The present disclosure relates generally to a backstop for flowable sealant and, more particularly, to a mortar collar adapted to facilitating installation and/or repairs of storm or wastewater sewers.
Sewer systems generally consist of infrastructure that conveys sewage or surface runoff (stormwater, melt, etc.) to collection/treatment facilities. Sewer systems (or more generally, “sewers”) incorporate collection points tied to conduit arranged to convey the sewage or surface runoff. The conduit may be arranged to convey its contents under a gravity flow and the sewer system may also incorporate one or more pumping stations to facilitate the operative flow. The conduit of a sewer system may by formed by polyvinyl chloride (PVC), concrete or vitrified clay pipe (VCP), for example. The conduit system of a sewer system comprises a number of conduit segments in fluid communication with, e.g., a number of basins serving a variety of purposes. For example, catch basins can be used as a collection point for runoff in a storm sewer (such catch basins being fluidly connected, e.g., to a street gutter). Catch basins also function to retain matter that would not be able to pass easily through the remainder of the sewer system. Basins in a sewer system may also serve to connect a number of inlet conduits to an one or more outlet conduits. Such basins are accessible through manholes and are often colloquially referred to simply as “manholes.”
At connection points between elements of a sewer system, it is important to prevent exfiltration of the contents conveyed by the sewer system to the surrounding environment. It is also important to the health of a sewer system to prevent infiltration of foreign objects such as soil. To prevent these deleterious effects, conduits are sealed to basins in sewer systems.
Components of a sewer system can become compromised by the ingrowth of roots, shifting of one buried component relative to another, or for a variety of alternative reasons. When repairing a sewer system or at initial installation, conduits are sealed to other structures, e.g., basins. The basins can be made of concrete, plastic or other materials. Without regard to the material of the basin, the procedure for sealing a conduit therewith is the same. A hole is cut through the basin having a size larger than the conduit to be connected to the basin. This allows for flexibility in the positioning of the conduit relative to the basin, which is an inexact procedure subject to influence by the surrounding excavation.
In an initial installation, the components of the system, e.g., a conduit and basin are set in the earth, with the conduit extending from an exterior of the basin to an interior of the basin. Owing to the inexactness and potential irregularities of the excavation into which the components are sunk, the conduit may extend more or less than initially thought into the basin. In a repair situation, the old and perhaps failed sealant will be removed and perhaps the hole through the basin through which the conduit extends enlarged as part of the repair.
In the past, flowable sealant in the form of mortar, grout, or concrete would be packed into the gaps between the conduit and the wall of the basin in which the aperture through which the conduit is positioned resides and could possibly be forced from its sealing position before becoming cured or non-flowable. For example, if the excavation was backfilled prior to curing of the flowable sealant, then the backfill could force the flowable sealant into the basin and out of the gap between the basin wall and the conduit.
The present disclosure provides a mortar collar positionable to contain and protect a flowable sealant during curing thereof.
In an exemplification thereof, the present disclosure provides a mortar collar for protecting a flowable sealant positioned between a wall having an aperture through which a conduit is positioned, the mortar collar comprising: a conduit clamp having a wall having a height spanning a first end and a second end of the wall, the wall of the conduit clamp positionable in a clamp configuration, in the clamp configuration an interior surface of the wall of the conduit clamp having a shape corresponding to a perimeter shape of a perimeter of the conduit, such that the wall is sealable against the conduit, in the clamp configuration, and with the conduit clamp is positioned about the perimeter of the conduit, the interior surface of the wall of the conduit clamp abutting a perimeter of the conduit; and a flange extending outwardly from an exterior surface of the wall of the conduit clamp at the first end of the wall, the flange sized to cover the aperture in the wall through which the conduit is positioned when the conduit clamp is positioned about the perimeter of the conduit.
In embodiments thereof, the mortar collar defines a continuous longitudinal slit through the wall of the conduit clamp and the flange, the mortar collar openable along the slit to be positionable over the perimeter of the conduit in a direction orthogonal to a longitudinal axis of the conduit. In certain embodiments, the perimeter comprises a circumference, as the conduit is cylindrical.
In additional embodiments thereof, the wall is a basin wall and the conduit is in fluid communication with an interior of the basin, the wall defining a wall radius of curvature in a plane perpendicular to a longitudinal axis of the basin, wherein the flange defines a flange radius of curvature mating with the wall radius of curvature, whereby, with the flange positioned atop the wall, the flange abuts the wall.
In further embodiments thereof, in the clamp configuration an interior surface of the wall of the conduit clamp substantially defines a cylinder.
In yet additional embodiments thereof, the conduit clamp further comprises a band clamp positionable over the wall of the conduit clamp and tightenable thereabout to secure the conduit clamp to the conduit.
In another exemplification thereof, the present disclosure provides a method of sealing a conduit within an aperture in a wall, comprising: positioning the conduit through the aperture in the wall; affixing a mortar collar about a periphery of the conduit and covering the aperture in the wall, the affixing step performed subsequent to the step of positioning the conduit through the aperture in the wall, the affixing step positioning the mortar collar to cover the aperture; and positioning a flowable sealant between the wall and the conduit in the aperture in the wall, the mortar collar covering the sealant on a first side of the wall.
In embodiments thereof, the method further comprises cutting the wall to create the aperture prior to the step of positioning the conduit through the aperture in the wall.
