[0001] The present application claims priority to U.S. Pat. App. No. 13/1 00,927 entitled "Retaining Wall Soil Reinforcing Connector and Method," which was filed on May 4, 201 1 as a continuation-in-part application of U.S. Utility Patent Application Serial No. 12/756,898, entitled "Retaining Wall Soil Reinforcing Connector and Method," filed on April 8, 2010, which claims priority as a continuation-in-part application to U.S. Utility Patent Application Serial No. 12/353,615, similarly titled and filed on January 14, 2009. The contents of each priority application are hereby incorporated by reference in their entirety.

Background

[0002] Retaining wall structures that use horizontally positioned soil inclusions to reinforce an earth mass in combination with a facing element are referred to as mechanically stabilized earth (MSE) structures. MSE structures can be used for various applications including retaining walls, bridge abutments, dams, seawalls, and dikes.

[0003] The basic MSE implementation is a repetitive process where layers of backfill and horizontally-placed soil reinforcing elements are positioned one atop the other until a desired height of the earthen structure is achieved. Typically, grid-like steel mats or welded wire mesh are used as soil reinforcing elements. In most applications, the soil reinforcing elements consist of parallel, transversely-extending wires welded to parallel, longitudinally-extending wires, thus forming a grid-like mat or structure. Backfill material and the soil reinforcing mats are combined and compacted in series to form a solid earthen structure, taking the form of a standing earthen wall.

[0004] In some instances, the soil reinforcing elements can be attached or otherwise coupled to a substantially vertical wall either forming part of the MSE structure or offset a short distance therefrom. The vertical wall is typically made either of concrete or a steel wire facing and not only serves to provide tensile resistance to the soil reinforcing elements but also prevents erosion of the MSE structure. The soil reinforcing elements extending from the compacted backfill may be attached directly to a vertical wall of the facing in a variety of configurations.

[0005] Although there are several different configurations and types of soil reinforcing elements known in the art, including different materials from which they are made, it nonetheless remains desirable to find improved configurations or materials that provide greater resistance to shear forces inherent in such structures.

Summary

[0006] Embodiments of the disclosure may provide a plate connection stud comprising a planar tab defining at least one hole therein and a planar stem extending longitudinally from the planar tab, the planar stem having first and second sides defining a plurality of grooves therein.

[0007] Embodiments of the disclosure may further provide a method of manufacturing a soil reinforcing element assembly. The method may include punching a hole in a planar tab of a plate connection stud, the plate connection stud further comprising a planar stem extending longitudinally from the planar tab, and forming a plurality of grooves in opposing first and second sides of the planar stem. The method may also include positioning the plate connection stud in a resistance welding device to be welded to a soil reinforcing element, the soil reinforcing element having first and second longitudinal wires coupled to a plurality of transverse wires, the first and second longitudinal wires terminating at first and second lead ends, respectively. The method may further include positioning the first lead end between the first side of the planar stem and a first electrode of the resistance welding device, positioning the second lead end between the second side of the planar stem and a second electrode of the resistance welding device, and biasing the first and second lead ends against the first and second sides of the planar stem, respectively, with the first and second electrodes. The method may then include activating the resistance welding device to weld the first and second lead ends to the first and second sides, respectively, and subsequently releasing the first and second electrodes from the first and second lead ends.

[0008] Embodiments of the disclosure may further provide a system for securing a facing to an earthen formation. The system may include a soil reinforcing element having first and second longitudinal wires welded to a plurality of transverse wires, the first and second longitudinal wires terminating at first and second lead ends, respectively, and a plate connection stud comprising a planar tab defining at least one hole therein and a planar stem extending longitudinally from the planar tab, the planar stem having first and second sides defining a plurality of grooves therein, wherein the first and second lead ends are coupled to the first and second sides, respectively. The system may also include a facing anchor having first and second connection plates extending from a back face of a facing and being vertically-offset from each other a distance X, each connection plate defining a horizontally-disposed perforation, and a coupling device extendable through each horizontally-disposed perforation and the hole of the plate connection stud to secure the plate connection stud to the facing anchor, wherein the soil reinforcing element is capable of swiveling in a horizontal plane and shifting vertically over the distance X.

