BACKGROUND Wind, flood water, and seismic activity are among the natural forces that act to rearrange objects on the surface of the earth. Man-made structures therefore are commonly designed to compensate or to limit the tendency of nature to move and to bend the objects. Vertically elongate structures such as communication towers, other antennas, and electrical transmission towers are examples of structures that may need protection against unwanted movement and sway.
BRIEF SUMMARY OF THE DISCLOSURE These and other needs in the art are addressed in one embodiment by a pre-fabricated anchor block. In an embodiment, the pre-fabricated anchor block comprises a structure that forms at least one multi-facetted channel to receive and capture an anchor rod.
These and other needs in the art are addressed in another embodiment by an anchor rod. In an embodiment, the anchor rod comprises at least one shaft. In addition, the anchor rod comprises a first end that is enlarged to engage and to couple with the channel of the anchor block. Further, the anchor rod comprises second end with at least one connection location. The anchor rod is rotatable within and removable from the channel of the anchor block.
These and other needs in the art are addressed in a method for preparing a pre-fabricated anchoring system. The method comprising a first step of installing a pre-fabricated anchor block in the earth and a second step of inserting and securing one enlarged end of an anchor rod within the pre-fabricated anchor block. The rod remains rotatable and removable with respect to the block.
Thus, embodiments described herein comprise a combination of features and advantages intended to address various shortcomings associated with certain prior devices, systems, and methods. The various characteristics described above, as well as other features, will be readily apparent to a person having ordinary skill in the art upon reading the following detailed description, and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS For a detailed description of the disclosed embodiment(s), reference will now be made to the accompanying drawings in which:
FIG. 1 is a perspective view of a tower anchored in accordance with the principles disclosed herein;
FIG. 2 is an elevation view of an embodiment of a pre-fabricated anchor block and a rotatable, removable anchor rod embedded in the earth in accordance with the principles disclosed herein;
FIG. 3 is an elevation view of a poured anchor block and anchor rod combination;
FIG. 4 is an top view of a the pre-fabricated anchor block shown in FIG. 2;
FIG. 5 is an front view of the pre-fabricated anchor block of FIG. 4;
FIG. 6 is an side view of the pre-fabricated anchor block of FIG. 4;
FIG. 7 is an isometric view of the locking channel of the pre-fabricated anchor block of FIG. 4;
FIG. 8 is top view of an embodiment of a rotatable, removable anchor rod in accordance with the principles disclosed herein;
FIG. 9 is an side view of the anchor rod of FIG. 8;
FIG. 10 is a flow chart of a method for installing a pre-fabricated anchor block in accordance with the principles disclosed herein;
FIG. 11 is a top view of an embodiment of a pre-fabricated anchor block in accordance with the principles disclosed herein; and
FIG. 12 is an isometric view of the locking channel of the pre-fabricated anchor block of FIG. 11.
DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS The following discussion is directed to various embodiments. The embodiments disclosed should not be interpreted or otherwise used as limiting the scope of the disclosure, including the claims. In addition, one skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.
Certain terms are used in the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form, and some details of conventional elements may not be shown in interest of clarity and conciseness. In addition, like or identical reference numerals may be used to identify common or similar elements.
In this disclosure and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples or is coupled to a second device, that connection may be through a direct connection, or through an indirect connection via other devices, components, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a given axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the axis. For instance, an axial distance refers to a distance measured along or parallel to the axis, and a radial distance means a distance measured perpendicular to the axis.
Furthermore, in this disclosure and in the claims, the following definitions will be used:
“Back-fill” means to fill a hole or recess with the dirt or other material that was previously removed from the hole or recess or with dirt or other material from another source.
“Dirt” means solid or semi-solid substances found within the earth, whether natural or man-made. The word dirt will be used to refer to one or more of the following material or combination of materials, including, for example: earthen dirt, sand, gravel, clay, rock, cement, concrete, and other similar substances.
Both terms “Guy wires” or, equivalently, “guy cables” refer to wires, cables, or ropes that may be used to couple a tower or another object to a fixed anchoring location. Guy wires or guy cables may also be written as guy-wires or guy-cables.
“J-shape” [noun] and “J-shaped” [adjective] describe an object or a space created by one or more features, wherein the object or space appears, in some fashion, to have a general shape or form similar to a capital letter “J,” which may be best seen in a san serif font, that is to say without any cross-member at the top.
“Lateral” means extending towards or from a left side or towards or from a right side, being generally parallel to a front end or front edge or generally parallel to or a back end or back edge.
“Site” means a location, such as, for example, the location of an existing or planned communications tower where an anchor block is currently installed or will be installed.
“Transverse” means extending towards or from a front end or towards or from a back end, being generally parallel to a left side or left edge or generally parallel to or a right end or right edge.
