Abstract:
A piering system includes a heave plate attached to a foundation and supported by a pier. A downward facing socket is permanently attached to the heave plate. The socket receives the top end of a heavy stud of a coupling assembly, the bottom end of the stud is screwed into a captive nut of a shim-block. A nut is welded to the stud leaving about ½ inch of the stud protruding upwards for insertion into the socket. The nut may be turned to adjust the height of the stud. The shim-block and coupling assembly are supported by a head plate which is supported by the pier. The head plate includes a wide table for supporting a pair of jacks on opposite sides of a house jack facilitating installation of the system. The cooperation of the ball and socket helps to prevent “off-set loads” which otherwise may break the piering system.

Description:
[0001]    The present application claims the priority of U.S. Provisional Patent Application Ser. No. 61/141,328 filed Dec. 30, 2008 and is a Continuation In Part of U.S. patent application Ser. No. 12/632,572 filed Dec. 7, 2009, which applications are incorporated by reference in their entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to piering systems and in particular to a concentrically loaded, adjustable, steel pipe foundation repair piering system. 
         [0003]    In many areas of the United States building foundations rest on unstable soil. Changes in local condition cause soil movement and damage to the building. Piering systems are used in such areas to provide support from bedrock under the buildings. Known piering systems include piers sunk below the foundation to a stable surface, for example, bedrock. The pier system reaches up to the foundation to provide vertical support. Unfortunately, the bottom of the foundation may not provide a horizontal surface for the support to push against and movement of the foundation may result in the foundation breaking away from the support. 
         [0004]    Further, concentrically loaded piering systems (those installed directly under the wall being supported or lifted, as opposed to being attached to the outer edge of the foundation footing) typically are easy to break with offset loads created by imperfect installation, and have loose adjusting components (“shims”) that can fall off if the structure moves after installation. Piers installed directly under the wall must be installed in very short “segments”. The link between the segments must be very strong to prevent breakage. 
         [0005]    Known piering systems typically require a number of loose adjusting components (or shims) which may fall off if the structure “heaves” or moves after installation. As a result, the piering system may require adjusting after a minor soil movement due to the lost shims even if the foundation returns to the original position. 
         [0006]    A need thus remains for an improved piering system which remains attached to the building foundation and can tolerate sloped foundation bottom surfaces. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    The present invention addresses the above and other needs by providing a piering system which includes a heave plate attached to a foundation and supported by a pier. A downward facing socket is permanently attached to the heave plate. The socket receives the top end of a heavy stud of a coupling assembly, the bottom end of the stud is screwed into a captive nut of a shim-block. A nut is welded to the stud leaving about ½ inch of the stud protruding upwards for insertion into the socket. The nut may be turned to adjust the height of the stud. The shim-block and coupling assembly are supported by a headplate and the headplate is supported by the pier. The headplate includes a wide table for supporting a pair of jacks on opposite sides of the shim-block allowing adjustment of the foundation. The cooperation of the stud and socket help to prevent “off-set loads” which otherwise may break the piering system. 
         [0008]    In accordance with one aspect of the invention, there is provided a piering system that makes a concentrically loaded pier stronger and provides an adjustable feature without loose components that could fall off if the structure “heaves” or moves after installation. The piering system may be used to support or lift a broken foundation requiring repair. 
         [0009]    In accordance with another aspect of the invention, there is provided a piering system with increased “side-load” strength, thereby eliminating breakage by creating a “solid” inner pipe link between segments. The assembly that contacts the bottom of the foundation, typically has many loose adjusting components (“shims”) that can fall off if the foundation “heaves” or moves after installation. The present invention provides for a wide range of adjustability without any loose components that may come loose or fall off. If the structure “heaves” up off the pier, it will return to it&#39;s properly supported position after the structure returns to its pre-heaving position. 
         [0010]    In accordance with still another aspect of the invention, there is provided a piering system compatible with footings lacking a level base. A heave plate is fastened to the base of the footing and is supported by a shim block through a socket, allowing the footing to shift. 
         [0011]    In accordance with yet another aspect of the invention, there is provided a method for constructing a pier system. The method includes constructing a pier performing the steps of: forming a hole reaching about 26 inches below the foundation; placing a pier base having a base cylinder portion in the bottom of the hole; placing a first outer cylinder over the base cylinder portion; inserting a first inner cylinder inside a recess in the first outer cylinder butting against the base cylinder portion; and repeating the steps of adding an additional overlapping outer cylinder and an additional inner cylinder providing a 50 percent overlap of consecutive cylinders; creating a link between the outer cylinders; and advancing the cylinders downward using a hydraulic ram until bedrock is reached. The 26 inch depth of the hole below the foundation is based on a combination of the pier segments of about 12 inches and a hydraulic ram just over 13 inched in length. If the length of the pier segments and/or the hydraulic ram are changed, the depth of the hole may change accordingly, is about the sum of the lengths. 
