Foundation stabilization system for manufactured housing

Abstract

A foundation system for bracing a manufactured home on its foundation is disclosed comprising a plurality of vertically stacked blocks stacked on footings, and a plurality of elongated braces connected to the mobile home and a foundation footing. A plurality of elongated braces comprising unitary brace tubes, flexible joints, and footing anchor tabs at first ends of the brace tubes, and adapted to connect to an I-beam of the home at a second remote end of the brace tube. Each footing anchors including a major leg and a minor leg, the major and minor legs being flattened to form an anchor tab intersecting the longitudinal axis of the brace tube at an acute angle of inclination. The flexible joint provides a degree of rotation of the brace tube relative to the anchor tab so that the angle of inclination may be changed.

Description

BACKGROUND OF THE INVENTION

This invention relates to a foundation stabilization system for bracing and stabilizing manufactured homes and the like portable buildings on their foundations.

The manufactured home typically has a pair of parallel, longitudinal I-beams. Each I-beam includes an upper and lower horizontal flange extending on either side of a vertical flange or web. The foundation system further includes a stabilization system for anchoring the manufactured home via the I-beams to the ground. Typically, the stabilization system includes a plurality of foundation plates or concrete footings on which foundation piers are supported. The I-beams of the manufactured home rest on top of the piers. The pier may include concrete blocks, jacks, or other pier foundations around the periphery and center of a manufactured home which support the I-beams. In the case of concrete blocks, the blocks rely on the compressive force of the manufactured home to hold the home in place on the foundation footing or footings. Longitudinal braces are attached at the foundation plate or footing and at the lower flanges of the I-beam extending in the longitudinal direction. In addition, at least one lateral brace is secured between the plate or footing and the upper flange of the adjacent parallel I-beam. In this manner, a bracing and stabilizing system is provided for the I-beams as they are supported on the pier to resist wind and other toppling forces.

The system shown in U.S. Pat. No. 4,261,149 is typical of present support systems using a foundation pad, pier, and longitudinal and lateral bracing struts which are secured between the manufactured home and the foundation pad. However, when using non-concrete plates anchoring of the plates into the ground is required before the pier is constructed and the braces are affixed. For example, U.S. Pat. No. 6,058,663 has proposed the use of a one piece metal foundation plate which is stamped out, the edges are bent down to form cleat walls, and the bent down cleat walls are embedded in the soil to prevent the plate from shifting. U.S. Pat. No. 5,873,679 discloses a foundation pier for removable dwelling, such as manufactured homes, having an anchor assembly for anchoring the pier to the ground. That invention relates to a height adjustment for the pier so as to engage the I-beam of the home. The rods are driven into the ground at an angle making it difficult, depending on the height of the pier.

There has been a trend toward using concrete footings, particularly to cylindrical footings of a smaller diameter. While prior foundation plate and footing systems have a sufficient surface area to accommodate one or more 16 inch stacked blocks, as well as 8 to 12 inches from the sides of the blocks to the edge of the foundation, the smaller concrete footings do not provide surface area for all the mounting hardware typically used in the foundation plate systems. Typically this hardware has included a bracket with sidewalls providing a pivot having a footprint of approximately 3×5 inches. Three of these pivoting brackets must be mounted to the foundation plate. However, in the case of a 18 inch diameter concrete footing, there is only an area for mounting hardware on the opposing longitudinal sides of the block because the ends lie close to the edge of the footing.

Accordingly, an important object of the present invention is to provide a foundation stabilization system for a manufactured home and the like having braces extending between the home and a foundation footing wherein the footing anchor at the end of the braces may be attached in a minimum space.

Another object of the present invention is to provide a manufactured home brace having a footing anchor with a unitary flexible joint providing adjustment of the horizontal inclination with the need of a pivot joint and bracket.

Yet another object of the present invention is to provide a unitary brace structure for a manufactured home foundation system by which longitudinal or lateral braces can be secured to a minimum sized footing and the like and can be easily adjusted in its horizontal inclination in a range of about 10° to 45° for alignment of the braces with the frame of the manufactured home, and thereafter being anchored.

Still another important object of the present invention is to provide a unitary brace and footing anchor for a manufactured home foundation system having a flexible joint which eliminates the separate pivot bracket hardware used in prior art systems.

