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Description  |
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FIELD OF THE INVENTION
The present invention relates to a method of sealing a manhole riser and a
catch basin, as well as sealing storm sewer pipes. More particularly, it
relates to an improved, economical method to seal a manhole riser and
catch basin from unwanted water and other contaminants which leak
therethrough.
BACKGROUND OF THE INVENTION
Manhole risers, manhole chimneys, all generically describe the top of the
unit which extends from sewer pipes to the ground surface. In particular,
the top portion of the manhole riser comprises numerous cement adjusting
rings, which sit atop each other and typically have specific dimensions.
Each ring may be added to increase the height that the manhole riser
extends to. As a road is repaved and new layers of pavement are added, it
often times is necessary to add an additional ring such that the manhole
covers stay flush with the road.
Catch basins are situated below storm sewer drainage grates found on roads.
The storm sewer grates are collection sites for water drainage from
streets which flow through catch basins. Catch basins generally comprise a
series of rectangular cement rails or collars. The cement collars are
stacked in a manner to create a rectangular "basin" through which water
passes. Each collar of the basin generally comprises two three-sided
cement rails which, when fitted together, create a rectangle. The catch
basins extend up to the grate, through which drainage water passes.
A problem that has existed with manhole risers and catch basins in the past
is surface water passes through gaps and spaces in the cement rings and
cement collars. Further, the water will often times freeze between and
within the cement structures, and the freeze/thaw cycle will deteriorate
and break up the cement structures, requiring them to be replaced.
Installation, repair or replacement of sanitary/storm manhole risers, storm
catch basins, and storm sewer pipes is a continuous process in maintaining
the infrastructure of municipalities. In this process, a special skill
called "adjustment" or "adjusting" occurs. Adjustment/adjusting is a
process whereby the manhole riser or storm catch basin is adjusted to the
height of the road surface.
As water utilities are installed, a manhole for access to the
infrastructure system is constructed according to engineering plans on a
straight line. If the road has a curve, it requires more manholes than a
straight road. The bottom section of the manhole utility access is called
a barrel, and between the barrel and riser is the "cone". The cone is made
of pre-cast concrete and will not leak because it is one piece. After the
cone is placed in position, the adjustment process begins at the top of
the cone in order to cause the manhole riser necking to meet flush with
the road surface.
By using concrete adjusting rings and mixed Portland cement on top of the
cone, rings are stacked to bring the manhole and top casting to the road
elevation. The procedure is similar for storm catch basins.
Poor workmanship, poor cement, improper grouting, and the freeze/thaw cycle
will cause hairline cracks in the adjustment necking. If a crack develops
in the asphalt, water seeks its lowest level and begins to work against
the cracks. Soon thereafter, the cracks enlarge and water, dirt and other
debris begin to seep into the infrastructure.
A further problem occurs at the road surface around manhole risers and
catch basins. When leaks develop, the soil erodes, and the erosion causes
the ground to sink. This ground sinking action then causes the catch basin
or manholes to protrude, and the road needs to be repaired. This loss of
supporting material causes the road to collapse around the resultant
voids.
Previously, contractors practicing the adjusting process for utilities and
municipalities have not had an economical solution for the above problems.
One solution, a "filter blanket", has been used in the past. The filter
blanket is a geo-textile fabric material that is placed on new roads that
have poor underlying soils. The filter blanket gives strength to the road
surface. Often times, a contractor will simply cut off a piece of the
filter blanket and wrap around the manhole neck to help prevent sand and
dirt from passing into the manhole. However, the filter blanket is not
adequate for the prevention of water to pass into the adjustment rings.
These problems are described in U.S. Pat. Nos. 4,475,845 and 4,469,467.
These patents describe the problems of water infiltration into manhole
chimney seals, and attempt to provide a solution. However, the problem
with the solutions proposed in the '845 and '467 patents has not been
satisfactory to date, due to the high cost of the product. The '845 patent
discloses a chimney seal having numerous sealing sections and a securing
means for the chimney seal. In particular, the sealing means describes a
retaining band to be used with different preformed skirts. The '467 patent
discloses a similar apparatus. The products allegedly covered by these
patents are very expensive, and not feasible for widespread use as manhole
riser sealer systems. Due to the numerous numbers of manholes which exist
and the increasingly tight budgets of municipalities, there exists a need
for an inexpensive apparatus and method of sealing, which does not employ
the use of "preformed" rings.
U.S. Pat. Nos. 4,540,310, 4,737,220 and Canadian Patent No. 1,142,009 all
claim to have some type of sealing means which could be used for sealing
water from manhole risers. However, none of these patents address the
problems associated with a need for a low cost product and a method for
sealing. The present invention addresses such a need, and is disclosed
herein. Further, the above patents and existing solutions are directed to
manhole risers, and do not address the needs addressed in the catch basin
market.
