Abstract:
An underground utility vault replacement method and system which create an inner structural envelope is shown to protect workers and equipment. It restores structural integrity and safety to the area within a decaying underground vault, without major disruptions above and/or below the ground. The system includes a plurality of structural walls, ceiling panels and structural beams and floor track. All structural elements are sized in width/height/thickness and methodically inserted through the existing manhole and maneuvered in place. Wall panels are attached to the floor by way of a secure track. Wall and ceiling panels are connected by way of a tongue and groove connection and an adhesive.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Prov. Pat. App. Ser. No. 61/275,402, filed Aug. 27, 2009, the entire contents of which is expressly incorporated herein by reference. 
     
    
     STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT 
       [0002]    Not Applicable 
       BACKGROUND 
       [0003]    The present invention relates to a method and a system for replacing a deteriorating underground vault. 
         [0004]    Utility distribution planners, city planners and the like typically develop a system for collecting, distributing and discharging vital elements to the residents of the city. By way of example and not limitation, electrical lines may be routed to a central location such as an electrical vault and distributed to the residents of the city from the central location. These vaults provide space in which the electrical lines would converge and controlling devices adjust the distribution of electrical flow out to the residents. When electricity was made available for mass consumption in a highly dense population, above ground power lines would crowd the skyline of the city. Accordingly, the electrical lines were routed to an electrical vault underground and rerouted through underground trenches. These underground vaults are fabricated from various materials such as hardwood, brick, reinforced concrete and polymers. Over a period of time, the materials degrade and deteriorate, creating an unsafe environment for workers and equipment alike, so that all currently existing underground vaults would eventually need to be replaced. The cost and inconvenience of replacement of these underground vaults are very expensive and onerous compared to their initial cost to purchase and install. One of the reasons is that the electrical supply may need to be interrupted so that residents of the city may be without electricity for a period of time during replacement. Additionally, the underground vault may have to be excavated thereby interrupting traffic flow and other public services. Moreover, some locations may be deemed unsafe and may have to be relocated when replaced. Unfortunately, other suitable locations may not be available due to existing easements, encroachments on other utility suppliers and potential legal implications, thereby further increasing the cost of replacement. 
         [0005]    Accordingly, there is a need in the art for addressing the issues of deteriorating underground utility vaults. 
       BRIEF SUMMARY 
       [0006]    The underground utility vault replacement system disclosed herein addresses the needs discussed above, discussed below and those that are known in the art. 
         [0007]    The underground utility vault replacement system replaces deteriorating existing underground vaults to restore the once safe environment to their inner space. The system may include a plurality of wall panels and ceiling panels and other components that are narrow enough so that they can be brought into the deteriorating underground vault through an existing manhole and reassembled to replace the deteriorating underground vault. The wall and ceiling panels are small and light enough for an installer to maneuver the panels within the space of the deteriorating underground vault and assemble the panels to form the replacement underground vault within the deteriorating underground vault. The wall and ceiling panels are also strong enough so that the replacement underground vault is built to the recommended structural parameters of the pertinent agency such as AASHTO H20-44. 
         [0008]    Tracks are secured to the floor of the existing underground vault. The wall panels are secured to the track and also laid adjacent or secured to each other to form a wall interior to the existing underground vault. A gap is created between the existing wall of the underground vault as well as the plurality of wall panels that form a new wall of the underground utility vault replacement system to not interfere with the existing deteriorating underground vault. A carry beam pattern is laid on top of the plurality of wall panels alongside a plurality of ceiling panels. The wall panels and the ceiling panels are interlocked to each other by way of a tongue and groove connection and by an adhesive. A gap is also formed between the ceiling panels and the ceiling of the existing underground vault. Filler material may be introduced within the gap between the wall panels and the wall as well as the ceiling panels and the ceiling to prevent the walls and ceiling of the deteriorating underground vault from falling down upon the wall and ceiling panels. Accordingly, the existing underground vault does not need to be excavated. The electricity and surrounding traffic does not need to be interrupted for extended periods of time in order to restore the inner space safety of the deteriorating underground vault. 
         [0009]    The wall panels and ceiling panels are structural components. The filler materials are not part of the structural components but merely prevent the deteriorating walls and ceilings from falling down onto the replacement underground vault. 
