FLARED REINFORCED PIER AND PIER BRACKET ASSEMBLY AND METHODS OF MANUFACTURING AND USE

A starter pier for a pier bracket assembly that is used support a structure (e.g., a foundation of a building, or the like). The starter pier has a first end, a second end, and an intermediate portion. The first end may be a flared first end that is swaged using a die. A reinforcing member may be inserted into the flared first end to provide support for the flared first end of the starter pier. The reinforcing member may be operatively coupled to the flared first end of the starter pier by compressing the flared first end around the reinforcing member using a mold. Additionally, or alternatively, the reinforcing member may be press-fit into the starter pier, connectors may be used, or the like to operatively couple the flared first end to the reinforcing member.

FIELD

The present invention relates to starter piers and pier bracket assemblies that use starter piers, and more particularly, improved starter piers and methods of manufacturing the starter piers.

BACKGROUND

Anchor assemblies, including structural piers, function under compression as footings or underpinnings for structures, such as building foundations, walls, platforms, towers, bridges, and other structures. Anchor assemblies are used in both new construction as well as in the repair of settled and damaged footings, foundations, or other supports of existing buildings and other structures. Structural pier devices used in anchor assemblies include helical anchors and push piers. A helical anchor includes a shaft that carries one or more bearing plates, or flights, generally arranged in a helical configuration on the shaft. In use, powered rotation is communicated to the shaft to screw the helical anchor into the ground to bedrock or to load-bearing strata sufficiently stable to support the desired structure. Once inserted into the ground, the structure to be supported may be built or repaired with some or all of its weight carried by the helical anchor. Push piers are linear shafts hydraulically driven into the ground alongside the structure to be supported until the push piers reach bedrock or a load bearing strata region at which the piers experience a desired amount of resistance sufficient to support the structure. Once a series of push piers or helical piers are driven into the ground, the structure is raised by a desired amount and fastened to the piers with a pier bracket assembly. The piers and bracket assemblies are coupled to one another in order to support the structure.

BRIEF SUMMARY

Embodiments of the present invention relate to a starter pier and/or a pier bracket assembly that uses the starter pier. The pier bracket assembly comprises a pier bracket, a sleeve, a starter pier, one or more push piers sections, and/or other components as will be described herein. The pier bracket is configured for operative coupling with a structure (e.g., a building foundation, wall, footers, or the like support member), and the piers (e.g., starter pier, one or more push piers sections, or the like) are inserted into the ground under force in order to support the weight of the structure.

The starter pier (e.g., otherwise described as a lower, lead, or the like pier) has a first end, a second end, and an intermediate portion. The starter pier may be a hollow tube. The first end may be a flared first end that is swaged such that the flared first end has a flared internal diameter that is greater than the interior diameter of the hollow tube of the starter pier, while the flared first end has a flared outer diameter that is greater than the outer diameter of the hollow tube of the starter pier. A reinforcing member (e.g., a cylindrical member) may be inserted into the flared first end to provide support for the flared first end of the starter pier. The reinforcing member may be a cylindrical ring member. The reinforcing member may be operatively coupled to the flared first end of the starter pier (e.g., through compressing the flared first end around the ring, press-fitting the ring into the tube, staking, using couplings, such as a weld, fasteners, or the like, or other like operative coupling). Also, the second end may comprise one or more couplers, such as an insert and fasteners, a female coupling (e.g., internal threaded section, or the like) that facilitates connection with a male coupling (e.g., externally threaded section, or the like), a male coupling that facilitates connection with a female coupling, fasteners (e.g., bolts, rivets, or the like), clamps, crimping, flares, dimples, slots, projections, groves, bosses, or the like in order to operatively couple the second end of a starter pier to an adjacent push pier section.

One embodiment of the invention comprises a pier for a pier bracket assembly. The pier comprises a tube having a first end and a second end, wherein the first end is a flared first end. The pier further comprises a reinforcing member operatively coupled to the flared first end and located at least partially within an internal surface of the flared first end.

