Lead Extension With Improved Assembly And Method Of Use

Abstract

A soil displacement pile for forming a composite pile column is disclosed. The soil displacement pile includes a lead with at least one soil displacement assembly and one or more extensions with paddle assemblies. The soil displacement assemblies include upper and lower helical plates with soil displacement plates between them. The paddle assemblies include triangular paddles extending from opposing sides of the extension shaft at an angle relative to the vertical axis. The combination of soil displacement assemblies and paddle assemblies efficiently creates cavities in the soil for forming pile columns, allowing for larger diameter columns and improved load capacity.

Claims

1. A soil displacement pile system comprising: a) a lead section including: i) a shaft extending along a longitudinal axis between a proximal end and a distal end; ii) at least one soil displacement assembly disposed on the shaft proximate the distal end; b) at least one extension section including: i) a shaft extending along a longitudinal axis between a proximal end and a distal end; ii) at least one pair of paddles extending radially from the shaft, each paddle of the pair disposed on opposing sides of the shaft; wherein the at least one pair of paddles is configured to displace soil radially outwardly and facilitate the flow and agitation of filler material during installation.

2. The system of claim 1, wherein each paddle of the at least one pair of paddles has a triangular shape with a base connected to the surface of the shaft and an apex extending radially outward from the surface.

3. The system of claim 2, wherein the base of each paddle is angled relative to the longitudinal axis of the shaft at an angle between 5 and 35 degrees.

4. The system of claim 3, wherein the angle is 15 degrees.

5. The system of claim 3, wherein the angle is between 10 and 25 degrees.

6. The system of claim 3, wherein the angle of each paddle relative to the longitudinal axis of the shaft is the same.

7. The system of claim 1, wherein the paddles include an opening extending through a surface thereof proximate to the apex, the opening configured to facilitate lifting of the extension section.

8. The system of claim 1, wherein the at least one extension section comprises multiple extension sections, each extension section including at least one pair of paddles.

9. The system of claim 1, wherein the paddles are welded to the surface of the shaft.

10. The system of claim 1, wherein the paddles further comprise radially extending segments fixed thereto, configured to improve channel structure and enhance agitation of filler material.

11. The system of claim 1, wherein the soil displacement pile system is configured to form pile columns greater than eight inches in diameter.

12. A method of forming a composite pile column using the system of claim 1, comprising: a) inserting the lead section into the ground to create an initial cavity; b) attaching the at least one extension section to the lead section; c) rotating the combined lead and extension sections to further displace soil and create a larger cavity; d) introducing filler material into the cavity, wherein the paddles agitate and distribute the filler material during installation.

13. In a soil displacement pile system having a lead section with a shaft and at least one soil displacement assembly, an extension section comprising: a) a shaft extending along a longitudinal axis between a proximal end and a distal end; b) at least one pair of paddles extending radially from the shaft, each paddle of the pair disposed on opposing sides of the shaft; wherein the at least one pair of paddles is configured to displace soil radially outwardly and facilitate the flow and agitation of filler material during installation.

14. The extension section of claim 13, wherein each paddle of the at least one pair of paddles has a triangular shape with a base connected to the surface of the shaft and an apex extending radially outward from the surface.

15. The extension section of claim 14, wherein the base of each paddle is angled relative to the longitudinal axis of the shaft at an angle between 5 and 35 degrees.

16. The extension section of claim 15, wherein the angle is 15 degrees.

17. The extension section of claim 15, wherein the angle of each paddle relative to the longitudinal axis of the shaft is the same.

18. The extension section of claim 13, wherein the at least one pair of paddles comprises multiple pairs of paddles disposed along the shaft.

19. The extension section of claim 13, wherein the paddles are welded to the surface of the shaft.

20. The extension section of claim 13, further comprising a plate connected between the pair of paddles and extending radially from the shaft.

21. The extension section of claim 20, wherein the plate extends about the entire circumference of the shaft.

22. The extension section of claim 20, wherein the plate is disposed at an angle relative to the longitudinal axis of the shaft.

23. The extension section of claim 20, wherein the plate defines an opening along the longitudinal axis between the plate and the shaft to allow for fluid flow therethrough during installation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] FIGS. 1A-1D illustrate a lead section in accordance with one embodiment of the present invention.