Brief Description of the Drawings

[0009] Figure 1 A is an exploded perspective view of a soil reinforcing system, according to one or more aspects of the present disclosure.

[0010] Figure 1 B is a side view of the system shown in Figure 1 A.

[0011] Figure 1 C is a side view of the system shown in Figure 1 A coupled together, according to one or more aspects of the present disclosure.

[0012] Figure 2A is an isometric view of a connection stud, according to one or more aspects of the present disclosure.

[0013] Figure 2B is an isometric view of another connection stud, according to one or more aspects of the present disclosure.

[0014] Figure 3A is an isometric view of an exemplary plate connection stud, according to one or more aspects of the present disclosure.

[0015] Figure 3B is a plan view of a soil reinforcing element coupled to the plate connection stud of Figure 3A, according to one or more aspects of the present disclosure.

[0016] Figure 4 is a flowchart of a method of manufacturing as soil reinforcing element assembly, according to one or more aspects of the present disclosure. Detailed Description

[0017] It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the various Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.

[0018] Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to." All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. Furthermore, as it is used in the claims or specification, the term "or" is intended to encompass both exclusive and inclusive cases, i.e., "A or B" is intended to be synonymous with "at least one of A and B," unless otherwise expressly specified herein.

[0019] The present disclosure is an improved apparatus and method of connecting an earthen formation to a concrete facing of a mechanically stabilized earth (MSE) structure. In particular, disclosed is a low-cost, one-piece MSE connector, and variations of the same, that allows soil reinforcing mats to swivel in order to avoid vertically-disposed obstructions, such as drainage pipes, catch basins, bridge piles, or bridge piers, which may be encountered in the adjacent backfill field. The MSE connector may also allow the connected soil reinforcing mats to shift vertically in reaction to MSE settling or thermal expansion/contraction of the MSE structure. The ability of the soil reinforcing element to shift and swivel provides a distinct advantage in that the structural integrity of the MSE system is not jeopardized over time, but that it may move in response to natural occurrences.

[0020] Referring to Figures 1A-1 C, illustrated is an exemplary system 1 00 for securing a facing 1 02 to an earthen formation 104, according to one or more aspects of the disclosure. The facing 102 may include an individual precast concrete panel or, alternatively, a plurality of interlocking precast concrete modules or wall members that are assembled into an interlocking relationship. In another embodiment, the facing 102 may be a uniform, unbroken expanse of concrete or the like which may be poured or assembled on site. The facing 102 may generally define an exposed face 105 (Figures 1 B and 1 C) and a back face 106. The exposed face 105 is usually a decorative architectural facing, while the back face 106 is located adjacent the earthen formation 104. Cast into the facing 1 02, or otherwise attached thereto, and protruding generally from the back face 106, is at least one exemplary facing anchor 1 08. In other embodiments, the facing anchor 1 08 may be mechanically-fastened to the back face 106, for example, using bolts or other mechanical fasteners.

[0021] The earthen formation 104 may encompass an MSE structure including a plurality of soil reinforcing elements 1 10 that extend horizontally into layers of backfill to add tensile capacity thereto. In an exemplary embodiment, the soil reinforcing elements 1 10 may serve as tensile resisting elements positioned in the backfill in a substantially horizontal alignment at spaced-apart relationships to one another against the compacted soil. Depending on the application, grid-like steel mats or welded wire mesh may be used as soil reinforcement elements 1 1 0, but it is not uncommon to employ "geogrids" made of plastic or other materials to accomplish the same end.

[0022] In the illustrated exemplary embodiment, the soil reinforcing element 1 10 may include a welded wire grid having a pair of longitudinal wires 1 1 2 that are substantially parallel to each other. The longitudinal wires 1 1 2 may be joined to a plurality of transverse wires 1 1 4 in a generally perpendicular fashion by welds at their intersections, thus forming a welded wire gridworks. In exemplary embodiments, the spacing between each longitudinal wire 1 12 may be about 2 in., while spacing between each transverse wire 1 14 may be about 6 in. As can be appreciated, however, the relative spacing and configuration may vary depending on the mixture of tensile force requirements that the reinforcing element 1 1 0 must resist.

