Modular, Transportable Foundation Systems and Methods of Making and Using Same

Abstract

A system for lifting and moving a pre-tensioned concrete a foundation system comprising a pair of bridles secured to ends of the foundation, at least one lifting tendon spanning the underneath the foundation between the bridles and lifting arms attached to the bridles and tendon to apply a compressive clamping force to the foundation while lifting the foundation.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit of and priority to the following U.S. Provisional Application No. 63/649,807, filed on May 20, 2024, and to U.S. Provisional Application No. 63/673,140, filed on Jul. 18, 2024. The entire contents of each are incorporated herein for all purposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO APPENDIX

Not applicable.

BACKGROUND OF THE INVENTION

Field of the Invention. The inventions disclosed and taught herein relate generally to pre-cast concrete foundation systems and methods for lifting and transporting same.

Description of the Related Art. U.S. Pat. No. 3,834,111 entitled “Method For Transporting Building Modules” discloses “A building module transporter for connection to a towing vehicle comprising a building module and module carriers attached to end walls of the module and resting on carrier supports. The carriers are firmly secured to the module at vertically spaced points to suspend the module between them and to permit the raising and lowering of the suspended module by pivoting the carriers about horizontal axes with respect to the supports. Means is provided for moving the module with respect to the carriers in a lateral direction to facilitate the precision alignment of the module with a foundation at the building site. The spaced connection points between the module and the carriers tension a lower portion of the suspended building and place an upper portion thereof in compression.”

U.S. Pat. No. 4,200,305 entitled “Trailer assembly for carrying overwidth loads” discloses “A trailer assembly for carrying overwidth loads such as large rectangular concrete slabs. The trailer includes two separate units, a front unit and a rear unit. Each unit includes a frame mounted on a set of tandem wheels. The front unit has upper and lower frames rotatably connected together, allowing the wheels to turn with respect to the upper frame. A tongue is hingedly connected to the front unit. It has a hitch for connection to the towing vehicle and a compression device to apply weight to the hitch for compressive connection with the towing vehicle. Longitudinal cross members are mounted across the front and rear units to support the load. The cross members can be removed and stored parallel to the length of the units for legal width return trip towing. On return trip, the rear unit is towed reverse to the direction towed while loaded. Also disclosed is an embodiment employing two units the same or similar to the front unit to enable being moved laterally to facilitate parking in close space.”

U.S. Pat. No. 7,112,029 entitled “Carrier Apparatus and Method” discloses “A carrier apparatus and method includes a pair of oppositely positioned carriers. At least one pair of steerable wheels is connected to at least one of the oppositely positioned carriers. A movable neck is connected to each of the oppositely positioned carriers and by compressive engagement to an object to be carried such that neither the movable neck, nor the pairs of steerable wheels, nor the pair of oppositely positioned carriers are underneath the object.”

U.S. Pat. No. 10,155,467 entitled “Systems And Methods For Transporting A Structure” discloses “A system and method for lifting and moving a structure comprises at least two bolster assemblies configured to engage substantially opposing ends of the structure, a plurality of tensioned components extending between the bolster assemblies, applying a compressive force to clamp the bolster assemblies to the structure, and applying a lifting force to the bolster assemblies to lift the structure.”

U.S. Pat. No. 11,313,125 entitled “Mobile modular foundation systems and methods for transporting same” discloses “A modular foundation system comprises a concrete reinforced matrix having embedded pre-tensioned components and a recessed tension bolster region adjacent the lower surface of the foundation at each end, and a pair of lifting safety bars partially embedded in the foundation within the recess and terminating at the end of the foundation.”

U.S. Pat. No. 11,891,807 entitled “Mobile modular foundation systems and methods for transporting same” discloses “A modular foundation system comprises a concrete reinforced matrix having embedded pre-tensioned components and a recessed tension bolster region adjacent the lower surface of the foundation at each end, and a pair of lifting safety bars partially embedded in the foundation within the recess and terminating at the end of the foundation.”

The present inventions are directed to pre-cast concrete foundation systems, methods of manufacturing pre-cast concrete foundation systems, and lifting and transporting pre-cast concrete foundation systems.

BRIEF SUMMARY OF THE INVENTION

A brief summary of the inventions indicating their nature and substance may be understood from the subject matter encompassed in the claims filed with this application, which are incorporated into this brief summary by reference for all purposes, and by the inventions encompassed in any claims that may be issued from this application, which claims also are incorporated into this brief summary by reference for all purposes.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following figures annotations form part of the present specification and are included to demonstrate further certain aspects of the present invention. The invention may be better understood by reference to one or more of these figures in combination with the detailed description of specific embodiments presented herein.

FIG. 1 illustrates one example of a transportable, pre-cast, reinforced foundation system according to one or more of the inventions disclosed and enabled herein.

FIGS. 2A and 2B illustrate an example of a foundation casting table suitable for casting transportable, pre-cast, reinforced foundation systems according to the inventions disclosed and enabled herein.

FIG. 3 illustrates an example of a foundation reinforcement assembly for a transportable, pre-cast, reinforced foundation system according to the inventions disclosed and enabled herein.

FIGS. 4A illustrates an end view of a foundation reinforcement assembly, including floor and perimeter beam reinforcements, for a transportable, pre-cast, reinforced foundation system according to the inventions disclosed and enabled herein.

FIG. 4B illustrates a close-up view of the left corner of FIG. 4A.

FIG. 5 illustrates a floor manufacturing step for a transportable, pre-cast, reinforced foundation system according to the inventions disclosed and enabled herein.

FIGS. 6A, 6B, and 6C illustrate an inner mold system for casting perimeter beams of a transportable, pre-cast, reinforced foundation system.

FIGS. 7A, 7B, 7C, and 7D illustrate an alternate inner mold system for casting perimeter beams of a transportable, pre-cast, reinforced foundation system.

FIGS. 8A and 8B illustrate a method of removing a transportable, pre-cast, reinforced foundation system according to the inventions disclosed and enabled herein from the mold and rotating the foundation system to a floor-up condition.

FIG. 9 illustrates a transportable, pre-cast, reinforced foundation system according to the inventions disclosed and enabled herein in a floor-up condition.