         [0010]    More particularly, an underground vault replacement method and system for replacing a deteriorating underground vault is disclosed. The system may comprise a plurality of interlocking wall panels, a plurality of interlocking ceiling panels and a plurality of structural beams. The plurality of interlocking wall panels forms an enclosed wall within the deteriorating underground vault. The plurality of interlocking ceiling panels and the plurality of structural beams are interlockable to an upper portion of the plurality of interlocking wall panels. Each of the interlocking wall and ceiling panels may be narrower compared to a manhole of the deteriorating underground vault so as to be capable of being brought through the manhole and into the deteriorating underground vault for subsequent assembly. 
         [0011]    The adjacent wall panels of the plurality of interlocking wall panels may be interlocked with each other by way of interlocking tongues and grooves. Likewise, the adjacent ceiling panels of the plurality of interlocking ceiling panels may be interlocked with each other by way of interlocking tongues and grooves. Moreover, the wall panels are interlockable with the ceiling panels by way of a tongue and groove connection. More particularly, the wall panels may have a groove and the ceiling panels have a tongue that interlocks with the groove of the wall panels. 
         [0012]    The system may further comprise a filler material disposable between the ceiling panels and a ceiling of the deteriorating underground vault to prevent the deteriorating underground vault from falling down on the wall and ceiling panels and mitigate formation of a sinkhole situation above the deteriorating underground vault if the ceiling of the deteriorating underground vault deteriorates further. Also, the filler material may be disposed between the wall panels and a wall of the deteriorating underground vault to prevent the deteriorating underground vault from falling down on the wall and ceiling panels and mitigate formation of a sinkhole situation above the deteriorating underground vault should the wall of the deteriorating underground vault deteriorates further. 
         [0013]    The system may further comprise one or more tracks securable to a floor of the deteriorating underground utility vault. The tracks have sidewalls that are spread apart so that the wall panels can snugly fit between the sidewalls. 
         [0014]    Additionally, a method of replacing a deteriorating underground vault is disclosed. The method may comprise the steps of a) forming a plurality of interlockable structural wall panels and structural ceiling panels, the structural wall panels and structural ceiling panels being sufficiently narrow to permit entry of the structural wall panels and structural ceiling panels through an existing entry (e.g., manhole) of the deteriorating underground vault; b) inserting the formed structural wall panels and the structural or ceiling panels into the deteriorating underground vault through the existing entry (e.g., manhole) of the deteriorating underground vault; c) securing the inserted structural wall panels to a floor of the deteriorating underground vault; d) securing the ceiling panels to the wall panels secured to the ground of the deteriorating underground vault; and e) repeating steps b) and d) until all of the structural wall and ceiling panels are in place within the deteriorating underground vault. Step c may include the step of anchoring wall panel tracks to the floor of the existing underground vault. The wall panels are inserted into the tracks to secure the wall panels to the floor of the existing underground vault. Similarly, the wall panels secured to the floor may refer to the wall panels secured to the floor by way of the tracks. 
         [0015]    The method may further comprise the step of filling a gap between a wall of the deteriorating underground vault and the wall panels and between a ceiling of the deteriorating underground vault and the ceiling panels with a filler material to prevent the deteriorating underground vault from falling down on the wall and ceiling panels. 
         [0016]    The securing the wall panels step may include the step of securing the wall panels sequentially so that the subsequent wall panel secured to the floor is immediately adjacent to previously secured wall panels. 