[0023] In one or more embodiments, the lead ends 1 16 of the longitudinal wires 1 12 may generally converge toward one another and be welded or otherwise attached to a connection stud 1 18. The connection stud 1 18 may include a first end or a stem 120 coupled or otherwise attached to a second end or a tab 122. In at least one embodiment, the stem 120 may include a cylindrical body having an axial length L. As illustrated, the lead ends 1 1 6 may be coupled or otherwise attached to the stem 120 along at least a portion of the axial length L. In one embodiment, the tab 122 may be a substantially planar plate and define at least one centrally-located perforation or hole 124.

[0024] In at least one embodiment, the facing anchor 1 08 may include a pair of horizontally-disposed connection points or plates 126a, 1 26b cast into and extending from the back face 1 06 of the panel 1 02. As can be appreciated, other embodiments include attaching the facing anchor directly to the back face 106, without departing from the disclosure. Other embodiments of the disclosure contemplate a facing anchor 108 having a single horizontal plate 126 (not shown), where the tab 122 is coupled only to the single plate 126 via appropriate coupling devices.

[0025] Each plate 126a,b may include at least one perforation 128 adapted to align with a corresponding perforation 128 on the opposing plate 126a,b. As illustrated in Figure 1 B, the plates 1 26,b may be vertically-offset from each other a distance X, thereby providing a gap 1 32 configured to receive the tab 122 for connection. The tab 122 may be inserted into the gap 132 to substantially align the hole 124 with the perforations 128 of each plate 126a,b. A coupling device, such as a nut and bolt assembly 1 30, or the like, may then be used to secure the connection stud 1 1 8 (and thus the soil reinforcing element 1 10) to the facing anchor 108. In one or more embodiments, the nut and bolt assembly 130 may include a threaded bolt having a central axis Y and being configured to mate with a nut and washer assembly. In other embodiments, the nut and bolt assembly 130 may be replaced with a pin-type connection having an end that prevents it from removal, such as a bent-over re-bar portion.

[0026] In the illustrated arrangement, the soil reinforcing element 1 1 0 (as coupled to the connection stud 1 18) may be allowed to swivel or rotate about axis Y in a horizontal plane Z (Figurel A). To avoid obstructions, such as a drainage pipe, catch basin, bridge pile, bridge pier, or the like, the soil reinforcing element 1 10 may be pivoted about axis Y to any angle relative to the back face 1 06, thereby swiveling to a position in the backfill where no obstacle exists.

[0027] Moreover, the gap 132 defined between two vertically-offset plates 1 26a,b may allow for a distance of settling of either the MSE structure or the soil reinforcing element 1 10 without the soil reinforcing element 1 10 binding on the facing 102. For instance, during settling the tab 1 22 may be able to shift or slide vertically about the nut and bolt assembly 130 the distance X, thereby compensating for a potential vertical drop of the soil reinforcing element 1 1 0 and preventing any buckling of the concrete facing 102. Varying designs of anchors 1 08 may be used that increase or decrease the distance X to compensate for potential settling or other MSE mechanical phenomena.

[0028] Furthermore, it is not uncommon for concrete facings 1 02 to shift in reaction to MSE settling or thermal expansion/contraction. In instances where such movement occurs, the soil reinforcing elements 1 10 are capable of correspondingly swiveling about axis Y and shifting the vertical distance X to prevent misalignment, buckling, or damage to the concrete facing 102.

