SOIL EXTRACTION/GROUTING DEVICE

Abstract

An extraction/grouting device which includes a fluid conduit having a longitudinal extent along a longitudinal axis, a pivoting wand and at least one cutting nozzle. The nozzle being in fluid communication with the fluid conduit. The cutting nozzle being coupled to the pivoting wand that is pivotably extendable relative to the longitudinal axis.

Claims

1-3. (canceled)

4. An extraction/grouting system, comprising: an extraction/grouting device including: a fluid conduit having a longitudinal extent along a longitudinal axis; a pivoting wand; and a plurality of cutting nozzles in fluid communication with the fluid conduit, the cutting nozzles being coupled to the pivoting wand that is pivotably extendable relative to the longitudinal axis; and a casing, the extraction/grouting device being movably extended at least partially within the casing, wherein the device includes a rotatable member to which the pivoting wand is coupled, the rotatable member is rotatable about the longitudinal axis, as the pivoting wand is pivoted about a pivoting axis the first nozzle is supplied with pressurized fluid from the fluid conduit causing soil to be softened, the softened soil flowing upward in the casing, the pressurized fluid supplied to the first nozzle is stopped when the pivoting wand is deployed to a desired angle and the pressurized fluid is supplied to the second nozzle as the rotatable member is rotated about the longitudinal axis, the movement of the rotatable member deploys the second nozzle to soften soil in a radial direction from the longitudinal axis, the system executing the steps of: driving the casing terminated in a sacrificial point into a soil, the driven casing being in proximity to a target structure; deploying the pivoting wand from the casing about a pivoting axis; pressurizing the fluid conduit to thereby send fluid through the cutting nozzles to soften the soil in a direction in which the wand deploys; rotating the pivoting wand about the longitudinal axis as the fluid flows through at least some of the nozzles; and conducting the softened soil up through the casing to form a cavity in the soil, the cavity in the soil having a shape reflective of the movement of the pivoting wand in the rotating step.

5. The extraction/grouting system of claim 4, wherein there is a channel between the casing and the fluid conduit.

6. The extraction/grouting system of claim 4, wherein the sacrificial point is coupled to a bottom of end of the casing, the sacrificial point allowing for displacement of soil as the device is forced into the soil.

7. The extraction/grouting system of claim 6, wherein the sacrificial point is fitted to the bottom end of the casing such that the sacrificial point will separate from the end of the casing when the casing is moved in an upward direction.

8. The extraction/grouting system of claim 6, wherein the casing has a slot through which the pivoting nozzle extends.

9. (canceled)

10. The extraction/grouting system of claim 4, wherein the fluid conduit is a high pressure flexible hose.

11. The extraction/grouting system of claim 4, wherein, the rotatable member to which the pivoting wand is coupled and the fluid conduit extend within the casing along the longitudinal axis.

12. The extraction/grouting system of claim 11, wherein the first nozzle is arranged along a first portion of the pivoting wand such that fluid emanating from the nozzle is directed in a leading first direction when the pivoting wand is pivoted about a pivoting axis.

13-16. (canceled)

17. A method of extraction and grouting, comprising the steps of: driving a casing terminated in a sacrificial point into a soil, the driven casing being in proximity to a target structure; deploying a pivoting wand from the casing about a pivoting axis, the pivoting wand having a plurality of cutting nozzles that are coupled to a fluid conduit having a longitudinal extent in the casing relative to a longitudinal axis; pressurizing the fluid conduit to thereby send fluid through the cutting nozzle to soften the soil in a direction in which the wand deploys; rotating the pivoting wand about the longitudinal axis; and conducting the softened soil up through the casing to form a cavity in the soil, the cavity in the soil having a shape reflective of the movement of the pivoting wand in the rotating step.

18. The method of claim 17, further comprising the step of separating the casing from the sacrificial point by moving the casing upwardly from the sacrificial point prior to the deploying step.

19. The method of claim 18, further comprising the step of further rotating the pivoting wand about the longitudinal axis thereby enlarging the cavity about the longitudinal axis proximate to the target structure.

20. The method of claim 19, further comprising the step of injecting a grout into the cavity under pressure to thereby move the target structure in a selected direction.

21. The method of claim 17, wherein the plurality of cutting nozzles are positioned on differing sides of the pivoting wand.

