Patent Publication Number: US-2012037231-A1

Title: Cementious washout container and method for same

Description:
RELATED APPLICATIONS  
     This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/373,721, filed on Aug. 13, 2010, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD  
     Disposal of cementious waste water. 
     BACKGROUND  
     As environmental standards and regulations affecting the construction industry have evolved practices have been modified to manage storm water runoff and enhance sensitivity to recycling excess and waste materials. One significant area is the handling of washout water from redimix concrete trucks. In the past, concrete chutes were simply washed and the waste water and some residual sand and aggregate dumped on the ground. 
     This practice may have serious environmental impact. State and federal agencies have begun prohibiting concrete washout water from being dumped on the ground. The redimix industry has responded by modifying their procedures to facilitate putting the washout water and waste materials back into the drum to return it back to the batch plant for further recycling. The Redimix companies have also instituted an additional surcharge to cover the cost of the extra handling. This procedure is labor intensive and expensive. 
     SUMMARY  
     A concrete washout &amp; recycling bucket or hopper is described that separates the aggregate and accumulates all the waste water until the last truck leaves the work site each day. The waste water is then emptied into the last redimix truck for recycling back at the plant. The design of the recycling hopper makes the process of washing the chutes much safer and efficient. Further, use of the recycling hopper eliminates the extra charge and labor needed to process washout water as each truck is unloaded. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete understanding of the present subject matter may be derived by referring to the detailed description and claims when considered in connection with the following illustrative Figures. In the following Figures, like reference numbers refer to similar elements and steps throughout the Figures. 
         FIG. 1  is a perspective view of one example of a cementious washout bucket. 
         FIG. 2A  is a perspective view of the cementious washout bucket shown in  FIG. 1 . 
         FIG. 2B  is a plan view of the cementious washout bucket shown in  FIG. 1 . 
         FIG. 3A  is a bottom perspective view of the cementious washout bucket shown in  FIG. 1 . 
         FIG. 3B  is a side view of the cementious washout bucket shown in  FIG. 1 , 
         FIG. 4  is a side view of another example of a container valve. 
         FIG. 5A  is a front view of the cementious washout bucket shown in  FIG. 1 . 
         FIG. 5B  is a rear view of the cementious washout bucket shown in  FIG. 1 . 
         FIG. 6A  is a first side view of the cementious washout bucket shown in  FIG. 1 . 
         FIG. 6B  is a second side view of the cementious washout bucket shown in  FIG. 1 . 
         FIG. 7  is a block diagram showing one example of a method for using a cementious washout bucket. 
       Elements and steps in the Figures are illustrated for simplicity and clarity and have not necessarily been rendered according to any particular sequence. For example, steps that may be performed concurrently or in different order are illustrated in the Figures to help to improve understanding of examples of the present subject matter. 
     
    
    
     DESCRIPTION OF THE DRAWINGS  
     In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific examples in which the subject matter may be practiced. These examples are described in sufficient detail to enable those skilled in the art to practice the subject matter, and it is to be understood that other examples may be utilized and that structural changes may be made without departing from the scope of the present subject matter. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present subject matter is defined by the appended claims and their equivalents. 
     The present subject matter may be described in terms of functional block components and various processing steps. Such functional blocks may be realized by any number of techniques, technologies, and methods configured to perform the specified functions and achieve the various results. 
       FIG. 1  shows a perspective view of a cementious washout container  100 . The cementious washout container  100  includes a container body  102  having a container reservoir  104 . A rotatable hinged chute  106  is rotatably coupled with the container body  102 . As will be described in further detail below the cementious washout container  100  is sized and shaped to receive waste cement, concrete and the like on the hinged chute  106 , strain fine particles and water from the waste concrete and then poor or dump the cleaned aggregate particles off the hinged chute  106  and away from the cementious washout container  100 . The container  100  thereby retains and stores fluid from the cementious material including washout water and fine particles therein until removed from a construction site for environmentally safe disposal. In one example, waste concrete from multiple trucks is consecutively deposited on the hinged chute  106  and the corresponding fluids such as washout water and fine particles are accumulated and stored in the container body  102  until it is desirable to empty the container body  102  into a single truck for environmentally appropriate disposal. 
     The container body  102  is constructed with, but is not limited to, durable materials such as, steel, cast iron, composites and the like. Similarly, the other components of the cementious washout container  100 , such as the hinged chute  106 , are constructed with steel, cast iron, composites and the like. 
     Referring now to  FIGS. 2A and 2B , the cementious washout container  100  is shown in corresponding perspective and plan views. As shown, the container  100  includes a container body  102  having a container reservoir  104  sized and shaped to receive fine particles and washout water from waste cementious materials. The hinged chute  106  is shown rotatably coupled with a container body  102  at a rotatable joint  207 . For instance, the hinged chute  106  is coupled with a rotatable hinge between a chute panel  109  and a hopper screen  110 . The hinged chute  106  including the chute panel  109  and the hopper screen  110  are included in a hinged chute assembly  105 , in one example. As shown, the hopper screen  110  includes perforations or openings therein to facilitate the passage of fluids through the hopper screen  110  as well as fine particles while at the same time straining out aggregate materials which are thereafter transferred from the container  100  across the chute panel  109  (e.g., with rotation of the hinged chute  106 ). the example shown in  FIG. 2A , a chute lever  112  is coupled with the chute panel  109  to facilitate rotation of the chute panel relative to the container body  102 . In another example, the container body  102  includes a supporting tube  114  extending across at least a portion of the container body  102 . In one example, the supporting tube  114  provides structural support to the container body  102  and the hopper assembly. 
     Optionally, the cementious washout container  100  includes a chute opening  108  within a cover  111  extending over the container reservoir  104 . The chute opening  108  is sized and shaped to receive at least the hopper screen  110 . The hopper screen  110  in combination with the cover  111  encloses the top of the container reservoir. Waste cementious materials are dumped over the hopper screen  110 , as described above, to strain washout water and fine particles from the materials. The cover  111  ensures the materials are not able to easily bypass the hinged chute assembly  105 . In another example, the cementious washout container is without a cover and the hopper screen  110  is formed as a bounded basket (see  FIG. 2A ) with a perforated screen on one or more sides of the hopper screen  110 . 
     In the example shown in  FIG. 2A , the cementious washout container  100  further includes one or more rails  116  sized and shaped to receive lifting features such as forks from a fork lift and lifting lugs  118  sized and shaped to receive hooks coupled with a crane, hoist or other similar mechanisms. The rails  116  and the lifting tugs  118  are configured to facilitate lifting and transporting of the cementious washout container  100  in a full or empty state. Where the cementious washout container  100  is, full lifting of the container  100  is performed to hoist and center the container over the orifice of a cement truck to facilitate draining of the washout fluid and fine particles into the cement truck. A chain  116 A (not depicted on drawing  2   a  but clearly seen on  FIG. 1 ) is included to secure the bucket to the forklift, which is an OSHA requirement when lifting operators. 
     Referring again to  FIGS. 2A and 2B  in another example, the cementious washout container  100  includes a ladder  120  coupled with the container body  102 . The ladder  120  facilitates easy and safe access for the operation of the hinged chute  106  of the hinged chute assembly  105 , for instance, by reaching and actuating the chute lever  112 . In one example, the ladder  120  is positioned on the container body  102  adjacent to the chute lever  112 . When the cementious washout container  100  is positioned adjacent to a cement truck for dispensing of washout water and fine particles into the cement truck the ladder  120  is positioned on the container body  102  so the ladder is positioned on the appropriate side of the cement truck. Stated another way the ladder  120  is positioned on the container body  102  to be adjacent to the driver&#39;s side of the truck relative to the remainder of the container body  102 . In addition, the left hand rail of the ladder includes tie off points  121  for the operator to attach his body harness as required when the unit is hoisted and positioned for unloading. (See  FIG. 1 ). 
     Referring to  FIG. 2A  again, the cementious washout container  100 , in another example, includes one or more supports  122  extending from the container body  102 . The supports  122  provide support to the container body  102  to make sure the container body  102  is maintained relatively level on a flat surface when positioned thereon. 
       FIGS. 3A and 3B  show the cementious washout container  100  in perspective and side views, respectively. Referring to both  FIG. 3B , the container body  102  is shown having a drain  202  extending from a lower surface of the container  102 . A drain shroud  208  at least partially surrounds the drain  202 . As shown in  FIG. 3B , the container body  102  is graduated or tapers (e.g., is funneled) toward the drain  202  to ensure funneling of washout water and fine particles to the drain  202  for emptying out the container  100 . The container valve  200  extends across the drain  202  and ensures the container body  102  is in the closed configuration while washout water and fine particles are accumulated within the container reservoir  104 . In the example shown in  FIGS. 3A and 3B , the cementious washout container  100  further includes a valve operating mechanism  204  (e.g., a (linkage) extending from the container valve  200  to a valve lever  206 . As shown in  FIGS. 3B and 3A , operation of the valve lever  206  is configured to open the container valve  200  and thereby allow the draining of washout water and fine particles through the drain  202 . The valve lever  206  is configured for remote operation of the container valve  200  with the valve operating mechanism  204  coupled there between. In one example, the valve operating mechanism includes a linkage having linkage bars  212 A, B that hold the container valve  200  in the closed configuration until the valve lever  206  is operated to move the valve operating mechanism  204  beyond a retention position (e.g., a center point or intermediate point  216 ) that allows the container valve  200  to assume the open configuration (see  FIGS. 3B and 4 ). Stated another way, the linkage bars  212 A, B are arranged to have a greater length in the deflected orientation (whether open or closed) between joints  214 A, B than when traversing the intermediate point where the bars are substantially parallel. The linkage bars  212 A, B are thereby biased into a closed configuration that engages the container valve  200  with the drain while the linkage bars are oriented below the intermediate point  216 . That is to say, the valve operating mechanism  204  biases the container valve  200  into the closed configuration. 
     As shown in  FIG. 3B , in another example, the valve operating mechanism  204  is rotatably coupled with the valve lever  206  and the container valve  200 . With the valve operating mechanism  204  an operator may open the container valve  200  from the side of the container and not from underneath. For instance, the operator may open the container valve  200  from the ladder  120  (see  FIG. 2A ) adjacent to the valve lever  206 . In yet another example, the valve operating mechanism  204  includes a pin, locking feature and the like configured to engage with the mechanism  204  and lock the mechanism in place (e.g., with the valve closed). The pin or locking feature is used by itself or in combination with the exemplary valve operating mechanism  204  including the linkage bars  212 A, B to retain the valve  200  in the closed position. 
     Referring again to  FIG. 3B , container body  102  is shown with a tapered portion  300  tapering toward the drain  202 . As shown the tapered portion  300  is proximate a lower end  302  of the container body  102 . Stated another way, the tapered portion  300  is remote from the upper end  304  of the container body  102  (e.g., it has a squat configuration near the lower end  302 ). The tapered portion  300  ensures washout water and fine particles are diverted substantially centrally to the drain  202 . For instance, in one example, the tapered portion  300  and the drain  202  are aligned or near a longitudinal axis  306  of the cementious washout container  100 . Additionally, positioning of the tapered portion  300  proximate to the tower end  302  ensures that the center of gravity of the cementious washout container  100  is centrally positioned. The center of gravity is similarly positioned centrally while the container body  102  is filled (partially or fully) with washout water. That is to say, the container body  102  in one example is without a tapered portion extending from proximate the upper end  304  and thereby accordingly does not include a center of gravity elevated with corresponding handling issues (e.g., tipping and difficulty of handling with forklift forks engaged near the lower end  302 ). 
       FIG. 4  shows one example of a container valve  200  in an open configuration relative to the drain  202 . As also shown in  FIG. 4 , the valve mechanism  204  extends away from the container valve  200  to a valve lever. Although  FIG. 4  shows the container valve  200  having a circular configuration in other embodiments, the container valve  200  has a square, oblong Or other configuration sized and shaped to engage with a correspondingly shaped drain  202 . The container valve  200  as shown provides a butt engagement with the drain  202 , Stated another way, the container valve  200  shown as an example in  FIG. 4  engages with the drain  202  perimeter at the lip  201  (e.g., edge) of the drain. The container valve  200  in the example shown is a flapper (e.g., clamp type valve) engaged with the drain  202 . Optionally, one or more of the valve  200  and the edge of the drain  202  includes a gasket configured to provide a tight sealing engagement between the container valve  200  and the drain  202  in the closed configuration. 
     The container valve  200  shown in  FIG. 4  is not received within the drain  202 . The cementious washout container  100  with the above described container valve  200  is configured for use in freezing temperatures (e.g., below 32 degrees Fahrenheit). The container valve  200  (e.g., a flapper) will reliably open and reseal even while the drain is frozen because of the engagement of the valve  200  around the edge  201  of the drain is  202 . Frozen washout water from the container  100  is not able freeze around a valve mechanism because of the direct engagement of the container valve  200  with the drain  202  on the drain exterior. Additionally, the valve operating mechanism  204  is similarly exterior to the container body  102  and thereby isolated from freezing of washout water therein. In another example, the container valve  200  includes, but is not limited to, a ball valve, gate valve and the like. 
       FIGS. 5A and 5B  show the cementious washout container  100  from respective side views with the hinged chute  106  of the hinged chute assembly  105  in an upright orientation. As shown the hinged chute  106  is rotatably coupled with the container body  102 . The hinged chute assembly  105  includes the chute panel  109  extending out of the container body  102 . As has been previously described, rotation of the hinged chute  106  allows for aggregate particles accumulated on the hopper screen  110  (see  FIGS. 2A and 2B ) to be dispensed away from the container body  102 , for instance, into a separate container adjacent to the cementious washout container  100 . Further, operation of the chute lever  112  to rotate the hinged chute  106  into a substantially horizontal position allows for the placement of waste cementious materials on the hopper screen  110  to facilitate straining of washout water and fine particles through the hopper screen  110  while aggregate particles are left on the hopper screen  110 . Further rotation of the chute lever  112  tips the chute panel  109  past horizontal and allows the cleaned aggregate particles to slide (e.g., are unloaded) off the chute panel  109  into another container or simply onto the ground adjacent to the container body  102 . 
       FIGS. 6A and 6B  show additional views of the hinged chute  106  with backward and forward rotational arrows depicting relative rotation of the hinged chute  106  relative to the container body  102 . Views of the hinged chute  106  are provided in phantom lines to show receiving and discarding positions  600 ,  602  of the chute, respectively. In the receiving position  600 , the hinged chute  106  of the hinged chute assembly  105  is positioned substantially horizontally. For instance, the hopper screen  110  substantially fills the chute opening  108 . In this position, washout water including fine particles and aggregate is deposited on the hopper screen  110 . As described herein, the washout water and the fine particles pass through the hopper screen  110  while the aggregate remains segregated on the hopper screen  110 . 
     After straining of the washout water with the hinged chute  106  in the receiving position  600 , the hinged chute is rotated to the discarding position  602  (also shown in phantom lines in  FIGS. 6A , B). The aggregate remaining on the hopper screen  110  slides from the screen to the chute panel  109 . The chute panel  109  directs the aggregate to the ground or a container adjacent to the cementious washout container  100 . in another example, the hinged chute  106  (e.g., the hinge chute assembly  105 ) is movable to a third position as shown in solid lines in  FIGS. 6A , B. In the third position, the hinged chute  106  is substantially vertical to facilitate the cleaning out of the container body  102 , for instance with pressurized water delivered by hose with an operator standing on the ladder  120 . Additionally, in yet another example, the hinged chute  106  is biased into the third position for transport, storage and the like of the cementious washout container  100  according to the weight and length of the hopper screen  110 . The substantially vertical orientation minimizes outlying projections of the container  100  during transport and handling. 
     Further shown in  FIG. 6A , is the ladder  120  previously described. As shown, the ladder  120  extends over the container body  102  and allows for easy access to the chute lever  112  by an operator. Also shown in  FIGS. 6A and 6B , are the valve lever  206  and the drain  202 . As previously described, a valve operating mechanism  204  extends between the valve lever  206  and the drain  202  to operate the container valve  200  remotely relative to the drain  202 . 
     The drain shroud  208  is also shown in  FIGS. 6A , B. The drain shroud  208  is positioned around the drain  202  and the container valve  200  to substantially prevent splashing and deflection of washout water emptying through the drain  202 . As shown in  FIG. 4 , in the open position container valve  200  is partially disposed below the drain  202 . Because of the flapper type configuration (e.g., for use in cold weather) of the container valve  200  washout water exiting the drain  202  may impinge upon the container valve  200  and deflect from its downward path. The drain shroud  208  extends around the drain  202  and intercepts deflected water and redirects it downwardly, for instance into the delivery chute of a cement truck. In one example, the drain shroud extends downwardly from the container body  102  and is opposed to at least the open face  210  of the container valve  200 . 
