Foundation

Abstract

A bracing system to brace a foundation pile that is or is to be located into and extend from ground below or adjacent a building. The bracing system utilises formwork to allow an in-situe concrete block to be cast, the concrete block being supported by the ground adjacent to where the pile is located and at least substantially surrounds the pile. The concrete block is operatively connected to the foundation pile at a location of the pile that is above the ground.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No. 14/128,206, which is a 35 U.S.C. 371 National Application of PCT/IB2012/053159, filed Jun. 22, 2012, which claims the benefit of priority from New Zealand Patent Application No. 597959, filed Feb. 1, 2012, and New Zealand Patent Application No. 593740, filed Jun. 24, 2011. The disclosures of all four above applications are explicitly incorporated by reference herein in their entirety.

FIELD OF THE INVENTION

The present invention relates to a foundation and/or brace for a foundation structure or pile of a building structure and/or a method and/or system for shoring up a building pile.

BACKGROUND OF THE INVENTION

Building piles in residential housing or commercial building structures are made of wood, steel or concrete. They are usually each located in a hole in the ground that is filled with concrete. These piles are strong enough so that in numbers they can vertically support a house or garage or similar above the ground. Floor joists or bearers usually sit on top of the piles.

However in an earthquake situation, floor joists or bearers have been found to slip or jump off the piles and a house then needs to be lifted back on. Sometimes the piles snap.

There is hence a need to allow piles for a building structure to be shored up. Such may be desirable at the time of construction of the building or as a retrofit solution.

Accordingly it is an object of the present invention to provide a foundation and/or brace for a foundation structure or pile of a building structure and/or a method and/or system for shoring up a building pile that is effective in reducing the prospects of a pile breaking and/or otherwise becoming ineffective in supporting a building structure and/or a formwork module for casting a concrete block and/or to at least provide the public with a useful choice.

BRIEF DESCRIPTION OF THE INVENTION

In a first aspect the present invention may consist in a bracing system to brace a foundation pile that is or is to be located into and extend from ground below or adjacent a building, said system comprising:

formwork to allow an in-situe concrete block to be cast, the concrete block being supported by the ground adjacent to where the said pile is located and at least substantially surrounds said pile,

wherein the concrete block is operatively connected to said foundation pile at a location of the pile that is above the ground.

Preferably the formwork is supported by the ground adjacent to where the foundation pile is located.

Preferably the formwork is located around the foundation pile to define a cavity between the pile and the formwork into which pourable concrete can be displaced to then set to form at least part of the concrete block.

Preferably the formwork includes at least one channel which extends in a direction substantially perpendicular to the longitudinal direction of the pile, each channel defines a region in which pourable concrete can be displaced to then set to form at least part of the concrete block.

Preferably each channels extends into the cavity so that the concrete block is cast as a single block inside the cavity and the channel(s).

Preferably the formwork is a module that surrounds the pile.

Preferably the module is formed from a polystyrene or other similar material and includes connecting features so that it can connect to other, like modules.

Preferably the formwork includes at least one channel on its underside, which is open to the ground, through which liquefaction that might emerge from the ground can be diverted.

Preferably the pile is tied to the concrete block via ties that extend from the pile into the concrete block.

Preferably wherein the concrete block has reinforcing materials embedded therein.

Preferably the pile is partially encased in the concrete block.

Preferably the pile is operatively connected to said concrete block by virtue of being encased in said concrete block at least at the location where said pile projects out of said concrete block.

Preferably the concrete block extends between said ground level and said building structure above.

Preferably the building is directly supported by the pile.

Preferably the concrete block defines a concrete floor section on which said building is supported.

In a second aspect the present invention consists in a foundation for a building, said foundation comprising:

at least one foundation pile located into and extending from the ground,

a concrete block being supported by the ground adjacent to where the pile is located and at least substantially surrounding said pile, the concrete block being cast into formwork to define its shape,

wherein the concrete block is operatively connected to said foundation pile at a location of the pile that is above the ground.