FIG. 10 illustrates in exploded view transportable, pre-cast, reinforced foundation system according to the inventions disclosed and enabled herein.

FIGS. 11A-11D illustrate various views of the complete system of FIG. 10.

FIGS. 12A-12C illustrate a preferred bridle for the foundation systems disclosed and enabled herein.

FIG. 13 illustrates a gooseneck adapter for use with the bridle illustrated in FIGS. 12A-12C.

FIG. 14 illustrates a pair of lift tendons for use with foundation systems disclosed and enabled herein.

FIGS. 15A-15E illustrate a method of connecting the systems illustrated in FIG. 10.

FIG. 16 shows the bridle of FIG. 12A-12C connected to a foundation system and gooseneck.

FIG. 17A illustrates a lift height lock system.

FIG. 17B illustrate a transporter suitable for use with foundation systems disclosed and enabled herein.

FIGS. 18A-18B illustrate another form of bridle for foundation systems disclosed and enabled herein.

FIGS. 19A-19C illustrate yet another form of bridle for foundation systems disclosed and enabled herein.

FIGS. 20A and 20B illustrate gooseneck attachment methods for the bridles of FIGS. 18A-19C.

FIGS. 21A-21C illustrate various aspects of transporting foundation systems disclosed and enabled herein.

While the inventions disclosed and enabled herein are susceptible to various modifications and alternative forms, only a few specific embodiments will described by way of example in the drawings and described in detail below. The figures and detailed descriptions of these embodiments are not intended to limit the breadth or scope of the inventive concepts or the appended claims in any manner. Rather, the figures and detailed written descriptions are provided to illustrate the inventive concepts to a person of ordinary skill in the art and to enable such person to make and use all of the inventive concepts without undue experimentation.

DETAILED DESCRIPTION

The Figures described above, and the written description of specific structures and functions below are not presented to limit the scope of what we have invented or the scope of the appended claims. Rather, the Figures and written description are provided to teach any person skilled in the art to make and use the inventions for which patent protection is sought. Those skilled in the art will appreciate that not all features of a commercial embodiment of the inventions are described or shown for the sake of clarity and understanding. Persons of skill in this art will also appreciate that the development of an actual commercial embodiment incorporating aspects of the present inventions will require numerous implementation-specific decisions to achieve the developer's ultimate goal for the commercial embodiment. Such implementation-specific decisions may include, and likely are not limited to, compliance with system-related, business-related, government-related, and other constraints, which may vary by specific implementation, location and from time to time. While a developer's efforts might be complex and time-consuming in an absolute sense, such efforts would be, nevertheless, a routine undertaking for those of skill in this art having benefit of this disclosure. It must be understood that the inventions disclosed and taught herein are susceptible to numerous and various modifications and alternative forms.

Reference throughout this disclosure to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment under discussion is included in at least one of the many possible embodiments of the present inventions. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.

Furthermore, the described features, structures, or characteristics of one embodiment may be combined in any suitable manner in one or more other embodiments. In the following description, numerous specific details are provided, such as examples of programming, software modules, user selections, network transactions, database queries, database structures, hardware modules, hardware circuits, hardware chips, etc., to provide a thorough understanding of embodiments of the disclosure. Those of skill in the art having the benefit of this disclosure will understand that the inventions may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the disclosure. The use of a singular term, such as, but not limited to, “a,” is not intended as limiting of the number of items. Also, the use of relational terms, such as, but not limited to, “top,” “bottom,” “left,” “right,” “upper,” “lower,” “down,” “up,” “side,” and the like are used in the written description for clarity in specific reference to the Figures and are not intended to limit the scope of the invention or the appended claims.

The description of elements in each Figure may refer to elements of proceeding Figures. Like numbers refer to like elements in all figures, including alternate embodiments of like elements. In some possible embodiments, the functions/actions/structures noted in the figures may occur out of the order noted in block diagrams and/or operational illustrations. For example, two operations shown as occurring in succession, in fact, may be executed substantially concurrently or the operations may be executed in the reverse order, depending upon the functionality/acts/structure involved.

To begin, the detailed background and history of my inventions disclosed herein are set forth in my related patents, U.S. Pat. No. 7,112,029, entitled Carrier Apparatus and Method,” U.S. Pat. No. 10,155,467, entitled Systems and Methods for Transporting a Structure” and U.S. Pat. No. 11,313, 125 entitled “Mobile modular foundation systems and methods for transporting same.” As allowed by 37 CFR 1.57, the entire contents, including description, figures, and claims, of each related patent are incorporated herein by reference for all purposes as if fully reprinted herein.

In general, the inventions disclosed herein for which protection is sought comprise transportable, pre-cast, reinforced foundation systems, and systems and methods for casting or forming transportable, pre-cast, reinforced foundation systems; and systems and methods for lifting and transporting transportable, pre-cast, reinforced foundation systems. Transportable, pre-cast, reinforced foundation systems according to the inventions disclosed and enabled herein are typically, but not exclusively, formed from a high strength concrete matrix with embedded stressed and unstressed reinforcing materials, such as structural steel bar (e.g., rebar), tube, channel, wire mesh, and/or wire cable.

The inventions disclosed and enabled herein allow a foundation system, with or without a structure or building thereon, to be repeatedly lifted, and to be transported over conventional roadways without a fully supporting trailer and without causing failure or damage, such as tension failure, of the foundation. It is well understood that concrete or cement-based foundations have superior compressive strength and poorer tensile strength. For example, lifting a conventional concrete-based slab or foundation (even with reinforcement) from the longitudinal ends likely will result in a transverse tension fracture. The inventions described and enabled herein allow a pre-cast foundation system to be manufactured and then repeatedly lifted and/or transported without compromising the structural integrity of the foundation system.

