Abstract
The invention relates to a system for erecting a building structure, the system comprising a foundation for receiving the building structure, and a plurality of inner and outer walls, roof and floor panels, the panels being adapted to engage each other for defining at least one story of the building structure, wherein the foundation comprises a first section and a second section, the first section being adapted to bear the load of the building structure and the second section being adapted to provide access to the interiors of the building structure.
Claims
1. A screw pile for supporting a building structure, the screw pile comprising a shaft having a proximal end and a distal end, and a bit attached to the distal end of the pile, wherein the shaft comprises a plurality of helical bearing plates arranged in a spaced apart relationship along the shaft.
2. The screw pile according to claim 1, wherein each helical bearing plate comprises a base plate having a plurality of cutting blades extending perpendicularly from the base plate, the cutting blades being arranged around the periphery of the plate.
3. The screw pile according to claim 1, wherein the helical bearing plates are of such diameter that a series of lines drawn between the outer edge of a bearing plate to the outer edge of the bearing plate adjacent to it and closer to the proximal end of the shaft would collectively form the shape of a cone when viewed from the side with the shaft in vertical orientation.
4. The screw pile according to claim 1, wherein each helical bearing plate incorporates a base plate and a series of cutting blades arranged in a spaced apart relationship with respect to each other, wherein each cutting blade has a cutting leading edge facing the direction of rotation, and a trailing edge.
5. The screw pile according to claim 4, wherein the leading edge is oriented such that its longer axis is substantially oriented at right angles to the base plate.
6. The screw pile according to claim 5, wherein the leading edge is longer than the trailing edge.
7. The screw pile according to claim 6 wherein the shape of each cutting blade is such that the trailing edge is slightly inset towards the center of the base plate thereby exposing the leading edge of the following cutting blade, when viewed in a direction opposite to the rotation, exposing a series of cutting edges in the direction of rotation.
8. The screw pile according to claim 1, wherein the bit comprises a plurality of blades arranged in a spaced apart relationship around the bit, and a plurality of indentations arranged in a spaced apart relationship around the bit, wherein one indentation is located between each pair of blades.
9. The screw pile according to claim 1, wherein an upper cylinder of the bit incorporates a series of substantially rectangular indentations, with the longer dimension of the indentation aligned with the longer axis of the bit.
10. The screw pile according to claim 9, wherein the indentations are arranged in a spaced apart relationship around the upper cylinder and the distal end of the shaft comprising slots corresponding in shape and position with the indentations, the indentations being adapted to receive tabs inserted through the slots in the shaft to increase the strength of the connection between the bit and the shaft.
11. The screw pile according to claim 1, wherein the proximal end of the shaft comprises a threaded bush adapted to receive shaft extensions for extending the length of the shaft.
12. The screw pile according to claim 11, wherein the upper end of the shaft incorporates a series of slots that provide access to the threaded bush to connect the bush and the shaft.
13. The screw pile according to claim 1, wherein a proximal end of the shaft of the screw pile is adapted to receive a cap for receiving a load, the cap having an upper end and a lower end.
14. The screw pile according to claim 13, wherein the upper end of the cap comprises a cavity for receiving concrete.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0193] Further features of the present invention are more fully described in the following description of several non-limiting embodiments thereof. This description is included solely for the purposes of exemplifying the present invention. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. The description will be made with reference to the accompanying drawings in which:
[0194] FIG. 1 is a schematic perspective view of a building structure in accordance with an embodiment of the invention.
[0195] FIG. 2 is a schematic perspective view of the foundation of the building structure shown in FIG. 1 prior casting of the foundation;
[0196] FIG. 3 is a schematic perspective view of the foundation of the building structure shown in FIG. 2 prior casting of the building structure incorporating means for forming voids in the foundation to account for soil expansion;
[0197] FIG. 4 is a schematic perspective view of the process of erecting the ground floor of the building structure shown in FIG. 1.
[0198] FIGS. 5 and 6 are schematic perspective views of the process of erecting the second and third story of the building structure shown in FIG. 1.
[0199] FIG. 7 is a schematic perspective view of the building structure shown in FIG. 1 including the ground floor, the first story and second story.
[0200] FIG. 8 is a schematic perspective view of the building structure shown in FIG. 1 including the upper story.
[0201] FIG. 9 contains a perspective view of a series of walls that form an enclosed space and are constructed of a series of multi-layered panels connected to each other.
[0202] FIG. 10 contains a plan view of a multi-layered panel, a perspective view of a single multi-layered panel and a perspective view of the top edge of a single multi-layered panel.
[0203] FIG. 11 contains a perspective view of a single multi-layered panel showing the placement of inner tubes.
[0204] FIG. 12 shows a plan view of a bottom channel configuration, a plan view of said bottom channel configuration with a series of multi-layered panels in position, a cross section of a bottom channel in relation to a foundation for a building, and a perspective view of a bottom channel.
[0205] FIG. 13 shows a number of perspective views to describe the means by which a corner may be formed using a steel column and the means by which a wall is seated in a bottom channel.
[0206] FIG. 14 shows perspective views of the means by which locking clips help to hold panels to each other and to a column.
[0207] FIG. 15 shows a cross section view of a wall to illustrate the general arrangement of the key components to each other. The elements illustrated are the foundation block, bottom channel, multi-layered panel, top channel, anchor rod, ferrule, tie rod, washer, nut and roof plate.
[0208] FIG. 16 shows the means by which a pillar is created using two multi-layered panels and the means by which a wall or pillar is fastened securely to the foundation.
[0209] FIG. 17 shows the means by which a column is fastened to a casting plate, which is embedded in the foundation.
[0210] FIG. 18 shows the means by which a corner is created using two multi-layered panels and a steel capping post.
[0211] FIG. 19 shows how a free standing column is created using two multi-layered panels, two steel tubes, and a combination of tie rods.
[0212] FIG. 20 shows an abstract arrangement of panels to indicate typical configurations in which the panel may be employed.
[0213] FIG. 21 shows an overall view of a panel and its components.
[0214] FIG. 22 shows the concrete casing and insulating core blocks in isolation and in relation to one another.
[0215] FIG. 23 shows the architecture of the insulating core blocks.
[0216] FIG. 24 shows the insulation blocks and the reinforcing elements in isolation and in relation to one another.
[0217] FIG. 25 shows the reinforcing skeleton in isolation.
[0218] FIG. 26 shows the means by which lifting chairs separate the reinforcing mesh from the insulation blocks.
[0219] FIG. 27 shows the structure and placement of the lifting plates.
[0220] FIG. 28 shows the grouting tubes and the vertically protruding reinforcing bars that engage with the corresponding tubes.
[0221] FIG. 29 depicts two casting locks each embedded in a precast panel and connected to each other such that the corresponding panels are joined in a precise and strong manner.
[0222] FIG. 30 depicts a pair of casting locks in a connected configuration. Panels are omitted for the purpose of clarity.
