Grout bridge and interlock

Abstract

A filtration system includes a plurality of underdrain blocks arranged in a side-by-side configuration so as to define a gap between, the gap configured to receive grout, each underdrain block comprising a top wall, a bottom wall, and a plurality of sidewalls connecting the top wall and the bottom wall; and a grout bridge arranged in the gap between adjacent underdrain blocks so as to form a grout seal between the grout bridge and adjacent sidewalls of the adjacent underdrain blocks. The grout bridge includes a base portion; and an interlock portion extending from a top surface of the base portion and into the gap. The interlock portion includes a hole. A method of arranging a filtration system and a grout bridge are also disclosed.

Description

GROUT BRIDGE AND INTERLOCKBACKGROUND OF THE INVENTIONField of the Invention

[0001] The present invention is directed to a filtration system including a grout bridge to provide a grout seal between adjacent underdrain blocks, as well as the grout bridge and a method of arranging a filtration system including the grout bridge.Description of Related Art

[0002] Typical gravity or pressure filters use some type of filter media that captures the dirt particles from a liquid being filtered as the liquid passes through the media to an underdrain or collection system. Generally, beneath the filter media are underdrain laterals made up of underdrain blocks. The underdrain blocks provide a filter bottom by arranging a number of underdrain blocks together on a filter floor in a filter bed to provide an upper surface for supporting the filter media. The filter bottom upper surface is provided with openings to allow the flow of filtered liquid from the filter media to pass into the filter bottom where chambers defined by the underdrain blocks carry the filtered liquid from the filter. The chambers also serve to provide backwashing fluids (liquid or gas) for cleaning.

[0003] An example of an underdrain block is shown and described in U.S. Patent No. 9,072,990, which is hereby incorporated by reference in its entirety. Rows of underdrain blocks (underdrain laterals) may be arranged side-by-side in a parallel formation along the filter floor of the filter bed. Grout may be used to secure the underdrain blocks in their position in the filtration system.

[0004] A filtration system may include a flume located next to or beneath the underdrain blocks. To prevent the grout used to secure the underdrain blocks from leaking into the flume, a grout bridge may be used. Previous designs of grout bridges were unsecure and allowed for exorbitant amounts of bowing and flexing, and this bowing and flexing permitted grout to leak therethrough and into the flume. Further, previous designs of grout bridges used excessive amounts of raw materials, leading to a prohibitively expensive solution that still leaks as flume width increases.

[0005] Therefore, there is a need in the art for a filtration system that includes a grout bridge that prevents leaking of grout therethrough when installed in the filtration system that is both cost efficient and effectively prevents leakage, regardless of the flume width.SUMMARY OF THE INVENTION

[0006] The present invention is directed to a filtration system including a plurality of underdrain blocks arranged in a side-by-side configuration so as to define a gap therebetween, the gap configured to receive grout, each underdrain block comprising a top wall, a bottom wall, and a plurality of sidewalls connecting the top wall and the bottom wall; and a grout bridge arranged in the gap between adjacent underdrain blocks so as to form a grout seal between the grout bridge and adjacent sidewalls of the adjacent underdrain blocks, the grout bridge including a base portion; and an interlock portion extending from a top surface of the base portion and into the gap, the interlock portion including a hole.

[0007] The interlock portion may include a plurality of holes. The adjacent sidewalls may include a rib and the grout bridge may include a slot, and the rib of the adjacent sidewalls may be positioned in the slot of the grout bridge. The adjacent sidewalls may include a plurality of ribs and the grout bridge may include a plurality of slots, where each rib of the plurality of ribs may be positioned in a slot of the plurality of slots. The filtration system may further include a filter floor over a flume, where the plurality of underdrain blocks sit on the filter floor, and the grout bridge is arranged substantially horizontally and positioned between the filter floor and the top walls of the underdrain blocks. The grout seal may be sufficiently tight that grout poured into the gap does not reach the flume. The grout seal may be sufficiently tight that grout poured into the gap does not penetrate between the grout bridge and the adjacent sidewalls of the adjacent underdrain blocks. The base portion may include a ridge having a first height along the outer edge of the base portion and a central portion having a second height.

[0008] The present invention is also directed to a method of arranging a filtration system including arranging a plurality of underdrain blocks in a side-by-side configuration so as to define a gap therebetween, the gap configured to receive grout, each underdrain block comprising a top wall, a bottom wall, and a plurality of sidewalls connecting the top wall and the bottom wall; and arranging a grout bridge in the gap between adjacent underdrain blocks so as to form a grout seal between the grout bridge and adjacent sidewalls of the adjacent underdrain blocks, the grout bridge including a base portion; and an interlock portion extending from a top surface of the base portion and into the gap, the interlock portion including a hole.

