Interlocking Steel Plate Foundation

Abstract

Disclosed are interlocking steel plate foundations of various configurations. Interlocking foundations eliminate the need for concrete foundations and have a much shorter assembly time. Interlocking foundations have fins which provide for increased torsional restriction for the same or less material than other metal foundations such as the metal fin tube style foundation. Optionally multiple foundations can also be linked together to construct foundations of any shape and size

Description

BACKGROUND

Over the last several years, metal foundations have been used to provide support for many different types of structures, because they offer many advantages over concrete foundations. Once installed, metal foundations can be used to instantly provide support for a structure, unlike concrete foundations which require a significant amount of time to cure. Metal foundations also can be installed in any weather condition and on any terrain; they are less damaging to the environment and they are easily moved when compared to concrete foundations.

One type of metal foundation is disclosed in U.S. Pat. No. 9,422,687. This invention is directed to a flat-plate foundation support which includes a lower portion extending longitudinally along a central longitudinal axis of the support and adapted for insertion into a ground surface. The lower portion has a plurality of flat non-slotted metal plates that are mutually connected in an adjacent manner along the central longitudinal axis of the foundation support forming fins that extend laterally or radially from the central longitudinal axis formed by the adjacent connection. The flat plates are beveled and have a sharpened leading edge at a lower end of the lower portion. An upper portion of the support such as a pipe without slots in its circumference; can be attached to a top end of the lower portion by a suitable method, such as welding along the lateral edges of the fins in the longitudinal direction. The upper portion of the support is attached to a ground supported apparatus to anchor that apparatus to the ground. However a disadvantage is for the above design is that welding is best known method to adjacently connect flat non-slotted plates along a central longitudinal axis.

Welding, either on site or offsite requires qualified people and special equipment. This adds to the expense of installing foundations. Usually because it is less expensive, the metal foundation bodies are welded together in a shop and then transported on to the worksite. Transporting pre-assembled metal foundations limits their size and shape. If the metal foundations necessary for a specific project are too large or awkward to transport, the individual pieces can be weld together on site. However, this increases the expense of installing metal foundations because all the necessary personnel and equipment must also be transported to the worksite. Welding also generates toxic fumes which is not healthy for people or environmentally friendly.

A non-welding solution is provided in U.S. patent application Ser. No. 14/827,477. Disclosed in this application are metal fin tube foundations that are assembled together without welding. In the disclosed invention, the fins are part of the metal foundation body. The bodies of the metal foundation of the disclosed invention are assembled manually via the integrated fins by mechanical fastening. The metal fin tube foundations of the invention can either be a perimeter geometric shape, a radial geometric shape or if the job requires, both shaped foundations can be combined/used in conjunction with one another. The mechanical fastening means can be any known in the field including, but not limited to Huck Bolts, rivets, clips, bolts, studs and clamps. However the manufacturing of these foundations can be complex and require excessive labor to manually fasten the foundation pieces into the specific geometric shapes. This can lead to extra cost because of both the labor needed and mechanical fastening means themselves.

What is needed is: Metal foundation with greater torsional resistance that are easier to assemble and that provide greater strength using less material that previous metal foundations. It is also desired to have a design that can be a basis for foundations of various shapes and sizes giving designers more flexibility to incorporate multiple designs as required for specific projects.

SUMMARY

What is disclosed is interlocking steel plate foundations of various configurations. Interlocking foundations eliminate the need for concrete foundations and have a much shorter assembly time. Interlocking foundations have fins which provide for increased torsional restriction for the same or less material than other metal foundations such as the metal fin tube style foundation. Optionally multiple foundations can also be linked together to construct foundations of any shape and size.

SHORT DESCRIPTION OF THE FIGURES

FIG. 1A shows a top plate for one embodiment of an interlocking foundation of this disclosure.

FIG. 1B shows a bottom plate for one embodiment of an interlocking foundation of this disclosure.

FIG. 1C shows the assembly of an embodiment of an interlocking foundation of this disclosure.

FIG. 2A is a top view of the interlocking foundation in FIG. 1C with an attached top mounting plate.

FIG. 2B is a side view of the interlocking foundation in FIG. 1C with an attached top mounting plate.

FIG. 3A shows a pipe with receiving slots for one embodiment of an interlocking pipe foundation of this disclosure.

