FOUNDATION SYSTEMS AND UTILITY POLE INSTALLATIONS AND METHODS INCLUDING SAME

A foundation system for mounting a utility pole includes a foundation base member, a plurality of anchor piles, and a plurality of anchor adapters. The foundation base member is configured to support the utility pole. The foundation base member includes a plurality of preformed holes defining an array of preformed through holes. The plurality of anchor piles is configured to be driven into the ground. The plurality of anchor adapters is configured to secure the foundation base member to the anchor piles. The plurality of preformed through holes are arranged to receive the anchor adapters.

FIELD

The present disclosure relates to foundation systems for utility poles.

BACKGROUND

Utility poles are commonly used to mount cellular communications antennas in cities. These antennas may form parts of mobile broadband networks. Poles with integrated cellular communications antennas or radio heads and are referred to as small cell poles.

In some instances, it is desired or necessary to replace an existing utility pole (e.g., a light pole) with a small cell pole. It may also be desirable or necessary to provide a foundation for the new small cell pole while leaving in place a foundation of the existing utility pole or other obstacles such as utility cables or pipes.

SUMMARY

According to some embodiments, a foundation system for mounting a utility pole includes a foundation base member, a plurality of anchor piles, and a plurality of anchor adapters. The foundation base member is configured to support the utility pole. The foundation base member includes a plurality of preformed holes defining an array of preformed through holes. The plurality of anchor piles is configured to be driven into the ground. The plurality of anchor adapters is configured to secure the foundation base member to the anchor piles. The plurality of preformed through holes are arranged to receive the anchor adapters.

In some embodiments, the foundation base member is a grate.

According to some embodiments, each anchor adapter includes a wedge connector configured to be received in a pile bore of a respective one of the anchor piles and to secure the anchor adapter to the respective anchor pile.

In some embodiments, each wedge connector includes a threaded rod, at least one wedge member, and a drive nut threadedly mounted on the threaded rod and operable to displace the wedge member.

In some embodiments, the at least one wedge member includes an elongate slot, the threaded rod extends into the wedge member through the elongate slot, and the slot permits the wedge member to translate radially relative to the threaded rod.

In some embodiments, each wedge connector includes a first wedge member and a second wedge member each having a sloped bearing face, the sloped bearing face of the first wedge member slidably engages the sloped bearing surface of the second wedge member, and the drive nut is drivable to displace the first wedge member relative to the second wedge member and thereby force at least one of the first and second wedge members radially outward to press against an inner surface of the respective pile bore.

In some embodiments, the foundation system includes: a retainer nut on the thread rod and coupling the thread rod to the second wedge member; and a cage member that prevents rotation of the retainer nut relative to the second wedge member.

According to some embodiments, a method for installing a foundation system for mounting a utility pole includes: providing a foundation base member including preformed through holes; thereafter, driving anchor piles into the earth until a prescribed minimum torque is achieved; installing respective anchor adapters on each anchor pile; positioning a foundation base member over the anchor adapters such that each anchor adapter aligns with a respective one of the preformed through holes of the plurality of preformed holes of the foundation base member, the foundation base member configured to support the utility pole; and, securing the foundation base member to the anchor piles.

In some embodiments, the plurality of preformed holes defines an array of preformed through holes.

According to some embodiments, the foundation base member is a grate.

In some embodiments, the method further includes the step of inserting a wedge connector of an anchor adapter into a respective one of the anchor piles and securing the anchor adapter to the respective anchor pile.

According to some embodiments, each wedge connector includes a threaded rod, at least one wedge member, and a drive nut threadedly mounted on the threaded rod and operable to displace the wedge member.

In some embodiments, the at least one wedge member includes an elongate slot, the threaded rod extends into the wedge member through the elongate slot; and the slot permits the wedge member to translate radially relative to the threaded rod.

In some embodiments, each wedge connector includes a first wedge member and a second wedge member each having a sloped bearing face, the sloped bearing face of the first wedge member slidably engages the sloped bearing surface of the second wedge member, and the drive nut is drivable to displace the first wedge member relative to the second wedge member and thereby force at least one of the first and second wedge members radially outward to press against an inner surface of the respective pile bore.