SUMMARY OF THE INVENTION

The above objectives are met according to the present invention by a foundation system for bracing a manufactured home on its foundation comprising a plurality of vertical piers, supported on foundations which support the I-beam frame of the home above the ground, including a plurality of vertically stacked blocks. The foundation footing includes a first anchor area and a second anchor area defined on each side of a pier base block of the pier. A plurality of elongated braces comprising unitary brace tubes and footing anchors with flexible joints at first ends of the brace tubes, and adapted to connect to an I-beam anchor at a second remote end of the brace tube, and the footing anchors and I-beam anchors being secured to the footing and I-beams, respectively. Each of the footing anchors includes a major leg and a minor leg having a shorter length than the major leg. The major and minor legs being flattened to form an anchor tab intersecting the longitudinal axis of the brace tube at an acute angle of inclination, the anchor tab adapted for attachment to the footing; and a flexible joint being formed at the junction of the brace tube and the anchor tab providing a degree of rotation of the brace tube relative to the anchor tab so that the angle of inclination may be changed. In this manner, the anchor footing of a brace tube may be attached to the footing, and the angle of inclination may be changed to provide for proper alignment and attachment to the I-beam of the manufactured home in a minimum of space and without the need of separate pivot bracket hardware. For small cylindrical footings, a first footing anchor being secured to the first anchor area, and second and third footing anchors being secured to the second anchor area. Non-anchor areas are defined at the ends of the base block on the footing.

The flexible joint includes a metallic indentation formed in opposing sides of the brace tube. The flexible joint is further defined by the minor leg terminating generally at a hinge line about which the brace tube may be rotated when the anchor footing is secured to the footing, and a curved transition merging from the hinge line to a straight upper side of the brace.

The flexible joint is further defined by the major leg extending past the hinge line and terminating at a curved transition which merges into a straight lower side of the brace tube.

The acute angle of inclination of the brace tube about the rotating joint is adjustable generally in a range of 10 to 45 degrees. The brace tube is formed to have a reference angle of inclination wherein the metallic indentation is in an initial configuration, and the indentation deforms generally to a more vertical configuration when the angle of inclination increases and to a more horizontal configuration as the angle decreases. The anchor tabs include an opening for receiving a fastener securing the footing anchor to the footing.

In accordance with the invention the flexible joint is advantageously created by forming indentations in opposing side walls of the brace tube, pressing upper and lower sides of the brace tube together so that the indented side walls are flattened and sandwiched between the upper and lower sides to form the anchor tab while the reference angle is formed. Preferably, the reference angle of inclination is set at about 30° providing an advantageous range of angles about the reference.

A method for bracing a manufactured home on its foundation is also taught, of the type which includes a plurality of vertical piers supported on footings spaced in longitudinal and lateral directions relative to a longitudinal axis of the home which support the home above the ground, and at least one elongated brace connected between the mobile home and a foundation footing contacting the ground with the pier supported on the footing. The method comprises providing a unitary brace comprising a brace tube, a flexible joint, and an anchor tab formed at a first end of the brace tube for attachment to the footing so that the brace tube may be rotated through the flexible joint in a vertical plane for adjusting an acute angle of inclination between the brace tube and the footing when the brace tube is attached to the footing. Attaching the anchor tab to the footing. Adjusting the angle of inclination to properly align with an adjacent longitudinal I-beam; and affixing a second end of the brace tube to the adjacent I-beam.

Advantageously, the footing anchor is formed by a bending process which includes forming indentations in opposing side walls of the brace tube, pressing upper and lower sides together causing the side walls to deform inwardly and be pressed together flat with the upper and lower sides to form a flattened anchor tab, and forming a reference angle of inclination relative to the flattened tab.

The method provides the advantage that for smaller footings, of attaching the anchor tube to a foundation footing with at least one pier block stacked on top of the footing in a manner that an anchor areas is formed on opposing sides of the block but not at the end of the block, and attaching the anchor tabs only at the anchor areas.

DESCRIPTION OF THE DRAWINGS

The construction designed to carry out the invention will hereinafter be described, together with other features thereof.