         [0017]    The method may also further comprise the step of disposing the wall panels gapped away from the wall of the deteriorating underground vault for subsequent filling with a suitable material. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which: 
           [0019]      FIG. 1  is a perspective view of an existing underground vault with an underground utility vault replacement system; 
           [0020]      FIG. 2  is a cross sectional view of the underground vault shown in  FIG. 1 ; 
           [0021]      FIG. 3  is a cross sectional view of the underground vault shown in  FIG. 2 ; 
           [0022]      FIG. 4  is a cross sectional view of the underground vault shown in  FIG. 2  at a different elevation; 
           [0023]      FIG. 5  is a cross sectional view of the underground vault shown in  FIG. 2  at a further different elevation; 
           [0024]      FIG. 6  is a cross sectional view of a wall panel and a track securable to a floor of the underground vault; 
           [0025]      FIG. 7  is a front view of an embodiment of a wall panel; 
           [0026]      FIG. 7A  is a bottom view of the wall panel shown in  FIG. 7 ; 
           [0027]      FIG. 8  is a front view of a further embodiment of the wall panel; 
           [0028]      FIG. 8A  is a bottom view of the wall panel shown in  FIG. 8 ; 
           [0029]      FIG. 9  is a further embodiment of the wall panel; 
           [0030]      FIG. 9A  is a bottom view of the wall panel shown in  FIG. 9 ; 
           [0031]      FIG. 10  is a front view of a further embodiment of the wall panel; 
           [0032]      FIG. 10A  is a top view of the wall panel shown in  FIG. 10 ; 
           [0033]      FIG. 11  is a further embodiment of the wall panel; 
           [0034]      FIG. 11A  is a top view of the wall panel shown in  FIG. 11 ; 
           [0035]      FIG. 12  is a further embodiment of the wall panel; 
           [0036]      FIG. 12A  is a bottom view of the wall panel shown in  FIG. 12 ; 
           [0037]      FIG. 13  is a further embodiment of the wall panel; 
           [0038]      FIG. 13A  is a bottom view of the wall panel shown in  FIG. 13 ; 
           [0039]      FIG. 14  is a further embodiment of the wall panel; 
           [0040]      FIG. 14A  is a bottom view of the wall panel shown in  FIG. 14 ; 
           [0041]      FIG. 15  is a cross sectional view illustrating interconnection between adjacent wall panels with a tongue and groove connection; 
           [0042]      FIG. 16  is an enlarged view of sections of the wall panel shown in  FIG. 14 ; 
           [0043]      FIG. 17  is a cross sectional view of the wall panel shown in  FIG. 8  illustrating a loop; 
           [0044]      FIG. 18  is a cross sectional view of the underground vault shown in  FIG. 4  illustrating a front view of a plurality of wall panels; 
           [0045]      FIG. 19  is a cross sectional view of the underground vault shown in  FIG. 4  illustrating a front view of a plurality of wall panels; 
           [0046]      FIG. 20  is a cross sectional view of the underground vault shown in  FIG. 5  illustrating a ceiling panel; 
           [0047]      FIG. 21  is an enlarged view of ceiling panels resting on carry beams and cross carry beams shown in  FIG. 5 ; 
           [0048]      FIG. 22  is a cross sectional view of adjacent ceiling panels as shown in  FIG. 5  having a tongue and groove connection; 
           [0049]      FIG. 23  is a cross sectional view illustrating a tongue and groove connection between a ceiling panel and a wall panel shown in  FIG. 5 ; 
           [0050]      FIG. 24  is a top view of an embodiment of a ceiling panel; 
           [0051]      FIG. 24A  is an elevation view of the ceiling panel shown in  FIG. 26 ; 
           [0052]      FIG. 25  is a top view of a further embodiment of a ceiling panel; 
           [0053]      FIG. 25A  is an elevation view of the ceiling panel shown in  FIG. 27 ; 
           [0054]      FIG. 26  is a top view of a further embodiment of the ceiling panel; 
           [0055]      FIG. 26A  is an elevation view of the ceiling panel shown in  FIG. 28 ; 
           [0056]      FIG. 27  is a top view of a further embodiment of the ceiling panel; 
           [0057]      FIG. 27A  is an elevation view of the ceiling panel shown in  FIG. 29 ; 
           [0058]      FIG. 28  is a top view of a further embodiment of the ceiling panel; 
           [0059]      FIG. 28A  is an elevation view of the ceiling panel shown in  FIG. 28 ; 
           [0060]      FIG. 29  is a top view of a further embodiment of the ceiling panel; 
           [0061]      FIG. 29A  is an elevation view of the ceiling panel shown in  FIG. 30 ; 
           [0062]      FIG. 30  is a cross sectional view of the ceiling panel shown in  FIG. 5 ; and 
           [0063]      FIG. 31  is a cross sectional view of the ceiling panel shown in  FIG. 5 . 