It is the object of this invention to create a barrier which may be placed
over adjustment necks of manhole risers and catch basins in a manner of
minutes with a one person operation.
It is the object of this invention to have an economical, cost effective
method, in dealing with water leaks and deterioration of adjustment necks
and catch basins. The present invention eliminates contaminated water,
sand, dirt and other debris from penetrating into water system
infrastructures, and thereby eliminates or reduces the amount of water
treatment needed at the city water treatment plant.
It is the object: of this invention to provide an economical method of
sealing the intersection between two adjoining pipes.
The present invention also reduces the amount of ground erosion associated
with cracks and leakage caused by cracks in manhole risers and catch
basins.
SUMMARY OF THE INVENTION
The present invention describes and claims an improved method for sealing a
manhole riser or catch basin. The invention also describes and claims an
improved kit for sealing manhole risers and catch basins. The method of
sealing a manhole riser, with adjusting rings, is described as follows:
a. selecting a first and second band of elastomeric material, said first
and second band having a total height of at least the height of the
manhole riser from the base of the bottom adjusting ring of the manhole
riser to the top edge of the top adjusting ring of the manhole riser;
b. placing the first band over the manhole adjustment area and positioning
the bottom edge below the adjustment on the cone; and
c. placing the second band over the manhole riser, positioning the second
band such that it extends over the top edge of the first band and also
extends over the top edge of the top adjusting ring.
The present invention also discloses a kit for sealing manhole risers. The
kit comprises:
a first and second band of elastomeric material, the first and second band
having a total height of at least the height of the manhole riser from one
inch below the base of the bottom adjusting manhole riser to the top edge
of the top adjusting ring of the manhole riser.
The present invention also addresses sealing catch basins. The method for
sealing catch basins comprises the following steps:
a. selecting a first and second band of elastomeric material, the first and
second band having a total height of at least the height of the catch
basin from the base of the bottom adjusting catch basin ring to the top
edge of the top adjusting ring of the catch basin;
b. placing the first band over the catch basin and positioning a bottom
edge of the band at the base of the catch basin, a top edge of the first
band extending toward the top of the top adjusting collar; and
c. if necessary, placing the second band over the catch basin, positioning
the second band such that it extends over the top edge of the first band
and also extends over the top adjusting ring and into the edge of the
catch basin casting.
The present invention also describes a kit for sealing catch basins. The
kit comprises:
a first and second band of elastomeric material, the first and second band
having a total height of at least the height from one inch below the
bottom of the catch basin from the base of the bottom adjusting catch
basin ring to the top edge of the top adjusting ring of the catch basin.
In another embodiment, a method to seal pipe intersections and barrel
intersections which are sealed together underground to support a cone,
comprise a tape having two strips of adhesive applied to one side of the
tape. The tape is dispensed, a release liner is peeled off of the
adhesive, and the tape is tightly wrapped around the riser, cone or other
conduit which needs to be sealed. The ends are overlapped and sealed with
a block of mastic.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of the present invention sealing a manhole
riser.
FIG. 2 shows a perspective view of the present invention sealing a catch
basin.
FIG. 3 shows individual components of the kit for sealing a manhole riser.
FIG. 4 shows one of the individual components of the kit of FIG. 3.
FIG. 5 shows the kit in boxed form.
FIG. 6 shows components of the present invention used in a method to seal
pipe junctures.
FIG. 7 shows components of the present invention used to seal barrels
supporting a cone.
DETAILED DESCRIPTION OF THE INVENTION
The present invention, although describing manhole risers and catch basins,
also is directed to large standard city sewer manholes which are commonly
called cones or barrels. Power and phone companies also have underground
cones, which are similar to manhole risers. The present invention
envisions the method of sealing a manhole riser, a catch basin, a pipe
juncture or any large structure with rings or collars secured together.
The present invention may also seal the area between the cone and the
barrel which often leaks.
As can be seen in FIG. 1, the present invention is a three-piece sealing
system shown generally as 10. The manhole riser is shown as 10, with a
break-away as 14. Risers can vary from 4 inches to 16 inches in height
depending on the soil and surface conditions. The break-away shows the
manhole riser with a portion of the sealing system removed for
illustration purposes. The individual adjusting rings 16, 18, 20, 22 and
24 are stacked atop one another. The adjusting rings are generally
cemented to one another, with the mortar or Portland cement visible as 26.
