U.S. patent application number 12/102131 was filed with the patent office on 2009-03-26 for lightweight aggregate unit and method of manufacture.
Invention is credited to Erik Anderlind, Dag Landvik, Terence Nielsen.
Application Number | 20090080976 12/102131 |
Document ID | / |
Family ID | 39588351 |
Filed Date | 2009-03-26 |
United States Patent
Application |
20090080976 |
Kind Code |
A1 |
Anderlind; Erik ; et
al. |
March 26, 2009 |
LIGHTWEIGHT AGGREGATE UNIT AND METHOD OF MANUFACTURE
Abstract
A water channeling system includes at least one channeling
member comprising fixed aggregate forming a solid body. In this
embodiment, the at least one channeling member has a first end, a
second end, and a plurality of fluidly connecting interstices
therewithin. In this version, the at least one channeling member is
water permeable longitudinally between the first end and the second
end. The at least one channeling member may be installed below
ground to channel water from a first location to a second location.
The channeling member may be an elongate member or a vertical
panel. The channeling member may comprise comprises polymeric
aggregate particles having irregular shapes. The fixed aggregate
may have a density of less than or equal to about 1 lb per cubic
foot. Multiple channeling members may be placed end-to-end.
Inventors: |
Anderlind; Erik; (Paris,
FR) ; Landvik; Dag; (Saltsjo-Boo, SE) ;
Nielsen; Terence; (Spencerville, OH) |
Correspondence
Address: |
FROST BROWN TODD, LLC
2200 PNC CENTER, 201 E. FIFTH STREET
CINCINNATI
OH
45202
US
|
Family ID: |
39588351 |
Appl. No.: |
12/102131 |
Filed: |
April 14, 2008 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60911751 |
Apr 13, 2007 |
|
|
|
Current U.S.
Class: |
405/45 ;
29/592 |
Current CPC
Class: |
Y10T 29/49 20150115;
E02D 31/02 20130101; E03F 1/002 20130101; E01C 11/225 20130101;
E02D 31/10 20130101; E02B 11/005 20130101 |
Class at
Publication: |
405/45 ;
29/592 |
International
Class: |
E02B 11/00 20060101
E02B011/00 |
Claims
1. A water channeling system at a site, comprising: a first
location and a second location a horizontal distance away from said
first location, at said site; and at least one elongate member
comprising fixed aggregate forming a solid body, wherein the at
least one elongate member has a first end, a second end, a greatest
linear dimension comprising a length between said first end and
said second end, and a plurality of fluidly connecting interstices
therewithin, wherein the at least one elongate member is water
permeable longitudinally between said first end and said second
end, wherein the at least one elongate member is installed below
ground and channels water from said first location to said second
location.
2. The system of claim 1 further comprising a plurality of elongate
members, wherein the first end of a first one of the plurality of
elongate members is adjacent the second end of a second one of the
plurality of elongate members.
3. The system of claim 1 in which the at least one elongate member
comprises polymeric aggregate particles bound together.
4. The system of claim 3 in which said polymeric aggregate
particles comprise expanded polystyrene.
5. The system of claim 2 in which said polymeric aggregate parties
are bound together by fusing.
6. The system of claim 2 in which said polymeric aggregate parties
are bound together by a binder material, wherein the binder
material is selected from the group consisting of a bitumen
material, an acrylic material, and combinations thereof.
7. The system of claim 1 further comprising a layer of barrier
material adjacent at least one of the at least one elongate
member.
8. The system of claim 7 wherein said layer of barrier material is
bonded to said at least one of said elongate members.
9. The system of claim 1 in which the at least one elongate member
comprises a length of pipe at least partly encased lengthwise
therein.
10. A pipeline unit, comprising: a solid body having a first end, a
second end, a linear dimension comprising a length between said
first end and said second end, and a plurality of fluidly
connecting interstices therewithin; wherein said plurality of
fluidly connecting interstices are formed by a plurality of fixed
aggregate members bound together; and a length of pipe at least
partially encased within said solid body along said length.
11. The pipeline unit of claim 10, wherein said pipe is selected
from the group consisting of perforated pipe, non-perforated pipe,
and combinations thereof.
12. The pipeline unit of claim 10, wherein said elongate solid body
comprises polymeric aggregate particles bound together.