Turning now to FIG. 1, a fully formed, transportable, pre-cast, reinforced foundation system with bridles 106a, 106b attached to the longitudinal ends is illustrated. The foundation system 100 comprises a floor surface 102 that is relatively flat as described herein, and a perimeter beam system of which side beam 104 is shown. The foundation system 100 may utilize a plurality of sleeved openings or “leave outs” spaced along the perimeter beam system as described herein. Coupled to each longitudinal end of the foundation system 100 are bridles 106a and 106b. As described herein, a bridle and tendon system allow a compressive force to be applied between longitudinal ends of the foundation system 100, such as adjacent and across the longitudinal ends of the floor 102. Bridle and tendon systems may be used to lift and move the foundation system around a plant as structures are erected on the foundation system, to transport the foundation system 100 on roadways without need for a trailer, and/or to transport a completed structure/foundation system assembly over roadways without need for a trailer.

FIG. 2A illustrates an overhead view of one of many possible embodiments of a foundation system casting table 200 suitable for creating the foundation systems disclosed herein, such as foundation system 100. The casting table 200 may comprise a floor forming surface 202, such as, but not limited to, steel sheets welded together and finished to create a smooth floor casting surface. In a preferred embodiment, a foundation system is cast floor-side down such that the floor surface of the foundation system contacts the floor forming surface 202 during the floor casting process. One of the many benefits of casting the foundation system floor-side down is that the finished floor is relatively flat with little to no longitudinal or transverse camber. By relatively flat, we mean no more than 0.15% variation in flatness along the length and/or width of the floor surface. In other words, and for example, for a 32′ long foundation system, no more than about a ½″ variation between the highest and lowest points on the floor surface.

It is preferred that the floor forming surface 202 be finished so the as-cast floor surface of concrete-based foundation system, such as floor 102, will have a Concrete Surface Profile of CSP 3 or less. Also, a concreter release agreement may be used on the floor forming surface and/or all mold surfaces, as desired.

As illustrated in FIG. 2A, the floor forming surface 202 may be surround along its perimeters by a tensioning frame 204 that is structurally sufficient to permit tensioning or pre-stressing of reinforcements, such as wire cable. For example, if ½ inch diameter wire cable is used as a pre-stressed reinforcement for the foundation system, the tensioning frame 204 should be able to react the tensioning loads (e.g., 500 lbf to 1,000 lbf) placed on each wire cable. It is preferred that the floor forming surface area defined by the tensioning frame 204 be large enough to cast foundation systems of various desired sizes, such as, for example, and not limitation, 12 feet by 24 feet or 12 feet by 32 feet. It being understood that the inventions herein are not limited to foundations systems of specific dimensions. It is preferred, but not required, that the tensioning frame 204 be comprised of multiple individual sections that are removably fastened, such as bolted, together and to the floor forming surface 202, such as along edges thereof.

FIG. 2A also illustrates mold side surfaces 206 and mold end surfaces 208 connected or coupled to define the shape of the desired foundation system, for example, a 12×32 foundation system. As illustrated, the overall casting table 200 is larger than the desired foundation system. This size difference has many advantages including forming a walkway or workspace 210 outside of the outer mold 206, 208. The height of the tensioning frame 204 and mold surfaces 206, 208 from the floor forming surface 202 will be dictated by the desired thickness of the floor and any floor beams for the specific foundation system under construction. For example, for a preferred rectangular foundation system of size 12′×32′ having a 4-½ inch floor height and 8-inch perimeter beam heights, creating a 12-½″ tall foundation system, the height of the tensioning frame 204 and mold surfaces 206, 208 are preferably greater than 12-½ inches.

Unlike the tensioning frame 204, it is preferred that the mold surfaces 206 and 208 not be bolted to the floor forming surface 202 so as not cause damage or irregularities in the floor casting surface. Rather, releasable magnetic clamping systems (not shown) may be used to hold the mold components in place. Alternately, and because the molds typically do not react movement-inducing loads, the mold components may simply rest on the floor forming surface 202 allowing gravity and friction to hold the molds in place. It is preferred that the floor surface have chamfered edges, rather than sharp edges, and it is preferred that this chamfer be built into the mold surfaces 206 and 208. Alternately, the edge chamfer may be machined into the foundation system such as by grinding.

FIG. 2B illustrates an end view of the casting table 200 showing that the floor forming surface 202 is preferably raised above the ground surface 212 and provided with supports 214 sufficient to reduce or prevent deflection of the floor forming surface 202 during casting. FIG. 2B illustrates a vibration system 220 comprising rails 222 coupled to the underside 224 of the floor forming surface 202, and a vibratory head 226 movably coupled to the rails 222. The vibratory head 226 and rails 222 are structured and coupled to transmit vibrations to the floor forming surface 202. For example, the vibratory head 226 may generate vibrations, such as by an eccentric rotating weight(s) 228, which vibrations are transmitted to the floor forming surface 202 through at least the rails 222. The vibrator head 226 may also and preferably does travel along the rails 222 for at least the length of the mold. The motive force for moving the vibratory head 226 along the rails 222 can be inherent in the vibratory head 226 or a motive force can be manually applied such as by cable system. As will be described below, the vibration system 220 may be used to provide vibratory energy or vibrations to the casting process to benefit the quality of the resulting foundation system.

FIG. 3 illustrates a foundation system reinforcement assembly comprising a first layer of wire mesh and one or more layers of rebar 304 for the floor portion of the foundation system. The reinforcement assembly of FIG. 3 is for a foundation system having a perimeter beam system. Thus, the assembly also comprises rebar 304 forming a skeleton 306 for the perimeter beams. Additionally, each corner of the foundation system may comprise additional rebar to provide additional strength for corner loads. In preferred embodiments, each floor surface will include an exposed metal plate (see, e.g., FIG. 9) for connections of structural building components in later phases of construction. In the embodiment illustrated in FIG. 3 the reinforcement assembly 300 is not pre-stressed but is tied or coupled together to form the assembly 300. For foundation systems that use pre-tensioned cables in the floor, the wire mesh may be suspended from the tensioned cables and the reinforcement assembly placed on top of the tensioned cables, or both the wire mesh and reinforcement assembly may be placed on and supported by the tensioned cables.

