Patent Application
20250109563
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
This invention relates to structures suitable for stabilizing soil for the construction of roads, buildings, and other construction.
Building a structure anchored on solid bedrock affords great support for the structure. However, many areas of desirable real estate do not have accessible bedrock. In some cases, suitable bedrock lies too far beneath the soil. In other cases, the nature of the soil requires stabilization measures in addition to or instead of merely resting a foundation on bedrock. In still other cases, stabilizing soil adjacent to a structure makes sense, allowing the stabilized adjacent soil to laterally support the structure by preventing subsidence.
Construction piles are known. High-strength pipes are driven into the ground tens of feet deep. Previously it has been considered a necessary cost to leave piles made of high-strength steel in the ground to support roads, buildings, and other construction on top of those piles. Further, it is known to enhance the performance of those piles with grout, or cement, providing additional material to bear the weight of the overlying construction.
However, Applicant has unexpectedly discovered that the high strength of a pile shaft is necessary only when driving the lead section into the ground. Materials of significantly lower cost can replace a portion of the pile shaft once a hole is made in the ground, and yet the same or sometimes better performance can be enjoyed with those lower-cost materials.
Unexpectedly, Applicant has invented economical methods of forming a pile in soil, one such method comprising driving a lead section comprising a shaft having a flight of helical screws between a top end and a bottom end into the soil, thereby forming a hole in the soil about the lead section, wherein the lead section is joined to a driving section that applies force to the lead section; optionally adding one or more extension sections between the lead section and the driving section, wherein the one or more extension sections are joined at a lower end to the lead section and are joined at an upper end to the driving section; wherein the top end is a depth below a surface of the soil; uncoupling the lead section from the driving section or, if present, from the lower end of the one or more extension sections; removing the driving section and, if present, the one or more extension sections from the hole; adding a reinforcing structure to the hole, thereby forming the pile in the soil.
Other embodiments of the present invention relate to piles in soil, one such pile including a lead section disposed in the soil, comprising a flight of helical screws between a top end and a bottom end, wherein the top end is a depth below a surface of the soil; a reinforcing structure having a first end proximal to the top end of the lead section and a second end proximal to the surface of the soil; and grout in contact with the reinforcing structure.
Further embodiments provide a lead section for a pile comprising a top end opposite a bottom end defining a shaft; one or more flights of helical screws disposed on the shaft; and a driver joiner proximal to the top end. As will be explained below, a driver joiner allows for the easy connection and disconnection of the lead section to other equipment during the construction of the pile.
While the disclosure provides certain specific embodiments, the invention is not limited to those embodiments. A person of ordinary skill will appreciate from the description herein that modifications can be made to the described embodiments and therefore that the specification is broader in scope than the described embodiments. All examples are therefore non-limiting.
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. The figures are not necessarily to scale, and some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. In the event that there is a plurality of definitions for a term herein, those in this disclosure prevail unless stated otherwise.
Wherever the phrase “for example,” “such as,” “including” and the like are used herein, the phrase “and without limitation” is understood to follow unless explicitly stated otherwise. Similarly “an example,” “exemplary” and the like are understood to be non-limiting.
The term “substantially” allows for deviations from the descriptor that don't negatively impact the intended purpose. Descriptive terms are understood to be modified by the term “substantially” even if the word “substantially” is not explicitly recited.
The term “about” when used in connection with a numerical value refers to the actual given value, and to the approximation to such given value that would reasonably be inferred by one of ordinary skill in the art, including approximations due to the experimental and or measurement conditions for such given value.
The terms “comprising” and “including” and “having” and “involving” (and similarly “comprises”, “includes,” “has,” and “involves”) and the like are used interchangeably and have the same meaning. Specifically, each of the terms is defined consistent with the common United States patent law definition of “comprising” and is therefore interpreted to be an open term meaning “at least the following,” and is also interpreted not to exclude additional features, limitations, aspects, etc. Thus, for example, “a device having components a, b, and c” means that the device includes at least components a, b and c. Similarly, the phrase: “a method involving steps a, b, and c” means that the method includes at least steps a, b, and c.
Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.
Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.
It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.
