U.S. patent application number 14/346656 was filed with the patent office on 2014-08-28 for foundation apparatus and method.
This patent application is currently assigned to Shaner Industries, LLC. The applicant listed for this patent is Shaner Industries, LLC. Invention is credited to William Martin Kronz, Davide Luidelli, Gary J. Reinert, Michael Francis Schuler.
Application Number | 20140237913 14/346656 |
Document ID | / |
Family ID | 47914925 |
Filed Date | 2014-08-28 |
United States Patent
Application |
20140237913 |
Kind Code |
A1 |
Kronz; William Martin ; et
al. |
August 28, 2014 |
Foundation Apparatus and Method
Abstract
A foundation apparatus comprised of flat plates that is used to
support above-ground structures is disclosed. A method of making,
using and installing a pile foundation for those applications is
also provided. The present invention relates to various flat plate
foundation supports that provide a foundation anchor for various
ground supported structures. Specifically, the present invention
relates to a foundation anchor support that comprises flat
longitudinally extending plates that are adapted to be inserted
beneath a ground surface.
Inventors: |
Kronz; William Martin;
(Pittsburg, PA) ; Schuler; Michael Francis;
(Allison Park, PA) ; Luidelli; Davide; (Carnegie,
PA) ; Reinert; Gary J.; (Baden, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Shaner Industries, LLC |
Ambridge |
PA |
US |
|
|
Assignee: |
Shaner Industries, LLC
Ambridge
PA
|
Family ID: |
47914925 |
Appl. No.: |
14/346656 |
Filed: |
September 21, 2012 |
PCT Filed: |
September 21, 2012 |
PCT NO: |
PCT/US12/56699 |
371 Date: |
March 21, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61537803 |
Sep 22, 2011 |
|
|
|
61671469 |
Jul 13, 2012 |
|
|
|
61671488 |
Jul 13, 2012 |
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Current U.S.
Class: |
52/169.9 ;
52/741.15 |
Current CPC
Class: |
E02D 5/28 20130101; E02D
13/04 20130101; E02D 27/32 20130101; E02D 27/50 20130101; E02D
27/02 20130101; E04H 12/2215 20130101; E02D 5/80 20130101; E02D
27/12 20130101; E02D 7/18 20130101; E02D 27/42 20130101; B21D 47/00
20130101 |
Class at
Publication: |
52/169.9 ;
52/741.15 |
International
Class: |
E02D 27/12 20060101
E02D027/12 |
Claims
1. A foundation apparatus for placement in the ground comprising: a
ground-engaging portion having at least one plate adapted to allow
insertion into the ground, the ground-engaging portion having a
bottom end and a top end; and an upper portion connected to the top
end of the ground-engaging portion, the upper portion adapted to
support an above-ground structure.
2. The foundation apparatus of claim 1 wherein the ground-engaging
portion further comprises an acute bottom end.
3. The foundation apparatus of claim 1 wherein the upper portion is
a pipe.
4. The foundation apparatus of claim 1 wherein the upper portion is
a plate.
5. The foundation apparatus of claim 3 or 4 wherein the upper
portion is welded to the ground-engaging portion.
6. The foundation apparatus of claim 1 wherein the ground-engaging
portion further comprises a plurality of plates connected along a
longitudinal axis.
7. The foundation apparatus of claim 1 wherein the ground-engaging
portion further comprises a plate with a first end, a second end,
and a center portion, the first end and the second end occupying a
plane perpendicular to the plane of the center portion.
8. The foundation apparatus of claim 1 wherein the foundation
apparatus is composed of steel.
9. The foundation apparatus of claim 8 wherein the foundation
apparatus is galvanized.
10. A method of installing the foundation apparatus of claim 1
comprising the steps of pushing the foundation apparatus into the
ground.
11. A method of using the foundation apparatus of claim 1
comprising the steps of mounting a structure to the upper portion
of the foundation apparatus.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present invention claims the benefit of U.S. Provisional
Application No. 61/537,803, filed 22 Sep. 2011, U.S. Provisional
Application No. 61/671,469, filed 13 Jul. 2012, and U.S.
Provisional Application No. 61/671,488, filed 13 Jul. 2012.
TECHNICAL FIELD
[0002] The present invention relates to a pile foundation used to
support structures or stabilize slopes and further relates to a
method of making, using and installing a pile foundation for those
applications. The present invention relates to foundation apparatus
that provides a foundation anchor for various ground supported
structures. Specifically, the present invention relates to a
foundation anchor support that comprises flat longitudinally
extending plates that are adapted to be inserted beneath a ground
surface.