In some embodiments, the wedge connector includes: a retainer nut on the thread rod and coupling the thread rod to the second wedge member; and a cage member that prevents rotation of the retainer nut relative to the second wedge member.

In some embodiments, each wedge connector includes a tension indicator operative to indicate a tension load on the threaded rod.

According to some embodiments, a foundation system for mounting a utility pole includes a foundation base member, a plurality of anchor piles, and a plurality of anchor adapters. The foundation base member is configured to support the utility pole. The plurality of anchor piles is configured to be driven into the ground. The plurality of anchor adapters is configured to secure the foundation base member to the anchor piles. Each anchor adapter includes a wedge connector configured to be received in a pile bore of a respective one of the anchor piles and to secure the anchor adapter to the respective anchor pile.

In some embodiments, each wedge connector includes a threaded rod, at least one wedge member, and a drive nut threadedly mounted on the threaded rod and operable to displace the wedge member.

According to some embodiments, the at least one wedge member includes an elongate slot, the threaded rod extends into the wedge member through the elongate slot, and the slot permits the wedge member to translate radially relative to the threaded rod.

In some embodiments, each wedge connector includes a first wedge member and a second wedge member each having a sloped bearing face, the sloped bearing face of the first wedge member slidably engages the sloped bearing surface of the second wedge member, and the drive nut is drivable to displace the first wedge member relative to the second wedge member and thereby force at least one of the first and second wedge members radially outward to press against an inner surface of the respective pile bore.

DETAILED DESCRIPTION

The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the disclosure are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

It is noted that aspects described with respect to one embodiment may be incorporated in different embodiments although not specifically described relative thereto. That is, all embodiments and/or features of any embodiments can be implemented separately or combined in any way and/or combination. Moreover, other apparatus, methods, and systems according to embodiments of the inventive concept will be or become apparent to one with skill in the art upon review of the following drawings and detailed description. It is intended that all such additional apparatus, methods, and/or systems be included within this description, be within the scope of the present inventive subject matter, and be protected by the accompanying claims.

As used herein, “monolithic” means an object that is a single, unitary piece formed or composed of a material without joints or seams. Alternatively, a unitary object can be a composition composed of multiple parts or components secured together at joints or seams.

Embodiments of the present technology are directed to foundation systems for utility poles and methods for using the same. According to some embodiments, the foundation system is configured to mount a small cell pole and the method includes forming a small cell utility pole installation using the foundation system.

As shown in FIGS. 1 and 2, a utility pole installation 10 according to some embodiments includes a utility pole 50 and a structural foundation system 101. The foundation system 101 is installed in the ground or earth 30. In some embodiments, the utility pole installation 10 is connected to underground cabling 32. The foundation system 101 may installed around and between pre-existing obstacles 34. The pre-existing obstacles 34 may be the foundation of utility pole that has been removed, underground cabling or pipes, or the like, for example.

In some embodiments, the utility pole 50 is a small cell utility pole. In some embodiments, the utility pole 50 is a monopole small cell utility pole. The utility pole 50 includes a pole body 52 having a lower end 52A and an opposing upper end 52B. In some embodiments, the utility pole 50 includes an integrated radio/antenna unit 54 configured to transmit one or more of RF communications signals, cellular communications signals and mobile broadband communications signals. In some embodiments, the utility pole 50 includes an integral light fixture 56. The integrated radio/antenna unit 54 and the integral light fixture 56 may be mounted on or proximate the upper end 52B. The utility pole 50 includes a pole base 58 on its lower end 52B. The utility pole 50 may be formed of metal or wood, for example.

In some embodiments, the utility pole 50 has a height H1 (FIG. 1) in the range of 15 feet to 50 feet.

With reference to FIGS. 2-4, the foundation system 101 defines a structural foundation assembly 100. The foundation system 101 includes a foundation base member 110, a pole mount system 131, and an anchor system 151.