Certain embodiments of the present invention involve a pile. As used herein, a pile in soil includes a lead section disposed in the soil that has a flight of helical screws between a top end and a bottom end of the lead section. The top end of the lead section is a depth below the surface of the soil. Then, from the top end of the lead section to the surface of the soil, a reinforcing structure having a first end proximal to the top end of the lead section and a second end proximal to the surface of the soil appears. Further, grout contacts the reinforcing structure.
The reinforcing structure generally speaking appears above the lead section in soil. A connection between the reinforcing structure and the lead section, such as bolts or welding, is not necessary, and may be difficult due to the method of constructing the pile, described below. Instead, hardened grout will hold the reinforcing structure in position relative to the lead section in some embodiments of the present invention. In contrast to conventional piles, in which a continuous steel pipe extends from the surface of the soil all the way down to the bottom end of the lead section, piles of the present invention have a reinforcing structure and hardened grout above the lead section to the surface of the soil.
As mentioned above, certain instances of the present invention provide methods for constructing a pile in soil, one such method comprising driving a lead section comprising a flight of helical screws between a top end and a bottom end into the soil, thereby forming a hole in the soil about the lead section. To drive the lead section, it is joined to a driving section that applies force to the lead section, such as a rotational force, a vertical insertion force, or a combination thereof. Optionally one or more extension sections are added between the lead section and the driving section, wherein the one or more extension sections are joined at a lower end to the lead section and are joined at an upper end to the driving section. The top end of the lead section will be positioned a depth below a surface of the soil. Once in position, the lead section is disconnected from the driving section or, if present, from the lower end of the one or more extension sections. The driving section and, if present, the one or more extension sections will be removed from the hole. A reinforcing structure will be added to the hole above the lead section, thereby forming the pile in the soil. In some cases, liquid grout is added, optionally at any or several points in the construction of the pile.
Any suitable lead sections can be employed. For example, a lead section for a pile may include a top end opposite a bottom end defining a shaft; one or more flights of helical screws disposed on the shaft; and a driver joiner proximal to the top end. A driver joiner is a structure that allows the easy joining of a driver section or, if present, an extension section, to the lead section for rotational driving of the lead section into the soil. Then, the driver joiner structure allows the easy disengagement of the driver section or extension section from the lead section, leaving the lead section in place in the soil. In some cases, a driver joiner includes an L-shaped notch that receives a corresponding stud on the lower end of the driver section or extension section. Any suitable number of such L-shaped notches can be used, such as, for example, one notch, two notches, or a dozen notches as desired.
As can be appreciated, the driver joiner must have the same “handedness” as the helical screws along the shaft of the lead section. In some cases, the one or more flights of helical screws are right-hand helical screws, and the driver joiner is a right-hand driver joiner. In other cases, the one or more flights of helical screws are left-hand helical screws, and the driver joiner is a left-hand driver joiner. For a right-handed driver joiner and right-hand helical screws, the driver section will rotated the lead section to the right, or clockwise if looking down. The helical screws will draw the lead section into the soil. Then, when the lead section reaches the desired depth, the driver section rotates to the left, or counterclockwise to disengage the driver joiner and lead section from the driver section and any extension sections present. The driver section, any extension sections, and optionally the bit are removed from the hole and used to install another pile. The flight of helical threads can provide a right-hand screw or a left-hand screw as desired. A right-hand screw is found when the pile drives deeper into the soil upon clockwise rotation, looking down the axis of the lead section. “Righty-tighty lefty-loosy” fits a right-hand screw. A left-hand screw drives the pile deeper into soil upon counterclockwise rotation, looking down.
To facilitate the addition of liquid grout deep into the soil where the pile is constructed, in certain instances the shaft is at least partially hollow to allow liquid grout to flow through the lead section. Optionally, the shaft can have one or more holes that allow liquid grout to flow from the interior of the shaft into the hole in the soil surrounding the lead section. It is possible, in some cases, to add grout through the driver section, through extension sections if present, and into the lead section in those cases. Liquid grout flows into the hole, optionally by pouring liquid grout into the hole in addition to the liquid grout entering the lead section.
