Modular foundation system

A modular foundation system having a punch pad; pre-formed, ring-shaped modular foundation units; and an axial column and a pole that extend through the modular foundation units. The modular foundation system may be used to support any type of structure, such as a pole building type structure; or may be used to provide pier footings for any non-pole building type structure, such as a terrace and wall type structure. The modular foundation system may have a modular foundation unit locking means for aligning and locking together adjacent modular foundation units; an axial column locking means for locking together the axial column and the modular foundation units; a modular foundation unit ground locking means for locking together the modular foundation units and the surrounding ground; an axial column connecting means for connecting together the punch pad and the axial column; a punch pad locking means for aligning and locking together the punch pad and the adjacent modular foundation unit; and punch pad ground locking means for locking together the punch pad and the surrounding ground. The punch pad and/or the modular foundation units may comprise a ring-shaped core and a used tire that may serve as a form for the ring-shaped core. The modular foundation units and the punch pad may be provided in various sizes; and one of the modular foundation units may be used as the punch pad.

CROSS-REFERENCE TO RELATED APPLICATIONS
 Not Applicable. That is, the benefit of the filing date of a co-pending
 application for a patent that was previously filed in the United States is
 not sought under 35 U.S.C. .sctn.120.
 STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
 Not Applicable. That is, the U.S. Government does not have a paid-up
 license in this invention or the right in limited circumstances to require
 the patent owner to license others on reasonable terms.
 BACKGROUND OF THE INVENTION
 The present invention relates to foundation systems for structures. More
 particularly, the present invention relates to a modular foundation system
 that may be assembled at the job site.
 SUMMARY OF THE INVENTION
 A conventional pole building foundation system comprises vertical load
 bearing wooden poles having their lower ends buried in the earth. The
 wooden poles must be treated with preservatives to repel insects and
 decay. In order to increase their load bearing capacity, the lower ends of
 the wooden poles may be supported by a punch pad and/or may be provided
 with a concrete encasement. The concrete encasement may be a butt
 encasement, in which only part of the lower end of the wooden pole that is
 located below the ground finish line is encased; or it may be a full
 encasement, in which all of the lower end of the wooden pole that is
 located below the ground finish line is encased. Whether a butt encasement
 or a full encasement is used, the encasement will also increase the wooden
 pole's uplift strength, and wind deflection resistance.
 Such conventional pole building foundation systems are economical and
 strong. However, they may be undesirable since they may be correctly
 perceived to have a relatively short lifetime, since even treated wooden
 poles will eventually be subject to failure due to insect damage and
 decay. In addition, the preservatives used to treat the wooden poles may
 present environment concerns since the preservatives are poisons that are
 toxic to many life forms. Further, if butt or full concrete encasements
 are desired, it may be difficult, or even impossible, for a conventional
 pre-mixed concrete delivery truck to reach the job site to pour the
 encasements; and it may be difficult and expensive to mix the large
 quantities of concrete needed for the encasements at the job site.
 Turning now to the modular foundation system of the present invention, it
 may comprise at least two ring-shaped, pre-formed, stackable, modular
 foundation units, each defining an axial opening. The modular foundation
 units may be made from any suitable material, such as concrete. The
 modular foundation system may further comprise a pole and an axial column
 that may extend through the axial openings of the modular foundation
 units. The pole may comprise several reinforced metal bars, or a metal
 pipe; and may have a length selected to enable it to extend upwardly to
 and/or into the structure it is intended to support.
 In order to use the modular foundation system, a foundation hole must first
 be formed at the job site for each modular foundation system. The modular
 foundation units may then be stacked in the foundation hole; the pole may
 be located in the axial holes of the modular foundation units; and the
 axial column may then be poured, with the modular foundation units serving
 as permanent forms for the axial column. The axial column may be made from
 any suitable material, such as concrete. Once it has hardened, the axial
 column may serve to hold the modular foundation units and the pole
 together as one strong, integral structure; and the pole may serve to not
 only support the structure, but to also reinforce the axial column and the
 modular foundation units.
 At least one of the modular foundation units may have an outer radial size
 that is greater than the outer radial size of at least one of the other
 modular foundation units, in order to help increase the load bearing
 capacity, uplift strength and wind resistance of the completed modular
 foundation system.
 The modular foundation system may further comprise modular foundation unit
 locking means for helping to properly align the adjacent modular
 foundation units with respect to each other; and/or for helping to prevent
 the adjacent modular foundation units from moving laterally with respect
 to each other. Such modular foundation unit locking means may comprise
 complimentary shapes or configurations in the adjacent upper and lower
 surfaces of the adjacent modular foundation units.
 The modular foundation system may also comprise axial column locking means
 for helping to lock the modular foundation units and the axial column
 together, and for helping to prevent relative axial motion between the
 modular foundation units and the axial column; after the axial column has
 been poured and has hardened. Such axial column locking means may comprise
 one or more grooves, flanges, lugs and/or recesses on the inner radial
 surfaces of at least one of the modular foundation units.
 The modular foundation system may further comprise modular foundation unit
 ground locking means for helping to lock the modular foundation units and
 the surrounding ground together; thereby desirably providing greater
 friction between the modular foundation units and the ground. The greater
 friction provided by the modular foundation unit ground locking means may
 increase the load bearing capacity, uplift strength and wind resistance of
 the modular foundation system. The modular foundation unit ground locking
 means may comprise one or more grooves, flanges, lugs and/or recesses on
 the outer radial surface of at least one of the modular foundation units.
