Patent Application
20230272589
The present invention relates to a soil extraction/grouting device, and, more particularly, to a soil extraction/grouting device which can be used to improve the density/stability of soils, and which can thereby stabilize the soils and overlying structures and/or lift and stabilize a structure and infrastructure or a pipeline which has become unstable or has settled due to a weak or unstable underlying soil conditions. Additional purposes include soil extraction to remove weak soils such as peat or other very compressible soils then replaced by non-compressible products such as cementious or foam grouts. Another use is to remove contaminated soils or water/solutions for remediation purposes.
Uniform soil foundation support has challenged civilization since man first set stone on stone for shelter, worship, landmark, or as a burial monument. The problem of differential settlement in structures supported on the ground is a very common problem experienced all over the world.
The forces of nature have resulted in the soil material covering our continent to be extremely variable. Some soil types are stable and provide excellent bearing support for structural foundation support while many areas lack the uniform characteristics that are needed to secure uniform bearing capacity. There are a wide range of conditions that contribute to the variability of soil bearing capacity.
Over time, as municipalities expand into less and less favorable lands for expansion development, with predictable and inevitable effects of distress on infrastructure and buildings, above- and below-grade utilities and structures alike are affected. In some instances when cost constraints are so prohibitive, typically due to the limits of poor soils, excavation and replacement is one method performed.
Other methods include piering, piles, or rammed aggregate piers to name a few, to support structures but rarely utilities. Other times, for cost savings, sites designated for redevelopment consist of urban fill and new infrastructure and structures are erected with minimal soil treatment if at all. Ultimately all, to varying degrees, experience structure and utility distress due to settlement.
In the last 50 years, soil grouting and ground modification advancements have surpassed most design and engineering professional’s imaginations. Advancements in products, procedures, equipment, and design have allowed for the installation of structures for new development and restoration of infrastructure where once unimaginable; however, even the most advanced applications have limits of what can be accomplished within the ability of today’s allowable features.
What we know is that soils still, in most instances if not all, dictate what can or cannot be done; however, this recent development which involves a variation and combination of soil pretreatments, soil extraction, and the replacement or introduction of products can raise below-and above-grade elements and structures or lower to a compromise level. Soils can be removed, remediated, and replaced.
The grouting technique most often used for densifying soils and urban fill is referred to as “compaction grouting”. This process uses a low-slump grout placed at controlled high pressure to strengthen low strength soils by displacement and densification of the soil. Settlement is corrected by placing additional grout volumes at controlled high pressure under carefully monitored and controlled procedures.
A similar process growing in popularity due to its simplicity and cost savings is the use of expanding polyurethane foams to densify weak soils.
Unfortunately, the prior art requires many steps requiring the management of: the volume of grout material placed; the high pressure required; and the development of confinement in the treated zone for grout and ground pressure-induced densification response within the targeted soil. Another soil property that impacts the application of pressure-injected grout for foundation stabilization and raising of settled structures is soil density. If the targeted soil is relatively dense, the grout injection process can be very difficult as high pressures are required and process control is compromised under these dense soil conditions.
Ground responses can be very quick and can jeopardize the structure and the safety of the installers. As a result of dense soil conditions, a particular application site may not have a soil profile or soil condition where pressure-injected grout material would be well suited for correcting all, or a portion of, the problem.
It is often desirable to densify soils for the purpose of stabilizing the soils. Soft soils, such as loose sand and mixtures which include sand, are unstable and will often allow a structure to sink or crack due to lack of uniform support of the foundation.
One method of densifying soil is to pump a low slump cementitious or chemical grout into the ground through a pipe driven beforehand. If a cementitious grout is used, it is placed under a high pressure so that it compacts the soil as it displaces it. Chemical grouts on the other hand, typically increase a soil’s density by permeating and hardening in a porous soil after they are in place, but they will not raise a structure.
The low slump technique, called compaction grouting, is used to raise a foundation, or a segment thereof if settlement has not been uniform. To do so, the grout pressure is increased and focused on the soils in direct support of the foundation. A difficulty with the procedure is that if the soil condition is not uniform, and few are, the grout tends to flow laterally in fingers or lenses through the most porous soil. When this is the case, a relatively large volume of material must often be placed at high pressures before there is adequate confinement to exert pressure within the targeted soil if a all. In some instances, failure to contain the grout in close proximity to the underside of the element to be raised can adversely affect adjacent utilities of structures.
