This invention concerns a method and apparatus for stabilizing and supporting a structural foundation of a building structure that has or is likely to experience settlement or movement, and more particularly to a method and apparatus for elevating and/or providing stabilization to a slab or turn-down slab foundation from further settlement.
Foundations for buildings and other structures that have settled in the earth after initial construction tend to cause movement of the building structure, deterioration to the building structure, and might require a lifting force to stabilize the building structure. The cause for foundations settling or sinking can be from many sources, such as shifting soils resulting from acts of God or from earth excavation by man, faulty foundation design, water drainage from rain, broken water pipes or other water sources that cause erosion, or just by poor initial construction practices. Resolving and correcting the building settlement problems can be costly to the building owner.
Slab or turn-down slab foundations are installed in certain geographical areas in order to take advantage of the support bearing characteristics of the underlying soils, or as a cheaper, more economical means of supporting a structure over other conventional means of foundation construction practices.
Some turn-down slab foundations that have experienced settlement can be stabilized by installing grout under pressure beneath the slab in order to raise or stabilize the slab when underpinning practices that are currently utilized do not provide proper stabilization for the slab. The grouting of a slab is occasionally a costly form of remediation and usually is not an exacting method of correcting the problem. Grouting with a cementitious material is sometimes unreliable in attempting to correct the settlement problem and, in some cases, can cause additional problems.
For example, grouting is sometimes considered as only a temporary fix, even when the application of grout has properly stabilized the structural slab. There still might be some likelihood of continued erosion and/or shifting of the earth, including the shifting about the grout installed beneath the slab. This tends to allow continued movement of the slab. Also, it usually is not practical to determine if all the voids beneath the slab are properly filled with grout. In some instances, the grout that is placed beneath the structural slab is more dense than the soil and tends to sink within the soil. Moreover, the insertion of grout can damage the structural slab by inadvertently lifting the slab due to the excess pressure of the grout applied by the grout pump. In addition, the application of grout is costly and the grout is likely to follow the paths of least resistance that may not be effective in raising the foundation slab.
In contrast to the stabilizing of a foundation slab with grout, mechanical jack devices can be used for stabilizing the slabs. Ground anchors are inserted in the ground about the portion of the slab to be stabilized so as to function as piles, and foundation-lifting brackets are mounted on the piles and are applied to slab. Jacks are used to raise the foundation lifting brackets with respect to the piles, resulting in applied lifting force to the slab. This keeps the excavation at the slab to a minimum and potentially out of the water table, holds a designed load in a specific soil, and has been proven in field tests to be more rigid, stable and predictable than the use of grout.
Examples of such slab stabilization devices are described in U.S. Pat. Nos. 5,120,163; and 5,213,448.
One of the problems with the prior art mechanical slab stabilization devices is that after the slab has been stabilized the components of the stabilization devices usually protrude above the slab at the edge of the building structure. There is a need to keep the top of the foundation-lifting bracket and its associated components that are mounted to the slab at a level lower than the upper surface of the slab, without sacrificing the strength of the foundation-lifting bracket and its related components. This lower profile arrangement avoids the objectionable upward protrusion of components of the devices that would be obnoxious to the visual appearance of the building structure and would avoid the possible reduced value of the building structure. By reducing the height of the foundation-lifting bracket and its associated components, they can be covered over with earth and become invisible.
As described in the above noted patents, prior art devices used for stabilizing structural foundations of buildings utilize hydraulic jacks that rest upon the power installed pile and lift an assembly of brackets that are connected downwardly to the foundation pile, thereby lifting the bracket and the foundation supported by the bracket. Once the foundation has been lifted to the desired position, the screws of the lifting apparatus are fixed in place and the jack and its associated components are removed from the structure. While this removes the jack and its components from sight, the prior art foundation-lifting bracket has permanent components that still extend too high about the foundation of the building structure.
In some instances, the operators of this type foundation-lifting apparatus have use shims placed on the lifting brackets to achieve the desired lift of the foundation but avoid having the apparatus protrude above grade. However, the addition of shims to the lifting brackets is undesirable since proper sized shims are not readily available and thew shims might shift during the lifting procedures or at a later time.