[0038] FIG. 2 is a view of a paddle from the section shown in FIG. 1.

[0039] FIG. 3 is a view of distal lead assembly having a soil displacement assembly disposed thereon.

[0040] FIGS. 4A-4C illustrate an assembly in accordance with a second embodiment of the present invention.

[0041] FIG. 5 illustrates the assembly shown in FIGS. 4A-4C.

[0042] FIG. 6 illustrates an alternative embodiment in accordance with one embodiment of the present invention.

[0043] FIG. 7A illustrates a top view of alternative embodiment in accordance with one embodiment of the present invention.

[0044] FIG. 7B illustrates a front view of the embodiment shown in FIG. 7A.

[0045] FIG. 8A illustrates a top view of alternative embodiment in accordance with one embodiment of the present invention.

[0046] FIG. 8B illustrates a front view of the embodiment shown in FIG. 8A.

[0047] FIG. 9A illustrates a top view of alternative embodiment in accordance with one embodiment of the present invention.

[0048] FIG. 9B illustrates a front view of the embodiment shown in FIG. 9A.

[0049] FIG. 10A illustrates a top view of alternative embodiment in accordance with one embodiment of the present invention.

[0050] FIG. 10B illustrates a front view of the embodiment shown in FIG. 10A.

[0051] FIG. 11A illustrates a top view of alternative embodiment in accordance with one embodiment of the present invention.

[0052] FIG. 11B illustrates a front view of the embodiment shown in FIG. 11A.

DETAILED DESCRIPTION

[0053] The present disclosure provides configurations of pile leads and extensions with soil displacement assemblies and paddle assemblies that facilitate the formation of grout, concrete, or cement-based pile columns. The soil displacement assemblies and paddle assemblies push the soil so as to displace it radially outwardly away from a shaft of the soil displacement pile lead and any extensions to form a cavity in which grout, cement, or concrete can be poured to at least partially surround the pile leads and any extensions. The cured grout, cement, or concrete with the embedded pile form a composite pile column. For ease of description, the word filler may be used when describing the material being poured into the cavity. The filler may include grout, cement, concrete, or other suitable material that can be poured into the cavity and hardened to form the composite pile column.

[0054] Referring to FIGS. 1A-1D, a segment 10 of a lead extension in accordance with one embodiment of the present invention is shown. The segment 10 extends between a distal end 20 and a proximal end 30. The segment 10 is connected to one or more second segments (not shown here) on its proximal end 30 or its distal end 20. The distal end segment of the completed unit may include a soil displacement assembly. This is disclosed in FIG. 5.

[0055] The segment 10 extends along a longitudinal axis between its ends 20, 30. In the embodiment disclosed, the segment 10 includes paddles 40 extending from an outer surface 12 of the segment at about a midpoint 14 between the proximal 30 and distal end 20. It will be understood by a person of skill in the art and familiar with this disclosure that the positions of the paddles 40 may vary between the proximal end 30 and the distal end 20, and are not limited to the midpoint 14. It should be noted that the paddles may also be referred to as wings.

[0056] It will be understood by a person of skill in the art and familiar with this disclosure that the positions of the paddles 40 may vary between the proximal end 30 and the distal end 20, and are not limited to the midpoint 14. The paddle 40 positioning may be optimized based on various factors including soil conditions, expected load distributions, installation depth requirements, and the specific characteristics of the filler material being used. For instance, in applications where enhanced agitation is required near the connection point with adjacent sections, the paddles 40 may be positioned closer to the proximal end 30. Conversely, when improved soil displacement is needed at the leading edge during installation, the paddles 40 may be positioned nearer to the distal end 20.

[0057] In alternative embodiments, pairs of paddles 40 may be positioned at multiple locations along the segment 10, such as at quarter-points, third-points, or other strategic intervals that provide enhanced soil displacement and filler material distribution characteristics. The positioning may also be asymmetrical, with paddles 40 located at different distances from each end to accommodate specific installation requirements or to compensate for anticipated loading conditions. Additionally, the segment 10 may incorporate paddles 40 of varying sizes or configurations at different positions along its length.

