The disclosure relates to a pile connection apparatus and method for supporting a vertical pile, such as may be useful to avoid the need for forming concrete foundations or other foundation types, for the same purpose.
Installations of many types (e.g., for streetlights, parking lot lights, fences, display signs, solar panels, and the like) may require a ground-contacting support structure. Such installations may require vertically driven piles that are driven into the ground to a specified depth to provide sufficient support. In many installations, piles are embedded in or attached to concrete foundations, either precast or poured on-site, for additional support. While concrete foundations utilize inexpensive materials, their installation may require significant equipment, labor, and time, thereby increasing their overall expense. In climates that are subject to freezing precipitation, exposed concrete foundations may also be vulnerable to ingress of liquid around surfaces thereof followed by freezing, and repeated freeze-thaw cycles with concomitant ice expansion may cause concrete foundations to rise relative to a ground level, thereby reducing their ability to support piles projecting upward therefrom.
Sometimes, a pile is driven to only a portion of a desired depth but then hits an obstruction, resulting in a refusal or rejection. A refusal refers to an inability for a pile (which may also be referred to as a beam) to reach a desired depth to maintain stability of a support structure. The obstruction or impediment (e.g., compacted substrates, rocks, foreign objects, etc.) impede driving the pile to the desired depth. In such circumstances, a pile usually cannot be moved to a different location when large integrated equipment is being installed. Accordingly, some installers remove a pile, drill through the obstruction, replace the pile, and pour concrete around the installed pile. Such a process is slow and expensive. Other times, a pre-existing pile may need further structural support, such as due to environmental changes. Processes for addressing such issues are typically slow, labor-intensive, and expensive.
Need therefore exists for improved pile connection apparatuses for supporting new or pre-existing vertical piles, to address limitations associated with piles supported by conventional foundations or otherwise driven into ground.
Aspects disclosed herein include a pile connection apparatus that comprises at least one fixture having a collar portion, a plurality of micropile sleeves, a plurality of gusset members extending between the collar portion and the micropile sleeves, and at least one connecting member coupling adjacent gusset members and being spaced apart from the collar portion. A recess (which in certain embodiments may surround approximately one-half of a perimeter or projected top area of a vertical pile) as defined by the collar portion is bounded by a wall of the collar portion configured to contact a portion of a vertical pile to add support thereto. One or more fasteners may be used to press the wall of the collar portion against the vertical pile, with certain embodiments employing two complementary fixtures that may be coupled to one another (e.g., using the fasteners) along opposing sides of the vertical pile. Each micropile sleeve is configured to receive a micropile that may be driven through the sleeve into the ground at a position radially or laterally spaced apart from the vertical pile.
In one aspect, the disclosure relates to a pile connection apparatus for supporting a vertical pile that comprises a first fixture comprising a first collar portion, a plurality of first micropile sleeves, a plurality of first gusset members coupling the plurality of first micropile sleeves to the first collar portion, and at least one first connecting member coupling adjacent first gusset members of the plurality of first gusset members. The first collar portion comprises a first recess configured to receive a first portion of the vertical pile, with the first recess being bounded by a first wall configured to contact a first pile surface of the first portion of the vertical pile. The plurality of first gusset members project laterally outward from the first collar portion, and the at least one first connecting member is spaced apart from the first collar portion. One or more of (i) the first collar portion and (ii) at least one first gusset member, either comprises, or is configured to receive, at least one fastener configured to cooperate with the one or more of (i) the first collar portion and (ii) at least one first gusset member, and cause the first wall to engage the first pile surface.
In certain embodiments, the plurality of first gusset members are intermediately coupled to the plurality of first micropile sleeves, with the at least one first connecting member arranged between (a) the plurality of first gusset members and (b) the plurality of first sleeve micropile sleeves.