“T-shape” [noun] and “T-shaped” [adjective] describe an object or a space created by one or more features, wherein the object or space appears, in some fashion, to have a general shape or form similar to a capital letter “T” or similar to a lower case letter “t.”
“Tower” means any vertically elongated structure that may be anchored or tethered to the earth and thus may benefit from this disclosure. Towers include, for example, various antenna, observation towers, electrical transmission poles, and electrical transmission towers.
When considering other applications of the disclosed technology, the term “another structure” may refer to any of the following: a building, a pre-manufactured building, a restraining wall, equipment (including air conditioning units, compressors, and power generators), an advertising sign, a tent, and the like.
The disclosure relates generally to equipment and methods for anchoring structures to the earth against wind and other natural forces that may act to move or to bend the structures. More particularly, the disclosure relates to an anchoring systems and methods that may be applied, for example, to hold the guy cables of elongate communication towers or electrical transmission towers.
FIG. 1 introduces an anchored tower 10, which in the disclosed example, is illustrated as a communications tower. Tower 10 comprises at least one mast 15, at least one pre-fabricated anchor block 30, at least one rotatable, removable anchor rod 150, and at least one diagonally extending guy cable 12. A centerline 11 defines the vertical centerline of the tower 10 structure. Guy cable 12 may be a single, contiguous cable or may be formed from a plurality of cable segments coupled by electrical insulators or other material. Mast 15 is coupled to one end of at least one guy cable 12, while the other end of the guy cable 12 is coupled to a rotatable, removable anchor rod 150 and pre-fabricated anchor block 30 embedded in the earth 14. Each anchor block 30 is buried at a horizontal distance from mast 15. A turnbuckle 18 may be positioned between each guy cable 12 and anchor rod 150. In some situations, like the one shown in FIG. 1, more than one guy cable 12 will couple to a particular rod 150 and block 30. The example of FIG. 1 has three anchor rods 150 and three pre-fabricated anchor blocks 30 coupled to mast 15 by a plurality of guy cables 12. In general a tower or a mast may couple any number of anchor blocks and anchor rods. In at least one embodiment tower 10 further comprises a system or method to reduce corrosion in any or all of its components. Like tower 10, another structure may be coupled, anchored, or tethered to the earth by a rod 150 and an anchor block 30. A closer view of a pre-fabricated anchor block 30 coupled with a rotatable, removable anchor rod 150 is shown in FIG. 2.
Alternatively, FIG. 3 shows a poured-in-place anchor block and rod 20, which comprises at least one fixed, rigid anchor rod integrally coupled to and partially embedded within a poured cement or concrete anchor block. The block and the lower portion of the rod are buried in the earth. The rod extends diagonally toward the tower and couples to the guy cables. For relatively newer anchors, the entire buried portion of the rod may be encased in cement or concrete to inhibit (meaning “to reduce the rate of”) corrosion. Therefore, although, not shown in FIG. 1, another tower or another structure that benefits from the disclosure herein is coupled to at least one rotatable, removable anchor rod 150 and at least one pre-fabricated anchor block 30, while the same tower or structure is coupled to one or more poured-in-place anchor block and rod 20. However, the installation of a new or replacement block and rod 20 may be costly and may extend over multiple days. On one or more days, the site is excavated and forms and reinforcing are installed for the cement. The block and the anchor rod encasement are poured with fixed anchor rods installed and partially protruding. The new poured anchor is allowed to cure or “to set.” On a later day, a crew returns to attach the guy cables to the anchor rod. If the direction of the force exerted by guy cables after coupling differs from the design, or if the direction of the force changes with time, added stress may be placed on the rod and its corrosion-inhibiting coating, such as a galvanized coating. Such are the complications of using a poured anchor block 20 to hold a structure like tower 10.
For one embodiment, FIG. 4 shows the top view of a generally rectangular pre-fabricated anchor block 30. Seen in FIG. 5, the front profile of anchor block 30 is generally trapezoidal with a top surface generally parallel to a bottom surface. The outermost dimensions of anchor block 30 are a width of W_30, a length of L_30, and a height of H_30. Anchor block 30 comprises a first or left side 32, a second or right side 34, a front end 36, a back end 38, a base blade 45, a plurality of lateral structural ribs 46, a plurality of transverse structural ribs 48, a central block 55, and at least one multi-facetted locking channel 65. In the example shown, anchor block 30 has eight lateral ribs 46, six transverse ribs 48, and two multi-facetted locking channels 65; however, other embodiments may have fewer or more of these features 46, 48, 65. In at least one embodiment, anchor block 30 comprises corrosion resistant material, such as, for example, fiberglass, graphite-reinforced composite material, glass-reinforced plastic, or another polymeric material, which may make anchor block 30 relatively light-weight, compared to Portland cement, for example. Alternatively, Portland cement, polymer-enhanced cement, concrete, metal, reinforced pre-cast concrete, pre-tensioned or post-tensioned pre-cast concrete, or another formable material could also be used. In addition, in at least one embodiment, one or more of the following features are embedded with structurally-reinforcing material: the ribs 46, 48, base plate 45, or central block 55. The ribs 46 and 48 may be positioned on either side or both sides of base plate 45. Therefore, in at least one embodiment, structurally-reinforcing material couples the material surrounding the two multi-facetted locking channels 65. The structurally-reinforcing material, which may also be called structurally-reinforcing members, may be, for example, rods or fibers.