13. The pipeline unit of claim 12, wherein said polymeric aggregate
particles comprise expanded polystyrene.
14. The pipeline unit of claim 12 in which said polymeric aggregate
parties are bound together by fusing.
15. The pipeline unit of claim 12 in which said polymeric aggregate
parties are bound together by a binder material.
16. The pipeline unit of claim 10 further comprising a layer of
barrier material bonded to said elongate solid body.
17. A method for producing a pipeline unit, comprising the steps
of: supplying a length of pipe; placing said length of pipe in a
mold; supplying polymeric aggregate particles; and introducing said
aggregate particles into said mold, and at least partially about
said length of pipe.
18. The method of claim 17, further comprising the step of heating
said aggregate particles to cause them to fuse.
19. The method of claim 17, further comprising the steps of:
supplying a binder material; and applying said binder material to
said aggregate particles.
20. The method of claim 19, further comprising the step of
agitating said aggregate particles with said binder material.
21. The method of claim 19, further comprising the step of spraying
said aggregate particles with said binder material.
22. The method of claim 19, wherein the binder material is selected
from the group consisting of a liquid bitumen material, an acrylic
material, and combinations thereof.
23. The method of claim 19, further comprising the step of applying
heat to said aggregate particles after they are introduced into
said mold.
24. A water channeling system at a site, comprising: a first
location and a second location a horizontal distance away from said
first location, at said site; at least one channeling member
comprising fixed aggregate forming a solid body, wherein the at
least one channeling member has a first end, a second end, and a
plurality of fluidly connecting interstices therewithin, wherein
the at least one channeling member is water permeable
longitudinally between said first end and said second end; wherein
the at least one channeling member comprises polymeric aggregate
particles bound together, wherein said polymeric aggregate
particles comprise irregular shapes; wherein said fixed aggregate
is of a density of less than or equal to about 1 lb per cubic foot;
and wherein the at least one channeling member are installed at
least partially below ground and channel water from said first
location to said second location.
25. The system of claim 24 further comprising a plurality of
channeling members, wherein said first end of one of the plurality
of channeling members is adjacent the second end of another one of
the plurality of channeling members.
26. The system of claim 24, wherein the at least one channeling
member comprises a vertical channeling panel having a first
surface, a second surface, a greatest linear dimension comprising a
height between said first surface and said second surface, and a
plurality of fluidly connecting interstices therewithin.
27. A method of producing a water channeling system comprising the
steps of: supplying polymeric aggregate particles; supplying a
binder material; mixing the polymeric aggregate particles and the
binder material, wherein the polymeric aggregate particles and the
binder material form a fluid concrete mixture; creating a void at
an installation site, wherein the void comprises one or more walls;
and introducing the fluid concrete mixture into the void, such that
the one or more walls provide support to the fluid concrete mixture
thereby allowing the fluid concrete mixture to solidify within the
void; wherein the fluid concrete mixture comprises a plurality of
fluidly connecting interstices therewithin after solidification.
Description
PRIORITY INFORMATION
[0001] This application claims priority to U.S. Provisional Patent
Application 60/911,751 filed Apr. 13, 2007, entitled "Lightweight
Aggregate Unit and Method of Manufacture," the disclosure of which
is incorporated by reference herein.
BACKGROUND
[0002] Embodiments of the present invention relate generally to
below-ground pipelines, conduits, channels and systems used, for
example, for draining water away from objects or areas such as
building foundations and footings, septic fields or other systems
or areas in which French drains have often been used. More
particularly, embodiments of the present invention relate to a
pre-formed below-ground system component that eliminates in part or
in whole the need for handling and installation of heavy, loose
materials such as gravel. Embodiments of the present invention also
relate to a method of manufacturing the disclosed system
component.
[0003] Conventional below-ground drainage systems such as French
drains and the like typically comprise a line or lines of
perforated pipe buried in a bed of aggregate material such as
gravel, crushed stone or like material. The pipe, together with the
aggregate material, are typically installed so as to lie at the
base of a ditch within or adjacent to the area to be drained. When
installed and located properly, these components provide a
mechanism that relieves hydrostatic pressure in surrounding soil,
and channels water away from the area. Before the gravel is
installed, the ditch may be lined with a layer of filter cloth or
similar barrier material, and after the gravel and pipe are
installed but before the ditch is backfilled with earth, the top of
the gravel bed also may be covered by a layer of filter cloth. The
barrier or filter cloth will serve to trap, block or otherwise
prevent silt or other fine waterborne particles from being carried
into and deposited within the gravel bed and eventually filling the
interstices thereof, clogging the bed and reducing the
effectiveness of the system.
