SYSTEM METHOD AND DEVICE FOR STRUCTURAL IMPROVEMENT WITH MICROPILES

Abstract

A reinforcing structure, system, or method may comprise forming a opening through a concrete member of the structure, disposing a sleeve within the opening, and coupling a micropile to the sleeve. The micropile may comprise a hollow interior and comprising a sacrificial tip. The micropile may comprise threading on an outer surface that mateably couples with the inner threading 2024/211452 of the sleeve. An end of the micropile may be advanced to a point of refusal in soil below the opening, and then retreat to form a void. The sacrificial tip of the micropile may be moved to expose the hollow interior, such as by being made to lie down horizontally. Cement grout may be disposed within the hollow interior of the micropile and around the sacrificial tip. The micropile may be torqued after the cement grout has hardened to exert an upward force against the concrete member.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent No. 63/493,980, entitled “System Method and Device for Structural Improvement with Micropiles,” filed on Apr. 3, 2023, the entire disclosure of which is hereby incorporated herein by this reference.

TECHNICAL FIELD

Embodiments of the present disclosure relate to a system, method, and device for one or more of structural improvements, reinforcement, remediation, or repair of structural elements, such as walls, panels, and slabs.

BACKGROUND

Structural elements, such as such as wall, retaining wall, sheer wall, panel, slab, column, butress, dike, levy, footing or any other structure can experience settling, which may increase stress on the structure and cause the structure to break or be at greater risk of breaking. In many cases, soils provide a base or platform on which the structure rests and serve to support the building. Soils can exhibit fluid characteristics, can settle, and as a consequence can compromise a structure or foundation, and cause the structure to experience greater stress, which can cause the structure to weaken, degrade, or fail. Many different types of soils are encountered in different geographic locations and in different building situations, which can require adaptations so that the building foundation interacts with the soil in such a way as to provide adequate support and reduces, minimizes, or maintains relative movement of the building and the soil within acceptable tolerances.

FIG. 1 illustrates a cross-sectional view of a portion of a structure or building 10 that is built using slab on grade construction. Structure 10 can include footings 12 and stem walls 14 that together form foundation 16. Footings 12 can be made or concrete reinforced with steel, such as rebar. Stem walls 14 can similarly be reinforced concrete, or alternatively can be masonry or block. In some instances, the foundation 16 may be formed monolithically. Together, foundation 16 can support a superstructure or other portion of structure 10 including interior walls 17, walls 18, exterior walls 19, and a roof 20, which can be constructed of one or more suitable material, including lumber, masonry, block, steel, metal, or other suitable natural or synthetic material. Walls 18 or other feature of the structure 10 can also be constructed as a structural element 50, which may comprise masonry, block, concrete, wood, lumber, metal, steel, aluminum, or other suitable material. Walls 18 may also be formed of, or covered entirely or partially, with drywall, plaster, siding, or other suitable material.

Foundation 16 can be disposed in, and supported by, soil, native soil, or fill soil 24. Soil 24 can also provide support for floor slab 26. Slab on grade construction may include a concrete floor slab 26 that can be poured, formed, or built within a perimeter formed by the stem wall 14. Floor slab 26 can be in contact, and often direct contact, with leveled or graded soil. The graded soil can be formed as a prepared pad of soil that has been compacted for stability and built to a particular elevation or grade to account for drainage away from the building and other issues. Advantageously, an intermediate layer of engineered soil or an aggregate base course (ABC) 28 including rock, sand, and dirt can be deposited, graded, wet, and compacted over native soil 24 before placing and finishing concrete floor slab 26 to reduce soil movement and attendant cracking of floor slab 26.

In other instances, foundation 16 may be disposed in, and supported by, native soil 24 while the floor is elevated above, and not in direct contact with, the soil 24. In such instances, an airgap or crawl space may be disposed or formed between the floor and the soil 24.

Movement and settling of structure 10, as well as changes in pH can put stress on structural elements 50, such as concrete or masonry wall 18, and cause crack or cracks 56 to form in the structural element 50 or wall 18. There is a need in the art for improved methods of repairing, limiting, and preventing cracking in structural elements 50, such as walls 18.

FIGS. 2A-2D, illustrate various negative structural results and structural failures that result from different types of soil movement. FIG. 2A illustrates a cross-sectional profile view of another structure or building 10 supported by a conventional foundation 16 and comprising an unreinforced floor slab 26 that is disposed over soil 24. Soil 24 is shown comprising a weakened layer of soil 30, that leads to at least partial settlement or collapse of the weakened soil 30. The weakened soil may be an expansive soil, such as a soil comprising clay. As a result, the floor 26 and interior walls 17 can deform, crack, sag, drop, or otherwise degrade, or shift 34 undesirably, due to the settlement 32.

FIG. 2B illustrates a cross-sectional profile view of another structure or building 10 supported by a conventional monolithic foundation 16m and comprising a reinforced or post tension concrete floor 26a comprising cable 44 for post tensioning the slab as known in the art. The floor slab 26a is disposed over soil 24 which comprises water 38 percolating, seeping, infiltrating, or inundating the soil at the edge of the structure 10 to create induced edge heave or post tension edge heave 42, which results (for example) from expansion of expansive soil 40 (such as clay) expanding with increased water content and pushing up the edges of the structure 10 over the expanded soil.

FIG. 2C illustrates an example of tipping settlement, where the wall 19 or structural element 50 structure is angled, tipped, or leaned in direction 60 of the settlement due to the weakened layer of soil 30 leading to settlement or collapse.

FIG. 2D illustrates an example of differential settlement, in which different amounts of settlement occur for different portions of the wall 19 or structural element 50, with the differences in movement forming cracks 56 in the structure, often in a diagonal or roughly 45° line. More specifically, FIG. 2D illustrates a downward or upward sloping crack through the brick wall, in which the soil on under the left side of the fence 19 settled, compacted, or moved down, leading to the foundation to crack and fail, and for the portion of the block wall 19 on the left to sink and move away (or crack away from) the portion of the brick wall 19 on the right.