Continuing to reference FIGS. 4 and 5, base plate 45 is a generally rectangular block, comprising a thickness H_45. In various embodiments, base plate 45 may be solid or may be perforated with holes or openings or may be imbedded with closed or open pores, for example. Central block 55 is generally rectangular and comprises a nearly solid volume, except that two multi-facetted locking channels 65 are disposed above and substantially near the center of central block 55. Central block 55 comprises a lateral length that may be smaller than L_30 and a transverse width that may be smaller than W_30. Central block 55 is affixed to or integral with the middle of plate 45. The combined height of base plate 45 and central block 55 corresponds to the height H_30. Central block 55 further comprises a top surface 56. A portion of the lateral ribs 46 extend from left side 32 to central block 55. A preferably equal portion of the lateral ribs 46 extend from right side 34 to the central block 55. The outermost lateral ribs 46 are inset away from front end 36 and back end 38 by an edge offset of W_46. Transverse ribs 48 extend across lateral ribs 46 and are coupled with them, forming ninety degree angles at each intersection of a lateral rib 46 and a transverse ribs 48, which is as best seen in FIG. 4. In other embodiments, at least some of the ribs 46, 48 may intersect to form angles that are not ninety degrees. In the example of FIG. 5, the height of lateral ribs 46 tapers from central block 55 down to a nearly zero height near the sides 32, 34. Correspondingly, the heights of transverse ribs 48 are reduced for those ribs 48 closer to sides 32, 34. The differing heights of the transverse ribs 48 can also be seen in FIG. 6. A plurality of recesses 52 are formed between the ribs 46, 48. In at least one embodiment, recesses 52 are filled with material. In some embodiments, some or all ribs 46, 48 and recesses 52 are replaced by or merged to become solid volumes or volumes containing closed pores or internal voids. These volumes may be embedded with reinforcing members.
As shown in the example of FIG. 4, each of the two multi-facetted locking channels 65 includes a T-shaped opening 72 along top surface 56 of central block 55. The voids formed by locking channel 65 are indicated by hidden lines (that is to say: dashed lines) in the top, front, and side views of FIGS. 4, 5, and 6. However, a more complete view of the shape of locking channel 65 is presented in FIG. 7, where T-shaped opening 72 is clearly distinguishable. T-shaped opening 72 may be explained as a combination of a first rectangular opening 122 disposed perpendicular to and connected to the middle of a second rectangular opening 92. The other surfaces (or equivalently “other facets”) seen in FIG. 7 represent the interfacial boundaries between the voids of locking channel 65 and the remaining solid material of the block in which channel 65 is formed. In the disclosed embodiment, channel 65 is formed in central block 55. T-shaped opening 72 is generally symmetric about a transverse centerline 73.
FIG. 7 show that each multi-facetted locking channel 65 further comprises a base 74, a J-shaped portion 85, and a trapezoidal portion 115. Due to the inclusion of portions 72, 85, 115 or any two or more similar portions having similar form or function, locking channel 65 may also be described as a channel with multiple portions or multiple sections. Locking channel 65 is characterized by a height H_65, a breadth B_65, and a length Z_65. Height H_65 is less than anchor block height H_30. Height H_65 may be less than the difference between height H_30 and base height H_45 so that locking channel 65 does not extend into base plate 45. Breadth B_65 is less than length L_30 and less than the lateral length of central block 55. Length Z_65 is less than width W_30 and less than the transverse width of central block 55.