The lead section can have any suitable dimensions. For example, the cross section of the lead section excluding the helical screws can have a lead section diameter that is at least about 2 inches, at least about 3 inches, at least about 4 inches, at least about 5 inches, at least about 6 inches, at least about 7 inches, at least about 8 inches, at least about 9 inches, at least about 10 inches, at least about 11 inches, at least about 12 inches, at least about 15 inches, or at least about 20 inches. If the lead section has a cross-section other than circular, “lead section diameter” then refers to the largest diameter of the cross section of the lead section excluding the helical screws. In further examples, a lead section diameter can be no more than about 3 inches, no more than about 4 inches, no more than about 5 inches, no more than about 6 inches, no more than about 7 inches, no more than about 8 inches, no more than about 9 inches, no more than about 10 inches, no more than about 11 inches, no more than about 12 inches, no more than about 15 inches, or no more than about 20 inches.
A lead section can have any suitable length. For example, the lead section can have a length from the top end to the bottom end of at least about 2 feet. For another example, the lead section has a length from the top end to the bottom end of no more than about 30 feet. In further cases, the bottom end of the lead section is adapted to penetrate soil by terminating in one or more points, or in other structure to break up and divert soil as the pile is driven into the ground. A point can have any suitable geometry. For example, the point can be a coaxial point, an offset point, and an edge point. A coaxial point appears on the geometric center of the first end of the lead section. An edge point appears at the circumference of the lead section, in some cases as if the lead section were a cylinder that was cut at a diagonal. An offset point appears between the edge and the geometric center. The precession of the edge point or the offset point helps break up and divert soil as the pile is rotated.
The lead section, the extension sections, the driver section, and the components of the reinforcing structure can have any suitable cross section geometry. Circular may represent the easiest to manufacture, for example when helixes must be welded to the lead section. Square or other polygonal shapes can offer advantageous forces on the helixes, so that the force from the rotation of the pile to the helixes is transferred by other than just the weld or other attachment between the flight of helical threads and the lead section. Accordingly, the lead section may have a cross-section chosen from circular, triangular, square, rectangular, pentagonal, hexagonal, heptagonal, and octagonal, in some embodiments.
Any suitable helixes can appear in the flight of helical threads. In some cases, the flight of helical threads comprises a single continuous thread. In other cases, the flight of helical threads comprises more than one continuous thread, such as two or three continuous threads. As used herein, a “continuous thread” indicates a helix that wraps around the lead section for more than 360 degrees. Further cases provide a flight of helical threads that comprises a plurality of distinct helixes. A “distinct helix” wraps around the lead section for 360 degrees or less. Still further cases allow a flight of helical threads to include any suitable combination of continuous threads and distinct helixes. Helical threads can extend from the shaft of the lead section any suitable distance. In some cases, helical threads extend at least one inch. In other cases, the helical threads extend no more than two feet.
In some cases, a bit is coupled in proximity to the lead section. A bit creates a wider hole in the soil. One example of a bit is described in U.S. Pat. No. 10,024,020 B2, which is incorporated by reference in its entirety herein, and is shown in
The lead section will define a distance from the surface of the soil called the depth. Any suitable depth can appear in the several embodiments of the present invention. In some cases, the depth is greater than about 1 foot, greater than about 3 feet, greater than about 5 feet, greater than about 10 feet, greater than about 15 feet, greater than about 20 feet, greater than about 25 feet, greater than about 30 feet, greater than about 40 feet, greater than about 50 feet, greater than about 60 feet, greater than about 75 feet, or greater than about 100 feet. In other cases, the depth is no greater than about 1 foot, no greater than about 3 feet, no greater than about 5 feet, no greater than about 10 feet, no greater than about 15 feet, no greater than about 20 feet, no greater than about 25 feet, no greater than about 30 feet, no greater than about 40 feet, no greater than about 50 feet, no greater than about 60 feet, no greater than about 75 feet, or no greater than about 100 feet.
Any suitable reinforcing structure can be used. In some cases, the reinforcing structure is chosen from a rebar cage, a pipe, or a combination thereof. The rebar cage requires no particular structure. Often, though, it may be useful to have horizontal members and vertical members form the rebar cage to strengthen the grout about the upper end of the pile. The vertical members, at least, can extend above the grout and above the soil in certain instances to engage the supported structure above the pile. Some cases allow a rebar cage to be constructed of straight vertical pieces of rebar tied to horizontal pieces of rebar. Those horizontal pieces can be straight, circular, spiral, another shape, or no defined shape at all. A circular piece can be made by bending straight rebar with a pipe bender or other suitable instrument. The circular pieces can have any desired diameter less than the diameter of the hole. The various members of the rebar cage can be spaced apart any suitable distance, such as, for example, at least two inches to no more than about 12 inches. In other embodiments, the reinforcing structure comprises a pipe. In still other embodiments, the reinforcing structure includes a rebar cage and a pipe.