 The modular foundation system may also comprise a punch pad upon which the
 modular foundation units may be stacked in the foundation hole. The punch
 pad may be pre-formed and lowered into the foundation hole; or it may be
 poured in the foundation hole and allowed to set before the modular
 foundation units are stacked upon it. The punch pad may be made from any
 suitable material, such as concrete. The punch pad may comprise a dowel to
 integrally connect it to the axial column when the axial column is poured.
 If a punch pad is used, then it may also serve as the permanent form for
 the bottom of the axial column. If a punch pad is not used, then the
 bottom of the foundation hole may serve as the form for the bottom of the
 axial column.
 The modular foundation system may further comprise a punch pad locking
 means for helping to properly align the punch pad and its adjacent modular
 foundation unit with respect to each other; and/or for helping to prevent
 the punch pad and its adjacent modular foundation unit from moving
 laterally with respect to each other. Such punch pad locking means may
 comprise complimentary shapes or configurations in the upper surface of
 the punch pad and the lower surface of its adjacent modular foundation
 unit. Such complimentary shapes or configurations may comprise, for
 example, complimentary grooves, flanges, lugs and/or recesses in the upper
 surface of the punch pad and the lower surface of its adjacent modular
 foundation unit.
 As an alternative, the punch pad may be eliminated and may be replaced by
 one of the modular foundation units that has an outer radial size that is
 larger than the outer radial size of at least one of the other modular
 foundation units in the modular foundation system.
 The modular foundation system may further comprise punch pad ground locking
 means for helping to lock the punch pad and the surrounding ground
 together; thereby desirably providing greater friction between the punch
 pad and the ground. The greater friction provided by the punch pad ground
 locking means may increase the load bearing capacity, uplift strength and
 wind resistance of the modular foundation system. The punch pad ground
 locking means may comprise one or more grooves, flanges, lugs and/or
 recesses on the outer radial surface of the punch pad.
 The modular foundation units, the axial column and/or the punch pad may
 further comprise reinforcing means, such as rebar (reinforcing bar),
 reinforcing mesh and/or reinforcing fibers.
 The modular foundation units and/or the punch pad may be preformed by
 pouring concrete, or any other suitable material, into used tires; with
 the used tires forming permanent parts of the modular foundation units
 and/or punch pad. Such use of used tires may offer many advantages. For
 example, their use may eliminate the cost of disposable forms; and may
 eliminate the cost and labor of using re-useable forms. In addition, since
 the used tires may form permanent parts of the modular foundation units
 and/or punch pad, the used tires are automatically, safely and permanently
 disposed of, in an environmentally friendly fashion, when the modular
 foundation units and/or punch pad are buried in the foundation hole.
 If a modular foundation unit and or a punch pad comprises a used tire, then
 the modular foundation ground locking means and/or the punch pad ground
 locking means may comprise any remaining tread on the used tire, and/or
 any suitable projecting members, such as rods, wires, nails or screws,
 that were driven through the tread of the tire from inside of the tire,
 before the tire was used as a mold for the modular foundation unit and/or
 the punch pad.
 The modular foundation system of the present invention may be used to
 support any type of structure in any suitable way. For example, it may be
 used to provide a foundation for a pole building type structure; or to
 provide pier footings for any kind of non-pole building type structure,
 such as a terrace and wall type structure. In addition, the modular
 foundation system of the present invention may be used to support any
 other kinds of objects or structures, such as, for example, towers, masts,
 commercial light poles, flag poles, antenna poles, electric power poles,
 roads and bridges; and may be used as reinforcing members, such to shore
 up or reinforce mines or roadway embankments. The modular foundation
 system of the present invention may be used when partially or entirely
 under water, such as when it is used in a foundation for a bridge or for
 any building on wetlands.
 The modular foundation system of the present invention offers numerous
 advantages. For example, its individual components may be quickly and
 easily manufactured and transported to virtually any job site, no matter
 how remote or inaccessible; and then quickly and easily assembled in its
 foundation hole at the job site. This is because although the total weight
 and size of the modular foundation system may be very substantial; the
 much smaller weight and size of each of its individual components may
 enable them to be manufactured, transported, handled and installed
 relatively easily.
 The modular foundation system of the present invention may offer the
 further advantage of drastically minimizing the amount of fluid concrete
 (or other suitable material) that must be transported to the job site.
 This is because the modular foundation units and/or the punch pad may be
 pre-formed at any convenient location before being transported to the job
 site. Thus, the only fluid concrete needing to be delivered to, or mixed
 at, the job site would be that needed for the modular foundation system's
 axial column; and for its punch pad, if the punch pad is poured in place
 at the bottom of the foundation hole. Thus, the volume of fluid concrete
 needed at the job site for the modular foundation system may comprise only
 a small fraction of the total volume of concrete used the entire modular
 foundation system.
 Another advantage of the modular foundation system of the present invention
 may be that the stackable nature of its modular foundation units and/or
 punch pad may permit the vertical height of the modular foundation system
 to varied at will, by simply varying the number and/or the axial thickness
 of the modular foundation units that are used; and/or by varying the axial
 thickness of the punch pad.
 A further advantage of the modular foundation system of the present
 invention may be that it may be easily adapted to accommodate any desired
 load bearing capacity, uplift strength, and wind deflection resistance.
 This may be done by suitably varying the outer radial size of the modular
 foundation units and/or the punch pad.
 It should be understood that the foregoing summary of the present invention
 does not set forth all of its features, advantages, characteristics,
 structures, methods and/or processes; since these and further features,
 advantages, characteristics, structures, methods and/or processes of the
 present invention will be directly or inherently disclosed to those
 skilled in the art to which it pertains by all of the disclosures herein.

DESCRIPTION OF THE PREFERRED EMBODIMENTS
 Referring now to the Figures, the modular foundation systems 10 of the
 present invention, each being located in a respective foundation hole 36
 in the ground 34, may be used to support any type of structure in any
 suitable way.
