REINFORCEMENT DEVICES, SYSTEMS AND METHODS FOR CONSTRUCTING AND REINFORCING THE FOUNDATION OF A STRUCTURE

Abstract

The present disclosure relates to reinforcement devices, systems and methods for use in constructing new structures, including post frame structures. Specifically, the present disclosure relates to reinforcement devices, systems and methods for replacing traditional wood and/or precast concrete columns utilized in building a new construction foundation, with a height adjustable foundation column assembly constructed from a corrosion resistant material. The present disclosure also relates to reinforcement devices, systems and methods useful for reinforcing existing post frame structures, particularly those with framing elements requiring repair.

Claims

1. A device for reinforcing an existing structural element of a building, the device comprising: a sleeve having an elongated body comprising a longitudinal center section integrally connected along opposing edges to a pair of opposing longitudinal panels, wherein the opposing panels and the center section form an adjustable opening for engaging the structural element.

2. The device of claim 1, wherein each panel has a length equal to a length of the center section.

3. The device of claim 1, wherein the longitudinal center section has a corrugated shape.

4. The device of claim 3, wherein the center section includes a plurality of alternate ridges and grooves along a length of the center section.

5. The device of claim 2, wherein each panel has a corrugated shape.

6. The device of claim 5, wherein each panel includes a plurality of alternate ridges and grooves along a length of the panel.

7. The device of claim 1, wherein the opening is substantially a C-shape.

8. The device of claim 7, wherein the opening includes an inside surface adapted for engagement with the structural element of the building.

9. The device of claim 7, wherein the inside surface is configured to engage an outer surface of the structural element forming a reinforcing structure.

10. The device of claim 1, wherein the structural element is a column or post of an existing building.

11. A sleeve for reinforcing an existing structural element for a building, the sleeve comprising: a longitudinal center section; a first longitundinal leg and a second opposing longitudinal leg, each leg having a length equal to the center section is connected parallel along opposing edges of the longitudinal center section; and, wherein the center section and opposing legs together form a substantially C-shape opening having an inner surface adapted for receiving an outer surface of the structural element.

12. The sleeve of claim 11, wherein the center section has a corrugated shape formed from alternate ridges and grooves.

13. The sleeve of claim 11, wherein the center section includes a longitudinal raised portion.

14. The sleeve of claim 11, wherein each leg has a corrugated shape formed from alternate ridges and grooves.

15. The sleeve of claim 11, wherein the inner surface of the sleeve contacts the outer surface of the structural element creating a reinforcement structure.

16. A method for reinforcing a support element of an existing structure, the method comprising the steps of: creating a space around the support element of the existing structure; placing a reinforcement device comprising a multi-sided corrugated sleeve having an opening in the space to substantially surround the support element; driving the reinforcement device below a grade level; and, securing the reinforcement device to the support element.

17. The method of claim 16, wherein the step of placing the multi-sided sleeve around the existing column further includes sliding the sleeve into contact with the support element.

18. The method of claim 17, wherein the opening of the sleeve is adjustable for contact with the support element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.

[0032] FIG. 1 illustrates a perspective view of a post frame structure incorporating an embodiment of a reinforcement device, particularly a height adjustable column assembly according to the present disclosure;

[0033] FIG. 2 illustrates a perspective view of the height adjustable column assembly in use with a post frame structure according to the present disclosure;

[0034] FIG. 3 illustrates an embodiment of the height adjustable column assembly according to the present disclosure;

[0035] FIG. 4 illustrates an embodiment of a the height adjustable column assembly according to the present disclosure supporting a board for a structure;

[0036] FIG. 4a illustrates a front view of an embodiment of a height adjustable column assembly according to the present disclosure;

[0037] FIG. 4b illustrates a front view of an embodiment of a height adjustable column assembly for use as a corner support according to the present disclosure;

[0038] FIG. 4c illustrates a front view of an embodiment of a height adjustable column assembly for use as a corner support according to the present disclosure;

