SWAGED PIER SYSTEM AND METHOD OF INSTALLING SAME

Abstract

A pier system (10) for at least partially supporting a-building broadly comprises a plurality of swaged pier segments (12) having a length, wherein each swaged pier segment (12) is operable to be connected to another of the swaged pier segments (12); a hinged lifting platform (14) operable to be secured to an uppermost one of the swaged pier segments (12′); at least one intermediate swaged pier segment (16) having a length, said length of the intermediate swaged pier segment (16) being different than the length of the swaged pier segment (12), said intermediate swaged pier segment (16) operable to be connected to the uppermost swaged pier segment (12′); and an encasement (22) for at least partial receipt of the at least one intermediate swaged pier segment (16).

Description

RELATED APPLICATIONS

This non-provisional patent application claims priority benefit, with regard to all common subject matter, of the following earlier-filed U.S. provisional patent applications: U.S. Provisional Application No. 60/945,522, filed Jun. 21, 2007, and entitled “Swaged Pier Segment”; U.S. Provisional Application No. 61/013,116, filed Dec. 12, 2007, and entitled “Swaged Pier Segment for a Pier System”; and U.S. Provisional Application No. 61/027,685, filed Feb. 11, 2008, and entitled “Helical Swaged Segment.” The identified earlier-filed provisional applications are hereby incorporated by reference in their entirety into the present application.

BACKGROUND

1. Field

The present invention relates to systems for lifting and supporting a building that has moved due to soil movement, erosion, earth compaction, or other geological movement. More particularly, the invention relates to a pier system comprising individual, stackable pier segments that can be placed under a building to support and lift the building.

2. Description of the Related Art

Movement of a building due to soil movement, erosion, earth compaction, or other geological movement is common. Often, movement is due to incorrectly preparing the earth beneath a building foundation before laying the foundation. For example, in clay-heavy regions, if the earth is not sufficiently compacted prior to laying a foundation, then as time progresses, and the ground heaves due to rain and drought, the earth underneath and surrounding the footing of the building will naturally move. This movement consequently results in movement of the building. Even a small amount of movement of the building, such as 1-2 inches, can cause multiple foundation and structural problems, such as water seeping into the building. Many systems have been developed to address building movement; however, each of these systems presents different, but significant, problems.

A prior art system for lifting and supporting a building is disclosed in U.S. patent application Ser. No. 11/457,547, entitled “Sleeved Segmented Foundation Support Product.” In the '547 Patent Application, a segmented pile disclosing interconnecting segments that form the pile is provided. Each segment comprises an outer sleeve surrounding an inner plug formed of concrete. (¶¶0023 and 0024). A portion of the concrete plug extends outside the outer sleeve (referred to as the plug projection 31). (¶0025). The sleeve includes a cavity formed by the outer sleeve and the plug. (¶0027). Therefore, a cavity of the first segment can extend over the plug projection of a second segment. (¶0041). Once assembled, there is a “small annular gap . . . between the projection and the sleeve.” (¶0046, FIG. 3). Thus, in the segmented pile of the '547 patent application, the concrete plugs are touching each other and bearing the compressive load of the building. (¶0037).

There are several problems with the segmented pile disclosed in the '547 patent application. First, because the compressive load of the building is borne on the concrete-to-concrete plugs, any lateral force on the segmented pile that occurs from heaving or other movement of the building will shear the concrete. Furthermore, if the concrete breaks or splits, the exposed annular gap will allow for increased lateral movement of adjoining segments.

The '547 patent application further discloses a cap 57 and cap blocks 58 that “block” the “remaining space between the installed segments and the foundation.” (¶0071). The cap 57 is essentially a segment with a platform perpendicularly secured thereto and operable to support three sets of “cap blocks 58.” Thus, when completed, the building foundation bears down on three vertical axes along the cap blocks. This is not preferable, however, due to ground heaving and movement. When the ground heaves, the building's footing may come to bear back down on the cap blocks at a different compressive and/or lateral force than when the segmented pier was first installed. For example, ground heaving might apply more load to the right cap block. This would then result in a greater compressive force on the right cap block than the other blocks, which would then result in lateral forces on the remaining blocks due to the resulting misalignment and inequality of the compressive forces on all the cap blocks. The end result would be lateral moving of the segments while under a very high compressive load.

Accordingly, there is a need for an improved pier system that overcomes the limitations of the prior art. More particularly, there is a need for a pier system that interlocks or stacks multiple pier segments, but that does not rely on concrete-on-concrete to bear the compressive load of a building. Additionally, there is a need for a pier system that provides one axis of support and that is not subject to lateral forces at a top end of the pier.

SUMMARY

Embodiments of the present invention solve the above-described problems and provide a distinct advance in the art of pier systems for lifting and supporting a building. More particularly, embodiments of the present invention provide a pier system for at least partially supporting a building that broadly comprises a plurality of swaged pier segments having a length, wherein each swaged pier segment is operable to be connected to another of the swaged pier segments; a hinged lifting platform operable to be secured to an uppermost one of the swaged pier segments; at least one intermediate swaged pier segment having a length, said length of the intermediate swaged pier segment being different than the length of the swaged pier segment, said intermediate swaged pier segment operable to be connected to the uppermost swaged pier segment; and first and second mating faceplates for at least partial receipt of the at least one intermediate swaged pier segment therebetween.

