Note: Descriptions are shown in the official language in which they were submitted.
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PILING APPARATUS AND METHOD OF INSTALLATION
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001 ] Priority of U. S. Provisional Patent Application Serial Number
60/248,349,
f led November 14, 2000, incorporated herein by reference, is hereby claimed.
This is a
continuation in part of Serial Number 09/993,321 filed November 14, 2001 and
incorporated
herein by reference.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0002] The present invention relates to composite piling and more particularly
to a
piling apparatus that includes a helical anchor lower end portion to which a
plurality of
connectable sections can be added, each section having a hollow interior
through which a
drive member can pass, and each section being joined to another section at a
joint that has a
specially shaped fitting to be engaged by an enlarged portion of the drive
member.
GENERAL BACKGROUND OF THE INVENTION
[0003] Piling must often be installed in locations wherein a full size pile-
driving rig
simply cannot be positioned. For example, if a building is having a settlement
problem,
piling must necessarily be driven below the building to support its lower most
structural
aspect, such as the lowest concrete horizontal section or slab.
[0004] It has been known in the art to cut holes through the slab of a
building and
then install a screw type anchor or screw type anchor piling system, in order
to add support
to an existing piling system that is already under the building. Once these
additional piling
have been paced, structural ties can be made between the building itself and
the new piling.
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[0005] Because pile-driving equipment is not able to fit into the ground floor
of
existing buildings, a screw threaded piling or helical anchor is employed
because it can be
installed using a hydraulic rotary drive, for example. Such drive units are
commercially
available.
[0006] High capacity pile-driving equipment is large and cumbersome to operate
in
confined areas. Conventional pile-driving equipment can cause stress and
fatigue on
adjacent stmctures from weight and vibration.
[0007] Piles are used to support structures, such as buildings, when the soil
underlying the structure is too weak to support the structure. There are many
techniques that
may be used to place a pile. One technique is to cast the pile in place. In
this technique, a
hole is excavated into the place where the pile is needed and the hole is
filled with cement.
A problem with this technique is that in weak soils the hole tends to
collapse. Therefore,
expensive shoring is required. If the hole is more than about 4 to 5 feet
deep, then safety
regulations typically require expensive shoring and other safety precautions
to prevent
workers from being trapped in the hole.
[0008] It is known to provide a cylindrical foundation support element having
an
open lower end and which may be rotatably driven into the ground by virtue of
the provision
of an integral annular helix permanently affixed to the outer surface of the
lower end of the
SllppOrt. The helix has an earth penetrating edge, and in conjunction with the
cylindrical
foundation defines an opening through which soil is allowed to pass into the
chamber formed
by the cylindrical wall of the foundation support. The opposite end of the
cylindrical
foundation support is adapted for releasable locking engagement to a drive
element, which is
used to rotate the support in a given direction, thus driving the support into
the ground to a
desired depth.
[0009] Langenbach, Jr., U. S. Patent Number 4,678,373 discloses a method for
supporting a structure in which a piling beating a footing structure is driven
down into the
ground by pressing from above with a large hydraulic ram anchored to the
structure. The
void cleared by the footing structure may optionally be filled by pumping
concrete into the
void through a channel inside the pile. The ram used to insert the Langenbach,
Jr. piling is
large, heavy and expensive.
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[0010] Another approach to placing piles is to insert a hollow form in the
ground
with the piles desired and then to fill the hollow form with fluid cement.
Hollow forms may
be driven into the ground by impact or screwed into the ground. This approach
is
cumbersome because the hollow forms are unwieldy and expensive. Examples of
this
approach are described in U. S. Patent Numbers 2,326,872 and 2,926,500.
[0011 ] Helical pier systems, such as the CHANCE ~ M helical pier system
available
from the A. B. Chance Company of Centralia, Mo. U.S.A., provide an attractive
alternative
to the systems described above. As described in more detail below, the CHANCE
helical
pier system includes a helical screw mounted at the end of a shaft. The shaft
is configured to
draw the helical screw downwardly into a body o.f soil. The screw is screwed
downwardly
lllltll the screw is seated in a region of soil sufficiently strong to support
the weight, which
will be placed on the pier.
[0012] Many piling systems have been patented that include multiple sections,
some
of which are provided with screw anchors or helical anchors.
[0013] An early patent is the Gray patent entitled "metal Pile", U. S. Patent
Number
415,037.
[0014] The Stevens patent 1,087,334 discloses and incased concrete piling.
[0015] A method for installing anchoring or supporting columns in situ is
disclosed
in U. S. patent Number 3,354,657.
