WO2021016187A1

WO2021016187A1 - Inground tank construction system and method

Info

Publication number: WO2021016187A1
Application number: PCT/US2020/042782
Authority: WO
Inventors: Timothy Burke
Original assignee: Timothy Burke
Priority date: 2019-07-19
Filing date: 2020-07-20
Publication date: 2021-01-28

Abstract

An inground tank construction method including locating a support structure on a surface proximate an inground tank location. A top perimeter is excavated around the inground tank location where the top perimeter has a width adapted to support a top ring of blocks around the perimeter. The top ring of blocks is installed around the perimeter and rebar reinforces the blocks. The top ring of blocks is secured to the block support structure with a plurality of clamping systems. A lower perimeter is excavated to a depth for placing a lower ring of staggered blocks beneath the top ring of blocks. Each subsequently lower ring of blocks is secured to the upper rings until the desired depth of the inground tank is reached.

Description

INGROUND TANK CONSTRUCTION SYSTEM AND METHOD

Technical Field

The present invention relates to systems and methods for constructing inground tanks. More particularly, the invention relates to a system and method for constructing an inground tank from the top down.

Background

As currently constructed, inground tanks, as for example cisterns and other types of holding tanks, consist in the main of buried tanks, aboveground tanks and excavated structures which are built from the bottom up. Each of these construction methods and systems have their own inherent disadvantages such as, for example, cost and lifespan as well as storage deficiencies.

Known inground tanks are constructed using conventional methods that require building from the ground up which is costly. These methods typically require excavation of a slope before construction or expensive excavation shoring to avoid collapse during construction. After installation, backfilling of the excavation is usually needed, thus adding to the expense.

A drawback of aboveground tanks used for cisterns is that they are subject to being warmed by the sun and supplying warm water for drinking which is not usually desirable. Aboveground tanks are also subject to damage from weather events, vehicle collisions and other accidents. Another disadvantage of aboveground tanks are that they occupy space and obstruct views.

A new system and method for constructing an inground tank has been devised by the sole inventor hereof.

Brief Summary of the Disclosure

This summary is provided to introduce, in a simplified form, a selection of concepts that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

An inground tank construction method including locating a support structure on a surface proximate an inground tank location is disclosed. A top perimeter is excavated around the inground tank location where the top perimeter has a width adapted to support a top ring of blocks around the perimeter. The top ring of blocks is installed around the perimeter and rebar reinforces the blocks. The top ring of blocks is secured to the block support structure with a plurality of clamping systems attached to the support structure. A lower perimeter is excavated to a depth for placing a lower ring of staggered blocks beneath the top ring of blocks. Each subsequently lower ring of blocks is secured to the upper rings until the desired depth of the inground tank is reached.

Brief Description of the Drawings

While the novel features of the invention are set forth with particularity in the appended claims, the invention, both as to organization and content, will be better understood and appreciated, along with other objects and features thereof, from the following detailed description taken in conjunction with the drawings, in which:

FIG. 1 schematically shows a cutaway side view of one example of an inground tank installed according to the method described herein.

FIG. 2 schematically shows a view of one example of equipment and materials used during installation of an inground tank.

FIG. 3 schematically shows an exploded view of one example of intermediate acts during installation of an inground tank.

FIG. 4 schematically shows a more detailed top view of one example of a building block used to build an inground tank.

FIG. 4A schematically shows an elevated front view of one example of a building block used to build an inground tank.

FIG. 4B schematically shows a cutaway side view of one example of a building block used to build an inground tank.

FIG. 4C schematically shows a more detailed enlarged view of one example of a block element used to align vertically adjacent blocks.

FIG. 5 conceptually shows a support structure for holding clamping systems used during installation of an inground tank.

FIG. 6 schematically shows a top view of one example of abutting building blocks used to build an inground tank.

FIG. 7 schematically shows a flow diagram outlining one example of a method for constructing an inground tank. FIG. 7A schematically shows a more detailed flow diagram outlining one example of a method for installing a top ring of blocks.

FIG. 7B schematically shows a flow diagram outlining one example of a method for installing a lower ring of blocks.

