Patent Grant
11073017
The invention relates to a barrier device for post-installation injection of a waterproofing fluid; and, more particularly, to a multi-layer device having first and second layers defining an intermediate open-matrix layer, and at least one injection conduit member disposed in parallel orientation with respect to the first and second layers to permit a waterproofing fluid to be injected into the open-matrix layer. The at least one injection conduit member may be located between the first and second layers and thus within the open matrix layer, at the edge of the multi-layer device and adjacent to an open matrix layer, along an outer face of the first layer if the first layer is made of nonwoven or woven fabric, or combination of these locations, whereby an injection fluid can be conveyed through the conduit member and into the open matrix layer.
The use of multi-layer devices for post-installation, in-situ creation of barriers for waterproofing of concrete constructions is known. An applicator places such devices against a substrate, such as formwork or existing wall, and applies concrete against the devices. Thereafter, an applicator can inject a waterproofing fluid into the devices. The waterproofing fluid may comprise waterproofing resins or cements, insecticides, mold preventatives, rust retardants, and the like, for creating a watertight barrier, or so-called “grout wall,” to protect the concrete structure. The injection of the fluid allows for remedial waterproofing treatment after installation of the device and after spraying or casting concrete against the device.
Brian Iske and others disclosed various devices for the creation of grout walls in U.S. Pat. Nos. 7,584,581, 7,836,650, 7,900,418, and 8,291,668, owned by the common assignee hereof. The grout wall devices can be attached to the exterior of a shoring system, a tunnel excavation wall, a concrete formwork, or other substrates or structures.
Characteristic of the Iske devices were a plurality of injection tubes that jutted perpendicularly out of the outermost layer of the multi-layered devices. The orientation and placement of these perpendicularly, outward-extending tubes enabled injection of the waterproofing fluid (e.g., grouts, resins, etc.) into the device after concrete was applied against the exterior of the installed multi-layer device. After the concrete was cast or sprayed against the installed device, Iske et al. taught that applicators could pump the waterproofing composition into the multi-layered device and thus completely fill the interior of the multi-layer device using spaced-apart tubes or pipes. The tubes or pipes extended perpendicularly through the outermost layer of the devices and through the placed concrete structure and required placement to ensure that the injection fluid would be able to fill completely the multi-layer device behind the concrete (See e.g., U.S. Pat. No. 7,836,650 at FIGS. 5-6).
The present inventors believe that such prior art multi-layer grout wall devices, due to the large number of perpendicularly extending tubes or pipes, required enormous preparation work on site, even when the devices were installed as pre-assembled integral units. The use of the perpendicularly extending tubing required a lot of preparation and steps during the injection process to ensure that a continuous grout wall could be established between the devices and the concrete placed against the devices.
In surmounting the deficiencies of the prior art, the present invention provides a multi-layer device that enables faster and more convenient installation of a grout wall system, and particularly for establishing a grout wall using an assembly of such multi-layer devices.
An exemplary device of the invention for post-installation in-situ barrier creation, comprises: a multi-layer fluid delivery device comprising first and second layers defining an intermediate open-matrix layer for an injection fluid; the first layer having an inwardly facing surface and an outwardly facing surface, the first layer being permeable to the injection fluid but at least nearly impermeable to a structural construction material to be applied against the outwardly facing surface of the first layer, and the second layer being water-impermeable and having an inwardly facing first side and an outwardly facing second side, the inwardly facing first side of the second layer being affixed, directly or indirectly to the inwardly facing surface of the first layer such that all or a substantial portion of the second layer is spaced apart from the first layer, using an open-matrix structure to create air space between the first layer and the second layer and thereby defining an open-matrix layer for conducting an injection fluid between said first and second layers; and at least one injection conduit member disposed in parallel orientation with respect to the first layer and second layer, the at least one injection conduit member for conveying an injection fluid into the open-matrix intermediate layer air space; and the at least one injection conduit member being: (i) located within the open-matrix layer and thus between the first and second layer, (ii) located adjacent the open-matrix layer; (iii) located against the outwardly facing surface of the first layer which is permeable to injection fluid; or (iv) located in a combination or all of the foregoing locations (i), (ii), and (iii).
The injection fluid may be chosen from waterproofing resin, grout, cement, insecticide, mold preventative, rust retardant, and mixtures thereof.
In further exemplary embodiments, the first layer is permeable to the injection fluid and nearly impermeable to the structural construction material (e.g., concrete), and comprises a non-woven or woven fabric; while the second layer is water-impermeable, and comprises a polymer film (e.g., polyethylene, polypropylene).
While the invention contemplates that the multi-layer device can be assembled from separate components at the construction site, the inventors believe that it is more convenient, efficient, and faster to use pre-assembled multi-layer devices, so that installation effort and time are minimized. In either case, one creates an “in situ” (or “in place”) barrier system that defines a confined flow area for injection fluids such as waterproofing resins and grouts.
The present invention has particular value in vertical wall applications, especially for sealing to prevent leakages at cold joints, as defined between concrete floors and subsequently poured vertical walls. The device is assembled or installed as a pre-assembled unit against a substrate (e.g., excavation, existing wall or foundation, formwork or mold, tunnel wall, etc.), and, subsequently, concrete is cast or sprayed against its outward-facing layer. The device may also be assembled or installed in horizontal applications, such as sub-layer or subflooring for concrete slabs, decks, and floor applications, including applications where the existence and location of joints and segment dimensions are not predictable or uniform. In either horizontal or vertical applications, the devices and assemblies of the invention can protect against moisture penetration due to crack formations or other leakage pathways formed within or between concrete structures.
