Theaggregate guide member 314 may be positioned in front of theresin guide member 326 with respect to the direction of rotation of themold 302. Further, the vertical height of the terminal ends 318 and 328 of theguides aggregate 312 accumulate in the mold, the terminal ends 318 and 328 may be raised. Alternatively, theentire mold 302 may be lowered. - A process of forming a resin-based structure using the
system 300 will now be explained. At startup, themold 302 may be placed in rotation at a constant rate in the direction shown by the arrow marked with thereference numeral 320. Alternatively, one or both of theguides mold 302 is placed in movement relative to theguides guides cavity 316. - Once the
mold 302 is rotating, a continuous flow ofaggregate 312 from thehopper 310 may commence to begin forming the first layer in the bottom of themold 302. A continuous flow ofresin 324 from thereservoir 322 may also then commence. Theresin 324 may be deposited on top of the first layer. Theresin 324 may flow at a predetermined rate. - At the time shown in
FIG. 7 , a first layer ofaggregate 330 withresin 324 has already been laid in the bottom of themold 302. A second layer ofaggregate 332 withresin 324 is shown in the process of getting laid on asurface 334 of the first layer ofaggregate 330. Each of the layers ofaggregate 312 in themold 302 may have a height, H. The rate of flow ofaggregate 312 may be adjusted to obtain any desired height, H. Alternatively, the rate of rotation of themold 302 may also be varied to obtain any desired height, H. The above-described process may continue by creating a continuous, stacked and spiraling upward layer ofaggregate 312 andresin 324 in themold 302 until the aggregate 312 andresin 324 mixture reach the top of themold 302. - It will be appreciated that, in an embodiment of the present disclosure, the
mold 302 may be held motionless while theguide members mold 302. In an embodiment of the present disclosure, both theguide members mold 302 may be moved. - It will be further appreciated that the above-described process may be adapted for non-circular molds, such a rectangular and square molds. For example, in an embodiment of the present disclosure, a mold, or aggregate and resin supply guides, or both, may be moved in a pre-set pattern to generate multiple and stacked layers of a mixture of aggregate and resin. In an embodiment of the present disclosure, the
mold 302 may be a vacuum tight mold such that the resin is drawn through the aggregate using a vacuum source. In an embodiment of the present disclosure, themold 302 may not be a vacuum mold. - Referring now to
FIGS. 1-7 , pursuant to an embodiment of the present disclosure, the height, H, of each layer of aggregate deposited in themolds molds molds - In an embodiment of the present disclosure, the resin-based structure formed by the
molds FIG. 5 . In an embodiment of the present disclosure, the height or length, H1, may be between about six feet to fifteen feet. A ratio of the height, H, of a layer of aggregate to the height of the overall resin-based structure, H1, may be less than about 3% or 5%. In an embodiment of the present disclosure, a ratio of the height, H, of a layer of aggregate to the height, H1, of the overall resin-based structure may be less than about 2%. In an embodiment of the present disclosure, a ratio of the height, H, of a layer of aggregate to the height, H1, of the overall resin-based structure may be less than about 1%. - In an embodiment of the present disclosure, it will be appreciated that a constraint on the height, H, of each layer of aggregate placed in the
molds - In an embodiment of the present disclosure, a suitable aggregate for use in creating a resin-based structure may include inert granular materials, such as sand, gravel, or crushed stone. A suitable aggregate may include both fine aggregates and coarse aggregates. In an embodiment of the present disclosure, a suitable aggregate may have minimal inert materials smaller than about 300 nanometers. In an embodiment of the present disclosure, a suitable aggregate may have minimal inert materials smaller than about 400 nanometers. In an embodiment of the present disclosure, a suitable aggregate may have minimal inert materials smaller than about 500 or 550 nanometers. In an embodiment of the present disclosure, a suitable aggregate may have minimal inert materials smaller than about 600 nanometers. In an embodiment of the present disclosure, a suitable aggregate may have minimal inert materials smaller than about 700 nanometers. As used herein, the term “minimal” may mean 0%, less that 1%, less than 5%, less than 10%, or less than between about 1% to 10%.
- In an embodiment of the present disclosure, a suitable aggregate may have inert materials all larger than about 400 to 600 nanometers. In an embodiment of the present disclosure, a suitable aggregate may have inert materials all larger than about 550 nanometers. In an embodiment of the present disclosure, a suitable aggregate may have inert materials all larger than about 600 nanometers.
- In an embodiment of the present disclosure, the aggregate may account for between 70-95% of the volume of a resin-based structure. In an embodiment of the present disclosure, the aggregate may account for approximately 80-90% of the volume of a resin-based structure. In an embodiment of the present disclosure, the aggregate may account for approximately 85% of the volume of a resin-based structure.