[0009] The plurality of underdrain blocks may include a first underdrain block and a second underdrain block, where the method further includes arranging the grout bridge in the filtration system; arranging a rib of the first underdrain block in a slot on a first side of the grout bridge; and arranging a rib of the second underdrain block in a slot on the second side of the grout bridge. The method may further include pouring grout into the gap. The grout may pass throughand fill the hole of the interlock portion of the grout bridge. The adjacent sidewalls may include a plurality of ribs and the grout bridge may include a plurality of slots, where each rib of the plurality of ribs is positioned in a slot of the plurality of slots. The filtration system may include a filter floor over a flume, where the plurality of underdrain blocks sit on the filter floor, and the grout bridge is arranged substantially horizontally and positioned between the filter floor and the top walls of the underdrain blocks. The grout seal may be sufficiently tight that grout poured into the gap does not reach the flume. The grout seal may be sufficiently tight that grout poured into the gap does not penetrate between the grout bridge and the adjacent sidewalls of the adjacent underdrain blocks.

[0010] The present invention is also directed to a grout bridge for a filtration system including a base portion; and an interlock portion extending from a top surface of the base portion, the interlock portion including a hole, where the interlock portion is configured to be arranged in a gap between sidewalls of a first underdrain block and a second underdrain block, and where a grout seal is formed between the grout bridge and the sidewalls of the first underdrain block and the second underdrain block.

[0011] The grout bridge may include a slot configured to receive a rib on the sidewalls of one of the first underdrain block or the second underdrain block. The grout bridge may include a plurality of slots on the first side and the second side of the grout bridge, where the plurality of slots positioned on the first side of the grout bridge may be configured to receive a plurality of ribs on the sidewalls of the first underdrain block and the plurality of slots on the second side of the grout bridge may be configured to receive a plurality of ribs on the sidewalls of the second underdrain block. The grout bridge may include plastic. The grout seal may be sufficiently tight that grout coming in contact with the grout bridge does not penetrate between the grout bridge and the sidewalls of the first underdrain block and the second underdrain block.

[0012] Various non-limiting examples and aspects of the present invention will now be described and set forth in the following numbered clauses:

[0013] Clause 1: A filtration system comprising: a plurality of underdrain blocks arranged in a side-by-side configuration so as to define a gap therebetween, the gap configured to receive grout, each underdrain block comprising a top wall, a bottom wall, and a plurality of sidewalls connecting the top wall and the bottom wall; and a grout bridge arranged in the gap between adjacent underdrain blocks so as to form a grout seal between the grout bridge and adjacent sidewalls of the adjacent underdrain blocks, the grout bridge comprising: a base portion; and an interlock portion extending from a top surface of the base portion and into the gap, the interlock portion comprising a hole.

[0014] Clause 2: The filtration system of clause 1, wherein the interlock portion comprises a plurality of holes.

[0015] Clause 3: The filtration system of clause 1 or clause 2, wherein the adjacent sidewalls comprise a rib and the grout bridge comprises a slot, and wherein the rib of the adjacent sidewalls is positioned in the slot of the grout bridge.

[0016] Clause 4: The filtration system of any of clauses 1-3, wherein the adjacent sidewalls comprise a plurality of ribs and the grout bridge comprises a plurality of slots, wherein each rib of the plurality of ribs is positioned in a slot of the plurality of slots.

[0017] Clause 5: The filtration system of any of clauses 1-4, further comprising a filter floor over a flume, wherein the plurality of underdrain blocks sit on the filter floor, and the grout bridge is arranged substantially horizontally and positioned between the filter floor and the top walls of the underdrain blocks.

[0018] Clause 6: The filtration system of clause 5, wherein the grout seal is sufficiently tight that grout poured into the gap does not reach the flume.

[0019] Clause 7: The filtration system of any of clauses 1-6, wherein the grout seal is sufficiently tight that grout poured into the gap does not penetrate between the grout bridge and the adjacent sidewalls of the adjacent underdrain blocks.

[0020] Clause 8: The filtration system of any of clauses 1-7, wherein the base portion comprises a ridge having a first height along the outer edge of the base portion and a central portion having a second height.

[0021] Clause 9: A method of arranging a filtration system comprising: arranging a plurality of underdrain blocks in a side-by-side configuration so as to define a gap therebetween, the gap configured to receive grout, each underdrain block comprising a top wall, a bottom wall, and a plurality of sidewalls connecting the top wall and the bottom wall; and arranging a grout bridge in the gap between adjacent underdrain blocks so as to form a grout seal between the grout bridge and adjacent sidewalls of the adjacent underdrain blocks, the grout bridge comprising: a base portion; and an interlock portion extending from a top surface of the base portion and into the gap, the interlock portion comprising a hole.

[0022] Clause 10: The method of clause 9, wherein the plurality of underdrain blocks comprise a first underdrain block and a second underdrain block, wherein the method further comprises: arranging the grout bridge in the filtration system; arranging a rib of the first underdrain block in a slot on a first side of the grout bridge; and arranging a rib of the second underdrain block in a slot on the second side of the grout bridge.

[0023] Clause 11: The method of clause 9 or clause 10, further comprising pouring grout into the gap.

[0024] Clause 12: The method of clause 11, wherein the grout passes through and fills the hole of the interlock portion of the grout bridge.

[0025] Clause 13: The method of any of clauses 9-12, wherein the adjacent sidewalls comprise a plurality of ribs and the grout bridge comprises a plurality of slots, wherein each rib of the plurality of ribs is positioned in a slot of the plurality of slots.