In other instances, other types of settling can occur, including uniform settlement where the structure moves, as an entirety, in a uniform direction without any cracking or significant cracking to the structure.

FIG. 3A provides an illustration of a conventional helical pier 62 of the sort that may be used in the repair or reinforcement of wall 19 or structural element 50 shown in FIGS. 3A-3C, whether at a perimeter of the structure 10 (as a perimeter pier) or whether extending through a floor slab 26 or a foundation 16. The helical pier 62 is a long steel post with helical (screw-like) blades along the shaft. The pier 62 is screwed through the ground 24 until it hits stable, undisturbed soil. A pressure gauge system is used to determine when the pier 62 has reached the necessary depth (soil level where it is stable enough to support the structure 19, 50). At the top of the pier a steel bracket or foundation bracket 64 is fitted to the shaft of the pier 62, so as to be under the foundation or footing 16, to give the wall 19 support and hold it in place. The bracket 64 allows the pier 62 to leverage the resistance between the deep solid ground at the bottom of the pier 62 and the structural element 50 being reinforced, thereby lifting the foundation 16 and wall 19 to its original, pre-settlement position. Thus, once the piers 64 are installed the wall 19 is stable.

FIGS. 3B and 3C illustrate another application in which helical or push piers 62 may be used, as known in the prior art. FIG. 3B illustrates opening O with a diameter Do of about 8″ through tile of floor covering 27 and slab 26. FIG. 3C illustrates an instance in which the bracket 64 is attached to the upper portion of the shaft of the helical pier 62, such as to be coupled with a foundation 16, floor 26, or structural element 50.

SUMMARY

In some aspects, the disclosure concerns a method of reinforcing a structure, comprising forming a first opening through a concrete member of the structure. The opening comprises a sidewall and an opening diameter that extends from opposing sides of the sidewall. The opening diameter comprises a distance in a range of 1-3 inches. A first sleeve may be inserted within the first opening. The first sleeve comprises an outer surface comprising an outer diameter and an inner surface comprising an inner diameter. The outer surface comprises first outer threading comprising a first height and second outer threading comprising a second height. The inner surface comprises inner threading formed with an inner thread recess offset from the inner surface. The first sleeve is threadedly coupled to the sidewall of the first opening of the concrete member. A first micropile comprising a hollow interior, a sacrificial tip, and pile threading on an outer surface is provided. The first micropile is coupled to the first sleeve with the pile threading on the outer surface of the first micropile mateably coupled with the inner threading of the first sleeve. A first end of the first micropile is advanced to a point of refusal in soil below the first opening. The first end of the micropile is retreated to form a void in the soil and the sacrificial tip is moved to expose the hollow interior of the micropile. Cement grout is passed through the hollow interior of the micropile into the void in the soil. The micropile is torqued after the cement grout has hardened to exert an upward force against the concrete member.

In some instances, the structure comprises a concrete floor slab or a fence footing. The micropile may be torqued to raise the concrete member to create a gap between a portion of the concrete member and the soil, wherein the gap comprises a distance in a range of 0.1″-4″. A second opening, a second sleeve, and a second micropile spaced 1-10 feet from the first opening, the first sleeve, and the first micropile may be present. The inner diameter of the first sleeve may comprise a distance in a range of ⅜″-2″. The first height of the first outer threading may be greater than the second height of the second outer threading. The first sleeve may comprise a first end that comprises a flange, and a second end opposite the first end, the second end comprising a tapered outer surface. The first outer threading may comprise a height in a range of 0.1-0.8 inches, and an outer threading spacing in a range of 0.4-2.2 inches. The second outer threading may comprise a height in a range of 1/32″-⅛″, and an outer threading spacing in a range of 0.4-2.2 inches. The inner thread recess may comprise a height in a range of 0.2-1.0 inches, and an inner threading spacing in a range of 0.5-2.5 inches. The first micropile may comprise a length in a range of 0.5-8 feet. The first micropile may be designed to carry a load of 3-5 kips. The first end of the first micropile may be retreated a distance of 1-3 inches to form the void, the void comprising a corresponding depth of 1-3 inches.

In other aspects, a method of reinforcing a structure may comprise forming an opening through a concrete member of the structure. A sleeve may be inserted within the opening, the sleeve comprising an outer surface threadedly coupled with the concrete member. A micropile may be coupled to a threaded inner surface of the sleeve, the micropile comprising an outer threaded surface sized to couple with the threaded inner surface of the micropile. The micropile may further comprise a maximum diameter in a range of 0.5-3 inches. The micropile may comprise a hollow interior and a sacrificial tip. A first end of the micropile may be advanced to a point of refusal in soil below the first opening. The first end of the micropile my retreat to form a void in the soil. The sacrificial tip may be moved to expose the hollow interior of the micropile. Cement grout may be passed through the hollow interior of the micropile into the void in the soil. The micropile may be torqued after the cement grout has hardened to exert an upward force against the concrete member.

In some instances, the threads on the outer surface of the sleeve may comprise a maximum height smaller than a maximum height the threads on the inner surface of the sleeve. Torquing the micropile may raise the concrete member to create a gap between a portion of the concrete member and the soil.

In other aspects, a method of reinforcing a structure may comprise forming an opening through a concrete member of the structure. A sleeve may be inserted within the opening, the sleeve being coupled with the concrete member. A micropile may be coupled to a threaded inner surface of the sleeve, the micropile comprising an outer threaded surface sized to couple with the threaded inner surface of the micropile. A first end of the micropile may be advanced to a point of refusal in soil below the first opening.