- In an embodiment of the present disclosure, the resin may be a polymer resin or a monomer resin. In an embodiment of the present disclosure, the resin may have a low viscosity, similar to that of water, such that the resin may percolate or gravity flow through a layer of aggregate. A suitable resin for use with the present disclosure may be an infusion resin. A suitable resin may be of a thermal-set type.
- In an embodiment of the present disclosure, the resin may account for between 5-30% of the volume of a resin-based structure. In an embodiment of the present disclosure, the resin may account for approximately 10-20% of the volume of a resin-based structure. In an embodiment of the present disclosure, the resin may account for approximately 15% of the volume of a resin-based structure. The amount of resin applied to a layer of aggregate may be determined from the foregoing to thereby maintain a desired volume of resin in a resin-based structure.
- In an embodiment of the present disclosure, the volume of resin deposited on top of a single layer of aggregate may be between about 5% to 30% of the volume of the layer of aggregate. In an embodiment of the present disclosure, the volume of resin deposited on top of a layer of aggregate may be between about 10% to 20% of the volume of the layer of aggregate. In an embodiment of the present disclosure, the volume of resin deposited on top of a layer of aggregate may be about 15% of the volume of the layer of aggregate.
- In an embodiment of the present disclosure, a resin-based structure created by a process disclosed herein may have a compressive strength of about 8,000-15,000 PSI, a tensile strength of about 1,500-5,000 PSI, and a bending strength of about 2,000-4,000 PSI.
- It will be appreciated by those having skill in the art, that the present disclosure may be adapted to form various resin-based structures using molds of various size, shapes and configurations. In an embodiment of the present disclosure, a resin-based structure may be formed by adding an aggregate and a resin separately into a mold. In an embodiment of the present disclosure, aggregate may be placed into a mold in stacked layers having predetermined thicknesses. Resin may be poured or injected onto each layer of aggregate prior to the subsequent layer of aggregated being stacked on top of it. A continuous pour of layers of aggregate and resin may allow structures of extended length to be formed.
- Referring now to
FIGS. 8-16 , there are depicted various resin-based structures that may be formed in accordance with the present disclosure. Referring now toFIG. 8 , there is depicted a fragmentary view of a resin-basedstructure 400 taking the form of aperforated manhole section 402. Theperforated manhole section 402 may includeperforations 404 that extend from anouter surface 406 to aninner surface 408. Theperforated manhole section 402 may include atongue 410 extending from one end and agroove 412 on the other end. It will be appreciated that thetongue 410 and thegroove 412 allow multipleperforated manhole sections 402 to be stacked end-to-end using lap joint type connections. Theperforated manhole section 402 may be formed in a mold where the aggregate and resin are added to the mold separately and in stacked layers as described above. - Referring now to
FIG. 9 , there is depicted a fragmentary view of a resin-basedstructure 500 taking the form of amanhole base 502. Themanhole base 502 may include abottom member 504 and acylindrical sidewall 506. Thebottom member 504 may close alower end 512 of ahollow passage 514 formed by thesidewall 506. Thesidewall 506 may include atongue 508 extending from itstop end 510. It will be appreciated that thetongue 508 may interlock with a groove in another member. Atop surface 516 of thebottom member 504 may include adepression 518. Thesidewall 506 may include openings 520 (only one visible) in alignment with thedepression 518. Themanhole base 502 may be formed in a mold where the aggregate and resin are added to the mold separately and in stacked layers as described above. - Referring now to
FIG. 10 , there is depicted a fragmentary view of a resin-basedstructure 600 taking the form of aneccentric manhole cone 602. Themanhole cone 602 may include aneccentric cone portion 604. Ahollow passage 606 may extend from atop opening 608 to abottom opening 610. Agroove 612 may be formed in thebottom opening 610 for interlocking with a tongue of another member. Themanhole cone 602 may be formed in a mold where the aggregate and resin are added to the mold separately and in stacked layers as described above. - Referring now to
FIG. 11 , there is depicted a fragmentary view of a resin-basedstructure 700 taking the form of anconcentric manhole cone 702. Themanhole cone 702 may include acone portion 704. Ahollow passage 706 may extend from atop opening 708 to abottom opening 710. Agroove 712 may be formed in thebottom opening 710 for interlocking with a tongue of another member. Themanhole cone 702 may be formed in a mold where the aggregate and resin are added to the mold separately and in stacked layers as described above. - Referring now to