In certain embodiments, each first gusset member of the plurality of first gusset members comprises: (i) a length extending in a direction from the first collar portion to a corresponding first micropile sleeve of the plurality of first micropile sleeves, (ii) a width orthogonal to the length, (iii) a proximal height at a point of contact with the first collar portion, and (iv) a distal height at a point of contact with the at least one first connecting member; wherein, for each first gusset member, the proximal height is greater than the distal height, and the distal height is greater than the width.
In certain embodiments, each first micropile sleeve of the plurality of first micropile sleeves has a first sleeve inlet, a first sleeve outlet, and a first sleeve axis extending through the first sleeve inlet and the first sleeve outlet; and for each first micropile sleeve, the first sleeve axis is non-parallel to the vertical pile to be supported by the pile connection apparatus.
In certain embodiments, each first gusset member of the plurality of first gusset members comprises: a first upper surface, a first lower surface, a first proximal surface proximal to the first collar portion, and a first distal surface distal from the first collar portion. For each first gusset member, a first imaginary plane is definable through the first upper surface, the first lower surface, the first proximal surface, and the first distal surface; and for each first gusset member, the first imaginary plane is non-vertical, and is substantially parallel to the first sleeve axis of the first micropile sleeve coupled to the first gusset member.
In certain embodiments, the first wall is curved in shape, with the pile connection apparatus being configured to support a vertical pile having a cylindrical shape; and the first proximal surface of each first gusset member abuts the first wall, with the first proximal surface being curved in shape to substantially conform to a curvature of the first wall.
In certain embodiments, the pile connection apparatus further comprises a second fixture comprising a second collar portion, a plurality of second micropile sleeves, a plurality of second gusset members coupling the plurality of second micropile sleeves to the second collar portion, and at least one second connecting member coupling adjacent second gusset members of the plurality of second gusset members. The second collar portion comprises a second recess configured to receive a second portion of the vertical pile, the second recess being bounded by a second wall configured to contact a second pile surface of the second portion of the vertical pile, wherein the second portion of the vertical pile opposes the first portion of the vertical pile. The plurality of second gusset members project laterally outward from the second collar portion, and the at least one second connecting member is spaced apart from the second collar portion. One or more of (iii) the second collar portion and (iv) the at least one second gusset member, comprises, or is configured to receive, the at least one fastener, and the at least one fastener is configured to cooperate with the one or more of (iii) the second collar portion and (iv) the at least one second gusset member, and cause the second wall to engage the second pile surface, with the second recess of the second fixture opposing the first recess of the first fixture.
In certain embodiments, each second micropile sleeve of the plurality of second micropile sleeves has a second sleeve inlet, a second sleeve outlet, and a second sleeve axis extending through the second sleeve inlet and the second sleeve outlet; and for each second micropile sleeve, the second sleeve axis is non-parallel to the vertical pile to be supported by the pile connection apparatus.
In certain embodiments, the first recess is configured to receive the first portion of the vertical pile extending around a first perimetral portion spanning a range of 40 to 50 percent of a perimeter or projected top area of the vertical pile, and the second recess is configured to receive the second perimetral portion of the vertical pile extending around a second perimetral portion spanning a range of 40 to 50 percent of the perimeter or a projected top area of the vertical pile.
In certain embodiments, a plurality of first fastener openings are defined in one or more of (i) the first collar portion and (ii) the at least one first gusset member, a plurality of second fastener openings is defined in one or more of (iii) the second collar portion and (iv) the at least one second gusset member, and wherein the first fastener openings are configured to be aligned with the second fastener openings to receive fasteners extending through the aligned first and second fastener openings.
In certain embodiments, one or more fasteners of the at least one fastener is affixed to or integrated with one or more of (i) the first collar portion, (ii) at least one first gusset member, (iii) the second collar portion, and (iv) the at least one second gusset member.
In certain embodiments, the plurality of first gusset members comprises at least three first gusset members.
In certain embodiments, one or more of (i) the first collar portion and (ii) the at least one first gusset member, comprises fastener openings configured to receive at least one U-bolt that is configured to extend around a portion of a perimeter of the vertical pile.