The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:

FIG. 1A is a perspective view illustrating a prior art stabilization and foundation system for a manufactured home;

FIG. 1B is a top plan view of a prior art anchored foundation plate for a manufactured home stabilization system;

FIG. 2 is a perspective view illustrating the stabilization system for a manufactured home having braces with footing anchors according to the invention;

FIG. 3 is a top view of a foundation stabilization system for saving space on a footing according to the present invention;

FIG. 4 is a side elevation of a foundation stabilization system according to the invention;

FIG. 5A is an enlarged cutaway side view of a brace having a flexible metallic joint for a space saving stabilization system which accommodates variable sized footings;

FIG. 5B is an end view of the brace of FIG. 5A;

FIGS. 6A-6C illustrate a range of horizontal inclinations of a unitary brace and flexible joint structure to adjust to different frame structures on a manufactured home according to the invention;

FIGS. 7A-7E illustrate a process for constructing a unitary brace, flexible joint, and footing anchor tab, according to the invention.

DESCRIPTION OF A PREFERRED EMBODIMENT

Referring now in more detail to the drawings, the invention will now be described in more detail.

FIGS. 1A and 1B illustrate a prior art foundation and stabilization system for a manufactured home wherein a foundation plate or footing 10 is provided. A pair of longitudinal braces 12 are attached at one end to the foundation plate and at the opposing end to the lower flange of I-beams 13. An I-beam clamp 14 is provided for this purpose having a pivot. Longitudinal braces include a pivot attachment 15 at the other end attached to the footing. A lateral brace 16 is provided which telescopes and is attached to the upper flange of the I-beam by means of an I-beam clamp 18. The lateral brace 16 telescopes so as to be adjustable to fit different lateral spacings of I-beams. The remote end of the lateral brace is secured by a pivotal attachment 15 to the plate or footing. A pier 20 is made by a stack of concrete blocks 22. FIG. 1B illustrates the spacings of pivotal brackets 15 mounted to the footing which must be a minimum of 4 inches from the edges of the footings. This is normally not a problem. However, concrete footings are often used in the north and other colder climates, and because the footing must be in the ground below the frost line, which can be four to five feet, footings are used having a diameter of 18 inches, in order to save on concrete costs. A manufactured house can require up to 75 footings, so significant concrete is saved using an 18 inch diameter footing.

According to the present invention, as can best be seen in FIGS. 2 and 3, a foundation stabilization system, designated generally as A, is illustrated for stabilizing and anchoring a manufactured home and the like portable building, which includes a cylindrical concrete footing 26 to which a plurality of braces 30, 32, and 34 are attached. Braces 30 and 32 are typically attached to an I-beam 13a of the pre-manufactured home chassis to brace and stabilize the home or building in a first, longitudinal direction. Brace 34 is typically attached to a parallel I-beam 13b for bracing in a second, lateral direction. In the illustration embodiment, a pier 20 which may be provided by stacked concrete blocks 22, or other suitable pier construction, such as mechanical jacks, towers, etc. The braces have a longitudinal axis X.

As can best be seen in FIG. 3, anchor areas 36 and 38 are formed on footing 26 on opposing sides of pier block 22a for anchoring braces 30-34, using standard concrete blocks (8″×16″×8″) on an 18 inch cylindrical footing. There is no anchor area at the ends of the pier block. Ordinarily, this would not leave room for placement of conventional pivot brackets since two pivot brackets would have to be mounted to one anchor area 36, 38, but there is not enough space for two 3×5 brackets.

Longitudinal braces 30, 32, are provided having first ends attached to lower flange 28 of I-beam 13a by means of conventional I-beam clamps 14. Lateral brace 34 extending from footing 26 to upper flange 29 of adjacent parallel I-beam 13b. A conventional over the top flange bracket 18 is provided on one end of the brace to secure it to the flange.

In accordance with the present invention braces 30-34 include the beam anchor 14 on first ends, and footing anchors B on remote second ends, as can best be seen at FIGS. 4 and 5A.

