Adjustable Monopole Support Structure
A support assembly includes a plurality of support arms coupled to a pole or tower structure. The plurality of support arms project radially from the pole or tower structure in a spaced relationship. A plurality of adjustable foot assemblies are coupled to respective distal ends of the plurality of support arms. Each of the plurality of adjustable foot assemblies is configured for coupling to an embedded helical pier. Each of the plurality of adjustable foot assemblies is capable of movement in each of three dimensions relative to the respective support arm to which it is coupled during installation of the support assembly.
This application is a continuation of U.S. application Ser. No. 14/056,639 filed Oct. 17, 2013 and entitled “Adjustable Monopole Support Structure,” which claims priority under 35 U.S.C. §119, based on U.S. Provisional Patent Application No. 61/721,167 filed on Nov. 1, 2012, the disclosure which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTIONThe present invention relates to the field of monopole structures, and more particularly to support systems associated with such structures.
Monopole structures may be employed for housing or supporting elements such as antennae and other communications equipment, signage, electrical transmission and distribution lines, or lighting in an elevated position. Such structures often include a long, hollow pole structure connected to an underlying surface such as a concrete pad formed in the ground. Such monopole structures are typically subjected to wind or other types of forces along their length, which may cause the structure to bend or sway. These forces create a bending moment or torque about the base termination, which in turn stresses the base termination location and can lead to fatigue and eventual failure of the base termination material.
Conventional monopole structures are often rigidly connected to the ground via direct embedment, via concrete base plates, via concrete encased anchor bolts, or via drilled, concrete filled caissons. These methods for installing monopole structures require significant amounts of time and labor, and they impact the chosen construction site. Direct embedment and anchor bolt foundations require the use of heavy equipment, which can lead to an adverse impact on the site environment and expensive installation costs. In each case, installers must be concerned about what to do with displaced ground material from the construction site. In addition, when using concrete base plates or concrete caissons with anchor bolts, for example, time must be spent waiting for the concrete to cure and set up before a monopole structure can be installed. Accordingly, none of these options is sufficient when a strict timeline must be met and minimal site disturbance is required.
The following detailed description refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements.
Consistent with implementations described herein, a number of support arm structures may be used to structurally connect a tubular monopole to a number of helical piers embedded within an environment surface. As described below, each support arm structure may be coupled to the monopole via an adjustable pin or bolt-based mounting assembly. More specifically, the adjustable mounting assembly may enable fine-tuned adjustment of the location of the helical piers relative to the support arm structures in three dimensions, thereby allowing the support assembly to adapt to variations in installation parameters, such as angle of inclination of the embedded piers. In contrast to existing monopole support systems using concrete base plates, concrete encased anchor bolts, or via drilled, concrete filled caissons, the described system may be employed in environments that are not conducive to the use of concrete or that are not conducive to the impact caused by driving conventional piers or piles. In addition, the described embodiments may be used to remediate or supplement existing monopole support structures with minimal environmental impact.
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Consistent with implementations described herein, monopole support structure 100 may include a base platform 106 and a plurality of support arm assemblies 108-1 to 108-6 (collectively referred to as “support arm assemblies 108” and individually as “support arm assembly 108”). In an exemplary implementation, monopole support structure 100 may include six support arm assemblies 108 projecting from a periphery of base platform 106 in a spaced relation relative to each other. For example, as shown in
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Bearing plate 202 may have a generally planar configuration and is welded to a bottom end of support tube 204. For example, bearing plate 202 may be welded to support tube 204 via groove welds or fillet welds. Similar to bearing plate 202, flange plate 206 may also have a generally planar configuration and is welded to a top end of support tube 204. In one embodiment, bearing plate 202 may have a circular outer periphery and may include an outside diameter greater than a maximum diameter of both support tube 204 and monopole 102.
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To provide adequate support for doublers 212, mounting plates 208 may project through respective openings (e.g., slots) in support layer 205 and may be welded to support layer 205 at the slots (not shown) at the time of manufacture. Supporting gussets 214 may extend between mounting plates 208 in each doubler 212 and may be welded to each mounting plate 208 at opposing ends. For example, in one embodiment, each doubler 212 may include two supporting gussets 214 positioned at a location distal from support tube 204. As described above in relation to support arm assemblies 108, doublers 212 may be positioned in a spaced relation about support tube 204 to correspond to the locations of support arm assemblies 108.