22. The method of claim 17, wherein the shape of the cavity is a hemispherical shape.

23. The method of claim 17, wherein the shape of the cavity is a cylindrical shape.

24. The method of claim 17, wherein the shape of the cavity is a semi-cylindrical shape.

25. The method of claim 17, wherein the nozzles are fixed to the wand and the plurality of nozzles including a first nozzle and a second nozzle, the first nozzle being directed parallel to the pivoting axis of the wand and the second nozzle being perpendicular to the direction of the first nozzle.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

[0035] FIG. 1 is a cross-sectional side view illustrating an embodiment of a soil extraction/grouting device according to the present invention inserted into a soil;

[0036] FIG. 2 is a side view of the extraction/grouting device of FIG. 1;

[0037] FIG. 3 is a partially sectioned side view of the extraction/grouting device of FIGS. 1 and 2;

[0038] FIG. 4 is a partially sectioned side view of the extraction/grouting device of FIGS. 1-3 in situ with the pivoting extraction wand shown both stowed and extended;

[0039] FIG. 5 illustrates the soil extraction/grouting device of the previous figures in situ with an underground pipe that is to be moved upward;

[0040] FIG. 6 is a perspective view of the extraction/grouting device of the previous figures schematically illustrating voids made in the soil;

[0041] FIG. 7 is a sectioned side view of two extraction/grouting devices of the previous figures shown in the ground with an underground feature that is to be displaced; and

[0042] FIG. 8 illustrates the extraction/grouting device of the previous figures schematically illustrating how additional soil can be removed with the device of the present invention.

[0043] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

[0044] Referring now to the drawings, and more particularly to FIG. 1, there is illustrated a soil extraction/grouting system 10 including a soil extraction/grouting device 12, a sacrificial point 14 and a casing 16 shown positioned in soil S. Extraction/grouting device 12 includes a rotatable member 18, a fluid conduit 20 and a pivoting wand 22. Pivoting wand 22 has a row of cutting nozzles 24 and a row of cutting nozzles 26. Pivoting wand 22 is pivotally coupled to rotatable member 18 about pivoting axis PA, allowing wand 22 to be extended in direction ED through a slot 28 in the side of casing 16. Rotatable member 18 is rotatable about a longitudinal axis LA, which also causes a rotation of wand 22 about axis LA.

[0045] Nozzles 24 are activated by pressurized fluid supplied through fluid conduit 20, which is attached to wand 22. Wand 22 has internal passageways and may have valves to variously direct the pressurized fluid. When nozzles 24 are activated the fluid that sprays therefrom softens and liquifies the local soil which flows up casing 16 and is extracted above the ground. As nozzles 24 spray, wand 22 is moved in direction ED, until deployed to a desired angle, which in FIG. 1 is perpendicular to longitudinal axis LA. As the soil is liquified and removed, a void V is formed where wand 22 has traveled. When wand 22 is at the desired angle nozzles 24 may be deactivated and nozzles 26 are activated to effect a soil removal in direction generally parallel with axis PA. Nozzles 24 provides an at least partially lateral spray relative to the longitudinal extent, and an at least partially radial spray as pivoting wand 22 is deployed.

[0046] Casing 16 is then either partially withdrawn from soil S, leaving sacrificial point 14 in soil S, and there by allowing extraction/grouting device 12 to be rotatable about axis LA, or casing 16 along with extraction/grouting device 12 are rotated about axis LA. As extraction/grouting device 12 is rotated nozzles 26 remove soil about an arc as wand 22 of extraction/grouting device 12 moves. Wand 22 can also be pivoted up and down as rotatable member 18 is rotated to create a hemispherically shaped void V in the event the rotation and pivoting action is completed for a full rotation of extraction/grouting device 12.

[0047] It is also contemplated that extraction/grouting device 12 can be vertically displaced in an up and down fashion while rotatable member 18 is rotated to thereby create a generally cylindrically shaped void V. Once the suitable void V is created, if desired, then a grouting material is supplied by extraction/grouting system 10 to void V to thereby exert pressure in soil S. The grouting may be supplied by way of extraction/grouting device 12, or after the removal of extraction/grouting device 12 from casing 16 (by forcing the grouting down casing 16), or by the insertion of another device into casing 16, not shown.

[0048] Now, additionally referring to FIG. 2 there is shown another view of the present invention rotated 90 degrees about axis LA from the view of FIG. 1, where slot 28 can be seen and an alternate row of nozzles 30 that allow fluid cutting/softening of soil S in an opposite direction from nozzles 26.

[0049] Now, additionally referring to FIG. 3, there is illustrated a feature of the present invention in that wand 22 can be positioned at a selected angle, which is illustrated here at 45 degrees. This allows for a very selective shaping of void V to provide for tailored settling, movement, or vertical displacement of a selected structure or general shaping of the soil.