[0004] An alternative use of gravel-based systems of this nature
has been to serve purposes converse to those of drainage--dispersal
of water. For example, such systems have been used as components of
leach beds for dispersing overflow from septic tanks, seepage pits,
sumps or the like into adjacent soils, or in systems used for
dispersing rain- or stormwater piped or channeled away from
building structures.
[0005] Additionally, other installations of below-ground systems
have included a pipeline or conduit buried in a bed of gravel,
crushed stone or like materials to distribute pressures and forces
within the soil and protect the pipeline or conduit from being
crushed.
[0006] Persons familiar with installation of such systems are
familiar with the difficulty and expense associated with
transporting and handling materials such as gravel or crushed
stone. Such material is relatively heavy, and because it is loose,
its installation often requires substantial machine and/or hand
labor to move and place properly. Various alternative systems have
been developed in the past which can reduce or eliminate the need
for gravel or similar material in a below-ground system. However,
to the best of the inventors' knowledge, no prior art systems have
all of the features and advantages of the present invention.
BRIEF DESCRIPTION OF FIGURES
[0007] It is believed the present invention will be better
understood from the following description of certain examples taken
in conjunction with the accompanying drawings, in which like
reference numerals identify the same elements and in which:
[0008] FIG. 1 depicts a perspective view of an exemplary embodiment
of an elongate unit of an underground water channeling system that
includes a piece of pipe enclosed therein.
[0009] FIG. 2 depicts a perspective view of an alternate exemplary
embodiment of an elongate unit of an underground water channeling
system that does not include a piece of pipe enclosed therein.
[0010] FIG. 3 depicts a perspective view of an exemplary embodiment
of individual aggregate particles used in the unit shown in FIG.
1.
[0011] FIG. 4 depicts a cross-sectional view of an exemplary
installation of the unit shown in FIG. 1.
[0012] FIG. 5 depicts a cross-sectional view of an alternate
exemplary underground water channeling system that includes a unit
as shown in FIG. 1 and an exemplary embodiment of a vertical
drainage panel.
[0013] FIG. 6 depicts a perspective view of the exemplary vertical
drainage panel shown in FIG. 5.
[0014] FIG. 7 depicts a front view of the exemplary vertical
drainage panel shown in FIG. 5.
DETAILED DESCRIPTION
[0015] Referring now to FIG. 1, one embodiment of the present
invention is an elongate unit 10 including a length of perforated
pipe 20 encased in a formed body 30. The body 30 may be formed of a
porous concrete consisting of aggregate particles held together.
(As used herein, unless otherwise indicated, the term "concrete"
means a porous material comprising aggregate particles effectively
held together following forming of the material in any suitable
manner.) Additionally, the unit 10 may have a layer of barrier
material 40 placed over one or more surfaces thereof. A layer of
suitable barrier material 40 also may be bonded or glued onto or
about one or more surfaces of the unit 10. Although the body 30 of
the unit 10 depicted in FIG. 1 has a square cross section, it will
be understood based on the description herein that the body 30 can
be formed to have a circular cross section or any other suitable
cross-sectional shape. Additionally, it will be understood that, if
a pipe is included in the unit, the longitudinal axis of the pipe
can be centered within the cross section of the body, or offset in
any desired location such as, for example, the location shown in
FIG. 1.
[0016] As used herein, the term "member," shall not be read to be
limited to a singular piece or a homogenous continuum of material.
In other words, a "member" may, but need not, comprise a plurality
of parts joined together in any suitable way.
[0017] The aggregate material preferably is of a lower density than
gravel, and is preferably effectively non-degradable over the
expected service life of the system. The inventors have determined
that a suitable aggregate may consist of an expanded polymeric
substance such as, for example, particles of expanded polystyrene,
but any other suitable material may be employed. In one particular
embodiment, the aggregate material is of a density of less than or
equal to about 1 lb per cubic foot. A relatively low density, such
as this, may provide a financial benefit compared to aggregate
material of a higher density.