 For example, the modular foundation systems 10 may be used to support the
 pole building type structure 12 of FIG. 1; or to provide pier footings for
 any type of non-pole building type structure, such as the terrace and wall
 type structure 12a of FIG. 2. In addition, the modular foundation systems
 10 may be used to support any other type of structure, such as a tower or
 a mast.
 Although several modular foundation systems 10 are illustrated as
 supporting the structures 12, 12a illustrated in FIGS. 1 and 2, as few as
 one modular foundation system 10 may be used, such as where the structure
 12 comprises a tower or a mast.
 In the description herein, only one modular foundation system 10 will be
 described in detail, it being understood that part or all of that
 description may apply equally well to one or more of the other modular
 foundation systems 10, as appropriate.
 Similarly, in the description herein regarding the punch pad 14, it will be
 understood that part or all of that description may apply equally well to
 the alternative punch pad 14a, as appropriate; and vice versa. Likewise,
 in the description herein regarding the modular foundation unit 16, it
 will be understood that part or all of that description may apply equally
 well to the alternative modular foundation units 16a, 16b, as appropriate;
 and vice versa.
 As seen in FIGS. 3-4, the modular foundation system 10 may comprise a punch
 pad 14; an axial column 15 having a cap 23; and at least one modular
 foundation unit 16. For any particular structure 12 having at least two
 modular foundation systems 10, the number of the modular foundation units
 16 in each of its modular foundation systems 10 may or may not be the
 same.
 Although the longitudinal axes of the punch pad 14, the axial column 15,
 and the modular foundation units 16 are illustrated as being coaxial with
 respect to each other; the longitudinal axes of the punch pad 14, the
 axial column 15, and/or the modular foundation units 16 may not be coaxial
 with respect to each other.
 The punch pad 14, the axial column 15, the axial column 15's cap 23, and
 each modular foundation unit 16 may comprise any suitable moldable,
 formable or castable construction material such as cement; concrete;
 grout; mortar; recycled rubber from tires; recycled steel, such as from
 cars and machinery; recycled resins or plastics, such as polyester; and
 recycled glass. The modular foundation unit 16, regardless of the material
 from which it is made, may also comprise any suitable reinforcing fibers
 or bars for increasing its strength and/or for making it lighter in
 weight. The punch pad 14 and/or the modular foundation units 16 may be
 made in any suitable form or mold. Alternatively, instead of using a
 separate mold or form for the punch pad 14, the bottom portion of the
 foundation hole 36 for the modular foundation system 10 may serve as the
 form or mold for the punch pad 14.
 Turning now to FIG. 5, an alternative form 14a of the punch pad 14 and an
 alternative form 16a of the modular foundation unit 16 may comprise a
 suitably sized used tire 40 and a ring-shaped core 41 of any suitable
 moldable, formable or castable construction material such as the ones
 described above regarding the punch pad 14 and modular foundation 16. The
 used tire 40 may serve as the form or mold for the ring-shaped core 41;
 and may comprise a permanent part of the finished punch pad 14a or modular
 foundation unit 16a. Such utilization of a used tire 40 may offer at least
 three advantages. First, the used tire 40 may serve as a free, or as an
 exceptionally inexpensive, form or mold for the punch pad 14a and/or the
 modular foundation unit 16a. Second, when the punch pad 14a and/or the
 modular foundation unit 16a is buried in the foundation hole 36 for the
 modular foundation system 10, its used tire 40 is simultaneously disposed
 of in a safe, convenient, inexpensive, and environmentally friendly
 manner. Third, any remaining tread pattern 42 on the used tire 40 of the
 punch pad 14a and/or modular foundation unit 16a may serve as ground
 locking means for helping to lock the surrounding ground 34 to the punch
 pad 14a and/or the modular foundation unit 16a; thereby desirably
 providing greater friction between the ground 34 and the used tire 40 of
 the punch pad 14a and/or the modular foundation unit 16a. The greater
 friction provided by the ground locking means may increase the load
 bearing capacity, uplift strength and wind resistance of the modular
 foundation system 10.
 The ground locking means for the punch pad 14a and/or the modular
 foundation unit 16a may further comprise one or more of any suitable
 projecting members 43, such as rods, wires, nails or screws, which may
 have been driven through the tread 42 of the used tire 40 from the inside
 of the used tire 40, before the used tire 40 is used as a mold or form for
 the ring-shaped core 41 of the punch pad 14a and/or the modular foundation
 unit 16a.
 Regarding the axial column 15, the punch pad 14, 14a and the modular
 foundation units 16, 16a may serve as the form or mold for the axial
 column 15.
 Referring now to FIGS. 1-4, the axial column 15 may further comprise a pole
 24 that may serve the dual functions of reinforcing the axial column 15
 and of supporting the structure 12, 12a. In addition, the axial column 15
 may also comprise any suitable arrangement of additional reinforcing
 material, such as rebar (reinforcing bar), reinforcing mesh and/or
 reinforcing fibers.
 As best seen in FIG. 1, the pole 24 may have an upper portion whose length
 may be selected to enable it to extend into the structure 12, such as when
 the modular foundation system 10 is used to support a pole building type
 structure 12. Alternatively, as seen in FIG. 2, the pole 24 may have an
 upper portion whose length may be selected to enable it to extend to the
 structure 12a, so that the modular foundation system 10 may serve as a
 pier footing for the structure 12a, such in the terrace and wall type
 structure 12a seen in FIG. 2.
