Underpinning device with pressurized grout anchor system

Abstract

An underpinning device for support a structure is provided. The underpinning device is anchored within the ground using a grout or cement. The underpinning device comprises a rod having a proximal rod end and a distal rod end. A first interacting element is coupled to the proximal rod end and is encased in the slab of a building. A second interacting element is coupled to the distal rod end and include a removable tip. Upon insertion into the ground, the tip dissociates from the second interacting element creating an opening at the distal rod end. A fluid, such as grout and/or cement is injected into the pipe and extruded through channels within the rod. The fluid is then allowed to cure thereby anchoring the underpinning device within the ground.

Claims

1. An underpinning system for supporting a structure comprising: an underpinning device configured to be secured to a link residing within a foundation of the structure prior to pouring cement around the link to create the foundation, the underpinning device including: a rod having a proximal rod end, a distal rod end, and a rod body encasing a cavity, the rod body extending from the proximal rod end to the distal rod end and having a length sufficient to extend though the foundation of a structure and into a ground below the foundation; a plurality channels formed between the cavity and an environment exterior to the rod, wherein at least some of the plurality of channels are longitudinally offset from each other about a longitudinal axis of the rod; a first interacting element coupled to the proximal rod end, the first interacting element including: a platform having a lateral span greater than a diameter of the rod, a first platform surface, a second platform surface, and a platform body extending between the first and the second platform surfaces, the first platform surface including: a first alignment protrusion extending away from the first platform surface and configured to receive the link within an alignment aperture formed between a first alignment end and a second alignment end of the first alignment protrusion; a second alignment protrusion extending away from the first platform surface and configured to receive the link within an alignment aperture formed between a first alignment end and a second alignment end of the second alignment protrusion; the second alignment protrusion aligned with the first alignment protrusion such that alignment apertures in the first and alignment protrusions are axially aligned to receive the link; wherein the first alignment protrusion is laterally spaced from the second alignment protrusion; a first adapter extending away from the second platform surface, the first adapter including a socket formed within a portion of the first adapter and configured to receive the proximal rod end, thereby coupling the first interacting element to the proximal rod end; a second interacting element coupled to the distal rod end, the second interacting element including: a second adapter having a first adapter end, a second adapter end, and an adapter body encasing a bore, the adapter body extending from the first adapter end to the second adapter end; a blade extending outwardly from at least a portion of an outer surface of the adapter body, wherein the blade is configured to drill a hole into the ground upon the rod rotating about a central longitudinal axis extending through the proximal rod end and the distal rod end; an open fluidic channel extending through the first interacting element and into the cavity in the rod, thereby providing a path for a fluidic anchoring material to enter the first interacting element and exit the plurality of channels in the rod to deliver the fluidic anchoring material in the ground below the foundation, wherein the first alignment protrusion and the second alignment protrusion are laterally spaced out of axial alignment and on opposing lateral sides with respect to the open fluidic channel; wherein the underpinning device is configured to reside both within the foundation and the ground to support the structure when secured within the ground.

2. The underpinning device of claim 1, further including: a tip configured to be at least partially received within the bore of the second adapter when a locking mechanism is in a locked configuration, and when the locking mechanism is in an unlocked configuration, the tip is configured to be spaced apart from the second adapter; and wherein the locking mechanism further includes a flange extending away from a portion of the tip and a locking channel formed within the adapter body, such that when in the locked configuration the tip is disposed fully within the locking channel and when in the unlocked configuration the tip is disposed away from the locking channel.

3. The underpinning device of claim 1, wherein the cavity is configured to receive a pressurized fluid to anchor the underpinning device within the ground.

4. The underpinning device of claim 1, wherein the socket includes a first set of threads configured to threadedly engage with a second set of threads disposed at the proximal rod end, wherein engagement of the first set of threads with the second set of threads secures the first interacting element to the proximal rod end.

5. The underpinning device of claim 1, wherein the first adapter end includes a third set of threads configured to threadedly engage with a fourth set of threads disposed at the distal rod end, wherein engagement of the third set of threads with the fourth set of threads secures the second interacting element to the distal rod end.

