The present disclosure relates generally to apparatus, compositions and methods for anchoring columns or posts in the ground, among other features.

BACKGROUND

[0001] Posts and columns when set into the ground frequently employ cement or a mortar to support the posts or columns. Over time, the cement or mortar may crack or degrade losing its supporting and anchoring capacity. If the posts or column comprise wood, the cracked cement or mortar accelerates the rotting of the wood. If the posts or column comprise a metal, the cracked cement or mortar accelerates the oxidation of the metal.

BRIEF DESCRIPTION OF THE DRAWINGS [0002] The accompanying drawings, which are included to provide a further understanding of the disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with the detailed description, serve to explain the principles of the disclosure. No attempt is made to show structural details of the disclosure in more detail than may be necessary for a fundamental understanding of the disclosure and the various ways in which it may be practiced. In the drawings:

[0003] Fig. 1 is a cross-sectional view of a column anchored in the ground using an expandable metal sleeve for setting the column, configured according to principles of the disclosure;

[0004] Fig. 2 is a cross-sectional view of a column being anchored with an auger made from an expandable metal, configured according to principles of the disclosure; and [0005] Fig. 3 is a cross-sectional view of a hollow column being anchored by driving a column into the ground and then installing one or more expanding metal rods through the core of the hollow column, configured according to principles of the disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE [0006] The disclosure and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and detailed in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the embodiments of the disclosure. The examples used herein are intended merely to facilitate an understanding of ways in which the disclosure may be practiced and to further enable those of skill in the art to practice the embodiments of the disclosure. Accordingly, the examples and embodiments herein should not be construed as limiting the scope of the disclosure. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings.

[0007] The terms including, comprising and variations thereof, as used in this disclosure, mean including, but not limited to, unless expressly specified otherwise. [0008] The terms “a”, “an”, and “the”, as used in this disclosure, means “one or more”, unless expressly specified otherwise. The terms column and post are synonymous herein. The term “about” refers to +/- 10% of a dimension specified, unless context specifies otherwise. [0009] Overview

[0010] In embodiments, preformed devices comprising expandable metals are described herein for setting columns into the ground. In an embodiment, a granular expandable composition is described. Expandable metals comprise one or more metals that expand in response to hydrolysis. The resulting hydrolyzed expanded metal is strong and tends to fill in spaces and cavities, even over time, which is a useful feature when setting columns into the ground. The hydrolysis can be accomplished by water ordinarily found in the ground in most locations for setting a column. Alternatively, a hydrolyzing fluid can be supplied, as necessary, to cause the hydrolysis of the expanding metal. Upon hydrolysis, the expanding metal expands around the column to adhere and grip the column securely, while the expandable metal may also expand outwardly in the ground to increase cross-sectional bulk lending to a more overall stabilization of a set column. If subject to stress that may create a fault, such as a crack, the hydrolyzed expanding metal tends to heal itself, if necessary, over time. The columns herein may be installed vertically or at an angle to the surface of the ground including horizontal installation such as, e.g., setting a column in a vertical orientated earthen wall or cliff

[0011] Fig. 1 is a diagram of a column 105 anchored in the ground 111 using an expandable metal sleeve 121 for setting the column 105. The column 105 may comprise a rod, post, pillar or the like. The column 105 be solid or may be hollow and may comprise metal, wood, stone, composites, plastic or similar materials. The column 105 may have any outer shape and circumference, such as round, circular oval, square or the like. The column 105 may be hollow and have an inner circumference about an interior surface. [0012] The expandable metal sleeve 121 may be preformed, and may be sized and shaped according to intended applications. That is, the bigger the column 105 to be supported, the expandable metal sleeve 121 may be sized accordingly. The expandable metal sleeve 121 may be preformed by casting, milling or other construction processes. The expandable metal sleeve 121 may have an internal cavity 116 formed by an inner surface of a wall 119 and the expandable metal sleeve 121 configured to accept a column 105 of a particular width or diameter d. The shape of the internal cavity 116 would match the shape of the outer perimeter or outer surface of the column. The expandable metal sleeve 121 may be preformed to have an overall height h. The overall height h may be selected in accordance with the anticipated overall height of the column, or other application requirement, to provide a sufficient stabilization capability. Therefore, different sized expandable metal sleeves 121 may have different sized diameters or width of internal cavities 116 for accepting a particular sized column with a similar diameter or width. Moreover, different sized expandable metal sleeves 121 may have different sized overall height h. The expandable metal sleeve 121 may be formed with a point 117 at the lower end for penetrating the ground 111.