[0223] FIG. 31 depicts a casting lock in pre-connection configuration ready for placement in the mould for the precast panel. The figure illustrates the relationship of the casting lock extremities to the panel boundaries.
[0224] FIG. 32 depicts a casting lock in pre-lock and post-lock configurations to illustrate the means by which the casting lock is employed following moulding of the corresponding pre-cast panel into which it is embedded.
[0225] FIG. 33 depicts two precast panels joined at right angles to each other using a corner casting lock.
[0226] FIG. 34 shows the elements of a corner casting lock and the means by which the threaded rod can exert tension while the head of the threaded rod lies within the body such that it does not protrude.
[0227] FIG. 35 shows a cut away view of an idealised wafflepod installation.
[0228] FIG. 36 shows an arrangement of 4 wafflepod segments and a stripped view of connector strips and spacer chairs.
[0229] FIG. 37 shows multiple views of a single wafflepod segment.
[0230] FIG. 38 shows an exploded view of a spacer chair.
[0231] FIG. 39 shows various views of an inverted U connector strip.
[0232] FIG. 40 shows a view of a quadruple inverted U connector and its employment in the joining of multiple wafflepod segments.
[0233] FIG. 41 shows the general layout of the components comprising the structural body relative to each other.
[0234] FIG. 42 shows the design of the bottom locator chair.
[0235] FIG. 43 shows a bottom reinforcing mesh seated in a series of bottom locator chairs.
[0236] FIG. 44 shows a hollow spheroid and its method of attachment to a bottom reinforcing mesh.
[0237] FIG. 45 shows a hollow spheroid and its method of attachment to a top reinforcing mesh.
[0238] FIG. 46 shows the design and structure of a hollow spheroid.
[0239] FIG. 47 shows the method by which top and bottom reinforcing meshes are positioned relative to each other and to a truss arrangement by means of connection via top locators and bottom locator chairs.
[0240] FIG. 48 shows the structure and design of a top locator.
[0241] FIG. 49 depicts an entire helical screw pile assembly.
[0242] FIG. 50 depicts a blade bit.
[0243] FIG. 51 depicts a shaft joined to a blade bit.
[0244] FIG. 52 depicts a helical bearing plate and its manner of incorporation with the shaft.
[0245] FIG. 53 depicts a cap of the helical screw pile assembly
DESCRIPTION OF EMBODIMENTS
[0246] FIG. 1 shows a particular arrangement of a building structure 10 in accordance with the present embodiment of the invention. The building structure 10 comprises a plurality of components that when assembled together define the building structure 10. These components include outer panels 12 and inner panels 14. The outer panels 12 include windows 18 and fixtures such as balcony barriers 16. In a particular arrangement the components and fixtures may be fabricated off site; in other arrangements they may be manufactured on site.
[0247] Further, the building structure 10 rests on a foundation 20. FIGS. 2 and 3 show the foundation 20 prior casting of the foundation 20.
[0248] The particular foundation 20 of the present embodiment of the invention comprises two sections 22 and 24. The section 22 is adapted to receive the load of the building structure 10 (referred to also as the load bearing section 22).
[0249] In the particular arrangement shown in the figures, the section 24 is T shaped having a longitudinal section 24a and a transversal section 24b. The section 22 partially surrounds the inner section 24. In particular, the section 22 comprises two areas 26 and a path 28. The two areas 26 are adjacent the longitudinal section 24a and the path 28 surrounds the transversal section 24b.
[0250] The two areas 26 and the path 28 are embedded into the ground such that the section 24 is elevated with respect to the section 22.
[0251] As mentioned earlier the section 22 is adapted to bear the load of the building structure 10. For this, a plurality of piles 30 is included in the section 22. The piles 30 are adapted to receive the load of the building structure 10. In a particular arrangement of the present embodiment, the piles 30 comprise the piles as shown in FIGS. 49 to 53 in accordance with the present embodiment of the invention.
[0252] We refer now FIG. 3.
[0253] As shown in FIG. 3, footings 32 are added to the section 22. The footing 32 provides a support surface for the cast to define the foundation 20. In the particular arrangement shown, the footings 32a cover the path 28 and the perimeter of the section 22. A footing 32b covers a particular section of the areas 26 of the section 22. The footings 32a are adapted to receive the outer side walls of the building structure 10. The footings 32b are adapted to receive shafts 34 (see FIG. 4). The shafts 24 may serve as elevator and staircase shafts to provide access to the upper storeys of the building structure 10.
[0254] Further, each section 26 of the sections 22 comprises a wafflepod system 36. As will be described at a later stage, the wafflepod slab 36 is adapted to define a plurality of voids and cavities for saving concrete during casting of the foundation 20 and to account for soil expansions and movement of the ground. In a particular arrangement of the present embodiment, the wafflepod system comprises the wafflepod system as shown in FIGS. 35 to 40 in accordance with the present embodiment of the invention.
[0255] We refer now to FIGS. 4 to 8. FIGS. 4 to 8 show the erection process of the building structure 10 shown in FIG. 1.
[0256] FIG. 4 shows the assembly process of the ground floor of the building structure 10. The first story is assembled by installing onto the foundation 20 outer and inner walls 38 and 40. Shafts 34 are mounted on footings 32b.
[0257] The inner and outer walls 38 and 40 are defined by panels that are adapted to be joined together to define the walls 38 and 40. As shown in, for example, FIG. 4, the side outer walls 38 are defined by three panels 42a, 42b and 42c. The inner walls 40 are defined also be a plurality of panels 42 that are adapted to be joined together. In a particular arrangement of the present embodiment, the inner panels may be the panels as shown in FIGS. 9 to 19 and the outer panels may be the panels shown in figures 20 to 28 in accordance with the present embodiment of the invention.
[0258] FIGS. 5 and 6 show installation of the first and second storeys of the building structure 10. The process for installing the first and second storeys includes providing the roof and floor structures of the first and second storeys.
[0259] As shown in FIG. 5, the roof and floor structures of the first story are provided by a floor panel 44 that covers the ground floor of the building structure 10. After installation of the floor panel 44 a layer of concrete is poured over the floor panel 44 to form the floor of the first story. At this stage, the inner walls 40 of the second story and the rear and front outer walls 46 are mounted on the floor panel 44.
[0260] As can be appreciated in FIGS. 6 and 7, the third story is erected via a floor panel 44 to define, respectively, the roof and floor structures of the second and third storeys and via inner wall panels 40 as was described in relation to the second story.
[0261] Referring now to FIG. 8, the fourth story is erected via a floor panel 44 to define the roof and floor structures of the third and fourth storeys and via inner wall panels 46 as was described in relation to the second and third story. The fourth story comprises a roof panel 48.
[0262] To finalise the building structure 10 as shown in FIG. 8 windows and fixtures such as the balcony barriers 16 are added in order to finalise the building structure 10 shown in FIG. 1.
