Note: Descriptions are shown in the official language in which they were submitted.
32606-15
MODULAR FOUNDATION SUPPORT SYSTEMS
AND METHODS INCLUDING SHAFTS WITH
INTERLOCKING, SELF-ALIGNING AND TORQUE
TRANSMITTING COUPLINGS
[0001]
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to foundation support
systems including assemblies of structural support elements, and more
specifically to
interlocking, self-aligning and torque transmitting couplers for connecting
modular
foundation elements in building structure foundation support systems and
related
methods for assembling and installing modular foundation support systems.
[0003] Foundation support stability issues are of concern in both new
building construction and in maintenance of existing buildings. While much
attention
is typically paid to the fabrication of a foundation in new construction to
adequately
support a building structure, on occasion foundation support systems are
desired to
accomplish the desired stability and prevent the foundation from moving in a
way that
may negatively affect the structure. As buildings age and settle there is
sometimes a
shifting of the foundation that can cause damage to the building structure,
presenting a
need for lifting or jacking the foundation to restore it to a level position
where repairs
to the structure can be made and further damage to the building structure is
prevented.
Numerous foundation support systems and methods exist that may capably provide
the desired foundation stability and/or may capably lift building foundations
to
another elevation where they may be optimally supported. Existing foundation
support systems and methods typically include a pier or piling driven into the
ground
proximate a building foundation, leaving a piling projecting upwards on which
a
support element or lifting element may be attached.
[0004] Existing foundation support systems and methods are,
however, disadvantaged in some aspects. For example, it is sometimes necessary
to
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extend the length of a piling by connecting an extension piece when conditions
are
such that a pier is driven deeply into the ground to provide the desired
amount of
support. Attaching the piling to an extension piece in some existing support
systems
involves a coupler having fastener holes that is attachable to both the piling
and the
extension piece.
[0005] Because the extension pieces may be many feet long and tend
to be relatively heavy it is often quite difficult to complete the desired
connections
with the proper alignment of the fastener holes in the coupler and the
fastener holes in
the extension piece so that the connection can be completed by installing a
fastener
through the aligned holes. If the connections are not properly aligned to make
the
connection, the integrity of the support system to provide the proper level of
support
can be compromised and system reliability issues can be presented.
Accordingly, the
needs of the marketplace have not been completely met with existing building
foundation support systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Non-limiting and non-exhaustive embodiments are described
with reference to the following Figures, wherein like reference numerals refer
to like
parts throughout the various drawings unless otherwise specified.
[0007] Figure 1 illustrates a perspective view of a first exemplary
embodiment of a foundation support system interacting with a building
structure.
[0008] Figure 2 shows a cross-sectional view of a first exemplary
embodiment of a piling assembly for the system shown in Figure 1 including a n
exemplary coupler assembly according to a first embodiment of the present
invention
and including an inner coupler and an outer coupler.
[0009] Figure 3 illustrates a perspective view of the inner coupler for
the coupling assembly shown in Figure 2.
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[0010] Figure 4 illustrates a side view of the inner coupler shown in
Figure 3.
[0011] Figure 5 illustrates a bottom view of the inner coupler shown
in Figure 3.
[0012] Figure 6 illustrates a cross-sectional view of the inner coupler
taken along line 6-6 in Figure 4.
[0013] Figure 7 illustrates a perspective view of the outer coupler
shown in Figure 2.
[0014] Figure 8 illustrates a cross-sectional view of the outer coupler
shown in Figure 7.
[0015] Figure 9 illustrates a cross-sectional view of the outer coupler
taken along line 9-9 in Figure 8.
[0016] Figure 10 illustrates a cross-sectional view of the outer
coupler taken along line 10-10 in Figure 8.
[0017] Figure 11 illustrates an exemplary modular foundation
support component including an inner coupler and an outer coupler as shown in
Figures 3-10 for the assembly shown in Figure 2 and the foundation support
system
shown in Figure 1.
[0018] Figure 12 illustrates a second exemplary embodiment of a
modular foundation system including the modular foundation support component
shown in Figure 11.
[0019] Figure 13 illustrates a third exemplary embodiment of a
modular foundation system including the modular foundation support component
shown in Figure 11.
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[0020] Figure 14 illustrates a first side view of another exemplary
embodiment of an inner coupler for a modular foundation support piling
assembly of
the present invention.
[0021] Figure 15 illustrates a cross-sectional view of the inner
coupler taken along line 15-15 in Figure 14.
[0022] Figure 16 illustrates a bottom view of the inner coupler shown
in Figure 11.
[0023] Figure 17 illustrates a second side view of the inner coupler
shown in Figures 14-16.
[0024] Figure 18 illustrates a cross-sectional view of the inner
coupler taken along line 18-18 in Figure 17.
[0025] Figure 19 illustrates a cross sectional view of the inner
coupler taken along line 19-19 in Figure 17.
[0026] Figure 20 illustrates a partial side view of an exemplary
embodiment of an outer coupler for completing a modular piling assembly in
combination with the inner coupler shown in Figures 14-19.
[0027] Figure 21 illustrates a first cross-sectional view of the outer
coupler taken along line 21-21 in Figure 20.
[0028] Figure 22 illustrates a second cross-sectional view of the
outer coupler taken along line 22-22 in Figure 20.
[0029] Figure 23 illustrates a top view of the outer coupler shown in
Figure 20.
[0030] Figure 24 illustrates a second side view of the outer coupler
shown in Figures 20-23.
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[0031] Figure 25 illustrates a cross-sectional view of the outer
coupler taken along line 25-25 in Figure 21.
[0032] Figure 26 illustrates a bottom view of the outer coupler shown
in Figure 24.
[0033] Figure 27 is a side view of an exemplary embodiment of a
drive tool coupler for a modular foundation support piling including the inner
coupler
shown in shown in Figures 14-19.
[0034] Figure 28 is a cross-sectional view of the drive tool coupler
taken along line 28-28 in Figure 27.
[0035] Figure 29 is a bottom view of the drive tool coupler shown in
Figure 27.
[0036] Figure 30 is a top view of the drive tool coupler shown in
Figure 27.
[0037] Figure 31 is a perspective view of another embodiment of a
foundation support shaft including an integral inner coupler on one end and an
integral outer coupler on the other end.
[0038] Figure 32 is a first side view of the shaft shown in Figure 31.
[0039] Figure 33 is a first end view of the shaft shown in Figure 32.
[0040] Figure 34 is a second end view of the shaft shown in Figure
32.
[0041] Figure 35 is a second side view of the shaft shown in Figure
32.
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DETAILED DESCRIPTION OF THE INVENTION
[0042] Exemplary embodiments of interlocking, self-aligning
coupler assemblies to connect structural elements such as foundation elements
of a
foundation support system and related methods of assembling, connecting
installing
and supporting building foundation elements are described that address certain
problems and disadvantages in the art. As described below, an interlocking
self-
aligning and torque transmitting coupler assembly of the present invention
facilitates
a simplified alignment and connection between, for example, a piling and an
extension piece during assembly of a building foundation support system, while
ensuring that an adequate lifting strength and support is reliably established
by
avoiding installation issues that can otherwise be problematic when subjected
to
torque to drive the pilings deeper into the ground. Foundation support
elements may
therefore be assembled more quickly and more reliably while reducing labor
costs and
simultaneously improving system reliability by avoiding problematic torque-
related
issues that can otherwise cause elements of a foundation support system to
deform
and negatively impact the stability of the system and its load bearing
capacity.
[0043] More specifically, the support system described herein
includes an interlocking, self-aligning, torque transmitting coupler assembly
that
includes first and second couplers and a plurality of mating alignment and
torque
transmission features provided in each coupler that assist in attaching first
and second
structural elements to each other with relative ease while ensuring proper
alignment of
the connections made, including but not limited to connections between
foundation
elements in a foundation support system. Multiple and different features are
provided
in each coupler in the coupler assembly that serve dual purposes of
facilitating
alignment and reliable connection of foundation elements in the field, as well
as to
more effectively transmit torque between the foundation elements after the
aligned
connections are established.
[0044] In a contemplated embodiment, the inventive coupler
assembly includes a first or inner coupler attached to a first foundation
element
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including a first shaft and an outer coupler attached to a second foundation
element
including a second shaft. The inner coupler includes a pair of primary
alignment and
torque transmitting ribs formed on a round outer surface thereof that are
configured to
be slidably inserted into a respective pair of primary alignment and torque
transmitting grooves formed in a round inner surface of the outer coupler. As
such,
when the first and second foundation elements are desired to be attached, the
inner
coupler is inserted partly into the outer coupler and rotated about its center
axis until
the primary alignment and torque transmitting ribs of the inner coupler align
and mate
with the primary alignment and torque transmitting grooves of the outer
coupler
where complete mating engagement of the inner and outer couplers may occur.
Only
when the alignment and torque transmitting features are fully mated can the
inner
coupler be completely received in the outer coupler to complete a connection
between
the first and second shafts while also effectively mechanically isolating any
fasteners
provided from torque as a foundation support system is installed. By virtue of
the
inventive coupler assembly, torsional force applied to one of the foundation
elements
is transmitted to the other by the engagement of the torque transmission
features
formed in the inner and outer couplers.
[0045] In another contemplated embodiment, a fastened connection
of the inner and outer couplers may include a cross-bolt connection wherein
first and
second bolts respectively extend through pairs of fastener holes or fastener
openings
formed in the respective inner and outer coupler. The fastener holes are self-
aligning
when the inner and outer couplers are completely engaged and the first and
second
bolts extend in mutually perpendicular directions through the fastener holes.
The first
and second bolts also extend at offset elevations to one another in the
coupler
assembly. Advantageously, no fastener holes in the pile and extension piece
are
needed to make the cross-bolt connection via the inner and outer coupler.
Alignment
difficulties associated with fastener holes in the pile and extension piece
are
completely avoided.
[0046] In other contemplated embodiments, however, a single
fastener may be utilized to complete a connection between the first and second
shafts
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through the coupler assembly and as such a single pair of fastener holes may
be
provided in each of the inner and outer couplers that are self-aligning when
the inner
and outer couplers are engaged.
[0047] In still another contemplated embodiment the mechanical
connection between the shafts may be completed without using any fasteners via
the
interlocking alignment and torque transmitting features formed in the inner
and outer
couplers.
[0048] As described in further detail below, an exemplary
embodiment of a coupler assembly is self-aligning and self-locking in a manner
that
enables quick and easy coupling of first and second shafts, and in some cases
accommodates a sturdy and easily accomplished cross-bolt fastening connection
between the first and second shafts in a desirable manner. Any torque imparted
onto
the coupled shafts via twisting of the upper shaft is contained within
interlocking
features of the coupler assembly as opposed to being transferred through
bolted
connections between the shafts in conventional support systems. Method aspects
of
the inventive concepts will be in part apparent and in part explicitly
discussed in the
following description.