In some instances, a maximum diameter of the micropile may comprise a distance in a range of 0.5-3 inches. The threads on the outer surface of the sleeve may comprise a maximum height smaller than a maximum height of the threads on the inner surface of the sleeve. The micropile may be provided with a hollow interior and with a sacrificial tip at a first end of the micropile. The first end of the micropile may be retreated to form a void in the soil. The sacrificial tip may be moved to expose the hollow interior of the micropile. Cement grout may be passed through the hollow interior of the micropile into the void in the soil. The micropile may be torqued, after the cement grout has hardened, to exert an upward force against the concrete member.

The foregoing and other aspects, features, applications, and advantages will be apparent to those of ordinary skill in the art from the specification, drawings, and the claims. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. The inventors are fully aware that he can be his own lexicographer if desired. The inventors expressly elect, as their own lexicographers, to use only the plain and ordinary meaning of terms in the specification and claims unless they clearly state otherwise and then further, expressly set forth the “special” definition of that term and explain how it differs from the plain and ordinary meaning. Absent such clear statements of intent to apply a “special” definition, it is the inventors' intent and desire that the simple, plain, and ordinary meaning to the terms be applied to the interpretation of the specification and claims.

The inventors are also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above.

Further, the inventors are fully informed of the standards and application of the special provisions of 35 U.S.C. § 112(f). Thus, the use of the words “function,” “means” or “step” in the Detailed Description or Description of the Drawings or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. § 112(f), to define the invention. To the contrary, if the provisions of 35 U.S.C. § 112(f) are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for”, and will also recite the word “function” (i.e., will state “means for performing the function of [insert function]”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for performing the function of . . . ” or “step for performing the function of . . . ,” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventors not to invoke the provisions of 35 U.S.C. § 112(f). Moreover, even if the provisions of 35 U.S.C. § 112(f) are invoked to define the claimed aspects, it is intended that these aspects not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the disclosure, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross-sectional profile view of a slab on grade structure, as known in the prior art.

FIGS. 2A-2D illustrate various structures subjected to undesirable movement because of soil conditions, as known in the prior art.

FIGS. 3A-3C illustrate various views of how conventional helical piers or push piers have been used for foundation repair and soil induced structural remediation efforts, as known in the prior art.

FIG. 4 illustrates a cross-sectional profile view of an improved micropile assembly or system in accordance with the disclosure.

FIG. 5 illustrates a flow-chart, wire frame, or method of reinforcing a structure in accordance with the disclosure.

FIGS. 6A-6C illustrate various views of a sleeve for an improved micropile assembly or system in accordance with the disclosure.

FIGS. 7A-7C illustrate various views of a sleeve and micropile assembly or system in accordance with the disclosure.

FIGS. 8A and 8B illustrate cross-sectional profile view of a sleeve and micropile assembly or system being used with a foundation in accordance with the disclosure.

FIGS. 9A and 9B illustrate cross-sectional profile view of a sleeve and micropile assembly or system being used with a slab on grade floor in accordance with the disclosure.

DETAILED DESCRIPTION

This disclosure, its aspects and implementations, are not limited to the specific material types, or other system component examples, or methods disclosed herein. Many additional components, construction and assembly procedures known in the art are contemplated for use with particular implementations from this disclosure. Accordingly, for example, although particular implementations are disclosed, such implementations and implementing components may include any components, models, types, materials, versions, quantities, and/or the like as is known in the art for such systems and implementing components, consistent with the intended operation.

The word “exemplary,” “example,” or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” or as an “example” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity.

As used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. For example, “a” or “an” means “at least one” or “one or more.”

Throughout this disclosure, various aspects of the claimed subject matter are presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the claimed subject matter. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range. For example, where a range of values is provided, it is understood that each intervening value, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the claimed subject matter. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and are also encompassed within the claimed subject matter, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the claimed subject matter. This applies regardless of the breadth of the range.

As used herein, “about” or “substantially” means a percent difference less than or equal to a 50% difference or less, a 40% difference or less, a 30% difference or less, a 20% difference or less, a 10% difference or less, or a 5% difference or less.

While this disclosure includes a number of embodiments in different forms, there is shown in the drawings and will herein be described in detail particular embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems and is not intended to limit the broad aspect of the disclosed concepts to the embodiments illustrated.

According to the present disclosure, a system or method of reinforcing a structure 10 using a micropile system 90 comprising one or more sleeves 100 and one or more micropiles, needle piles, or shafts 160 is discussed. The micropiles 160 in some instances may comprise a length of one integrally or unitarily formed unit, and in other instances may comprise multiple shorter units that are joined together to form an overall desired length, such as when soil refusal is achieved. The multiple shorter units that are joined together to form the micropile 160 may be welded, fused, chemically joined, mechanically joined, and may be notched and interlocked together, so as to attachable during installation, but held together in compression after installation. Similarly, the sacrificial tip 169 or drilling point may be modular, added to the micropile 160 on site, or added to micropile segments as needed.

The structure 10 may comprise one or more structural element 50 to be reinforced, such as a floor slab 26 (see, e.g. FIGS. 4 and 9A-9B), a footing 16, 16m such as fence footing (see, e.g., FIGS. 8A and 8B), or other suitable structure or structural element 50. The structure 10 or structural element 50 may be made or formed of concrete, cementitious materials, masonry, block, brick, stone, rock, adobe, rammed earth, or other suitable support material (hereinafter “concrete”). The micropiles 160 may be light weight peers. Generally, the micropiles are too light to lift foundations or heavier items and structures. The micropiles 160 described herein may be designed to carry a load of 3-5 kips, or more, where 1 kip is equal to 1,000 pounds-force (lbf) or 4.448 kilo Newtons (kN). As such, the system, method, and devices described herein may be advantageously used to raise floors 26, such as concrete slab on grade floors (including post tension concrete floors 26a), especially, e.g., those floors 26 that have a bowl or recessed area 610, such as in the middle of the floor 26. Similar application may be advantageously used with elevating or straightening fences 70 that are tipping or shifting due to soil movement (see, e.g. FIGS. 2C, 8A, and 8B), where existing technology and approaches would be cost prohibitive.