[0016] A piling that includes a cylindrical foundation support drivable into
ground
with a removable helix is disclosed in the Holdman patent 5,066,168.
[0017] The Watts patent 3,422,629 discloses a construction support system and
method and apparatus for construction thereof. A helical member is part of the
apparatus.
[0018] U. S. Patent 3,864,923 discloses a method and means for providing a
pile
body in an earth situs, including driving casing into situs to define a cavity
of required depth.
An auger positioned within the casing is rotatable in screwing direction to
remove earth from
defined cavity, and caries expansible cutter means rotatable with auger to
enlarge cavity girth
below inner end of casing. Earth removed from casing and cavity enlargement is
replaced
with different material, such as self hardenable cement, to form pile body
with load carrying
enlargement at inner end of casing.
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[0019] An earth auger is disclosed in U. S. Patent 3,938,344 in which an auger
shaft
is provided with freely expansible and contractible rotary blades in such
manner that said
rotary blades may expand automatically when said auger shaft is rotated in the
forward
direction and may contract automatically when said auger shaft is rotated in
the reverse
direction. Also a method for driving piles and the like is disclosed which
comprises the steps
of positioning a pile or shoring adjacent to said auger shaft and above said
blades, advancing
said pile or the like into an earth bore excavated by said rotary blades, and
filling said bore
excavated by the rotary blades with mortar or the like.
[0020] The Turzillo patent 3,962,879 discloses a concrete pile or like
concrete
column forn~ed in earth situs by rotating a continuous flight auger consisting
of one or more
sections into the earth to form a cavity of given depth; rotating the auger to
remove augured
earth from the cavity without removing the auger therefrom, and replacing the
removed earth
from the auger flights with fluid cement mortar, which hardens to form a
column reinforced
by the auger resultantly anchored in the same. A plurality of short auger
sections may be
connected together in succession during drilling to form a cavity of requisite
depth by
increments when low headroom conditions exist. A portion of the auger or a
shaft portion
without auger flighting thereon may also protrude above the earth situs for
extension through
water and the like and be filled with cementitious material which is allowed
to harden. The
method may also include first filling the auger shaft with the fluid mortar
and allowing the
same to harden. The method may also include first filling the auger shaft with
the fluid
mortar and allowing the same to harden in the shaft with a passage extending
therethrough,
and supplying more mortar through the passage to fill the cavity to form the
column against
backing of hardened mortar in the shaft.
[0021] The Vickars patent 5,707,180 discloses a method and apparatus for
forming
piles in situ. The '180 patent provides a method for making piles and
apparatus for
pl'aCtlClllg the IllethOd. The piles may be used to support the foundation of
a structure, such
as a building. The method draws a soil displacer on a shaft down through a
body of soil by
turning a screw at the lower end of the shaft. The soil displacer forces soil
out of a
cylindrical region around the shaft. The cylindrical region is filled with
grout to encapsulate
and strengthen the shaft. The grout may be fed by gravity from a bath of grout
around the
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shaft. The soil displacer has a diameter smaller than a diameter of the screw
and may be a
disk extending in a plane generally perpendicular to the shaft.
BRIEF SUMMARY OF THE INVENTION
[0022] The present invention provides an improved method and apparatus for
forming piles in situ. The apparatus of the present invention includes a lower
helical screw
anchor to which are attached a number of add on sections.
[0023] The present invention utilizes a screw threaded piling or helical
anchor
because it can be installed in confined areas, using smaller and more agile
equipment (such
as a BobcatOO type skidsteer equipped with a boom mounted hydraulic powered
high torque
planetary auger drive made by Eskridge, for example). Such units as these are
commercially
avai Table.
[0024] In the preferred embodiment, each section is in the form of a hollow
member
(e.g. Thin wall pipe such as .188" wall thickness or 0.125 wall thickness or
Schedule 10
pipe) having a bore that receives a drive member or tool. The outer surface of
each of the
sections has soil displacing ribs that aid in pushing soil away from the
sections as the pile
apparatus is screwed down into the earth. The hollow bore of each of the
sections receives
an elongated drive member. The drive member is comprised of connectable
sections
wherein each of the connectable drive section sis about the same length as
each of the pile
sections. An enlarged drive member is provided at intervals as part of the
drive member, the
enlarged section registering wit a correspondingly shaped joint that connects
two pile
sections together.
[0025] The present invention provides an improved method and apparatus for
installing an in-situ pile apparatus.