FIG. 4A illustrates an end view of the reinforcement assembly 300 showing reinforcements 304 and sleeves 402 to create apertures or leave outs in the foundation system. Sleeves 402 may comprise any material or shape, such as circular or rectangular, and preferably are made from lengths of polyvinylchloride (PVC) schedule 40 pipe. In a preferred embodiment, the sleeves comprise 2″ schedule 40 PVC pipe that are located in at least the end beams and preferably in both the end beams and side beams of the foundation system. FIG. 4 illustrates a close-up view of left corner of assembly 300 showing placement of tensioned wire cable. As mentioned previously, it is preferred that a plurality of tensioned wire cables be placed longitudinally in the floor portion at, for example, every 2 feet on center. High strength wire cable of ½″ diameter has been found suitable, but other types and sizes of tensioned reinforcement are contemplated.

FIG. 5 illustrates an overhead view of the casting table 200 in which the reinforcement assembly 300 has been placed within the mold defined by the mold walls 206 and 208. Multiple strands of 1/2 inch steel wire cable 502, 504 are shown strung longitudinally across the width of the mold The cables 504 are placed within the floor thickness (e.g., 4-½″ floor thickness) whereas cables 502 can be placed in the floor and/or in the longitudinal perimeter beams. The floor cables 504 are not shown in the inner area of the mold as the floor has been cast and the floor portion of the reinforcement assembly is covered in foundation material 506, such as 6-8 ksi high strength concrete. It will be appreciated that the wire cables 504 and 506 are tensioned against the tensioning frame 204 and the tension or load or stress is locked into the cables used load nuts, such as edge nuts, 508. The vibratory system 220, if supplied, may be activated, and preferably is used, to vibrate the floor portion of the concrete 506 into full and structural contact with the floor forming surface 202, the floor portion of the reinforcement assembly 300, and the tensioned floor cables 504.

Those of skill will appreciate that an inner mold may be constructed to facilitate the casting of the beams on the underside of the floor. FIGS. 6A, 6B, and 6C illustrate one type of inner mold system suitable for use with the foundation systems disclosed herein. Specifically, FIGS. 6A-6C illustrate a casting table 200 with side and end molds 206, 208 as well as corner inner mold section 602 and wall inner mold section 604. Each inner mold section is shown to comprise two or more hangers 606 that permit each inner mold section to be mounted to the side and end molds so the inner molds touch the poured or cast floor portion. In other words, the inner mold portions are spaced away from the floor forming surface 202 by an amount, such as the thickness of the floor.

FIGS. 7A-7D illustrate a presently preferred method and system for casting floor beams for our transportable, pre-stressed, reinforced foundation systems. FIG. 7A illustrates the tensioning frame 204 and the side and end molds 206, 208 of the casting table 200. Within the mold is shown perimeter beam reinforcement assembly 306 as well as longitudinal pre-stressed cables 504 and 506. FIG. 7A also illustrates cast floor portion 506.

In this method of production, the walls of the inner mold are formed from blocks of rigid foam 702, such as extruded polystyrene foam, polyisocyanurate foam or expanded polyurethane foam, a bottom surface 704 of which directly contacts the cast or poured floor portion 506. In other words, the bottom surface 704 directly contacts concrete forming the underside of the floor portion. The side walls 706 of the blocks 702 define an inner surface of the perimeter beams. It is found that as the concrete cures and hardens, the rigid foam adheres to the concrete. Thus, unlike the mold system of FIGS. 6, the adhered rigid foam provides both a thermal and auditory insulation to the foundation system. Because of this benefit, it is preferred that the blocks 702 fully span the floor underside as illustrated in FIGS. 7A-8B.

FIG. 7B illustrates that the blocks may be formed in several discrete sections for ease of handling and sections may be formed of smaller portions joined together. FIGS. 7B and 7C also show how the block walls 706 defined the perimeter beams. Two PVC sleeves are shown in FIG. 7C placed with the end beam reinforcement to form apertures through the end beam. FIG. 7C also shows the use of commercial metal wall studs 710 to aid the lifting and placement of the blocks within the molds. FIG. 7D illustrates a found system under construction in which the floor has been cast or poured and the rigid foam blocks have been placed directly contacting the wet floor concrete, with the outer sides and ends of the rigid foam defining the side and end beams of the foundation system. Once the rigid foam is in place, the perimeter beams may be cast or poured. It is preferred that the perimeter beams be cast within about 30 minutes of casting the floor. It is contemplated, but not required the concrete used to cast the floor is not the same type or grade of concrete used to cast the beams. For example, the concrete used for the floor may be of higher strength than the concrete used for the beams.

It is contemplated that the rigid foam may be treated with pesticides or insecticides during extrusion or while the foundation is curing to resist pest and insect intrusion into any building or structure erected on a foundation system.

FIG. 8A illustrates a cured or hardened foundation system 800, but without the adherent rigid foam for clarity purposes. To remove the foundation system from the casting table, some or all of the mold components may be removed from the floor casting surface 202, such as by releasing the magnetic lock downs, so that lifting rings or lifting pipes can be inserted in at least two set of leaves outs 802 and 804. In this example of a 32′ long foundation system, the lifting points may be placed at about 6-8 feet from each end. The foundation system 800 can then be lifted from the casting table and rotated as shown in FIG. 8B to the floor-up condition shown in FIG. 9.

FIG. 9 illustrates a presently preferred embodiment of a foundation system utilizing inventions disclosed herein. The foundation system 900 shown is 12 about feet wide and is manufactured as described herein with the floor surface 802 cast upside down contacting a floor surface mold, such as mold surface 202. The foundation system 900 has a rebar and wire mesh reinforcement assembly and a plurality, such as 7, of ½ inch diameter wire cables 904 within the floor portion of the foundation system 900 and pre-tensioned to between about 500 and 750 lbf. After the foundation system has cured or hardened, the tensioned wire cables may be cut flush with the end beams 906 without releasing the tension. Additionally, each side beam 908 may comprise a plurality, such as 4, ½ inch diameter wire cables 910 positioned within the bottom ⅓ of the side beams, as shown. The wire cables 910 have been pre-tensioned to between about 500 and 750 lbf and also may be cut flush. Two sleeved, 2″ diameter apertures 912 are formed through each end beam 906 and four sleeved, 2″ diameter apertures 914 are formed through each side beam 908 as illustrated. Additional sleeved apertures may be provided as desired. FIG. 9 also shows the exposed and embedded metal plates 906 that are desirable for construction of building and other structures on the foundation system 900. Although only 4 plates at each corner are shown, additional plates may be embedded along the sides, ends, or other places on the floor as needed by the structures to be erected.

