Patent Publication Number: US-6705053-B2

Title: Method and apparatus for utilizing non-cylindrical support sections to lift and level existing buildings from a location underneath the buildings

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to the copending U.S. provisional patent application entitled, “Lifting, Leveling And Stabilizing Of Existing Structures System,” having Ser. No. 60/252,814, and filed Nov. 22, 2000, which is entirely incorporated herein by reference. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     The present invention relates to lifting and leveling (i.e., repairing) existing buildings that have settled unevenly or, for some other reason, have become unstable and need to be re-leveled and stabilized. More particularly, the present invention relates to a method and apparatus for repairing existing buildings by utilizing a support system that comprises an apparatus having non-cylindrical support sections that are driven into the earth underneath the building foundation. The non-cylindrical support sections are strong and have relatively low bearing characteristics and relatively high friction characteristics. 
     BACKGROUND OF THE INVENTION 
     Several methods and systems have been developed and used for lifting, leveling and stabilizing existing buildings. One common technique used for re-leveling and stabilizing buildings and houses is accomplished by digging a hole underneath a building foundation to a depth generally equal to the length of a cylindrical cement support piling (e.g., 12 inches), driving the cylindrical cement support pilings into the ground one on top of the other until a particular depth has been reached, and jacking a portion of the building up to a particular height by utilizing a jack that is located on the top surface of the uppermost piling. 
     The pilings are typically driven into the ground until a rock strata is encountered or until the depth of the hole containing the pilings is believed to be sufficiently deep. In situations where a rock strata cannot be reached, the pilings are typically driven to a depth great enough to cause friction between the earth and the outer surfaces of the pilings to prevent substantial movement of the pilings. 
     One of the problems associated with using this approach is that the cement pilings must have relatively large diameters to provide them with sufficient strength to be driven into the ground to a particular depth and to support the building. The larger the diameter of the cement piling, the more bearing it has, which makes it more difficult to drive the piling into the ground. Another problem associated with using cement pilings is that they often shatter when rock strata and/or tree roots are encountered. For all of these reasons, this type of support system is undesirable. 
     Another common technique for re-leveling and stabilizing buildings utilizes steel cylindrical pipe sections that are driven into the earth adjacent the side of the building until a sufficient depth is reached. The building foundation is then jacked up using a hydraulic jack to a desired height, and then the foundation is bracketed to the uppermost steel pipe section. The jack is then removed and the building is supported and stabilized by the support system. One of the benefits of using hollow steel pipe sections for this purpose is that they have less bearing than the aforementioned concrete pilings due to the fact that the steel pipe support sections are smaller in diameter than the concrete pilings. Also, steel pipe used for this purpose is normally stronger than concrete and therefore is unlikely to break when rock or tree roots are encountered. However, the steel pipe support sections may bend, which results in instability in the support structure. 
     One of the disadvantages of using hollow steel pipes for this purpose is that the smaller diameter results in overall less friction between the earth and the surfaces of the steel pipe sections. Also, steel pipes, even if they are galvanized, tend to rust due to water collecting within the pipes after the system has been installed. Furthermore, bracketing the steel-pipe support system to the side of the building foundation tends to exert undesirable pressure on the outside of the building, which can result in structural damage to the building. 
     SUMMARY OF THE INVENTION 
     Accordingly, it would be desirable to provide a method and an apparatus for lifting and leveling existing buildings that overcome the aforementioned problems associated with existing support systems. The present invention provides a method and an apparatus for lifting and leveling existing buildings by utilizing a support system that lifts and levels an existing building from underneath the building utilizing non-cylindrical support sections. The apparatus of the present invention comprises at least one non-cylindrical support section that is substantially rectangular in shape and has first and second ends. The non-cylindrical support section is, in accordance with the method of the present invention, driven into the earth at a position underneath the existing building such that the first end of the first non-cylindrical support section is located beneath the second end of the first non-cylindrical support section. A cap support section is then placed in contact with the second end of the first non-cylindrical support section. A jack is disposed on the upper side of the cap support section and raised until the foundation of the existing building has been lifted to a desired height. 
     The non-cylindrical support section has low bearing and high friction characteristics. The low bearing characteristics enable the apparatus to be driven further into the earth than cylindrical pilings that are commonly used to lift and level existing buildings. The high friction characteristics assist in maintaining the stability of the apparatus once it has been installed. 
     These and other features and advantages of the present invention will become apparent from the following description drawings and claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1A is an end view of an H-beam that may be used to lift and level existing buildings in accordance with the method of the present invention. 
     FIG. 1B is a side view of the H-beam shown in FIG.  1 A. 