In another aspect, the disclosure relates to a pile connection apparatus for supporting a vertical pile, the apparatus comprising a first fixture, a second fixture, and a plurality of fasteners. The first fixture comprises a first collar portion, a plurality of first micropile sleeves, a plurality of first gusset members coupling the plurality of first micropile sleeves to the first collar portion, and at least one first connecting member coupling adjacent first gusset members of the plurality of first gusset members. The first collar portion comprises a first recess configured to receive a first portion of the vertical pile, the first recess being bounded by a first wall configured to contact a first pile surface of the first portion of the vertical pile. The plurality of first gusset members project laterally outward from the first collar portion, and the at least one first connecting member is spaced apart from the first collar portion. The second fixture comprises a second collar portion, a plurality of second micropile sleeves, a plurality of second gusset members coupling the plurality of second micropile sleeves to the second collar portion, and at least one second connecting member coupling adjacent second gusset members of the plurality of second gusset members. The second collar portion comprises a second recess configured to receive a second portion of the vertical pile, the second recess being bounded by a second wall configured to contact a second pile surface of the second portion of the vertical pile. The plurality of second gusset members project laterally outward from the second collar portion, and the at least one second connecting member is spaced apart from the second collar portion. The plurality of fasteners is configured to cooperate with the first fixture and the second fixture to cause the first wall to engage the first pile surface, to cause the second wall to engage the second pile surface, and to cause the vertical pile to be frictionally engaged between the first fixture and the second fixture.
In certain embodiments, the plurality of first gusset members are intermediately coupled to the plurality of first micropile sleeves, with the at least one first connecting member arranged between (a) the plurality of first gusset members and (b) the plurality of first sleeve micropile sleeves; and the plurality of second gusset members are intermediately coupled to the plurality of second micropile sleeves, with the at least one second connecting member arranged between (c) the plurality of second gusset members and (d) the plurality of second micropile sleeves.
In certain embodiments, each first gusset member of the plurality of first gusset members comprises: (i) a first length extending in a direction from the first collar portion to a corresponding first micropile sleeve of the plurality of first micropile sleeves, (ii) a first width orthogonal to the length, (iii) a first proximal height at a point of contact with the first collar portion, and (iv) a first distal height at a point of contact with the at least one first connecting member, wherein for each first gusset member, the first proximal height is greater than the first distal height, and the first distal height is greater than the first width. Each second gusset member of the plurality of second gusset members comprises: (i) a second length extending in a direction from the second collar portion to a corresponding second micropile sleeve of the plurality of second micropile sleeves, (ii) a second width orthogonal to the length, (iii) a second proximal height at a point of contact with the second collar portion, and (iv) a second distal height at a point of contact with the at least one second connecting member; wherein for each second gusset member, the second proximal height is greater than the second distal height, and the second distal height is greater than the second width.
In certain embodiments, each first micropile sleeve of the plurality of first micropile sleeves has a first sleeve inlet, a first sleeve outlet, and a first sleeve axis extending through the first sleeve inlet and the first sleeve outlet; wherein, for each first micropile sleeve, the first sleeve axis is non-parallel to the vertical pile to be supported by the pile connection apparatus. Each second micropile sleeve of the plurality of second micropile sleeves has a second sleeve inlet, a second sleeve outlet, and a second sleeve axis extending through the second sleeve inlet and the second sleeve outlet; wherein, for each second micropile sleeve, the second sleeve axis is non-parallel to the vertical pile to be supported by the pile connection apparatus.
In certain embodiments, each first gusset member of the plurality of first gusset members comprises: a first upper surface, a first lower surface, a first proximal surface proximal to the first collar portion, and a first distal surface distal from the first collar portion; and each second gusset member of the plurality of second gusset members comprises: a second upper surface, a second lower surface, a second proximal surface proximal to the second collar portion, and a second distal surface distal from the second collar portion. For each first gusset member, a first imaginary plane is definable through the first upper surface, the first lower surface, the first proximal surface, and the first distal surface; and for each first gusset member, the first imaginary plane is non-vertical, and is substantially parallel to the first sleeve axis of the first micropile sleeve coupled to the first gusset member. For each second gusset member, a second imaginary plane is definable through the second upper surface, the second lower surface, the second proximal surface, and the second distal surface; and for each second gusset member, the second imaginary plane is non-vertical, and is substantially parallel to the second sleeve axis of the second micropile sleeve coupled to the second gusset member.
