Modular Overflow Spout for Concrete Tanks
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Solution Overview
Problem
Existing overflow spouts on pre-stressed concrete industrial tanks are difficult to install and repair due to their heavy, monolithic construction, which often requires extensive reconstruction if damaged or malfunctioning.
Innovation Solution
A modular overflow spout system with a curb assembly that allows for staged installation and easy removal or replacement of components, featuring an adjustable angle and height to ensure proper orientation, and can be manufactured from lighter materials such as fiberglass or UHPC, enabling separate installation and repair without disturbing the tank structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional monolithic concrete overflow spouts are used, then structural strength and durability are improved, but ease of installation and repair deteriorates due to heavy weight and difficulty of replacement
Solution Approach 1:
The overflow spout is divided into multiple segments: a fixed base portion integrated with the tank structure, and a removable cover portion that can be easily detached and replaced. This segmentation allows the heavy structural component to remain fixed while the lighter cover can be easily maintained, resolving the contradiction between structural strength and ease of repair.
2Strength
If traditional monolithic concrete overflow spouts are used, then structural strength is improved, but ease of installation deteriorates due to heavy weight requiring extensive reconstruction
Solution Approach 1:
The overflow spout is divided into a permanently installed base portion and a removable cover portion. The base can be installed during initial construction using traditional concrete methods, while the cover can be easily added or replaced later without reconstruction, resolving the contradiction between structural strength and ease of installation.
Solution Approach 2:
The base portion is prepared and installed in advance during tank construction, with pre-formed attachment features (such as rebars or mounting structures) already in place. This preliminary preparation enables the cover to be easily attached later without requiring extensive reconstruction or complex installation procedures.
3Adaptability or versatility
If adjustable curb assembly is used, then adaptability to different roof pitches is improved, but device complexity increases
Solution Approach 1:
The curb assembly incorporates adjustable elements that allow the cover to be positioned at different angles to match various roof pitches. The adjustment mechanism uses simple mechanical means (such as adjustable brackets or movable support structures) rather than complex systems, achieving adaptability while minimizing added complexity.
Data Source
AI summary
A modular overflow spout that covers a tank outlet comprising an overflow cover removably attached to a curb assembly. The overflow cover includes a canopy and a cover plate. The curb assembly comprises an outer curb having a lower curb flange that can be incorporated into the tank outlet and an upper curb flange that is positioned above the tank outlet. An inner curb is attached to the outer curb and can be incorporated into the tank outlet with the inner curb. The modularity allows the outer curb to be adjustable within the outlet so that the angle of the upper curb flange is conducive for attachment of the cover plate on the overflow cover after the curb assembly is incorporated into the tank roof.