In further accord with embodiments, the reinforcing member is a cylindrical member.

In other embodiments, the cylindrical member is a ring with an aperture therethrough.

In yet other embodiments, the ring is continuous.

In still other embodiments, the ring is discontinuous.

In other embodiments, the ring has an outer surface and an inner surface, and wherein the outer surface and the inner surface of the ring are uniform and concentric.

In further accord with embodiments, the pier is a starter pier.

In other embodiments, the flared first end is compressed around at least a portion of the reinforcing member.

In yet other embodiments, the reinforcing member is press fit into the flared first end.

In still other embodiments, the pier further comprises one or more connectors to aid in operatively coupling the flared first end to the reinforcing member.

In other embodiments, the tube has a circular shape.

Another embodiment of the invention comprises a method of manufacturing a pier. The method comprises flaring a first end of a tube to form a flared first end, inserting a reinforcing member into at least a portion of the flared first end, and operatively coupling the reinforcing member to the flared first end.

In further accord with embodiments, flaring the first end of the tube comprises using a press and flare die to swage the first end of the tube.

In other embodiments, operatively coupling the reinforcing member to the flared first end comprises using a press and a mold to compress at least a portion of the flared first end around the reinforcing member.

In yet other embodiments, operatively coupling the reinforcing member to the flared first end comprises using a press to press-fit the reinforcing member to the first end.

In still other embodiments, operatively coupling the reinforcing member to the flared first end comprises using one or more connectors between the flared first end and the reinforcing member.

Another embodiment of the invention is pier bracket assembly comprising a pier bracket configured to be operatively coupled to a structure and a starter pier. The starter pier comprising a tube having a first end and a second end, wherein the first end is a flared first end, and a reinforcing member operatively coupled to the flared first end and located at least partially within an internal surface of the flared first end. The pier bracket assembly further comprises one or more push piers sections configured to be operatively coupled to the second end of the starter pier or each other. The starter pier and the one or more push piers are operatively coupled to the pier bracket to support the structure.

In further accord with embodiments, the reinforcing member is a cylindrical member.

In other embodiments, the flared first end is compressed around at least a portion of the reinforcing member.

Another embodiment of the invention is a method of installing a pier bracket assembly. The method comprises assembling a pier bracket to a structure, and assembling a starter pier to the pier bracket. The starter pier comprises a tube having a first end and a second end, wherein the first end is a flared first end, and a reinforcing member operatively coupled to the flared first end and located at least partially within an internal surface of the flared first end. The method further comprises assembling a drive assembly to the bracket and starter pier, pushing the starter pier into the ground using the drive assembly, assembling a push pier section to the second end of the starter pier, and driving the push pier at least partially into the ground using the drive assembly. The flared first end with the reinforcing member pushes the ground and reduces the friction between the ground and an intermediate portion and second end of the starter pier and the push pier assembled to the starter pier.

To the accomplishment of the foregoing and the related ends, the one or more embodiments of the invention comprise the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth certain illustrative features of the one or more embodiments. These features are indicative, however, of but a few of the various ways in which the principles of various embodiments may be employed, and this description is intended to include all such embodiments and their equivalents.

DETAILED DESCRIPTION

Referring now to the drawings, wherein like reference numerals designate corresponding or similar elements throughout the several views, embodiments of a starter pier100and/or a pier bracket assembly10using the starter pier100are shown inFIGS.1through10. The pier bracket assembly10(otherwise described as an anchor assembly, or the like) may comprise a pier bracket20, a sleeve38, a starter pier100, one or more push piers sections52(e.g., otherwise described as push piers), and/or other components as will be described herein. The pier bracket20is configured for operative coupling with a structure2(e.g., a building foundation, wall, footers, or the like support member), and the piers50(e.g., starter pier100, one or more push pier sections52, or the like) are inserted into the ground under force in order to support the weight of the structure.