[0018] The aggregate particles may have any suitable shape(s). For
example, the aggregate particles may comprise spherical shapes. The
inventors have determined that particles having differing and/or
irregular shapes that when brought into coalescence leave
substantial interstitial spaces or voids in fluid communication
within the concrete during formation of the unit and under pressure
exerted by surrounding soils after installation and during service
can provide for a finished unit having substantial water passage
capacity. In the embodiment depicted, the individual aggregate
particles 50 consist of expanded polystyrene, extruded in the
shapes depicted in FIG. 3. In one embodiment, the aggregate
particles may be shaped to produce a percentage of void of at least
about 55%. Depending upon the aggregate material used, the shapes
selected should be effectively strong enough to withstand
compression of the unit 10 by in-service soil pressures so as not
to break up to an extent that interstitial spaces or voids are
substantially reduced in number and/or volume.
[0019] The aggregate particles may be held together by a suitable
binder material. The binder material may be any suitable material
that is compatible with the aggregate material. In particular the
binder material may have the ability to effectively adhere to the
aggregate particles while not causing substantial degradation of
the aggregate particles over the expected service life of the
system. The aggregate material-binder material combination may also
allow a reasonable time for molding or forming of the body before
setting. The inventors have determined that a rubberized bitumen
emulsion product sold under the trademark CROMAPRUFE, sold by
Cromar Building Products Limited, North Yorkshire, UK, mixed with a
quantity of Neoprene Liquid Dispersion 671A sold by DuPont
Performance Elastomers L.L.C., Wilmington, Del., in a ratio of
three parts Cromaprufe to one part Neoprene Liquid Dispersion 671A,
creates a suitable binder material for use with polystyrene
aggregate particles. Of course, alternate binder materials may be
used in place of or in addition to the bitumen material described
above. For example, the inventors have determined that an acrylic
material known as Kool Seal, manufactured by The Sherwin Williams
Company, Memphis, Tenn. is a suitable binder material for use with
polystyrene aggregate particles. It should be noted that the binder
material selected may be, but does not necessarily have to be,
effectively non-degradable over the expected service life of the
system. Once units embodying features disclosed herein are
transported and installed, binding of the aggregate particles may
not be critical because the surrounding soils may serve to hold the
aggregate particles in place following installation and
backfilling. Additionally, in some cases it may be desirable for
the body 30 of the unit 10 to be flexible and/or malleable to
accommodate, for example, curves or irregularities within a ditch.
The inventors have determined that the above-identified bitumen
binder provides flexibility and malleability in this regard, being
somewhat fluid and elastic after setting. Similarly, the
above-identified acrylic material also provides flexibility and
malleability in this regard. Alternatively, however, it may be
desirable in some applications that the body be relatively rigid
and not substantially malleable. In that case, a binder material
having differing properties may be used. It should be noted that
different types of binder material provide differing levels of
flexibility and malleability. Accordingly, the binder material may
be selected based on the level of flexibility and malleability
desired for a specific use of this embodiment of the invention.
[0020] As an alternative to use of a binder material to hold the
aggregate particles together, the particles may be bound together
by other means, for example, by application of heat in an
appropriate process to cause surface melting and fusing of polymer
particles to one another.
[0021] It should be noted that binding the aggregate material
together, whether accomplished via use of a binder material,
application of heat, or some other method, may reduce the movement
of the aggregate after forming, thereby reducing the amount of
settling and shape deformation during installation and use of the
unit.
[0022] As noted, a layer of barrier material 40 may be placed over
one or more surfaces of the unit, and may be bonded or glued
thereto using at least one of the above-identified binder materials
or other suitable adhesive material. The barrier material 40 may be
bonded or glued to the body 30 while the body 30 is in a mold,
thereby eliminating the need to apply the barrier material to the
body 30 at the time of installation. However, this is not required.
A layer of barrier material may be desired to serve to prevent silt
or other fine waterborne particles from being carried into the
interstices of the concrete and deposited therein. A suitable
barrier material may be selected to be water permeable, or
effectively water impermeable so as to selectively block water
pathways into the concrete. A suitable barrier material may
comprise paper, natural or synthetic cloth or felt, filter cloth,
or any other suitable material having desired properties. In
particular, the barrier material may comprise a nonwoven geotextile
material.