6. The underpinning device of claim 1, wherein the link is a section of rebar.

7. The underpinning device of claim 1, wherein the platform is rectangular.

8. An underpinning device anchored within the ground for supporting a structure comprising: a rod having a proximal rod end, a distal rod end and a rod body encasing a cavity, the rod body extending from the proximal rod end to the distal rod end, each of the proximal and distal rod ends defining a rod opening; a plurality of tabs disposed about a perimeter of the rod, each tab including a first tab end formed integrally with the rod body and a terminal second tab end spaced apart from the rod body, such that a channel is formed between the cavity and an environment exterior to the rod; a first interacting element coupled to the proximal rod end, the first interacting element including: a platform having a first platform surface, a second platform surface, and a platform body extending between the first and the second platform surfaces, the first platform surface including an alignment protrusion extending away from the first platform surface and configured to receive a section of rebar within an alignment aperture formed between a first alignment end and a second alignment end of the alignment protrusion; a first adapter extending away from the second platform surface, the first adapter including a socket formed within a portion of the first adapter and configured to receive the proximal rod end, thereby coupling the first interacting element to the proximal rod end; a second interacting element coupled to the distal rod end, the second interacting element including: a tip comprising a flange extending away from at least a portion of the tip, the tip configured to be at least partially received within a bore of a second adapter and secured therein by a locking mechanism; the second adapter having a first adapter end, a second adapter end, and an adapter body encasing a second bore, the adapter body extending from the first adapter end to the second adapter end, each of the first and the second adapter ends defining an opening to the second bore, the second bore including a locking channel configured to receive the flange of the tip when the locking mechanism is in the locked configuration, when in the unlocked position, the flange is disposed away from the second adapter; a blade extending outwardly from at least a portion of an outer surface of the adapter body, wherein the blade is configured to drill a hole into the ground upon the rod rotating about a central longitudinal axis extending through the proximal rod end and the distal rod end, and wherein the underpinning device is configured to support the structure when secured within the ground.

9. The underpinning device of claim 8, wherein the socket includes a first set of threads configured to threadedly engage with a second set of threads disposed at the proximal rod end, wherein engagement of the first set of threads with the second set of threads secures the first interacting element to the proximal rod end.

10. The underpinning device of claim 8, wherein the first adapter end includes a third set of threads configured to threadedly engage with a fourth set of threads disposed at the distal rod end, wherein engagement of the third set of threads with the fourth set of threads secures the second interacting element to the distal rod end.

11. The underpinning device of claim 8, wherein the blade further includes a first blade portion and a second blade portion, the first blade portion abutting the outer surface of the rod body of the second adapter and the second portion having a tapered end forming a cutting edge.

12. The underpinning device of claim 8, wherein the platform is rectangular in shape.

13. The underpinning device of claim 8, wherein the section of rebar forms a section of foundation of the structure.

14. The underpinning device of claim 1, wherein the alignment aperture in the first alignment protrusion and the alignment aperture in the second alignment protrusion are sized to be less than double a diameter of the rod intended to pass therethrough.

15. The underpinning device of claim 1, wherein the plurality of channels formed in the rod are preconfigured as open channels.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:

(2) FIG. 1 depicts an in-use view showing a plurality of underpinning devices anchored within the ground and supporting a structure.

(3) FIG. 2 depicts a perspective view of the rod.

(4) FIG. 3 depicts a cross-sectional view of the rod taken along line A-A of FIG. 2.

(5) FIG. 4A depicts a top view of the underpinning support with a link disposed through the alignment protrusions.

(6) FIG. 4B depicts a side view of the underpinning support with a link disposed thro the alignment protrusions.

(7) FIG. 4C depicts a cut-away view taken along line B-B in FIG. 4A.

(8) FIG. 4D depicts a cut-away view taken along line B-B in FIG. 4A depicting the rod spaced apart from the socket.