The pier bracket20, may be any type of pier bracket20that is operatively coupled to a structure2(e.g., through the use of bolts, one or more connectors, such as anchors, or the like). As will be described in further detail herein, the one or more piers50may be operatively coupled to each other and forced into the ground so as to form an anchor to carry the loading of the structure2. The one or more piers50may be any type of tube of any shape (e.g., square, oval, rectangular, non-uniform, or the like), but are typically round (e.g., circular, or the like). The one or more piers50may be solid, hollow, partially solid, partially hollow, or the like; however, the one or more piers50are typically hollow. The first of a plurality of piers50may comprise a starter pier100(e.g., otherwise described as a lower, lead, or the like pier). The starter pier100may have a first end110, a second end120, and an intermediate portion130. The starter pier100may be a tube102(e.g., a hollow tube, or the like of any shape) that has an interior diameter104and an exterior diameter106. The first end110may be a flared first end112(otherwise described herein as a flared end112) that is swaged such that the flared first end112has a flared internal diameter114that is greater than the interior diameter104of the starter pier100(e.g., the intermediate portion130, or the like), while the flared first end112has a flared outer diameter116that is greater than the outer diameter106of the starter pier100(e.g., intermediate portion130, or the like). In some embodiments, the flared internal diameter114may converge from a distal end (outer end) of the flared first end112to a proximal end (end adjacent the intermediate portion130) of the flared first end112. An intermediate portion130may extend between the first end110and the second end120. The second end120may comprise one or more couplers140. The one or more couplers140may comprise, an insert142(e.g., tube, other type of insert) that is operatively coupled to the starter pier100(e.g., the second end120) through the use of insert connections144(e.g., welds, clamps, clips, bosses, fasteners, such as screws, bolts, rivets, or the like, or other like connections). In other embodiments, the one or more couplers140may comprise a female coupling (e.g., internal threaded section, or the like) that facilitates connection with a male coupling (e.g., externally threaded section, or the like) of a push pier52(or vice versa). However, it should be understood that any type of couplers140may be used, such as fasteners (e.g., bolts, rivets, or the like), clamps, crimping, flares, dimples, bosses, slots, projections, groves, or the like in order to operatively couple the second end120of a starter pier100to an adjacent push pier section52section, which in turn is operatively coupled to one or more additional push piers sections52in series in the same or similar ways using couplers140. While the coupler140, such as the insert142, is illustrated as being operatively coupled to the second end120of the starter pier100, it should be understood that the coupler140, such as the insert142, may be operatively coupled to a first end of a push pier section52and operatively coupled to the second end120of the starter pier100during installation.

A reinforcing member180(otherwise described herein as a reinforcement member180) may be inserted into the flared first end112to provide support for the flared first end112of the starter pier100. In some embodiments, the reinforcing member180may have a shape that corresponds to the shape of the pier100(e.g., a flared first end112, or the like). As such, in some embodiments, the reinforcing member180may be a cylindrical member. In some embodiments the cylindrical member may be a ring182with an aperture therethrough. The ring182may be continuous (e.g., no breaks) or discontinuous (e.g., have one or more slots, or the like to allow the ring to flex). The ring182may have an inner member diameter184with an inner member surface185and an outer member diameter186with and outer member surface187. The inner member diameter184and outer member diameter186may be uniform and concentric with each other. Alternatively, the inner member surface185and/or the outer member surface187may converge or diverge from each other (e.g., may be at least partially semi-conical, or the like). The outer member diameter184may be the same as or similar to (e.g., slightly smaller or larger) than one or more portions of the flared internal diameter114.