Preferably the formwork is supported by the ground adjacent to where the foundation pile is located.

Preferably the formwork is located around the foundation pile to define a cavity between the pile and the formwork into which pourable concrete can be displaced to then set to form at least part of the concrete block.

Preferably the formwork includes at least one channel which extends in a direction substantially perpendicular to the longitudinal direction of the pile, each channel defines a region in which pourable concrete can be displaced to then set to form at least part of the concrete block.

Preferably each channel extends into the cavity so that the concrete block is cast as a single block inside the cavity and the channel(s).

Preferably the formwork comprises individual modules that surround each pile.

Preferably the module is formed from a polystyrene or other similar material and includes connecting features so that it can connect to other, like modules.

Preferably the foundation comprises a plurality of foundation piles, each pile surrounded by a module, and each module being connected to an adjacent, like module.

Preferably pourable concrete can be displaced to then set to form a concrete block extending across multiple modules and surrounding multiple piles.

Preferably the formwork includes at least one channel on its underside, which is open to the ground, through which liquefaction that might emerge from the ground can be diverted.

Preferably each pile is tied to the concrete block via ties that extend from the pile into the concrete block.

Preferably the concrete block has reinforcing materials embedded therein. Preferably each pile is partially encased in the concrete block.

Preferably each pile is operatively connected to said concrete block by virtue of being encased in said concrete block at least at the location where said pile projects out of said concrete block.

Preferably the concrete block extends between said ground level and said building structure above.

Preferably the building is directly supported by the pile.

Preferably the concrete block defines a concrete floor section on which said building is supported.

In a third aspect the present invention consists in a formwork module to allow an in-situe concrete block to be cast around a foundation pile, the formwork module being supported by the ground adjacent to the foundation pile and dimensioned to at least partially surround the foundation pile while defining a cavity between the pile and the formwork module into which pourable concrete can be displaced to then set to form a concrete block, wherein the concrete block cast into the formwork module being operatively connected to the foundation pile at a allocation of the pile that is above the ground.

Preferably the module has an opening through which the foundation pile extends, such that the module completely surrounds the foundation pile while defining a cavity between the pile and the module.

Preferably the module includes at least one channel which extends in a direction substantially perpendicular to the longitudinal direction of the foundation pile when the module is placed on level ground around the foundation pile, each channel defines a region in which pourable concrete can be displaced to then set to form at least part of the concrete block.

Preferably each channels extends into the cavity so that the concrete block is cast as a single block inside the cavity and the channel(s).

Preferably the formwork module is quadrilateral in plan shape and a channel extends from each side of the quadrilateral to the opening in the centre of the quadrilateral.

Preferably the channels are adapted to receive a reinforcing material for reinforcing the concrete that is cast into the channels.

Preferably the module is formed from a polystyrene or other similar material. Preferably the formwork module includes connecting features so that it can connect to adjacent, like modules.

Preferably the connecting features enable adjacent, like modules to connect edge to edge with one another.

Preferably the formwork module includes at least one channel on its underside, which is open to the ground, through which liquefaction or any other material that might emerge from the ground can be diverted.

Preferably the formwork module includes a plurality of downwardly extending protrusions which contact the ground when the module is positioned on the ground, between the downwardly extending protrusions is defined a void in which liquefaction or any other material that might emerge from the ground can be diverted.

Preferably the downwardly extending protrusions are of a truncated conical shape.

In a fourth aspect the present invention consists in a concrete floor slab for a building comprising:

a concrete pad that has a substantially planar upper surface which defines at least a section of the floor or a substrate for a floor of the building,

at least one pile extending from the ground below said concrete pad to, into and/or through the concrete pad.

Preferably formwork is used to cast the concrete pad.

Preferably said formwork remains in place after casting.

Preferably the formwork defines a cavity into which pourable concrete can be displaced to then set.

Preferably a plurality of piles extend from the ground below said pad to and/or through the concrete pad.

Preferably each pile extends into the concrete pad but not beyond the planar upper surface.