For example, in an embodiment, micropile system 90 according the to present disclosure may comprise micropiles 160 placed a distance or offset O_x of about 3-10 feet or about every 6 feet on-center along the footing or foundation 16 or the structural element 50, of the wall or fence 70 to remediate settling of the wall 70 or undesired movement. For example, the offset O_x may be measured, e.g., between the first sleeve or collar 100a and second sleeve or collar 100b or first micropile 160a and second micropile 160b. A cost of the micropile system 90 at the time of filing of this application may be about $500 per micropile 160 and sleeve 100 (installed), whereas conventional fence repairs using piers or piles cost about $2,500 each (installed) and are not economical, being about, on the order of, 5 times (5×) more expensive than the micropile system 90. In the above example, a conventional repair for 60 feet of fence with 6 ft on-center spacing results in a cost of $25,000 (10×$2,500=$25,000), whereas a cost for starting over and replacing the same 60 feet of block wall may cost much less, such as on the order of $3,000-$6,000 (i.e. $50-$100 per linear foot). However, by simply replacing rather than remediating the underlying soil issue affecting the wall 70, the underlying problem still exists, and next fence 70 will likely experience similar issues. On the other hand, having an option of using micropile system 90 to repair or remediate the fence 70 as described herein, the underlying problem may be solved for a cost of about $5,000, or ⅕ of a conventional repair using peers or piles, and comparable to a cost of building a new fence that will be subject to near-term failure due to an un-remediated latent soil problem.

FIG. 4 illustrates a cross-sectional profile view of at least a portion of the micropile system 90, comprising sleeve 100 and micropile or shaft 160. A method of deploying the same is shown and discussed in greater detail with respect to FIG. 5. A first opening O may be formed through a concrete member 50, 26 of the structure 10. The opening O may comprise a sidewall S and an opening diameter Do extending from opposing sides of the sidewall S. The opening diameter Do comprises a distance in a range of 1-3 inches. A first sleeve 100 may be inserted within the first opening O, the first sleeve 100 comprising an outer surface 110 comprising an outer diameter 120 and an inner surface 130 comprising an inner diameter 140. The outer diameter 120 may also be referred to as a minor outer diameter, wherein the minor diameter is the diameter that extends to a low point between threads and a major diameter is the diameter that extends to peaks of the threads. While the term “diameter” is used herein for simplicity and ease of description, the diameter also comprises a cross-sectional width or distance for non-circular cross-sectional areas, including multi-sided regular or irregular polygons or other geometric and organic shapes.

The outer surface 110 comprises first outer threading 112 comprising a first height H₁ and second outer threading 116 comprising a second height H₂. The heights H₁ and H₂ of the threading 112 and 116 is measured between the base and the tip of the respective threading. Stated another say, the heigh to the threading is equal to the difference between the major outer diameter 122 and the minor outer diameter 120. See, e.g., FIG. 6B.

The inner surface 130 of the sleeve 100 comprises inner threading 132 formed with an inner thread recess 134 offset from the inner surface 130. The first sleeve 100 is threadedly coupled to the sidewall S of the first opening O of the concrete member 50, 26. Thus, the heigh H₃ of the inner threading 132 is equal to the difference between the major inner diameter 142 and the inner minor diameter 140. See, e.g., FIG. 6B.

A first micropile or shaft 160 may be provided. The first micropile 160 comprises a hollow interior 164, a sacrificial tip 168, and pile threading 172 on or at an outer surface 176 of the micropile 160. The first micropile 160 may be coupled to the first sleeve 100 with the pile threading 172 on the outer surface 176 of the first micropile 160 mateably coupled with the inner threading 132 of the first sleeve 100.

A first end 161 of the first micropile 160 may be advanced to a point of refusal in soil 24 below the first opening O. The first end 161 of the micropile 160 may be retreated, reversed, or backed out to form a void 180 in the soil 24. Retreating the first end 161 of the micropile 160 to form the void 180 further comprises retreating the first end 161 of the first micropile 160 a distance of 1-3 inches to form the void 180, the void 180 comprising a corresponding depth of 1-3 inches. The sacrificial tip 168 at the first end 161 may be moved, pushed aside, or at least partially removed to expose the hollow interior 164 of the micropile 160. Cement grout or soil stabilizing material 184 may be passed through, plunged, or pumped through the hollow interior 164 of the micropile 160 into the void 180 in the soil 124.

The micropile 160 may be torqued, rotated, spun, advanced, or driven, after the cement grout 184 has hardened to form a hardened mass or support 186. The advanced micropile 160 will break a seal, bond, or connection between the grout 184 that was within the hollow interior 164 and the hardened mass 186 and further contact the hardened mass 186 to exert an upward force against the concrete member 50, 26, which can include, without limitation, a concrete slab or floor 26, as well as a foundation 16 or fence footing. Torquing the micropile 160 can raise the concrete member 50, 26, to create a gap or offset 190 between a portion of the concrete member 50, 26, and the soil 24, wherein the gap 190 comprises a distance in a range of 0.1″-4″.