[0026] A lower helical anchor lead unit with variable size helical discs is
screwed
into the soil, followed by a comically shaped cutting and soil-displacing
unit. This unit has
strategically placed (2-4) triangular ribs for cutting and displacing soil
outwardly away from
the sectional pipe sections. This same unit will work as a pile cap for
concrete that is poured
into upper pipe sections. With this improved shape, it cuts the soil when
rotated. The upper
flat round plate of the conical will work as a bearing plate to the soil.
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...... .."". .., .,.-. ...
.~..,~. ...,
6
[0027] Once the conical unit has reached the soil, a drive tool will be
attached to the
helical lead unit, connected with a plastic or wooden dowel placed through the
typical
bolthole.
[0028] A forced (thin wall .188" or Schedule - 10 .125") pile section that has
squared ends is placed over the drive tool and bolted to the conical unit.
Silicone caulking
can be installed at each square section makeup joint to prevent water or mud
from entering
the pipe sections.
[0029] A hydraulic planetary drive unit is attached to the square drive tool.
The
hydraulic auger driver unit is engaged and the helical anchor, conical unit,
attached pipe
sections) will be screwed downwardly into the soil. The hydraulic auger unit
is then
stopped and removed.
[0030] A second drive installation tool is bolted to the first. A second
formed square
sectional hollow foam is placed over the drive tool and bolted. The hydraulic
planetary drive
unit is placed on top of the drive tool and the complete pile section is then
screwed down
into the soil until the top section reaches near ground level. This same
process of installing
drive tools and sectional hollow form units is repeated until the proper depth
form which has
been reached (i.e. to satisfy the pile load requirements). As the complete
pile unit is screwed
down into the earth, the soil displacer ribs will push the soil outward away
from the hollow
pipe sections, creating less friction on the sections and therefore less
torque.
[0031 ] With the proposed pile apparatus, the helical anchor will pull the
hollow pipe
forms down. At the same time, the soil displacer ribs push the soil radially.
This will allow
the pipe to penetrate deeper with less friction and a truer ft. 1b. Torque to
capacity ratio. This
method allows the pile to be installed as a joint bearing pile, relying on the
capacity of the
helical discs that are screwed into the soil. In time, soil will reconsolidate
around the larger
diameter pipe forms, which will develop a known friction capacity, which will
increase the
overall pile capacity.
[0032] In one embodiment, a rod is provided that can be left with the pile
section
upon completion of installation to act as tensile rod or reinforcement for
concrete that can be
added to the internal bores of the various pile sections as connected end to
end.
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[0033] In another embodiment, plastic pipe sections can be added to the pile
sections
such as for example in water installations, the plastic pipe sections
extending between the
mud line and water surface.
[0034] Other embodiments show various connectors for attaching the internal
drive
members together and for connecting the rod sections together.
BRIEF DESCRIPTON OF THE DRAWINGS
[0035] For a further understanding of the nature, objects, and advantages of
the
present invention, reference should be had to the following detailed
description, read in
conjunction with the following drawings, wherein like reference numerals
denote like
elements and wherein:
[003G] Figures l A-1 C disclose the preferred embodiment of the apparatus of
the
present invention, wherein Figure lA fits the drawing Figure 1B at match line
A-A and
wherein the drawing Figure 1B fits the drawing Figure 1C at match line B-B.
[0037] Figure 2 is a schematic sectional elevational view of the preferred
embodiment of the apparatus of the apparatus of the present invention
illustrating a joint
between two pile sections;
[0038] Figure 3 is a partial, perspective view of the preferred embodiment of
the
apparatus of the present invention.
[0039] Figure 4 is a sectional view taken along lines 4-4 of Figure 2;
[0040] Figure 5 is a partial perspective view of the preferred embodiment of
the
apparatus of the present invention illustrating the drive portion thereof;
[0041 ] Figures G and 7 are partial perspective views of the preferred
embodiment of
the apparatus of the present invention illustrating die members that can be
used to form the
joint that is at the end of each of the pile sections;
[0042] Figures 8 and 9 are plan and elevation views respectively that
illustrate the
method of forming the pile joint sections.
[0043] Figures 10 and l0A are schematic illustrations showing the formation of
the
joint sections that are at the end of each of the pile sections.
