Abstract:
A method for supporting and securing structural members, such as girders, to remediated pilings utilizes a pipe segment and cap plate positioned on the planed top section of the piling and welded to the pipe segment. Structural member supports, such as girder brackets or lally type jacks, are secured to the cap plate. The girder is positioned on the structural member supports and is secured thereto. By this method the girder is solidly and effectively supported by a fully formed, reinforced piling.

Description:
FIELD OF THE INVENTION 
     The present invention relates to methods of reconditioning and reforming old or deteriorating in situ pilings, especially timber pilings, and, more particularly, to preparing these pilings for connection to and for supporting girders and like structural members. 
     BACKGROUND OF THE INVENTION 
     Pilings are utilized in a variety of different environments and for many uses, e.g. in marine environments for supporting and reinforcing piers and vessel docking structures, in the construction industry for supporting and framing buildings, for structure supporting foundations, and supporting and maintaining raised homes and buildings in flood prone areas. The structural members such as girders are quite often utilized on pilings to provide the foundation support for such structural members. 
     Regardless of the environment or context, pilings, which routinely and advantageously are wood or timber pilings, will eventually erode, deteriorate, rot or otherwise become damaged as a result of the passage of time, weather, wear and tear, wave and tidal action in marine situations, insect infestations, battering, etc. In many cases, the lower, less exposed section of the piling sustains far less damage, since it is often not directly affected by weather, it is imbedded in the ground and/or, in marine circumstances, may have cathodic protection. As a result, when deterioration of or damage to the upper section of a piling has become very severe, even though the piling&#39;s lower section is in tact, the piling must be repaired or totally replaced. 
     This is especially significant where pilings are relied upon to maintain and support homes and buildings above ground in shore communities, near oceans, lakes or rivers. In these areas, damage from flooding often damages the upper sections of support pilings, requiring pile replacement. 
     However, total replacement of pilings is an expensive and involved process, especially in marine environments. Even the repair of pilings is quite costly and time consuming, since these types of repairs usually involve the construction of a wall, cofferdam, or like barrier around the piling, with the subsequent removal of ambient water, in order to provide a dry space in which to work. 
     When it is necessary to secure girders or like supporting structural members to existing pilings, the current practice known as “banding” requires that a section of the piling be cut out to accept the girder, which is then attached to the piling.  FIG. 1  depicts typical piling banding, in which section  202  of piling  200  is cut out and girder  203  is positioned within the section. Bolts/nuts  204  extend through piling  200  and girder  203  to secure the girder to the piling. This common method has the obvious deleterious effect of severely weakening the piling, which now must support the girder with less than its full structural compliment. 
     These time-consuming processes, many of which provide less than effective structural connections, and their resulting expense are exacerbated when major catastrophes create the need to address numerous piling failures. Property damage, such as occurred as a result of superstorm Sandy in 2012, highlights the need for effective, efficient, and economical means to repair deteriorated and partially destroyed pilings and their supporting structures. Such is needed not only to connect in situ pilings to new pilings in routine situations, e.g. docks, piers, docking stations, etc., but also for emergent construction, for instance to renew damaged pilings which support raised homes and other building structures in flood plague locations. In fact, new government requirements since Sandy require existing homes, buildings, and other shoreside structures to be built on timber pilings, raised to new elevations of up to three feet or more. 
     SUMMARY OF THE INVENTION 
     It is thus the object of the present invention to provide a method for remediating and reforming pilings and efficiently and effectively securing girders and other supporting structural members to the rehabilitated pilings. 
     These and other objects are accomplished by the present invention, a method for supporting and securing structural members, such as girders, to remediated pilings utilizing a pipe segment and cap plate positioned on the planed top section of the piling and welded to the pipe segment. Structural member supports, such as girder brackets or lally type jacks are secured to the cap plate. The girder is positioned on the structural member supports and is secured thereto. By this method the girder is solidly and effectively supported by a fully formed, reinforced piling. 
     The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The invention, itself, however, both as to its design, construction and use, together with additional features and advantages thereof, are best understood upon review of the following detailed description with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts a prior art method of securing or banding a structural member, such as a girder, to a piling. 
         FIG. 2  is a bottom isometric view of the planing tool used in the method of the present invention, without its spacer rings attached. 
         FIG. 3  is a top view of the planing tool used in the method of the present invention. 
         FIG. 4  is a partial cross-sectional view of the planing tool used in the method of the present invention, taken from  FIG. 2 , with its spacer rings attached. 
         FIGS. 5-6  depict the steps of the method of planing pilings, used in the method of the present invention. 
         FIG. 7  is an exploded view of the components utilized in the method of the present invention. 
         FIG. 8  is a cross-sectional view taken from  FIG. 7 . 
         FIGS. 9-11  depicts the continuing steps in completing the method of the present invention. 
         FIG. 12  depicts an alternate structural support member utilized in the method of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The piling planing tool  1  used in the method of the present invention has been initially disclosed in co-pending application Ser. No. 13/888,469. A method of use of tool  1  is disclosed in U.S. Pat. No. 8,579,548. Planing tool  1  and its method of operation are depicted in  FIGS. 2-6 . 