In certain embodiments, the first wall is curved in shape, with the pile connection apparatus being configured to support a vertical pile having a cylindrical shape; the first proximal surface of each first gusset member abuts the first wall, with the first proximal surface being curved in shape to substantially conform to a curvature of the first wall; the second wall is curved in shape, with the pile connection apparatus being configured to support the vertical pile having a cylindrical shape; and the second proximal surface of each second gusset member abuts the second wall, with the second proximal surface being curved in shape to substantially conform to a curvature of the second wall.
In certain embodiments, the vertical pile configured to be supported by the pile connection apparatus comprises a pile cross-sectional width or diameter; the first recess comprises a maximum horizontal depth with a dimension in a range of 40 to 50 percent of the pile width or diameter; and the second recess comprises a maximum horizontal depth with a dimension in a range of 40 to 50 percent of the pile width or diameter.
In certain embodiments, a plurality of first fastener openings are defined in one or more of (i) the first collar portion and (ii) the at least one first gusset member, a plurality of second fastener openings is defined in one or more of (iii) the second collar portion and (iv) the at least one second gusset member, and wherein the first fastener openings are configured to be aligned with the second fastener openings to receive fasteners extending through the aligned first and second fastener openings.
In certain embodiments, one or more fasteners of the plurality of fasteners is affixed to or integrated with one or more of (i) the first collar portion, (ii) at least one first gusset member, (iii) the second collar portion, and (iv) the at least one second gusset member.
In another aspect, the disclosure relates to a method for supporting a vertical pile, the method comprising: positioning a pile vertically to a ground to form a vertical pile; coupling a pile connection apparatus as disclosed herein to the vertical pile, with the first collar portion of the first fixture receiving a first portion of the vertical pile, with the second collar portion of the second fixture receiving a second portion of the vertical pile, and with the plurality of fasteners cooperating with the first and second collar portions to cause the vertical pile to be frictionally engaged therebetween; inserting a plurality of first micropiles through the plurality of first micropile sleeves and into the ground; and inserting a plurality of second micropiles through the plurality of second micropile sleeves and into the ground.
In another aspect, any of the foregoing aspects or embodiments disclosed herein may be combined for additional advantage. Moreover, it is specifically contemplated that features of any one or more embodiments disclosed herein may be combined with or substituted for one another, unless indicated to the contrary.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary and are intended to provide an overview or framework for understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s) and, together with the description, serve to explain principles and operation of the various embodiments.
Reference will now be made in detail to the presently preferred embodiments, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.
Terms such as “left,” “right,” “top,” “bottom,” “front,” “back,” “horizontal,” “parallel,” “perpendicular,” “vertical,” “lateral,” “coplanar,” and similar terms are used for convenience of describing the attached figures and are not intended to limit this description. For example, terms such as “left side” and “right side” are used with specific reference to the drawings as illustrated, and the embodiments may be in other orientations in use. Further, as used herein, terms such as “horizontal,” “parallel,” “perpendicular,” “vertical,” “lateral,” etc., include slight variations that may be present in working examples.
It will be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element without departing from the scope of the present disclosure. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.