FIG. 5, illustrates a flow-chart, wire frame, or method 500 of reinforcing a structure, comprising a plurality of elements, in which the features referenced as shown throughout the figures, including, e.g., at FIGS. 6A-6C. Element 502 illustrates forming a first opening O through a concrete member 50 of the structure 10, wherein the opening O comprises a sidewall S and an opening diameter Do extending from opposing sides of the sidewall S. Element 504 illustrates disposing a sleeve or first sleeve 100, 100a within, and threadedly coupled to, the opening or first opening O, Oa. The sleeve or first sleeve 100, 100a comprising an outer surface 110 comprising an outer diameter 120 and an inner surface 130 comprising an inner diameter 140. The outer surface 110 comprises first outer threading 112 comprising a first height H₁ and second outer threading 116 comprising a second height H₂. The inner surface 130 comprises inner threading 132 formed with an inner thread recess 134 offset from the inner surface 130. Element 506 illustrates coupling a micropile or first micropile 160, 160a comprising a sacrificial tip 168, to the first sleeve 100a, wherein the first micropile 160a comprises a hollow interior 164 and pile threading 172 on an outer surface 176 of the first micropile 160a mateably couples with the inner threading 132 of the first sleeve 100a. Element 508 illustrates advancing or torquing a first end 161 of the first micropile 100a to a point of refusal in soil 24 below the first opening O. Element 510 illustrates retreating the first end 161 of the first micropile 160 to form a void 180 and removing the sacrificial tip 168, or forcing the sacrificial tip 168 to lie down horizontally, or be offset and away from the hollow interior 164. Element 512 illustrates placing cement grout or soil stabilizing material 184 within the hollow interior 165 of the first micropile 160. Element 514 illustrates plunging the cement grout 184 down to a bottom (or the first end 161) of the micropile 160 and around the sacrificial tip 168 and allowing the cement grout 184 to cure and harden. Element 516 illustrates torquing or advancing the first micropile 160 to raise the concrete member 50, thereby creating a gap 190 between the concrete member and the soil.

FIGS. 6A-6C illustrate various views and details of the sleeve 100 that may be placed in an opening O of the concrete member 150 and receive the micropile 160 through the opening 106 or center of the sleeve 100. In particular, FIG. 6A illustrates a top or plan view of the sleeve 100.

FIG. 6B illustrates a cross-sectional side view of the sleeve 100, as taken along the section line 6B shown in FIG. 6A. FIG. 6B illustrates the first sleeve 100 comprising the outer surface 110 comprising an outer diameter 120 and an inner surface 130 comprising an inner diameter 140. The first sleeve 100 may be formed of metal, such as steel, aluminum, or alloys thereof, as well as other suitable materials including composites, plastics, and compressed fibers. The first sleeve 100 may be installed within, and coupled to the opening O through the concrete or structural member 50, using a suitable tool, such as, e.g., with an impact hammer drill. The sleeve 100 may be threadedly coupled to the sidewall S of the first opening O of the concrete member 50 with the first outer threading 112, the second outer threading 116, or both the first outer threading 112 and the second outer threading 116 (as shown and described, e.g., with respect to FIGS. 8A-9B). The inner diameter 140 of the first sleeve 110 may comprise a distance in a range of, or about, 0.1-4″ or ⅜″-2″.

The first sleeve may comprise a first end 101 and a second end 103 opposite the first end 101. The first end 101 may comprise a flange 102 and the second end 103, which is opposite the first end 103, may comprise a tapered end 104 or tapered outer surface. The outer surface 110 of the first sleeve 100a may comprise first outer threading 112 comprising a first height H₁ and second outer threading 116 comprising a second height H₂. The first height H₁ of the first outer threading 112 may be greater than the second height H₂ of the second outer threading 116. Alternatively, in some instances, the second height H₂ of the second outer threading 116 may be equal to the first height H₁ of the first outer threading 112. As such, the outer surface threading 112, 116 may be of one height, thereby functionally having only a first threading 112 or only or second threading 116. The first outer threading 112 may comprise a height H₁ in a range of, or about, 0″-2″, 0.1″-0.8″, or 0.2″-0.5″, and an outer threading spacing or pitch P₁ in a range of, or about, 0″-4″, 0.4″-2.2″, or 0.6″-1.6″. The second outer threading 116 may comprise a height H₂ in a range of, or about, 0″-2″, or 1/32″-⅛″, and an outer threading spacing or pitch P₂ in a range of, or about, 0″-4″, 0.4″-2.2″, or 0.6″1.6″.

FIG. 6C illustrates an enlarged cross-sectional side view taken along the section-line 6C, shown in FIG. 6B. A close-up view of the spacing of threading is shown in the close-up cross-sectional view of FIG. 6C, which is taken along the section line 6C shown in FIG. 6B. The inner surface 130 may comprise inner threading 132 formed with an inner thread recess 134 offset from the inner surface 130. The inner thread recess 134 may comprise a height H₃ in a range of, or about, 0″-2″, or 0.2″-1.0″, and an inner threading spacing or pitch P₃that may be in a range of, or about, 0″-4″, or 0.5″-2.5″.

FIGS. 7A-7C illustrate the sleeve 100 (see, e.g., FIG. 7A), the micropile or shaft 160 (which may for convenience of reference (as with other reference numbers) be denominated as a first micropile 160a or a second micropile 160b). The micropile 160 may comprise a sacrificial tip 168 (see, e.g. FIGS. 4, 7B, and 7C), and a diameter D. FIG. 7C illustrates the micropile 160 being coupled to the sleeve 100. The first micropile 160a may comprises a hollow interior 164 and pile threading 172 on an outer surface 176 of the first micropile 16, which may extend between the first end 161and the second end 162. In some instances, the micropile 160 may be solid without a hollow interior 164. The pile threading 172 on the outer surface 176 of the first micropile 160a may mateably couple with the inner threading 132 of the first sleeve 100a. The first micropile 160a may comprise a diameter D in a range of, or about, 0.25″-4″ or 0.5″-2″ and a length L (perpendicular to the diameter D) in a range of, or about, 0.5-20 feet (′) or 2′-10′. In an embodiment, the micropile 160 may comprise a diameter of, or about, 0.5″-2″, or about 1.2″ (30 mm) while the sleeve 100 may comprise an outer diameter 122 of, or about, 1″-4″, or about 1.5″ and an inner diameter 140 of, or about, 0.5″-3″, or about 1.2″ and a wall thickness (outer diameter 120—major inner diameter 142) of, or about, 0.1″-0.5″, or about 0.3″.