         [0012]    After bedrock is reached, completing the piering system with the steps of: cutting the top cylinders to be approximately ten inches below the foundation; positioning a head plate and house jack on top of the pier to provide a stable platform; placing a heave plate between the house jack and the bottom of the foundation to distribute force applied by the house jack to the foundation; adjusting the foundation to stabilize and/or level the foundation of the structure; after adjusting is achieved, positioning additional jacks on the head plate on either side of the house jack to support the heave plate; removing the house jack; positioning a shim block and coupling assembly with the coupling assembly screwed down into the shim block; advancing the coupling assembly upward until the coupling assembly reaches into a socket of the heave plate, removing the additional jacks; drilling holes through holes in the heave plate and into the foundation; and driving concrete anchors through holes in the heave plate and into the holes drilled into the foundation to fix the heave plate to the foundation. The shim block may be attached to the head plate by bending straps over to lock the shim block to the head plate or by bolting the shim block to the head plate. The head plate and shim block thus work together to create a fully adjustable leveling mechanism that is locked together with no loose components that can fall or shift if the structure moves after installation. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         [0013]    The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein: 
           [0014]      FIG. 1  shows a piering system according to the present invention supporting a foundation. 
           [0015]      FIG. 2  shows an exploded view of a pier of the piering system. 
           [0016]      FIG. 3A  is a front view of a heave plate according to the present invention. 
           [0017]      FIG. 3B  is a side view of the heave plate according to the present invention. 
           [0018]      FIG. 3C  is a top view of the heave plate according to the present invention. 
           [0019]      FIG. 3D  is a bottom view of the heave plate according to the present invention. 
           [0020]      FIG. 4  is a prior to assembly side view of a coupling assembly according to the present invention. 
           [0021]      FIG. 5A  is a side view of the coupling assembly according to the present invention. 
           [0022]      FIG. 5B  is a top view of the coupling assembly according to the present invention. 
           [0023]      FIG. 6  is a prior to assembly side view of a shim block according to the present invention. 
           [0024]      FIG. 7A  is a side view of the shim block according to the present invention. 
           [0025]      FIG. 7B  is a top view of the shim block according to the present invention. 
           [0026]      FIG. 8  is a cross-sectional view of the shim block taken along line  8 - 8  of  FIG. 6 . 
           [0027]      FIG. 8A  is a cross-sectional view of the shim block taken along line  8 - 8  of  FIG. 6  having bolts for attachment to the head plate. 
           [0028]      FIG. 9A  is a front view of a head plate according to the present invention. 
           [0029]      FIG. 9B  is a side view of the head plate according to the present invention. 
           [0030]      FIG. 9C  is a top view of the head plate according to the present invention. 
           [0031]      FIG. 9D  is a bottom view of the head plate according to the present invention. 
           [0032]      FIG. 10A  is a front view of a strap according to the present invention. 
           [0033]      FIG. 10B  is an edge view of the strap according to the present invention. 
           [0034]      FIG. 11A  describes a method for constructing a pier system according to the present invention. 
           [0035]      FIG. 11B  describes a method for completing a pier system according to the present invention. 
       
    
    
       [0036]    Corresponding reference characters indicate corresponding components throughout the several views of the drawings. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0037]    The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims. 
         [0038]    A piering system  10  according to the present invention is shown supporting a foundation  24  in  FIG. 1 . The piering system  10  includes a heave plate  12 , a coupling assembly  16 , a shim-block  18 , a head plate  20  and a pier  22 . The heave plate  12  is attached to the foundation  24  by attachments  14  which may be stakes, bolts, studs, or the like and fix the heave plate  12  to the foundation  24 , and are preferably concrete anchors driven into the foundation  24  through pre-drilled holes  13  in the heave plate  12 , permanently attaching the heave plate to the foundation. As a result, unlike known piering systems, the heave plate  12  of the piering system  10  according to the present invention moves with the foundation  24 . The coupling assembly  16  reaches into a socket  26  welded or otherwise fixedly attached to the heave plate  12 . The socket  26  and coupling assembly  16  are similar to a ball and socket arrangement (although the coupling assembly  16  need not have a spherical upper end) and socket  26  and coupling assembly  16  remain in engagement with the heave plate  12  through the socket  26  during typical translation, pivotal, or rotational movement of the heave plate  12  attached to the foundation  24 . The socket  26  merely need be slightly larger that the top end of the coupling assembly  16 . The height of the coupling assembly  16  is adjustable and eliminates the need for shims in known piering systems, which shims are often displaced and lost when the foundation  24  moves. The piering system  10  allowed simple readjustment to compensate for foundation movement. 
