WO2016100345A1

WO2016100345A1 - Metal foundation

Info

Publication number: WO2016100345A1
Application number: PCT/US2015/065824
Authority: WO
Inventors: Michael Pope
Original assignee: New Generation Steel Foundations, LLC
Priority date: 2014-12-16
Filing date: 2015-12-15
Publication date: 2016-06-23

Abstract

A foundation including first and second wings, each including first and second wing portions, a bent portion, first and second connection plates disposed respectively on the bent portions of the first and second wings. The foundation also includes connectors connecting the first and second connection plates and the bent portions of the first and second wings to each other, and a base portion disposed on an edge of each of the first and second wings and first and second connection plates. The first and second wing portions and the bent portion, of each of the first and second wings, comprise a single sheet of metal.

Description

Title of Invention: METAL FOUNDATION

TECHNICAL FIELD

[0001] Exemplary embodiments of the present invention relate to a foundation and method of fabricating and using the same. In particular, exemplary embodiments of the present invention relate to metal plates that are bent and bolted together, which can then be inserted into the ground and used as a foundation.

BACKGROUND ART

[0002] Conventionally, various types of structural loads may be supported through the use of foundations inserted into the ground. Foundations may be used to support communication towers, transmission and utility poles, roadway signs, retaining and sound walls, and the like. Foundations may be subject to four testing forces comprising compression, uplift, lateral, and torsional. The effect of the testing forces may be understood by moment and shear stress calculations deduced by measuring deflection, rotation, settlement, and uplift of the foundation. Foundations may be subject to shear and bending stresses to measure settlement, uplift, rotation, and deflection before installation.

[0003] One type of foundation is a concrete caisson, where a hole is drilled in the ground and cast concrete fills the drilled hole. Structural reinforcement, such as steel rebar, may be disposed in the concrete. However, there are some disadvantages to concrete caissons, such as associated construction costs. For instance, it may be necessary to build roads leading to the installation site for the caisson so a truck can pour concrete therein. Construction costs may quickly escalate since multiple trucks carrying concrete may be needed to fill a single caisson. Further costs and time delays associated with caisson formation may be from rebar, rebar piers, machinery such as excavators, front loaders, and cranes, fuel, grounding wire, and labor.

[0004] There may also be a lengthy construction period for forming concrete caissons, including site selection, equipment deployment, hole excavation and dewatering, rebar installation, and concrete pouring. Concrete caissons may require strength testing between 14 and 28 days, and only after the concrete has set may the top load then be installed. There is also the potential for delays due to weather, further increasing the construction period.

[0005] The above information disclosed in this Background section is only for enhancement of understanding of the background of the inventive concept and therefore it may contain information that does not form any part of the prior art nor what the prior art may suggest to a person of ordinary skill in the art.

SUMMARY OF THE INVENTION

[0006] Exemplary embodiments of the present invention provide a foundation including wings each made of a single metal sheet and that are connected together.

[0007] Additional features of the inventive concept will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the inventive concept.

[0008] A foundation including first and second wings, each including first and second wing portions, a bent portion, first and second connection plates disposed respectively on the bent portions of the first and second wings. The foundation also includes connectors connecting the first and second connection plates and the bent portions of the first and second wings to each other, and a base portion disposed on an edge of each of the first and second wings and first and second connection plates. The first and second wing portions and the bent portion, of each of the first and second wings, comprise a single sheet of metal. [0009] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The accompanying drawings, which are included to provide a further understanding of the inventive concept, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the inventive concept, and, together with the description, serve to explain principles of the inventive concept.

[0011] Fig. 1 illustrates a perspective view of a metal foundation according to an exemplary embodiment of the present invention.

[0012] Fig. 2 illustrates a cross-sectional view of the metal foundation of Fig. 1, taken along line Ι-Γ.

[0013] Figs. 3A and 3B illustrate cross-sectional views of one wing of the metal foundation of Fig. 1.

[0014] Fig. 4 illustrates a side view of a metal foundation according to an exemplary embodiment of the present invention.

[0015] Figs. 5 A and 5B illustrate partial side views of the metal foundation of Fig. 1.

[0016] Fig. 6 illustrates a side view of a connection plate of the metal foundation of

Fig. 1.