[0039] FIG. 5 illustrates an interior view of a post frame structure incorporating an embodiment of a reinforcement device, particularly a reinforcement sleeve according to the present disclosure;

[0040] FIG. 6 illustrates a perspective view of an embodiment of a reinforcement sleeve according to the present disclosure;

[0041] FIG. 6a illustrates a close-up of an uplift tab found on the reinforcement sleeve shown in FIG. 6;

[0042] FIG. 6b illustrates a perspective view of an embodiment of a reinforcement sleeve according to the present disclosure;

[0043] FIG. 7 illustrates the reinforcement sleeve according to the present disclosure positioned around a target column; and,

[0044] FIG. 8 illustrates an interior view of a post frame structure incorporating an embodiment of a reinforcement sleeve according to the present disclosure.

DETAILED DESCRIPTION

[0045] The present disclosure relates to devices, systems and methods for constructing a foundation and replacing the traditional wood and/or precast concrete columns used for supporting a structure, such as a post-frame building. Specifically, the present disclosure relates to improved reinforcement devices, systems and methods useful in the construction of solid, corrosion-resistant foundations for new buildings, including pole or post-frame buildings. The present disclosure also relates to another embodiment of improved reinforcement devices, systems and methods useful for reinforcing and stabilizing existing structural posts of a building, such as existing wooden columns of a post frame or pole buildings. Additionally, the present disclosure relates to a system and method for utilizing a reinforcement device for increasing the height of an existing structure, thereby increasing the useful interior space of a structure to accommodate larger pieces of equipment and machinery and/or to provide additional storage capacity.

[0046] Now referring to the figures, wherein like numerals refer to like parts, FIGS. 1-4a-4c illustrate a reinforcement device 100, specifically, a height adjustable column assembly having a height adjustment mechanism therein. FIGS. 5-7 illustrate a reinforcement device, specifically a reinforcement sleeve useful for stabilizing and strengthening existing columns and/or posts of existing building structures, such as pole barns constructed from wooden posts. FIG. 8 illustrates an embodiment of a reinforcement device used for lifting an existing structure and increasing the interior space of the structure.

[0047] Creating a foundation for a structure, particularly a post-frame or pole barn structure 500, that is resistant to changing weather conditions, rot or decay, and insect-infestation, is vital for the long-term survival of the structure. Additionally, having options away from traditional wood and precast concrete as foundations supports is desirable to meet many of these requirements. As shown in FIGS. 1-3 and 4a-4c, an embodiment of a reinforcement device in the form of a height adjustable column assembly 100, is provided for use in the construction of a structure 500. The height adjustable column assembly 100 includes a column body 102 having a top 104 and a bottom 106, a bracket 120, 128 at the top of the column and a height adjustment mechanism 130. As shown in FIG. 2, for use as a foundation column, the column body 102 of the height adjustable column assembly 100 is placed within a hole 400 excavated for the perimeter of the foundation 520, while the bracket 120, 128 remains above the ground 420 for receiving and securing boards 300 (also referred to as planks or splashboards) used to create the foundation ultimately supporting the entire structure 500.

[0048] As shown in FIGS. 3 and 4a-4c, the column body 102 of the present height adjustable column assembly 100 is generally a cage formed from a plurality of reinforcing vertical bars 112, also referred to as rebar, positioned to form an outer perimeter of the cage. For example, in one embodiment shown in FIG. 4a, four, evenly-spaced vertical bars 112 form a rectangular cage of the column 102. It should be understood that although four bars are shown, any number of vertical bars may be used to create the cage structure of the column. At least one reinforcement anchor 114 spans an interior space 116 inside the perimeter of the cage. Depending on the configuration of the column body 102, any number of reinforcement anchors may be incorporation. The reinforcement anchor 114 has generally a four leg star-shape, where each leg 114a of the anchor is rigidly connected, such as by welding, to each of one of the vertical bars 112. The reinforcement anchor 114 provides additional strength to the column body 102 and maintains the integrity of the column body as it is surrounded by dirt, gravel or concrete after the column assembly 100 is placed in the ground and leveled appropriately.