In other exemplary embodiments, the outward face layer of the multi-layer device is preferably porous, such as in a nonwoven or woven fabric, which allows the injection fluid to fill in the open-matrix intermediate layer and flows through the outward face porous layer to fill in voids or discontinuities in the construction material (e.g., concrete) that is cast or sprayed against the multi-layer device.
The present invention also has particular value in shotcrete applications, wherein concrete is sprayed against the outward face of the device. When the device of the invention is installed against a wall, and concrete is poured or spray-applied against rebar adjacent the installed device, the device will allow a subsequently injected resin or grout to permeate through the outward face porous layer and fill in “shadow” areas where the rebar interrupts the path of the poured or sprayed concrete (or shotcrete), thereby creating a full contact seal with the concrete (or shotcrete).
In other embodiments, the barrier devices of the present invention having the at least one injection conduit member in parallel orientation with respect to the first and second layers are provided in rollable or stacked form that can be used conveniently and quickly at the construction site. In other words, two or more pre-assembled multi-layer fluid delivery units can be connected together to form a monolithic barrier layer wherein their at least one injection conduit member(s) are connected to permit an injection fluid (e.g., grout, resin, cement) to be pumped through and/or into several barrier devices at once, thereby creating a monolithic water-resistive curtain over an area that is larger than an individual barrier device. The concrete which is subsequently cast or sprayed against the installed barrier devices allow the in-situ barriers to stay in place during fluid injection, and to resist the compressive pressure required to inject the fluid into the open-matrix intermediate layer and through the permeable outward porous (e.g., woven or nonwoven) fabric which comprises the outward face layer.
In further exemplary multi-layer barrier devices of the invention, the layer installed against a formwork or other substrate comprises a water-impermeable polymer film (e.g., polyolefin), and the layer disposed outwards for bonding with cast or sprayed concrete comprises a non-woven material (e.g., polypropylene, nylon, polyamide). The film layer side of the device can be attached to formwork, an existing wall, or other substrate using a two-sided tape or pre-attached pressure-sensitive adhesive layer. The outward-facing non-woven layer, on the other hand, allows for permeation of the injection fluid (e.g., grout, resin, cement) into and out of the intermediate open-matrix layer, while essentially blocking concrete or other construction material cast against the barrier device from entering into the open-matrix intermediate layer.
The present invention also provides a method for creating an in-situ barrier device (or assembly), wherein the above barrier device is attached or assembled against an excavation wall, lagging form, or shoring system, where concrete is thereafter applied (e.g., sprayed, poured) against the outer layer of the barrier device; and an injection fluid is subsequently injected through the at least one injection conduit and into the space defined by the open-matrix intermediate layer.
Especially preferred devices of the invention comprise one or more injection conduit members disposed in parallel orientation with respect to the first and second layers, and can be (i) located within the open-matrix layer and thus between the first and second layer, (ii) located adjacent the open-matrix layer (along an edge of the device); (iii) located against the outwardly facing surface of the first layer which is permeable to injection fluid; or (iv) located in a combination or all of the foregoing locations (i), (ii), and (iii).
The present invention avoids the inconvenience of having to install numerous injection tubes extending perpendicularly across the outward face of the device, as well as the inconvenience of applying concrete around the perpendicularly extending tubes.
In a further exemplary multi-layer device of the invention, a gelation activator is pre-applied within the open-matrix layer defined between the first and second layers (hereinafter “gel activator”). The gel activator functions as an accelerator, catalyst, hardener, resin and/or curative agent to increase or to initiate gelation (e.g., hardening, stiffening, polymerization) of the injection fluid once it is introduced into the open matrix layer. For example, the injection fluid could be a polyol resin, and the gel activator could be an isocyanate functional resin, to generate a polyurethane grout wall composition within the barrier device.
As another example, the injection fluid could be an isocyanate resin, and the gel activator could be an amine resin, to generate a polyurea grout wall within the barrier device. An amine gel activator or a free radical gel activator could be used for injection fluids that were based on polyacrylate. A still further example involves use of an epoxy resin injection fluid, and an amine resin as gel activator.
As another example, the gel activator for hydratable cementitious injection fluids could be a set accelerator (e.g., calcium nitrite and/or nitrate) to quicken the setting of the cement. As yet another example the injection fluid may comprise a sodium silicate solution and the gel activator may comprise an acid or an alkaline earth salt or an aluminum salt. The gel activator is pre-installed or preapplied (e.g. coated, sprayed, brushed) into the open-matrix layer structure, such as into a non-woven geotextile mat used for separating the first and second layers of the barrier device. Consequently, a highly flowable injection fluid can be introduced into the barrier device without the need for high-powered, multi-component pump equipment. A simple, single component pump equipment is used. Upon contact with the gel activator located within the open-matrix layer, the injection fluid will begin to gel (e.g., assume higher viscosity) and ensure that a grout wall is established against concrete that was cast against the installed barrier.