[0017] Fig. 7 illustrates a top view of the metal foundation of Fig. 4.

[0018] Fig. 8 illustrates a cross-sectional view of the metal foundation of Fig. 4.

MODE FOR CARRYING OUT THE INVENTION

[0019] In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of various exemplary embodiments. It is apparent, however, that various exemplary embodiments may be practiced without these specific details or with one or more equivalent arrangements. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring various exemplary embodiments.

[0020] In the accompanying figures, the size and relative sizes of layers, films, panels, regions, etc., may be exaggerated for clarity and descriptive purposes. Also, like reference numerals denote like elements.

[0021] When an element or layer is referred to as being "on," "connected to," or "coupled to" another element or layer, it may be directly on, connected to, or coupled to the other element or layer or intervening elements or layers may be present. When, however, an element or layer is referred to as being "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers present. For the purposes of this disclosure, "at least one of X, Y, and Z" and "at least one selected from the group consisting of X, Y, and Z" may be construed as X only, Y only, Z only, or any combination of two or more of X, Y, and Z, such as, for instance, XYZ, XYY, YZ, and ZZ. Like numbers refer to like elements throughout. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

[0022] Although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers, and/or sections, these elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are used to distinguish one element, component, region, layer, and/or section from another element, component, region, layer, and/or section. Thus, a first element, component, region, layer, and/or section discussed below could be termed a second element, component, region, layer, and/or section without departing from the teachings of the present disclosure. [0023] Spatially relative terms, such as "beneath," "below," "lower," "above," "upper," and the like, may be used herein for descriptive purposes, and, thereby, to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the drawings. Spatially relative terms are intended to encompass different orientations of an apparatus in use, operation, and/or manufacture in addition to the orientation depicted in the drawings. For example, if the apparatus in the drawings is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the exemplary term "below" can encompass both an orientation of above and below. Furthermore, the apparatus may be otherwise oriented (e.g., rotated 90 degrees or at other orientations), and, as such, the spatially relative descriptors used herein interpreted accordingly.

[0024] The terminology used herein is for the purpose of describing particular embodiments and is not intended to be limiting. As used herein, the singular forms, "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. Moreover, the terms "comprises," comprising," "includes," and/or "including," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components, and/or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

[0025] Various exemplary embodiments are described herein with reference to sectional illustrations that are schematic illustrations of idealized exemplary embodiments and/or intermediate structures. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, exemplary embodiments disclosed herein should not be construed as limited to the particular illustrated shapes of regions, but are to include deviations in shapes that result from, for instance, manufacturing. Thus, the regions illustrated in the drawings are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to be limiting.

[0026] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure is a part. Terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense, unless expressly so defined herein.

[0027] Fig. 1 illustrates a perspective view of the metal foundation 10 according an exemplary embodiment of the present invention, and Fig. 2 illustrates a cross-sectional view of the metal foundation 10, taken along line Ι-Γ of Fig. 1.

[0028] The metal foundation 10 may include a first wing 100, a second wing 200, and connection plates 400. The wings 100 and 200 and connection plates 400 may be made of galvanized steel or other metal suitable for permanent installation into the ground. Each wing 100 and 200 and connection plates 400 may be formed through any process that can create each single metal sheet template having the proper dimensions. The final wing form is fabricated by placing the template in a brake and bending at appropriate angles.

[0029] According to the present exemplary embodiment, the first and second wings 100 and 200 are formed to be substantially symmetrical. By forming each wing to be symmetrical, it is possible to utilize economies of scale. Also, symmetrical wings that have not yet been assembled into the metal foundation 10 may be easily transported to a construction site, since the wings may be stacked on each other.

[0030] The first and second wings 100 and 200 and connection plates 400 each have holes 300 disposed therein, and the first and second wings 100 and 200 and connection plates 400 may be connected together using connectors (not shown) disposed through the holes 300. Although not shown, the entire first and second wings 100 and 200 may contain the holes 300. The connectors may include mechanical fasteners such as bolts, rivets, clips, studs, and clamps. That is, the first and second wings 100 and 200 and connection plates 400 are not welded together since connectors are used instead. Alternatively, only the first and second wings 100 and 200 may be used to form the metal foundation 10, using only two pieces of metal (excluding connectors).