As illustrated inFIGS.1through6, regardless of the shape and/or size of the reinforcing member180it may be inserted into and compressed by (e.g., pressed fit into, or the like), secured with one or more connectors to, and/or the like at least a portion of the flared first end112of the starter pier100, as will be described with respect to the process described and illustrated inFIGS.11A through13. For example, the reinforcing member180may be inserted into at least a portion of the flared first end112of the starter pier100, and at least a portion of the flared first end112may be compressed (e.g., squeezed, crimped, or the like) around at least a portion of the reinforcing member180. Additionally, or alternatively, at least a portion of the reinforcing member180may be press fit into the flared first end112of the starter pier100. Additionally, or alternatively, the reinforcing member180may be inserted into at least a portion of the flared first end112of the starter pier100, and one or more connectors may be used to aid in operatively coupling the reinforcing member180to the flared first end112. The one or more connectors may be fasteners, rivets, set-screws, dimple crimps, projections on the internal surface of the flared first end112, projections on the outer member surface187of the reinforcing member180, a rib on the internal surface of the flared first end112, a rib on the outer member surface187of the reinforcing member180, or other like connector. Regardless of how the reinforcing member180is operatively coupled to the flared first end112of the starter pier100, the flared outer diameter116of the flared first end112is greater than the outer diameter106of the intermediate portion130and/or the second end120of the starter pier100. As will be described in further detail herein, the reinforced flared first end112of the starter pier100pushes the ground away from the starter pier100such that it is easier for the outer diameter106of the starter pier100and/or one or more additional push pier sections52to pass through the ground.

The reinforcing member180may be operatively coupled to the flared first end112such that the end face of the reinforcing member180and the end face of the flared first end112are approximately flush with each other (e.g., in the same plane, or the like as illustrated inFIG.4). However, in some embodiments the end face of the reinforcing member180may extend outwardly past at least a portion of the end of the distal end of the flared first end112(e.g., in different planes, or the like as illustrated inFIGS.5and6). In still other embodiments, the end face of the reinforcing member may sit within at least a portion of the end face of the distal end of the flared first end112(e.g., in different planes, or the like—not illustrated).

It should be understood that the flared first end112of the starter pier100may have any type of shape or configuration. For example, the external flared end surface117of the flared first end112may be a smoothed radiused surface, a flat angled surface, different sections having different radiuses and/or flat sections. In some embodiments, the flared outer diameter116located at the distal end of the flared first end112may range from 3 to 4 inches, the flared inner diameter114may range from 2.75 to 3.5 inches, and the flared first end may have a flared angle that ranges from 1 to 5 degrees. Should the reinforcing member180be a cylindrical hollow ring, in some embodiments, the outer ring diameter186may range from 2.75 to 3.5 inches, the length may range from 0.5 to 2 inches, and the thickness of the ring may range from 0.1 to 0.3 inches. However, it should be understood that the dimensions may fall outside, overlap, or fall within these ranges or any value within or outside of these ranges dependent on the application of the starter pier100.

As illustrated inFIGS.7,9, and10, a plurality of push pier sections52may be added to the starter pier100of the pier bracket assembly10during installation. The plurality of push piers52may have similar inside and outside diameter dimensions as the starter pier100(i.e., the internal and outer diameter of the intermediate portion130and/or the second end120). Axial end-to-end operative coupling of plurality of push piers52may occur through the use of couplers140, as previously described herein with respect to the operative coupling of the push pier52to the second end120of the starter pier100.

The pier bracket20may be any type of pier bracket. However, in some embodiments, as illustrated inFIG.8, the pier bracket20may comprise a one piece monolithic body member22. The pier bracket20may comprise a seat24(e.g., L-shaped seat, or the like) operatively coupled to a ground-engaging base26(e.g., a sand plate). The seat24may include a base leg28operatively coupled to an upper leg29(e.g., welded, bent, attached, or the like). The base leg28of the L-shaped seat24is configured to extend under and support the structure to be supported. The L-shaped seat may be operatively coupled to the structure2(e.g., through the use of fasteners, such as anchors, bolts, or the like). As such, a pair of spaced slots31may be provided in the upper leg29for receiving fasteners for securing the pier bracket20to the structure. While and L-shaped seat is illustrated, it should be understood that the seat24may have a different shape is configured for operative coupling with a support member of a structure2.