[0026] Clause 14: The method of any of clauses 9-13, wherein the filtration system comprises a filter floor over a flume, wherein the plurality of underdrain blocks sit on the filter floor, and the grout bridge is arranged substantially horizontally and positioned between the filter floor and the top walls of the underdrain blocks.

[0027] Clause 15: The method of clause 14, wherein the grout seal is sufficiently tight that grout poured into the gap does not reach the flume.

[0028] Clause 16: The method of any of clauses 9-15, wherein the grout seal is sufficiently tight that grout poured into the gap does not penetrate between the grout bridge and the adjacent sidewalls of the adjacent underdrain blocks.

[0029] Clause 17: A grout bridge for a filtration system comprising: a base portion; and an interlock portion extending from a top surface of the base portion, the interlock portion comprising a hole, wherein the interlock portion is configured to be arranged in a gap between sidewalls of a first underdrain block and a second underdrain block, and wherein a grout seal is formed between the grout bridge and the sidewalls of the first underdrain block and the second underdrain block.

[0030] Clause 18: The grout bridge of clause 17, wherein the grout bridge comprises a slot configured to receive a rib on the sidewalls of one of the first underdrain block or the second underdrain block.

[0031] Clause 19: The grout bridge of clause 17 or clause 18, wherein the grout bridge comprises a plurality of slots on the first side and the second side of the grout bridge, wherein the plurality of slots positioned on the first side of the grout bridge are configured to receive a plurality of ribs on the sidewalls of the first underdrain block and the plurality of slots on the second side of the grout bridge are configured to receive a plurality of ribs on the sidewalls of the second underdrain block.

[0032] Clause 20: The grout bridge of any of clauses 17-19, wherein the grout bridge comprises plastic.

[0033] Clause 21: The grout bridge of any of clauses 17-20, wherein the grout seal is sufficiently tight that grout coming in contact with the grout bridge does not penetrate between the grout bridge and the sidewalls of the first underdrain block and the second underdrain block.BRIEF DESCRIPTION OF THE DRAWINGS

[0034] FIG. 1 is a perspective view of a grout bridge according to the present invention;

[0035] FIG. 2 is a front view of a filtration system according to the present invention having two underdrain blocks joined by a grout bridge;

[0036] FIG. 3 is a perspective view of a filtration system according to the present invention having underdrain blocks arranged side-by-side in a parallel configuration on a filter floor before grout is added;

[0037] FIG. 4 is another perspective view of a filtration system according to the present invention having underdrain blocks arranged side-by-side in a parallel configuration on a filter floor before grout is added;

[0038] FIG. 5 is an underside view of a filtration system according to the present invention having a flume and underdrain blocks arranged side-by-side in a parallel configuration over top of the flume, the underdrain blocks joined by a grout bridge;

[0039] FIG. 6 is a perspective view of a filtration system according to the present invention having underdrain blocks arranged side-by-side in a parallel configuration on a filter floor after grout is added;

[0040] FIG. 7 is another perspective view of a filtration system according to the present invention having underdrain blocks arranged side-by-side in a parallel configuration on a filter floor after grout is added;

[0041] FIG. 8 is an underside view of a filtration system after grout has been added thereto according to the present invention having a flume and underdrain blocks arranged side-by-side in a parallel configuration over top of the flume, the underdrain blocks joined by a grout bridge; and

[0042] FIG. 9 is a front cross-sectional view of a filtration system according to the present invention having two underdrain blocks joined by a grout bridge after grout is added.DETAILED DESCRIPTION OF THE INVENTION

[0043] For purposes of the description hereinafter, the terms “end,” “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to beunderstood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments or aspects of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments or aspects disclosed herein are not to be considered as limiting.

[0044] Referring to FIGS. 1 and 2, a grout bridge 2 having a length L and width W and a first end 3 and a second end 5 opposite of the first end 3 is shown which may be used in a filtration system 12 to join adjacent underdrain blocks 13a, 13b. In some non-limiting embodiments, like the one shown in FIG. 1, the grout bridge 2 may comprise a base portion 4 and an interlock portion 6. The base portion 4 of the grout bridge 2 may be a rectangular in shape and may be of sufficient length to span between two adjacent underdrain blocks 13a, 13b installed in the filtration system 12. However, the base portion 4 is not limited to a rectangular shape and may be of any sufficient shape and length in order to securely join two adjacent underdrain blocks 13a, 13b. The base portion 4 may comprise a ridge 8 along the outer edge of the base portion 4. The ridge 8 may have height Hi which may be any height known in the art. The base portion 4 may comprise a central portion 8 contained by the ridge 8. The central portion 8 may have a height H2 extending from the top of the ridge to a top surface 7 of the base portion 4. The height H2 of the central portion 8 may be greater than the height Hi of the ridge 8. In some nonlimiting embodiments, the base portion 4 may comprise a slot 10, such as a plurality of slots 10. The slot 10 may extend through at least a portion of the base portion 4 of the grout bridge 2. For example, the slot 10 may extend through the entire height H2 the central portion 7, but not through the height Hi of the ridge 8. The slot 10 may have a specific shape. For example, the slot 10 may have a shape that corresponds to the shape of a rib 24 of an underdrain 13, such that the slot 10 is configured to receive the rib 24 of the underdrain 13. During operation, the slot(s) 10 of the grout bridge 2 couple with the rib(s) 24 of the underdrain(s) 13 such that the base portion 4 of the grout bridge 2 prevents grout from entering the flume 29.