Preferably the formwork consists of polystyrene modules.

Preferably an independent polystyrene module surrounds each pile.

Preferably adjacent polystyrene modules are connected together.

In a fifth aspect the present invention consists in a method of shoring up a foundation pile that is located in the ground and extends therefrom to support a building structure above, said method comprising:

assembling formwork adjacent said pile, said formwork defining a cavity for a concrete pour that is to set to create a concrete block that provides bracing for said pile at a location of the pile that is above the ground,

pouring concrete into said cavity.

Preferably said concrete block provides bracing for said pile that acts on said pile at a level above the ground and on the ground adjacent said pile.

Preferably the method involves assembling formwork around said pile so that said pile passes through said concrete block.

Preferably the formwork is a polystyrene module with an opening through which the pile can extend.

In another aspect the present invention consists in a building foundation comprising a pile extending from the ground and being tied to or embedded in concrete at an upper region of the pile, wherein the concrete is set into formwork which is supported by the ground adjacent to the foundation pile, and wherein at the interface between the ground and the formwork there is at least one void to receive liquefaction sediment that may emerge from the ground.

Preferably the void or voids is/are defined by pockets or channels in the underside of the formwork.

Preferably the underside of the formwork includes a plurality of downwardly extending protrusions, the space between the protrusions defining the void or voids through which liquefaction sediment or any other material that might emerge from the ground can flow.

Preferably the formwork is a polystyrene module.

Preferably the formwork elevates the concrete above the ground.

Preferably the formwork can receive the concrete in a precursor poured concrete condition, the formwork, supported on the ground presenting an upper surface to receive said poured concrete that is elevated above the ground.

Preferably the upper surface of the formwork is located at or below the upper end of the pile.

Preferably the formwork is shaped and adapted, adjacent said pile, for providing form to the poured concrete in a manner to allow said pile to be at least partially embedded in said concrete.

Preferably the upper end of the pile is embedded in said concrete.

Preferably the concrete encase the entire section of the pile that is above the ground.

Preferably the formwork is unitary.

Preferably the formwork is modular and comprises of a plurality of units that can be assembled receive a concrete pour.

Preferably the concrete is unitary.

Preferably the concrete is formed from a single pour of concrete.

Other aspects of the invention may become apparent from the following description which is given by way of example only and with reference to the accompanying drawings.

As used herein the term “and/or” means “and” or “or”, or both.

As used herein “(s)” following a noun means the plural and/or singular forms of the noun.

The term “comprising” as used in this specification and claims means “consisting at least in part of”. When interpreting statements in this specification and claims which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present. Related terms such as “comprise” and “comprised” are to be interpreted in the same manner.

As used herein the term “ground” should be construed to mean the solid ground and any loose fill material that may be located on top of that solid ground.

The entire disclosures of all applications, patents and publications, cited above and below, if any, are hereby incorporated by reference.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred form of the present invention will now be described with reference to the accompanying drawings in which:

FIG. 1 is a perspective cut away view of a building such as a residential house showing joists and structural piles,

FIG. 2 is a side view of a joist or bearer supported by piles and where a concrete block is provided about the piles,

FIG. 3 is a sectional view through a concrete block and pile,

FIG. 4 is a perspective view of formwork through which two piles extend to become partially embedded in the concrete pour to be received in the formwork,

FIG. 5 is a perspective view of formwork that may define the configuration of the block and pile as shown in FIG. 3 showing part of a tie/reinforcing engaged to the pile to become embedded in the concrete pour,

FIG. 6 is a view of an alternative arrangement of formwork and piles,

FIG. 7 is a top perspective view of yet an alternative arrangement of the formwork and piles,

FIG. 8 shows a bottom perspective view of FIG. 7,

FIG. 9A is a perspective view of formwork through which piles extend,

FIG. 9B is another perspective view of formwork through which piles extend,

FIG. 10 is a bottom view of formwork as used in FIGS. 9A and 9B,

FIG. 11 is a perspective view of a concrete block and through which a pile extends that includes a joist bracket,