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Foot assembly mounting slot 312 may be configured to include a width that is larger than its height. As shown in
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Upon assembly, the exposed end of helical pier 128 is inserted into sleeve portion 414 of pier cap 140. Mounting holes are drilled (e.g., on site) through helical pier 128 through pier fixing holes 418. As shown in
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For example, in operation, jam nut 422 is configured to secure anchor bolt assembly to pier cap 140, while leveling nut 424 and top nut 426 enable vertical positioning of anchor bolt assembly 134 (and thus, helical pier 128) relative to foot plate assembly 130. More specifically, during installation, anchor bolt 420 is inserted through top plate 416 in pier cap assembly 132 and into pier cap nut 413. Jam nut 422 is tightening down onto top plate 416 to secure anchor bolt 420 to pier cap assembly 132. Leveling nut 424 and one of washers 428 are then threaded onto anchor bolt 420.
Support arm assembly 108 may then be lowered onto the anchor bolt 420. For example, anchor bolt 420 may be received within anchor bolt mounting slot 412 in main plate 402 of foot plate assembly 130. Once a suitable positioning of helical pier 128 relative to a respective support arm assembly 108 is determined (e.g., determined to cause support arm assemblies 108 to be coplanar with each other), leveling nut 424 may be positioned in a corresponding location on anchor bolt 420. As briefly described above, the slotted nature of anchor bolt mounting slot 412 allows the location of anchor bolt 420 (and hence helical pier 128) to be positioned in variable locations in relation to foot plate assembly 130.
Once all six pier mounting foot assembly 120 have been positioned within their respective support arm assemblies 108, top nuts 426 and foot mounting nuts 127 are tightened to secure helical pier 128 to monopole support structure 100 in a level and plumb orientation. Consistent with embodiments described herein, such an adjustable configuration allows for helical piers 128 to be precisely secured even where the exposed ends deviate from a true center by as much as three inches or more.
Following insertion of helical pier 128 into the Earth to a desired or predetermined depth, shaft portion 505 may be trimmed or cut so that retaining end 520 projects from the Earth by a predetermined amount. As shown in
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Consistent with implementations described herein, monopole support structure 600 may include a base platform 606, a plurality of mounting plates 608 (collectively referred to as “mounting plates 608” and individually as “mounting plate 608”), and a plurality of pier mounting foot assemblies 610-1 to 610-3 (collectively referred to as “pier mounting foot assemblies 610” and individually as “pier mounting foot assembly 610”). In an exemplary implementation, monopole support structure 600 may include three mounting plates 608 that project from a periphery of base platform 606 in a spaced relation relative to each other. For example, as shown in
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Bearing plate 702 may have a generally planar configuration and is welded to a bottom end of support tube 704. For example, bearing plate 702 may be welded to support tube 704 via groove welds or fillet welds. Similar to bearing plate 702, flange plate 706 may also have a generally planar configuration and is welded to a top end of support tube 704. In one embodiment, bearing plate 702 may have a circular outer periphery and may include an outside diameter greater than a maximum diameter of both support tube 704 and monopole 602.
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As shown in Fig. SA, consistent with embodiments described herein, bottom 806 of main plate 802 may include an anchor bolt mounting slot 812 formed therein. Anchor bolt mounting slot 812 may be configured to include an “x” dimension that is larger than its “y” dimension, resulting in an elongated opening. As shown in
As shown in Figs. SD and SE, pier cap assembly 632 includes a generally tubular sleeve portion 814 and a top plate 816. Sleeve portion 814 may be sized to receive an exposed end of embedded helical pier 628 and may include a plurality of pier fixing holes 818 formed therethrough. Top plate 816 encloses one end of sleeve portion 814 and includes a pair of anchor bolt receiving apertures 819 formed therethrough. As shown in
Upon assembly, the exposed end of helical pier 628 is inserted into sleeve portion 814 of pier cap assembly 632. Mounting holes are drilled (e.g., on site) through helical pier 628 through pier fixing holes 818. Pier fixing pins are inserted through pier fixing holes 818 (and corresponding mounting holes drilled into helical pier 128) and secured (e.g., via pin bolts, nuts, etc.).
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For example, in operation, bottom nuts 821 and jam nuts 822 are configured to secure anchor bolts 820 to pier cap assembly 632, while leveling nuts 824 and top nuts 826 enable vertical positioning of anchor bolt assemblies 820 (and thus, helical pier 628) relative to foot plate assemblies 630. More specifically, during installation, anchor bolts 820 are inserted through top plate 816 in pier cap assembly 632 via anchor bolt receiving apertures 819. Bottom nuts 841 are then threaded onto anchor bolts 820 below top plate 816 and jam nuts 822 are threaded onto anchor bolts 820 above top plate 816, thereby securing top plate 816. Leveling nuts 824 and washers 828 are then threaded onto anchor bolts 820.