 As best seen in FIGS. 3-4, the pole 24 may comprise several axial bars 25
 or axial pipes 25 that may be assembled together and reinforced with
 cross-bars 26 or cross-pipes 26. Although the pole 24 is illustrated as
 comprising four axial bars 25 or axial pipes 25, it may comprise fewer, or
 more, axial bars 25 or axial pipes 25. The axial bars 25 or axial pipes 25
 may be made from any suitable construction material, such as wood or
 steel.
 Alternatively, the pole 24 may comprise a single solid member or a single
 pipe made from any suitable construction material, such as wood or steel.
 As a further alternative construction, the axial column 15's cap 23 may be
 eliminated.
 Turning now to the punch pad 14 again, although it is illustrated as having
 a circular shape and a uniform thickness, it may have any other suitable
 shape and its thickness may not be uniform. Although the punch pad 14's
 outer radial surface 30 is illustrated as being oriented at a right angle
 with respect to its upper and lower surfaces 27, 31, its outer radial
 surface 30 may not be oriented at a right angle with respect to its upper
 and/or lower surfaces 27, 31; and/or a partial or continuous chamfer may
 be provided at the intersections between its outer radial surface 30 and
 its upper and/or lower surfaces 27, 31, to help prevent chipping or
 breakage of the outer edges of the punch pad 14.
 Although the punch pad 14's upper and lower surfaces 27, 31 are illustrated
 as being equal in outer radial size, they may not 16 be equal in outer
 radial size. For example, if the punch pad 14 is 17 to be made by slip
 forming, then its upper and lower surfaces 27, 31 may be selected to be
 unequal in outer radial size, so that its outer radial surface 30 is
 tapered; in order to assist the easier removal of the punch pad 14 from
 its slip form after the material from which it is made has hardened. In
 addition, the intersections between the punch pad 14's outer radial
 surface 30 with its upper and/or lower surfaces 27, 31 may be chamfered,
 to help prevent chipping or breakage of the punch pad 14.
 The upper surface 27 of the punch pad 14 and the lower surface 17 of the
 adjacent modular foundation unit 16 may be entirely flat. Alternatively,
 their respective surfaces 27, 17 may be, in whole or in part, not entirely
 flat; and/or may comprise punch pad locking means for helping to properly
 align their respective surfaces 27, 17 with respect to each other, and for
 helping to prevent undesired lateral movement of their respective surfaces
 27, 17 with respect to each other.
 The punch pad locking means may comprise, for example, corresponding
 complimentary shapes or configurations of their respective surfaces 27,
 17; wherein the corresponding complimentary shapes or configurations may
 be sized and shaped so as to at least partially mate with each other. For
 example, one of their respective surfaces 27, 17 may have, in whole or in
 part, a concave shape, and the other may have a corresponding
 complimentary convex shape, in whole or in part, that may at least
 partially mate with the concave shape.
 Alternatively, as seen in FIG. 6, most of their respective surfaces 27, 17
 may be flat; and the surface 27 of the punch pad 14 may be provided with a
 projecting flange 45 or lug 46; while the surface 17 of the adjacent
 modular foundation unit 16 may be provided with a corresponding
 complimentary groove 47 (to at least partially mate with the flange 45),
 or with a corresponding complimentary recess 48 (to at least partially
 mate with the lug 46).
 The flange 45 and/or the lug 46 may extend to the punch pad 14's outer
 radial surface 30. Similarly, the groove 47 and/or the recess 48 may
 extend to the modular foundation unit 16's inner and/or outer radial
 surfaces 19, 20.
 There may be more than one flange 45, with each flange 45 having any
 desired cross-sectional shape, size, length, and orientation on the
 surface 27 of the punch pad 14; and there may be more than one
 corresponding complimentary groove 47, with each groove 47 having any
 desired corresponding complimentary cross-sectional shape, size, length,
 and orientation on the surface 17 of the adjacent modular foundation unit
 16. Similarly, there may be more than one lug 46, with each lug 46 having
 any desired cross-sectional shape, size and orientation on the surface 17
 of the adjacent modular foundation unit 16; and there may be more than one
 corresponding complimentary recess 48, with each recess 48 having any
 desired corresponding complimentary cross-sectional shape, size and
 orientation on the surface 17 of the adjacent modular foundation unit 16.
 In addition, although the flange 45 and lugs 46 are illustrated as being
 separate elements, the flange 45 and one or more of the lugs 46 may be
 extended so as to merge into each other, to form one integral part.
 Similarly, although the groove 47 and the recesses 48 are illustrated as
 being separate elements, the groove 47 and one or more of the recesses 48
 may be extended so as to merge into each other, to form one integral part.
 The sides of the flange 45 and its corresponding groove 47 may have
 complimentary tapers, to assist in their easy mating with each other, and
 to increase their resistance to chipping or breakage. Similarly, the sides
 of the lugs 46 and their corresponding recesses 48 may have complimentary
 tapers, to assist in their easy mating with each other, and to increase
 their resistance to chipping or breakage.
 Naturally, the groove(s) 47 and/or the recess(es) 48 may be located on the
 surface 27 of the punch pad 14; and the flange(s) 45 and/or the lug(s) 46
 may be located on the surface 17 of the adjacent modular foundation unit
 16.
 Alternatively, the punch pad locking means may comprise one or more of any
 suitable projecting members, such as rods, wires, nails or screws, on the
 surface 27 of the punch pad 14 and/or on the surface 17 of the adjacent
 modular foundation unit 16; with appropriate corresponding recesses for
 the projecting members being provided in the corresponding surface 27 of
 the punch pad 14 and/or the surface 17 of the adjacent modular foundation
 unit 16. Such projecting members may be the same as, or similar to, the
 projecting members 43 illustrated in FIG. 5.