The term “vertical” as used herein, may be generally vertical, such as +/−30 degrees, +/−15 degrees, +/−10 degrees, +/−5 degrees, or +/−3 degrees in certain embodiments.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including” when used herein specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Disclosed is a pile connection apparatus intended to add support to a vertical pile. A pile connection apparatus may utilize one fixture or complementary matching fixtures configured to be coupled with a vertical pile, wherein each fixture includes multiple micropile sleeves each configured to receive a micropile at a location laterally spaced apart from the vertical pile. When one fixture is used, a coupling member and fasteners, or alternatively only fasteners such as U-bolts, may be used to cause a fixture to be coupled with a vertical pile. When multiple fixtures (e.g., two complementary fixtures) are used, such fixtures may be coupled to one another using fasteners (e.g., threaded bolts and nuts, rivets, or other conventional fasteners) around a vertical pile to be supported. Each fixture includes a collar portion that defines a recess configured to receive a portion of a vertical pile. For example, first and second collar portions of complementary fixtures may include walls defining recesses that are semicircular when viewed from above, and when the collar portions are mated together, the recess-defining walls of the respective collar portions may surround substantially an entire perimeter of a portion of a cylindrical pile to be supported. Alternatively, first and second collar portions of complementary fixtures may include walls defining recesses that are rectangular in shape when viewed from above, and when the collar portions are mated together, the recess-defining walls of the respective collar portions may surround substantially an entire perimeter or projected top boundary of a portion of a pile having a rectangular cross-sectional shape. If a single fixture is used in connection with a coupling member, the coupling member may define a recess that may at least partially conform to one half of a perimeter or a projected top boundary of a portion of a vertical pile to be supported, with the fixture defining a complementary recess at least partially conforming to another half of a perimeter of a projected top boundary of the vertical pile.
In certain embodiments, a pile useable with a pile connection apparatus as disclosed herein includes structural metal, such as structural steel, structural aluminum, or other materials. In certain embodiments, the structural metal includes circular tubing, rectangular tubing, square tubing, and flanged bearing piles of various cross-sectional shapes (e.g., I-shaped piles, H-shaped piles, W-shaped piles, C-shaped piles, S-shaped piles, etc., which may also be referred to as beams). In certain embodiments, a pile includes timber (e.g., rectangular cross-section, square cross-section, round cross-section, etc.).
In one embodiment, a pile connection apparatus includes two matching fixtures configured to support (e.g., by compressive engagement) an elongated vertical pile extending along a pile axis. The pile connection apparatus includes a first fixture having a first collar portion defining a recess configured to receive (and preferably match) one side of an elongated pile extending along a pile axis. The first fixture is configured to partially surround the elongated pile. The first fixture includes multiple micropile sleeves coupled with the first collar portion by radially extending first gusset members. Each (first) micropile sleeve comprises a first inlet, a first outlet, and a bore extending therebetween, and is configured to receive a corresponding micropile. A micropile may embody a stake, shaft, or other elongated implement that is generally smaller in length and/or width (e.g., diameter) than a vertical pile to be supported by the pile connection apparatus. The pile connection apparatus further includes a second fixture having a second collar portion configured to receive (and preferably match) an other side of the elongated pile. In certain embodiments, the second fixture may mirror the first fixture. The second fixture further includes multiple micropile sleeves coupled with the second collar portion by radially extending second gusset members. Each (second) micropile sleeve comprises a first inlet, a first outlet, and a bore extending therebetween, and the is configured to receive a corresponding micropile. The first and second fixtures may define holes (e.g., in gusset members, in collar portions (including extending tab portions thereof), or other locations) configured to be aligned with one another to permit the passage of fasteners (e.g., bolts, rivets, etc.) so that the fixtures may be coupled to one another to compressively engage the vertical pile, thus tightly securing the fixtures to the vertical pile.
Fixtures and coupling members as disclosed herein may desirably be formed of metal such as stainless steel, carbon steel, aluminum, or another suitable metal or metal alloy. Since fixtures and coupling members may be positioned outdoors and in contact with a ground surface, such items may have corrosion-resistant features or coatings (e.g., galvanization, paint, and/or other coatings). Material processing methods that may be used for fabricating fixtures and coupling members (and components thereof) may include one or more of rolling, bending, stamping, casting, cutting, machining, welding, and other metal processing steps known in the art.