[0044] Figure I I is a partial, perspective view of the preferred embodiment
of the
apparatus of the present invention;
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[0045] Figure 12 is another partial, perspective view of the preferred
embodiment of
the apparatus of the present invention;
[004G] Figure 13 is another partial, perspective view of the preferred
embodiment of
the apparatus of the present invention;
[0047] Figure 13A is a partial, sectional view of the preferred embodiment of
the
apparatus of the present invention showing drive tool removed and concrete
added;
[0048] Figure 14 is a partial, perspective view of the preferred embodiment of
the
apparatus of the present invention illustrating the hydraulic drive connected
to the drive
member, and showing an alternate construction that uses a hollow plastic
section that is
adapted for use in between a water bed and a water surface;
[0049] Figure 15 is a partial elevation, sectional view of an alternate
construction for
the drive member;
[0050] Figure 16 is a sectional view taken along lines 1G-1G of Figure 15;
[0051 ] Figure 17 is a sectional view taken along lines 17-17 of Figure 15;
[0052] Figure 18 is a partial, sectional elevation view illustrating an
alternate
construction for the internal drive member;
[0053] Figure 19 is a partial perspective view of the connection shown in
Figure 18;
[0054] Figure 20 is a partial, sectional elevation view illustrating the
connection of
Figures 18 and 19;
[0055] Figure 21 is a partial, perspective, exploded view illustration the
connection
of Figures 18-20;
[OOSG] Figure 22 is a sectional, elevation view showing the system of Figures
18-21
after installation;
[0057] Figure 23 is a perspective view of another alternate embodiment of the
apparatus of the present invention;
[0058] Figure 24 is another perspective view of an alternate embodiment of the
apparatus of the present invention;
[0059] Figure 25 is a perspective exploded view of an alternate embodiment of
the
apparatus of the present invention;
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[OOGO] Figure 2G is a plan view illustrating the die and forming apparatus for
shaping
the pile end portions for an alternate embodiment;
[00G 1 ] Figure 27 is an elevation view of the forming apparatus of Figure 2G;
[00G2] Figure 28 is a sectional view taken along lines 28-28 of Figure 27;
[00G3] Figure 29 is a fragmentary view of the forming apparatus portion of an
alternate embodiment of the apparatus of the present invention;
[00G4] Figure 30 is another fragmentary view of the forming apparatus portion
of an
alternate embodiment of the apparatus of the present invention;
[0065] Figures 31-32 are schematic end views of a piling showing formation of
the
end portion of the piling section with the dies;
[OOGG] Figure 33 is a fragmentary elevation view of an alternate embodiment of
the
apparatus of the present invention illustrating the swaging machine;
[00G7] Figure 34 is an end view of the swaging machine of Figure 33;
[00G8] Figure 35 is a fragmentary side view of the swaging machine of Figure
33
illustrating a swaging of the end portion of the pile section;
[00G9] Figure 3G is a partial perspective view of the swaging machine;
[0070] Figure 37 is a fragmentary perspective view of an alternate embodiment
of the
apparatus of the present invention illustrating a joint between the helical
anchor and the pile
section;
[0071] Figure 38 is a partial perspective view of an alternate embodiment of
the
apparatus of the present invention illustrating the pile driving tool and its
connection to the
pile section; and
[0072] Figure 39 is a partial perspective view of the alternate embodiment of
the
apparatus of the present invention illustrating the pile-driving tool and its
connection to the
pile section.
DETAILED DESCRIPTION OF THE INVENTION
[0073] In Figures lA-1C, the preferred embodiment of the apparatus of the
present
invention is designated generally by the numeral 10. It should be understood
that in order to
fit an entire elevation, sectional view of the apparatus 10 of the present
invention on a single
page, matchline type drawings are used wherein Figure 1A fits to the top of
Figure 1B along
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with matchlines A-A. In situ pile apparatus 10 includes generally a lowermost,
first section
in the form of helical anchor I l, a second section 12 which is a hollow pile
form section, a
third section 13 and a fourth section 14. The third and fourth sections 13, 14
are also hollow
pile form sections. Each section 12, 13, 14 has an internal bore, Section 12
has bore 28.
Section 13 has bore 27. Section 14 has bore 26.
[0074] In the preferred embodiment, the Sections 12, 13, 14 are preferably
interchangeable pile sections. An internal drive member IS extends through a
hollow bore
of each of the sections 12, 13, 14. The drive member 15 has an upper end
portion 16 to
which a commercially available hydraulic rotary drive motor can be attached.
The drive
member 15 has a lower end portion 17 that forms an attachment with an
extension 18 at the
upper end of helical anchor I 1.
[0075] The drive member 15 can be comprised of a number of connectable
sections
as shown, including drive sections 19, 20, 21. Each drive section 19, 20, 21
provides a lower
connector 22 (for example, a female connector) that forms a connection with an
upper
connector 23 (for example, a male connector). The lowest drive section 19
provides a
corrector 22 that forms a connection with extension 18 of helical anchor 11 as
shown in
Figure I C.