[0031] The metal foundation 10 according to the present exemplary embodiment may be held together by at least one connector extending through the first and second wings 100 and 200 and the connection plates 400. Since the metal foundation 10 according to the present exemplary embodiment has first and second wings 100 and 200 that are made of a continuous piece of metal across the device, torsional, compression, uplift, and lateral forces may be dispersed along the wings of the foundation. Forces acting on one wing are dispersed into the other wing of the foundation. The metal, such as A50 steel, comprising the wings also doubles in thickness where the wings are connected, further increasing resistance to torsional, compression, uplift, and lateral forces.

[0032] The connection plates 400 further increase the thickness of the metal foundation 10 and increase resistance to these forces, and improve the structural integrity of the metal foundation. The holes 300 in the connection plate 400 may be countersunk in order to accommodate bolt heads or nuts, for example, and keep the surface of the connection plate flat.

[0033] Since the metal foundation 10 is designed to be installed in the ground, there is friction between the installed foundation and the ground surrounding it. Thus, downward axial and uplift forces are countered by friction plus the weight of the foundation, preventing the foundation from being pushed in or pulled out of the ground. Further, since the first and second wings 100 and 200 may have a large surface area, friction with the ground may be increased.

[0034] Figs. 3 A and 3B illustrate cross-sectional views of the first wing 100 of the metal foundation 10. The various dimensions of the first wing 100 are presently indicated. The metal forming the first wing 100 has a thickness tl and a width wl . According to the present exemplary embodiment, the metal forming the first wing 100 may have a thickness tl in a range of 0.5 to 1.0 inches, and width wl in the range of 60.0 to 72.0 inches. Width wl is the total width of the first wing 100, and is the sum of width w2 of the first wing portion 1 10, width w3 of the second wing portion 120, and width w4 of the bent portion 130 between the first and second wing portions 110 and 120. The widths w2 and w3 are substantially the same, and may be each greater than the width w4. The widths (w2 + w3) to w4 may be in the range of a 3 : 1 to a 12: 1 ratio.

[0035] Because the first wing 100 is made of a single sheet of metal, there are various bend points used to form the wing shape, including the bent portion 130. A first bend point 141 is located between the first wing 110 and the bent portion 130. A second bend point 142 is located between the second wing 120 and the bent portion 130. The first and second bend points 141 and 142 may each form the same obtuse angle between the first wing portion 1 10 and the first bent portion 130, and the second wing portion 120 and the bent portion 130, respectively. Accordingly, angle Θ1 , measured from the plane extending along the first wing portion 110 to the bent portion 130, is an obtuse angle. In the present exemplary embodiment, Θ1 may be 135 degrees. Angle Θ2, measured at the interior of first and second bend points 141 and 142, may be 45 degrees.

[0036] Fig. 4 illustrates a side view of a metal foundation according an exemplary embodiment of the present invention. The metal foundation of Fig. 4 is substantially similar as the metal foundation 10 of Fig. 1, but further includes a base plate 500, bracket 520, and a bolt circle plate 600. Although not shown, the metal foundation 10 of Fig. 1 may also include the base plate 500, bracket 520, and bolt circle plate 600.

[0037] The metal foundation of Figs. 1 and 4 have a width wl . The metal foundation is symmetrical about an axis running between the bent portions of the first and second wings 100 and 200 on the y-z axial plane. The two-wing diamond foundation 10 is also symmetrical about an axis running between the first wing 100 and the second wing 200 on the x-y axial plane. The metal foundation has a length 11 that is substantially

perpendicular to the top portion having width wl . Length 11 is divided into three portions, 13, 14, and 15. The length 13 is the length of the bent portion 130 and/or connection plate 400 that extends below where the first and second wing portions 1 10 and 120 are tapered.

Length 13 is about 3.0 inches. Length 14 is the length of the first and second wings 100 and 200 from the top of the metal foundation to where the taper begins, and may be about 4/5 the length of the entire metal foundation, for example 192.0 inches when length 11 equals 240.0 inches. Length 15 is the remaining length from where the taper begins to the terminus thereof. An angle is formed at the intersection of lengths 14 and 15 for both the first and second wing portions 110 and 120, where the taper begins, and may be 150 degrees.