[0023] In an alternate embodiment, shown in FIG. 2, a unit 10' is
formed of a suitable concrete as described above with regard to
unit 10, with no included length of pipe. The interstitial spaces
or voids in the concrete will still serve to function to relieve
hydrostatic pressure in surrounding soils and allow water to pass
therethrough, while the channel formed and held open by the
presence of unit 10' in the earth can serve to channel water away
from an area, in the same way that drainage systems relying only on
gravel beds without pipes function. In another embodiment, a unit
(not shown) may be formed to have an open channel through its
length having a circular or any other suitably shaped cross
section. It will be appreciated that in drainage systems, it may be
desirable for a unit to have an open channel along its length, or
perforated pipe encased therein, where high water passage capacity
is desired. Conversely, where high water passage capacity is deemed
unnecessary, an open channel or perforated pipe may not be deemed
necessary.
[0024] In another alternate embodiment, a unit (not shown) may
comprise a plurality of pipes encased in aggregate material. By way
of example only, the plurality of pipes may be identical or similar
types of pipe, or they may comprise pipes of different shapes and
sizes. The plurality of pipes may also include one or more
specialty pipes or conduits.
[0025] The body 30 of the unit may be formed to have ends that
enable two or more units to be connected endwise, to extend a
drainage or other below-ground line. The ends may be suitably
formed so that an end of one unit will mate or join in any suitable
fashion with an end of another unit. Each unit may have, for
example, a "male" end and a "female" end. Alternatively, the ends
may be adapted, for example, to receive and/or fit into or onto a
suitable joint fitting or other coupling fitting. If the unit
includes a length of pipe encased in the body, one or both ends of
the pipe may include suitable connecting or coupling features. A
length of pipe in a unit may have, for example, a "male" end and a
"female" end. Alternatively, each pipe end may be adapted, for
example, to receive and/or fit into a suitable joint fitting or
other coupling fitting.
[0026] It will be noted that a pipe encased within a body as
described herein can have applications other than use in a drainage
system. For example, a unit embodying certain features described
herein may consist of a non-perforated pipe encased within a formed
concrete body as described herein. In this embodiment, the
non-perforated pipe may be protected from being crushed by
pressures in the soil after below-ground installation, through
distribution of pressure within the concrete body, reducing or
eliminating the need for a gravel bed for similar purposes in
similar applications. A unit formed with non-perforated pipe might
be used as a component in, for example, a water line, a sewage
line, a storm drain line, a gas, oil or other fluid line, a
below-ground conduit for electrical lines, telephone lines,
television or other cable lines, fiber optic cable lines, etc.
[0027] In another embodiment, the body 30 may be molded to encase
other features and or equipment included with pipe, such as valves,
adapters, connectors, and any other suitable features. Following
molding, these features or equipment can be accessed as necessary
or desired by cutting through the molded concrete, which will be
relatively easy if the concrete comprises a relatively soft
aggregate material such as expanded polystyrene. Alternatively, a
mold as further described below can be designed with features that
form access ports or holes in the body that provide ready access to
valves, connectors, adapters or other equipment, in the molded
body.
[0028] FIG. 4 schematically depicts one possible installation of a
unit 10. Shown in cross-section in FIG. 4, a unit 10 with encased
pipe 20 is installed at the bottom of a ditch cut into earth 100.
Following installation of unit 10, the ditch may be backfilled with
soil or other backfill material 101. In such an installation, if
pipe 20 is perforated pipe, the unit 10 installed in this manner
will provide a length of a drainage line or system, whereby unit 10
can receive water or other fluid from surrounding soil 100 and
relieve hydrostatic pressure therein. In this embodiment, unit 10
and pipe 20 can provide pathways by which water or other fluid can
be drawn and channeled away from the area by gravity. The shapes
and relative sizes for the unit 10, pipe 20 and ditch shown in FIG.
4 are only examples of a variety of combinations of shapes, sizes
and configurations that are possible but still within the scope of
the present invention.
