Abstract:
Assemblies for improving the installation of pilings into the ground are disclosed. The assemblies may include a modified pipe pile and a removable point inserted into the end of the pile. Methods of using the assemblies in the installation of pipe piling into the ground are also disclosed.

Description:
FIELD OF THE DISCLOSURE 
       [0001]    This disclosure relates to methods of installing piles into the ground and for improving the strength and stability of the installed piles. 
       BACKGROUND OF THE DISCLOSURE 
       [0002]    Helical pipes or piles are typically hollow pipes with helical, spiral, or screw-like flanges on the exterior of the pipe. The piles are installed into the ground with the assistance of a rotational motor drive transmits rotational force or torque into the pipe or pile. The motor turns the reversible drive in the direction that advantageously uses the helical flanges to help move the pipe into the ground. Once a first section of pipe is placed into the ground, a second section of helical pile may be attached to the top end of the first section, and the process is repeated until a column of multiple joined helical pile sections is installed into the ground at the desired depth. 
         [0003]    During the installation process, the earth surrounding the pile will be disturbed and will experience some displacement that loosens the area immediately around the pipe column. The stability and bearing strength of the piles, therefore, may be improved with the inclusion of grout, cement or other cement-like products that cure in place between the pipe exterior and the earth, particularly at or near the bottom of the pipe column. In typical installations, however, each section of pipe is hollow so that dirt, rocks and earth move into the hollow pipe column itself as the piles are installed further into the ground. Less energy from the rotational drive motor is needed to turn and install hollow piles into the ground because the pipe column in such cases does not address compacted, displaced earth as the piles move downward. As a result, grout and similar products cannot be conveyed to the bottom of the column through the hollow interior of the pipes. 
       BRIEF SUMMARY OF THE DISCLOSURE 
       [0004]    The disclosure relates to apparatus and methods of installing piles with adhesive material around the exterior of the piles. Piles have upper, or top, ends and lower, or bottom ends, when the piles are in substantially vertical position. Pile segments may be connected together by means known in the art, which include without limitation the use of fasteners, threaded couplers, or coupling mechanisms, to increase the overall length of the pile assembly. The interior of the pipes are hollow, and the pipes are open at both the upper and lower ends. 
         [0005]    In a first aspect, the disclosure includes an assembly having a cylindrical pipe or pile with a first and second end having one or more helical, spiral, or screw-like flanges or blades fixed onto the exterior of the pile. The blades or flanges may be placed proximate to second, or lower, end of the pile. When the pile is attached to a rotational drive motor, the flanges assist in the installation of the pile into the ground when the motor turns in a positive direction. The assembly includes a device that plugs or substantially closes the bottom of the first pipe in the column to prevent dirt and earth from accumulating within the piles. The device includes an insert portion and a digging portion. The cross section of the device is circular, and the outer diameter is configured to be less than the inner diameter of the hollow helical pile. 
         [0006]    In another aspect, the disclosure includes a method of installing helical pile assemblies that includes forming the pile assembly, placing the tip of the plug device in the ground, installing the piles to a desired depth, and delivering grout through the piles to the bottom of the pile column. 
     
    
     