FIG. 12 , there is depicted a fragmentary view of a resin-basedstructure 800 taking the form of amanhole base 802. Themanhole base 802 may include abottom member 804 and acylindrical sidewall 806. Thebottom member 804 may close alower end 812 of ahollow passage 814 formed by thesidewall 806. Thesidewall 806 may include atongue 808 extending from itstop end 810. It will be appreciated that thetongue 808 may interlock with a groove in another member. Themanhole base 802 may be formed in a mold where the aggregate and resin are added to the mold separately and in stacked layers as described above. - Referring now to
FIG. 13 , there is depicted a fragmentary view of a resin-basedstructure 900 taking the form of amanhole lid 902. Themanhole lid 902 may be substantially disc shaped and include atop surface 904 and abottom surface 906. Thetop surface 904 and thebottom surface 906 may be separated by asidewall 908. A locking lip 910 may protrude downwardly from thebottom surface 906. Themanhole lid 902 may be formed in a mold where the aggregate and resin are added to the mold separately and in stacked layers as described above. - Referring now to
FIG. 14 , there is depicted a view of a resin-basedstructure 1000 taking the form of amanhole ring 1002. Themanhole ring 1002 may be substantially disc shaped and include atop surface 1004 and abottom surface 1006. Thetop surface 1004 and thebottom surface 1006 may be separated by asidewall 1008. A hollow passage 1010 may be formed in thering 1002. Thering 1002 may be formed in a mold where the aggregate and resin are added to the mold separately and in stacked layers as described above. - Referring now to
FIG. 15 , there is depicted a section view of a resin-basedstructure 1100 taking the form of amanhole riser 1102. Theriser 1102 may include asidewall 1104 having anouter surface 1106 and aninner surface 1108. Theriser 1102 may include atongue 1110 extending from atop end 1112 and agroove 1114 formed in abottom end 1116. It will be appreciated that thetongue 1110 and thegroove 1114 may allowmultiple risers 1102 to be stacked end-to-end using lap joint type connections. Theriser 1102 may be formed in a mold where the aggregate and resin are added to the mold separately and in stacked layers as described above. - Referring now to
FIG. 16 , there is depicted a section view of a resin-basedstructure 1200 taking the form of apipe 1202. Thepipe 1202 may include asidewall 1204 having anouter surface 1206 and aninner surface 1208. Theinner surface 1208 may define ahollow passageway 1209 through thepipe 1202. Thepipe 1202 may include atongue 1210 extending from atop end 1212 and agroove 1214 formed in abottom end 1216. It will be appreciated that thetongue 1210 and thegroove 1214 may allowmultiple pipes 1202 to be stacked end-to-end using lap joint type connections. A diameter, D, and a length, L, of thepipe 1202 may vary. Thepipe 1202 may be formed in a mold where the aggregate and resin are added to the mold separately and in stacked layers as described above. In an embodiment of the present disclosure, the length, L, of thepipe 1202 may be between about six feet and twenty feet. In an embodiment of the present disclosure, the diameter, D, of thepipe 1202 may be between about ten inches and one hundred inches and the wall thickness between theouter surface 1206 and aninner surface 1208 of thesidewall 1204 may be between about two inches and ten inches. - Referring now to
FIG. 17 , there is depicted a method of forming a polymer concrete structure using themold 100 pursuant to an embodiment of the present disclosure, where like reference numerals indicate like components. In contrast to the procedure described in relation toFIGS. 2-7 , as shown inFIG. 17 , aresin 1300 is first poured into themold 100. The amount ofresin 1300 poured into themold 100 may comprise a sufficient amount for forming the structure. For example, in an embodiment of the present disclosure, theresin 1300 poured initially into themold 100 may account for between 5-30% of the volume of a resin-based structure formed by themold 100. In an embodiment of the present disclosure, theresin 1300 may account for approximately 10-20% of the volume of a resin-based structure formed by themold 100. In an embodiment of the present disclosure, theresin 1300 may account for approximately 15% of the volume of a resin-based structure formed by themold 100. - Referring now to
FIG. 18 , once a desired amount ofresin 1300 has been placed into themold 100, aggregate 1302 may be placed into themold 100 on top of theresin 1300. Theresin 1300 may flow upwards through theaggregate 1302. In an embodiment of the present disclosure, the aggregate 1302 may fill to the top of themold 100. In an embodiment of the present disclosure, the aggregate 1302 may be placed into themold 100 in lifts. In an embodiment of the present disclosure, the aggregate 1302 may account for between 70-95% of the volume of a resin-based structure formed by themold 100. In an embodiment of the present disclosure, the aggregate 1302 may account for approximately 80-90% of the volume of a resin-based structure. In an embodiment of the present disclosure, the aggregate 1302 may account for approximately 85% of the volume of a resin-based structure. It will be appreciated that placingresin 1300 into themold 100 separately from the aggregate 1302 precludes the need for pre-mixing the aggregate 1302 and theresin 1300. It will be further appreciated that placing substantially the entire amount ofresin 1300 into themold 100 first and then adding theaggregate 1302 eliminates the need for layering theaggregate 1302 andresin 1300 as described above. - Referring now to