     FIG. 2A is an end view of an I-beam that may be used to lift and level existing buildings in accordance with the method of the present invention. 
     FIG. 2B is a side view of the I-beam shown in FIG.  2 A. 
     FIG. 3 is an illustration of the support system of the present invention once it has been installed to lift and level the foundation of a building. 
     FIG. 4A illustrates a side view of the apparatus of the present invention in accordance with one embodiment for attaching the sections shown in FIGS. 1A and 1B together as they are driven into the ground. 
     FIG. 4B illustrates a front view of the apparatus shown in FIG.  4 A. 
     FIG. 5 is a flow chart demonstrating the method of the present invention in accordance with the one embodiment. 
     FIG. 6 is a flow chart demonstrating the method of the present invention in accordance with a second embodiment. 
     FIG. 7 is a plan view of the apparatus shown in FIG. 1B wherein the end of the apparatus is sharpened, or tapered, to further reduce bearing when the apparatus is driven into the earth in accordance with the method of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As stated above, the present invention is directed to a method and an apparatus for lifting and leveling (i.e., repairing) existing structures, such as buildings and houses (hereinafter referred to collectively as “buildings”). The apparatus of the present invention in accordance with one embodiment comprises one or more H-beams  1 , such as the H-beam shown in FIGS. 1A and 1B. FIG. 1A is a top (or bottom) view of an H-beam  1  of the type typically used in constructing large commercial buildings. FIG. 1B is a front view (or rear view) of the H-beam  1  shown in FIG.  1 A. In accordance with the present invention, it has been determined the a beam having a non-cylindrical cross-section, such as a cross-section of the type shown in FIGS. 1A and 1B, for example, has decreased bearing characteristics, meaning that it can be driven into the ground easier and deeper than the concrete and steel piling sections that are currently used for lifting and leveling existing buildings. 
     The H-beam  1  shown in FIGS. 1A and 1B has decreased bearing characteristics due to the fact the area of the end (end view shown in FIG. 1A) of the beam  1  that is driven into the ground is less than that typically used for cement and hollow, steel pipe pilings. However, the outside area surface of the H-beam  1  (shown in FIG. 1B) is large enough to create friction between the earth and the beam  1  to help maintain the beam  1  in place once it has been installed. Therefore, the apparatus of the present invention has very desirable bearing and friction characteristics. Furthermore, the apparatus of the present invention is much stronger than steel pipes and cement pilings, and therefore has much greater stability than support apparatuses or systems comprised of steel pipes or cement pilings. 
     FIGS. 2A and 2B show an alternative embodiment of the present invention in which I-beam support sections  4  are used by the support system of the present invention. The I-beam support sections  4  have similar bearing and friction characteristics as those of the H-beam  1 , except that the I-beam  4  has a longer mid-section  5  that separates the top and bottom sections  6  of the I-beam  4 . Those skilled in the art will understand, in view of the present disclosure, that non-cylindrical support sections other than those shown in FIGS. 1A-2B have similar bearing and friction characteristics and therefore are suitable for use with the present invention. For example, a second mid-section could be added to either of the H-beam or I-beam support sections (i.e., another section that would be parallel to mid-sections  3  or  5 , respectively), or the support section could be constructed simply as a cross having to equal length perpendicular sections that intersect each other at their respective mid-points. Those skilled in the art will understand, in view of the description provided herein, the manner in which such alternative non-cylindrical support section designs could be used to achieve the goals of the present invention. 
     FIG. 3 illustrates a side view of the apparatus of the present invention in accordance with one embodiment wherein the apparatus is comprised of a plurality of H-beams that are utilized in accordance with the method of the present invention to lift and level a building. The apparatus  10  is shown installed and supporting a building foundation  8  after being driven into the ground, which is represented by the numeral  7 . The method for installing the apparatus  10  of the present invention will be discussed below with reference to FIG.  5 . 
     The apparatus  10  is shown as comprising three H-beam sections  11 ,  12  and  13 , although, in reality, many more sections will typically be required to reach a suitable depth in the earth (designated by numeral  7 ), e.g., until a depth is reached at which a rock strata is encountered. The support section  11  is driven into the ground through a hole  15  that has been formed in the earth (i.e., by digging) underneath the foundation  15 . Once the first section  11  has been driven into the ground, the next section  12  is driven into the ground on top of the first section  11 . Once a suitable depth has been reached, an H-beam support section  13  is disposed between the upper end of support section  12  and the bottom surface of the foundation  5 . A jack (not shown) is then placed on the top surface of support section  13  and the building is jacked up to a suitable height to thereby lift and level the building. Friction between the apparatus  10  (i.e., support sections  11 ,  12  and  13 ) and the earth and between the apparatus  10  and the bottom surface of the foundation  5  ensures that the support system will remain stable over time. 