[0049] Figure 1 illustrates a perspective view of an exemplary
embodiment of a foundation support system 100 interacting with a building
foundation 102 of a structure. The foundation support system 100 may interact
with
new foundation upon which a structure is to be built, or may alternatively
interact
with a foundation supporting an existing structure. That is, the foundation
support
system 100 may be applied to new building construction projects as well as to
existing
structures for maintenance and repair purposes. Of course, the support system
100
may alternatively be used to support an object other than a building
foundation as
desired.
[0050] After determining, according to known engineering
methodology and analysis, how the foundation 102 or other structure needs to
be
supported, primary piles or pipes (hereinafter collectively referred to as a
"pile" or
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"piles") 104 of appropriate size and dimension may be selected and may be
driven
into the ground or earth at a location proximate or near the foundation 102
using
known methods and techniques. The primary piles 104 typically consist of a
long
shaft 106 driven into the ground, upon which a support element such as a plate
or
bracket (not shown) or a lifting element such as the lifting assembly 108 is
assembled.
The shaft 106 of the primary pile 104 may include one or more lateral
projections
such as a helical auger 110. The piles 104 may be, for example, helical steel
piles
available from Pier Tech Systems (www.piertech.com) of St. Louis, Missouri,
although other suitable piles available from other providers may likewise be
utilized
in other embodiments.
[0051] The helical auger 110 may in some embodiments be
separately provided from the piling 104 and attached to the piling 104 by
welding to a
sleeve 112 including the auger 110 provided as a modular element fitting. As
such,
the sleeve 112 of the modular fitting is slidably inserted over an end of the
shaft 106
of the piling shaft 104 and secured into place, for example with fasteners
such as the
bolts as shown in Figure 1. In such an embodiment, the sleeve 112 includes one
or
more pairs of fastener holes or openings for attachment to the piling shaft
106 with
the fasteners shown. In the embodiment illustrated there are two pairs of
fastener
holes formed in the sleeve 112, which are aligned with corresponding fastener
holes
in the shaft 106 to accept orthogonally-oriented fasteners and establish a
cross-bolt
connection between the shaft 106 and the sleeve 112. To make a primary pile
104
with a particular length one merely slides the sleeve 112 onto a piling shaft
106 of the
desired length and affixes the sleeve 112 in place. In the illustrated
embodiment, the
end of the piling shaft 106 is provided with a beveled tip 114 to better
penetrate the
ground during installation of the pile 104. In different embodiments, the
tapered tip
114 may be provided on the shaft 106 of the piling 104, or alternatively, the
tip 114
may be a feature of the modular fitting including the sleeve 112 and the auger
110.
[0052] The lifting assembly 108 may be attached to an upper end of
the primary pile 104 after being driven into the ground. If the primary pile
104 is not
sufficiently long enough to be driven far enough into the ground to provide
the
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necessary support to the foundation 102, one or more extension piles 116 can
be
added to the primary pile 104 to extend its length in the assembly, as
described in
further detail below. The lifting assembly 108 may then be attached to one of
the
extension piles 116.
[0053] As shown in Figure 1, the lifting assembly 108 interacts with
the foundation 102 to support and lift the building foundation 102. In a
contemplated
embodiment, the lifting assembly 108 may include a bracket body 118, one or
more
bracket clamps 120 and accompanying fasteners, a slider block 122, and one or
more
supporting bolts 124 (comprising allthread rods, for example) and accompanying
hardware. In another suitable embodiment the lifting assembly 108 may also
include a
jack 126 and a jacking block 128. Suitable lifting assemblies may correspond
to those
available from Pier Tech Systems (www.piertech.com) of St. Louis, Missouri,
including for example only the TRU-LIFT bracket of Pier Tech Systems,
although
other lifting assemblies, lift brackets, and lift components from other
providers may
likewise be utilized in other embodiments.
[0054] The bracket body 118 in the example shown includes a
generally flat lift plate 130, one or more optional gussets 132, and a
generally
cylindrical housing 134. The lift plate 130 is inserted under and interacts
with the
foundation or other structure 102 that is to be lifted or supported. The lift
plate 130
includes an opening, with which the cylindrical housing 134 is aligned and to
accommodate one of the primary pile 104 or an extension pile 116. The housing
134
is generally perpendicular to the surface of lift plate 110 and extends above
and below
the plane of lift plate 130.
[0055] In the exemplary embodiment shown, one or more gussets
132 are attached to the bottom surface of the lift plate 130 as well as to the
lower
portion of the housing 134 to increase the holding strength of the lift plate
130. In one
embodiment, the gussets 132 are attached to the housing 134 by welding,
although
other secure means of attachment are encompassed within this invention.
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[0056] In the exemplary embodiment, the bracket clamps 120
include a generally Q-shaped piece having a center hole at the apex of the "a"
to
accommodate a fastener. The Q-shaped bracket clamp 120 includes ends 136,
extending laterally, that include openings to accommodate fasteners. The
fasteners
extending through the openings in the ends 136 are attached to the foundation
102,
while the fastener extending through the center opening at the apex of the "Q"
extends
into an opening in the housing 134. In one embodiment the fastener extending
through the center opening in the bracket clamp 120 and into the housing 134
further
extends through one of the primary pile 104 or the extension pile 116 and into
an
opening on the opposite side of the housing 134, and then anchors into the
foundation
102. In such cases, however, the fastener is not inserted through one of the
primary
pile 104 or the extension pile 116 until jacking or lifting has been
completed, since
bracket body 118 must be able to move relative to pile 104 or 116 in order to
effect
lifting of the foundation 102.
[0057] In one embodiment, the bracket body 118 is raised by
tightening a pair of nuts 138 attached to the top ends of the supporting bolts
124. The
nuts 138 may be tightened simultaneously, or alternately, in succession in
small
increments with each step, so that the tension on the bolts 124 is kept
roughly equal
throughout the lifting process. In another suitable embodiment, the jack 126
is used
to lift the bracket body 118. In this embodiment, longer support bolts 124 are
provided and are configured to extend high enough above the slider block 122
to
accommodate the jack 126 resting on the slider block 122, the jacking block
128, and
the nuts 138.
[0058] When all of the components are in place as shown and
sufficiently tightened, the jack 126 (of any type, although a hydraulic jack
is
preferred) is activated so as to lift the jacking plate 128. As the jacking
plate 128 is
lifted, force is transferred from the jacking plate 128 to the support bolts
124 and in
turn to the lift plate 130 of the bracket body 118. When the foundation 102
has been
lifted to the desired elevation, the nuts immediately above the slider block
122 (which
are raised along with support bolts 124 during jacking) are tightened down,
with
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approximately equal tension placed on each nut. At this point, the jack 126
can then
be lowered while the bracket body 118 will be held at the correct elevation by
the
tightened nuts on the slider block 122. The jacking block 128 can then be
removed
and reused. The extra support bolt material above the nuts at the slider block
122 can
be removed as well, using conventional cutting techniques.
[0059] The lifting assembly 108 and related methodology is not
required in all implementations of the foundation support system 100. In
certain
installations, the foundation 102 is desirably supported and held in place but
not
moved or lifted, and in such installations the lifting assembly shown and
described
may be replaced by a support plate, support bracket or other element known in
the art
to hold the foundation 102 in place without lifting it first. Support plates,
support
brackets, support caps, and or other support components to hold a foundation
in place
are available from Pier Tech Systems (wvvw.piertech.com) of St. Louis,
Missouri and
other providers, any of which may be utilized in other embodiments of the
foundation
support system.
[0060] As shown in Figure 1, the exemplary foundation support
system 100 includes a coupler assembly 200 according to an embodiment of the
present invention that establishes a mechanical connection between the shaft
106 of
the primary pile 104 and the shaft of the extension pile 116. It is
appreciated,
however, that more than one coupler assembly 200 may be utilized to connect
another
extension pile 116 to the extension pile 116 shown 200 or to mechanically
connect
other ones of the foundation elements 112, 134 to the respective piles 104 and
116
shown and described above. Further, it should be appreciated that the coupler
assembly 200 may be utilized in a foundation support system 100 that does not
include an extension pile 116. For example, the coupler assembly 200 could
establish
a connection between the pile 104 and the housing 134, or between the pile 104
and
the sleeve 112 of the modular fitting. The connector assembly 200 may
accordingly
facilitate a modular assembly of the foundation elements shown and described
in
various combinations.
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[0061] Figure 2 shows the coupler assembly 200 in cross-sectional
view wherein the coupler assembly 200 is seen to include an inner coupler 202
attached to a shaft of a first piling 300 and an outer coupler 204 attached to
a shaft of
a second piling 302. In one embodiment, pilings 300 and 302 include a length
of pipe
fabricated from a metal such as steel. The couplers 202, 204 may likewise be
integrally formed from a metal material such as steel according to known
techniques
to include the features described. The first piling 300 may be of the same
dimension
in terms of its inner and outer diameter and correspond in cross sectional
shape to the
second piling 302, to which it is attached. Alternatively stated, the pilings
300, 302
being connected via the coupler assembly 200 are constructed to be the same,
albeit
with possibly different lengths, although this not necessarily required in all
embodiments. The cross-sectional shape of the pilings 300, 302 can be
circular,
square, hexagonal, or another shape as desired. The pilings 300, 302 can be
made to
different lengths, however, as the application requires, and the pilings 300,
302 can be
hollow or filled with a substance such as concrete, chemical grout, or another
known
suitable cementitious material or substance familiar to those in the art to
enhance the
structural strength and capacity of the pilings in use. The pilings may be
prefilled
with cementitious material in certain contemplated embodiments.
[0062] Likewise, in other contemplated embodiments, cementitious
material, including but not necessarily limited to grout material familiar to
those in the
art, may be mixed into the soil around the pilings 300, 302 as they are being
driven
into the ground, creating a column of cementitious material around the pilings
for
further structural strength and capacity to support a building foundation.
Grout and
cementitious material may be pumped through the hollow pilings under pressure
as
the pilings are advanced into the ground, causing the hollow pilings to fill
with grout,
some of which is released exterior to the pilings to mix with the soil at the
installation
site. Openings and the like can be formed in the pilings to direct a
flow of
cementitious material through the pilings and at selected locations into the
surrounding soil.
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[0063] In the exemplary embodiment shown, the first piling 300 may
correspond to an extension piling, such as the extension piling 116 shown in
Figure 1,
and the second piling 302 may correspond to a primary piling, such as the
primary
piling 104 shown in Figure 1. As noted above, the coupler assembly 200,
however,
may alternatively be used to connect other shafts of other foundation elements
in the
foundation support system 100 previously described, or still further may be
utilized to
connect other structural shaft elements in another application apart from
foundation
support. In the exemplary embodiment shown, the shaft of the first piling 300
includes a distal end 304, to which is coupled the inner coupler 202, and the
shaft of
the second piling 302 includes a distal end 306, to which is coupled the outer
coupler
204. The distal ends 304 and 306 are positioned adjacent each other such that
the
inner coupler 202 is configured to be at least partially inserted into the
outer coupler
204, as described in further detail below.