[0050] Now, additionally referring to FIG. 4, there is illustrated the upward extraction of casing 16 (leaving point 14 in soil S) and the rotational movement of extraction/grouting device 12 about axis LA in a direction R. Here both nozzles 24 and 26 are being used to address the soil. The movements of wand 22 and the activation of nozzles 24, 26 and 30 are carried out by way of controls above ground with the control signals, pressures, or mechanical movements being conducted through an internal structure within rotatable member 18, depending upon the selected control method used in a specific rendition of the present invention.

[0051] Now, additionally referring to FIG. 5, there is illustrated how a targeted structure P, here a pipe P is moved upward. Here a void V has been created beneath structure P with an extraction/grouting system 10, not illustrated here for the purpose of clarity, and another extraction/grouting device 12 is shown with a longitudinal nozzle 32 creating a release void RV. Nozzle 32 may be coupled to wand 22 or an end of member 18. Release void RV is created to remove soil above structure P to ease the downward pressure on structure P. As the movement arrows indicate, a pressurized grout G is inserted into void V causing upward movement of the soil above grout G causing structure P to move upward toward void RV. If structure P is a building, which extends above the surface of soil S, then of course no void RV would be utilized as grout G would be used to stabilize structure P, or to move structure P vertically. Alternately, void V could not be filled with grout and void V along with other voids beneath a structure P can be placed to cause a settling of structure P in a downward direction. With the precise application of voids and grouted voids along a structure a combination of movements can be applied to a structure to settle portions and to raise portions of the structure.

[0052] Now, additionally referring to FIG. 6, there is illustrated the making of voids V1 and V2, with void V1 being hemispherically shaped and void V2 being cylindrically shaped. Voids V1 and V2 could be made sequentially in either order. For purposes of discussion, lets assume that void V2 is formed first to relieve soil from above a structure P, shown here in a schematic form, then void V1 is formed to extend beneath structure P. Then a grout is forced into void V1 to cause structure P to move upward. This is illustrated in another manner in FIG. 7, where two extraction/grouting systems 10 are used to accomplish the movement of structure P.

[0053] Extraction/grouting systems 10 in FIG. 7, may illustrate two systems working in tandem, or sequential uses of one system 10. If used simultaneously then they may be offset along the extent of structure P so as to not physically interfere with each other. It is also contemplated the numerous systems 10 may be used along the extent of structure P. Here soil has been removed from void V3 and is being removed from void V2 in direction 34. Void V1 is semi cylindrically shaped, and grout is being applied as illustrated by arrow 36 to pressurize void V1 putting upward pressure on structure P.

[0054] Now, additionally referring to FIG. 8, there is illustrated how system 10 can be moved vertically to selectively remove soil in sequential steps as illustrated in the dashed sections that can subsequently be formed to join void V. Here structure P is schematically shown above void V, which may be used to provide for a settling of structure P in a controlled manner.

[0055] The present invention includes the special tooling of system 10 as well as, pumps, casings, and directional fluid jets 24, 26, 30 and 32 are used to accomplish the soil extraction from deep within the ground without needing conventional excavation methods. The extraction process removes soil from predetermined locations and elevations below the surface of the ground. The manufactured cavities V, V1, V2, V3 allow the pressure grouting process, as compared to the prior art, to be: [0056] More uniform in volume of grout placed; [0057] More uniform in pressure required to place the grout; [0058] More controlled as pressure and volume become more uniform; [0059] More easily achieves the desired result; and [0060] Minimally invasive.

[0061] Steel pipe or casings 16, typically varying in diameter from 2″-5″ are driven or drilled into the soils beneath the structure P. Depending on the application and results desired, depths can range from just a few feet below the structure to much greater depths. Depending upon the cavity V size desired, soil types, or weight of the structure to be raised, a single-, double-, or quadruple-tipped nozzle arm 22 can be employed. Vertical or horizontal nozzles affixed to the arm can be self-rotating on manually rotated from the surface.

[0062] In preparation to create a cavity, utilizing one embodiment of the present invention, the installed casing or pipe 16 is first retracted a few inches to open the end of the pipe. The retraction separates the casing from the sacrificial drive point 14 or “lost” drill bit, exposing the surrounding soils. The special tooling arm 22 that does the cavity erosion can be referred to as a “jetting knife”. Device 12 is next inserted into the pipe 16 and is positioned at the end of the casing at the exposed soil location. Once device 12 is set in position, water at high pressure is pumped through a hose 20 connected to the arm 22.

[0063] The high-pressure water activates the nozzles 24, which may be rotating tips 24 positioned at the edge of the jetting knife 22 that directs the erosive jets out, perpendicular to the axis of the jetting knife 22 and casing 16. The water jets 24 erode the adjacent soil and flush the eroded soil debris up the pipe 16 to a discharge chamber. The pressures and volumes are adjustable and are set based on cavity requirements, soil types, and density. Wand 22 is deployed outward about pivoting axis PA as the eroded soil debris continues to flow up casing 16.