FIG. 19 , there is shown asystem 1500 for casting polymer concrete structures, including structures for use in manhole assemblies, such as the structures shown inFIGS. 6 and 8-16 . Thesystem 1500 may include anelongated mixing tube 1502 having an auger (not visible) disclosed therein. The mixingtube 1502 may have adischarge end 1506 where an aggregate/resin mixture may be discharged. Amotor 1504 for turning the auger may be disposed on an end of themixing tube 1502 opposite thedischarge end 1506. In an embodiment, themotor 1504 may be an electric motor. In an embodiment, themotor 1504 may be a hydraulic motor. - In an embodiment, the mixing
tube 1502 may include anaggregate feeder port 1508, aresin feeder port 1510, and acatalyst feeder port 1512. Ahopper 1514 may be connected to theaggregate feeder port 1508. In an embodiment, thehopper 1514 may be fed by one or more conveyors (not shown) that direct a coarse and a fine aggregate into thehopper 1514 at a predetermined rate. The aggregate directed into thehopper 1514 may gravity feed through theaggregate feeder port 1508 into the mixingtube 1502 where it is moved towards thedischarge end 1506 by the turning of the auger. - In an embodiment, the
system 1500 may further include aresin reservoir 1516. Theresin reservoir 1516 may be connected to theresin feeder port 1510 by aresin supply tube 1518. In an embodiment, resin in thereservoir 1516 may be pumped or gravity fed into theresin feeder port 1510 where it enters into the mixingtube 1502. Once in themixing tube 1502, the resin may be mixed with the aggregate by the auger to form a resin and aggregate mixture. In an embodiment, theresin feeder port 1510 may disposed on themixing tube 1502 within 8 to 16 inches from thedischarge end 1506. In an embodiment, theresin feeder port 1510 may disposed on themixing tube 1502 at about 12 inches from thedischarge end 1506. - In an embodiment, the
system 1500 may further include acatalyst reservoir 1520. Thecatalyst reservoir 1520 may be connected to thecatalyst feeder port 1512 by acatalyst supply tube 1522. In an embodiment, a catalyst in thereservoir 1520 may be pumped or gravity fed into thecatalyst feeder port 1512 where it enters into the mixingtube 1502. Once in themixing tube 1502, the catalyst may be mixed with the resin/aggregate mixture by the auger. In an embodiment, the auger moves the resin/aggregate/catalyst mixture in themixing tube 1502 to thedischarge end 1506 where it is directed by asnorkel 1524 into amold 1526. - In an embodiment, the aggregate directed into the
hopper 1514 may include a coarse aggregate and a fine aggregate. The coarse aggregate may comprise rocks. The fine aggregate may comprise π70 fine sift sand. In an embodiment, theresin reservoir 1516 may contain resin and pigments. The resin may include one or more of a polymer resin, a pure cast resin, a crushed glass resin, fiberglass, a composite material, plastic, and an inorganic material. The catalyst in thecatalyst reservoir 1520 may include any substance that causes the resin to harden as is known to those having ordinary skill in the art. - The
mold 1526 may take substantially the same form asmold 100 shown inFIG. 1 above. Themold 1526 may include aninner mold 1528 and anouter mold 1530. In an embodiment, theinner mold 1528 and theouter mold 1530 may be cylindrical in shape such that they may form a hollow cylindrical structure such as a riser portion of a manhole structure. - The
inner mold 1528 and theouter mold 1530 may define mold space between them. In an embodiment, the width of the mold space may define a wall thickness of a polymer concrete structure formed by themold 1526. Further, anouter surface 1532 of theinner mold 1528 may form an inner diameter of a polymer concrete structure formed by themold 1526 while an inner surface of theouter mold 1530 may form an outer surface of the polymer concrete structure. - In an embodiment, the width of the mold space between the
outer surface 1532 of the inner mold 1258 and the inner surface of theouter mold 1530 may be less than 1/12th of a diameter of theouter surface 1532 of theinner mold 1528. In an embodiment, the width of the mold space may be between one and three inches, or about two inches, or greater than about one-half of an inch. - In an embodiment, a structure formed by the
mold 1532 may be cut to a suitable size. For example, a height of a structure formed by themold 1532 may be ten feet in length (meaning that themold 1532 is at least this same height). The structure may be cut to a desired length to form multiple sections, such as a four foot section and a six foot section from a ten foot structure formed by themold 1532. - The
system 1500 may further include amold support structure 1600 for rotating, vibrating and indexing themold 1526 beneath thedischarge end 1506 of themixing tube 1502. Thestructure 1600 may include abase member 1602 mounted on a set ofwheels 1604. Thewheels 1604 may be guided bytracks 1606. Aram arm 1608 may operated to move thebase member 1602 on thetracks 1606. In an embodiment, theram arm 1608 is operated by ahydraulic cylinder 1609. - A
first support structure 1610 may be supported by thebase member 1602. In particular, thefirst support structure 1610 may be coupled to ashaft 1612. In an embodiment, amotor 1614 may rotate theshaft 1612 such that thefirst support structure 1610 rotates about a vertical axis to thereby turn themold 1526. - A