       
    
    
     DETAILED DESCRIPTION 
       [0064]    Referring now to the drawings, an underground utility vault replacement system  10  is shown which can be used to replace a deteriorating underground vault  18  fabricated of concrete or other material, as shown in  FIG. 1 . The system  10  comprises a plurality of wall panels  12  secured to the floor  14  by way of tracks  16 . The wall panels  12  may be brought into underground utility vault  18  by way of the existing manhole  20  to the existing underground vault  18  to minimize disruption to the residents. Additionally, ceiling panels  22  may be brought into the underground utility vault  18  through the existing manholes  20  and laid on top of the wall panels  12  and secured to the wall panels  12 . Wall panels  12  and ceiling panels  22  may be narrow enough to be brought into the existing underground vault  18  through the existing manhole  20 . A gap  24  may be left between the wall panels  12  and the wall  26  when assembling the wall panels  12  so that the existing underground vault does not interfere with the underground vault installation. The gap  24  may be filled with a filler material  28  to prevent the deteriorating underground vault from falling down onto the wall and ceiling panels. Additionally, a gap  30  may be left between the ceiling panels  22  and a ceiling  32  of the underground utility vault  18  so that the replacement underground vault does not interfere with the existing underground vault. Similarly, the gap  30  may be filled with the filler material  28  to prevent the deteriorating underground vault from falling down onto the wall and ceiling panels. The wall panels  12  and ceiling panels  22  may be strong enough so that the replacement underground vault is built to recommend structural parameters of the pertinent agency such as AASHTO H20-44. Accordingly, the underground utility vault replacement system  10  provides a way to replace the existing underground utility vault and build a new underground vault  18  to current industrial specification without extended utility disruptions or extensive tear down and rebuild of the existing underground utility vault  18  as well as other legal and physical issues. 
         [0065]    Referring now to  FIG. 2 , a cross sectional view of the underground utility vault  18  with the underground utility vault replacement system  10  assembled therein is shown.  FIGS. 3-5  illustrate three (3) different elevations within the underground utility vault  18  as indicated in  FIG. 2 . At the ground level shown in  FIG. 3 , a track  34  may be secured to the floor  14 . A cross sectional view of the track  34  and wall panel  12  are shown in  FIG. 6 , as indicated in  FIG. 2 . The track  34  may be secured to the floor  14  by way of fasteners  36 . The track  34  may have two (2) sidewalls  38   a, b  that are generally perpendicular to the floor  14  and also to a base plate  40 . The base plate  40  may have a groove  42  which is sized and configured to receive a tongue  44  of the wall panels  12 . The distance  46  between the sidewalls  38   a, b  may be equal to a width  48  of the wall panels  12 . The wall panel  12  may be inserted between the sidewalls  38   a, b  and the tongue  44  received into the groove  42 . In this manner, the wall panels  12  do not shift left to right. The head  50  of the fasteners  36  may be disposed within the groove  42 . The tongue  44  of the wall panel  12  may have a cut out section that receives the head  50  so that the tongue  44  can mate with the groove  42 . More particularly, the groove  42  may have two (2) inclined surfaces  52   a, b  joined by a flat lower surface  54 . The tongue  44  may have corresponding inclined surfaces  56   a, b  and a flat lower surface  58 . When the wall panel  12  is inserted into the track  34 , the inclined surfaces  52   a, b  contact inclined surfaces  56   a, b . Additionally, the lower surface  54  contacts the lower surface  58 . In this manner, the tongue and groove connection  44 ,  42  as well as the sidewalls  38   a, b  limit movement of the wall panels  12 . An adhesive may also be laid on the tongue  44  and/or groove  42  to further secure the wall panels  12  together. 
         [0066]    The track  34  may be fabricated from an epoxy reinforced glass and carbon fibers or other similar material known in the art or developed in the future. The track  34  may be a pultruded carbon reinforced epoxy part or other similar material known in the art or developed in the future having the cross sectional configuration shown in  FIG. 6 . It is also contemplated that the track  34  may be fabricated from a non conductive material suitable to secure the wall panels to the floor. One or more holes may be drilled through the lower surface  54  to receive the fasteners  36  which secure the track  34  to the floor  14  of the underground utility vault  18 . 
         [0067]    Still referring to  FIG. 6 , the wall panels  12  may have an aluminum honeycomb core  60 . The aluminum honeycomb core  60  may be encased within a structural composite skin  62   a, b  which covers the interior and exterior sides of the wall panels  12 . A lower distal end portion  64  of the wall panel  12  may have a formed shaped  66  that covers the distal end of the wall panel  12  and overlaps the structural composite skin  62 . The formed shape  66  defines the tongue  44 . A filler material such as Bolsa structural filler  69  or other similar product may be disposed between the distal end of the wall panels  12  and the formed shape  66  within the recess defined by the tongue  44 . 