FIG. 9 also illustrates that the end perimeter beams 906 are not flush along the bottom but rather have an area or pocket of reduced height 916 to accommodate transport tendons (not shown), which will be discussed below. While the area of reduced height 916 is shown to span a majority of the width of the foundation system, it will be understood that individual pockets of reduce height may be formed to accommodate the one or more lift tendons that are used To form these pockets, it will be understood that as the perimeter beams 906 are being cast, one or more blocks of rigid foam may be placed in the end beam to create the desired pockets. These rigid foam blocks may be removed once the foundation system has hardened to allow access through the pockets 916 by the transport tendons. Foundation system 900 also shows embedded and exposed metal plates 918 that are useful when constructing structures or buildings on the foundation system, such as for welding or attaching posts or studs to the floor. While a metal plate 918 is shown in each corner, additional metal plates may be embedded along the perimeter beams or anywhere on the floor as may be required by the structure or building.

It will be appreciated that individual foundation systems may be connected together in modular fashion to form foundation systems of various combined sizes. Apertures in the end beams and/or side beams can be used to bolt or otherwise secure individual foundation systems together.

Now that methods of manufacturing a transportable, pre-cast, reinforced foundation system have been disclosed, we turn to methods and systems for lifting, transporting, and setting such foundation systems. FIG. 10 illustrates a foundation system, such as foundation system 800, shown in exploded relationship to a foundation system 800 comprising a bridle 1002, bridle pins, and bridle safety arms 1006, lifting tendons 1008, a bridle gooseneck 1010, and a wheeled bogie 1012. The combination of a the gooseneck and bogie are referred to as a transporter and, as discussed further herein, the transporters may be individually powered and steered. As explained herein, these systems cooperate to lift the foundation system 800, to transport the foundation system 800, including any structures built thereon, around a plant or on roadways, and to set the foundation system 800 on footings or other prepared structures.

FIG. 11A illustrates the foundation system 800 with an attached bridle system 1000, including lifting tendons 1008. As illustrated in FIG. 1, the bridle system 1000 may be attached to the foundation system 800, and remain with the foundation system 800 until removed, without the lifting tendons 1008. In FIG. 11A, the bridle systems 1000 as shown are operatively connected to the bridle gooseneck 1010 and the goosenecks operatively connected to the wheeled bogies 1012.

FIG. 11B shows the underside of the foundation system 800 in FIG. 11A and shows the lift tendons 1008 transiting the underside of the foundation system 800. As disclosed above, the lift tendons exit the ends of the foundation systems 800 through the pocket or pockets. The perimeter beam system is also seen in this view. The safety arms 1006 may be secured the side beams by connecting pins or bolts into apertures 1016 (FIG. 10) and fastening the pins or bolts to the inside surface of the side beams, as shown at 1102.

FIG. 11C shows the foundation system 800 in a lifted condition. As disclosed herein, to lift the foundation system 800, the hydraulic rams 1104 on the bridle goosenecks 1010 are extended, which causes a compressive force to be applied to the foundation system 800 between the ends and to cause the foundation system 800 to lift with increasing extension of the rams. While FIG. 11C illustrates hydraulic rams, it is contemplated that electrical linear motors, other types of electrical motors, and other force producing devices may be employed. FIG. 11D shows an overhead view of the systems in FIGS. 11A-C

FIGS. 12A and 12B illustrate a front and rear view of a preferred embodiment of a bridle 1200. The bridle 1200 is fabricated, such as by welding, from preferably structural steel. The bridle 1200 may be shaped in the form of an elongated box and preferably has an end-to-end length that effectively matches the width of the foundation system to which it will be attached. For example, for a 12 feet wide foundation system, the bridle 1200 preferably would have an end-to-end length of 12 feet as well. The bridle 1200 also has a height “H” that effectively matches the height of the foundation system. For example, for a foundation system having a height (bottom of side beam to top of floor) of 20 inches, the preferred height of the bridle 1200 is also twenty inches. The bridle may comprise ISO shipping container corners 1202, which may be useful in securing a foundation system to a conventional trailer bed or shipping container trailer.

FIG. 12A shows the outer face 1204 of the bridle 1200 whereas FIG. 12B shows the inner face 1206 that contacts the end of the foundation system. As shown in bridle embodiment of FIG. 14A, the inner face 1206 preferably has a compression pad, which may be adhered thereto, to protect the end of the foundation system during lifting and transporting. The inner face 1206 also comprise two sleeves 1208 that are sized and located to engage with the sleeved apertures shown in FIG. 9 (912) and FIG. 10 (1014). A pin, nut or other retainer mechanism may be used to secure the bridle 1200 to the end of the foundation system, as illustrated in FIG. 14D. The connection between the bridle 1200 and the foundation system does not have to be tight, but it may be. In other words, it is acceptable for the pin and retainer to simply hold the bridle 1200 in place against the end beam face.

The bridle 1200 also comprises a pair of gooseneck adapter guides 1210 that are open through the bridle thickness and have encasing walls 1212, as shown. The adapter guides 1210 each have a vertical pin guide 1214 open from the top of the bridle 1200 through the adapter guide 1210 and open on the bottom of the bridle 1200. Pin guide locks 1216 may be located on the top surface of the bridle to lock the pin that traverses the pin guide 1210 to the bridle. This preferred bridle 1200 also comprises a pair of cable anchors 1218 each having a plurality of slots, such as 2 or 3, that are open at their bottoms. When a pair of bridles are attached the end surfaces of the foundation system, wire cable, such as ½ high strength wire cable can be run longitudinally underneath the foundation system between each cable anchor. Each cable can be tensioned, such as to 500 lbf to 1,000 lbf and fasteners, such as a releasable wedge lock may be used to retain the tension and forcibly engage the bridles 1200 to the foundation system. FIG. 12C shows a cable anchor 1218 having 3 tensioned cables 1220a, 1220b, and 1220c locked in place with releasable wedge locks 1222.