In additional embodiments thereof, the mortar collar comprises: a conduit clamp having a wall having a height spanning a first end and a second end of the wall, the wall of the conduit clamp positioned in the affixing step in sealing relationship with the conduit.
In further embodiments thereof, the mortar collar defines a continuous longitudinal slit through the wall of the conduit clamp, the affixing step comprising: opening the mortar collar along the slit; and positioning the conduit through the opened slit of the mortar collar.
In yet additional embodiments thereof, the step of positioning the conduit through the opened slit of the mortar collar comprises: moving the mortar collar orthogonal to a longitudinal axis of the conduit.
In yet further embodiments thereof, the mortar collar comprises: a flange extending outwardly from an exterior surface of the wall of the conduit clamp at a first end of the wall, the flange covering the aperture in the wall and abutting the wall about the aperture as a result of the affixing step.
In further additional embodiments thereof, the mortar collar comprises: a conduit clamp having a wall having a height spanning a first end and a second end of the wall, the wall of the conduit clamp positioned in the affixing step in sealing relationship with the conduit; and a flange extending outwardly from an exterior surface of the wall of the conduit clamp at a first end of the wall, the flange covering the aperture in the wall and abutting the wall about the aperture as a result of the affixing step.
In yet further additional embodiments thereof, the mortar collar defines a continuous longitudinal slit through the wall of the conduit clamp and the flange, the affixing step comprising: opening the mortar collar along the slit; and positioning the conduit through the opened slit of the mortar collar.
In still additional embodiments thereof, the step of positioning the conduit through the opened slit of the mortar collar comprises: moving the mortar collar orthogonal to a longitudinal axis of the conduit.
In still further embodiments thereof, the wall forms a part of a basin having an interior, and wherein the step of positioning the conduit through the aperture in the wall comprises positioning an end of the conduit in fluid communication with the interior of the basin.
In additional embodiments thereof, the step of affixing a mortar collar about a periphery of the conduit and covering the aperture in the wall comprises positioning the mortar collar within the interior of the basin.
In further embodiments thereof, the step of affixing a mortar collar about a periphery of the conduit and covering the aperture in the wall comprises positioning the mortar collar exterior of the basin.
In yet additional embodiments thereof, the method further comprises: affixing a second mortar collar about the periphery of the conduit and covering the aperture in the wall, the step of affixing a second mortar collar performed subsequent to the step of positioning the conduit through the aperture in the wall, the step of affixing a second mortar collar positioning the second mortar collar to cover the aperture.
The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates an exemplary embodiment of the invention and such exemplification is not to be construed as limiting the scope of the invention in any manner.
The embodiments disclosed below are not intended to be exhaustive or limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings.
When creating the assemblies illustrated in
In a new installation, an aperture is cut in the basin to allow connection of a conduit.
With aperture 33 formed in wall 30 of manhole 22, conduit 20 can be positioned therethrough as shown in
Mortar collar 34 of the present disclosure protects the sealant during the curing process by shielding the sealant during curing. Mortar collar 34 is illustrated in detail in
Mortar collar 34 features continuous longitudinal slit 42 (
Slit 42 allows mortar collar 34 to be operably positioned about conduit 20 and relative to a basin such as manhole 22 without requiring exacting arrangement of conduit 20 and manhole 22, as mortar collar 34 can be positioned along the length of conduit 20 at whatever location is desired, as will become further apparent based on the description below. Mortar collar 34 does not present an impediment to assembly of conduit 20 with manhole 22, as mortar collar 34 can be operably positioned after insertion of conduit 20 through aperture 33 (
With opening 48 sized larger than the diameter of conduit 20, mortar collar 34 can be radially (relative to longitudinal axis 40 shown in
With riser 36 and flange 38 positioned in the clamp configuration, as described above, mortar collar 34 is secured in position as shown in
When operatively positioning mortar collar 34 as described above, ends 44, 46 can overlap as illustrated, e.g., in
Flange 38 is configured to have a geometry corresponding to the geometry of the wall of the basin against which it will bear in the operative position. For example, flange 38 can be curved to match the curvature of a curved wall of manhole 22, as shown in
Referring to
Mortar collar 34 can be designed as a single use item. In such a configuration, it can be left in place after use, allowing the backfill process to begin prior to curing of sealant 52. Without mortar collar 34, backfilling prior to curing of sealant 52 could cause a blowout of sealant 52 by the pressure of the backfill.
The process of utilizing mortar collar 34 described above with respect to
Mortar collar 34 can be made in a number of different sizes corresponding to the components of the desired sewer system. Mortar collar 34 will, in certain embodiments thereof, be constructed of plastic. In embodiments made of plastic, the material will be sized to provide a living hinge 180 degrees opposite ends 44, 46 (measured about riser 36) to allow positioning of mortar collar about conduit 22, as described above. Alternative materials of construction for mortar collar 34 include rubber, lightweight steel, and aluminum. Depending on the rigidity of these alternative materials of construction, the aforementioned living hinge may be replaced with an actual hinge. Flange 38 will be sufficiently rigid to prevent flowable sealant 52 from escaping from between flange 38 and manhole 22 during installation of flowable sealant 52. In the event that flange 38 is nominally planar, mortar collar 34 could be sized to accommodate the largest expected construct and simply trimmed to size, as needed.