[0263] In a particular arrangement of the present embodiment, the panels that define the floors and roofs of the first to fourth storeys are the floor panels as shown in FIGS. 41 to 48 in accordance with the present embodiment of the invention.
[0264] As has been mentioned above, particular arrangements of the building structure 10 shown in FIG. 1 to 9 may incorporate a plurality of components such as: the wall and floor panels, mechanical joints, the wafflepod system and the piles as shown in FIGS. 1 to 53. The following paragraphs provide descriptions of particular arrangements of any of these components.
[0265] Furthermore, these pluralities of components are adapted to be joined together so as to define particular arrangements of the building structure 10 in accordance with an embodiment of the invention. The following paragraphs also provide descriptions of how these components are joined together to define the building structure 10.
[0266] We refer now to FIGS. 9 to 19.
[0267] Referring to FIG. 9 a series of multi-layered panels 201 (also referred to as panels) are connected to form an enclosed shape representing a single room. The multi-layered panels 201 are placed in a bottom channel 202 and are capped by a top channel 3 with the combined effect of constraining the multi-layered panels 201 such that they form a practically rigid structure that acts as a wall. A wall thus formed is not limited to the geometric configuration depicted, but may form a geometric shape composed of any combination of segments that are made up of a series of multi-layered panels joined together in a straight line. The segments may be arranged at any desired angle to each other. Segments are supported by upright columns 204 at intervals not exceeding 3 metres. Multi-layered panels 201 may be cut to specific lengths to enable formation of apertures for windows and doors as in 205 and 206 respectively.
[0268] Referring to FIG. 10, a single multi-layered panel 207 is shown to be composed of three layers of components. A polystyrene core 208 is encased within two 16 mm thick low density cement fibre sheets 209 with strong adhesive used to bind the three components together. The polystyrene core 208 has a central hole 210 extending the full height of the respective multi-layered panel and two edge holes 211 also extending the full height of the respective panel. The edge holes 211 are of a shape that allows for the insertion of locking clips shown in subsequent figures. Each outer sheet 209 has one edge forming a tongue shape 212 while the opposing edge has a corresponding groove shape 213 such that when one multi-layered panel 207 is joined to another along the edge, the tongue 212 fits neatly within the groove 213. The polystyrene core 208 has one edge shaped into a nine-face tongue 214 and an opposing edge shaped into a nine-face groove 215, such that when one multi-layered panel 207 is joined to another along its edge the nine-face tongue 214 fits neatly within the nine-face groove 215.
[0269] Referring to FIG. 11, a 50 mm diameter PVC tube 216 is placed within a central hole 217 extending from the top edge to the bottom edge of a single multi-layered panel 218. When in its final position the top and bottom of the central tube 216 lie flush with the top and bottom edges of the multi-layered panel 218 respectively. Two outer 50 mm diameter PVC tubes 219 are placed in the respective edge holes 220, both of which extend from the top edge to the bottom edge of the multi-layered panel 218. When in their final position, the top and bottom of each of the two outer tubes 219 lie flush with the top and bottom edges of the multi-layered panel 218 respectively. The tubes 216 and 219 provide extra compressive strength to the panel 218, which may be further increased by filling with appropriate material that converts from a liquid to a high strength solid to form a solid core that completely fills the respective tube.
[0270] Referring to FIG. 12, a series of multi-layered panels 220 are placed such that their bottom edges lies within a bottom channel 221. The bottom channel 221 is of a size and shape 222 to enable the bottom edge of a multi-layered panel to be seated tightly within the bottom channel 222 when placed vertically. Two bottom channels may be positioned to form a right angle to each other where the respective inner edges of the bottom channels meet at their inner corners 223. The multi-layered panels at the edge of each of the two segments forming the right angle are connected to the respective edge of a vertical column 224 so as to form a robust join and maintain wall thickness at the right angle transition.
[0271] Referring to FIG. 13, inter-panel locking clips 225 are shown in readiness for insertion into the locking clip recess 226 prior to the multi-layered panel being seated in the bottom C-channel 227 thus providing resistance against the respective multi-layered panels parting from one another.
[0272] Referring to FIG. 14, inter-panel locking clips 227 are shown ready for insertion into the locking clip recesses 228 in each of the multi-layered panels 229 to provide resistance against the respective multi-layered panels parting from one another. Panel-to-column locking clips 230 are shown ready for insertion in the hollow section of the column 231 and the locking clip recess in the adjacent panel 232, the dimensions of the clip being such that the respective multi-layered panel is held tightly against the column 231 so as to provide resistance against a parting of the multi-layered panel from the column.
[0273] Referring to FIG. 15, a multi-layered panel 233 is shown placed upright in bottom C-channel 234 that is placed on a foundation block 235. A threaded anchor rod 236 is fixed in the foundation block by means of a strong bonding agent within the hole created for the threaded anchor rod 236. A threaded tie rod 237 is connected to the threaded anchor rod 236 by means of a threaded ferrule 238. A compressive force is exerted on the multi-layered panel 233 by means of tightening locking nut 239 on threaded tie rod 237 following placement of top C-channel 240, roof plate 241 and tie rod washer 242. By this means, a strong resistance to a parting between the multi-layered panel 233 and the foundation block 235 is produced.
[0274] Referring to FIG. 16, an arrangement is shown whereby tie rods 243 are inserted in two multi-layer panels, one of which 244 forms part of a wall segment as described in preceding figures and the other panel 245 which is placed adjacent to the former such that their two wider faces butt against each other in readiness for tensioning and thereby creating a strong connection between the participating multi-layer panels and the foundation block 246 when the tie rods 243 are finally tensioned as shown in FIG. 15. The tie rods 247 are threaded into ferrules 248 that are threaded onto anchor rods embedded in foundation block 246 as depicted in FIG. 15. Tie rod locking plates 249 are placed over tie rods 243 so as to form a rigid connection between a tie rod in one multi-layered panel and a tie rod in the adjacent multi-layered panel thus creating a strong resistance against a parting between the two multi-layered panels. The tie rods are eventually tensioned by tightening the corresponding nut.
[0275] Referring to FIG. 17, a metal column 250 is shown in readiness for attachment to metal casting plate 251, which is embedded in the concrete foundation. The metal column 250 is welded to casting plate 251 to form a strong unit 52 ready to support any attached multi-layered panel.
[0276] Referring to FIG. 18, two multi-layered panels 253 and 254 are abutted against one another to form a right angle join by placing one edge of each in one open channel of a metal capping post 255. The metal capping post 255 is composed of two C-channels welded together such that the channel of one C-channel is at a right angle to the channel of the other C-channel and the height of the capping post 255 is equal to that of the multi-layered panels 253 and 254 to be joined. The edge of each panel 253 and 254 to be joined is firmly inserted into that channel of the capping post 255 that has its opening orientated in line with the respective panel. Mechanical fastenings 256 are used to fasten the outside faces of the capping post to the edge or face of the respective panel.