       BRIEF SUMMARY OF THE DRAWINGS 
         [0007]      FIG. 1  illustrates the bottom end portion of a helical pile and a plug. 
           [0008]      FIG. 2  illustrates the end of a pile column with the plug in place. 
           [0009]      FIG. 3  illustrates the separation of the end of a helical pile from the plug. 
           [0010]      FIG. 4  shows the pile assembly in the ground. 
           [0011]      FIG. 5  shows the separation of the end of a helical pile from the plug in the ground. 
           [0012]      FIG. 6  shows grout delivered into a cavity. 
           [0013]      FIG. 7  illustrates the installed pile assembly. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0014]    As described herein, the disclosure includes a helical pile assembly comprising a pipe or pile and a device or plug. The pipe or pile is a hollow cylinder with a first, upper, or top end and a second, lower, or bottom end. The pipe includes a helical, spiral, or other screw-like flange or blade fastened to or attached to the exterior of the pipe through fasteners, welded joints, adhesive joints, or other means known in the art. The helical flange may be located proximate to the lower end of the pipe. In many embodiments, the helical pile assembly further comprises additional segments of pipe that are joined or connected lengthwise to the first, and bottommost, helical pile. These additional pipe segments may also comprise helical flanges or blades. The helical pile assembly also includes a device or plug that may be removably inserted into the bottom end of the first helical pile of the assembly. The plug, or digging point, includes a pipe insert with a top and bottom and a blade. The outer diameter of the pipe insert is less than that the inner diameter of the helical pile to ensure that the insert may be easily released upon rotational withdrawal of the pile. In some cases, the bottom of the pipe insert is closed, while in other cases, the top of the pipe insert is closed. In yet other cases, both the top and bottom of the pipe insert is closed. 
         [0015]    In many embodiments, the flange of the digging point extends outward from the external sides of the pipe insert. In such instances, the lower end of the helical pile may be configured with one or more notches, slots, grooves or other cutaway portions that permits the flanges to engage the pile when the pipe insert is placed into the helical pile. In many cases, the shape of the notch, groove or cutaway allows the helical pile to engage the digging point when the pile moves in a positive, or downward, direction, and to disengage the digging point when the pile is turned in a negative, or upward, direction. The notches are configured with sufficient room to allow the pipe to disengage from the plug easily when retracted. 
         [0016]    In many embodiments, the assemblies of the disclosure are practiced with metal and metal alloy pipes or piles that are installed into the ground or earth. In other cases, the assemblies of the disclosure may be practiced with plastic or composite pipes installed into the ground, earth or other materials. Those of skill in the art will recognize that the disclosed assemblies may be useful in applications for installing and anchoring pipe or piles in different materials. Moreover, methods of installation may occur at an angle relative to the surface of the ground, i.e., at an angle less than 90 degrees. 
         [0017]    As described herein, a method of the disclosure comprises the assembly of a helical pile and a plug or digging point, placing the tip of the digging point into the ground or earth, and turning the helical pile with a reversible drive in a positive downward direction while engaging the digging point until a desired depth is reached. The method further includes reversing the drive to rotate the helical pile in a negative upward direction to disengage the helical pile from the digging point. As the helical pile moves away from the digging point, a cavity or opening is formed between the bottom of the helical pipe and the top of the digging point pipe insert. The disclosure includes placing grout, cement, or cement-like materials into the formed opening. In many cases, the materials are poured into the cavity through the pipes or piles. In other cases, the materials may be pumped into the cavity through a line or hose placed inside of the pipe or piles. The method includes reversing the drive to rotate the pile again in a positive downward direction until the desired depth is reached while the grout moves outward to surround the exterior of the pile assembly. 
         [0018]    In other embodiments of the invention, the grout is deposited into the pipe interior before the pipe is separated from the digging point. After the grout is poured or pumped into the helical pile interior, the drive is reversed and the helical pile rotated in a negative upward direction. The grout inside of the pile will spread outward from the pile column. The drive direction is reversed again and the helical pile turned to move in a positive downward direction until the target depth is reached while the grout moves outward to surround the exterior of the pile assembly. 
         [0019]    Having now generally provided the disclosure, the same will be more readily understood through reference to the following examples which are provided by way of illustration, and are not intended to be limiting of the disclosure, unless specified. 
       Example 1 
       [0020]    Referring to  FIG. 1 , helical pile assembly  100  includes helical pile  200  and digging point  300 . Helical pile  200  includes pipe  210  and helical flange  220 . Digging point  300  includes pipe insert  310  that is open at the top end but closed at the bottom end, and blade  320 . Blade  320  has flanges that extend upwards and away from the exterior of pipe insert  310 . 
         [0021]    The outer diameter of pipe insert  310  is less than the inner diameter of pipe  210  so that digging point  300  fits easily into the helical pile  200  as shown in  FIG. 2 . Notch  230  in pipe  210  allows pipe  210  to fit pipe insert  310  into the pipe over blade  320 . When helical pile  200  is retracted from digging point  300 , the weight of digging point  300  and the configuration of notch  230  allow easy separation as shown in  FIG. 3 . 
       Example 2 
       [0022]    Referring to  FIG. 4 , helical pile assembly is installed into ground  500  at a desired depth. The drive motor is reversed and helical pipe  200  is retracted upward away from pipe insert  310 , leaving opening  600  as shown in  FIG. 5 . Grout  400  is poured through helical pipe  200  to fill opening  600  in  FIG. 6 . Helical pile  200  is rotated positively downward again until the desired depth is re-attained, while grout  400  moves outward and around helical pile assembly  100  as seen in  FIG. 7 . Grout  400  cures in place and provides additional stability and bearing strength to helical pile  200 . 
       Example 3 
       [0023]    Referring to  FIG. 4 , helical pile assembly is installed into ground  500  at a desired depth. Grout  400  is poured through helical pipe  200  to fill the hollow interior of the pipe. The drive motor is reversed and helical pipe  200  is retracted upward away from pipe insert  310 , while grout  400  spreads outward as shown in  FIG. 6 . Helical pile  200  is turned in a downward direction again until the target depth is achieved, while grout  400  moves outward and around helical pile assembly  100  as seen in  FIG. 7 . 
       REFERENCES 
       [0024]    All references cited herein, including patents, patent applications, and publications, are hereby incorporated by reference in their entireties, whether previously specifically incorporated or not. 
         [0025]    The citation of documents herein is not to be construed as reflecting an admission that any is relevant prior art. Moreover, their citation is not an indication of a search for relevant disclosures. All statements regarding the date(s) or contents of the documents is based on available information and is not an admission as to their accuracy or correctness. 
         [0026]    Having now fully described the inventive subject matter, it will be appreciated by those skilled in the art that the same can be performed within a wide range of equivalent parameters, concentrations, and conditions without departing from the spirit and scope of the disclosure and without undue experimentation. 
         [0027]    While this disclosure has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications. This application is intended to cover any variations, uses, or adaptations of the disclosure following, in general, the principles of the disclosure and including such departures from the present disclosure as come within known or customary practice within the art to which the disclosure pertains and as may be applied to the essential features hereinbefore set forth.