It is to this problem that this invention is addressed.
Briefly described, the present invention comprises an apparatus for stabilizing the structural foundation of a building of the type that has a concrete slab. The earth is excavated at the sides about the structural slab where the stabilization is required. Elongated ground anchors are placed in the excavations. The ground anchors each include a shaft with a lower end and an upper end, and an auger thread extends from the lower end and is used for screwing the anchor into the earth. The upper end of the shaft is exposed at the level of the earth. The upper end of thee shaft might be cut away for locating the shaft at the desired height. This forms a pile on which a foundation-lifting bracket can be mounted.
A jacking tool assembly is mounted to the upper end of the pile. The jacking tool assembly includes a mounting sleeve that telescopically mounts downwardly about the upper end of the exposed shaft of the pile that has been cut to grade, and a jack and pile bearing plate that is supported by the mounting sleeve. A foundation-lifting bracket is positioned about the mounting sleeve of the jacking tool assembly at a level below the jack platform. The foundation-lifting bracket includes an L-shaped foundation engaging plate having both laterally and upwardly extending flanges for engagement at the lower edge of the foundation slab. Parallel strengthening plates are mounted to the support flanges of the L-shaped foundation engaging plate and straddle the mounting sleeve of the jacking tool assembly, and a pair of inverted elevator brackets are mounted on opposite sides of the parallel strengthening plates. Each inverted elevator bracket is L-shaped with a laterally extending plate that defines a lifting screw opening. Lifting screws extend vertically through the lifting screw openings of the inverted elevator brackets and through aligned lifting screw openings of the jack and pile bearing plate, and connectors are mounted to the ends of the lifting screws. This functions to suspend the foundation-lifting bracket from the jacking tool assembly.
When the apparatus is installed at the edge of a structural foundation slab, the foundation-lifting bracket is positioned at the lower edge of the slab and a jack is placed on the jack and pile bearing plate and connected to the elevator screws. The jack is actuated to lift the elevator screws through the jacking tool assembly platform so that the foundation-lifting bracket moves upwardly, raising the foundation slab. Once the jack has properly lifted the foundation slab to a proper elevation, nuts are tightened between the elevator screws and the jack and pile bearing plate, thereby maintaining the foundation-lifting bracket in the desired position where it supports the foundation slab. The jack and its components are then removed from the structure, thereby lowering the profile of the structure. If desired, the upwardly protruding ends of the elevator screws can be removed by cutting them away from the lower structural components, thereby reducing the height of the overall structure, so that the structure does not protrude to a level as high as the upper horizontal surface of the structural slab.
A preferred embodiment of the invention includes the pair of inverted elevator brackets being mounted on opposite sides of the parallel strengthening plates, with each elevator bracket being L-shaped and forming with the parallel strengthening plates a U-shaped recess. This places the lifting screw openings of the inverted elevator brackets through the laterally extending bottom plate, so that the lower connectors of the lifting screws are located at the bottom side of the laterally extending bottom plates. Thus, the threads of the lifting screws are located as low as practical in the arrangement of the components of the foundation-lifting bracket, so that the foundation-supporting bracket has a large vertical amplitude of movement along the jacking tool assembly. As the foundation-lifting bracket is raised the structural slab moves up with respect to the jacking tool assembly. This tends to effectively lower the structural components of the foundation-stabilizing device with respect to the structural slab.
One of the ways to avoid having a high profile of the apparatus after it has been installed is to configure the parts so that the L-shaped foundation-supporting bracket so that the vertical flange does not rise to a level higher than the jack and pile bearing plate. For example, the vertical flange can be foreshortened so that it cannot reach upwardly beyond the bearing plate when the L-shaped foundation-supporting bracket reaches its highest position.
Thus, it is an object of this invention to provide an improved apparatus and method for stabilizing structural foundations of buildings that have adequate strength properties and are of such low profile as to avoid protrusion above the level of the slab being stabilized.
Another object of this invention is to provide an improved strength apparatus for stabilizing structural foundations of buildings wherein a jack can be mounted to the apparatus for lifting the slab and, once raised, the apparatus can be set to hold the slab in its raised position, and the jack removed so as to avoid the presence of upwardly extending components from the apparatus.