[0076] TIle internal drive 18 and member 1 S is positioned internally of pile
sections
12, 13, 14 and occupying the respective bores 28, 27, 26 as shown in Figures 1
A, 1 B, 1 C, 2,
4, and 11-13.
[0077] Tn Figure 2, an enlarged view shows the joint between second section 12
and
third section 13. It should be understood that a similar connection is formed
between section
13 and section 14. In Figure 2, each of the sections 12, 13 has a plurality of
circumferentially spaced radially extending soil displacing ribs 24. Soil
displacing ribs 24
can also be seen in the plan view of Figure 4. The drive section 19 carries an
enlarge drive
member as shown in Figures 2 and 5.
[0078] In Figures 2, 3, and 4, the details of a connection between a pair of
pile
sections is shown such as, for example, between the second pile section 12 and
the third pile
section 13. In Figures 2-4, the pile section 12 has an upper end portion that
provides an
upper squared end portion 29. Similarly, the third pile section 13 provides a
lower square
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end portion 30 that has a socket 73 that is slightly smaller than the square
end portion 29 so
that the end portion 30 fits into the section 29 at socket 73 forming a snug
fit therewith.
[0079] Each of the square end portions 29-30 provides a plurality of lugs. The
upper
square end portion 29 provides a plurality of lugs 31. The lower square end
portion 30
provides a plurality of lugs 32. Each of the lugs 31, 32 provides an opening
35 through
which a bolted connection can be placed as shown in Figures 1A - 1C, and 2-4.
The bolted
connections include a plurality of bolts 33 and a plurality of nuts 34 as
shown.
[0080] As shown in Figure 2, the lower squared end portion 30 at the bottom of
pile
section 13 fits snugly into the socket 73 of upper square end portion 30 at
the top of pile
section 12. As shown in Figure 2, enlarged drive member 25 of internal drive
member 15
closely fits and conforms to the assembly of upper square end portion 29 and
lower end
portion 30 as shown. Enlarged drive member 25 occupies the socket 74 at the
lower end
portion of pile section 13 (see Figure 2).
[0081] In the preferred embodiment, an enlarged drive member 25 is positioned
at
every joint between pile sections such as shown in Figures lA-1B. However, it
should be
understood that any desired number of pile sections 12, 13, 14 can be added to
configure or
"make-up" a very long pile apparatus. As each pile section 12, 13, 14 is
added, an additional
drive section such as 19, 20, 21 is added, in each case an enlarged drive
member 25
registering at the joint between sections such as 12 and 13 as shown in Figure
2.
[0082] When bolting the helical anchor L I to lower square end portion 30 of a
pile
section such as 12 (see Figure 11), the anchor 11 provides a round plate 36
having peripheral
openings 75 through which bolts 33 can pass as shown in Figure 1C. For
stiffening and soil
cutting and soil displacement purposes, a plurality of radially extending
triangular plates 37
are provided at the upper end portion of helical anchor 11 just below plate 36
as shown in
Figure 1 C and 11.
[0083] In Figures 13-13A, the apparatus 10 of the present invention is shown
after
placement and wherein the bore 26, 27, 28 of each of the sections 12, 13, 14
is filled with a
suitable filler material such as concrete and rebar reinforcement. In such a
case, the
connection between the extension 18 of helical anchor I1 and the lower end
portion l7of
drive section 19 is broken by simply pulling up on the various components of
the drive
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member 15 to shear pin (e.g. Wood or plastic) 38 (see Figure 13). At other
location such as
the connection between drive section 19 and drive section 20, a strong bolted
connection
using boll 39 and nut 40 can be provided as shown in Figure 5, passing through
openings 41
in drive member 19 and opening 42 in drive member 20.
[0084j Figures 6-9 and l0A-lOB show a die construction for forming upper
squared
end portion 29 and lower squared end portion 30. A pair of dies 43, 44 can be
provided, the
die 43 being used for forming the lower squared end portion 30 and thus having
a
longitudinal dimension A that is longer than the corresponding dimension B of
die 44, and a
transverse dimension C that is smaller than the transverse dimension D of die
44. The die 43
in Figure 6 forms the smaller cross sectional, but longitudinally longer lower
squared end
portion 30 whereas the die 44 in Figure 7 forms the transversely wider by
longitudinally
shorter upper squared end portion 29.