[0277] A 50 mpa cement grout is injected into the void formed between the edge of each multi-layered panel 253 and 254 and the capping post 255 face that is perpendicular to it to provide a strong medium for the mechanical fastenings 256 to take purchase.
[0278] A tie rod 257 is installed within the vertical holes of each multi-layered panel 253 and 254 participating in the join, each tie rod 257 being firmly fastened to the foundation block 258 by means of threading into a metal ferrule that is fastened to an anchor rod fixed in the foundation block 258. A 50 mpa cement grout is injected into each hole of each participating panel 253 & 254 so as to increase their load bearing capacity. A metal locking plate 259 is placed over the two adjoining tie rods 260, each of which is inserted in one of the participating multi-layered panels 256 & 254, to form a mechanical connection between the participating panels 253 & 254. Tension is applied to each tie rod 257 via a nut and washer arrangement 261 so as to fasten the participating panels securely to the foundation block 258.
[0279] Referring to FIG. 19, a free-standing column 262 is created by fixing two vertical steel tubes 263 to the foundation block 264 via a steel plate 264 that is mechanically fastened to foundation block 264. The vertical steel tubes 263 are positioned such that they correspond with the outer holes 265 of one of the multi-layered panels 266, hereon known as the primary panel, which is placed over the steel tubes 263 to sit on foundation block 264. A multi-layered panel 267, hereon known as the secondary panel, is placed adjacent to the primary panel 266 such that one face of the secondary panel 267 is pressed against one face of the primary panel 266 and the edges of both panels are in line with one another.
[0280] Tie rods 268 are placed in the centre hole of each of the primary panel 266 and secondary panel 267 and are attached to the foundation block 264 via ferrules connected to anchor rods as described in FIG. 15. The tie rods 268 are connected together by a locking plate 269. A nut and washer arrangement 270 is used on each tie rod to fasten the participating panels securely to the foundation block 264. Tie rods 271 are placed in each of the outer holes of the secondary panel 267 and securely fastened to foundation block 264 by same means as that described for tie rods 268. A 50 mpa grouting cement is injected into the outer holes of the secondary panel 267 after it has been secured to the foundation block 264 by means of a nut and washer arrangement 272 exerting a compressive force via single tie rod plates 273.
[0281] The resultant free standing column 263 is therefore securely fixed to foundation block 264 and is able to withstand significant compressive and lateral forces enabling it to act as a load bearing element.
[0282] We refer now to FIGS. 20 to 28.
[0283] Referring to FIG. 20, an abstract representation 301A of a series of encased core precast panels (also referred to as panel in this description, for the sake of brevity) is shown, depicting two wall segments, one positioned above the other as in a two storey building, each composed of three encased core precast panels joined together. The respective vertical and horizontal joins are shown white to help distinguish between the panels. The representation is intended to convey a general class of configuration, which are multiple storeys of walls.
[0284] The encased core precast panels may also be configured at right angles, but not limited to the right angle, to each other 301B so as to form a corner between two walls. The configuration represented by the top view representation 301B may be repeated over multiple storeys. Joins between panels are shown in white to distinguish between individual panels.
[0285] A panel or wall made of multiple panels may be joined 301C to another wall, preferably at right angles, at an intermediate point of the latter so as to form a partition, such as in the case of an interior wall in a building. The configuration represented by the top view representation 301C may be repeated over multiple storeys. Joins between panels are shown in white to distinguish between individual panels.
[0286] Referring to FIG. 21, the main elements of a typical encased core precast panel in production orientation (flat to the floor) are depicted. Two blocks of insulating core 302E, preferably made of polystyrene, are encased within a concrete casing 302D. Preferably, the insulating core 302E lies between two sheets of reinforcing mesh 302F, with only the top sheet visible in this depiction, and a pattern of rebars 302M running longitudinally. The top mesh 302F is separated from the insulating core 302E by means of spacer chairs 302L. An edge frame 302G made of an assembly of reinforcing bars forms the structural foundation for all the elements. A pattern of protruding reinforcing bars extend perpendicular 302A to the face of the panel and parallel 302H to the face of the panel provide for strong mating with other panels or building bodies, such as floors, at the desired orientation. A series of middle casting locks 302G for joining the panel edge to the edge of another panel are embedded within the concrete. A series of corner casting locks 302K for joining the face of the panel to the edge of another panel, as in the case of a wall corner, can also be embedded within the concrete structure and edge frame. The said arrangement of casting locks represents only one configuration. For instance, in the case of the panel forming part of a straight wall the middle casting locks would be located at both long edges of the panel. Multiple lifting plates 302N are embedded within the structure and securely fixed to the edge frame 302G providing a robust means of attaching lifting devices to the panel for the purpose of handling and installation.
[0287] Referring to FIG. 22, two insulating cores 303B are encased within a concrete body 303A. A side view 303D shows the placement of the insulating cores 303B in the concrete body 303A. A top view shows insulating core 303B incorporating hollow tubes 303C open at the upper edge of insulating core 303B so as to provide for the insertion of pipes or cables forming part of the plumbing, electrical and associated services. All other elements of the encased core precast panel are excluded from this depiction for the sake of clarity.
[0288] Referring to FIG. 23, two core insulation bodies 304A, preferably made of polystyrene, as would typically be included in an encased core precast panel, are shown in isolation for the purpose of illustration. Said core insulation bodies 304A are typically joined at their longer edge, but are shown as separated for the sake of illustration.
[0289] The core insulation body 304B incorporates hollow tubes 304D that preferably extend the full height of the insulation core 304B such that each tube presents an open face at the edge of the insulation core 304B that corresponds to the upper edge of the encased core precast panel when in its working vertical position. Said tubes provide a means of installing electrical and plumbing services (as well as other services requiring pipes or cables) in the panel itself. Said tubes can be accessed post-installation by means of drilling a hole in the face of the panel.
[0290] As indicated above, said core insulation bodies can be joined along their vertical (when in working position) edges. The two longer edges of each insulation core are formed such that the cross sectional profile of one edge is the reverse of the cross sectional profile of the opposing edge as depicted in 304C. In this manner, a multi-step join between two insulation core bodies can be created, whereby the edge of one insulation core body fits neatly into the edge of the adjoining insulation core body.