FIG. 13 illustrates a gooseneck 1010 adapter 1300 for use the bridle of FIGS. 12A-12C.

The adapter 1300 comprises a guide interface 1302 sized and shaped to mate with the adapter guide 1210 formed in each bridle 1200. The interface 1302 has a vertical opening 1304 that is preferably sleeved 1306. The interface emanates from a bridle plate 1308 having an exterior surface that contacts the outer surface 1204 of the bridle 1200 and supplies compressive loads to the bridle 1200. The side of the plate 1308 opposite the guide interface 1302 has a plurality of elongated flanges 1310. Two such flanges are illustrated in FIG. 13. An upper portion of the flanges is structurally configured as a hanger component 1312 having an underside adapted to hang off a pin or other structure on the gooseneck 1010. The hanger component 1312 also may function as a pivot relative to the gooseneck. A lower portion of the flanges 1310 comprises an opening 1314 for receiving a pin (not shown).

FIG. 14 illustrates a pair of telescoping lift tendons 1008. Each tendon comprises a main portion 1402 having a hollow elongated body and two arms 1404 that can telescope within the main body 1402 so that the length of the tendon 1010 can be adjusted for foundation systems of various lengths. The arms 1404 may be solid or hollow and preferably are hollow to reduce their weight. The tendons comprise arm locks 1408 that lock the arms 1404 in relation to the main portion 1402. The locks 1408 are sized and structured to react the tensile load imposed on the tendons 1010 while lifting and transporting the foundation system. In FIG. 14, the arm locks 1408 are shown on the main portion 1402. Each distal end of the tendon 1010 comprises a gusseted adapter connector 1406. While the lift tendons illustrated in FIG. 14 are manufactured as telescoping tubes, other embodiments of lift tendons, such as wire cable, solid or hollow fixed-length rods and other structural component capable of maintaining a lifting tension load without deformation may used. It will be understood that depending on the type of bridle used, the lifting tendons will require connectors, such as 1406, at each end.

FIGS. 15A-15E illustrate how the tendons 1008, gooseneck adapter 1300, and gooseneck 1010 interface and function. FIG. 15A shows gooseneck pin 1502 from which the adapter 1300 is hung and which aids the lifting of the foundation system. The gooseneck 1010 is shown to have a shoe 1504 at its distal end, which comprises a main pin aperture 1506 and secondary pin slot 1508. FIG. 15B shows the adapter 1300 in position on the gooseneck pin 1502. The tendon arm adapter connector 1406 is shown to comprise a main pin sleeved aperture 1510 and a secondary pin aperture 1512. As shown in FIG. 15A, the tendon arm 1404 is first connected to the gooseneck shoe 1504 by placing a secondary pin 1514 through the pin slot 1508 and through the pin aperture 1512 in the adapter connector 1406. The gooseneck shoe 1504 and/or the tendon arm 1404 can be adjusted to align the sleeved aperture 1510 with the opening 1312 in the adapter 1300 and with the main pin aperture 1506 in the shoe 1504. Once align, the main pin 1516 can be inserted therethrough. FIG. 15C shows the tendon arm 1404 securely pinned to the adapter 1300 and shoe 1504.

With the lift tendons 1008 attached to the gooseneck 1010, the bogie 1012 can position the gooseneck up to the bridle 1200, which has already been attached to the foundation system as described above. Because the lift tendons 1008 are pinned in two places on each shoe 1504, the lift tendons can be guided underneath the foundation through the pocket or pockets 916. FIG. 15D shows the adapter 1300 approaching the bridles 1200 (attached foundation system not shown). As shown in FIG. 15E, Once the guide interface 1302 is positioned within the bridle adapter guide 1210, a locking pin 1518 can be inserted through the aligned apertures to securely connect one end of the foundation system to the gooseneck 1010/bogie 1012.

FIG. 16 illustrates a completed connection at one end of a foundation system 800. The bridle 1202 is shown connected to the end of the foundation system 800 with a compression pad 1600 compressed between the two. At the other end of the foundation system, the adapter 1300 can be connected to the bridle 1200 using another locking pin 1518. Another bogie 1012 and gooseneck 1010 system is driven toward the bridle 1200/adapter 1300 assembly. The tendon connector 1406 is pinned to the secondary pin slot 1508 with secondar pin 1514. Thereafter, the gooseneck and/or the lift tendon 1008 can be adjusted so the primary pin 1516 can be inserted through the apertures. Once that is done the foundation system is ready to be lifted and transported if desired.

As illustrated in FIG. 17A, the gooseneck can be fitted with lift height locks to take the loads off of the hydraulic rams 1104. The height lock illustrated in FIG. 17 comprises a spur 1702 and detent 1704 that self-adjusts and locks as the foundation system 800 is lifted. As the rams 1104 extend to move the gooseneck arms 1706 out away from the gooseneck frame 1708 to compress the bridles against the foundation system, the spur 1702 will drop into the next lower detent 1704 and prevent the arm 1706 from relaxing the compression and lift height. The lock system can be released by extending the rams 1104 a little more to take load off of the lock and then raising the spur 1702 out of the detents 1704.

FIG. 17B illustrate a transporter 1740 comprising a gooseneck 1010 and a wheeled bogie 1012. FIG. 17B also illustrates a bridle 1742 connected to the gooseneck. The gooseneck 1010 has been described previously other than note that the gooseneck may connect to the bogie 1012 conventional fifth wheel coupling with kingpin, as illustrated for example in FIGS. 20A and 20B. the gooseneck comprises one or more force producing devices, such as hydraulic rams for supplying compression to the foundation systems. The bogie comprises a chassis with one or two opposed pairs of wheels 1744. As illustrated in FIG. 17B, this embodiment of a transporter 1740 has two sets of opposed wheels (i.e., two axles) disposed forward and aft on the chassis. The forward set of wheels may pivot about the chassis to allow steering of the transporter 1740. In a preferred embodiment, both the forward and aft wheels rotate relative to the chassis to allow precise maneuvering when, for example, setting a foundation system on site. The bogie 1012 comprises a power pack, which comprises a power source 1748 and power converters 1750. For example, a power source 1748 may comprise and internal combustion engine (gasoline, Diesel, or hydrocarbon gas) producing rotational power or an electrical genset producing electrical power. The power converter 1752 or power converters may comprise one more hydraulic and/or pneumatic pumps. Such pumps may provide fluidic energy (oil or air) to hydraulic rams, such as rams 1104, wheel steering systems, motors for driving the wheels, brakes and other such moving vehicle systems. Alternately, the power converters 1752 may comprise electrical motors for driving the wheels, compressing and lifting the foundation systems, steering the bogie 1012, and other such moving vehicle systems. It is contemplated that both radial flux and axial flux electric motors may be used on a bogie 1012. For example, some embodiments may use axial flux motors coupled directly to the wheel systems on the forward axle.