FIG. 12 is a view of an alternative form of a concrete block that may be utilised for the purposes of implementing the present invention,

FIG. 13 shows a plurality of such blocks of FIG. 12 located around a pile,

FIG. 14 shows the configuration of FIG. 13 where in addition further regions of concrete are provided to connect the individual concrete blocks of FIG. 13 together, and

FIG. 15 shows an elevation view of a foundation system of the present invention,

FIG. 16 shows a section view of a foundation system supporting a concrete floor slab,

FIG. 17 shows a section view of a foundation system supporting a timber floor,

FIG. 18 shows a preferred foundation system supporting a concrete floor slab,

FIG. 19 shows a preferred foundation system supporting a timber floor and shows enlarged views of a connection system that may exist between adjacent formwork modules,

FIG. 20 shows the underside of a formwork module of the present invention,

FIG. 21 shows the top side of a formwork module of the present invention,

FIG. 22 shows the top side of a formwork module of the present invention with reinforcing material located therein, and

FIG. 23 shows the top side of a formwork module of the present invention with a reinforcing mesh located thereon.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a brace and system and related methods for shoring up a structural pile for a building or building structure. Where reference herein is made to a pile it is to be understood to also include posts and pillars and other such building elements that may be used for providing vertical support to a building structure above. The building structure is preferably a residential or commercial building but may be an awning or canopy or elevated walkway or similar that is supported above the ground at least by a plurality of piles.

Where reference herein is made to a joist it is to be understood that such may instead be a bearer on top of which joists are supported or alternatively some other element that may be used in the construction and structuring of a building. FIG. 1 is a perspective cut away view of a building such as a residential house showing joists, such as joist 60, and structural piles, such as structural pile 3.

With reference to FIG. 2 there is shown a concrete block 2, two piles 3 and a joist 60. The concrete block 2 sits on top of ground 4. The ground 4 may be dirt or other. It is above this ground 4 that the building structure is supported at least partially by the piles 3. The piles 3 are preferably located into the ground as shown in FIG. 3. The piles 3 are preferably set into a hole in the ground that has been filled with concrete that has set. The concrete block 2 may be cast in place at the same time as the piles are erected on site or alternatively may be retrofitted well after the piles have been in put in place. The present invention lends itself to both remedial work, retrofit and new construction.

The concrete block 2 can sit on the ground 4 and does not necessarily need to project into the ground 4 although ties may be used for connecting the concrete block 2 to the ground 4. Such ties may for example be metal or composite ties that can be partially embedded in the concrete block 2 and project into the ground 4. The concrete block 2 makes an operative connection with the pile 3 at a region 6 of the pile that is some distance above ground level 7 on top of which the concrete block 2 has been cast or located or positioned. The operative connection is preferably a direct connection by virtue of the concrete block 2 making contact with the pile at the region 6.

Lateral forces F applied to the pile such as during an earthquake reduce any bending moment of the pile at where it projects from ground level 7. This is because the concrete block 2 provides support to the pile at a region 6 and effectively reduces the distance between stabilising support for the pile and the location at where the lateral forces are applied. During an earthquake a pile 3 will be subjected to lateral forces F at its upper end as well as at where it projects from the ground at ground level 7. The provision of support intermediate of where such forces are applied by way of the concrete block 2, will reduce the bending moments that are applied to the pile 3. The concrete block 2 may also reduce the bending deflection of the pile at its upper end and can hence assist in keeping the connection between the pile 3 and the structural members such as the joist 60 above intact.

A pile tie 9 may be provided that is connected directly to or about the pile 3 and is embedded in the concrete block 2, to provide additional operative connection between the pile 3 and the concrete block 2. The pile tie may be rebar.

Formwork such as formwork 11 shown in FIG. 4 may be utilised to allow for the concrete block 2, to be cast in-situe adjacent the pile or piles. The example of the formwork shown in FIG. 4 allows for a single concrete block to be cast about two piles. The formwork 11 is preferably of a shape and configuration that allows for the formwork to be manufactured from a relatively weak material that is sufficiently strong due to its shape and configuration to allow for it to handle the hydraulic pressures of the poured concrete placed into the formwork 11.

