METHOD AND ARRANGEMENT FOR PRECAST FLOATING FOUNDATION

Abstract

A floating foundation assembly includes a plurality of piers and one or more decks. The plurality of piers are screwed into or otherwise secured to a ground surface at predetermined distances from each other, at predetermined depths. The one or more decks include a precast prestressed deck with standardized geometries. The one or more precast prestressed decks are installed transversely across tops of the plurality of piers and are configured for affixing a structure above them. The one or more precast prestressed decks are manufactured in a controlled environment at an off-construction site, after which they are transported to a construction site and installed on top of the plurality of piers to form the floating foundation assembly. These resulting decks and supporting floating foundation assemblies have superior quality, durability, weatherproofing, and crack resistance.

Description

FIELD OF THE INVENTION

The present disclosure generally relates to design and construction technology. In particular, the disclosure relates to an arrangement of precast floating foundations for use in construction technology and the method of assembly thereof.

BACKGROUND OF THE INVENTION

Existing construction technologies involve one-off (e.g., customized) build-on site approaches in which construction material is brought to a construction site where the actual construction is performed. This has been the traditional methodology and approach for many years but has certain inherent challenges, including non-availability of skilled workforce (e.g., manual labor), heavy and expensive on-site machinery, incorrect estimates of completion times of construction projects, delays in delivery of projects, inclement weather, poor quality and wastage of materials, noise and air pollution, and cost involved in disposal of debris. This approach is also “one-off” as it provides no repeatability or scalability leverage. Each building is constructed, or each project is performed, differently, and results vary widely, which may be undesirable considering present day demand for symmetrical construction projects with enhanced look and feel. Furthermore, constructing each individual component of a building on site incurs significant expenditures in time and resources. It also increases vulnerability of a project to unforeseen factors, such as poor weather, worksite accidents, improper pour, etc.

Further, the execution of construction projects needs an ensemble of technologies or domains, such as structural integration, civil engineering, mechanical joints, materials science, etc. Although there have been significant advancements in construction technologies, due to the above factors, the average cost of construction and the effective cost of owning a house is still high for most aspiring owners. Needless to say, housing still remains beyond the reach of many due to associated construction costs.

In order to address the aforesaid shortfalls of these build-on site approaches, some construction projects use prefabricated building modules. Further, construction methods (used in the completion of construction projects) have been accelerated by using prefabricated building modules including precast decks. Precast decks are commonly used at construction sites.

In conventional structures, including precast decks, movement of a portion or all the deck or a foundation support structure may occur as the soil expands or contracts annually as a result of imposition of loads on an individual pier or footing where the load exceeds the load bearing capacity of the soil. Independent movement of each footing may generate forces to one or more points of attachment in the deck or the foundation support structure. Such movement will often be unevenly distributed, and damage or failure of the deck or the foundation support structure may occur. Seismic activity may also result in uneven forces being applied to various areas of the deck or the foundation support structure. If the deck or the foundation support structure is attached to a building, as is common, the building may also be damaged.

Therefore, there remains a need for improved prefabricated foundation elements that provide significant improvement in the construction of various structures and buildings.

SUMMARY OF THE INVENTION

Embodiments for designing, constructing, and arranging structures in construction technology are disclosed that address at least some of the above challenges and issues.

In an aspect, the present disclosure is directed to a floating foundation assembly. The floating foundation assembly comprises a plurality of piers arranged at predetermined distances from each other in a ground surface and one or more precast prestressed decks, arranged transversely across tops of the plurality of piers, configured for affixing a structure on top of the one or more precast prestressed decks.

In an embodiment of the present disclosure, the plurality of piers are screwed at predetermined depths in the ground surface.

In an embodiment of the present disclosure, the predetermined distances and the predetermined depths are based on at least one of a size of the structure, a shape of the structure, a load of the structure, and one or more characteristics of soil underlying sections of the structure.

In an embodiment of the present disclosure, the one or more decks are precast and prestressed in an environment at a location different from a location of the plurality of piers. Also, the one or more precast prestressed decks are transported to the location of the plurality of piers once the plurality of piers is arranged at the predetermined distance from each other in the ground surface.

In an embodiment of the present disclosure, the one or more precast decks are prestressed on a 300 to 400 feet prestressing line prior to their arrangement across the tops of the plurality of piers.

In an embodiment of the present disclosure, the one or more precast prestressed decks are spaced apart to spread a load of the structure in a predetermined manner over the piers.

In an embodiment of the present disclosure, the plurality of piers comprises helical steel screw piers.

In an embodiment of the present disclosure, the one or more precast prestressed decks comprise green concrete.

In an embodiment of the present disclosure, the one or more precast prestressed decks comprise a ribbed deck, a waffle deck, or both.

In an aspect, the present disclosure is directed to a method for manufacturing a foundation assembly. The method comprises arranging a plurality of piers at predetermined distances from each other in a ground surface and installing one or more precast prestressed decks, transversely across tops of the plurality of piers, for affixing a structure on top of the one or more precast prestressed decks.

