SUPPORT MEMBER

Abstract

A support member comprises abeam (12) having flanges (16, 18) connected to a central web (14). A first set of wings (20, 22) and a second set of wings (30, 32) are connected to the flange (16). A plurality of angled plates (80, 82, 84, 86) are attached to the flanges (16, 18) of the beam (12). to form receptacles defined between the plates, the web (14) and the flanges, (16, 18) of the beam (12). The receptacle has a relatively large upper opening. The plate (80) has a lower edge that is spaced away from the web (14) so that a bottom opening in the form of a slot between the lower edge of the plate (80) and the web (14) is formed. Alternatively, the lower edge of the plate (80) may come into contact with the web (14) (and be welded thereto), and the receptacle thus formed may have a lower opening formed by having a hole opening in the plate (80) at a lower region of the plate (80).

Claims

1. A support member comprising a beam adapted to be driven into the ground, and one or more wings extending generally transversely outwardly from the beam.

2. A support member as claimed in claim 1 wherein the one or more wings comprise plates extending transversely to the beam.

3. A support member as claimed in claim 1 wherein the wings have an outer edge that extends in a direction that is generally parallel to a longitudinal axis of the beam.

4. A support member as claimed in claim 1 wherein each wing extends in a plane that is parallel to a longitudinal axis of the beam.

5. A support member as claimed in claim 1 wherein the one or more wings have lower edges that extend at an acute angle to the longitudinal axis of the beam, thereby assisting penetration of the leading edge of the one or more wings into the ground.

6. A support member as claimed in claim 1 wherein the support member has a plurality of wings.

7. A support member as claimed in claim 6 wherein at least some of the wings are located such that when the beam is driven into the ground to a desired depth, the one or more wings are wholly located below ground level.

8. A support member as claimed in claim 1 wherein the one or more wings comprise a first set of wings located at a first region and a second set of wings located at the second region, the second region being spaced along the beam from the first region.

9. A support member as claimed in claim 8 wherein the wings in the first set of wings are of a different size to at least one of the wings in the second set of wings.

10. (canceled)

11. (canceled)

12. A support member as claimed in claim 1 wherein at least one of the one or more wings is welded to the beam in a manner such that a face of the wing is in abutment with a face of the beam.

13. A support member as claimed in claim 12 wherein the beam comprises an I-beam or a H-beam and at least one of the wings is welded to a flange of the I-beam or H-beam.

14. A support member as claimed in claim 13 comprising a first wing welded to a flange on one side of a central web of the beam and a second wing welded to a flange on another side of the central web of the beam.

15. A support member as claimed in claim 12 wherein the beam comprises an I-beam or a H-beam and at least one wing is welded to an inside face of a flange of the H-beam or I-beam, wherein a face of the wing is in abutment with an inside face of the flange of the beam.

16. A support member as claimed in claim 12 wherein the beam comprises an I-beam or a H-beam and the one or more wings comprises a pair of stabilising wings, with a first wing of the pair being welded to an inside face of a flange of the beam and a second wing of the pair being welded to an inside face of the flange on an opposite side of the central web of the beam.

17. A support member as claimed in claim 16 wherein the at least one wing comprises a first pair of stabilising wings and a second pair of stabilising wings located towards a lower end of the beam, the second pair of stabilising wings being spaced from a first pair of stabilising wings.

18. A support member as claimed in claim 17 wherein the beam comprises an I-beam or a H-beam and the second pair of stabilising wings comprises a first wing of the pair being welded to an inside face of a flange of the beam and a second wing of the pair being welded to an inside face of the flange on an opposite side of the central web of the beam.

19. A support member as claimed in claim 18 wherein the support member comprises a further stabilising wing attached to and extending transversely from a flange or a face of the beam.

20. (canceled)

21. (canceled)

22. A support member as claimed in claim 1 wherein the support member is provided with one or more receptacles to receive soil or earth when the support member is inserted into the ground.

23. A support member as claimed in claim 22 wherein the one or more receptacles include at least one upwardly and outwardly extending wall.

24. A support member as claimed in claim 23 wherein the one or more receptacles have a lower opening in a lower part to allow soil to enter into the receptacle through the opening during insertion of the support member into the ground.

25. A support member as claimed in claim 22 wherein the one or more receptacles have an upper opening and a lower opening, the opening being larger than the lower opening.

26. A support member as claimed in claim 22 wherein a receptacle is formed by positioning a plate between flanges of the beam, the plate being angled outwardly and upwardly relative to a longitudinal axis of the beam.

27. (canceled)

28. A support member as claimed in claim 26 wherein an inner edge of the plate is spaced from the web of the beam to thereby form a lower opening between the web and the inner edge of the plate.