Continuing with FIG. 7, J-shaped portion 85 comprises a back end 86, a front end 88, a top opening 92, a base 94, a long arm 95, a short arm 105, a lateral breadth of B_65, and a width W_85. Top opening 92 corresponds to the cross-member portion of T-shaped opening 72. At the base of long arm 95, back end 86 and base 94 intersect forming an angle φ (theta). Thus, the angle φ describes the orientation of back end 86 and long arm 95 with respect to base 94. In the disclosed embodiment φ (theta) is approximately ninety degrees. However, arm 95 may instead slope laterally forward, causing φ (theta) to be less than 90 degrees, or arm 95 may slope laterally backward, causing φ (theta) to be greater than 90 degrees. A curved or filleted section 107 connects short arm 105 to long arm 95 in the vicinity of base 94. Short arm 105 slopes diagonally upward, away from long arm 95 and rises a height of H_105 from base 94. Height H_105 is less than height H_65 so short arm 105 does not reach top surface 56 of central block 55. In the disclosed example, short arm 105 is disposed at an angle greater-than-zero with respect to long arm 95. The upper end 108 of short arm 105 may be, for example, rounded with a radius of curvature equal to half the width W_85. In at least one embodiment, the upper end 108 is generally flat, possibly parallel to top opening 92. Base 94 generally defines a majority or all of base 74 of locking channel 65, spanning a lateral breadth of B_65 and a transverse length of Z_74. Base 94 is shown to be generally flat and horizontal, but may be curved upward or downward in the transverse direction, that is to say, in a direction that may extend generally from front end 36 to back end 38 of anchor block 30. Preferably for a channel 65 embedded within block 30, short arm 105 is positioned closer to front end 36 than is long arm 95. As stated earlier, the J-shaped portion 85, which includes long arm 95, section 107, short arm 105, and upper end 108, extends through the lateral breadth of B_65.
The J-shaped portion 85 of channel 65 may be explained as a combination of facets and features in central block 55 that form a first generally rectangular void, called long arm 95, the bottom of which is connected to a curved or filleted void section 107, which is also connected to a second generally rectangular void, called short arm 105. Any of these sections 95, 107, or 105 may have more or possibly less curvature than depicted in FIG. 7. It is possible that long arm 95 be directly connected to short arm 105 with no curved or filleted section 107 between arms 95, 105. In other embodiments with a longer transverse length Z_74, section 107 may be longer.
In the example locking channel 65 of FIG. 7, generally trapezoidal portion 115 is superimposed through the center of J-shaped portion 85, sharing at least one or more common surfaces or one or more common volumes (voids). Trapezoidal portion 115 comprises a back end 116, a front end 118, a top opening 122, a base 124, and a width W_115. In at least one embodiment, top opening 122 is parallel to base 124. In at least one embodiment width W_115 is equal to width W_85. Top opening 122 corresponds to the “leg” portion of T-shaped opening 72 and also extends straight through the cross-member of opening 72, which is equivalent to top opening 92. Therefore top opening 122 overlaps (extends into or through) a region of top opening 92. In the example shown, back end 116 overlaps a region of back end 86, the lower region of front end 118 overlaps a region of front end 88, and base 124 overlaps a region of base 94. However, in at least one embodiment, the front end 118 extends laterally beyond front end 88, and back end 116 extends laterally beyond back end 86. Other derivations are possible.
FIGS. 1 and 2 illustrate that a rotatable, removable anchor rod 150 may be coupled to tower 10 and to locking channel 65 in anchor block 30 in order to secure tower 10. FIGS. 8 and 9 explain one embodiment of anchor rod 150 in greater detail. Anchor rod 150 comprises a first end 151, a second end 152, at least one shaft 155, an end rod 165, and a connector plate 175. Shaft 155 comprises a central axis 156 and a cross-section that may be round with a diameter of dimension D_155, may be square and defined by the dimension D_155, or may be any other shape as desired. A round cross-section will be assumed for convenience. Diameter D_155 is less than the width W_115 within locking channel 65. Anchor rod 150 may comprise carbon steel, a stainless steel, or any other suitable metal or non-metallic material. End rod 165 is disposed at first end 151 and comprises a central axis 166, a length of L_165, and a round cross-section with a diameter of D_165. Length L_165 is less than breadth B_65 of locking channel 65. Diameter D_165 is less than the width W_85, and in at least one embodiment, diameter D_165 is equal to diameter D_155. Shaft 155 is attached to the middle of end rod 165, and central axis 156 is perpendicular to central axis 166. As a result, first end 151 of anchor rod 150 comprises a “T-shape”, formed by the intersection of shaft 155 and end rod 165. T-shaped first end 151 may be described as being enlarged in comparison to other axial positions along the shaft 155.
Continuing to reference FIGS. 8 and 9, connector plate 175 comprises a first end 176, a second end 178, a face 182, and through-holes 184. First end 176 couples with shaft 155. At least one, but preferably a plurality of through-holes 184 pass through face 184 near second end 178. In the example shown, plate 175 includes five through-holes 184. Each through-hole 184 is suited to be a connection location for coupling at least one guy cable from tower 10 or another structure. In some embodiments, anchor rod 150 comprises more than one shaft 155. In some other embodiments, all or a portion of anchor rod 150 is covered by a corrosion resistant coating or surface finish 190.
Discussion of the installation and use of any embodiment or any component in this disclosure is merely representative of the possible uses of the disclosed equipment and should not be interpreted as limiting any embodiment or any component. While some of the capabilities or characteristics of the embodiment(s) and components are described, others may not be described but are within the scope of this disclosure. In one or more other installations, some modifications may be made to the sequence of the steps described below, to the number of steps performed, or to other factors.
