FLARED REINFORCED PIER AND PIER BRACKET ASSEMBLY AND METHODS OF MANUFACTURING AND USE

FIELD

The present invention relates to starter piers and pier bracket assemblies that use starter piers, and more particularly, improved starter piers and methods of manufacturing the starter piers.

BACKGROUND

Anchor assemblies, including structural piers, function under compression as footings or underpinnings for structures, such as building foundations, walls, platforms, towers, bridges, and other structures. Anchor assemblies are used in both new construction as well as in the repair of settled and damaged footings, foundations, or other supports of existing buildings and other structures. Structural pier devices used in anchor assemblies include helical anchors and push piers. A helical anchor includes a shaft that carries one or more bearing plates, or flights, generally arranged in a helical configuration on the shaft. In use, powered rotation is communicated to the shaft to screw the helical anchor into the ground to bedrock or to load-bearing strata sufficiently stable to support the desired structure. Once inserted into the ground, the structure to be supported may be built or repaired with some or all of its weight carried by the helical anchor. Push piers are linear shafts hydraulically driven into the ground alongside the structure to be supported until the push piers reach bedrock or a load bearing strata region at which the piers experience a desired amount of resistance sufficient to support the structure. Once a series of push piers or helical piers are driven into the ground, the structure is raised by a desired amount and fastened to the piers with a pier bracket assembly. The piers and bracket assemblies are coupled to one another in order to support the structure.

BRIEF SUMMARY

Embodiments of the present invention relate to a starter pier and/or a pier bracket assembly that uses the starter pier. The pier bracket assembly comprises a pier bracket, a sleeve, a starter pier, one or more push piers sections, and/or other components as will be described herein. The pier bracket is configured for operative coupling with a structure (e.g., a building foundation, wall, footers, or the like support member), and the piers (e.g., starter pier, one or more push piers sections, or the like) are inserted into the ground under force in order to support the weight of the structure.

The starter pier (e.g., otherwise described as a lower, lead, or the like pier) has a first end, a second end, and an intermediate portion. The starter pier may be a hollow tube. The first end may be a flared first end that is swaged such that the flared first end has a flared internal diameter that is greater than the interior diameter of the hollow tube of the starter pier, while the flared first end has a flared outer diameter that is greater than the outer diameter of the hollow tube of the starter pier. A reinforcing member (e.g., a cylindrical member) may be inserted into the flared first end to provide support for the flared first end of the starter pier. The reinforcing member may be a cylindrical ring member. The reinforcing member may be operatively coupled to the flared first end of the starter pier (e.g., through compressing the flared first end around the ring, press-fitting the ring into the tube, staking, using couplings, such as a weld, fasteners, or the like, or other like operative coupling). Also, the second end may comprise one or more couplers, such as an insert and fasteners, a female coupling (e.g., internal threaded section, or the like) that facilitates connection with a male coupling (e.g., externally threaded section, or the like), a male coupling that facilitates connection with a female coupling, fasteners (e.g., bolts, rivets, or the like), clamps, crimping, flares, dimples, slots, projections, groves, bosses, or the like in order to operatively couple the second end of a starter pier to an adjacent push pier section.

One embodiment of the invention comprises a pier for a pier bracket assembly. The pier comprises a tube having a first end and a second end, wherein the first end is a flared first end. The pier further comprises a reinforcing member operatively coupled to the flared first end and located at least partially within an internal surface of the flared first end.

In further accord with embodiments, the reinforcing member is a cylindrical member.

In other embodiments, the cylindrical member is a ring with an aperture therethrough.

In yet other embodiments, the ring is continuous.

In still other embodiments, the ring is discontinuous.

In other embodiments, the ring has an outer surface and an inner surface, and wherein the outer surface and the inner surface of the ring are uniform and concentric.

In further accord with embodiments, the pier is a starter pier.

In other embodiments, the flared first end is compressed around at least a portion of the reinforcing member.

In yet other embodiments, the reinforcing member is press fit into the flared first end.

In still other embodiments, the pier further comprises one or more connectors to aid in operatively coupling the flared first end to the reinforcing member.

In other embodiments, the tube has a circular shape.

Another embodiment of the invention comprises a method of manufacturing a pier. The method comprises flaring a first end of a tube to form a flared first end, inserting a reinforcing member into at least a portion of the flared first end, and operatively coupling the reinforcing member to the flared first end.

In further accord with embodiments, flaring the first end of the tube comprises using a press and flare die to swage the first end of the tube.

In other embodiments, operatively coupling the reinforcing member to the flared first end comprises using a press and a mold to compress at least a portion of the flared first end around the reinforcing member.