[0064] Figure 3, 4 and 5 respectively illustrate a perspective view,
bottom view and rear cross-sectional of the inner coupler 202 of the coupler
assembly
200 that will be described collectively in the following discussion.
[0065] In the exemplary embodiment illustrated, the inner coupler
202 includes a first end 206, a second end 208, and a hollow round body
portion 210
extending therebetween. The inner coupler 202 accordingly includes a generally
round opening 212 extending therethrough between the ends 206, 208. The first
end
206 includes a collar portion 214 including a counter bore 216 configured to
receive
the distal end 304 of the shaft of the first piling 300. In the exemplary
embodiment
shown, the counter bore 216 includes an inner diameter or circumference that
is sized,
shaped and dimensioned to be large enough to accommodate the outer diameter of
the
shaft of the piling end 300 (Figure 2) such that when the piling end 304 is
inserted
into the counter bore 216 the end of the shaft is received in the counter bore
216. In
an alternative embodiment, the outer diameter of the collar 214 may be
selected to be
small enough to fit within the inner diameter of the shaft of the piling end
300.
Regardless, the shaft of the first piling 300 is fixedly attached to the inner
coupler 202
by any known means, such as, but not limited to, welding. As previously
mentioned,
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the shaft may include a round cross-section, a square cross-section, or
another cross-
sectional shape, and accordingly the end 206 of the inner coupler 202 has a
complementary round shape, square shape or other shape to facilitate the
connection
of the shaft end to the counter bore 216.
[0066] As further seen in the figures, the body portion 210 of the
inner coupler 202 is attached to the collar 214 via a seating surface 218.
More
specifically, the seating surface 218 obliquely extends between an outer
surface 220
of the body portion 210 and a lip surface 222 of the collar 214.
[0067] The inner coupler 202 also includes a pair of axially
extending ribs 224 that project or extend radially outward from the round
outer
surface 220 of the body portion 210. In the exemplary embodiment, the axially
extending ribs 224 are positioned opposite each other on the round body 210 of
the
inner coupler 202. That is, the ribs 224 are extended about 180 from one
another on
an outer surface of the round body 210, and extend lengthwise or in a
direction
parallel to a longitudinal axis of the shafts that are connected with the
coupler
assembly.
[0068] In another suitable embodiment, the ribs 224 are positioned at
any point on the round body 210 that facilitates operation of the coupler
assembly 200
as described herein. Each rib 224 includes a pair of side surfaces 226 and a
seating
surface 228 that each extends obliquely from round outer surface 220 of the
body 210.
The ribs 224 serve as a primary alignment feature to align the inner coupler
202 with
the outer coupler 204 to enable connecting the first piling 300 to the second
piling 302
as well as a primary torque transmitting feature when the inner coupler 202 is
mated
to the outer coupler 204. More specifically, the pair of ribs 224 are
configured to
cooperatively engage a pair of grooves defined in the outer coupler 204 to
accomplish
alignment and torque transmission, as described in further detail below. While
a pair
of ribs 224 are shown, it is understood that greater or fewer number of ribs
may
likewise be provided in further and/or alternative embodiments.
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[0069] In the exemplary embodiment shown, the inner coupler 202
also includes a secondary alignment and torque transmission feature that
includes a
pair of circumferentially extending recesses 230 defined in the round body 210
proximate the second end 208 of the inner coupler 202.
Specifically, the
circumferential recesses 230 extend from an end surface 232 of the inner
coupler
second end 208 partly around the circumference of the body 210. Similar to the
ribs
224, the recesses 230 are configured to engage a pair of projections defined
in the
outer coupler 204, as described in further detail below. Further, the recesses
230 are
circumferentially offset from the ribs 224, such that the recesses 230 and the
ribs 224
are not aligned with one another. In another suitable embodiment, the recesses
230
may be circumferentially aligned with the ribs 224 if desired. While a pair of
circumferential recesses 230 are shown, it is understood that greater or fewer
number
circumferential recesses 230 may likewise be provided in further and/or
alternative
embodiments. As best seen in Figure 5, at the locations of the circumferential
recesses 230, the inner surface of the coupler 202 includes flat regions that
maintain a
desired wall thickness in the coupler body 210. As such, inner surface of the
coupler
202 in cross-section seen in Figure 5 includes two rounded curve portions
separated
by straight or linear portions at the locations of the recesses 230 whereas
the inner
surface of the coupler 202 is otherwise uniformly round and circular in cross
section
at other locations in the body 210 as shown in the figures.
[0070] The inner coupler body portion 210 in the example illustrated
also is formed with one or more pairs of fastener holes or openings 234, 236
defined
therethrough to allow for fastening of the inner coupler 202 and the outer
coupler 204.
The two openings 234 are shown on opposite sides or locations in the round
body
portion 210 such that a fastener such a bolt extending through the openings
234 will
be generally perpendicular to the longitudinal axis and will enter and leave
the body
portion 210 approximately normal to the round outer surface 220. In a further
embodiment, the body portion 210 includes the first pair of openings 234
proximate
the first end 206 and a second pair of openings 236 located proximate the
second end
208. The pairs of openings 234 and 236 are angularly offset from one another
by 90
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'
such that fasteners inserted into the openings 234 and 236 are mutually
perpendicular
to one another when received through the respective openings 234, 236. This
particular configuration is sometimes referred to as a cross-bolt connection
and is
shown in Figure 1 wherein the coupler assembly 200 connects the shafts 106 and
116.
[0071] Figure 7 illustrates a perspective view of the outer coupler
204 of the coupling assembly 200 that may be used with the foundation support
system 100 shown in Figure 1 and the inner coupler 202 shown in Figures 3-6.
Figure
8 illustrates a cross-sectional view of the outer coupler 204. Figure 9
illustrates a
cross-sectional view of the outer coupler 204 taken along line 9-9 in Figure
8. Figure
illustrates a cross-sectional view of the outer coupler 204 taken along line
10-10 in
Figure 8. The following discussion shall collectively refer to Figures 7-10.
[0072] In the exemplary embodiment shown, the outer coupler 204
includes a first end 238, a second end 240, and a hollow round body portion
242
extending therebetween. The outer coupler 204 accordingly includes an opening
244
extending between ends 238 and 240. As shown in Figure 8, the second end 240
includes a flange 246 extending from an inner surface 248 of the round body
242.
The flange 246 defmes a cavity 250 at the second end 240 that configured to
receive
the distal end 306 of the shaft of the second piling 302. In the exemplary
embodiment, the cavity 250 includes an inner diameter that is large enough to
accommodate the outer diameter of the shaft at the piling end 306 such that
the shaft
of the piling end 306 is inserted in to the cavity 250 to join the outer
coupler 204 with
the second piling 302. In another suitable embodiment, at least a portion of
the outer
diameter of the second coupler body 242 is small enough to fit within the
inner
diameter of shaft of the piling end 306. The shaft of the second piling 302 is
fixedly
attached to the second end 240 of the outer coupler 204 by any known means,
such as,
but not limited to, welding. As previously mentioned, the shaft of the second
piling
302 may include a round cross-section, a square cross-section, or another
cross-
sectional shape, and accordingly the end 240 of the outer coupler 204 has a
complementary round shape, square shape or other shape to facilitate the
connection
of the shaft end to the coupler 204. It should also be noted here that the
couplers 202,
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204 may be configured to receive and connect to shafts having different cross
sectional shapes as desired in further and/or alternative embodiments.
[0073] The outer coupler 204 also includes a pair of axially
extending grooves 252 that are formed in the round inner surface 248 and
extend from
a first end surface 254 toward the second end 240. In the exemplary
embodiment, the
grooves 252 are positioned opposite each other on the body 242 of the outer
coupler
204. In another suitable embodiment, the grooves 252 are positioned at any
point on
the body 242 that facilitates operation of the coupler assembly 200 as
described
herein. The grooves 252 are configured to receive the pair of ribs 224 of the
inner
coupler 202 as a primary alignment feature with the inner coupler 202 to more
easily
connect the shaft of first piling 300 to the shaft of the second piling 302,
as well as
transmit torque in a manner contained within the coupler assembly. Each groove
252
includes a seating surface 256 proximate the second end 240 that is configured
to
mate with the seating surface 228 on a rib 224 of the inner coupler 202, as
described
in further detail below.
[0074] In the exemplary embodiment, the outer coupler 204 also
includes a pair of wings or flares 258 that extend outward from a round outer
surface
260 of the outer coupler body 242. Each wing or flare 258 is positioned
approximate
the respective groove 252 such that the wings or flares 258 facilitate a
substantially
constant thickness of the outer coupler body 242. Each wing or flare 258
extends
from the end surface 254 toward the second end 240 and terminates at
approximately
the same axial position at the groove 252. The wings or flares 258 impart a
rounded
outer surface having a discontinuous outer diameter in the outer surface of
the outer
coupler 204. As seen in the cross sections of Figure 9 and 10, the outer
coupler has an
eccentric, complex curvature and elliptical shape where the rings or flares
258 reside.
[0075] The outer coupler 204 also includes a secondary alignment
and torque transmission feature that includes a pair of circumferential
projections in
the form of tabs 262 extending outwardly from the round body portion 242
proximate
the second end 240. Specifically, the circumferential projections 262 extend
radially
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inward from the inner surface 248 proximate the flange 246. The
circumferential
projections 262 are configured to engage the pair of circumferential recesses
230
defined in the inner coupler 202 when the coupler assembly 200 is assembled.
Further, the circumferential projections 262 are circumferentially offset from
the
grooves 252 in the outer coupler, such that the projections 262 and the
grooves 252
are not aligned. In another suitable embodiment, the projections 262 may be
circumferentially aligned with the grooves 252.
[0076] Additionally, the outer coupler body portion 242 may be
formed with one or more pairs of fastener holes or openings 264, 266 defined
therethrough to allow for joining of the outer coupler 204 to the inner
coupler 202.
Two openings 264 may be formed on opposite sides of the body portion 242 such
that
a fastener extending through openings 264 will be generally perpendicular to
the
longitudinal axis and will enter and leave the body portion 242 approximately
normal
to the surface 260. In a preferred embodiment, the body portion 242 includes
the first
pair of openings 264 proximate the first end 238 and a second pair of openings
266
located proximate the second end 240. The pairs of openings 264 and 266 are
preferably rotationally offset from one another by 90 such that fasteners
inserted into
the openings 264 and 266 are perpendicular to one another when coupler
assembly
200 is viewed in cross-section. This orientation of fastener holes facilitates
a cross-
bolt connection as described above.
[0077] As mentioned above, however, the cross-bolt connection is
not required in all embodiments, however, and instead one fastener may be
employed
to complete a connection with the coupler assembly 200 in another embodiment.
Still
further, a mechanical connection may be completed without a fastener at all in
certain
applications as explained further below.