In other embodiments of the present invention, a pier system for use with a helical swaged pier segment is provided. The helical swaged pier segment is similar to the swaged pier segment of embodiments of the present invention, except that the helical segment includes a helix surrounding the generally cylindrical body of the pier segment. The helical segment can be used to create a manufactured point of refusal when it is not economically warranted to use the swaged pier segments of embodiments of the present invention to the natural point of refusal.

By constructing a pier system of embodiments of the present invention, numerous advantages are realized. For example, the load of a building is held on only one vertical axis, as opposed to multiple vertical axes in the prior art. Additionally, any vertical or lateral movement of the building does not result in shearing or lateral movement of the individual components of the pier system with respect to each other. Further, because the individual pier segments present a body and swaged segment that is entirely made of steel, the concrete held within the swaged pier segment is reinforced, and the pier segments, when stacked, result in steel on top of steel, which provides an improved resistance to shearing from lateral and compressive forces. An even further advantage of the present invention is that the individual pier segments may be more easily and inexpensively manufactured, due to use of a single piece of steel for the segment. Moreover, lateral movement is limited because each segment does not include telescoping parts. Further, the swaged configuration of the pier segment allows for securement of the lifting platform to the segment.

These and other important aspects of the present invention are described more fully in the detailed description below.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 is a perspective, fragmented view of a pier system of embodiments of the present invention driven into bedrock or other dense material and supporting a sunken portion of a building;

FIG. 2 is a perspective, fragmented view of the pier system of embodiments of the present invention and illustrating multiple swaged pier segments interconnected and stacked on each other;

FIG. 3 is a perspective view of a lifting platform and a lifting apparatus of embodiments of the present invention and illustrating the building lifted to level;

FIG. 4 is a perspective view of the lifting platform and the lifting apparatus of embodiments of the present invention and illustrating an intermediate swaged pier segment connected to an uppermost swaged pier segment of the pier system;

FIG. 5 is an exploded, perspective view of first and second faceplates of embodiments of the present invention operable to be secured to the intermediate swaged pier segment;

FIG. 6 is a perspective view of the intermediate swaged pier segment and further illustrating use of a spacer and shims;

FIG. 7 is a perspective, upward view of the lifting platform lifting apparatus, and faceplates of embodiments of the present invention when installation is complete;

FIG. 8 is a perspective, downward view of the lifting platform, lifting apparatus, and faceplates of embodiments of the present invention when installation is complete;

FIG. 9 is a cross-sectional view taken along line 9-9 of FIG. 8 and illustrating the uppermost swaged pier segment, two intermediate swaged pier segments, the spacer, the shims, and the first and second faceplates;

FIG. 10 is a perspective view of the lifting platform of embodiments of the present invention and particularly illustrating first and second sections of the platform;

FIG. 11 is a perspective view of the lifting platform of embodiments of the present invention and particularly illustrating the uppermost swaged pier segment mated with a contoured section of the platform;

FIG. 12 is a perspective, collective view of the swaged pier segment, the plurality of intermediate swaged pier segments of varying length, the plurality of spacers of varying length, and the plurality of shims of varying length of embodiments of the present invention;

FIG. 13 is a perspective, environmental view of a helical swaged pier segment of embodiments of the present invention and being used in conjunction with the swaged pier segments of embodiments of the present invention; and

FIG. 14 is a perspective view of the helical swaged pier segment of embodiments of the present invention.

The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.

DETAILED DESCRIPTION

Turning now to the drawing figures, and particularly FIGS. 1-5, a pier system 10 constructed in accordance with embodiments of the present invention is illustrated. The pier system 10 is operable to lift and support at least a portion of a perimeter of a building that has shifted due to soil movement, erosion, earth compaction, or other geological movement. The pier system 10 broadly comprises a plurality of stackable swaged pier segments 12 of generally equal length, a hinged lifting platform 14 for receipt of an uppermost swaged pier segment 12′ during installation of the pier system 10, a plurality of intermediate swaged pier segments 16 of generally varying length for positioning atop the uppermost pier segment 12′, a plurality of spacers 18 of generally varying length, a plurality of shims 20, and an encasement for 22 receipt of the intermediate pier segments 16, the spacers 18, and the shims therebetween 20. When assembled, the pier system 10 of embodiments of the present invention is aligned along only one vertical axis, including at a general top of the pier system 10 that is proximal to the building, such that a compressive load of the building supported by the pier system 10 is along the only one vertical axis.

For any structural features described below that are the similar or the same, the same reference numeral will be used to indicate the structural feature.

As illustrated in FIG. 12, each swaged pier segment 12 comprises a substantially cylindrical body 24 having distal and proximal ends 26,28, a swaged segment 30 at the proximal end 28 of the body 24 and operable to mate with another swaged pier segment 12 or the intermediate swaged pier segment 16, high-strength concrete 32 held within a portion of the body 24 and the swaged segment 30, and an open segment 34 at the distal end 26 of the body 24. The body 24 is preferably made of galvanized steel or other suitable material. A length of the body, and the swaged segment 30 is approximately 8-20 inches, more approximately 10-18 inches, and preferably approximately 14 inches. The body 24 of the swaged pier segment 12 is preferably circular in cross-section, although the body 24 may be formed in other shapes, such as square, octagonal, etc. However, a circular shape was chosen due to ease in manufacture and generally even load distribution from supporting the building.

