Interlocking Ballast Blocks for Pump Station Uplift
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Solution Overview
Problem
The existing methods for providing ballast to subterranean grinder pump and septic tank effluent stations face challenges such as the need for large concrete quantities, limited access for concrete mixer trucks, and difficulties in forming precise earthen forms, leading to increased costs, labor, and time in installation, especially under varying soil and groundwater conditions.
Innovation Solution
A system of interlocking ballast block ring segments with male and female connectors, a containment form shell, and corrosion-resistant locking pins, allowing for pre-casting and easy assembly around the pump station, which can be made from HDPE, composite resin PVC, or blow molded thermoplastic resin, with a placement handle and conforming profile to secure the station effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-mixed ready-mixed concrete is used to provide ballast, then uniform strength and consistency are achieved, but minimum order requirements of 5.0 cubic yards create coordination challenges and increased costs
Solution Approach 1:
The ballast system is divided into multiple pre-cast concrete blocks (typically 4-6 blocks) that can be individually delivered and assembled. Each block contains a portion of the total ballast weight, eliminating the need for large-volume ready-mixed concrete orders while maintaining uniform strength through factory pre-casting.
Solution Approach 2:
The concrete blocks are pre-cast in a controlled factory environment before delivery to the installation site. This preliminary action ensures uniform strength and consistency are achieved during manufacturing, while the blocks can be delivered in smaller quantities matched to actual installation needs.
2Quantity of substance
If concrete mixer trucks are used to deliver ballast material, then sufficient concrete quantity is provided, but limited access at remote pump station locations prevents truck access
Solution Approach 1:
The ballast material is segmented into multiple transportable concrete blocks that can be delivered by standard delivery vehicles capable of accessing remote locations. This segmentation allows the same total ballast quantity to be delivered to sites inaccessible to large concrete mixer trucks.
Solution Approach 2:
Pre-cast concrete blocks serve as an intermediary between the concrete production facility and the remote installation site. Instead of delivering liquid concrete that requires mixing equipment, the blocks are pre-formed and can be transported via smaller vehicles suitable for restricted access locations.
3Shape
If earthen forms are constructed in the field to shape concrete ballast, then ballast can be formed to match pump basin shape, but varying soil conditions make precise shaping problematic
Solution Approach 1:
The ballast system uses multiple standardized pre-cast blocks with predetermined shapes designed to conform to pump basin geometries. This segmentation eliminates the need for field-formed earthen molds while achieving consistent shape conformity through factory precision manufacturing of each block.
Solution Approach 2:
The solution transitions from variable field-formed earthen shapes to standardized pre-cast block shapes with controlled geometric parameters. The blocks are manufactured with precise dimensions and contours that conform to pump basin shapes, eliminating the precision problems associated with field construction under varying soil conditions.
4Ease of manufacture
If field mixing of pre-mixed bag mix is used, then concrete can be produced on-site, but proper mixing and uniform consistency are difficult to achieve
Solution Approach 1:
The concrete mixing and curing process is performed in advance at a controlled factory environment before the blocks are shipped to the installation site. This preliminary action ensures proper mixing and uniform consistency are achieved under controlled conditions, eliminating the need for on-site mixing operations.
Solution Approach 2:
The pre-cast blocks are self-contained units that arrive at the installation site ready for placement. The concrete within each block has already achieved proper mixing and consistency through factory processes, so no additional mixing or quality control operations are needed at the installation location.
5Adaptability or versatility
If ballast ring is constructed in the field, then it can be adapted to site conditions, but additional time for form construction and concrete curing is required
Solution Approach 1:
The ballast system is segmented into multiple pre-cast blocks that can be quickly assembled in various configurations to adapt to different site conditions and pump basin shapes. This segmentation eliminates the time-consuming form construction and curing processes while maintaining adaptability through flexible block arrangement.
Solution Approach 2:
The concrete blocks are pre-cast and cured at the factory before delivery, completing the time-consuming manufacturing process in advance. At the installation site, only assembly is required, dramatically reducing on-site construction time while the blocks can be configured to adapt to various site conditions.
6Area of stationary object
If wider concrete earthen area is poured to secure station, then coverage area is increased, but additional concrete material and time are required
Solution Approach 1:
The ballast system uses multiple discrete pre-cast blocks arranged in a pattern around the pump basin to achieve wide coverage area. This segmentation provides the same or greater coverage as a single large concrete pour while using less total material by eliminating the need for excessive concrete to create a continuous wide area.
Data Source
AI summary
A ballast system is provided for use with least partially buried pre-formed chamber, the system having at least one ring formed of a plurality of interlocking ballast block ring segments; each ring segment being configured with at least one male interconnect and at least one female interconnect, each said female interconnect being configured to receive a corresponding male interconnect, each ring segment comprising a containment form shell and cast mass; and corrosion resistant locking pins whereby each female interconnect is secured to a corresponding male interconnect.