Patent Application
20240254716
Embodiments of the present invention relate to systems and methods to increase the capacities of underground foundations and more particularly with systems and methods for deploying supports into the adjacent substrate before, during or post installation of the foundation element.
It is well known that current foundation elements have limited capacities to bear weight. Some of the main challenges faced on construction sites relate to the use of drilled shafts and driven piles to establish foundations. Foundations must often be installed in soils having inadequate capacity to bear the required structural loads which consequently require many foundation elements or very deep or large-diameter foundation elements. In addition, foundation installation often seeks to terminate a foundation within a relatively thin layer of adequate material, e.g., rock, or hard material that is sandwiched between two layers of less desirable materials such as soft soils or clay. Such soil conditions may require many foundation elements to mobilize the needed soil bearing capacity to carry the structure loads. Due to unfavorable soil conditions, more foundation elements must be drilled or driven deeper, and/or larger diameter shafts or piles must be used to develop the required capacities. Both approaches increase costs and involve higher risk and complexity. The result is a requirement to use larger equipment, deeper holes, larger rebar cages, more concrete, all of which carry a higher risk of structural failure, collapses during excavation, larger environmental impact, higher complexity of the installation, higher risk of accidents and problems during construction, and less room for redundancy. What is needed is a foundation support system and its associated methodology that provides increased foundation capacity and enhanced frictional soil interaction thereby reducing, for a stated capacity need, the number, depth, and size of the required foundation elements. These and other deficiencies of the prior art are addressed by one or more embodiments of the disclosed invention.
Additional advantages and novel features of this invention shall be set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the following specification or may be learned by the practice of the invention. The advantages of the invention may be realized and attained by means of the instrumentalities, combinations, compositions, and methods particularly pointed out in the appended claims.
A system and associated methodology for enhancing the capacity of foundation elements laterally penetrates the surrounding substrate creating a more stable and stronger underpinning. The load bearing capacity of a foundation element is increased by deploying extensible components, also referred to herein as outriggers, quills and fins, into the surrounding substrate/soil. The breadth of a foundation element is expanded laterally by extending quills or fins into the surrounding soil. Much like the roots of a tree, the quills and fins increase interaction with the substrate creating a larger area on which to distribute a load. The extensible components are integrated within the foundation element and the like and deployed into the surrounding substrate once the foundation element is positioned in the ground.
The disclosed methodology and associated system includes outriggers, fins, or quills deployed from the sides of a foundation element into the adjacent soil when installed in or near its final position. Deployment may occur either before, during or after concreting for the drilled shafts and after driving for the driven piles. The deployment may also occur, before or after the introduction of the partial or final building load on the foundation element. The deployed extensible components improve the foundation element's strength against mechanical shear, improve friction, and/or increase load-bearing capacity. As a result, the depth, size, and/or number of foundation elements can be reduced. The disclosed systems and methods can increase the capacity of foundation elements to resist downward loads and uplift forces as well as increase the lateral capacity of foundation elements. Responsive to the use of the disclosed invention, foundation efficiency, construction safety, building schedules, cost and environmental impact are improved. Moreover, foundation capacity enhanced from employing the present invention can be tested and verified in the field prior to final loading.
In one embodiment of the present invention a foundation support apparatus includes a foundation element within a substrate having a length along a longitudinal axis. Within the foundation element is an expansion mechanism integrated within an outer dimension of the foundation element that is coupled to an extensible component. The expansion mechanism is configured to extend a portion of the extensible component outside the outer dimension of the foundation element to an extended configuration thereby penetrating the substrate.
Other features of the foundation support apparatus include that the expansion mechanism may be aligned with or offset from a central longitudinal axis. In one embodiment two or more extensible components are independently coupled to one or more expansion mechanism(s). In one instance two extensible components are opposingly coupled to the expansion mechanism. While a variety of orientations and distributions of the expansion mechanisms and associated extensible components within the foundation element are possible and contemplated, in one instance of the present invention a portion of extensible components is configured to penetrate the substrate at an angle less than 90 degrees as measured from a distal end of the foundation element relative to the longitudinal axis. In another instance a portion of extensible components is configured to penetrate the substrate at an angle greater than 90 degrees as measured from a distal end of the foundation element relative to the longitudinal axis.
In another embodiment of the present invention the extensible component includes an inner component and an outer component, wherein the outer component is hollow having an outer component interior dimension and wherein an inner component exterior dimension is less than the outer component interior dimension, the inner component being movable within the outer component. A fluid source is coupled to the expansion mechanism and channeled to an interior portion of the outer component thereby creating a pressure gradient translating the inner component within the outer component to the extended configuration.