As noted above, the swaged segment 30 is located at the proximal end 28 of the body 24, and, similar to the body 24, is preferably made of galvanized steel. The swaged segment 30 is either integral with the body 24 due to the body 24 and swaged segment 30 being formed as a unitary item or form a unitary piece of steel, or, alternatively, the swaged segment 30 is directly coupled with the proximal end 28 of the body, such as via welding the body 24 and swaged segment 30 together.

The swaged segment 30 includes a swaged or tapered rise 36 extending from the body 24 and a cylindrical neck 38 having a diameter less than a diameter of the body 24 of the swaged pier segment 12. The swaged rise 36 is tapered or angled towards the neck 38 so as to connect the body 24 and the neck 38. The neck 38 is similar to the cylindrical body 24, except that it has the smaller diameter so as to receive the open segment 34 at the distal end 26 of the body 24 of a substantially similar pier segment 12, as discussed in more detail below. The neck 38 preferably has a circular cross-section to conform to the cross-section of the body 24; however, if the body 24 is manufactured with a different cross-section, the neck 38 should preferably have a similar cross-section.

The concrete 32 held within the body 24 and the swaged segment 30 preferably has a high compressive force but a low shear force so as to receive the load of the building. The concrete 32 is poured, formed, or otherwise held within the cylindrical body 24 and swaged segment 30 in any suitable manner. However, concrete 32 is not formed within the entire cylindrical body 24, as the open segment 34 at the distal end 26 of the body 24 does not include concrete 32 and is open to atmosphere so as to receive the neck 38 of the swaged segment 30. As such, a length of the open segment is approximately the same length as the neck 38, although as illustrated in FIG. 6, the lengths need not be exactly equal. In particular, the neck's 38 and open segment's 34 lengths are approximately 0.5-3 inches, more approximately 1-2 inches, and preferably approximately 1.6 inches. As noted above and in more detail, the diameter of the neck 38 is preferably slightly less than an inner diameter of the body 24, so that the neck 38 can be received within the open segment 34 of the body 24, as illustrated in FIG. 9.

To connect two or more pier segments 12, the neck 38 of the first lower pier segment 12a is inserted into the open segment 34 of the second, upper pier segment 12b by simply hand-fitting the two segments 12a, 12b together, as illustrated in FIGS. 2 and 9. Once the two segments 12a, 12b are mated, the weight of the second, upper pier segment 12b rests generally atop the swaged rise 36 of the first, lower pier segment 12a. This is advantageous, as the rise 36 can support the load of the second segment 12b. Additionally, the rise 36 provides a relatively large surface area for the second pier segment 12b to rest upon.

After the appropriate number of pier segments 12 has been installed, as described in operation in more detail below, the uppermost pier segment 12′ is installed. At this juncture, there will be a distance between the uppermost pier segment 12′ and a footing 40 of the building, as illustrated in FIG. 9. This distance is filled in by at least one swaged intermediate pier segment 16 (also hereinafter referred to as the “intermediate pier segment”), at least one spacer 18, if needed, and at least one shim 20, if needed. However, prior to installation of the intermediate pier segment 16, the spacer 18, and the shim 20, an installer of the pier system 10 will first temporarily and removably install the lifting platform 14 on the uppermost pier segment 12′. The platform 14 is not included in the finished, installed pier system 10 but is instead used during the installation to complete the installation of the pier system 10 under the building and then removed.

As illustrated in FIGS. 4 and 10, the lifting platform 14 comprises left and right hinged sections 42,44 of generally similar construction. Each section 42,44 includes a base 46, a contoured pier segment-receiving section 48, a stabilizing arm 50, a pivotable securing lever 52, and a lever receiving section 54. The platform 14 is preferably made of steel or other suitable material that can support the load of the building during installation, as described in more detail below.

The left and right sections 42,44 of the platform 14 are connected via one or more hinges 56 positioned along the contoured pier segment-receiving section 48. The contoured pier segment-receiving section 48 of each platform section 42,44 presents a profile 58 of approximately one-half an outer surface of the uppermost pier segment 12′, such that when the sections 42,44 of the platform 14 are joined, they approximately substantially surround the uppermost pier segment 12′, as discussed in more detail below. Alternatively defined, the hinged sections 42,44, when joined, present the profile of the uppermost pier segment 12′. The profile 58 further includes a swaged rise 60 that mates with the swaged rise 36 of the swaged segment 30 of the uppermost pier segment 12′.

The bases 46 of the left and right sections 42,44 are generally perpendicular to the pier segment-receiving sections 48. The bases 46 and the pier segment-receiving sections 48 are connected by the stabilizing arms 50, which are generally triangularly shaped, although any shape may be used. The base 46 of each section 42,44 includes both the securing lever 52 and the lever-receiving section 51. Each securing lever 52 is at least partially threaded and includes a washer and nut 62 operable to be threaded thereon. Additionally, each lever 52 is pivotably secured to the base 46 and operable to be rotated approximately 180°. Each lever-receiving section 54 comprises a pair of parallel, upstanding arms 64 spaced to receive a width of the lever 52. Thus, the securing lever 52 of the left section 42 is operable to be received within the lever-receiving section 54 of the right section 44 of the platform 14. Similarly, the lever 52 of the right section 44 is operable to be received within the lever-receiving section 54 of the left section 42 of the platform 14. A length of each lever 52 is such that approximately 1.25 inches of the lever 52 extends past the arms 64 of each lever-receiving section 54. When the hinged sections 42,44 of the platform 14 are rotated together, the sections 42,44 are secured by removing the washers and nuts 62 from each lever 52, positioning the lever 52 of each respective section 42,44 within the lever-receiving section 54 and, in particular, between the upstanding arms 64, and securing the washers and nuts 62 on the portions of the lever 52 extending past the arms 64 of each lever-receiving section 54, so as to act as a stop and prevent the levers 52 from pivoting out of the upstanding arms 64 of the lever-receiving sections 54.