[0078] Although the inner coupler 202 is shown and described herein
as including ribs 224 and outer coupler 204 is described herein as having
grooves 252,
it is contemplated that this arrangement of features may be reversed and/or
combined
in another embodiment. That is, in an alternative embodiment the inner coupler
202
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'
may include grooves instead of or in addition to ribs 224, and the outer
coupler 204
may likewise include ribs instead of or in addition to grooves 252. Further,
the inner
coupler 202 may include at least one of each a rib and a groove, while outer
coupler
may include a corresponding rib and a corresponding groove. Similarly,
although the
inner coupler 202 is described herein as including the circumferential recess
230 and
the outer coupler 204 is described herein as having the circumferential
projection 262,
it is contemplated that the inner coupler 202 may include a circumferential
projection
instead of or in addition to the circumferential recess 230, and that the
outer coupler
204 may include a circumferential recess instead of or in addition to
projection 262.
Generally, the inner coupler 202 includes at least one alignment and torque
transmission feature that is configured to engage with a corresponding
alignment and
torque transmission feature of the outer coupler 204 to facilitate alignment
of the
couplers 202 and 204 to couple shafts of different foundation elements in the
foundation support system.
[0079] Further, although ribs 224 and grooves 262 are shown as
substantially linear, axially extending features oriented in parallel with the
longitudinal axis of the shafts of the piles to which they are coupled, it is
contemplated that the ribs 224 and grooves 262 may be in a non-parallel
orientation
with respect to the longitudinal axis of the shafts of the piles, such as
obliquely-
oriented. Additionally, it is contemplated that ribs 224 and grooves 262 may
be non-
linear in nature and form a curved shape such as, but not limited to, a spiral
shape
about their outer and inner surfaces of the respective couplers 202 and 204.
[0080] Referring again to Figure 2, the coupler assembly 200
facilitates connecting the shaft of the first piling 300 with the shaft of the
second
piling 302. As described above, the first piling 300 may be an extension
piling 116
(shown in Figure 1). The second piling 302 may be one of the primary piling
104
(shown in Figure 1) or an extension piling 116.
[0081] In another suitable embodiment, the coupler assembly 200
may be utilized to connect any two structural shaft components and is not
restricted to
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use within a foundation support system 100, as described herein. That is, the
shafts
being connected with the coupler assembly 200 need not be shafts of piles or
piers or
any of the components shown and described in the foundation support system
described above, but instead other structural elements for other purposes.
Provided
that the ends of the structural elements being connected are shaped to fit the
counter
bores in the inner and outer couplers 202, 204, the structural elements need
not even
be shafts.
[0082] In operation, the inner coupler 202 is fixedly attached to the
end 304 of the shaft of the first piling 300 and the outer coupler 204 is
fixedly
attached to the end 306 of the shaft of the second piling 302. The second end
208 of
the inner coupler 202 is then partly inserted into the first end 238 of the
outer coupler
204 such that at least a portion of the inner coupler 202 is received within
the opening
244. The diameter of the inner coupler 202 at the location of the ribs 244 is
larger
than the inner diameter of the outer coupler inner surface 248 such that the
inner
coupler 202 can only be inserted into the outer coupler 204 in a predetermined
orientation. More specifically, the diameter of the outer coupler 204 at the
location of
the grooves 254 is large enough to accommodate the diameter of the inner
coupler
202 at the location of the ribs 244. As such, the ribs 224 of the inner
coupler 202
must be aligned with the grooves 254 of the outer coupler 204 to assemble the
coupler
assembly 200. Once the second end 208 of the inner coupler 202 is partially
inserted,
simple rotation of the first piling 300 causes automatic alignment of the
couplers 202
and 204. Because the pile 300 is relatively heavy, the inner coupler 202 once
aligned
will fall into place via gravitational force as the piling 300 is rotated to
the point of
alignment. Therefore, the ribs 224 and the grooves 254 serve as a self-
alignment
feature that makes it easier to connect the pilings 300 and 302 to each other.
[0083] Once the ribs 224 are aligned with the grooves 254, the inner
coupler 202 may then be removably inserted into the outer coupler 204.
Insertion
terminates when the lip surface 222 and the seating surface 218 of the inner
coupler
202 mate, respectively, with the end surface 254 and a seating surface 268 at
the first
end 238 of the outer coupler 204. As such, in the exemplary embodiment, the
collar
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portion 214 of the inner coupler 202 remains exposed and is not inserted into
the
opening 244 of the outer coupler 204. In another suitable embodiment, the
inner
coupler 202 is fully inserted into the outer coupler 204.
[0084] Referring to the second ends 208 and 240, when the ribs 224
are fully inserted into the grooves 254, the seating surface 228 on the ribs
224 is in
contact with the seating surface 256 on the grooves 254. Additionally, the end
surface
232 on the inner coupler 202 contacts the flange 246 on the outer coupler 204.
As
such, seating surfaces 218, 268, 228, and 256, end surface 232, and flanges
246 are
configured to ensure that the inner coupler 202 is properly positioned within
the outer
coupler 204 with respect to depth.
[0085] Furthermore, each circumferential recess 230 in the second
end 208 of the inner coupler 202 receives a circumferential projection tab 262
in the
second end 240 of the outer coupler 204 to further ensure proper alignment of
the
couplers 202 and 204 as well as torque transmission. Over time and through
continued usage, it is possible that friction may erode away small portions of
the ribs
224. However, the circumferential recesses 230 and projections 262 serve as a
secondary alignment and torque transmission feature to facilitate assembly of
the
coupler assembly 200.
[0086] When the combination of alignment features have been
properly seated and aligned between the couplers 202 and 204, the first piling
300 is
spaced from the second piling 302 by a distance equal to the distance between
the
counter bore 216 in the inner coupler 202 and the flange 246 in the outer
coupler 204.
As such, the pilings 300 and 302 are not directly connected to the same
component of
the coupler assembly 200 and no component of the coupler assembly 200 overlaps
both pilings 300 and 302. In such a configuration, any torque imparted onto
the
support system 100 is contained within the coupler assembly 200 instead of
being
transferred between the pilings 300 and 302 using fasteners such as bolts
extending
through fastener holes in the pilings 300 and 302. Advantageously, by virtue
of the
couplers 202 and 204, the connections can be established between the pilings
300 and
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302 without fastener holes and fasteners extending through the pilings 300,
302. As
clearly seen in the Figures, the fasteners, when provided extend only through
the
couplers 202, 204. As such, torque related issues associated with deformation
of
fastener holes in the pilings 300, 302 that may occur in conventional systems
are
eliminated by the coupler assembly 200.
[0087] More specifically, if the first piling 300 were to be rotated
while the inner coupler 202 is positioned within and engaged with the outer
coupler
204 to drive the pilings 300, 302 deeper into the ground, the torque is
distributed in
the coupler assembly 200 between the ribs 224 and the grooves 254, between the
circumferential recesses 230 and the circumferential projections 262. Further,
because the primary alignment and secondary alignment features described are
differently sized and proportions, as well as being offset and spaced apart
from one
another in the coupler assembly 200, any applied torque is distributed across
multiple
locations in the coupler assembly 200 where the alignment and torque
transmitting
features are engaged. Because some of the alignment and torque transmitting
features
are axially oriented while others are circumferential, a particularly strong
and sturdy
connection is realized that facilitates torque transfer without deformation of
either
coupler 202, 204 or the connecting shafts of the piles 300, 302. Finally,
because the
couplers 202 are each fabricated from high strength steel in a contemplated
embodiment, they are capable of withstanding high torsional forces to install
a
foundation support system by driving piles into the ground. Simpler and easier
connections of foundation elements such as piles are therefore realized with
improved
reliability that likewise facilitates simpler and easier installation of a
foundation
support system with improved reliability.
[0088] Further, in such a configuration, the first pair of fastener holes
or openings 234 on the inner coupler 202 is automatically aligned with the
first pair of
fastener holes or openings 264 on the outer coupler 204 when the couplers 202,
204
are mated. Similarly, the second pair of fastener holes or openings 236 on the
inner
coupler 202 is automatically aligned with the second pair of fastener holes or
openings 266 on the outer coupler 204. As such, a technician can easily insert
a first
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fastener through openings 234 and 264 and a second fastener through openings
236
and 266 to secure the inner 202 to the outer coupler 204 and establish a cross-
bolt
connection. As such, the coupler assembly 200 configured as shown in the
Figures is
sometimes referred to as a cross-bolt and cross-lock coupler.
[0089] As mentioned above, a single fastener may also be utilized in
another embodiment. In such a scenario, one of the pairs of fastener holes may
be
omitted in the construction of the couplers 202, 204 or only one of the pairs
of
fastener holes may be utilized to receive a fastener.
[0090] In still another embodiment no fasteners may be utilized and
the couplers 202, 204 could either be formed without fastener holes at all or
the
fastener holes provided may simply not be utilized with fasteners. Because the
pilings
in the example of the foundation support system are driven and loaded with
compression force in use, the fastened connection may not be strictly
necessary
because of the interlocking engagement of the alignment and torque
transmission
features that may transmit torsional force in the absence of any fasteners.
The
configuration of the couplers 202, 204 further facilitates direct and
distributed
transmission of compressive forces by the seating surfaces described on each
coupler
that mate with one another when the couplers 202, 204 are engaged. The flush
engagement of the mating ends when the coupler assembly 200 is fully
assembled, in
combination with the seating surfaces described, provides a high strength
connection
in the assembly.
[0091] Such a configuration of coupler assembly 200 and shafts of
the piles 300 and 302 reduces, and substantially eliminates the stress in the
assembly
that may otherwise result because of the difficulties in aligning relatively
long and
heavy pieces in the assembly. If fasteners are intentionally or
unintentionally forced
through openings that are not completely aligned in adjacent shafts in the
assembly
the joint between adjacent shafts may be subject to a significant amount of
mechanical stress that in conventional systems may lead to deformation of the
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fastener holes and weakening of the shafts. Because the coupler assembly 200
is self-
aligning, however, such issues are avoided.
[0092] Additionally, deformation of the fastener holes via
unintentional misalignment of piles in conventional support systems may result
in
some relative movement, sometimes referred to as play, in the coupled
connection
that can also adversely affect the load bearing capacity of the system. Also,
increased
stress caused by misalignment of adjacent components may cause a reduction in
the
effective service life of the piles, thus requiring more frequent replacement.
By virtue
of the self-aligning and self-locking coupler assembly and system described,
these
problems are substantially minimized, if not completely eliminated, in most
cases
where the coupler assembly 200 is properly used. The inter-engagement of the
coupler features described, and in particular the alignment and torque
transmission
features of each coupler 202 and 204, mechanically isolates the fasteners,
when
provided, from torsional force.
[0093] The fasteners, when utilized with fully engaged couplers 202,
204, are further mechanically isolated from compression forces in the coupler
assembly 200 when the pilings are driven further into the ground via
application of
torsional force on and end of an above ground piling. The seating surfaces
described
in the coupler assembly 200 that bear upon and inter-engage with one another
when
the coupler assembly 200 is fully engaged, provide direct transmission of
compression forces through the couplers 202, 204.