In an embodiment of the present disclosure, arranging the plurality of piers comprises screwing the plurality of piers at predetermined depths in the ground surface.

In an embodiment of the present disclosure, the predetermined depths and the predetermined distances at which the plurality of piers are screwed in the ground surface are based on at least one of a size of the structure, a shape of the structure, a distributed load of the structure, characteristics of the underlying soil, and local historical weather conditions.

In an embodiment of the present disclosure, the method further comprises prestressing the one or more precast prestressed decks at a location different from a location of the plurality of piers and transporting the one or more precast prestressed decks to the location of the plurality of piers.

In an embodiment of the present disclosure, prestressing the one or more precast prestressed decks occurs prior to installing the one or more precast prestressed decks on top of the plurality of piers.

In an embodiment of the present disclosure, the method further comprises prestressing the one or more precast prestressed decks on a 300 to 400 feet prestressing line.

In an embodiment of the present disclosure, the method further comprises coupling the one or more precast prestressed decks to the plurality of piers and loading walls of the structure on the installed one or more precast prestressed decks.

In an embodiment of the present disclosure, the one or more precast prestressed decks are configured to evenly spread loads of the structure across the piers.

In an embodiment of the present disclosure, the plurality of piers comprise helical steel screw piers.

In an embodiment of the present disclosure, the one or more precast prestressed decks comprise green concrete.

In an embodiment of the present disclosure, the one or more precast prestressed decks comprise a ribbed deck, a waffle deck, or both.

In an aspect, the present disclosure is directed to a method of determining locations and depths of piers for supporting a foundation. The method comprises determining load distributions for a structure across an area supporting the structure. The method further comprises, based on the load distribution and soil characteristics across the area, determining locations and corresponding depths of the piers to support the structure, inserting the piers into the soil at the locations to the corresponding depths, and coupling precast, prestressed decks to the piers, thereby forming a floor of a foundation.

In an embodiment of the present disclosure, the soil characteristics comprise the load-bearing properties of the soil.

In an embodiment of the present disclosure, the soil characteristics correspond to types of the soil, a slope of the soil, or any combination thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages of the disclosure will become apparent by reference to the detailed description of preferred embodiments when considered in conjunction with the drawings. In the drawings, identical numbers refer to the same or a similar element.

FIG. 1 illustrates an architecture of a floating foundation assembly in accordance with embodiments of the present disclosure.

FIG. 2 illustrates an architecture including a plurality of piers in accordance with embodiments of the present disclosure.

FIG. 3 illustrates an architecture of a structure supported by a foundation in accordance with embodiments of the present disclosure.

FIG. 4 shows the steps of a process for determining the locations and depths of piers for a floating foundation assembly in accordance with embodiments of the present disclosure.

FIG. 5 shows the steps of a process for manufacturing a floating foundation assembly in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

The following detailed description is presented to enable any person skilled in the art to make and use the disclosure. For purposes of explanation, specific details are set forth to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required to practice the disclosure. Descriptions of specific applications are provided only as representative examples. Various modifications to the preferred embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the disclosure. The present disclosure is not intended to be limited to the embodiments shown, but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.

With modernization in construction-related methodologies and technologies, there has been a rapid shift from normal customized build on-site construction methodologies to construction using modules or blocks that may be built off-site and then assembled on-site to form a construction or a building. However, in such an approach, it may be of utmost concern that foundation support structure or foundation elements including, but not limited to, decks, piers, and the like, are manufactured in such a manner that they are easy to mount on any construction site.

Further, in conventional precast decks, movement of a portion or all the deck may occur as the soil expands or contracts annually as a result of imposition of loads on an individual pier or footing where the load exceeds the load bearing capacity of the soil. Such movement will often be unevenly distributed, and damage or failure of the deck may occur. Therefore, in order to improve the durability of the foundation elements, it is important to have pre-compression force across decks to minimize the predisposition of decks to crack under loading. In particular, it is important to have an improved foundation assembly with precast and prestressed decks of standardized geometries that work perfectly fine for any given structure in any given condition.

Current construction methodologies and technologies fail to address this concern. The embodiments of the present disclosure address this concern by providing improved and better-quality foundation assemblies in the form of precast floating foundation elements that solve the above-mentioned concerns and provide other benefits.

The disclosed architecture/solution provides a floating foundation assembly including precast prestressed decks and piers. The precast decks that are manufactured under a controlled environment at an off-site location are easy to build, prestressed, slim and sleek, durable, weatherproof, and crack resistant, among other benefits, thereby improving the supply chain efficiencies. This is because environmental conditions at an off-site location are consistent and can be better managed as compared to on-site construction. Further, raw materials can be better obtained, processed, and monitored at an off-site location.

Further, the proposed piers of the floating foundation assembly provide improved load bearing capabilities, thereby preventing damage of the foundation assembly, and hence, the building structure. By leveraging a controlled manufacturing/production environment, embodiments of the present disclosure ensure quality, cost reduction, and speedy arrangement of floating foundation elements to form the building structure at a construction site.