The braces are formed from brace tubes having a rectangular configuration, preferably square, having sides 64a-64d. It may be possible that the brace tubes can be formed from cylindrical tubes also. The footing anchors are formed by a bending process which will be described hereafter. Basically, each anchor end B includes a major leg 40 and a minor leg 42. A metallic indentation 44 is formed in the brace tube by the bending process. The major and minor legs 40, 42, and the metallic indentation 44, are formed by the bending processes so as to provide a flexible or bendable joint about which the anchor orientation of the brace tube relative to the footing may be had. An anchor hole 46 is provided for receiving a concrete fastener 48 to secure the anchor to the footing by means of a insert 49. FIG. 5B represents a cross-section and an end view of the anchor end wherein the opposing side walls 64a, 64b, of the brace tube collapse inwardly underneath upper and lower sides 64c, 64d. The top and bottom of the brace tubes 50c, 50d, arrange generally undistorted.

As can best be seen in FIGS. 6A through 6C, brace tubes B make adjustment in their horizontal inclination with respect to the footing generally between 10 and 45 degrees. Typically the brace tube is on an angle of 30 degrees in an average position, but may be adjusted +15 and −20 degrees from the position as shown in FIGS. 6B and 6C. FIG. 6A illustrates major leg 40 as extending significantly past minor leg 42. A bend line 54 is formed at a bend in minor leg 42 which forms the terminus of minor leg 42. The bend extends upward in a curved transition 56 which merges into the straight top wall 64c of the brace extending toward the I-beam. As can best be seen in FIG. 6B, brace tube B has been rotated counterclockwise approximately 15 degrees to reach a horizontal inclination of 45 degrees. In this case, the metallic indentation 44 is somewhat deformed to a vertical lopsided position 44a. In this case, the major leg may be lifted slightly from its flush position 58 with the footing. FIG. 6C illustrates a flexing or bending of the tube clockwise where it assumes a horizontal inclination of about 10 degrees. In some cases, a minimum pier height of twelve inches is allowed requiring a small angle of inclination. In this case, the brace tube flexes mainly about the hinge line 54 whereupon the metallic indentation is deformed downwardly to a somewhat horizontal lopsided configuration at 44b.

According to a bending process, illustrated in FIG. 7 the tube is first placed into a bending machine where upper and lower triangular-shaped tools 70 are forced together with their apex engaging side walls 64a, 64d, of the brace tube forming V-shaped indentures 72 in the side walls 64a, 64d, of the tube. Second, the upper and lower sides 64c, 64b, are pressed together flat by an anvil 80. The tube is formed by a bend upwardly to a reference angle a of approximately 30° which forms the major leg 40 and minor leg 42 and indentations 44. This is controlled by the amount of tube fed into the flat anvil 80. Bottom plate 82 extends further longitudinally than top plate 80 (FIG. 7E) causing the tube to bend when plate 80 is pressed down. A reference angle of about 30° has been found to provide a sufficiently flexible joint that yields angles of inclination in the proper range. In this process, a flex point or line 54 is formed at the intersection of an upper curved transition 42a and minor leg 42. Minor leg 42 is approximately 1-¾ inches, and major leg 40 is approximately 2-⅝ inches. It has been found in the application of the present invention, that tubular brace 30-34 mounted to footing 26 at a 30° inclination from the horizontal, can be flexed and adjusted between a 10° to 45° inclination. Of course, other bending processes known in the art may also be used to form the aforesaid brace tube described above.

In a preferred embodiment, longitudinal braces 30, 32, are made as one-piece and are not adjustable. The fixed length of the struts are made adjustable depending on the number of pier blocks and total height of the pier. Preferably, lateral brace 34 is adjustable, such as by two telescoping legs, in order to accommodate the pier height.

Thus, it can be seen that an advantageous construction for a unitary brace, flexible joint, and footing anchor can be had according to the present invention for braces fitting between a footing and I-beams of a manufactured home wherein a small footprint for the footing anchor is provided, and the need for separate pivoting hardware eliminated. Yet the adjustability of the inclination of the brace may be had in order to accommodate varying distance between adjacent I-beams.

While a preferred embodiment of the invention has been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.