In yet other embodiments, operatively coupling the reinforcing member to the flared first end comprises using a press to press-fit the reinforcing member to the first end.

In still other embodiments, operatively coupling the reinforcing member to the flared first end comprises using one or more connectors between the flared first end and the reinforcing member.

Another embodiment of the invention is pier bracket assembly comprising a pier bracket configured to be operatively coupled to a structure and a starter pier. The starter pier comprising a tube having a first end and a second end, wherein the first end is a flared first end, and a reinforcing member operatively coupled to the flared first end and located at least partially within an internal surface of the flared first end. The pier bracket assembly further comprises one or more push piers sections configured to be operatively coupled to the second end of the starter pier or each other. The starter pier and the one or more push piers are operatively coupled to the pier bracket to support the structure.

In further accord with embodiments, the reinforcing member is a cylindrical member.

In other embodiments, the flared first end is compressed around at least a portion of the reinforcing member.

Another embodiment of the invention is a method of installing a pier bracket assembly. The method comprises assembling a pier bracket to a structure, and assembling a starter pier to the pier bracket. The starter pier comprises a tube having a first end and a second end, wherein the first end is a flared first end, and a reinforcing member operatively coupled to the flared first end and located at least partially within an internal surface of the flared first end. The method further comprises assembling a drive assembly to the bracket and starter pier, pushing the starter pier into the ground using the drive assembly, assembling a push pier section to the second end of the starter pier, and driving the push pier at least partially into the ground using the drive assembly. The flared first end with the reinforcing member pushes the ground and reduces the friction between the ground and an intermediate portion and second end of the starter pier and the push pier assembled to the starter pier.

To the accomplishment of the foregoing and the related ends, the one or more embodiments of the invention comprise the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth certain illustrative features of the one or more embodiments. These features are indicative, however, of but a few of the various ways in which the principles of various embodiments may be employed, and this description is intended to include all such embodiments and their equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which illustrate embodiments of the invention and which are not necessarily drawn to scale, are as follows:

FIG. 1 is a perspective view of a starter pier for a pier bracket assembly, in accordance with embodiments of the present disclosure.

FIG. 2 is a side view of the starter pier of FIG. 1.

FIG. 3 is a first end view the end of the starter pier of FIG. 1.

FIG. 4 is a cross-sectional side view of the starter pier of FIG. 2.

FIG. 5 is a perspective side view of a starter pier, in accordance with embodiments of the present disclosure.

FIG. 6 is an enlarged perspective view of a flared first end of a starter pier, in accordance with embodiments of the present disclosure.

FIG. 7 is a side elevation cut-away view of a pier bracket assembly installed on a structure and in the ground, in accordance with embodiments of the present disclosure.

FIG. 8 is a perspective side view of a pier bracket, in accordance with embodiments of the present disclosure.

FIG. 9 is an exploded rear elevation view of the pier bracket assembly, in accordance with embodiments of the present disclosure.

FIG. 10 is a partially exploded side elevation view of the pier bracket assembly, in accordance with embodiments of the present disclosure.

FIG. 11A is a perspective view of a flare die and press for flaring a tube, in accordance with embodiments of the present disclosure.

FIG. 11B is a perspective view of an end of a tube installed on a flare die within a press for flaring the tube, in accordance with embodiments of the present disclosure.

FIG. 11C is a perspective view of the flare die initiating the flaring of an end of a tube, in accordance with embodiments of the present disclosure.

FIG. 11D is a perspective view of the flare die in process of flaring an end of a tube, in accordance with embodiments of the present disclosure.

FIG. 11E is a perspective view of the flare die completing the flare of an end of the tube, in accordance with embodiments of the present disclosure.

FIG. 12A is a perspective view of a compression mold and press for compressing a portion of the flared end, in accordance with embodiments of the present disclosure.

FIG. 12B is a perspective view of a compression mold with the tube inserted into a mold, in accordance with embodiments of the present disclosure.

FIG. 12C is a perspective view of a compression mold with a reinforcing member being inserted into the flared end of the tube, in accordance with embodiments of the present disclosure.

FIG. 12D is a perspective view of a compression mold with a reinforcing member located in the flared end of the tube, in accordance with embodiments of the present disclosure.

FIG. 12E is a perspective view of a press die operatively coupled to the reinforcing member, in accordance with embodiments of the present disclosure.

FIG. 12F is a perspective view of a press die forcing the reinforcing member and the flared tube through the compression mold, in accordance with embodiments of the present disclosure.

FIG. 12G is a perspective view of the press die before forcing the reinforcing member and the flared tube through the compression mold, in accordance with embodiments of the present disclosure.