The formwork 11 may be made from a polystyrene, polypropylene or other material that may for example be injection moulded, rotary moulded or otherwise formed. Using a material that is of a shape and configuration that has been designed to cope with the hydraulic pressures of the setting concrete yet still be light, allows for the formwork 11 to be conveniently and simply placed on the ground adjacent the piles without requiring any machinery to do so. A split plane may be provided to allow for the formwork to be assembled in at least two parts, about a pile or piles. This may be advantageous where for example the concrete block is to be cast in place around the piles of an existing building structure where the convenience of such assembly can mean that a block can be cast in place relatively quickly.

The concrete block 2 provides both a mass to create resistance by virtue of momentum, to the pile 3 and is of a shape and configuration to allow for lateral forces FF to be transmitted in direction XX to the ground below. Accordingly in the preferred form the concrete block is of a shape and configuration to provide sufficient mass yet not necessarily a mass that is in excess of what is required.

As such the formwork may include void defining features to create a void 16 and/or other voids at where concrete is not necessarily required for the purposes of providing structural integrity to the concrete block 2. Such a void may for example be a conical shaped void 16 located about the pile between the region 6 and ground level 7. The void 16 may alternatively be of a multifaceted pyramid shape or cylindrical shape or other.

The concrete block 2 preferably includes an upper surface 18 that includes a substantially flat surface. In the most preferred form the entire upper surface 18 of the concrete block 2 is substantially flat. Should a joist 60 fall off the pile 3 the joist has a landing to fall onto in the form of the upper surface 18. This can assist in preventing the building from becoming badly damaged since the distance that the joist would then fall is not as great as if it were to fall to ground level 7. As such the concrete block 2 is preferably of shape and configuration to position the upper surface 18 proximate the top of the pile 3. In the preferred form the upper surface 18 is closer to the top of the pile 3 than it is to ground level 7.

Other rebar or other reinforcing may be incorporated in the concrete block 2 to provide the concrete block with further structural integrity.

In the preferred form the joist 60 is located on top of the pile 3. The pile 3 is preferably a wooden or concrete pile and the joist may be appropriately tied or connected or fastened to the top of the pile. Alternatively the joist 3 may be connected to a side of the pile 3. As seen in FIG. 11, a joist bracket 19 may be provided into which a joist can be located. The joist bracket 19 may be directly connected to the pile 3 or may alternatively be adjustably connected to the pile 3 so that the height of the joist bracket 19 is able to be adjusted. A threaded connection may be provided for these purposes in the form of a turn buckle or similar.

In the preferred form the pile 3 penetrates into the ground 4 to thereby tie the entire assembly of the pile and the concrete block 2, to the ground 4. However it will be appreciated that such an in-ground connection may not necessarily need to be established but does provide significant advantages.

FIG. 5 illustrates formwork 11 for defining a concrete block about only one pile 3. The void defining region 21 is frustoconical shaped. The upper surface 22 of the void defining surface 21 sit below the peripheral rim 23 of the formwork 11. This ensures that the pile 3 has concrete surrounding the pile at the region 6. The tie 9 projects from the pile to present itself into the concrete at or about the region 6.

FIG. 6 shows an alternative form of formwork 11 and where the void defining region 21 is of a four-faceted pyramid shape. Other void defining regions 29 may also be provided. The peripheral rim 23 provides a surface to allow for a screening of the upper surface of the poured concrete to occur during construction.

FIG. 7 illustrates a single pile shoring formwork 11 and FIG. 8 is a bottom perspective view of FIG. 7 illustrating that the formwork need not define a complete containment region because the ground on which the formwork 11 may be placed may complete the definition of the containment region.

