Information
-
Patent Grant
-
6543967
-
Patent Number
6,543,967
-
Date Filed
Friday, February 22, 200222 years ago
-
Date Issued
Tuesday, April 8, 200321 years ago
-
Inventors
-
-
Examiners
Agents
- Bracewell & Patterson, L.L.P.
-
CPC
-
US Classifications
Field of Search
US
- 405 230
- 405 229
- 405 231
- 405 233
- 405 239
- 405 249
- 405 251
- 405 252
- 405 256
-
International Classifications
-
Abstract
Pilings are installed for leveling a foundation. A first segment is driven into the ground. Then two support rods of varying length are positioned and grouted into a passage running through the segment. The first support rod is one-half of the height of the piling segment, while the second is one and one-half times the height of the piling segment. An additional piling segment is driven on top of the first segment. Support rods which are twice the height of a single segment are positioned and grouted into the passage. This process is repeated until the assembly is the required depth.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to a foundation and repair method and apparatus utilizing precast cylinder pilings with metal support rods extending axially through and bonded to the pilings to create a column which is sequentially driven into the earth to form an underground pier.
2. Description of the Related Art
One of the older methods for repairing foundations of buildings having slab-on-ground foundations uses drilled underground piers. Holes are drilled approximately eight to twelve feet in depth and filled with concrete. After the concrete has dried, jacks are placed on top of the pier and the foundation is brought to a level position. The jack is replaced by blocks, shims, and grout. A more recent and less expensive method is the use of driven precast solid concrete cylindrical pile sections, which are approximately one foot in height and six inches in diameter. These sections are driven into the earth one on top of the other to form a column or stack of concrete cylinders. The depth to which the bottom of the pier is driven into the earth depends upon the type of soil and zone of the seasonal moisture change. A cylinder having a larger diameter, or a pile cap, is a placed on top of the previously driven sections. Jacks are placed on top of the pile cap and the foundation is lifted.
The precast pile method relies upon the skin friction with the soil for its strength. It has the advantage of being faster since the concrete does not have to cure and precasting allows better control of concrete strength. A major disadvantage is that the one-foot cylindrical sections may shift and become misaligned during or after the driving operation. Different methods have been proposed for maintaining alignment between sections. However, most do not ensure that there is a least one support rod running completely through an individual piling section.
SUMMARY OF THE INVENTION
The precast pile in this invention is made up of piling segments that are driven into the ground one on top of the other. Each segment has a passageway running axially through each segment that aligns with the passageway of the other piling segment. A short support rod that is one-half the height of the first segment is placed in the passageway of the deepest piling segment. An intermediate support rod that is one and a half times the height of the first segment is placed in the passageway of the deepest segment next to the short support rod. A long support rod is positioned in the first and second passageways so that the long rod abuts with the top of the short support rod. The long support is twice the height of a single segment, so the long rod protrudes above the second piling segment a distance of about one-half the height of the second piling segment.
The method for installing the piling described above is made up of the steps as follows. A first piling segment is driven into the earth. The segment has a passage running axially through it in which a short support rod and an intermediate support rod are placed side-by-side. A second piling segment is driven on top of the first segment. A long support rod is then placed on top of the short support rod inside the passageway. Another long rod is placed on top of the intermediate support rod inside the passageway. The passageways are pre-filled with grout to secure the support rods in the piling segments. Additional pilings are driven into the earth, and additional long rods are placed and grouted into the passage on top of long rods already in place until the pilings are the desired depth. The short and the intermediate rods cause there to be at least one solid rod traversing each piling without a joint at an intersection of piling segments. This interfaces the rods at depths that are not the same as the intersections of the piling segments and helps to provide lateral support and prevent misalignment problems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
comprises a cross-sectional view of a first piling segment driven into the ground in accordance with this invention.
FIG. 2
comprises a cross-sectional view of a second piling segment driven into the ground in accordance with this invention.
FIG. 3
comprises a cross-sectional view of a third piling segment driven into the ground in accordance with this invention.
FIG. 4
comprises a cross-sectional view of a fourth piling segment driven into the ground in accordance with this invention.