BACKGROUND ART
[0003] U.S. Pat. Nos. 4,882,891 and 4,974,997 are both assigned to
the Assignee of the current application and disclose a foundation
apparatus and a foundation setting apparatus.
DISCLOSURE OF INVENTION
[0004] The present invention relates to a foundation apparatus, a
method of providing structural support, and method of making,
using, and installing the foundation apparatus for structural
support. The foundation of the present invention eliminates the
need for specialized installation equipment such as is the case for
drilled foundations. The present invention also eliminates the
expenses associated with the handling and disposal of excavation
spoils, placing of concrete reinforcing rods, trucking and
placement of concrete, and time delay associated with concrete
curing before the foundation can be put in service.
[0005] Several types of pile foundations are used in industry, such
as displacement pile foundations and replacement pile foundations.
Replacement piles are installed into a drilled borehole;
cast-in-place concrete replaces the dirt removed from the borehole.
A disadvantage of the replacement pile is that the excavated
material must be collected and removed from the construction site.
Displacement pile foundations are typically H-beam, pipe, or
pre-cast concrete foundations that are driven or vibrated into the
ground. Disadvantages associated with displacement pile foundations
include the tendency to deviate when obstructions are encountered
underground and the potential for difficult installation in dense
soil conditions.
[0006] Additionally, foundations supporting specialized structures
such as solar panel heliostats are subject to lateral loads and
bending moments where lateral and rotational deflections must be
limited to values much lower than is permitted for typical building
structures. In order to accommodate tolerable deflection limits for
these and other specialized structures, typical steel pile
foundations and precast pile foundations need to have
cross-sectional geometric properties that make them prohibitively
large, expensive, and time consuming to construct.
[0007] Construction schedules are critical to project owners.
Project owners desire a method to expeditiously install foundations
and complete their structure in order to limit the overall duration
of construction and complete their project as fast as possible. The
foundation apparatus of the present invention accomplishes these
goals by providing a structure that is relatively inexpensive to
fabricate and quick to install. Once installed, the foundation
apparatus of the present invention is immediately ready to use.
[0008] The foundation apparatus of the present invention utilizes
flat steel plate to create a ground-engaging portion capable of
being inserted into the ground. Once set in the ground, the
foundation apparatus provides support for mounting a structure to
the upper portion. The bottom end of the ground-engaging portion is
beveled, decreasing the force required to insert the foundation
apparatus into the ground.
[0009] An advantage of the foundation apparatus of the present
invention is that less material is used to fabricate the foundation
apparatus. For example, as compared to H-beam foundations, the
foundation apparatus of the present invention engages the same soil
area but is constructed with only 2/3 of the steel. Fabrication
costs are greatly reduced as well due to the simple design.
[0010] The bottom end of the ground engaging portion of the
foundation apparatus is angled to allow easier penetration into the
ground. This angled portion is especially beneficial when
subsurface obstructions or dense soil conditions are
encountered.
[0011] Another advantage of the foundation apparatus of the present
invention is that it can be removed from the ground. For example,
if a temporary installation is required, the foundation apparatus
can be removed simply by pulling on the foundation apparatus in the
vertical direction. Another example of a situation where the
foundation apparatus might be removed is if the foundation
apparatus is installed in an area where unexpected soil conditions
are present. The foundation apparatus can be removed and
re-installed in a different area more suitable for
installation.
[0012] In one embodiment of the invention, a single piece of flat
steel plate is bent to create a web with fins extending in opposite
directions. The angle that each fin forms with the web is
preferably substantially 90 degrees. The bottom of the plate is
tapered to form a point, allowing easier penetration of the ground.
In addition, the leading edges of the flat steel plate are
sharpened to aid installation. The upper portion of the foundation
apparatus is provided with holes to allow the splicing of
additional sections if extra length is required. Alternatively, the
upper portion is constructed from a plate or other similar mounting
surface to provide support for an above-ground structure.
[0013] In another embodiment, two pieces of flat steel plate are
used. One plate is bent at its center to create two fins with an
angle of 120 degrees between them. The second piece of steel plate
is then attached to the first piece at the apex of the bend. In
this configuration, the angle between each fin is 120 degrees. The
two pieces of flat plate steel can be joined by welding or other
suitable methods.
[0014] In yet another embodiment, the ground-engaging portion of
the foundation apparatus is an elongated plate having a beveled
bottom end. Two side plates of substantially smaller width are
disposed on both sides of the elongated plate. The length of the
side plates is shorter than the length of the wide plate so that
the top ends of the side plates are beneath the ground when
installed. An A-frame structure or plural ground supported
structures may be supported according to this embodiment.