[0029] It will be appreciated that several of the exemplary
embodiments described herein can be applied for uses in fluid
dispersal systems, the converse of drainage systems. For example,
the installation depicted in FIG. 4 will be suitable for use in a
water dispersal system, its dispersal capacity being enhanced by
situation of pipe 20 at the top of the unit as installed. In this
particular exemplary application and installation, the pipe
selected may be perforated pipe, oriented and encased within the
unit 10 to have a plurality of drainage holes through the pipe wall
and situated along the bottom portion of the pipe (relative to its
installed position), so that water flowing inside the pipe will
tend to drain by gravity out of the pipe through the holes and into
the interstitial spaces in the aggregate beneath, and subsequently,
be dispersed along the ditch and into the surrounding soils. It
also will be appreciated, however, that an alternative embodiment
to be used for soil drainage rather than fluid dispersal may have
the pipe situated at the bottom of the unit (as installed), and
have a plurality of inlet holes through the pipe wall and situated
along the bottom portion of the pipe (relative to its installed
position), so that fluid draining into the unit from surrounding
soils will flow downward by gravity through the interstitial spaces
in the aggregate to the bottom, where it can then enter the pipe
through the inlet holes therein, and be channeled away.
[0030] A method for manufacturing units of the type described
herein will now be described. First, suitable aggregate particles
of, for example, expanded polystyrene or any other suitable
material, may be extruded or otherwise produced by known processes
and techniques. Next, a suitable quantity of a binder material,
such as, by way of example only, at least one of a bitumen
material, an acrylic material, or any other suitable binder, may be
introduced to a quantity of aggregate particles. The binder
material and the aggregate particles may then be agitated together
to achieve effective coverage of aggregate particles. For example,
loose expanded polystyrene aggregate particles extruded in the
shapes depicted in FIG. 3 may be mixed with the binder material,
such as an acrylic material, in a tumbler such as one used for
mixing Portland cement-based mortars and concretes, at a ratio of
one quart of binder material to 6 cubic feet of loose aggregate.
Alternatively, a binder material such as acrylic material, bitumen
material or any other suitable binder material, may be sprayed via
several spray atomizers onto dry aggregate particles as they flow
through a pipe to a mold, at a similar ratio of binder material to
aggregate.
[0031] Next, the concrete mixture, which still will be relatively
fluid, may be introduced into a mold of any desired shape. A
suitable mold may be constructed of, for example, any rigid
material such as wood, metal, plastic, or any other suitable
material. The mold may have one or more lengths of pipe located
therewithin, to be encased and fixed within the body formed of the
concrete material, held in place by the binder material on the
surfaces of the aggregate particles adhering to the surface of the
pipe. Of course, one or more lengths of pipe are not required.
Alternatively, a pipe length may be coated with oil or other
suitable material prior to molding so that the binder will not
adhere to it, and so that it may be removed from the body following
molding to leave an open channel through the body. Alternatively,
the mold may be constructed with other features that form channels
or voids in the molded body. The mold surfaces may be coated with
oil or other suitable material to prevent the binder material from
adhering to the mold, and provide for ease of removal of the molded
body from the mold. The concrete material may be compressed in the
mold during and/or after filling to ensure that all larger spaces
within the mold are filled and no unwanted large voids in the
material are present. Compression of the concrete material may be
done in order to eliminate large voids that may compromise the
structural properties of the finished unit. A layer of barrier
material may be placed into the mold before introduction of the
concrete, or alternatively, may be laid and pressed over an exposed
surface of the concrete, using additional binder material or other
adhesive if necessary.
[0032] In an alternate method of manufacture, unit 10 may be formed
utilizing a pour-in-place method. In the alternate method, the
aggregate particles may be produced and mixed with a binder
material as described above. Next, a void may be created at the
installation site. By way of example only, the void may comprise a
ditch dug in the ground. Once the aggregate particles and binder
material have been sufficiently combined to produce a fluid
concrete mixture, the fluid concrete mixture may be sprayed or
poured directly into the void. In this pour-in-place method, the
walls of the void function similarly to the mold described above by
providing support for the fluid concrete mixture as it solidifies.
Similar to the mold described above, the void may have any suitable
shape, depth, or length. One or more lengths of pipe may be placed
in the void prior to or during pouring to allow the pipe to be
encased by the fluid concrete mixture. But, the use of one or more
lengths of pipe is not required. A layer of barrier material may be
placed in the void prior to pouring the fluid concrete mixture, or,
alternatively, a layer of barrier material may be placed on the top
surface of the fluid concrete mixture after pouring is complete.