In the drawings, identical reference numbers identify similar elements or components. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not intended to convey any information regarding the actual shape of the particular elements, and have been solely selected for ease of recognition in the drawings.

Detailed Description of the Preferred Embodiments

The following disclosure describes processes, devices, and materials for construction of an inground tank. Several features of methods and systems in accordance with example embodiments are set forth and described in the figures. It will be appreciated that methods and systems in accordance with other example embodiments can include additional procedures or features different than those shown in the figures. Example embodiments are described herein with respect to construction of an inground tank, such as a cistern, using reinforced curved interlocking concrete blocks. However, it will be understood that these examples are for the purpose of illustrating the principles, and that the invention is not so limited. Definitions

Generally, as used herein, the following terms have the following meanings when used within the context of inground water storage structures.

The use of the word “a” or“an” when used in conjunction with the term “comprising” in the claims or the specification means one or more than one unless the context dictates otherwise. The term“about” means the stated value plus or minus the margin of error of measurement or plus or minus 10% if no method of measurement is indicated. The use of the term“or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or if the alternatives are mutually exclusive. The terms“comprise”,“have”,“include” and“contain” (and their variants) are open-ended linking verbs and allow the addition of other elements when used in a claim.

Reference throughout this specification to "one example" or "an example embodiment," "one embodiment," "an embodiment" or combinations and/or variations of these terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases like "in one example" or "in an example" in various places throughout this specification are not necessarily all referring to the same embodiment or example. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

Example Embodiments

Referring now to FIG. 1 , a cutaway side view of one example of an inground tank installed according to the method disclosed for the first time herein. Each ring of blocks 45 includes a plurality of building blocks 42 reinforced with rebar 44. The base floor 46 may comprise concrete or other suitable material. A block support structure 40 is deployed prior to beginning excavation of the inground tank. The support structure 40 is constructed around the excavation area and located so as to distribute the weight of construction materials and equipment into ground areas away from the excavation area so as to prevent collapse of the excavation area. Support structure 40 includes a base 41 . After installing base floor 46 a plurality of block attachment devices 48 may be left in place at the bottom or removed as desired.

Referring now to FIG. 2, a view of one example of equipment and materials used during installation of an inground tank is schematically shown. A plurality of winch assemblies 54 are mounted on the support structure 40 around the perimeter of the excavation area 43. Each winch assembly 54 includes a winch 56. Each of the winch assemblies may be driven manually or by motors. The winch assemblies are components of a plurality of clamping systems including cables 52 which are inserted into cavities (shown in FIG. 4) in the blocks 42. Each block clamping system will be understood to comprise a winch assembly, a cable, and a block attachment device 48 attached to the cable end. Each block 42 may advantageously be supported by a pair of clamping systems. In one example the building blocks may comprise concrete blocks or equivalents. In some examples, hand clamps may be temporarily applied to hold adjacent blocks together horizontally in a ring of blocks.

After the first block ring 45 is installed, a lower excavation area 43A is dug out to a depth greater than the depth of a building block 42. A lower block ring is then installed one block 42 at a time as described further below with respect to FIG. 4. The winches are used to both lower the cables into the cavities of the blocks and also pull and secure blocks as excavation continues by removing layers of strata below the blocks. A similar clamping system may also be employed to install rebar rings in each block ring.

Referring now to FIG. 3, an exploded view of one example of intermediate acts during installation of an inground tank is schematically shown. During construction, after a first ring of blocks 45A has been installed and temporarily secured with the winches holding block attachment devices 48, a second block ring 45B is installed using a process whereby one of the block attachment devices, 48A for example is removed from block 42A and cable 52A is lowered through block cavities 62A and 62A’. The block clamping system attachment device 48A then is used to hold block 42D on one side. Following the same procedure, a second block clamping system attachment device 48B is removed from block 42B, cable 52B is lowered using the winches through cavity 62B’ to hold the other side of block 42D. Mortar is applied to the top of block 42D as needed to fill gaps. Block 42D is then pulled up to bear against upper blocks 42A and 42B by using the pair of attached block clamping systems to pull upwards with their winches. When a predetermined load is applied, block 42D will interlock with blocks 42A and block 42B. In this way, a subsequent lower ring of blocks can be interlocked with each upper ring of blocks by staggering the lower blocks in alternate rows and individually removing and reapplying the block attachment devices.