FIG. 3B shows upwards producing foundation with pipe slots for one embodiment of an interlocking pipe foundation of this disclosure.

FIG. 3C shows the assembly of an embodiment of an interlocking pipe foundation of this disclosure.

FIG. 4A shows a top plate for one embodiment of a foundation for use in a second embodiment of an interlocking pipe foundation of this disclosure.

FIG. 4B shows a bottom plate for one embodiment of a foundation for use in a second embodiment of an interlocking pipe foundation of this disclosure.

FIG. 4C shows the assembly of an embodiment of an interlocking plate foundation for use in a second embodiment of an interlocking pipe foundation of this disclosure.

FIG. 4D shows a pipe for use in a second embodiment of an interlocking pipe foundation of this disclosure.

FIG. 4E shows the assembly of a second embodiment of an interlocking pipe foundation of this disclosure.

FIG. 5A shows a zee-shaped top plate of an embodiment of an interlocking foundation of this disclosure.

FIG. 5B shows a zee-shaped bottom plate of an embodiment of an interlocking foundation of this disclosure.

FIG. 5C shows the assembly of an embodiment of an interlocking bent foundation of this disclosure.

FIG. 6A is a top view of the interlocking bent foundation in FIG. 5C with an attached top mounting plate.

FIG. 6B is a side view of the interlocking bent foundation in FIG. 5C with an attached top mounting plate.

FIG. 7 is an isometric view of the interlocking bent foundation in FIG. 5C with attached straps.

FIG. 8A shows a bottom plate with legs and leg flanges of an embodiment of an interlocking angle plate foundation of this disclosure.

FIG. 8B shows a top plate with legs and leg flanges of an embodiment of an interlocking angle plate foundation of this disclosure.

FIG. 8C shows the assembly of an embodiment of an interlocking angle plate foundation of this disclosure.

FIG. 9A is a top view of the interlocking angle plate foundation in FIG. 8C with an attached top mounting plate.

FIG. 9B is a side view of the interlocking angle plate foundation in FIG. 8C with an attached top mounting plate.

FIG. 10A shows a top view of the assembly of an embodiment of an interlocking pipe foundation of this disclosure that uses flat plates.

FIG. 10B shows a top view of a pipe used in an embodiment of an interlocking pipe foundation of this disclosure.

FIG. 10C shows a side view of a pipe used in an embodiment of an interlocking pipe foundation of this disclosure.

FIG. 10D shows a side view of a flat plate with slots used in an embodiment of an interlocking pipe foundation of this disclosure.

FIG. 11 shows the assembly of multiple interlocking pipe foundations of this disclosure.

FIG. 12A shows the assembly of an embodiment of an interlocking metal fin foundation of this disclosure.

FIG. 12B shows a top view of a metal fin used in an embodiment of an interlocking metal fin foundation of this disclosure.

FIG. 12C shows a side view of a metal fin used in an embodiment of an interlocking metal fin foundation of this disclosure.

FIG. 12D shows a side view of a flat plate with slots used in an embodiment of an interlocking metal fin foundation of this disclosure.

DETAILED DESCRIPTION

The interlocking steel plate foundation disclosed is comprised of two or more flat steel plates joined together by complementary slots. Steel plates can be cut to a certain length and a certain width as required by the specific project. This can be done by any steel plate manufacturer. Slots can then be cut into the steel plates as desired. The most economic means is by a computer numeric control (CNC) plasma cutter or a CNC laser. The plates can also be hot dip galvanized if required. Note on all the Figures holes are represented as circles, these holes are not necessary for to understand the inventive concept nor are required, but are only depicted as potential fastening or connecting means.

One embodiment of the interlocking steel plate foundation is disclosed in FIG. 1A-1C. Bottom plate 1 has slot 2 that opens upward. Top plate 3 has slot 4 that opens downward. Slots 2 and 4 are used to interlock plates 1 and 3 together to form foundation 5. The length of the slot is determined by the specific project that necessitates by the design of the foundation and how much intersection is desired between the two plates. As shown here, the two plates are preferably identical, but unequal plates are also contemplated by this disclosure. Ideally, the plates are flush with respect to their edges on the top and the bottom of foundation 5 and therefore in the identical plates shown in this figure, preferably the slots 2 and 4 would be cut from the edge of the plate to the midpoint. Also preferably, the lateral sides of the foundation are even and therefore the slots 2 and 4 would be centered. Though flush edges and lateral sides are preferred, the invention also contemplates uneven lateral sides and edges. The width of the slots 2 and 4 are to be slightly larger than the plate thickness with which it is engaging. Fins 6 in foundation 5 provide torsional resistance when foundation 5 is inserted into the ground.