[0049] The top 104 of the column body 102 further supports a bracket 120, 128. The bracket 120, 128 is designed to receive and secure the boards 300, such as the splashboards or planks used to create the foundation, as well as, the upright column walls 510 for the building (FIGS. 3 and 4). As shown in detail in FIGS. 4a and 4b, the bracket 120 includes at least one upright arm 122 connected to a base 124. Each upright arm 122 further includes a notch 122a on an outer edge of each upright arm, the notch adapted for receiving a levelling string (not shown) useful in determining the overall level position of the column assembly 100. In another embodiment, the bracket 128 includes two upright arms 122 opposing each other and connected together by the base 124, forming a U-shaped bracket 128. The designated use of the height adjustable column assembly 100, as either a side wall column 128 (FIG. 4a) for use in the construction of a long side of the proposed building, or as a corner column 120 (FIG. 4b) for use in the joining of a corner of the propose building, dictates which embodiment of the bracket 120, 128 is needed. The bracket 120, 128 further includes a lip 129 which is used to further guide and support the vertical wall column 510 placed within the bracket 120, 128.

[0050] As shown in FIGS. 4a and 4b, the bracket 120 includes at least one integrated side support bracket 126. The side support bracket 126 is designed to receive a board 300 or plank, such as a splashboard or grade board used to create the foundation 520 of the building (FIGS. 3, 4 and 4c). Side support bracket 126 includes a vertical centerline in the form of a slot 126a used for accurate measurement of column spacing (typically about 8 feet apart) allowing precise placement of building columns (FIGS. 4a, 4b) when setting out the perimeter of the building. Depending on the placement of the height adjustable column assembly 100 in the construction of the foundation, the integrated side supports 126 are positioned on one side of the base 124 of the bracket 128 (FIG. 4a), or on perpendicular connected sides of the bracket 120, such as for corner placement (FIGS. 4b and 4c).

[0051] During construction of a new building, after multiple adjustable column assemblies 100 are placed in each of the respective excavated holes around the proposed perimeter of a building, the side supports 126 of each assembly engage a board 300, spanning across each of the assemblies (FIG. 4) to begin building the foundation 520. The column assemblies 100 are leveled through placement of a leveling string along each notch 122a on the outer edge of each upright arm 122. A laser level (not shown) is used in conjunction with the leveling string after it is placed in the notch 122a to assist in accurately leveling each of the column assemblies 100 after placement. After leveling the assemblies 100, grade boards or splashboards 300 are placed within each of the side support brackets 126. Because each grade board 300 interlocks within the side supports 126 of the column assembly 100, the entire foundation system is stabilized and no post movement occurs when installing structural columns 510 for ultimately supporting trusses 512 of the structure 500. The combination of the side supports 126 with the splashboards 300 keeps each of column assemblies 100 in position in the excavated hole 400 before the hole is filled with dirt, gravel or concrete and secured.

[0052] The present height adjustable column assembly 100 further includes a height adjustment mechanism 130. The height adjustment mechanism 130 includes a first threaded rod 132 disposed vertically above and through the bracket 120, 128, and into a second threaded rod 134, which is disposed vertically from the top 104 of the column body. The first threaded rod 132 extends downward through the column body ending at a base or foot plate 136, which is set at the bottom of an excavated hole. The foot plate 136 includes an angled bottom 137, which is adapted to engage the floor of the excavated hole, providing resistance when the height adjustment mechanism 130 is rotated to adjust the height of the assembly 100.