To secure the platform 14 to the uppermost pier segment 12′, the platform sections 42,44 are wrapped around the uppermost pier segment 12′. In particular, each contoured pier segment-receiving section 48 is positioned against the respective half of the uppermost pier segment 12′. As illustrated in FIG. 11, the swaged rise 60 of the pier segment-receiving section 48 rests against the swaged rise 36 of the uppermost pier segment 12′ during installation. Because each contoured pier segment-receiving section 48 includes the profile that mates with the shape of the uppermost pier segment 12′, including the segment's swaged rise 36, the pier segment-receiving sections 48 of the platform 14 are all that are required to temporarily secure the platform 14 to the uppermost pier segment 12′ during installation.

Once the lifting platform 14 is installed, the installer will position one or more lifting apparatus 66, preferably a bottle jack, on each base 46 of the platform 14, as illustrated in FIGS. 3-5 and 8. The installer will then use the bottle jacks 66 to raise the building to level. As discussed in more detail below, the amount to be raised will vary but may be as little as ⅛ inch to as much as 12 inches. At this juncture, the installer will then complete installation by installing the intermediate swaged pier segment 16, spacers 18, shims 20, and encasement 22.

The intermediate swaged pier segments 16 are substantially similar to the swaged pier segments 12, except that the intermediate pier segments 16 are provided in a plurality of lengths. In particular, the intermediate pier segments 16 include the substantially cylindrical body 24 having distal and proximal ends 26,28, the swaged segment 30 at the proximal end 28 of the body 24, high-strength concrete 32 held within a portion of the body 24 and the swaged segment 30, and the open segment 34 at the distal end 26 of the body 24 and operable to mate with the uppermost pier segment 12′.

The only difference between the pier segments 12 and the intermediate pier segments 16 is the respective length, and embodiments of the pier system 10 provide at least three intermediate pier swaged pier segments 16, each having a different length. A length of the shortest intermediate pier segment 16a is preferably approximately 1-6 inches, more preferably approximately 2-5 inches, and most preferably approximately 4 inches. Similarly, a length of the middle intermediate pier segment 16b is preferably approximately 4-10 inches, more preferably approximately 5-8 inches, and most preferably approximately 6 inches, and a length of the longest intermediate segment 16c is preferably approximately 6-14 inches, more preferably approximately 8-12 inches, and most preferably approximately 10 inches.

Again, depending on the distance between the uppermost pier segment 12′ and the footing 40 of the building, the installer will choose the most appropriate length intermediate pier segment 16 for positioning atop the uppermost pier segment 12′. As can be appreciated, embodiments of the pier system 10 of the present invention may include fewer or more intermediate pier segments 16 with varying lengths, as desired. Additionally, and as illustrated in FIG. 9, one or more intermediate swaged pier segments 16 may be used, depending on the distance from the uppermost pier segment 12′ to a footing of the building. However, in most circumstances, only one intermediate pier segment 16 will be used.

As with the body 24 of the pier segment 12, high-strength concrete 32 is also poured, formed, or otherwise held within the swaged segment 30. Due to the neck 38 also being formed of galvanized steel, the tolerances required for receipt of the neck 38 within the open segment 34 are fairly lenient, which reduces manufacturing complexities and cost.

It is expected that it will be unlikely that the distance between the uppermost pier segment 12′ and the footing 40 of the building will correspond exactly with the length of any of the intermediate pier segments 16a, 16b, 16c. Therefore, embodiments of the pier system 10 of the present invention also provide the plurality of spacers 18 of generally varying length to fill in a majority of the remaining distance between the intermediate pier segment 16 and the footing 40 of the building. Each spacer 18 comprises a generally straight, cylindrical body 68 having a diameter generally equal to the diameter of the neck 38 of the pier segment 12. As with the pier segment 12, concrete 32 is formed within the body 68 of the spacer 18.

As with the intermediate pier segments 16, embodiments of the pier system 10 of the present invention provide for at least three spacers 18, each having a different length. (Only two spacers are shown in FIG. 12). A length along a vertical axis of the shortest spacer 18a is preferably approximately 0.25-2 inches, more preferably approximately 0.5-1.5 inches, and most preferably approximately 1 inch. Similarly, a length of the middle spacer 18b is preferably approximately 0.5-3 inches, more preferably approximately 1-2.5 inches, and most preferably approximately 2 inches, and a length of the longest spacer 18c is preferably approximately 1-4 inches, more preferably approximately 2-3.5 inches, and most preferably approximately 3 inches.

Again, depending on the distance between the intermediate pier segment 16 and the footing 40 of the building, the installer of the pier system 10 will choose the most appropriate length spacer 18 for positioning atop the intermediate pier segment 16. As can be appreciated, embodiments of the pier system 10 of the present invention may include fewer or more spacers 18 with varying lengths, as desired. Additionally, as also can be appreciated, one or more spacers 18 may be used, depending on the distance from the intermediate pier segment 16 to the footing 40 of the building. However, in most circumstances, only one or two spacers 18 will be used.