[0085] Figures 8 and 9 illustrate formation of these end portions 29 and 30
using a
hydraulic jack 45 to force corresponding pairs of these dies 43, 44 apart
while support 46 has
clamp members 47, 48 that securely hold sections 12, 13. The support 46 thus
functions as a
slide top having runways 49, 50 that receive and track die supports 51, 52
that carry dies 43,
44 respectively.
[0086] In Figure 12, it should be understood that the helical anchor 11 can
include a
number of connected sections such as 1 I A, 11B connected together using
bolted connections
39, 40 that are similar to the connection shown in Figure 5.
[0087] Figure 14 illustrates a system that can be used in water wherein a
plastic
cylindrical pipe section or sections 53 can be joined to an uppermost section
such as 12, 13,
14 using rivets and/or glue. In such a situation, the pile section that is the
upper most section
(such as section 13 or 14 in Figure 1 A) will be replaced with a transition
section 54 having a
circular connector 55 that receives the lower end portion of pipe section 53.
The internal
drive 15 extends through the plastic pipe section 53 for connecting with
hydraulic drive 56.
As shown in Figure 14, more than one of the plastic pipe section s53 can be
employed,
connected end to end and glued as is known in the art.
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[0088] The embodiment of Figure 14 can be used in aquatic environments wherein
the pipe sections 53 extend between the mudline and the waterline and/or can
be used in any
corrosive environment.
[0089] Figures 15-17 shown an alternate arrangement for the internal drive
member
15. In Figures 15-17, each of the internal drive members 15 is replaced with a
specially
configured drive member 57 wherein each of the drive members is hollow,
providing a bore
58 that receives internally positioned rod 59. The extension 18 of anchor 11
is replaced with
an extension 60 that has an upper end portion that is internally threaded at
61 to receive an
externally treaded portion 62 at the lower end of rod 59 as shown in Figure
15. This
construction enables the drive member 57 to be removed, leaving the rod 59
behind for
reinforcement purposes.
[0090] Radially extending projections 63 on extension 60 stop the drive tool
57 from
slipping down the shaft 60. Torque can be imparted from drive member 57 to
extension 60
and thus to helical anchor 11.
[0091 ] In order to remove the internal drive member 57, the operator simply
lifts the
drive member 57 off the stops 63, disengaging the drive too 57 from extension
60. Figures
18-22 show another arrangement for connecting internal drive member 57 to an
enlarged
drive member 25 as shown in Figures 19-21.
[0092] In Figures 19-21, a pair of steel pins 65 are inserted through openings
66
when the lower end 67 of a drive member section is to be connected to another
drive member
section. The drive member section 67 fits over the fitting 68 above enlarged
drive member
25 and pins 65 are placed through openings 66 and under horizontal surfaces
69.
[0093] Figure 21 shows two (2) drive tool retainer clamps 70, 71 held together
by the
O-ring 72. The retainer clamps 70, 71 grip rod 59 and thus hold the shaft of
the drive tool 57
to prevent it from moving up during installation. Once the drive tool 57 is
installed the
clamps 70, 71 are removed.
[0094] Figures 23-29 show additional alternate embodiments of the apparatus of
the
present invention designated by the numeral 102 in Figure 23, 102A in Figure
24 and 80 in
Figure 25. Each of the piling apparatus shown in Figures 23-25 utilize a
specially
configured piling section having end portions that are not circular and so
that they transfer
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rotation and torque, and that can be shaped using the apparatus shown in
Figures 27-32. One
of the piling apparatus 102 of Figure 23 has a swaged transition 113 that can
be formed using
the apparatus shown in Figures 35-37.
[0095] Each of the piling apparatus of Figure 23-24 can be installed using
hydraulic
rotary driver 151 having drive tool 152 that engages one of the shaped end
portions of the
pile sections shown in Figures 23-25.
[0096] Piling apparatus 80 provides a lower, helical anchor section 81 that
connects
to cylindrical section 85 using circular plate 82 and triangular plates 83.
The connection of
circular plate 82 to cylindrical section 85 can be welded connections. The
helical anchor 81
provides one or more helical blades 101 that embed the piling apparatus 80
into a selected
soil medium when uppermost shaped section 97 is rotated using hydraulic rotary
driver 151.
[0097] Piling section 89 has an upper shaped (e.g. squared) non-circular
section 86
provided with a plurality of lugs 95, each having an opening 96 through which
a bolt can be
attached when joining one more pile sections 89 together. Similarly, a lower
squared section
99 has a plurality of lugs 100, each having an opening 96 that receives a
bolted connection
1 10. In Figure 25, the squared section 99 is a male section that fits squared
section 86 of
helical anchor 81. The squared section 86 provides lugs 87, each lug having an
opening 88
that accepts a bolted connection 110. The cylindrically shaped central section
98 of piling
section 89 is an unformed portion of the piling section 89. Thus the piling
section 89 can
begin as a cylindrically shaped section of pipe such as Schedule 10 or
Schedule 20 pipe, for
example.
