U.S. patent application number 11/710387 was filed with the patent office on 2007-09-27 for novel surface structures and methods thereof.
Invention is credited to Richard J. Gagliano.
Application Number | 20070224001 11/710387 |
Document ID | / |
Family ID | 38533611 |
Filed Date | 2007-09-27 |
United States Patent
Application |
20070224001 |
Kind Code |
A1 |
Gagliano; Richard J. |
September 27, 2007 |
Novel surface structures and methods thereof
Abstract
A novel foundation system, method of manufacture and method of
implementation are disclosed, comprising a simplified cast
structure/pile combination advantageously shaped for selective
positioning in different soil conditions to become a supporting
foundation. In at least one aspect, the shape comprises a cavity or
shaped recess that is initially empty, and operable to accept soil
displaced by soil heave. The cavity preferably is configured to
have a depth estimated to be equal to or greater that an estimated
vertical heave displacement of a given site soil, in order to
minimize soil heave displacement of the cast structure/pile
combination. In at least one other aspect, the shape comprises a
portion configured to cleave soil if the soil heaves.
Inventors: |
Gagliano; Richard J.; (Gig
Harbor, WA) |
Correspondence
Address: |
MORGAN LEWIS & BOCKIUS LLP
1111 PENNSYLVANIA AVENUE NW
WASHINGTON
DC
20004
US
|
Family ID: |
38533611 |
Appl. No.: |
11/710387 |
Filed: |
February 22, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11149047 |
Jun 8, 2005 |
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11710387 |
Feb 22, 2007 |
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10633155 |
Jul 31, 2003 |
6910832 |
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11149047 |
Jun 8, 2005 |
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Current U.S.
Class: |
405/229 |
Current CPC
Class: |
E02D 27/02 20130101;
E02D 27/14 20130101 |
Class at
Publication: |
405/229 |
International
Class: |
E02D 31/00 20060101
E02D031/00 |
Claims
1. (canceled)
2. A foundation support system comprising a form means configured
to receive a cementitious material in a fluid form for subsequent
curing, (a) said form means dimensioned so that said cementitious
material, after it has cured, is configured on a lower portion so
as to allow the cured cementitious material to cleave soil if said
soil heaves; or (b) said form means comprises a cavity dimensioned
to have a depth estimated to be equal to or greater than an
estimated vertical heave displacement of said soil.
3. A system as in claim 2, wherein said lower portion has an
inverted wedge shape.
4. A system as in claim 2, wherein said lower portion has a
pyramidal shape.
5. A foundation support system comprising a form means configured
to receive a cementitious material in a fluid form for subsequent
curing, (a) said form means dimensioned so that said cementitious
material, after it has cured, is configured and adapted on a lower
portion so as to cleave soil if said soil heaves; or (b) said form
means comprises a cavity with a triangular cross-sectional
shape.
6. A foundation support system as in claim 5, wherein said cavity
is dimensioned to have a depth estimated to be equal to or greater
that an estimated vertical heave displacement of said soil.
7. A system as in claim 2, wherein said cavity has a wedge
shape.
8. A system as in claim 2, wherein said cavity has a pyramidal
shape.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent
application Ser. No. 11/149,047, filed Jun. 8, 2005, which is a
continuation-in-part of U.S. patent application Ser. No. 10/633,155
(now U.S. Pat. No. 6,910,832), filed Jul. 31, 2003. The entire
contents of those applications are incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to systems for the
support of surface structures. More specifically the present
invention relates to improvements to hybrid foundation systems
comprised of piles and engaging cementious components, and to the
methods and processes for preparing them.
BACKGROUND OF THE INVENTION
[0003] The construction of surface structures based on the rising
concern for sustainable use of materials and developable lands
leads in many cases to the use of minimal ground impact foundation
technologies. These technologies reduce the effects of excavation
and site manipulation, thereby limiting environmental impacts to
surface and subsurface water flows, and soil biological functions.
They also reduce erosion by curbing the volume of excavated
materials, and can in many cases provide similar structural
function with less material than traditional foundation
solutions.
[0004] In developing these technologies for widespread use, and
therefore the greatest overall environmental benefit, cost
reductions are imperative. These costs can be reduced through the
development of alternate component parts, or the development of
more efficient means of production.
[0005] The present invention is a result of these development
efforts.
[0006] Disclosure of U.S. Pat. Nos. 5,039,256 and 6,578,333 are
hereby incorporated for reference. Please also refer to U.S. Pat.