 Alternatively, the punch pad locking means may be mechanical in nature and
 may comprise, for example, any suitable fastener(s), tie(s), latch(es),
 etc.
 As best seen in FIG. 4, the punch pad 14 may be provided with a dowel 28
 that extends upwardly from the punch pad 14 into the axial column 15. The
 dowel 28 was omitted from FIG. 6, for clarity. The dowel 28 may serve at
 least five purposes, namely: (a) reinforcing the punch pad 14; (b)
 reinforcing the axial column 15; (c) tying the punch pad 14 and the axial
 column 15 together; (d) properly aligning the punch pad 14, the adjacent
 modular foundation unit 16 and the axial column 15 with respect to each
 other; and (e) preventing any lateral movement of the punch pad 14, the
 adjacent modular foundation unit 16 and the axial column 15 with respect
 to each other. Thus, the dowel 28 may comprise part of the punch pad
 locking means that was described above. The dowel 28 may be of any
 suitable construction and may comprise, for example, several L-shaped
 lengths of steel rebar 29.
 As an alternative, the punch pad 14 and the axial column 15 may be tied
 together in any other suitable way in addition to, or in lieu of, the
 dowel 28. The punch pad 14 may also comprise any suitable arrangement of
 additional reinforcing material, such as rebar, reinforcing mesh and/or
 reinforcing fibers that may, or may not, extend into the axial column 15.
 As an additional alternative, the foundation system 10's punch pad 14 may
 be eliminated, in which case the lowest modular foundation unit 16 may
 serve as the modular foundation system 10's punch pad 14. The modular
 foundation unit 16 serving as the modular foundation system 10's punch pad
 14 may comprise a modular foundation unit 16b having an outer radial size
 that is larger than that of at least some of the other modular foundation
 units 16 in the modular foundation system 10.
 Turning now to the modular foundation units 16, in the description which
 follows only one modular foundation unit 16 will be described in detail,
 it being understood that part or all of that description may apply equally
 well to one or more of the other modular foundation units 16 in the
 modular foundation system 10, as appropriate.
 As best seen in FIGS. 7-9, the modular foundation unit 16 may comprise a
 lower surface 17; an upper surface 18; an inner radial surface 19; an
 outer radial surface 20; an axial opening 21 defined by the inner radial
 surface 19; and a longitudinal axis 22. The axial opening 21 may, or may
 not, be centered on the modular foundation unit 16's longitudinal axis 22.
 The modular foundation unit 16 may be generally ring-shaped; and its inner
 and outer radial surfaces 19, 20 may be circular in cross-sectional
 configuration. Alternatively, its inner and/or outer radial surfaces 19,
 20 may have any other suitable cross-sectional configuration, such as
 elliptical, square, rectangular, triangular, etc. The inner and outer
 radial surfaces 19, 20 of the modular foundation unit 16 may, or may not,
 have the same cross-sectional configuration.
 The modular foundation unit 16 may have an inner radial size defined by its
 inner radial surface 19; an outer radial size defined by its outer radial
 surface 20; a radial thickness defined between its inner and outer radial
 surfaces 19, 20; and an axial thickness defined between its lower and
 upper surfaces 17, 18.
 The modular foundation units 16 in the modular foundation system 10 may all
 have the same inner radial size, outer radial size, radial thickness and
 axial thickness. Alternatively, one or more of the modular foundation
 units 16 in the foundation system 10 may have a different inner radial
 size, outer radial size, radial thickness and/or axial thickness. For
 example, as seen in FIGS. 1-4, one of the modular foundation units 16 in
 any particular modular foundation system 10 may comprise a modular
 foundation unit 16b that may have a larger outer radial size than the rest
 of the modular foundation units 16, in order to increase the load bearing
 capacity, uplift strength, and wind deflection resistance of the modular
 foundation system 10. In general, the larger the outer radial size of the
 modular foundation units 16, 16b, the greater will be their load bearing
 capacity, uplift strength, and wind deflection resistance.
 The modular foundation unit 16's lower and upper surfaces 17, 18 may be
 flat and parallel with respect to each other. Alternatively, the surfaces
 17, 18 of the modular foundation unit 16 may not be flat and/or may not be
 parallel with respect to each other.
 In addition, the upper surface 18 of a first modular foundation unit 16 and
 the lower surface 17 of an adjacent second modular foundation unit 16 may
 not be entirely flat, and may comprise modular foundation unit locking
 means for helping to properly align their respective surfaces 18, 17 with
 respect to each other, and for helping to prevent undesired lateral
 movement of their respective surfaces 18, 17 with respect to each other.
 The modular foundation unit locking means may comprise, for example,
 corresponding complimentary shapes or configurations of their respective
 surfaces 18, 17; wherein the corresponding complimentary shapes or
 configurations may be sized and shaped so as to at least partially mate
 with each other. For example, one of their respective surfaces 18, 17 may
 have a concave shape, in whole or in part, and the other may have a
 corresponding complimentary convex shape, in whole or in part, that may at
 least partially mate with the concave shape.
 Alternatively, as seen in FIG. 8, most of their respective surfaces 18, 17
 may be flat; and the surface 18 of the first unit 16 may be provided with
 a projecting flange 55 or lug 56; while the surface 17 of the adjacent
 second unit 16 may be provided with a corresponding complimentary groove
 57 (to at least partially mate with the flange 55), or with a
 corresponding complimentary recess 58 (to at least partially mate with the
 lug 56).
 There may be more than one flange 55, with each flange 55 having any
 desired cross-sectional shape, size, length, and orientation on the
 surface 18 of the first unit 16; and there may be more than one
 corresponding complimentary groove 57, with each groove 57 having any
 desired corresponding complimentary cross-sectional shape, size, length,
 and orientation on the surface 17 of the adjacent second unit 16.