Interlocking assembly can occur at the manufacturer and then the foundation can be shipped as a completed piece, or the fabricated steel plates can be transported individually and the foundation is then assembled on site. Assembly can be done by any means. The most effective and easy slotting methods is using physical force to push the interlocking pieces together; this method will suffice for most foundation designs. If desired optionally, the interlocking plates can be welded or mechanically fastened together for increased stability. On site either the completed interlocking foundation is vibrated or pushed into the ground or the bottom plate is vibrated or pushed partially into the ground the top plate is interlocked via the slots and then the rest of the foundation is inset into ground. In either case, a portion of the foundation remains above ground to connect with any suitable above ground structure or equipment the foundation was intended to support. One advantage of using the vibration method is that soil is not displaced from the local area; displacement of soil can be environmentally damaging and the removal of soil can be costly and a time burden.

This interlocking foundation can either connect directly to the above ground structure, or it may connect via a top mounting plate as depicted in FIG. 2A-2B. Atop of foundation 5 is top mounting plate 7. Depicted here top mounting plate 7 is comprised of a flat piece 8 with side overhangs 9. Top mounting plate 7 can be comprised of a single formed piece or several individual pieces fastened together. Also note that a top mounting plate comprised of a flat piece alone that is connected to the foundation is also contemplated by this disclosure. Mechanical means such as bolts can be used fasten the top mounting plate 7 to foundation 5.

Optionally, a pipe support can be used in conjunction with an interlocking foundation as depicted in FIG. 4A-4E. Plate 11 is comprised of central slot 12 and pipe slots 13 whereby central slot 12 is formed on the same edge of the plate 11 as pipe slots 13. Plate 14 is comprised of central slot 15 and pipe slots 13 whereby central slot 15 is formed on the opposite edge of the plate 14 as pipe slots 13. Pipe 16 is comprised of plate receiving slots 17 facing upwards. Plate 11 and plate 14 are interlocked via central slots 12 and 15 to form foundation 18 with pipe slots 13 facing downward. Pipe 16 and foundation 18 are interlocked via pipe slots 13 and receiving slots 17 to form pipe foundation 19. Though a circular pipe is depicted here, any other structural shape in which slots can be cut that correspond to the slots in the flat plates of interlocking foundation are contemplated by this invention. The pipe foundation can connect directly to an above ground structure or optionally, a top mounting plate can be used for connecting to the above ground structure.

In FIG. 3A-3C is an alternative pipe support foundation. The same plate configurations 11 and 14 as seen in FIG. 4 are interlocked in the same manner, however the pipe slots 13 are used facing upwards producing foundation 58. Pipe 56 is comprised of plate receiving slots 57 facing downwards. Pipe 56 and foundation 58 are interlocked via pipe slots 13 and receiving slots 57 to form pipe foundation 59. Pipe 56 can any length required for the specific project.

Another embodiment of the interlocking foundation is shown in FIG. 5A-5C. This embodiment has increased torsional resistance. Instead of the plates being flat, the plates are comprised of bends that are formed into longitudinally with respect to the plate and slots. Bottom plate 20 is Zee shaped and comprised of web 22 and two leg flanges 23 and has slot 21 that opens upward. Top plate 24 is Zee shaped and comprised of web 25 and two leg flanges 26 and has slot 27 that opens downward. Slots 21 and 27 are used to interlock plates 20 and 24 together to form bent foundation 28. As above, the length of the slot is determined by the specific project that necessitates by the design of the foundation and how much intersection is desired between the two plates. As shown here, the two plates are preferably identical, but unequal plates are also contemplated by this disclosure. Ideally, the plates are flush with respect to their edges on the top and the bottom of bent foundation 28 and therefore in the identical plates shown in this figure, preferably the slots 21 and 27 would be cut from the edge of the plate to the midpoint. Also ideally the lateral sides of the foundation are even and therefore the slots 21 and 27 would be centered. Though flush edges and lateral sides are preferred, the invention also contemplates uneven lateral sides and edges. The width of the slot is to be slightly larger than the plate thickness with which it is engaging. The webs and flanges form bent fins 29. The bent fins 29 in foundation 28 provide torsional resistance when foundation 28 is inserted into the ground. Any steel shapes that has bends are contemplated by this invention, including but not limited to angle plates (1 bend) channel plates (2 bends same direction), and as seen above Zee plates (2 bends opposite direction).

