Manhole base assembly with internal liner and method of manufacturing same

• US 9,617,722 B2
• Filed: 11/20/2015
• Issued: 04/11/2017
• Est. Priority Date: 11/20/2014
• Status: Active Grant

• Current Assignee: Press-Seal Corporation
• Original Assignee: Press-Seal Corporation
• Inventors: Skinner, James W., Gamble, Jimmy D., Slocum, Robert R., Kaczmarczyk, John M.
• Primary Examiner(s): MINTZ, RODNEY K
• Application Number:
  US14/947,615
• Publication Number:
  US 20160145848A1
• Time in Patent Office: 508 Days
• CPC Class Codes: B28B 7/02 Moulds with adjustable parts specially for modifying at will the dimensions or form of the moulded article
• CPC Class Codes: E02D 29/125 characterised by the lining of the shaft
• CPC Class Codes: E02D 29/149 Annular gaskets
• CPC Class Codes: E03F 5/021 Connection of sewer pipes to manhole shaft
• CPC Class Codes: E03F 5/027 The bottom made of prefabricated segments

Abstract

A manhole base assembly and a method for making the same, in which a non-cylindrical, low-volume concrete base is fully lined to protect the concrete against chemical and physical attack while in service. This lined concrete manhole base assembly may be readily produced using a modular manhole form assembly which can be configured for a wide variety of geometrical configurations compatible with, e.g., varying pipe angles, elevations and sizes. The form assembly is configurable to provide any desired angle and elevation for the pipe apertures using existing, standard sets of form assembly materials, and may also be used in conjunction with industry-standard cylindrical casting jackets for compatibility with existing casting operations. The resulting system provides for flexible construction of a wide variety of lined manhole base assemblies at minimal cost, reduced concrete consumption and reduced operational complexity. The modular nature of the production form assembly also facilitates reduced inventory requirements when various manhole base assembly geometries are needed.

Claims

1. A manhole base assembly comprising:

a concrete base comprising an upper opening, a first side opening below the upper opening, and a second side opening below the upper opening, the concrete base having a non-cylindrical outermost profile; and

a liner received within the concrete base, the liner comprising;

an entry aperture aligned with the upper opening of the concrete base;

a first side wall having a first pipe aperture therethrough, the first pipe aperture below the entry aperture and aligned with the first side opening of the concrete base;

a second side wall positioned radially outside the entry aperture and having a second pipe aperture therethrough, the second pipe aperture below the entry aperture and aligned with the second side opening of the concrete base; and

a flow channel extending between the first pipe aperture and the second pipe aperture, the flow channel in fluid communication with the entry aperture.

2. The manhole base assembly of claim 1, wherein the first side wall and the second side wall are both positioned radially outside the entry aperture, the liner further comprising a top wall extending radially outwardly from the entry aperture to the first and second side walls.

3. The manhole base assembly of claim 1, wherein the liner is formed from a composite material including an inner layer and an outer layer joined to the outer layer.

4. The manhole base assembly of claim 3, wherein the inner layer of the liner is a polymer material and the outer layer of the liner is fiberglass.

5. The manhole base assembly of claim 1, further comprising a plurality of reinforcement rods forming a reinforcement assembly at least partially surrounding the liner and fixed to the liner, the reinforcement assembly cast into the concrete base, whereby the liner and the concrete base are integrally joined to one another via the reinforcement assembly.

6. The manhole base assembly of claim 5, wherein the liner comprises a plurality of anchors each having a connection portion fixedly connected to the liner and an anchoring portion fixed to the reinforcement assembly, such that the plurality of anchors fix the reinforcement assembly to the liner.

7. The manhole base assembly of claim 5, wherein the reinforcement assembly includes a plurality of subassemblies attachable to the liner and to one another.

8. The manhole base assembly of claim 1, wherein:

the entry aperture of the liner comprises a tubular structure extending upwardly away from the flow channel; and

the entry aperture includes a bench disposed within the entry aperture, the bench defining a surface extending inwardly from a wall of the tubular structure toward a longitudinal axis of the tubular structure.

9. The manhole base assembly of claim 8, wherein the liner comprises a back wall extending downwardly from an inner edge of the bench, such that a void is created within a periphery of the entry aperture and below the bench, the manhole base assembly further comprising a concrete displacement wedge disposed adjacent with the back wall and within the void.