FIG. 5
comprises a cross-sectional view of a fifth piling segment driven into the ground in accordance with this invention.
FIG. 6
comprises a cross-sectional view of a sixth piling segment driven into the ground in accordance with this invention.
FIG. 7
comprises a cross-sectional view of a top piling segment driven into the ground in accordance with this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-6
show the progressive steps of the preferred embodiment of the method for installing a pier assembly for leveling a foundation. Referring to
FIG. 1
, a first piling segment
11
is driven into the ground
13
. Piling segment
11
has a substantially flat bottom edge
15
and a substantially flat top edge
17
. Piling segment
11
is normally a precast concrete segment having a cylindrical shape. A passage
19
runs axially through piling segment
11
from bottom edge
15
to top edge
17
.
After first segment
11
is driven, a grouting material
22
is poured into passage
19
. A short support rod
21
is placed in grout
22
in passage
19
until the bottom of short support rod
21
is in contact with ground
13
. Short support rod
21
is shorter in height than piling segment
11
. In the preferred embodiment, short support rod
21
is approximately one-half the height of piling segment
11
. Normally short support rod
21
is an iron rod, which is commonly referred to as “rebar.”
An intermediate support rod
23
is placed in grout
22
in passage
19
along side of short support rod
21
until intermediate support rod is in contact with ground
13
. Intermediate support rod
23
is taller than piling segment
11
and short than two piling segments
11
stacked one on top of the other. Intermediate support rod
23
is substantially the same material as short support rod
21
. In the preferred embodiment, intermediate support rod is approximately one and one-half times the height of piling segment
11
. A grouting material
22
is preferably filled to the top of passage
19
, as shown, although it could be filled only to a point near the upper end of short support rod
21
. Grout material
22
may be any type of cement of adhesive for bonding steel to concrete. Once cured, grout
22
secures support rods
21
and
23
into passage
19
.
Referring to
FIG. 2
, a second piling segment
27
is driven into ground
13
on top of piling segment
11
. Normally segment
27
is driven in before grout
22
cures in passage
19
. Segment
27
is a precast concrete cylinder having substantially the same shape and dimensions as piling segment
11
. Passage
29
aligns with passage
19
when segment
27
is placed on top of segment
11
. Intermediate support rod
23
extends from the top of piling segment
11
into passage
29
, for about one-half of the height of piling segment
27
. Intermediate rod
23
provides a means for maintaining the alignment of passages
19
and
29
while piling
27
is driven into ground
13
. Grout
22
is placed in passage
29
. A long support rod
31
is placed in grout
22
in passage
29
, so that the bottom end of long rod
31
abuts with the top end of short rod
21
, forming a joint
33
. Any grout
22
in passage
19
above short support rod
21
must still be viscous to enable long support rod
31
to be installed. In the preferred embodiment, long rod
31
is substantially the same material as rods
21
and
23
, and is approximately twice the height of piling segment
11
.
Grouting material
22
also fills any remaining area of passage
19
that is not taken up by rods
21
,
23
, and
31
. Once cured, grout
22
secures rod
31
to piling segment
11
. Grout
22
also fills the area of passage
29
around rods
23
and
31
at least up to a level below the top end of intermediate rod
23
. Grout
22
could be filled to the top of passage
29
, as shown. Rods
23
and
31
prevent misalignment between piling segments
11
and
27
when other piling segments are driven into the ground on top of segments
11
and
27
, by stopping any horizontal slippage at the level in which segments
11
and
27
are in contact.
Referring to
FIG. 3
, a third piling segment
37
is driven into ground
13
on top of piling segment
27
. Segment
37
is a precast concrete cylinder having substantially the same shape and dimensions as piling segments
11
and
27
. Passage
39
aligns with passages
19
and
29
when segment
37
is placed on top of segment
27
. Grout
22
is placed in passage
39
. Long support rod
31
extends from the top of piling segment
27
into passage
39
. In the preferred embodiment long support rod
31
extends into passage
39
for about one-half of the height of segment
37
. Long support rod
31
provides a means for maintaining the alignment of passages
19
,
29
, and
39
while piling
37
is driven into ground
13
. A long support rod
41
is placed into passage
39
, so that the bottom end of long rod
41
is in contact with the top end of intermediate rod
23
. In the preferred embodiment, long rod
41
is substantially the same material as rods
21
,
23
, and
31
. In the preferred embodiment, long rod
41
, like rod
31
, is approximately twice the height of piling segment
11
(or
27
, or
37
).