     Piling planing tool  1  comprises unitary, cylindrically shaped cutter head  2  having circular top wall  4 , bottom circular ring  6 , and circular middle section  8 , with sidewall  10  extending between the top wall and bottom ring. Top wall  4  and bottom ring  6  each extend past sidewall  10  of middle section  8 . Top wall  4  and middle section  8  encompass internal space  12  which extends through bottom ring  6 . Cutter head  2  has an open bottom. For purposes of context, it is contemplated that the height of cutting head  2 , from its top wall  4  to bottom ring  6 , will be approximately four to six inches. 
     Drill bits  14  and  16 , sized to be in excess of one inch in diameter, extend through top wall  4  and into and out of internal space  12 . Longer drill bit  14  is initially utilized in the method of the invention, and is replaced by smaller drill bit  16  during the later steps of the method, as will be described hereinafter. The drill bits are secured to cutter head  2  by means of motive power connection means, e.g. mandrel  18 /lock nut connection  20 , on the top surface of top wall  4 . Drill bits  14  and  16  are configured to be attached to a power motive means, e.g. feed mag drill  22 , which raises, lowers, and rotates the bits, as well as the other components of planing tool  1 . For purposes of context, it is contemplated that drill bit  14  will be approximately 30-36 inches long and drill bit  16  will be approximately four to six inches long. However, the dimensions of the drill bits are not to be considered restricted to those stated herein. 
     Piling planing means, e.g. circular flat cutting blade  24  with downwardly extending cutting teeth  26  on the lower surface of the blade, is located parallel to and below top wall  4 , in internal space  12 . Blade  24  is secured to top wall  4  by screws  25  extending from the top wall. Blade  24  has an opening through which drill bits  14  and  16  extend and is mounted perpendicularly to the drill bits. 
     Bottom ring  6  has openings for the insertion of screws  30  which attach cutter head  2  to cutter ring  40 , as shown in  FIG. 2 , and subsequently to spacer rings  60   a  and  60   b , as described below. 
     Second planing means, e.g. cutter ring  40 , comprises circular outer rim  42  having an inner circular edge with downwardly extending planing teeth  44  circumferentially located within the outer rim of the cutter ring. Outer rim  42  has openings for the insertion of screws  30  which attach cutter ring  40  to cutter head  2 , as shown in  FIG. 2 , and subsequently to spacer rings  60   a  and  60   b , as described below. 
     As shown in detail in  FIG. 4 , extension means, e.g. spacer rings  60   a  and  60   b , are configured to lengthen planing tool  1 , during the pile connection method described hereinafter. Spacer rings  60   a  and  60   b  comprise circular top rings  62   a  and  62   b  and circular bottom rings  64   a  and  64   b , interconnected by circular middle sections  66   a  and  66   b , and internal spaces  68   a  and  68   b . The top and bottom rings of spacer rings  60   a  and  60   b  extend past middle sections  66   a  and  66   b  and each has openings for the insertion of screws  30  which attach spacer ring  60   a  to cutter head  2 , screws  31  which attach spacer ring  60   a  to spacer ring  60   b , and screws  32  which attach spacer ring  60   b  to cutter ring  40 . 
     As will be described hereinafter, the length of planing tool  1  will be changed, as the method progresses, by attaching additional spacer rings to the planing tool. It is contemplated that, for purposes of the herein method, planing tool  1 , with cutter head  2 , cutter ring  40 , and two spacer rings  60   a  and  60   b  attached, will reach a length of approximately 30-36 inches, but such is not to be considered so restrictive. It should be understood that additional spacer rings could be added if there is a need to extend the length of the planing tool. 
     For example,  FIGS. 4 and 6  show planing tool  1  with cutter head  2  attached to spacer ring  60   a , spacer ring  60   a  attached to spacer ring  60   b , and spacer ring  60   b  attached to cutter ring  40 . Drill bit  16  extends partly through the components making up planing tool  1 , as is described below. 
     The dimensions of planing tool  1  are critical and contribute to its uniqueness, in that the tool must be capable of encircling an in situ piling and of planing a significant length of the outer surface of the piling in order to accomplish the piling remediation method of the invention. As such, planing tool  1  is an integral component in the basic piling connection method of the present invention. 
     As seen in  FIG. 5 , planing tool  1  is attached to feed mag drill  22 , which itself is maintained on existing, in situ piling  80 , by support bracketing  82  or an equivalent support. Lower portion  84  of piling  80  is imbedded into the ground or seabed  86 , depending on the targeted environment. Upper portion  88  extends above ground and, as a result of age, ambient conditions, wear and tear, and similar deteriorating factors, has rough, worn and uneven outer surface  90  and top surface  92 . Again as shown in  FIG. 5 , planing tool  1  is initially positioned over top surface  92  of piling  80 , with longer drill bit  14  centered over the piling. At this initial stage, planing tool  1  is comprised of cutter head  2  connected directly to cutter ring  40  by screws, as previously described. 