The present inventors believe that the use of a pre-installed gel activator will benefit the use of the herein-described barrier devices having injection conduit members disposed in parallel orientation with respect to the first and second layers. The pre-installed gel activator will also benefit conventional grout wall barrier designs (e.g., U.S. Pat. No. 7,565,799) which employ tubes extending perpendicularly from the structure. Hence, another exemplary multi-layer fluid delivery device of the present invention comprises first and second layers defining an intermediate open-matrix layer for an injection fluid; the first layer having an inwardly facing surface and an outwardly facing surface, the first layer being permeable to the injection fluid but at least nearly impermeable to a structural construction material to be applied against the outwardly facing surface of the first layer, and the second layer being water-impermeable and having an inwardly facing first side and an outwardly facing second side, the inwardly facing first side of the second layer being affixed, directly or indirectly to the inwardly facing surface of the first layer such that all or a substantial portion of the second layer is spaced apart from the first layer, using an open-matrix structure to create air space between the first layer and the second layer and thereby defining an open-matrix layer for conducting an injection fluid between said first and second layers; and at least one injection conduit member disposed in parallel orientation with respect to the first layer and second layer, the at least one injection conduit member for conveying an injection fluid into the open-matrix intermediate layer air space; and the at least one injection conduit member being (a) located within the open-matrix layer and thus between the first and second layer, (b) perpendicular and connected to and disposed outside of the open-matrix layer; or (c) both (a) and (b); and having a gel activator located within the open-matrix structure. The present invention thus provides barrier devices and methods, wherein a gel activator is pre-installed, wherein gelation is initiated or accelerated in injection fluids introduced through parallel and/or perpendicular injection tubes, or even where injection fluid is introduced without injection tubes but through holes drilled in concrete that was hardened against the installed barrier device.
Further features and benefits of the invention are described hereinafter.
The present invention may be more readily comprehended when the following written description of exemplary embodiments is considered in conjunction with the drawings, wherein
The present invention relates to a multi-layer assembly or device for a post-installation in-situ barrier, as well as a method for assembling the barrier, using one or more injection conduit members that are parallel to the major faces or layers of the assembly or device, in contrast to the prior art use of perpendicularly extending pipes as taught by Iske et al. as mentioned in the Background section.
The terms “assembly” and “device” may be used interchangeably throughout this specification. Ideally, relatively little assembly of an individual multi-layer device is required at the construction site, although the establishment of a grout wall against concrete that is poured or sprayed against a number of such individual multi-layer devices will require some “assembly” to join individual multi-layer devices together, including injection conduit members to permit filling two or more of the devices using a single source of injection fluid. (This will be described further hereinafter during discussion of
As will be explained in further detail hereinafter, two or more multi-layered devices can be joined together, thereby allowing for the creation of a grout wall to seal against subsequently applied concrete, using injection conduit members which can be (i) located within the open-matrix layer and thus between the first and second layers of the multi-layered device, (ii) located adjacent the open-matrix layer at an edge of one or more multi-layered devices; (iii) located against the outwardly facing surface of the first layer(s) which is permeable to injection fluid; or (iv) located in a combination or all of the foregoing locations (i), (ii), and (iii).
For example, a barrier device can be assembled at a construction site by providing the multi-layer device having a first layer (e.g., a nonwoven which is permeable to a waterproofing grout, resin, cement, or other injection fluid), a second layer (e.g., a water-impermeable polymeric film), and an open-matrix structure for connecting the first and second layers together but defining a space for filling with injection fluid; and an injection conduit (e.g., spiral wrap tubing) can be taped against the first layer (nonwoven) in a manner to allow injection fluid to be pumped through the nonwoven first layer so as to fill the intermediate open-matrix layer and to fill any gaps or discontinuities in concrete which is applied against the outer layer of the device.
As another example, the barrier device can be adhered in strip form against a substrate, and an injection conduit member can be placed next to one or both edges along the strip, and taped in place, such that injection fluid can be pumped through and out of the injection conduit member and into the intermediate open matrix layers of the adjacent barrier device or devices.
As a further example, the multi-layer barrier device may be pre-assembled having at least one integral injection conduit member between the first and second layers and thus embedded already within the intermediate open-matrix layer. This may facilitate installation, as well as waterproofing performance, because the applicator may also install additional injection conduit members in parallel fashion along an edge and/or outward face of the barrier devices, whereby an injection grout, cement, resin, or other fluid can be introduced from openings along the length of the injection conduit member into spaces within the intermediate open-matrix layers of the barrier devices.
As shown in the plan cross-sectional diagram of
In further exemplary devices or assemblies of the invention, the first layer 12 of the at least two spaced-apart layers is preferably non-permeable or semi-permeable to the injection fluid which is introduced into the intermediate open-matrix layer 16; while the second 14 of the at least two spaced-apart co-extensive layers is preferably a polymer film which is non-permeable to the injection fluid which is introduced into the intermediate open-matrix layer 16. For example, the first layer 12 can be a non-woven synthetic fabric of the kind used for bonding with fresh concrete cast or sprayed against it and allowed to cure into a hardened state.
In a further exemplary embodiment, a pressure-sensitive adhesive layer 22 may be attached to the second layer 14 to facilitate installation of the device or assembly 10 against a substrate, such as an excavation wall, a concrete wall or foundation, a formwork, a scaffolding structure, or other mounting surface.
