DEVICES, SYSTEMS, AND METHODS FOR ANCHORING STRUCTURAL LOADS

Abstract

Disclosed are devices, systems and methods for anchoring buildings to foundations. The disclosed devices, methods and systems comprise an embedment block comprising fasteners attaching a load bearing structure to a foundation anchor. Anchors comprise a head such as pierhead, loop, or plate or other assemblies that easily affix the anchor to its load.

Description

BACKGROUND

High load bearing structures such as building columns require anchor piles attaching to and extending below a building's foundation. Anchor piles are often used where a shallow foundation is insufficient due to a variety of reasons including large structural loads. Unfortunately, building pilings often require drilling large and deep holes in the earth to set reinforced concrete or otherwise require driving large metal spikes into the ground. After reinforced concrete pilings set, they are susceptible to shear and torsion forces that can crack or displace the pilings. Use of unreinforced concrete foundations, termed “floating” foundations, are limited to situations where the weather is favorable and the soil is suitable for pouring shallow foundations.

Moreover, load-bearing pilings, such as those providing support for arches, columns, and other structures must be connected to each other by a system of footings linked to the foundation, creating additional weight and structural risk of shear and torsional weaknesses between the structural components. In some instances, steel helical anchors have been used instead of concrete pilings. However, the sectional diameter of such anchor heads or piers are small thereby requiring elaborate mating joints to connect the load bearing structure. Thus, what is needed are devices, systems and methods that do not require pilings to anchor load bearing structures; as well as devices, systems and methods that eliminate mating joints between a load bearing structure and an anchor, but retain the necessary stability and strength to anchor the structure to the earth.

SUMMARY

Presented herein are devices, systems and methods for joining a load bearing structure, such as a column, for example, to an anchor without need for a mating assembly. In one embodiment, the device is an integrated embedment block holding together (or capable of holding together) the head of an anchor and a fastener for a load bearing structure such as a column, beam, arch, etc. In one embodiment, a method of embedding the head of an anchor into a concrete block with an integrally attached fastener for a load bearing structure is disclosed. In yet another embodiment, a system of transferring load forces from a load-bearing structure into an embedment block and subsequently into an embedded anchor is described. The disclosed devices, systems and methods do not rely on mating assemblies connecting the load-bearing structure and the anchor, and specifically are intended to exclude such assemblies, including mating assemblies between a load-bearing foot and a load-bearing anchor head. While not limited to use in construction, such a system is specifically intended to allow the rapid erection of a structure in situations where weather and soil conditions are unfavorable including using a floating foundation in boggy soil. Various uses included construction of buildings, pre-engineered buildings, bridges, piers, pipelines and other structures benefiting from a foundation anchor.

Certain benefits are realized by the devices, systems and methods disclosed herein. The particular arrangement of a fastener for a load bearing structure embedded into the same block as an anchor head enjoys the benefits of a floating concrete foundation, such as lighter weight, while retaining the benefits of a piling-anchored foundation, which had been mutually exclusive until disclosed herein. The disclosed devices, systems and methods lack the need for a mating assembly between a load bearing structure and an anchor. Similarly, the disclosed devices, systems and methods reduce the time and cost of constructing a building's foundation as well as create a strong, lightweight and durable joint between the anchor and the load-bearing structure.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 illustrates an overhead view of an exemplary embedment block used to anchor an endwall column.

FIG. 2 illustrates a sideview of an exemplary embedment block used to anchor an endwall column.

FIG. 3 illustrates an overhead view of an exemplary embedment block used to anchor a sidewall column.

FIG. 4 illustrates a sideview of an exemplary embedment block used to anchor a sidewall column.

FIG. 5 illustrates an overhead view of an exemplary embedment block used to anchor a centerwall column.

FIG. 6 illustrates a sideview of an exemplary embedment block used to anchor a centerwall column.

FIG. 7 illustrates a hex bolt fastener having a threaded end for receiving nuts embedded into the top of an embedment block.

FIG. 8 illustrates a bolt fastener embedded into the top of an embedment block.

FIG. 9 illustrates an epoxied bolt integrally attached to the top of an embedment block.

FIG. 10 illustrates curved bolt fastener embedded into the top of embedment block.

DETAILED DESCRIPTION

Disclosed are devices, systems and methods for fixing a load bearing structure to an anchored foundation. The disclosed devices, methods and systems rely on transfer of forces from the load bearing structure though a concrete embedment block into the head of an embedded anchor without the need for a direct mechanical mating assembly between the load bearing structure's foot and its anchor's head.

In certain embodiments, the term “embedment block” comprises concrete, cement, or other castable material but specifically excludes mating assemblies coupling an embedded anchor head and an embedded load attachment point. Similarly, the term “anchor” refers to any device or combination of devices that fix a structure to the ground, and include but are not limited to helical anchors, piles, cables, and the like extending into the ground. Anchors comprise a head such as pierhead, loop, or plate or other assemblies that easily affix the anchor to its load. The term “mating assembly” is to be construed as any mechanical assembly linking a load-bearing base and an anchor head together including such devices as couplers. The disadvantages of using such devices as couplers in an embedment block, such as increased weight, cost and time to construct are thereby eliminated as disclosed herein.

