POLYMER MANHOLE BASE

Abstract

A polymer manhole base comprising a base portion having an upper surface. An annular sidewall may extend upward from the base portion and may circumscribing the upper surface. The annular sidewall may have a diameter. A thickness of the annular sidewall may less than 1/12th of the diameter.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent application Ser. No. 13/844,487, filed Mar. 15, 2013, which is hereby incorporated by reference herein in its 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 application is inconsistent with this application, this application supercedes the above-referenced application.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND

1. The Field of the Present Disclosure

The present disclosure relates generally to wastewater systems, and more particularly, but not necessarily entirely, to manhole base structures.

2. Description of Related Art

Components of wastewater systems may be formed from pre-cast concrete structures. For example, pre-cast concrete structures may include concrete pipes, box culverts, vaults, catch basins, and manhole assemblies. These pre-cast concrete structures may be formed off site and transported to a work site as needed. At the work site, the pre-cast concrete structures may be installed into wastewater systems, including sewage systems, as is known to one having ordinary skill in the art. Typically, the pre-cast concrete structures may be installed underground.

The pre-cast concrete structures used in wastewater systems are highly susceptible to microbial induced corrosion. Microbial induced corrosion is caused when hydrogen sulfide gas is released from wastewater. The gas is transformed into sulfuric acid by microbes present in the wastewater system. The sulfuric acid produced by the microbes may then quickly corrode the concrete structures by dissolving the cement binder used during the casting process. The corrosion caused by sulfuric acid may lead to severe damage to the pre-cast concrete structures.

Some attempts have been made in the prior art to reduce the damage caused by microbial induced corrosion. For example, one attempt at reducing microbial induced corrosion may include spraying a coating, such as an epoxy coating, on the pre-cast concrete structures. Disadvantageously, these coatings have been known to spall; thereby creating a pathway for the acid to eat away at the concrete. Other attempts to reduce the damage caused by microbial induced corrosion have included the use of plastic liners, which have also been demonstrated as not being completely effective.

The prior art is thus characterized by several disadvantages that are addressed by the present disclosure. The present disclosure minimizes, and in some aspects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein.

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.

BRIEF DESCRIPTION OF THE DRAWINGS

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 perspective view of a polymer manhole base according to an embodiment of the present disclosure;

FIG. 2 is a cross-sectional view of the polymer manhole base shown in FIG. 1;

FIG. 3 is a top view of the polymer manhole base shown in FIG. 1;

FIG. 4 is a top view of a polymer manhole base according to an embodiment of the present disclosure;

FIG. 5 is a top view of a polymer manhole base according to an embodiment of the present disclosure; and

FIG. 6 is an exploded, fragmentary view of a manhole assembly according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

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.

In describing and claiming the present disclosure, the following terminology will be used in accordance with the definitions set out below. 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. As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” “having,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps.

Pursuant to an embodiment of the present disclosure, applicant has discovered a polymer manhole base having a thin annular sidewall. In an embodiment, a thickness of the sidewall is defined by the difference between an outer diameter and an inner diameter of the sidewall. In an embodiment, the sidewall may have a thickness that is less than 1/12th of the inner diameter of the sidewall. Applicant's polymer manhole base may be formed of an resin and aggregate mixture.

Referring now to FIG. 1, there is depicted a polymer manhole base 100 according to an embodiment of the present disclosure. The manhole base 100 may be adapted for use in a municipal wastewater system. In an embodiment, the base 100 may comprise a solid base portion 101. In an embodiment, the base 100 may comprise an optional extended solid base portion 102 that provides additional stability and support to the base 100. The extended base portion 102 may comprise a bottommost surface 104 that may be adapted to rest on a bottom of an excavated hole.

Extending upwardly from the extended base portion 102 may be an annular sidewall 106 that terminates at an annular top surface 108. The annular sidewall wall 106 may comprise an outer surface 110 and an inner surface 112. The inner surface 112 may define an annular passageway 114 in the interior of the base 100. The passageway 114 may provide worker access to the interior of the manhole base 100.

The polymer manhole base 100 may further comprise an inlet 116 and an outlet 118 (outlet 118 is not explicitly visible in FIG. 1) for connecting the base 100 to a municipal wastewater system as is known to those having ordinary skill in the art.