When the reinforcing structure includes pipe, the pipe can have any suitable dimensions. For example, a suitable pipe may have a pipe diameter that is at least about 4 inches, at least about 5 inches, at least about 6 inches, at least about 7 inches, at least about 8 inches, at least about 9 inches, at least about 10 inches, at least about 11 inches, at least about 12 inches, at least about 15 inches, or at least about 20 inches. In another example, a reinforcing structure's pipe has a pipe diameter that is no more than about 5 inches, no more than about 6 inches, no more than about 7 inches, no more than about 8 inches, no more than about 9 inches, no more than about 10 inches, no more than about 11 inches, no more than about 12 inches, no more than about 15 inches, no more than about 20 inches, or no more than about 30 inches.
Certain instances of the present invention provide the reinforcing structure extending above the surface of the soil to tie in the supported structure to the pile itself. For example, the second end of the reinforcing structure may extend above the surface of the soil at least about 6 inches, at least about 1 foot, at least about 2 feet, at least about 3 feet, at least about 5 feet, at least about 10 feet, at least about 12 feet, or at least about 20 feet. Similarly, the second end of the reinforcing structure may extend above the surface of the soil no more than about 6 inches, no more than about 1 foot, no more than about 2 feet, no more than about 3 feet, no more than about 5 feet, no more than about 10 feet, no more than about 12 feet, or no more than about 20 feet.
Piles of greater length can be formed by driving the lead section using one or more extension sections. An extension section usually is a length of pipe ranging from 5 feet to 20 feet that connects the driving section to the lead section. The extension section may be bolted to the driving section, and is joined to the lead section with appropriate structure that matches the driver joiner structure on top end of the lead section. In this way, sturdy extension sections can be used to drive the lead section deep into the soil and create a hole, but then are removed and do not remain in the pile once formed. Instead, the extension sections are used again and again to drive numerous lead sections in the construction of numerous piles. Once the extension sections are removed, reinforcing structures are added to the holes along with (more) liquid grout, thereby forming numerous piles. Extension sections can be connected to each other and to the driver section with any suitable structure. In some cases, the one or more extension sections are added with at least one bolted splice.
Certain methods involve adding liquid grout to the hole. Liquid grout can be added in any suitable manner, and at any suitable time. Sometimes, at least some of the liquid grout is added during the driving the lead section. At other times, at least some of the liquid grout is added before uncoupling the lead section. Further, at least some of the liquid grout can be added after the reinforcing structure is placed in the hole. Any amount of grout may be added. To prevent corrosion and otherwise to protect the reinforcing structure while ensuring adequate performance of the pile, the liquid grout may completely surround the reinforcing structure below the surface of the soil.
When liquid grout is added to form the pile, the grout hardens about the reinforcing structure. In some instances, the grout protects the reinforcing structure from contact with the soil. In further instances, the grout protects the reinforcing structure from corrosion.
A pile of the present invention can have any suitable dimensions. For example, a pile can have a pile diameter at the surface of the soil that is no more than about 6 inches, no more than about 7 inches, no more than about 8 inches, no more than about 9 inches, no more than about 10 inches, no more than about 11 inches, no more than about 12 inches, no more than about 15 inches, no more than about 20 inches, no more than about 24 inches, no more than about 36 inches, no more than about 48 inches, no more than about 60 inches, no more than about 72 inches, or no more than about 120 inches. For another example, a pile may have a pile diameter at the surface of the soil that is greater than about 6 inches, greater than about 7 inches, greater than about 8 inches, greater than about 9 inches, greater than about 10 inches, greater than about 11 inches, greater than about 12 inches, greater than about 15 inches, greater than about 20 inches, greater than about 24 inches, greater than about 36 inches, greater than about 48 inches, greater than about 60 inches, greater than about 72 inches, or greater than about 120 inches.