second support structure 1616 may be disposed above, and may be supported by, thefirst support structure 1610. Thesecond support structure 1616 may include amold receiving surface 1618 onto which themold 1526 is placed. Themold 1526 may be held in place on themold receiving surface 1618 by a locking mechanism (not shown). - Attached to the
second support structure 1616 may be vibrators 1620. Thevibrators 1620 may be utilized to vibrate themold 1526 as it is filled with an aggregate/resin mixture. In an embodiment, thevibrators 1620 may include a rotating weight mounted to a motor driven shaft. For example, a rotating shaft may be mounted in any suitable manner on or in connection with thesecond support structure 1616, and a weight (not shown) may be disposed on the shaft in an asymmetrical configuration about the shaft, such that a weight density of the weight is distributed in an asymmetrical manner about a rotational axis of the shaft. Stated another way, the weight is unbalanced, or mounted off center, on the shaft. In an embodiment, thevibrators 1620 may operate at a low frequency, high amplitude. - Referring now to
FIG. 22 , there is shown a schematic of avibrator 1700 suitable for use as thevibrators 1620. Thevibrator 1700 may include ahousing 1702. Thehousing 1702 may be mounted to a structure using fasteners, such as bolts. Disposed within thehousing 1702 may be amotor 1704, such as an electrical or pneumatic motor. Themotor 1704 may drive ashaft 1706. Disposed on the end of theshaft 1706 may be aweight 1708 that is mounted off center from the axis of rotation of theshaft 1706. As theshaft 1706 is turned by themotor 1704, theweight 1708 vibrates thehousing 1702 and the structure to which thehousing 1702 is mounted. - In an embodiment, at least one
vibration isolator 1622 may be interposed between thefirst support structure 1610 and thesecond support structure 1616. In an embodiment, the at least onevibration isolator 1622 may be pneumatic, such as an airbag. It will be appreciated that the at least onevibration isolator 1622 may minimize the effects of vibrations on thefirst support structure 1610 to prevent damage to themotor 1614. In an embodiment, thesecond support structure 1616 rotates when thefirst support structure 1610 rotates. - The manner in which the
mold 1526 may be filled with polymer concrete using thesystem 1500 will now be described. Themold 1526 may placed onto themold receiving surface 1618 using a lift (not shown). Themold 1526 may then be indexed by theram arm 1608 beneath thedischarge end 1506 of themixing tube 1502. Themotor 1614 may then be activated to rotate themold 1526 around a vertical axis. Thevibrators 1620 may then be activated to cause themold 1526 to vibrate. - Next, the
motor 1504 may be activated to cause the auger (not shown) inside of themixing tube 1502 to turn. With the auger turning, aggregate may be fed into thehopper 1514 where it is gravity fed into the mixingtube 1502. A resin mixture in thereservoir 1516, with any desirable pigments, may be fed through thetube 1518 into the mixingtube 1502 where it is mixed with the aggregate. The catalyst in thereservoir 1520 is then fed into the mixingtube 1502 through thetube 1522 and mixed by the auger with the resin and aggregate mixture. - The aggregate/resin/catalyst mixture in the
mixing tube 1502 is then pushed by the auger out of thedischarge end 1506 and into thesnorkel 1524 where it is guided into themold 1526. As shown by thecutaway portion 1550 of themold 1526 inFIG. 19 , thesnorkel 1524 directs that mixture from thedischarge end 1506 of themixing tube 1502 into themold 1526. In an embodiment, thesnorkel 1524 may comprise a flexible material. - As shown in
FIG. 19 , because of the rotation and vibration of themold 1526, the mixture from the mixingtube 1502 may form afirst layer 1650 having atop surface 1652 and asecond layer 1654. This process continues, layer by layer, until themold 1526 is filled to the top with the mixture discharged from the mixingtube 1502. - Once the
mold 1526 is full, it may be hoisted off of themold receiving surface 1618 onto the ground, where theinner mold 1528 and theouter mold 1530 are removed. It will be appreciated that themold 1526 used with thesystem 1500 may take a wide variety of forms, including molds to form the structures shown inFIGS. 6 and 8-16 . - Referring now to
FIGS. 6 and 20 , as previously discussed, thestructure 200 that may be formed by thesystem 1500 shown inFIG. 19 . In an embodiment, thestructure 200 may be used as a riser in a manhole assembly. In an embodiment, the height, H1, of thestructure 200 may be between one foot and six feet, such as one foot, two feet, three feet, four feet, five feet, or six feet. In an embodiment, the height, H1, of thestructure 200 may be greater than four feet, greater than five feet, greater than six feet, greater than seven feet, or greater than eight feet. - In an embodiment, the inner diameter, D1, may be between 36 inches and 72 inches, or between 48 inches and 60 inches, or 48 inches, or 60 inches. In an embodiment, the wall thickness, T (also D2 minus D1), between the
outer surface 202 and theinner surface 204 may be less than 1/12th of the length of the inner diameter, D1. In an embodiment, the outer diameter D2, may be the length of the inner diameter, D1, plus the wall thickness, T. In an embodiment, the wall thickness, T, may be between one and three inches. In an embodiment, the wall thickness, T, may be two inches. In an embodiment, the wall thickness, T, may be greater than one-half of an inch. - A desirable characteristic of the