In one version of the present invention, the foundation element includes
reinforcement bars (rebar) configured into a rebar cage. A void exists between the substrate and an outer dimension of the rebar cage and between the reinforcement bars of the rebar cage. In this version a matrix such as concrete is configured to occupy the void and integrate with the rebar cage responsive to the portion of the extensible component being in the extended configuration. In another version of the invention the matrix is configured to occupy the void and integrate with the rebar cage prior to or concurrently with the portion of the extensible component being in the extended configuration.
The present invention includes expansion mechanism that are electrically, hydraulically, mechanically, and chemically driven. Another feature of the invention is that the portion of the extensible components when in the extended configuration includes a grout. The grout is configured to occupy an area void of material between the extensible components penetrating the substrate and the substrate itself.
In yet another embodiment of the present invention, the extensible component include a projection proximate to an exterior surface of the foundation element that is substantially aligned with the longitudinal axis of the foundation element when in a nonextended configuration. The projection includes a first end rotatably coupled to the foundation element and a second end associated with the expansion mechanism. When the expansion mechanism moves the extensible component into its extended configuration the second end is angularly offset about the first end thereby penetrating substrate.
In another embodiment of the present invention support of a foundation element is established by integrating an expansion mechanism within a foundation element. The method continues by coupling an extensible component to the expansion mechanism and thereafter establishing the foundation element within a substrate. Once placed into the substrate, a portion of the extensible component is extended outside of an outer dimension of the foundation element penetrating the substrate.
The features and advantages described in this disclosure and in the following detailed description are not all-inclusive. Many additional features and advantages will be apparent to one of ordinary skill in the relevant art in view of the drawings, specification, and claims hereof. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes and may not have been selected to delineate or circumscribe the inventive subject matter; reference to the claims is necessary to determine such inventive subject matter.
The features and objects of the present invention and the manner of attaining them will become more apparent, and the invention itself will be best understood, by reference to the following description of one or more embodiments taken in conjunction with the accompanying drawings, wherein:
The Figures depict embodiments of the present invention for purposes of illustration only. Like numbers refer to like elements throughout. In the figures, the sizes of certain lines, layers, components, elements, or features may be exaggerated for clarity. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the invention described herein.
The capacity and stability of a foundation element is enhanced by lateral extensions that penetrate the surrounding substrate creating a more stable and stronger underpinning. The load bearing capacity of a foundation element is increased by deploying extensible components of the present invention, also referred to herein as quills and fins, into the surrounding substrate/soil. The breadth of a foundation element is expanded by extending quills or fins (extensible components) into the surrounding soil via an expansion mechanism. The quills and fins of the present invention increase interaction with the substrate creating a larger area and rougher surface with lateral deformation on which to distribute a load. The extensible components are integrated within a foundation element, and the like, and deployed into the surrounding substrate once the foundation element is positioned in the ground.
Embodiments of the present invention are hereafter described in detail with reference to the accompanying Figures. Although the invention has been described and illustrated with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example and that numerous changes in the combination and arrangement of parts can be resorted to by those skilled in the art without departing from the spirit and scope of the invention.
The following description includes various specific details to assist in understanding the present invention but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. Also, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
Accordingly, the terminology used herein is for the purpose of describing embodiments only and is not intended to be limiting of the invention. 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. Thus, for example, reference to “a component surface” includes reference to one or more of such surfaces.
As used herein any reference to “one embodiment” or “an embodiment” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
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 invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity.
It will be also understood that when an element is referred to as being “on,” “attached” to, “connected” to, “coupled” with, “contacting”, “mounted” etc., another element, it can be directly on, attached to, connected to, coupled with, or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, “directly on,” “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.
Spatially relative terms, such as “under,” “below,” “lower,” “over,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of a device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of “over” and “under”. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly,” “downwardly,” “vertical,” “horizontal” and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.
By the term “substantially” it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.
By the term “foundation” it is meant a part of a structure, building or bridge that supports and anchors the structure above it and transfers its weight to the ground. There are different types of foundations, depending on the design of the structure the soil conditions, the site conditions, and the budget. Drilled shafts, shafts, caissons, drilled caissons, drilled piles, drilled piers, bored shafts, bored piles, cast-in-drilled-hole piles, CIDH, replacement piles, slurry wall panels, barrettes, and the like are foundations that are constructed by excavating the soil, before installing rebar (if needed) and/or pouring concrete creating the foundation. These types of foundations can have various geometric shapes including round, square or rectangular cross sections. Excavation for this type of foundation can be accomplished using dry holes, bentonite slurry, polymer slurry, casings or other similar methods.