FIG. 13 is a process for manufacturing the starter pier and installing the pier bracket assembly with the starter pier, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

Embodiments of the present invention may now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure may satisfy applicable legal requirements. Like numbers refer to like elements throughout.

Referring now to the drawings, wherein like reference numerals designate corresponding or similar elements throughout the several views, embodiments of a starter pier 100 and/or a pier bracket assembly 10 using the starter pier 100 are shown in FIGS. 1 through 10. The pier bracket assembly 10 (otherwise described as an anchor assembly, or the like) may comprise a pier bracket 20, a sleeve 38, a starter pier 100, one or more push piers sections 52 (e.g., otherwise described as push piers), and/or other components as will be described herein. The pier bracket 20 is configured for operative coupling with a structure 2 (e.g., a building foundation, wall, footers, or the like support member), and the piers 50 (e.g., starter pier 100, one or more push pier sections 52, or the like) are inserted into the ground under force in order to support the weight of the structure.

The pier bracket 20, may be any type of pier bracket 20 that is operatively coupled to a structure 2 (e.g., through the use of bolts, one or more connectors, such as anchors, or the like). As will be described in further detail herein, the one or more piers 50 may be operatively coupled to each other and forced into the ground so as to form an anchor to carry the loading of the structure 2. The one or more piers 50 may be any type of tube of any shape (e.g., square, oval, rectangular, non-uniform, or the like), but are typically round (e.g., circular, or the like). The one or more piers 50 may be solid, hollow, partially solid, partially hollow, or the like; however, the one or more piers 50 are typically hollow. The first of a plurality of piers 50 may comprise a starter pier 100 (e.g., otherwise described as a lower, lead, or the like pier). The starter pier 100 may have a first end 110, a second end 120, and an intermediate portion 130. The starter pier 100 may be a tube 102 (e.g., a hollow tube, or the like of any shape) that has an interior diameter 104 and an exterior diameter 106. The first end 110 may be a flared first end 112 (otherwise described herein as a flared end 112) that is swaged such that the flared first end 112 has a flared internal diameter 114 that is greater than the interior diameter 104 of the starter pier 100 (e.g., the intermediate portion 130, or the like), while the flared first end 112 has a flared outer diameter 116 that is greater than the outer diameter 106 of the starter pier 100 (e.g., intermediate portion 130, or the like). In some embodiments, the flared internal diameter 114 may converge from a distal end (outer end) of the flared first end 112 to a proximal end (end adjacent the intermediate portion 130) of the flared first end 112. An intermediate portion 130 may extend between the first end 110 and the second end 120. The second end 120 may comprise one or more couplers 140. The one or more couplers 140 may comprise, an insert 142 (e.g., tube, other type of insert) that is operatively coupled to the starter pier 100 (e.g., the second end 120) through the use of insert connections 144 (e.g., welds, clamps, clips, bosses, fasteners, such as screws, bolts, rivets, or the like, or other like connections). In other embodiments, the one or more couplers 140 may comprise a female coupling (e.g., internal threaded section, or the like) that facilitates connection with a male coupling (e.g., externally threaded section, or the like) of a push pier 52 (or vice versa). However, it should be understood that any type of couplers 140 may be used, such as fasteners (e.g., bolts, rivets, or the like), clamps, crimping, flares, dimples, bosses, slots, projections, groves, or the like in order to operatively couple the second end 120 of a starter pier 100 to an adjacent push pier section 52 section, which in turn is operatively coupled to one or more additional push piers sections 52 in series in the same or similar ways using couplers 140. While the coupler 140, such as the insert 142, is illustrated as being operatively coupled to the second end 120 of the starter pier 100, it should be understood that the coupler 140, such as the insert 142, may be operatively coupled to a first end of a push pier section 52 and operatively coupled to the second end 120 of the starter pier 100 during installation.

A reinforcing member 180 (otherwise described herein as a reinforcement member 180) may be inserted into the flared first end 112 to provide support for the flared first end 112 of the starter pier 100. In some embodiments, the reinforcing member 180 may have a shape that corresponds to the shape of the pier 100 (e.g., a flared first end 112, or the like). As such, in some embodiments, the reinforcing member 180 may be a cylindrical member. In some embodiments the cylindrical member may be a ring 182 with an aperture therethrough. The ring 182 may be continuous (e.g., no breaks) or discontinuous (e.g., have one or more slots, or the like to allow the ring to flex). The ring 182 may have an inner member diameter 184 with an inner member surface 185 and an outer member diameter 186 with and outer member surface 187. The inner member diameter 184 and outer member diameter 186 may be uniform and concentric with each other. Alternatively, the inner member surface 185 and/or the outer member surface 187 may converge or diverge from each other (e.g., may be at least partially semi-conical, or the like). The outer member diameter 184 may be the same as or similar to (e.g., slightly smaller or larger) than one or more portions of the flared internal diameter 114.