[0058] In the embodiment disclosed, the segment 10 includes a pair of paddles 40 wherein a first paddle extends from a first surface of the segment and a second paddle extends from a second surface of the segment. In the disclosed embodiment, the first paddle and the second paddle are substantially opposite on the outer circumference surface 12 of the segment 10. In the disclosed embodiment, each paddle 40 has a triangular shape having a base that is connected to the surface of the segment and having an apex 43 radially extending from the surface 12. It will be understood by a person of skill in the art and familiar with this disclosure that the shape of the paddle may vary.

[0059] It should be understood that the number and arrangement of paddles 40 may vary from the paired configuration shown in the disclosed embodiment, and the present invention is not limited to paddle arrangements requiring opposing or balanced configurations. In alternative embodiments, the segment 10 may include a single paddle 40 extending from one surface of the segment without a corresponding opposing paddle. Furthermore, the segment 10 may incorporate three, four, five, or more paddles 40 arranged around the circumference of the segment at various angular positions, not necessarily in opposing pairs. For example, a three-paddle configuration might position paddles at 120-degree intervals around the circumference, while a four-paddle arrangement could utilize 90-degree spacing. The angular positioning of multiple paddles need not be symmetrical or evenly distributed, as operational requirements may dictate specific orientations optimized for particular soil conditions, installation methods, or structural loading patterns. Additionally, paddles of different sizes, shapes, or orientations may be combined on a single segment to achieve customized performance characteristics tailored to specific installation requirements and site conditions.

[0060] In reference to the FIGS., the paddle 40 includes an opening extending 45 through a surface thereof proximate to the apex 43. This hole 45, which is optional, facilitates lifting the segment via a hoist or crane. In other embodiments, the opening 45, is provided for fasteners that mat be used to fix radial protrusions to one or more of the paddles 40. In reference to FIG. 5, the base 41 of the paddle 42 is shown. A person of skill in the art and familiar with the invention will understand the base 41 may be provided with a concave arcuate geometry that corresponds with a concave arcuate geometry of the segment 10, thereby facilitating connection of the paddle 42 to the segment 10.

[0061] The paddles 40 are welded to the surface of the segment. The present invention is not limited in this regard and other forms of fixation may be employed.

[0062] In the embodiment disclosed, the paddles 40 are angled relative to the longitudinal axis of the segment such that the base 41 of the paddle intersects the longitudinal axis at an angle. In the embodiment disclosed in the FIGS., the angle is 15 degrees, although this may vary, for example between 5 and 35 degrees, or more. In some embodiments of the present invention, the base 41 of the paddle 40 is substantially parallel to the longitudinal axis of the segment 10. In reference to FIGS. 1A and 1B, showing top views of the structure, and in reference to FIG. 1C, the surface of each paddle extends in a parallel plane. That is, they are angled in the same direction and not opposing directions.

[0063] It was known to include a soil displacement assembly 60 on the distal segment 50 of the lead. This is illustrated, for example, in FIG. 3. Such soil displacement assemblies were known in the art.

[0064] Up until the present invention, it was understood by people of skill in the art that a soil displacement assembly was required on segment of the assembly. The inventors have discovered that by substituting the paddles for the soil displacement assembly, it is possible to achieve and maintain a better opening for receipt of the grout and it is possible to agitate the grout as it is fed into the system, thereby helping to ensure a more structurally uniform pile.

[0065] The inventors have also discovered that by forming the angle of the paddles in the same direction, it results in improved agitation because it creates a lifting effect on a first side and a pulling down effect on a second side, thereby creating a circulation of grout in the system that enhances the agitation. The inventors have also discovered that the paddles reduce restriction of mobility of grout in the annulus, facilitate mobility of grout along the pile shaft, and achieve greater structural uniformity throughout the pile.

[0066] It should be understood that the number and position of the paddles may vary. For example, in some embodiments, the segment may include multiple pairs of paddles. In other embodiments, the segment may include an odd number of paddles, i.e., there is no opposing paddle.

[0067] In reference to FIG. 2, a view of the paddle of FIG. 1 is shown. Dimensions are provided for reference; however, the present invention is not limited in that regard. The size and dimensions of the paddle may vary in accordance with a number of variables, including the size of the section, soil conditions, installation requirements, and the specific performance characteristics desired for the pile formation process.