In other exemplary embodiments, the first layer 12 is preferably made from a synthetic felt or other non-woven fiber material, which is permeable to the injection grout, resin, cement or other fluid, but partly impermeable to fresh concrete that is cast against it. By “partly impermeable,” it is intended that the fresh concrete is able to flow into interstices between the fibers of the felt or non-woven fiber material and to create a bond with the concrete when the concrete becomes hardened; and it is preferable to select the felt or non-woven fiber material such that the concrete does not entirely penetrate into the intermediate open-matrix layer 16 thereby to prevent the grout, resin, or other injection fluid from being able to fill up the spaces defined by the open matrix layer 16 within the barrier device 10, or to block the injection fluid from permeating the nonwoven, felt, or other fiber material which constitutes the first layer 12 and from filling gaps or discontinuities between the applied concrete and the first layer 12.
Various exemplary structures 16 can be used for spacing apart the first and second layers 12/14 and defining the space within the intermediate open-matrix layer 16. For example, in U.S. Pat. No. 7,565,779, Iske et al. taught the use of frusto-conical shaped structures in addition to other protuberances, wave-shaped ribs, and geotextile non-woven layers. At column 10, lines 3 and following, Iske et al. identified commercially available construction drainage products that could be utilized in forming the open-matrix layer, for example, Colbond Enkadrain®, Pozidrain®, Terradrain®, Senergy®, Tenax®, Blanke Ultra-Drain®, AmerDrain®, Superseal SuperDrain®, J-Drain®, Viscoret® dimpled membrane, Terram® drainage composites, and Delta®-MS drainage membranes. The present inventors consider these various brands of geotextile products to be suitable for use in the present invention, and their selection would be subject to the preference of the device designer, assuming compatibility with the size of internal injection fluid conduit tubing 20 used between the first and second layers 12/14 of the barrier device 10.
For exemplary intermediate open-matrix layers 16 having a fast filling area for containing the injection fluid while providing rollability and sufficient structure to the multi-layer device, the present inventors contemplate the use of a three-dimensional membrane with open cell structure formed by continuous extrusion of two intersecting high density polyethylene (HDPE) strands to form a high profile, biaxial netlike mesh. The polymer strands may intersect randomly, and the form the shape of evenly spaced ribs or undulations, for spacing apart the first layer 12 and second layer 14, and permitting air channels having high capacity for the injection of chemical fluids such as grouts, resins, and cements which are typically used in waterproofing. The present inventors believe that three-dimensional geosynthetic textiles provide high fluid flow characteristics in both machine and cross directions without generating unnecessary flow resistance. Such open matrix structures will allow uniform flow of the injected fluid and create a curtain wall (e.g., chemical grout) in every direction.
The preferred thickness of this exemplary open-matrix layer is about ⅛ inches to ⅜ inches. The density of the open-matrix layer may, for example, be in the range of 20 gm/ft2 to 80 gm/ft2, more preferably between 30 gm/ft2 to 70 gm/ft2, and most preferably between 45 gm/ft2 to 60 gm/ft2.
As mentioned above, the second layer 14 is preferably a water-impermeable polymer film (e.g., polyolefin). More preferably, both first layer 12 and second layer 14 will each have linear edges along their respective width and length dimensions. If an injection conduit member 20 is positioned parallel to one of the width or length linear edges of the device 10, it may comprise a plurality of openings to permit an injection fluid to be introduced into the intermediate open-matrix layer 16 of a given device 10, or have separate holes or “T” or “X” joints to permit fluid communication/connection to injection conduit members that are located within the devices 10.
As shown in
In further exemplary embodiments, the injection conduit member 20 can be formed by spiral wrapping of a ribbon shaped polymer to form a tubing; whereby openings to allow exit of the injection fluid are defined by spaces between the spiral wrap. A further variation of this concept is to employ two concentric spiral wrapped tubings, wherein the spiral direction may be same or opposite. Where two concentric spiral wraps are used to define a conduit 20 tubing, the innermost concentric spiral wrap tubing will function to convey an injection fluid through the length of the tubing; and the outermost concentric spiral wrap tubing will function to control expansion of the innermost tubing and to minimize or prevent re-entry of fluid that has been ejected from the innermost tubing. Again, the “opening” of the conduit member in this case is defined by the spaces between the respective spiral wrappings which form the tubing.
In a further exemplary injection conduit member, a mesh sleeve which is made by woven or braided fibers of polyolefin (e.g., polyethylene, polypropylene) or polyamide (e.g., NYLON), may be positioned concentrically outside of one or more spiral wrap tubing members to control the expansion of the tubing(s) under pressure and to protect the integrity of the tubing shape formed by the spiral wrappings.
In a still further exemplary injection conduit member, a polymer mesh (braided or woven) sleeve or one or more spiral wrapping tubing(s) can be concentrically arranged around a metal or plastic spring. The spring helps to resist collapse of the tubing when the device is in rolled or unrolled form, and particularly where the barrier device is installed or assembled in locations which will be subject to large compressive forces (large rocks) or potential mechanical threats (movement of large structures such as rebar or machinery) in the vicinity of the barrier device 10 installation or assembly.