No. 7,076,925, incorporated herein by reference.
OBJECTS AND SUMMARY OF THE PRESENT INVENTION
[0007] An object of this invention is to provide an improved
foundation that is applicable to a wide variety of site and soil
conditions, architectural typologies, loading conditions.
[0008] A further object of this invention is to provide an improved
foundation that is installed with less excavation than conventional
foundation systems.
[0009] An object of this invention is to provide an improved
foundation that preserves the inherent structural integrity,
moisture content, and biological life of its engaged soil.
[0010] An object of this invention is to provide an improved
foundation that can be used as a standardized construction
component.
[0011] An object of this invention is to provide an improved
foundation that has some replaceable and maintainable parts.
[0012] An object of this invention is to provide an improved
foundation that can withstand frost and expanding soil conditions
without jeopardizing structural function.
[0013] An object of this invention is to provide an improved
foundation that requires substantially less resources than current
methods require.
[0014] An object of this invention is to provide an improved
process for preparing a cementious structural foundation body
through which piles are driven, but without the use of embedded
sleeves or selectively re-enforcing elements.
[0015] The above and other objects of the present invention are
realized in a novel foundation system and method based on
selectively constructed diamond piers. A novel casting method is
employed to create the piers, using tapered inserts and a
bifurcated mold with selectively arranged openings, mounts and the
like. The casting uses a cementious material with re-enforcing
elements dispersed evenly therewith. The resulting cast pier is
advantageously shaped for selective positioning in many different
soil conditions to become a supporting foundation.
[0016] The forgoing features of the present invention are more
fully described in the following detailed discussion of the
specific illustrated embodiments, and in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0017] For a more complete understanding of the specific
embodiments, FIGS. 1-6 are provided as illustrations relating to
the practice of the present invention, wherein:
[0018] FIG. 1 is a section view of the primary components used in
the inventive process to create the first embodiment, including a
tapered dowel and a top and bottom casting form with specific
features;
[0019] FIG. 2 is a side view of the components of FIG. 1 assembled
with secondary components in preparation for the creation of the
first embodiment;
[0020] FIG. 3 is a perspective view of the first embodiment
depicting the resulting structural body created by the components
in FIG. 1, and having a cut away section which reveals the specific
features;
[0021] FIG. 4 is a section view of a modified version of the
primary components of FIG. 1 used now in the inventive process to
create a second embodiment;
[0022] FIG. 5 is a side view of the two structural bodies the two
embodiments installed in a given soil with driven piles, and
including a diagram of the reactions and forces at work in the soil
in relation to the shape of the bases of the embodiments and the
anchoring action of the piles; and
[0023] FIG. 6 illustrates the diameters sequence and relationships
necessary for the proper application of the inventive process.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention is an improved structural component
for use in hybridized cementious head and driven pile foundation
systems whereby (sleeveless) cavities for receiving driven battered
piles are created within a cast structural body, shaped at its base
in a pyramidal or wedge configuration to facilitate its structural
integration with the surrounding soil. The cavities are created
through an inventive process involving the use of a tapered dowel
component and specifically shaped openings in a casting form,
dimensioned and prepared for the insertion and removal of these
dowels and the subsequent curing of an appropriately configured
cavity and adequately re-enforced surrounding structural body. The
process avoids the inclusion of sleeves or independent retaining
support structures, in part, by using a cementious material with
dispersed steel re-enforcing fibers. These fibers enhance the
tensile strength of the resulting pier, vastly simplifying the
design.
[0025] In the following discussion, like numerals are used to
indicate common elements depicted in various views.
First Embodiment
[0026] Referring now to FIG. 1, views of the primary components
used in the inventive process to create the first embodiment are
shown. There is a section view of a two part thermoplastic form 1a.
and 1b, with side flanges 2 including a flange male and female
interlock 3a and 3b. The form 1b. has a square shaped top 4, though
this could be of any desired geometry, circular, rectangular,
triangular, with a centered hole 5 for the placement of an embedded
anchor bolt (see component 14, FIGS. 2 and 3). The form 1a. has an
open end 6 for receiving a poured, curable cementious medium, and
the subsequent placement of a pyramidal shaped plug 7. The use of
this plug 7 will be more fully described in FIGS. 2 and 3, and in
the example description. The main walls of the forms la. and 1b.
are angled at approximately 45 degrees relative to the side flanges
2 and/or the top square plane 4. These sides contain round holes 8
in form 1b, and opposing, corresponding dimpled round holes 9 in
form 1a. The tapered dowels 10 are of specific, continually
reducing diameter to fit within the form holes 8 & 9. The
dowels may be solid in cross section or hollow provided the wall
thickness, after tapering, is sufficient for casting purposes. The
upper diameter 10a. (shaded) corresponds with the form hole 9, and
will tighten to perform a pressure fit within that hole.
