Abstract:
An improved tarp and ballast system that includes a plurality of panels attached to one another along the lengths thereof, wherein the lengths of the panels correspond to the length of the tarp. The tarp also includes chain pockets located at the sides of the tarp which run the length of the tarp and have chains secured therein. The tarp further includes a plurality of cable pockets and associated ballast anchors oriented across the width of the tarp which are adapted to secure a plurality of ballast cables to the tarp.

Description:
BACKGROUND OF THE INVENTION 
     The present application claims the benefit of U.S. Provisional Application No. 61/497,634, filed Jun. 16, 2011; which is incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to improvements in the construction of, and ballast systems for, large industrial tarps, particularly those used in temporarily covering sanitary landfill sites. 
     DESCRIPTION OF THE RELATED ART 
     While the present invention is directed to improvements in the construction of, and ballast systems for, large industrial tarps generally, it is particularly well suited for use as a temporary landfill cover. Landfill operators are required to cover the working face of the landfill when the site is not being worked. That is, the working face must be covered to prevent debris from blowing away, minimize odor, and minimize access by pests and rodents. Traditionally, the working face is covered with a layer of soil. However, repeatedly covering the working face with soil requires a significant amount of time, and the soil occupies valuable space in the landfill. Therefore, many landfills have begun using large industrial tarps to temporarily cover the working face when it is not in use. 
     The tarps used as landfill covers must be very large in order to be able to cover the working face. As such, the tarps are generally fabricated by sewing together numerous panels of material, the length thereof corresponding to the width of the finished tarp. The tarps must also be able to withstand high-speed winds without being displaced. Accordingly, it is common for these tarps to include sleeves sewn across the width thereof along the seams connecting the panels. Weights, or ballasts, are inserted into these sleeves to keep the tarps in place. One type of ballast commonly used is a large diameter cable. Generally, a plurality of these cables are inserted into the sleeves running across the width of the tarp, and then both ends of the sleeves are sealed shut. When the tarp eventually wears out, the sleeves are cut open and the cables are removed and reinstalled in a new tarp. However, if the ends of the cable fray, they can damage the tarp and allow the cable to be dislodged from the sleeve. In addition, it can be difficult to withdraw and insert a cable that has frayed ends. Furthermore, it is tedious and time consuming to seal both ends of each sleeve after insertion and unseal one end of each sleeve prior to withdrawal of the cables. 
     These tarps are often deployed and removed using an Automatic Tarping Machine, such as the one disclosed in U.S. Pat. No. 5,304,014 to John D. Slutz, which is hereby incorporated by reference. Whether the tarp is deployed and removed using an Automatic Tarping Machine, or manually, the tarp is subjected to large forces along the length of the tarp (i.e., transverse to the seams connecting the panels). Accordingly, the panel seams are a common place for the tarps to tear. In addition, if the tarp is being deployed and removed with an Automatic Tarping Machine and a ballast cable becomes dislodged from it&#39;s sleeve, this can cause a danger to the equipment or the operator when the Automatic Tarping Machine is rotating. Furthermore, because the ballast cables serve an additional function of maintaining full extension of the width of the tarp, a dislodgement of a ballast cable can allow bunching of the tarp, thereby diminishing the functionality thereof. 
     Another common location where the tarps tear is the edge along the length of the tarp. This location on the perimeter of the tarp is often subjected to extraneous forces, for example, from being impacted by the wheels or tracks of heavy machinery working next to the tarp. Accordingly, it is imperative to maintain the integrity of the tarp material along the edges. 
     The present invention seeks to alleviate one or more of these problems by providing a tarp that eliminates the seams that run transverse to the length of the tarp and provides for a secure connection for the ends of the ballast cables that allow easy insertion and removal of ballasts without affecting the structural integrity of the tarp material along the perimeter thereof. 
     SUMMARY OF THE INVENTION 
     The present invention in one preferred embodiment is drawn to a large industrial tarp for use as a temporary landfill cover, constructed of a plurality of panels that are connected via seams oriented along the length of the tarp. The improved tarp has lengthwise ballast pockets, or chain pockets, at both sides of the tarp extending the length thereof. Both of the chain pockets have an elongated ballast, or length of chain fixed therein. The improved tarp also has a plurality of widthwise ballast pockets, or cable pockets, oriented in a direction transverse to the panel seams. The tarp also includes various reinforcement straps attached thereto. A first and second reinforcement strap are located proximate the chain pockets. Lateral reinforcement straps are attached across the width of the tarp, alongside each of the cable pockets. Finally, there are seam reinforcement straps attached to each of the panel seams proximate the ends of the tarp. The lateral reinforcement straps include a looped portion proximate the sides of the tarp. Each of the cable pockets houses an extended ballast, or a ballast cable therein, and the ballast cables have a cap on the ends thereof. The caps, and therefore the ballast cables, are attached via a fastener to the looped portion of the lateral reinforcement straps. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. 