[0064] Following the extraction of soils adjacent to/below the pipe as wand 22 pivots outward, horizontal jets 26 on the jetting knife 22 are activated and the jetting knife is manually, or by water pressure, activated to rotate about axis LA to create a cylindrical cavity V.

[0065] During the jetting and soil erosion process, the extracted soil and water is contained within the pipe casing 16 with a special cap that inhibits fluid loss out of the top. The cap also holds the jet packer assembly 12 in position and allows for easy vertical alignment adjusting for the heights of cavity V as required. The excess water and soil cuttings are directed out through a “T” connection above ground surface. Following the erosion and water flush steps, compressed air is forced through the jet packer 12 to purge remaining soil cuttings and water from the formed cavity V.

[0066] If utilizing the device 12 to collect soil samples or relics related to historical site investigations, fluid viscosities can be adjusted to extract heavy particles for collection.

[0067] Compaction Grouting: The process most applicable to stabilization of weak soils, and can also be used to raise structure P, which has settled. Its primary use is for soil densification for utility and foundation raising. Due to the lack of lateral confinement, compaction grouting is generally not effective nearer than about 10′ of the surface or an unrestrained downslope. Although densification and raising are obtainable through compaction grouting and adaptable to a wide variety of soil types, it requires extensive investigation, planning, engineering, and with varying results. It also has difficulty lifting masonry, block, or stone foundations due to damage.

[0068] Advantages of the present invention: Applications have minimal disruption and duration since excavation is not required. Work can be performed from inside or outside of a particular structure. All cutting fluids are confined to the discharge hose, so no mess.

[0069] Installations are performed in ½-¼ of the time of compaction grouting requirements. Compaction grouting often requires primary, secondary, and tertiary grouting where the process using the present invention does not. Pipe and/or casing may also be left in place to expedite ongoing operations.

[0070] Most soil types can be compacted to greater densities to increase anticipated greater load requirements. Grouts can be contained to specific locations keeping material volumes low, prices down, limited duration for installation, and faster results in densification and raising. Results are predictable with structures in excess of 2½ inches of settlement or lift.

[0071] Due to the grout's containment, higher soil densities are achieved, with higher load-lifting capabilities and allows a structure to function as designed. The process of the present invention can lift stone, brick, or cinder block foundations uniformly without point-loading as with piers or piles and, to some extent, the same is true with compaction grouting.

[0072] The use of the present invention is far less likely to cause lateral damage to surrounding structure or utilities than conventional compaction grouting due to the forces being directed vertically, not laterally. Pressures are easily controlled and do not require extensive site investigation, planning, or soil analysis.

[0073] In the past, most grouting applications including results, feasibility, pressure application, performance, duration, costs, difficulty, disruption, material consumption, and volumes have been dictated by soil conditions. Many engineers and applicators have attempted to dictate otherwise. Attempting to take a specific soil site condition and say “I'm going to inject this material, at this location, at this pressure, at this volume, and get this result” and most fail to achieve the desired and/or predicted results.

[0074] Advantageously, this new inventive process allows for fairly predictable results due to the containment of grout in a preconceived/preconstructed location V.

[0075] Variable Applications: For very loose cohesive soils, such as sandy and/or silty soils, pre-grouting down the casing increases the cohesiveness of the soil allowing jetting to create a void within the solidified soil mass.

[0076] The pre-treatment grouting inhibits the soil from collapsing into the cavity V during the jetting operation and helps contain the grout, helping to create containment and increased soil densification. A grouted soil mass above the cavity also provides for a more uniform lift of the structure or element, limiting damage. This is especially useful on block, brick, or masonry structures. Greater containment of the grout also allows for higher pumping pressures for lifting heavy structures.

[0077] The extraction/grouting of the present invention is a process and system by which a soil is removed from deep within the ground without excavation. Soils are removed in pre-determined locations and volumes for the purpose of replacing them with various grout composition, including cementitious, to increase soil densities or to raise whole or partial elements of a structure. One use of the present invention is to densify soils in order to increase their load-bearing capacities and stability beneath settled structures to inhibit further settlement or raise the settled segment. Another is to weaken soil cohesiveness and density to create soil consolidation to lower structures or infrastructure to a compromise level.

[0078] Six Soil Extraction Device Applications:

[0079] 1. For the purpose of creating a cavity directly beneath a structure or element, above- or below-grade, to raise it. Particularly in constrained interior applications where high-water tables inhibit excavation without de-watering, or in contaminated soils where excavation is prohibitive.