After installation of the intermediate pier segment 16 and the spacers 18, the distance between the footing 40 of the building and the spacer 18 should be no more than approximately 5 inches, and preferably no more than approximately 3 inches. At this time, the installer will usually mount the encasement 22, which at least partially surrounds the intermediate pier segment 16 and the spacer 18. It can be appreciated that the entire length of the intermediate pier segment 16 need not be surrounded by the encasement 22.

The encasement 22 preferably comprises first and second faceplates 70,72. Because of the varying-length intermediate pier segments 16 and spacers 18, and the combination of lengths each provide, the installer can often size the intermediate pier segments 16 and spacers 18 within ⅛ inch of the needed height for final installation.

The first and second faceplates 70,72 are configured to mate with each other and to each be positioned around approximately half of the width of the intermediate pier segment 16 and spacers 18. As illustrated in FIGS. 5 and 6, the first faceplate 70 comprises a half-cylindrical body 74, a pair of flanges 76 extending therefrom and along a length of the body, and a planar footing plate 78 positioned on top of the body 74 and generally perpendicular to the length of the body 74. Similarly, the second faceplate 72 comprises a half-cylindrical body 74 and a pair of flanges 76 extending therefrom and along a length of the body 74. Unlike the first faceplate 70, however, the second faceplate 72 does not include a footing plate. In preferred form, the faceplates 70,72 are made of galvanized steel, although any suitable material may be used. Additionally, in preferred form, the body 74, flanges 76, and footing plate 78 are integral or directly coupled with each other, such as via welding.

Each of the flanges 76 of the faceplates 70,72 includes a plurality of holes 80 operable to receive a carriage bolt 82 therethrough for securement of the first and second faceplates 70,72 to each other. As illustrated in FIG. 5, carriage bolts 82 are inserted through the holes 80 in the flanges 76 of the first faceplate 70. Alternatively, the carriage bolts 82 could be secured to or integrally formed with the first faceplate 70, or, the carriage bolts 82 could be inserted first through the second faceplate 72 and/or secured to or integrally formed with the second faceplate 72. In the illustrated embodiment of FIG. 5, once the carriage bolts 82 are inserted through the holes 80 in the flanges 76 of the first faceplate 70, the second faceplate 72 is mated with the first faceplate 70 by positioning the bolts 82 through the holes 80 of the flanges 76 of the second faceplate 72. Nuts are then threaded onto the bolts 82 to secure the faceplates 70,72 together.

As can be appreciated, after the installer positions the first faceplate 70 against the intermediate pier segment 16 and the spacers 18, there may still be a distance between the footing plate 78 of the faceplate 70 and the spacer 18. As illustrated in FIGS. 6 and 7, the footing plate 78 of the first faceplate 70 actually contacts the footing 40 of the building, and preferably, is generally adjacent to the footing 40 of the building. As can be appreciated, the footing 40 of the building may not be exactly planar, and therefore, the footing plate 78 of the first faceplate 70 may not exactly contact the footing 40 of the building at every surface along the plane of the footing plate 78.

Because the footing plate 78 has a certain height along the vertical axis (approximately ½ inch), the installer needs to leave at least a few inches, preferably at least approximately 1 inch, between the top spacer 18 and the footing 40 of the building when installing the first faceplate 70, as noted above. Thus, it is expected that the height of the footing plate 78 will take up most of the remaining distance between the footing 40 of the building and the spacer 18. However, it is further expected that there will often still be a very small gap, usually no more than 1 inch, between a bottom 86 of the footing plate 78 and the spacer 18. To accommodate this remaining gap, embodiments of the pier system 10 of the present invention provide for the plurality of thin, planar shims 20, one or more of which may be inserted between the bottom 86 of the footing plate 78 and the spacer 18 to fill in the remaining distance, as illustrated in FIG. 6. At this juncture, placement of the shims 20 may be tight, and the installer may need to hammer the shims 20 into place. Similar to the intermediate pier segments 16 and the spacers 18, embodiments of the pier system 10 of the present invention provide for at least three shims 20, each a different height (approximately ⅛ inch, ¼ inch, and ½ inch, respectively, along a vertical axis). (Only two shims 20 are illustrated in FIG. 2). Of course, as can also be appreciated, the second faceplate 72 is not secured to the first face 70 plate until all shims 20 are inserted in place.

In operation, the installer of the pier system 10 of the present invention may install one or more pier systems 10 under the footing 40 of a particular building, depending on how severe the geological movement and accompanying movement of the building. To begin installation, the installer excavates an area under the footing approximately 24 in³-36 in³. The installer then positions a hydraulic press (not shown) under the footing 40 and in the excavated area. The hydraulic press is positioned such that the weight or load of the building bears on the hydraulic piston of the press, and, contemporaneously, the press is pushing against the pier segments 12 so as to drive the segments 12 into the earth.

In preferred operation of embodiments of the present invention, a first pier segment 12a is driven almost completely into the earth via the hydraulic press, such that only the swaged segment 30 of the pier segment 12a is showing. It can be appreciated that at this juncture, the amount of pier segment 12a driven into the earth is not critical, and the installer will often use his best judgment in determining if a sufficient amount of the pier segment 12a is driven into the earth so as to continue the installation process.