Grouting material
22
fills the remaining area of passage
29
that is not taken up by rods
23
,
31
and
41
. Grout
22
secures rod
41
to piling segment
27
and also fills the area of passage
39
around rods
31
and
41
at least up to a level below the top end of long rod
31
.
Rods
31
and
41
prevent misalignment between piling segments
27
and
37
when other piling segments are driven into the ground on top of segments
27
and
37
, by stopping any horizontal slippage at the level in which segments
27
and
37
are in contact. Furthermore, long rod
31
runs from approximately halfway in segment
11
, through segment
27
, to approximately halfway into segment
37
, therefore providing further resistance to segments
11
,
27
, and
37
shifting out of alignment.
Referring to
FIG. 4
, a fourth piling segment
47
is driven into ground
13
on top of piling segment
37
. Segment
47
is a precast concrete cylinder having substantially the same shape and dimensions as piling segments
11
,
27
, and
37
. Passage
49
aligns with passages
19
,
29
, and
39
when segment
47
is placed on top of segment
37
. Grout
22
is placed in passage
49
and any remaining part of lower passage
39
. Long support rod
41
extends from the top of piling segment
37
into passage
49
. In the preferred embodiment long support rod
41
extends into passage
49
for about one-half of the height of segment
47
. Long support rod
41
in conjunction with the previously installed support rods provides a means for maintaining the alignment of passages
19
,
29
,
39
, and
49
while piling
47
is driven into ground
13
. A long support rod
51
is placed into passage
49
, so that the bottom end of long rod
51
is in contact with the top end of long rod
31
. In the preferred embodiment, long rod
51
is substantially the same material as rods
21
,
23
,
31
, and
41
. In the preferred embodiment, long rod
51
, like rods
31
and
41
, is approximately twice the height of piling segment
11
,
27
,
37
, or
47
.
Rods
41
and
51
prevent misalignment between piling segments
37
and
47
when other piling segments are driven into the ground on top of segments
37
and
47
, by stopping any horizontal slippage at the level in which segments
37
and
47
are in contact. Furthermore, long rod
41
runs from approximately halfway in segment
27
, through segment
37
, to approximately half way into segment
47
, therefore providing further resistance to segments
27
,
37
, and
47
shifting out of alignment.
Referring to
FIG. 5
, a fifth piling segment
57
is driven into ground
13
on top of piling segment
47
. Segment
57
is also a precast concrete cylinder having substantially the same shape and dimensions as piling segments
11
,
27
,
37
, and
47
. Passage
59
aligns with passages
19
,
29
,
39
, and
49
when segment
57
is placed on top of segment
47
. Long support rod
51
extends from the top of piling segment
47
into passage
59
. In the preferred embodiment long support rod
51
extends into passage
59
for about one-half of the height of segment
57
. Long support rod
51
in conjunction with the previously installed support rods provides a means for maintaining the alignment of passages
19
,
29
,
39
,
49
, and
59
while piling
57
is driven into ground
13
. A long support rod
61
is placed into passage
59
, so that the bottom end of long rod
61
is in contact with the top end of long rod
41
. In the preferred embodiment, long rod
61
is substantially the same material as rods
21
,
23
,
31
,
41
, and
51
. In the preferred embodiment, long rod
61
, like rods
31
,
41
, and
51
, is approximately twice the height of piling segment
11
,
27
,
37
,
47
, or
57
.
Grouting material
22
fills the remaining area of passage
49
located around rods
31
,
41
,
51
, and
61
. Grout
22
secures rod
61
to piling segment
47
and fills any remaining area of passage
59
around rods
51
and
61
at least up to a level below the top end of long rod
51
.