In other exemplary embodiments, the multi-layer fluid delivery device 10 is pre-assembled with one or more injection conduit members 20 located within the intermediate open-matrix layer, against an outer edge of the device, or along the outward nonwoven layer of the device (or combination thereof). Regardless of whether the injection conduit members are pre-assembled in combination with the multi-layer structure, the barrier unit may be conveniently and relatively easily rolled up for shipment and unrolled at the construction site for installation. Accordingly, an exemplary device 10 of the invention comprises the at least two spaced-apart layers 12/14, the intermediate open-matrix layer 16, and the at least one injection conduit member 20 pre-assembled into an integral unit and transportable in a rolled form. At the site, two or more exemplary devices 10 having integral injection conduit members 20 can be assembled together to form a monolithic in-situ barrier.
While
A barrier of the present invention for creating a grout wall may be assembled at the construction site using (a) a multi-layer device that does not contain an injection conduit member; and (b) an injection conduit member that is installed along an edge of the device (See e.g.,
As shown in
In still further exemplary embodiments, the conduit member 20 may comprise a spiral wrap member, optionally surrounded by a second spiral wrap member 38, and an outer mesh sleeve 40 surrounding the inner spiral wrap member.
As shown in
In a further exemplary multi-layer fluid delivery device 10 of the invention, the first layer 12 is a non-woven material and the second layer 14 is a polymer film material, wherein the first and second layers 12/14 are generally co-extensive with each other, the device having generally parallel edges along its width and length dimensions. The multi-layer device 10 may have at least one injection conduit member 20 contained between the first and second layers 12/14 and/or against an edge or outward face of the first (nonwoven layer. At least one conduit member, as illustrated in
In other exemplary devices 10, one end of the conduit member 20 member and the first and second layers 12/14 are sealed (See e.g.,
As shown in
As illustrated in the cross-section plan diagram of
The plan diagram of
Also in
The various exemplary aspects of the invention may be set forth as follows.
In a first aspect of the invention, an exemplary device for post-installation in-situ barrier creation, comprises:
a multi-layer fluid delivery device comprising first and second layers defining an intermediate open-matrix layer for an injection fluid;
the first layer having an inwardly facing surface and an outwardly facing surface, the first layer being permeable to the injection fluid but at least nearly impermeable to a structural construction material to be applied against the outwardly facing surface of the first layer, and the second layer being water-impermeable and having an inwardly facing first side and an outwardly facing second side, the inwardly facing first side of the second layer being affixed, directly or indirectly to the inwardly facing surface of the first layer such that all or a substantial portion of the second layer is spaced apart from the first layer, using an open-matrix structure to create air space between the first layer and the second layer and thereby defining an open-matrix layer for conducting an injection fluid between said first and second layers; and
at least one injection conduit member disposed in parallel orientation with respect to the first layer and second layer, the at least one injection conduit member for conveying an injection fluid into the open-matrix intermediate layer air space; and
the at least one injection conduit member being: (i) located within the open-matrix layer and thus between the first and second layer, (ii) located adjacent the open-matrix layer; (iii) located against the outwardly facing surface of the first layer which is permeable to injection fluid; or (iv) located in a combination or all of the foregoing locations (i), (ii), and (iii).
In a second exemplary aspect of the invention, based on the multi-layer fluid delivery device describe above in the first example, the first and second layers each have linear edges along width and length dimensions, wherein the water-impermeable second layer is a polymer film having linear edges along the width and length dimensions, and the first layer, which is permeable to the injection fluid and nearly impermeable to the structural construction material, is a non-woven or woven fabric.
In a third exemplary aspect of the invention, which may incorporate any of the first or second exemplary aspects above, the first layer and second layer each have linear width or length edges, and the least one injection conduit member is parallel to one of the linear width or length edges.
In a fourth exemplary aspect of the invention, which may incorporate any of the first through third exemplary aspects above, the fluid delivery device comprises at least one injection conduit member located between the first and second layers extends within the intermediate open-matrix layer and extending the width or length of the multi-layer fluid delivery device.
In a fifth exemplary aspect of the invention, based on any of the first through fourth exemplary aspects above, the first layer and second layer which define an intermediate open-matrix layer, and the at least one injection conduit member which is disposed within the intermediate open-matrix layer, are pre-assembled into an integral unit (i.e., before installation at a construction site).
In a sixth exemplary aspect of the invention, the device is based on any of the first through fifth exemplary aspects above, wherein the at least one injection conduit member comprises polymer tubing having openings which are resiliently movable from a closed to open position when the conduit member is filled with an injection fluid under positive pressure.
In a seventh exemplary of the invention, the device is based on any of the first through sixth exemplary aspects above, wherein the at least one injection conduit member comprises at least one spiral wrap sleeve member.
In an eighth aspect of the invention, the exemplary device is based on any of the first through seventh exemplary aspects above, wherein the at least one injection conduit member further comprises at least two spiral wrap sleeve members. As discussed above, two or more spiral wrap sleeve members are concentric, with the inner spiral wrap sleeve forming a tubing for conveying an injection fluid the length of the tubing as well as openings (between the edges of the spiral wrap) for allowing injection fluid to flow into the open-matrix layer 16 defined between the first and second layers 12/14 of the devices 10.