[0015] The upper portion of the foundation apparatus is adapted to
support an above-ground structure. Suitable structures include a
plate, a saddle, or a pipe. Preferably, the upper portion is welded
to the ground-engaging portion.
[0016] After the foundation apparatus is completely fabricated, it
is hot dip galvanized or otherwise treated to protect the raw steel
from corrosion. The foundation can be fabricated offsite and
shipped to the construction site ready for installation.
[0017] The foundation apparatus is installed by pushing it into the
ground. Heavy equipment, such as an excavator adapted with a
vibrator or hydraulic arm, can be used for installation. Once
installed, the foundation apparatus is ready for immediate use.
Unlike other types of foundations, the foundation apparatus of the
present invention eliminates the need to remove excavation spoils,
deliver and pour concrete, place reinforcing rods, and wait for
poured concrete to cure. The method of installation of the present
invention reduces cost and time of installation as compared to
other types of pile foundations.
[0018] Further details and advantages of the foundation apparatus
of the present invention will become apparent upon reading the
following detailed description in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a side view of a foundation apparatus according to
one embodiment utilizing two plates.
[0020] FIG. 2 is a cross-sectional view of the foundation apparatus
taken along lines "A-A", shown in FIG. 1.
[0021] FIG. 3 is a cross-sectional view of the foundation apparatus
taken along lines "B-B", shown in FIG. 1.
[0022] FIG. 4 is a side view of a foundation apparatus according to
another embodiment.
[0023] FIG. 5 is a cross-sectional view of the foundation apparatus
taken along lines "A-A", shown in FIG. 4.
[0024] FIG. 6 is a top plan view of the foundation apparatus of
FIG. 4.
[0025] FIG. 7 is a detailed side view of the foundation apparatus
of FIG. 4, illustrating a connection between the upper portion and
a structure.
[0026] FIG. 8 is a front side view of a foundation apparatus
according to another embodiment.
[0027] FIG. 9 is a left side view of the foundation apparatus of
FIG. 8.
[0028] FIG. 10 is a top plan view of the foundation apparatus of
FIG. 8.
[0029] FIG. 11 is a detailed view of a gusset plate for use in the
foundation apparatus of FIG. 8.
[0030] FIG. 12 is profile view of a foundation apparatus according
to another embodiment.
[0031] FIG. 13 is a front view of the foundation apparatus shown in
FIG. 12.
[0032] FIG. 14 is a side view of the foundation apparatus shown in
FIG. 12.
[0033] FIG. 15 is a top view of the foundation apparatus shown in
FIG. 12.
BEST MODE FOR CARRYING OUT INVENTION
[0034] In the following discussion of the non-limiting embodiments
of the invention, spatial or directional terms, such as "inner",
"outer", "up", "down", and the like, relate to the invention as it
is shown in the drawing figures. However, it is to be understood
that the invention can assume various alternative orientations and,
accordingly, such terms are not to be considered as limiting.
Further, in the discussion of the non-limiting embodiments of the
invention, it is understood that the invention is not limited in
its application to the details of the particular non-limiting
embodiments shown and discussed since the invention is capable of
other embodiments.
[0035] FIGS. 1-3 illustrate a foundation apparatus for supporting
and anchoring a ground-supported structure according to an
embodiment of the present invention. The foundation apparatus
extends longitudinally along a central axis. The ground-engaging
portion of the foundation apparatus is adapted to be inserted into
the ground. The embodiment as shown in FIG. 1-3 includes two
plates. This first plate, which is roughly two times the width of
the second plate, is bent in its middle to form an angle of about
120 degrees. The bend effectively creates two fins. The second
plate is attached to the apex of the bend of the first plate. In
this preferred embodiment, the two plates are attached by a weld
along the length of the plates. As shown in FIG. 2, which views the
foundation apparatus from the top, the space between each equally
spaced fin is about 120 degrees. It is to be appreciated that the
ground-engaging portion of the foundation apparatus may be of a
variety of different configurations of plates or even a single
plate. Additionally, the angle between the plates can vary
depending on the installation.
[0036] As shown in FIG. 1 and FIG. 4, the ground-engaging portion
of the foundation apparatus has an acute bottom end. More
specifically, in this preferred embodiment, the bottom end is
angled at 60 degrees relative to a line that is parallel to the
surface of the ground. Depending on the hardness of the ground in
which the foundation apparatus is being installed, this angle may
vary. In addition, the leading edge of the fin at the bottom end of
the ground-engaging portion is beveled to facilitate placement of
the foundation apparatus into the ground. The driving force would
be greater if these bevels were not provided.