[0013] In use, the preformed expandable metal sleeve 121 may be set into the ground 111 at the surface 110 and partially driven into the ground 111. The column 105 may be inserted into, or coupled with, the expandable metal sleeve 121 and both column 105 and expandable metal sleeve 121 may be driven into the ground 111 to a desired depth. Alternatively, the column 105 may be inserted into the expandable metal sleeve 121 at the surface 110 and both the column 105 and the expandable metal sleeve 121 may be driven together into the ground to a desired depth. A hydrolyzing fluid, such as water, may be applied from the surface to the expandable metal sleeve 121 in the ground 111 to initiate hydrolysis, or water from the ground itself may cause the hydrolysis. Once the expanding metal has expanded due to hydrolysis, the column is firmly set into the ground with the expandable metal sleeve 121 solidly binding to the column 105. The column 105 may be a solid column, or may be a hollow column, and also may have any shape such as round, circular, oval, square, or the like

[0014] In an embodiment, granular expandable metal 118 may be used and poured down the column 105 for added strength at the base of the column 105, but is not required. Granular expandable metal may hydrolyze and bond with the preformed expanding metal 121 at the base of the column 105. In embodiments, the granular expandable metal 118 may be used alone in lieu of the preformed expanding metal 121 to set the column 105 into the ground 111, but would require a hole to be dug beforehand, as is analogously done when using cement. Granular expanding metal may be hydrolyzed by ground water or as otherwise supplied from the surface.

[0015] Fig. 2 is a diagram of a column 115 being anchored with an auger 120 made from an expandable metal. The column 115 be solid or may be hollow and may comprise metal, wood, stone, composites, plastic or similar materials. The column 115 may have an outer circumference about an outer surface and may have any outer shape, such as round, circular, oval, square or the like. The column 115 may be have an inner circumference about an interior surface, and also may have any shape such as round, oval, square, or the like.

[0016] The auger 120 may be preformed and may comprise a blade 125 that may be a continuous spiral about, connected with, and extending laterally from a wall 135, and may have an end tip 136. The wall 135 of auger 120 forms a hollow compartment 134 for receiving a column 115 therewithin. The compartment 134 has an inner circumference and is shaped to accept a column 115 having a particular outer circumference and shape. Therefore, there may be different sized augers 120 having different sized or shaped compartments 134, and/or different sized overall blade 125 in a circumferential dimension, and different sized height of the auger 120. A more common shape of the compartment 134 may be a circular compartment for accepting circular columns 115. But, other shapes may be employed, such as a square, oval, rectangle, or the like to match expected shapes of columns for an application. The column 115 may be a solid or hollow column and may be inserted into, or coupled with, the auger 120, such as by sliding the column 115 into the auger 120. The outer circumference of the column 115 slideably couples with the inner circumference of the wall 135. A retaining mechanism 137, such as, e.g., a bolt, may be used to hold the column within the auger 120 so that a rotation force 130 can be imparted to the column 115 and the auger 120 for driving or turning the column 115 and auger 120 into the ground 111 from the surface 110.