The piles of the present invention can be manufactured with any suitable materials. In certain instances, a pile is made from steel. Any suitable steel can be used. Stainless steels, carbon steels, and the like may be mentioned. The steel components can be welded together, molded as one, or otherwise attached in any suitable manner. The piles can exhibit any suitable properties and performance. In some cases, the casing has a minimum tensile strength of about 50 ksi and a minimum yield strength of about 40 ksi. In further instances, the shaft has a minimum tensile strength of about 50 ksi and a minimum yield strength of about 40 ksi. Optionally, some or all of the metal of the pile is protected from corrosion by being encased in grout, by partial or complete galvanization, or a combination thereof. For example, the lead section, the reinforcing structure, or both may be galvanized before installation. Suitable galvanization treatments include those known in the art.
A pile can be tied to supported structure above in any suitable manner. For example, a layer of reinforced concrete can represent a pile cap encompassing the upper end and a portion of the reinforcing structure. The pile cap can have any suitable dimensions. One foot thick, to several feet thick, may be mentioned. Supported structure may include, but is not limited to, pile caps, grade beams, concrete masonry unit (“CMU”) columns and structures, concrete column and structures other than pile caps, beams such as steel or timber, and traditional bracing, alone or in combinations.
The reinforcing structure can have its uppermost feature extend above the surface of the soil a vertical distance of at least about 2 inches, at least about 3 inches, at least about 4 inches, at least about 5 inches, at least about 6 inches, at least about 7 inches, at least about 8 inches, at least about 9 inches, at least about 10 inches, at least about 11 inches, at least about 1 foot, at least about 1.5 feet, at least about 2 feet, or at least about 3 feet. In other cases, the uppermost feature of the reinforcing structure extends above the surface of the soil no more than about 2 inches, no more than about 3 inches, no more than about 4 inches, no more than about 5 inches, no more than about 6 inches, no more than about 7 inches, no more than about 8 inches, no more than about 9 inches, no more than about 10 inches, no more than about 11 inches, no more than about 1 foot, and no more than about 1.5 feet, more than about 2 feet, or no more than about 3 feet.
Several methods of stabilizing soil using the piles described herein may be mentioned. Certain of those methods involve driving the pile into the soil. Driving the pile can include any suitable efforts. In some cases, the pile is pounded, screwed, or pressed into soil, or a combination of such efforts are employed. Optionally, the soil where the pile will go can be opened with an auger and a quantity of soil removed, creating a void in the soil for the pile to enter. Such void can represent substantially the entire volume the pile, or only a portion of that volume. In certain cases, however, no soil is removed, but rather the driving of the pile compresses the soil around the pile, and the compressed soil aids its stabilization. In a further step, liquid grout can be added to the pile as it has been positioned in the soil, for example, by injecting liquid grout into the lead section or an extension section so the liquid grout flows deep into the pile.
Any suitable liquid grout can be used. Very large rocks in the liquid grout are discouraged, as they could lodge in the holes and hinder the flow of liquid grout into the casing. Otherwise, concretes such as are known in the art using a suitable cement such as those known as Portland cement can be used as liquid grout, for example. Polymeric grouts may be used in some applications. It is desired that the liquid grout flows along the pile to form solid domains of grout supporting the pile. In some cases, the solid grout forms a solid case of concrete around the pile when installation is complete and the grout has fully cured. In other cases, pouring the liquid grout might not lead to a perfect encasement of the pile by the solidified grout.
As used herein, “soil” indicates any solid material found on Earth with the exception of monolithic rock. Soils may include mud, silt, sand, clay, pebbles, compacted forms of any of those, and combinations thereof. Placing the piles of the present invention in monolithic rock such as bedrock may require pre-formed channels in the rock formed by suitable methods such as those known in the art.
The structures that can be built on the soils stabilized with the piles described herein are not limited. Roads, sidewalks, runways, parking lots, bridge footings, docks, boardwalks, swimming pools, storage tanks, chemical processing equipment such as refineries, windmills, and oil drilling platforms including those deployed at sea, may be mentioned. Foundations for buildings, and the buildings themselves, such as homes, warehouses, factories, office buildings, and the like may be mentioned. Further, at least some of the piles of the present invention can be used to stabilize soil when the only purpose is to stabilize the soil. It may be beneficial to have the soil adjacent a structure be stabilized in the event of flooding or earthquake, and that can be accomplished with piles of the present invention.