The layer of barrier material may be adhered to the aggregate
particles as described above. Of course, the use of a layer of
barrier material is not required. The void may be filled completely
or partially with the fluid concrete mixture. If the void is
partially filled with the fluid concrete mixture, then backfill
material, such as soil, may be placed on top of the fluid concrete
mixture.
[0033] If rapid production is desired, application of forced air,
forced heated air, or heat will cause water in a bitumen emulsion
binder to evaporate faster, causing the emulsion to break faster
and the concrete to "set" faster. Alternatively, the water may be
allowed to evaporate naturally. After the concrete has set (and
cooled, if necessary), the finished unit may be removed from the
mold. Multiple units may be formed in a single longer length in
this process and then cut to shorter lengths using, for example, a
saw or heated wire cutter.
[0034] As an alternative to the use of a binder material, the body
may be formed without use of a binder. For example, dry polystyrene
aggregate particles may be poured into a steam or heat transfer
molding machine cavity, which can then be utilized to introduce
heat to the mold, thereby causing surface melting and fusing of
adjacent aggregate particles.
[0035] FIGS. 5-7 depict an alternate embodiment of an underground
water channeling system 200. In this embodiment, system 200
comprises an elongated unit 210 and a panel 260. Similar to body 30
described above, panel 260 may be formed of a porous concrete
consisting of aggregate particles held together. Similar to the
embodiment described above, panel 260 may comprise individual
particles having differing and/or irregular shapes that when
brought into coalescence leave substantial interstitial spaces or
voids in fluid communication within the concrete during formation
of the panel and under pressure exerted by surrounding soils after
installation and during service. Panel 260 may also comprise
barrier material affixed to one or more surfaces of panel 260. The
barrier material may be similar to the barrier material 40
described above. Similar to the embodiments described above, the
aggregate particles for panel 260 may be held together using any
suitable binder material, including, but not limited to a bitumen
material, an acrylic material, or any other suitable material. In
particular, panel 260 may be formed using Chromaprufe.TM. or Kool
Seal.TM..
[0036] As shown in FIG. 10, panel 260 is positioned adjacent to the
exterior surface 272 of a wall 270. In this version, panel 260
comprises a first surface 262 and second surface 264 and includes
the greatest linear dimension of panel 260 is the height H from
first surface 262 to second surface 264. A panel 260 may be
positioned such that it is entirely underground or it may be
positioned such that an upper portion 266 extends above the ground
surface 202, as shown in FIG. 5. In the illustrated embodiment,
panel 260 is configured to allow water from the surrounding soil
201 to pass into panel 260 providing hydrostatic relief. Once water
has passed into panel 260, the interstitial spaces between the
aggregate particles allow the water to travel downward toward
elongated unit 210. Panel 260 may also facilitate horizontal
movement of the water along the length of panel 260. Elongated unit
210 is configured as described above to drain water horizontally
away from wall 270. Panel 260 may be configured to provide thermal
R-value for wall 270 in addition to facilitating the removal of
water surrounding wall 270. Obviously, a panel may be used in
conjunction with an elongated unit, as shown in FIG. 5, or,
alternatively, an underground water channeling system may
exclusively use one or more panels to facilitate water removal.
[0037] From the foregoing it will be appreciated that use of a
concrete material comprising a relatively lightweight aggregate, to
form a unit, provides numerous benefits and advantages over use of
loose gravel, crushed stone or the like as a component of a
below-ground drainage, pipe or conduit system. The unit may be
easily portable and may eliminate the need to transport and handle
heavy, loose material in a ditch at a project site. The unit may be
easily and inexpensively manufactured. If the aggregate particles
are suitably sized and shaped to provide for substantial
interstitial spaces among the aggregate particles in the formed
unit, the unit may allow for rapid passage of substantial volumes
of water therethrough. Thus, it will be appreciated that the
embodiments disclosed and described herein are only examples of a
greater number of possible embodiments of devices and methods that
may be constructed and utilized to attain the benefits and
advantages described herein. Accordingly, the scope of the
invention is limited only by the claims appended hereto, and
equivalents thereof.
* * * * *