         [0039]    When variations in the length of the pier  22  are desired or required, a shorter inner pipe  25  may be welded to one end of a segment, creating a coupling sleeve, thereby saving the additional steel needed to make a complete connection. 
         [0040]    An exploded view of a pier of the piering system  22  is shown in  FIG. 2 . The piering system includes a base  21  having a flange  21   a  which preferably rests on a stable base  17 , for example, bed rock, outer cylinders  23  and inner cylinders  25 . The cylinders overlap providing a double wall thickness for the pier  22 . The bottom most outer cylinder  23  overlaps the cylinder portion  21   b  of the base  21 , the bottom most inner cylinder  25  fits into the top half of the bottom most outer cylinder  23  and butts against the cylinder portion  21   b,  and such construction is repeated to form the complete pier  22 . The flange  21   a  is preferably an approximately three inch diameter disk, the cylinder portion  21   b  is an approximately six inch long segment of approximately 2⅜ inch Outside Diameter (OD) pipe, the outer cylinders  23  are preferably approximately twelve inch long segment of approximately 2⅞ inch OD pipe, and the inner cylinders  25  are preferably approximately twelve inch long segment of approximately 2⅜ inch OD pipe. The cylinders are preferably made of approximately 0.220 thickness or schedule 40 steel tubing and more preferably made of schedule 40 high carbon steel tubing. 
         [0041]    The bottom most outer cylinder  23  is preferably welded to the base  21  to prevent separation of the base  21  from the bottom most outer cylinder  23  during installation. For example, if an install drives only the inner cylinders  25 , the base  21  may separate from the pier  22  and “kick” sideways in the hole, and be very difficult to re-attach. If the bottom most outer cylinder  23  is welded to the base  21 , it is much easier to re-capture the larger diameter bottom most outer cylinder  23 . Further, when the flange  21   a  is not much larger than the cylinder portion  21   b,  a weld bead  21   c  around the bottom of the base  21  may provide an increased diameter called a “friction ring”. The friction ring pushes the soil away from the pier  22  during installation, reducing skin friction by the soil which tends to inhibit the desired depth being achieved. 
         [0042]    A front view of the heave plate  12  according to the present invention is shown in  FIG. 3A , a side view of the heave plate  12  is shown in  FIG. 3B , a top view of the heave plate  12  is shown in  FIG. 3C , and a bottom view of the heave plate  12  is shown in  FIG. 3D . The heave plate  12  includes a table  12   a  for residing against the foundation  24  and a substantially vertical ledge (or angle)  12   b  attached along the length of one edge of the table  12   a  to strengthen the heave plate  12 . The heave plate  12  may alternatively be cut from angle material. A socket  26  is welded or similarly attached to a bottom surface of the table  12   a  and provides an open mouth for capturing the coupling assembly  16 . The table  12   a  is preferably approximately six inches by fourteen inches and the ledge  12   b  is preferably approximately four inches high. The heave plate  12  may, for example, be cut from four by six inch, ⅜ inch thick steel angle, cut in 14 inch lengths. 
         [0043]    Examples of the socket  26  may be a 2⅞ by ¾ inch pipe nipple, or may be a short section (e.g., about ¾ inches long) of pipe or the like welded to the bottom surface of the table  12   a.  The top of a stud  30  is captured in the socket  26 . The inside diameter of the socket  26  has sufficient diameter to allow both the translation and rotation of the heave plate  12  relative to the stud  30  to allow for movement of the foundation during leveling, and later for settling. For example, angles of up to 15 to 20 degrees between the heave plate  12  and the stud  30  may be experienced if the foundation has previously settled significantly and/or the structure has been altered to compensate for the settling, and in some of these situation it may not be practical to force the foundation to level. Preferably, the inside diameter of the socket  26  is at least ¼ inches greater than the diameter of the stud  30  and is more preferably between ¼ inches and 1½ inches greater than the stud  30 . In a preferred example, the stud may be 1½ inches in diameter and the inside diameter of the socket may be 2½ inches, but the stud  30  may be as small as 1 inch in diameter and the corresponding socket  26  may be 1¼ in inside diameter. 