Another difficulty is that if the targeted soil is relatively dense, it will not be wholly penetrable. As a result, a particular area may not yield the profile desired to direct the maximum hydraulic force vertically. If for example, the strata permits only 20% penetration of the soil in direct support of a foundation, the grout pressure must be five times as great as would be required if the grout pressure could be fully directed on the soil directly beneath the foundation.
Piers and piles are known systems which are primarily used for residential and light commercial applications. Installations require engineers to design their installation, and building permits, because piers change the design function of the structure by raising the structures footings off the soil. The voids created beneath the footing allow water to accumulate and migrate under the footing thereby compromising the load bearing capacities of unsupported areas. Jacking a structure with pilings or piers causes point loading of a foundation, a situation for which the foundation is not designed. This point loading often causes foundations to crack. Jacking systems are also often limited to concrete structures, and are not useable with most block, stone, and brick foundations. These systems require excavation to the depth of the footing for installation often with medium heavy-duty equipment. The procedure requires days to install, disruption, slab removal, and is usually limited to concrete structures. Pier and pile loads are also much less than the structure itself could carry as designed, even if on competent soil.
Compaction grouting is a known process which is most applicable to stabilization of fine-grained soils and can also be used to raise structures which have settled. Its primary use is for soil densification and foundation raising. Due to the lack of lateral confinement, compaction grouting is generally not effective nearer than about 15 foot (4.6 m) of the surface or an unrestrained down slope. Although densification and raising are obtainable through compaction grouting, it is limited to a single soil condition, expensive, requiring extensive investigation, planning, engineering, and with varying results. It too has difficulty lifting masonry, brick or stone foundations due to the possibility of causing potential damage.
Known chemical grouts typically increase a soil’s density by expanding or hardening in a porous soil after they are in place, but they will not raise a structure. Known methods/devices of densifying a soil by simply pumping grout into the soil has the disadvantages of being very dependent on the porosity of the soil, which can require very high grout pressure to produce an adequate hydraulic lift, and/or require a relatively large volume of grout material.
Other disadvantages of conventional methods are that the results, feasibility, pressure application, performance, duration, costs, difficulty, disruption, material consumptions, and grout volumes are dictated by soil conditions.
What is needed in the art is an extraction/grouting device which can be used efficiently and effectively to provide support and movement in a variety of structures.
The present invention provides an extraction/grouting device which can be used efficiently and effectively to provide lifting and support for a variety of structures.
The invention comprises, in one form thereof, a method of moving an underground pipeline including the steps of: driving a casing into a soil proximate to the pipeline; deploying a pivoting wand from the casing about a pivoting axis, the pivoting wand having a plurality of cutting nozzles that are coupled to a fluid conduit having a longitudinal extent in the casing relative to a longitudinal axis; pressurizing the fluid conduit to thereby send fluid through the cutting nozzle to soften the soil in a direction in which the wand deploys; rotating the pivoting wand; conducting the softened soil up through the casing to form a cavity in the soil proximate the pipeline, the cavity in the soil having a shape reflective of the movement of the pivoting wand in the rotating step; positioning a lifting device beneath the pipeline. And, lifting the pipeline with the lifting device thereby drawing the pipeline toward or into the cavity.
The invention comprises, in yet another form thereof, a buried pipeline lifting system including an extraction/grouting system and a pipeline lifting device. The extraction/grouting system includes, a fluid conduit having a longitudinal extent along a longitudinal axis; a pivoting wand; a plurality of cutting nozzles in fluid communication with the fluid conduit, the cutting nozzles being coupled to the pivoting wand that is pivotably extendable relative to the longitudinal axis; and a casing, the extraction/grouting device being movably extended at least partially within the casing. The extraction/grouting system is used to carry out the following steps: driving at least one casing into a soil proximate to the pipeline; deploying a pivoting wand from the casing about a pivoting axis, the pivoting wand having a plurality of cutting nozzles that are coupled to a fluid conduit having a longitudinal extent in the casing relative to a longitudinal axis; pressurizing the fluid conduit to thereby send fluid through the cutting nozzle to soften the soil in a direction in which the wand deploys; rotating the pivoting wand; and conducting the softened soil up through the casing to form a cavity in the soil proximate the pipeline, the cavity in the soil having a shape reflective of the movement of the pivoting wand in the rotating step. The pipeline lifting device is used to carry out the following steps: positioning the pipeline lifting device beneath the pipeline; and lifting the pipeline with the pipeline lifting device thereby drawing the pipeline toward or into the cavity.
An advantage of the present invention is that it can be used to raise a structure such as a pipeline.