FIGS. 8A and 8B illustrate cross-sectional side views of a wall 18, exterior wall 19, or fence 70 (hereinafter wall 18), formed of masonry, block, brick, stone, rock, adobe, rammed earth, concrete, wood, plastic metal, other suitable support material or combinations of any of the above. The wall 18 rests on a foundation 16, which may comprise a footing, or a footing and a stem wall. The foundation 16 may be disposed within and supported by a first soil 24a of a first composition, with a second soil 24b of a second composition disposed below the first soil 24a. In some instances, the second soil 24b will be more stable than the first soil 24a, and so the wall 18 and foundation 16 will be reinforced or repaired by coupling the wall 18 and the foundation 16 to the second soil 24b, such as with the micropile system 90.

FIG. 8A illustrates on opening O formed through the foundation 16 and the sleeve 100 disposed in the opening O and coupled with the foundation 16. The micropile 160 is shown disposed over the opening O and being lowered into the sleeve 100 to be coupled with the sleeve 100. FIG. 8B illustrates the micropile 160 coupled with the sleeve 100 and the first end 161 of the micropile 160 inserted into the more stable second soil 24b to provide support for the footing 16 and the wall 18.

Placement of the sleeve 100 in the foundation 16 or structural element 50 can comprise forming a first opening O through the structural element 50, which may be accessed or made by moving excavated soil 600. The opening O may comprise a sidewall S and an opening diameter Do extending from opposing sides of the sidewall S, wherein the opening diameter Do comprises a distance in a range of about 1-3 inches. As used herein, “diameter” includes cross-sectional distance or length of any desirable shape across its widest distance, and as such is not limited to just openings with a circular cross-sectional area, footprint, or form factor.

The size and shape of the opening O may also accommodate the flange 102 or wider portion of the sleeve 100, when present. In an embodiment, the opening O may comprise a diameter of 1.5″. Additionally at an upper surface of the structural element 50 (e.g., floor 26 or footing 16) a size of the opening O may be larger around the central diameter of the opening O that extends through the structural element 50. For example, the surface of the structural element 50 may be counter sunk (such as by about ¼″ or by a depth of a sleeve flange 102) so as to accommodate the sleeve flange 102 (first end 101) and allow the top surface of the sleeve flange 102 to be flush with the top surface of the structural element 50.

FIG. 8A illustrates an arrow 602 extending downward from a dashed line bowing down from the bottom of the footing 16, indicating the footing 16 or structural element 50 settling, deflecting, or being subjected to other movement or deformation, which in some instances could comprise heave. FIG. 8B, after deploying the micropile system 190 shows an arrow 606 indicating a flat dashed line along the bottom of the footing 16 or structural element 50, indicating there is no appreciable deflection or settlement 602 of the foundation 16 or structural element 50 within the first soil 24a.

Taken together, FIGS. 8A-8B illustrate advancing the first end 161 of the first micropile 160 to a point of refusal in soil below the first opening. The micropiles can be advanced with any suitable tool, such as a small hydraulic torque driver. For purposes of this disclosure, the micropile reaches the point of refusal 604 when an amount of force or number of blows at a particular force per length of movement (of the micropile 160) is achieved, such as 3-5 blows for 0.1-5 cm of movement per blow. In other instances, refusal can be defined at a given force, which is sufficient to support the load that will be placed thereon. After having advanced the micropile 160 to a point of refusal 604, the micropile 160 can then be moved back or caused to retreat, such as by unscrewing or reversing the torque on the micropile 160. Retreating the micropile 160 can comprise moving back the first end 161 of the first micropile 160 a distance of 1-3 inches (or about 2 inches) to form a void 180, the void 180 comprising a corresponding depth of 1-3 inches.

The sacrificial tip 168 of the micropile 160 may be moved or forced to detach or pivot away from a direction of the length L of the micropile 160, such that the sacrificial tip 168 may lie down horizontally or substantially horizontally, and be disposed within the void 180 formed by retreating the micropile 160. In some instances, a rod thinner than the hollow interior 164 will be used to force the sacrificial tip 168 aside. In some instances, the sacrificial tip 168 will partially detach from the first micropile 160, and pivot or remain partially attached to the micropile 160. In other instances, the sacrificial tip 168 will detach completely from the micropile 160, and will then contact the micropile 160 directly or indirectly through the grout 184, for additional support. In some instances, the sacrificial tip 168 may be made to lay down horizontally by being knocked out or detached, such as by being pushed by the rod from a hollow inside of the micropile.

Cement grout 184, as used herein, may also comprise, or other suitable hardening material including epoxy, resin, or other binder with other filler, such as sand, aggregate or other material (collectively hereinafter “grout” 184), may be placed within the hollow interior 164 of the first micropile 160a. At least a portion of the cement grout 184 may then be forced or moved down through the hollow interior 164 of the micropile 160 to a bottom of the micropile 160, pass through and out of the micropile 160, and be disposed withing the void 180 and around the sacrificial tip 168 before the grout 184 hardens and cures. Once the grout 184 is in place, then the grout 184 may be allowed to cure and harden to form a hardened mass or support 186. The grout 184 can be fast setting grout, such as a grout that hardens to 60-100%, or 80% of full strength or hardness within 0.25-10 hours, 0.5-4 hours, or 0.5-2 hours. Use of the grout 184 may increase the load or force that can be supported by the micropile 160. In some instances, no grout may be used, such as when loading is less, and lighter loads do not require or suggest it. The micropile 160 may be grouted within, or extend through, as permanent or temporary casing, and may also be installed without a casing, such as a casing or sleeve 100 separate from the hollow micropile 160.