In certain embodiments, micropile sleeves may be coupled directly to gusset members. In certain embodiments, micropile sleeves may be indirectly coupled to gusset members, with one or more connecting members coupled to the gusset members, and with the micropile sleeves coupled to the one or more connecting members.
One or more connecting members may be used to enhance torsional and structural rigidity of a fixture, which may permit use of longer gusset members (potentially enhancing stability of a pile supported by the pile connection apparatus) and/or permit use of thinner gusset members or less robust mechanical joining (e.g., smaller weld beads) between gusset members and a collar portion. Spacing the connecting members away from a collar portion (e.g., instead of using a continuous plate connecting the collar portion and the gusset members), and providing a gap therebetween, minimizes the potential for accumulation of precipitation, which could facilitate more rapid corrosion and potential for mechanical failure of a fixture.
In certain embodiments, micropile sleeves may include bores configured to guide micropiles in a direction that is not perpendicular to ground, such as an angle in a range of 5 to 35 degrees, or in a range of 10 to 30 degrees, or 15 to 25 degrees, away from true vertical. In certain embodiments, different micropile sleeves may be arranged at different absolute angles, but the same relative angle in comparison to a gusset member proximate to a corresponding micropile sleeve. In certain embodiments, micropile sleeves may include bores configured to guide micropiles in a vertical direction so that micropiles may be driven straight downward into ground.
Reference will now be made to various figures and embodiments disclosed therein.
Referring to
As an alternative to using a coupling member or a second fixture, in certain embodiments a fixture may be used with one or more U-bolts to provide support to a vertical pile.
Although various preceding figures have shown vertical piles having generally circular and generally rectangular cross-sectional shapes or borders, it is to be appreciated that collar portions of fixtures and coupling members disclosed herein may be shaped to receive vertical piles of any suitable external cross-sectional shape.
In certain embodiments, micropile sleeves may be indirectly coupled to gusset members, such as by positioning one or more (inter-gusset) connecting members therebetween. Additionally, in certain embodiments, fasteners may extend through holes defined in outwardly projecting tab extensions of a collar portion and defined in inwardly projecting tab extensions of a connecting member.
It is to be appreciated that in any embodiments shown herein, gusset members may be arranged along imaginary planes (e.g., definable through an upper surface, a lower surface, a proximal surface adjacent to a collar portion, and a distal surface distal from a collar portion) that are non-vertical and that are substantially parallel to a sleeve axis of a micropile sleeve affixed to the gusset member. If such a gusset member is coupled to a collar portion having a curved wall, then a proximal surface (or proximal edge) of the gusset member may be curved to substantially conform to a curvature of the curved wall of the collar portion.
The present disclosure includes a method for supporting a vertical pile. The method comprises: positioning a pile vertically to a ground to form a vertical pile; coupling a pile connection apparatus as disclosed herein to the vertical pile, with the first collar portion of the first fixture receiving a first portion of the vertical pile, with the second collar portion of the second fixture receiving a second portion of the vertical pile, and with the plurality of fasteners cooperating with the first and second collar portions to cause the vertical pile to be frictionally engaged therebetween; inserting a plurality of first micropiles through the plurality of first micropile sleeves and into the ground; and inserting a plurality of second micropiles through the plurality of second micropile sleeves and into the ground. In certain embodiments, a pile connection apparatus may be coupled to the vertical pile after a portion of the vertical pile is driven into the ground. In certain embodiments, a pile connection may be coupled to the vertical pile before a portion of the vertical pile is driven into the ground.
Many modifications and other embodiments of the embodiments set forth herein will come to mind to one skilled in the art to which the embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the description and claims are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. It is intended that the embodiments cover the modifications and variations of the embodiments provided they come within the scope of the appended claims and their equivalents. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
This application claims priority to U.S. Provisional Patent Application No. 63/312,223 filed on Feb. 21, 2022, wherein the entire contents of the foregoing application are hereby incorporated by reference herein.
Number | Date | Country | |
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63312223 | Feb 2022 | US |