What is meant by a “substrate” is something that lies beneath or supports something else. In a construction context a substrate is any material that exists or is extracted from beneath the topsoil, and that is used to support or incorporate into the structure. Some examples of substrates are organic soils, sand, silt, clay, rock, and gravel. The type of substrate affects the design and selection of the foundation, which is the part of the structure that transfers its load to the ground. Different substrates have different properties, such as strength, stability, moisture, and compressibility, that influence how well they can support the structure and prevent it from sinking, tilting, or cracking.
What is meant by a “foundation casing” is a type of exterior or sheath that is used to support and stabilize the excavation of a drilled shaft or a caisson foundation. These casings are used to prevent collapse during the drilling and excavation stages prior to concreting. Alternatively, Drilling fluids, Bentonite slurry, Polymer slurry or other means could be used to stabilize the excavation. When a casing is to remain after the concreting, provisions for lateral holes or windows will be implemented to enable the extension of the extensible components of the present invention into the substrate.
What is meant by an “expansion mechanism” is a process or a device that causes something to increase in size, volume, or extent. There are different types of expansion mechanisms, depending on the context and the purpose.
What is meant by an “extensible component” is structure or item that is capable of being extended or having the ability to be extended. Extensible is used to describe things that can be modified or adapted to suit a need. For example, an extensible web browser can be customized with different extensions or plugins that add new features or functions. With respect to physical objects as in the present invention extensible is used to describe materials that can be stretched or expanded. For example, an extensible measuring tape can be pulled out to measure different lengths. An extensible fabric can be stretched to fit different shapes or sizes. An extensible tongue can be protruded to reach different distance. Extensible components may change in size/length from a first length to a second length, the second length being larger than the first length.
What is meant by a “foundation element” is a structural element that supports the weight of a structure (building, bridge, or the like) and transfers that load to the surrounding soil. A foundation element may comprise the rebar cage (where used), the post tensioning strand (where used), the concrete and the post grouting (when used). Rebar, short for “reinforcing bar” or “reinforcement bar”, is a metal bar that is used to help increase the strength of concrete. As a result, it helps concrete structures withstand tensile, bending, torsion, and shearing load. The foundation element of the present invention can be cast in place in and around a rebar cage in an excavated hole or precast/prefabricated and driven in the ground. A foundation footing is a block of concrete or other material that is placed proximate to the ground surface, basement level or as specified by the design to distribute the load over a larger area and to distribute the loads to the one or more foundation elements. A foundation element can be made of different materials, such as concrete, steel, wood, or masonry, depending on the design requirements.
What is meant by a “rebar cage” is a steel framework that is used to reinforce concrete structures, such as foundations, foundation elements, beams, walls, and bridges. A rebar cage is made of longitudinal bars that run along the length of the structure, transverse bars, diagonal bars and spirals that wrap around the longitudinal bars at regular intervals. The bars are usually connected by wire ties, clamps, or welds. A rebar cage provides strength to a concrete structure, and helps it resist various forces, such as compression, tension, bending, and shear.
What is meant by a “driven pile” or “pile” or “piling” is a type of foundation used to support a structure by transferring its load to a deeper and more stable layer of soil or rock. A piling is usually a long and slender foundation element that is made of timber, steel, concrete, or a combination of these materials. In most instances, including that of the present invention, pilings include a post tension strand or strands. Post-tensioning is a method of reinforcing (strengthening) concrete or other materials with high-strength steel strands or bars, typically referred to as tendons. A piling can be driven, or jetted, into the ground, depending on the site conditions and the design requirements. Piles or pilings may also be referred to as soldier piles, displacement piles, precast piles, pipe piles, square piles, hollow piles, and steel piles. Piles are prefabricated prior to driving or jetting them in the ground. In the case of hollow piles, the soil inside the hollow pile could be excavated prior to pouring concrete if needed, these could be round, square, or rectangular cross section. Screw piles or continuous auger piles are a subset of the drilled shaft type of foundations that are constructed by pouring/pumping the concrete while excavating the soils and then installing the rebar cages if need before the concrete hardens. The present invention is applicable to all these types of foundations elements.