[0017] The blade 125 of the auger 120 may be a continuous blade or may be a discontinuous blade. That is, the blade does not have to be continuously spiraled about the wall 135, but may have breaks or interruptions. The blade 125 may also have serrations on its edge to help bite into the ground 111. The blade 125 and wall 135 may comprise an expandable metal. Once set into the ground 111, the combination of column 115 and auger 120 become bonded together once the expandable metal of the wall 135 hydrolyzes. Moreover, the expandable metal of the auger 120 also expands outwardly into the ground 111 increasing support strength even more. The expandable metal of the auger 120 also tends to heal itself over time if any damage or stress fractures develop. Hydrolyzing fluid may be supplied from the surface 110 or, water in the ground 111 may provide the hydrolyzing fluid as water, which can come from rain.

[0018] In an embodiment, the column 115 may be pre-bonded to the auger

120 before installation by inserting the column 115 into the auger 120 and hydrolyzing the expandable metal so that the column 115 and auger 120 are bonded together. This embodiment may not require a securing mechanism 137 to hold the column 115 and auger 120 together for rotation 130.

[0019] Fig. 3 is a diagram of a hollow column 315 being anchored by driving a column 315 into the ground 111 and then installing one or more expanding metal rods 325, 330 through the core 335 of the hollow column 315. The core 335 may be formed by the inner surface 336 of the wall of the column 315. The column 315 may comprise metal, wood, stone, composites, plastic or similar materials. The outer surface 345 of the expanding metal rods 325, 330 may be slideably coupled to the inner surface 336 while the expanding metal rods 325, 330 are being guided and driven through the core 335, the coupling still permitting movement of the expanding metal rods 325, 330 along the core 335. In this embodiment, the hollow column 315 may be driven into the ground 111 at a desired location. One or more expanding metal rods 325, 330 may be driven 320 by a suitable driving device through the core 335 of the hollow column 315.

[0020] The expanding metal rods 325, 330 may be pre-sized to approximate the inner diameter and shape of the core 335, but with sufficient tolerance to still slide through the core 335. Therefore, there may be different sized expanding metal rods 325, 330 of different diameters for insertion into a column 315 of a particular sized core 325. [0021] One or more of expanding metal rods 325, 330 may be driven past the bottom end 340 of the column 315 so that the expanding metal rods hydrolyze and expand to provide a strong base, as well as reinforce the inner diameter of the column 315 near the bottom end 340. This will also keep the column 315 dry to prevent rust or rot. Moisture present typically will be absorbed by the expanding metal rods 325, 330. Moreover, the base formed by the expanding metal rods 325, 330 is less likely to crack, and if it does crack will tend to heal itself. The column 315 may be hollow and have an inner circumference about an interior surface, and also may have any shape such as round, oval, square, or the like.

[0022] The expandable metal described in relation to Figs. 1-3 may be granulated, or the expandable metal may be machined as a preformed device to any specific size/shape, extruded, formed, cast or other conventional ways to produce the desired shape of an expandable metal sleeve 121, auger 120, or expanding metal rods 325, 330. The expandable metal may have a thickness that supplies a desired strength before and after hydrolysis. For example, the overall width D of expandable metal sleeve 121 may be selected from a range of about 2” to about 16”, but can be more or less, and may depend on the column 105 size to be used. The thickness of expandable metal of the blades 125 may be selected from a range of about 0.25” to about 1.0”, but can be more or less. The diameter of the expanding metal rods 325, 330 may be selected from a range of about 1.0” to about 8.0”, but can be more or less, and may depend on column size to be used.

[0023] In general, and in relation to the previously described uses of the expandable metal of Figs. 1-3, the hydrolysis of any metal can create a metal hydroxide. The formative properties of alkaline earth metals (Mg - Magnesium, Ca - Calcium, etc.) and transition metals (Zn - Zinc, A1 - Aluminum, etc.) under hydrolysis reactions demonstrate structural characteristics that are favorable for use with the present disclosure. Hydration results in an increase in size from the hydration reaction and results in a metal hydroxide that can precipitate from the fluid.