The disclosed architecture/solution provides several other objects and advantages, some of which are discussed below. The present disclosure supports rapid construction of a structure including precast (prefabricated) decks and piers accommodating erratic site constraints and/or tight construction schedules. Further, the present disclosure provides at least pre-compression forces across joints between precast decks, thus improving the durability of precast decks. Furthermore, the present disclosure eliminates the effect of expansive soil movement, as the disclosed floating foundation assemblies are elevated and not in contact with the soil. In some embodiments, a gap equal to 1.5 times the expected vertical movement of the soil is kept between the disclosed foundation assembly and the soil. This also means that no special soil preparation, soil stabilization, soil compaction, rolling, grading, etc. is required for the present disclosure. Additionally, an increase in the load resistance of the structure (including of the precast decks and piers) may be obtained by means of embodiments in accordance with the present disclosure. In particular, the disclosed foundation assemblies have very minimal settlement and little or no future cracking, hence, little or no future maintenance is required. At the least this durability makes the structure economical and also helps quicken the construction schedule.

Certain terms and phrases have been used throughout the disclosure and will have the following meanings in the context of the ongoing disclosure.

“Precast decks” refer to decks that are one of the most used precast (prefabricated) decks. Within a system that employs such decks, a deck is poured and cast in sections before being delivered and installed at a construction site.

“Prestressed concrete” refers to concrete substantially prestressed (compressed) during manufacturing to strengthen it against tensile forces during use. Typically, the concrete includes tendons (e.g., wires, wire strands, or threaded bars) embedded within or placed adjacent to the concrete and tensioned during its manufacture.

“Piles” refer to columns constructed or inserted into the grounds to transmit loads to a lower level of the subsoil.

“Piers” refer to a platform supported by pillars or girder and are preferably of steel. Piers include screw-in pilings and ground anchoring systems used for building deep foundations. Screw piers are typically manufactured from high-strength steel using varying sizes of tubular hollow sections. Screw piers are also referred to as screw piles, screw anchors, screw foundations, ground screws, helical piles, helical piers, helical anchors, and the like. To simplify the discussion below, the term “piers” refers to both piers and piles.

“Precast curved connectors” refer to connectors required by construction structures between precast decks to transfer interface shear and to achieve the desired action that at least includes increasing the load resistance of a construction structure.

In accordance with some embodiments, the present disclosure is directed to a floating foundation assembly including piers/piles screwed into a ground surface at predetermined distances from each other. In different embodiments, the distances are either uniform or non-uniform. In some embodiments, the piers include steel screw piers that are helical in shape. In some embodiments, the piers are screwed into the ground surface via either a hydraulic drill or an electric drill.

Floating foundation assemblies in accordance with some embodiments further include one or more precast prestressed decks placed on top of the piers/piles. In some embodiments, the one or more precast prestressed decks are anchored down to the piers/piles via at least a threaded bar and a nut. In some embodiments, a shear key is added into the one or more precast prestressed decks to resist the vertical movement of the decks. The one or more precast prestressed decks have standardized geometries and are prestressed, for example, on a 300 feet to 400 feet prestressing line. In some embodiments, the precast decks include ribbed or waffle precast decks, resulting in decks that are very sleek and slim. Further, because of such prestressing, less cement is consumed in the floating foundation assembly including piers and precast prestressed decks, and therefore, there is a reduction in carbon dioxide emissions. The precast prestressed decks are well suited for high expansive soil, and therefore, little or no grading or soil preparation is required to install the precast prestressed decks and piers.

In some embodiments, the decks are precast and prestressed in a controlled environment off the construction site. Preferably, once the piers have been installed at the construction site, the precast prestressed decks are transported to the construction site and installed and tightened on top of the piers. In other embodiments, the decks are transported to the construction site before the piers have been installed. The disclosed floating foundation assemblies are elevated and not in contact with soil on the ground surface. In some embodiments, a gap equal to at least 1.5 times the expected vertical movement of the soil is kept between the soil on the ground surface and the floating foundation assembly. Thus, in these embodiments, the precast prestressed decks do not contact the soil or ground surface.

The construction and arrangement of floating foundation assemblies in accordance with some embodiments is rapid. Preferably, once the piers are installed on the ground surface, the one or more precast prestressed decks are immediately loaded on top of the installed piers. Further, once the precast prestressed decks are loaded, walls are able to be loaded on top of the one or more precast prestressed decks to form a structure. Therefore, the installation of the floating foundation assembly is easy and fast.

As discussed above, preferably, the decks are manufactured under a controlled environment resulting in durable, weatherproof, and crack-resistant precast prestressed decks. Further, in some embodiments, the decks include green lightweight concrete, a material that results in less wastage and is less labor intensive. As a person of ordinary skill in the art will understand, a green lightweight concrete is used for precast structural elements that may be used in building construction to increase the speed of construction, to enhance green construction environments by reducing wet trade on the construction site, and to keep dust levels at the construction site to the minimum.

In some embodiments, floating foundation assemblies further include a precast curved connector that provides stability to a floor by connecting the precast decks to each other. The precast curved connectors further provide rigidity to joints of the precast prestressed decks in case of differential settlements of the floor.