29. A support member as claimed in claim 26 wherein the one or more plates do not extend beyond outer edges of the flanges.

30. A support member comprising a beam adapted to be driven into the ground, and one or more receptacles to receive soil or earth when the support member is inserted into the ground.

31. A support member as claimed in claim 30 wherein the beam comprises a web having flanges extending from the web and the one or more receptacles are located between the flanges.

32. A support member as claimed in claim 31 wherein a receptacle is formed by joining an upwardly and outwardly angled plate to the one or more flanges.

33. A support member as claimed in claim 30 wherein the one or more receptacles have a lower opening in a lower part to allow soil to enter into the receptacle through the opening during insertion of the support member into the ground.

34. A support member as claimed in claim 30 wherein the one or more receptacles have an upper opening and a lower opening, the opening being larger than the lower opening.

35. (canceled)

36. (canceled)

37. A support member as claimed in claim 32 wherein an inner edge of the plate is spaced from the web of the beam to thereby form a lower opening between the web and the inner edge of the plate.

38. (canceled)

Description

BRIEF DESCRIPTION OF DRAWINGS

[0039] Various embodiments of the invention will be described with reference to the following drawings, in which:

[0040] FIG. 1 shows a perspective view from one side of a support member in accordance with an embodiment of the present invention;

[0041] FIG. 2 shows a perspective view from another side of the support member shown in FIG. 1;

[0042] FIG. 3 shows a side view of the support member shown in FIG. 1. The view of FIG. 3 is taken from an aspect such that a flange of the beam can be seen;

[0043] FIG. 4 shows a side view of the support member shown in FIG. 1. The view of FIG. 4 is taken from an aspect such that the full extent of a web of the beam can be seen;

[0044] FIG. 5 shows a top plan view of the support member shown in FIG. 1;

[0045] FIG. 6 shows a bottom plan view of the support member shown in FIG. 1;

[0046] FIG. 7 shows a side elevation (from the same aspect as shown in FIG. 3) of the support member shown in FIG. 1, with FIG. 7 diagrammatically showing the support member inserted into the ground;

[0047] FIG. 8 shows a similar view to FIG. 7, but taken from the aspect as shown in FIG. 4;

[0048] FIG. 9 shows a diagrammatic side elevation of a 5.5 m conventional beam that has been driven 4 m into the ground;

[0049] FIG. 10 shows a diagrammatic side elevation of a 6.5 m beam that has been driven 5 m into the ground;

[0050] FIG. 11 shows diagrammatic views of interaction with the ground and lateral loads for a support member in accordance with an embodiment of the present invention and for a conventional steel driven beam;

[0051] FIG. 12 shows a perspective view of a support member in accordance with another embodiment of the present invention; and

[0052] FIG. 13 shows a side view of the support member shown in FIG. 12.

DESCRIPTION OF EMBODIMENTS

[0053] It will be appreciated that the drawings have been provided for the purposes of illustrating preferred embodiments of the present invention. Therefore, it will be understood that the present invention should not be considered to be limited solely to the features as shown in the attached drawings.

[0054] FIGS. 1 to 6 show various views of a support member in accordance with an embodiment of the present invention. The support member 10 shown in FIGS. 1 to 6 comprises an I-beam 12. The I-beam 12 has a central web 14, a first flange 16 and a second flange 18, as best shown in FIGS. 5 and 6. The I-beam is suitably made from steel and it may be galvanised for corrosion protection.

[0055] As shown in FIGS. 1 to 4, the support member 10 also includes two sets of wings. The first set of wings is positioned at an intermediate portion of the beam 12 and the second set of wings is positioned at a lower end of the beam 12.

[0056] Throughout this specification the terms upper and lower are used to indicate the orientation of the support member when it is in its installed position in the ground.

[0057] The first set of wings comprises wings 20 and 22. Wings 20, 22 are basically identical to each other. Wing 20 has a leading edge 24, a side a 26 and a trailing edge 28. Again, the terms leading and trailing are used with reference to the orientation that the support member adopts once it has been inserted into the ground. The leading edge 24 sweeps backward and upwardly at an acute angle, which assists in the wing penetrating the ground as the support member 10 is being driven into the ground.

[0058] As can be seen from FIGS. 4 to 6, the wing 20 is connected to the beam 12 by positioning the wing 20 such that a face of the wing 20 comes into contact with an underside of flange 18 of the beam 12. Appropriate welds can then be used to connect the wing 20 to the beam 12. For example, lines of weld metal can be positioned adjacent to regions where edges of the wing 20 are adjacent to the underside of flange 18 of beam 12 and where an inner edge of the wing 20 is adjacent to the central flange 14. The wing 22 is similarly joined to the other side of flange 18 that lies on the other side of the central web 14.

