System for Forming a Movable Slab Foundation

Abstract

An embodiment of the system for forming a movable slab foundation as comprised by the present invention has a slab foundation, at least one support pier, at least one housing, a seal plate, and at least one support sleeve. The seal plate is positioned within the at least one housing and its outer peripheries are sealingly engaged with the inner surfaces of the at least one housing. The at least one housing and the seal plate are positioned within the at least one support pier. The at least one support sleeve is encased within the slab foundation and its lower end is positioned in abutting contact with the housing. A port is located in and extends through the upper end of the housing and into a cavity between the housing and the seal plate. The at least one housing is capable of movement upward relative to the seal plate.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 61/238,291, filed on Aug. 31, 2009, and herein incorporated by reference in its entirety.

FIELD OF THE INVENTION

[0002] This invention relates in general to forming an adjustable foundation, and in particular, to a concrete slab foundation capable of being raised above the ground.

BACKGROUND OF THE INVENTION

[0003] Many structures have been built on foundations or slabs made of concrete poured on top of soil. Constant changes in the weather and moisture levels in the soil frequently cause damage to such a foundation. In many instances, the foundation may buckle or even crack. This phenomenon occurs for a variety of reasons, including uneven changes in the water content of supporting soils, uneven compacting of soils, and uneven loads being placed on soils. Over time, uneven movement in the soils under a foundation can cause a foundation to bend or crack.

[0004] Therefore, it would be desirable to provide a method and apparatus that would allow a foundation to be poured on top of soil and subsequently raised to a desired height to eliminate potential problems caused by soil movement and/or problematic soils.

SUMMARY OF THE INVENTION

[0005] An embodiment of the system for forming a movable slab foundation as comprised by the present invention has a slab foundation and at least one support pier. At least one housing is positioned within the at least one support pier. The at least one housing has a closed upper end and an open lower end. A seal plate is positioned within and surrounded by the at least one housing. The outer peripheries of the seal plate sealingly engage the inner surfaces of the at least one housing. The at least one housing is upwardly moveable within the support pier relative to the seal plate. A cavity is defined by the space between the upper surface of the seal plate and the upper end of the at least one housing. A port is located in and extends through the closed upper end of the at least one housing and into the cavity. At least one support sleeve is encased within the slab foundation. The bottom surface of the at least one support sleeve abuttingly contacts the upper end of the at least one housing.

[0006] An embodiment of the system for forming a movable slab foundation as comprised by the present invention has a slab foundation and at least one support pier. At least one housing is positioned within the at least one support pier. The at least one housing has a closed upper end and an open lower end. A seal plate is positioned within and surrounded by the at least one housing. The outer peripheries of the seal plate sealingly engage the inner surfaces of the at least one housing. The at least one housing is upwardly moveable within the support pier relative to the seal plate. A cavity is defined by the space between the upper surface of the seal plate and the upper end of the at least one housing. A port is located in and extends through the closed upper end of the at least one housing and into the cavity. At least one support sleeve is encased within the slab foundation. The bottom surface of the at least one support sleeve abuttingly contacts the closed upper end of the at least one housing. A pumping device is connected to the port for pumping a support media into the cavity to thereby expand the cavity and move the housing, the support sleeve, and the slab foundation upwards relative to the seal plate.

[0007] An embodiment of the present invention is directed to a method for forming a movable slab foundation. The method comprises providing a housing with a closed upper end and an open lower end. A seal plate is positioned within and surrounded by the housing. The outer peripheries of the seal plate are sealingly engaged with the inner surfaces of the housing. A cavity is defined by the space between the upper end of the housing and the upper surface of the seal plate. A port located in and extends through the closed upper end of the housing and into the cavity. A support pier is placed below an intended slab foundation area. The inner and outer surfaces of the housing are treated with a form releaser. The housing and the seal plate are positioned within the support pier. A support sleeve is placed in abutting contact with the closed upper end of the housing. A slab foundation is formed such that it encases the support sleeve. A support media is pumped through the port and into the cavity, thereby expanding the cavity and simultaneously lifting the housing and the support sleeve to move the slab foundation upward relative to the seal plate to a desired height.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] So that the manner in which the features and benefits of the invention, as well as others which will become apparent, may be understood in more detail, a more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof which are illustrated in the appended drawings, which form a part of this specification. It is also to be noted, however, that the drawings illustrate only various embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it may include other effective embodiments as well.

[0009] FIG. 1 is a sectional view of a single slab support, illustrating a concrete pier, housing, seal plate, and concrete slab.

[0010] FIG. 2 is a sectional view of the single slab support with the housing and the slab raised to a desired height.