         [0044]    A prior to assembly side view of the coupling assembly  16  according to the present invention is shown in  FIG. 4 , a side view of the assembled coupling assembly  16  is shown in  FIG. 5A , and a top view of the assembled coupling assembly  16  is shown in  FIG. 5B . The coupling assembly  16  is preferably constructed from an approximately seven inch length of approximately 1¼ inch diameter to approximately 1½ inch diameter grade-8 threaded material stud  30  and the nut  28  is a matching thread nut preferably welded to the stud  30 , but the nut  28  may be attached using, for example, permanent Loctite® threadlock or similar material. Alternatively, other fittings may be attached to the stud to allow turning the stud for adjustment and a coupling assembly including any means for turning is intended to come within the scope of the present invention. 
         [0045]    A prior to assembly side view of the shim block  18  according to the present invention is shown in  FIG. 6 , a side view of the assembled shim block  18  is shown in  FIG. 7A , a top view of the assembled shim block  18  is shown in  FIG. 7B , and a cross-sectional view of the shim block  18  taken along line  8 - 8  of  FIG. 7  is shown in  FIG. 8 . The shim block  18  includes a base  33 , a shaft  34 , and a shim block nut  32 . The base  33 , column  34 , and nut are preferably welded together. The nut  32  is held rotationally fixed in the top of the shaft  34  has the same thread as the stud  30  allowing the coupling assembly  16  to be advanced and retreated vertically by turning the stud  30 . 
         [0046]    A cross-sectional view of the shim block  18  taken along line  8 - 8  of  FIG. 6  having bolts  19   a  for attachment to the head plate  20  is shown in  FIG. 8A . 
         [0047]    The column  34  is preferably constructed of an approximately 2 1/16 inch pipe  34   c  inside an approximately 2⅜ inch pipe  34   b  inside an approximately 2⅞ inch pipe  34   a,  and the pipes  34   b  and  34   c  are preferably recessed approximately ½ inches into the pipe  34   a  providing a recess and vertical support for the nut  32 . The base  33  preferably measures approximately 4 inches by approximately 4 inches, and is preferably approximately ½ inch thick steel plate. 
         [0048]    Straps  19  (also see  FIGS. 9A   10   a  and  10 B) are provided to attach the shim block  18  to the head plate  20 . The straps  19  are preferably welded to the base  33  on both sides of the shim block  18 . The straps  19  allow the shim block  18  to be locked to the head plate  20  using only a hammer. In an alternative embodiment, the straps  19  are replaced by two bolts in opposite front corners attaching the shim block  18  to the head plate  20 . 
         [0049]    A front view of the head plate  20  according to the present invention is shown in  FIG. 9A , a side view of the head plate  20  is shown in  FIG. 9B , a top view of the head plate  20  is shown in  FIG. 9C , and a bottom view of the head plate  20  is shown in  FIG. 9D . The head plate  20  includes a head plate table  36 , head plate cylinder  40 , and gussets  38 . The table  36  supports the shim block  18  and is preferably made from approximately six inches by approximately fourteen inches of ½ inch thick steel plate. The cylinder  40  is welded to the bottom of the table  36  and is sized to fit over the top of the pier  22  and is approximately six inches high. The gussets  38  brace the table  36  to the cylinder  40 . 
         [0050]    A front view of the strap  19  according to the present invention is shown in  FIG. 10A  and an edge view of the strap  19  is shown in  FIG. 10B . The straps  19  are preferably approximately eight inches long and are made from approximately ½ inch by approximately ¼ inch steel strap. 
         [0051]    A method for constructing a pier system according to the present invention includes the following steps. A hole is formed about 26 inches below the foundation  24 . The base  21  including a cylinder portion  21   b  is placed in the bottom of the hole. A first outer cylinder  23  is placed over the cylinder portion  21   b  creating a six inch recess inside the outer cylinder  23 . A first inner cylinder  25  is placed inside the recess in the first outer cylinder  23  butting against the cylinder portion  21   b.  The steps of adding an additional overlapping outer cylinder  23  and an additional inner cylinder  25  are repeated providing a 50 percent overlap of consecutive cylinders  23  and  25  creating a link between the outer cylinders  23  which cannot be broken because the inner cylinders  23  extend six inches on both sides of the joint between the outer cylinder  23 . The cylinders  23  and  25  are added and the forming pier  22  is advanced downward using a hydraulic ram until a stable base, preferably bedrock, is reached. 