In certain embodiments, the embedment block comprises fasteners for attaching a load bearing structure to the top of an embedment block. The term “fastener” is to be construed as any device or combination of devices for linking the foot of a load bearing structure to an embedment block, and include screws, bolts, hex bolts, nut and bolts, curved bolts, pins, rivets, resins, epoxy, and the like, operating alone or in combination with each other. The term “load-bearing” can refer to any device or combination of devices that transmits force downwards and include such structures as columns, studs, beams, arches, and the like. Load-bearing structures may comprise a “foot” that may include plates and the like for attaching the base of the load bearing structures to fasteners in an embedment block. The term “membrane skirt” includes any concrete slab insulation or vapor barrier designed to provide a thermal break or moisture barrier between a slab and a grade and includes but is not limited to multilayer blanket insulation, cross woven polyethylene, high density closed-cell foam, high density polyethylene bubble, reflective aluminum, and the like.

In FIG. 1 a simplified top-down view of a non-limiting embodiment of the disclosure wherein an anchor head 1, also known as a pierhead, is embedded at the bottom of a concrete embedment block 2, surrounded by rebar 3, wherein the embedment block also comprises four attachment bolts 4, at the top of the embedment block to fasten a load bearing structural column to the fasteners. The position of the embedment block is shown in relation to the foundation 5, wherein the embedment block is located at the end of two perpendicular walls (not shown).

In FIG. 2 a simplified side view of a non-limiting embodiment of the disclosure is shown wherein an anchor head 1, also known as a pierhead, is embedded into the bottom of a concrete embedment block 2, surrounded by rebar 3 wherein the embedment block also comprises four attachment bolts 4, at the top of the embedment block to affix a load bearing structural column to the fasteners. The position of the embedment block is shown in relation to the foundation 5, wherein the embedment block is located at the end of two walls that are perpendicular to each other (not shown). The pierhead 1, is attached to a shaft extending into the ground via a coupler 6, wherein the shaft comprises multiple helical blades 7 forming a helical pile 8 thereby anchoring a load bearing structure to the ground (not shown). Optionally, a membrane skirt 9 may be attached to the embedment block wherein the skirt extends outwards from a building.

In FIG. 3 a simplified top-down view of a non-limiting embodiment of the disclosure is shown wherein an anchor head 1, also known as a pierhead, is embedded at the bottom of a concrete embedment block 2, surrounded by rebar 3, wherein the embedment block also comprises four attachment bolts 4, at the top of the embedment block to fasten a load bearing structural column to the fasteners. The position of the embedment block is shown in relation to the foundation 5, wherein the embedment block is located at underneath a length of a side wall (not shown).

In FIG. 4 a simplified side view of a non-limiting embodiment of the disclosure is shown wherein an anchor head 1, also known as a pierhead, is embedded into the bottom of a concrete embedment block 2, surrounded by rebar 3 wherein the embedment block also comprises four attachment bolts 4, at the top of the embedment block to affix a load bearing structural column to the fasteners. The position of the embedment block is shown in relation to the foundation 5, wherein the embedment block is located at the center of the length of a wall (not shown). The anchor heads are attached to shafts extending into the ground via a coupler 6, wherein the shaft comprises multiple helical blades 7 forming a helical pile 8, thereby anchoring a load bearing structure to the ground (not shown). The helical piles are offset at an angle 10 thereby distributing the load over a greater cross-section area of ground beneath the wall. Optionally, a membrane skirt 9 may be attached to the embedment block wherein the skirt extends outwards from a building.

In FIG. 5 a simplified top-down view of a non-limiting embodiment of the disclosure is shown wherein an anchor head 1, also known as a pierhead, is embedded at the bottom of a concrete embedment block 2, surrounded by rebar 3, wherein the embedment block also comprises four attachment bolts 4, at the top of the embedment block to fasten a load bearing structural column to the fasteners. The position of the embedment block is shown in relation to the foundation 5, wherein the embedment block is located at the center of a length of a wall (not shown).

In FIG. 6 a simplified side view of a non-limiting embodiment of the disclosure is shown wherein an anchor head 1, also known as a pierhead, is embedded into the bottom of a concrete embedment block 2, surrounded by rebar 3 wherein the embedment block also comprises four attachment bolts 4, at the top of the embedment block to affix a load bearing structural column to the fasteners. The position of the embedment block is shown in relation to the foundation 5, wherein the embedment block is located at the center of a length of a wall (not shown). The anchor heads 1, are attached to shafts extending into the ground via a coupler 6, wherein the shaft comprises multiple helical blades 7 forming a helical pile 8, thereby anchoring a load bearing structure to the ground (not shown). The helical piles are offset at an angle 10 thereby distributing the load over a greater cross-section area of ground. Optionally, a membrane skirt 9 may be attached to the embedment block wherein the skirt extends outwards from a building.