As illustrated in FIGS. 1 through 6, regardless of the shape and/or size of the reinforcing member 180 it may be inserted into and compressed by (e.g., pressed fit into, or the like), secured with one or more connectors to, and/or the like at least a portion of the flared first end 112 of the starter pier 100, as will be described with respect to the process described and illustrated in FIGS. 11A through 13. For example, the reinforcing member 180 may be inserted into at least a portion of the flared first end 112 of the starter pier 100, and at least a portion of the flared first end 112 may be compressed (e.g., squeezed, crimped, or the like) around at least a portion of the reinforcing member 180. Additionally, or alternatively, at least a portion of the reinforcing member 180 may be press fit into the flared first end 112 of the starter pier 100. Additionally, or alternatively, the reinforcing member 180 may be inserted into at least a portion of the flared first end 112 of the starter pier 100, and one or more connectors may be used to aid in operatively coupling the reinforcing member 180 to the flared first end 112. The one or more connectors may be fasteners, rivets, set-screws, dimple crimps, projections on the internal surface of the flared first end 112, projections on the outer member surface 187 of the reinforcing member 180, a rib on the internal surface of the flared first end 112, a rib on the outer member surface 187 of the reinforcing member 180, or other like connector. Regardless of how the reinforcing member 180 is operatively coupled to the flared first end 112 of the starter pier 100, the flared outer diameter 116 of the flared first end 112 is greater than the outer diameter 106 of the intermediate portion 130 and/or the second end 120 of the starter pier 100. As will be described in further detail herein, the reinforced flared first end 112 of the starter pier 100 pushes the ground away from the starter pier 100 such that it is easier for the outer diameter 106 of the starter pier 100 and/or one or more additional push pier sections 52 to pass through the ground.

The reinforcing member 180 may be operatively coupled to the flared first end 112 such that the end face of the reinforcing member 180 and the end face of the flared first end 112 are approximately flush with each other (e.g., in the same plane, or the like as illustrated in FIG. 4). However, in some embodiments the end face of the reinforcing member 180 may extend outwardly past at least a portion of the end of the distal end of the flared first end 112 (e.g., in different planes, or the like as illustrated in FIGS. 5 and 6). In still other embodiments, the end face of the reinforcing member may sit within at least a portion of the end face of the distal end of the flared first end 112 (e.g., in different planes, or the like—not illustrated).

It should be understood that the flared first end 112 of the starter pier 100 may have any type of shape or configuration. For example, the external flared end surface 117 of the flared first end 112 may be a smoothed radiused surface, a flat angled surface, different sections having different radiuses and/or flat sections. In some embodiments, the flared outer diameter 116 located at the distal end of the flared first end 112 may range from 3 to 4 inches, the flared inner diameter 114 may range from 2.75 to 3.5 inches, and the flared first end may have a flared angle that ranges from 1 to 5 degrees. Should the reinforcing member 180 be a cylindrical hollow ring, in some embodiments, the outer ring diameter 186 may range from 2.75 to 3.5 inches, the length may range from 0.5 to 2 inches, and the thickness of the ring may range from 0.1 to 0.3 inches. However, it should be understood that the dimensions may fall outside, overlap, or fall within these ranges or any value within or outside of these ranges dependent on the application of the starter pier 100.

As illustrated in FIGS. 7, 9, and 10, a plurality of push pier sections 52 may be added to the starter pier 100 of the pier bracket assembly 10 during installation. The plurality of push piers 52 may have similar inside and outside diameter dimensions as the starter pier 100 (i.e., the internal and outer diameter of the intermediate portion 130 and/or the second end 120). Axial end-to-end operative coupling of plurality of push piers 52 may occur through the use of couplers 140, as previously described herein with respect to the operative coupling of the push pier 52 to the second end 120 of the starter pier 100.

