Patent Publication Number: US-9903085-B2

Title: Pile repair clamp

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional application No. 62/131,581, filed Mar. 11, 2015, the contents of which are incorporated herein by reference. 
    
    
     FIELD OF INVENTION 
     The present application relates to repairing structures, and more specifically to a method and apparatus wherein the structure is protected or strengthened by a shell or facing constructed on or assembled to the exterior of the structure, or by a substance applied to the exterior to form a layer thereon. 
     BACKGROUND 
     Concrete pilings and piers are utilized in industrial, bridge and marine construction projects due to their strength, corrosion resistance and ability to withstand long term exposure to adverse elements. However, over time these pilings and piers can deteriorate due to factors such as corrosion from salt intrusion, exposure to salt water, marine life and extreme weather conditions, or can become damaged from collisions with vehicles including ships and land vehicles. When a concrete pile or pier is damaged or deteriorated, it may be necessary to reinforce the outer surface of the pile or pier with new concrete, epoxy, or other structural repair material. 
     The process of repairing a pile or pier (collectively referred to hereafter as “pile”) typically involves the use of various pieces of custom built equipment and, in marine environments, the need for underwater divers to access the damaged area and to effectuate a repair. There are currently three major problems with the traditional repair process. First, the platform used to support the rebar and jacket (also known as a “form”) used to contain concrete, epoxy, or other repair material is very time-consuming to install. Second, concrete, epoxy, or other repair material can leak out from beneath the jacket due to platform-to-jacket alignment issues. Third, the clamping force between the platform and pile is not consistently applied which can result in slippage of the platform when the jacket is filled. As a result, there is a need in the industry for an improved and simplified apparatus and method for repairing pile that does not require difficult and time consuming labor. 
     SUMMARY 
     The present invention solves the foregoing problems by providing a pile repair apparatus that can be pre-assembled on dry land and positioned easily around a pile to be repaired. For marine applications an additional flotation member can be added to achieve neutral buoyancy thereby enhancing underwater movement of the present invention. 
     One aspect of the invention is an apparatus, including a clamp made of metal or some other form of material, such as composites, sufficiently strong to sustain the required clamping forces; a friction member positioned along an inner surface of the clamp; and a platform connected to a top surface of the clamp. The apparatus may further include a means for providing neutral buoyancy to the apparatus. 
     A second aspect of the invention is an apparatus, including a clamp comprising left and right brackets connected by a hinge member; a friction member positioned along an inner surface of the clamp; a platform connected to a top surface of the clamp; and a means for providing neutral buoyancy to the pile repair apparatus. 
     A third aspect of the invention is a method for repairing a pile, including securing a friction member along an inner surface of a clamp adapted to wrap around a pile, pier or other structure to be repaired; connecting a platform to a top surface of the clamp; and securing the clamp to the pile, pier or other structure to be repaired. 
     The entire apparatus can be preassembled in a dry environment to ensure a high-quality platform is installed underwater. A single clamp assembly can support an entire structural repair load, including, but not limited to, concrete, epoxy, and other structural repair material without slippage of the clamp on the pile. A removable flotation member can be attached to the top of the platform to provide neutral buoyancy to the entire assembly, which makes it easy for divers to maneuver the clamp into position anywhere along the pile. Once in position, by virtue of the geometry and load path of the clamping force, the platform self-aligns to the pile to prevent leakage when the concrete, epoxy, or other repair material is poured. A tedious platform installation process that can take several hours to complete can be performed in a significantly shortened time period using the apparatus described herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other features of this disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings, in which: 
         FIG. 1  is a top perspective view of an apparatus of the present invention; 
         FIG. 2  is a top perspective view of left and right brackets of the apparatus; 
         FIG. 3  is a side perspective view of one of the brackets; 
         FIG. 4  is a side perspective view of a hinge member connecting the left and right brackets; 
         FIG. 5  is a top perspective view showing friction surfaces secured to the left and right brackets; 
         FIG. 6  is a top perspective view of one or more platforms connected to the left and right brackets; 
         FIG. 7  is a top perspective view of the means for providing neutral buoyancy the apparatus; and 
         FIG. 8  illustrates an embodiment of the apparatus of the invention applied to a marine pile. 
     
    
    