In a ninth aspect of the invention, the exemplary device is based on any of the first through eighth exemplary aspects above, wherein at least one injection conduit member further comprises at least one mesh sleeve member. For example, the mesh sleeve member can surround one, two, or more spiral wrap members that form the tubing through which an injection fluid is conveyed.
In a tenth aspect of the invention, based on the exemplary devices based on the ninth exemplary aspect above, the at least one injection conduit member comprises at least two spiral wrap members having opposite spiral directions, the at least two spiral wrap members being surrounded by the at least one mesh sleeve member.
In an eleventh aspect of the invention, the exemplary device is based on any of the first through tenth exemplary aspects above, wherein the at least injection conduit member consists essentially of a first spiral wrap member that is surrounded by a second spiral wrap member, and the first and second wrap members have opposite spiral directions.
In an twelfth aspect of the invention, based on the eleventh exemplary aspect above, the multi-layer fluid delivery device further comprises a mesh sleeve member surrounding the first and second spiral wrap members.
In a thirteenth aspect of the invention, wherein the device is based on any of the second through twelfth exemplary aspects above, the multi-layer fluid delivery device has at least one injection conduit member disposed parallel with respect to a linear edge of the device in the width dimension, and at least one injection conduit member disposed perpendicularly with respect to a linear edge of the device in a length or width dimension, the device being a pre-assembled unit wherein the injection conduit members form a “T” junction.
In a fourteenth aspect of the invention, wherein the multi-layer fluid delivery device is based on any of the first through thirteen exemplary aspects above, the at least one injection conduit does not terminate flush with a width edge or length edge of the multi-layer device, in that the at least one injection conduit extends beyond a width edge or length edge of the device.
In a fifteenth aspect of the invention, wherein the multi-layer fluid delivery device is based on any of the first through fourteenth exemplary aspects above, the device has at least two at least two conduits or openings of one or more conduits located at two different edges of the device, to permit two or more devices to be connected for injecting an injection fluid to form a grout curtain with a structural construction material that is cast against the two or more devices.
In a sixteenth aspect of the invention, wherein the multi-layer fluid delivery device is based on any of the first through fifteen exemplary aspects above, the outwardly facing second side of the second layer further comprises a pressure-sensitive adhesive layer for adhering the multi-layer fluid delivery device to a substrate, formwork, a building structure, or other surface.
In a seventeenth aspect of the invention, wherein the multi-layer fluid delivery device is based on any of the first through sixteenth exemplary aspects above, an end of the at least one injection conduit member is closed, and the first and second layers of the device are sealed to define a containment cavity for containing an injection fluid that is injected into the at least one injection conduit member which is closed at an end.
In an eighteen aspect of the invention, wherein the multi-layer fluid delivery device is based on any of the first through seventeenth exemplary aspects above, the device further comprises at least one tubing member penetrating the first layer (e.g., nonwoven). Such an exemplary embodiment has a number of potential benefits. First, concrete can be cast or sprayed against the first layer (and thus around tubing which will jut through the concrete, and when an injection liquid (e.g., grout, resin) is injected into the device, the jutting tubing will provide a confirmation port, so that an applicator can inject concrete into the edge-situated conduit or conduits, and obtain confirmation, by visual inspection of injection liquid emitting from the jutting tubing, that the a grout wall is being established against the concrete at the interface between the device and concrete. In a further variation of this embodiment, a multi-layer device of the invention may have an injection conduit (tubing) which is parallel to the first and second layers 12/14 and located between these layers 12/14, as well as one or more tubings which extend through the first layer (See e.g., Iske et al., U.S. Pat. No. 7,565,799). The tubing or tubings which extends through the first layer can be used as confirmation ports, so that applicators can confirm that grout, resins, cement, or other injection fluids are adequately being conveyed by other injection conduits which are located inside the barrier devices 10, such as between the first and second layers 12/14 or along outer edges of the barrier devices 10.
In a nineteenth aspect of the invention, wherein the multi-layer fluid delivery device is based on any of the first through eighteenth exemplary aspects above, the device comprises at least one injection conduit member located at an edge of the device, the edge-located at least one injection conduit member having openings disposed for allowing an injection fluid to be injected into a second multi-layer fluid delivery device installed against the edge-located at least one injection conduit member.
In a twentieth aspect of the invention, a method for waterproofing a concrete structure, the method comprises installing against a substrate chosen from e.g., formwork, wall, foundation, or existing building surface, at least one multi-layer device according to any of the foregoing first through nineteenth exemplary aspects above; and applying concrete against the at least one multi-layer device.
In a twenty-first aspect of the invention, an exemplary method based on the above twentieth aspect, comprises: installing against the substrate at least two multi-layer devices having at least one conduit member (i) located within the intermediate open-matrix layer, (ii) located at the edge of a multi-layer device and adjacent to an intermediate open-matrix layer, (iii) located along an outward face of the first layer, or (iv) located at a mixture of locations (i), (ii), and (iii), the conduit members being connected together to enable injection fluid to be injected into the at least two multi-layer devices from a common source.