Included in the description are flowcharts depicting examples of the methodology which may be used to provide lateral support of a foundation. In the following description, it will be understood that each block of the flowchart illustrations, and combinations of blocks in the flowchart illustrations are processes that can be implemented by various means. The blocks of the flowchart illustrations support combinations of means for performing the specified functions and combinations of steps for performing the specified functions. It will also be understood that each block of the flowchart illustrations, and combinations of blocks in the flowchart illustrations, can be implemented by special purpose hardware or systems that perform the specified functions or steps, or combinations of special purpose hardware.
Upon reading this disclosure, those of skill in the art will appreciate still additional alternative structural and functional designs for a system and a process for lateral support of foundation elements through the disclosed principles herein. Thus, while embodiments and applications have been illustrated and described, it is to be understood that the disclosed embodiments are not limited to the precise construction and components disclosed herein. Various modifications, changes, and variations, which will be apparent to those skilled in the art, may be made in the arrangement, operation and details of the method and apparatus disclosed herein without departing from the spirit and scope defined in the appended claims.
Establishing a foundation is a crucial step in the construction of any building or structure, serving several essential purposes. The primary purpose of a foundation is to support the entire weight of the building or structure, transferring the load to the underlying soil or rock. It ensures that the structure remains stable and does not settle or collapse under its own weight or external forces such as wind, earthquakes, or other loads. Foundations provide a stable base for the construction of the superstructure (above-ground portion of the structure). This is crucial for ensuring that the piers, decks, floors, walls, and other structural elements remains as designed, providing a safe and comfortable environment for the end users.
In addition to vertical loads, foundations must also resist horizontal forces such as wind, seismic activity, unbalanced earth loads, and soil pressure. Specialized foundation designs, such as shear walls and pilings, help to counteract these lateral forces and enhance the overall stability of the structure.
The size and depth of a foundation are determined by several factors related to the building, site conditions, and the properties of the soil. The type and bearing capacity of the soil at the construction site are crucial factors. Different soils have varying abilities to support loads. The weight of the building, including the dead load (the weight of the structure itself) and live loads (occupant loads, furniture, equipment, wind, seismic, vehicles, dynamic loads, unbalanced earth loads, etc.), directly influences the size and depth of the foundation. Heavier structures require larger and deeper foundations.
Different types of foundations have varying size and depth requirements. For example, shallow foundations (e.g., spread footings) are used when the soil can adequately support the loads near the surface. Deep foundations (e.g., drilled shafts, driven piles) are employed when the soil near the surface is not suitable, and load-bearing capacity must be found deeper underground.
One aspect of the present invention is that it enhances, supplements, and expands upon the traditional mechanism of skin friction in the vertical walls of a shaft. The present invention enhances soil/foundation side friction in a competent substrate that cannot be normally realized through traditional means and thereby increasing the foundation capacity to minimize depth, risk, and cost.
While the invention is hereafter shown and described with reference to embodiments, it will be understood by those skilled in the art that various other changes in the form and details may be made without departing from the spirit and scope of the invention.
The foundation element 101 may also experience lateral loads 130. For example, wind blowing on the side of a tall building may increase the downward force due to a moment 135 but also invoke a lateral load. The lateral load 130 and the moment 135 realized by the lateral load are resisted by opposing forces 138 from the substrate along the foundation element's length Y 110. These loads, determined during the design of the building, are a significant factor is the size and depth of the foundation.
The portion of extensible component that extends into the substrate provides additional contact (interaction) with the underlying substrate providing additional mechanisms for load transfer. Rather than the entirety of the compressive load 114 being supported by the base or sides of the foundation element 101, one embodiment of the present invention enhances the foundation element's contact with the substrate 125 thereby providing additional regions at which the load can be transferred to the substrate. In
The effect of including the supports shown in
The lateral supports of the present invention also provide lateral load mitigation.
As with a compressive load, the lateral supports of the present invention increase the foundation element's ability to withstand a lateral load. Knowing a design required lateral load, a foundation element embodying one more lateral support of the present invention can reduce the size and/or number of foundation elements thereby reducing risk, cost, and time. Again, one of reasonable skill in the art will recognize that multiple configuration and numbers of extensible components can be integrated into each foundation element.