After completing each lower ring, rebar may be installed as described above. Broken directional arrow 60 represents the progression of installing block rings downwards to a predetermined depth where the last ring will rest on base floor 46 which is excavated and poured after the last ring of blocks is installed. When the final block ring is installed and before the concrete base floor is poured, caps, such as plastic foam or wooden caps, may be used to cover the attachment devices 48 of the plurality of clamping systems. This may be done to keep the attachment devices from being embedded in the concrete. After the base floor is installed, the attachment devices may be removed by breaking the caps and pulling the ends out of the depressions molded in the base floor by the removed caps. Alternatively, the ends may be left embedded in the concrete.

Referring now to FIG. 4, a more detailed top view of one example of a block element used to build an inground tank using the method of FIG. 1 is schematically shown. A building block 42 may comprise, for example a curved building block or the like having at least two cavities 62 and a bottom groove 72 (shown in FIG. 4B) for affixing reinforcing bar (rebar) or the like for strengthening a ring of blocks.

Referring now to FIG. 4A, an elevated front view of one example of a building block used to build an inground tank is schematically shown. The building block 42 may be a curved block adapted to be interlocked with identically shaped building blocks. In one example a suitable building block includes opposing side walls 444. A plurality of interlocking elements 448 have a pyramidical shape with a flat top each sized to mate with a similarly shaped hollow 449 in the bottom of each block.

Referring now to FIG. 4B, a more detailed section view of one example of an interlocking block element used to build an inground tank using the method of FIG. 1 is schematically shown. Each block 42 includes a rebar groove 72 for receiving and retaining rebar in the building block. Mortar can be applied in the groove to hold the rebar in place to facilitate installation of the rebar.

Referring now to FIG. 4C, a more detailed enlarged view of one example of a block element used to align vertically adjacent blocks is schematically shown. Each of the plurality of interlocking elements 448 have a pyramidical shape with a flat top each sized to mate with a similarly shaped hollow 449 in the bottom of each block. The mating elements are sized to provide a stop and support a portion of the distributed load applied to the overall structure such that a uniform mortar gap 450 is left between the bottom 452 of an upper block 42A and the top 454 of a lower block 42D. Mortar may be applied to a portion of the surfaces of the blocks that will form the uniform mortar gap before interlocking the blocks. Care must be taken not to introduce mortar onto the surfaces of the interlocking elements as it could affect the uniformity of the gap. Any remaining gaps may later be filled with mortar. In one example, the uniform gap may be about ¼ inch. Referring now to FIG. 5, an example of a support structure for holding clamping systems used during installation of an inground tank is shown in a conceptual drawing. A plurality of winch assemblies 54 are located on the support structure 40 . Each winch assembly includes a winch attached to a cable. The number of cables necessary will be at least two cables for each block 42 in a single ring. That is, if each ring in a plurality of stacked rings is, for example N, the number of clamping assemblies each comprising a winch, cable and block attachment device will be 2N. In one useful example, the cables and attachment devices are inserted into the block cavities during construction.

Referring now to FIG. 6, a top view of one example of abutting building blocks used to build an inground tank is schematically shown. A pair of building blocks 42A and 42B are shown as mortared together in a typical ring of blocks. Each block includes a partially recessed side wall 57 which is filled with mortar 73 prior to bringing the blocks together. After the blocks are made to bear against each other by abutting one side of each block to the other, a substantially mortar-filled gap 59 is left between the blocks.