In a twenty-second aspect of the invention, an exemplary method for establishing a barrier assembly for post-installation in-situ incorporation of a grout, resin, cement, or other injection fluid, comprises: installing at least two devices according to any of the foregoing first through eighteenth exemplary aspects above, in side-by-side fashion whereby the two devices are taped together and the at least one conduit member of one device is connected to the at least one conduit member of the other device; placing concrete against the at least two devices which are side-by-side; and injecting an injection fluid into the open-matrix layers of the at least two multi-layer devices simultaneously through the conduit connection, whereby a continuous grout wall curtain is established. One exemplary method for installation of two barrier devices 10 is shown in
In a twenty-third aspect of the invention, an exemplary multi-layer fluid delivery device, comprises: first and second layers defining an intermediate open-matrix layer for an injection fluid, the first layer having an inwardly facing surface and an outwardly facing surface, the first layer comprising a non-woven synthetic fabric permeable to the injection fluid but at least nearly impermeable to concrete applied against the outwardly facing surface of the first layer, and a second layer, the second layer being water-impermeable polymer film and having an inwardly facing first side and an outwardly facing second side, the inwardly facing first side of the second layer being affixed directly or indirectly to the inwardly facing surface of the first layer such that all or a substantial portion of the second layer is spaced apart from the first layer; the device further comprising an open-matrix structure to create air space between the first layer and the second layer thereby defining an open-matrix layer for conducting an injection fluid through the multi-layered device; and the multi-layer fluid delivery device further comprising at least one injection conduit member disposed in parallel orientation with respect to the first layer and second layer, the at least one injection conduit member comprising at least one spiral wrap tube; and the at least one injection conduit member being: (i) located within the open-matrix layer and thus between the first and second layer, (ii) located adjacent the open-matrix layer; (iii) located against the outwardly facing surface of the first layer which is permeable to injection fluid; or (iv) located in a combination or all of the foregoing locations (i), (ii), and (iii).
In a twenty-fourth aspect of the invention, an exemplary method for establishing a continuous grout wall curtain against a concrete structure, comprises: providing at least two multi-layer fluid delivery assemblies, each assembly having first and second layers defining intermediate open-matrix layers for an injection fluid; the first layers having an inwardly facing surface and an outwardly facing surface, the first layers being permeable to the injection fluid but at least nearly impermeable to a structural construction material to be applied against the outwardly facing surface of the first layer, and the second layers being water-impermeable and having an inwardly facing first side and an outwardly facing second side, the inwardly facing first side of the second layers being affixed directly or indirectly to the inwardly facing surface of the first layers such that all or a substantial portion of the second layers is spaced apart from the first layers to create air space between the first layers and the second layers; and each of the multi-layer assemblies comprising at least one injection conduit member disposed in parallel orientation with respect to the first layers and second layers, the at least one injection conduit members having openings for introducing an injection fluid between the first and second layers and into the open-matrix intermediate layer air spaces, the at least one injection conduits being in communication to enable an injected fluid to flow between the adjacent multi-layer assemblies, each of the at least one injection conduits comprising at least one spiral wrap member tubing for conveying an injection fluid and openings for conveying an injection fluid; applying concrete against the at least two multi-layer fluid delivery assemblies; and introducing an injection fluid into the at least two multi-layer fluid delivery assemblies through the injection conduits which are in communication, whereby a grout wall curtain is established continuously against the concrete applied against the fluid-delivery assemblies.
In a twenty-fifth aspect of the invention, the invention provides a kit or system for making an assembly of fluid-delivery devices, comprising: at least two multi-layer devices 10 according to any of the first through nineteenth exemplary aspects above, and an injection conduit member 20 for connecting together and conveying an injection fluid simultaneously into the at least two multi-layer devices. For example, the kit may comprise two fluid delivery devices (e.g., as designated at 10 in
As an alternative of the foregoing exemplary aspect, the kits or system can comprise a barrier device 10 such as illustrated in
As a further alternative of the foregoing exemplary aspect, the kits or system can comprise at least two barrier devices which comprise at least three sides which are made of woven or non-woven material (as designated at 10/12 in
Further exemplary embodiments of the present invention involve a system wherein the multi-layer barrier is injected with waterproofing grout fluid using a grout pump, injection fluid components, and catalysts (gel activators). As illustrated in
In a twenty-sixth aspect of the invention, which may be based on any of the foregoing first through twenty-fifth exemplary aspects described above, a multi-layer barrier device 10 further comprise an injection fluid gelation activator (hereinafter “gel activator”) within the device between the first layer and second layer. The gel activator would function to initiate or accelerate gelation, viscosity increase, and/or hardening of the injection fluid material. Locating a gel activator, such as a resin, hardener, catalyst or accelerator, within the open matrix space would avoid the need to use a multicomponent grout system as depicted in
In a twenty-seventh aspect, which can be based on any of the first through twenty-sixth exemplary aspects, barrier devices 10 of the invention may comprise a gel activator located on the open-matrix structure 16 between the first and second layers 12/14. Alternatively, the gel activator may be coated against the film layer 14, the open matrix layer 16 (i.e., the open mesh or nonwoven structure which defines the open cavity between layers 12 and 14), the outer layer 12, or any combination of these. In a preferred exemplary embodiment, the open-matrix structure 16 is a three-dimensional filament structure polyamide matting, having a thickness of 8-25 mm, supplied in roll form, which is attached to the first layer 14 and coated with gel activator, in the manner illustrated in
As illustrated in
Exemplary grout or resin components and gel activators contemplated for use in the invention include, but are not necessarily limited, to acrylics, polyurethanes, epoxies, cementitious and (sodium) silicates, for example, and may employ two components that are mixed before pumping and pumped to the desired area/location where the grout wall curtain is to be established. Thus, one of the components may be located or positioned within the open matrix structure (e.g., ENKA™ brand geotextiles or mats have an open structure and inner surfaces which could be coated with one of the components).