[0094] The fasteners provided may, however, realize tension force
depending on how the support system is configured and applied. More
specifically,
the fasteners may experience a tensile load from a loading of a pile with a
uplift force,
or if the pile should need to be removed the fasteners when provided ensure
that the
connection maintains engagement.
[0095] Figure 11 illustrates an exemplary modular foundation
support component 400 in the form of an elongated shaft with opposed ends 402,
404
and coupling features on each end 402, 404 that correspond to the inner
coupler 202
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and the outer coupler 204 in the coupler assembly 200 (Figure 2) and as shown
and
described in Figures 3-10 as set forth above. The shaft 400 may be fabricated
from
steel in contemplated embodiments and has a length and cross section to meet
the
structural strength requirements of a foundation support assembly wherein the
shaft
400 serves as a portion of a foundation support pile in a modular foundation
support
system. The shaft 400 may be hollow or filled with a cementitious
material as
described above.
[0096] In one embodiment, the coupling features of the couplers 202,
204 (e.g., the ribs 224, grooves 252, seating surfaces for coupler engagement,
and
fastener holes) may be integrally formed and cast in the fabrication of the
shaft 400.
In another embodiment, the coupling features of the couplers 202, 204 may be
integrally swaged on the shaft ends 402, 404 in a forging process. In still
another
embodiment, the coupling features of the couplers 202, 204 may be provided
separately and welded on the shaft ends 402, 404 via the respective coupler
body
portions 220, 242 described above. Other mechanical connections of the
coupling
features to the shaft 400 are possible. Whether integrally formed and built-in
the
fabrication of the shaft 400 or separately joined and connected, the coupling
features
of the couplers 202, 204 are provided for assembly in a modular foundation
support
system with the couplers 202, 204 present on the ends 402, 404.
[0097] The shaft 400 in contemplated embodiments may be
configured as an extension piece or pile of a foundation support system such
as the
foundation support system 100 (Figure 1) when both the coupler features are
provided
on both ends 402, 404 as shown. In another embodiment wherein coupler features
are
provided only on one of the ends 402 or 404, the shaft may be configured as a
primary
support pile with a helical auger component 110 and may have a beveled end or
tip as
shown in Figure 1. The shaft 400 may alternatively be provided and used as a
modular component in a coupled shaft assembly other than a foundation support
assembly with similar effect and benefits.
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[0098] The modular component shaft 400 as shown including the
couplers on both ends may be quickly coupled to additional modular components
that
include a mating coupler 202, 204 with similar effects and advantages to those
described above. For example, when the modular shaft component 400 is provided
as
a first modular component, a second modular component having an outer coupler
204
may be connected to the shaft end 402 including coupling features of the inner
coupler 202, while a third modular component including an inner coupler 202
may be
connected to the shaft end 404 including coupling features of the outer
coupler 204.
The connections may be beneficially made in a self-aligning manner as
described
above with the self-aligning fastener holes to quickly complete connections of
the
modular components in a highly reliable manner.
[0099] When the modular components being coupled are each
elongated shaft components, when the corresponding couplers 202, 204 are
engaged
to complete a connection between two shafts, a coupled shaft component
assembly is
realized having a combined shaft length about equal to the axial lengths of
the
modular component shafts being assembled. An overlap of the inner and outer
couplers when fully mated to facilitate the shaft connections is relatively
small (e.g.
six inches) in comparison to the axial lengths of the shafts in contemplated
embodiments that are many feet long, such that the combined length of coupled
shafts
using the inner and outer couplers is slightly less than, but about equal to,
the sum of
the lengths of the modular shafts being assembled via the couplers 202, 204.
As
shown in Figure 11, the modular shaft 400 has an axial length L measured end-
to-end
between the distal ends of the couplers 202, 204, with the axial length of the
couplers
202, 204 on the shaft ends 402, 404 each contributing only a small fraction of
the total
axial length L.
[00100] By providing a set of modular shafts 400 (or modular shaft
components to be assembled with the modular shaft 400) of respectively
different
axial length L, coupled shaft assemblies can be provided to effectively
accommodate
a wide variety of particular needs in the foundation support field with a
limited set of
modular components. For example, n number of modular shafts 400 may be
provided
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each having a selected cross-sectional shape (e.g., circular) and dimension
(e.g.,
diameter) to provide the structural strength required of a foundation support
installation, but in respectively different axial lengths L.
[00101] Considering a case wherein n equals three, a first modular
shaft may be provided with a large axial length L1 of 84 inches (2.13 m), a
second
modular shaft may be provided with an intermediate axial length L2 of 63
inches (1.6
m), and a third modular shaft may be provided with a small axial length L3 of
42
inches (1.07 m). Such relatively large, relatively small and intermediate
length shafts
can be utilized alone and in combination to realize a versatile number of
different
foundation support piling lengths to meet the needs of a particular foundation
support
installation.
[00102] Following the example above, the set of three modular shafts
400 having lengths LI, L2, L3 can be used to realize the following coupled
shaft
lengths in a foundation support pier installation.
Table 2
_
Modular Shaft 1 Modular Shaft 2 Modular Shaft 3 Approximate
Coupled
Shaft Length
L3 (42 in.) None None 42 in.
L2 (63 in.) None None 63 in.
L1(84 in.) None None 84 in.
L2 (63 in.) L3 (42 in.) None 105 in.
LI (84 in.) L3 (42 in.) None 126 in.
LI (84 in.) L2 (63 in.) None 147 in.
LI (84 in.) L2(63 in.) L3 (42 in.) 189 in.
In view of Table 1, an installer having one complete set of three modular
shafts LI, L2,
L3 can complete seven different foundation support piers having the coupled
shaft
lengths ranging from 42 inches to 189 inches on the same installation site or
different
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installation sites. Also, two different foundation support piers of different
combined
length can be installed using a single set of three modular shafts with the
lengths LI,
L2, L3.
[00103] The versatility of the modular shaft assembly is extended if
multiple sets of modular shafts are made available on an installer. For
instance, three
sets of modular shafts 400 of lengths LI, L2, L3 can be used separately and in
combination to realize foundation support piers having the different lengths
shown
below in Table 2.
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Table 2
Modular Shaft 1 Modular Shaft 2 Modular Shaft 3
Approximate Coupled
Shaft Length
L3 (42 in.) None None 42 in.
L2 (63 in.) None None 63 in.
Li (84 in.) None None 84 in.
L3 (42 in.) L3 (42 in.) None 84 in.
L2 (63 in.) L3 (42 in.) None 105 in.
L1(84 in.) L3 (42 in.) None 126 in.
L2 (63 in.) L2 (63 in.) None 126 in.
L3 (42 in.) L3 (42 in.) L3 (42 in.) 126 in.
Li (84 in.) L2 (63 in.) None 147 in.
Li (84 in.) Li (84 in.) None 168 in.
L1(84 in.) L3 (42 in.) L3 (42 in.) 168 in.
L2(63 in.) L2 (63 in.) L3 (42 in.) 168 in.
L1(84 in.) L2(63 in.) L3 (42 in.) 189 in.
L2(63 in.) L2(63 in.) L2(63 in.) 189 in
L1(84 in.) L2(63 in.) L3 (63 in.) 210 in.
L1(84 in.) L1(84 in.) LI (84 in.) 252 in.
An installer having three complete sets of modular shafts with the lengths L1,
L2, L3
shown can therefore selectively use the modular shafts in the three sets to
complete
foundation support systems having eleven different coupled shaft lengths
ranging
from 42 inches to 252 inches with varying incremental coupled shaft length
differences between the eleven possible coupled shaft lengths.
[00104] Some of the coupled shaft lengths (e.g., 84 inches, 126
inches, 168 inches) shown in Table 2 may beneficially be realized using
different
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combinations and different numbers of the modular shafts to realize the
coupled shaft
length. This provides additional versatility to assembling a foundation
support
assembly in view of the availability of the modular components at any given
time.
For example, if an installer has two shafts with large length L1 for a
foundation
support system installation, the 168 inch coupled shaft length may be obtained
directly by assembling the two shafts, but if the same assembly has only one
shaft
with length L1 as long as the installer also has two shafts of length L2 the
installer may
still proceed to realize the 168 inch coupled shaft.
[00105] Table 3 below illustrates another example of coupled shaft
lengths made possible with three sets of modular shafts including alternative
shaft
lengths L1, 1,2, L3 to that shown in Table 2 and providing correspondingly
different
coupled shaft lengths and increments between coupled shaft lengths using
different
combinations of the modular shafts.
Table 3
Modular Shaft 1 Modular Shaft 2 Modular Shaft 3 Approximate
Coupled Shaft
Length
L3 (48 in.) None None 48 in.
L2 (60 in.) None None 60 in.
Li (84 in.) None None 84 in.
L2(48 in.) L2(48 in.) None 96 in.
L2 (60 in.) L3 (48 in.) None 108 in.
L2 (60 in.) L2 (60 in.) None 120 in.
L2 (60 in.) L3 (48 in.) L3 (48 in.) 126 in.
Li (84 in.) L3 (48 in.) None 132 in.
L1(84 in.) L2(60 in.) None 144 in.
L3 (48 in.) L3 (48 in.) L3 (48 in.) 144 in.
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L2(60 in.) L3 (48 in.) L3 (48 in.) 156 in.
L2 (60 in.) L2 (60 in.) L3 (48 in.) 168 in.
LI (84 in.) Li (84 in.) None 168 in.
LI (84 in.) L3 (48 in.) L3 (48 in.) 180 in.
L2 (60 in.) L2(60 in.) L2 (60 in.) 180 in.
LI (84 in.) Li (84 in.) None 186 in.
L1(84 in.) L2(60 in.) L3 (48 in.) 192 in.
Li (84 in.) LI (84 in.) Li (48 in.) 216 in.
LI (84 in.) L1(84 in.) L1(60 in.) 228 in.
_
L1(84 in.) L1(84 in.) L1(84 in.) 252 in.
In view of Table 3, an installer having three sets of modular shafts with the
lengths L15
L2, L3 shown can selectively use the modular shafts to complete foundation
support
systems having seventeen different coupled shaft lengths ranging from 48
inches to
252 inches with varying incremental differences between the possible coupled
shaft
lengths.
[00106] Of course, the specific lengths L 1 , L2, L3 of modular shafts
illustrated in Tables 1 through 3 are exemplary only. Different values of L1,
L2,
and/or L3, whether greater and lesser than the values shown in Tables 1
through 3,
may be selected in another embodiment to achieve other coupled shaft lengths
and
other increments between possible shaft lengths. Additional modular shafts may
be
introduced having additional varying length (e.g., a selected length L4 or L5
that is
different from L1, L2 and L3) to realize other combinations of shafts to
realize
foundation pier or piles in other lengths using single sets of multiple sets
of modular
shafts.
[00107] Therefore, to a foundation pier or pile installer having a
relatively small inventory of modular shafts 400 of different axial length L,
assembly
of modular systems is possible having a selected combined shaft length to meet
the
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'
unique needs of particular projects at installation sites and/or soil
conditions at each
site. The installer need not order conventional shafts of specific lengths,
sometimes
of a custom fabricated length, to meet the unique needs of a particular
installation.