Referring now to FIG. 2, there is depicted a cross-section of the base 100 along the Section A-A shown in FIG. 1 where like reference numerals depict like components. The base 100 may have a base height, H. In an embodiment, the annular wall may define an inner diameter, ID, and an outer diameter, OD, as shown in FIG. 2. In an embodiment, the base height, H, may be between two feet and six feet. In an embodiment, the inner diameter, ID, may be between about 48 inches and 60 inches. In an embodiment, the outer diameter, OD, may be between about 48 inches and 64 inches.

A wall thickness, T, of the annular sidewall 106 may be defined by a difference between the outer diameter, OD, and the inner diameter, ID. In an embodiment, the wall thickness may be between one inch and three inches, or about 2 inches, or one-half inch or greater. In an embodiment, the wall thickness, T, may be less than 1/12th of the inner diameter, ID, of the annular sidewall 106.

Disposed at the bottom of the annular passageway 114 may be a surface 120. In an embodiment, the surface 120 may define a trough 122 that extends between the inlet 116 and a outlet 118. The trough 122 may provide a fluid pathway for wastewater between the inlet 116 and a outlet 118. The surface 120 may define a bench portion 124 on either side of the trough 122. In an embodiment, the bench portion 124 may be sloped at an angle, θ. In an embodiment, the angle θ may vary from 0° and 45°.

In an embodiment, the base 100 may be cast by a continuous casting machine using polymer concrete. In an embodiment, the polymer concrete may comprise a polymer resin and aggregate mixture. In an embodiment, the aggregate may comprise a coarse aggregate and a fine aggregate. In an embodiment, the entire base 100 may be poured in one casting as a monolithic structure. The base 100 may be cast with or without the extended base 102. As seen in FIG. 2, extending from the surface 120 may be a plurality of anchors 126 that may be utilized to lift the base 100 using a lift mechanism. In an embodiment, the anchors 126 may comprise a hook or an eyelet.

Referring now to FIG. 3, where like reference numerals depict like components, in an embodiment the trough 122 may be substantially linear as it extends between the inlet 116 and the outlet 118. FIG. 4 depicts an embodiment of a base 100A with a trough 122A having a ninety-degree bend between an inlet 116A and an outlet 118A. FIG. 5 depicts an embodiment of a base 100B with a y-shaped trough 122B extending between a pair of inlets 116A and an outlet 118A. The inlet 116 may be connected to an upstream side of a municipal wastewater system and the outlet 118 may be connected to a downstream side of the municipal wastewater system.

Referring now to FIG. 6, there is depicted an exploded, fragmentary view of a manhole assembly 200 according to an embodiment of the present disclosure. The manhole assembly may comprise the base 100. The base 100 is adapted to be placed into an excavated hole. An inlet and an outlet of the base 100 is connected to a municipal wastewater system as is known to those having ordinary skill in the art.

Once the base 100 is placed into an excavated hole, one or more risers 202 are positioned onto the base 202. Next, a cone 204 may be positioned onto the riser 202. Disposed on the cone 204 may be a grade ring 206. An annular metal ring 208 and manhole cover 210 may be installed onto the grade ring 206. The hole into which the manhole assembly 200 is installed may then be backfilled. In an embodiment, the base 100, riser 202, cone 204, and grade ring 206 may be formed from a polymer resin and aggregate mixture.

Those having ordinary skill in the relevant art will appreciate the advantages provide by the features of the present disclosure. For example, it is a feature of the present disclosure to provide a polymer manhole base. Another feature of the present disclosure to provide such a base formed of polymer concrete.

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

1. A manhole base comprising:

a base portion having an upper surface;

an annular sidewall extending upward from the base portion and circumscribing the upper surface;

a wastewater inlet and a wastewater outlet formed in the sidewall; and

a wastewater trough formed in the upper surface, the wastewater trough extending between the wastewater inlet and the wastewater outlet;

wherein the annular sidewall comprises an inner diameter;

wherein a thickness of the annular sidewall is less than 1/12th of the inner diameter.