[0080] 2. To remove contaminated soils or fluids for collection and treatment and a means of washing the soils to better reclaim the contaminated product. Also, a means of introducing bacteria, enzymes, or other products to remediate contaminated soils.

[0081] 3. To isolate contaminated soils via encapsulation.

[0082] 4. To extract soils beneath a structure for the purpose of lowering the item to a comprise level. By accurately constructing a cylindrical cavity to exact dimensions and at specific elevations, soil consolidation can be calculated and predicable. If a more rapid approach is desired, cylindrical cavities can be enlarged, more can be installed, or at multiple elevations. Movement or total arrest can be initiated rapidly by filling any number of the cavities with a cementitious or foam grout, only to be reinitiated at a different elevation if so desired.

[0083] Once the extraction casing is in place, it can remain for weeks or years if needed to continue soil extraction operations as soils compress within the cavity to attain the desired elevation.

[0084] 5. Soil extraction is a minimally invasive, rapid means of extracting soil samples at various elevations below ground or below old sensitive structures without excavation to locate historically significant sites of ancient civilizations. The process can be performed in lakes, rivers, and oceans when excavation is not possible and lidar and radar are ineffective.

[0085] 6. To remove and then replace a weak soil or peat directly beneath a structure or element, to then replace the soils with a higher load-bearing product.

[0086] When heavy relics are found and due to their weight and depths located, it may be necessary to introduce a lower viscosity solution and air volume to retrieve the items for collection and evaluation.

[0087] The following four applications are particularly advantageous for the use of the present invention:

[0088] 1. For lifting: pipelines, foundations, RR trackage, roadways, tunnels, reservoirs.

[0089] 2. Contaminated soils: for washing to collect contaminants, for the removal of soils for collection and treatment, to extract and encapsulate a contaminant and then reintroduce the contaminant into the cavity from whence removed. Introducing enzymes or treatment products into contaminated soils on super fund sites or elsewhere.

[0090] 3. Remove soils: to level pipelines, RR trackage, roadways tunnels, reservoirs, old historically significant structures in Europe and Asia, churches, libraries, castles, hotels, museums.

[0091] 4. Collecting Historical information and artifacts: ancient sites or historically significant sites. Ancient civilizations.

[0092] The following site condition is used as an example of the use of the present invention with the method steps provided as the solution. The client desires to have an interior 6″ diameter pipeline lifted to its original design elevation. Presently, the pipeline distress spans 16 linear feet with a maximum settlement of 3″. Soils have been determined to consist of loose, sandy urban fill.

[0093] Step 1 Locate and Verify Pipeline Distress—This is performed by installing a sewer camera within the pipeline and using a surface sensor to locate the camera head location within the pipeline. A crayon, chalk, or masking tape can be used to mark the location of the pipeline at grade. By installing water within the pipeline, the height of the standing water is an excellent means of estimating the depth and span of the pipe settlement.

[0094] The exact below-grade location of the pipeline can also be determined using small diameter steel rods probing perpendicular to the pipe from above.

[0095] Step 2 Corrective Procedures—Following the verification of the pipeline location, depth, diameter, and the amount of settlement and spans, corrective procedures would be as follows:

[0096] A total of four (4) 3″ diameter holes will be drilled through the slab on grade adjacent to the pipeline and the cores removed. The Pipeline Lifting Device (PLD) component casing 16 is then driven to a depth of 1 foot below the underside of the pipeline. Each system 10 will be offset on 3 foot centers along the span to be lifted. The internal lifting components to extract soil and lift the pipe are then inserted within the casings 16. Soils are displaced with systems 10, and the PLD arms are activated to a horizontal position followed by lifting the PLDs to contact the underside of the pipeline. Liquid spoils are collected in a tote designated to separate liquid (water) from soils.

[0097] Water and the sewer camera are then reinserted during the lifting process to monitor the lifting progress. Hydraulic rams are then used to lift the four PLDs simultaneously.

[0098] When grout is used, the control of the high pressure needed for densification, and especially for lifting, is key to the success of this process. The grout placement process is hydraulic, the larger the surface area contacted by the fluid under pressure directly impacts the extent of pressure required to achieve the desired results, and to move the load. The relationship as to the size of the fluid pool (the spread of the grout volume placed) and the load resistance (weight of the soil zone and structure) are proportional to the extent of pressure required to act on the fluid pool area and lift (move) the load.

[0099] The success of soil and settled structure remediation is dependent upon the ability of the installers and applicators to control the placement of the stiff mortar or foam pressure placed in measured volumes and at controlled high pressures.

[0100] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.