After the first pier segment 12a is at least partially driven into the earth, preferably to the point where approximately only the swaged segment 30 extends from the earth, the installer connects a second pier segment 12b to the first pier segment 12a by simply sliding the open segment 34 of the second pier segment 12b atop the swaged segment 30 of the first pier segment 12a. The installer again then uses the hydraulic press to drive the combined first and second pier segments 12a, 12b into the earth until almost all of the second segment 12b is driven into the earth. This process is repeated with multiple pier segments 12 until the bottommost, first pier segment 12a reaches refusal, i.e., reaches bedrock, solid subsurface strata, or other dense earth. (See FIGS. 1 and 2) It can be appreciated that the depth the bottommost pier segment 12a is driven until it reaches refusal is highly dependent on the geological conditions of the particular area. In the Applicant's experience in the Kansas City, Mo. area, refusal is often at a depth of approximately 20-25 feet. However, the depth may vary widely, and in some instances, may be too deep to economically warrant use of pier segments 12 to refusal. In those instances, the installer may use a helical pier segment described in more detail below.

Regardless of the exact depth the bottommost pier segment 12a is driven, it can be appreciated that multiple pier segments 12 will be required. In practice, if the bottommost pier segment 12a is being driven to the point of refusal, this depth is deemed by the installer to be reached when the hydraulic piston stops driving the pier segments 12 into the earth and instead begins pressing back on the building. At this point, the installer knows that the hydraulic press cannot drive the pier segments 12 any further and is instead reactively pushing back against the building. Thus, the last pier segment to be inserted, and which is at least partially inserted in the earth, is the uppermost pier segment 12′.

Once the pier segments 12 have been driven to the point of refusal, the installer then temporarily and removably secures the lifting platform 14 to the uppermost pier segment 12′. Once the lifting platform 14 is installed, and as discussed above, the installer places one or more lifting apparatus 66, such as the bottle jack, on each base 46 of the lifting platform 14. The bottle jacks 66 are raised to lift the building to level. The amount the building needs to be lifted can vary widely but usually is approximately 1-10 inches.

Once the bottle jacks 66 are in place and the building is at level, the installer can then begin the process of stacking the intermediate pier segment 16 and spacers 18 on top of the uppermost pier segment 12′ to fill in the distance between the uppermost pier segment 12′ and the footing 40 of the building. Usually, the distance between the uppermost pier segment 12′ and the footing 40 of the building is between approximately 8-24 inches, although this distance can vary depending on the particular positioning of the building, the amount of excavation performed under the building, and the amount of the uppermost pier segment 12′ extending from the earth. If the distance is small, e.g., approximately less than eight inches, no intermediate pier segment 16 may be used. Instead, the installer may fill in the distance between the uppermost pier segment 12′ and the footing 40 of the building with one or more spacers 18. However, in the majority of installations, at least one of the intermediate pier segments 16 will be used.

When the installer has installed the intermediate pier segment 16 and spacers 18 to within approximately 1-3 inches of the footing 40 of the building, the installer will then position for installation the first faceplate 70. Alternatively, the installer may install the first faceplate 70 contemporaneously with installing the spacers 18. In particular, the installer usually holds the first faceplate 70 against the intermediate pier segment 16, such that the footing plate 78 of the first faceplate 70 is contacting the footing 40 of the building. While holding the first faceplate 70, or more preferably given the weight of the first faceplate 70, while a second installer holds the faceplate 70, the first installer will fill in the remaining distance between a top of the intermediate pier segment 16 and the bottom 86 of the footing plate 78 of the first faceplate 70 with one or more spacers 18 and any needed shims 20. As noted above, it is common that there will be a less than one inch gap between the last spacer 18 inserted and the bottom 86 of the footing plate 78. The shims 20 serve to fill in this remaining space. Because the positioning of the shims 20 may be tight, the installer may need to hammer the shims 20 into place.

Once the intermediate pier segment 16, spacers 18, and shims 20 are in place, and the pier system 10 is completely supporting the building's footing 40, the installer will secure the second faceplate 72 to the first faceplate 70, remove the bottle jacks 66 from the lifting platform 14, and remove the platform 14 from the uppermost pier segment 12′. At this juncture, installation of the pier system 10 is complete. However, it is to be noted that suitable lifting and supporting of a building along a partial perimeter of the building will often require multiple pier systems 10 to be installed, with 10-15 pier systems being an approximate average amount of pier systems 10 installed, depending on the perimeter size and load of the building.

Advantageously, due to the first and second faceplates 70,72 approximately substantially surrounding the intermediate pier segment 16, the spacers 18, and the shims 20, and further the load of the building maintaining the first faceplate 70 in the secured position by pressing in the footing plate 78, any vertical or lateral movement of the building will not result in shearing or lateral movement of the individual components of the pier system 10 with respect to each other. For example, if the ground heaves, resulting in the building moving both laterally and vertically, then the building simply fall backs on the footing plate 78 of the first faceplate 70. The individual components of embodiments of the pier system 10 of the present invention do not, however, move out of alignment, even though the load to the pier system 10 is removed during heaving of the building. This is beneficial, as movement of the components of any pier system 10 reduces the system's ability to accommodate earth movement, which is commonly continuous and often.