Starting with FIG. 2, a method for the coupling of a pre-fabricated anchor block (such as anchor block 30), an anchor rod (such as a rotatable, removable anchor rod 150), and a tower (such as tower 10) or another structure will be described. FIG. 10 presents an installation method 400, which begins at 401 and ends at 430. Method step 410, includes installing a pre-fabricated anchor block (e.g. block 30) in the earth. Method step 420 includes inserting and securing one enlarged end of an anchor rod within the pre-fabricated anchor block. Additional steps may include any action described in this disclosure. Before installation of an anchor block 30 and anchor rod 150, a user may determine prescribed values for the mean (average) installation depth Δ (delta) and installation angle α (alpha) for the pre-fabricated anchor block 30, and for the installation angle β (beta) of pre-fabricated anchor rod 150 based on the height of tower 10, maximum anticipated wind speed for the location where tower 10 is located, the prevailing direction of the wind, and other factors. Preferably, α (alpha) is greater than or equal to 0 degrees. Preferably, β (beta) is less than or equal to 90 degrees. The installation site may be prepared by the removal of surrounding vegetation or by excavation of the general area around the site. During installation, a minimally sized hole (not shown) is dug in the earth 14 to accommodate anchor block 30 at the prescribed mean depth Δ (delta) and angle α (alpha) and to accommodate anchor rod 150 at an installation angle of β (beta). The dirt removed from the hole maybe set aside for later use. Anchor block 30 is placed in the hole with front end 36 closer to tower 10 than back end 38 and with the transverse center line 31 of the anchor block 30 (FIG. 4) radially aligned or generally radially aligned with the vertical axis 11 of tower 10. Subsequently, anchor rod 150 is installed in or coupled to anchor block 30. To accomplish this task, first end 151 of end rod 165 (FIG. 8) is inserted into the top opening 92 of T-shaped opening 72 (FIG. 7) and travels downward through long arm 95 of J-shaped portion 85. Simultaneously, a portion of shaft 155 enters top opening 122 of T-shaped opening 72 and into trapezoidal portion 115. End rod 165 continues to travel in J-shaped portion 85, eventually being pulled generally upward into short arm 105, arriving at upper end 108. As a consequence, the enlarged, T-shaped first end 151 slidingly engages locking channel 65 with the result being that first end 151 rotatably couples within channel 65. Thereby, channel 65 of anchor block 30 couples or captures anchor rod 150 while anchor rod 150 remains free to rotate or pivot. For example, anchor rod 150 may pivot about axis 166 with shaft 155 moving within trapezoidal portion 115.
Indicated in FIG. 4, a seal 80 may be coupled to an occupied (active) locking channel 65. In one embodiment seal 80 covers a portion of surface 56. In another embodiment, seal 80 extends within channel 65. In yet another embodiment seal 80 both covers a portion of surface 56 and extends within channel 65. Seal 80 may be, for example, formed from rubber, adhesive tape, silicon, or caulking and may be pre-molded or configured on-site. When an anchor block 30 has more than one locking channel 65, any unused channel 65 may be covered or filled by a seal 80.
Referring now to FIGS. 1 and 8, one or more guy cables may be coupled between the anchor rod and tower 10. The coupling may be accomplished using one or more through-holes 184 on connector plate 175 and, if desired, one or more turnbuckles 18. The hole in earth 14 is back-filled, covering and securing anchor block 30 within the earth 14 and, for some systems, covering a portion of anchor rod 150 within earth 14. During coupling, tension along axis 156 is developed in anchor rod 150 and each guy cable 12 by rotating turnbuckle(s) 18 or by another tensioning method. Perhaps best evaluated in reference to FIGS. 2 and 7, the tensioning may rotate shaft 155 within trapezoidal portion 115 and end rod 165 within upper end 108 of short arm 105. The tensioning pulls end rod 165 firmly within upper end 108 of short arm 105. Shaft 155 assumes a final angle β (Beta) that may differ from the target value of β determined previously. When installed as described, even as shaft 155 rotates within trapezoidal portion 115, the tension on anchor rod 150 keeps end rod 165 firmly locked or captured within upper end 108 of locking channel 65. When anchor block 30 is disposed within earth 14 as described, and block 30 is coupled to anchor rod 150, tower 10, and at least one guy cable 12, then these components 30, 150, 10, 12 are thereby anchored to the earth 14 and may be said to be secured to the earth 14 or coupled to earth 14.