Methods and floating foundation assemblies in accordance with some embodiments are described in more detail with reference to FIGS. 1-5.

FIG. 1 illustrates an architecture 100 including a plurality of piers 102 in accordance with some embodiments.

Referring to FIG. 1, the plurality of piers 102A-J (collectively, “piers 102) are installed for a given structure to form a base of a floating foundation assembly. In some embodiments, each pier of the plurality of piers 102 is screwed into a ground surface, such as via either a hydraulic drill or an electric drill. In some embodiments, the plurality of piers 102 are installed on the ground surface on the first day of construction of the floating foundation assembly. This process of installation of the plurality of piers 102 on the ground surface minimizes the installation time and requires little or no soil preparation, thus making the entire process of construction of the floating foundation assembly easy and quick.

Further, in some embodiments, the plurality of piers 102 installed for a given structure are substantially identical in characteristics such as shape, size, material, etc. In other embodiments, at least some of the plurality of piers differ in these characteristics. These characteristics are determined based on factors such as the surrounding soil and ground conditions including, but not limited to, load bearing capacity of the soil (e.g., type of the underlying soil), geometry of the floating foundation assembly, load distribution of a structure, and local historical weather conditions/environments. Further, in some embodiments, configurations of the plurality of piers 102, including, but not limited to, the number of the piers 102 installed on the ground surface depends on structural requirements, such as the building structure including dimensions of the building. A person of ordinary skill in the art will understand that piers, also known as anchors, piles, screw foundations, ground screws, helical piles, helical piers, helical anchors, screw piles, or the like, are foundation solutions used to secure new or repair existing foundations.

In some embodiments, as depicted in FIG. 1, each pier of the plurality of piers 102 is spaced at predetermined distances from each other to spread the load of the structure that will be affixed on top of them. As shown in FIG. 1, some piers (e.g., 102A-102E) are clustered together, while others (e.g., 102F-102J) are more widely distributed. This arrangement can accommodate weight distributions of the structure and the weight-bearing characteristics of the underlying soil. Further, in some embodiments, each pier of the plurality of piers 102 is screwed at predetermined depths into the ground surface based on factors such as (1) parameters of the structure such as, but not limited to, size, shape, and load of the structure, including distributions of loads across different areas or sections of the structure, (2) the type of soil, such as clay, sand, and loam, classified, for example, according to the U.S. Occupational Safety and Health Administration (OSHA) classifications, from solid rock to Type C, (3) the local weather, such as wet and rainy, resulting in less stable soil, versus cold and dry, resulting in more stable soil, or (4) any combination of these. As some examples, to support a given load, a pier must be sunk deeper into sandy soil than into solid rock. As another example, in the same soil, the depth a pier is sunk into the soil varies with the load to be supported. As still another example, the distance between adjacent piers depends on the load that must be supported above the area spanning the piers and the depth of the piers in the soil. In short, in some embodiments, the number, location, and depth of the plurality of piers 102 installed on the ground surface are based on a variety of factors.

Further, in some embodiments, each of the plurality of piers 102 is made preferably of steel, but may be made of other materials (e.g., concrete) that provide sufficient structural integrity. In some embodiments, a pier 102 includes a cap or other platform made preferably of concrete. A person of ordinary skill in the art will understand that other configurations and shapes are also possible for piers installed on the ground surface.

FIG. 1 merely exhibits a non-limiting example architecture of the plurality of piers 102. However, any number of piers are able to be included herein to implement the embodiments presented herein. Other configurations and shapes are also possible for implementing the embodiments presented herein.

FIG. 2 illustrates an architecture of a floating foundation assembly 200 in accordance with some embodiments. In accordance with these embodiments, the floating foundation assembly 200 includes a plurality of piers 202 and one or more decks 204. In this example, the plurality of piers 202 is functionally equivalent to the plurality of piers 102 of FIG. 1. Therefore, for the sake of brevity, the functionality of the piers 202, including their structure and configuration, are not described again.

In some embodiments, the plurality of piers 202 are identical to each other in characteristics, such as size and shape. In other embodiments, at least some of the piers 202 differ in these characteristics. In some embodiments, the size and shape of the plurality of piers 202 is determined based on surrounding soil and ground conditions including, but not limited to, load bearing capacity of the soil, geometry of the floating foundation assembly 200, and distributed load of a structure. As some examples, a first pier underlying and supporting a first section of the structure is inserted into rocky soil, and a second section underlying a second section of the structure is inserted into sandy soil. In some embodiments, the number of piers 202 required for the floating foundation assembly 200 is based on structural requirements, such as the building structure including the dimensions and layout of the building or the structure along the different sections. It will be appreciated that in some embodiments, the entire structure is characterized as a single section to be supported, such as by piers at one or more vertexes of the section or by a single pier at an interior location of the section, to name only a few examples. Further, in some embodiments, each pier of the plurality of piers 202 is screwed to a ground surface either via a hydraulic drill or an electric drill. Such installation of the plurality of piers 202 in the ground surface minimizes the installation time and requires little or no soil preparation, thus making the entire process of construction of the floating foundation assembly easy and quick.