 Similarly, there may be more than one lug 56, with each lug 56 having any
 desired cross-sectional shape, size and orientation on the surface 18 of
 the first unit 16; and there may be more than one corresponding
 complimentary recess 58, with each recess 58 having any desired
 corresponding complimentary cross-sectional shape, size and orientation on
 the surface 17 of the adjacent second unit 16.
 In addition, although the flange 55 and the lugs 56 are illustrated as
 being separate elements, they may be extended so as to merge into each
 other, to form one integral part. Similarly, although the groove 57 and
 the recesses 58 are illustrated as being separate elements, they may be
 extended so as to merge into each other, to form one integral part. For
 example, as seen in FIG. 11 the flange 55a and one or more of the lugs 56a
 may be extended so as to merge into each other, to form one integral part.
 Similarly, as also seen in FIG. 11, the groove 57a and one or more of the
 recesses 58a may be extended so as to merge into each other, to form one
 integral part.
 Further, at least one of the flange 56, the groove 57, the lugs 56, and/or
 the recesses 58 may extend to the respective unit 16's inner and/or outer
 radial surfaces 19, 20. For example, in FIG. 11, the inner surfaces of the
 flange 56a and the groove 57a are illustrated as extending to the inner
 radial surfaces 19 of their respective units 16.
 The sides of the flange 55 and its corresponding groove 57 may have
 complimentary tapers, to assist in their easy mating with each other, and
 to increase their resistance to chipping or breakage. Similarly the sides
 of the lugs 56a and their corresponding recesses 58a may have
 complimentary tapers, to assist in their easy mating with each other, and
 to increase their resistance to chipping or breakage. For example, in FIG.
 11, the sides of the flange 55a, groove 57a, lugs 56a and recesses 58a are
 illustrated as having such complimentary tapers.
 Naturally, the groove(s) 57, 57a and/or the recess(es) 58, 58a may be
 located on the surface 18 of the first unit 16; and the flange(s) 45, 45a
 and/or the lug(s) 46, 46a may be located on the surface 17 of the adjacent
 second unit 16.
 Alternatively, the modular foundation unit locking means may comprise one
 or more of any suitable projecting members, such as rods, wires, nails or
 screws, on the surface 18 of the first unit 16 and/or on the surface 17 of
 the adjacent second unit 16; with appropriate corresponding recesses for
 the projecting members being provided in the corresponding surfaces 17, 18
 of the first and/or second units 16. Such projecting members may be the
 same as, or similar to, the projecting members 43 illustrated in FIG. 5.
 Alternatively, the modular foundation unit locking means may be mechanical
 in nature and may comprise, for example, any suitable fastener(s), tie(s),
 latch(es), etc.
 Although the modular foundation unit 16's inner and outer radial surfaces
 19, 20 are illustrated as being oriented at a right angle with respect to
 the unit 16's lower and upper surfaces 17, 18, its inner and/or outer
 radial surfaces 19, 20 may not be oriented at a right angle with respect
 to its lower and/or upper surfaces 17, 18; and/or a partial or continuous
 chamfer may be provided at the intersections between its inner and/or
 outer radial surfaces 19, 20 and its lower and/or upper surfaces 17, 18,
 to help prevent chipping or breakage of the outer edges of the unit 16.
 Although the modular foundation unit 16's lower and upper surfaces 17, 18
 are illustrated a being equal in size, they may not be equal in size. For
 example, if the modular foundation unit 16 is to be at least partially
 made by slip forming, then its lower and upper surfaces 17, 18 may be
 selected to be unequal in size, so that its inner and/or outer radial
 surfaces 19, 20 are tapered; in order to assist the easier removal of the
 modular foundation unit 16 from its slip form after the material from
 which it is made has hardened.
 The modular foundation unit 16 may further comprise axial column locking
 means on its inner radial surface 19 for helping to lock the modular
 foundation unit 16 and the axial column 15 together, and for helping to
 prevent relative axial motion between the modular foundation unit 16 and
 the axial column 15; after the axial column 15 has been poured and has
 hardened.
 The axial column locking means may comprise any variation in the inner
 radial size of the modular foundation unit 16 as one travels along its
 longitudinal axis 22. For example, the inner radial surface 19 of the
 modular foundation unit 16 may be, in whole or in part, concave or convex
 in longitudinal cross-section. Alternatively, the inner radial surface 19
 of the modular foundation unit 16 may be tapered, in whole or in part, as
 one travels between the lower and upper surfaces 17, 18 of the modular
 foundation unit 16.
 Alternatively, the axial column locking means may, as seen in FIGS. 4-5,
 comprise a ring-shaped groove 32 of any desired size on the inner radial
 surface 19 of the modular foundation unit 16. Although only one groove 32
 is illustrated, there may be more than one groove 32 which may be spaced
 equally, or unequally, about the inner radial surface 19 of the modular
 foundation unit 16. Although the groove 32 is illustrated as following a
 straight path, it may follow any other suitable path, such a zig-zag,
 curved and/or sinuous.
 Although the groove 32 is illustrated as being continuous, it may be
 discontinuous and it may comprise two or more groove segments which may,
 or may not, lie in a common plane. Although the groove 32 is illustrated
 as having a generally rectangular cross-sectional configuration, it may
 have any other suitable cross-sectional configuration. Although the groove
 32 is illustrated as being located in a plane that intersects the modular
 foundation unit 16's longitudinal axis 22 at a right angle, it may be
 located in a plane that does not intersect the modular foundation unit
 16's longitudinal axis 22 at a right angle.