[0018] The hydration reactions for magnesium is:

Mg + 2H2O -> Mg(OH)2 + H2, where Mg(OH)2 is also known as brucite. Another hydration reaction uses aluminum hydrolysis. The reaction forms a material known as Gibbsite, bayerite, and norstrandite, depending on form. The hydration reaction for aluminum is:

A1 + 3H2O -> Al(OH)3 + 3/2 H2.

Another hydration reactions uses calcium hydrolysis. The hydration reaction for calcium is:

Ca + 2H2O -> Ca(OH) ₂ + H2,

Where Ca(OH)2 is known as portlandite and is a common hydrolysis product of Portland cement. Magnesium hydroxide and calcium hydroxide are considered to be relatively insoluble in water. Aluminum hydroxide can be considered an amphoteric hydroxide, which has solubility in strong acids or in strong bases.

[0019] In an embodiment, the metallic material used can be a metal alloy. The metal alloy can be an alloy of the base metal with other elements in order to either adjust the strength of the metal alloy, to adjust the reaction time of the metal alloy, or to adjust the strength of the resulting metal hydroxide byproduct, among other adjustments. The metal alloy can be alloyed with elements that enhance the strength of the metal such as, but not limited to, A1 - Aluminum, Zn - Zinc, Mn - Manganese, Zr - Zirconium, Y - Yttrium, Nd - Neodymium, Gd - Gadolinium, Ag - Silver, Ca - Calcium, Sn - Tin, and Re - Rhenium, Cu - Copper. In some embodiments, the alloy can be alloyed with a dopant that promotes corrosion, such as Ni - Nickel, Fe - Iron, Cu - Copper, Co - Cobalt, Ir - Iridium, Au - Gold, C - Carbon, gallium, indium, mercury, bismuth, tin, and Pd - Palladium. The metal alloy can be constructed in a solid solution process where the elements are combined with molten metal or metal alloy. Alternatively, the metal alloy could be constructed with a powder metallurgy process. The expandable metal sleeves 160a, 160b can be cast, forged, extruded, or a combination thereof.

[0020] Optionally, non-expanding components may be added to the starting expanding metal materials. For example, ceramic, elastomer, glass, or non-reacting metal components can be embedded in the expanding metal or coated on the surface of the expanding metal. Alternatively, the starting metal may be the metal oxide. For example, calcium oxide (CaO) with water will produce calcium hydroxide in an energetic reaction. Due to the higher density of calcium oxide, this can have a 260% volumetric expansion where converting 1 mole of CaO goes from 9.5cc to 34.4cc of volume. In one variation, the expanding metal is formed in a serpentinite reaction, a hydration and metamorphic reaction. In one variation, the resultant material resembles a mafic material. Additional ions can be added to the reaction, including silicate, sulfate, aluminate, and phosphate. The metal can be alloyed to increase the reactivity or to control the formation of oxides.

[0021] The expandable metal can be configured as a preformed device in many different fashions, as long as an adequate volume of material is available for fully expanding to provide column support. Additionally, a coating may be applied to one or more portions of the expandable metal to delay the expanding reactions.

[0024] The use of the expandable metals as described herein does not require any use of cement or mortar to set columns, pilings, posts, vertical structures or the like. The use of the expandable metals as described herein provides a long term solution for self-healing cracks or defects that might arise from use, and may be left in the ground permanently.

[0025] The following paragraphs include an alternate description of certain aspects of the disclosure.

[0026] Clause 1 : An apparatus for setting a column into the ground, comprising a preformed device comprising an expandable metal that expands in response to hydrolysis, the preformed device having at least one circumference, wherein the at least one circumference of the preformed device is sized to couple with a surface of a column having a circumference of about the same dimension as the at least one circumference of the preformed device for setting the column into the ground.

