Modular buttress foundation

Abstract

A ground surface cast-in-place foundation assembly adapted to vertically engage a perimeter beam of a level modular housing comprising a buttress assembly that includes a means for seating the perimeter beam, a tubular stanchion having an upper and lower end, an anchor base plate fixedly connected to the lower end of the stanchion and a couple of transverse tabs attached to the intermediate portions of the stanchion; and a flowable and settable foundation material which envelopes at least a portion of the buttress assembly, wherein the foundation material conforms to the shape of a porous fabric container into which it is poured, and it sets with the enveloped portion of the buttress assembly embedded therein.

Description

BACKGROUND OF THE INVENTION

A. Field of the Invention

The present invention generally relates to an apparatus of establishing cast-in-place and on-ground surface foundation, and more particularly to a foundation to support a perimeter joist for the underside of manufactured homes at exterior doors and wide openings.

B. Description of the Prior Art

Manufactured homes are transported to a customer's site for a permanent or semi-permanent setup. One way in practice is through cast-in-place and on-the-ground building foundations wherein the complete building is suspended while vertical supports such as construction piers and stanchions at selected locations in the foundation plan are engaged at their top ends to an undercarriage of the building and their bottom ends are buried in fabric containers of cementitious slurry until the piers and stanchions become an integral foundation in the solid block of concrete conformed to the ground for the leveled dwelling house.

In U.S. Pat. No. 5,664,377, there is a description with reference to its FIG. 5 of a foundation assembly comprising a fabric container housing slurry that partially embeds a stanchion equipped with a bracket. In operation, the stanchion of the foundation is subject to the cast-in-place installation that requires measuring the distance between ground surface and the joist to cut the stanchion to an optimal adjusted length using a tube-cutter. The cut stanchion is then suspended inches above ground surface as the fabric container is positioned underneath for pouring a concrete slurry therein in order to obtain a structurally integral foundation that conforms to the ground.

Since the introduction of the same product to the market by the applicant and as the market has grown up there has been a need for an improvement to the perimeter foundation to fit the updated environment of the manufactured home building. As the perimeters of manufactured building under the rim joist need to be blocked with walls for a trimmed finish, an improved buttress foundation system also became necessary while maintaining the benefit of the same rigidity as provided by the above applicant's patent '377,

U.S. Pat. No. 6,347,489 to Marshall, Jr. et al. discloses a storm anchor system including foundation column to receive and support housing structures of various sizes at its top. However, the anchor system is not an on-ground but an on-board system having its base fastened to a separate base of the housing structure and recognizes no needs in perimeter blocking.

Thus, the present invention provides a solution to the aesthetical and structural additions of perimeter blocking to the modular housing as well as the direct support that can be custom made on-ground without additional works for foundation base.

SUMMARY OF THE INVENTION

When a manufactured housing arrives at the site, the flooring assembly is typically supported at its underside by horizontal parallel beams or joists and also vertically supported by foundations that stand firmly on the ground. Rim or perimeter joists define the outer bottom edges of the housing which are suspended like the other joists but need an aesthetical consideration in addition to the basic requirements of support with high structural rigidity. If the mobile housing is double sized, it is made in two subassemblies for a joint set up into one building where mate line blocking supports are necessary. The perimeter and mate line blocking supports have common place where they support not the undercarriage beams at the interior of the building but the peripheral beams whether they are on mate line in the center or perimeter line, which will be visible from the outside.

The mobile housing buttress foundation of the present invention is adapted to provide a perimeter blocking with an anchor plate uniquely combined with the ground surface cast-in-place foundation process developed earlier by the applicant with its practice successful in the field. Thus, the description and specification of the '377 patent are incorporated herein by reference for better general understanding of the present invention.

The present invention provides a ground surface cast-in-place foundation assembly adapted to vertically engage a perimeter beam of a level modular housing comprising a buttress assembly that includes a means for seating the perimeter beam, a tubular stanchion having an upper and lower end, an anchor base plate fixedly connected to the lower end of the stanchion and a couple of transverse tabs attached to the intermediate portions of the stanchion; and a flowable and settable foundation material like concrete which envelopes at least a portion of the buttress assembly, wherein the foundation material conforms to the shape of a porous fabric container into which it is poured, and it sets with the enveloped portion of the buttress assembly embedded therein. For purpose of the invention, flowable and settable foundation material means any material utilized for stabilizing vertical stanchion including cement, mortar and slurries, which contain such materials.

The buttress foundation of the present invention is placed under the bottom floor structure of the modular housing behind the sidewall thereof where perimeter-blocking supports are required.

Accordingly, the general object of the present invention is to provide an improved buttress foundation for modular housing perimeter-blocking sidewalls in speed and rigidity.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a buttress assembly in operation according to the present invention.

FIG. 2 is a perspective view of the buttress assembly of FIG. 1 in more detail.

FIG. 3 is a schematic view of a modular home employing the inventive buttress assembly and having perimeter foundation.

