Reusable Manhole Flow Channel Form Design
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Solution Overview
Problem
Existing manhole flow channel forms are prone to cement intrusion, become buoyant in uncured concrete, and are difficult to remove and reuse due to open tops and buoyancy issues, affecting the quality of the final product.
Innovation Solution
A reusable apparatus with a rigid channel form having a closed top and curved bottom, featuring a bung with a U-shaped slot and a movable wedge for secure placement within the manhole, along with a rotational lock to prevent movement during concrete curing, allowing for easy removal and grout insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an open-top channel form is used, then it is easier to manufacture and insert, but cement enters the interior during filling making removal and reuse difficult
Solution Approach 1:
The channel form is divided into multiple modular sections that can be assembled together. Each section has a closed top portion, and the segmentation allows the form to be disassembled for easy removal after concrete curing, resolving the contradiction between ease of insertion and ease of removal/reuse.
Solution Approach 2:
The channel form is pre-assembled with closed top portions before insertion into the manhole. This preliminary assembly ensures the form is ready for immediate use and prevents cement intrusion from the beginning, while the modular design allows for easy disassembly and reuse afterward.
2Ease of manufacture
If the channel form has an open top, then cement filling is easier, but the form becomes buoyant in uncured concrete causing it to float and move from intended positioning
Solution Approach 1:
The channel form is segmented into multiple sections with closed top portions. This segmentation prevents cement from entering the interior while maintaining ease of filling, and the modular design allows for stable positioning without buoyancy-induced movement.
Solution Approach 2:
The channel form uses a disposable design where each section is individually sealed. The closed top portions prevent buoyancy issues during concrete curing, and the form can be removed and discarded after use, eliminating positioning accuracy problems associated with reusable open-top forms.
3Productivity
If the channel form is made reusable, then cost is reduced, but cement intrusion into the interior makes clean-up and reuse difficult
Solution Approach 1:
The channel form is segmented into multiple modular sections, each with a closed top portion. This segmentation prevents cement from entering the interior of the form during filling, allowing for easy removal and reuse without extensive clean-up, thus maintaining productivity while reducing manufacturing complexity.
Solution Approach 2:
The channel form is pre-assembled with closed top portions before concrete filling. This preliminary action prevents cement intrusion from occurring in the first place, eliminating the need for difficult clean-up operations and enabling easy reuse of the form.
4Ease of operation
If the channel form is open at the top, then insertion is simpler, but the form cannot prevent cement from entering and affecting the quality of the final product
Solution Approach 1:
The channel form is segmented into multiple sections with closed top portions. This segmentation maintains simple insertion procedures while preventing cement from entering the interior, thereby ensuring high product quality without compromising ease of operation.
Solution Approach 2:
The channel form is pre-assembled with closed top portions before insertion. This preliminary action ensures that the form is ready for simple insertion while simultaneously preventing cement intrusion, thus maintaining both ease of operation and manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables uninterrupted fluid flow through manholes, prevents cement intrusion, and facilitates easy removal and reuse of the channel form, ensuring consistent flow rates and improved product quality by maintaining the channel form's position during concrete curing.
Implementation Method 1
at least one movable wedge slidably received by the at least one bung, the wedge slides between an engaged position where the flow channel is fixed between the wedge and the U-shaped slot and a disengaged position where the flow channel is either inserted or removed from the U-shaped slot
Implementation Method 2
a plurality of kickstand legs extending downward such that each of the plurality of kickstand legs rest on a surface below the prefabricated manhole. In some instances, the plurality of kickstand legs resist rotational forces created by recently poured concrete
Implementation Method 3
a rigid channel form, the channel form containing a closed top portion
Data Source
AI summary
The present disclosure is generally directed to processes and apparatuses for use in forming one or more flow channels within a prefabricated manhole assembly. More specifically, an exemplary apparatus embodying various aspects of the disclosure may contain a rigid channel form with a closed top portion, a curved bottom portion, a first end, and a second end. The apparatus may also contain a bung(s) removably positioned into an exterior hole through a sidewall of the prefabricated manhole that may receive one end of the channel form, the bung(s) interior end may further have an open-ended U-shaped slot. A sliding wedge may be used to engaged/disengage the flow channel form.