GRP Floor Insert for Corrosive Wastewater Shaft Renovation
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Solution Overview
Problem
Shaft structures, particularly those in wastewater transport systems, suffer from corrosive wear, necessitating frequent replacement of concrete and mechanical equipment within 10 to 15 years, with existing renovation methods being costly and inefficient, especially when dealing with the uniquely shaped shaft bases housing pumps.
Innovation Solution
A floor insert made of glass fiber reinforced plastic, featuring a hemispherical formwork with a flat bottom and vertical fastening wall, designed for easy assembly and stability, which includes features like scraper corners, inlet bottom ribs, and an angle profile for improved fluid flow and stability, and can be fastened using screws or nail anchors, allowing for precise renovation and extension of shaft structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional concrete shaft structures are used, then the shaft structure can be initially constructed, but it suffers from corrosive wear and requires replacement every 10 to 15 years
Solution Approach 1:
The patent applies composite materials by using glass fiber reinforced plastic (GRP) for the floor insert and shaft lining. This composite material combines the strength of glass fibers with the protective properties of plastic, creating a structure that is highly resistant to corrosive wear from wastewater while maintaining structural integrity. The GRP floor insert specifically replaces the concrete base to prevent corrosion at the pump mounting area, directly addressing the reliability issue.
2Reliability
If inliners are installed for wall areas, then corrosion protection is improved, but the shaft base requiring special shaping for pumps requires additional specially designed and manufactured installation parts
Solution Approach 1:
The patent merges the floor insert and pump mounting structure into a single integrated GRP component. The floor insert includes an integrated pump mounting area with pre-formed attachment points and appropriate geometry, eliminating the need for separate specially designed installation parts. This unified design reduces device complexity while maintaining corrosion protection and proper pump mounting capabilities.
3Volume of moving object
If the pump sump is made very small to save space, then the shaft structure becomes more compact, but it becomes difficult to prevent accumulation of solids
Solution Approach 1:
The patent applies spheroidality by designing the pump sump with a hemispherical shape. This curved, dome-like geometry prevents solids from accumulating in corners or flat areas, as there are no sharp angles where debris can collect. The smooth curved surface allows solids to be naturally directed toward the pump intake, enabling effective pumping while maintaining a compact small volume sump.
4Object-generated harmful factors
If scraper corners are added to prevent solid accumulation, then solid accumulation is reduced, but the device complexity increases
Solution Approach 1:
The patent merges the scraper function into the hemispherical shape itself. The curved geometry of the pump sump acts as an inherent scraper, naturally directing solids toward the pump intake without requiring separate scraper components. This integrated approach prevents solid accumulation while avoiding additional device complexity, as the shape itself performs the scraping function.
Data Source
Figure 1
Figure 2
AI summary
The bottom insert has a shaft of round shape, having a bottom portion (2). The duct inlet openings are provided in bottom portion in which a pump is arranged. The bottom portion is constructed as a sump pump by inclined wall portions. The fixing devices are provided for machine portions. The bottom insert is configured as a wall-forming lining element and is made of hemispherical formwork (1) with a flat, circular base portion. A vertical mounting wall (3) is formed in the pump sump. The bottom portion and vertical wall are stably fastened by the fixing device, to form stiffened angle. An independent claim is included for method for restoring manhole due to corrosion damage.