     In accordance with the embodiment shown in FIG. 3, the H-beams  11 ,  12  and  13  comprising the apparatus are not fastened together, but are kept in place through their contact with adjacent support sections, through the downward force associated with the weight of the building and though the settling of the soil about the support sections  11  and  12 . FIGS. 4A and 4B illustrate side and front views, respectively, of the apparatus  10  shown in FIG. 3 further comprising fastening devices that are utilized to fasten adjacent support sections together, and further comprising a fourth support section  16 , which is shown for the purposes of clearly demonstrating the manner in which the support sections can be fastened together in accordance with one embodiment. Although it is not necessary that adjacent support sections be fastened together, fastening adjacent support sections together in the manner shown in FIGS. 4A and 4B enhances stability and further ensures that the apparatus  10 , once installed, will not shift, bend, etc. over time. 
     In accordance with one embodiment, a first type of fastening device is used for fastening the lower support sections ( 16 / 11  and  11 / 12 ) together and a second type of fastening device is used for fastening the top two support sections ( 12 / 13 ) together. The first type of fastening device is comprised of a plate  20  located on opposing sides of the support sections (only front side shown in FIG.  4 A), bolts  21 , and nuts (not shown). The bolts  21  pass through openings formed in the plates  20  and the plates  20  on each side of the support section are pulled tightly against the support section by nuts that are fastened to the ends of the bolts  21 . With respect to the top two support sections, the second type of fastening device is comprised of a U-bolt (FIG. 4B) that passes through an opening  22  formed in a location in the second-from-the-top upper support section ( 12 ) and through two openings (FIG. 4B) formed in the top support section  13 . A plate  23  similar in design to plate  20  has openings formed therein through which the ends  24  of the U-bolt pass, which have nuts  25  fastened thereto to pull the two support sections  12  and  13  together. 
     FIG. 4B is a front view of the apparatus  10  shown in FIG.  4 A. The view provided in FIG. 4B illustrates the bolt  21  passing through two plates  20 A and  20 B, and a nut  28  fastened to the end of the bolt  21  to thereby pull the plates toward each other, which, in turn, fastens ends of adjacent support sections together. The two plates comprised by any given fastening device of the first type are collectively represented by a thick dark line, which is labeled  20 A and  20 B. It will be understood by those skilled in the art, in view of the present disclosure, that the many fastening device configurations can be used to accomplish the task of coupling the non-cylindrical support sections together. The configuration of the fastening device of the first type is an example of one suitable design for this purpose and is not intended to represent the only suitable design for this purpose. Those skilled in the art will understand, in view of the present disclosure, that this task can be accomplished in virtually an unlimited number of ways. 
     FIG. 4B also illustrates the configuration of the second type of fastening device, which is used for coupling the top and second-to-the-top support sections  12  and  13 , respectively, together. This view shows the U-bolt  24  having ends  24 A and  24 B that pass through an opening (FIG. 4A, item  22 ) formed in the mid-portion of support section  12 , through two openings (not shown) formed in the top support section  13  and through openings (not shown) formed in a plate  23 . The ends  24 A and  24 B of the U-bolt  24  have nuts  25 A and  25 B, respectively, fastened thereto, thereby locking support sections  12  and  13  together. As with the first type of fastening device, the fastening device utilized for coupling the non-cylindrical support sections  12  and  13  together is not limited to any particular design. Those skilled in the art will understand, in view of the present disclosure, the manner in which various designs can be used for this purpose, and that these support sections can be coupled together in virtually an unlimited number of ways. Other suitable securing means that can be used in place of the first and/or second fastening device designs, include, but are not limited to, welding, utilizing sleeves, bolts, rivets, etc., in such a way that one solid piling is created that substantially eliminates or reduces the possibility of lateral and/or vertical movement of the piling, even if normal types of lateral and/or vertical movement in the earth about the piling occurs. 
     FIG. 5 is a flow chart illustrating the steps for performing the method  30  of the present invention in accordance with one embodiment. It should be noted that many of the steps shown in FIG. 5 do not need to be performed in the order depicted. Some steps are performed before others, but other steps may be performed in different sequences and/or simultaneously. The first step in the method depicted in the flow chart of FIG. 5 is to dig a hole that begins on the side of the building and extends underneath the building. The hole may be, for example, approximately 2 feet×2 feet wide across the top, about 4 feet deep, and extending approximately 1 foot underneath the building. This step is represented by block  31  in FIG.  5 . 