[0038] Fig. 5 A shows a side view of the metal foundation 10 of Fig. 1 , which also may be applied to the metal foundation of Fig. 4. The first and second wing portions 1 10 and 120 each have a length 12 that extends along the taper from the full width thereof to the bent portion 130 and/or the connection plate 400. Length 12 may be about 36.0 inches. Similar to Fig. 4, the metal foundation has the width wl and length 3.

[0039] Fig. 5B illustrates a side view of the metal foundation 10 of Fig. 1 , showing hole 300 spacing in detail. Holes 300 are spaced apart from each other laterally by spacing si , lateral edges of the first wing 100 by spacing s2, vertical edges of the first wing 100 by spacing s3, and spaced apart from each other vertically by spacing s4. Spacing s i is about 2.0-8.0 inches, s2 is in the range of 2.0-4.0 inches, s3 is about 2.0 inches, and s4 is about 12.0 inches, according to the present exemplary embodiment. Holes 300 may have a diameter dl , which according to the present exemplary embodiment is 0.75 inch. These spacing and measurements may generally apply to holes 300 in the metal foundation described above.

[0040] Fig. 6 illustrates a side view of a connection plate 400. The connection plate 400 has a width w5, which is about 6 inches according to the present exemplary

embodiment. Width w5 of the connection plate 400 is less than or equal to the width w4 of the bent portion 130 of the first wing 100. Holes 300 in the connection plate 400 are spaced apart from each other laterally by spacing si , lateral edges of the connection plate 400 by spacing s5, vertical edges of the connection plate 400 by spacing s3, and spaced apart from each other vertically by spacing s4. Spacing s5 is about 1.75 inches, according to the present exemplary embodiment.

[0041] Fig. 7 is a top view of the metal foundation of Fig. 4, including the base plate 500 and bolt circle 600. The base plate 500 has an upper surface that is exposed so that a load, such as a device or structure (not shown), may be attached thereto. The base plate 500 may be generally parallel to the ground, or angled in a direction in which the device or structure should project. The bolt circle 600 may be disposed on the base plate 500.

[0042] Fig. 8 shows a cross-sectional view of the metal foundation of Fig. 4, showing the first and second wings 100 and 200, as well as angle irons 520. As shown by the phantom lines in Fig. 7, the first and second wings 100 and 200 and angle irons 520 may be centered under the base plate 500 and the bolt circle 600. The angle irons 520 have a width w4, which is 16.0 inches according to the present exemplary embodiment. The angle irons 420 may be connected to a bottom surface of the base plate 500 opposite to the upper surface thereof. The bottom surface of the base plate 500 may contact the upper edge surface of the first and second wings 100 and 200.

[0043] Base plate holes 530 are formed in the base plate 500, and connection holes 540 are formed in the angle irons 520, so the angle irons may be connected to the base plate 500 using connectors (not shown). The connection holes 540 are spaced apart from the sides of the angle irons 520 by spacing s6, and are spaced apart from each other by spacing s7. Spacing s6 also represents the spacing of respective connections holes from first and second bend points 241 and 242. According to the present exemplary embodiment, s6 is 4.0 inches, and s7 is 8.0 inches. Similar to the connectors used to connect the first and second wings 100 and 200 and the connection plates 400, connectors may include mechanical fasteners such as bolts, rivets, clips, studs, and clamps. That is, the base plate 500 and the angle irons 520 are not welded together since connectors are used instead.

[0044] It will be apparent to those skilled in the art that various modifications and variation can be made in the present invention without departing from the spirit or scope of the inventive concept. Thus, it is intended that the present invention cover the modifications and variations of the inventive concept provided they come within the scope of the appended claims and their equivalents.

Claims

CLAIM:

1. A foundation, comprising:

first and second wings, each comprising:

first and second wing portions; and

a bent portion;

first and second connection plates disposed respectively on the bent portions of the first and second wings;

connectors connecting the first and second connection plates and the bent portions of the first and second wings to each other; and

a base portion disposed on an edge of each of the first and second wings and the first and second connection plates,

wherein the first and second wing portions and the bent portion, of each of the first and second wings, comprise a single sheet of metal.