[0098] Piling section 89 provides a hollow bore and has upper and lower end
portions 91, 92. One or more helical blades 93, 94 can be provided on the
cylindrical section
98 of piling section 89, being welded thereto for example. A tapered
transition section is
provided and defined by plate 82, triangular plate sections 83, and the anchor
shaft 111. In
this fashion, the helical mchor 81 pulls the piling apparatus 80 is rotated
using hydraulic
rotary driver 151.
[0099] In Figures 23 and 24, different transition sections are provided.
Otherwise,
the apparatus 102, 102A of Figures 23 and 24 is similarly driven into a
selected soil medium
using a hydraulic rotary driver 151. In Figures 23 and 24, piling apparatus
102, 102A
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includes a central cylindrically shaped section 103, upper end portion 104 and
lower end
portion 105. The upper end portion provides a shaped (e.g. squared) section
106 having lugs
107 with openings 108 that enable bolted connections 110 to be used to join a
piling section
89 to the piling apparatus 102, 102A showing in Figures 23 or 24. Anchor shaft
111 can be
provided with one or more helical vanes 112.
[0100] In Figures 23, a swaged joint 113 is provided at lower end portion 105.
Additionally, a circular plate 114 can be welded at the joint between
cylindrical section 103
and swaged joint 113. In Figure 24, anchor shaft 11 extends to and through
plate 114, being
welded to it. A second or third or additional number of plates 114 can be
positioned
internally of cylindrical section 103, shaft 111 being welded thereto. Figures
26-32 show a
fabrication device 115 that can be used to form the pile section 89 of Figure
25, a plurality of
such pile sections being connectable end-to-end and wherein a lower most of
said pile
sections 89 can be connected to helical anchor 81, pile apparatus 102, or pile
apparatus
102A.
[0101] Fabrication device 115 includes a frame 116 that can be comprised of a
plurality of transverse beams 117 and a plurality of longitudinal beams 118.
The transverse
beams 117 can be anchored (for example, bolted) to an underlying floor 119 or
other suitable
support.
[0102] Rails 120 are provided on longitudinal beams 118 for support a first
carriage
121 and a second carriage 122. Carriage 121 has a pair of forming members 124,
and 125,
each being pivotally attached to first carriage 121 at pivot 123. Hydraulic
cylinder 126
enables dies 129, 130 mounted respectively upon forming members 124, 125, to
be moved
together or apart. Hydraulic cylinder 126 can be attached to forming member
127 at pivotal
connection 127. Hydraulic cylinder 126 can be attached to forming member 125
at pivotal
connection 128.
[0103] Each forming member 124 has a die. The forming member 124 has die 129.
The forming member 125 has die 130 (see Figures 26-32). Second carriage 122
has the
same construction as first carriage 121 with the exception of die members
129A, 130A being
of different dimensions than the die members 129, 130. The die members 129,
130 are used
to form the male end portion of pile section 89, which is preferably a longer
section. The die
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members 129A, 130A form the female end portion of piling section 89. The die
members
129A, 130A are dimensioned so that when they form an end portion of pile
section 131, the
squared end potion 97 is a female section that is slightly larger than the
squared end portion
99 that is a male end portion. Similarly, the squared section 86 is a female
section that
receives the squared end portion 99.
[0104] In Figure 26, an unformed pile section 131 is shown resting upon
supports
132. Each of the first and second carriage 121, 122 is provided with one or
more casters or
wheels 133 that ride upon rails 120. As shown in Figures 31 and 32, unformed
pile section
131 has a bore 134 that is cylindrically shaped prior to forming (Figure 31).
The dies 129,
130 or 129A, l 30A are expanded in the direction of arrows 135 (Figure 32)
when forming a
squared end portion to form pile section 89 or helical anchor 81. The formed
squared section
136 as shown in hard lines in Figure 32 while the original cylindrical shape
of unformed pile
section 131 is shown in phantom lines in Figure 32.
[0105] Figures 33-37 show a swaging device 140 that can a used to form the
swaged
joining 133 shown on piling apparatus 102 in Figure 23. Swaging device 140
includes a
support frame 139 for holding a section of conventional pipe or other unformed
pile section
131 by grasping the cylindrical section 103 thereof. A plurality of shaped
heads are mounted
on pushrods 142 of hydraulic cylinders 143 that can be positioned about
90° apart as shown
on Figure 34.