Referring now to FIG. 7, a flow diagram outlining one example of a method for constructing an inground tank is schematically shown. An inground tank construction method 10 starts with deploying a block support structure on a surface proximate an inground tank location 12. This construction method is particularly amenable to building inground cisterns, for example. Construction proceeds by excavating a top perimeter around the inground tank location where the top perimeter has a width adapted to support a top ring of blocks around the perimeter 14. Construction further proceeds by installing the top ring of blocks around the perimeter 16. A lower perimeter is then excavated to a depth suitable for placing a lower ring of blocks beneath the top ring of blocks 22. This is followed by installing the lower ring of blocks around the lower perimeter 24. A plurality of rings of blocks, each lower than the prior ring, for a predetermined number of rings of blocks are similarly built until the predetermined depth of the inground tank has been excavated and has its wall enclosed with blocks 32. At that point, the inground tank base floor is installed by excavating below the last ring of blocks and pouring concrete level with the bottom of the last ring of blocks 34. When completed the cavities in the rows of blocks will substantially be vertically aligned from top to bottom and concrete can be poured into cavities in the blocks extending from the top of the first ring of blocks to the last ring of blocks at the floor level 36.

Referring now to FIG. 7A, a more detailed flow diagram outlining one example of a method for installing a top ring of blocks is schematically shown. Throughout this description, the letters N and A each represent an integer number each beginning with the number 1 and incremented thereafter. After excavating below the surface, construction begins by positioning a first block N, where initially N is set at N=1 , in the excavated perimeter at 212. Next, a clamping system A, where A initially is set at A=1 , is applied to a location on block N at 214. For example, a clamping system can include a cable attached to a winch at a top end and having a block attachment device at a lower end for attaching to the block. The clamping system A may be installed through a first block cavity. Next, a second clamping system, A+1 , is installed at a second block location A+1 at 218. Using the clamping systems, a load is applied to block locations A and A+1 to pull the block up to the base 220. As explained hereinabove, mortar is poured into side gaps before lifting the block into place and abutting it to the previously installed block. If there are more blocks needed to complete the ring at 222 the process proceeds to the next action 224 where N is incremented by 1 and A is incremented by 2. When the last block is in place all clamping systems have been activated to apply a predetermined amount of force. Optionally, a ring of reinforcing bar (rebar) is affixed to the block ring 228 and the process flows to action 24. In one example, rebar is affixed to the ring by installing it in curved grooves in the bottom of the blocks in the ring and applying mortar as needed to hold the rebar in place.

Referring now to FIG. 7B, a flow diagram outlining one example of a method for installing a lower ring of blocks is schematically shown. Throughout this description, the letters A and M each represent an integer number beginning with the number 1 and incremented thereafter. After digging a lower excavated perimeter below the first ring, construction begins by positioning a first lower block M, where initially M is set to M=1 , in the lower excavated perimeter 330 in a position staggered below the ring directly above the lower excavated perimeter. Next a clamping system A is applied to a location A on block M at 312. Next, a second clamping system, A +1 , is installed on a second block location A +1 at 318. A load is applied to the lower block locations A and A +1 at 320 by activating the clamping systems to pull up the block. Mortar is applied on top of each block and into side gaps before lifting into place and abutting it to the previously installed block. If there are more blocks needed to complete the lower ring 322 the process proceeds to the next block 324 where M is incremented by 1 and A is incremented by 2. When the last block is in place all clamping systems will have been activated to apply a predetermined amount of force. As an optional step before installing the next ring, concrete reinforcement bar (rebar) is affixed to the lower block ring 328 and the process flows to action 32.

Other examples of the method for constructing an inground in an excavation area include the steps of:

a) deploying a weight distributed block support structure around the excavation area;

b) mounting a plurality of winch assemblies on the support structure around the excavation area;

c) beginning excavation to a depth not substantially greater than the thickness of a building block;

d) installing a first plurality of blocks configured to form a first block ring, wherein each block includes at least 2 cavities;

e) operating the plurality of winch assemblies to secure the first block ring with block attachment devices;

f) installing reinforcement bar rings in the first block ring;

g) excavating a lower excavation area to a second depth not substantially greater than the thickness of a building block;

h) installing a second plurality of blocks configured to form a lower block ring;

i) operating the plurality of winches to lower the cables into the cavities of the first plurality of blocks and the second plurality of blocks;

j) operating the plurality of winches to pull and secure the first plurality of blocks and the second plurality of blocks with block attachment devices; k) installing reinforcement bar rings in the second block ring;

L) continuing excavation by removing layers of strata below the second plurality of blocks; and

m) repeating steps d) through I) until a predetermined excavation depth is reached. In another example the steps include removing a first block attachment device from a first block of the first plurality of blocks and lowering a cable through a first block cavity of the first block and a first lower block cavity of a first lower block of the second plurality of blocks; using the attachment device to hold the first block to the first lower block; removing a second block attachment device from a second block of the first plurality of blocks abutting the first block and lowering a cable through a third block cavity of the second block and a second lower block cavity of the first lower block; and using the attachment device to hold the second block of the first plurality of blocks to the second lower block of the second plurality of blocks.