Claims

1-13. (canceled)

14. A foundation system for bracing a manufactured home on its foundation comprising: a plurality of vertical piers spaced in first and second directions relative to a longitudinal axis of said home which support the home above the ground, said piers including a plurality of vertically stacked blocks; a plurality of elongated braces connected to the mobile home and a foundation footing, said foundation footing having an upper pier supported surface on which said pier is supported; said pier support surface of said foundation footing having a first anchor area and a second anchor area defined on each side of a pier base block of said pier; a plurality of elongated braces comprising unitary brace tubes and footing anchors at first ends of said brace tubes, said brace tube adapted to connect to an I-beam anchor at a second remote end of said brace tube, and said footing anchors and I-beam anchors being secured to said footing and I-beams, respectively; each said footing anchor including a major leg and a minor leg having a shorter length than said major leg, said major and minor legs being flattened to form an anchor tab intersecting the longitudinal axis of said brace tube at an acute angle of inclination, said anchor tab adapted for attachment to said footing; and a flexible joint including concave indentures formed on opposing sides at the intersection generally formed at intermediate said brace tube, and said flexible joint providing a degree of rotation of said brace tube relative to said anchor tab so that said angle of inclination may be changed;

Whereby said anchor footing of a brace tube may be attached to said footing, and said brace tube may be rotated to change the angle of inclination for proper alignment and attachment to the I-beam of said manufactured home in a minimum of space and without the need of separate pivot bracket hardware.

15. The system of claim 14 including a first footing anchor being secured to said first anchor area, and second and third footing anchors being secured to said second anchor area.

16. The system of claim 15 including a non-anchor area defined at the ends of said base block on said base black.

17. The system of claim 14 wherein said concave indentures include a metallic indentation formed in opposing sides of said brace tube.

18. The system of claim 17 wherein said flexible joint is further defined by said minor leg terminating generally about a hinge line about which said brace tube may generally be rotated when said anchor footing is secured to said footing, and a curved transition merging from said hinge line to an upper side of said brace.

19. The system of claim 18 wherein said flexible joint is further defined by said major leg extending past said hinge line in a generally straight fashion and terminating at a curved transition which merges into a lower side of said brace tube.

20. The system of claim 19 wherein said acute angle of said brace tube about said rotating joint is adjustable generally in a range of 10 to 45 degrees.

21. The system of claim 18 wherein said brace tube is formed to have a reference angle of inclination wherein said metallic concave indentations are in an initial configuration, and said concave indentations deform generally to a more vertical configuration when the angle of inclination increases and to a more horizontal configuration as said angle decreases.

22. The system of claim 14 including wherein said anchor tabs include an opening for receiving a fastener securing said footing anchor to said footing.

23. The system of claim 22 including ground anchors having an insert sleeve secured within said footing and a threaded bolt securely threaded through said anchor tab opening into said insert sleeve.

24. The system of claim 14 wherein said flexible joint is created by forming indentations in opposing side walls of said brace tube, pressing upper and lower sides of said brace tube together so that said indented side walls are flattened and sandwiched between said upper and lower sides to form said anchor tab while said reference angle is formed.

25. A method for bracing a manufactured home on its foundation of the type which includes a plurality of vertical piers supported on footings space in longitudinal and lateral directions relative to a longitudinal axis of said home which support the home above the ground, and at least one elongated brace connected between the mobile home and a foundation footing contacting the ground with the pier supported on the footing; and said method comprising:

providing a one-piece brace comprising a brace tube, a flexible joint, and an anchor tab formed at a first end of said brace tube for attachment to said footing so that said brace tube may be rotated about the flexible joint in a vertical plane for adjusting an acute angle of inclination between said brace tube and the footing when said brace tube is attached to said footing;

attaching said anchor tab to said footing;

adjusting the angle of inclination to properly align with an adjacent longitudinal I-beam; and

affixing a second end of said brace tube to said adjacent I-beam.

26. The method of claim 25 wherein said footing anchor is formed by a bending process which includes forming indentations in opposing side walls of said brace tube, pressing upper and lower sides together causing said side walls to deform inwardly and be pressed together flat with said upper and lower sides to form a flattened anchor tab, and forming a reference angle of inclination relative to said flattened tab.

27. The method of claim 26 wherein said flexible joint is formed to provide a range of angles of inclination of about 10° to 45°.

28. The method of claim 25 including attaching said anchor tube to a foundation footing with at least one pier block stacked on top of said footing in a manner that anchor areas are formed on opposing sides of said block but not at the end of said block, and attaching said anchor tabs only at said anchor areas.

29. The method of claim 26 wherein said tubular braces have a rectangular cross-section.

30. The system of claim 24 wherein said tubular braces have a rectangular cross-section.