(9) FIG. 5A depicts a side view of an embodiment of the underpinning support showing the first interacting element in the form of a corner piece secure to the rod.

(10) FIG. 5B depicts a top view of an embodiment of the underpinning support showing the first interacting element in the form of a corner piece.

(11) FIG. 6A depicts a side view of the second interacting element with the tip uncoupled from the second adapter.

(12) FIG. 6B depicts a top view of the tip of the second interacting element showing the flanges extending outwardly from a portion of the tip.

(13) FIG. 6C depicts a cross-sectional view of the second adapter taken along line C-C of FIG. 6A.

(14) FIG. 6D depicts a side view of an embodiment of the second interacting element and the distal rod end.

(15) FIG. 7A depicts a top view of the injection adapter.

(16) FIG. 7B depicts a cut-away view of the injection adapter of FIG. 7A taken along line D-D.

(17) FIG. 8 depicts an exemplary process-flow diagram of underpinning a structure using one or more underpinning devices.

DETAILED DESCRIPTION OF THE INVENTION

(18) In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part thereof, and within which are shown by way of illustration specific embodiments by which the invention may be practiced. It is to be understood that other embodiments may be utilized, and structural changes may be made without departing from the scope of the invention.

(19) As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the context clearly dictates otherwise.

(20) The present invention includes an underpinning device for supporting a structure. The underpinning device is drilled into the ground and anchored using a pressurized fluid that is allowed to cure. As shown in FIG. 1, the underpinning device 10 includes first interacting element 12 and second interacting element 14 coupled to rod 16. Underpinning devices 10 are secured within ground 18 to support structure 20 built upon foundation 22. Each underpinning device 10 is coupled to the next underpinning device 10 using one or more links 24. Links 24 may be uncoated rebar, galvanized steel rebar, stainless steel rebar, epoxy-coated rebar, or any other linking device or material known to tie one or more underpinning device 10 to the next in series. First interacting element is encased within foundation 22 to prevent movement of underpinning device 10 and to provide support for structure 20.

(21) As shown in FIG. 2, rod 16 includes proximal rod end 26, distal rod end 28, and rod body 30 defining cavity 32. Opening 34 is defined by each of the proximal 26 and distal 28 rod ends. Rod 16 may be formed from iron, steel, acrylonitrile-butadiene-styrene (ABS), nylon, polyvinylchloride (PVC), aluminum, brass, bronze, lead, nickel, steel, stainless steel, galvanized steel, carbon steel, titanium, wood, carbon fiber, or other suitable material. Further, rod 16 may have any number of cross-sectional geometries such as circular, triangular, square, or similar geometric shapes.

(22) FIGS. 2 and 3 depict a plurality of tabs 36 disposed about a circumference of rod 16. Tabs 36 may be spaced apart from one another and arranged in a pattern about the circumference of rod 16 or may be arranged in a pattern. In embodiments in which rod 16 is not circular, the plurality of tabs 36 are disposed about a perimeter of rod 16. Each tab includes first tab end 38 formed integrally with rod body 30 and a terminal second tab end 40 spaced apart from rod body 30 forming channel between cavity 32 and an environment external to rod 16. Tabs 36 are angled and arranged such that when the underpinning device 10 is being driven into ground 18, dirt and other debris is prevented from entering cavity 32 and blocking pressurized fluid 44 from being extruded during the injection process. Channel 42 permits pressurized fluid 44, injected within cavity 32, to be extruded through channel 42 to the environment external to rod 16. Pressurized fluid 44 may be grout, cement, adhesive, molten metal, and/or other material known to anchor underpinning device 10 within ground 18.

(23) As shown in FIGS. 4A-4D, first interacting element 12 includes platform 46 having first platform surface 48, second platform surface 50, and platform body 52 extending between each of the first 48 and second 50 platform surfaces. Platform 46 may include a variety of geometric shapes depending on the position of first interacting element 12 relative to structure 20 being supported. For example, when underpinning device 10 is positioned near the corner of structure 20, platform 46 may include first platform portion 49 and second platform portion 51 in an orthogonal relationship with one another forming a corner bracket as depicted in FIGS. 5A and 5B. In another embodiment, platform 46 may be square or rectangular in shape.