     Feed mag drill  22  is actuated to lower and then rotate cutting tool  1  at high speed, e.g. 100-1000 RPM. As the bitter end of rotating drill bit  14  contacts top surface  92  of piling  80 , it begins boring center channel  74  (see  FIG. 6 ) through the piling. When rotating cutter ring  40  reaches piling  80 , its circumferential rotating planing teeth  44  begin planing outer surface  90  of the piling. When cutting blade  24  contacts top surface  92  of piling  80 , it begins shaving and planing the top surface, thus smoothing the top surface, ultimately creating a flat, concentric top surface. 
     After outer surface  90  of piling  80  is planed for a distance equal to the height of planing tool  1 , with cutter head  2  and cutter ring  40  attached, rotation of the cutting tool is halted and it is lifted above the piling by feed mag drill  22 . Cutter ring  40  is detached from cutter head  2  and one or more of the spacer rings  60   a  and  60   b  are inserted between and attached to the cutter ring and cutter head by screws in the top and bottom rings of the spacer rings and to the cutter ring and cutter head, as previously described. At this point, drill bit  14  has bored center channel  74  into piling  80  to the requisite depth to perform the method. Drill bit  14  is now removed and replaced with smaller bit  16 , e.g. one which is shorter than the current length of planing tool  1 . Drill bit  16  now serves to assist in the stability of planing tool  1  as it continues to plane outer surfaces  90  of piling  80 . 
     After planing tool  1  has been lengthened with space rings  60   a  and  60   b , feed mag drill  22  is again actuated to lower and rotate the cutting tool and its rotating cutter head  2  with rotating cutting ring  40  to continue planing outer surface  90  of piling  80 , thus shaving off outer surface pieces  80   a , and, by means of cutting blade  24 , planing off top surface pieces  80   b.    
     The process of planing outer surface  90 , by adding spacer rings  60   a  and  60   b  as previously described, continues until smooth milled piling section  93  is created. Milled piling section  93  has a diameter less than the diameter of piling  80  and lip surface  95  is formed along the bottom end of the milled section of the piling. The piling has been planed such that its milled section  93  is a given length, typically approximately two feet, and comprises smooth level top surface  92  which is substantially perpendicular to outside surface  95  of the piling. In this manner, piling  80  has been prepared to support a structural member, such as girder  100 . 
     Cylindrical pipe segment  102  is provided having an internal diameter slightly larger than the diameter of milled piling section  93 . Pipe segment  102  is thus sized to snugly fit around milled piping section  93 , such that the bottom of the pipe segment rests on lip surface  95  and its top edge  104  extends up to and substantially level with smooth top surface  92  of the piling. In this position, outside surface  106  of the pipe segment is in substantially the same vertical plane as outside surface  90  of the non-milled section of piling  80 . 
     Flat cap plate  108  with threaded openings  109  is next positioned atop smooth top surface  92  of piling  80  and top edge  104  of pipe segment  102 , the top surface having been milled flat for bearing maximum loads. Weld  120  is applied around top edge  104  to permanently secure cap plate  108  to pipe segment  102 . Bolts  105  extend through holes  107  of pipe segment  102  and then through holes  110  of milled section  93  of piling  80  to secure the pipe segment to the piling. See  FIGS. 7 and 9 . 
     Structural member supports, shown in  FIGS. 7 ,  10  and  11  as girder brackets  112  and  113 , are secured by bolts  114  through holes  109  in cap plate  108  and then into holes  111  drilled into piling  80 . Girder  100  is then positioned within brackets  112  and  113  and secured therein by bolts  122  into the girder. 
       FIG. 12  shows application of the inventive method utilizing lally screw jacks  130 ,  132 , and  134  as structural support members. In this embodiment, pipe segment  102  is secured to piling  80  by screws  138 . The lally jacks are secured by bolts  136  to cap plate  108  and into piling  80 . Once secured to the cap plate, the lally jacks are raised up and adjusted sufficiently to contact and support an existing girder  140  or support a newly installed girder. The jacks can be permanently secured to the girder, if necessary. Significantly, bolting jacks to the top of rough, unreformed pilings would be impossible, without the steps of the present inventive method. As a practical matter, and contrary to effective, proper, and safe construction techniques, jacks can not be fastened to the tops of uneven wooden pilings, without fabricating extensive and expensive structural steel supports. 
     It is anticipated that cap plate  108  would be constructed of steel, e.g. approximately one quarter inch thick for girder brackets  112  and  113  and up to one half inch thick when lally jacks  130 ,  132 , and/or  134  are used. Since cap plate  108  is installed on smooth top surface  92  of piling  80 , it will be square with the pile and level, thereby permitting effective fastening of structural member supports such as the girder bracket and the lally jacks. 
     By this method, worn pilings can be reformed and rejuvenated to support girders and like structural members. The method also ensures that such pilings can be effectively installed below existing structures, without the need to move the structures or attempt to calculate and try to “fit” new pilings between in situ pilings and structures. 
     Certain novel features and components of this invention are disclosed in detail in order to make the invention clear in at least one form thereof. However, it is to be clearly understood that the invention as disclosed is not necessarily limited to the exact form and details as disclosed, since it is apparent that various modifications and changes may be made without departing from the spirit of the invention.