[0291] Referring to FIG. 25, insulating core 5C, reinforcing mesh 305B and reinforcing bars 305A are shown in isolation from the other components of the encased insulation precast panel for the sake of illustration. Preferably, insulating core 5C is located between two layers of reinforcing mesh 305B. Insulating core 305C is positioned closer to one face of the panel. Top reinforcing mesh 305D is separated from insulating core 305C via spacer chairs, omitted from the current figure for the sake of simplicity. Preferably, two bodies of insulating core 305C are positioned within the boundaries of the panel such that a gap exists between the two core insulating bodies. In this manner, a region of solid concrete is formed in the corresponding volume so as to act as a strength element. Said bodies of insulating core are joined together when in top view. Preferably, said insulating core bodies incorporate hollow tubes 305E that present an opening at the top edge of said insulating core bodies in top view, such hollow tubes being for the purpose of accommodating the installation of pipes, cabling and the like within the body of the panel post-lockup.
[0292] Referring to FIG. 26, the edge frame 306E of the encased insulation precast panel is shown in isolation for the sake of clarity. Said edge frame is composed of an arrangement of reinforcing bars 306D positioned in relation to each other via a series of reinforcing elements 306C each composed of a length of reinforcing bar formed into an approximate rectangle orientated approximately perpendicular to the longitudinal axis of the reinforcing bar 306D. Said reinforcing elements 306C are positioned at regular intervals 306B along the lengths of said reinforcing bars 306D, which are positioned 306A so as to form the shape of the respective panel and of a length and width slightly less than that of the panel. An arrangement of reinforcing bars 306D and positioning elements 306C extends from the approximate midpoint of a long edge (in production orientation) of the panel to the corresponding midpoint of the opposite long edge so as to provide a region of reinforcing across the middle of the panel.
[0293] Referring to FIG. 27, an arrangement of spacer chairs 307B is shown 307A in relation to the core insulating bodies and reinforcing arrangement 307D described in earlier figures. Said space chairs 307B are seated on the core insulating bodies and incorporate an arrangement of rods formed into shape and located so as to support the reinforcing mesh in the desired position in relation to the concrete body of the panel.
[0294] Referring to FIG. 28, multiple lifting plates 308A are shown embedded within the structure of the panel. Said lifting plates 308A incorporate a steel plate 308B strongly attached to an arrangement of structural arms 8C. Said structural arms arrangement is designed to directly engage with reinforcing bars 308D and 308E such that the lifting plate 308A is firmly fixed to the reinforcing edge of the panel and encased within the concrete body of the panel. Preferably, steel plate 308B incorporates threaded holes 308F to enable attachment to external lifting devices and equipment.
[0295] Referring to FIG. 29, the design of the encased core precast panel 309A incorporates a series of reinforcing connector bars 309B (and 309J) embedded within the body of the panel 309A and protruding from the top edge 309H (when viewed in a typical vertical orientation) of the panel 309A (and 309M). Reinforcing connector bars 309B and 309J incorporate a metal head 309N at that end of the reinforcing connector bar 309J embedded within panel 309M shaped in such a fashion as to firmly fix reinforcing connector bar 309J within panel 309M along the axis of the long edge of panel 309M and in relation to rotation around the long axis of reinforcing connector bar 309J.
[0296] Said panel 309A also incorporates a series of connector tunnels 309C (and 309K) along its bottom edge 30309G extending from the face of the bottom edge towards the centre of the panel and aligned with the long edge of panel 309L. The pattern of tunnels 309K (and 309C) is designed to correspond with the pattern of reinforcing connector bars 309J (and 309B) such that when panel 309L is installed on top of panel 309M, as in the case of a two storey construction, with the bottom edge 30309G of panel 309L seated on edge 309H of panel 309M, the reinforcing connector bars 309J completely penetrate into the corresponding tunnels 309K.
[0297] Connector tunnels 309K present one open face 309D at the bottom edge 30309G of panel 309L and one open face 309F at the face of panel 309L, having been formed by the incorporation of correspondingly shaped tubes into the respective panel mould prior to casting. By this means concrete may be injected via open tunnel face 309F into the void between connector reinforcing bar 309J and connector tunnel 309K upon panel 309L having been seated on panel 309M, thus fixing panel 309L to 309M along both the axis of the short edge and the axis of the long edge.
[0298] We refer now to FIGS. 29 to 34.
[0299] Referring to FIG. 29, first panel 401A is joined to second panel 401C, with the edges of each panel butted to each other, through the connection of first casting lock 401B and second casting lock 401D.
[0300] A top view of the dual casting lock configuration shows each casting lock to include a retreat tunnel 401E, which allows threaded rod 401F to be placed in casting lock body 401G such that it does not protrude beyond casting lock body 401G during the process of incorporating the respective casting lock into the panel mould. Retreat tube 401E includes a ridge spiralling externally around its circumference and along its length in order to ensure an effective bonding to the hardening material. Preferably, retreat tube 401E is attached to casting lock body 401G by means of a coarse thread. When in connecting mode, threaded rod 401F extends across the boundary 401H between the panels 401A and 401C such that tightening nut 401K of each casting lock in the pair can be tightened against casting lock body 401G via spring washer 401J such that tension is produced in threaded rod 401F thus forcing the first casting lock 401B against the second casting lock 401D. A locking nut 401L is tightened against tightening nut 401K to fix it in position relative to threaded rod 401F.
[0301] By this means, the connection of casting locks 401B and 401D firmly fixes first panel 401A to second panel 401C in all dimensions.
[0302] Location markings 1N and 1M enable the precise placement of a casting lock in its respective precast panel with reference to the relevant edges of the precast panel. Location markings 1N and 1M enable precise monitoring and adjustment of the geometry of the mould during casting to ensure that the geometry of each panel is identical and the positioning of the respective casting locks is consistent. By such means the casting locks are positioned accurately relative to each other, enabling the effective mating of one casting lock to its corresponding partner in the adjacent panel.
[0303] Referring to FIG. 30, a post-lock configuration 2R of two casting locks is shown in exploded form for the purposes of illustration. Each casting lock assembly is embedded in its host panel as described in FIG. 31. A threaded rod 402B runs through the body 402C of each casting lock in the post-lock configuration. An arrangement 402E of a washer, tightening nut and locking nut engages with the threaded rod such that a tightening of the opposing arrangements 402E creates tension in the threaded rod 402B thus fixing the two casting locks, and therefore the panels within which they are embedded, in relation to each other. The retreat tubes 402A and positioning bolts 402D are shown detached for the purposes of illustration.
[0304] A pre-lock configuration 402K is shown whereby threaded rod 402V is contained within the length of casting lock 402T and retreat tube 402F during the moulding process, as described in FIG. 31. Nut and washer assembly 402G is not engaged with the casting lock body in this pre-lock configuration 402K. The aperture within casting lock body 402U is free of threaded rod while void 402J lies empty. Thus, there are two forms of pre-lock configuration. The first form includes a threaded rod protected within the casting lock and retreat tube as well as a tightening nut, locking nut and washer arrangement, while the second form excludes the threaded rod and tightening assembly. However, each form can be converted into the other simply by the addition or subtraction of the threaded rod and tightening assembly. This transformation can occur post-moulding on the basis that access to the void within the casting lock body is available post-moulding. Thus, each form of the pre-lock configuration represents a convenience rather than a fundamental distinction.