         [0068]    Referring back to  FIG. 3 , the track  34  may be laid and secured to the floor  14  about an inner perimeter of the wall  26  of the underground utility vault  18 . The track  34  may have different configurations. The tracks  34  shown in  FIG. 3  have a corner track  34   a  as well as straight connecting tracks  34   b . Other types of tracks  34  are also contemplated such as Z-shaped, U-shaped, etc. These tracks  34  may be sized and configured to fit the inner perimeter of the underground utility vault  18 . The square or rectangularly shaped underground utility vaults  18  shown in the Figures are for illustration purposes and not to limit application of the system to any particular configuration. Accordingly, other shaped underground vaults may be replaced with the utility underground vault replacement system  10  discussed herein. These other types of configurations include circular, oval, triangular, etc. The tracks  34  are gapped away from the wall  26  of the underground utility vault  18 . The gap  24  provides for space between the wall panels  12  and the wall  26  of the underground utility vault  18 . The deteriorating underground vault does not interfere with the replacement vault installation. 
         [0069]    Referring now to  FIG. 4 , the gap  24  is more clearly shown between the wall panels  12  and the wall  26  of the underground utility vault  18 . The wall panels  12  may be provided in various configurations as shown in  FIGS. 7-14A . The wall panel  12   a  shown in  FIGS. 7 and 7A  may have two (2) adjacent sides formed with tongues  44  and two (2) adjacent sides formed with grooves  68 . When the wall panel  12   a  is disposed within the track  34 , wall panel  12   a  may be laid end to end as shown in  FIG. 15  so that adjacent tongues  44  and grooves  68  engage each other. The vertical side of the wall panel  12   a  may have a tongue  44  that fits into a groove  68  on the vertical side of the wall panel  12   b . The tongue and grooves  44 ,  68  may have respective inclined surfaces  56   a, b  and flat surface  58  that contact inclined surfaces  70   a, b  and a lower flat surface  72  of the groove  68 . The wall panel  12   a  may have a different size as shown in  FIGS. 9 ,  9 A so that the plurality of wall panels  12  may fit snugly within the underground utility vault  18 . By way of example and not limitation, a width  74   a  (see  FIG. 7 ) of the wall panel  12   a  may be greater than the width  74   b  (see  FIG. 9 ) of the wall panel  12   b . Referring now to  FIG. 4 , a plurality of wall panels  12   a  may be laid from left to right. To accommodate different sized underground utility vaults  18 , the wall panel  12   a  may be made of different sizes as shown in  FIGS. 7 and 9 . The wall panel  12   b  shown in  FIG. 9  may be laid adjacent the wall panel  12   a . The wall panels  12  eventually surround the inner perimeter of the underground vault  18 . 
         [0070]    As the wall panels  12  are erected, the underground utility vault  18  may have various utility lines  78  that come into the underground utility vault  18  through the wall  26 . In this instance, wall panel  12   c  (see  FIGS. 13 and 13A ) may be inserted into the track  34  adjacent the wall panel  12   b . The wall panel  12   c  may comprise three (3) different components  76   a, b, c . The wall panel  12   c  has a tongue  44  formed at its lower edge. Grooves  68  are formed on the opposed vertical edges as well as the top edge of the wall panel  12   c . The wall panel section  76   a  is inserted into the track  34  and under the pipes  78 . Section  76   b  is inserted between upper and lower pipes  78 . Section  76   c  is laid on top of the upper row of pipes  78 . The wall panel  12   b  shown in  FIGS. 9 and 9A  may be slightly narrower compared to the wall panel  12   a  shown in  FIGS. 7 and 7A . Moreover, the wall panel sections  76   a, b  and  c  may have mating utility apertures  80 . When these utility apertures  80  are mated together, they surround the pipes  78 . The wall panel sections  76   a, b, c  may also held together by pins  82 . The pins  82  are embedded in adjacent holes  84  formed in adjacent wall panel sections  76   a, b  and wall panel sections  76   b, c . A block filler  86  may be disposed about the utility pipes  78  and about the utility pipe apertures  80 . The block filler  86  may be applied at the perimeter of the pipes  78 . Additionally, the block filler  86  may be applied on the side facing the decaying underground vault to avoid the filler blocking the unused utility pipes  78 . Although only three components  76   a, b , and  c  are shown and described, the wall panel may have two or more components  76   a - n  depending on the number of existing cable accesses. 