In another installation, a new anchor rod 150 may be installed and rotatably coupled in an existing anchor block 30, the block 30 being already installed in the earth 14. In some situations, an existing anchor rod 150 may be removed from a multi-facetted locking channel 65 in the existing anchor block 30, and new anchor rod 150 may be installed in the same channel 65. In other situations, the new anchor rod 150 may be installed in a previously unused locking channel 65. If a seal 80 covers a locking channel 65, the seal would be removed or adjusted to allow engagement of the new rod 150. The installation steps described previously would be altered accordingly. The same or similar preparation, installation, and completion steps may be accomplished when anchoring another structure besides tower 10.
Referring to the embodiment shown in FIG. 11, pre-fabricated anchor block 230 may couple to tower 10 of FIG. 1. Anchor block 230 is similar to pre-fabricated anchor block 30 of a FIGS. 4, 5, and 6, except, for example, multi-facetted locking channel 265 replaces multi-facetted locking channel 65. Because many of the features on anchor block 230 are similar to corresponding features on anchor block 30, the discussion of block 230 will use some of the same identifiers as shown in the previously referenced figures or described elsewhere in this disclosure. A few of the similar aspects of anchor block 230 include first or left side 32, a second or right side 34, a front end 36, a back end 38, a base plate 45, a plurality of lateral structural ribs 46, and a plurality of transverse structural ribs 48. In the example shown, anchor block 230 has eight lateral ribs 46 and six transverse ribs 48; however, other embodiments may have fewer or more of these features 46, 48. Uniquely, anchor block 230 comprises a central block 255 with at least one locking channel 265, having a cross-shaped opening 272 along top surface 256. In the example shown, anchor block 230 has two locking channels 265. The voids formed by locking channel 265 are indicated by hidden lines (that is to say: dashed lines). A more complete view of the shape of a locking channel 265 is presented in FIG. 12. Cross-shaped opening 272 is clearly distinguishable. Cross-shaped opening 272 may be explained as a combination of a first rectangular opening 322 disposed perpendicular to and connected to second rectangular opening 292. Openings 322, 292 are connected at approximately their middles. The other surfaces (or equivalently “other facets”) seen in FIG. 12 represent the interfacial surfaces between the voids of locking channel 265 and the remaining solid material of central block 255. Cross-shaped opening 272 is generally symmetric about a transverse centerline 273 and is also generally symmetric about lateral centerline 276. In some respect, the cross-shaped opening 272 comprises two overlapping T-shaped openings aligned along transverse centerline 273, wherein one T-shaped opening is flipped over lateral centerline 276.
FIG. 12 shows that each multi-facetted locking channel 265 further comprises a base 274, a mirrored J-shaped portion 285, and a trapezoidal portion 315. Due to the inclusion of portions 272, 285, 315 or any two or more similar portions having similar form or function, locking channel 265 may be described as a channel with multiple portions or multiple sections. Locking channel 265 is characterized by a height H_265, a breadth B_265, and a length Z_265. Height H_265 is less than anchor block height H_30. Height H_265 may be less than the difference between height H_30 and base height H_45 so that locking channel 265 does not extend into base plate 45. Breadth B_265 is less than block length L_30, and less than the lateral length of central block 255. Length Z_265 is less than width W_30 and less than transverse width of central block 255.
Continuing with FIG. 12, mirrored J-shaped portion 285 comprises a back end 286, a front end 288, a top opening 292, a base 294, a long arm 295, two short arms 305A, 305B, lateral breadth of B_265, and a channel width W_285. Top opening 292 corresponds to the cross-member of cross-shaped opening 272. Long arm 295 comprises a front surface 297 and a generally parallel rear surface disposed a distance of W_285 from front surface 297. If extended, front surface 297 would intersect base 294 forming an angle φ (theta). Even though surfaces 297 and 294 may not intersect, the angle φ describes the orientation of surface 297 and long arm 295 with respect to base 294. In the disclosed embodiment φ (theta) is approximately ninety degrees. However, arm 295 may instead slope laterally forward, causing φ (theta) to be less than 90 degrees, or arm 95 may slope laterally backward, causing φ (theta) to be greater than 90 degrees. A curved or filleted section 307A connects the first short arm 305A to long arm 295 in the vicinity of base 294. Short arm 305A slopes diagonally upward, away from long arm 295, and rises a height of H_305A from base 294. Height H_305A is less than height H_265 so short arm 305A does not reach top surface 256 of central block 255. In the disclosed example, short arm 305A is disposed at an angle greater than zero with respect to long arm 295. The upper end 308A of first short arm 305A may be, for example, rounded with a radius of curvature equal to half the width W_285. In at least one embodiment, the upper end 308A is generally flat, possibly parallel to top opening 292. For a channel 265 embedded within block 230, short arm 305A may be positioned closer to front end 36 than is long arm 295.