[0106] These four hydraulic cylinders 143 are simultaneously activated to
extend
pushrods 142 in the direction of arrows 144 to engage a squared, shaped end
portion 136 that
has been formed using the apparatus of Figures 26-32. The completed swag joint
113 as
shown on Figure 37 having a squared opening 153 that receives shaft 111 of
pile apparatus
102. A weld can be used to join shaft 111 and swaged joint 113. Additionally,
the folds 154
can be welded at the lower end portion of swaged joint 113 to provide
additional strength.
Additionally, one or more circular plates 114 can be welded inside of
cylindrical section 103
and to shaft 111 for additional bracing and reinforcement.
[0107] Figures 38 and 39 illustrate a suitable connection that joins hydraulic
rotary
drive 151 to pile section 89. Drive tool 152 can be removably attachable to
rotary driver 1 S 1
using C01111ect1011 155 such as the projection and socket shown with bolted
connection 156 to
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attain the connection 155. Drive tool 152 has an enlarged, square drive member
157 that fits
a female squared end portion 97 of pile section 89.
[0108] Connector 145 includes four ell shaped portions 147, each having a pair
of
sleeves 148 with sleeve openings 149 for receiving bolted connections 150. By
tightening
the bolted connections 150, the squared end portion 97 closely conforms to
square drive 157
and reduces the chance of deformation or damage to squared end 97 if an
operator should
apply too much torque to hydraulic rotary driver 151. The brackets 146 that
include ell
shaped portions 147 and sleeves 148 can be of welded steel construction for
example.
PARTS LIST
[0109] The following is a list of suitable parts and materials for the various
elements
of the preferred embodiment of the present invention.
in-situ pile apparatus
11 helical anchor, first
section
11 A anchor section
11B anchor section
12 second section
13 third section
14 fourth section
drive member
16 upper end portion
17 lower end portion
18 extension
19 drive section
drive section
21 drive section
22 lower connector
23 upper connector
24 rib
enlarged drive member
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26 bore
27 bore
28 bore
29 upper square end portion
30 lower square end portion
31 lug
32 lug
33 bolt
34 nut
35 opening
36 round plate
37 triangular plate
38 shear pin
39 bolt
40 nut
41 opening
42 opening
43 die
44 die
45 jack
46 support
47 clamp
48 clamp
49 runway
50 runway
51 die support
52 die support
53 pipe section
54 transition section
55 connector
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56 hydraulic drive
57 internal drive member
58 bore
59 rod
60 extension
61 internal thread
62 external thread
63 tool stops
64 stops below drive
tool
65 pin
66 opening
67 lower end
68 fitting
69 horizontal surface
70 retainer clamp
71 retainer clamp
72 O-ring
73 socket
74 socket
75 opening
76 concrete
A dimension arrow
B dimension arrow
C dimension arrow
D dimension arrow
80 piling apparatus
81 helical anchor
82 circular plate
83 triangular plate
84 sleeve
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85 cylindrical section
86 squared section
87 lug
88 opening
g9 piling section
90 hollow bore
91 upper end
92 lower end
93 helical blade
94 helical blade
95 lug
96 opening
97 squared section
98 cylindrical section
99 squared section
100 lug
101 helical blade
102 piling apparatus
102A piling apparatus
103 cylindrical section
104 upper end
1 OS lower end
106 squared section
107 lug
108 opening
109 helical vane
110 bolted connection
111 anchor shaft
112 helical vane
113 swaged joint
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114 circular plate
115 fabrication device
11 G frame
1 17 transverse beam
118 longitudinal beam
119 floor
120 vail
121 first carriage
122 second carriage
123 pivot
124 forming member
125 forming member
126 hydraulic cylinder
127 pivotal connection
128 pivotal connection
129 die
129A die
130 die
130A die
131 uniformed pile section
132 support
133 caster
134 bore
13 5 arrow
13G formed, squared section
137 pile support
138 clamp
139 support frame
140 swaging device
141 shaped head
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142 pushrod
143 hydraulic cylincer
144 arrow
145 connector
146 bracket
147 ell shaped portion
148 sleeve
149 sleeve opening
150 bolted connection
151 hydraulic rotary driver
152 drive tool
153 squared opening
154 fold
155 connection
156 bolted connection
157 square drive
158
[0110] The foregoing embodiments are presented by way of example only; the
scope
of the present IIlVellt1011 1S to be limited only by the following claims.
