Note: Descriptions are shown in the official language in which they were submitted.
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BACKGROUND OF r~'ElE INVENTION:
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This invention is directed to a system for plugging
holes, and in particular to s~ealing with an impermeable plug the
rod holes extending through from face to face of poured concrete
walls, using a range of materials so as to encompass continental
climatic extremes and variations.
PRIOR ART SYSTEMS AND ENVIRONMENTAL REQUIREMENTS: ,¦
-In the residential construction~field in the United
States and Canada, widespread use is made of poured concrete for
foundations,~ more particularly for below grade basement walls of
houses and other residential buildings.
Shuttering or-other forms are erected, within which the
-concrete is to be poured, the shuttering being secured in spaced
relation by steel tension rods, secured by wedging at the outside
of the shuttering. When the concrete is placed, and sets up, the
rods and shuttering are removed, leaving a concrete wall having a
large number of side to side rod hole penetrations extending
therethrough. The rod holes are plugged, usually externally, at
the outside wall surface, and the wall may be parged to
waterproof it, and the excavation is then back filled with soil.
In these conditions water can accumulate, and in the
absence of effective rod hole seals, signiEicant water seepage,
and even flooding can ensue. It is even know to experience the
occurrence of hydrostatic pressure build-up sufficient to drive a
sealing cork through the rod hole, leaving the unprotected hole
as a drain passage into the basement, with consequent flooding.
Recti-fication of this type of occurrence, particularly subsequent -
to backfilling, is extremely costly.
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Prior art solutions are set forth in United States
Patents Nos: 3,390,~98, ROY et al, issued July 2, 1968; 3,889,436
ELLIOT, issued June 17, 1975; 4,016,696, MESS et al, issued April
- 12, 1977.
ROY e-t al provides an oversize wedge shaped plug o~
polyethylene! having serrated surfaces, which is driven into the
two ends of the rod hole at the time of striking the formwork.
ELLIOT shows the use of a precast portland cement plug,
cemented into the rod holes.
10 MESS et al teaches a system having an elastromeric plug
containing a closed bore into which a placement tool is inserted
to elongate and diametrically contract the plug as it is driven
into place In the rod hole. Upon withdrawal of the placement
tool, the plug contacts axially and expands diametrically to grip
the walls of the rod hole.
It is noteworthy that these patents are all well
established in time, and yet the problem persists. It can only be
inferred that, for whatever reason, these prior art systems are
ineffective.
In accordance with the present invention there is
~ provided a climatically compatible, low cost, rod hole sealing
; system incorporating a compressible oversize plug selected from
natural fibre or synthetic foam material in combination with a
suitable curing liquid resin material. The liquid resin is
usually an epoxy material having a resin selected from a number
of suitable resins, and reacted with an amine hardener; but it
may also be a high solids polyisocyanate prepolymer, suitably
modified with surfactants and catalysts so as to harden to a
polyurethane polymer in the presence of moisture. Any of the
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liquid resins used should harden or set up in a period of a few
minutes to several hours -- usually 30 minutes to 4 hours.
The compressible oversize plug is selected from a
natural fibre such as jute or hemp, or from synthetic foam
material in the form of a rod or rope of open cell or closed cell
polyurethane, polyethylene or polystyrene. As to the resin, the
functional requirements of the material are: it must be able to
set up and remain effective in the presence of water, and it must
be compatible with and bondable to the plug material and to
]o concrete. The hardener for a two part resin system, in
particular, requires to be selectively climatically compatible
with the extremes of temperature experienced in a continental
climate, and to have sufficient time before set-up to permit the
- preparation of a batch of plugs with the resin, and their
insertion into the rod ho]es. At the same time it is economically
imperative that the unset resin shall have an adequate pot life.
Thus, it is desireable to specify a "summer" hardener or curing
agent, and a "winter" hardener or curing agent.
It has been found that soaking the entire plug in the
liquid resin achieves consistent sealing results, to the extent
that under tests carried out with the subject plugs no occurrence
of subsequent plug failure has yet taken place.
It will be noted that the selection of closed cell foam
as the plug material permits a saving in the quantity of liquid
25 resin absorbed by the plug, as compared with the open-cell plug,
while achieving satisfactory sealing results.
In accordance with a preferred embodiment of the present
invention, a system for plugging holes in concrete with water
resistant plugs is provided which incorporates the use of
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diametrically oversized plugs selected from a natural fibre or
;synthetic foam, providing a liquid resin material which possesses
su~icient setting time under existing ambient temperature
conditions to utilize a plurality of plugs with a batch of the
liquid resin adhesive, soaking the plurality of plugs by total
imrnersion in the liquid resin rnaterial, and inserting the plugs
individually within the holes to be sealed. Once inserted, the
liquid resin will cure and harden, whereupon the plugs will each
be adhesively or interstitially secured in place.