Rods
51
and
61
prevent misalignment between piling segments
47
and
57
when other piling segments are driven into the ground on top of segments
47
and
57
, by stopping any horizontal slippage at the level in which segments
47
and
57
are in contact. Furthermore, long rod
51
runs from approximately half way in segment
37
, through segment
47
, to approximately half way into segment
57
, therefore providing further resistance to segments
37
,
47
, and
57
shifting out of alignment.
Referring to
FIG. 6
, a sixth piling segment
67
is driven into ground
13
on top of piling segment
57
. Segment
67
is also a precast concrete cylinder having substantially the same shape and dimensions as piling segments
11
,
27
,
37
,
47
and
57
. Passage
69
aligns with passages
19
,
29
,
39
,
49
and
59
when segment
67
is placed on top of segment
57
. Long support rod
61
extends from the top of piling segment
57
into passage
69
. In the preferred embodiment long support rod
61
extends into passage
69
for about one-half of the height of segment
67
. Long support rod
61
in conjunction with the previously installed support rods provides a means for maintaining the alignment of passages
19
,
29
,
39
,
49
,
59
, and
69
while piling
67
is driven into ground
13
. A long support rod
71
is placed into passage
69
, so that the bottom end of long rod
71
is in contact with the top end of long rod
51
. In the preferred embodiment, long rod
71
is substantially the same material as rods
21
,
23
,
31
,
41
,
51
, and
61
. In the preferred embodiment, long rod
71
, like rods
31
,
41
,
51
, and
61
, is approximately twice the height of piling segment
11
,
27
,
37
,
47
,
57
, or
67
.
Grouting material
22
is poured into passage
69
and flows into any remaining space in passage
59
. Grout
22
fills the remaining area of passage
59
located around rods
31
,
41
,
51
,
61
, and
71
. Grout
22
secures rod
71
to piling segment
57
and also fills the area of passage
69
around rods
61
and
71
up at least to a level below the top end of long rod
61
.
Rods
61
and
71
prevent misalignment between piling segments
57
and
67
when other piling segments are driven into the ground on top of segments
57
and
67
, by stopping any horizontal slippage at the level in which segments
57
and
67
are in contact. Furthermore, long rod
61
runs from approximately halfway in segment
47
, through segment
57
, to approximately halfway into segment
67
, therefore providing further resistance to segments
47
,
57
, and
67
shifting out of alignment.
Additional piling segments are driven into ground
13
on top of the segment
11
,
17
,
27
,
37
,
47
,
57
, and
67
, and additional long rods are added, until the piling assembly reaches the desired depth, based upon the ground conditions. When the piling assembly reaches the desired depth, then the piling assembly needs to be prepared to have a pile cap (not shown) placed above the piling assembly. Referring to
FIG. 7
, final long rod
76
extends up from a top piling segment
77
, which has been driven into ground
13
on top of piling segments
11
,
17
,
27
,
37
,
47
,
57
,
67
, and any additional segments needed to reach the desired depth. Final long rod
76
had been placed and grouted into the top piling segment passage
79
in the same manner as described above. A top rod
81
is placed into passage
79
so that the bottom end of top rod
81
is in contact with the top end of a second to final rod
82
. Top rod
81
is long enough so that it extends past the top of top piling segment
77
. Top rod
81
and final long rod
76
provide a guide for aligning and placing the pile cap (not shown) onto the pile assembly. Prior to installing rod
81
, grout
22
is poured into passage
79
to a level substantially even with the top surface of top piling segment
77
.
With a piling assembly made in accordance with this method, the support rods are staggered in such manner that prevents the pilings from sliding out of alignment. Each interface between two piling segments is stabilized by solid portions (no joints) of the support rods, which are grouted into the passages. A piling segment should not slide or shear across the surface of another piling segment when, in accordance with this method, there are no joints located at the same level as the piling segment interface. There is only one interface between upper and lower rods located between each segment interface.
Further, it will also be apparent to those skilled in the art that modifications, changes and substitutions may be made to the invention in the foregoing disclosure. Accordingly, it is appropriate that the appended claims be construed broadly and in the manner consistent with the spirit and scope of the invention herein. For example, the same results and advantages would be realized if short support rod
21
were two-thirds the height of piling segment
11
and intermediate support rod were one and two-thirds the height of piling segment
11
.