structure 200 cast by thesystem 1500 may be its strength. In an embodiment, the sidewall of thestructure 200 is adapted to bear at least 10,000 psi in compression without failure. In an embodiment, the sidewall of thestructure 200 is adapted to bear at least 2,000 psi in tension without failure. As used herein, the concept of a material or a structure that experiences failure in compression or tension, means that the material or structure undergoes breaking, fracturing, cracking, or buckling. - In an embodiment, the resin content of the
structure 200 is between 5% to 35% of the volume of thestructure 200. In an embodiment, the resin content of thestructure 200 is 7% to 27% of the volume of thestructure 200. In an embodiment, the resin content of thestructure 200 is 10% to 17% of the volume of thestructure 200. In an embodiment, the resin may include one or more of a polymer resin, a polyester resin, a pure cast resin, a crushed glass resin, fiberglass, a composite material, plastic, and an inorganic material. - In an embodiment, the
structure 200 formed by thesystem 1500 comprises aggregate. In an embodiment, the aggregate comprises coarse aggregate and fine aggregate. In an embodiment, the coarse aggregate comprises 30% to 60% of the volume of thestructure 200. In an embodiment, the coarse aggregate comprises 45% to 55% of the volume of thestructure 200. In an embodiment, the coarse aggregate comprises 30% of the volume of thestructure 200. In an embodiment, the fine aggregate comprises 30% to 60% of the volume of thestructure 200. In an embodiment, the fine aggregate comprises 45% to 55% of the volume of thestructure 200. In an embodiment, the fine aggregate comprises 30% of the volume of thestructure 200. - In an embodiment, the
structure 200 may have a height, H1, that is less than twice the inner diameter, D1. In an embodiment, thestructure 200 may have a height, H1, that is less than one to two times the inner diameter, D1. In an embodiment, thestructure 200 may have a height, H1, that is less than 1.25 to 1.75 times the inner diameter, D1. - Referring now to
FIG. 20 , extending from theinner surface 204 of thestructure 200 may beprojection members 210. In an embodiment, theprojection members 210 may allow thestructure 200 to be attached to a lift device, such as a chain, strap or hook. In this regard, theprojections 210 allow thestructure 200 to be easily lifted, moved, and transported. In an embodiment, each of theprojection members 210 may include a threadedshaft 212 in the polymer sidewalls of thestructure 200 that is treadably coupled to acap 214. In an embodiment, theprojection members 210 are formed from plastic. In an embodiment, theprojection member 210 may comprise an eyelet. It will be appreciated that thestructure 200 is characterized by an absence of cement. It will be appreciated that thestructure 200 is formed of a non-corrosive material by thesystem 1500. - Referring now to
FIG. 21 , there is depicted amodular manhole structure 2100 pursuant to an embodiment of the present disclosure. Thestructure 2100 may be connected to a municipal wastewater system at aninlet 2102A and anoutlet 2102B. Thestructure 2100 may allow access to the wastewater system as is known to one having ordinary skill in the art. - The
structure 2100 may comprise abase section 2104. Thebase section 2104 may have abottom portion 2106. Thebottom portion 2106 may have anupper surface 2108. Theupper surface 2108 may include a bench orshelf 2110 and aninvert 2112 that forms a trough or flow channel to provide access to the wastewater. Theinvert 2112 may be connected topipes - The
base section 2104 may have an upwardly ascendingriser portion 2114. Theriser portion 2114 may have aninner surface 2116 and anouter surface 2118. Theinner surface 2116 may form part of an access passageway from the top of thestructure 2100 to theinvert 2112. Theriser portion 2114 may circumscribe thesurface 2108. - The
riser section 200 may be stacked on theriser portion 2114 of thebase section 2104. Theriser section 200 may have aninner surface 204 and anouter surface 202. Acone section 2126 may be stacked on theriser section 200. Thecone section 2126 may include aninner surface 2128 and anouter surface 2130. Afirst ring section 2132 and asecond ring section 2134 may be stacked upon thecone section 2126. Ametal support ring 2136 and amanhole cover 2138 may be installed onto thesecond ring section 2134. - In an embodiment of the present disclosure, the
base section 2104, theriser section 200, thecone section 2126, and therings system 1500. Thebase section 2104, the riser section 2120, thecone section 2126, and therings - It will be appreciated that the
wastewater structure 2100 may take multiple forms to satisfy a wide range of operating requirements. For example, thestructure 2100 may havemultiple risers 200. Thestructure 2100 shown inFIG. 21 is exemplary and should not be considered limiting on the present disclosure. - In the foregoing Detailed Description, various features of the present disclosure are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description of the Disclosure by this reference, with each claim standing on its own as a separate embodiment of the present disclosure.