The seat24, such as the base leg28may be operatively coupled to a stand26(e.g., a sand plate26) which may provide a surface for vertically standing the pier bracket20when the pier bracket20is not operatively coupled to the structure2. In the illustrated embodiments, the shape of the stand26, base leg28, and/or upper leg29are square or rectangular; however, these components may be any type of shape (e.g., oval, circular, half-circular, hexagonal, any polygonal, non-uniform, or the like shape).

One or more side plates30(e.g., a pair of truncated triangular side plates, or the like) may extend from and interconnect the seat24to the stand26(e.g., the base leg28to the sand plate). The side plates30may taper in width from their connection at an upper edge to the base leg28to a smaller width at their connection at a lower edge to the stand26. One or more of the side plates30may having openings32(e.g., oblong opening, or other shape) that are sized to fit a hand so that an installer has a handhold for carrying the pier bracket20. The side plates30may converge from the outer free edge of the base leg28to the inner edge of the base leg28. The inner edges of the side plates may30project beyond the upper leg29of the L-shaped seat24and may be operatively coupled to the tubular member34(e.g., hollow tubular member that is circular, oval, square, rectangular, pentagonal, hexagonal, any polygonal shape, or the like). The tubular member34may be operatively coupled to the seat24, such as the upper leg20of the seat (e.g., extending substantially parallel with the upper leg29, or the like). For example, the upper end of the tubular member34may be operatively coupled to the upper leg29. In in the illustrated embodiments, the upper end of the tubular member34may be operatively coupled to the upper leg29through the use of a flange36, such as at a point intermediate the length of the upper leg and the tubular member34. The tubular member34operatively coupled to the seat24and stand26defines an axial through bore configured to receive an elongated sleeve38for passing piers50therethrough for supporting the structure2, as will be described below. However, it should be understood that the pier bracket20may not include a tubular member34, and instead the sleeve38and/or the one or more piers50may be operatively coupled to the pier bracket20in other ways, such as through the use of one or more securing members (e.g., clamps, plates, bars, rods, or the like) and/or fasteners that restrict horizontal movement of the piers50with respect to the pier bracket20, but allow for the sleeve38and/or one or more piers to move vertically with respect to bracket20(e.g., until the one or more piers50are installed in the ground).

The sleeve38may comprise a hollow tubular element having outer diameter dimensions larger than that of the structural support devices. The sleeve38may have a restriction portion39that restricts the movement of restriction portion39of the sleeve38past the pier bracket20(e.g., a portion of the sleeve cannot pass through the tubular member34, or the like). As such, the restriction portion39may have a restriction outer diameter that is greater than the outer diameter of the remainder of the sleeve38. As such, in some embodiments the restriction portion39of the sleeve38may be a flared end (e.g., formed by swaging, or the like) with or without a reinforcing member located within the flared end. In other embodiments the restriction portion39may be a collar located outside of a portion of the sleeve38, such as a ring collar welded to the periphery at an end of the sleeve38.

The tubular member34may support a pair of opposed ears40extending outwardly from the periphery of the tubular member34and parallel with the flange36. The flange36and each of the ears40define two pairs of aligned bolt holes42so that the pier bracket20may be fastened to the underpinning drive assembly. The peripheral edges of both the flange36and the ears40are rounded at their corners. This configuration facilitates placement of the drive assembly proximate the pier bracket20in preparation for driving the structural piers50. As illustrated inFIG.9, a threaded rod connector44extends through each of the pairs of bolt holes42for attachment to the drive assembly (not shown). Fasteners, such as nuts and washers may be used to operatively couple each rod44and a pier cap66to the pier bracket20. It is to be understood that any number and size of threaded rods44may be used with corresponding pre-drilled bolt holes42located within the pier bracket20. As such, after the piers50(e.g., the starter pier100and/or the one or more additional push pier sections52) are driven into the ground, the rods44, pier cap66, and/or the drive assembly may be utilized to lift and/or support the structure2.