The bogie 1012 also may comprise a main controller 1754 configured to control the hydraulic, pneumatic and/or electrical systems on the bogie 1012, such as to control steering, direction (forward, reverse) and the other operations of the transporter 1740. Preferably the controller 1754 allows wired or wireless control of the transporter 1740 from an industrial portable joystick controller 1762 so that a person can use the portable controller 1762 to drive the transporter 1740 to connect to a bridle and/or to move a foundation system. It is preferred that when two transporters are used to move a foundation system 800, each transporter can communicate with each other, such as by wired or wireless communication and one main controller can control both transporters, such as from one portable controller 1762. When the transporters are used for roadway travel, such as highway travel, each wheel or wheel set is disconnected from its power converter (e.g. electric or hydraulic motor) so that the wheel can free wheel, such as through use of manual or automatic Lock/Unlock hubs 1760. Alternately, if the power source is a rechargeable battery pack, one or more electrical motors can be used to generate electricity to charge the battery pack. For roadway use, the axles can be locked, manually or automatically, to the chassis in a trailering orientation, and unlock the axles when on site to allow precise maneuvering by the transporters 1740.

FIGS. 18A and 18B illustrate another embodiment of a bridle for use with foundation systems disclosed and enabled herein. Bridle 1800 is like bridle 1200 described above in the sense that the bridle is shaped as an elongated rectangular box and spans the width of the foundation system. Bridle 1800 has several components that are also used with bridle 1200 and such components are identified in FIGS. 18A and 18B. Bridle 1800 differs from bridle 1200 in that the adapter or quick connect 1802 that connects the bridle 1800 to the gooseneck arms is integral with the bridle 1800, rather than a separate component like adapter 1300. Like adapter 1300, adapter 1802 comprises a latching or lifting surface 1804 and flanges 1806. Bridle 1800 also uses a compression mat 1808 between the bridle and the end of the foundation system.

FIGS. 19A, 19B, and 19C illustrate yet another bridle for use with foundation systems disclosed and enabled herein. FIG. 19A shows that bridle 1900, like bridle 1800, has integral gooseneck quick connections 1902, but has 3 foundation system pins 1904. For both bridles 1800, and 1900, and unlike bridle 1200, the foundation system pins pass through openings 1904 through the bridles, as shown in FIG. 19A. With this construction, fastener systems 1906, such as threaded studs 1908, nuts and washers, may be inserted through the sleeves and through the apertures formed in the foundation system to secure the bridles 1800, 1900 to the foundation system. See

FIG. 19C. FIG. 19B illustrates an alternate safety arm system 1920 comprising tensioned wire cables spanning and apertures in the side beam of the foundation system 800. As illustrated, a first cable is attached adjacent to an upper surface of the bridle at the bridle end, and the other end of the cable is attached to a fastener, such as a bolt and nut or pin in a first aperture in the foundation system. A turnbuckle may be used to apply tension to the cable thereby additionally securing the bridle the end of the foundation system. A second cable is attached adjacent a lower surface of the bridle at the bridle end, and the other end of the second cable is attached to a fastener, such as a bolt and nut or pin in a second aperture in the foundation system. A turnbuckle may be used to apply tension to the second cable thereby additionally securing the bridle the end of the foundation system.

FIGS. 20A and 20B illustrate, like FIGS. 15A-15E, how the transporter (gooseneck 1010/bogie 1012 assembly) may be driven toward an end of the foundation system to which a bridle 1800, 1900 has been secured. For these embodiments, the lift tendons 1008 are located underneath the foundation system prior attaching the tendons to the gooseneck arms 1706. FIG. 20B illustrates how the lift tendons 1008 and bridle connect to the gooseneck so that a tensile force is induced the tendons and a compressive force is induced against the end of the foundation system adjacent the floor portion to lift and carry the foundation system.

FIG. 21A illustrates a foundation system 800 and a structure 2102 built thereon being transported by a bridle/gooseneck/bogie assemblies attached as described herein to the foundation system, including the use of lift tendons. It will be note that only one bogie is used at the rear and the gooseneck at the front is attached directly to the highway tractor. FIG. 21B illustrates two transporters (i.e., a gooseneck 1010 and bogie 1012 assembly) being driven and steered to locate a foundation system with building 2102 at the desired site for use of the building. Once the transporters are have located the building on the particular site, lift locks, if used, can be released and the foundation lowered such as to prepared footings. Once the foundation is on the footings or on the ground, the transporters can be detached from the bridles and tendons and moved from the site. The tendons can be removed from underneath the foundation system separately from the bridles, or the tendons and bridles can be removed together. FIG. 21C illustrates that a transporter can be attached directly to a gooseneck and tractor for hauling the assemblies back to the plant. The tendons 1008 may be secured to the assemblies for transport as well.

Other and further embodiments utilizing one or more aspects of the inventions described above can be devised without departing from the spirit of Applicant's invention. Further, the various methods and embodiments of the methods of manufacture and assembly of the system, as well as location specifications, can be included in combination with each other to produce variations of the disclosed methods and embodiments. Discussion of singular elements can include plural elements and vice-versa.

The order of steps can occur in a variety of sequences unless otherwise specifically limited. The various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps. Similarly, elements have been described functionally and can be embodied as separate components or can be combined into components having multiple functions.