In another example the method includes staggering the plurality of blocks in each ring of blocks in alternate rows.

In another example the method includes applying mortar to each block in each ring of blocks before operating the plurality of winches to pull and secure the first plurality of blocks and the second plurality of blocks with block attachment devices.

In another example the method includes excavating and pouring a base floor after the last ring of blocks is installed.

In another example the method includes deploying a block support structure, having a base, on a surface proximate an inground tank location;

a) excavating a top perimeter around the inground tank location where the top perimeter has a width adapted to support a top ring of blocks around the perimeter;

b) installing the top ring of blocks around the top perimeter;

c) affixing rebar to the top ring of blocks;

d) excavating a lower perimeter to a depth suitable for placing a lower ring of blocks beneath the top ring of blocks;

e) installing the lower ring of blocks around the lower perimeter; f) affixing rebar to the lower ring of blocks; and

g) repeating steps f) through g) for a plurality of rings of blocks each lower than the prior ring for a predetermined number of rings of blocks.

In another example, each block ring includes a plurality of blocks, each block having a set of block cavities, and the method further includes:

h) pouring concrete into each of the sets of block cavities;

i) applying mortar to all crevices as each ring is built; and j) pouring a floor under a last block ring of the predetermined number of rings of blocks.

In another example, N and A represent integer numbers initially set to 1 , and wherein installing the top ring of blocks around the top perimeter comprises:

k) positioning a block, N, in the excavated top perimeter;

L) applying a clamping system A to a first location A on block N; m) installing a second clamping system, A+1 , at a second block location A+1 ;

n) applying a load to block positions A and A +1 to pull the block N up to the base; and

o) if there are more blocks needed to complete the block ring then incrementing N by 1 , increment A by 2 and repeat steps k) through p).

In another example M and A represent integer numbers initially set to 1 , and wherein installing a lower ring of blocks around a lower perimeter includes:

p) positioning a lower block M, in a lower excavated perimeter staggered between a pair of blocks in a ring directly above the lower excavated perimeter;

q) applying a clamping system A to a first location A on block M r) installing a second clamping system, A+1 , on a second lower block location A+1 ;

s) applying a load to block positions A and A+1 ;

t) if there are more blocks needed to complete the lower ring of blocks, then incrementing M by 1 and A by 2 and repeat steps q) through u).

In another example, affixing rebar includes installing it in curved grooves in the bottom of the blocks in a ring and applying mortar in the groove.

In another example, each building block includes at least two cavities where the act of installing the top ring of blocks comprises clamping inside the at least two cavities one block at a time.

In another example, the act of deploying a support structure comprises:

constructing support elements around an opening around the excavation area; and

mounting a plurality of winches on the support elements. In another example, each block has a first end and a second end and a first cavity and a second cavity, wherein the act of applying a load comprises:

operating a first clamping system to hold a first block cavity;

operating a second clamping system to hold a second block cavity; and applying a load to the clamping systems to lift the block so that it bears against a base or upper ring of blocks.

In another example, the act of mounting a plurality of cable winches on the support structure comprises installing at least two winches for operating cables where the number of cables includes at least two cables for each block in a single ring.

The invention has been described herein in considerable detail in order to comply with the Patent Statutes and to provide those skilled in the art with the information needed to apply the novel principles of the present invention, and to construct and use such exemplary and specialized components as are required. However, it is to be understood that the invention may be carried out by different equipment, and devices, and that various modifications, both as to the equipment details and operating procedures, may be accomplished without departing from the true spirit and scope of the present invention.