FIGS.11A through12Gillustrate a process of forming the starter pier100.FIG.11Aillustrates a press200and flare die240(otherwise described as a swage die) that is used to form the starter pier100. As illustrated inFIG.11A, the flare die240may include a converging die portion242(e.g., angled die portion, or the like) that has a converging surface (e.g., from the bottom of the illustrated flare die240to the top of the flare die240). The converging die portion242is illustrated as a conical die portion, but it may have another shape, such as a radiused surface, uniform, non-uniform, or the like surface. The flare die240may further have a shoulder244operatively coupled to the converging die portion242. The flare die240may also have a base portion246. The flare die240may be located adjacent the base202of the press200. For example, the press200may have a plate204on which the flare die240may be located. The press200may further comprise a ram210(e.g., arm211, head212, or the like) and an actuator214(e.g., hydraulic, pneumatic, electric, or the like), which actuates the ram210(e.g., the arm211, head212, or the like thereof).

As illustrated inFIG.11B, an unflared starter pier tube102may be installed over the flared die240(e.g., the top of the flare die240) and positioned manually (as illustrated), or through the use of a jig, automated holders, and/or the like to hold the starter pier tube102in place. The press200may be activated such that the actuator214moves the ram210until the ram210engages the starter pier tube102(e.g., the second pier end114or a component attached thereto).

As illustrated inFIG.11C, the ram210is further actuated until the first pier end110begins to flare as the flare die240engages the inner surface of the stater pier tube102.FIGS.11D and11Eillustrate that as the ram210is actuated the flare die240continues to form the flared first end112of the starter pier100until the flared first end112of the starter pier tube102reaches the shoulder244of the flare die240. It should be understood that once the edge of the flared first end112of the stater pier tube102is adjacent to (e.g., before touching, after touching, or the like) the shoulder244, the actuation of the ram210is stopped and/or reversed. After which, the starter pier tube102with the flared first end112is removed from the flare die240.

FIG.12Aillustrates that the flare die240may be removed and replaced adjacent the base202of press200with a compression mold260. It should be understood that the compression mold260may have a compression aperture262(e.g., through-hole). The compression aperture262may have an internal surface264that is uniform, non-uniform, straight, converging, or the like. In the illustrated embodiment, the internal surface264of the compression aperture262may have at least a portion that is converging and at least a portion that is straight (or diverging). This configuration may allow for the formation of the outer flared surface117of the flared first end112of the starter pier100to have a leading portion with a uniform leading diameter and a trailing portion with a converging trailing portion. However, it should be understood that the internal surface264may be sized and shaped in order to create different outer flared surfaces117for the flared first end112.

As illustrated inFIG.12Bthe compression aperture262allows for the second end130of the starter pier tube102to be placed through the compression aperture262until the flared first end112of the starter pier tube102engages a surface of the compression aperture262.

FIGS.12C and12Dillustrates that the reinforcing member180is inserted into the flared first end112of the starter pier tube10located in the compression mold260. Thereafter, as illustrated inFIGS.12E through12G, in some embodiments a press die280may be coupled to the ram212of the press200. The press die280may be sized to correspond with the reinforcing member180, the end face of the flared first end112of the starter pier tube102, or both. In some embodiments, the press die280is sized (e.g., has an outer diameter) to allow the press die280to push the flared first end112and the reinforcing member180through the compression aperture262of the compression mold260. As discussed above, the internal surface of the compression aperture262may allow at least a portion of the flared first end112to pass through the compression aperture262without compressing a portion of the outer flared surface of the flared first end112to create a trailing portion of the flared first end112having a converging flared surface. However, the compression aperture262may compress at least a portion of the outer flared surface of the flared first end112around a portion of the reinforcing member180in order to aid in securing the reinforcing member180within the flared first end112at the leading portion of the flared first end112. In some embodiments, it should be understood that the leading portion may be formed with a leading outer surface that has a uniform outer diameter.