The micropile 160 may be torqued to raise (reinforce) the structural element 50. The torque may be applied with any suitable tool, including the same small hydraulic torque driver previously used to insert and then reverse the micropile 160. Raising the structural element 50 may comprise elevating the 10 by a distance in a range of 0″-20″, or 0.1″-4″. Raising the structural element 50 may create a gap or offset 190 between the concrete member 50, 26 and the soil 24, which may compensate for settling of soil underlying the structure. In other applications the micropile 160 may be used to provide lateral support.

FIGS. 9A-9B illustrate cross-sectional views of reinforcing or remediating a sunken or bowed floor slab 26, such as a concrete slab 26 or a post-tension concrete slab 26a.

In particular, FIG. 9A illustrates multiple openings O and sleeves 100a and 100b placed within the slab 26, 26a and separated from each other by a distance or offset O_x in a range of 1-10 feet. A dashed below the slab 26 and ABC layer 28 illustrates a direction the floor slab 26 may deform based on settlement of the soil 24a, 24b, below the slab 26. Micropiles 160 are shown as black lines disposed above the sleeves 100 with arrows disposed thereover indicating the downward direction in which the piles 160 will be positioned.

FIG. 9B, continuing from FIG. 9A, illustrates the micropiles 160 extending through the first layer of soil 24a and being positioned with a first end 161 of the micropile 160 within the second layer 24b of more supportive soil. As noted and described above, the micropiles 160 may be positioned according to the system and method recited in FIGS. 4 and 5. FIG. 9B also includes a dashed line indicated by arrow 602 below the slab 26 and ABC 28 illustrating that undesired bowing or deformation of the slab 26 may be remediated with the use of the micropiles 160.

As illustrated in FIG. 9B, more than one micropile 160 may be used. The method or micropile system 90 may comprise a plurality of sleeves 100 and a plurality of micropiles 160, forming a line, length, grid, or array of micropiles 160 and sleeves 100 (comprising 2-200 in number, or any suitable number), such as to affect an area or length of the structure. When a plurality of micropiles 160 and sleeves 100 are used, multiple openings O, sleeves 100, and micropiles 160 may be used, which may be spaced at a distance O_x of 1-10 feet from each other. For example, a second opening Ob, second sleeve 100b, and second micropile 160 b may be spaced 1-10 feet from the first opening Oa, first sleeve 100 a, and first micropile 160a. As many subsequent micropiles 160 and sleeves 100 as needed or desired may also be used. When multiple micropiles 160 are installed, the torquing or final torquing of the micropiles 160 in done incrementally so that partial movement from each micropile 160 is achieved. Then, additional partial movement from each of the micropiles 160 is again obtained. By raising the structural element 50 (e.g. foundation 16, slab 26) incrementally, better results are obtained (and cracking and weakening are reduced or limited) than is otherwise achieved by raising each micropile 160 the full amount (or most of the full amount), all at once. Raising one micropile 160 all at once and then moving to and raising the next micropile 160 all at once creates greater differences in displacement (lift) and stress in the structural element 50. As such, incrementally raising each micropile incrementally or a little at a time to raise the structural element 50 more equally is preferred. Additionally, different micropiles 160 can be raised different amounts to overcome uneven surfaces and differential settling, and to bring the treated structural element 50 to a level condition.

In some instances, micropiles 160 could be used to raise the structural element 50, such as the floor slab 26 shown in FIGS. 9A and 9B, and then in conjunction with airflow could dry expansive soils, such as the first or top soil 24a, to reduce moisture, reduce volume, and reduce heave of the soil 24a.

Accordingly, the micropile system 90 disclosed herein provides a number of advantages over the prior art and the problems presented by the prior art. Difficulties or problems that applicant has discovered with the approaches in the prior art include at least the following. First, on expansive soils, foam injection carries extreme risk of exacerbated future heave. Second, current pile technology or accepted or prevalent technology requires, or focuses on, coring 8″ holes in slabs for each pile, with spacing recommended at 5 ft and 4 ft being commonly used. Holes this large spaced so closely effectively destroy the integrity of slab, creates shaky spans, creates creep problems, and cracking problems. Third, conventional pile technology is over engineered and not cost effective (30,000 lb capacity for 900 lb load) and an installed price between $1,800 and $2,500 each, which is too expensive for slabs 26. With a large area to repair, this can get very expensive quickly. An example is a relatively small area of 1,000 sf would require 62 piles with a 4 foot spacing for a total repair price of $111,600-$155,000, which is cost prohibitive in almost all applications. Additionally, the intervention requires an invasive, messy, and time-consuming process.

The micropile system 90 provides a number of advantages over the prior art, which include at least the following. First, only a small hole or opening O is made, thereby preserving the strength of the existing slab 26 or structural element 50. Second, the system 90 is cheap and easy to install making small spans affordable and practical. Third, the system 90 can be adjusted up or down during install or later if conditions change. Fourth, the system 90 is not dependent on near surface soils avoiding future settlement or heave. Fifth, the system 90 can be installed with small equipment like air impact drills. Sixth, installation is very fast with only a few minutes per pile. Seventh, the micropiles 60 have a 5,000 lb capacity. Eighth, the materials cost less than $200 per pile and less than $500 per pile installed. Ninth, the slab 26 or structural element 50 at each pile can be raised or lowered at any point.

The present disclosure includes one or more aspects or embodiments in the following description with reference to the figures, in which like numerals represent the same or similar elements. Those skilled in the art will appreciate that the description is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the disclosure as defined by the appended claims and their equivalents as supported by the following disclosure and drawings. In the description, numerous specific details are set forth, such as specific configurations, compositions, and processes, etc., in order to provide a thorough understanding of the disclosure. In other instances, well-known processes and manufacturing techniques have not been described in particular detail in order to not unnecessarily obscure the disclosure. Furthermore, the various embodiments shown in the FIGs. are illustrative representations and are not necessarily drawn to scale.