[0045] In some non-limiting embodiments, the grout bridge 2 comprises an interlock portion 6. The interlock portion 6 may extend along the length L of the grout bridge 2 and may be positioned at approximately the center of the width W of the grout bridge 2 so as to separate the base portion 4 into a first side 23 and a second side 25 opposite of the first side 23 from the interlock portion 6. The interlock portion 6 may have a height H3 extending from the top surface 7 of the base portion 4 of the grout bridge 2. The height H3 may be any height sufficient to provide an interlock portion 6 that improves the bonding of the grout 30 subsequently added tothe filtration system 12. The interlock portion 6 may comprise a hole 11 extending through the width W of the interlock portion 6 of the grout bridge 2. When grout is added to the filtration system 12, the grout 30 will be capable of moving through the interlock portion 6 via passing through the hole(s) 11 and filling the hole 11 (see FIG. 9). Providing a grout bridge 2 with an interlock portion 6 that allows grout 30 to pass through results in a stronger bond within the grout. In some non-limiting embodiments, two different grout pours are needed to install of the underdrains 13. A first pour may only include enough grout to raise slightly off of, such as a few inches off of, the filter floor, and once the first pour is cured, a second pour will fill the basin until the grout is at the top of the underdrains 13. This two pour process can result in a cold joint at the interface between where the two pours meet, which compromises the strength of the grout 30. Providing the interlock portion 6 with holes 11 will strengthen the bonds of the grout 30 regardless of any weakened bonds due to multiple pours.

[0046] In some non-limiting embodiments, the grout bridge 2 is made of plastic, such as high density polyethylene (HDPE). However, the grout bridge 2 may be made of any other suitable material.

[0047] Referring to FIG. 2, the grout bridge 2 may be used to join two adjacent underdrain blocks 13a, 13b in a filtration system 12. The filtration system 12 may be any type of filtration system 12, such as a gravity filtration system 12 using filter media to capture dirt and other particles from liquid passing through the media. An underdrain block 13a, 13b may include a top wall 14 and a bottom wall 16 connected by a plurality of sidewalls 18 to define at least a primary chamber 20. The underdrain blocks 13a, 13b may also include at least one secondary chamber 22, as shown in FIG. 2. The underdrain blocks 13a, 13b in FIG. 2 are shown as a rectangular block, but the underdrain blocks 13 a, 13b are not limited to a rectangular block. For example, the underdrain blocks 13 a, 13b may take any sufficient shape required by the design of the filtration system 12.

[0048] Referring to FIGS. 1 and 2, the underdrain blocks 13a, 13b may comprise a rib 24, such as a plurality of ribs 24. The rib(s) 24 may be flange-like member extending from and around at least a portion of the sidewalls 18 as an integrated part of the sidewall 18. In some nonlimiting embodiments including a first underdrain block 13a and a second underdrain block 13b, rib(s) 24 of the first underdrain block 13a may be configured to couple with slot(s) 10 on a first side 23 of the base portion 4 of the grout bridge 2 such that the first side 23 of the base portion 4 covers at least a portion of the rib(s) 24 and / or sidewall 18 of the first underdrain block 13a, and rib(s) 24 of the second underdrain block 13b may be configured to couple with slot(s) 10 on a second side 25 of the base portion 4 of the grout bridge 2 such that the secondside 25 of the base portion 4 covers at least a portion of the rib(s) 24 and / or sidewall 18 of the second underdrain block 13b. This may create a grout seal formed between the grout bridge 2 and the sidewalls 18 of the first underdrain block 13a and the second underdrain block 13b.

[0049] Referring to FIG. 3, the sidewall 18 may include a plurality of ribs 24. Ribs 24 of the sidewall 18 may be spaced apart from one another along part of a length of the underdrain blocks 13a, 13b, such as along the entire length of the underdrain blocks 13a, 13b. The spacing of the ribs 24 may be uniform or non-uniform along the length of the underdrain blocks 13a, 13b. Spacing of the ribs 24 along the length of the underdrain blocks 13a, 13b may be such that sufficient strength is provided to the installed grout bridge 2 in the case that the grout bridge 2 supports a load, such as a load of grout. Spacing of the ribs 24 along the underdrain blocks 13 a, 13b may range from one inch to several feet apart. In some non-limiting embodiments, the ribs 24 are spaced between one inch and two feet apart, such as about two inches, such as about four inches, such as about six inches, such as about eight inches, such as about ten inches, such as about twelve inches, such as about fourteen inches, such as about sixteen inches, such as about eighteen inches, such as about twenty inches, or such as about twenty-two inches.

