Method for constructing a plastic lined concrete structure and structure built thereby

Abstract

A method for constructing a plastic lined concrete tank includes the forming of a plurality of plastic lined concrete panels. Each of the panels is made up of a concrete slab and a plastic sheet. The concrete slabs have opposed, laterally spaced, elongated edges and an inner surface and the plastic sheet each have a plurality of anchoring projections protruding outwardly from a face thereof. The panels are formed in such a way that the face of each plastic sheet is engaged against the surface of a corresponding concrete slab with the anchoring projections embedded in the concrete of said corresponding slab. The plastic sheets are arranged, configured and positioned such that a respective edge flap portion thereof projects outwardly beyond each edge of the corresponding slab and each such edge flap portion has an outboard segment. The panels are preferably constructed flat on the ground and then erected into a standing position and arranged in adjacent, aligned positions around a periphery of a tank foundation with the inner surfaces of the slabs facing inwardly, with the elongated edges of the slabs extending upwardly, with the respective elongated edges of each slab disposed in opposing spaced relationship relative to the elongated edges of adjacent slabs to thereby present elongated gaps therebetween, with the plastic sheets disposed within the tank periphery, and with the outboard segments of the edge flap portions of each sheet overlapping the outboard segments of the edge flap portions of the sheets of adjacent panels at said gap. The overlapping outboard segments are then welded together.

1 . A method for constructing a plastic lined concrete structure comprising: 
 forming first and second plastic lined concrete panels, each panel including a concrete slab having an elongated edge and a surface, and a plastic sheet having a plurality of anchoring projections protruding outwardly from a face thereof, said forming being conducted in such a way that said face of each plastic sheet is engaged against the surface of a corresponding concrete slab and said anchoring projections are embedded in the concrete of the corresponding slab, said plastic sheets each being arranged and positioned such that an edge flap portion thereof projects outwardly beyond the edge of the corresponding slab;    causing said panels to be arranged in adjacent, aligned positions with the elongated edge of the concrete slab of the first panel disposed in opposing spaced relationship relative to the elongated edge of the concrete slab of the second panel to thereby present an elongated gap between the edges, and with an outboard segment of the edge flap portion of the plastic sheet of the first panel overlapping an outboard segment of the edge flap portion of the plastic sheet of the second panel at said gap; and    welding said overlapping segments together.    
   
   
       2 . A method as set forth in  claim 1 , wherein a wedge welder is used for welding said overlapping segments together.  
   
   
       3 . A method as set forth in  claim 2 , wherein a main body portion of said welder is located on an opposite side of the plastic sheets from the concrete slabs during said welding.  
   
   
       4 . A method as set forth in  claim 1 , wherein said edges are coextensive in length and said edge flap portions project outwardly beyond the edges along essentially the entire length thereof.  
   
   
       5 . A method as set forth in  claim 1 , wherein said panels are initially formed with said edges thereof disposed to extend in an essentially horizontal direction, and said causing includes erecting said panels so that the edges extend in an essentially upright direction.  
   
   
       6 . A method as set forth in  claim 3 , wherein a second portion of said wedge welder is positioned within said gap between said edges during said welding.  
   
   
       7 . A method as set forth in  claim 1  comprising filling said gap with a grouting material after said welding has been completed.  
   
   
       8 . A method as set forth in  claim 2 , wherein said panels are initially formed with said edges thereof disposed to extend in an essentially horizontal direction, and said causing includes erecting said panels so that the edges extend in an essentially upright direction.  
   
   
       9 . A method as set forth in  claim 8 , wherein said welding is accomplished by causing said welder to move upwardly along said overlapping segments.  
   
   
       10 . A method for constructing a plastic lined concrete structure comprising: 
 providing first and second plastic sheets, each sheet having a face and a plurality of anchoring projections protruding outwardly from said face;    forming a first plastic lined concrete panel by causing a first quantity of wet cementitious material to come into contact with and cover a portion of said face of the first plastic sheet, permitting the first quantity of cementitious material to set in the form of a first solid concrete slab having the anchoring projections of the first plastic sheet embedded therein, said concrete slab having an elongated edge, and arranging said first plastic sheet and said first quantity of wet cementitious material relative to one another such that an edge flap portion of the first plastic sheet projects outwardly beyond said edge of the first slab after the cementitious material has become set;    forming a second plastic lined concrete panel by causing a second quantity of wet cementitious material to come into contact with and cover a portion of said face of the second plastic sheet, permitting the second quantity of cementitious material to set in the form of a second solid concrete slab having the anchoring projections of the second plastic sheet embedded therein, said concrete slab having an elongated edge, and arranging said second plastic sheet and said second quantity of wet cementitious material relative to one another such that an edge flap portion of the second plastic sheet projects outwardly beyond said edge of the second slab after the cementitious material has become set;    causing said panels to be arranged in adjacent, aligned positions with the elongated edge of the first concrete slab disposed in opposing spaced relationship relative to the elongated edge of the second concrete slab to thereby present an elongated gap between the edges, and with an outboard segment of the edge flap portion of the plastic sheet of the first panel overlapping an outboard segment of the edge flap portion of the plastic sheet of the second panel at said gap; and    welding said overlapping outboard segments together.    
   