(24) Extending away from first platform surface 48, alignment protrusion 54 receives link 24 disposed within alignment aperture 56. In an embodiment, one or more alignment protrusions 54 may extend away from first platform surface 48. Alignment aperture 56 is formed between first alignment aperture end 58 and second alignment aperture end 60. Alignment aperture 56 may be any shape that is capable of receiving links 24 when linking one or more underpinning devices 10 to one another. Link 24 may be rebar—such as European rebar, carbon steel rebar, epoxy-coated rebar, galvanized rebar, glass-fiber-reinforced-polymer (GFRP), stainless steel rebar, or similar material.

(25) Extending away from second platform surface 50, first adapter 62 includes socket 64 formed within a portion of first adapter 62. Socket 64 is configured to receive proximal rod end 26 when first interacting element 12 is secured to proximal rod end 26. Socket 64 may include first set of threads 66 configured to threadedly engage with second set of threads 68 disposed on proximal rod end 26 to secure first interacting element 12 to rod 16. In an embodiment, first interacting element 12 is secured to rod 16 using a tang and locking strip mechanism, welding, adhesive, or any other method known in the art.

(26) Depicted in FIGS. 6A-6D, second interacting element 14 includes second adapter 70 having first adapter end 72, second adapter end 74, and adapter body 76 encasing bore 78. Adapter body 76 extends from first adapter end 72 to second adapter end 74 with each adapter end 72, 74 defining an opening. Extending outwardly from at least a portion of outer adapter surface 80 of adapter body 76, blade 82 is configured to drill a hole within ground 18 upon rotation of rod 16 about central longitudinal axis 84 when second interacting element 14 is coupled to distal rod end 28. Blade 82 may extend from outer adapter surface 80 in an auger like configuration. Central longitudinal axis 84 extends through proximal rod end 26 and distal rod end 28. To facilitate the drilling of the hole within ground 18, blade 82 may include first blade portion 86 abutting or formed integrally with outer surface 80 of adapter body 76 and second blade portion 88 having a tapered end. Tapered end forms cutting edge 92 and aids in blade 82 being capable of drilling through ground 18. In an embodiment, cutting edge 92 may be angled away from blade body 90 of blade 82.

(27) Removable tip 94 is configured to be at least partially disposed within bore 78 of second adapter 70 and secure therein using locking mechanism 100. Locking mechanism 100 includes flange 100b extending away from a portion of tip 94 and is configured to be removably secured within locking channel 100a of locking mechanism 100. Locking channel 100a is formed within interior wall 102 of adapter body 76. Engagement of flange 100b within locking channel 100a coupled tip 94 to second adapter 70 of second interacting element 14. Upon rotating second interacting element 14 about central longitudinal axis 84 in a first direction, flange 100b is transitioned within locking channel 100a from a first position to a second position, thereby securing tip 94 to second adapter 70. Consequently, rotating second interacting element 14 about central longitudinal axis 84 in a second direction, tip 94 is uncoupled from second adapter 70 as a result of flange 100b transitioning from a second position to a first position within locking channel 100a, thereby uncoupling tip 94 from second adapter end 70.

(28) As shown in FIG. 6D, first adapter end 72 includes third set of threads 104 configured to threadedly engage within fourth set of threads 106 of distal rod end 28. Engagement of third set of threads 104 with fourth set of threads 106, secures second interacting element 14 to distal rod end 26.

(29) As shown in FIGS. 7A and 7B, injection adapter 108 includes injection body 110 and injection pipe 112 disposed through the center of injection body 110. Injection pipe 112 may be secured within or formed integrally with injection body 110. Injection pipe 112 include inlet 114 configured to couple to a source of pressurized fluid 44 and outlet 116 configured to resides within cavity 32 of rod 16. Injection pipe 112 is secured in place with respect to proximal rod end 26 by injection body 110. Injection body 110 includes first body end 118 and second body end 120.