[0050] In some non-limiting embodiments, the filtration system 12 may include a plurality of underdrain blocks 13a, 13b, and adjacent underdrain blocks 13a, 13b include adjacent sidewalls 18. Each of the adjacent sidewalls 18 may include a plurality of ribs 24. The ribs 24 of the plurality of underdrain blocks 13a, 13b may be arranged in adjacent slots 10 of the base portion 4 of the grout bridge 2. The grout bridge 2 may run a length of the adjacent underdrain blocks 13a, 13b, such as an entire length of the adjacent underdrain blocks 13a, 13b.

[0051] Referring back to FIGS. 1 and 2, as previously discussed, the ribs 24 may be configured to be received by the grout bridge 2, such as configured to be received by the slots of the grout bridge 2. For example, a rib 24 of the plurality of ribs 24 may be configured to be received by a slot 10 of the plurality of slots 10 of the grout bridge 2. The ribs 24 may be configured to be received by the grout bridge 2, such as by the slots 10 of the grout bridge 2, such that a grout seal is made between the ribs 24 and the grout bridge 2. A grout seal may be defined as a tight enough barrier between adjacent sidewalls 18 and the installed grout bridge 2 such that liquid, dry particulate matter, or a mixture thereof (e.g., grout) is prevented from leaking through the interface between the grout bridge 2 and the sidewalls 18. In addition, the grout bridge 2 may be of sufficient strength and adequately supported by the ribs 24 to prevent or minimize deflection, bowing, and flexing of the grout bridge 2, even when supporting a full load of grout. In some non-limiting embodiments, the slot 10 of the grout bridge 2 may be of a shape thatcorresponds to a shape of the ribs 24 of the underdrain blocks 13a, 13b, such that the ribs 24 may be received by the slots 10.

[0052] With continued reference to FIG. 2, two adjacent undrain blocks 13a, 13b may be joined by a grout bridge 2. In some non-limiting embodiments, the underdrain blocks 13a, 13b may be arranged side-by-side in a parallel or substantially parallel configuration. The underdrain blocks 13a, 13b may be joined by coupling the grout bridge 2 to the ribs 24 of the adjacent underdrain blocks 13a, 13b, to connect the two adjacent underdrain blocks 13a, 13b together. In some non-limiting embodiments, multiple grout bridges 2 may be used, for instance, end- to-end, along the length of adjacent underdrain blocks 13a, 13b to join the underdrain blocks 13a, 13b. In some non-limiting embodiments, a single grout bridge 2 that runs the entire length of the underdrain blocks 13a, 13b may be used to join the adjacent underdrain blocks 13a, 13b. In some embodiments, the grout bridge 2 runs a length of the underdrain blocks 13a, 13b that is sufficient to cover a flume 29 under the underdrain blocks 13 a, 13b. The underdrain blocks 13a, 13b may be installed using the grout bridge 2 to join the underdrain blocks 13a, 13b using any sufficient method. In one contemplated method, the grout bridge 2 is arranged in the filtration system 2 and then the first underdrain block 13a may be added such that the ribs 24 of the first underdrain block 13a are received by the slots 10 on the first side 23 of the grout bridge 2, followed by adding the second underdrain block 13b such that the ribs 24 of the second underdrain block 13b are received by the slots 10 on the second side 25 of the grout bridge 2. This results in the configuration shown in FIG. 2. The ribs 24 of the underdrain blocks 13a, 13b may be installed in the slots 10 of the grout bridge 2 using sealant. A sealant may be used by first applying the sealant to the slots 10 of the grout bridge 2 or to the ribs 24 of the underdrain blocks 13 a, 13b and then installing the underdrain blocks 13 a, 13b onto the grout bridge 2 such that the slots 10 of the grout bridge 2 receive the ribs 24 of the underdrain blocks 13a, 13b. However, in some non-limiting embodiments, sealant may not be used for installing the grout bridge 2 onto the underdrain blocks 13a, 13b.

[0053] Referring to FIGS. 3-5, in some non-limiting embodiments, a plurality of underdrain blocks 13a, 13b, 13c, 13d, 13e may be arranged side-by-side in a parallel configuration in a filter bed 27 to form a filtration system 12. FIGS. 3-5 show a filter bed 27 defined by four walls. In some non-limiting embodiments, the filtration system 12 may include the filter bed 27 and a filter floor 31, upon which the underdrain blocks 13a, 13b, 13c, 13d, 13e may be arranged. The grout bridge 2 may be arranged substantially horizontally (parallel with the top wall 14) and positioned between the filter floor 31 and the top walls 14 of the underdrain blocks 13a, 13b, 13c, 13d, 13e (above the filter floor 31 and below the top walls 14). The filtrationsystem 12 may also include the filter floor 31 over the flume 29. The flume 29 may be positioned beneath the underdrain blocks 13a, 13b, 13c, 13d, 13e of the filtration system 11, as shown in FIG.5. The filtration system 12 may be large enough to fit a plurality of underdrain blocks 13a, 13b, 13c, 13d, 13e. In the non-limiting embodiment shown in FIG. 3, the filtration system 12 fits at least five underdrain blocks 13a, 13b, 13c, 13d, 13e in a side-by-side parallel arrangement.