Delay associated with obtaining shafts ordered specifically for a given job
site are
avoided and jobs may be completed much more quickly using the modular shafts
400.
[00108] By virtue of the modular shafts 400 as described, a
foundation pier or pile installer also need not undertake additional work to
utilize
conventional shafts that may be in hand, but which are not the optimal length
for a
given job. As an example of such a scenario, consider a job site that requires
a
foundation piling of 144 inch length to support a particular foundation in
view of soil
conditions at the foundation site, but the installer only has conventional 84
inch piles
on hand. To avoid cost and delay of acquiring a (possibly custom fabricated)
additional shaft or shafts to provide the ideal combined length of 144 inches,
an
installer may opt to use two of the 84 inch conventional shafts on hand to
install the
foundation support pile instead. Of course, this conventionally means that the
combined shaft length exceeds the 144 inches needed and accordingly either
means
that the installer has to drive the coupled 86 inch shafts deeper into the
ground to
complete the installation, or cut off the excess shaft length at the top end
and drill
holes in the top shaft to make the required connections at the top end of the
shaft to
another component (e.g., a foundation support bracket) to complete the
installation.
Either way, installation time and difficulty is presented, and in the latter
case,
reliability issues may result via difficulty in properly aligning fasteners to
complete
connections, causing increased mechanical stress on the shafts and fasteners
and
deformation of the shafts and/or fasteners.
[00109] Following the examples above, however, the modular shafts
400 including the self-aligning coupler features as seen in Tables 1 and 2 may
be
quickly assembled having a combined shaft length of 147 inches (just above the
required 144 inch length) on site without delay and avoid additional work
required by
longer shafts to drive them much farther into the ground or to cut off the
excess shaft
length and establish connections after cutting the upper shaft per the
discussion above.
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Likewise, the modular shafts 400 shown in Table 3 can be assembled to the
exact 144
inch length required of this installation and therefore requires no extra work
to drive
the piling into the ground beyond the point required. Over a large number of
jobs, the
modular shafts 400 can realize significant time and labor savings in
completing jobs
in these aspects. Considering that the fastener holes are self-aligning with
one another
to make connections between the couplers provided in the modular shafts of
Tables 1
and 2 system reliability is practically ensured.
[00110] From a modular component manufacturer level or distributor
level, the modular shafts 400 can quickly be provided to customer installers
without
customized fabrication and delay to provide custom fabricated shafts uniquely
suited
to meet specific requirements. In the scenario described above, if a
particular
foundation support system requires a piling shaft length of about 144 inches,
the
manufacturer or distributer can immediately ship a large and intermediate
shaft 400 in
the examples of Tables 1 and 2 or Table 3 (providing a combined shaft length
of 147
inches or 144 inches) instead of custom fabricating one or more shafts to meet
the
desired 144 inch length and shipping them post-fabrication. Delay and
increased
costs of custom fabricated shafts at the manufacturer level and distributor
level may
therefore be reduced, if not eliminated using modular shafts 400.
[00111] Shafts 400 of different lengths as described may be quickly
and easily connected to one another in modular form to establish the cross-
bolt and
cross-lock, rotational torque transmitting coupler benefits described above.
The shafts
400 can be fabricated in different cross-sectional shapes including circular,
square,
hexagonal, or another shape as desired. Shafts 400 of different cross-
sectional shape
can easily be connected to one another via the couplers 202, 204 described.
[00112] Additional modular foundation support components may be
provided for assembly with the modular shaft components 400. For example, a
foundation support bracket could be provided with an outer coupler 204 for
assembly
with the shaft end 402 including the inner coupler 202, and a foundation
support shaft
including a beveled end 114 and helical auger 110 could be assembled to the
end 404
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' of the shaft 400 via an inner coupler 402. More than one shaft 400 may be
assembled
between the foundation support bracket and a shaft including a beveled end and
auger.
Different type of brackets, different types of tips including beveled ends or
other
features, or different types of auger components and configurations may
likewise be
provided, in the same or different axial lengths, to complete various
different types of
modular foundation support systems including modular shaft(s) 400 or mating
coupler
features to meet the needs of specific installations.
[00113] While in the example shown, the shaft 400 includes the
inner coupler 202 on the first end 402 and the outer coupler 204 on the second
end
404, in an alternative embodiment the two ends 402, 404 of the shaft 400 could
be
provided with the same type of coupler (e.g., either the inner coupler or the
outer
coupler) instead of different types of couplers (e.g., inner coupler on one
end and
outer coupler on the other end as shown). So long as the respective ends 402,
404 of
the modular shaft 400 are mated with the complementary inner or outer coupler
of
additional shafts 400 or other foundation support components having mating
coupler
features as discussed above, the beneficial cross-bolt and cross-lock,
rotational torque
transmitting coupler benefits described above may be realized in the mating
modular
components in the foundation support system.
[00114] Figure 12 illustrates an exemplary embodiment of a modular
foundation support system 420 including the modular foundation shaft 400 in
the
form of an extension support pile coupled to a foundation support bracket 422
including an outer coupler 204 for mating engagement with the inner coupler
202 on
the first end 402 of the shaft 400. An end shaft 424 in the form of a primary
support
pile having an inner coupler 202 on end and the beveled tip 114 and auger 110
is
coupled to the end 404 of the shaft 400 via the outer coupler 204. The auger
110 is
shown coupled to the end shaft 110 at a distance from the beveled tip 114,
although
the auger 110 could be another modular component having a coupler 202 or 204.
More than one auger 110 may be provided on the shaft 424, and more than one
different type of auger may be provided on the end shaft 424 or for modular
assembly
to the end shaft 424 as separately provided modular components. The end shaft
424
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may be provided in different axial lengths, in addition to the modular shaft
being
provided in different axial lengths, such that various combinations of end
shafts and
modular shafts may be selectively assembled to provide different combined pile
lengths as described above.
[00115] As installed, the end shaft 424 is driven into the ground via
the beveled tip 114 and auger 110 with the inner coupler 202 of the shaft 424
exposed. The outer coupler 204 of the shaft 400 at the end 404 is then mated
with the
exposed inner coupler 202 of the shaft 424 in the interlocking, self-aligning
and
torque transmitting manner described above. Cross-bolt fasteners may be
inserted
through each of the mated couplers 202, 204 via the fastener openings provided
to
positively secure the shafts 424 and 400, and the coupled shafts 400, 424 may
then be
driven further into the ground while the cross-bolt fasteners are mechanically
isolated
from torque transmission. The inner coupler 202 of the shaft 400 and the outer
coupler 204 of the bracket assembly 422 are then mated in the interlocking,
self-
aligning manner described above, and the bracket assembly 422 is finally
placed in
position supporting the foundation. While one modular shaft 400 is shown
between
the bracket 422 and the end shaft 424, if needed or as desired, additional
shafts 400 of
the same or different length L may be assembled between the bracket 422 and
the end
shaft 424.
[00116] While Figure 12 shows a particular coupling arrangement
including inner and outer couplers 202, 204 connecting the mated components on
each end 402, 404 of the shaft 400, the coupling arrangement could be
effectively
reversed in another embodiment. For example, the shaft 400 could be inverted
for
assembly to an end shaft 424 provided with an outer coupler 204 rather than an
inner
coupler 202 as shown in Figure 12, and a bracket 422 may likewise be provided
with
an inner coupler 202 instead of the outer coupler 204 as shown for mating with
the
opposite end of the shaft 400 to that shown. Likewise, the shaft 400 could be
provided with outer couplers 204 on each end for assembly with a bracket and
end
shaft including an inner coupler 402, or the shaft 400 could be provided with
inner
couplers 202 on each end for assembly with a bracket and end shaft including
an outer
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=
coupler 404. As long as each component connection includes a mating inner and
outer coupler, the locations or orientations of the inner and outer couplers
in the
respective components of the modular system may be varied.
[00117] Figure 13 illustrates another exemplary embodiment of a
modular foundation system 440 including the modular foundation shaft 400 in
the
form of an extension support pile coupled to a foundation support plate 442
including
an outer coupler 204 which mates with the inner coupler 202 on the first end
402 of
the shaft 400. The end shaft 424 in the form of a primary support pile having
an inner
coupler 202 on end and the beveled tip 114 and auger 110 opposite the inner
coupler
202 is coupled to the outer coupler 204 at the end 404 of the shaft 400. The
modular
foundation support system 442 is installed in a similar manner to that
described
above. If needed, additional shafts 400 of the same or different length may be
assembled between the bracket 442 and the end shaft 424.
[00118] It should now be realized that various different types of
brackets, support plates, other types of support components, and various
accessories
as desired may be provided for modular assembly in a selected combination and
in a
selected shaft length to construct a foundation support system. As one
example, if
two different types of modular component support brackets, two different types
of
modular component support plates, two different types of modular component end
shafts 424 including different ends or tips, and two different types of
helical auger
configurations are provided in the end shafts as or as separate modular
components,
16 different foundation support assemblies are provided using combinations of
such
modular components, apart from the various combined shaft lengths made
available
from modular components having different shaft length as discussed above.
[00119] As another example, if three types of each of the four
modular components is made available, 81 different foundation support systems
may
be assembled from the various combinations of components, apart from the
various
combined shaft lengths made available from the modular components having
different
shaft length. Therefore, by providing a relatively small set of modular
components of
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each type, a large number of foundation support systems can be assembled and
installed to meet a spectrum of needs presented to installers in different
locations to
meet the needs of a great variety of installation sites and specific
foundations for
varying building sites. As such, modular foundation systems can be more or
less
universally used to meet the needs of any job that an installer may expect to
encounter.
[00120] In contemplated embodiments, the modular components
including the couplers described could be provided as kits to be assembled on-
site by
an installer, with each kit including the components needed to install a
particular type
of foundation support system. In other embodiments, a set of modular
components
may be provided to the installer that can be used to construct different types
of
modular systems, with the installer selecting a desired combination of modular
components to construct a foundation support system meeting particular needs
for
particular job sites and/or different projects at the same or different sites.
As such,
instead of specific kits of component parts a distributor may obtain a number
of each
modular component desired and selectively mix and match the modular components
to assemble an appropriate modular support system for a specific site from the
modular components already at hand.
[00121] Figures 14-19 are various views of another embodiment of
an inner coupler 460 for a modular foundation support piling assembly
(sometimes
referred to as a modular foundation support pier assembly) of the present
invention.
The inner coupler 460 may be used in lieu of the coupler 202 to assemble a
modular
foundation support system of the type described above.
[00122] The inner coupler 460 is similar in aspects to the inner
coupler 202 as described above but includes four elongated, axially extending
ribs
462 projecting outwardly from a round body 464 rather than two. The inner
coupler
460 likewise includes a seating surface 466 to complete a coupled connection
to a
mating coupler such as the outer coupler 500 described below, and a collar
portion
468 including a counter bore 470 configured to receive a distal end of a shaft
such as
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the shaft 400, end shaft 424, a bracket shaft, a support plate shaft, or any
other shaft or
modular component described herein to facilitate assembly of modular
foundation
support systems.