[0068] In the disclosed embodiment, the radial extent of the paddles 40 relative to the centerline of the segment 10 is less than or equal to the radial extent of the soil displacement assembly disposed on the lead section. This dimensional relationship ensures that the paddles 40 do not extend beyond the cavity initially created by the soil displacement assembly, thereby maintaining the integrity of the soil displacement process while providing effective agitation and filler material distribution within the established cavity boundaries. It will be understood that while this dimensional relationship represents a disclosed embodiment for many applications, alternative configurations may be employed where specific soil conditions or installation requirements warrant different paddle sizing approaches, provided that the fundamental benefits of soil displacement and filler material agitation are maintained.

[0069] In reference to FIG. 3, a distal lead section is shown. In this embodiment, the distal lead segment does not include any paddles. The section includes a soil displacement assembly 60 at a distal end thereof. This assembly creates the channel behind the assembly.

[0070] In reference to FIG. 4A, an alternative embodiment of the present invention is disclosed, wherein the lead 100 comprises a first segment 120 and a second segment 130. The lead 100 may comprise additional segments not shown herein. The first segment 120 is distal-most in the assembly and it includes a soil displacement 160 assembly at its distal end 122. The first segment 120 further includes a pair of paddles 140 remote from the distal end 122. The second section 130 is fixed axially to the first segment 120 along the longitudinal axis. The second segment 130 includes a pair of paddles 150. In reference to FIG. 4C, the base 151 of the paddle 150 is curved to accommodate the concave arcuate surface of the segment relative to the angle of the base of the paddle when fixed thereto. FIG. 5 shows the components in FIGS. 4A and 4B being assembled. It should be understood that additional lead segments may be used to form the assembly to achieve a longer or deeper pile.

[0071] FIGS. 6-11B disclose alternate embodiments of the paddles, wherein radially extending plates and other protuberances are fixed thereto.

[0072] In reference to FIG. 6, one embodiment is shown. The assembly 200 includes a segment 210 extends along a longitudinal. In the embodiment disclosed, the segment 210 includes paddles 240 extending from an outer surface. The paddles 240 are angled relative to the longitudinal axis of the segment 210 such that the base of the paddle intersects the longitudinal axis at an angle. In the embodiment disclosed in the FIGS., the angle is 15 degrees, although this may vary, for example between 5 and 35 degrees, or more. The assembly 200 further includes a plate 250 fixed thereto. In the embodiment disclosed, the plate 250 is substantially planar and defines an annulus having an outer diameter and an inner diameter. In the embodiment disclose, the plate 250 is angled relative to the longitudinal axis of the segment such the paddle intersects the longitudinal axis at an angle. In the embodiment disclosed in the FIGS., the angle is 75 degrees, although this may vary. The minus indicates that the plate is angled in the opposite direction as the paddles. The plate extends radially outward with an axially extent due to the angle relative to axis. The outer radial extent of the plate is less than the diameter of the displacement assembly.

[0073] The plate serves as a bridging element that connects the opposing paddles, creating a unified displacement and agitation system. By connecting the paddles through the plate structure, the system achieves improved rigidity and enhanced load distribution capabilities, while simultaneously providing additional surface area for soil displacement and filler material interaction.

[0074] The plate's radial extension from the shaft creates an expanded interface with the surrounding soil and filler material, facilitating more effective displacement of soil particles and promoting better distribution of grout, concrete, or cement throughout the cavity. This expanded interface area increases the contact surface between the extension section and the filler material, resulting in enhanced agitation and mixing characteristics that contribute to improved structural uniformity in the completed pile column.

[0075] In the embodiment disclosed in FIG. 6, the plate defines an opening along the longitudinal axis between the plate and the shaft to allow for fluid flow therethrough during installation. This opening configuration provides controlled fluid communication through the plate structure, enabling filler material to flow both above and below the plate during installation while maintaining the structural and displacement benefits of the plate configuration. The opening allows for pressure equalization and improved filler material distribution along the length of the extension section, preventing the formation of air pockets or void spaces that could compromise the structural integrity of the completed pile. The size, shape, and positioning of the opening can be optimized to balance fluid flow characteristics with the structural and displacement functions of the plate, ensuring optimal performance across varying installation conditions and filler material properties. A person of ordinary skill in the invention will understand that it may be practiced without providing the opening.