Two foot plate assemblies 630 may then be lowered onto the anchor bolts 820. For example, anchor bolts 820 may be received within anchor bolt mounting slots 812 in main plates 402 of foot plate assemblies 630. Top nuts 826 may then be loosely threaded onto anchor bolts 820 to secure the foot plate assemblies 630 to anchor bolts 820. As briefly described above, the slotted nature of anchor bolt mounting slots 812 allows the location of anchor bolts 820 (and hence helical pier 128) to be positioned in variable locations in the “x” dimension.
Mounting plates 608 may be inserted between corresponding pairs of foot plate assemblies 630 such that mounting holes 810 in foot plate assemblies 630 align with foot plate assembly mounting slot 710 in mounting plates 608. As described above, the slotted nature of foot plate assembly mounting slot 710 allows the location of foot plate assemblies 630 to be adjusted or moved in the “y” dimension.
Once all mounting plates 608 have been positioned within their respective foot plate assemblies 630, and the entire monopole support assembly 600 has been leveled and plumbed, top nuts 826 and foot mounting nuts 627 are tightened to secure helical pier 628 to monopole support structure 600. Consistent with embodiments described herein, such an adjustable configuration allows for helical piers 628 to be precisely secured even where the exposed ends deviate from a true center by as much as three inches or more.
By providing an adjustable support mechanism for a helical pier-based monopole support system, embodiments described herein may provide an efficient and environmentally sensitive alternative to existing monopole support systems, while accommodating deviations in the locations of the embedded helical piers. More particularly, helical piers may be driven into the ground surrounding a monopole with minimal environment impact. The above-described adjustable support assemblies may be secured to both the helical piers and the monopole to provide an effective support system with minimal impact and cost.
The foregoing description of exemplary implementations provides illustration and description, but is not intended to be exhaustive or to limit the embodiments described herein to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the embodiments.
Although the invention has been described in detail above, it is expressly understood that it will be apparent to persons skilled in the relevant art that the invention may be modified without departing from the spirit of the invention. Various changes of form, design, or arrangement may be made to the invention without departing from the spirit and scope of the invention. Therefore, the above-mentioned description is to be considered exemplary, rather than limiting, and the true scope of the invention is that defined in the following claims.
In addition, although embodiments described here and depicted in the Figures primarily relate to structures for supporting monopoles having a single member, in other embodiments consistent with aspects described herein, the described support structures may be used with other non-monopole configurations, such as H-frames, V-towers, Y-towers, Delta towers, Gull Wing towers, etc. In such embodiments, the base or bases of each type of tower or structure may be secured using helical piers in the manner described above.
No element, act, or instruction used in the description of the present application should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.
Claims
1. A support assembly, comprising:
- a plurality of support arms coupled to a pole or tower structure,
- wherein the plurality of support arms project radially from the pole or tower structure in a spaced relationship;
- a plurality of adjustable foot assemblies coupled to respective distal ends of the plurality of support arms,
- wherein each of the plurality of adjustable foot assemblies is configured for coupling to an embedded helical pier, and
- wherein each of the plurality of adjustable foot assemblies is capable of movement in each of three dimensions relative to the respective support arm to which it is coupled during installation of the support assembly.
2. The support assembly of claim 1, wherein the pole or tower structure comprises:
- a monopole; and
- a base structure configured to support the monopole,
- wherein the plurality of support arms are coupled to the base structure.
3. The support assembly of claim 2, further comprising:
- a plurality of mounting plates coupled to the base structure,
- wherein the plurality of support arms are coupled to the plurality of mounting plates.
4. The support assembly of claim 3, wherein the plurality mounting plates are configured as a plurality of doublers, with each doubler comprising two of the plurality of mounting plates,
- wherein the plurality of support arms are coupled to the plurality of doublers.
5. The support assembly of claim 4, wherein the plurality of support arms each comprise:
- a pair of polygonal plates coupled together by a plurality of support gussets,
- wherein the polygonal plates each include a foot assembly mounting slot for enabling movement of the adjustable foot assembly in a first direction relative to the respective support arm during installation.
6. The support assembly of claim 5, wherein each of the plurality of adjustable foot assemblies comprise:
- a foot structure having a bottom and at least one side,
- wherein the bottom of the foot structure includes an anchor bolt mounting slot for enabling movement of the helical pier in a second direction relative to the foot structure during installation,
- wherein the at least one side includes a mounting hole configured to align with the foot assembly mounting slots in the polygonal plates,
- wherein the foot structure is coupled to the respective support arm via a bolt or pin inserted into the mounting hole and the foot assembly mounting slots.