A similar advantage is that the load of the building compresses on one vertical axis, as opposed to multiple vertical axes as found in the prior art. Thus, when movement arises, the one vertical axis does not encourage misalignment, in contrast to multiple axes that are susceptible to lateral movement due to lateral forces.

Another advantage of the pier system 10 of embodiments of the present invention is that because the individual pier segments 12 present the body 24 and swaged segment 30 that is entirely made of steel, the concrete held within the body 24 and swaged segment 30 is reinforced, and the pier segments 12, when stacked, result in steel on top of steel. This is beneficial because steel on steel (assuming the same type of steel) will shear upon application of the same compressive and lateral force. Moreover, steel on steel will move with each other, as compared to steel on concrete, for example, which have different compressive and lateral forces. For example, if steel surrounds concrete, then the concrete may shear upon application of a compressive or lateral force, because concrete will shear more easily than steel, even if high-strength concrete is used. In contrast, if steel surrounds a steel neck 38 within which is concrete 32, then the steel on steel will not as easily shear from any compressive or lateral force.

An even further advantage of the present invention is the swaged pier segments 12, which allow for ease of manufacturing because a single piece of steel is used, and which further limit lateral movement, because each segment 12 does not include telescoping parts. Further, the swaged configuration of the uppermost pier segment 12′ allows for securement of the lifting platform 14 to the segment 12′. If the pier segment 12′ was a right-angle cylindrical body with no swaged component, then there would be no profile for the lifting platform 14 to rest on. Additionally, use of the lifting platform 14 is advantageous for final lifting of the building and placement of the intermediate pier segment 16, spacers 18, and shims 20.

As noted above, in some installations, the depth to refusal, i.e., bedrock, solid subsurface strata, or dense earth, may be too deep to economically warrant driving pier segments to that depth. Such depths are often greater than 70 feet. In such instances, a helical swaged pier segment 88 (hereinafter “helical pier segment” or “helical segment”) illustrated in FIGS. 13 and 14 can be used to create a manufactured or artificial point of refusal. The helical segment 88 is similar to the swaged pier segment 12 of embodiments of the present invention, except that the helical segment 88 includes a helix 90 surrounding the generally cylindrical body 24 of the pier segment 88. As illustrated in FIGS. 13-14, the helical segment 88 includes a substantially cylindrical body 24 having distal and proximal ends 26,28, a swaged segment 30 at the proximal end 22 of the body 24 and operable to mate with another swaged pier segment 12, another helical pier segment 88, or the intermediate swaged segment 16, high-strength concrete 32 held within a portion of the body 24 and the swaged segment 30, and an open segment 34 at the distal end 26 of the body 24.

The helix 90 surrounding the body 24 of the helical segment 88 is either integral to or directly coupled to the body 24, such as via welding. The helix 90 surrounds the body 24 preferably approximately 200°-500°, more preferably approximately 300°-400°, and most preferably approximately 330°-370°. The helix 90 extends past the body 24 approximately 5-20 inches, more preferably approximately 7-15 inches, and most preferably approximately 9-12 inches to provide a bearing surface.

When driven into the earth via the above-described method of using a hydraulic press, the helical pier segment 88 gathers dirt, sediment, and rock. As the helical segment 88 is further driven into the earth, the segment 88 eventually encounters denser soil. This denser soil is torqued around the helix 90, creating a bearing surface at least as wide as the extension of the helix 90 from the body 24 of the segment 88. Eventually, the soil is torqued to the point that it essentially is a manufactured point of refusal.

The helical pier segment 88 is usually used after two pier segments 12 are driven into the earth. Additional pier segments 12 are then used after the helical segment 88, as illustrated in FIG. 13. The pier segments 12, including the helical segment 88, are driven into the ground to the point of refusal, which is commonly where the helical segment 88 torques enough soil to create a point of refusal. Alternatively, if the natural point of refusal is very deep, two or more helical pier segments 88 may be used to increase the amount of torqued soil, and therefore, the amount of bearing surface.

Although the invention has been described with reference to the preferred embodiment illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims. For example, although galvanized steel has been described for the body 24 and swaged segment 30 of the pier segments 12, non-galvanized steel may be used. Additionally, the lengths of the segments 12 described herein may be changed depending on manufacturing costs and complexity and the particular geological conditions of a particular area.

Claims

1. A pier system for at least partially supporting a building, the pier system comprising:

a plurality of swaged pier segments having a length, wherein each swaged pier segment is operable to be connected to another of the swaged pier segments;

a lifting platform operable to be secured to an uppermost one of the swaged pier segments;

at least one intermediate swaged pier segment having a length, said length of the intermediate swaged pier segment being different than the length of the swaged pier segment, said intermediate swaged pier segment operable to be connected to the uppermost swaged pier segment; and

first and second mating faceplates for at least partial receipt of the at least one intermediate swayed pier segment therebetween.

2. The pier system of claim 1, wherein each swaged pier segment includes a body and a swaged segment, and together the body and swaged segment are formed of a generally unitary piece of steel.

3. The pier system of claim 2, wherein concrete is formed within at least a partial portion of the body and the swaged segment of each swaged pier segment.

4. The pier system of claim 1, wherein each swaged pier segment includes

proximal and distal ends,

an open segment generally at the distal end, and

a swaged segment generally at the proximal end, the swaged segment further including a swaged rise, and a neck, such that the swaged rise is tapered to the neck so as to connect the body of the swaged pier segment with the neck.

