US 5,209,603 A · Secondary containment structure and method of manufacture

Abstract

A secondary containment structure formed of a slurry infiltrated fiber concrete composite is used above ground or underground to enclose material storage containers and to safely contain any materials leaked from the container. The structure is a hollow configuration having a bottom wall, at least one side wall, and a removable top wall. The interior volume of the structure exceeds the volume capacity of the container which is enclosed therein. The bottom wall is sloped to facilitate drainage of any liquid leaked from the container and the top wall may have covered apertures to allow access to the container. The structure is formed of a slurry infiltrated fiber concrete composite which is produced by first placing a plurality of individual short fibers or fiber mats of organic or inorganic materials into a form to create a bed of fibers substantially filling the form and having a predetermined fiber volume density and then adding the slurry mixture into the form to completely infiltrate the spaces between the fibers. The slurry mixture includes a composition of Portland cement, fly ash, water, a high range water reducer (superplasticizer), and may also include fine grain sand, chemical admixtures, and other additives. Due to its fiber volume density and method of manufacture, the resulting secondary containment structure has thinner walls, greater strength, and a gross weight significantly less than conventional reinforced and pre-stressed concrete structures of the same size.

Claims26

Dependent claims

An improved secondary containment structure of the type used in isolating material storage containers and containing materials leaked therefrom, the improved structure comprising;

a fiber concrete composite bottom wall, at least one fiber concrete composite side wall, and a removable top wall defining an interior volume configured to receive and enclose a container of hazardous material and the interior volume exceeding the volume capacity of the hazardous material container, and
said fiber concrete composite bottom wall and said fiber concrete composite side wall each containing a uniform continuous mass of individual interlocked fibers completely infiltrated by and embedded in a cementious matrix mixture of Portland cement, fly ash, water, and a water-reducing superplasticizer and having a fiber volume density in the range of from about 5% to about 20%.

A method for forming slurry infiltrated fiber concrete products comprising the steps of;

(a) providing a form having a bottom and core component with a side wall form component having opposed lateral side walls joined together to form a hollow box construction open at the top and bottom ends,
(b) placing said bottom and core component on a generally flat surface with the core member up,
(c) placing said side wall component on said bottom and core component to enclose its open bottom end and surrounding said core member to form a cavity surrounding said core member,
(d) placing a plurality of fibers selected from organic or inorganic materials into said cavity to form a bed of fibers substantially filling said cavity with spaces between said fibers,
(d) adding a slurry mixture of a concrete composition into the form components to completely infiltrate the spaces between said fibers and fill the cavity surrounding said core member and above said core member,
(e) vibrating the mold components as required sufficient to insure complete infiltration of the slurry into the fiber bed, eliminate voids, and compact the concrete therein,
(f) allowing the uncured concrete product to completely cure and thereafter removing said side wall component from said bottom and core component, and
(g) lifting the cured concrete product from said bottom and core component.

5 more elements

A method of forming a fiber concrete composite secondary containment structure comprising the steps of;

(a) providing a form having a bottom and core component with a side wall form component having opposed lateral side walls joined together to form a hollow box construction open at the top and bottom ends,
(b) placing said bottom and core component on a generally flat surface with the core member up,
(c) placing said side wall component on said bottom and core component to enclose its open bottom end and surrounding said core member to form a cavity surrounding said core member,
(d) placing a mass of fibers selected from the group of materials consisting of steel, plastic, aramids, carbon and boron into said cavity to form a bed of fibers interlocked with one another substantially filling said cavity and having a fiber volume density in the range of from about 5% to about 20% with spaces between said fibers,
(e) after forming the bed of fibers, adding a concrete composition slurry mixture comprising Portland cement, fly ash, water, and a water-reducing plasticizer into the form components to completely infiltrate the spaces between said fibers and fill the cavity surrounding said core member and above said core member,
(f) vibrating the mold components as required sufficient to insure complete infiltration of the slurry into the fiber bed, eliminate voids, and compact the concrete therein,
(g) allowing the uncured secondary containment structure to completely cure and thereafter removing said side wall component from said bottom and core component, and thereafter
(h) removing the cured secondary containment structure from said bottom and core component.

5 more elements

Dependencies are inferred from the claim text.

Secondary containment structure and method of manufacture

Life of this patent

Secondary containment structure and method of manufacture

Life of this patent

Abstract

Claims26