(30) First injection body end 118 houses power supply 122 and is configured to supply an amount of power to magnetic coils 124 disposed about the perimeter of the second injection body end 120. In an embodiment, power supply 122 may be batteries or may be electrical thermals coupled to an external power supply. Recess 126 is formed within injection body 110 and received proximal rod end 26 when outlet 116 is disposed within cavity 32. When injection adapter 108 is disposed over proximal rod end 26 and magnetic coils 124 are energized within an amount of power supplied from power supply 122, a magnetic field is generated which magnetically couples injection adapter 108 to proximal rod end 26. When the amount of power is withdrawn, the magnetic field dissipates, and injection adapter 108 is uncoupled from proximal rod end 26. Gasket 128 may be position within recess 126 and provides a seal between injection body 110 and proximal rod end 26 to provide an airtight seal and prevent the leaking of pressurized fluid 44 from the proximal rod end 26 during the injecting process. Handles 130 may be provided to facilitate the easy installation, removal, and transport of injection adapter 108.

(31) Referring now to FIG. 8, in conjunction with FIGS. 1-7, an exemplary process-flow diagram is provided, depicting a method for underpinning a structure using one or more underpinning devices. The steps delineated in the exemplary process-flow diagram of FIG. 8 are merely exemplary of a preferred order for the supporting a structure. The steps may be carried out in another order, or with or without additional steps included therein. Additionally, the steps may be carried out with an alternative embodiment of underpinning device 10, as contemplated in the description above.

(32) The method for underpinning a structure using one or more underpinning devices begins at step 500, during which first 10a and second 10b underpinning device are provided. Underpinning devices 10a and 10b includes the components discussed above. The method then proceeds to step 502, in which first underpinning device 10a is rotated in a first direction, such that blade 82a drills a hole into ground 18 upon second interacting element 14a being rotated about central longitudinal axis 84a. In step 504, first underpinning device 10a is rotated in a second direction, such that tip 94a is uncoupled from second adapter 14a. Step 506 details second underpinning device 10b rotating in a first direction, such that blade 82b drills a hole into ground 18 upon second interacting element 14b being rotated about central longitudinal axis 84b. In step 508, second underpinning device 10b is rotated in a second direction, such that tip 94b is uncoupled from second adapter 70b.

(33) In step 510, injection adapter 108 is provided and configured to inject pressurized fluid 44 within rod 16. In step 512, injection adapter 108 is coupled to proximal rod end 26a of first underpinning device 10a. Step 514 details injecting pressurized fluid 44 into rod 16a, such that pressurized fluid 44 is disposed within channel 42a and extruded through channel 42a to an environment external to rod 16a. In step 516, injection adapter 108 is uncoupled from proximal end 26a of first underpinning device 10a.

(34) The method then proceeds to step 518, in which injection adapter 108 is coupled to proximal rod end 26b of second underpinning device 10b. Step 520 details injecting pressurized fluid 44 into rod 16b, such that pressurized fluid 44 is disposed within channel 42b and extruded through channel 42b to an environment external to rod 16b. In step 522, injection adapter 108 is uncoupled from proximal rod end 26b of second underpinning device 10b.

(35) In step 524, first interacting element 12a of first underpinning device 10a is coupled to proximal rod end 26a. In step 526, first interacting element 12b of second underpinning device 10b is coupled to proximal rod end 26b of second interacting element 12b. The method then proceeds to step 528, in which a portion of link 24 is disposed through first alignment aperture 56a of first underpinning device 10a and through first alignment aperture 56b of second underpinning device 10b, thereby linking first 10a and second 10b underpinning devices to one another. Finally, in step 530, pressurized fluid 44 is allowed to cure, thereby anchoring first 10a and second 10b underpinning device within ground 18 to support structure 20.

(36) The advantages set forth above, and those made apparent from the foregoing description, are efficiently attained. Since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

(37) It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.