Field of the Invention
This invention relates to foundation systems and more particularly to modular foundation systems for supporting structures such as towers, shelters, antennas, and the like as well as apparatuses such as generators, fuel tanks, and the like.
Description of the Related Art
Structures such as towers, antennas, and shelters and apparatuses such as generators and fuel tanks often require foundations to ensure proper support and stability. Numerous foundation systems have been developed over the years to attempt to stabilize such structures and apparatuses. However, many of these structures and apparatuses are often needed in remote locations where access can be difficult and/or in locations where installation of a traditional, onsite poured foundation is not cost-effective or practical. It is thus desirable to provide a foundation system that is customizable and can be easily transported to any location and assembled onsite.
In U.S. Pat. No. 6,050,038 to Fey el al., a foundation system for supporting superstructures that is readily transported to remote locations and assembled onsite is disclosed. The foundation system is comprised of a plurality of rectangular/square blocks that can be arranged in a number of configurations and then secured to one another using post-tensioning. However, due to the shape of each block and the orientation of the post-tensioning mechanisms, there are multiple hinge points along the foundation system. The lines of the post-tensioning mechanism run in two different directions, both parallel and perpendicular to the various joints between the foundation blocks. The lines running perpendicular to any given hinge points are the only mechanisms preventing the blocks from bending. This results in a foundation that can readily bend at various hinge points should the post-tensioning mechanism fail, which can weaken the overall foundation.
Moreover, various existing foundation systems comprise overall shapes that may not match the base shape of the structure and/or apparatus the system is supposed to stabilize. This can be inefficient or less efficient than providing a foundation system with an overall shape that generally matches the base shape of what is to be stabilized. Additionally, it can be problematic as the bolts and bolt holes used to anchor the structure or apparatus to the foundation system may not take site variations into account and thus may not be perfectly aligned during onsite assembly. It is desirable to provide a foundation system that not only substantially matches the overall shape of the base of the structure or apparatus it is used to stabilize, but also provides a customizable means to anchor the structure or apparatus to the foundation system with onsite adjustment. It is also desirable to provide a foundation system with modular components that are durable for shipping and handling and limited to weights appropriate for transfer to remote locations.
The present invention seeks to provide modular foundation systems and methods for securing and stabilizing structures and apparatuses with an improved and customizable approach that is durable, cost-effective, and incomplex.
One embodiment comprises a modular foundation system with a plurality of blocks, a plurality of holes through each of said blocks, and a plurality of cables or bars running through said holes. Each of the blocks is configured next to at least one other of the blocks such that the holes of adjacent blocks are aligned. The cables or bars fix the blocks together. The cables run in different directions than the joint lines between adjacent blocks.
Another embodiment comprises a block for a modular foundation, with the block comprising a first surface, a second surface opposite the first surface, a plurality of side surfaces, and a plurality of elongated holes extending through the side surfaces. Each of the elongated holes extend in a direction different from the direction of said side surfaces.
In still another embodiment, a modular foundation system is provided, comprising a plurality of hexagonal blocks, a plurality of elongated holes through each of the blocks and running in at least three different directions, and a plurality of cables running through the holes in the at least three directions. Each of the blocks is configured next to at least one other of the blocks such that the holes of adjacent blocks are aligned. The cables fix the blocks together via post-tensioning. The at least three directions the cables run in differ from the direction of any joint lines between adjacent blocks, such that there are no bendable points along the joints of any adjacent blocks.
In yet another embodiment, a method for making a modular foundation system is provided, comprising arranging a plurality of pre-fabricated, hexagonal blocks in a desired configuration such that elongated holes disposed in each of the blocks are aligned with holes in adjacent blocks. Furthermore, cables or rods are passed through the elongated holes, with the cables or rods and their respective holes running in at least three different directions. The directions differ from the direction of any joint lines disposed between adjacent blocks. The cables or rods are then post-tensioned such that said blocks are tightly secured to each other.
These and other further features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings, in which:
The present invention is described herein with reference to certain embodiments, but it is understood that the invention can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.
Although the terms first, second, etc. may be used herein to describe various elements, components, regions, and/or sections, these elements, components, regions, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, or section from another element, component, region, or section. Thus, a first element, component, region, or section discussed below could be termed a second element, component, regions, or section without departing from the teachings of the present invention.
The first surface 12 of the modular block 10 is preferably substantially flat, with second surface 13 opposite the surface 12 and also preferably comprising a substantially flat surface. Middle section 14 is preferably equidistant between first surface 12 and second surface 13. Middle section 14 is between first and second sections 22, 24, and may also be slightly askew of the central longitudinal axis of first and second sections 22, 24. As such, three of middle section's six sides extend past three of the first and second sections' six sides, and three of middle section's six sides are indented in relation to three of the first and second sections' six sides. As will be described in more detail below, this arrangement of middle section 14 allows for two or more modular blocks 10 to be configured side-by-side, with the extended portion of one block's middle section 14 fitting into the indented portion of another block's middle section 14. Middle section 14 is preferably cast concurrently with first and second sections 22, 24 from the same mold; as such, the sections 14, 22, 24 all comprise a singular block unit. Alternatively, sections 14, 22, 24 may all be cast separately and later connected to each other using methods commonly known in the art.