The pier bracket 20 may be any type of pier bracket. However, in some embodiments, as illustrated in FIG. 8, the pier bracket 20 may comprise a one piece monolithic body member 22. The pier bracket 20 may comprise a seat 24 (e.g., L-shaped seat, or the like) operatively coupled to a ground-engaging base 26 (e.g., a sand plate). The seat 24 may include a base leg 28 operatively coupled to an upper leg 29 (e.g., welded, bent, attached, or the like). The base leg 28 of the L-shaped seat 24 is configured to extend under and support the structure to be supported. The L-shaped seat may be operatively coupled to the structure 2 (e.g., through the use of fasteners, such as anchors, bolts, or the like). As such, a pair of spaced slots 31 may be provided in the upper leg 29 for receiving fasteners for securing the pier bracket 20 to the structure. While and L-shaped seat is illustrated, it should be understood that the seat 24 may have a different shape is configured for operative coupling with a support member of a structure 2.

The seat 24, such as the base leg 28 may be operatively coupled to a stand 26 (e.g., a sand plate 26) which may provide a surface for vertically standing the pier bracket 20 when the pier bracket 20 is not operatively coupled to the structure 2. In the illustrated embodiments, the shape of the stand 26, base leg 28, and/or upper leg 29 are square or rectangular; however, these components may be any type of shape (e.g., oval, circular, half-circular, hexagonal, any polygonal, non-uniform, or the like shape).

One or more side plates 30 (e.g., a pair of truncated triangular side plates, or the like) may extend from and interconnect the seat 24 to the stand 26 (e.g., the base leg 28 to the sand plate). The side plates 30 may taper in width from their connection at an upper edge to the base leg 28 to a smaller width at their connection at a lower edge to the stand 26. One or more of the side plates 30 may having openings 32 (e.g., oblong opening, or other shape) that are sized to fit a hand so that an installer has a handhold for carrying the pier bracket 20. The side plates 30 may converge from the outer free edge of the base leg 28 to the inner edge of the base leg 28. The inner edges of the side plates may 30 project beyond the upper leg 29 of the L-shaped seat 24 and may be operatively coupled to the tubular member 34 (e.g., hollow tubular member that is circular, oval, square, rectangular, pentagonal, hexagonal, any polygonal shape, or the like). The tubular member 34 may be operatively coupled to the seat 24, such as the upper leg 20 of the seat (e.g., extending substantially parallel with the upper leg 29, or the like). For example, the upper end of the tubular member 34 may be operatively coupled to the upper leg 29. In in the illustrated embodiments, the upper end of the tubular member 34 may be operatively coupled to the upper leg 29 through the use of a flange 36, such as at a point intermediate the length of the upper leg and the tubular member 34. The tubular member 34 operatively coupled to the seat 24 and stand 26 defines an axial through bore configured to receive an elongated sleeve 38 for passing piers 50 therethrough for supporting the structure 2, as will be described below. However, it should be understood that the pier bracket 20 may not include a tubular member 34, and instead the sleeve 38 and/or the one or more piers 50 may be operatively coupled to the pier bracket 20 in other ways, such as through the use of one or more securing members (e.g., clamps, plates, bars, rods, or the like) and/or fasteners that restrict horizontal movement of the piers 50 with respect to the pier bracket 20, but allow for the sleeve 38 and/or one or more piers to move vertically with respect to bracket 20 (e.g., until the one or more piers 50 are installed in the ground).

The sleeve 38 may comprise a hollow tubular element having outer diameter dimensions larger than that of the structural support devices. The sleeve 38 may have a restriction portion 39 that restricts the movement of restriction portion 39 of the sleeve 38 past the pier bracket 20 (e.g., a portion of the sleeve cannot pass through the tubular member 34, or the like). As such, the restriction portion 39 may have a restriction outer diameter that is greater than the outer diameter of the remainder of the sleeve 38. As such, in some embodiments the restriction portion 39 of the sleeve 38 may be a flared end (e.g., formed by swaging, or the like) with or without a reinforcing member located within the flared end. In other embodiments the restriction portion 39 may be a collar located outside of a portion of the sleeve 38, such as a ring collar welded to the periphery at an end of the sleeve 38.

The tubular member 34 may support a pair of opposed ears 40 extending outwardly from the periphery of the tubular member 34 and parallel with the flange 36. The flange 36 and each of the ears 40 define two pairs of aligned bolt holes 42 so that the pier bracket 20 may be fastened to the underpinning drive assembly. The peripheral edges of both the flange 36 and the ears 40 are rounded at their corners. This configuration facilitates placement of the drive assembly proximate the pier bracket 20 in preparation for driving the structural piers 50. As illustrated in FIG. 9, a threaded rod connector 44 extends through each of the pairs of bolt holes 42 for attachment to the drive assembly (not shown). Fasteners, such as nuts and washers may be used to operatively couple each rod 44 and a pier cap 66 to the pier bracket 20. It is to be understood that any number and size of threaded rods 44 may be used with corresponding pre-drilled bolt holes 42 located within the pier bracket 20. As such, after the piers 50 (e.g., the starter pier 100 and/or the one or more additional push pier sections 52) are driven into the ground, the rods 44, pier cap 66, and/or the drive assembly may be utilized to lift and/or support the structure 2.