         [0071]    Wall panels similar to wall panel  12   c  may also be used. By way of example and not limitation, wall panels  12   d, e  are shown in  FIGS. 12 ,  12 A,  14  and  14 A. Wall panel  12   d  (see  FIGS. 12 and 12A ) also has three (3) different sections  88   a, b, c . These sections  88   a, b, c  are installed around utility pipes  78  which are received into utility apertures  80 . Adjacent sections  88   a, b  and  88   b, c  are held together by pins  82  formed in the sections  88   a, b, c  and by way of an adhesive. The sections  88   a, b, c  are also held together by adjacent wall panels  12  since adjacent wall panels  12  are engaged to each other by corresponding tongues and grooves  44 ,  42 . The wall panel  12   d  also may have grooves  42  and tongues  44  that mate up with adjacent wall panel  12  and ceiling panels  22 . The wall panel  12   d  may additionally have a block filler  86  which may be applied to the wall panel  12   d  on the side facing the underground decaying vault by way of adhesive, etc. 
         [0072]    The wall panel  12   e  (see  FIGS. 14 and 14A ) may also be formed of three (3) sections  90   a, b, c . The wall panel  12   e  may have the same structure as that in wall panels  12   d  and  12   c . The grooves  42  are formed on the edges of the wall panel  12   e . However, the grooves  42  on the top edge do not extend entirely across the top edge of the wall panel  12   e . Additionally, a tongue  44  is formed on the planar side of the wall panel  12   e . A groove  44  is also formed on the lower edge of the wall panel  12   e . For all wall panels  12 , tongues and grooves  44 ,  42  may be formed in any combination on any of the edges of the wall panel  12  as well as on the planar sides  91  of the wall panel  12 . The tongues and grooves  44 ,  42  may be formed in the same manner as discussed in relation to  FIG. 15 . 
         [0073]    Referring now to  FIG. 16 , the panel sections  90   a, b, c  of the wall panel  12   e  shown in  FIG. 14  are more clearly shown. The pins  82  may initially be embedded within holes  84  formed in one of the panel sections  90   a, b, c . When the sections  90   a, b, c  are stacked upon each other, the pins  82  are embedded within holes  84  of an adjacent panel section  90   b ,  90   c . Any combination of holes and pins  84 ,  82  are contemplated. The sections  76   a, b, c  and  88   a, b, c  may have the same structure. 
         [0074]    Referring now to  FIGS. 8 and 8A , the wall panel  12   f  may be similar to the wall panel  12   a  except that the wall panel  12   f  has a loop  92  fabricated from a steel rod and allows for a cable pull. Although the loop  92  is mounted to the wall panel  12   f , the loop  92  may be mounted to any one of the wall panels discussed herein as well as the ceiling panels  22 . Referring now to  FIG. 17 , the loop  92  may be attached to the wall panel  12  as follows. In particular, apertures  94  may be formed through the wall panel  12 . The loop  92  may have a U-shaped configuration with distal end portions  96   a, b  with threads  98  formed thereon. The threads  98  may engage nuts  100  which are used to clamp down upon the wall panel  12 . The nuts  100  bear down upon washer plates  102 . The nuts  100  are clamped down to secure the loop  92  to the wall panel  12 . As discussed above, the loop  92  may also be secured to the ceiling panels  22  or other wall panels discussed herein. 