Further embodiments of the present invention can be described by reference to the accompanying drawings.
In
Reinforcing structure 1190 has a first end 1193 in proximity to top end 1105 of lead section 1101, and a second end 1194 in proximity to surface 1166 of soil 1180. That allows pile 1100, such as via holes 1133, 1134 at second end 1194, to connect to supported structure to be built above pile 100. Reinforcing structure 1190 includes holes 1131, 1132, 1133, and 1134. Those holes may serve one or more purposes, such as, for example, attaching via bolts (not shown) to other equipment (also not shown) for easier manipulation and installation, facile flow of liquid grout during construction of pile 1100, and the like. As shown in
Further aspects of the present invention may be understood by consideration of the following clauses.
Clause 1. A method for constructing a pile in soil, comprising: driving a lead section comprising a shaft having a flight of helical screws between a top end and a bottom end into the soil, thereby forming a hole in the soil about the lead section, wherein the lead section is joined to a driving section that applies force to the lead section;
Clause 2. The method of clause 1, wherein a bit is coupled in proximity to the lead section.
Clause 3. The method of any one of the preceding clauses, wherein the reinforcing structure is chosen from a rebar cage, a pipe, or a combination thereof.
Clause 4. The method of any one of clauses 1-3, wherein the depth is greater than about 1 foot, greater than about 3 feet, greater than about 5 feet, greater than about 10 feet, greater than about 15 feet, greater than about 20 feet, greater than about 25 feet, greater than about 30 feet, greater than about 40 feet, greater than about 50 feet, greater than about 60 feet, greater than about 75 feet, or greater than about 100 feet.
Clause 5. The method of any one of clauses 1-4, wherein the depth is no greater than about 1 foot, no greater than about 3 feet, no greater than about 5 feet, no greater than about 10 feet, no greater than about 15 feet, no greater than about 20 feet, no greater than about 25 feet, no greater than about 30 feet, no greater than about 40 feet, no greater than about 50 feet, no greater than about 60 feet, no greater than about 75 feet, or no greater than about 100 feet.
Clause 6. The method of any one of clauses 1-5, further comprising:
Clause 7. The method of clause 6, wherein at least some of the liquid grout is added during the driving the lead section.
Clause 8. The method of any one of clauses 6-7, wherein at least some of the liquid grout is added before the uncoupling the lead section.
Clause 9. The method of any one of clauses 6-8, wherein at least some of the liquid grout is added after the adding the reinforcing structure.
Clause 10. The method of any one of clauses 6-9, wherein the liquid grout completely surrounds the reinforcing structure below the surface of the soil.
Clause 11. The method of any one of clauses 1-10, wherein the bit remains in the hole after the uncoupling the lead section.
Clause 12. The method of any one of clauses 1-10, wherein the bit is removed from the hole before the adding the reinforcing structure.
Clause 13. The method of any one of clauses 1-12, wherein the one or more extension sections are added with at least one bolted splice.
Clause 14. A pile in soil, comprising:
Clause 15. The pile of clause 14, further comprising a bit proximal to the top end of the lead section.
Clause 16. The pile of any one of clauses 14-15, wherein the depth is greater than about 1 foot, greater than about 3 feet, greater than about 5 feet, greater than about 10 feet, greater than about 15 feet, greater than about 20 feet, greater than about 25 feet, greater than about 30 feet, greater than about 40 feet, greater than about 50 feet, greater than about 60 feet, greater than about 75 feet, or greater than about 100 feet.
Clause 17. The pile of any one of clauses 14-16, wherein the depth is no greater than about 1 foot, no greater than about 3 feet, no greater than about 5 feet, no greater than about 10 feet, no greater than about 15 feet, no greater than about 20 feet, no greater than about 25 feet, no greater than about 30 feet, no greater than about 40 feet, no greater than about 50 feet, no greater than about 60 feet, no greater than about 75 feet, or no greater than about 100 feet.
Clause 18. The pile of any one of clauses 14-17, wherein the lead section has a length from the top end to the bottom end of at least about 2 feet.
Clause 19. The pile of any one of clauses 14-18, wherein the lead section has a length from the top end to the bottom end of no more than about 30 feet.
