Modular Containment Mat System with Lap Joint Sealing
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Solution Overview
Problem
Current matting and lining systems for environmentally sensitive areas, such as oil and gas drilling sites, are time-consuming and costly to install, and prone to tears and punctures, which reduces their effectiveness in preventing environmental impact and containment of spills.
Innovation Solution
A modular containment mat system comprising interconnected boards with a middle layer perpendicular to the top and bottom layers, secured with adhesive or fasteners, and covered with a geotextile and impervious coating, providing a reliable and reusable surface for drilling operations and spill containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liner material is placed directly on the ground surface, then containment coverage is achieved, but tears and punctures occur reducing effectiveness
Solution Approach 1:
A protective matting layer is installed beforehand on the ground surface to cushion and protect the liner material from punctures and tears caused by ground irregularities, rocks, and equipment. This prior protective measure prevents damage before it occurs, maintaining containment effectiveness throughout the operational period.
2Object-affected harmful factors
If traditional lining and matting systems are installed, then environmental protection is achieved, but installation time and cost increase significantly
Solution Approach 1:
The containment system is divided into modular matting units that can be independently manufactured, transported, and installed. These segmented modules can be quickly assembled on-site like puzzle pieces, dramatically reducing installation time compared to traditional continuous liner installation while maintaining complete environmental protection coverage.
Solution Approach 2:
The matting units are pre-assembled and prepared off-site before deployment to the installation location. This preliminary preparation includes pre-attaching protective layers, sealing edges, and configuring modular components, so that on-site installation requires only simple placement and connection, minimizing installation time and labor requirements.
3Object-affected harmful factors
If traditional matting systems are used, then ground protection is achieved, but installation cost increases
Solution Approach 1:
The matting system uses standardized dimensions, material specifications, and connection parameters that enable efficient manufacturing and deployment. By optimizing parameters such as mat size, thickness, and interconnection mechanisms, the system achieves ground protection at reduced cost through economies of scale and simplified installation procedures.
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 system enables fast, cost-effective installation of a reliable and impermeable working surface that effectively prevents spills and reduces environmental impact, with enhanced traction and durability for repeated use.
Implementation Method 1
The top, middle, and bottom surfaces may be interconnected through any of a number of techniques, such as adhesive, nails or bolts, for example. In some examples, boards of the top, bottom, and middle layers may be placed directly against adjacent boards of the layer, and all of the boards of each layer may be secured to adjacent boards with an adhesive.
Implementation Method 2
In some examples, the assembled mat may be heat treated to a relatively high temperature to set the adhesive securing the boards to create a mat that is highly impenetrable to water and chemicals.
Implementation Method 3
A water and chemical impervious coating may be applied to the top of the top surface
Implementation Method 4
A geotextile, such as a strip of a 100 mil well pad liner, may be placed over the lap joint seams between adjacent mats
Data Source
AI summary
Improved containment mats and systems of containment mats may include multiple adjoining mats with a top surface and a bottom surface. The multiple mats may provide a modular structural mat system that may be installed at a drill site, with multiple mats placed adjacent to each other with a lap joint connecting adjacent mats. A geotextile may be used to cover the lap joints and a coating applied to the geotextile. Such a system may provide containment of potential spills, a reliable working surface for drilling operations, and relatively fast and less expensive installation.