In some embodiments, each pier of the plurality of piers 202 is screwed into the soil on the ground surface until a desirable load capacity for a given structure has been achieved. In some embodiments, each pier of the plurality of piers 202 is spaced at predetermined distances from each other in order to spread the load of the structure that rests on top of them. In some embodiments, each pier of the plurality of piers 202 is screwed into the ground surface at predetermined depths into the ground surface. In some embodiments, the depths at which each pier of the plurality of piers 202 is screwed is based on parameters of the structure such as, but not limited to, size, shape, and load distribution of the structure, as well as on load-bearing characteristics (e.g., type of soil) and contours of the underlying soil (e.g., sloping vs. flat landscape), among other such like factors. In some embodiments, the depths are the same. In other embodiments, the depths are different.

In some embodiments, each pier 202 in the plurality of piers is made preferably of steel and/or precast concrete to prevent corrosive deterioration of the pier 202, among other advantages, but each is able to be made of other materials that provide sufficient structural strength. In some embodiments, each pier of the plurality of piers 202 is a helical pier. Such piers 202 are highly effective in surroundings having challenging soil conditions. A person of ordinary skill in the art will understand that other configurations and shapes are also possible for piers being installed in the ground surface.

Referring to FIG. 2, the floating foundation assembly 200 includes one or more precast prestressed decks 204. The one or more precast prestressed decks 204 are placed on top of and transversely to the installed plurality of piers 202. In some embodiments, the one or more precast prestressed decks 204 fit into or align on top of the plurality of piers 202. In some embodiments, the one or more precast prestressed decks 204 are securely mounted on the plurality of piers 202. In some embodiments, the one or more precast prestressed decks 204 are anchored to the plurality of piers 202 using at least a threaded bar and nut. In some embodiments, a shear key is added into the one or more precast prestressed decks 204 to resist the vertical movement of the decks. A person of ordinary skill in the art will understand that, in accordance with embodiments, the one or more precast prestressed decks 204 interlock with the plurality of piers 202 in a variety of ways. In some embodiments, the one or more precast prestressed decks 204 have standardized geometries, which are based on structural requirements.

In some embodiments, the one or more precast prestressed deck 204 is a ribbed or waffle type. A person of ordinary skill in the art will understand that a ribbed deck is made of wide band beams running between columns with narrow ribs orthogonal to the wide band beams. Further, a person of ordinary skill in the art will understand that a waffle deck is deeper than an equivalent ribbed deck and has narrow ribs spanning in both directions between column heads and band beams. Both these types of decks tend to reduce the overall weight of the deck, making it slim and sleek.

In some embodiments, the one or more decks 204 are made of green light weight concrete, i.e., precast with green concrete at an off-site location, to provide structural strength and prevent corrosive deterioration, among other like advantages, but are able to be made of other materials that provide sufficient structural strength. A person of ordinary skill in the art will understand that green concrete is concrete made of concrete wastes that are environmentally friendly. Further, as is well known in the art, green concrete assures eco-friendly structure, longer lifetimes, higher energy efficiencies, less carbon dioxide emissions, and less drainage or wastewater, among other like benefits. Thus, decks made of green concrete are slim and sleek, yet have the desired structural strength, which contribute to improvement in supply chain efficiencies.

Further, in some embodiments, the one or more precast decks 204 are prestressed at the off-site location. In some embodiments, the one or more precast decks 204 are prestressed, for example, on a 300 to 400 feet prestressing line. Such precast prestressed decks 204, as shown in FIG. 2, have longer lifespans, require less maintenance, have reduced corrosion, have limited to no possibility of cracking, are thin, and provide other like benefits.

The precast prestressed decks 204 prevent lateral movement and undue settling of the entire floating foundation assembly 200, thereby preventing damage to the floating foundation assembly 200, and in turn, to the overlying structure. This arrangement has improved damping resistance, thereby generating stability for the structure affixed on the floating foundation assembly 200. Hence, the proposed floating foundation assembly 200 is durable, weatherproof, etc., and overcomes the concerns and problems of conventional foundation structures.

Although FIG. 2 depicts a single deck 204, it will be appreciated that any number of precast prestressed decks are able to be installed at the construction site based on structural requirements. It will also be appreciated that other configurations and scenarios are also possible for decks being installed at the construction site.

Referring to FIG. 2, in some embodiments, once the plurality of piers 202 have been installed on the ground surface, the one or more precast prestressed decks 204 constructed at the off-site location are transported to the construction site, and installed over the plurality of piers 202, thus forming the floating foundation assembly 200.

In some embodiments, the method of constructing the floating foundation assembly 200 is easy and fast as compared to conventional methods of construction. Preferably, the installation of the plurality of piers 202 is initiated and completed on day one of the construction project. On day two, the one or more precast prestressed decks 204 are transported to the construction site and installed on top of the plurality of piers 202 with complete connections and grouting, thus, making the floating foundation assembly 200 ready for affixing the building structure above the floating foundation assembly 200. Finally, on day three, the building structure including non-exhaustive elements such as, but not limited to, bolts, walls, bar anchors, and the like, are affixed on top of the floating foundation assembly 200.