FIG.13illustrates a process200for manufacturing the starter piers100and then installing the pier bracket assembly10to a structure2using the starter piers100. As illustrated in block302ofFIG.13, one or more tubes are procured (e.g., purchased, cut from a longer tubes, performing additional manufacturing processes, or the like). For example, the one or more tubes102may be purchased having the second end130with the coupler140formed therein, a coupler140may be formed within a second end130of the tube102after receiving the tube, a coupler140may be formed within a first end of an adjacent push pier52, or a coupler140may be incorporated and/or used during installation of the piers50(e.g., the starter pier100, the push pier52, or the like), which will be described in further detail herein. The one or more tubes102may be used for or to create the piers50, such as the starter pier100and/or the one or more push piers sections52. Moreover, one or more reinforcing members180may be procured (e.g., purchased, formed by cutting a tube into rings, or the like).

Block304ofFIG.13illustrates that with respect to the starter piers100, the first end110of the tubes may be swaged to create a flared first end112. The swaging of the first end110may occur by any type of process (e.g., pressing a die, inserting an expandable tool into the first end110of the tube102, or the like); however, in some embodiments the swaging of the first end110may occur as discussed with respect toFIGS.11A through11Eabove. As described herein, the flared first end110has a flared outer diameter116that is greater than the outer diameter of the remainder of the starter pier100(e.g., intermediate portion130, second end120, and/or the like).

Blocks306through310illustrate that a reinforcing member180may be operatively coupled to the flared first end112of the starter tube102in order to form a reinforced flared first end112of the starter pier100. That is, the reinforcing member180member is located in the flared first end and at least a portion of the flared first end112may be compressed around the reinforcing member180through the use of any compression process. However, in some embodiments, it should be understood that the reinforcing member180may be operatively coupled to the starter tube102as previously described herein with respect toFIGS.12A through12G. As such, during the compressing process at least a portion of the interior and/or exterior surfaces of the flared first end112may be at least partially deformed around the reinforcing member180.

Alternatively, or additionally, as illustrated in block308ofFIG.11, the reinforcing member180may be press fit into the flared first end112of the starter tube100. For example, by press-fitting the reinforcing member180into the flared first end112, the reinforcing member180may at least partially deform the interior and/or exterior surfaces of the flared first end112of the starter pier100.

Furthermore, as illustrated in block310ofFIG.11, additionally or alternatively, one or more connectors may be used to operatively couple the flared first end112to the reinforcing member180. For example, fasteners maybe be used to operatively couple the flared first end112to the reinforcing member180(e.g., extend through the outer and interior surfaces of the flared first end112and contact the outer surface of, extend through at least a portion of the outer surface, and/or extend through the inner surface of the reinforcing member180). In other examples, the reinforcing member180may be welded to a portion of the flared first end112, such between and end face of the distal end of the flared first end112and the end face and/or exterior surface of the reinforcing member180, between the interior surface of the flared first end112and an end face of the reinforcing member180, or the like.

After the components of the pier bracket assembly10are procured (e.g., purchased, manufactured, or the like), one or more pier bracket assemblies10may be installed on a structure2. In use, an area of earth is excavated immediately adjacent a structure2, such as adjacent to a foundation, to expose a portion of the structure2, such as a footer of the foundation. This excavation area may extend beneath the base of the footer. The structure2, such as a footer may be prepared by using a tool, such as a chipping hammer, to remove dirt, debris, and/or loose concrete from the structure2in order to provide bearing surfaces for the pier bracket20.

As illustrated in block310ofFIG.13, the pier bracket20is operatively coupled to a structure2, such as through the use of fasteners. In some embodiments, the pier bracket20is mounted on the underpinning drive assembly and then lowered into the excavation area adjacent the foundation. In other embodiments, the pier bracket20may be lowered into the excavation area and operatively coupled to structure20before the drive assembly is attached. The pier bracket20may be seated against the footer and operatively coupled to the foundations (e.g., fastened to the foundation through fasteners, such as steel concrete anchors, or other like couplings).