A gelation activator is pre-applied within the open-matrix layer defined between the first and second layers (hereinafter “gel activator”). The gel activator functions as an accelerator, catalyst, hardener, resin and/or curative agent to increase or to initiate gelation (e.g., hardening, stiffening, polymerization) of the injection fluid once it is introduced into the open matrix layer. For example, the injection fluid could be a polyol resin, and the gel activator could be an isocyanate functional resin, to generate a polyurethane grout wall composition within the barrier device.
As another example, the injection fluid could be an isocyanate resin, and the gel activator could be an amine resin, to generate a polyurea grout wall within the barrier device. An amine gel activator or a free radical gel activator could be used for polyacrylate-containing injection fluids. A still further example involves use of an epoxy resin injection fluid and amine resin as gel activator.
As another example, the gel activator for hydratable cementitious injection fluids could be a set accelerator (e.g., calcium nitrite and/or nitrate) to quicken the setting of the cement. As yet another example the injection fluid may comprise a sodium silicate solution and the gel activator may comprise an acid or an alkaline earth salt or an aluminum salt. The gel activator is pre-installed or pre-applied (e.g. coated, sprayed, brushed) into the open-matrix layer structure, such as into a non-woven geotextile mat used for separating the first and second layers of the barrier device. Consequently, a highly flowable injection fluid can be introduced into the barrier device without the need for high-powered, multi-component pump equipment. A simple single-component pump may be used. Upon contact with the gel activator located within the open-matrix layer of an installed barrier device (10), the injection fluid will begin to gel (i.e., to increase in viscosity) and ensure that a grout wall is established against concrete that was cast against the installed barrier (10).
A preferred grout system of the present invention is illustrated in
In a second example option, the injection fluid 24 may comprise Component A (54), Component B (56), and Activator B (57) (again to borrow the numbering from
It is also possible that some portion of the gel activator can be mixed into the injection fluid at a point in the injection conduit system before the injection fluid enters into the open matrix, so as to provide more time for the chemical reaction to occur. Thus, a designer or operator of the system has flexibility in terms of being able to adjust when, where, and how much of the gel activator is introduced to the injection resin, thereby enhancing control over the viscosity or other rheological characteristics of the injection resin composition during the installation process.
In a twenty-eighth aspect, the invention provides a multi-layer barrier device 10 having an impermeable film (14) and nonwoven face (12) and an open-matrix structure (16) defining an open space between layers 12 and 14, as illustrated in
Thus, an exemplary device for post-installation in-situ barrier creation, comprises: a multi-layer fluid delivery device comprising first and second layers defining an intermediate open-matrix layer for an injection fluid; the first layer having an inwardly facing surface and an outwardly facing surface, the first layer being permeable to the injection fluid but at least nearly impermeable to a structural construction material to be applied against the outwardly facing surface of the first layer, and the second layer being water-impermeable and having an inwardly facing first side and an outwardly facing second side, the inwardly facing first side of the second layer being affixed, directly or indirectly to the inwardly facing surface of the first layer such that all or a substantial portion of the second layer is spaced apart from the first layer, using an open-matrix structure to create air space between the first layer and the second layer and thereby defining an open-matrix layer for conducting an injection fluid between said first and second layers; and a gel activator located within the space defined by the open-matrix structure.
In a twenty-ninth aspect, which can be based any of the foregoing first through twenty-eighth exemplary aspects, a barrier device of the invention further comprises tubing for introducing an injection fluid into the device, the tubing being disposed (i) in parallel orientation with respect to the first and second layers, (ii) perpendicularly with respect to the first and second layers, or (iii) in both parallel and perpendicular orientations with respect to the first and second layers.
The invention also provides packages or systems wherein the exemplary barrier devices 10 can be shipped or sold together along with injection fluids that correspond with gel activators contained in the device 10. The use of gel activator located within the cavity of the multi-barrier device, preferably located on the open-matrix structure (26), is particularly advantageous when internal conduit tubing (20) is used for conveying injection fluid into the device, as described in the first through twentieth exemplary aspects, as highly flowable injection fluid can be used, and this would greatly facilitate quick and efficient completion of a grout wall waterproofing project, and ensure that the injection fluid would be able to flow into even the minutest of cracks in the concrete situated against the non-woven face 12 of the barrier device 10.
In a thirtieth aspect of the invention, which may be based on any of the foregoing first through twenty-ninth exemplary aspects, the barrier wall device is connected to a source of positive pressure, negative pressure (e.g., vacuum), or combination of positive pressure and negative pressure sources.
While the foregoing specification sets forth various principles, preferred embodiments, and modes of operation, the present invention is not limited to the particular forms disclosed, since these are illustrative rather than restrictive. Skilled artisans can make variations and changes based on the specification without departing from the spirit of the invention.
| Filing Document | Filing Date | Country | Kind |
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| PCT/US2018/032035 | 5/10/2018 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
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| WO2018/209063 | 11/15/2018 | WO | A |
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