   
       11 . A method as set forth in  claim 10 , wherein a wedge welder is used for welding said overlapping segments together.  
   
   
       12 . A method as set forth in  claim 11 , wherein a main body portion of said welder is located on an opposite side of the plastic sheets from the concrete slabs during said welding.  
   
   
       13 . A method as set forth in  claim 10 , wherein said edges are coextensive in length and said edge flap portions project outwardly beyond the edges along essentially the entire length thereof.  
   
   
       14 . A method as set forth in  claim 10 , wherein said panels are initially formed with said edges thereof disposed to extend in an essentially horizontal direction, and said causing includes erecting said panels so that the edges extend in an essentially upright direction.  
   
   
       15 . A method as set forth in  claim 12 , wherein a second portion of said wedge welder is positioned within said gap between said edges during said welding.  
   
   
       16 . A method as set forth in  claim 10  comprising filling said gap with a grouting material after said welding has been completed.  
   
   
       17 . A method as set forth in  claim 11 , wherein said panels are initially formed with said edges thereof disposed to extend in an essentially horizontal direction, and said causing includes erecting said panels so that the edges extend in an essentially upright direction.  
   
   
       18 . A method as set forth in  claim 17 , wherein said welding is accomplished by causing said welder to move upwardly along said overlapping segments.  
   
   
       19 . A method for constructing a plastic lined concrete tank comprising: 
 forming a plurality of plastic lined concrete panels, each panel including a concrete slab having opposed, laterally spaced, elongated edges and an inner surface, and a plastic sheet having a plurality of anchoring projections protruding outwardly from a face thereof, said forming being conducted in such a way that said face of each plastic sheet is engaged against the surface of a corresponding concrete slab with said anchoring projections embedded in the concrete of said corresponding slab, said plastic sheets each being arranged, configured and positioned such that a respective edge flap portion thereof projects outwardly beyond each edge of the corresponding slab, each said edge flap portion having an outboard segment;    causing said panels to be arranged in adjacent, aligned positions around a periphery of a tank foundation with the inner surfaces of the slabs facing inwardly, with the elongated edges of the slabs extending upwardly, with the respective elongated edges of each slab disposed in opposing spaced relationship relative to the elongated edges of adjacent slabs to thereby present elongated gaps therebetween, with the plastic sheets disposed within said periphery, and with the outboard segments of the edge flap portions of each sheet overlapping the outboard segments of the edge flap portions of the sheets of adjacent panels at said gap; and    welding said overlapping outboard segments together.    
   
   
       20 . A method as set forth in  claim 19 , wherein a wedge welder is used for welding said overlapping segments together.  
   
   
       21 . A method as set forth in  claim 20 , wherein a main body portion of said welder is located on an opposite side of the plastic sheets from the concrete slabs during said welding.  
   
   
       22 . A method as set forth in  claim 19 , wherein said panels are initially formed with said elongated edges extending in a generally horizontal direction and said causing includes erecting the panels so that said elongated edges extend in an upright direction.  
   
   
       23 . A method as set forth in  claim 19 , wherein said placing includes positioning said elongated edges in a generally parallel relationship on opposite sides of said gap.  
   
   
       24 . A method as set forth in  claim 19 , wherein said forming includes applying a respective quantity of a wet cementitious material to a portion of the face of each of said sheets, and thereafter allowing the respective quantities of cementitious material to set with said anchoring projections submerged therein.  
   
   
       25 . A method as set forth in  claim 19  comprising filling said gaps with a grouting material after said welding has been completed.  
   
   
       26 . A method as set forth in  claim 21 , wherein a second portion of said wedge welder is positioned within said gap between said edges during said welding.  
   
   
       27 . A method as set forth in  claim 20 , wherein said panels are initially formed with said elongated edges extending in a generally horizontal direction and said causing includes erecting the panels so that said elongated edges extend in an upright direction.  
   
   
       28 . A method as set forth in  claim 27 , wherein said welding is accomplished by causing said welder to move upwardly along said overlapping segments.  
   
   
       29 . A method as set forth in  claim 6 , wherein said panels are initially formed with said edges thereof disposed to extend in an essentially horizontal direction, and said causing includes erecting said panels so that the edges extend in an essentially upright direction.  
   