         [0052]    After the stable base is reached, the top most cylinders  23  and  25  are cut to be approximately ten inches below the foundation  24 . The head plate  20  is positioned on top of the pier  22  to provide a stable platform for a house jack (preferably a ten-ton house jack) which is used in conjunction with other piers  22  and house jacks to adjust (i.e., stabilize and/or level) the foundation  24  of the structure. A heave plate  12  is sandwiched between the house jack and the foundation  24  to distribute the lifting force of the house jack to avoid damaging the foundation  24 . After stabilization is achieved, additional jacks are placed on the head plate  20  either side of the house jack to support the heave plate  12  and foundation  24 , and the house jack is removed. The house jack is replaced by the shim block  18  with the coupling assembly  16  screwed down into the shim block  18 . The shim block  18  which is adjusted by turning the coupling assembly  16  until the coupling assembly  16  reaches into the socket  26  of the heave plate  12 . The additional jacks may then be removed. Holes are drilled through the holes  13  in the heave plate  12  and into the bottom of the foundation  24  and concrete anchors  14  are driven through the holes  13  in the heave plate  12  and into the holes to fixedly attach the heave plate  12  to the foundation  24 . The straps  19  are then bent over to lock the shim block  18  to the head plate  20  or bolts are installed attaching the shim block  18  to the head plate  20 . The head plate  20 , shim block  18 , and heave plate  16  thus work together to create a fully adjustable leveling mechanism that is locked together with no loose components that can fall or shift if the structure moves after installation. 
         [0053]    A method for constructing a pier system according to the present invention is described in  FIG. 11A . The method includes constructing a pier performing the steps of: forming a hole below the foundation at step  100 ; placing a pier base having a base cylinder portion in the bottom of the hole at step  102 ; placing a first outer cylinder over the base cylinder portion at step  104 ; inserting a first inner cylinder inside a recess in the first outer cylinder butting against the base cylinder portion at step  106 ; and repeating the steps of adding an additional overlapping outer cylinder and an additional inner cylinder providing a 50 percent overlap of consecutive cylinders at step  108 ; creating a link between the outer cylinders and advancing the cylinders downward using a hydraulic ram until bedrock is reached at step  110 , and after bedrock is reached, completing the piering system at step  112 . The 26 inch depth of the hole formed in step  100  below the foundation is based on a combination of the pier segments of about 12 inches and a hydraulic ram just over 13 inches in length. If the length of the pier segments and/or the hydraulic ram are changed, the depth of the hole may change accordingly, and is preferable slightly greater than the sum of the lengths. 
         [0054]    A method for completing a pier system  112  according to the present invention is described in  FIG. 11B . After bedrock is reached, completing the piering system with the steps of: cutting the top cylinders to be approximately ten inches below the foundation at step  120 ; positioning a head plate and a house jack on top of the pier to provide a stable platform at step  122 ; placing a heave plate between the house jack and the bottom of the foundation to distribute force applied by the house jack to the foundation at step  124 ; adjusting the foundation to stabilize and/or level the foundation of the structure at step  126 ; after adjusting is achieved, positioning additional jacks on the head plate on either side of the house jack to support the heave plate at step  128 ; removing the house jack at step  130 ; positioning a shim block and coupling assembly with the coupling assembly screwed down into the shim block at step  132 ; advancing the coupling assembly upward until the coupling assembly reaches into a socket of the heave plate, removing the additional jacks at step  134 ; drilling holes through holes in the heave plate and into the foundation at step  136 ; and driving concrete anchors through holes in the heave plate and into the holes drilled into the foundation to fix the heave plate to the foundation at step  138 . The shim block may be attached to the head plate by bending straps over to lock the shim block to the head plate or by bolting the shim block to the head plate. The head plate and shim block thus work together to create a fully adjustable leveling mechanism that is locked together with no loose components that can fall or shift if the structure moves after installation. 
         [0055]    Placing a house jack on the head plate in step  122  may be placing a single house jack or a pair of house jacks. When a pair of house jacks are used to adjust the foundation, the step of placing additional jacks in step  128  is not required. Further, a hydraulic manifold jacking system may be used which provides jacks attached to a computer directed pump that lifts all the jacks at the same time instead of using bottle jacks. 
         [0056]    While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.