For the purposes of the present application, "manhole riser" refers to what
is shown in FIG. 1, which comprises a plurality of adjusting rings which
lead up to the top casting, which is shown as 12. The casting 12 is an
annular collar, which supports the manhole cover (not shown). It is
intended that the manhole cover be flush or a bit below the road surface.
Beneath the riser 10, is a one-piece cone (not shown). The one-piece cone
is typically made of concrete, and need not be shown for the present
invention. As discussed above, leaks occur through the adjusting rings,
particularly between the adjusting rings, and the present invention
discusses a solution to these leaks.
FIG. 2 discloses a catch basin generally shown as 50. The catch basin has
individual adjusting collars, which are shown at the break-away portion of
the sealing system 52 as 54, 56, 58, 60 and 62. A top casting is shown as
63. The collars are secured in place with Portland cement or mortar, shown
generally as 64. Generally, two collars are fitted together with a point
of intersection shown as 66. It is intended that the casting 63 with a
grate on top (not shown) be marginally below the road surface, with the
road surface tilted in a manner such that storm water drains into the
catch basin 50. Water passes through a grate which appears on top of the
casting 63, through the middle of the collars, into the storm sewer
system. The storm sewer system typically discharges into areas used as
irrigation, lakes, rivers, etc. This is different from manhole risers,
which typically are involved in the treatment of water which is thereafter
piped to homes and businesses for consumption. Although the manhole riser
and catch basin perform different functions, as described above, the same
problems apply to both. The mortar or cement holding the rings or collars
in place often breaks down with the freeze/thaw cycle or with age.
Furthermore, cracks may develop in the rings or adjusting collars, whereby
water, sand, and other contaminants may freely pass through the cracks.
The present invention addresses these concerns. Referring back to FIG. 1,
there is a three-piece sealing system, with a bottom band being 30, a
middle band being 32 and a top band being 34. The bands are large,
continuous bands of an elastomeric material, with the ends secured
together to form a continuous loop. Preferably, the ends are secured
together by a vulcanizing process. The first band 30, is a circular shaped
elastomeric band which is adapted to fit the bottom of manhole riser 10.
The second band, shown as 32, is placed in the mid region of the manhole
riser 10. Preferably, the band is an EPDM elastomeric material (ethylene
propylene diene) or Neoprene. EPDM and Neoprene materials are abrasion
resistant, rubber like synthetic polymers. Other types of possible
elastomeric materials include nitrile, Hypalon, and CPE (chlorinated
polyethylene) rubbers.
Preferably some bands of the present invention have a mastic adhesive on at
least a portion the interior of the band. Preferably, a release liner
covers the exterior of the adhesive. Once the bands are in place, the
release liner is removed. The adhesive thereafter secures the band to the
riser. FIGS. 3 and 4 disclose the use of an adhesive on the bands. FIG. 3
shows the preferable adhesive positioning. Another preferred adhesive
position is to have an adhesive on the top and bottom of the interior of
the bands with no adhesive in the middle portion of the band. The top band
34 has adhesive on about the top half of the band. Band 32, preferably,
has no need for adhesive as it is secured by the overlapping of bands 34
and 30, preferably, bottom flange portion 36 has adhesive thereon.
The first band 30 is drawn over the adjustment neck to the bottom of riser
10. If a slab is involved, the band will automatically flair out and
adhere to the slab catch basin. This "flair" is especially preferred if
the cone is sitting on a cement slab. The "flair" flares out to meet the
cement slab. Preferably, the bottom band extends partially below the base
of the bottom adjusting ring (about one inch).
In the preferred embodiment, the top band 34 terminates at the top of the
top adjusting ring 24 on the bottom edge of the casting 12. Preferably,
band 34 has an approximate height of 6 inches and is of an elastomeric
material that stretches over the top edge of the top adjusting ring 24 to
the bottom edge of the casting 28 to create a tight seal. The entire
structure is now water tight.
Thus, to summarize the method, prior to installing the invention, remove
all dirt from around the base of the riser or basin. Clean the riser or
basin so it will receive the adhesive. Smooth all sharp corners with an
abrasive stone. Wipe clean with a rag. A first ring of material 30 is
pulled over the manhole riser 10, and pulled down to the bottom. The top
of the first band must reach the top of the top adjusting ring. If the
bottom band does not reach the top adjusting ring, and extension band must
be used. Preferably, adhesive is previously applied to the inside, and a
release liner is pulled off the band 30. A second band 32 is pulled over
riser 10 and positioned to overlap riser 10 by approximately 2 inches.
After the second band 32 is in place, the third, smaller top band 34 is
put in place after adhesive is applied or exposed from the inside of band
34. This extends below the top portion of the second band 32, and extends
over the top portion of the top adjusting ring, and extends onto the
casting 28. Preferably, this third band is approximately a 6 inch band.