This interlocking foundation can either connect directly to the above ground structure, or it may connect via a top mounting plate as depicted in FIG. 6A-6B. Optionally atop of foundation 28 is top mounting plate 30. Depicted here top mounting plate 30 is comprised of a flat piece 31 with side overhangs 32. Top mounting plate 30 can be comprised of a single formed piece or several individual pieces fastened together. Also note that a top mounting plate comprised of a flat piece alone that is connected to the foundation is also contemplated by this disclosure. Mechanical means such as bolts can be used fasten the top mounting plate 30 to foundation 28. Alternatively 90 degree bends facing upwards (in opposite direction from the ground) may be incorporated made at the upper edges of the bent fins to allow for the attachment of a top mounting plate that is either mechanically fastened or welded. If desired for additional stability, as depicted in FIG. 7, optionally straps 49 connecting via their lengths adjacent bent fins 29 can be used. Straps 49 are comprised of steel strips only several inches in width and are connected to bent fins 29 by mechanical means. Straps 49 can further prevent any slippage while inserting foundation 28 into the ground and be placed on the top of, on the bottom of, or on both sides of the foundation 28. This embodiment is preferred when multiple foundations placed short distances apart are being used to support the same ground structure and precise alignment is required.

Another interlocking foundation embodiment utilizes angle plates 34 and 35 in which each individual plate has two interior slots in close proximity to on either side of a central angle for form angle plate foundation 33 as depicted in FIG. 8A-8C. Though shown here with bends in addition to the central angle, embodiments with a central angle alone are also contemplated. When the plates interlock to form foundation 33, the intersection forms a central tube 36; increasing strength and stability. Bottom plate 34 comprised of legs 37 and two leg flanges 38 and has slots 39 that open upward. Preferably the legs 37 are angled at 90 degrees to one another, and preferably each leg flange 38 is angled at 90 degrees to its respective leg 37. Top plate 35 comprised of legs 40 and two leg flanges 41 and has slots 42 that open downward. Preferably the legs 40 are angled at 90 degrees to one another, and preferably each leg flange 41 is angled at 90 degrees to its respective leg 40. Slots 39 and 42 are used to interlock plates 34 and 35 together to form angle plate foundation 33. As above, the length of the slots is determined by the specific project that necessitates by the design of the foundation and how much intersection is desired between the two plates. As shown here, the two plates are preferably identical, but unequal plates are also contemplated by this disclosure. Ideally, the plates are flush with respect to their edges on the top and the bottom of angle plate foundation 33 and therefore in the identical plates shown in this figure, preferably the slots 39 and 42 would be cut from the edge of the plate to the midpoint. Also ideally the lateral sides of the foundation are even and therefore the slots 39 and 42 would be equally distanced from their respective central angles. Though flush edges and lateral sides are preferred, the invention also contemplates uneven lateral sides and edges. The width of the slot is to be slightly larger than the plate thickness with which it is engaging. The legs and flanges form bent fins 43. The bent fins 43 in angle plate foundation 33 provide torsional resistance when foundation 33 is inserted into the ground.

Optionally atop of angle plate foundation 33 is top mounting plate 50. Depicted in FIG. 9A-9B, top mounting plate 50 is comprised of a flat piece 51 with side overhangs 52. Top mounting plate 50 can be comprised of a single formed piece or several individual pieces fastened together. Also note that a top mounting plate comprised of a flat piece alone that is connected to the foundation is also contemplated by this disclosure.

Using any of the above described embodiments, it is also possible to add slots toward the outer edges of the either fins or bent fins, and interlock individual foundations together via the slotting method to increase the platform size and the stability of the foundation. These large foundations can be any number and combinations of slotted plates, pipes tubes or shapes; all of which can be connected via the same slotting method to form a large foundation area. There is no limit to its size. Top mounting plates can be attached as required.