DETAILED DESCRIPTION OF THE INVENTION

[0011] The present invention now will be described more fully hereinafter with reference to the accompanying drawings in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein; rather, this embodiment is provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

[0012] Referring to FIG. 1, a foundation slab 11 may be used to support a house or other building. In this embodiment, the slab 11 is of concrete and initially rests on a ground surface 12 and a support surface or pier 13. The foundation or slab 11 is typically supported by a plurality of support surfaces or piers 13, but for simplification purposes, the single pier 13 will be discussed. In this embodiment, the pier 13 is of concrete and has a lifting assembly 15 embedded therein. The lifting assembly 15 consists of a liner 17 (optional), a housing 19, and a seal plate 21. In this embodiment, the housing 19 is a capped cylinder and the seal plate 21 is circular in shape. The seal plate 21 rides within the interior of the cylinder 19 and is sealingly engaged with an inner surface 23 of the cylinder 19 by an O-ring 25, which rides in a slot around the outer surface of the seal plate 21. A plurality of vent tubes 27 are located in and extend through the seal plate 21 before extending upward a select distance. A void 29 is initially present between the upper surface of the seal plate 21 and the closed end of the cylinder 19. A plurality of apertures 31 are located in and extend through the closed end of the cylinder 19. The apertures 31 are aligned with the vent tubes 27 and are adapted to accept the vent tubes 27 therein. An injection tube 33 is connected to a port 35 that is located in and extends through the closed end of the cylinder 19. The injection tube 33 may be built as an integral part of the cylinder 19 or may be threaded thereon. In this embodiment, the injection tube 33 is formed as an integral part of the cylinder 19.

[0013] The hole for the pier 13 is dug with a diameter such that the lifting assembly 15 is fully encased within the concrete. Once the hole is dug, the pier 13 is formed by pouring concrete into the hole. The lifting assembly 15 is then inserted into the concrete and pushed downward until the top surface of the cylinder 19 is substantially flush with the ground surface 12. As previously discussed, the liner 17 surrounding the cylinder 19 may be simultaneously inserted into the pier 13. Alternatively, the outer surface of cylinder 19 may be coated with a lubricant or form releaser. The inner surface 23 of the cylinder 19 is coated with a lubricant or form releaser to prevent the concrete of the pier 13 from bonding to the cylinder 19. As the lifting assembly 15 is lowered into the concrete pier 13, the air trapped within the cylinder 19 escapes through the vent tubes 27 and the apertures 31. Once the concrete pier 13 has solidified, the seal plate 21 will be securely encased within the pier 13.

[0014] In this embodiment, a hollow pipe or support sleeve 39 has a diameter that is less than the diameter of the cylinder 19. In an alternate embodiment, various reinforcing members may be connected to and extend outwardly from the outer peripheries of the support sleeve 39 in various shapes and configurations.

[0015] The support sleeve 39 is placed on top of the closed end of cylinder 19 such that it surrounds the port 35 and the injection tube 33 (if attached). The diameter of the support sleeve 39 is such that the apertures 31 in the seal plate 21 are positioned radially outward from the port 35 a greater distance than the walls of the support sleeve 39. The concrete may be kept from bonding to the concrete pier 13 and the liner 17 by a bond breaker layer (not shown) which is optional.

[0016] Referring to FIG. 2, after the slab 11 and the pier 13 have hardened, the injection tube 33, if not already connected to the port 35, is connected to the cylinder 19. After the injection tube 33 is connected to the port 35, a pumping device 41 is then connected to the injection tube 33 by a connecting link 43. In this embodiment, the pumping device 41 is a concrete pump. Concrete or grout is then pumped by the concrete pump 41 into the link 43, through the injection tube 33, the port 35, and into the void 29 (FIG. 1) between the closed end of cylinder 19 and the seal plate 21. As grout or concrete fills the space between the cylinder 19 and the seal plate 21, the cylinder 19 acts as a piston as the concrete forces the cylinder 19 upwards relative to the ground surface 12. The O-ring 25 maintains sealing contact between the seal plate 21 and the inner surface 23 of the cylinder 19. The bottom surface of the concrete slab 11 abuts against the apertures 31, thereby preventing the concrete or grout from exiting the cylinder 19 through the aperture 31. The concrete or grout is pumped into the cylinder 19 until the foundation slab 11 is lifted above the ground to the desired height. Once the slab 11 has reached its desired height, the injection tube 33 may be crimped or sealed and the grout or concrete within the cylinder 19 is permitted to harden and set up. The connecting link 43 and the concrete pump 41 may be disconnected and removed. Once the concrete or grout has set up, the new positions of the cylinder 19 and the slab 11 are securely fixed at the desired heights.

[0017] The invention has significant advantages. The invention provides a method and apparatus that allows a foundation to be poured on top of soil and subsequently raised to a desired height to eliminate potential problems caused by soil movement and/or problematic soils.

[0018] In the drawings and specification, there have been disclosed a typical preferred embodiment of the invention, and although specific terms are employed, the terms are used in a descriptive sense only and not for purposes of limitation. The invention has been described in considerable detail with specific reference to these illustrated embodiments. It will be apparent, however, that various modifications and changes can be made within the spirit and scope of the invention as described in the foregoing specification and as set forth in the following claims

Claims

1. A system for forming a movable slab foundation, the system comprising: a slab foundation; at least one support pier; at least one housing positioned within the at least one support pier, the at least one housing having a closed upper end and an open lower end; a seal plate positioned within and surrounded by the at least one housing, the outer peripheries of the seal plate sealingly engaging the inner surfaces of the at least one housing, the at least one housing being upwardly moveable within the support pier relative to the seal plate; a cavity defined by the space between the upper surface of the seal plate and the upper end of the at least one housing; a port located in and extending through the closed upper end of the at least one housing and into the cavity; and at least one support sleeve, the at least one support sleeve being encased within the slab foundation, the bottom surface of the at least one support sleeve abuttingly contacting the upper end of the at least one housing.