[0027] Clause 2: The apparatus of clause 1, wherein the at least one circumference is formed by a surface of an inner wall of the preformed device, and the surface of the column comprises an outer surface of the column.

[0028] Clause 3: The apparatus of clauses 1 or 2, wherein the preformed device comprises a sleeve with a cavity formed therewithin, the cavity having an inner surface, the circumference of the inner surface being the at least one circumference. [0029] Clause 4: The apparatus of clauses 1 or 2, wherein the preformed device comprises an auger.

[0030] Clause 5: The apparatus of clause 4, wherein the auger comprises a spiral blade configured about a wall, the wall also forming a hollow compartment for receiving the column therewithin, an inner circumference of the wall being the at least one circumference, wherein the spiral blade and the wall comprises expandable metal. [0031] Clause 6: The apparatus of clauses 4 or 5, further comprising a retaining mechanism configured to secure the auger to the column during rotation of the auger. [0032] Clause 7: The apparatus of clause 1, wherein the at least one circumference is formed by an outer surface of the preformed device and the surface of the column comprises and inner surface of the column.

[0033] Clause 8: The apparatus of clause 7, wherein the preformed device is insertable into a core of the column formed by the inner surface.

[0034] Clause 9: The apparatus of clause 8, wherein the preformed device comprises an expanding metal rod that expands in response to hydrolysis and is drivable through the column for setting the column into the ground.

[0035] Clause 10: The apparatus of any one of clauses 1-9, wherein the at least one circumference of the preformed device is circular.

[0036] Clause 11 : An apparatus for setting a column into the ground, comprising: a preformed device comprising an expandable metal that expands in response to hydrolysis, the preformed device having a circumference sized and shaped to match a circumference of a column for setting the column into the ground.

[0037] Clause 12: The apparatus of clause 11, wherein the preformed device comprises a sleeve having a wall with an internal circumference for receiving the column therewithin.

[0038] Clause 13: The apparatus of clause 12, wherein the sleeve is configured to be driven into the ground by the column, and the sleeve is configured to be hydrolyzed while in the ground.

[0039] Clause 14: The apparatus of clause 11, wherein the preformed device comprises an auger with blades, the auger configured to receive the column therewithin for setting the column in the ground, the auger and blades hydrolysable in the ground. [0040] Clause 15: The apparatus of clause 11, wherein the preformed device comprises an expanding metal rod that is drivable through the column for setting the column into the ground, and expanding metal rod is hydrolyzable in the ground.

[0041] Clause 16: A method comprising: providing at least one preformed device comprising an expandable metal that expands in response to hydrolysis, the at least one preformed device having at least one circumference, wherein the at least one circumference of the at least one preformed device is sized to couple with a surface of a column having a circumference of about the same dimension as the at least one circumference of the preformed device; and setting the column into the ground using the preformed device.

[0042] Clause 17: The method of clause 16, wherein in the providing step, the preformed device comprises a sleeve having a wall with an internal circumference for receiving the column therewithin, and the sleeve is configured to be driven into the ground by the column, and the sleeve is configured to be hydrolyzed while in the ground.

[0043] Clause 18: The method of clause 16, wherein in the providing step, the preformed device comprises an auger with blades, the auger configured to receive the column therewithin for setting the column in the ground, the auger and blades hydrolyzable in the ground.

[0044] Clause 19: The apparatus of clause 16 wherein in the providing step, the preformed device comprises an expanding metal rod that is drivable through the column for setting the column into the ground, and hydrolyzes in the ground.

[0045] Clause 20: The apparatus of clause 16, wherein in the providing step, the at least one circumference of the at least one preformed device is circular. [0046] While the disclosure has been described in terms of exemplary embodiments, those skilled in the art will recognize that the disclosure can be practiced with modifications in the spirit and scope of the appended claim, drawings and attachment. The examples provided herein are merely illustrative and are not meant to be an exhaustive list of all possible designs, embodiments, applications or modifications of the disclosure.