Another advantage of the present invention is that it is not dependent on the porosity of the soil in which it is acting on.
Yet another advantage of the present invention is that it requires less grout pressure for the same amount of hydraulic lift, when compared to other methods/devices.
Yet another advantage of the present invention is that it requires less grout for the same amount of hydraulic lift, when compared to other methods/devices.
Yet another advantage of the present invention is that there is minimal disruption of surrounding soils and structures since is not required.
Yet another advantage of the present invention is that there is minimal duration of the extraction/grouting process since excavation starting from the soil surface is not required.
Yet another advantage of the present invention is that the pipe and/or casing may also be left in place to expedite ongoing operations.
Yet another advantage of the present invention is that densification and raising results are predictable.
Yet another advantage of the present invention is that structures other than buildings, such as roads and pipelines, can be lifted.
Yet another advantage if the present invention is far less likely to cause lateral damage to surrounding structures or utilities than conventional methods devices due to the forces being directed more vertically, and not laterally.
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
Referring now to the drawings, and more particularly to
Nozzles 24 are activated by pressurized fluid supplied through fluid conduit 20, which is attached to wand 22. Wand 22 has internal passageways and may have valves to variously direct the pressurized fluid. When nozzles 24 are activated the fluid that sprays therefrom softens and liquifies the local soil which flows up casing 16 and is extracted above the ground. As nozzles 24 spray, wand 22 is moved in direction ED, until deployed to a desired angle, which in
Casing 16 is then either partially withdrawn from soil S, leaving sacrificial point 14 in soil S, and there by allowing extraction/grouting device 12 to be rotatable about axis LA, or casing 16 along with extraction/grouting device 12 are rotated about axis LA. As extraction/grouting device 12 is rotated nozzles 26 remove soil about an arc as wand 22 of extraction/grouting device 12 moves. Wand 22 can also be pivoted up and down as rotatable member 18 is rotated to create a hemispherically shaped void V in the event the rotation and pivoting action is completed for a full rotation of extraction/grouting device 12.
It is also contemplated that extraction/grouting device 12 can be vertically displaced in an up and down fashion while rotatable member 18 is rotated to thereby create a generally cylindrically shaped void V. Once the suitable void V is created, if desired, then a grouting material is supplied by extraction/grouting system 10 to void V to thereby exert pressure in soil S. The grouting may be supplied by way of extraction/grouting device 12, or after the removal of extraction/grouting device 12 from casing 16 (by forcing the grouting down casing 16), or by the insertion of another device into casing 16, not shown.
Now, additionally referring to
Now, additionally referring to
Now, additionally referring to
Now, additionally referring to
Now, additionally referring to
Extraction/grouting systems 10 in
Now, additionally referring to
The present invention includes the special tooling of system 10 as well as, pumps, casings, and directional fluid jets 24, 26, 30 and 32 are used to accomplish the soil extraction from deep within the ground without needing conventional excavation methods. The extraction process removes soil from predetermined locations and elevations below the surface of the ground. The manufactured cavities V, V1, V2, V3 allow the pressure grouting process, as compared to the prior art, to be:
Steel pipe or casings 16, typically varying in diameter from 2″ - 5″ are driven or drilled into the soils beneath the structure P. Depending on the application and results desired, depths can range from just a few feet below the structure to much greater depths. Depending upon the cavity V size desired, soil types, or weight of the structure to be raised, a single-, double-, or quadruple-tipped nozzle arm 22 can be employed. Vertical or horizontal nozzles affixed to the arm can be self-rotating on manually rotated from the surface.
In preparation to create a cavity, utilizing one embodiment of the present invention, the installed casing or pipe 16 is first retracted a few inches to open the end of the pipe. The retraction separates the casing from the sacrificial drive point 14 or “lost” drill bit, exposing the surrounding soils. The special tooling arm 22 that does the cavity erosion can be referred to as a “jetting knife”. Device 12 is next inserted into the pipe 16 and is positioned at the end of the casing at the exposed soil location. Once device 12 is set in position, water at high pressure is pumped through a hose 20 connected to the arm 22.
The high-pressure water activates the nozzles 24, which may be rotating tips 24 positioned at the edge of the jetting knife 22 that directs the erosive jets out, perpendicular to the axis of the jetting knife 22 and casing 16. The water jets 24 erode the adjacent soil and flush the eroded soil debris up the pipe 16 to a discharge chamber. The pressures and volumes are adjustable and are set based on cavity requirements, soil types, and density. Wand 22 is deployed outward about pivoting axis PA as the eroded soil debris continues to flow up casing 16.