     The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the invention and together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a top view of a tarp in accordance with a preferred embodiment of the present invention. 
         FIG. 2  is a detailed top view of a portion  2  of the tarp of  FIG. 1 . 
         FIG. 3  is a cross-sectional view of portion  2  of the tarp shown in  FIG. 2  taken along line  3 - 3 . 
         FIG. 4  is a cross-sectional view of portion  2  of the tarp shown in  FIG. 2  taken along line  4 - 4 . 
         FIG. 5  is a detailed top view of portion  2  of the tarp show in  FIG. 1  with an alternative ballast anchor. 
         FIG. 6  is a cross-sectional view of the portion  2  shown in  FIG. 5  taken along line  6 - 6 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings. 
       FIGS. 1 to 6  show a preferred embodiment of a tarp  100 . In this preferred embodiment, tarp  100  is primarily configured to be used as a temporary cover for the working face of a landfill. Furthermore, tarp  100  is preferably configured to be used in conjunction with an Automatic Tarping Machine, such as the one disclosed in U.S. Pat. No. 5,304,014 to John D. Slutz. The preferred elements of tarp  100  and their interrelationship are described below. 
     Referring to  FIG. 1 , tarp  100  is constructed from a plurality of panels  102 . Panels  102  are preferably sewn together along the lengths thereof, thereby creating panel seams  104  that run along the length of tarp  100 . The lengths of panels  102  are approximately the same length as the overall length of tarp  100 . Panels  102  may be attached to one another in other ways without departing from the scope of the present invention. Both ends of each panel seam  104  are bolstered by seam reinforcement straps  106 , which are preferably sewn into panel seams  104 . Optionally, seam reinforcement straps  106  may run the entire length of panel seams  104 . Seam reinforcement straps  106  may extend beyond the ends of tarp  100 , and may include a D-ring  122  at the free end of strap  106 . D-rings  122  may be used to attach tarp  100  to adjacent tarps in order to cover a larger area or to anchor tarp  100  to the ground. D-rings  122  may also be used to attach tarp  100  to the Automatic Tarping Machine to facilitate deployment and removal of tarp  100  from the working face. 
     As shown in  FIGS. 1 ,  2 , and  4 - 6 , the edges of panels  102  located at opposite sides of tarp  100  are folded over onto themselves along the length of tarp  100  and have a side reinforcement strap  112  sewn on top of the fold, thereby forming a lengthwise ballast pocket, or chain pocket  108 , at each side of tarp  100 . An elongated ballast, or a chain  110 , may be housed within each chain pocket  108 . Chains  110  act as ballasts to hold down the edges of tarp  100 . Optionally, chains  110  may extend beyond the ends of tarp  100 . If chains  110  do extend beyond the ends of tarp  100 , they may be used to attach tarp  100  to the Automatic Tarping Machine to facilitate deployment and removal of tarp  100  from the working face. Similar to seam reinforcement straps  106 , side reinforcement straps  112  may extend beyond the ends of tarp  100 , and may include D-rings  122  at the ends of straps  112 . In order to add additional strength, tarp  100  may include additional side reinforcement straps  112  sewn in a parallel orientation to one another. 
       FIGS. 1 to 4  show a plurality of widthwise ballast pockets, or cable pockets  114 , formed by sewing strips of material to the top of tarp  100  across the width thereof. Each cable pocket is attached on one side with a cable pocket seam  116  and on the other side with a lateral reinforcement strap  118 . Proximate the open ends of cable pockets  114  are ballast anchors. In one preferred embodiment, the ballast anchors are formed when both ends of each lateral reinforcement strap  118  extend beyond cable pocket  114  and are looped across the open ends of cable pocket  114  and sewn to one of side reinforcement straps  112 , thereby forming strap loops  120 . In another preferred embodiment, as shown in  FIGS. 5 and 6 , the ballast anchors are D-rings  121 . 