With reference to
Once in place within the prepare drilled shaft 210, and as depicted in
In the configuration shown in
The extensible components 460 are extended to an extended configuration into the substrate 125 in
Once deployed, the extensible component may be post-grouted to increase strength and load bearing capacity. The grout material could be cementitious, polymer, epoxy, composite, or other suitable material. Grouting may be performed using an independent grouting system or by using the hydraulic jack/actuator (expansion mechanism) system. Post-grouting improves load bearing capacities by creating a bulb at each (or some) of the extensions to further consolidate the soil in that area, increase the effective influence area of the extension, fill any voids around the extension, and/or provide enhanced corrosion protection. These features increase foundation element capacity and durability. When using hollow extensible components, the components may be structurally reinforced and/or have preinstalled rebar in the void prior to deployment and grouting. Finally, the deployment of the extensible components is monitored and confirmed by pressure monitoring, volumetric analysis, sensors, by instrument measurements, and/or by other suitable means.
A wide variety of configurations are possible and contemplated to optimize the lateral support system of the present invention for the required application. For example, the extensible components may be constructed of metal, fiber, carbon fiber, fiberglass, plastics, polymers, or other suitable materials. Some applications may benefit from more rigid extensible components, i.e., steel, and others from more flexible extensible components, i.e., fiberglass, to optimize horizontal or vertical load bearing capacity. The cross sections of the extensible components may also be configured to optimize performance and improve friction. Extensible component may be barbed for easy insertion into the earth and increasing the effective capacity when fully expanded and deployed. Various surface treatments for each extensible component may be used, such as ridges or fins. Different combinations of shapes, materials, or surface treatments may be used to optimize performance for a particular application. And the orientation of each extensible component as it interacts with the substrate may vary based on the design requirements. Indeed, the interaction of the extensible components and the substrate is a critical consideration. Post grouting, the interaction between the extensible component and grout bulb or region must provide a certain degree of movement to share loading subjected to the foundation element. The degree of movement varies based on the application and the composition/characteristics of the substrate. In some instances, the extensible components may be perpendicular to a longitudinal axis of a foundation element while in other embodiments the extensible components may penetrate the substrate at various angles to enhance and optimize the foundation element's load bearing capacity.
In this rendition of the foundation support system 540 the extensible components 560, 580 are configured at two telescoping parts with a pressure seal 585 between the exterior dimension/surface of the interior component 560 and the interior dimension/surface of the exterior component 580. In one embodiment a gap exists between the exterior surface of the inner component and the interior surface of the exterior component. This gap or void is filled by a pressure seal (not shown) of a known rating. The seal maintains pressure within the interior area thereby pushing the interior component outward until either a maximum pressure is reached or a mechanical stop is reached. As pressure raises it reaches a point upon which the seal fails. Upon failure of the seal grout flows through the gap between the exterior surface of the inner component and the interior surface of the exterior component into the area or void (void could be air or water) surrounding foundation element, the extension component, and the adjacent substrata forming an area or blub of grout 591. Grout is pumped until either a volumetric or pressure limit is reached. As the grout solidifies, the grout, foundation element and extensible components are rigidly integrated with the substrate.
Another deployment mechanism for the assembly shown in
According to another embodiment of the present invention, and with reference to
The present invention integrates one or more expansion mechanisms within an outer dimension of the foundation element. In one embodiment a foundation element positions 730 a plurality of foundation support systems at various locations and orientations along the foundation elements longitudinal axis. As the foundation element is, in most instances lowered into a shaft 740 or driven 750 into the substrate, each expansion mechanisms and associated 720 extensible components, are configured to be within the outer dimension of the foundation element as the foundation element is positioned within the substrate. In the case of a foundation element comprising a rebar cage the exterior dimension is defined by the outermost layer of rebar or similar surface as compared to the size of the shaft in which it is inserted which is therefore filled 760 by concrete.
Based on the load which the foundation element is designed to support, one or more lateral support systems, comprising an expansion mechanism and extensible components, are positioned 730 along the foundation element's longitudinal axis. Each of the expansion mechanisms and the extensible components are sized, shaped, oriented, and located to address a required need of the foundation element. For example, enhancing a foundation elements longitudinal load capacity may require multiple extensible components extending from the foundation element and penetrating a specific substrate at a certain depth and orientation along the longitudinal axis of the foundation element. In instances in which lateral load enhancement is needed, different extensible components may be configured to penetrate another specific substrate at a different depth and orientation along the foundation elements longitudinal axis.