Mirrored J-shaped portion 285 of channel 265 comprises two overlapping J-shaped portions mirrored about the plane (not shown) that passes through lateral centerline 276, the two J-shaped portions sharing long arm 295 in common. The stated plane passing through centerline 276 would be vertical within the view depicted in FIG. 12. The first J-shaped portion within mirrored J-shaped portion 285 may be explained as a combination of facets and features in central block 255 that form a first generally rectangular void, called long arm 295, joined with a curved or filleted void section 307A and joined with second rectangular void, called short arm 305A. Any of these sections 295, 307A, or 305A may have more or less curvature than depicted in FIG. 12. It is possible that long arm 295 be directly jointed or connected to short arm 305A with no curved or filleted section 307A between arms 295, 305A. In other embodiments with a longer transverse length Z_274, section 307A may be longer.
The remainder of mirrored J-shaped portion 285 may also be understood from FIG. 12. The second short arm 305B of portion 285 may be essentially a mirror image of first short arm 305A, comprising similar characteristics. A curved or filleted section 307B connects the second short arm 305B to long arm 295 in the vicinity of base 294. Second short arm 305B is positioned further from surface 297 of arm 295 than is first short arm 305A. Arm 305B slopes diagonally upward, away from long arm 95, and rises a height of H_305B from base 294. Height H_305B is less than height H_265, so short arm 305B does not reach top surface 256 of central block 255. In the disclosed example, short arm 305B is disposed at an acute angle with respect to long arm 295. Second short arm 305B comprises a rounded upper end 308B and is connected by a curved section 307B to long arm 295. In at least one embodiment (not shown), height of H_305B differs from height of H_305A. In at least one embodiment, the upper end 308B is generally flat, possibly parallel to top opening 292.
From the previously described geometry, the second J-shaped portion within mirrored J-shaped portion 285 may be explained as a combination of facets and features in central block 255 that form a first generally rectangular void (long arm 295) joined with a curved or filleted void (section 307B) and joined with second generally rectangular void (short arm 305B). Any of these sections 295, 307B, or 305B may have more or less curvature than depicted in FIG. 12. It is possible that long arm 295 be directly connected to short arm 305B with no curved or filleted section 307B between arms 295, 305B. In other embodiments with a longer transverse length Z_274, section 307B may be longer. As stated earlier, the mirrored J-shaped portion 285, which includes long arm 295, sections 107A, 107B, short arms 305A, 305B, and upper ends 308A, 308B extends through the lateral breadth of B_265.
As indicated in FIG. 12, base 294 of mirrored J-shaped portion 285 generally defines a majority or all of base 274 of locking channel 265, spanning lateral breadth of B_265 and a transverse length of Z_274. Base 294 is shown to be generally flat and horizontal, but may be curved upward or downward in the transverse direction, that is to say, in a direction that may extend generally from front end 36 to back end 38 of anchor block 230.
In the example locking channel 265 of FIG. 12, generally trapezoidal portion 315 is superimposed through the center of mirrored J-shaped portion 285, sharing at least one or more common surfaces or one or more common volumes (voids). Trapezoidal portion 315 comprises a back end 316, a front end 318, a top opening 322, a base 324, and a width W_315. In at least one embodiment, top opening 322 is parallel to base 324. In at least one embodiment, width W_315 is equal to width W_285. Top opening 322 corresponds to the elongate member of cross-shaped opening 272, extending a transverse length of Z_265 through and beyond the top opening 292 in two directions. In the example shown, the front end 318 extends beyond front end 288, back end 316 extends beyond back end 286, and base 324 overlaps a portion of base 294. However, in at least one embodiment, a region of front end 318 overlaps a region of front end 288, and in at least one embodiment a region of back end 316 overlaps a region of back end 286. Other derivations are possible.
Referring to FIGS. 1 and 2, the installation and coupling of pre-fabricated anchor block 230 is similar to the installation and coupling of an anchor block 30 with a few adjustments. Previously described, steps 401 to 430 of method 400 in FIG. 10 also pertain to anchor block 230. During installation, a minimally sized hole (not shown) is dug in the earth 14 to accommodate anchor block 230 at the prescribed mean depth Δ and angle α and to accommodate anchor rod 150 at an installation angle of β. The dirt removed from the hole may be set aside for later use. Anchor block 230 may be placed within the hole in one of two orientations. Anchor block 230 may be placed in the hole with front end 36 closer to tower 10 than back end 38. Alternatively, anchor block 230 may be placed in the hole with back end 38 closer to tower 10 than front end 36. In either orientation, the transverse center line 31 of anchor block 230 is radially aligned or generally radially aligned with the vertical axis 11 of tower 10. (See also FIG. 11.) Subsequently, anchor rod 150 is installed in or coupled to anchor block 230. To accomplish this task, end rod 165 at first end 151 (FIG. 8) is inserted into the top opening 292 of cross-shaped opening 272 (FIG. 12) and travels downward through long arm 295 of mirrored J-shaped portion 285. Simultaneously, a portion of shaft 155 enters top opening 322 of cross-shaped opening 272 and into trapezoidal portion 315. When end rod 165 reaches the bottom of long arm 295, anchor rod 150 would be preferably pulled toward front end 36 of anchor block 230 if front end 36 is closer to tower 10. Otherwise, if back end 38 is closer to tower 10, then anchor rod 150 would be preferably pulled toward back end 38. As a result, end rod 165, travels generally upward into a short arm 305A, 305B, preferably the short arm that is closer to tower 10. End rod 165 eventually arrives at an upper end 308A, 308B. As a consequence, the enlarged, T-shaped first end 151 slidingly engages locking channel 265 with the result being that first end 151 rotatably couples within channel 265. Thereby, channel 265 of anchor block 230 couples or captures anchor rod 150 while anchor rod 150 remains free to rotate or pivot. For example, anchor rod 150 may pivot about axis 166 with shaft 155 moving within trapezoidal portion 315.