10. The manhole base assembly of claim 1, wherein the concrete base comprises planar side walls having the first and second pipe openings formed therein respectively.

11. The manhole base assembly of claim 10, further comprising a plurality of gaskets respectively disposed at the first pipe aperture and the second pipe aperture and adapted to receive a pipe of a pipe system, one of the plurality of gaskets extending across each of the planar side walls of the concrete base.

12. The manhole base assembly of claim 11, wherein each of the plurality of gaskets comprises:

an anchoring section adjacent to a rim of the neighboring pipe aperture and anchored within the concrete base around the periphery of the first or second pipe opening; and

a sealing section extending outwardly away from the anchoring section and the concrete base.

13. A manhole base assembly comprising:

a polymeric liner comprising;

an entry aperture;

a first side wall positioned radially outside the entry aperture and having a first pipe aperture therethrough, the first pipe aperture below the entry aperture;

a second side wall positioned radially outside the entry aperture and having a second pipe aperture therethrough, the second pipe aperture below the entry aperture;

a top wall extending radially outwardly from the entry aperture to the first and second side walls; and

a flow channel extending between the first pipe aperture and the second pipe aperture, the flow channel in fluid communication with the entry aperture.

14. The manhole base assembly of claim 13, wherein the liner is formed from a composite material including an inner layer and an outer layer joined to the outer layer.

15. The manhole base assembly of claim 14, wherein the inner layer of the liner is a polymer material and the outer layer of the liner is fiberglass.

16. The manhole base assembly of claim 13, further comprising a plurality of reinforcement rods forming a reinforcement assembly at least partially surrounding the liner and fixed to the liner.

17. The manhole base assembly of claim 16, further comprising a concrete base comprising:

an upper opening aligned with the entry aperture of the liner;

a first pipe opening below the upper opening and aligned with the first pipe aperture of the liner; and

a second side opening below the upper opening and aligned with the first pipe aperture of the liner,

the concrete base having a non-cylindrical outermost profile,

the reinforcement assembly cast into the concrete base, whereby the liner and the concrete base are integrally joined to one another via the reinforcement assembly.

18. A manhole base forming assembly comprising:

a liner comprising;

an entry aperture,

a first side wall having a first pipe aperture therethrough, the first pipe aperture below the entry aperture,

a second side wall having a second pipe aperture therethrough, the second pipe aperture below the entry aperture; and

a flow channel extending between the first pipe aperture and the second pipe aperture, the flow channel in fluid communication with the entry aperture; and

a manhole form assembly comprising;

a plurality of aperture supports sized to fit in the first pipe aperture and the second pipe aperture respectively, each having a portion protruding outwardly from one of the first pipe aperture and the second pipe aperture;

a first forming plate secured to one of the plurality of aperture supports and adjacent to the first pipe aperture, the first forming plate having a back edge and an opposing front edge;

a second forming plate secured to another one of the plurality of aperture supports and adjacent to the second pipe aperture, the second forming plate having a back edge and an opposing front edge;

a back wall extending partially around the liner from the back edge of the first forming plate to the back edge of the second forming plate; and

a front wall extending partially around the liner from the front edge of the first forming plate to the front edge of the second forming plate,

the first forming plate, the second forming plate, the back wall and the front wall and the liner forming a pre-casting assembly in which a non-cylindrical peripheral boundary is formed around the liner with the entry aperture forming an open upper end of the pre-casting assembly, and

the non-cylindrical peripheral boundary of the pre-casting assembly is sized to be received in a casting jacket.

19. The manhole form assembly of claim 18, further comprising the casting jacket formed as a cylinder, such that when the pre-casting assembly is received in the casting jacket, a first void bounded by the first forming plate and the casting jacket, a second void bounded by the second forming plate and the casting jacket, a third void at least partially bounded by the front wall and the casting jacket, and a fourth void bounded by the back wall and the casting jacket.

20. The manhole form assembly of claim 18, wherein:

the back wall comprises a hinged wall comprising a plurality of segments including a first segment, a last segment, and at least one intermediate segment between the first segment and the last segment, the plurality of segments hingedly connected to one another about a vertical axis.