Middle section 14 also comprises first cable hole 16, second cable hole 18, and third cable hole 20. Each of cable holes 16, 18, 20 are elongated and extend from one of the middle section's six sides all the way through the modular block 10 to an opposite side surface. The elongated holes 16, 18, 20 preferably follow a straight path parallel to the horizontal plane of middle layer 14. Holes 16, 18, 20 also each preferably follow paths along varying depths of middle section 14, such that cable hole 16 is at the shallowest depth, cable hole 18 is approximately midway through layer 14, and cable hole 20 is at the lowest depth. Reinforcement layers 19 may be added between each of the stacked holes. The holes 16, 18, 20 in each of modular blocks 10 are standardized such that they are in identical positions. As such, when two or more modular blocks are later configured side-by-side, the holes 16, 18, 20 of one block 10 align with the holes 16, 18, 20 of an adjacent block 10. While three holes are depicted in this example, it is understood that one or more holes may be included through each face of block(s) 10.
When two or more modular blocks 10 are configured side-by-side such that holes 16, 18, 20 of adjacent blocks 10 are aligned, the blocks may be fixed firmly to one another by passing cables or bars through the holes 16, 18, 20. When more than one hole is included through each face of the block(s) 10, additional cables or bars will likewise be run through each hole. The number of holes and cables/bars required will depend on the size of the foundation system to be constructed, as well as the force needed to pull the blocks of a foundation system together.
To securely connect adjacent blocks 10, post-tensioning techniques as are well known in the art may be applied (e.g. the post-tensioning techniques and products offered by VSL at www.vsl.net). For example, cables may be passed through the holes discussed above, tensioned, and then secured/anchored to the outside of the foundation system using anchoring devices such as wedges that are mounted to the end of the cables in the field using automatic, hand or other mechanical tools. Rods may also be used, which are threaded on the ends and secured with nuts and bolts.
At least one advantage of the post-tensioning techniques in conjunction with the cable holes and hexagonal blocks of the present invention is the ability for cables to run in directions different from any of the joint lines between adjacent blocks. One of the cable holes will always be perpendicular to one joint position, while the other two cable holes will be at an angle to the joint position (such as at a 30° angle). In this way, once post-tensioning is applied and adjacent blocks are secured to one another, there are no bendable points along the joints of adjacent blocks. Unlike prior art systems using square or rectangular blocks, the structure of the present invention results in a much stronger foundation; there are no continuous straight joints to act as hinge points.
At least one other advantage of the present invention is that the hexagonal shape of the individual blocks 10, along with the elongated holes 16, 18, 20, allows for post-tensioning of multiple, connected blocks to occur in three different directions. As such, no matter which direction the loading is from, there are always at least two post-tension cables or bars running in a different direction so as to better secure individual blocks to one another.
The blocks 84 represented by the dots are the blocks the structure and/or apparatus will be directly attached to onsite. In this particular embodiment, the structure and/or apparatus would comprise a substantially triangular base. The blocks 84 may comprise integrated steel plates, which allow for anchor/bolt holes to be drilled into the blocks 84 onsite such that they will match the configuration of the structure and/or apparatus' anchor/bolt holes. When blocks 84 are cast, they may be cast such that a steel plate assembly is cast into the block. Alternatively, a steel plate assembly may be integrated with the block 84 post-casting and on location.
Blocks 86 represent regular modular blocks as depicted in
As in configuration 80, the darker shaded blocks 82 represent spaces where thicker modular blocks may be used. The cross-hatched block 92 represents where a modular block approximately three times the thickness of a typical block may be placed. The blocks 82 and 92 represent areas where greater strength and stability can be achieved.
As in
Although
In practice, the modular blocks would be pre-fabricated, with the size and number of blocks varying according to the structure and/or apparatus they will stabilize and secure. The pre-fabricated blocks will then be transported to a desired location, where they will be fitted together into a desired configuration. Cable or rods will be passed through the various holes in the middle layer of each block, and post-tensioning techniques will be employed to tightly secure individual blocks to one another such that they act together as a single foundation unit. The anchor holes of the structure and/or apparatus can then be assessed such that corresponding bolt holes may be drilled into steel plate assemblies onsite. The structure and/or apparatus can then be securely bolted down to the foundation system.
Although the present invention has been described in considerable detail with reference to certain preferred configurations and methods, other versions are possible. The modular blocks can be used in many different types of stabilizing applications. Different block shapes, dimensions, configurations, tensioning techniques, and side-by-side connection techniques can be used in conjunction with the new modular system and method. A variable number of modular blocks can be used to provide for any configuration and/or number of stabilizing footings utilizing the modular systems and methods contemplated by the present invention. Therefore, the spirit and scope of the above description should not be limited to the versions described above.
This application claims the benefit of U.S. Provisional Application No. 61/243,026 to Zarraonandia, which was filed on 16 Sep. 2009.
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