However, the present method and kit may work if the top band reaches from
a mid point region measured from the base of the riser to the top edge of
top adjusting ring. Thus, the actual size of the bands is not important,
with the criteria that the bands cover the whole exterior of the manhole
riser.
Optionally, the middle third band may or may not be needed, depending on
the number of adjusting rings used. Regardless of whether there are two
bands or three bands, the system is sealed in place with adhesive, mortar
and the manhole riser is thereafter buried.
Catch basin 50, shown in FIG. 2, utilizes a band system whereby the bands
are rectangular in shape. The first band 68 is placed over the catch basin
such that it is pulled to the base of the catch basin 50. The bottom band
68 is cut about 1/2 inch on 3 inches either side of the corner to relieve
tension. Flange 74 thereafter contacts the slab, allowing water to
run-off. Top band 22 is thereafter placed on top of the catch basin 50.
The bottom edge of the top band 72 is positioned below the top edge of the
second rectangular band 70. The top edge of the third band 72 thereafter
extends beyond the top edge of the top adjusting collar 62, and extends on
to the bottom edge of the casting 63. Thereafter, catch basin is sealed
and buried.
The circular bands used for the manhole riser and the rectangular bands
used for the catch basin of the present invention are elastomeric
material, which is generally cut from a pattern and is made into a band
from a rectangular cut piece of material with the use of a vulcanizing
process to secure the band. The same procedure is performed with the
rectangular band.
FIG. 3 shows a preferred "kit" of bands for the catch basin and the manhole
riser of the present invention. As is evident, the top band has an
adhesive portion 35 at the top. This is so the top band is secure to the
top collar and/or casting of the catch basin. The kit includes an
extension band 32 and the bottom band 30, which has an adhesive portion 31
on the bottom portion.
FIG. 4 shows a perspective view of the inside of band 34 of the present
invention.
FIG. 5 shows a complete kit of the present invention, with bands 30, 32 and
34.
In the preferred embodiment, the bottom band is 12 inches high and has is
capable of being flaired if a slab is involved. All of the bands have a
thickness of about 0.06 inches and have a 60 durometer. Adhesive is
applied to the interior surface. The top band lays on the casting to seal
against infiltration. The vertical part of the top band fits over the top
portion of the bottom or middle band and should overlap at least 2 inches.
An extension band with a height of approximately 8 inches may be used to
gain additional height as described above. The extension piece fits over
the bottom piece and should preferably overlap by at least 2 inches. The
top piece will thereafter fit over the extension band, which overlaps by
at least about 2 inches over the extension band.
Preferably the extension band should have an adhesive or strip of mastic on
the bottom edge, where the bottom of the extension band contacts the top
of the bottom band. Thus, the extension band would have adhesive on the
bottom, inner surface which contacts the top, outside surface of the
bottom band. This ensures the integrity of the seal. Likewise, the top
band should have adhesive or mastic which is on the interior surface, and
contacts the top, outer surface of the extension band. Again, this ensures
the integrity of the seal. The sealant used as an adhesive for the bands
is a flexible butyl mastic sealant.
The present invention also provides an economical method of sealing the
area around a pipe juncture. As shown in FIG. 6, pipes 80 and 82, which
may be cement pipes, are often connected together with a "male" 82 and
"female" 80 pipe. The male pipe 82 is inserted into an enlarged, female
end of another pipe 80. The tape or connector has adhesive sections 86,
and 88 and has two ends 90, and 92.
However, often times the juncture 94 or intersection formed by these pipes
is not water tight or impervious to infiltration. The present invention
addresses these problems with the use of a tape system.
As is shown in FIG. 6, a pull away of the tape 92 is illustrated. The
method of sealing the pipe juncture utilizes a roll of elastomeric tape.
The tape 92 preferably comes in a dispenser (not shown), with the tape
being 50 feet long, rolled in the dispenser box, and the tape 92 is made
of EPDM and is 8 inches wide and 0.60 inches thick. The tape 92 has mastic
on the top and bottom of the tape 92 running lengthwise. The mastic
preferably is 1.5 inches.times.0.25 inches thick. Preferably it is the
same mastic as described above.
The method involved having two pipes which are configured as shown in FIG.
6 is described below. A section of elastomeric tape is cut, with the
stretched length of the tape being greater than the circumference of the
pipe juncture that the tape is covering.
The tape has previously applied to it at least two strips of adhesive
extending lengthwise along the tape. The tape is positioned such that
about one-half of the width of the tape is on one side of the pipe
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