5. The pier system of claim 4, wherein the neck has a diameter smaller than a diameter of the body, so as to receive the open segment at the distal end of the body of the swaged pier segment for connecting one or more swaged pier segments together.

6. The pier system of claim 1, further including a plurality of intermediate swaged pier segments each having a length that is different than the length of any other intermediate swaged pier segment and the swaged pier segment.

7. The pier system of claim 1, further including a plurality of spacers, each spacer having a generally cylindrical body with concrete formed therein, and each spacer having a length that is different than a length of the other spacers.

8. The pier system of claim 1, wherein one of the first and second mating faceplates has a footing plate extending generally perpendicular from a vertical axis of the said one faceplate, such that the footing plate is configured to be positioned generally adjacent to the building.

9. The pier system of claim 2, the lifting platform further including

left and right sections, each having a base for receipt of a lifting apparatus for lifting the building during installation of the pier system,

a contoured pier segment-receiving section for receipt of the uppermost pier segment during installation, the contoured section presenting a profile of the swaged segment of the uppermost pier segment that mates with the swaged segment for temporary securement of the lifting platform to the uppermost pier segment.

10. A pier system for at least partially supporting a building, the pier system comprising:

a plurality of swaged pier segments having a length, a proximal end, and a distal end, each swaged pier segment including a generally cylindrical body having a diameter, a swaged segment at a generally proximal end of the pier segment, the swaged segment including a swaged rise extending from the body to a neck having a diameter less than the diameter of the body, concrete formed within an at least partial portion of the body and the swaged segment, and an open segment at the distal end of the pier segment, the open segment operable to receive the neck of the swaged segment of another pier segment for connection of the pier segment to the other pier segment;

a lifting platform operable to be removably secured to an uppermost one of the swaged pier segments, the platform including a contoured pier segment-receiving section presenting a profile of the swaged segment of the uppermost pier segment, such that the platform is operable to be secured to the uppermost pier segment by mating the contoured section with the swaged section of the uppermost pier segment;

at least one intermediate swaged pier segment having a length, said length of the intermediate swaged pier segment being different than the length of the swaged pier segment, said intermediate swaged pier segment operable to be connected to the uppermost swaged pier segment; and

first and second mating faceplates for at least partial receipt of the at least one intermediate swaged pier segment therebetween, said one of the first and second mating faceplates having a footing plate positioned generally perpendicular to a vertical axis of the faceplate, such that the footing plate is configured to be positioned generally adjacent the building so that a compressive load of the building is along only one vertical axis of the pier system.

11. The pier system of claim 10, wherein the body and the swaged segment of each pier segment are together formed of a generally unitary piece of steel.

12. The pier system of claim 10, wherein the first and second faceplates each includes a half-cylindrical body and a pair of flanges extending therefrom along a length of the body.

13. The pier system of claim 12, further including at least one spacer for positioning atop the intermediate swaged pier segment.

14. The pier system of claim 13, further including at least one shim for positioning atop the spacer.

15. The pier system of claim 14, wherein the half-cylindrical bodies of the first and second faceplates are configured to generally surround at least a portion of the intermediate swaged pier segment, the spacer, and the shim.

16. The pier system of claim 10, further including a plurality of intermediate swaged pier segments each having a length that is different than the length of any other intermediate swaged pier segment and the swaged pier segment.

17. A method for installing a pier system for at least partially supporting a building, the method comprising the steps of:

(a) providing a plurality of swaged pier segments having a length, a proximal end, and a distal end, each swaged pier segment including a generally cylindrical body having a diameter, a swaged segment at a generally proximal end of the pier segment, the swaged segment including a swaged rise extending from the body to a neck having a diameter less than the diameter of the body, concrete formed within an at least partial portion of the body and the swaged segment, and an open segment at the distal end of the pier segment, the open segment operable to receive the neck of the swaged segment of another pier segment for connection of the pier segment to the other pier segment;

(b) driving a first of the swaged pier segments at least partially into the earth;

(c) connecting a second of the swaged pier segments to the first swaged pier segment by placing the open segment of the second pier segment over the neck of the first pier segment;

(d) repeating steps (c) and (d) until the first swaged pier segment driven into the earth reaches a point of refusal;

(e) providing a lifting platform operable to be removably secured to an uppermost one of the swaged pier segments;

(f) securing the lifting platform to the uppermost pier segment;

(g) providing at least one intermediate swaged pier segment having a length that is different than the length of the swaged pier segment and that is operable to be connected to the uppermost swaged pier segment;

(h) connecting the intermediate pier segment to the uppermost pier segment; and

(i) providing an encasement for at least partial receipt of the at least one intermediate swaged pier segment and configured to be at least partially adjacent the building.

18. The method of claim 17, wherein upon installation of the pier system, a compressive load of the building supported by the pier system is along only one vertical axis of the pier system.

19. The method of claim 17, wherein the lifting platform includes a contoured pier segment-receiving section presenting a profile of the swaged segment of the uppermost pier segment, such that the platform is operable to be secured to the uppermost pier segment by mating the contoured section with the swaged section of the uppermost pier segment.

20. The method of claim 17, wherein the encasement comprises first and second faceplates, said one of the first and second mating faceplates having a footing plate positioned generally perpendicular to a vertical axis of the faceplate, such that the footing plate is configured to be positioned generally adjacent the building so that a compressive load of the building is along only one vertical axis of the pier system.