The invention is practised by use of a kit comprising a
plurality of oversize plugs of predetermined diameter selected
from -a natural fibre group comprising jute and hemp, or a
- - synthetic foam selected from the group comprising closed cell or
open cell polyurethane, polyethylene and polystyrene; and a
s~itable liquid resin material, which may be a high solids
polyisocyanate prepolymer which will harden to a polyurethane
polymer in the presence of water, or a two part epoxy adhesive
comprising a first component liquid selected from a group having
an epoxide equivalent weight in the range 182 to 190, and a
separately pa-ckaged hardener selected in accordance with seasonal
setting requirements frorn the group comprising polyamines,
aliphatic amines, aliphatic amine adducts, aromatic amines,
cycloaliphatic amines, phenol formaldehyde adducts, amido amines,
polyoxypropylene amines and polyamides.
In general, the present invention contemplates that
sealing plugs be inserted only into the inner (inside) ends of
all rod holes that are left in a poured concrete foundation wall.
There is little or no need to place the plugs of the~ present
invention in the outer ends of the rod holes -- which, however,
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may be closed in the usual manner by driving cork plugs into them
so as to preclude gross water infiltration flow, or the entr~ of
soil or other materials into the rod holes during back filling of
the excavation at the exterior side of the foundation walls. It
is sufficient to plug the inner ends of the rod holes in the
manner provided by the present invention, to preclude water
seepage o~ any sort through the rod holes.from the exterior side
of the wall to the interior.
Thus, the present inven:tion provides for the
combination of a concrete wall having a plurality of penetrating
holes of predetermined size extending through the thickness
- thereof, and a plug inserted within each of the holes in secured
adherent sealing relation with the walls of the holes, the plug
comprising an initially oversized compliant material selected
from the group oE natural fibres comprising jute and hemp or and
the group of synthetic foams comprising open cell or closed cell
polyurethane polyethylene, or polystyrene; and being sealed in
adherent relation to the wall of the hole by either a high solids
polyisocyanate prepolymer which will harden to a polyurethane
polymer in the presence of moisture (water), or a two part epoxy
adhesive comprising an admixture of a first liquid component
selected from the group of epoxy resins having an ~epoxide
equivalent weight in the range of 182 to 190 and a compatible
liquid hardener possessing suitable seasonal time setting
requirements selected from the gro~up comprising polyamines,
aliphatic amines, aliphatic amine adducts, aromatic amines,
cycloaliphatic amines, phenol formaldehyde adducts, amido amines,
polyoxypropylene amines and polyamides.
In carrying out the invention, the subject plug is
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inserted within the rod hole, usually so as to be a slight
distance below the surrounding wall surface, between one eighth
inch and one quarter inch being the recommended depth of recess.
While not forming part of the present invention, it has been
found that a surface rendering to cover the hole and piug
provides a greatly enhanced appearance.
~ The sur~ace rendering is preferably of a thick, non-sag
epoxy topping compound tha-t is compatible with the epoxy materlal
which coats the plug.
The usual manner of carrying out the invention is to
manually place the plugs in the interior (i.e., inside) ends of
the rod holes that are left in the formed concrete walls aftee
the shuttering has been removed. The plugs may be placed
immediately a~ter the shuttering is removed; however, it is more
usual to wait until the concrete has at least a 48 hour to 7 day
set, and it is most usual to place the plugs after the concrete
basement floor has been poured and set -- usually well on in the
construction of the house or building. The plugs may, of course,
be put in place by a mechanical means, such as a piston or air-
operated gun that inserts the resin-soaked plugs into the rod
hole.
BRIEF DESCRIPTION OF THE DRAWINGS:
Certain embodiments of the present invention are
described, reference being made to the accompanying drawings,
wherein;
Figure l is a transverse section through a portion of a
concrete wall having a rod hole therethrough, showing the subject
plug installed therein; and
Figure 2 is a general view of the plug.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS:
Referring first to the drawings, portions of a wall 10
having a rod hole 1-2 extending therethrough are shown. The rod
hole 12 is provided with an outer plug 14 adjacent the wall outer
surface 16, and an inner plug 18 located in recessed relation
from the wall inner surface 20. A surface patch 22 of epoxy
-topping compound is illustrated, although it does not form a part
of the present invention.
~s mentioned, the outer plug may be -- and usually is --
the standard cork plug that is used in such structures forclosiny the outer end of the rod hole.
- I'he subject plug 18 is of suitable material as specifled
above, having a length of about one inch, and a diameter slightly
greater than the diameter of the rod hole 12, so as to compress
the resin soaked plug 18 when it is inserted under manual
pressure (or otherwise, as discussed hereafter) into the rod hole
12. The elastic memory of the plug material tends to restore its
diameter, holding the resin soaked peripheral surface 19 of the
plug 18 in intimate bonding contact against the wall portion 13,
which the plug 18 overlies. There may also be an interstitial
bonding, by which the hardened resin physically intrudes into
interstices or other irregularities in the bore of the rod hole,
and thereby creates a mechanical linking as well as an adhesive
bonding.
- It has been found that a permanent bond is formed by the
subject system between plug 18 and surface 13 of hole 12.
It should also be noted that the system, and method, of
the present invention may be automated; it being only necessary
that the plug be at least somewhat diametrically compressed prior
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to being placed in the rod hole, and that the placement be
carried out before the resin sets up and hardens.
The usually employed two part epoxy adhesive comprises a
number of variants, which may conveniently be selected from
compatible resins, diluents and hardeners listed below, together
with their commercial sources.