FIG. 4 is a combination schematic view of a prior art mobile home support system with a modular home support system employing the inventive buttress assembly to support the perimeter.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, the novel and improved buttress assembly 10 is comprised of a selected length of tubular stanchion 12 having at its top an L-shaped bracket 11 to abut the perimeter joist 22 at its bottom plane 23 and an inside plane 24. The stanchion 12 has four side walls and a rectangular cross section. The L-shaped bracket 11 has a vertical flange 14 with a number of apertures through which attaching bolts 15 are threaded into the interior side of the joist 22 such that the base portion of the stanchion 12 is suspended several inches above ground surface 16.

A base plate 17 is welded to the base portion of the stanchion 12. On the bottom of the base plate 17 a number of anchor bolt heads 18 are protruded downwardly. Alternatively, J-shaped bolts can also replace the straight bolts 18.

On a wall of the stanchion 12 away from the vertical flange 14 two steel tabs 19 are welded intermediately with a longitudinal distance from each other to hold a girt 20.

Fabric container 1 is placed beneath the stanchion 12 and while the bottom end of the container 1 resides on the ground surface 16, a rebar 2 is inserted into the container 1 and the entrance to container 1 is suitably tied around stanchion 12, concrete slurry 6 is poured into container 1 to its full capacity. The three dimensional shape of the base plate 17 with anchor heads 18 will also provide an exceptional holding force in the resulting concrete base 6 of the buttress foundation 10.

Thus, the buttress foundation 10 has been completed for the overlying structure of the perimeter joist 22 upon which the floor assembly 25 and building walls 26 are rested as shown in the drawings. Attached to the building walls 26 covering the joist 22, an exterior siding 27 protects the building against elements. As described above, the girt 20 is attached to the stanchion 12 at its steel tabs 19 by the attaching screws 21 from the exterior side of the girt 20. An elongated board 28 is then applied to the girt 20. Then, an elongated strip or trim 29 is attached to the bottom edge of the siding 27 covering the top edge of the elongated board 28. The mounting location of the elongated strip or trim 29 optionally allows a concealed air gap vent formed between the trim 29 and the elongated board 28.

FIG. 3 shows the manufactured home in two parts each having the junction between the home parts, i.e. the mate line 32 is defined by a couple of mate line joists 22 and suspended by mate line piers 30. The buttress assemblies 10 with the concrete portion 6 and fabric container 1 provide a perimeter support embodiment. The fabric container is formed as an elongated sleeve that is wrapped and installed around the buttress assemblies 10 allowing the concrete portion 6 to form a perimeter foundation that connects all of the buttress assemblies 10 in a single piece of concrete. The elongated fabric sleeve can be stored as a roll so that it can be cut to length on the job site. Also, the elongated fabric sleeve can be a continuous sleeve having no opening, allowing the openings to be cut at the job site.

FIG. 4 shows a combined view of a mobile home support juxtaposed on the present embodiment, which is a modular housing system. The combined view provides a comparison of the prior art mobile home configuration with the present invention modular housing system.

The mobile home support has four undercarriage I-beams 31 held above the ground by a plurality of piers 34. The traditional mobile home would be rolled in as a doublewide trailer on a wheeled axle configuration, installed on the pier supports 34 to allow semi permanent support.

On the other hand, the modular house has two parts divided above along the ridge of the roof shown in dotted line and below at the mate line 32. The junction between the modular home parts, i.e. the mate line 32 is defined by a couple of coupled mate line joists 22 supported by mate line piers 30. Buttress assemblies 10 disposed under perimeter joists 22 provide perimeter support. Buttress assemblies 10 are shown in block support embodiment that do not form a perimeter allowing connection between the block supports 6.

The modular house has a more detailed assembly process than the prior art mobile home. The pair of elongated sections of the modular house can be brought to the construction site by a pair of trucks. Preferably, the width of each module can fit on a single flatbed truck. The sections of the modular house can be placed upon temporary supports by a crane and leveled. The buttress assemblies 10 arrive at the job site fully assembled and welded including the tubular stanchion 12, L-shaped bracket 11, vertical flange 14, base plate 17, anchor bolt heads 18 or J shaped bolts, and steel tabs 19. Each of the sections of the modular house is joined to the others. Underneath the house the mate line piers 34 are attached to mate line joists 33. The improved buttress assembly 10 is installed to the perimeter joist so that the tubular stanchion 12 having at its top an L-shaped bracket 11 abuts the perimeter joist 22 at a perimeter joist bottom plane 23 and a perimeter joist inside plane 24. The fabric container 1 is unfurled allowing pouring of the concrete portion 6 into the fabric container 1. After the concrete portion 6 cures, the modular house temporary support is removed.

The house then receives installation of exterior siding 27 and elongated board 28. Later, an appropriate finish such as stucco can be applied to the board 28 so that when the perimeter of the house receives landscape backfill, the backfill will cover a portion of the board 28.