[0054] With continued reference to FIGS. 3-4, underdrain blocks 13a, 13b, 13c, 13d, 13e arranged in a side-by-side parallel arrangement and placed in filtration system 12 may define gaps 28. These gaps 28 may be defined between adjacent sidewalls 18 of two adjacent underdrain blocks 13a, 13b, 13c, 13d, 13e. These gaps 28 may also be defined between the sidewall 18 of the underdrain block 13a, 13b, 13c, 13d, 13e and an adjacent wall of the filter bed 27. For example, in FIG. 3, the five underdrain blocks 13a, 13b, 13c, 13d, 13e in the filter bed 27 define six gaps 28. These gaps 28 may be configured to receive liquid, dry particulate matter, or a mixture thereof (e.g., grout). As shown in FIG. 4, the grout bridge 2 may run a length of the underdrain blocks 13a, 13b, 13c, 13d. In some non-limiting embodiments, the grout bridge 2 does not run the entire length of the underdrain blocks 13a, 13b, 13c, 13d but a length sufficient to cover the flume 29 beneath the underdrain blocks 13a, 13b, 13c, 13d, but does not cover at least a part of the filter floor 31. In some non-limiting embodiments, the grout bridge 2 runs the entire length of the underdrain blocks 13a, 13b, 13c, 13d.

[0055] FIG. 5 shows an underside of the filtration system 2 with underdrain blocks 13a, 13b, 13c over top of the flume 29 in a filter floor 31. As shown in FIG. 5, the ribs 24 may extend from the sidewalls 18 of the underdrain blocks 13a, 13b, 13c so that the grout bridge 2, when installed, is arranged proximate the bottom of the underdrain blocks 13a, 13b, 13c (e.g., proximate the bottom wall 16). The ribs 24 may be defined in a bottom half of the underdrain blocks 13a, 13b, 13c, such as the bottom one-third, such as the bottom one-quarter, such as the bottom one-fifth, or such as the bottom one-tenth, so that the grout bridge 2, when installed, is arranged proximate the bottom half of the underdrain blocks 13a, 13b, 13c, such as the bottom one-third, such as the bottom one-quarter, such as the bottom one-fifth, or such as the bottom one-tenth. The grout bridge 2 may be installed such that the ribs 24 of the underdrain blocks 13a, 13b, 13c are positioned in the slots 10 of the grout bridge 2, as shown in FIG. 5. As previously discussed, the sidewalls 18 may include ribs 24 spaced apart along part or the entire length of the underdrain blocks 13a, 13b, 13c. These ribs 24 may be spaced several inches to a couple feet apart.

[0056] Referring to FIGS. 6-9, in some non-limiting embodiments, a plurality of underdrain blocks 13a, 13b, 13c, 13d, 13e are arranged side-by-side in a parallel configuration in a filtration system 12 filled with grout 30. The grout 30 may be any type of grout 30, such as wet mono pour grout 30. The grout 30 may refer to a flowable material that includes a mixture of a liquid, such as water, and a dry particulate material, such as cement. The cement may be standard brand Portland cement conforming to ASTM C150, Type II. In some non-limiting embodiments, the grout 30 is mixed with other materials including, but not limited to, sand.

[0057] After the underdrain blocks 13a, 13b, 13c, 13d, 13e are arranged in the filtration system 12, grout 30 may be added to the filtration system 12 to further secure the position of the underdrain blocks 13a, 13b, 13c, 13d, 13e. This grout 30 may be added after the grout bridge 2 is arranged in the gap 28 and installed to join the underdrain blocks 13a, 13b, 13c, 13d, 13e so as to form the grout seal between the grout bridge 2 and the adjacent sidewalls 18 of the adjacent underdrain blocks 13a, 13b, 13c, 13d, 13e. The grout 30 may be added to the gaps 28 defined by the side-by-side parallel arrangement (or any other arrangement) of the underdrain blocks 13a, 13b, 13c, 13d, 13e and create the grout seal between the grout bridge 2 and the sidewalls 18. The grout 30 may be added to the filtration system 12 and fill the gaps 28 until the grout 30 reaches near the top of the underdrain blocks 13a, 13b, 13c, 13d, 13e, such as leaving less than one inch to one foot between the top of the grout 30 and the top walls 14 of the underdrain blocks 13a, 13b, 13c, 13d, 13e, such as about 0.25 inches, such as about 0.5 inches, such as about one inch, such as about two inches, such as about four inches, such as about six inches, such as about eight inches, or such as about ten inches. In another non-limiting embodiment, the grout 30 may be added to the filtration system 12 until the level of the grout 30 is even with the top walls 14 of the underdrain blocks 13a, 13b, 13c, 13d, 12e.