Claims

Claims What is claimed is:

1 . A method for constructing an inground in an excavation area, the method comprising:

f) installing reinforcement bar rings in the first block ring;

m) repeating steps d) through I) until a predetermined excavation depth is reached.

2. The method of claim 1 wherein step j) comprises:

removing a first block attachment device from a first block of the first plurality of blocks and lowering a cable through a first block cavity of the first block and a first lower block cavity of a first lower block of the second plurality of blocks; using the attachment device to hold the first block to the first lower block; removing a second block attachment device from a second block of the first plurality of blocks abutting the first block and lowering a cable through a third block cavity of the second block and a second lower block cavity of the first lower block; and

using the attachment device to hold the second block of the first plurality of blocks to the second lower block of the second plurality of blocks.

3. The method of claim 1 wherein step h) further comprises:

staggering the plurality of blocks in each ring of blocks in alternate rows.

4. The method of claim 3 further comprising applying mortar to each block in each ring of blocks before operating the plurality of winches to pull and secure the first plurality of blocks and the second plurality of blocks with block attachment devices.

5. The method of claim 1 further comprising excavating and pouring a base floor after the last ring of blocks is installed.

6. An inground tank construction method comprising:

a) deploying a block support structure, having a base, on a surface proximate an inground tank location;

b) excavating a top perimeter around the inground tank location where the top perimeter has a width adapted to support a top ring of blocks around the perimeter;

c) installing the top ring of blocks around the top perimeter;

d) affixing rebar to the top ring of blocks;

e) excavating a lower perimeter to a depth suitable for placing a lower ring of blocks beneath the top ring of blocks;

f) installing the lower ring of blocks around the lower perimeter; g) affixing rebar to the lower ring of blocks; and

h) repeating steps f) through g) for a plurality of rings of blocks each lower than the prior ring for a predetermined number of rings of blocks.

7. The inground tank construction method of claim 6, wherein each block ring includes a plurality of blocks, each block having a set of block cavities, the method further comprising:

i) pouring concrete into each of the sets of block cavities;

j) applying mortar to all crevices as each ring is built; and

k) pouring a floor under a last block ring of the predetermined number of rings of blocks.

8. The inground tank construction method of claim 7, where N and A represent integer numbers initially set to 1 , and wherein installing the top ring of blocks around the top perimeter comprises:

L) positioning a block, N, in the excavated top perimeter;

m) applying a clamping system A to a first location A on block N; n) installing a second clamping system, A+1 , at a second block location A+1 ;

o) applying a load to block positions A and A +1 to pull the block N up to the base; and

p) if there are more blocks needed to complete the block ring then incrementing N by 1 , increment A by 2 and repeat steps k) through p).

9. The inground tank construction method of claim 8, where M and A represent integer numbers initially set to 1 , and wherein installing a lower ring of blocks around a lower perimeter comprises:

q) positioning a lower block M, in a lower excavated perimeter staggered between a pair of blocks in a ring directly above the lower excavated perimeter;

r) applying a clamping system A to a first location A on block M s) installing a second clamping system, A+1 , on a second lower block location A+1 ;

t) applying a load to block positions A and A+1 ;

u) if there are more blocks needed to complete the lower ring of blocks, then incrementing M by 1 and A by 2 and repeat steps q) through u).

10. The method of claim 6 wherein affixing rebar comprises installing it in curved grooves in the bottom of the blocks in a ring and applying mortar in the groove.

1 1 . The inground tank construction method of claim 6 wherein each building block includes at least two cavities where the act of installing the top ring of blocks comprises clamping inside the at least two cavities one block at a time.

12. The inground tank construction method of claim 6 wherein the act of deploying a support structure comprises:

constructing support elements around an opening around the excavation area; and

mounting a plurality of winches on the support elements.

13. The inground tank construction method of claim 6 wherein each block has a first end and a second end and a first cavity and a second cavity, wherein the act of applying a load comprises:

operating a first clamping system to hold a first block cavity;

14. The inground tank construction method of claim 12 wherein the act of mounting a plurality of cable winches on the support structure comprises installing at least two winches for operating cables where the number of cables includes at least two cables for each block in a single ring.

15. An inground tank made according to the method of claims 1 or 6.