FIGS. 11A through 12G illustrate a process of forming the starter pier 100. FIG. 11A illustrates a press 200 and flare die 240 (otherwise described as a swage die) that is used to form the starter pier 100. As illustrated in FIG. 11A, the flare die 240 may include a converging die portion 242 (e.g., angled die portion, or the like) that has a converging surface (e.g., from the bottom of the illustrated flare die 240 to the top of the flare die 240). The converging die portion 242 is illustrated as a conical die portion, but it may have another shape, such as a radiused surface, uniform, non-uniform, or the like surface. The flare die 240 may further have a shoulder 244 operatively coupled to the converging die portion 242. The flare die 240 may also have a base portion 246. The flare die 240 may be located adjacent the base 202 of the press 200. For example, the press 200 may have a plate 204 on which the flare die 240 may be located. The press 200 may further comprise a ram 210 (e.g., arm 211, head 212, or the like) and an actuator 214 (e.g., hydraulic, pneumatic, electric, or the like), which actuates the ram 210 (e.g., the arm 211, head 212, or the like thereof).

As illustrated in FIG. 11B, an unflared starter pier tube 102 may be installed over the flared die 240 (e.g., the top of the flare die 240) and positioned manually (as illustrated), or through the use of a jig, automated holders, and/or the like to hold the starter pier tube 102 in place. The press 200 may be activated such that the actuator 214 moves the ram 210 until the ram 210 engages the starter pier tube 102 (e.g., the second pier end 114 or a component attached thereto).

As illustrated in FIG. 11C, the ram 210 is further actuated until the first pier end 110 begins to flare as the flare die 240 engages the inner surface of the stater pier tube 102. FIGS. 11D and 11E illustrate that as the ram 210 is actuated the flare die 240 continues to form the flared first end 112 of the starter pier 100 until the flared first end 112 of the starter pier tube 102 reaches the shoulder 244 of the flare die 240. It should be understood that once the edge of the flared first end 112 of the stater pier tube 102 is adjacent to (e.g., before touching, after touching, or the like) the shoulder 244, the actuation of the ram 210 is stopped and/or reversed. After which, the starter pier tube 102 with the flared first end 112 is removed from the flare die 240.

FIG. 12A illustrates that the flare die 240 may be removed and replaced adjacent the base 202 of press 200 with a compression mold 260. It should be understood that the compression mold 260 may have a compression aperture 262 (e.g., through-hole). The compression aperture 262 may have an internal surface 264 that is uniform, non-uniform, straight, converging, or the like. In the illustrated embodiment, the internal surface 264 of the compression aperture 262 may have at least a portion that is converging and at least a portion that is straight (or diverging). This configuration may allow for the formation of the outer flared surface 117 of the flared first end 112 of the starter pier 100 to have a leading portion with a uniform leading diameter and a trailing portion with a converging trailing portion. However, it should be understood that the internal surface 264 may be sized and shaped in order to create different outer flared surfaces 117 for the flared first end 112.

As illustrated in FIG. 12B the compression aperture 262 allows for the second end 130 of the starter pier tube 102 to be placed through the compression aperture 262 until the flared first end 112 of the starter pier tube 102 engages a surface of the compression aperture 262.

FIGS. 12C and 12D illustrates that the reinforcing member 180 is inserted into the flared first end 112 of the starter pier tube 10 located in the compression mold 260. Thereafter, as illustrated in FIGS. 12E through 12G, in some embodiments a press die 280 may be coupled to the ram 212 of the press 200. The press die 280 may be sized to correspond with the reinforcing member 180, the end face of the flared first end 112 of the starter pier tube 102, or both. In some embodiments, the press die 280 is sized (e.g., has an outer diameter) to allow the press die 280 to push the flared first end 112 and the reinforcing member 180 through the compression aperture 262 of the compression mold 260. As discussed above, the internal surface of the compression aperture 262 may allow at least a portion of the flared first end 112 to pass through the compression aperture 262 without compressing a portion of the outer flared surface of the flared first end 112 to create a trailing portion of the flared first end 112 having a converging flared surface. However, the compression aperture 262 may compress at least a portion of the outer flared surface of the flared first end 112 around a portion of the reinforcing member 180 in order to aid in securing the reinforcing member 180 within the flared first end 112 at the leading portion of the flared first end 112. In some embodiments, it should be understood that the leading portion may be formed with a leading outer surface that has a uniform outer diameter.