[0027] As the forms age and the pressure fit is worn loose, a
locking clamp 11 may be used to provide the same function whereby
the tapered dowel is inserted in the form assembly through hole 9
and into and through hole 8 but will only reach to a certain depth.
The lower diameter 10b. corresponds with the diameter of form hole
8. At the thinner end of the dowel is a tapping point 12, the
function of which, along with the specific positioning of the dowel
within the forms, will be described in the discussion of FIG.
2.
[0028] FIG. 2 is a side view of the components of FIG. 1 assembled
in preparation for the casting of the first embodiment. In the
inventive process, form 1b is attached by any ordinary mechanical
means to a casting base 13. This base may be of wood, steel,
plastic or any suitable material to provide a firm platform for the
placement of the forms on a casting table or work surface. The
casting base has a hole 13a. drilled a partial distance into the
base specific to the desired final protrusion height of an anchor
bolt 14. (This bolt function will become obvious in the discussion
of FIG. 3.) Forms 1a and 1b are now clamped together along the side
flanges 2 in any number of appropriate spots necessary to keep the
forms interlocked throughout the pouring and curing process, and by
any standard mechanical clamping device 15 known in general
industry.
[0029] The tapered dowel 10 is then inserted through the dimple
hole 9 and with its lower end through the round hole 8. The
pressure fitting of the larger diameter section of the dowel 10a.
restricts the extent to which the dowel protrudes from hole 8. This
establishes a sufficient distance, measured from the tapping point
12 of the dowel to the casting base below, to allow the free swing
of a hammer or other tapping tool to strike the point and deliver
an axial impact force to the dowel. The tapping point may be marred
and deformed over time by repeated strikes, therefore its diameter
is substantially less than that of the thinnest end of the dowel.
In this fashion, deformities of the tapping point will not restrict
the removal of the dowel through the cured cavity it will
subsequently create.
[0030] Once the tapered dowels have been inserted (at least 2) into
the form assembly, the next step involves the pouring of a
cementious, curable matrix 6a into the forms from above, through
the top hole 6. The matrix is made up of an appropriate curable
medium, and in contrast to previous art or traditional pours of
cementious structural bodies, no specifically configured
reinforcing rod or pre-placed tensioning element is employed. The
strength and mix of this medium will be more fully described in
FIG. 3. Once poured, the plugging element 7 is placed into the
receiving hole 6, and the cast body is allowed to begin its curing
process. At this point the casting base may be shaken or vibrated
to ensure uniform flow of the cementious medium, and additional
matrix may be added through the top if necessary, and
re-plugged.
[0031] The dowels will be removed during the curing process,
(recognizing that for some cement, curing extends long after form
extraction) but before the forms are removed from the cast body.
The forms are removed after the concrete has "set," i.e., that it
can survive intact form removal. The taper of the dowels
facilitates this removal as they will be extracted up and out of
the forms such that the moving dowel will slide a continuously
thinner diameter through the partially cured or cured cavity it has
created. To facilitate its removal, the dowel may be rotated about
its longitudinal axis to break any chemical bonds that may begin to
form during the curing process of the medium. This rotating step
may be done once or repeated several times as the variability in
the setting chemistry unfolds. Assuming a set time of twenty-four
hours, rotation should be performed every two hours, for the first
eight hours. It may also not be necessary at all to rotate the
dowel, and the it may be extracted cleanly with the simple tap on
the tapping point to break any chemical bonds, and the dowel
removed with a subsequent upward sliding extraction motion just
prior to form removal. This rotation and extraction process can be
done by hand or by mechanical or robotic means.
[0032] Once fully cured, with the dowels extracted, the forms are
unclamped, the plug removed and the upper form 1a. is lifted off
the cast body. The casting base and form 1b. assembly is then
rolled to one side and the cast structural body pulled or gravity
dropped from the form. The forms and components may then be cleaned
and re-assembled for a subsequent casting. The resulting structural
component is shown in FIG. 3.