     Cable pockets  114  are preferably large enough to allow for easy insertion of extended ballasts, or ballast cables  200  therein, while being small enough to prevent excessive movement of ballast cables  200  relative to cable pockets  114 , so as to reduce abrasion of tarp  100  caused by friction. Ballast cables  200  are configured to provide lateral structure to tarp  100 , in order to prevent tarp  100  from bunching, in addition to supplying sufficient weight to keep tarp  100  in place during high winds. 
     Each end of ballast cables  200  are inserted into a cable end cap  202 . Cable end cap  202  is secured to the end of ballast cable  200  by inserting end cap bolts  204  into openings located on opposing sides of end cap  202 . End cap bolts  204  are preferably threaded along the shaft thereof and are inserted into matching threaded, and countersunk, holes on cable end caps  202 . Alternatively, end cap bolts  204  may be replaced with self-tapping screws which thread into ballast cables  200  upon insertion. Countersinking the holes on cable end caps  202  enables the heads of end cap bolts  204  to be recessed even with the surface of cable end cap  202 , in order to eliminate abrasion of tarp  100  caused by end cap bolts  204 . An alternative method of eliminating abrasion caused by end cap bolts  204 , is to wrap end cap  202  and the heads of end cap bolts  204  with a cloth or scrim-backed pressure sensitive tape, such as, duct or gaffer tape. Furthermore, to reduce abrasion, it is preferred that all of the exposed edges and surfaces of end caps  202  are smooth and round. Cable end caps  202  have an opening  206 , through which a fastener  208  is passed. Fastener  208  is then attached to either strap loop  120  or D-ring  121 , thereby securing ballast cable  200  within cable pocket  114 . 
     The tarp of the present invention may be made of a variety of materials. For example, the tarp panels are preferably made of a durable, flexible fabric such as canvas or polypropylene. The reinforcement straps are preferably made of a durable, flexible fabric, such as nylon or polyester webbing. The ballast cables are preferably made of a durable, non-corrosive, semi-rigid material, such as stainless steel cable. Optionally, the stainless steel cable may be coated with plastic or rubber to increase the durability thereof and decrease the likelihood of cable fray. The D-rings, the side chains, the end caps and bolts, and the cable fasteners are all preferably made of a durable, non-corrosive metal, such as stainless steel. 
     Preferred dimensions are set forth below, although it will be appreciated that the dimensions are representative only, and therefore, may be varied as suitable for the intended application. Tarp  100  is made of seven tarp panels  102 , each of tarp panels  102  being about 6 ft. wide and 100 ft. long. The overlapped fabric in seams  104  and chain pockets  108  reduces the overall size of tarp  100  to about 40 ft. wide and 100 ft. long. Tarp  100  may be made of any number of tarp panels  102  of varying sizes so as to create any finished size desired. The preferred size of side chains  110  is a standard ⅜-in. chain cut to about 100 ft. long, so the chain runs the full length of tarp  100 . The preferred size of ballast cables  200  is ⅞-in. diameter cable cut to a length of about 39 ft. long. Preferably, cable pockets  114  are located at 10-ft. intervals along the length of tarp  100 . Cable pockets  114  may be spaced closer or farther apart depending on the conditions in which tarp  100  is to be used. Furthermore, while not required, cable pockets  114  may be included proximate the ends of tarp  100 . The preferred width of reinforcement straps  106 ,  112 ,  118  is 3 in. 
     Having described the preferred components of tarp  100 , a preferred method of use will now be described with reference to  FIGS. 1 to 4 . To set up tarp  100  for use in covering the working face of a landfill, ballast cables  200  are inserted in cable pockets  114  and fasteners  208  are attached to either strap loops  120  or D-rings  121 . A specialized tool (not shown) may be used to install the ballast cables  200 . The tool includes a smooth, bullet-shaped body with a diameter smaller than ballast cables  200  with a rope attached to a trailing end of the body. An opposite end of the rope is attached to fastener  208 . The body, given it&#39;s size and shape, is then easily slid through cable pocket  114 . Finally, ballast cable  200  may then be pulled into cable pocket  114  using the rope attached to fastener  208 . This initial setup step is only required before the first use of tarp  100 ; the ballast cables  200  remain installed until tarp  100  must be replaced. At which time, fasteners  208  are detached from either strap loops  120  or D-rings  121 , and ballast cables  200  are removed from tarp  100 , so they may be reused in a new tarp. 
     The present invention in a preferred form provides the advantages of extending the useable life of a landfill cover, and increasing the functionality and ease of use thereof. 
     The foregoing description is by way of example only, and may be varied considerably without departing from the scope of the present invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.