[0037] The upper portion of the foundation apparatus is adapted to
support an above-ground structure. As shown in FIG. 1, the upper
portion is a pipe that is attached to the ground-engaging portion.
The pipe is disposed over the top end of the ground-engaging
portion so that the pipe is co-extensive with the ground-engaging
portion along the central longitudinal axis for a certain length,
such as 15 cm (6 inches). The inner surface of the cylindrical pipe
is connected to the lateral edges of the flat plates by a suitable
method, such as welding along the lateral edges of the fins.
[0038] As shown in FIG. 4-7, the upper portion may be constructed
from a plate that is substantially horizontal to the surface of the
ground. The upper portion is disposed on the top end of the
ground-engaging portion. Typically, the plate is located at or near
the surface of the ground after the foundation apparatus is
installed. A structure can be mounted to the plate using known
methods of attachment, such as bolts as shown in FIG. 7.
Additionally, FIG. 7 shows gussets attached between the upper
portion and the ground-engaging portion, creating a stronger
connection between the upper portion and the ground-engaging
portion and providing a more stable mounting point for an
above-ground structure.
[0039] In another preferred embodiment of the foundation apparatus,
the ground-engaging portion consists of an elongated plate having a
beveled bottom end. As shown in FIGS. 8-10, the bevel in the center
of the bottom end is at a greater angle than the bevel of the
outside of the bottom end. The bevel can be the same for the entire
bottom end of the ground engaging portion depending on the width of
the elongated plate. However, by using a double angle bevel, less
material is required while still allowing a point at the center of
the bottom end sharp enough to penetrate the ground. As in the
other embodiments, the leading edges of the fins on the bottom end
are beveled to aid insertion of the foundation apparatus into the
ground.
[0040] In the embodiment shown in FIGS. 8-10, an elongated plate is
provided with two plates of smaller width attached to its sides.
Preferably, these side plates are attached near the center of the
elongated plate on opposite sides, perpendicular to its surface. In
the preferred embodiment, each side plate is joined to the
elongated plate by a weld along the length of the plates'
intersection. The bottom ends of the two side plates are also
beveled to aid installation. Like the other embodiments, the
leading edge of the fins on the bottom end is also beveled. The
length of the side plates is shorter than the length of the
elongated plate, such that the side plates are buried below the
ground surface, while the top end of the elongated plate extends
above the ground surface when installed.
[0041] As shown in FIGS. 8-10, the upper portion of the foundation
apparatus is a pair of support plates disposed on the top of
opposing lateral ends of the elongated plate. As shown in FIG. 10,
the support plates include adjustable mounting holes to facilitate
attachment of different types of ground supported structures.
[0042] The upper portion may additionally be supported by one or
more triangular gussets extending between the elongated plate and
the upper portion, as shown in FIGS. 9 and 11. One structure, such
as an A-frame structure shown in FIG. 8, or multiple ground
supported structures may be anchored by a single foundation
apparatus according this embodiment. In particular, each of the
legs of the A-frame structure shown in FIG. 8 includes a mounting
plate attached to the upper portion of the foundation apparatus by
one or more fasteners.
[0043] In another preferred embodiment of the foundation apparatus,
the ground-engaging portion is created by placing two bends in
single piece of flat plate. The bends run along the length of the
plate. The first bend creates a fin in one direction, while the
second bend creates a fin oriented in the opposite direction. A
center fin is left between the two bends and is roughly
perpendicular to the plane of the two fins created by the bends, as
shown in FIG. 9. The ground-engaging portion of this foundation
apparatus can extend to lengths of around 4.5 meters (15 feet).
[0044] As with the other preferred embodiments, the bottom end of
the ground-engaging portion is beveled in order to allow easier
penetration into the ground. In the preferred embodiment, the angle
of the bevel relative to a line parallel to the ground is between
45 and 60 degrees. The leading edges are beveled for the same
purpose.
[0045] The upper portion of the foundation apparatus contains
mounting holes used as an attachment point for a ground supported
structure. In this configuration, the upper portion can be attached
to the bottom end of the ground-engaging portion of a second
foundation apparatus, splicing the two units together. Two
foundation apparatus units are spliced together if a single unit is
not long enough for a particular installation and additional length
is required.