FIG. 2 merely exhibits a non-limiting example architecture of a floating foundation assembly 200 in accordance with some embodiments. However, any number of piers and precast prestressed decks are able to be included to implement the embodiments. Other configurations and scenarios are also possible for implementing the embodiments presented herein. For example, in different embodiments, a construction project will take fewer than 3 days or more than three days.

FIG. 3 illustrates an architecture of a superstructure 300 in accordance with some embodiments. In accordance with these embodiments, the architecture 300 includes a plurality of piers 302, one or more precast prestressed decks 304, and walls 306. In some embodiments, the plurality of piers 302 are functionally equivalent to the plurality of piers 102 of FIG. 1 and/or the plurality of piers 202 of FIG. 2, and the one or more precast prestressed deck 304 are functionally equivalent to the one or more precast prestressed decks 204 of FIG. 2.

Referring to FIG. 3, in some embodiments, once the floating foundation assembly, such as the floating foundation assembly 200 of FIG. 2, has been erected, the walls 306 are installed or loaded over the floating foundation assembly to form the superstructure 300. Preferably, the walls 306 are installed on the one or more precast prestressed decks 304. As described above, the entire process of construction of the superstructure 300 including the floating foundation assembly (i.e., the plurality of piers 302 and one or more precast prestressed decks 304) is easy and quick. As soon as the plurality of piers 302 are installed on a ground surface, the one or more precast prestressed decks 304, which are manufactured at an off-site location, are transported to the construction site, and loaded over the plurality of piers 302 to form the floating foundation assembly. This makes the floating foundation assembly ready for affixing the structure, and specifically, the walls 306 on top of it. Thereafter, the walls 306 are installed over the one or more precast prestressed decks 304 to form the superstructure 300. Later, other building components, such as a trusses, roofs, doors and the like are able to be added.

Advantageously, construction of the superstructure 300 is rapid, with the desired structural integrity and strength. This configuration limits the transmission of pre-compression forces across joints between the one or more precast prestressed decks 304 and the walls 306, thereby improving the durability of the superstructure 300, and especially that of the floating foundation assembly. Further, as described above, this process of construction provides stability for the superstructure 300, makes it durable, weatherproof, does not need special attention for preparation of soil or ground, among other such advantages mentioned in detail above.

Although a particular structure has been depicted in FIG. 3, it will be apparent to a person skilled in the art that any type of structure is able to be constructed using the proposed floating foundation assembly. It will be appreciated that other configurations and shapes are also possible for implementing the embodiments presented herein.

FIGS. 4 and 5 illustrate the steps of methods of constructing a floating foundation assembly for a structure in accordance with some embodiments. In some embodiments, the floating foundation assembly described herein is functionally equivalent to the floating foundation assembly 200 of FIG. 2. Other elements, such as the plurality of piers, one or more precast prestressed decks, walls, and structure described herein are functionally equivalent to respective plurality of piers 102, 202, 302 of FIGS. 1, 2, and 3, one or more precast prestressed decks 204, 304 of FIGS. 2 and 3, the walls 306 of FIG. 3, and the structure 300 of FIG. 3. FIGS. 4 and 5 are described in conjunction with the elements in FIGS. 1-3.

FIG. 4 shows the steps of a method 400 of determining the number, locations, types, and depths of piers in soil for supporting a foundation and overlying structure (for simplicity, referred to collectively as “structure”) in accordance with some embodiments of the invention. After a start step 401, in step 405 the structure is divided into sections each having substantially the same weight to be supported, thereby determining a load distribution of the structure. For example, a first section supporting a stone wall will be smaller in area than a second section supporting open floor space. Next, in step 410, characteristics of soil (e.g., type of soil, contour of the soil, such as sloped or flat) underlying each section is determined. For example, the first section of the structure overlies rocky soil on flat ground, and the second section overlies sandy soil on a slope. Next, in step 415, for each section, based on the size and shape of the section, and the characteristics of the underlying soil, the number, locations, depths, and types of the piers are determined. For example, if the first section has a small area (e.g., 5 feet×5 feet) that overlies the rocky soil, a single steel pier at the center of the section at a depth of four feet is sufficient to support the first section on the ground. If the second section is a larger area (e.g., 30 feet×10 feet) overlying the sloped, sandy soil, multiple concrete piers located at the vertexes of the section (e.g., vertexes of a rectangle) at a depth of 20 feet are sufficient to support the structure on the ground. In some embodiments, local historical weather conditions are considered in determining the location, depths, and types of the piers, such as when the structure is located in a wet environment, a windy environment, or a cold environment. As some examples steel piers are suitable for wet, windy environments, and concrete piers are suitable for hot, dry environments. In step 415, the numbers, types, locations, and depths of each pier, or any combination these, are collected. Next, in step 420, the method ends.