Clause 20. The pile of any one of clauses 14-19, wherein the second end of the reinforcing structure extends above the surface of the soil.
Clause 21. The pile of clause 20, wherein the second end of the reinforcing structure extends above the surface of the soil at least about 6 inches, at least about 1 foot, at least about 2 feet, at least about 3 feet, at least about 5 feet, at least about 10 feet, at least about 12 feet, or at least about 20 feet.
Clause 22. The pile of any one of clauses 20-21, wherein the second end of the reinforcing structure extends above the surface of the soil no more than about 6 inches, no more than about 1 foot, no more than about 2 feet, no more than about 3 feet, no more than about 5 feet, no more than about 10 feet, no more than about 12 feet, or no more than about 20 feet.
Clause 23. The pile of any one of clauses 14-22, wherein the grout is hardened about the reinforcing structure.
Clause 24. The pile of any one of clauses 14-23, wherein the grout protects the reinforcing structure from contact with the soil.
Clause 25. The pile of any one of clauses 14-24, wherein the grout protects the reinforcing structure from corrosion.
Clause 26. The pile of any one of clauses 14-25, wherein the reinforcing structure comprises a rebar cage, a pipe, or a combination thereof.
Clause 27. The pile of clause 26, wherein the reinforcing structure comprises the pipe, and the pipe has a pipe diameter that is at least about 4 inches, at least about 5 inches, at least about 6 inches, at least about 7 inches, at least about 8 inches, at least about 9 inches, at least about 10 inches, at least about 11 inches, at least about 12 inches, at least about 15 inches, or at least about 20 inches.
Clause 28. The pile of clause 26, wherein the reinforcing structure comprises the pipe, and the pipe has a pipe diameter that is no more than about 5 inches, no more than about 6 inches, no more than about 7 inches, no more than about 8 inches, no more than about 9 inches, no more than about 10 inches, no more than about 11 inches, no more than about 12 inches, no more than about 15 inches, no more than about 20 inches, or no more than about 30 inches.
Clause 29. The pile of any one of clauses 14-28, wherein the pile has a pile diameter at the surface of the soil that is no more than about 6 inches, no more than about 7 inches, no more than about 8 inches, no more than about 9 inches, no more than about 10 inches, no more than about 11 inches, no more than about 12 inches, no more than about 15 inches, no more than about 20 inches, no more than about 24 inches, no more than about 36 inches, no more than about 48 inches, no more than about 60 inches, no more than about 72 inches, or no more than about 120 inches.
Clause 30. The pile of any one of clauses 14-29, wherein the pile has a pile diameter at the surface of the soil that is greater than about 6 inches, greater than about 7 inches, greater than about 8 inches, greater than about 9 inches, greater than about 10 inches, greater than about 11 inches, greater than about 12 inches, greater than about 15 inches, greater than about 20 inches, greater than about 24 inches, greater than about 36 inches, greater than about 48 inches, greater than about 60 inches, greater than about 72 inches, or greater than about 120 inches.
Clause 31. A lead section for a pile comprising:
Clause 32. The lead section of clause 31, wherein the one or more flights of helical screws are right-hand helical screws, and the driver joiner is a right-hand driver joiner.
Clause 33. The lead section of clause 31, wherein the one or more flights of helical screws are left-hand helical screws, and the driver joiner is a left-hand driver joiner.
Clause 34. The lead section of any one of clauses 31-33, wherein the shaft is at least partially hollow to allow liquid grout to flow through the lead section.
Clause 35. The lead section of any one of clauses 31-34, having a lead section diameter that is at least about 2 inches, at least about 3 inches, at least about 4 inches, at least about 5 inches, at least about 6 inches, at least about 7 inches, at least about 8 inches, at least about 9 inches, at least about 10 inches, at least about 11 inches, at least about 12 inches, at least about 15 inches, or at least about 20 inches.
Clause 36. The lead section of any one of clauses 31-35, having a lead section diameter
As previously stated, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. It will be appreciated that many modifications and other variations stand within the intended scope of this invention as claimed below. Furthermore, the foregoing description of various embodiments does not necessarily imply exclusion. For example, “some” embodiments may include all or part of “other” and “further” embodiments within the scope of this invention. In addition, “a” does not mean “one and only one;” “a” can mean “one and more than one.”