         [0075]    Referring now to  FIGS. 10 ,  10 A,  11  and  11 A, the wall panels  12   g, h  may allow for turning of the wall of the wall panels  12  at a corner, as shown in  FIG. 4 . The wall panel  12   g  (see  FIGS. 10 and 10A ) may have grooves  42  that extend across the vertical edge as well as a portion of the top edge. As can be seen in  FIG. 4 , the groove  42  of the wall panel  12   g  mates up with a tongue  44  of an adjacent wall panel  12 . The wall panel  12   h  may have a groove  42  along its top edge and tongue  44  on the planar surface  91  vertical edge as well as bottom edge. As discussed herein, the tongues and grooves  44 ,  42  may be fabricated or incorporated into the wall panels  12  and ceiling panels  22  along any edge or planar surface  91  of the wall panel  12  or ceiling panel  22 . The tongues and grooves  44 ,  42  are formed so as to mate with adjacent corresponding and mating grooves and tongues  42 ,  44  of adjacent wall panel  12  or ceiling panel  22 . 
         [0076]    When erecting the plurality of wall panels  12  in the track  34  (see  FIG. 6 ), adhesive may be applied within the tongue and groove connection  44 ,  42  to assist in rigidizing the wall panels  12 . 
         [0077]    After the wall panels  12  are assembled edge to edge, the plurality of wall panels  12  form a solid wall, as shown in  FIGS. 18 and 19 . One or more struts  104  may be attached to the wall panels  12 . The struts  104  may also be attached to one or more ceiling panels  22  or wall panels  12 . The struts  104  may have a U shaped configuration with an attachment that allows electrical wires and other objects to be hung from the strut. One example of the strut  104  is a strut manufactured and sold under the tradename UNISTRUT. 
         [0078]    After the wall panels  12  are installed into the track  34 , the ceiling panels  22  may be assembled upon the top edge of the wall panels  12 . As shown in  FIG. 5 , the ceiling panels  22  may extend from one wall  106  of wall panels  12  to a second wall  108  of a plurality of wall panels  12 . To allow for the manhole  20 , carry beams  110  may extend from the wall  106  of wall panels  12  to the wall  108  of wall panels  12 . A cross carry beam  112  is supported by the carry beams  110 . Ceiling panels  22  are supported by the wall panels  12 , the carry beam  110 , and cross carry beam  112 . 
         [0079]    To begin installation of the ceiling panels  22 , the ceiling panels  22  are brought into the existing underground vault  18  through the manhole  20 . The ceiling panels  22  similar to the wall panels  12  are narrow enough so that the ceiling panels  22 , wall panels  12 , and tracks  34  may be slipped through the manhole  20  without breaking or opening up the manhole  20 . As needed, the ceiling panels  22  and carry beams  110 ,  112  are brought into the existing underground vault  18 . The other components disclosed herein may also be narrow enough to be brought in through the existing manhole  20 . 
         [0080]    Although the wall panels  12 , ceiling panels  22  and the other components of the system are fabricated to be narrow enough to be slipped through the manhole, it is also contemplated that in those situations that the wall panels  12  and ceiling panels  22  or other components cannot be fabricated to be sufficiently narrow so as to slip through the man hole, a top cap  130  of a neck  132  of the existing underground vault may be removed. Wall panels  12  and ceiling panels  22  wider than the manhole but narrower than an opening of the neck  132  may be slipped into the deteriorating underground vault through the opening of the neck  132 . Even if the top cap  130  is removed, doing so will not cause as much disruption to the surrounding businesses and people compared to total excavation of the deteriorating existing underground vault. 
         [0081]    The carry beams  110  may be laid on top of the walls  106 ,  108  of wall panels  12 . In particular, one of the wall panels  12  of the wall  108  may have a notch  114  (see  FIG. 18 ). The notch  114  may receive a flange  116  of the carry beam  110 , as shown in  FIG. 20 . The carry beam  110  rests upon the wall panel  12   a  of the wall  108 . The carry beam  110  may also rest within a notch  114  formed within one of the wall panels  12  of the wall  106 . Two (2) carry members  110  are laid upon the walls  106 ,  108  of wall panels  12  as shown in  FIG. 5 . The carry members  110  mark out the perimeter of the manhole  20 . No ceiling panels  22  are placed on the manhole side  116  to allow clearance or passageway from the manhole  20  to inside of the replacement underground vault. A filler block  118  (see  FIG. 20 ) may be disposed between the carry beam  110  and ceiling  32  of the underground vault  18 . A filler  120  may be disposed within the gap  30  between the ceiling panel  22  and ceiling  32 . The cross carry beam  112  extends between the carry beams  110 . The cross carry beam  112  is attached to the carry beams  110  by way of epoxy, adhesive or the like. 