In FIG. 7, a simplified side view of a non-limiting embodiment of the disclosure is shown comprising a bolt fastener 11, embedded into the top of an embedment block 12, wherein the bolt comprises a threaded end 13 with an attached nut 14 above an attachment plate 15.

In FIG. 8, a simplified side view of a non-limiting embodiment of the disclosure is shown comprising a bolt fastener 11, embedded into the top of an embedment block 12, wherein the bolt comprises opposing threaded ends 13 with attachments nuts 14 above and below an attachment plate 15.

In FIG. 9, a simplified side view of a non-limiting embodiment of the disclosure is shown comprising a bolt fastener 11, embedded into the top of an embedment block 12, wherein the bolt comprises threads 13 with an attached nut 14 above an attachment plate 15 further wherein the bolt fastener 11 is affixed in an epoxy resin 16.

In FIG. 10, a simplified side view of a non-limiting embodiment of the disclosure is shown comprising a bolt fastener 11, embedded into the top of an embedment block 12, wherein the bolt comprises a threaded end 13 with an attached nut 14 above an attachment plate 15, also wherein the fastener bolt is bent at 90° degrees 17 within the embedment block.

In certain other embodiments, a plurality of anchors are used, such as two, three, four or more anchors. As such, a plurality of anchor heads are also embedded into the embedment block. Anchors may be sunk parallel to an attached wall or extend outwards at an angle of 120° degrees, or other suitable offset from parallel. An anchor head may comprise a pier cap as shown in the Figures, but the pier cap is considered optional and the anchor head may be used without a pier cap in some embodiments, particularly where a helical pile has shifted prior to pouring the embedment block. In certain embodiments wherein a pier cap is excluded, the bare anchor head may be affixed to rebar that is to be embedded in the embedment block.

In order to construct the devices disclosed herein, various methods are used. In certain embodiments, a foundation trench line for a building is first excavated. Next, one or more helical piers are sunk into the ground in the trench positions where load bearing columns are to be affixed. Helical piers are sunk into the trench positions such that at least the pierheads extends upward from the trench. Optionally, formers and rebar may be placed around the pierhead or surround the pierhead to form a cast. Concrete is then poured over the pierheads to cast an embedment block wherein the pierhead is embedded. Subsequently, fasteners are either embedded into the block while the concrete is still wet, or, later, integrally attached to the block by setting fasteners into drilled holes with epoxy or other resins. An embedment block may be formed prior to laying a foundation or formed simultaneously while pouring a foundation. In certain embodiments, a membrane skirt is embedded or attached to the edge of the embedment block to act as insulation and a moisture barrier prior to pouring the concrete.

In certain embodiments, the embedment block comprises a membrane skirt embedded or attached to the edge of the embedment block extending into the ground away from the foundation and acting as insulation and a moisture barrier. For buildings susceptible to frost heave, the combination of the embedment block and membrane skirt are especially advantageous. Specifically, the interior temperature of a heated building will transfer heat to the embedment block, but the addition of a membrane skirt will retain the heat being transferred, thereby preventing or mitigating the freezing of the ground under the skirt and around the embedment block.

Other modifications and embodiments of the invention will come to mind in one skilled in the art to which this invention pertains having the benefit of the teachings presented herein. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed. Although specific terms are employed, they are used in generic and descriptive sense only and not for purposes of limitation, and that modifications and embodiments are intended to be included within the scope of the appended claims.

Claims

1. A pre-engineered building comprising: a foundation wherein a helical pile is sunk into the ground with an at least one pierhead extending above ground,wherein the pierhead is embedded into an entrenched concrete embedment block having a top and a bottom, and,wherein the top of the block comprises integrally inserted fasteners for attaching an endwall column, a centerwall column, or a sidewall column to which the pre-engineered building is also attached.

2. The building of claim 1, wherein the fasteners are selected from the group consisting of screws, bolts, hex bolts, curved bolts, pins, rivets, resins, and epoxy, and combinations thereof.

3. The building of claim 2, comprising a plurality of the helical piles such that a plurality of the pierheads are embedded into the block.

4. The building of claim 3, wherein the embedment block excludes a mating assembly that directly links the pierhead and the fastener.

5. The building of claim 4, wherein the embedment block further comprises a membrane skirt adjacent the embedment block.

6. A pre-engineered building consisting essentially of: a foundation wherein a helical pile is sunk into the ground with an at least one pierhead extending above ground,wherein the pierhead is embedded into an entrenched concrete embedment block having a top and a bottom, and,wherein the top of the block comprises integrally inserted fasteners for attaching an endwall column, a centerwall column, or a sidewall column to which the pre-engineered building is also attached.

7. The building of claim 6, wherein the fasteners are selected from the group consisting of screws, bolts, hex bolts, curved bolts, pins, rivets, resins, and epoxy, and combinations thereof.

8. The building of claim 7, comprising a plurality of the helical piles such that a plurality of the pierheads are embedded into the block.

9. The building of claim 8, wherein the embedment block excludes a mating assembly that directly links the pierhead and the fastener.

10. The building of claim 9, wherein the embedment block further comprises a membrane skirt adjacent the embedment block.