 Alternatively, the groove 32 and the modular foundation unit 16's
 longitudinal axis 22 may be at least generally co-planar; and such a
 groove 32 may, or may not, extend the full distance between the modular
 foundation unit 16's lower and upper surfaces 17, 18. There may be two, or
 more, such grooves 32, which may be spaced equally, or unequally, about
 the inner radial surface 19 of the modular foundation unit 16. If the
 inner radial surface 19 of the modular foundation unit 16 is to be slip
 formed, then the groove(s) 32 and the modular foundation unit 16's
 longitudinal axis 22 may be at least generally co-planar, and the
 groove(s) 32 may extend part or all of the full distance between the
 modular foundation unit 16's lower and upper surfaces 17, 18; in order to
 assist the easier removal of the modular foundation unit 16 from its slip
 form after the material from which it is made has hardened.
 As best seen in FIG. 9, the axial column locking means may comprise a
 ring-shaped flange 33 of any desired size on the inner radial surface 19
 of the modular foundation unit 16. Although only one flange 33 is
 illustrated, there may be more than one flange 33, which may be spaced
 equally, or unequally, about the inner radial surface 19 of the modular
 foundation unit 16. Although the flange 33 is illustrated as following a
 straight path, it may follow any other suitable path, such a zig-zag,
 curved and/or sinuous.
 Although the flange 33 is illustrated as being continuous, it may be
 discontinuous and comprise two or more flange segments which may, or may
 not, lie in a common plane. Although the flange 33 is illustrated as
 having a generally rectangular cross-sectional configuration, it may have
 any other suitable cross-sectional configuration. Although the flange 33
 is illustrated as being located in a plane that intersects the modular
 foundation unit 16's longitudinal axis 22 at a right angle, it may be
 located in a plane that does not intersect the modular foundation unit
 16's longitudinal axis 22 at a right angle.
 Alternatively, the flange 33 and the modular foundation unit 16's
 longitudinal axis 22 may be at least generally co-planar; and such a
 flange 33 may, or may not extend the full distance between the modular
 foundation unit 16's lower and upper surfaces 17, 18. There may be two, or
 more, such flanges 33, which may be spaced equally, or unequally, about
 the inner radial surface 19 of the modular foundation unit 16. If the
 inner radial surface 19 of the modular foundation unit 16 is to be slip
 formed, then the flange(s) 33 and the modular foundation unit 16's
 longitudinal axis 22 may be at least generally co-planar, and the
 flange(s) 33 may extend part or all of the full distance between the
 modular foundation unit 16's lower and upper surfaces 17, 18; in order to
 assist the easier removal of the modular foundation unit 16 from its slip
 form after the material from which it is made has hardened.
 Alternatively, as seen in FIGS. 9 and 11, the axial column locking means
 may comprise a pattern of lugs 60 and/or recesses 61 of any suitable size,
 shape and number on the inner radial surface 19 of the modular foundation
 unit 16 (FIG. 9), or a pattern of recesses 61a on the inner radial surface
 19 of the unit 16 (FIG. 11). There may be as few as one lug 60 and/or
 recess 61, 61a. One or more of the groove 32, the flange 33, the lugs 60,
 and/or the recesses 61, 61a may merge into each other, to form one
 integral part, and/or may extend to the lower and/or upper surfaces 17, 18
 of the unit 16.
 Alternatively, the axial column locking means may comprise one or more of
 any suitable projecting members, such as rods, wires, nails or screws,
 which project radially inwardly from the inner radial surface 19 of the
 modular foundation unit 16 into the axial opening 21 of the modular
 foundation unit 16. Such projecting members may be the same as, or at
 least similar to, the projecting members 43 of the modular foundation unit
 16a of FIG. 5.
 The modular foundation unit 16 may further comprise ground locking means
 for helping to lock the modular foundation units 16 and the surrounding
 ground 34 together, after the foundation hole 36 has been back-filled. The
 ground locking means may desirably provide greater friction between the
 modular foundation unit 16 and the surrounding ground 34 than may
 otherwise be the case; thereby increasing the load bearing capacity,
 uplift strength and wind resistance of the completed modular foundation
 system 10.
 The modular foundation unit 16's ground locking means may comprise any
 variation in the outer radial size of the modular foundation unit 16 as
 one travels along its longitudinal axis 22. For example, the outer radial
 surface 20 of the modular foundation unit 16 may be, in whole or in part,
 concave or convex in longitudinal cross-section.
 Alternatively, the outer radial surface 20 of the modular foundation unit
 16 may be tapered, in whole or in part, as one travels between the lower
 and upper surfaces 17, 18 of the modular foundation unit 16.
 Alternatively, the modular foundation unit 16's ground locking means may
 comprise a partial or continuous pattern 75 of any size, shape, length and
 orientation of grooves and/or recesses on the outer radial surface 20 of
 the modular foundation unit 16. For clarity, the pattern 75 is not
 illustrated on the outer radial surface 20 of the foundation unit 16 in
 FIGS. 1-3, 5, 7, and 9-10. A similar ground locking means pattern 75 may
 be provided on the outer surface 30 of the punch pad 14, as best seen in
 FIGS. 4 and 6. Although not illustrated, for clarity, such a pattern 75
 may also be provided on the inner radial surface 19 of the unit 16, to
 serve as an axial column locking means for the unit 16.
 Alternatively, as seen in FIG. 10, the modular foundation unit 16's ground
 locking means may comprise a ring-shaped flange 70 and/or groove 71 of any
 desired size on the outer radial surface 20 of the modular foundation unit
 16. Although only one flange 70 and groove 71 are illustrated, there may
 be more than one flange 70 and/or groove 71 which may be spaced equally,
 or unequally, about the outer radial surface 20 of the modular foundation
 unit 16. Although the flange 70 and groove 71 are illustrated as following
 a straight path, the flange 70 and/or groove 71 may follow any other
 suitable path, such a zig-zag, curved and/or sinuous.