[0058] FIG. 8 shows an underside of the filtration system 12 having a flume 29, showing the underdrain blocks 13a, 13b, 13c, 13d arranged in a side-by-side parallel configuration over the flume 29, and with grout 30 added to the filtration system 12 after the grout bridges 2 have been installed to join the underdrain blocks 13a, 13b, 13c, 13d and create the grout seal between the grout bridge 2 and the sidewalls 18. As can be seen in FIG. 8, no grout leakage or bridge deflection is seen, even after the grout 30 is added to the filtration system 12. Thus, in some non-limiting embodiments, the grout bridge 2 installed in may be configured and installed so as to prevent grout 30 from leaking therethrough, with or without the use of sealant to install the grout bridge 2 against the ribs 24 of the underdrain blocks 13a, 13b, 13c, 13d. In other words, the grout bridge 2 may provide a grout seal to provide a tight enough seal between the sidewalls 18 of the underdrain blocks 13a, 13b, 13c, 13d so as to prevent grout 30 frompenetrating through the interface between the grout bridge 2 and the adjacent sidewalls 18 so that the grout 30 poured into the gap 28 does not reach the flume 29 located beneath the adjacent underdrain blocks 13a, 13b, 13c, 13d. In addition, grout bridge 2 may be of sufficient strength to prevent or minimize grout bridge 2 deflection, bowing, and flexing, even when supporting the full load of grout 30.

[0059] FIG. 9 shows a cross-sectional view of a filtration system 12 after the grout bridge 2 has been installed and grout 30 has been added. The grout bridge 2 may be arranged in the filtration system 12 such that the ribs 24 of the first underdrain block 13a are positioned in the slots 10 on the first side 23 of the grout bridge 2 and the ribs 24 of the second underdrain block 13b are positioned in the slots on the second side 25 of the grout bridge 2. Once the grout bridge 2 has been installed and the underdrain blocks 13a, 13b have been positioned, the grout 30 may then be added to the filtration system 12. The grout 30 is added to the gaps 28 between the adjacent underdrain blocks 13a, 13b to create a grout seal between the grout bridge and the adjacent sidewalls 18 of the adjacent underdrain blocks 13a, 13b. As shown in FIG. 9, the interlock portion 6 of the grout bridge 2 extends at least a portion into the gap 28 between the adjacent underdrain blocks 13a, 13b. The grout bridge 2 may be positioned in such a way that the interlock portion 6 is located at approximately the center of the width of the gap 28. The interlock portion 6 includes a hole 11, such as a plurality of holes 11. The hole 11 of the interlock portion 6 allows grout to pass from one side 23, 25 of the grout bridge 2 to the other side 23, 25 of the grout bridge 2, as well as allowing grout 30 to harden within the holes 11 of the interlock portion 6. Providing a grout bridge 2 with an interlock portion 6 that allows grout 30 to pass therethrough results in a stronger bond within the grout 30 contained in the gap 28. For example, in some filtration systems 12, grout 30 is poured in multiple steps. A first pour includes only a few inches of grout 30 that is poured into the gap 28 and allowed to harden. Once the first pour of grout 30 has hardened, a second pour of grout 40 added to fill the gap 28 the rest of the way to the desired height of grout 30. However, such a process results in a weak grout bond resulting in a cold joint between the two pours. Providing the grout bridge 2 with the interlock portion 6 having holes 11 improves the strength of the grout 30 to counteract the loss in strength from the cold joint.

[0060] The filtration system 12 as described above may be arranged by a method that includes arranging a plurality of underdrain blocks 13a, 13b, 13c, 13d, 13e (described above) in a side- by-side configuration so as to define a gap 28 therebetween. The gap 28 may be configured to receive grout 30. The grout bridge 2 may be arranged in the gap 28 between the adjacent underdrain blocks 13a, 13b, 13c, 13d, 13e so as to form the grout seal between the grout bridge10 and the adjacent sidewalls 18 of the adjacent underdrain blocks 13a, 13b, 13c, 13d, 13e. The adjacent sidewalls 18 and bottom wall 16 may each include the rib 24. The grout bridge 2 may be arranged such that the ribs 24 of the adjacent underdrain blocks 13a, 13b, 13c, 13d 13e are positioned in the slots 10 of the grout bridge 2. Grout 30 may be poured into the gap 28.

[0061] In some non-limiting embodiments of the method, the plurality of underdrain blocks 13a, 13b, 13c, 13d, 13e includes at least a first underdrain block 13a and an adjacent second underdrain block 13b. However, any number of underdrain blocks 13a, 13b, 13c, 13d, 13e may be included. The first underdrain block 13a may be arranged. The first side 23 of the grout bridge 2 may be arranged such that the ribs 24 of the first underdrain block 13a are positioned in the slots 10 on the first side 23 of the grout bridge 2. The second underdrain block 13b may be arranged such that the ribs 24 of the second underdrain block 13b are positioned in the slots 10 on the second side 25 of the grout bridge 2.

[0062] In another non-limiting embodiment of the method, the plurality of underdrain blocks 13a, 13b, 13c, 13d, 13e includes at least a first underdrain block 13a and a second underdrain block 13b. The first underdrain block 13a may be arranged side-by-side with the second underdrain block 13b. The grout bridge 2 may then be arranged such that the ribs 24 of the first underdrain block 13a are positioned in the slots 10 on the first side 23 of the grout bridge 2 and the ribs 24 of the second underdrain block 13b are positioned in the slots 10 on the second side 25 of the grout bridge 2.