FIG. 13 illustrates a process 200 for manufacturing the starter piers 100 and then installing the pier bracket assembly 10 to a structure 2 using the starter piers 100. As illustrated in block 302 of FIG. 13, one or more tubes are procured (e.g., purchased, cut from a longer tubes, performing additional manufacturing processes, or the like). For example, the one or more tubes 102 may be purchased having the second end 130 with the coupler 140 formed therein, a coupler 140 may be formed within a second end 130 of the tube 102 after receiving the tube, a coupler 140 may be formed within a first end of an adjacent push pier 52, or a coupler 140 may be incorporated and/or used during installation of the piers 50 (e.g., the starter pier 100, the push pier 52, or the like), which will be described in further detail herein. The one or more tubes 102 may be used for or to create the piers 50, such as the starter pier 100 and/or the one or more push piers sections 52. Moreover, one or more reinforcing members 180 may be procured (e.g., purchased, formed by cutting a tube into rings, or the like).

Block 304 of FIG. 13 illustrates that with respect to the starter piers 100, the first end 110 of the tubes may be swaged to create a flared first end 112. The swaging of the first end 110 may occur by any type of process (e.g., pressing a die, inserting an expandable tool into the first end 110 of the tube 102, or the like); however, in some embodiments the swaging of the first end 110 may occur as discussed with respect to FIGS. 11A through 11E above. As described herein, the flared first end 110 has a flared outer diameter 116 that is greater than the outer diameter of the remainder of the starter pier 100 (e.g., intermediate portion 130, second end 120, and/or the like).

Blocks 306 through 310 illustrate that a reinforcing member 180 may be operatively coupled to the flared first end 112 of the starter tube 102 in order to form a reinforced flared first end 112 of the starter pier 100. That is, the reinforcing member 180 member is located in the flared first end and at least a portion of the flared first end 112 may be compressed around the reinforcing member 180 through the use of any compression process. However, in some embodiments, it should be understood that the reinforcing member 180 may be operatively coupled to the starter tube 102 as previously described herein with respect to FIGS. 12A through 12G. As such, during the compressing process at least a portion of the interior and/or exterior surfaces of the flared first end 112 may be at least partially deformed around the reinforcing member 180.

Alternatively, or additionally, as illustrated in block 308 of FIG. 11, the reinforcing member 180 may be press fit into the flared first end 112 of the starter tube 100. For example, by press-fitting the reinforcing member 180 into the flared first end 112, the reinforcing member 180 may at least partially deform the interior and/or exterior surfaces of the flared first end 112 of the starter pier 100.

Furthermore, as illustrated in block 310 of FIG. 11, additionally or alternatively, one or more connectors may be used to operatively couple the flared first end 112 to the reinforcing member 180. For example, fasteners maybe be used to operatively couple the flared first end 112 to the reinforcing member 180 (e.g., extend through the outer and interior surfaces of the flared first end 112 and contact the outer surface of, extend through at least a portion of the outer surface, and/or extend through the inner surface of the reinforcing member 180). In other examples, the reinforcing member 180 may be welded to a portion of the flared first end 112, such between and end face of the distal end of the flared first end 112 and the end face and/or exterior surface of the reinforcing member 180, between the interior surface of the flared first end 112 and an end face of the reinforcing member 180, or the like.

After the components of the pier bracket assembly 10 are procured (e.g., purchased, manufactured, or the like), one or more pier bracket assemblies 10 may be installed on a structure 2. In use, an area of earth is excavated immediately adjacent a structure 2, such as adjacent to a foundation, to expose a portion of the structure 2, such as a footer of the foundation. This excavation area may extend beneath the base of the footer. The structure 2, such as a footer may be prepared by using a tool, such as a chipping hammer, to remove dirt, debris, and/or loose concrete from the structure 2 in order to provide bearing surfaces for the pier bracket 20.

As illustrated in block 310 of FIG. 13, the pier bracket 20 is operatively coupled to a structure 2, such as through the use of fasteners. In some embodiments, the pier bracket 20 is mounted on the underpinning drive assembly and then lowered into the excavation area adjacent the foundation. In other embodiments, the pier bracket 20 may be lowered into the excavation area and operatively coupled to structure 20 before the drive assembly is attached. The pier bracket 20 may be seated against the footer and operatively coupled to the foundations (e.g., fastened to the foundation through fasteners, such as steel concrete anchors, or other like couplings).