As best shown in FIG. 4, the foundation base member 110 has a substantially square or rectangular shape defined by a first set of spaced apart walls 114 extending along a first axis D1 and a second set of spaced apart walls 116 extending along a second axis D2 transverse (e.g., perpendicular) to the first. It is understood that the substantially square or rectangular shape of the foundation base member 110 is merely exemplary and is not intended to be limiting. In embodiments, the foundation base member 110 may be round, oval, triangular or more generally any geometric shape. In embodiments, the foundation base member 110 may have an irregular non-geometric shape to avoid and be installed around and between pre-existing obstacles 34. By way of example, the foundation base member 110 may be U-shaped or L-shaped to avoid an overground or underground pre-existing obstacle 34.

The foundation base member 110 is defined by a top side 112A and an opposing bottom side 112B, where the top side 112A and an opposing bottom side 112B define thickness T1 (as best shown in FIG. 2) of the foundation base member 110. In embodiments, the thickness T1 is in the range of 2 inches to 6 inches.

The foundation base member 110 further includes a plurality of preformed through holes 120 extending through the thickness T1 and parallel to the walls 114, 116, the holes 120 collectively defining an array 122 of preformed through holes 120. In some embodiments, the array 122 substantially covers the surface area of the foundation base member 110. In some embodiments, the array 122 covers a portion of the surface area of the foundation base member 110. In some embodiments, the array 122 defines a first portion of the surface area of the foundation base member 110, and an opening or plurality of openings define a second portion of the surface area of the foundation base member 110. The openings may be positioned on the surface area to avoid an overground or underground pre-existing obstacle 34.

In some embodiments, the holes 120 are arranged in a grid of parallel rows and columns extending along the axes D1 and D2. The base member 110 thus takes the form of a grate. Other hole patterns or wall arrangements may be used to form the grate. In embodiments, the holes form an irregular array 122 to avoid an overground or underground pre-existing obstacle 34.

In some embodiments, a length L1 (FIG. 4) and a width W1 (FIG. 4) of the foundation base member 110 are each in the range of 3 feet to 8 feet.

In some embodiments, each through hole 120 has a hole width W2 (FIG. 4) in the range of 1 inch to 4 inches. In some embodiments, each through hole 120 is rectangular, square or round. In some embodiments, the array 122 of preformed through holes 120 is at least a ten (10) by ten (10) array. In some embodiments, the array 122 includes at least fifty (50) preformed through holes 120. In some embodiments, the number of holes 120 in the array 122 is in the range or one hundred (100) to five hundred (500) preformed through holes 120. In some embodiments, the spacing between centers of adjacent preformed through holes 120 in the array 122 is less than 1 inch. The foundation base member 110 may be formed of any suitable material. In some embodiments, the foundation base member is formed of iron or steel. In some embodiments, the foundation base member 110 is formed by casting. In some embodiments, the foundation base member 110 is monolithic. In some embodiments, the foundation base member 110 is a cast iron grate. In other embodiments, the foundation base member 110 may be formed using other materials and/or other methods of fabrication.

As best shown in FIG. 5, the pole mount system 131 defines a pole mount subassembly 130. The pole mount system 131 includes a first mount plate 132, a second mount plate 134, and pole mount fasteners (e.g., bolts 140 and nuts 142). Each of the first and second mount plates (132, 134) comprises a respectively aligned conduit hole 138 for passing electrical or signal conduits through the first and second mount plates (132, 134). In some embodiments, the mount plates 132, 134 are formed of a metal or metal alloy (e.g., steel).

The anchor system 151 defines at least one anchor subassembly 150. In embodiments, three or four anchor subassemblies 150 are incorporated in an installation. Each anchor subassembly 150 includes a respective anchor pile 152 and an anchor adapter 160.

As best shown in FIGS. 2 and 3, in some embodiments and as illustrated, each anchor pile 152 includes an elongate rod 154 and one or more bearing plates 158. Each respective rod 154 has a tubular body defined by a proximal end 154A and an opposing distal end 154B with a pile bore 156 defined therein. The bore 156 defines an inner sidewall surface 156A of the rod 154. In some embodiments and as illustrated, the bearing plates 158 are helical bearing plates. The helical profile of the bearing plates 158 are merely exemplary and are not intended to be limiting. As disclosed herein, according to some embodiments, the anchor piles are helical piles. According to further embodiments, piles of other types and configurations may be used in place of the helical anchor piles 152. In some embodiments, each anchor pile 152 has a length in the range of 5 feet to 12 feet.