In conformance to current technology, it is appreciated that stanchion 12, bracket 14, base plate 17, anchor heads 18, girt 20 and bolts 15 and 21 of this invention be constructed of iron, steel, cast aluminum or other appropriately rigid material. Fabric container 1 is composed of any one of the many geo-textile materials well known in the art. The elongated board 28 of the present invention may be of treated plywood or other water resistant material.

Therefore, while the presently preferred form of the manufactured housing buttress foundation has been shown and described, and several modifications thereof discussed, persons skilled in this art will readily appreciate that various additional changes and modifications may be made without departing from the spirit of the invention, as defined and differentiated by the following claims.

Claims

1. A ground surface cast-in-place foundation assembly adapted to vertically engage a perimeter beam of a level modular housing comprising:

a. a buttress assembly having a means for seating the perimeter beam, a tubular stanchion having upper and lower ends, an anchor base plate fixedly connected to the lower end of said stanchion and a couple of transverse tabs attached to the intermediate portions of the stanchion between said upper and lower ends;

b. a girt having opposite side edges fastened to said transverse tabs of said buttress assembly for blocking a clearance of said modular housing from the ground; and

c. a flowable and settable foundation material which envelopes at least a portion of said buttress assembly, wherein the foundation material conforms to the shape of a porous fabric container into which said foundation material is poured and it sets with the enveloped portion of said buttress assembly embedded therein.

2. The foundation assembly set forth in claim 1, wherein said anchor plate of said buttress assembly further includes a plurality of anchor heads protruding downwardly of the bottom surface of said anchor plate.

3. The foundation assembly set forth in claim 1, wherein said seating means is an L-shaped bracket to abut said perimeter beam at its bottom and side planes, said bracket having a vertical flange with a number of apertures through which attaching bolts are threaded into the interior side of said perimeter beam, whereby the base portion of said stanchion is suspended above ground surface.

4. The foundation assembly set forth in claim 1, wherein each of said stanchion, bracket, base plate, anchor heads, girt and attaching bolts is constructed of iron, steel, cast aluminum or other appropriately rigid material.

5. A modular buttress system adapted to engage a perimeter beam of a level modular housing comprising:

a. a plurality of buttress members having a seat for a perimeter beam, a tubular stanchion having upper and lower ends, an anchor base plate fixedly connected to the lower end of said stanchion;

b. a girt having opposite side edges fastened to said buttress assembly; and

c. a concrete pouring which envelopes at least the anchor base plate of the buttress members, wherein the concrete conforms to the shape of a porous fabric container into which said concrete is poured and sets with the enveloped portion of said buttress members embedded therein.

6. The modular buttress system of claim 5, further comprising a couple of transverse tabs attached to the intermediate portions of the stanchion between said upper and lower ends, wherein a girt has opposite side edges fastened to said couple of transverse tabs on said buttress assembly.

7. The modular buttress system of claim 5, wherein said anchor plate of said buttress assembly further includes a plurality of anchor heads protruding downwardly from the bottom surface of said anchor plate.

8. The modular buttress system of claim 5, wherein said seat is an L-shaped bracket to abut said perimeter beam at its bottom and side planes, said bracket having a vertical flange with a number of apertures through which attaching bolts are threaded into the interior side of said perimeter beam, whereby the base portion of said stanchion is suspended above ground surface.

9. The modular buttress system of claim 5, wherein each of said stanchion, bracket, base plate, anchor heads, girt and attaching bolts is constructed of iron, steel, cast aluminum or other appropriately rigid material.

10. A modular buttress system adapted to engage a perimeter beam of a level modular housing comprising:

a. a plurality of buttress members having a seat for a perimeter beam, a tubular stanchion having upper and lower ends, and an anchor base plate fixedly connected to the lower end of said stanchion, the plurality of buttress members arranged at intervals affixed to the perimeter beam;

b. a girt having opposite side edges fastened to said buttress assembly; and

c. a concrete pouring which envelopes at least the anchor base plate of the buttress members, wherein the concrete conforms to the shape of a porous fabric container formed as an elongate sleeve into which said concrete is poured and sets with the enveloped portion of said buttress members embedded therein, wherein the concrete pouring is rebar reinforced at its footing, wherein said concrete pouring structurally connects said plurality of buttress members.

11. The modular buttress system of claim 10, further comprising a couple of transverse tabs attached to the intermediate portions of the stanchion between said upper and lower ends, wherein a girt has opposite side edges fastened to said couple of transverse tabs on said buttress assembly.

12. The modular buttress system of claim 10, wherein said anchor plate of said buttress assembly further includes a plurality of anchor heads protruding downwardly from the bottom surface of said anchor plate.

13. The modular buttress system of claim 10, wherein said seat is an L-shaped bracket to abut said perimeter beam at its bottom and side planes, said bracket having a vertical flange with a number of apertures through which attaching bolts are threaded into the interior side of said perimeter beam, whereby the base portion of said stanchion is suspended above ground surface.

14. The modular buttress system of claim 10, wherein each of said stanchion, bracket, base plate, anchor heads, girt and attaching bolts is constructed of iron, steel, cast aluminum or other appropriately rigid material.