[0053] The height adjustment mechanism 130 provides an advantage over standard foundation columns because it provides the option to adjust the present adjustable column assembly 100 on-site, with precision, while the assembly is in an upright position and placed within an excavated hole. Rough height adjustments can be made prior to installation of the adjustable column assembly 100 into the excavated hole; however final adjustments can be made through the height adjustment mechanism 130. Specifically, the first threaded rod 132 passes through the bracket 120 for telescoping engagement with the second threaded rod 134. Using an appropriate tool, such as a screw gun, the first threaded rod 132 is rotated to precisely adjust the vertical height of the bracket 120, 128 after placement of the column assembly 100 into the excavated hole 400. The first threaded rod 132 can then either be removed or cut, so that a wall board 510 can be secured upright in the bracket 120 using known fasteners (FIG. 3). Thus, the adjustment mechanism 130 is useful to accommodate post holes of inconsistent depths and levels, because it permits custom, on-site levelling of the foundation boards 300.

[0054] The present height adjustable column assembly 100 is designed to replace the standard wood, concrete, or combination of both, traditionally used as foundation columns in post-frame or pole barn construction. Constructed from any suitable corrosion-resistant material, such as galvanized steel, the present height adjustable column assembly 100 is light-weight (weighing less than 60 pounds) and easily maneuverable for placement within an excavated hole 400. However, and unlike traditional wooden posts, which can rot and potentially fail, the present column assembly 100 is not susceptible to the elements or insect infestation, nor will the present column assembly expand and contract due to freezing and thawing. Additionally, and unlike traditional precast concrete columns, which are heavy and hard to maneuver once set in place, the light-weight construction of the present column assembly 100 allows for easy placement and adjustability, particularly in view of the height adjustment mechanism 130. Concrete columns as well can be susceptible to cracking and water damage, which can again jeopardize the overall stability of a structure.

[0055] Installation of the present height adjustable column assembly 100 in the construction of a post-frame building 500 is significantly easier than traditional foundation systems. Initially, a series of holes 400 are dug using known methods (for example, manually or using an auger) to create the intended perimeter of the building 500. A separate height adjustable column assembly 100 is set into each hole 400 (FIG. 2). Each height adjustable column assembly 100 comes preassembled, and the pre-drilled holes make for simple attachment using known fasteners to the integrated grade boards 300 or splash boards, which are set into the side support brackets 126 of the column assembly. The present column assembly 100 is much lighter than traditional wooden posts, making lifting safer, easier and reducing the need for heavy machinery to assist in transportation and installation. Each column 100 can be adjusted without difficulty and with precision while upright, which eliminates the need to correct wood post lengths on site. Additionally, another advantage of using the present adjustable column assembly 100 is that post hole depths do not need to be exact, and the standard height industry variation of +/3 inches is done away with. After the appropriate height adjustment is complete using the height adjustment mechanism 130, the excavated holes 400 can be filled with dirt, gravel or concrete to set the adjustable foundation column assemblies 100 in place to create the foundation.

[0056] The features and advantages offered by the present height adjustable column assembly 100 mean that installation of the foundation column is quick, yet precise. Each column assembly 100 can be accurately put in place quickly, with a typical installation of an entire foundation for a post-frame structure being completed in a single day. The speed and precision of installation makes the column assembly 100 ideal for stub ahead projects; crews can dig, set the columns and install the splashboard prior to concrete backfill. This is also beneficial to the new building owner because it allows subsurface work (plumbing, electrical, in-floor heat, etc.) to be complete and concrete flooring poured prior to the crew returning to build the building.

[0057] In short, the time savings in installation combined with the durability of foundation built using the present adjustable column assembly 100 translate directly into extensive cost and labor savings when compared to other foundation methods. The lightweight nature of the present column assembly 100 and the reduced need for tools make job sites safer, resulting in more efficient crews. Since column heights can be easily adjusted on site, supporting structural wood columns can arrive pre-cut and ready for attachment to the foundation system.