After reading this disclosure, those skilled in the art will recognize other methods of determining the number, locations, depths, and types of the piers. As one other example, the piers are uniformly distributed under the structure (e.g., under the structure's footprint), at substantially the same depth, sufficient to support the heaviest overlying section, at uniform distances between adjacent ones. It will also be appreciated that in other embodiments, different information about the piers are generated. For example, in some embodiments, the types of the piers are not determined. In other embodiments, historical weather is not considered. In still other embodiments, the locations of the piers are determined so as to provide at least a minimum measure of stability for each section using the fewest number of piers.

Referring to FIG. 5, in step 501, a method of arranging piers in accordance with some embodiments starts. In some embodiments, step 501 includes the method 400. Next, in step 502, a plurality of piers is arranged at predetermined distances from each other and at predetermined depths into the ground surface. In some embodiments, the predetermined distances between the plurality of piers and the predetermined depths that the piers are inserted into the ground are based on structural requirements such as, but not limited to, to spreading the load of a structure that rests on top of them and a type of the underlying soil, to name only a few examples. In some embodiments, the step 502 also includes screwing the plurality of piers into the ground surface, such as at predetermined depths. In some embodiments, the number, locations, and depths of the piers in the grounds are based on parameters described herein, such as, but not limited to, the size, shape, and load of the structure, the type of underlying soil, to name only a few possible parameters. Preferably, the plurality of piers is screwed, inserted, or otherwise fastened into the ground surface until a desirable load capacity for the overlying structure is achieved. In some embodiments, the number of piers arranged on the ground surface is based on structural requirements. Preferably, each of the plurality of piers includes steel. In some embodiments, each pier of the plurality of piers is a helical pier. It will be appreciated that other configurations and shapes are possible for arranging the plurality of piers in the ground surface.

Still referring to FIG. 5, following step 502, in step 504, one or more precast prestressed decks are installed adjacent to each other, transversely to and on top of the plurality of piers, thereby forming a substantially planar floor. In some embodiments, the one or more precast prestressed decks fit into or align on top of the plurality of piers using at least a threaded bar and nut. In some embodiments, a shear key is added to the one or more precast prestressed decks to resist vertical movement of the decks. In some embodiments, the one or more decks are precast and prestressed at an off-site location under a controlled environment. The one or more decks are preferably made of green concrete, which is light weight. In some embodiments, the one or more decks are prestressed on a 300 to 400 feet prestressing line to make them more durable, though prestressing lines of other lengths are also contemplated. Preferably, once the one or more decks are precast and prestressed at the off-site location and the plurality of piers are installed at the construction site, the one or more decks are transported to the construction site and mounted securely on top of the plurality of piers. In some embodiments, the number of precast prestressed decks required for the floating foundation assembly is based on structural requirements. In some embodiments, the precast prestressed decks are joined substantially adjacent to each other, transversely to and attached to the plurality of piers through at least one of precast curved connectors, a plurality of box connectors, and a plurality of iron bars. Preferably, the precast prestressed decks thus span the area outlines by the piers.

In some embodiments, after step 504, in step 506, the one or more precast prestressed decks are coupled to the plurality of piers through at least one of precast curved connectors, a plurality of box connectors, a plurality of iron bars, and the like, to form the floating foundation assembly. In some embodiments, the construction of the floating foundation assembly is quick and easy as compared to conventional methods. A person of ordinary skill in the art will understand that other configurations and shapes/scenarios are also possible for installing the one or more precast prestressed decks at the construction site.

Still referring to FIG. 5, after step 506, in step 508, walls are erected/installed on the one or more precast prestressed decks to form the structure.

It will be appreciated that the steps of the methods 400 and 500 are merely illustrative. In different embodiments, other steps are added, some of the steps are deleted, steps are performed in different orders, or any combination of these occur, to name only a few examples of different embodiments. In different embodiments, the steps are manual, semi-automated, or completely automated.

In some embodiments, a system for performing the steps of the methods 400, 500, or both is automated. Preferably, the system includes a computer having a processor, a memory storing computer-executable instructions that when executed by the processor perform one or more of the steps of methods 400 and 500.

With reference to the aspects disclosed in FIGS. 1-5, in some embodiments, various joining methodologies and/or technologies (in an example, precast curved connectors, etc.) are used to join sub-modules/sub-units of individual building blocks or to join one building block with another. For example, joining methodologies and/or technologies are used to build modular building blocks that when assembled make a building envelope/enclosure structurally and environmentally seamless. In another example, interconnection methodologies are used between: foundation and wall of a construction project; wall and wall of a construction project; wall to wall with floor level slab of a construction project, wall and roof truss of a construction project; and roof truss and roof truss of a construction project. In yet another example, interconnection technologies are used that speed up the assembly process and reduce the need for skilled labor. In yet another example, interconnection technologies are used that allow a high degree of module completion in the factory or at an off-site location. In yet another example, digitization of modular building blocks enables repeatability with higher quality levels than traditional methodologies.