- It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present disclosure. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present disclosure and the appended claims are intended to cover such modifications and arrangements. Thus, while the present disclosure has been shown in the drawings and described above with particularity and detail, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein.
Claims (33)
1. A manhole apparatus having a wastewater inlet and a wastewater outlet configured and adapted to be connected to a municipal wastewater system, the manhole apparatus comprising:
a base portion having an upper surface that includes a fluid trough extending between the wastewater inlet and the wastewater outlet;
a top portion defining a worker access opening; and
a riser portion interposed between the base portion and the top portion, the riser portion having a sidewall that defines a circular passageway having an inner diameter;
wherein a thickness of the sidewall is between one inch and three inches, and wherein the sidewall comprises a polymer concrete material including: a polymer resin and aggregate mixture wherein the polymer resin comprises between 5% and 35% of the polymer resin and aggregate mixture.
2. The manhole apparatus of claim 1 , wherein a thickness of the sidewall of the riser portion is less than 1/12th of the inner diameter of the circular passageway and the sidewall is adapted to bear at least 10,000 psi in compression and at least 2,000 psi in tension, without failure.
3. The manhole apparatus of claim 1 , wherein the inner diameter of the circular passageway is at least 48 inches.
4. The manhole apparatus of claim 1 , wherein the sidewall is formed from a non-corrosive material.
5. The manhole apparatus of claim 1 , wherein the sidewall is characterized by an absence of cement.
6. The manhole apparatus of claim 1 , wherein the polymer resin and aggregate mixture has only a coarse aggregate and a fine aggregate.
7. The manhole apparatus of claim 1 , wherein the polymer resin and aggregate mixture includes a coarse aggregate and a fine aggregate.
8. The manhole apparatus of claim 1 , wherein the polymer resin comprises between 7% and 27% of the polymer resin and aggregate mixture.
9. The manhole apparatus of claim 1 , wherein the polymer resin comprises between 10% and 17% of the polymer resin and aggregate mixture.
10. The manhole apparatus of claim 7 , wherein the coarse aggregate comprises one of 30%, 30% to 60%, and 45% to 55% of the aggregate in the polymer resin and aggregate mixture.
11. The manhole apparatus of claim 7 , wherein the fine aggregate comprises one of 30%, 30% to 60%, and 45% to 55% of the aggregate in the polymer resin and aggregate mixture.
12. The manhole apparatus of claim 7 , wherein the fine aggregate comprises a fine sift sand.
13. The manhole apparatus of claim 1 , wherein the aggregate in the polymer resin and aggregate mixture comprises one or more of a pure cast resin, a crushed glass resin, fiberglass, a composite material, plastic, and an inorganic material.