2. The manhole base of claim 1, wherein the manhole base comprises a resin and an aggregate mixture.

3. The manhole base of claim 2, wherein the thickness of the sidewall is between one and three inches.

4. The manhole base of claim 2, wherein the thickness of the sidewall is about two inches.

5. The manhole base of claim 2, wherein the wastewater trough comprises a ninety-degree bend.

6. The manhole base of claim 2, wherein the upper surface comprises one or more anchors extending therefrom.

7. The manhole base of claim 2, wherein a height of the annular sidewall is between two feet and six feet.

8. The manhole base of claim 2, wherein the inner diameter of the annular sidewall is between 48 inches and 60 inches.

9. The manhole base of claim 2, further comprising a bench formed on the upper surface.

10. The manhole base of claim 9, wherein the bench comprises a slope of between 1 degree and 45 degrees.

11. A manhole system comprising:

a manhole base comprising: a base portion having an upper surface, an annular sidewall extending upward from the base portion and circumscribing the upper surface, a wastewater inlet and a wastewater outlet formed in the sidewall, and a wastewater trough formed in the upper surface, the wastewater trough extending between the wastewater inlet and the wastewater outlet, wherein the annular sidewall comprises an inner diameter, wherein a thickness of the annular sidewall is less than 1/12th of the inner diameter;

a cone defining a worker access opening; and

a riser portion interposed between the manhole base and the top portion.

12. The manhole system of claim 11, wherein the manhole base comprises a resin and an aggregate mixture.

13. The manhole system of claim 12, wherein the thickness of the sidewall is between one and three inches.

14. The manhole system of claim 12, wherein the thickness of the sidewall is about two inches.

15. The manhole system of claim 12, wherein the wastewater trough comprises a ninety-degree bend.

16. The manhole system of claim 12, wherein the upper surface comprises one or more anchors extending therefrom.

17. The manhole system of claim 12, wherein a height of the annular sidewall is between two feet and six feet.

18. The manhole system of claim 12, wherein the inner diameter of the annular sidewall is between 48 inches and 60 inches.

19. The manhole system of claim 12, further comprising a bench formed on the upper surface.

20. The manhole system of claim 12, wherein the bench comprises a slope of between 1 degree and 45 degrees.

21. A method of forming an access to a municipal wastewater system, said method comprising:

excavating a hole;

placing a manhole base at a bottom of the hole;

placing one or more risers on top of the manhole base;

placing a cone on top of the one or more risers; and

backfilling the hole;

wherein the manhole base comprises: a base portion having an upper surface, an annular sidewall extending upward from the base portion and circumscribing the upper surface, a wastewater inlet and a wastewater outlet formed in the sidewall, and a wastewater trough formed in the upper surface, the wastewater trough extending between the wastewater inlet and the wastewater outlet, wherein the annular sidewall comprises an inner diameter, wherein a thickness of the annular sidewall is less than 1/12th of the inner diameter.

22. The method of claim 21, wherein the manhole base comprises a resin and an aggregate mixture.

23. The method of claim 22, wherein the thickness of the sidewall is between one and three inches.

24. The method of claim 22, wherein the thickness of the sidewall is about two inches.

25. The method of claim 22, wherein the wastewater trough comprises a ninety-degree bend.

26. The method of claim 22, wherein the upper surface comprises one or more anchors extending therefrom.

27. The method of claim 22, wherein a height of the annular sidewall is between two feet and six feet.

28. The method of claim 22, wherein the inner diameter of the annular sidewall is between 48 inches and 60 inches.

29. The method of claim 22, further comprising a bench formed on the upper surface.

30. The method of claim 22, wherein the bench comprises a slope of between 1 degree and 45 degrees.

31. A manhole base comprising:

a base portion having an upper surface;

an annular sidewall extending upward from the base portion and circumscribing the upper surface;

a wastewater inlet and a wastewater outlet formed in the sidewall;

a wastewater trough formed in the upper surface, the wastewater trough extending between the wastewater inlet and the wastewater outlet; and

a bench formed on the upper surface;

wherein the annular sidewall comprises an inner diameter;

wherein a thickness of the annular sidewall is less than 1/12th of the inner diameter;

wherein the manhole base comprises a resin and an aggregate mixture;

wherein the thickness of the sidewall is between one and three inches;

wherein the upper surface comprises one or more anchors extending therefrom;

wherein a height of the annular sidewall is between two feet and six feet;

wherein the inner diameter of the annular sidewall is between 48 inches and 60 inches;

wherein the bench comprises a slope of between 1 degree and 45 degrees.