The inventions have been described in the context of preferred and other embodiments and not every embodiment of the invention has been described. Obvious modifications and alterations to the described embodiments are available to those of ordinary skill in the art. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention conceived of by the Applicants, but rather, in conformity with the patent laws, Applicants intend to protect fully all such modifications and improvements that come within the scope or range of equivalent of the following claims.

Claims

1. A bridle system for compressing against and lifting a concrete foundation, comprising:

a pair of bridles, each comprising: an elongated body having a first elongated face and a second elongated face between first and second ends; the first face having a plurality of sleeves extending away from the first face, the sleeves spaced along the first face between the first and second ends, each sleeve having a length greater than a thickness of the foundation through which the sleeves will extend; a compression pad disposed on at least a portion of the first face for sandwiching between the first face and the foundation; a plurality of adapter guides disposed between the first and second ends and open at least at the second face, the adapter guides comprising a wall surface or wall surfaces within the body; a pin guide associated with each of the plurality of adapter guides, the pin guide open from a top surface of the body through the adapter guide to a bottom surface of the body, the pin guide structurally configured to receive a pin for securing a portion of a bridle adapter into the adapter guide; at least one tension member anchor emanating from the bottom surface of the body and structurally configured to react a tension load imposed by a tension member; and

wherein when the pair of bridles engage opposed ends of the foundation, at least one tension member spans between the bridles and reacts tension against the at least one tension member anchor.

2. The bridle system of claim 1, wherein the plurality of sleeves are round tubes

3. The bridle system of claim 1, wherein the plurality of adapter guides comprise two rectangular boxes.

4. The bridle system of claim 3, wherein the plurality of sleeves are two round tubes and a first tube is located between the first end of the body and a first adapter guide and a second tube is located between the second end of the body and a second adapter guide

5. The bridle system of claim 3, wherein the two adapter guides are open on both the first and second faces of the body.

6. The bridle system of claim 5, comprising locking pins structurally configured to engage the two pin guides and lock the pins to the top surface of the body.

7. The bridle system of claim 1 comprising safety arm anchors disposed adjacent each end of the body.

8. A system for lifting and moving a concrete foundation, comprising:

a pair of bridles each having a compression face, a plurality of sleeves extending perpendicularly from the compression face, at least one bridle adapter receptacle for securing at least one bridle adapter to the bridle, and at least one tension member anchor disposed on a bottom surface of the bridle;

at least one bridle adapter for each bridle, the adapter having a portion structurally sized and shaped to mate with the at least one bridle adapter receptable, the bridle adapter having an opening adjacent a bottom surface for connecting to a lifting tendon, and having a lifting connection for engaging a lifting arm on a gooseneck;

at least one lifting tendon having a length spanning the foundation between the bridle adapter openings, each end of the at least one tendon having a structure for connecting the tendon end to the bridle adapter opening; and

a pair of steerable bogies to which the pair of goosenecks are operatively coupled.

9. A method of moving a foundation with the system of claim 8, comprising:

attaching a bridle to each end of the foundation by passing the sleeves through apertures in first and second ends of the foundation, and securing the bridles to the foundation using the sleeves;

attaching the at least one tendon to one of the at least one bridle adapter for a first bridle;

driving the steerable bogie to position the at least one tendon beneath the foundation;

securing the bridal adapter to the first bridle;

securing another end of the at least one tendon to the at least one bridal adapter for the second bridle;

securing the at least one bridal adapter to the second bridle;

applying tension to the at least one tendon and compression to the foundation through the pair of bridles;

lifting the foundation by applying additional tension to the at least one tendon; and

moving the lifted foundation with the steerable bogies.

10. The system of claim 8, the a first of the pair of goosenecks is coupled to a first of the pair of bridles and a second of the pair of goosenecks is coupled to a second of the pair of bridles, and wherein each bogie and gooseneck combination comprises one or more force-producing devices for applying compressive force to a portion of the foundation through the compression face on each bridle while simultaneously applying a tensile force to the at least one tendon.

11. The system of claim 10, wherein the at least one or more force-producing devices also lift the foundation while it is being compressed.

12. The system of claim 11, wherein the pair of bogies move the lifted foundation without causing tensile failure of the foundation.

13. A bridle system for compressing against and lifting a concrete foundation, comprising:

a pair of bridles, each bridle comprising: an elongated body having a first elongated face and a second elongated face between first and second ends; the first face having a plurality of projections extending away from the first face, the projections spaced along the first face between the first and second ends, each having a length greater than a thickness of the foundation for securing the bridle to an end of the foundation; a plurality of adapter guides disposed between the first and second ends of the body and open at least at the second face; a pin guide associated with each of the plurality of adapter guides, the pin guide communicating from a top surface of the body to the adapter guide, the pin guide structurally configured to receive a pin for securing a portion of a bridle adapter into the adapter guide; at least one cable anchor disposed at a bottom of the bridle body; and

wherein when the pair of bridles engage opposed ends of the foundation, at least one pretensioned cable spans underneath the foundation between the at least one cable anchor on each bridle for securing the bridles to the foundation in combination with the projections.

14. The system of claim 13, wherein each bridle comprises first and second cable anchors disposed adjacent the first and second ends and each cable anchor accommodating a plurality of pretensioned cables.

15. A method of lifting a concrete foundation with the system of claim 13 comprising:

mating a first bridle to a first end of the foundation by inserting the projections into corresponding apertures in the first end of the foundation;

mating a second bridle to a second end of the foundation by inserting the projections into corresponding apertures in the second end of the foundation;

using the projections to secure the first and second bridles to the ends of the foundation;

applying tension to a cable strung between the at least one cable anchor on each bridle to secure the bridles to the ends of the foundation;

lifting the foundation by applying force to the bridles to compress an upper portion of the foundation between the bridles while reacting the force against the tension cable.

16. The method of claim 15, further comprising moving the lifted foundation.

17. The method of claim 16, wherein each bridle comprises first and second cable anchors disposed adjacent the first and second ends and each cable anchor accommodates a plurality of pretensioned cables.

18. The method of claim 17, wherein applying tension is applying a load to teach of the plurality of the cables of between 500 lbf and 1,000 lbf.