FIG.13further illustrates in block312that the sleeve38is operatively coupled to the pier bracket20and/or at least partially inserted into the ground. The sleeve38may be located within an opening dug into the ground or may be driven into the ground before, during, or after the starter pier100is first inserted into the ground. The sleeve38aids in resisting bending forces generated by driving the piers50in the ground and supporting the structure2when the starter pier100reaches a resistance point (e.g., packed soil, bedrock, or the like).

Block314ofFIG.13illustrates that the starter pier100may be operatively coupled to the pier bracket20directly (when a sleeve38is not used), or indirectly through the sleeve38. The starter pier100may already be located in the sleeve38when the sleeve38is installed, it may be inserted through the sleeve38after the sleeve38is operatively coupled to the pier bracket20, or the like.

A drive assembly is used to drive the starter pier100into the ground, as illustrated by block316inFIG.13. The drive assembly may include a hydraulic, pneumatic, electric, or the like ram that drives the starter pier100downward into the ground. The larger diameter of the flared first end112of the starter pier100pushes the earth and creates an annular space around the smaller diameter of the remainder of the starter pier100as it is advanced through soil. In some soft soils (e.g., soft clay, clean sand, or gravel) the space may only be temporary, while in harder soils (e.g., hard clay, packed dirt) the space may last longer. Regardless, the space or backfilling of the space with earth, reduces frictional resistance on the outside surface of the starter pier100and/or the one or more push piers52following the starter pier100. After the piers50are installed, the soil will settle within the space providing additional frictional capacity for supporting the structure.

As illustrated by block318, additional push piers52(e.g., push pier sections) may be operatively coupled to the second end130(e.g., through couplers140, or the like) of the starter pier100axially with respect to the starter pier100and each second end of the push piers52as additional push piers52are added in series. The one or more push piers52may be operatively coupled to the starter pier100and/or each other before the end of the previous push pier is passed through the sleeve38and/or pier bracket20. Each push pier52is driven into the ground using the drive assembly until resistance is met (e.g., load bearing resistance), such as bedrock, packed soil, or the like. Thereafter, the drive assembly is used to raise the structure, or the drive assembly is removed from the pier bracket20and other components are used to raise the structure to the desired level. In some embodiments, the last push pier52in the assembly may have a portion removed (e.g., a portion of the intermediate portion, second end, or the like is cut, disassembled, or the like) before or after raising the structure2in order to keep a low profile of the pier bracket assembly10such that at least a portion of (or all of) the pier bracket assembly10may be buried under the ground.

The pier bracket assembly10including the starter pier100has many advantages, including but not limited to improved manufacturing, such as manufacturing that does not require any machining to create the flared first end212, use of a press, dies, and/or molds to create the flared first end112and to operatively couple the reinforcing member180to the flared first end112of the starter pier100, and/or the like. Moreover, the reinforced flared end112provides for a strengthened end of the starter pier100that is used to push soil out of the way and create an annular space (e.g., with loose soil) to reduce the friction between the soil and the external surface of the piers50.

Also, it will be understood that, where possible, any of the advantages, features, functions, devices, and/or operational aspects of any of the embodiments of the present invention described and/or contemplated herein may be included in any of the other embodiments of the present invention described and/or contemplated herein, and/or vice versa. In addition, where possible, any terms expressed in the singular form herein are meant to also include the plural form and/or vice versa, unless explicitly stated otherwise. Accordingly, the terms “a” and/or “an” shall mean “one or more.”

Certain terminology is used herein for convenience only and is not to be taken as a limiting. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” “downward,” “top” and “bottom” merely describe the configurations shown in the FIGs. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. The words “interior” and “exterior” refer to directions toward and away from, respectively, the geometric center of the core and designated parts thereof. The terminology includes the words specifically mentioned above, derivatives thereof and words of similar import.

It should be understood that “operatively coupled,” when used herein, means that the components may be formed integrally with each other, or may be formed separately and coupled together. Furthermore, “operatively coupled” means that the components may be formed directly to each other, or to each other with one or more components located between the components that are operatively coupled together. Furthermore, “operatively coupled” may mean that the components are detachable from each other, or that they are permanently coupled together.