2. The system of claim 1, wherein: the at least one housing is cylindrical in shape; and the seal plate is circular in shape.

3. The system of claim 1, further comprising: an O-ring positioned between the outer peripheries of the seal plate and the inner surfaces of the at least one housing.

4. The system of claim 1, further comprising: an injection tube connected to the port and extending upwardly through the interior of the support sleeve; and a pumping device connected to the injection tube for pumping a support media into the cavity to thereby expand the cavity and move the housing, the support sleeve, and the slab foundation upwards relative to the seal plate.

5. The system of claim 1, further comprising: a plurality of apertures located in and extending through the closed upper end of the housing; and a plurality of vent tubes connected to and extending upwardly from the seal plate, the plurality of vent tubes being aligned with and extending through at least a portion of the plurality of apertures.

6. The system of claim 1, further comprising: a liner surrounding and positioned in abutting contact with the outer peripheries of the housing, the liner fixably secured within the support pier.

7. A system for faulting a movable slab foundation, the system comprising: a slab foundation; at least one support pier; at least one housing positioned within the at least one support pier, the at least one housing having a closed upper end and an open lower end; a seal plate positioned within and surrounded by the at least one housing, the outer peripheries of the seal plate sealingly engaging the inner surfaces of the at least one housing, the at least one housing being upwardly moveable within the support pier relative to the seal plate; a cavity defined by the space between the upper surface of the seal plate and the upper end of the at least one housing; a port located in and extending through the closed upper end of the at least one housing and into the cavity; at least one support sleeve, the at least one support sleeve being encased within the slab foundation, the bottom surface of the at least one support sleeve abuttingly contacting the closed upper end of the at least one housing; and a pumping device connected to the port for pumping a support media into the cavity to thereby expand the cavity and move the housing, the support sleeve, and the slab foundation upwards relative to the seal plate.

8. The system of claim 7, wherein: the at least one housing is cylindrical in shape; and the seal plate is circular in shape.

9. The system of claim 7, further comprising: an O-ring positioned between the outer peripheries of the seal plate and the inner surfaces of the housing.

10. The system of claim 9, further comprising: a plurality of apertures located in and extending through the closed upper end of the housing; and a plurality of vent tubes connected to and extending upwardly from the seal plate, the plurality of vent tubes being aligned with and extending through at least a portion of the plurality of apertures.

11. The system of claim 10, further comprising: a liner surrounding and positioned in abutting contact with the outer peripheries of the housing, the liner fixably secured within the support pier.

12. The system of claim 7, further comprising: an injection tube connected to and extending between the port and the pumping device, the injection tube extending upwardly through the interior of the support sleeve.

13. A method for forming a movable slab foundation, the method comprising: (a) providing a housing with a closed upper end and an open lower end, a seal plate positioned within and surrounded by the housing, the outer peripheries of the seal plate being sealingly engaged with the inner surfaces of the housing, a cavity defined by the space between the upper end of the housing and the upper surface of the seal plate, a port located in and extending through the closed upper end of the housing and into the cavity; (b) placing a support pier below an intended slab foundation area; (c) treating the inner and outer surfaces of the housing with a form releaser; (d) positioning the housing and the seal plate within the support pier; (e) placing a support sleeve in abutting contact with the closed upper end of the housing; (f) forming a slab foundation such that it encases the support sleeve; and (g) pumping a support media through the port and into the cavity, thereby expanding the cavity and simultaneously lifting the housing and the support sleeve to move the slab foundation upward relative to the seal plate to a desired height.

14. The method of claim 13, wherein step (a) further comprises: providing a plurality of apertures located in and extending through the closed upper end of the housing, and a plurality of vent tubes located in and extending upwardly from the seal plate, the vent tubes being aligned with the plurality of apertures; and wherein step (d) further comprises: lowering the housing and the seal plate into the support pier; and venting any air trapped in the housing through the vent tubes and the apertures.

15. The method of claim 13, wherein the support pier is of concrete; and Wherein the method further comprises between step (d) and step (e), allowing the concrete support pier to set up, thereby encasing the seal plate in the support pier.

16. The method of claim 13, further comprising after step (g): allowing the support media to set up, thereby securing the position of the housing, the support sleeve, and the slab foundation relative to the seal plate.

17. The method of claim 13, further comprising after step (g): sealing the port in the closed upper end of the housing, thereby securing the position of the housing, the support sleeve, and the slab foundation relative to the seal plate.

18. The method of claim 13, wherein step (a) further comprises: providing a liner surrounding and in abutting contact with the outer peripheries of the housing; and wherein step (d) further comprises: positioning the liner within the support pier.

19. The method of claim 13, wherein step (g) further comprises: extending an injection tube through the interior of the support sleeve and connecting the injection tube between the port and a pumping device.