[0058] Advantages of the present height adjustable column assembly 100 include that it is invulnerable to the rot, decay and insect damage that traditional wooden posts are susceptible to, nor will the present foundation column expand and contract due to freezing and thawing. The superior strength of the galvanized steel foundation column of the present assembly 100 means that the structural foundation will never twist or warp, allowing foundations that utilize the present device and system to be more durable and well-protected against destructive natural forces than the average post frame building foundation.

[0059] As an alternative to new construction of a building, oftentimes there is a need or desire to repair and reinforce existing post-frame structures, specifically the wood foundation columns found in many post-frame structures, barns and other buildings. Repair or reinforcement is preferred in terms of time and costs over complete replacement of wooden columns in many of these structures. Additionally, razing a structure may not be an option if the structure has historical or family value.

[0060] As shown in FIGS. 5-8, an embodiment of a reinforcement device in the form of a multi-sided sleeve 200, is provided, which is useful for engagement with existing wooden columns 250 in post frame buildings. As illustrated in FIGS. 5 and 6, the reinforcement sleeve 200 includes an elongated body 210 comprising a longitudinal center section 212 integrally connected to a pair of opposing longitudinal legs 214 or side panels having a length equal to the center section. Each leg 214 includes multiple angles or bends 216. It should be understood that the angles or bends can vary in number and degree, and are adjustable for accommodating columns or posts of varying sizes. The resulting structure is a three-side configuration with an opening 218 having an inner surface 218a that enables the sleeve to be adjusted and wrapped around three sides (the face and two sides) of an existing column 250 or post having a variety of shapes and sizes. Optionally, as shown in FIG. 6b, the sleeve 201 may include a slightly modified configuration, which is useful for corner or jamb columns. In this corner sleeve 201, the side panels 202 include an outer lip 203 configured for meeting the walls of a structure at the corner of the structure.

[0061] The reinforcement sleeve 200 has an overall corrugated shape, including a plurality of curved bends 216, folds or parallel and alternating ridges and grooves formed within the side panels 214 and the center section 212. For example, and as shown in FIG. 5, in one embodiment, the center section 212 is includes a raised center 212a. Additionally, each side panel 214 includes a raised portion 214a in each panel. The raised center 212a and side panel raised portions 212a, 214a provide the sleeve 200 with the adjustability to fit any shape of existing column 250, and lends strength to the sleeve. It should be understood that the raised portions 212a and 214a of the center section and side panels, respectively, can have any shape of bend, curve, ridges or grooves, and thus the disclosure should not be limited to the embodiment shown.

[0062] As shown in FIGS. 6 and 6a, the reinforcement sleeve 200 further includes at least one uplift tab 222 positioned on one or both of the side panels 214, The uplift tab 222 includes a plurality of teeth 224 (FIG. 6a). When the reinforcement sleeve 200 is placed over the existing wooden column 250, and driven down around the column with a suitable manual tool (i.e., hammer or maul), jack hammer, hydraulic device or another other suitable means for driving the sleeve into the ground, the teeth 224 of the uplift tab 222 engage into the sides of the column 250 (FIGS. 7 and 8). In this manner, the reinforcement sleeve 200 is secured around the wooden column 250, and it cannot be removed.

[0063] The reinforcement sleeve 200 can be constructed from any suitable material, preferably steel, including galvanized steel for strength, longevity and corrosion-resistance. Additionally, the reinforcement sleeve 200 can have any length required for the particular project. For example, a sleeve 200 used for strengthening an existing column or post may be shorter in length than a sleeve that will be used for extending the height of a structure. Once installed into the ground 230 around an existing support column 250, the reinforcement sleeve 200 can be secured to the existing support column, using any manner of fastener including nails, screws, bolts, etc., through fastener holes 220 on the sleeve. The reinforcement sleeve 200 acts to stiffen and reinforce the lower portion of the wooden column 250 against lateral, uplift, and downward pressures. Additionally, straps (not shown) may be used to further fasten the reinforcement sleeve 200 around the column 250 or post.