     The next step is to press (e.g., by using a hydraulic ram) the non-cylindrical support section into the ground at the bottom of the hole, as indicated by blocks  32  and  33 . The bottom end of the next support section is then placed on the top end of the lower support section and is pressed or rammed into the ground, as indicated by blocks  34  and  35 . This process of driving the support sections into the ground is repeated until the non-cylindrical support sections cannot be further pressed into the ground (which typically occurs when the lower-most support section is at a depth of between 10 and 80 feet, but possibly more) and/or stable soil or rock has been reached, or simply a desired depth has been reached, as indicated by block  36 . The cap support section (support section  13  in FIGS. 3-4B) is then placed on top of the uppermost support section (support section  12  in FIGS. 3-4B) as indicated by block  37 . A jack, preferably a hydraulic jack, is then disposed between the cap support section and the foundation of the building and the building is lifted and leveled using the jack, as indicated by blocks  38  and  39 . 
     Once the foundation is lifted and stabilized, another support section having a suitable length will be placed next to the jack on top of the cap support section and shimmed tight, preferably with steel shims (step not shown). The jack can then be lowered and removed. 
     Once these steps have been performed, the hole that was dug will be covered with dirt so that none of the piling is showing. These steps will be performed at each location(s) that needs lifting, leveling and stabilization. The length of the piling may be adjusted if further lifting/leveling is ever needed. This can be accomplished by digging down to the cap support section and following the steps discussed above (i.e., placing the jack at the proper position, re-raising the area at issue and inserting the shim). 
     FIG. 6 is a flow chart illustrating the method  40  of the present invention in accordance with another embodiment, wherein the apparatus of the present invention illustrated in FIGS. 4A and 4B is utilized to lift and level an existing building. It should be noted that many of the steps shown in FIG. 6 do not need to be performed in the order depicted. Some steps are performed before others, but other steps may be performed in different sequences and/or simultaneously. The first step in the method depicted in the flow chart of FIG. 6 is to dig a hole that begins on the side of the building and extends underneath the building. The hole may be, for example, approximately 2 feet×2 feet wide across the top, about 4 feet deep, and extending approximately 1 foot underneath the building. This step is represented by block  41  in FIG.  6 . 
     The next step is to press (e.g., by using a hydraulic ram) the non-cylindrical support section into the ground at the bottom of the hole, as indicated by blocks  42  and  43 . The bottom end of the next support section is then placed on the top end of the lower support section and is pressed or rammed into the ground, as indicated by blocks  44  and  45 . The support sections are then coupled together in the manner described above with reference to FIGS. 4A and 4B, as indicated by block  46 . This process of driving the support sections into the ground and coupling them together is repeated until the non-cylindrical support sections cannot be further pressed into the ground (which typically occurs when the lower-most support section is at a depth of between 10 and 80 feet, but possibly more) and/or stable soil or rock has been reached, or simply until a desired depth has been reached, as indicated by block  47 . The cap support section (support section  13  in FIGS. 3-4B) is then placed on top of the uppermost support section (support section  12  in FIGS.  3 - 4 B), as indicated by block  48 . A jack, preferably a hydraulic jack, is then disposed between the cap support section and the foundation of the building and the building is lifted and leveled using the jack, as indicated by blocks  49  and  51 . 
     Once the foundation is lifted and stabilized, another support section having a suitable length will be placed next to the jack on top of the cap support section and shimmed tight, preferably with steel shims. The jack can then be lowered and removed. Once these steps have been performed, the hole that was dug will be covered with dirt so that none of the piling is showing. These steps will be performed at each location(s) that needs lifting, leveling and stabilization. The length of the piling may be adjusted if further lifting/leveling is ever needed. This can be accomplished by digging down to the cap support section and following the steps discussed above (i.e., placing the jack at the proper position, re-raising the area at issue and inserting the shim). 
     In accordance with another embodiment of the present invention, the first support section driven into the ground as a tapered end. For example, if the apparatus of the present invention comprised a non-cylindrical support section having the shape shown in FIGS. 1A and 1B, the lowermost support section could have the shape shown in FIG. 7, which is a front view of an H-beam  50  having a tapered lower end  52 . This tapered, or sharpened, lower end would result in even less bearing encountered when the piling is being installed. However, the piling would still have essentially the same desirable friction characteristics as if it were formed of support sections such as those shown in FIGS. 1A-2B. 
     It should be noted that while the present invention has been described with reference to the particular embodiments, it is not limited to the particular embodiments described herein. Those skilled in the art will understand, in view of the present disclosure, that modifications can be made to the embodiments described herein and that such modifications are within the scope of the present invention.