Following the extraction of soils adjacent to/below the pipe as wand 22 pivots outward, horizontal jets 26 on the jetting knife 22 are activated and the jetting knife is manually, or by water pressure, activated to rotate about axis LA to create a cylindrical cavity V.
During the jetting and soil erosion process, the extracted soil and water is contained within the pipe casing 16 with a special cap that inhibits fluid loss out of the top. The cap also holds the jet packer assembly 12 in position and allows for easy vertical alignment adjusting for the heights of cavity V as required. The excess water and soil cuttings are directed out through a “T” connection above ground surface. Following the erosion and water flush steps, compressed air is forced through the jet packer 12 to purge remaining soil cuttings and water from the formed cavity V.
If utilizing the device 12 to collect soil samples or relics related to historical site investigations, fluid viscosities can be adjusted to extract heavy particles for collection.
Compaction Grouting: The process most applicable to stabilization of weak soils, and can also be used to raise structure P, which has settled. Its primary use is for soil densification for utility and foundation raising. Due to the lack of lateral confinement, compaction grouting is generally not effective nearer than about 10′ of the surface or an unrestrained downslope. Although densification and raising are obtainable through compaction grouting and adaptable to a wide variety of soil types, it requires extensive investigation, planning, engineering, and with varying results. It also has difficulty lifting masonry, block, or stone foundations due to damage.
Advantages of the present invention: Applications have minimal disruption and duration since excavation is not required. Work can be performed from inside or outside of a particular structure. All cutting fluids are confined to the discharge hose, so no mess.
Installations are performed in ½ - ¼ of the time of compaction grouting requirements. Compaction grouting often requires primary, secondary, and tertiary grouting where the process using the present invention does not. Pipe and/or casing may also be left in place to expedite ongoing operations.
Most soil types can be compacted to greater densities to increase anticipated greater load requirements. Grouts can be contained to specific locations keeping material volumes low, prices down, limited duration for installation, and faster results in densification and raising. Results are predictable with structures in excess of 2 \-½ inches of settlement or lift.
Due to the grout’s containment, higher soil densities are achieved, with higher load-lifting capabilities and allows a structure to function as designed. The process of the present invention can lift stone, brick, or cinder block foundations uniformly without point-loading as with piers or piles and, to some extent, the same is true with compaction grouting.
The use of the present invention is far less likely to cause lateral damage to surrounding structure or utilities than conventional compaction grouting due to the forces being directed vertically, not laterally. Pressures are easily controlled and do not require extensive site investigation, planning, or soil analysis.
In the past, most grouting applications including results, feasibility, pressure application, performance, duration, costs, difficulty, disruption, material consumption, and volumes have been dictated by soil conditions. Many engineers and applicators have attempted to dictate otherwise. Attempting to take a specific soil site condition and say “I’m going to inject this material, at this location, at this pressure, at this volume, and get this result” and most fail to achieve the desired and/or predicted results.
Advantageously, this new inventive process allows for fairly predictable results due to the containment of grout in a preconceived / preconstructed location V.
Variable Applications: For very loose cohesive soils, such as sandy and/or silty soils, pre-grouting down the casing increases the cohesiveness of the soil allowing jetting to create a void within the solidified soil mass.
The pre-treatment grouting inhibits the soil from collapsing into the cavity V during the jetting operation and helps contain the grout, helping to create containment and increased soil densification. A grouted soil mass above the cavity also provides for a more uniform lift of the structure or element, limiting damage. This is especially useful on block, brick, or masonry structures. Greater containment of the grout also allows for higher pumping pressures for lifting heavy structures.
The extraction/grouting of the present invention is a process and system by which a soil is removed from deep within the ground without excavation. Soils are removed in predetermined locations and volumes for the purpose of replacing them with various grout composition, including cementitious, to increase soil densities or to raise whole or partial elements of a structure. One use of the present invention is to densify soils in order to increase their load-bearing capacities and stability beneath settled structures to inhibit further settlement or raise the settled segment. Another is to weaken soil cohesiveness and density to create soil consolidation to lower structures or infrastructure to a compromise level.
Six Soil Extraction Device Applications:
1. For the purpose of creating a cavity directly beneath a structure or element, above- or below-grade, to raise it. Particularly in constrained interior applications where high-water tables inhibit excavation without de-watering, or in contaminated soils where excavation is prohibitive.
2. To remove contaminated soils or fluids for collection and treatment and a means of washing the soils to better reclaim the contaminated product. Also, a means of introducing bacteria, enzymes, or other products to remediate contaminated soils.