[0059] As can be seen in FIGS. 5 and 6, by joining the wing 20 to the underside of flange 18, the effective thickness of flange 18 is increased, thereby increasing thickness of the flange and resulting in a significant increase in bending moment strength. A similar outcome would be achieved if the wing 20 was joined to the other side of the flange 18.

[0060] The support member 10 shown in FIGS. 1 to 4 also comprises a second set of wings that is positioned towards the lower end of the beam 12. The second set of wings includes wing 30 and wing 32. The wings 30 and 32 are joined to the underside of flange 18 in a manner that is similar to wing 20 being joined to the underside of flange 18. As can be seen, the wings 30, 32 are smaller than the wings 20, 22. The wings 30, 32 also have swept back or angled leading edges in order to facilitate penetration into the ground.

[0061] The flanges, 16, 18 at the lower end of the beam 12 are Delta cut in order to assist in penetration of the support member 10 into the ground. This results in the central web forming an apex 34 with the leading edges 36, 38 of the flanges being swept back at an acute angle. Effectively, as best shown in FIG. 3, the lower end of the support member 10 is generally V-shaped.

[0062] The first set of wings 20, 22 are located such that when the support member 10 is properly driven into the ground to the desired depth, the first set of wings are located wholly below ground level and with the top of the wings 20, 22 being located close to the soil surface. This is shown in FIGS. 7 and 8, where the soil level is shown at 40. If a lateral load is applied to the top of the member, the first set of wings and the beam work together to raise to raise the effective pivot point, increasing turnover resistance with high levels of stored elastic energy, for maintaining the support member 10 in the desired vertical position even after a high wind or high frequency event. In this regard, the wings 20, 22 mobilise or engage with a large bulb of soil and can be effective in resisting lateral loads applied to the top of the support member 10.

[0063] The second set of wings 30, 32 may not be required in all situations. However, where the second set of wings are present, the second set of wings 30, 32 also mobilise a bulb of soil near the lower end of the support member 10. This also assists in maintaining the support member 10 in position when lateral loads applied to the top of the support member 10.

[0064] In some embodiments, the width of the beam 12 is sufficient to resist twisting forces applied to the support member 10. In this regard, the width of the beam 12 is effectively the height of the central web 14 of the beam 12. However, in some embodiments, it may be desirable to include a further set of wings that are joined to the flanges 16, 18 and extend transversely to the flanges 16, 18. With reference to FIGS. 5 and 6, these additional wings can be seen at 42 and 44. Similarly, the wings 42, 44 can be clearly seen in FIG. 8. These wings may be joined to the respective flanges 16, 18 by running weld metal along the edges of the wings 42, 44 that are in abutment with the flanges 16, 18.

[0065] FIGS. 7 and 8 show the support member 10 being positioned in the ground. The ground level is shown at 40. In FIGS. 7 and 8, the region of soil that comes under the influence of the wings can be seen in the darker shaded background.

[0066] FIGS. 9 and 10 show a conventional steel driven beam being placed on the ground. In FIG. 9, the beam 50 is 5.5 m long and has been driven 4 m into the ground. In FIG. 10 the beam 52 is 6.5 m long and has been driven 5 m into the ground. As can be seen by comparing FIGS. 7 and 8 with FIGS. 9 and 10, the region of soil that reacts with the support member 10 shown in FIGS. 7 and 8 is of similar size to the region of soil that reacts with the conventional beams 50, 52 as shown in FIGS. 9 and 10. However, the support member 10 shown in FIGS. 7 and 8 is only 4.5 m long and has been driven 3 m into the ground, in comparison to the 5.5 m beam being driven 4 m into the ground in FIG. 9 and the 6.5 m beam driven 5 m into the ground in FIG. 10. Therefore, a significantly shorter beam can be used to attain similar resistance to lateral loading by using the support member in accordance with embodiments of the present invention.