[0033] FIG. 3 is a perspective view of the cast structural body 16
now rotated to its application orientation with the anchor bolt 14
on top, and revealing a cut away section of one of the cast
cavities 17 created by the tapered dowel. Theses cavities will
receive driven piles 18. These piles have a continuous constant
diameter, smaller than the most restrictive cross-section of the
tapered cavity at its lowest end. You can see at this lower end of
the longitudinal cavity, the recess 19 created by the dimple hole
shape in the casting form 1a. of FIG. 1. This recess provides
protection against the breaking of the cured surface cementious
material, typically referred to as a surface spall, under the
loading action of the pile.
[0034] Under load, a vertical force would be applied downward on
the structural body, forcing the pile, which is embedded in
surrounding earth, up against the upper edge of the lower end of
the cavity. This load would typically cause a surface spall since
the interlocking nature of the cementious medium cannot restrain
this exposed section of the body from separating and lifting away.
If such a spall occurs, it leads to further spalling since a new
surface has been exposed, which, similarly, cannot resist the
strain of the pile.
[0035] By creating the recess 19, the upward force of the pile is
applied at a point 19a, at a distance sufficiently setback from the
surface, and thereby contained by enough surrounding medium, to
resist breaking within the loading parameters of the specific
structural body. As applied, this dimpling technique may be
increased and varied by increasing its depth within the cast body,
depending on the scale of loads anticipated and the relative
interlocking strength of the curable matrix employed.
[0036] The matrix depicted herein shows a multitude of corrugated
steel fibers 20 within the binding medium. Unlike the use of these
fibers in other traditional cementious applications in industry,
where they are employed as secondary re-enforcing, these fibers
comprise the primary re-enforcing elements within the structural
body. This fact is integral with the inventive process described in
the discussion of FIG. 2, since the use of these fibers directly
within the matrix eliminates the costly and time consuming step of
forming and placing specifically shaped re-enforcing rod components
within the casting forms, and allows for easier placement, rotation
and extraction of the cavity creating tapered dowels.
[0037] These fibers, through their corrugated shape and inherent
tensile characteristics, significantly enhance the interlocking
strength of the cured cementious medium. The proportion of fibers
to matrix volume can be varied, and, as with the recessed dimple
19, may be adjusted to the loading requirements and mix medium
anticipated. A suitable matrix composition includes corrugated
steel fibers, one inch in length having a one-tenth inch width, 20
mils (0.020 inches) thick, and height of corrugation around 50 mils
(0.050 inches). dispersed in the concrete at a ratio of one pound
fiber to fifty pounds of concrete. This results, on a volumetric
basis, in three pounds of steel fiber in one cubic foot of
concrete. Per se, well-known industry standard mixtures of portland
cement, water and stone are adequate for this application.
[0038] FIG. 3 also reveals the shape 21 of the base of the
structural body created by the plug shown in FIG. 2. This angle
shape, is similar in angular degree and function to the main sides
of the cast body, which relate specifically as perpendicular planes
the angle of the dowels and subsequent driven piles. The pitch of
the angle may be varied and may take single or multiple forms,
creating, but not limited to, conical, pyramidal or wedge shapes.
Its function will be more fully defined in the discussion of FIG.
5.
[0039] FIG. 3 also depicts a conventional bracket attachment 22,
which is bolted to the cast anchor bolt 14. This anchor bolt
provides a flexible means of structural load transfer between the
structural body and attached bracket.
Second Embodiment
[0040] FIG. 4 is a variation on the first embodiment, creating a
more rectilinear shaped structural body 30, which may be cast as a
block to support point loads as in the first embodiment, but is
more naturally employed as a continuous or longitudinal section of
fixed width and utilizing a series of paired cast cavities along
its length. In this application, rather than a top and bottom form,
side forms 31a and 31b are employed. They are connected at the top
and base by a restricting element 32 preventing the lateral outward
movement of the forms under internal side pressures from the
cementious pour. These restricting cleats are common in industry
and do not represent an inventive step. The wedge block 33 is
employed similar to the plug element 7 in FIG. 2. It is continuous
along the full length of the forms, and will generate the necessary
base shape 34 in the final cast body. The forms have round holes 8
in a section of the form shaped to be perpendicular to the axis of
the dowel, and dimpled holes 9.
