CROSS REFERENCE TO RELATED APPLICATIONS

[001] The present invention claims the benefit of U.S. Provisional Application No. 61/537,803, filed 22 September 2011, U.S. Provisional Application No. 61/671,469, filed 13 July 2012, and U.S. Provisional Application No. 61/671,488, filed 13 July 2012.

TECHNICAL FIELD

[002] 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

[003] U.S. Patent 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

[004] 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.

[005] 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.

[006] 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.

[007] 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.

[008] 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.

[009] 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.

[010] 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. [Oil] 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.

[012] 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.

[013] 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.

[014] 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.

[015] 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.

[016] 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. [017] 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.

[018] 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

[019] Fig. 1 is a side view of a foundation apparatus according to one embodiment utilizing two plates.

[020] Fig. 2 is a cross-sectional view of the foundation apparatus taken along lines "A- A", shown in Fig. 1.

[021] Fig. 3 is a cross-sectional view of the foundation apparatus taken along lines "B- B", shown in Fig. 1.

[022] Fig. 4 is a side view of a foundation apparatus according to another embodiment.

[023] Fig. 5 is a cross-sectional view of the foundation apparatus taken along lines "A- A", shown in Fig. 4.

[024] Fig. 6 is a top plan view of the foundation apparatus of Fig. 4.

[025] Fig. 7 is a detailed side view of the foundation apparatus of Fig. 4, illustrating a connection between the upper portion and a structure.

[026] Fig. 8 is a front side view of a foundation apparatus according to another embodiment.

[027] Fig. 9 is a left side view of the foundation apparatus of Fig. 8.

[028] Fig. 10 is a top plan view of the foundation apparatus of Fig. 8.

[029] Fig. 11 is a detailed view of a gusset plate for use in the foundation apparatus of

Fig. 8.

[030] FIG. 12 is profile view of a foundation apparatus according to another embodiment. [031] FIG. 13 is a front view of the foundation apparatus shown in FIG. 12.

[032] FIG. 14 is a side view of the foundation apparatus shown in FIG. 12.

[033] FIG. 15 is a top view of the foundation apparatus shown in FIG. 12.

BEST MODE FOR CARRYING OUT INVENTION

[034] 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.

[035] 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.

[036] 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.

[037] 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.

[038] 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.

[039] 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.

[040] 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.

[041] 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.

[042] 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.

[043] 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).

[044] 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.

[045] 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. [046] 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.

[047] 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.

[048] 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.

[049] 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 United States Patents Nos. 5,660,504; 5,570,975; 5,733,068; and 5,944,452.

[050] 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. [051] 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.

[052] 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.

[053] 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.

[054] 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

[055] 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.