[0305] Post-lock configuration 402L shows threaded rod 402P extending into void 402W of casting lock 402U. Tightening assembly 402Q is engaged with threaded rod 402P such that the coordinated tightening of nut and washer assemblies 402N and 402Q imposes tension in threaded rod 402P when the respective panel edges press against one another (as depicted in FIG. 29). Retreat tube 402M lies empty due to the post-lock position of threaded rod 402P.
[0306] Referring to FIG. 31, a casting lock is shown ready for incorporation into a panel mould. The casting lock is positioned precisely within the panel mould such that face plate 403A is slightly flush of the edge 403E of the panel mould when viewed in top view. Positioning bolts 403B are of a total length that is equal to the thickness of the panel as represented by bottom edge 403F and top edge 403G when viewed from front view. Positioning bolt caps 403B incorporate conical ends 403D to rest on the panel mould basin such that upon the introduction of hardening material, such as concrete, and the subsequent hardening, the area occupied by each positioning bolt cap 403D is so minor as to produce a practically imperceptible visual footprint.
[0307] Referring to FIG. 32, a casting lock is shown in pre-mould configuration ready for incorporation into a panel mould as described in FIG. 31. Cavity protector cap 404A is in position to prevent hardening material entering the cavity that provides access to the tightening arrangement. Threaded face plate 404B is threaded in position to prevent intrusion of hardening material into the aperture that provides the avenue by which threaded rod 404D may be wound into position through the exercising of the tightening arrangement 404C, which comprises a spring washer, tightening nut and locking nut as described in FIG. 30.
[0308] The post-mould configuration shows the cavity protector cap removed so as to reveal the tightening arrangement 404C. Threaded face plate 404B is also removed to enable threaded rod 404D to be progressively extended into the tunnel of a casting lock embedded in the panel to be joined (not shown) such as to engage with another tightening arrangement.
[0309] Following the tightening of the connection between the two casting locks the central body cavity of each casting lock is injected with hardening material so as to complete the immersion of the casting lock within the panel structure.
[0310] Referring to FIG. 33, a configuration is shown in which two precast panels, typically in vertical orientation, at right angles to each other relative to the top view, are joined by a combination of a casting lock and a corner casting lock. Side view 405A shows Panel 5C joined at right angles to panel 5G via corner casting lock 405D and middle casting lock 405F. Top view 405B shows such configuration from a different perspective.
[0311] Referring to FIG. 34, middle casting lock 406A is shown connected to corner casting lock 406D via tension place on threaded rod 406B through tightening nut 406C against the body of middle casting lock 406A. Threaded rod 406B contains hexagonal head 406E, the shoulder of which seats against spring washer 406F when in tension.
[0312] We refer now to FIGS. 35 to 40.
[0313] Referring to FIG. 35, a schematic foundation utilising the triple concave wall wafflepod 501B is shown. Wafflepod segments 501B are placed on synthetic sheeting, preferably plastic, to create a moisture barrier between the underlying soil and the wafflepod sections 501B. Reinforced mesh 501C is placed on spacer chairs 501E such that a separation is achieved between the topmost surface of the wafflepod segments 501B and the reinforced mesh 501C. Wet concrete 501A is introduced into the entire arrangement such that the voids created by the wafflepods 501B are filled with concrete 501A and a layer of concrete 501A covers the mesh to a thickness sufficient to meet the particular specifications of the respective foundation.
[0314] Referring to FIG. 36, a configuration of multiple wafflepod segments 502B is joined by inverted U connector 502D is shown. Preferably, inverted U connectors 502D are joined to each other by inverted quadruple U connector 502F. Preferably, each wafflepod segment 502B includes four tri-concave-wall pods 502C, preferably arranged symmetrically on and integrated with an approximately flat base, which includes a middle pod 502E positioned at its centre. Preferably, the middle pod 502E forms a truncated square pyramid such that its based is parallel with the wafflepod segment base 502B and its top forms a smaller square surface parallel to the base and with its centre aligned with the centre of the base of the central pod 502E. Preferably, the base of middle pod 502E is orientated such that its corners bisect the space between the innermost corners of the tri-concave-wall pods and are extended such that the base of middle pod 502E largely occupies the space between the innermost bottom corners of tri-concave-wall pods 502C, but leaving sufficient room for the legs of spacer chair 502A to be place on the surface of wafflepod segment 502B.
[0315] Preferably, the height of tri-concave-wall pod 502C is less than the thickness of the respective foundation such that the difference corresponds to the desired thickness of the contiguous concrete layer covering the mesh as described in FIG. 35. Preferably, the height of middle pod 502E is lower than the height of tri-concave-wall pod 502C such that the top of spacer chair 502A, which sits above the top of middle pod 502E, positions the reinforcing mesh (not shown, refer to FIG. 35) at the desired displacement from the topmost surfaces of tri-concave-wall pods 502C.
[0316] Referring to FIG. 37, a single complex void wafflepod segment 503B is depicted. Preferably, each wafflepod segment 503B incorporates four tri-concave-wall pods 503A and a middle pod 503D. Preferably, middle pod 503D is placed in the centre of wafflepod segment 503B. Preferably, tri-concave-wall pods 503A (also called outer pods) are placed symmetrically around middle pod 503D. Preferably, each outer pod 503A emanates from the base of wafflepod segment 503B with its vertical axis approximately perpendicular to the base. Preferably, the height of the topmost surface of outer pod 503A is such that a reinforcing mesh (not shown, see FIG. 36) placed slightly above the topmost surface lies at a height less than the thickness of the respective foundation (not shown, see FIG. 35).
[0317] Preferably, each outer pod 503A forms three concave faces 503E orientated outwards from the centre of the outer pod 503A, the vertical axis of which is approximately perpendicular to the base of wafflepod segment 503B. Preferably, the three concave faces 503E of each outer pod 503A are distributed evenly around the centre of each outer pod 503A. Preferably, the size, shape and positioning of the outer pods 503A and middle pod 503D are such that the resultant voids are of sufficient volume and placed such that the concrete structure resulting from the introduction of wet concrete into the wafflepod arrangement possesses the strength necessary to meet the design requirements.
[0318] Referring to FIG. 38, a spacer chair is shown composed preferably of four legs 504J supported by cross struts 504K between each pair of logs 504J. The legs 504J are attached to or integrated with a seat 504G with a central hole 504G preferably threaded, into which the barrel 504D of support clip 504E fits neatly. A cover plate 504C is attached to or integrated with barrel 504D. Emanating from cover plate 504C are two reinforcing rod clips 504A and two mesh clips 504A. Rod clips 504A are able to accept reinforcing rod and mesh rod (from which the mesh is constructed). Preferably, each pair of clips is positioned such that each clip sits at the outer edge of cover plate 504C diametrically opposite to the other clip of the pair. Preferably, the two pairs of clips 504A and 504B are orientated such that the horizontal axis passing through the centres of each pair are at right angles to the horizontal axis passing through the centres of the remaining pair.