Indicated in FIG. 11, a seal 280 may be coupled to an occupied (active) locking channel 265. In one embodiment seal 280 covers a portion of surface 256. In another embodiment, seal 280 extends within channel 265. In yet another embodiment seal 280 both covers a portion of surface 256 and extends within channel 265. Seal 280 may be, for example, formed from rubber, adhesive tape, silicon, or caulking and may be pre-molded or configured on-site. When an anchor block 230 has more than one locking channel 265, any unused channel 265 may be covered by a seal 280.
The remainder of the installation of anchor block 230 is similar to the installation of anchor block 30 as previously discussed. Similar to the view of FIG. 1, when anchor block 230 is disposed within earth 14 as described, and block 230 is coupled to anchor rod 150, tower 10, and at least one guy cable 12, then these components 230, 150, 10, 12, are thereby anchored to the earth 14 and may be said to be secured to the earth 14 or coupled to earth 14.
In another installation, a new anchor rod 150 may be installed and rotatably coupled in an existing anchor block 230 already installed in the earth 14. In some situations, an existing anchor rod 150 may be removed from a multi-facetted locking channel 265 in the existing anchor block 230, and new anchor rod 150 may be installed in the same channel 265. In other situations, the new anchor rod 150 may be installed in a previously unused locking channel 265. If a seal 280 covers a locking channel 265, the seal would be removed or adjusted to allow engagement of the new rod 150. The installation steps described previously would be altered accordingly.
The magnitude of the several dimensions referenced regarding anchor block 30, 230 may be determined based on an engineering evaluation of the loads (that is to say, the forces) that are anticipated to be exerted on anchor block 30, 230 through anchor rod 150 and one or more guy cables 12. Similarly, the magnitude of the dimensions referenced regarding anchor rod 150 may be determined based on an engineering evaluation of the loads that are anticipated to be exerted on anchor rod 150 by anchor block 30, 230 and one or more guy cables 12. Additionally, in at least one embodiment, the magnitude of edge offset W_46 is nearly zero or equal to zero, making the width of central block 55, 255 nearly equal or equal to base plate width W_30. Although, FIGS. 4 and 11 and may be interpretted to illustrate that length L_30 of anchor block 30, 230 is greater than width W_30, in at least one embodiment of anchor block 30, 230, the magnitude of width W_30 is greater than length L_30. In at least one other embodiment of anchor block 30, 230, the orientation of multi-facetted locking channel 65, 265, respectively, may be rotated.
Additional derivations to the shape and dimensions of multi-facetted locking channel 65, 265 are possible. In addition to locking channel 65, 265 or in place of locking channel 65, 265, other means of connection may be included on an anchor block like block 30, 230. For example, an attachment loop (not shown) or a horizontal tie-down rod with a recess beneath the loop or rod (not shown) may be disposed near top surface 56, 256 forming a multi-facetted channel. In at least one embodiment, a pre-fabricated anchor block has at least one locking channel 65 and at least one locking channel 265, blending the features of the anchor blocks 30, 230. In place of anchor rod 150, a rope, cable or other flexible member may couple between block 30, 230 and the tower 10 or between block 30 and another structure, such as a camping tent. In at least one embodiment, second end 152 of anchor rod 150 couples more directly to tower 10 or another structure without an intervening guy cable 12. The embodiment(s) may include a modification to second end 152 resulting in a modified anchor rod. When an anchor block 30, 230 is disposed within earth 14 as previously described, a coupled combination of block 30, 230, anchor rod 150 (or modified anchor rod), and tower 10 may thereby be anchored, secured, or coupled to earth 14.
While disclosed embodiments have been shown or described, modifications thereof can be made by person having ordinary skill in the art without departing from the teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible. For example, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied, in addition to or in conjunction with the variations already disclosed herein. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims.