FIG. 6 illustrates an exemplary configuration of an anchor adapter 160. The anchor adapter 160 has a proximal end 162A and an opposing distal end 162B. In embodiments, the anchor adapter 160 includes a threaded rod 164, a clamp nut 166, an upper clamp washer 167, a lower clamp washer 168, and a connector 170. The clamp nut 166, the upper clamp washer 167, and the lower clamp washer 168 define a clamping mechanism 169 on the proximal end 162A.

In the illustrated embodiment, the connector 170 is an expansion wedge connector. The connector 170 is located on the distal end 162B. In embodiments, the connector 170 has a proximal end 170A and an opposing distal end 170B. The connector 170 includes a portion of the threaded rod 164, a drive nut 172, a retainer 174, a stop washer 176, an upper wedge member 177, and a lower wedge member 179. In embodiments, the wedge members 177, 179 and the stop washer 176 are axially slidably mounted on the threaded rod 164. In embodiments, the retainer 174 may be a nut and is affixed to the distal end of the threaded rod 164 (e.g., by adhesive or welding). The drive nut 172 is threaded onto the threaded rod 164. The upper wedge member 177 and the lower wedge member 179 each have a sloped bearing face 177A, 179A and a semi-cylindrical anchoring surface 177B. 179B. The bearing faces 177A, 179A engage one another and may be complementary. A lubricant (e.g., wax) may be provided on the bearing faces 177A, 179A.

In other embodiments, the connector 170 may be n expansion connector of a different type, such as a sleeve anchor, a strike anchor, a drop-in anchor or an epoxy connector.

With reference to FIGS. 9-13, an anchor adapter 260 according to further embodiments of the disclosure is shown therein. An anchor adapter 260 may be used in place of each of the anchor adapters 160 in the anchor system 151 and the foundation system 101 to form anchor subassemblies with the anchor piles 152. The anchor adapter 260 has a proximal end 262A and an opposing distal end 262B. In embodiments, the anchor adapter 260 includes a threaded rod 264, a pair of clamp nuts 266, an upper clamp washer 267, a lower clamp washer 268, three intermediate washers 265, and a connector 270. The clamp nuts 266, the upper clamp washer 267, and the lower clamp washer 268 form a clamping mechanism 269 on the proximal end 262A.

The connector 270 is an expansion wedge connector. The connector 270 is located on the distal end 262B. In embodiments, the connector 270 has a proximal end 270A and an opposing distal end 270B. The connector 270 includes a portion of the threaded rod 264, a drive nut 272, a retainer nut 274, a washer 278, a tension indicator 275, an upper wedge member 277, and a lower wedge member 279.

The upper wedge member 277 includes a tubular wedge body 277C and an end cap or stop washer 276 affixed (for example, bonded, welded or adhered) to the upper end of the wedge body 277C. The stop washer 276 includes an elongate slot 276A and a peripheral notch 276B defined therein. The upper wedge member 277 has a sloped bearing face 277A and a semi-cylindrical anchoring surface 277B. The elongate slot 276A in the stop washer 276 facilitates smooth and even movement of the upper wedge member 277 relative to the threaded rod 264 so that the semi-cylindrical anchoring surface 277B makes good contact with the inner surface of the bore inner surface 156A. With reference to FIG. 13, in embodiments, the lengthwise axis A-A of the slot 276A is substantially parallel to the wedge displacement directions DE. The slot 276A is configured to allow the upper wedge member 277 to translate radially outward relative to the threaded rod 264. The notch 276B enables proper alignment of the stop washer 276 during a step of securing the stop washer 276 to the wedge body 277C.

