One Piece Watertight Concrete Tank Manufacturing Process
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Solution Overview
Problem
Conventional precast concrete septic tanks with multiple pieces and seals are prone to leaks due to shifting soil, high water tables, and internal water pressure, despite manufacturer-sealed top seams.
Innovation Solution
A three-step manufacturing process creates a one-piece watertight concrete tank by extending reinforcing steel above the walls, incorporating a water stop between the tank and lid, and pouring concrete to fully encase the reinforcement, eliminating joints and ensuring a stronger, leak-resistant structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If precast concrete tanks are manufactured in multiple pieces with manufacturer-sealed top seams, then manufacturing efficiency is improved, but the tank becomes prone to leaks due to shifting soil, high water tables, and internal water pressure
Solution Approach 1:
The patent merges multiple separate tank pieces into a single monolithic precast concrete structure. The tank is formed as one continuous piece with an integral lid, eliminating all joints and seams that would otherwise require sealing. This combining approach maintains manufacturing efficiency while ensuring complete watertight integrity by removing the vulnerable connection points between separate components.
2Adaptability or versatility
If multiple pieces are assembled at the job site with sealing, then adaptability to site conditions is improved, but the seal reliability deteriorates under soil shifts and water pressure
Solution Approach 1:
The tank is fully assembled and sealed at the manufacturing facility before transport to the job site. All concrete elements, including the lid and body sections, are cast and interconnected in a controlled factory environment where precise alignment and sealing can be ensured. This preliminary assembly eliminates the need for field sealing operations that would be subject to variable site conditions and potential failures from soil shifts or water pressure.
3Reliability
If a one-piece structure is used, then watertight integrity is improved by eliminating joints, but manufacturing complexity increases
Solution Approach 1:
While the final product is a monolithic structure, the manufacturing process is segmented into distinct, manageable phases: formwork preparation with integrated reinforcement, controlled concrete pouring in stages, systematic curing procedures, and standardized demolding operations. This segmentation of the manufacturing process into discrete steps reduces complexity by making each phase routine and repeatable, despite the overall one-piece nature of the tank.
Data Source
AI summary
A manufacturing process for a one piece tank that involves three steps results in a consistently watertight and structurally stronger unit than previous tanks. The three steps comprise a process for producing the body of the tank, a process for producing a preliminary lid, and a process for producing the final tank. An important step in the process for producing the body of the tank is extending reinforcing steel (rebar) a distance above the concrete walls of the tank. After the preliminary lid is placed into a groove of the tank, the rebar is bent over the lid and a water stop is applied between the walls of the tank and the preliminary lid. The water stop can be any of several forms. In one form, the water stop is in the form of butyl or rubber strip which projects from the walls of the tank above the walls with the rebar. In an alternate form, the water stop is in the form of a gasket of plastic or other suitable material inserted in a groove at the top of the tank. Once the preliminary lid is in place and the rebar bent over the preliminary lid, reinforcing steel (rebar) is bent over the preliminary lid and secured to proper locations. Then concrete is poured to the top and above the sidewalls of the tank until completely full. The resulting cured structure is a one piece water tight tank with an integral water stop.