   
       30 . A method as set forth in  claim 29 , wherein said welding is accomplished by causing said welder to move upwardly along said overlapping segments.  
   
   
       31 . A method as set forth in  claim 15 , wherein said panels are initially formed with said edges thereof disposed to extend in an essentially horizontal direction, and said causing includes erecting said panels so that the edges extend in an essentially upright direction.  
   
   
       32 . A method as set forth in  claim 31 , wherein said welding is accomplished by causing said welder to move upwardly along said overlapping segments.  
   
   
       33 . A method as set forth in  claim 26 , wherein said panels are initially formed with said elongated edges extending in a generally horizontal direction and said causing includes erecting the panels so that said elongated edges extend in an upright direction.  
   
   
       34 . A method as set forth in  claim 33 , wherein said welding is accomplished by causing said welder to move upwardly along said overlapping segments.  
   
   
       35 . A plastic lined concrete structure built using the method of  claim 1 .  
   
   
       36 . A plastic lined concrete structure built using the method of  claim 30 .  
   
   
       37 . A plastic lined concrete structure built using the method of  claim 10 .  
   
   
       38 . A plastic lined concrete structure built using the method of  claim 32 .  
   
   
       39 . A plastic lined concrete tank built using the method of  claim 19 .  
   
   
       40 . A plastic lined concrete tank built using the method of  claim 34 .  
   
   
       41 . A method as set forth in  claim 1 , wherein the edge flap portion of the plastic sheet of the second panel has at least one anchoring projection which projects into said gap after the overlapping segments have been welded together.  
   
   
       42 . A method as set forth in  claim 41  comprising filling said gap with a grouting material after said welding has been completed.  
   
   
       43 . A method as set forth in  claim 10 , wherein the edge flap portion of the plastic sheet of the second panel has at least one anchoring projection which projects into said gap after the overlapping segments have been welded together.  
   
   
       44 . A method as set forth in  claim 43  comprising filling said gap with a grouting material after said welding has been completed.  
   
   
       45 . A method as set forth in  claim 19 , wherein the edge flap portions of the plastic sheets of said adjacent panels each has at least one anchoring projection which projects into said gap after the overlapping segments have been welded together.  
   
   
       46 . A method as set forth in  claim 45  comprising filling said gap with a grouting material after said welding has been completed.  
   
   
       47 . A method as set forth in  claim 1 , wherein said plastic sheets have a thickness ranging from about 0.05 mm to about 7 mm.  
   
   
       48 . A method as set forth in  claim 1 , where in said sheets are formed from either a high density polyethylene or a linear low density polyethylene.  
   
   
       49 . A method as set forth in  claim 47 , where in said sheets are formed from either a high density polyethylene or a linear low density polyethylene.  
   
   
       50 . A method as set forth in  claim 1 , wherein the anchoring projections are in the form of elongated, T-shaped ribs.  
   
   
       51 . A method as set forth in  claim 10 , wherein said plastic sheets have a thickness ranging from about 0.05 mm to about 7 mm.  
   
   
       52 . A method as set forth in  claim 10 , where in said sheets are formed from either a high density polyethylene or a linear low density polyethylene.  
   
   
       53 . A method as set forth in  claim 51 , where in said sheets are formed from either a high density polyethylene or a linear low density polyethylene.  
   
   
       54 . A method as set forth in  claim 10 , wherein the anchoring projections are in the form of elongated, T-shaped ribs.  
   
   
       55 . A method as set forth in  claim 19 , wherein said plastic sheets have a thickness ranging from about 0.05 mm to about 7 mm.  
   
   
       56 . A method as set forth in  claim 19 , where in said sheets are formed from either a high density polyethylene or a linear low density polyethylene.  
   
   
       57 . A method as set forth in  claim 55 , where in said sheets are formed from either a high density polyethylene or a linear low density polyethylene.  
   
   
       58 . A method as set forth in  claim 19 , wherein the anchoring projections are in the form of elongated, T-shaped ribs.  
   
   
       59 . A method as set forth in  claim 1 , wherein said causing includes forming said panels in situ.  
   
   
       60 . A method as set forth in  claim 10 , wherein said causing includes forming said panels in situ.  
   
   
       61 . A method as set forth in  claim 19 , wherein said causing includes forming said panels in situ.  
   
   
       62 . A method as set forth in  claim 8 , wherein said welding is accomplished by causing said welder to move upwardly along said overlapping segments.  
   
   
       63 . A method as set forth in  claim 17 , wherein said welding is accomplished by causing said welder to move upwardly along said overlapping segments.  
   
   
       64 . A method as set forth in  claim 29 , wherein said welding is accomplished by causing said welder to move upwardly along said overlapping segments.