 Although the flange 70 and groove 71 are illustrated as being continuous,
 the flange 70 and/or the groove 71 may be discontinuous and the flange 70
 and/or the groove 71 may comprise two or more segments which may, or may
 not, lie in a common plane. Although the flange 70 and the groove 71 are
 illustrated as having generally rectangular cross-sectional
 configurations, the flange 70 and/or the groove 71 may have any other
 suitable cross-sectional configurations. Although the flange 70 and the
 groove 71 are illustrated as being located in a plane that intersects the
 modular foundation unit 16's longitudinal axis 22 at a right angle, the
 flange 70 and/or the groove 71 may be located in a plane that does not
 intersect the modular foundation unit 16's longitudinal axis 22 at a right
 angle.
 Alternatively, the modular foundation unit 16's longitudinal axis 22, and
 the flange 70 and/or the groove 71, may be at least generally co-planar;
 and such a flange 70 and/or groove. 71 may, or may not, extend the full
 distance between the modular foundation unit 16's lower and upper surfaces
 17, 18. There may be two, or more, such flanges 70 and/or grooves 71,
 which may be spaced equally, or unequally, about the outer radial surface
 20 of the modular foundation unit 16. If the outer radial surface 20 of
 the modular foundation unit 16 is to be slip formed, then the modular
 foundation unit 16's longitudinal axis 22, and the flange(s) 70 and/or the
 groove(s) 71, may be at least generally co-planar, and the flange(s) 70
 and/or the groove(s) 71 may extend part or all of the full distance
 between the modular foundation unit 16's lower and upper surfaces 17, 18;
 in order to assist the easier removal of the modular foundation unit 16
 from its slip form after the material from which it is made has hardened.
 Alternatively, the modular foundation unit 16's ground locking means may
 comprise a pattern of lugs 72 (FIG. 7) and/or recesses 73 (FIG. 10) of any
 suitable size, shape and number on the outer radial surface 20 of the
 modular foundation unit 16. There may be as few as one lug 72 and/or
 recess 73.
 In addition, one or more of the flange 70, the groove 71, the lugs 72,
 and/or the recesses 73 may merge into each other, to form one integral
 part, and/or may extend to the lower and/or upper surfaces 17, 18 of the
 unit 16.
 Alternatively, the modular foundation unit 16's ground locking means may
 comprise one or more of any suitable projecting members, such as rods,
 wires, nails or screws, which project radially outwardly from the outer
 radial surface 20 of the modular foundation unit 16 into the axial opening
 21 of the modular foundation unit 16. Such projecting members may be the
 same as, or at least similar to, the projecting members 43 of the modular
 foundation unit 16a of FIG. 5.
 The modular foundation unit 16 may also comprise any suitable arrangement
 of reinforcing material, such as rebar, reinforcing mesh and/or
 reinforcing fibers.
 Turning again to the punch pad 14, it may also further comprise ground
 locking means for helping to lock the punch pad 14 and the surrounding
 ground 34 together, after the foundation hole 36 has been back-filled. The
 punch pad ground locking means may desirably provide greater friction
 between the punch pad 14 and the surrounding ground 34 than may otherwise
 be the case; thereby increasing the load bearing capacity, uplift strength
 and wind resistance of the completed modular foundation system 10. The
 punch pad ground locking means may be the same as, or at least similar to,
 any of the modular foundation unit ground locking means that were
 described above in detail.
 Turning now to the installation of the modular foundation system 10, its
 foundation hole 36 may be formed in the ground in any suitable way, such
 as by auguring. Once the foundation hole 36 has been formed, the punch pad
 14 may be lowered to the bottom of the foundation hole 36, if the punch
 pad 14 has been pre-made, after which the punch pad 14 may be leveled so
 that its upper surface 18 is at least generally horizontal. It should be
 recalled that the punch pad 14 may comprise a modular foundation unit 16
 or 16a.
 Alternatively, the punch pad 14 may be poured in place in the bottom of the
 foundation hole 36 by using the bottom portion of the foundation hole 36
 as the form for the punch pad 14; after which the punch pad 14 may then be
 allowed to harden for the desired length of time. The upper surface 18 of
 such a poured in place punch pad 14 may be self-leveling, due to the force
 of gravity.
 After the finished punch pad 14 is in place at the bottom of the foundation
 hole 36, the modular foundation units 16, 16a may then be stacked on top
 of the punch pad 14, with their axial openings 21 at least generally
 axially aligned. The pole 24 for the axial column 15 may then be lowered
 into the axial opening(s) 21 of the modular foundation units 16, and
 centered; and the bottom of the pole 24 may be supported by the upper
 surface 27 of the punch pad 14. The pole 24 may then be held in place in
 any suitable way. After the pole 24 is in place, the axial column 15 may
 then be poured and its cap 23 may be formed and finished. After the axial
 column 15 has been allowed to harden for the desired length of time, the
 foundation hole 36 for the modular foundation system 10 may then be
 back-filled; at which time the modular foundation system 10 may be ready
 for use. As best seen in FIG. 4, the hardened axial column 15 may serve to
 hold the punch pad 14, the modular foundation units 16, 16a and the pole
 24 together as one strong, integral structure.
 It is understood that the foregoing forms of the invention were described
 and/or illustrated strictly by way of non-limiting example.
 In view of all of the disclosures herein, these and further modifications,
 adaptations and variations of the present invention will now be apparent
 to those skilled in the art to which it pertains, within the scope of the
 following claims.