         [0082]    Once the carry beams  110 ,  112  are in place, the ceiling panels  22  may be laid on top of the wall panels  12 . The ceiling panels  22  are interlocked to each other by tongue and groove connection  44 ,  42 , as shown in  FIGS. 5 and 22 . Additionally, the ceiling panels  22  may be attached to the wall panels  12  also by a tongue and groove connection  44 ,  42 , as shown in  FIG. 23 . The tongue and groove  44 ,  42  of the ceiling panels  22  may be fabricated in the same manner that the tongue and grooves  44 ,  42  are fabricated for the wall panel  12 , as discussed above. 
         [0083]    Referring now to  FIGS. 24-29A , ceiling panels  22   a - e  are shown. The ceiling panel  22  may be formed with tongues  44  on the periphery thereof (see  FIGS. 24-29A ). The tongues  44  are received into the grooves  42  of a respective ceiling panel  22  as shown in  FIGS. 5 and 22 . For example, as shown in  FIG. 22 , the right edge of the ceiling panel  22   a  is formed with a tongue  44  which is received into a corresponding groove  44  of the adjacent ceiling panel  22  which in this case is ceiling panel  22   b . (see  FIGS. 5 and 22 ). The lower surface of the ceiling panel  22  has a tongue  44  formed on its lower surface that is received into corresponding grooves on the upper edge of the corresponding wall panel  12  as shown in  FIG. 23 . The left edge of the ceiling panel  22   c  may engage the ceiling panel  22   b . The right edge of the ceiling panel  22   c  may be flat as shown in  FIG. 26A . The ceiling panel  22   c  may rest on the opposing wall panels  12  but also on a flange  122  of the carry beam  110 , as shown in  FIGS. 26A and 20 . The ceiling panels  22   a, b, c  may also be installed on the other side in the same manner but may have a mirror configuration. 
         [0084]    Referring now to  FIGS. 27-29A , the ceiling panel  22   d, e  may be formed in left and right configurations (see  FIGS. 27 and 29 ). The ceiling panel  22   b  may be placed on the carry beams  110 ,  112  as shown in  FIGS. 5 ,  21 ,  30  and  31 . A mirror version of the ceiling panel  22   d  (i.e.,  22   e ) may be placed on the other side on the carry beams  110 ,  112 . The ceiling panel  22   d  is supported on the flange  122  of the carry beam  110 , as shown in  FIG. 30 . The ceiling panel  22   e  is also supported by the cross carry beam  112 . The ceiling panel  22   f  is disposed between the ceiling panel  22   d  and  22   e  with a tongue and groove connection  44 ,  42 . The ceiling panel  22   f  also is supported by flange of cross carry beam  112  and the wall  106 . 
         [0085]    As discussed herein, the various components of the system  10  may be brought in through the existing manhole. However, in certain instances, it may be difficult to bring the various components of the system  10  into the deteriorating vault through the existing manhole. One reason may be that the existing components within the existing vault may block the manhole  20  so that the elongate wall panel or ceiling panel cannot be brought into the deteriorating vault. Another reason is that the wall panels and ceiling panels may have to be made wider than the existing manhole so that the wall panels and ceiling panels cannot be slipped into the deteriorating underground vault through the existing manhole. In this instance, the existing manhole may have to be opened up to allow the ceiling panels and wall panels to be inserted into the existing vault. Fortunately, such destruction of the manhole  20  may be minor and does not significantly disrupt traffic and electrical supply to residents of the local city. In certain circumstances, it is also contemplated that the portion of or the entire ceiling must be removed to install the replacement vault described herein. Nonetheless, the disruption may be minimal to pedestrians, vehicles, city and other public uses. The deteriorating underground vault does not need to be excavated to install the replacement underground vault. 
         [0086]    The wall panels and ceiling panels are attached to each other through a unique tongue and groove connection. However, it is also contemplated that the other attachment means are also contemplated that are known in the art or developed in the future. 
         [0087]    The wall panels and ceiling panels are described as having an aluminum honeycomb core. However, other materials and structure are also contemplated so long as the wall and ceiling panels are sufficiently strong to support the required weight and light enough so that personnel can manipulate the wall and ceiling panels to assemble these parts within the existing underground vault. 
         [0088]    The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein, including various ways of forming the tongues and grooves. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments.