IP Library Granted Patent US 11,268,256
Granted Patent B2
US 11,268,256 · App. 17/001,866 · Granted Mar 8, 2022

Culvert system with flexible toe wall

Inventors: Darrell J. Sanders (Mason, OH); Brian N. Flint (Mason, OH)
Assignee: CONTECH ENGINEERED SOLUTIONS LLC
E02D29/0225E01F5/005E02D17/202
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 11,268,256
App. No.
17/001,866
Granted
Mar 8, 2022
Kind
B2
Abstract

A culvert system includes a flexible toe wall that connects to and extends down from the bottom of the culvert. The flexible toe wall is capable of readily conforming to various shapes of the trench conditions provided to receive the toe wall, before or as the trench is backfilled.

Claims (35)

1. A culvert system, comprising:

a culvert structure defining a through passage from an inlet end to an outlet end, the culvert structure including an invert;

a flexible toe wall connected at one of the inlet end or the outlet end of the culvert structure, the flexible toe wall extending downward from the invert, wherein the flexible toe wall is comprised of a flexible water impermeable material that is configured to change shape upon installation so as to conform to a non-planar ground material surface;

wherein the flexible water impermeable material is a polymer material.

2. The culvert system of claim 1 , wherein the polymer material is a high-density polyethylene.

3. The culvert system of claim 1 , wherein the polymer material has a thickness of 60 mil or higher.

4. The culvert system of claim 1 , wherein the culvert structure is formed of metal plate material, and wherein the flexible toe wall is fastened to the invert of the culvert structure via an assembly comprised of a rib and a mount plate, wherein each of the rib and the mount plate run along a width of the culvert.

5. The culvert system of claim 4 , wherein an upper portion of the flexible toe wall is sandwiched between the rib and the mount plate.

6. The culvert system of claim 5 , wherein the rib is an L-shaped rib having a first leg secured to the invert of the culvert structure and a second leg extending downward from the invert, wherein the mount plate is secured to the second leg.

7. The culvert system of claim 6 , wherein the first leg is secured to the invert by a plurality of fasteners, and the mount plate is secured to the second leg by a plurality of fasteners.

8. The culvert system of claim 1 , wherein the culvert structure is located along a water flow path having an associated flow direction, wherein the inlet end of the culvert structure is located at an upstream side of the water flow path relative to the water flow direction and the outlet end of the culvert structure is located a downstream side of the water flow path relative to the flow direction, wherein the flexible toe wall is located at the inlet end and extends downward within the ground with a non-planar configuration that conforms to ground material at a downstream side of the flexible toe wall and backfill forward of the flexible toe wall.

9. The culvert system 9 , wherein one or more portions of the flexible toe wall extend behind a mount plane of the flexible toe wall.

10. The culvert system of claim 8 , wherein one or more portions of the flexible toe wall extend forward of the mount plane of the flexible toe wall.

11. The culvert system of claim 8 , wherein one or more portions of the flexible toe wall extend behind a mount plane of the flexible toe wall and one or more portions of the flexible toe wall extend forward of the mount plane of the flexible toe wall.

12. The culvert system of claim 1 , wherein the culvert structure is formed of a precast concrete material.

13. A method of installing a culvert structure, comprising:

placing a culvert structure along a water flow path with an inlet end of the culvert structure at an upstream side of a flow direction of the water flow path;

providing a trench along the inlet end of the culvert structure, the trench including a downstream side wall and an upstream side wall;

placing a flexible toe wall that is connected to the inlet end of the culvert structure within the trench, wherein the flexible toe wall is formed of a flexible polymer material;

back filling a material into the trench on an upstream side of the flexible toe wall; and

the back filling causing the flexible toe wall to change shape so as to be pushed into conformity with a non-planar shape of the downstream side wall of the trench.

14. The method of claim 13 , wherein the trench is created after placing of the culvert structure or before placing of the culvert structure.

15. The method of claim 13 , wherein the flexible toe wall is connected to the inlet end of the culvert structure after placing of the culvert structure or before placing of the culvert structure.

16. The method of claim 13 , wherein an action of the back filling material on the flexible toe wall causes the flexible toe wall to be pushed into conformity with the non-planar shape of the downstream side wall of the trench.

17. The method of claim 13 , wherein prior to the back filling, a bedding material is placed in a downstream side of the trench, the bedding material forming a forwardly sloped surface, wherein the back filling causes the flexible toe wall to be pushed into conformity with the forwardly sloped surface.

18. A culvert assembly, comprising:

a culvert structure defining a through passage from an inlet end to an outlet end, the culvert structure including an invert;

a first flexible toe wall at the inlet end of the culvert structure, the first flexible toe wall extending downward from the invert and being configured to change shape upon installation so as to conform to a non-planar surface, wherein the first flexible toe wall is formed of a flexible polymer material;

a second flexible toe wall at the outlet end of the culvert structure, the first flexible toe wall extending downward from the invert and being configured to change shape upon installation so as to conform to a non-planar surface, wherein the second flexible toe wall is formed of a flexible polymer material.

19. The culvert assembly of claim 18 , wherein

the flexible polymer material of which the first flexible toe wall is formed is water impermeable;

the flexible polymer material of which the second flexible toe wall is formed is water impermeable;

the culvert structure is formed of metal plate material;

the first flexible toe wall is fastened to the invert of the culvert structure via an assembly comprised of a first rib and a first mount plate, wherein each of the first rib and the first mount plate run along a width of the culvert, with an upper portion of the first flexible toe wall sandwiched between the first rib and the first mount plate;

the second flexible toe wall is fastened to the invert of the culvert structure via an assembly comprised of a second rib and a second mount plate, wherein each of the second rib and the second mount plate run along the width of the culvert, with an upper portion of the second flexible toe wall sandwiched between the second rib and the second mount plate.

Assignments (5)
PATENT SECURITY AGREEMENT Recorded Feb 10, 2025
From: BEST BLOCK, LLC; CONTECH ENGINEERED SOLUTIONS LLC; CUSTOM BUILDING PRODUCTS, LLC; FORTERRA CONCRETE PRODUCTS, LLC; FORTERRA PIPE & PRECAST, LLC; KEYSTONE RETAINING WALL SYSTEMS LLC; PAVESTONE, LLC; THE QUIKRETE COMPANIES, LLC; UNITED STATES PIPE AND FOUNDRY COMPANY, LLC; USP HOLDINGS, LLC
To: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
Reel/Frame 070170/0919 →
PATENT SECURITY AGREEMENT (ABL) Recorded Mar 23, 2022
From: UNITED STATES PIPE AND FOUNDRY COMPANY, LLC; GRIFFIN PIPE PRODUCTS CO., LLC; CUSTOM FAB, INC.; BIO CLEAN ENVIRONMENTAL SERVICES, INC.; MODULAR WETLAND SYSTEMS, INC.; FORTERRA PIPE & PRECAST, LLC; FORTERRA CONCRETE PRODUCTS, INC.; FORTERRA PRECAST CONCEPTS, LLC; BEST BLOCK, LLC; PAVESTONE, LLC; CONTECH ENGINEERED SOLUTIONS LLC; KEYSTONE RETAINING WALL SYSTEMS LLC
To: WELLS FARGO BANK, NATIONAL ASSOCIATION, AS AGENT
Reel/Frame 059479/0336 →
PATENT SECURITY AGREEMENT (ABL) Recorded Mar 23, 2022
From: UNITED STATES PIPE AND FOUNDRY COMPANY, LLC; GRIFFIN PIPE PRODUCTS CO., LLC; CUSTOM FAB, INC.; BIO CLEAN ENVIRONMENTAL SERVICES, INC.; MODULAR WETLAND SYSTEMS, INC.; FORTERRA PIPE & PRECAST, LLC; FORTERRA CONCRETE PRODUCTS, INC.; FORTERRA PRECAST CONCEPTS, LLC; BEST BLOCK, LLC; PAVESTONE, LLC; CONTECH ENGINEERED SOLUTIONS LLC; KEYSTONE RETAINING WALL SYSTEMS LLC
To: WELLS FARGO BANK, NATIONAL ASSOCIATION, AS AGENT
Reel/Frame 059479/0437 →
SECURITY INTEREST Recorded Mar 18, 2022
From: CONTECH ENGINEERED SOLUTIONS LLC
To: WELLS FARGO BANK, N.A., AS AGENT
Reel/Frame 059314/0291 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 25, 2020
From: SANDERS, DARRELL J.; FLINT, BRIAN N.
To: CONTECH ENGINEERED SOLUTIONS LLC
Reel/Frame 053585/0942 →
Continuity (2)
Provisional Application 62891550 · Aug 26, 2019
Related Publication 20210062452A1 · Mar 4, 2021
Cited By (1)
US 12,378,736