Another object of this invention is to provide an improved apparatus for stabilizing the structural foundation of a building that is easy to operate, inexpensive to construct, and which provides an improved appearance.
Other objects, features, and advantages of the present invention will become apparent upon reading the following specification, when taken in conjunction with the accompanying drawings.
Referring now in more detail to the drawings in which like numerals indicate like parts throughout the several views,
The stabilizer apparatus 10 includes a ground anchor 20 that has a shaft 23 having a lower end 21 and an upper end 22, and an auger blade 24 mounted to the lower end 21. The ground anchor 20 is driven into the ground adjacent the corner 18 of the horizontal slab 12, by rotating the shaft of the anchor so that the auger blade rotates and draws the ground anchor downwardly into the earth. Once the auger blade 24 reaches the proper depth in the earth, the upper portion of the shaft of the ground anchor can be cut to the proper desired height. In this way, the ground anchor functions as a pile for supporting the foundation stabilizing apparatus. There may be several similar piles spaced at intervals along the edge of a horizontal slab where the slab is in need of stabilization.
The foundation stabilizing apparatus further includes a jack and pile bearing plate support 26 that is mounted to the upper end of the ground anchor 20, and a foundation-lifting bracket 28 that is mounted to the jacking tool assembly in a manner described hereinafter. The foundation-lifting bracket engages the structural slab 11.
As shown in
As shown in
Parallel strengthening plates or gussets 41 and 42 are each formed with an L-shaped edge that engages the back and bottom surfaces of the L-shaped foundation engaging plate. The parallel gussets 41 and 42 define a space therebetween that corresponds to the diameter of the mounting sleeve 30 of the jack and pile bearing plate support 26, so that the mounting sleeve 30 can be received between the gussets 41 and 42, as shown in
A pair of inverted elevator brackets 47 and 48 are positioned outside of and in contact with gussets 41 and 42. The inverted elevator brackets are substantially mirror images of each other and each is L-shaped with a laterally extending bottom plate 50 affixed to the adjacent gusset and to the upper extending positioning flange 39 of the L-shaped foundation engaging plate 37, and an upwardly extending plate 51 mounted to the upwardly extending flange 39 of the L-shaped foundation engaging plate 37. The inverted elevator brackets 47 and 48 each form a U-shaped recess with the gussets 41 and 42 and the upwardly extending positioning flange 39. Lifting screw openings 53 are formed through the laterally extending plate 50. This palaces the lifting screw openings very low in the overall configuration of the foundation lifting bracket 28.
Cross bar 56 is connected at its ends to the lower edges of the gussets 41 and 42, extending across the space between the gussets. The cross bar is adapted to stabilize the lower edges of the gussets and also to bear against the mounting sleeve 30 ofjack and pile bearing plate support 26 in response to a weight being applied to the foundation-lifting bracket 28.
Lifting screws 57 and 58 are vertically oriented, with their upper end portions extending upwardly through the lifting screw openings 32 and 33 of the jack and pile bearing plate 31, and their lower end portions extending downwardly through the lifting screw openings 53 of each of the inverted elevator brackets 47 and 48. Connectors, such as nuts 61 are threadedly connected to the threads at the upper ends of the lifting screws, and bolt heads 59 or other connectors are positioned on the ends of the lifting screws below the inverted elevator brackets 47 and 48.
With the lifting screws 58 in place as shown in
In order to more expediently lift the foundation-lifting bracket 28, a jacking tool assembly 62 is employed, as shown in
Once the foundation slab 11 has been stabilized by raising the foundation-lifting bracket with the jack and lifting screws, the nuts 61 of the lifting screws are rotated on the threads of the lifting screws to move down into engagement with the jack and pile bearing plate 31 to lock the foundation-lifting bracket in place. The jack 63 and its keeper bolts 65 and 66 and coupling nuts 67 and 68 are disconnected and removed from the foundation stabilizing apparatus 10. The excavation about the affixed foundation stabilizing apparatus is then backfilled with earth.