The terms “comprising,” “including,” and “having,” as used in the specification herein, shall be considered as indicating an open group that may include other elements not specified. The terms “a,” “an,” and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. The term “one” or “single” may be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as “two,” may be used when a specific number of things is intended. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition, or step being referred to is an optional (not required) feature of the disclosure. The term “connecting” includes connecting, either directly or indirectly, and “coupling,” including through intermediate elements.

The disclosure has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the disclosure. It will be apparent to one of ordinary skill in the art that methods, devices, device elements, materials, procedures, and techniques other than those specifically described herein may be applied to the practice of the disclosure as broadly disclosed herein without resort to undue experimentation. All art-known functional equivalents of methods, devices, device elements, materials, procedures, and techniques described herein are intended to be encompassed by this disclosure. Whenever a range is disclosed, all subranges and individual values are intended to be encompassed. This disclosure is not to be limited by the embodiments disclosed, including any shown in the drawings or exemplified in the specification, which are given by way of example and not of limitation. Additionally, it should be understood that the various embodiments of the building blocks described herein contain optional features that may be individually or together applied to any other embodiment shown or contemplated here to be mixed and matched with the features of that building block.

While the disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the spirit and scope of the disclosure as disclosed herein.

Claims

1. A floating foundation assembly, comprising:

a plurality of piers arranged at predetermined distances from each other in a ground surface; and

one or more precast prestressed decks, arranged transversely across tops of the plurality of piers, configured for affixing a structure on top of the one or more precast prestressed decks.

2. The floating foundation assembly of claim 1, wherein the plurality of piers are screwed at predetermined depths in the ground surface.

3. The floating foundation assembly of claim 2, wherein the predetermined distances and the predetermined depths are based on at least one of a size of the structure, a shape of the structure, a load of the structure, and one or more characteristics of soil underlying sections of the structure.

4. The floating foundation assembly of claim 1, wherein the one or more decks are precast and prestressed in an environment at a location different from a location of the plurality of piers, and wherein the one or more precast prestressed decks are transported to the location of the plurality of piers once the plurality of piers is arranged at the predetermined distance from each other in the ground surface.

5. The floating foundation assembly of claim 1, wherein the one or more precast decks are prestressed on a 300 to 400 feet prestressing line prior to their arrangement across the tops of the plurality of piers.

6. The floating foundation assembly of claim 1, wherein the one or more precast prestressed decks are spaced apart to spread a load of the structure in a predetermined manner over the piers.

7. The floating foundation assembly of claim 1, wherein the plurality of piers comprise helical steel screw piers.

8. The floating foundation assembly of claim 1, wherein the one or more precast prestressed decks comprise green concrete.

9. The floating foundation assembly of claim 1, wherein the one or more precast prestressed decks comprise a ribbed deck, a waffle deck, or both.

10. A method for manufacturing a foundation assembly, the method comprising:

arranging a plurality of piers at predetermined distances from each other in a ground surface; and

installing one or more precast prestressed decks, transversely across tops of the plurality of piers, for affixing a structure on top of the one or more precast prestressed decks.

11. The method of claim 10, wherein arranging the plurality of piers comprises screwing the plurality of piers at predetermined depths in the ground surface.

12. The method of claim 11, wherein the predetermined depths and the predetermined distances at which the plurality of piers are screwed in the ground surface are based on at least one of a size of the structure, a shape of the structure, a distributed load of the structure, characteristics of the underlying soil, and local historical weather conditions.

13. The method of claim 10, further comprising:

prestressing the one or more precast prestressed decks at a location different from a location of the plurality of piers; and

transporting the one or more precast prestressed decks to the location of the plurality of piers.

14. The method of claim 13, wherein prestressing the one or more precast prestressed decks occurs prior to installing the one or more precast prestressed decks on top of the plurality of piers.

15. The method of claim 10, further comprising prestressing the one or more precast prestressed decks on a 300 to 400 feet prestressing line.

16. The method of claim 10, further comprising:

coupling the one or more precast prestressed decks to the plurality of piers; and

loading walls of the structure on the installed one or more precast prestressed decks.

17. The method of claim 10, wherein the one or more precast prestressed decks are configured to evenly spread loads of the structure across the piers.

18. The method of claim 10, wherein the plurality of piers comprise helical steel screw piers.

19. The method of claim 10, wherein the one or more precast prestressed decks comprise green concrete.

20. The method of claim 10, wherein the one or more precast prestressed decks comprise a ribbed deck, a waffle deck, or both.

21. A method of determining locations and depths of piers for supporting a foundation, the method comprising:

determining load distributions for a structure across an area supporting the structure;

based on the load distributions and soil characteristics across the area, determining locations and corresponding depths of the piers to support the structure;

inserting the piers into the soil at the locations to the corresponding depths; and

coupling precast, prestressed decks to the piers, thereby forming a floor of a foundation.

22. The method of claim 21, wherein the soil characteristics comprise the load-bearing properties of the soil.

23. The method of claim 22, wherein the soil characteristics correspond to types of the soil, a slope of the soil, or any combination thereof.