The present invention allows for itself to be used not just for providing concrete blocks about individual piles but may also allow for the formation of a concrete floor slab and through which piles extend. A plurality of formwork as hereinbefore described may be assembled together to cover a larger area and into which concrete can be poured to create a floor surface and through which piles can project.

The present invention may also utilise formwork in the form of void defining forms as shown in FIGS. 9A and 9B about which a separate formwork can be placed to define the cast floor as for example shown in FIG. 9A. For example with reference to FIG. 9A, a box shuttering 36 may be assembled on a ground surface to define a perimeter for a concrete slab. A plurality of piles may be located within this perimeter that each have formwork 42 located about the piles 3 so as to create the void extending from ground level up towards the region 6 of each of the piles. Concrete can then be poured into the zone defined by the shuttering 36 to embed all of the piles into the concrete slab and to create the plurality of voids 47 about each of the piles 3. This can allow for a reduction in the volume of concrete going into the floor slab 50.

FIG. 10 is a bottom view of formwork as used in FIGS. 9A and 9B.

Whilst mass is a desirable characteristic of the concrete block of the present invention the shoring up of a pile 3 may occur by use of a concrete block 2 as for example shown in FIG. 12 that locates adjacent part of the pile at its region 6 and is located on the ground at region 62 of the concrete block 2. A plurality of individual concrete blocks 2 may be placed around the pile 3 as seen in plan view in FIG. 13. These concrete blocks 2 may be manufactured offsite and moved into place and appropriately connected to the pile 3 by fasteners. Alternatively formwork may be provided to cast the individual concrete blocks 2 as shown in FIGS. 12 and 13 onsite. Formwork may be provided to allow for a skeletal type of concrete block 2 as shown in FIG. 14 to be defined about the pile 3 where components of a shape as shown in FIG. 12 are presented to operatively connect to the pile at its region 6.

Embodiments of the present invention are shown with respect to FIGS. 15 to 17.

FIG. 15 shows a foundation system comprising a plurality of piles 3 embedded in the solid ground 4. There may be a layer of loose fill 30 on top of the solid ground 4. For example the loose fill layer 30 may be sand or soil and the solid ground 4 may be clay, bedrock or similar. The formwork 11 is placed on top of the loose fill layer 30 (or in the absences of such a layer, on top of the solid ground 4). Preferably the formwork 11 is a series of polystyrene modules. Concrete is poured over the polystyrene modules and surrounds the piles 3 to define a concrete slab 31.

The manner in which the piles are tied to one another and to the concrete slab is illustrated in FIG. 16. A sleeve 32 may be provided through the piles 3. The sleeve 32 allows a reinforcing bar 33 to pass through the piles as shown in FIG. 16. Reinforcing bar 33 can pass through the sleeves 32 of multiple piles 3 that are aligned. Other reinforcing bars 34 and 35 may be provided above the pile 3 and embedded in the concrete slab 31 to reinforce it. A steel mesh (not shown) may be installed over the piles and embedded in the concrete slab 31 just below the surface. A vertically orientated tie 37 may be provided which extends from the pile upwardly into the concrete slab 31. As would be apparent to a person skilled in the art, the reinforcing bar and steel mesh may be tied together before the concrete is poured. The concrete can be poured in one pour over the entire foundation area to establish a concrete slab 31. The concrete slab 31 defines a concrete floor on which a dwelling can be built.

The foundation system of the present invention may also be utilised for supporting a timber floor section as shown with reference to FIG. 17. A timber bearer 38 is supported by piles 3. The timber bearers 38 in turn support a layer of timber flooring 39. The vertically orientated tie 37 or any other suitable bracket may be used to fasten the pile 3 to the bearer 38. Concrete can be poured into the cavity region 40 between the pile and the formwork 11 so that a concrete block is established around the pile 3. Preferably the cavity region 40 extends to the ground level, so that the concrete block that is formed contacts the ground at its lower extent.

A waterproof seal 41 may be provided on the underside of the polystyrene modules to deter moisture entering the modules. Any suitable seal may be used, for example a Basf Peripor type seal.