[0046] Additionally, the upper portion may consist of a pipe,
plate, or other mount adapted to be connected to an above-ground
structure. For example, FIG. 10 depicts a journal as the upper
portion of the foundation apparatus. The structure to be supported
can be mounted to this journal. If a pipe, plate, or other mount is
used as the upper portion, it can be connected to the
ground-engaging portion by a weld, bolts, or other method known in
the art.
[0047] It is to be appreciated that the foundation apparatus may be
of any length and the upper and ground-engaging portions may be of
varying relative lengths depending on the conditions of use.
Additionally, the plates may also be of varying thickness and
lateral lengths extending from the central longitudinal axis and
the diameter of the cylindrical pipe of the upper portion may be of
a corresponding diameter depending on the conditions of use.
[0048] While the description of the foundation apparatus of the
present invention has focused on supporting structures, a person of
ordinary skill in the art will appreciate that the foundation
apparatus can be used for other purposes. For example, the
foundation apparatus can be used to stabilize a slope by driving a
number of the elements into the slope face perpendicular to the
slope face to the required depth beyond the slip surface.
[0049] In all of the embodiments shown, the foundation apparatus
may be pre-assembled and then shipped to a construction site for
installation. The installation of foundation apparatus of the
present invention is, preferably, accomplished utilizing a piece of
tracked or wheeled equipment such as a hydraulic excavator, fitted
with a vibratory or hydraulic driving mechanism. The driving
mechanism attaches to the foundation apparatus by gripping the top
end of the ground-engaging portion or the upper portion. A Deere
& Company (John Deere) Model 240 DLC or equivalent can serve as
the excavator. An ABI Model HV460 Vibrator or the equivalent can be
mounted to the excavator. The foundation can also be installed
using a "push-it" machine of the type disclosed in U.S. Pat. Nos.
5,660,504; 5,570,975; 5,733,068; and 5,944,452.
[0050] Alternatively, an installation horn as shown in FIG. 11 is
attached to the upper portion of the foundation apparatus. The
vibratory or hydraulic driving mechanism attaches to this
installation horn, driving the foundation apparatus into the
ground. Once installation is complete, the installation horn is
removed and used on the next foundation apparatus to be
installed.
[0051] It is also to be appreciated that, depending on the
application and condition of the ground, the foundation apparatus
may be inserted into the ground without the necessity of
pre-drilling a hole. Alternatively, if the ground is harder than
anticipated or obstructions are present, the foundation apparatus
may be installed in a pre-drilled hole. Even if a hole is drilled,
the amount of excavation spoils that must be removed is minimal
given the relatively small volume of the foundation apparatus that
is positioned below the surface of the ground. Unlike a concrete or
pipe foundation, there is not a large cylindrical volume of dirt
that must be removed from the ground and disposed from the
construction site.
[0052] The foundation apparatus of the present invention can be
removed should unexpected soil conditions be encountered. Despite
the fact that the engineering characteristics of the soil are known
in advance where the foundation apparatus is to be installed, the
installation site could have a buried obstruction, an unexpected
layer of softer (weaker) soil, or an unexpected layer of harder
soil. Encountering an obstruction can greatly increase penetration
resistance during pile installation. Increased penetration
resistance encountered due to an obstruction cannot be relied upon
for the long term performance of the foundation, providing a false
indication of the load capacity of the system. In such situations,
the foundation apparatus may be easily extracted, and if undamaged
the foundation can be relocated to an area where there are more
favorable subsurface conditions.
[0053] It is to be appreciated that the above-described embodiments
of the foundation apparatus may be manufactured according to any
technique known to be suitable to those having ordinary skill in
the art. Likewise, the foundation apparatus may be made from any
material known to be suitable to those having ordinary skill in the
art. According to the preferred embodiment of the present
invention, the foundation apparatus is made from steel and
individual steel pieces of the foundation apparatus are connected
by welding. In the preferred embodiment, the steel foundation
apparatus is hot dip galvanized after fabrication to protect the
foundation apparatus. Other treatments to protect the steel can
also be used.
[0054] While several embodiments of the foundation apparatus were
described in the foregoing detailed description, those skilled in
the art may make modifications and alterations to these embodiments
without departing from the scope and spirit of the invention.
Accordingly, the foregoing description is intended to be
illustrative rather than restrictive. The invention described
hereinabove is defined by the appended claims and all changes to
the invention that fall within the meaning and the range of
equivalency of the claims are embraced within their scope.
INDUSTRIAL APPLICABILITY
[0055] The foundation apparatus of the present invention can be
used to support structures like solar heliostats, border fencing,
highway signs, light posts, traffic control devices, airport
approach lights, conveyor supports, communication towers, power
distribution towers, utility poles, and others.
* * * * *