[0319] Referring to FIG. 39, two wafflepod segments 505E and 505G are shown as joined edge to edge by inverted U connector strip 505F. Inverted U connector strip 505F is comprised of a strip body 505C composed preferably of plastic, which forms an approximate isosceles trapezoid in the cross section. A channel 505D with a cross section preferably approximating a downward facing parabola runs the entire length of connector strip body 505C and 505A. Preferably, two symmetrical flared sections 505B are incorporated into strip body 505A, effectively widening the channel 505D at those positions. These flares 505B correspond to the shape and position of two protrusions (not shown) extending inwards from the outside edges of each wafflepod segment.
[0320] Joining of wafflepod segments 505E and 505G involves placing their two edges together, such that the corresponding perpendicular edges are in line, and placing inverted U connector strip 505A and 505F such that the inner edges of strip body 505C engage with the inner walls of the outside edges of wafflepod segments 505E and 505G that are formed by cavities running along the inside perimeter of each wafflepod segment. The inverted U connector is positioned such that symmetrical flares 505B engage with the corresponding protrusions in the edges of the wafflepod segments. In this fashion, wafflepod segments 505E and 505G are fixed such that they cannot move relative to each other along the longitudinal axis of the joined edges and cannot be separated from each other.
[0321] Referring to FIG. 40, a configuration of wafflepod segments 506B is shown whereby wafflepod segments 506B are joined to each other via inverted U connectors 506C. Quadruple inverted U connector 506A is shown, whereby four wafflepod segments are joined at their common intersection by placing an inverted U arm 506D over the edge lips of each pair of adjoining wafflepod segments 506B.
[0322] Referring to FIG. 41, a series of hollow spheroids 601D are shown positioned between a bottom steel reinforcing mesh 601A and a top steel reinforcing mesh 601E. The bottom reinforcing mesh 601A and the top reinforcing mesh 601E are held in a fixed position in relation to each other and to a series of trusses 601C via a combination of bottom connector chairs 601F and top connectors 601B. The bottom connector chairs 601F elevate the overall assembly relative to the ground. The hollow spheroids 601D are fixed relative to the bottom reinforcing mesh 601A and the top reinforcing mesh 601E via an arrangement of clips. The overall assembly is thus an integrated unit that can be transported and installed as a single entity.
[0323] Referring to FIG. 42, a bottom connecting chair 602A is shown. The body 602F of the bottom connecting chair 602A is constructed of a high strength plastic and includes a set of integrated legs 602E to elevate any mesh attached to it off the surface on which the current invention is applied. An aperture 602C is provided in order to accept insertion of an element of mesh such that the mesh is fixed in the lateral dimension relative to the bottom connecting chair 602A. An aperture 602D is provided in order to accept insertion of an element of a steel truss such that the truss is fixed in the lateral dimension relative to the bottom connecting chair 602A. A plastic strap 602B is fixed at one end to the body 602F of the bottom connecting chair 602A and is passed through a slit in an inner protrusion 602G and a slit in an outer protrusion 602H such that the mesh engaged with aperture 602C and the truss engaged with aperture 602D are both held fixed relative to the bottom connecting chair 602A in the vertical dimension. The protrusions 602G and 602H are part of the moulded body 602F.
[0324] Referring to FIG. 43, a bottom reinforcing mesh 603C is shown connected to a series of bottom connecting chairs 603A via engagement with integrated apertures 603B in bottom connecting chairs 603A. In this manner, bottom reinforcing mesh 603C is elevated relative to the respective surface on which the invention is being applied.
[0325] Referring to FIG. 44, a hollow spheroid 604A is affixed to bottom reinforcing mesh 604B via clips 604C that are integrated into the hollow spheroid 604A. Clips 604D are shown ready to be engaged with a top reinforcing mesh.
[0326] Referring to FIG. 45, a hollow spheroid 605C is shown fixed to top reinforcing mesh 605A via clips 605B, which are integrated into the structure of hollow spheroid 605C.
[0327] Referring to FIG. 46, the structure of a hollow spheroid 606A is shown to consist of a top segment 606B and a bottom segment 606C. The two are combined to form a hollow spheroid by means of sliding top segment 606B over an indented lip 606D protruding from and being part of bottom segment 606C and being a close fit with the maximum inside diameter of top segment 606B, thus ensuring that that the two segments are fixed laterally in relation to each other.
[0328] The upper partial spheroid 606B contains two or more indentations in the inner surface, each of which forms an inverted wedge on its cross section with the deeper end of the wedge closest to the surface of dissection but not coincident with it. The lower partial spheroid contains protrusions corresponding in number, location and cross section to the wedge indentations in the upper segment. The cross section of the lower protrusion is a reverse reflection of the cross section of the upper wedge such that when the two segments are joined the wedge indentation engages tightly with the wedge protrusion. The wedge indentation presents a face at its thickest end as does the wedge protrusion. Upon engagement, the faces of the two wedge elements coincide with one another and fix the two segments firmly in relation to the direction of separation. By this means the two segments resist being pulled apart.
[0329] The indented lip in the lower partial spheroid 606C presents a face 606D concentric to the circle formed at the dissection. This face contains one or more protrusions 606H, the thickness of each being such that the outer face of the protrusion is flush with the surface of the partial spheroid. The outer face of the protrusion is preferably approximately rectangular but can be any desired shape within the constraints of engineering and manufacturing. Upper partial spheroid 606B contains one or more slots 606G with their open face at the dissection. The slots 606G are located and shaped so as to coincide precisely with the protrusions 606H when the two partial spheroids 606B & 606C are joined together to form a complete spheroid. By this means the two partial spheroids are fixed relative to each other in relation to rotational displacement.
[0330] Incorporated into the surface profile of lower partial spheroid 606C are a series of cavities, preferably four in number. Upon hardening of material, such as concrete, following its introduction into the structural body being the subject of the current invention, the lower partial spheroid is fixed to the hardened material. By this means the lower partial spheroid, and therefore the entire spheroid by way of both partial spheroids being firmly fixed relative to each other, is fixed relative to the hardened material along the horizontal dimension in all directions.
[0331] Referring to FIG. 47, a bottom reinforcing mesh 607A is fixed relative to a top reinforcing mesh 607M via the engagement of both top and bottom reinforcing meshes 607A & 607C with truss assembly 607C. The truss assembly 607C is connected to the top reinforcing mesh 607M via top locator nut 607B and is connected to the bottom reinforcing mesh 607A via bottom joiner chair 60607D.