[00123] Each of the four axially extending ribs 462 in the inner
coupler 460 extend from and between the seating surface 466 to a seating
surface 472
on the distal end of each rib 462 which extends obliquely from the round body
464 to
define an inwardly tapered distal end at the location of each rib 462. The
ribs 462 are
evenly spaced around the circumference of the round body 464 at 90 center
positions
from one another. The ribs 462 extend outwardly from the round outer surface
of the
body 464 at an increased radius relative to the body 464 such that the ribs
462 project
outwardly from the body 464. As seen in Figures 14 and 17, the ribs 462 are
elongated in the longitudinal, axial length direction and relatively narrow in
the
lateral, width direction. Further, each rib 462 has a constant or uniform
width in the
lateral direction.
[00124] As best shown in Figures 16 and 19, however, the ribs 462
in the example shown do not have the same width relative to one another.
Specifically, the ribs 462 include a first pair of ribs 462a oppositely
positioned from
one another at about 180 positions on the round body 464. A second pair of
ribs
462b is also oppositely positioned from one another at about 180 positions
from one
another on the round body 464, but the pair of ribs 462b are offset 900 in
position with
respect to the first pair of ribs 462a. The first pair of ribs 462a is
proportionally larger
than the second pair of ribs 462b in terms of occupying a greater portion of
the
circumference of the body 464 in the width dimension. In other words, the ribs
462a
are wider on the arcuate circumference of the body 464 than the ribs 462b,
while
being the same axial length as the ribs 462b. The wider ribs 462a, in
combination
with the relatively smaller width ribs 462b effectively serve as primary and
secondary
torque transmission features as well as primary and secondary alignment
features
when mated with a complementary coupler described below. In another
contemplated
embodiment, however, the ribs 462a and 462b may the same width rather than
different.
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[00125] The body 464 of the inner coupler 460 also includes, as
shown in the Figures, one or more pairs of fastener holes or openings 474, 476
defined therethrough to allow for fastening of the inner coupler 460 and a
complementary outer coupler 500 described below. Each of the pairs of fastener
holes or openings 474, 476 is angularly offset and axially offset from one
another and
are further spaced from the ribs 462 on the body 464 in the example shown.
That is,
the fastener openings 474, 476 are respectively located between respective
ones of the
ribs 462a and 462b on the body 464. In the specific example shown, the ribs
462a,
462b are respectively located at 00, 90 , 180 , and 270 positions on the
circumference of the body 464 as seen in Figures 16 and 19, whereas the
fastener
openings 474, 476 are located at 45 , 135 , 225 and 315 positions on the
body 464.
As such, the fastener holes 474, 476 extend through the relatively thin
portion of the
outer body 464 instead of through the thicker portions where the ribs 462a,
462b
extend.
[00126] In alternative embodiments, one or both of the fastener holes
474, 476 could be considered optional and may be omitted as fasteners are not
necessarily required to complete interlocking connections of the modular
components
described. Additional, and to the extent that fastener holes are desired, such
fastener
holes could be provided at locations other than those specifically shown and
described
above in the illustrated embodiment of Figures 14-19.
[00127] Figures 20-26 are various views of an exemplary
embodiment of an outer coupler 500 for completing a modular foundation support
pier assembly in combination with the inner coupler 462 shown in Figures 14-
19.
The outer coupler 500 may be used in lieu of the outer coupler 204 to assemble
a
modular foundation support system.
[00128] The outer coupler 500 includes four axially extending
grooves 502 that are formed in a round inner surface 504 of a body 506. The
body
506 is formed with a seating surface 508 on a distal end thereof. Opposite the
seating
surface 508, the outer coupler 500 includes a flange 510 defining a cavity 512
that
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receives a distal end of a shaft such as the shaft 400, end shaft 424, a
bracket shaft, a
support plate shaft, or any other shaft or modular component described herein
to
facilitate assembly of modular foundation support systems. The outer coupler
500
may be mated with any modular component that includes the inner coupler 460 or
the
alignment features of the inner coupler 460.
[00129] Each of the four axially extending grooves 502 extends from
and between the seating surface 508 to a seating surface 514 on which extends
obliquely from round body 464. The axially extending grooves 502 are spaced
around the circumference of the round body 506 at 90 positions from one
another as
shown.
[00130] As best shown in Figures 22 and 23, the four axially
extending grooves 502 includes a first pair of axially extending grooves 502a
oppositely positioned from one another on the round body 506 and a second pair
of
axially extending grooves 502b oppositely positioned from one another on the
round
body 506 but in a 90 position with respect to the first pair of ribs 502a.
The first pair
of axially extending grooves 502a is proportionally larger than the second
pair of
axially extending grooves 502b in terms of occupying a greater portion of the
circumference of the body 506. In other words, the axially extending grooves
502a
are wider on the circumference of the body 506 than the axially extending
grooves
502b. The grooves 502a, 502b are complementary in shape to the ribs 462a, 462b
of
the inner coupler 460 such that the grooves 502a, 502b are elongated in the
longitudinal, axial length direction and relatively narrow in the lateral,
width
direction. Further, each groove 502 has a constant or uniform width in the
lateral
direction.
[00131] The body 506 of the outer coupler 500 also includes, as
shown in the Figures, first and second pairs of fastener holes or openings
514, 516
extend through the body 506 which are angularly offset from one another and
axially
offset from one another to allow for fastening of the outer coupler 500 and
the
complementary inner coupler 460 described above. The fastener holes or
openings
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514, 516 are further spaced from and between the respective grooves 502a, 502b
in
respectively similar positions on the body 506 as the corresponding fastener
holes in
the inner coupler 460. In alternative embodiments, one or both of the fastener
holes
514, 516 could be considered optional and may be omitted as fasteners are not
necessarily required to complete interlocking connections of the modular
components
described. Likewise, alternative locations of fasteners holes are possible in
other
embodiments.
[00132] Like the couplers 202, 204 described above, when the distal
end of the inner coupler 460 is partly inserted into the distal end of the
outer coupler
500 simple rotation of the outer coupler 500 causes automatic alignment of the
ribs
462a, 462b and the grooves 502a, 502b, and once so aligned, the outer coupler
500
will fall into place in engagement with the inner coupler 460 via
gravitational force.
Therefore, the ribs 462a, 462b and the grooves 502a, 502b serve as a primary
and
secondary self-alignment features that makes it easier to connect shafts to
one another
other in a modular foundation support system assembly. When the ribs 462a,
462b
and grooves 502a, 502 are mated, a complete torque transmitting interlocking
engagement of the couplers 460, 502 is established, and the fastener holes in
each
coupler are self-aligning with one another to quickly and easily secure the
couplers
460, 500 to one another with bolts in a cross-bolt arrangement.
[00133] Because the couplers 460, 500 include the respective pairs of
ribs 462a, 462b and pairs of grooves 502a, 502b instead of one pair of ribs
and
grooves as in the couplers 202, 204 described above, the couplers 460, 500
have
greater structural strength for use with larger foundation support piles or
piers that are
subject to increased torque and rotational force while being installed. As
best seen in
Figure 22, the structural strength needed to withstand greater torque
transmission
results at least in part in a square shaped outer surface of the body 506 of
the outer
coupler 500. The square shape also facilities cross-bolt fastener connections
with
mechanical isolation of the fasteners from torque.
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[00134] The couplers 460, 500 may be provided on opposing ends of
the same modular shaft such as that described above in lieu of the couplers
202, 204
to provide an alternative modular shaft to the shaft 400 described above. For
example, the couplers 460, 500 may be integrally provided in the shaft 400 via
casting
in the fabrication of a shaft 400, swaged on the shaft ends 402, 404 in a
forging
process, provided on a separate body and welded on the shaft ends 402, 404, or
otherwise connected to the shaft 400 in another manner. Other modular
foundation
components such as the end shaft 424, support bracket 422, support plate 442
or other
accessories may be provided with one of the couplers 460, 500 for connection
to the
modular shaft at its respective ends in a similar manner to that described
above in the
modular foundation support systems 420 and 440 (Figures 12 and 13).
[00135] While embodiments of couplers 202, 204 have now been
described as having two ribs mating with two grooves and embodiments of
couplers
460, 500 are described as having four ribs mating with four grooves,
additional
embodiments of couplers, or shafts including such coupling features, are
possible
having other numbers of ribs or grooves. For example only, three ribs and
three
grooves may be provided in another embodiment for modular assembly. The number
of ribs and grooves in such alternative embodiments and the locations of the
ribs and
grooves may necessitate changes in the number of fastener openings provided
and the
locations of the fastener openings in such embodiments such that single
fastener
connections may result or dual fastener connections that are not orthogonal.
As noted
above, however, fasteners are not necessarily required in all instances, and
in some
cases fastener holes may be omitted.
[00136] Figures 27 through 30 are various views of an exemplary
embodiment of a drive tool coupler 530 for a modular foundation support piling
including the inner coupler 460 shown in shown in Figures 14-19. The drive
tool
coupler 530 includes a coupler body 532 having a drive tool end 534 bad a
shaft
coupling end 536. The coupling end 538 includes a seating surface 538 in
communication with a plurality of axially extending grooves 540 that engage
with the
ribs 462 of the inner coupler 460 as described above in a rotationally
interlocked,
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torque transmitting arrangement. A pair of fastener openings 542 is provided
in the
body 532 for positive attachment to a drive tool (not shown) for installing a
shaft 400
or 424 in a modular foundation support assembly as described above. The drive
tool
coupler 530 is compatible with each of the end shaft 424 and the modular shaft
extension 400 such that each can be separately attached to the drive tool for
driving
them into the ground, first the shaft 424 and then the shaft 400 after
attachment to the
shaft 424 via the coupling features provided.
[00137] While the drive tool coupler 530 is complementary to the
inner coupler 460 for mating engagement therewith, in another embodiment the
drive
tool coupler may be adapted to complement the outer coupler from mating
engagement therewith by providing the drive tool coupler with ribs instead of
grooves. In certain embodiments, more than one drive tool may be made
available for
use by a foundation support system installer, including but not necessarily
limited to a
drive tool coupler configured to mate with one of the couplers 202, 204
described
above. So long as the drive tool coupler utilized matches the coupler features
of the
modular component being driven into the ground, the drive tool coupler
facilitates
drive tool engagement via self-aligning coupling features for quick connection
and
disconnection of the drive tool coupler to install a modular foundation
support system.
[00138] Figures 31-35 are various views of another embodiment of a
foundation support shaft 550 including an integral inner coupler 552 on one
end and
an integral outer coupler 554 on the other end. The axially extending ribs 224
on the
inner coupler 552 and the axially extending grooves 252 on the outer coupler
554
provide for interlocking torque transmission to mating components having
complementary coupler features. Pairs of fastener openings 234, 236 are
provided to
facilitate cross-bolt connections while mechanically isolating the fasteners
used.