[0029] Referring now to Figures 2A and 2B, illustrated is one or more exemplary embodiments of the connection stud 1 18. In one embodiment, the connection stud 1 18 can be created from a one-piece forging process. In other embodiments, however, the connection stud 1 18 can be created by welding or otherwise attaching the stem 120 to the tab 122. As illustrated, the stem 1 20 may include a plurality of indentations or grooves 202 defined along its axial length L. In one embodiment, the grooves 202 may be cast or otherwise machined into the stem 120. In other embodiments, the grooves 202 can include standard thread markings machined along the axial length L of the stem 120. As can be appreciated, the grooves 202 may provide a more suitable welding surface for attaching the lead ends 1 16 of the longitudinal wires 1 12 (Figures 1A-1 C) thereto, thereby resulting in a stronger resistance weld.

[0030] As illustrated in the embodiment shown in Figure 2B, the stem 120 may include an axial channel 204 extending along the axial length L on opposing sides. In at least one embodiment, the axial channels 204 may be formed during a casting or forging process. In other embodiments, the axial channels 204 may be generated by applying longitudinal pressure to the opposing sides of the stem 120 with a cylindrical die or the like (not shown). The axial channels 204 may include the grooves 202 machined or otherwise formed therein. The grooves 202 may be generated during the forging process, or via a cylindrical die that forms the axial channels 204. In other embodiments, however, the grooves 202 may be subsequently machined into the axial channels 204 after a forging process and/or the application of a cylindrical die. As can be appreciated, the axial channels 204 may add arcuate surface area for welding the lead ends 1 1 6 of the longitudinal wires 1 1 2, thereby creating a more solid resistance weld. Moreover, because of the added amount of arcuate surface area, the axial channels 204 may also protect the resistance weld from corrosion.

[0031] Referring now to Figures 3A and 3B, illustrated is an exemplary plate connection stud 318 (Figure 3A) used in conjunction with a soil reinforcing element assembly 300 (Figure 3B). As illustrated, the soil reinforcing element assembly 300 includes the plate connection stud 31 8 coupled or otherwise attached to a soil reinforcing element 1 10. The plate connection stud 318 may be similar in some respects to the connection stud 1 18 described above and therefore may be best understood with reference to Figures 2A and 2B, where like numerals correspond to like elements that will not be described again in detail. It will be appreciated that the plate connection stud 318 may also be used in conjunction with the facing anchor 1 08 generally described above with reference to Figures 1 A-1 C. [0032] The plate connection stud 31 8 may be a generally flat, plate-like structure having a generally planar stem 1 20 extending from a generally planar tab 122. In one embodiment, the plate connection stud 31 8 is formed or otherwise machined from a generally flat piece of sheet metal via a punch pressing process, or the like. In other embodiments, the plate connection stud 318 may be the result of a forging or a casting process. The planar tab defines a hole 124, as described above.

[0033] As illustrated, the plate connection stud 318 may include a first side 302 and a second side 304, and a plurality of serrations or grooves 202 may be defined in each side 302, 304 along at least the length L of the planar stem 120. The grooves 202 may be cast, punched, or otherwise machined into the planar stem 1 20. In other embodiments, a shaped die (not shown) may be used to cold-form the grooves 202 into the planar stem 120. As with embodiments described above, the grooves 202, and especially the extended or protruding ridges defined by the grooves 202, provide a stronger resistance weld for attaching the lead ends 1 16 of the longitudinal wires 1 12 to each side 302, 304 of the planar stem 120.

[0034] In one embodiment, the planar stem 120 also defines longitudinal channels 306 extending along the length L on its opposing sides 302, 304. The longitudinal channels 306 may be substantially similar to the axial channels 204 described above, except formed in the planar stem 1 20 as opposed to a generally cylindrical stem 120, as in the embodiments discussed with reference to Figures 2A and 2B. The longitudinal channels 204 may provide a generally concave or arcuate surface area extending longitudinally along the sides 302, 304 of the planar stem 120, and may be combined with the grooves 202. The channels 204 may be formed during a casting or forging process. In other embodiments, however, the longitudinal channels 204 may be created through cold-forming by applying longitudinal pressure against the opposing sides 302, 304 of the planar stem 120 with a cylindrical die or the like (not shown).