14. The manhole apparatus of claim 1 , wherein a thickness of the sidewall is about two inches.
15. The manhole apparatus of claim 1 , wherein a height of the riser portion is greater than 4 feet.
16. The manhole apparatus of claim 1 , wherein the base portion is separated from the riser portion by a joint.
17. The manhole apparatus of claim 16 , where the riser portion is separated from the top portion by a joint.
18. The manhole apparatus of claim 1 , wherein the top portion comprises a cone.
19. The manhole apparatus of claim 18 , wherein the top portion further comprises a grade ring.
20. A manhole apparatus having a wastewater inlet and a wastewater outlet configured and adapted to be connected to a municipal wastewater system, the manhole apparatus comprising:
a base portion having an upper surface that includes a fluid trough extending between the wastewater inlet and the wastewater outlet;
a top portion defining a worker access opening;
a riser portion interposed between the base portion and the top portion, the riser portion having a sidewall that defines a circular passageway having an inner diameter;
wherein a thickness of the sidewall of the riser portion is less than 1/12th of the diameter of the circular passageway;
wherein the sidewall is characterized by an absence of cement;
wherein the sidewall, having a volume, comprises a polymer concrete material including: a polymer resin and an aggregate mixture having a coarse aggregate and a fine aggregate, wherein the coarse aggregate comprises 30-60% of the volume of the sidewall and the fine aggregate comprises 30-60% of the volume of the sidewall; and
wherein a thickness of the sidewall is between one inch and three inches.
21. The manhole apparatus of claim 20 , wherein at least one of the course aggregate and the fine aggregate is composed of rocks.
22. The manhole apparatus of claim 20 , wherein at least one of the course aggregate and the fine aggregate is composed of sand.
23. The manhole apparatus of claim 20 , wherein a thickness of the sidewall of the riser portion is less than 1/12th of the inner diameter of the circular passageway and the sidewall is adapted to bear at least 10,000 psi in compression and at least 2,000 psi in tension, without failure.
24. The manhole apparatus of claim 20 , wherein the inner diameter of the circular passageway is at least 48 inches.
25. The manhole apparatus of claim 20 , wherein the sidewall is formed from a non-corrosive material.
26. The manhole apparatus of claim 20 , wherein the sidewall is characterized by an absence of cement.
27. The manhole apparatus of claim 20 , wherein a thickness of the sidewall is between one inch and three inches.
28. The manhole apparatus of claim 20 , wherein the polymer resin comprises between 5% and 35% of the polymer resin and aggregate mixture.
29. The manhole apparatus of claim 28 , wherein the polymer resin comprises between 7% and 27% of the polymer resin and aggregate mixture.
30. The manhole apparatus of claim 29 , wherein the polymer resin comprises between 10% and 17% of the polymer resin and aggregate mixture.
31. The manhole apparatus of claim 20 , wherein the coarse aggregate comprises 45% to 55% of the aggregate in the polymer resin and aggregate mixture.
32. The manhole apparatus of claim 20 , wherein the fine aggregate comprises 45% to 55% of the aggregate in the polymer resin and aggregate mixture.
33. A manhole apparatus having a wastewater inlet and a wastewater outlet configured and adapted to be connected to a municipal wastewater system, the manhole apparatus comprising:
a base portion having an upper surface that includes a fluid trough extending between the wastewater inlet and the wastewater outlet;
a top portion defining a worker access opening; and
a riser portion interposed between the base portion and the top portion, the riser portion having a sidewall that defines a circular passageway having an inner diameter;
wherein the sidewall comprises a polymer concrete material including: a polymer resin and an aggregate mixture having only a coarse aggregate and a fine aggregate; and
wherein a thickness of the sidewall is between one inch and three inches.
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Cited By (2)
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US10329719B1 (en) | 2018-05-28 | 2019-06-25 | Richard P Giles | Composition and method for surface repair |
US20220105663A1 (en) * | 2020-10-01 | 2022-04-07 | Hancock Concrete Products, Llc | Manhole urethane mold and method of producing the same |
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US9567760B2 (en) | 2010-09-24 | 2017-02-14 | Geneva Polymer Products, Llc | System and method for making polymer concrete |
US9631339B2 (en) * | 2010-09-24 | 2017-04-25 | Geneva Polymer Products, Llc | Rehabilitation of deteriorated manhole and other sewer structures |
DE102012018429A1 (en) * | 2012-06-20 | 2013-12-24 | Thomas Gmbh + Co. Technik + Innovation Kg | Method and device for producing a hollow plastic article having at least one transverse reinforcement |
US10214893B2 (en) | 2014-11-20 | 2019-02-26 | Press-Seal Corporation | Manhole base assembly with internal liner and method of manufacturing same |
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US20210309573A1 (en) * | 2020-04-03 | 2021-10-07 | Composite Construction, LLC | Chemical resistant polymer concrete and methods of use thereof |
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CN113898199B (en) * | 2021-10-25 | 2023-08-15 | 周口师范学院 | Building construction safety device |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10329719B1 (en) | 2018-05-28 | 2019-06-25 | Richard P Giles | Composition and method for surface repair |
US20220105663A1 (en) * | 2020-10-01 | 2022-04-07 | Hancock Concrete Products, Llc | Manhole urethane mold and method of producing the same |
Also Published As
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US9567760B2 (en) | 2017-02-14 |
US20140115975A1 (en) | 2014-05-01 |
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