When the ribs 224 and grooves 552 are aligned, which may be accomplished by
relative rotation of the ribs 224 with respect to the grooves 552, connected
foundation
support components may fall into place with fastener openings 234, 236 being
aligned
to receive the fasteners. The shaft 550 may be filled with cementitious
material as
described above.
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=
[00139] The couplers 552, 554 may be integrally provided in the
shaft 550 via casting in the fabrication of a shaft 550, swaged on the shaft
ends in a
forging process, welded on the shaft ends, or connected to the shaft 500 in
another
manner. To accommodate increased torque transmission forces, ribs 224 and
grooves
252 are proportionally larger on a shaft of increased diameter. The flared,
built-up
material around the grooves 252 partly encroaches the fastener openings 234,
236 on
the corresponding end of the shaft and the fastener openings extending through
relatively thicker material on the shaft end than an otherwise similar shaft
550
fabricated for a lesser torque transmission. The shaft 550 may be used in the
assembly of modular foundation support systems as described above including
mating
couplers or component having integral coupling features.
[00140] The benefits and advantages of the inventive concepts
described herein are now believed to have been amply illustrated in relation
to the
exemplary embodiments disclosed.
[00141] An embodiment of a modular foundation support system has
been disclosed including a first foundation support component having a first
distal end
and a plurality of axially elongated ribs extending from an outer surface of
the first
distal end, and a first pair of fastener holes extending through the outer
surface
proximate the first distal end. A second foundation support component is also
provided having a second distal end and plurality of spaced apart, axially
elongated
grooves on an inner surface of the second distal end, and a second pair of
fastener
holes extending through the inner surface of proximate the second distal end.
When
the plurality of axially elongated ribs are mated with the plurality of
axially extending
grooves, the first and second foundation support components are rotationally
interlocked with one another and the first and second pair of fastener holes
are self-
aligning with one another to receive a first fastener therethrough such that
the fastener
is mechanically isolated from rotational torque transmission.
[00142] Optionally, the plurality of ribs may include a first pair of
ribs opposing one another on the outer surface. The plurality of ribs may
include a
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second pair of ribs opposing one another on the outer surface between the
first pair of
ribs. The first pair of ribs may be proportionally larger than the second pair
of ribs.
Each of the first pair of ribs and the second pair of ribs may include an
angled seating
surface facilitating self-alignment of the plurality of ribs and the plurality
of grooves.
[00143] The first foundation support component shaft may include a
third pair of fastener openings axially offset and angularly offset from the
first pair of
fastener openings proximate the first distal end, and the second foundation
support
component shaft may include a fourth pair of fastener openings axially offset
and
angularly offset from the second pair of fastener openings proximate the first
distal
end. When the plurality of axially elongated ribs are mated with the plurality
of
axially extending grooves, the first and second pair of fastener holes are
self-aligning
with one another to receive a second fastener therethrough such that the
second
fastener is mechanically isolated from rotational torque transmission. The
first and
second fasteners may be received to extend orthogonally to one another.
[00144] The first and second foundation support component may
each have one of a circular, square, or hexagonal cross-section. One of the
first
foundation support component and the second foundation support component may
be
a modular shaft having an axial length extending between opposing distal ends
thereof, and each of the opposing distal ends may include either the plurality
of
axially elongated ribs or the plurality of axially elongated grooves. One of
the
opposing distal ends of the modular shaft includes the plurality of axially
elongated
ribs and the other of the opposing distal ends of the modular shaft includes
the
plurality of axially elongated grooves.
[00145] As further optional features, the first pair of fastener
openings may be spaced from each of the plurality of axially elongated ribs on
the
first distal end, and the inner surface of the second distal end may be round
and an
outer surface of the second distal end is square. Each of the first foundation
component and the second foundation component may be a steel shaft, and the
plurality of axially elongated ribs or the plurality of axially extending
grooves may be
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cast into the respective steel shaft. The plurality of axially elongated ribs
or the
plurality of axially extending grooves may alternatively be swaged on the
respective
steel shaft, or may be coupled to the respective steel shaft via a body welded
to the
steel shaft.
[00146] The first foundation support component may be a steel
foundation support pier, and the steel foundation pier may be provided with a
helical
auger. The second foundation support component may be selected from the group
of
a modular foundation support pier extension, a foundation support bracket, a
foundation support plate, and a drive tool coupler.
[00147] The modular foundation support system may also be
provided in combination with a drive tool coupler having a complementary
coupler
feature to each of the first and second foundation support components. The
drive tool
coupler may include a plurality of axially extending grooves.
[00148] Another embodiment of a modular foundation support
system has been disclosed including a modular foundation support system having
a
first modular foundation support component comprising at least one elongated
modular shaft selected from a set of modular elongated shafts including shafts
of
respectively different axial length for constructing a foundation support pier
in a
selected one of a plurality of foundation support pier lengths to support a
building
foundation at an installation site. Each of the plurality of modular elongated
shafts in
the set has opposing distal ends and a plurality of torque transmitting
coupler features
proximate each of the opposing distal ends. The plurality of torque
transmitting
coupler features proximate each of the opposing distal ends includes outwardly
projecting axially elongated ribs or inwardly depending axially elongated
grooves for
interlocking torque transmitting engagement with a second modular foundation
support component having complementary coupler features.
[00149] Optionally, the plurality of axially extended ribs may
include at least a pair ribs having a seating surface obliquely extending from
the
respective distal end of the modular shaft. The plurality of axially extended
ribs may
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also include a first rib and a second rib having proportionally different
size. The first
rib and the second rib may have a proportionally different circumferential
width on
the outer surface. The plurality of axially extended ribs may include at least
four
axially extending ribs.
[00150] As further options, the plurality of axially extended grooves
may be located between a seating surface obliquely extending from the
respective
distal end of the modular shaft. The plurality of axially extended grooves may
include a first groove and a second groove having proportionally different
size. The
first groove and the second groove may have a proportionally different
circumferential width on the inner surface. The plurality of axially extended
grooves
may include at least four axially extending grooves.
[00151] A first pair of fastener holes may optionally be provided on
each of the opposing distal ends of the first modular component, each of the
first pair
of fastener holes being spaced from each of the coupler features on the
respective
opposing distal ends. The second modular foundation support component includes
a
distal end with coupler features complementary to one of the opposed distal
ends of
the first modular foundation support component, and a second pair of fastener
openings spaced from the coupler features in second the modular foundation
support
component, wherein the first pair of fastener holes in the first modular
foundation
support are self-aligning with the second pair of fastener holes in the second
modular
foundation support when the coupler features of the second modular foundation
support component are mated to the coupler features of one of the opposing
distal
ends of the first modular foundation support component, whereby a first
fastener may
be received in the first and second pair of fastener holes in mechanical
isolation from
torque transmission by the mated coupler features. Additionally, the first
modular
foundation support component may optionally include a third pair of fastener
holes
axially and angularly offset from the first pair of fastener holes on each of
the
opposing distal ends of the first modular foundation support component,
wherein the
second modular foundation support component further comprises a fourth pair of
fastener holes axially and angularly offset from the second pair of fastener
holes,
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'
wherein the third pair of fastener holes in the first modular foundation
support
component are self-aligning with the fourth pair of fastener holes in the
second
modular support component when the coupler features of the second modular
foundation support component are mated to the coupler features of one of the
opposing distal ends of the first modular foundation support component,
whereby a
second fastener may be received in the third and fourth pair of fastener holes
in
mechanical isolation from torque transmission by the mated coupler features.
The
first and second fasteners extend orthogonally to one another.
[00152] One of the opposing distal ends of the first modular
foundation support component may include the plurality of axially elongated
ribs and
the other one of the opposing distal ends may include the plurality of axially
elongated grooves. The coupler features may be cast into at least one of the
opposing
distal ends of the first modular foundation support component, swaged on at
least one
of the opposing distal ends of the first modular foundation support component,
or
separately provided and welded to the distal end.
[00153] An embodiment of a coupler assembly for connecting a first
modular foundation support component to a second modular foundation support
component in a modular foundation support system has also been disclosed. The
coupler assembly includes an outer coupler for an end of the first foundation
support
component, the outer coupler comprising an inner surface formed with at least
one
pair of axially extending grooves extending between a seating surface
extending
obliquely on a distal end of the outer coupler, and an inner coupler for an
end of the
second foundation support component. The inner coupler includes an outer
surface
formed with at least one pair of axially extending ribs having an obliquely
extending
seating surface on a distal end on the inner coupler. When the at least one
pair of
axially extending ribs and the at least one pair of axially extending grooves
of the
inner coupler and the outer coupler are engaged in a self-aligning manner via
the
seating surfaces, an interlocking torque transmission structure is established
between
the end of the first foundation support component and the end of the second
foundation support component.
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[00154] Optionally, the at least one pair of ribs includes a first pair of
ribs and a second pair of ribs of proportionally different size than the first
pair of ribs.
The outer coupler may include a round inner surface and a square outer
surface. The
first and second modular foundation support components are each selected from
the
group of a primary support pile, an extension pile, a support plate, and a
support
bracket. One of the first and second modular foundation support components may
include a helical auger.
[00155] An embodiment of a modular coupled shaft assembly has
also been disclosed including a first modular foundation support component and
a
second modular foundation support component in a modular foundation support
system. The first modular foundation support component and the second modular
support component are each selected from a set of otherwise similar modular
support
components having different predetermined axial lengths. The modular coupled
shaft
assembly including: an outer coupler for an end of the first modular
foundation
support component, the outer coupler comprising an inner surface formed with
at least
one pair of axially extending grooves extending between a seating surface
extending
obliquely on a distal end of the outer coupler; and an inner coupler for an
end of the
second modular foundation support component, the inner coupler comprising an
outer
surface formed with at least one pair of axially extending ribs having an
obliquely
extending seating surface on a distal end on the inner coupler. When the at
least one
pair of axially extending ribs and the at least one pair of axially extending
grooves of
the inner coupler and the outer coupler are engaged in a self-aligning manner
via the
seating surfaces, an interlocking torque transmission structure is established
between
the end of the first modular foundation support component and the end of the
second
modular foundation support component, providing an assembled axial length
corresponding to the combined selected length of the first modular support
component
and the second selected modular support component.
[00156] Optionally, the outer coupler may include a round inner
surface and a square outer surface. The first and second modular foundation
support
components may each be selected from the group of a primary support pile and
an
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' extension pile. One of the first and second modular foundation support
components
may include a helical auger. The first modular foundation support component
and the
second modular foundation support component may be filled with a cementitious
material.
[00157] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person skilled in
the art to
practice the invention, including making and using any devices or systems and
performing any incorporated methods. The patentable scope of the invention is
defined by the claims, and may include other examples that occur to those
skilled in
the art. Such other examples are intended to be within the scope of the claims
if they
have structural elements that do not differ from the literal language of the
claims, or if
they include equivalent structural elements with insubstantial differences
from the
literal languages of the claims.
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