The lower wedge member 279 includes a tubular wedge body 279C, a U-shaped cage member 279D and an end plate 279E. The lower wedge member 279 has a sloped bearing face 279A and a semi-cylindrical anchoring surface 277B. The cage member 279D and the end plate 279E are affixed (for example, bonded, welded or adhered) to the lower end of the wedge body 279C. The retainer nut 274 is captured between the cage member 279D and the end plate 274E such that the retainer nut 274 is prevented from rotating relative to the tubular wedge body 279C. In some embodiments, the retainer nut 274 is bonded or otherwise affixed to the lower end of the threaded rod 264.

The tension indicator 275 is axially interposed between the stop washer 276 and the washer 278. In some embodiments, the tension indicator 275 is a direct tension indicator (DTI) comprised of an annular body 275B and integral, deformable indicator protrusions 275A.

In embodiments, the wedge members (277, 279), the annular body 275B of the tension indicator 275, and the washer 278 are axially slidably mounted on the threaded rod 264. The drive nut 272 is threaded onto the threaded rod 264. The bearing faces 277A, 279A engage one another and may be complementary. A lubricant (e.g., wax) may be provided on the bearing faces 277A, 279A.

In use, the anchor adapter 260 is installed on a respective anchor pile 152. More particular, the connector 270 of the anchor adapter 260 is inserted into the bore 156 through the proximal opening 156B of the rod 154. The depth of insertion is limited by the stop washer 276. The installer then turns the drive nut 272 to force the upper wedge member 277 toward the retainer nut 274 (in direction DT as shown in FIG. 8). The lower wedge member 279 is axially constrained by the retainer nut 274 and the relative movement between the bearing faces 277A and 279A therefore drives the wedge members 277 and 279 radially outward (in directions DE) relative to one another and into forced engagement with the bore inner surface 156A. The drive nut 272 is driven until the wedge members (277, 279) are sufficiently expanded and loaded against the bore inner surface 156A. In this manner, the connector 260 is securely locked into the bore 156 of the anchor pile 152 by a friction fit.

The loading of the wedge members (277, 279) on the bore inner surface 156A may be determined by monitoring the torque applied to the drive nut 272. In some embodiments, the loading of the wedge members (277, 279) on the bore inner surface 156A is determined using the tension indicator 275. In some embodiments, the tension indicator 275 includes deformable protrusions 275A disposed on at least one annular surface of the tension indicator 275. Loading on the wedge members (277, 279) deforms and at least partially flattens the protrusions 275A such that the installer or an inspector can assess and confirm whether sufficient tension is present in the threaded rod 264 by measuring the distance (i.e., gap) between the body 275B of the tension indicator 275 and the washer 287. The gap may be checked using a feeler gauge, for example.

FIG. 14 illustrates a method 300 of installing the foundation system 101. The site is first prepared as needed. Site preparation may include removing an existing utility pole (e.g., light pole), excavating earth and/or existing concrete foundation, removing or relocating utilities (e.g., cabling, conduits and/or pipes), and/or locating obstructions (e.g., existing foundation, utilities and the like).

At step 302, the method 300 comprises driving the anchor piles 152 into the earth 30 until a prescribed minimum torque is achieved. The anchor piles 152 may be driven using any suitable driver. The torque applied to each anchor pile may be monitored using a suitable torque detector. If necessary, an extension anchor pile 152 may be added to the proximal end of the driven anchor pile 152 such that the extended anchor pile coupled to the driven anchor pile 152 can be further driven into the earth 30 until the prescribed torque is achieved. The locations into which the anchor piles 152 are driven may be selected so as to avoid pre-existing overground and/or underground obstacles (e.g., the foundation of a utility pole that has been removed or underground cabling or pipes). In embodiments. after the anchor piles 152 have been driven to the prescribed torque, the proximal end of each anchor pile 152 is cut to a height corresponding to the depth at which the installer intends to mount the utility pole 50. In some embodiments, this height is below grade level FG (FIG. 1).

In some embodiments, the through holes 120 are formed in the foundation base member 110 prior to the step of driving the anchor piles 152 into the earth 30. For example, the through holes 120 may formed in the foundation base member 110 at the time of manufacture of the foundation base member 110, prior to delivery of the foundation base member 110 to the customer or installer.