[0063] Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.

Claims

THE INVENTION CLAIMED IS:

1. A filtration system comprising: a plurality of underdrain blocks arranged in a side-by-side configuration so as to define a gap therebetween, the gap configured to receive grout, each underdrain block comprising a top wall, a bottom wall, and a plurality of sidewalls connecting the top wall and the bottom wall; and a grout bridge arranged in the gap between adjacent underdrain blocks so as to form a grout seal between the grout bridge and adjacent sidewalls of the adjacent underdrain blocks, the grout bridge comprising: a base portion; and an interlock portion extending from a top surface of the base portion and into the gap, the interlock portion comprising a hole.

2. The filtration system of claim 1 , wherein the interlock portion comprises a plurality of holes.

3. The filtration system of claim 1, wherein the adjacent sidewalls comprise a rib and the grout bridge comprises a slot, and wherein the rib of the adjacent sidewalls is positioned in the slot of the grout bridge.

4. The filtration system of claim 3, wherein the adjacent sidewalls comprise a plurality of ribs and the grout bridge comprises a plurality of slots, wherein each rib of the plurality of ribs is positioned in a slot of the plurality of slots.

5. The filtration system of claim 1, further comprising a filter floor over a flume, wherein the plurality of underdrain blocks sit on the filter floor, and the grout bridge is arranged substantially horizontally and positioned between the filter floor and the top walls of the underdrain blocks.

6. The filtration system of claim 5, wherein the grout seal is sufficiently tight that grout poured into the gap does not reach the flume.

7. The filtration system of claim 1, wherein the grout seal is sufficiently tight that grout poured into the gap does not penetrate between the grout bridge and the adjacent sidewalls of the adjacent underdrain blocks.

8. The filtration system of claim 1, wherein the base portion comprises a ridge having a first height along the outer edge of the base portion and a central portion having a second height.

9. A method of arranging a filtration system comprising: arranging a plurality of underdrain blocks in a side-by-side configuration so as to define a gap therebetween, the gap configured to receive grout, each underdrain block comprising a top wall, a bottom wall, and a plurality of sidewalls connecting the top wall and the bottom wall; and arranging a grout bridge in the gap between adjacent underdrain blocks so as to form a grout seal between the grout bridge and adjacent sidewalls of the adjacent underdrain blocks, the grout bridge comprising: a base portion; and an interlock portion extending from a top surface of the base portion and into the gap, the interlock portion comprising a hole.

10. The method of claim 9, wherein the plurality of underdrain blocks comprise a first underdrain block and a second underdrain block, wherein the method further comprises: arranging the grout bridge in the filtration system; arranging a rib of the first underdrain block in a slot on a first side of the grout bridge; and arranging a rib of the second underdrain block in a slot on the second side of the grout bridge.

11. The method of claim 9, further comprising pouring grout into the gap.

12. The method of claim 11, wherein the grout passes through and fills the hole of the interlock portion of the grout bridge.

13. The method of claim 10, wherein the adjacent sidewalls comprise a plurality of ribs and the grout bridge comprises a plurality of slots, wherein each rib of the plurality of ribs is positioned in a slot of the plurality of slots.

14. The method of claim 9, wherein the filtration system comprises a filter floor over a flume, wherein the plurality of underdrain blocks sit on the filter floor, and the grout bridge is arranged substantially horizontally and positioned between the filter floor and the top walls of the underdrain blocks.

15. The method of claim 14, wherein the grout seal is sufficiently tight that grout poured into the gap does not reach the flume.

16. The method of claim 9, wherein the grout seal is sufficiently tight that grout poured into the gap does not penetrate between the grout bridge and the adjacent sidewalls of the adjacent underdrain blocks.

17. A grout bridge for a filtration system comprising: a base portion; and an interlock portion extending from a top surface of the base portion, the interlock portion comprising a hole, wherein the interlock portion is configured to be arranged in a gap between sidewalls of a first underdrain block and a second underdrain block, and wherein a grout seal is formed between the grout bridge and the sidewalls of the first underdrain block and the second underdrain block.

18. The grout bridge of claim 17, wherein the grout bridge comprises a slot configured to receive a rib on the sidewalls of one of the first underdrain block or the second underdrain block.

19. The grout bridge of claim 18, wherein the grout bridge comprises a plurality of slots on the first side and the second side of the grout bridge, wherein the plurality of slots positioned on the first side of the grout bridge are configured to receive a plurality of ribs on the sidewalls of the first underdrain block and the plurality of slots on the second sideof the grout bridge are configured to receive a plurality of ribs on the sidewalls of the second underdrain block.

20. The grout bridge of claim 17, wherein the grout bridge comprises plastic.

21. The grout bridge of claim 17, wherein the grout seal is sufficiently tight that grout coming in contact with the grout bridge does not penetrate between the grout bridge and the sidewalls of the first underdrain block and the second underdrain block.

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