Another embodiment of an interlocking pipe foundation 55 shown in FIG. 10A-10D is comprised of a plurality of flat plates 44; each flat plate 44 is comprised of two slots 45 emanating from the same side of said flat plate, equidistance from and very near the outer edge. Preferably four flat plates 44 are placed in a square configuration 48 with respect to one another with a space between adjacent corners. A plurality of pipes 46, each pipe 46 with four slots 47 emanating from the same and equidistance from one another is then interlock with the flat plates 44 via the slotting method so as to “fill in” the corners of the square. As only two the slots 47 in the individual pipes are used in the square configuration, the other two slots 47 are open to receive a slot 45 from additional flat plates 44, which in turn have a slot 45 available to receive additional pipes 46, and so on and so forth to form additional square configurations 48. The foundation can grow to be any size and shape; a non-limiting example of foundation 54 is shown in FIG. 11. The only limitation would be the amount of flat plates 44 and pipes 46 available. Top mounting plates can be attached as required.

As an alternative to using pipes, one could also use any of the several perimeter geometric shape metal fin foundations described in U.S. patent application Ser. No. 14/827,477. A non-limiting example using an octagonal shape metal fin tube foundation is shown in FIG. 12A-12D. Interlocking metal fin tube foundation 60 is comprised of a plurality of flat plates 61; each flat plate 61 is comprised of two slots 62 emanating from the same side of said flat plate, equidistance from and very near the outer edge. Preferably four flat plates 61 are placed in a square configuration 63 with respect to one another with a space between adjacent corners. A plurality of octagonal shape metal fins 64, each octagonal shape metal fin 64 is comprised of four bodies 66; each body 66 is of long fins 65 and short fins 67. The individual bodies are assembled together by fastening means 68. Each octagonal shape metal fins 64 has four slots 69 emanating from the same and equidistance from one another is then interlock with the flat plates 61 via the slotting method so as to “fill in” the corners of the square.

There are several advantages of using interlocking metal foundations over other metal foundations. To achieve the same strength requires less material. This ultimately makes the interlocking foundations more economical than other metal foundations such as radial and perimeter foundations. Studies have shown that when an interlocking foundation utilizes the same footprint as a previous metal foundation there is a 65% increase in strength, with interlocking foundation being approximately 40% cheaper to produce and assemble. If one desires an interlocking foundation to have the same footprint and the same strength of a previous metal foundation, the cost of the interlocking foundation is ˜80% less.

Claims

1. An interlocking foundation comprising:

a bottom plate with an upward slot and a top plate with a downward slot;

whereby the upward slot and the downward slot are used to interlock the bottom plate and the top plate to form an interlocking foundation.

2. The interlocking foundation of claim 1, further comprising a top mounting plate, the top mounting plate comprising a flat plate and a plurality of side overhangs.

3. The interlocking foundation of claim 1, wherein the upward slot and the downward slot are centered within their respective plates.

4. The interlocking foundation of claim 1, wherein the bottom plate and the top plate are identical in size and shape.

5. An interlocking pipe support foundation comprising:

a bottom plate with a central upward slot and two upward pipe slots on the same side of the bottom plate; each upward pipe slot being equidistant from the central upward slot;

a top plate with a central downward slot and two upward pipe slots; the central downward slot and two upward slots being on opposite sides of the top plate; each upward pipe slot being equidistant from the central downward slot;

whereby the central upward slot and the central downward slot are used to interlock the bottom plate and the top plate to form a base foundation;

a pipe with downward receiving slots that align with the upward pipe slots of the base foundation;

whereby the upward pipe slots and the downward receiving slots interlock to form an interlocking pipe support foundation.

6. An interlocking angle foundation comprising:

a bottom plate comprised of two legs connected at an angle to one another, each leg comprised of an angled leg flange, and each leg comprised of an upward slot;

a top plate comprised of two legs connected at an angle to one another, each leg comprised of an angled leg flange and each leg comprised of a downward slot;

whereby the upwards slots and the downward slots are used to interlock the bottom plate and the top plate to form an interlocking angle foundation comprised of a central tube and four bent fins.

7. The interlocking angle foundation of claim 6 wherein the two legs are connected to one another at a 90 degree angle.

8. The interlocking angle foundation of claim 6 wherein each angled leg flange is angled at 90) degrees to its respective leg.

9. The interlocking angle foundation of claim 6, further comprising a top mounting plate, the top mounting plate comprising a flat plate and a plurality of side overhangs.

10. The interlocking angle foundation of claim 6, wherein the bottom plate and the top plate are identical in size and shape.