[0067] FIG. 11 also shows a similar comparison between a 4.5 m long support member that has been driven 1.5 m into the ground, with the top of the first set of wings being located 25 cm below soil level, with a 6 meter long conventional beam that has been driven 4.5 m into the ground. As can be seen, the first set of wings of support member 10 moves the pivot point to close to the top of the first set of wings, due to the large mobilised soil bulb that interacts with the wings 20, 22. Accordingly applying a lateral load that forces the top of the support member 10 to the left causes the first set of wings to mobilise the soil bulb 60, which resists the lateral load. It also moves the pivot point close to the region as shown at 62. As a result, the lower end of the support member 10 wants to move to the right but the lower set of wings mobilises soil bulb 64 to resist movement about the pivot point. In contrast, applying a lateral load to the conventional beam 52 shown in FIG. 11 results in insufficient lateral resistance from the weak or friable soil. As a result, the pivot point 66 is quite low down the beam. Due to the insufficient lateral resistance of the week or friable soil at the lower end of the beam 52, the lower end of the beam 52 can also be moved to the right. As a result, the top of the beam 52 can bend or move in response to the applied lateral load.

[0068] As a further advantage, due to the stiffening effect of the wings 20, 22 and 30, 32 on the flange 18 of the beam 12, the beam 12 can be made from a lighter gauge steel.

[0069] The size and strength of the beam and the size and positioning of the wings can be varied in accordance with design requirements and the geotechnical requirements of the particular site where the support members are to be driven into the ground. In some embodiments, the additional wings that extend transversely to the flanges may be included. However, in other embodiments, the beam web face area may be sufficient to support the specified loads, in which case the transverse wings can be omitted.

[0070] The support member 100 shown in FIGS. 12 and 13 also includes a plurality of angled plates 80, 82, 84, 86 attached to the flanges 16, 18 of the beam 12. As can best be seen with reference to plate 80 in FIG. 12, this forms a receptacle defined between the plate 80, the web 14 and the flanges, 16, 18 of the beam 12. The receptacle has a relatively large upper opening. The plate 80 has a lower edge that is spaced away from the web 14 so that a bottom opening in the form of a slot between the lower edge of the plate 80 and the web 14 is formed. In some embodiments, the lower edge of the plate 80 may come into contact with the web 14 (and be welded thereto), and the receptacle thus formed may have a lower opening formed by having a hole opening in the plate 80 at a lower region of the plate 80.

[0071] The plates 80, 82, 84 and 86 may be described as cupping plates that form a cup having an upper opening and a lower opening for soil capture and drainage. The cups fill with soil or earth when the support member 100 is inserted into the ground. If any forces applied to the support member attempt to force the support member upwardly, the soil retained within the receptacles will resist that upward movement. In some ways, the plates act similarly to angled barbs on a spear, which resist extraction of the spear from flesh.

[0072] Although not shown in FIGS. 12 and 13, similar plates are located on the other side of the web 14. These are essentially in their image orientation to the plates 80, 82, 84 and 86 shown in FIGS. 12 and 13. The plates also act to reinforce the lower part of the beam.

[0073] The plates may have bevelled leading bottom edges, for superior ground penetration during installation and correction of soil to optimise the end bearing pressure bulb sizes and shapes, around the support members, for improved compression and tension loading.

[0074] The plates may have bevelled leading bottom edges, for superior ground penetration during installation and direction of soil to optimise the end bearing pressure bulb sizes and shapes, around the support members, for improved compression and tension loading.

[0075] Sites that contain very weak soil/founding materials generally comprise the following 3 soil types:

Silty clay (firm/stiff and some sand),
Sandy silty clay mix (medium density to loose sand with some silty clay), all
Pure sand dune areas (loose to very loose sand).

[0076] Each soil type provides a different source strength and soil action/reaction, which directly affects how the support members should be tuned for optimising performance and cost. In some instances, particularly in instances where the site contains loose to very loose sand, installation of the piles may involve installing the piles into the ground. The piles could then be watered with a very small amount of cement added to the water to create a very light grey water slurry. The low viscosity of the very light grey water slurry will ensure that the water penetrates down around the support members. The permeable nature of the very loose sand displaced during installation of the support members will settle with the water and then set down and around the support member. This is similar to a bucket of water being poured onto loose beach sand, but due to the concentration, depth and overburden pressure, it is far more effective. The sand will also filter the water, capturing the cement and bonding the sand granules together as it dries out. The end result will be a large sand/cement bulb bonded down and around the support member, for increased skin friction and therefore improved overall compression and tension load capability of the piles.

[0077] In simple terms, this added, simple, low-cost soil stabilisation/mediation process enables the weakest sand sites to be converted into superior soil strength sites. This particularly results in improved vertical skin friction loads for improved compression and tension load performance.

[0078] The support member may have a mounting arrangement or a connection plate attached to its upper end to enable a structure to be connected to the support member. The skilled person would readily understand how this can be achieved.

[0079] In the present specification and claims (if any), the word comprising and its derivatives including comprises and comprise include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0080] Reference throughout this specification to one embodiment or an embodiment means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases in one embodiment or in an embodiment in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0081] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.