Claims
- 1. A piling assembly, comprising:a first and second piling segments for providing support to the foundation that is being repaired; a passageway running through each of the piling segments from an upper surface to a lower surface of each segment, the passageway in the first segment aligning with the passageway in the second piling segment; a short support rod located in the passageway of the first piling segment that is shorter in height than the first piling segment, for helping to prevent lateral movements of the piling segments; an intermediate support rod located in the passageway of the first piling segment that is taller than the first piling segment but shorter than a combine height of the first and the second piling segments, so that an upper end of the intermediate support rod is halfway between the upper and lower surfaces of the second piling segment; and a long support rod having a lower end located in the passageway of the first piling segment and extending upward from the upper end of the short support rod and above the upper surface of the second piling segment for a distance at least one-half the height of the second piling segment.
- 2. The piling assembly of claim 1, wherein:the segments are driven one on top of the other, with the lower surface of the segment on top in contact with the upper surface of the segment on bottom.
- 3. The piling assembly of claim 1, further providing that the passageway running through each of the segments is located substantially along the centerline of each of the segments.
- 4. The piling assembly of claim 1, further providing that:the upper end of the short support rod abuts a lower end of the long support rod; and the upper end of the intermediate support rod abuts a lower end of the long support rod.
- 5. The piling assembly of claim 1, comprising:a third piling segment driven on top of the second piling segment, the thrid piling segment having a passageway running there through; and a long support rod having a lower end in the second piling segment and an upper end protruding above the third piling segment a distance at least one-half the height of the third piling segment.
- 6. The piling assembly of claim 1, further providing that:the short support rod is substantially one-half the height of each piling segment; the intermediate support rod is substantially one and one-half the height of each piling segment; and the long support rod is substantially twice the height of each piling segment.
- 7. The piling assembly of claim 1, further comprising a grout filled in the passageway around the rods.
- 8. A method for installing a piling comprising the following steps:(a) driving into the earth a first piling segment having a first passageway there through; (b) placing a short and an intermediate length support rod into the first passageway, wherein the short support is shorter than the first piling segment, and wherein the intermediate support rod is taller than the first segment; (c) driving a second piling segment into the earth on top of the first piling segment, the second piling segment having a second passageway; and (d) placing long support rods into the first and second passageways so that the lower end of one of the long support rods abuts the upper end of the short rod, the lower end of another one of the long support rods abuts the upper end of the intermediate rod, the long support rods being greater in length than the intermediate rod.
- 9. The method for installing a piling in claim 8, further comprising:repeating steps (c) and (d) with additional piling segments until the desired depth is reached.
- 10. The method for installing a piling in claim 8, further providing that in step (b) the short support and the intermediate support rods are placed in the first and second passageways until the bottoms of both rods are at the same depth as the lower surface of the first segment.
- 11. The method for installing a piling in claim 8, wherein segments are substantially equal in height, the short rod is approximately one-half the height of the segments, the intermediate rod is approximately one and one-half times the height of the segment, and the long rod is approximately twice the height of the segment.
- 12. The method for installing a piling in claim 8, wherein:step (b) further comprises placing grout in the first passageway; and step (d) further comprises placing grout in the second passageway.
- 13. A method for installing a piling comprising the following steps:(a) driving into the earth a first piling segment having a first passageway there through; (b) placing grout in the first passageway and inserting a short and an intermediate length support rod into the first passageway until the bottom of both rods are at the same depth as the lower surface of the first segment, wherein the short support is one-half the height of the first piling segment, and wherein the intermediate support rod is one and one-half times the height of the first segment; (c) driving a second piling segment into the earth on top of the first piling segment, the second piling segment being equal in height to the first segment, the second piling segment having a second passageway; (d) placing grout in the passageway and inserting long support rods into the first and second passageways so that the lower end of one of the long support rods abuts the upper end of the short rod, the long support rods being twice the height of the segments; and (e) repeating steps (c) and (d) with additional pilings until the desired depth is reached.
US Referenced Citations (14)