Where the above examples, embodiments, and implementations reference examples, it should be understood by those of ordinary skill in the art that other systems, devices, and examples could be intermixed or substituted with those provided. In places where the description above refers to particular embodiments of stabilization and construction methods, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these embodiments and implementations may be applied to other technologies as well. Accordingly, although particular component examples may be disclosed, such components may be comprised of any shape, size, style, type, model, version, class, grade, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended purpose, method and/or system of implementation. Thus, the presently disclosed aspects and embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. The disclosed subject matter is intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the disclosure and the knowledge of one of ordinary skill in the art, as set forth in the claims.

Claims

1-19. (canceled)

20. A method of reinforcing a structure, comprising:

forming a first opening through a concrete member of the structure, wherein the opening comprises a sidewall and an opening diameter extending from opposing sides of the sidewall, wherein the opening diameter comprises a distance in a range of 1-3 inches;

inserting a first sleeve within the first opening, the first sleeve comprising an outer surface comprising an outer diameter and an inner surface comprising an inner diameter, wherein: the outer surface comprises first outer threading comprising a first height and second outer threading comprising a second height, the inner surface comprises inner threading formed with an inner thread recess offset from the inner surface, and the first sleeve is threadedly coupled to the sidewall of the first opening of the concrete member;

providing a first micropile comprising a hollow interior, a sacrificial tip, and pile threading on an outer surface;

coupling the first micropile to the first sleeve with the pile threading on the outer surface of the first micropile mateably coupled with the inner threading of the first sleeve;

advancing a first end of the first micropile to a point of refusal in soil below the first opening;

retreating the first end of the micropile to form a void in the soil and moving the sacrificial tip to expose the hollow interior of the micropile;

passing cement grout through the hollow interior of the micropile into the void in the soil; and

torquing the micropile after the cement grout has hardened to exert an upward force against the concrete member.

21. The method of claim 20, wherein the structure comprises a concrete floor slab or a fence footing.

22. The method of claim 20, wherein torquing the micropile raises the concrete member to create a gap between a portion of the concrete member and the soil, wherein the gap comprises a distance in a range of 0.1″-4″.

23. The method of claim 20, further comprising a second opening, second sleeve, and second micropile spaced 1-10 feet from the first opening, first sleeve, and first micropile.

24. The method of claim 20, wherein the inner diameter of the first sleeve comprises a distance in a range of ⅜″-2″.

25. The method of claim 20, wherein the first height of the first outer threading is greater than the second height of the second outer threading.

26. The method of claim 20, wherein the first sleeve comprises:

a first end that comprises a flange; and

a second end opposite the first end, the second end comprising a tapered outer surface.

27. The method of claim 20, wherein:

the first outer threading comprises a height in a range of 0.1-0.8 inches, and an outer threading spacing in a range of 0.4-2.2 inches; and

the second outer threading comprises a height in a range of 1/32″-⅛″, and an outer threading spacing in a range of 0.4-2.2 inches.

28. The method of claim 20, wherein the inner thread recess comprises a height in a range of 0.2-1.0 inches, and an inner threading spacing in a range of 0.5-2.5 inches.

29. The method of claim 20, wherein the first micropile comprises a length in a range of 0.5-8 feet.

30. The method of claim 20, wherein the first micropile is designed to carry a load of 3-5 kips.

31. The method of claim 20, wherein retreating the first end of the micropile to form the void further comprises retreating the first end of the first micropile a distance of 1-3 inches to form the void, the void comprising a corresponding depth of 1-3 inches.

32. A method of reinforcing a structure, comprising:

forming an opening through a concrete member of the structure;

inserting a sleeve within the opening, the sleeve comprising an outer surface threadedly coupled with the concrete member;

coupling a micropile to a threaded inner surface of the sleeve, the micropile comprising an outer threaded surface sized to couple with the threaded inner surface of the micropile, the micropile further comprising a maximum diameter in a range of 0.5-3 inches, wherein the micropile comprises a hollow interior and a sacrificial tip;

advancing a first end of the micropile to a point of refusal in soil below the first opening;

retreating the first end of the micropile to form a void in the soil and moving the sacrificial tip to expose the hollow interior of the micropile;

passing cement grout through the hollow interior of the micropile into the void in the soil; and

torquing the micropile after the cement grout has hardened to exert an upward force against the concrete member.

33. The method of claim 32, wherein the threads on the outer surface of the sleeve comprise a maximum height smaller than a maximum height the threads on the inner surface of the sleeve.

34. The method of claim 32, further comprising torquing the micropile raises the concrete member to create a gap between a portion of the concrete member and the soil.

35. A method of reinforcing a structure, comprising:

forming an opening through a concrete member of the structure;

inserting a sleeve within the opening, the sleeve coupled with the concrete member;

coupling a micropile to a threaded inner surface of the sleeve, the micropile comprising an outer threaded surface sized to couple with the threaded inner surface of the micropile; and

advancing a first end of the micropile to a point of refusal in soil below the first opening.

36. The method of claim 35, wherein a maximum diameter of the micropile comprises a distance in a range of 0.5-3 inches.

37. The method of claim 35, wherein the threads on the outer surface of the sleeve comprise a maximum height smaller than a maximum height of the threads on the inner surface of the sleeve.

38. The method of claim 35, further comprising:

providing the micropile with a hollow interior and with a sacrificial tip at a first end of the micropile;

retreating the first end of the micropile to form a void in the soil and moving the sacrificial tip to expose the hollow interior of the micropile;

passing cement grout through the hollow interior of the micropile into the void in the soil; and

torquing the micropile after the cement grout has hardened to exert an upward force against the concrete member.