The polystyrene modules may include channels 43 on their undersides. The channels 43 define a void above the ground. During an earthquake or other seismic event liquefaction sediment may be forced upwardly through the ground and disrupt building foundations. The presence of the channels 43 allows for the liquefaction to be deflected so as not to disrupt the foundation. Preferably the liquefaction sediment can be deflected away from the foundation area via the channels 43. Alternatively, or in addition to the channels 43 the formwork modules 11 may include protrusions 73 on their undersides, as shown with reference to FIG. 22. Preferably the protrusions 73 are of a truncated cone like shape but may be any other shape. The protrusions 73 also may help to deflect liquefaction sediment.

Preferred forms of the present invention are shown with respect to FIGS. 18 and 19. An imported sand layer 70 may be provided on top of the loose fill layer 30. The formwork 11 may then be placed on top of the sand layer 70. Each formwork module 11 may be connected to adjacent formwork module 11 via a connection system illustrated in FIGS. 20 and 21. In this way the formwork modules can be connected together before the concrete is poured over them. In the preferred embodiment of the invention the connection system comprises complementary connecting features 71 located at the edge of each formwork module 11. The complementary connecting feature 71 of one formwork module 11 can engage with the complementary connecting feature 71 of an adjacent module to connect the two modules together. Preferably the connecting features 71 include male and female parts which engage with female and male parts of an adjacent formwork module 11. Alternatively, any other suitable means for connecting adjacent formwork modules may be employed.

Fibre-cement boards 72 may be attached to external formwork pods 11 as shown in FIGS. 18 and 19.

FIG. 22 shows the underside of a formwork module 11 and the location of the channels 43 and the protrusions 73. Opening 74 is the location where the pile 3 extends through the formwork module 11. The modules 11 are preferably quadrilateral in plan shape, however may be any other suitable shape.

FIG. 23 shows the top side of a formwork module 11. Upwardly facing Channels 75 extend across the module from each side towards the cavity region 40 where the concrete is poured. The upwardly facing channels 75 also receive concrete. As shown in FIG. 24, reinforcing bars 33 may be placed inside the channels 75 before the concrete is poured. The reinforcing bars 33 reinforce the concrete. Further reinforcement may be provided via an overlaid reinforcing mesh 76 as shown in FIG. 25 which would be placed on top of the formwork module 11 prior to the concrete pour.

It should be appreciated that the piles 3 of the present invention may be from any suitable material such as timber, steel, concrete etc. Likewise, the method by which the piles are tied to the concrete slab may differ depending on requirements.

Further, the formwork modules 11 are preferably moulded polystyrene, however may be manufactured from any other suitable material such as recycled rubber or recycled plastic.

The following steps describe the installation process for a new dwelling:

• • mark out and cut the foundation area required.
  • install piles using information from site geotechnical and engineering reports.
  • install the pre-formed polystyrene modules in the foundation area.
  • install all reinforcing bar.
  • install the pile brackets and joints to piles and reinforcing bar.
  • install service ducting as required.
  • install steel mesh over the modules and tie all steel work together.
  • pour all concrete in one pour over the foundation area.
  • house construction may now commence.

The following steps describe the installation process for an existing dwelling:

• • remove existing building from current foundation area to free area of the site.
  • deconstruct and/or cap services.
  • remove old foundations and/or concrete slab.
  • mark out and cut the foundation area required.
  • install piles using information from site geotechnical and engineering reports.
  • install the pre-formed polystyrene modules in the foundation area.
  • install all reinforcing bar.
  • install the pile brackets and joints to piles and reinforcing bar.
  • install service ducting as required.
  • install steel mesh over the modules and tie all steel work together.
  • pour all concrete in one pour over the foundation area.
  • move building back over foundation area.
  • attach piles to secured bearers of the building structure to foundation.
  • house reconstruction may now commence.