[0332] The truss assembly 607C is held in position relative to top mesh by means of top rod 607J passing through an aperture 607N in top locator 607B and subjected to a compressive force relative to top locator 607B via a tightening mechanism described in FIG. 48. The truss assembly 607C is held in position relative to the bottom mesh 607A by means of bottom rods 607K passing through corresponding apertures 607L and held in place by straps 607P.
[0333] Top mesh 607M is held in position relative to top locator 607B via a rod 60607E of top mesh 607M passing through an aperture 607F in top locator 607B and subjected to a compressive force relative to top locator 607B via a tightening mechanism described in FIG. 48.
[0334] Bottom mesh 607A is held in position relative to bottom locator chair 60607D via rods 607G passing through corresponding apertures 607H in bottom locator chair 60607D and being held in place by straps 607P.
[0335] By the combination of connections so described, a structure is obtained whereby the top and bottom meshes 607A & 607M are held in a fixed position relative to one another and given vertical strength by means of being commonly joined by the top and bottom locators 607B & 60607D respectively.
[0336] Referring to FIG. 48, the structure of top locator 608A is shown. A top locator nut 608B incorporates a hollow threaded cylinder 608C and a solid unthreaded stem 608F of a diameter less than threaded cylinder 608C emanating from the inside face of threaded cylinder 608C and terminating short of the lower face of top locator nut 608B.
[0337] An intermediate locator disk 608D incorporates a hollow centre with a diameter sufficient to allow unthreaded stem 608F to pass through and contains two pairs of notches 608G and 608H with openings at the face furthest removed from top locator nut 608B when assembled in the correct manner. One pair of notches 608G are positioned such that a line drawn through the centres would pass through the centre of the circle formed by the hollow interior of intermediate locator disk 608D. The size and shape of apertures 608G are designed to coincide precisely with the diameter of the top rod of the truss assembly as described in FIG. 47. The size and shape of apertures 608H are designed to fit over both the top rod of the truss assembly and a rod of the top reinforcing mesh as described in FIG. 47.
[0338] The top locator threaded stem 608E incorporates a solid base 608J from which four threaded bars 608K emanate. The bars are curved across their width such that were there to be no spaces between the bars they would form a threaded cylindrical stem. The threaded bars 608K are arranged such that two apertures are formed at right angles to each other, each running through the centre of the circle formed by the inner surface of solid base 608J and each extending to an open face at the opposite end of the solid base 608J. The apertures are of a size and shape to produce a snug fit with the rods of the top reinforcing mesh and the top rod of the truss assembly as explained in FIG. 47 when placed over them.
[0339] Thus, the method for connecting the top reinforcing mesh to the truss assembly such that the two elements are fixed strongly relative to each other involves sliding the threaded stem 608E over an arrangement of reinforcing mesh and truss assembly as described in FIG. 47. The intermediate top locator disk 608D is then placed over the threaded stem 608E such that the apertures 608G & 608H mate with the respective rods of the reinforcing mesh and truss assembly. Top locator nut 608B is then threaded onto threaded stem 608E until unthreaded stem 608F places the desired compressive force on the respective rods.
[0340] We refer now to FIGS. 49 to 53.
[0341] Referring to FIG. 49, a complete blade pile is shown with blade bit 701C attached to shaft 701A. A series of helical bearing plates 701B are firmly fixed to shaft 701A.
[0342] Referring to FIG. 50, a blade bit is shown composed of bit shaft 702A, bit body 702D and blades 702B. Bit shaft 702A incorporates slots 2C to create contact lines with the shaft (not shown) that can be welded to strengthen the connection between the shaft and the blade bit. Preferably, blades 702B are fixed to bit body 702D by welding. Preferably, blades 702B are produced with one side shorter than the other and sloping out from the outer edge to create a leading edge in order to enhance the penetration ability for a given torque.
[0343] Referring to FIG. 51, shaft 703A is shown connected to blade bit 703B. Preferably, a threaded bush 703C is welded to top of shaft 703A to provide a means of threading a segment of shaft so as to extend the length of shaft 703A. Shaft 703A incorporates slots 703D to create contact lines for welding threaded bush 703C to shaft 703A added strength beyond that provided by welding the outer circumference of threaded bush 703C to the inner circumference of shaft 703A. Shaft 703A incorporates rectangular protrusions 703E to provide a means by which torque can be applied to shaft 703A by means of an appropriate machine.
[0344] Blade bit 703B incorporates slots 703F to provide contact lines between bit 703B and shaft 703A that can be welded to add further strength to the weld 703G connecting the inner circumference of blade bit 703B and the outer circumference of shaft 703A.
[0345] Referring to FIG. 52, a complete blade pile is shown, with shaft 704B attached to blade bit 704D and incorporating threaded bush 704A. Helical bearing plates 704C are welded firmly to shaft 704B and arranged so as to form an outside diameter progressively larger in proportion to the distance of the helical bearing plate 704C from blade bit 704D.
[0346] Helical bearing plate 704C is composed of helical base plate 704F, which incorporates central hole 704G with a diameter equal to the outside diameter of shaft 704B. Split 704H is the result of helical base plate 704F being evenly deformed perpendicular to its width such that a wide helical strip 704F is created around hole 704G. Helical bearing plate blades 704E are attached to the outer circumference of helical base plate 704F perpendicular to the base plate 704F and in series. Blade 704E is shaped in such a manner that the large edge 704J of the blade 704E contacts the soil prior to the small edge of the blade 704E when the helical bearing plate is rotated clockwise (from the top perspective). In this manner, the larger edge of each blade is able to make direct contact with the soil.
[0347] Referring to FIG. 53, a screw pile cap is depicted, which is circular in shape from the top view, but shows a wider diameter at the bottom than the top when viewed from the side. Preferably, a series of indentations 705B are imposed in the outer surface of the cap, so as to facilitate an integration of the cap with the surrounding soil. A closed cylinder 705C protrudes from the top centre of the cap, separated from outer body 705D so as to form a void 705A. The diameter of cylinder 705C at its bottom where it intersects with the horizontal face of body 705D is smaller than the diameter at its top. Similarly, the diameter of the circular void 705A at its bottom is larger than its diameter at the top. The result is that any material, whether it be soil or concrete, filling void 705A will resist the vertical dislocation of the cap relative to it.
[0348] The body 705D of the cap is hollow, with a closed face offset from the top and an open face presenting at the bottom. A hollow cylinder 5F protrudes from the closed face, sharing the same vertical axis and terminating slightly lower than the bottom of body 705D. Said cylinder incorporates two keyways in order to couple firmly with the top of the blade pile, which contains rectangular protrusions of a matching shape. A regular series of walls connect the outside of said hollow cylinder to the inside surface of the larger cylinder formed by the hollow body such that a series of cavities are formed between the inside and outside cylinders. The said arrangement of cavities, each offering an open face in the downward orientation, enhances the integration of the cap with the host soil.
[0349] Throughout this specification, unless the context requires otherwise, the word comprise or variations such as comprises or comprising, will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.