FIG. 13 further illustrates in block 312 that the sleeve 38 is operatively coupled to the pier bracket 20 and/or at least partially inserted into the ground. The sleeve 38 may be located within an opening dug into the ground or may be driven into the ground before, during, or after the starter pier 100 is first inserted into the ground. The sleeve 38 aids in resisting bending forces generated by driving the piers 50 in the ground and supporting the structure 2 when the starter pier 100 reaches a resistance point (e.g., packed soil, bedrock, or the like).

Block 314 of FIG. 13 illustrates that the starter pier 100 may be operatively coupled to the pier bracket 20 directly (when a sleeve 38 is not used), or indirectly through the sleeve 38. The starter pier 100 may already be located in the sleeve 38 when the sleeve 38 is installed, it may be inserted through the sleeve 38 after the sleeve 38 is operatively coupled to the pier bracket 20, or the like.

A drive assembly is used to drive the starter pier 100 into the ground, as illustrated by block 316 in FIG. 13. The drive assembly may include a hydraulic, pneumatic, electric, or the like ram that drives the starter pier 100 downward into the ground. The larger diameter of the flared first end 112 of the starter pier 100 pushes the earth and creates an annular space around the smaller diameter of the remainder of the starter pier 100 as it is advanced through soil. In some soft soils (e.g., soft clay, clean sand, or gravel) the space may only be temporary, while in harder soils (e.g., hard clay, packed dirt) the space may last longer. Regardless, the space or backfilling of the space with earth, reduces frictional resistance on the outside surface of the starter pier 100 and/or the one or more push piers 52 following the starter pier 100. After the piers 50 are installed, the soil will settle within the space providing additional frictional capacity for supporting the structure.

As illustrated by block 318, additional push piers 52 (e.g., push pier sections) may be operatively coupled to the second end 130 (e.g., through couplers 140, or the like) of the starter pier 100 axially with respect to the starter pier 100 and each second end of the push piers 52 as additional push piers 52 are added in series. The one or more push piers 52 may be operatively coupled to the starter pier 100 and/or each other before the end of the previous push pier is passed through the sleeve 38 and/or pier bracket 20. Each push pier 52 is driven into the ground using the drive assembly until resistance is met (e.g., load bearing resistance), such as bedrock, packed soil, or the like. Thereafter, the drive assembly is used to raise the structure, or the drive assembly is removed from the pier bracket 20 and other components are used to raise the structure to the desired level. In some embodiments, the last push pier 52 in the assembly may have a portion removed (e.g., a portion of the intermediate portion, second end, or the like is cut, disassembled, or the like) before or after raising the structure 2 in order to keep a low profile of the pier bracket assembly 10 such that at least a portion of (or all of) the pier bracket assembly 10 may be buried under the ground.

The pier bracket assembly 10 including the starter pier 100 has many advantages, including but not limited to improved manufacturing, such as manufacturing that does not require any machining to create the flared first end 212, use of a press, dies, and/or molds to create the flared first end 112 and to operatively couple the reinforcing member 180 to the flared first end 112 of the starter pier 100, and/or the like. Moreover, the reinforced flared end 112 provides for a strengthened end of the starter pier 100 that is used to push soil out of the way and create an annular space (e.g., with loose soil) to reduce the friction between the soil and the external surface of the piers 50.

Also, it will be understood that, where possible, any of the advantages, features, functions, devices, and/or operational aspects of any of the embodiments of the present invention described and/or contemplated herein may be included in any of the other embodiments of the present invention described and/or contemplated herein, and/or vice versa. In addition, where possible, any terms expressed in the singular form herein are meant to also include the plural form and/or vice versa, unless explicitly stated otherwise. Accordingly, the terms “a” and/or “an” shall mean “one or more.”

Certain terminology is used herein for convenience only and is not to be taken as a limiting. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” “downward,” “top” and “bottom” merely describe the configurations shown in the FIGs. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. The words “interior” and “exterior” refer to directions toward and away from, respectively, the geometric center of the core and designated parts thereof. The terminology includes the words specifically mentioned above, derivatives thereof and words of similar import.

It should be understood that “operatively coupled,” when used herein, means that the components may be formed integrally with each other, or may be formed separately and coupled together. Furthermore, “operatively coupled” means that the components may be formed directly to each other, or to each other with one or more components located between the components that are operatively coupled together. Furthermore, “operatively coupled” may mean that the components are detachable from each other, or that they are permanently coupled together.

While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations, modifications, and combinations of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.

FLARED REINFORCED PIER AND PIER BRACKET ASSEMBLY AND METHODS OF MANUFACTURING AND USE

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CROSS REFERENCE AND PRIORITY CLAIM UNDER 35 U.S.C. § 119

Provisional Applications (1)