[0035] Each longitudinal channel 204 adds arcuate surface/contact area for welding to the lead ends 1 1 6 of the longitudinal wires 1 12. The added arcuate surface area results in a more solid and corrosion-resistant resistance weld. Moreover, the longitudinal channels 204 may be used to more properly seat the lead ends 1 16 against the grooves 202. As can be appreciated, this may increase the quality control and quality assurance of the ensuing resistance weld. [0036] Referring now to Figure 4, with continued reference to Figures 3A and 3B, illustrated is a flowchart of a method 400 of manufacturing a soil reinforcing element assembly, such as the soil reinforcing assembly 300 shown in Figure 3B. The method 400 may include punching a hole in a planar tab of a plate connection stud, as at 402. The planar connection stud may be the planar connection stud 318 described above and may therefore include a planar stem 1 20 extending longitudinally from the planar tab 1 22.

[0037] A plurality of grooves may be formed in opposing first and second sides of the planar stem, as at 404. The plurality of grooves 202 may be formed in the first and second sides 302, 304 via a variety of processes such as, but not limited to, machining, cold-forming, casting, combinations thereof, or the like. In one embodiment, longitudinal channels 306 may be formed in the first and second sides 302, 204 of the planar stem 120. This may be done via a variety of processes such as, but not limited to, machining, cold-forming, casting, combinations thereof, or the like.

[0038] The method 400 may further include positioning the plate connection stud in a resistance welding device to be welded to a soil reinforcing element, as at 406. The soil reinforcing element may be substantially similar to the soil reinforcing element 1 10 described above with reference to Figures 1A-1 C, and therefore may include first and second lead ends 1 16. The resistance welding device may be any known resistance welder known in the art and adapted to produce a weld through a combination of electrical resistance and pressure. The resistance welding device may include first and second electrodes carried by first and second electrode arms, respectively. The electrodes may be made of copper and the electrode arms may be adapted to apply pressure and current to the work-piece, which in this instance includes the first and second lead ends 1 16 and the first and second sides 302, 304 of the planar stem 120. The electrode arms may be formed with concave slots adapted to seat the lead ends 1 16 as the arms are pressed toward the first and second sides 302, 304 for welding.

[0039] To that end, the first lead end may be positioned between the first side of the planar stem and the first electrode of the resistance welding device, as at 408, and the second lead end may be positioned between the second side of the planar stem and the second electrode of the resistance welding device, as at 410. Using the electrode arms, the first and second electrodes may bias the lead ends against the first and second sides, as at 412. The electrode arms may be mechanically-actuated to force the first and second lead ends 1 16 into contact with the first and second sides 302, 304, respectively. In one embodiment, the amount of biasing force applied by the electrode arms may be adjustable depending on the desired weld.

[0040] The resistance welding device may then be activated to weld the first and second lead ends to the first and second sides, respectively, as at 414. In operation, electricity is passed to the electrodes as the lead ends 1 16 make contact with the sides 302, 304, thereby creating a localized, high electrical resistance. Specifically, small points of contact are made between the lead ends 1 1 6 and the ridges of the plurality of grooves 202 formed in the planar stem 1 20. As the points of contact begin to melt and form pools of molten metal, the pressure applied by the electrode arms forces the lead ends 1 1 6 deeper into the molten metal. In one embodiment, the lead ends 1 16 may slightly converge toward one another during this process. In other embodiments, the lead ends 1 16 may be configured such that relative convergence with respect to each other does not occur. The pressure is maintained until after the electricity has stopped in order to allow the molten steel to cool into one unified mass and prevent the lead ends 1 16 from un-fusing from the plate connection stud 318. The first and second electrode arms may then release the first and second lead ends, as at 414.

[0041] Accordingly, a strong resistance weld is made without the need to add filler welding material to the connection stud, such as in other welding processes (e.g. , TIG welding, arc welding applications). Moreover, the design and addition of the plurality of grooves and longitudinal channels provides for a more solid resistance weld that is less-prone to corrosion overtime, unlike other welding processes that often generate weld gaps that promote and accelerate corrosion.

[0042] The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.