One of the advantages conferred by the present invention is that the concrete block acts as a bracing to the pile. The bracing acts on the pile at a height above the ground. The concrete is heavy so does not necessarily need to be tied to the ground in order for it support the pile when the pile is under lateral load F. The concrete block could be solid all the way to ground level around the pile. But to save on concrete, a void or voids could exist. A void does not compromise the bracing properties of the concrete block as the bracing needs to happen closer to the top of the pile. So to reduce on the amount of concrete, a void can exist. Further advantages include:

• • The system is retrofittable.
  • Both to existing buildings that are still in good health and to buildings that have fallen off their piles.
  • The formwork is light weight.
  • It provides stability to the piles further up than merely at ground level.
  • The concrete block is easy to cast in place and can be replaced individually if they are damaged in a subsequent seismic event.
  • There may be a plurality of these concrete blocks under the dwelling that each have some independence of movement which can be important if there are ground waves rippling through.
  • Where a metal tie posts is used directly from the concrete block or from the pile, and it snaps in another seismic event, then that part is easy to replace compared to a snapped pile.

Claims

1. A formwork module for the casting of an in-situ concrete block around a foundation pile when the formwork module is supported by the ground adjacent to the foundation pile, the formwork module being shaped to define a cavity between the pile and the formwork module so that the concrete block that is cast into the formwork module is operatively connected in the cavity to the foundation pile at a location of the pile that is above the ground.

2. The formwork module of claim 1, in which the module has an opening through which the foundation pile extends, such that the module completely surrounds the foundation pile while defining the cavity between the pile and the module.

3. The formwork module of claim 2, in which the module includes at least one channel that extends in a direction substantially perpendicular to a longitudinal direction of the foundation pile when the module is placed on level ground around the foundation pile, each channel defining a region in which pourable concrete can be displaced to then set to form at least part of the concrete block.

4. The formwork module of claim 3, in which each channel extends into the cavity so that the concrete block is cast as a single block inside the cavity and the channel.

5. The formwork module of claim 3, in which the formwork module is quadrilateral in plan view and a channel extends from each side of the quadrilateral to the opening in the centre of the quadrilateral.

6. The formwork module of claim 3, wherein the channels are adapted to receive reinforcing material for reinforcing the concrete that is cast into the channels.

7. The formwork module of claim 1, wherein the formwork module includes connecting features so that it can connect to adjacent, like modules.

8. The formwork module of claim 1, wherein the formwork module includes at least one channel on its underside, which is open to the ground, through which liquefaction or any other material that might emerge from the ground can be diverted.

9. The formwork module of claim 1, wherein the formwork module includes a plurality of downwardly extending protrusions which contact the ground when the module is positioned on the ground, a void being defined between the downwardly extending protrusions in which liquefaction or any material that might emerge from the ground can be diverted.

10. A method of casting an in-situ concrete block using one or more formwork modules, the formwork module being shaped to define a cavity between the pile and the formwork module so that the concrete block that is cast into the formwork module is operatively connected in the cavity to the foundation pile at a location of the pile that is above the ground, the method including the steps of:

positioning one or more formwork modules on the ground adjacent to a foundation pile, so that the formwork module(s) and the pile define the cavity between the pile and the formwork module(s); and

pouring concrete onto the formwork module(s).

11. The method as claimed in claim 10, in which the module has an opening and is positioned so that the pile extends through the opening with the module completely surrounding the foundation pile.

12. The method as claimed in claim 11, in which the module includes at least one channel that extends in a direction substantially perpendicular to a longitudinal direction of the foundation pile when the module is placed on level ground around the foundation pile, the method including the step of displacing pourable concrete into a region defined by the channel.

13. The method as claimed in claim 12, in which each channel extends into the cavity, the method including the step of casting the concrete block as a single block inside the cavity and the channel.

14. The method as claimed in claim 13, which includes positioning reinforcing material in the channels for reinforcing the concrete that is cast into the channels.

15. The method as claimed in claim 13, which includes connecting the formwork module to other adjacent formwork modules.

16. The method as claimed in claim 10, in which a reinforcing mesh is positioned on the module prior to pouring the concrete.