3. To isolate contaminated soils via encapsulation.
4. To extract soils beneath a structure for the purpose of lowering the item to a comprise level. By accurately constructing a cylindrical cavity to exact dimensions and at specific elevations, soil consolidation can be calculated and predicable. If a more rapid approach is desired, cylindrical cavities can be enlarged, more can be installed, or at multiple elevations. Movement or total arrest can be initiated rapidly by filling any number of the cavities with a cementitious or foam grout, only to be reinitiated at a different elevation if so desired.
Once the extraction casing is in place, it can remain for weeks or years if needed to continue soil extraction operations as soils compress within the cavity to attain the desired elevation.
5. Soil extraction is a minimally invasive, rapid means of extracting soil samples at various elevations below ground or below old sensitive structures without excavation to locate historically significant sites of ancient civilizations. The process can be performed in lakes, rivers, and oceans when excavation is not possible and lidar and radar are ineffective.
6. To remove and then replace a weak soil or peat directly beneath a structure or element, to then replace the soils with a higher load-bearing product.
When heavy relics are found and due to their weight and depths located, it may be necessary to introduce a lower viscosity solution and air volume to retrieve the items for collection and evaluation.
The following four applications are particularly advantageous for the use of the present invention:
1. For lifting: pipelines, foundations, RR trackage, roadways, tunnels, reservoirs.
2. Contaminated soils: for washing to collect contaminants, for the removal of soils for collection and treatment, to extract and encapsulate a contaminant and then reintroduce the contaminant into the cavity from whence removed. Introducing enzymes or treatment products into contaminated soils on super fund sites or elsewhere.
3. Remove soils: to level pipelines, RR trackage, roadways tunnels, reservoirs, old historically significant structures in Europe and Asia, churches, libraries, castles, hotels, museums.
4. Collecting Historical information and artifacts: ancient sites or historically significant sites. Ancient civilizations.
The following site condition is used as an example of the use of the present invention with the method steps provided as the solution. The client desires to have an interior 6″ diameter pipeline lifted to its original design elevation. Presently, the pipeline distress spans 16 linear feet with a maximum settlement of 3″. Soils have been determined to consist of loose, sandy urban fill.
Step 1 Locate and Verify Pipeline Distress - This is performed by installing a sewer camera within the pipeline and using a surface sensor to locate the camera head location within the pipeline. A crayon, chalk, or masking tape can be used to mark the location of the pipeline at grade. By installing water within the pipeline, the height of the standing water is an excellent means of estimating the depth and span of the pipe settlement.
The exact below-grade location of the pipeline can also be determined using small diameter steel rods probing perpendicular to the pipe from above.
Step 2 Corrective Procedures - Following the verification of the pipeline location, depth, diameter, and the amount of settlement and spans, corrective procedures would be as follows:
A total of four (4) 3″ diameter holes will be drilled through the slab on grade adjacent to the pipeline and the cores removed. The Pipeline Lifting Device (PLD) component casing 16 is then driven to a depth of 1 foot below the underside of the pipeline. Each system 10 will be offset on 3 foot centers along the span to be lifted. The internal lifting components to extract soil and lift the pipe are then inserted within the casings 16. Soils are displaced with systems 10, and the PLD arms are activated to a horizontal position followed by lifting the PLDs to contact the underside of the pipeline. Liquid spoils are collected in a tote designated to separate liquid (water) from soils.
Water and the sewer camera are then reinserted during the lifting process to monitor the lifting progress. Hydraulic rams are then used to lift the four PLDs simultaneously.
When grout is used, the control of the high pressure needed for densification, and especially for lifting, is key to the success of this process. The grout placement process is hydraulic, the larger the surface area contacted by the fluid under pressure directly impacts the extent of pressure required to achieve the desired results, and to move the load. The relationship as to the size of the fluid pool (the spread of the grout volume placed) and the load resistance (weight of the soil zone and structure) are proportional to the extent of pressure required to act on the fluid pool area and lift (move) the load.
The success of soil and settled structure remediation is dependent upon the ability of the installers and applicators to control the placement of the stiff mortar or foam pressure placed in measured volumes and at controlled high pressures.
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
This is a division of U.S. Pat. Application Serial No. 17/469,389, entitled “SOIL EXTRACTION/GROUTING DEVICE ”, filed Sep. 8, 2021, which is incorporated herein by reference. The foregoing application being incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17469389 | Sep 2021 | US |
| Child | 18314511 | US |