[0064] Installation of the reinforcement sleeve 200 may be completed with a specialty hydraulic driving device, similar to an automatic jack hammer, which mechanically drives the sleeve into the ground around the target column 250. An advantage of using the hydraulic driver is that it reduces the amount of digging required to place the reinforcement device 200 into position. Although a slight amount of digging may be required around the base of the post or column to initially place the reinforcement device 200, the driver secures the reinforcement device below grade using less time and manpower than traditionally required to place a second securing post. It should be understood that in place of the described driver, the reinforcement sleeve can also be installed using any suitable manual tool (i.e., hammer or maul), jack hammer, or another other suitable means for driving the sleeve into the ground.

[0065] Wood columns used to construct post frame buildings tend to fail over time due to dry rot and decay caused by microbial activity at the soil surface and just below the surface. This creates a risk of column failure or building damage, which is a real problem for the building owner, and can be very expensive to repair. The present disclosure also includes a system and method for reinforcing a column, post or other supporting structure for a building using the reinforcement device 200.

[0066] The system and method for reinforcing and/or stabilizing a column 250 or post includes the steps of initially digging a shallow hole 230 or trench around the base of the target column 250. The reinforcement sleeve 200 is then positioned within the hole 230 and over the existing column 250 from inside the building. Because of the corrugated shape of the reinforcement sleeve 200, the center section 212 and legs or side panels 214 of the sleeve cradle and contact the column at multiple contact points as shown in FIG. 5. For example, as noted in the figure, the raised portions 212a, 214a of each of the center section and legs do not directly contact the column 250. The corrugated shape of the reinforcement sleeve 200 provides strength and spacing needed to drive the sleeve into position around the column. If the sleeve 200 fit tight against the column 250, it would be harder to drive the sleeve down into position.

[0067] Although a reinforcement sleeve 200 is described as an option for reinforcing an existing wooden column, there is an option to use the height adjustable column assembly 100 described above in the repair of a structural column. Specifically, the existing column can be dug out of the ground and removed. The adjustable column assembly 100 would then be positioned in the ground, completely replacing the wooden column. Because the adjustable column assembly is not susceptible to the elements, or insect infestation, it would provide a long-term solution to maintaining the foundation of the existing building.

[0068] For decades, post frame buildings were built all across America that were designed to store equipment and machinery that was much smaller than what is in use on today's modern farms. As a result, many of these otherwise useful buildings are being removed to make room for new buildings with higher interior clearances. However, there is often a reason to save and restore existing buildings, including costs, historical value and sentimental value.

[0069] The present disclosure includes a system and method for raising the height of an existing structure by up to 36, thereby increasing the useful interior space. The system and method for raising the height of a structure includes using the present reinforcement sleeve 200. The reinforcement sleeve 200 can have any suitable length, for example up to 12 feet long, which makes the reinforcement sleeve useful for raising an older, shorter building to a newer height. Once the reinforcement sleeve 200 is installed around an existing column 250 as previously described, the existing wood columns can be extended up to 36, thereby increasing the interior clearance and allowing the height needed for today's modern farm equipment, construction equipment, or just to provide additional interior storage space within an existing structure.

[0070] The method of raising an existing structure begins with cutting an existing column will both sides and on the face of the column. The reinforcement sleeve 200 will be driven into the ground (using some form of a driver as described above), leaving a suitable portion of the sleeve above grade. The remaining portion of the column 250 would then be cut separating the column into two pieces. The building or structure would be jacked up or lifted incrementally using known methods and equipment (i.e., jacks), until it reached the desired height. The gap from the lift would be filled with an appropriate filler. A vertical fastener, such as a steel strap would be used to fasten and tie all the pieces together, including the sleeve 200, which would also be attached to the column 250. After raising the structure to the desired height, any void left under the existing sidewall would be filled in with appropriate material, for example, a new steel wainscot.

[0071] It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. Further, references throughout the specification to the invention are nonlimiting, and it should be noted that claim limitations presented herein are not meant to describe the invention as a whole. Moreover, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.