     As previously described, in operation, the cementious washout container  100  is placed at a work site where multiple loads of ready mix concrete or cement are delivered. Where waste cement remains in the cement trucks the method includes dumping the cementious liquids including fluids such as water, aggregate particles and fine particles onto a hopper screen, such as hopper screen  110 . In one example, the hopper screen  110  is part of a hinged chute assembly  105 , such as the hinged chute  106  shown in  FIGS. 2A and 2B . The hopper screen  110  overlies a container reservoir  104  of the container body  102 . The method further includes screening the fluid and fine particles through the hopper screen  110  into the container reservoir  104  and leaving the aggregate particles on the hopper screen  110 . 
     After screening of the fluid and fine particles the hinged chute assembly  105 , including for instance, the hinged chute  106  is rotated relative to the container body and the aggregate particles are diverted away from the container body  102  by a chute panel  109  included with the hinged chute assembly  105  (e.g., hinged chute  106 ). 
     The method further includes accumulating washout water including the fluid (e.g., water) and fine particles in the container body  102 . After accumulation of the washout water and the fine particles, for instance, after receiving multiple loads of cement or concrete at a job site, the accumulated washout water and fine particles are funneled to a concrete chute (e.g., on a truck, trailer or the like) through a container drain  202  opened a container valve  200  on the container body  102 . The container valve  200 , in one example, is operated by a valve operating mechanism  204  that facilitates drainage operation of the valve  200  with the valve lever  206 . In another example, the valve operating mechanism  204  includes a locked configuration. For instance, the valve operating mechanism  204  includes linkage bars  212 A, B that deflect between locked and open configurations when moving past an intermediate point. The linkage bars  212 A retains the container valve  200  against the drain  202  and substantially prevents leakage of washout water. Movement of the valve lever  206  and corresponding movement of the linkage bars  212 A, B beyond the intermediate point releases the container valve  200  to open the drain  202 . 
     CONCLUSION  
     The cementious washout container described herein separates aggregate particles from waste water and fine particles and accumulates the waste water and fine particles until the last truck having cement or concrete is delivered to a job site. The waste water (including fine particles) is then emptied back into the drum of the last truck at the end of the day for recycling back at the concrete or cement plant. By accumulating and retaining the waste water and fine particles at the job site throughout the day intensive labor and expense for continuously refilling each chute of each truck with washout water and correspondingly transporting and dumping the washout water individually at a waste site is thereby avoided. 
     In the foregoing description, the subject matter has been described with reference to specific exemplary examples. However, it will be appreciated that various modifications and changes may be made without departing from the scope of the present subject matter as set forth herein. The description and figures are to be regarded in an illustrative manner, rather than a restrictive one and all such modifications are intended to be included within the scope of the present subject matter. Accordingly, the scope of the subject matter should be determined by the generic examples described herein and their legal equivalents rather than by merely the specific examples described above. For example, the steps recited in any method or process example may be executed in any order and are not limited to the explicit order presented in the specific examples. Additionally, the components and/or elements recited in any apparatus example may be assembled or otherwise operationally configured in a variety of permutations to produce substantially the same result as the present subject matter and are accordingly not limited to the specific configuration recited in the specific examples. 
     Benefits, other advantages and solutions to problems have been described above with regard to particular examples; however, any benefit, advantage, solution to problems or any element that may cause any particular benefit, advantage or solution to occur or to become more pronounced are not to be construed as critical, required or essential features or components. 
     As used herein, the terms “comprises”, “comprising”, or any variation thereof, are intended to reference a non-exclusive inclusion, such that a process, method, article, composition or apparatus that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such process, method, article, composition or apparatus. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials or components used in the practice of the present subject matter, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters or other operating requirements without departing from the general principles of the same. 
     The present subject matter has been described above with reference to examples. However, changes and modifications may be made to the examples without departing from the scope of the present subject matter. These and other changes or modifications are intended to be included within the scope of the present subject matter, as expressed in the following claims. 
     It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other examples will be apparent to those of skill in the art upon reading and understanding the above description. It should be noted that examples discussed in different portions of the description or referred to in different drawings can be combined to form additional examples of the present application. The scope of the subject matter should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.