[0076] In reference to FIGS. 7A and 7B, one embodiment is shown. The segment 310 extends along a longitudinal axis and includes paddles 340 extending from an outer surface. The paddles 340 are angled relative to the longitudinal axis of the segment 310 such that the base of the paddle intersects the longitudinal axis at an angle. A displacement member 350 extends between the paddles 340. The displacement member 350 defines a convex arcuate outer surface and a concave arcuate inner surface in the plane perpendicular to the longitudinal axis. In the embodiment shown, the radial extent of the displacement member 350 is the same as the radial extent of the paddles. There is an opening between the inner surface of the displacement member 350 and the segment 310, thereby providing for free movement and flow of material.

[0077] In reference to FIGS. 8A and 8B, one embodiment is shown. The segment 410 extends along a longitudinal axis and includes paddles 440 extending from an outer surface. The paddles 440 are angled relative to the longitudinal axis of the segment 410 such that the base of the paddle intersects the longitudinal axis at an angle. A displacement member 450 extends between the paddles 440. The displacement member 450 defines a convex arcuate outer surface and a concave arcuate inner surface in the plane perpendicular to the longitudinal axis. In the embodiment shown, the radial extent of the displacement member 450 is the same as the radial extent of the paddles. There is an opening between the inner surface of the displacement member 450 and the segment 410, thereby providing for free movement and flow of material. An axially extending bar 460 is affixed to the displacement member 450 between the paddles.

[0078] In reference to FIGS. 9A and 9B, one embodiment is shown. The segment 510 extends along a longitudinal axis and includes paddles 540 extending from an outer surface. The paddles 540 are angled relative to the longitudinal axis of the segment 510 such that the base of the paddle intersects the longitudinal axis at an angle. A displacement member 550 extends between the paddles 540. The displacement member 550 defines a convex arcuate outer surface and a concave arcuate inner surface in the plane perpendicular to the longitudinal axis. In the embodiment shown, the radial extent of the displacement member 550 is the same as the radial extent of the paddles. There is an opening between the inner surface of the displacement member 550 and the segment 510, thereby providing for free movement and flow of material. A circumferentially extending bar 560 is affixed to the displacement member 550 between the paddles.

[0079] In reference to FIGS. 10A and 10B, one embodiment is shown. The segment 610 extends along a longitudinal axis and includes paddles 640 extending from an outer surface. The paddles 640 are angled relative to the longitudinal axis of the segment 610 such that the base of the paddle intersects the longitudinal axis at an angle. A first displacement member 650 extends between the paddles 640. The displacement member 650 defines a convex arcuate outer surface and a concave arcuate inner surface in the plane perpendicular to the longitudinal axis. A second displacement member 652 extends between the paddles 640, the second displacement member 652 being opposite the first displacement member. The displacement members 650, 652 define a convex arcuate outer surface and a concave arcuate inner surface in the plane perpendicular to the longitudinal axis. In the embodiment shown, the radial extent of the displacement members 650, 652 is the same as the radial extent of the paddles. There is an opening between displacement members and the segment.

[0080] In reference to FIGS. 11A and 11B, one embodiment is shown. The embodiment is similar to that shown in FIGS. 10A and 10B. The interior surface of the first displacement member is configured to receive an additional element. In the embodiment shown, the interior surface includes threads. An exterior shaft or casing may be attached to the system for a number of reasons including grout conveyance, maintenance of open soil annulus, increase cross sectional material of the in place pile assembly, or installation of a bond break.

[0081] The soil displacement pile and soil displacement assembly of the present disclosure can be adapted to form any size pile column needed for a particular job. For example, the soil displacement pile and soil displacement assembly of the present disclosure can easily form pile columns that are greater than eight inches in diameter.

[0082] The present disclosure describes aspects of the present invention with reference to the exemplary embodiments illustrated in the drawings; however, aspects of the present invention are not limited to the exemplary embodiments illustrated in the drawings. It will be apparent to those of ordinary skill in the art that aspects of the present invention include many more embodiments. Accordingly, aspects of the present invention are not to be restricted in light of the exemplary embodiments illustrated in the drawings. It will also be apparent to those of ordinary skill in the art that variations and modifications can be made without departing from the true scope of the present disclosure. For example, in some instances, one or more features disclosed in connection with one embodiment can be used alone or in combination with one or more features of one or more other embodiments.