With the rebar cage and extension components positioned 740 within the excavated shaft, or when a prefabricated/precast pile has been driven 750 into the substrate to a predetermine depth, the expansion mechanism extends 770 the extensible components thereby forcing a portion of the extensible component(s) outward thereby penetrating the surrounding substrate and creating an extended configuration of the extensible component(s). In one version of the present invention the extensible components are hydraulically driven into the substrate while in another embodiment the extensible components are extended by the expansion mechanism because of a chemical reaction or expansive gaseous reaction. In yet another embodiment driving the extensible components into the substrate is accomplished via an electrically, electromagnetically, or mechanically driven system.
The size, shape and configuration of the extensible components may vary as may the composition, rigidity, and fixity of each extensible component. The timing of penetrating the substrate by the extensible components may also vary. When a rebar cage is inserted 740 into a drilled shaft, a gap exists between the outer dimension of the rebar cage and the substrate. The rebar cage itself and the gap must be filled with a matrix (concrete) 760 to create the foundation element supportive of a structure. In one embodiment of the present invention, the expansion mechanism extends the extensible components into the substrate prior to filling the foundation element with its matrix such as concrete or the like. In other embodiment the filling of the shaft and foundation element is done concurrently with activation of the expansion mechanism to drive the extensible components into the surrounding substrate. And in yet another embodiment, the extensible components penetrate the substrate after the foundation element are filled with a matrix. The matrix could be still in the fluid stage, soft hardened or completely hardened.
With respect to a piling 750, once the foundation element has reached its desired depth the expansion mechanism integrated within the piling can be activated thereby driving the associated extensible components into the surrounding substrate.
As the extensible components penetrate the substrate a gap or void may exist between the components themselves and the substrate as well as between the outer surface of the foundation element and the shaft/substrate. In one version of the present invention a grout is channeled 780 through expansion mechanism and extensible components (or through an independent network of piping) to fill any void or gap that may exist between the substrate, the extensible components, and/or the foundation element. The grout is distinguishable from the concrete matrix used to form a foundation element in situ. Grout may be more liquid in nature lacking large aggregate and can, in one embodiment, be channeled and directed through the expansion mechanism to interact with the extensible components and substrate. The post grouting could also be used to consolidate the surrounding substrata, increase the effective area of the extensible components, and to provide corrosion protection.
When the extensible components are rotatably coupled to the foundation element, the expansion mechanism drives the extensible component outward thereby rotating the component about its pivot point (fins). A portion of the extensible component penetrates the substrate thereby supporting the foundation element.
The disclosed foundation support system of the present invention provides several advantages over existing foundation elements. These advantages include:
The foundation support system of the present invention enhances the overall capacity of the foundation element. The support system of the present invention does not necessarily need to be deployed on all the foundation elements as needed to improve the capacity of that element. In doing so the foundations can be installed and fabricated quicker, safer, and with lower cost. The reduce size of the foundation elements drives reduced needs for equipment such as cranes and the like and results in lower site congestion at a reduced size construction footprint.
These and other implementation methodologies for supporting a foundation element can be successfully utilized by lateral support system of the present invention. Construction implementation methodologies known within the art and the specifics of their application within the context of the present invention will be readily apparent to one of ordinary skill in the relevant art considering this specification.
The lateral support of the load bearing strata resulting from the deployment of the extensible components of the present invention is also applicable when deployed on foundation elements along the longitudinal axis in an orientation inclined from vertical position.
Although the invention has been described and illustrated with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example and that numerous changes in the combination and arrangement of parts can be resorted to by those skilled in the art without departing from the spirit and scope of the invention, as hereinafter claimed.
Embodiments of the present invention and many of its improvements have been described with a degree of particularity. This description has been made by way of example, and that the invention is defined by the scope of the following claims.
While there have been described above the principles of the present invention in conjunction with a foundation element lateral support system and its associated methodology, it is to be clearly understood that the foregoing description is made only by way of example and not as a limitation to the scope of the invention. Particularly, it is recognized that the teachings of the foregoing disclosure will suggest other modifications to those persons skilled in the relevant art. Such modifications may involve other features that are already known per se and which may be used instead of or in addition to features already described herein. Although claims have been formulated in this application to particular combinations of features, it should be understood that the scope of the disclosure herein also includes any novel feature or any novel combination of features disclosed either explicitly or implicitly or any generalization or modification thereof which would be apparent to persons skilled in the relevant art, whether or not such relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as confronted by the present invention. The Applicant hereby reserves the right to formulate new claims to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom.
| Number | Date | Country | |
|---|---|---|---|
| 63481923 | Jan 2023 | US |