7. The support assembly of claim 6, wherein the first direction is perpendicular to the second direction.
8. The support assembly of claim 7, wherein the first direction is radially aligned with the respective support arm to which the adjustable foot assembly is coupled.
9. The support assembly of claim 6, wherein each of the plurality of adjustable foot assemblies further comprise:
- a pier cap configured to securely receive an exposed end of a respective of the helical piers; and
- an anchor bolt assembly configured to couple the pier cap to the foot structure via the anchor bolt mounting slot.
10. The support assembly of claim 9,
- wherein the pier cap comprises: a sleeve portion to receive the an exposed end of the respective of the helical piers; a top plate enclosing an end of the sleeve portion; and a pier cap nut coupled to the top plate and aligned with an aperture in the top plate; and
- wherein the anchor bolt assembly comprises: a threaded anchor bolt; a jam nut; a leveling nut; and a top nut,
- wherein the pier cap nut is configured to receive one end of the threaded anchor bolt,
- wherein the jam nut is configured to secure the threaded anchor bolt to the pier cap via the,
- wherein the foot structure is configured to receive the other end of the threaded anchor bolt via the anchor bolt mounting slot,
- wherein the leveling nut is moveable along the threaded anchor bolt in a third direction to set a distance between the foot structure and the pier cap, and
- wherein the top not is configured to secure the threaded anchor bolt to the foot structure at the set distance.
11. The support assembly of claim 10, wherein the third direction is perpendicular to both the first and second directions.
12. The support assembly of claim 2, wherein the plurality of support arms comprise the plurality of mounting plates, and
- wherein each of the plurality of mounting plates include a foot assembly mounting slot for enabling movement of at least one of adjustable foot assemblies in a first direction relative to the respective mounting plate during installation.
13. The support assembly of claim 12, wherein each of the plurality of adjustable foot assemblies comprises:
- a foot structure having a bottom and a side,
- wherein the bottom of the foot structure includes an anchor bolt mounting slot for enabling movement of the helical pier in a second direction relative to the foot structure during installation,
- wherein the side includes a mounting hole configured to align with the foot assembly mounting slots in a respective mounting plate,
- wherein the foot structure is coupled to the respective mounting plate via a bolt or pin inserted into the mounting hole and the foot assembly mounting slot.
14. The support assembly of claim 13, wherein the first direction is perpendicular to the second direction.
15. The support assembly of claim 13, wherein each of the plurality of adjustable foot assemblies further comprises:
- a pier cap configured to securely receive an exposed end of a respective one of the helical piers; and
- at least one anchor bolt assembly configured to couple the pier cap to the foot structure via the anchor bolt mounting slot.
16. The support structure of claim 15,
- wherein the each of the adjustable foot assemblies comprises two foot structures coupled to the respective mounting plate in a back to back manner via the foot assembly mounting slot.
17. The support assembly of claim 1, wherein the pole or tower structure, the plurality of support arms, and the plurality of adjustable foot assemblies comprise galvanized steel.
18. A foundation system for an electrical utility structure, comprising:
- a base platform for supporting the electrical utility structure;
- a plurality of mounting plates secured to the base platform in a radially spaced configuration;
- a plurality of support arms coupled to respective mounting plates for supporting the electrical utility structure; and
- a plurality of adjustable foot assemblies coupled to respective ends of the plurality of support arms,
- wherein the plurality of adjustable foot assemblies are coupled to exposed ends of embedded helical piers upon installation of the foundation system,
- wherein the plurality of adjustable foot assemblies allow for positioning of the helical pier in each of three dimensions.
19. The foundation system of claim 18, wherein each of the plurality of support arms comprises a foot assembly mounting slot,
- wherein the respective adjustable foot assembly is coupled to the respective support arm via a bolt or pin inserted through the foot assembly mounting slot to allow relative movement in a first direction between the adjustable foot assembly and the support arm.
20. The foundation system of claim 19, wherein each of the plurality of adjustable foot assemblies comprises an anchor bolt mounting slot,
- wherein the respective helical pier is coupled to the respective adjustable foot assembly via an anchor bolt coupled to the respective helical pier and inserted through the anchor bolt mounting slot to allow relative movement between the helical pier and the adjustable foot assembly in a second direction.
21. The foundation system of claim 20, wherein the anchor bolt comprises a leveling nut for enabling setting of a distance between the helical pier and the adjustable foot assembly.
Type: Application
Filed: Jul 14, 2015
Publication Date: Jan 21, 2016
Inventor: Mark H. Fairbairn (Red Wing, MN)
Application Number: 14/798,559