It will be understood that the season of year in which
the plugs are to be installed will affect the ehoice o~ a rapid i!
eure hardener agent, or a slower curing hardener agent.
Suitable liquid resins whieh are the two part epoxy
materials used in this inven-tion, are produced by reacting epoxy
resins with amine hardeners.
Typieally the epoxy resin liquid has an epoxide-
equivalent weight in the range 182 to 190 such as DER 331
supplied by Dow Chemical Company, Midland, Miehigan, 48640,
U.S.A. Variations of this resin sueh as DER 317, 330, 332 or 337
may also be used.
The resins described above may also be diluted with
reactive diluents such as the following:
Butyl Glyeidyl Ether
Cresyl Glycidyl Ether
Phenyl Glycidyl Ether
p-tert.-Butyl Phenyl Glycidyl Ether
2-Ethylhexyl Glycidyl Ether
C8 ~ C10 Alkyl Glycidyl Ether
C12- C 14Alkyl Glycidyl Ether
Di Functional Glyeidyl Ethers
Diglyci~yl Ether of 1.4 Butanediol
Diglycidyl Ether of Neopentyl Glyeol.
Diglyeidyl Ether of Cyclohexane-Dimethanol
Diglyeidyl Ether of Resorcinol
Tri Functional Glyeidyl Ether
Triglycidyl Ether of Aliphatic Polyols such as WC-84 as
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supplied by Wilmington Chemical Corporation, Pyles Lane,
Wilmington, Delaware, ~.S ~An 198S9.
Epoxy modified with urethanes such as WC-8598,
Wilmington Chemical, P.O. Box 66, Pyles Lane, Wilmington,
Delaware, 19899, U.S.A.
- Epox~ modified with synthetic buatadiene acrylonitrile
such as WC-8005, WC-8006 and WC 8028, Wilmington, Chemical.
Other addi-tive material such as phenols, nonyl phenol,
oils, etc. may also be added to modify the epoxy resinO The epoxy
resins described above are all based on bisphenol-A as a
principal reactant. They may also be based on bisphenol-F as a
principal reactant, e.g.,- DER 351 and 352 (Dow Chemicals). Other
modified epoxy resins such as the Polysulphides may also be used
as the epoxy resin for the purpose of this invention, e.g., Dion
15 3.800 as supplied by Diamond Sharnrock, 350 Mt. Kimble, Moristown,
New Jersey, 07960, U.S.A.
Many hardeners of the amine type may be used as
crosslinking agents for the epoxy resins described above. These
fall into, but are not limited to, the following categories:
Those promoting a preferred rapid cure~ such as:
Polyamines: Such as Aliphatic Amines, Aromatic amines or
Cylcloaliphatic Amines;
Aliphatic Amines e.g., Diethylenetriamine (DETA)
Triethylenetetramine (TETA);
Aliphatic Amine Adducts: Formed by reacting excess
quantities of aliphatic amines with epoxy containing materials;
Aromatic Amines, e.g. Anacamine LO and Ancamine LOS from
Pacific Anchor Chemical Corp. 6055 East Washington Blvd., Suite
700, Los Angeles, CA 90040 U.S.A., e.g., Hardener850 and Hardener
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830 from Ciba-Geigy Corporation, Ardsley, New York, 10502,
U.S.A.;
Cycloaliphatic Amines e.g. Ancamine MCA and Ancamine
1561 from Pacific Anchor; or
Phenol Formaldeh~de Adducts e.g., -Versamine F-20 from
~lenkel Corporation, 7900 West 78th Street, Minneapolis, MN 55435,
U.S.A.
Those that modify the curing time, as slower curing ~!
hardeners, such as:
-10 Amido Amines, Pol~oxyprop~lene amines and Polyamides.
Amido Amines eg., Ancamide 500 and Ancamide 501 from
Pacific Anchor;
Polyoxypropyleneamines, e.g., Jeffamine D230 and
Jeffamine D200 from Jefferson Chemical Company Inc. subsidiary
f Texaco Inc.; or
Polyamides e.g., Versamid 140,150 from Henkel
Corporation.
Alternatively, the liquid resin may be a single
component resin that is a high solids (i.e., non-solvent)
polyisocyanate prepolymer that is suitably modified with
surfactants and catalysts so as to cure (i.e., react) in the
presence of moisture (water) to a hardened polyurethane polymer.
Such liquid resins require the presence of water to cure in a
reasonable time (say thirty minutes to four hours); and may
indeed require that the rod holes be wetted down if they are
being used in a hot and dry environment.
Suitable polyisocyanate prepolymers include: -
~ CAPPAR CS 149 (from Cappar Limited of Brampton, Ontario,
Canada), which is a modified high solid composition that mav be
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used in such circumstances where the concrete surrounding the rod
hole is still quite young but may be dry to the touch; or
DECI 16 (from N.V. Den~s of Gent, Belgium), which is a
polyfunctional polyol with isocyanate groups, and which will
react with in-situ water to form an insoluble polyurethane
; polymer.
The scope of the present invention is defined by the
accompan~ing claims.