[0041] These forms may be made of any suitable structurally stiff
material which can withstand the internal forces of the curing
cementious material, and be re-used for repeatable castings. Again
a tapered dowel 10 is used, complete with the necessary tapping
point, and appropriate diameters corresponding to the form
holes.
[0042] In casting the rectilinear structural body 30, the assembled
forms, dowels and wedge block must be "book-ended" with rigid
panels 35 which will restrict the flow of the cementious material.
These may be integral to the side forms, or, as depicted, simply
secondary components attached by some mechanical means to the side
forms or restricted from movement by weights or other means
external to the panels to keep them from movement during the pour
and subsequent curing. It is possible as well to form an entire
self contained shape such as a square or rectangle with a series of
interconnected side forms and cast not a discreet block 30, but a
continuous perimeter shape such as would employed for a continuous
perimeter foundation.
[0043] FIG. 5 shows the function of the wedge or pyramidal shape at
the base of either embodiment, now installed with the application
of driven piles into a surrounding soil. The installation involves
clearing an appropriately sized opening for placing the pier. Piles
are initially tapped slightly into the ground, positioning and
orienting the pier. Using a sequential rotational process (e.g.,
clockwise), once oriented correctly, the piles are collectively
driven into the ground slowly increasing their ground penetration
until the necessary depth is achieved.
[0044] The shapes at the base of each embodiment act to cleave the
soil when it heaves under frost or expansive soil conditions. In a
traditional application, a foundation typically rests a flat
horizontal surface against a given soil bearing area. If soils
below this foundation heave, the foundation is lifted and this is
undesirable as it can lead to concrete cracking, differential
settlements and structural failure. In order to alleviate such a
heaving soil pushing up against a conventional foundation, the
horizontal flat base is typically set deeper in the soil, below
what is referred to as the frost line (in the case of freeze thaw
regions) or below the heaving line (in areas where silts and clay
soils are subject to volumetric change to the addition (or
deletion) of moisture). This step leads to the extensive excavation
that causes dramatic impacts to building sites and surrounding
areas.
[0045] The structural bodies 30 and 16 depicted are examples of
minimal impact foundation systems which are typically installed in
surface soils with little or no excavation well above region frost
or heaving lines 80. The cleaving shapes 21 and 34 address the
problem of heave. In the diagram the number 50 represents the first
soil movement that takes place when a soil begins to heave.
[0046] In this application, the upward pushing force of the soil,
(a volumetric expansion at the molecular level which translates to
true volumetric change in the soil medium) first tries to lift the
cast structural component. The component is of course restricted
from upward movement by the anchoring action of the driven piles
18. They are still well below the heaving soil and "fight" to keep
the cast component in place. But something must move since the
molecular changes in the soil will not be stopped. Since there is
no flat horizontal surface for the soil to push against directly,
the result is that the soil spreads away from the specifically
shaped cast body--it is cleaved to the side as shown in the arrow
60. As the soil heaving works its way incrementally downward (due
to the nature of freezing temperatures or moisture permeating the
soil) the process continues, as in heave areas 51 & 52 and the
resulting sideways motions 61 & 62.
[0047] Having established this pattern of movement, the soil will
continue to work in this way heaving away, but not directly
against, the cast body, while the pins keep the system anchored in
place. In this type of application, it is imperative that the lower
ends of the driven pins are below the frost or heaving line in
order to maintain anchoring resistance. Also, where the wedge
configuration is internalized such as in the second embodiment 34
or the very center of the base of the first embodiment, that the
depth 70 created by the plug or wedge block used in the casting
process, is at least equal or greater than the estimated vertical
heave displacement of a given site soil.
[0048] FIG. 6 again diagramatically shows the relationships between
the relative diameters of the system components, where the driven
piles 18 are of a constant cross section and a have a diameter x
and; the tapered dowels 10 have, near the thinner end, a diameter
10b just larger than the pile=x+c, and at the larger end, a
diameter also larger than the pile but more so=x+c+c. These
diameters correspond to the round hole in a given casting form
8=x+c+c, and the dimpled hole 9=x+c. When cast to create a tapered
cavity 17, the pile will be allowed a free sliding motion through
the cavity without binding.
[0049] A variety of shapes containing these salient features, may
be employed provided the primary components and relationships
described herein are maintained.
[0050] The above description is merely illustrative of select
embodiments of the present invention and does not, in any way, act
to restrict the variations available to accomplish the inventive
features therein. The foregoing inventions are solely limited by
the appended claims on this patent.
* * * * *