At step 304, the method 300 further comprises installing respective anchor adapters 160 on each anchor pile 152. More particular, the connector 170 of the anchor adapter 160 is inserted into the bore 156 through a proximal opening 156B of the rod 154 such that the stop washer 176 abuts the proximal opening 156B of the rod 154.

At step 306, the method 300 further comprises securing each respective anchor adapter 160 to each anchor pile 152 by torquing the drive nut 172 such that the upper wedge member 177 is urged toward the retainer 174 (in direction DT). The lower wedge member 179 is axially constrained by the retainer 174 and the relative movement between the bearing faces 177A and 179A therefore drives the wedge members 177 and 179 radially outward (in directions DE) relative to one another and into forced engagement with the bore inner surface 156A. The drive nut 172 is torqued until the wedge members 177, 179 are sufficiently expanded and loaded against the bore inner surface 156A. In this manner, the connector 160 is securely locked into the bore 156 of the anchor pile 152 by a friction fit. The loading of the wedge members 177, 179 on the bore inner surface 156A may be determined by monitoring the torque applied to the drive nut 172. In some embodiments, adapters of other types and configurations may be used in place of the anchor adapters described herein.

At step 308, the method 300 further comprises positioning the foundation base member foundation base member 110 over the anchor adapters 160 such that each anchor adapter 160 aligns with a respective preformed through hole 120 of the foundation base member 110. In particular, a lower clamp washer 168 is mounted on each threaded rod 164 and the foundation base member 110 is then mounted on the anchor adapters 160 such that each of the threaded rods 164 is inserted through a respective one of the preformed through holes 120. The configuration and pattern of the foundation base member 110 (e.g., the size, number, arrangement and spacing) of the preformed through holes 120 enables the threaded rods 164 to be inserted through the respective preformed through holes 120 without needing to form new holes in the foundation base member or adjust the locations of the anchor piles 152 or the anchor adapters 160.

At step 310, the method 300 further comprises securing the foundation base member 110 to the anchor adapters 160. In particular, an upper clamp washer 168 and a clamp nut 166 are installed on the protruding end of each threaded rod 164. Each clamp nut 166 driven to clamp the foundation base member 110 between the washers 166, 168 and apply tension to the threaded rod 164. In this manner, the foundation base member 110 is firmly and securely attached to the anchor piles 152.

In embodiments, the pole mount subassembly 130 is pre-installed onto the foundation base member 110 such that the pole mount subassembly 130 and the foundation base member 110 are together installed onto the anchor adapters 160 in step 310. In embodiments, at step 312 the method 300 further comprises installing the pole mount subassembly on the foundation base member 110. In particular, the first mount plate 132 and the second mount plate 134 are placed on the top and bottom sides, respectively, of the foundation base member 110 and clamped thereon using the bolts 140 and nuts 142 as shown in FIG. 3, for example. The bolts 140 are inserted through respective preformed through holes 120. Thereafter, the pole 150 is secured to the pole mount subassembly 130 to mount the pole 150 on the foundation base member 110.

Prior art systems require drilling holes into the mounting plate on-site and aligning the drilled holes with the installed anchor piles, necessarily having a tolerance limited by the diameter of the drilled holes and the respective diameter of the threaded rod. As set forth in the present disclosure, the array 122 of preformed through holes 120 in the foundation base member 110 provides ease and flexibility in installation both because the preformed through holes 120 are preformed, and because the preformed through holes 120 cover a substantial portion of the foundation base member 110. The wide array 122 of preformed through holes 120 accommodates a wide variety of anchor pile 152 locations and enables flexibility in locating the placement of the foundation base member 110 relative to the anchor piles 152. For example, the anchor adapters 160 can be aligned with any preformed through holes 120 enabling greater flexibility in the placement of the anchor piles 152 to avoid obstacles.

Foundation systems as disclosed herein (e.g., the foundation system 101) can be used to retrofit a utility pole, and in particular a small cell pole, into a location previously occupied by another utility pole. The foundation system can be installed such that it straddles existing utilities, foundations and other underground obstacles without costly removal or re-routing. The anchor piles 152 can be placed where needed and torqued to site specifications.