     DETAILED DESCRIPTION 
     An apparatus of the invention (or “apparatus”)  100  is shown generally in  FIG. 1 . The apparatus  100  optionally but preferably includes a flotation member  102  secured to a platform  104 . The platform  104  is positioned atop a clamp  106  that is adapted for mounting the apparatus  100  to a pile, pier or other structure to be repaired as shown in  FIG. 8 . For purposes of this application, “pile” shall refer to marine pile or piling, piers, towers, and any other structure capable of being repaired by adding concrete, epoxy, or other suitable repair material to its circumference or perimeter. A friction member  108  is provided within the interior of the clamp  106  to enhance the connection of the clamp  106  to the pile. 
     Clamp 
     As shown more clearly in  FIG. 2 , the clamp  106  optionally but preferably includes a left bracket  161  and a right bracket  162  that are for practical purposes mirror images of one another, and, which when combined with friction member  108 , have an inside dimension that corresponds to the outside dimension of a pile to be repaired. The left and right brackets  161 ,  162 , respectively, are optionally but preferably detachably secured to one another by a hinge member  463 . Each of bracket  161 ,  162  has a top surface  164  and a bottom surface  365 . The top surface  164  has a generally uniform width adapted for accommodating the platform  104 . The top surface  164  further has one or more apertures  166  that serve to lessen the overall system weight and a plurality of holes  167  that correspond to holes in the platform  104 . 
       FIG. 3  shows the bottom surface  365  of one of the brackets  161 ,  162 . The bottom surface  365  has one or more bottom plates  368  positioned at the bottom surface  365  of the clamp  106 . One or more ribs  369  extend vertically between the top and bottom surfaces  164 ,  365  of the bracket  161 . A band  370  extends along the length of the top surface  164  of the bracket  161 . The first and second side bracket  161  and  162  contain a nut  371  on an angled side plate  373  for receiving a bolt. On the mirrored side of the first and second side bracket  161  and  162 , a clearance hole  374  is provided to allow the threaded portion of a bolt to pass through the angled side plate  373 , with the head of the bolt, or alternatively a washer under the head of the bolt, exerting a force on the angled side plate when torqued. One side of the bracket  161  and  162  has one or more rods  372  adapted for forming a hinge  463  to enhance installation of the apparatus  100  to a pile. An example of a hinge  463  is shown more clearly in  FIG. 4 . 
     Friction Surface 
     Referring to  FIG. 5 , a friction member  108 , such as wood, rubber, plastic or other synthetic material with a high coefficient of friction, can be secured to the inside surface of the clamp brackets  161 ,  162 . In a preferred embodiment, the friction member  108  is one or more wood planks dimensioned to fit inside the inner surface of the brackets  161 ,  162 . The friction member  108  contacts the outer surface of a pile to be repaired and improves the connection between the apparatus  100  and the pile. 
     Platform 
     As shown in  FIG. 6 , one or more platforms  104  can be connected to the top surface  164  of each of the brackets  161 ,  162 . The platform optionally but preferably is a wood panel having a width equal or greater than the width of the top surface  164  of the brackets  161 ,  162 . The platform has holes  660  that correspond to the holes  167  in the top surface  164  of the brackets  161 ,  162 . The platform  104  further can include hook and loop closures  650  adapted for receiving a corresponding hook and loop closure. 
     Means for Providing Neutral Buoyancy 
     An example of a means for providing neutral buoyancy to the apparatus  100  is shown in  FIG. 7 . In a preferred embodiment, the means for providing neutral buoyancy is a flotation member  102  made of foam or other buoyant material, such as, but not limited to, polyethylene, cross-linked polyethylene, polyurethane foams, detachably secured to the platform  104 . The flotation member  102  has a plurality of holes  710  that correspond to the holes  660  in the platform  104 . The flotation member  102  and platform  104  can be connected by zip ties, bungie cords, rope, wire, or other appropriate fastening means. 
     In operation, the left and right brackets  161 ,  162  of the apparatus  100  are clamped together by bolts or other mechanical closure mechanism of sufficient strength to provide adequate clamping forces. The hinge member  463  allows the apparatus  100  to be opened and to be positioned around a pile to be repaired. One or more friction members  108  is secured to the inner surface of the left and right brackets  161 ,  162  of the clamp  106 . One or more platforms  104  is secured to the top surface  164  of each of the left and right brackets  161 ,  162 . If the repair is to be performed under water or if the apparatus otherwise must be transported in water, a flotation member  102  can be attached to the platform  104 . The flotation member  102  makes the apparatus  100  neutrally buoyant, which allows a diver to easily transport and submerse the apparatus  100  when commencing to repair a pile. Once in a desired location, and after tightening of the bolts or other mechanical closure mechanism, the flotation member  102  can be removed by cutting or otherwise severing the mechanical fastening means affixing the flotation member  102  to the platform  104 . The apparatus  100  can be opened about its hinge member  463  and placed around a section of pile to be repaired. The friction member  108  enhances the connection of the apparatus  100  to the pile. The apparatus  100  is secured in place around the pile by inserting bolts between the left and right brackets  161 ,  162 . Once in place, with the bolts or other mechanical closure mechanism tightened, the apparatus  100  self-aligns to the pile to prevent leakage when concrete, epoxy, or repair material is poured during the repair process. The apparatus  100  can be moved easily along the pile by removing or loosening the bolt between the left and right brackets  161 ,  162  and sliding the apparatus  100  up or down along the pile as needed. Any gap between the left and right brackets,  161 ,  162 , which may exist due to variation in the outside dimension of piles to be repaired, may be closed by affixing a corresponding hook and loop closure to the hook and loop closure  650  on the platform  104 . 
     CONCLUSION 
     While various preferred embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings herein. The embodiments herein are exemplary only, and are not limiting. Many variations and modifications of the apparatus disclosed herein are possible and within the scope of the invention. Accordingly, the scope of protection is not limited by the description set out above.