When the foundation stabilizing apparatus 10 is to be placed in use, an excavation 9 is formed at the edge of the structural foundation 11 for each foundation stabilizing apparatus, to expose the corner 18 of the foundation slab. The ground anchor 20 is positioned with its helical plate 24 in the excavation and is hydraulically rotated so as to cause the helical plate to draw the ground anchor down into the earth until a suitable support is founded for the ground anchor. If the upper portion of the shaft 23 of the ground anchor extends too high, it can be cut so as to provide the ground anchor to exist at the right height. The ground anchor is to function as a pier or a pile support.
The jack and pile bearing plate support 26 is connected to the ground anchor by telescoping the mounting sleeve 30 over the exposed upper portion of the ground anchor until the upper end of the ground anchor engages the jack and pile bearing plate 31.
The foundation-lifting bracket 28 is then mounted to the jack and pile bearing plate support 26 by placing the L-shaped foundation engaging plate 37 in engagement with the lower edge of the horizontal slab 12 and then placing the lock pin 45 through the aligned openings 43 and 44, behind the mounting sleeve 30. The lifting screws 57 and 58 are passed upwardly through the lifting screw openings 53 of the inverted elevator brackets 47 and 48 with the heads 59 or other connectors positioned below the inverted elevator brackets, and the threaded portions of the lifting screws extending upwardly through the lifting screw openings 32 and 33 of the jack and pile bearing plate 31. The nuts 61 are applied to the protruding ends of the lifting screws. This supports the foundation-lifting bracket 28 on the jack and pile bearing plate 31 in sliding relationship on the mounting sleeve 30 of the jack and pile bearing plate support 26.
The jack assembly 62 is then mounted to the jack and pile bearing plate support 26 by placing the jack 63 directly on the jack and pile bearing plate 31 and by connecting the internally threaded coupling nuts 67 and 68 to the upper ends of the threaded lifting screws. With the jacking tool assembly in place, the jack is then actuated, lifting the jacking plate 64 and its parallel keeper bolts 65 and 66 upwardly, thereby lifting the coupling nuts 67 and 68 upwardly to then lift the lifting screws 57 and 58 up through the lifting screw openings 32 and 33 of the jack and pile bearing plate 31. This causes the foundation-lifting bracket 28 to move upwardly, with the lifting screws passing through the openings of the jack and pile bearing plate 31.
As a result of the foundation-lifting bracket moving upwardly as described, the engagement of the foundation-lifting bracket 28 against the horizontal bottom surface 16 of the structural slab 12 causes the structural slab to bear the weight of the slab and to begin upward movement of the slab.
Once the desired upward movement of the slab has been achieved, the nuts 61 are tightened on the lifting screws downwardly toward engagement with the jack and pile bearing plate 31, locking the lifting screws in place. Then the jack assembly 62 is removed from the stabilizing apparatus and moved to another location and the procedure repeated.
In the meantime, the foundation stabilizing apparatus acquires a low profile in comparison to the height of the horizontal slab 12. It can be seen that as the slab is lifted, the jack and pile bearing plate 31 acquires downward relative movement with respect to the structural foundation so that the jack and pile bearing plate can acquire a position immediately above the gussets 41 and 42. If desired, the upper end portions of the lifting screws can be cut, thereby removing any extended portions of the assembly that protrude upwardly beyond the nuts 61 on the top of the jack and pile bearing plate 31. This is shown in
As shown in
The placement of the oblong connector openings laterally of the inverted elevator brackets instead of over the inverted elevator brackets allows the height of the upwardly extending positioning flange to be shorter and therefore avoids its having a high profile and avoids its protruding upwardly adjacent the slab. Also, in the inverted elevator brackets 47 and 48 the location of the laterally extending plates 50 that have the lifting screw openings 53 at a low position provides a longer stroke of the elevator screws and more range of lifting of the foundation lifting bracket 28.
Although a preferred embodiment of the invention has been disclosed in detail herein, it will be obvious to those skilled in the art that variations and modifications of the disclosed embodiment can be made without departing from the spirit and scope of the invention as set forth in the following claims.
This application claims the benefit of U.S. Provisional Application Ser. No. 60/565,682 filed Apr. 27, 2004, which is incorporated herein by reference.
Number | Date | Country | |
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60565682 | Apr 2004 | US |