Patent Description:
Conventional pole erection having a base plate requires lowering a pole onto a foundation with embedded threaded anchor bolts. The threaded anchor bolts pass through the pole's base plate. The pole is then secured to the foundation and then plumbed. The entire process of erecting a conventional pole and foundation is lengthy, requiring coordination between material suppliers and construction trades. The construction process is time sensitive. Coordinating multiple parties comes with risks of delay. These delay risks are compounded when having to work in outdoor conditions subject to unpredictable weather. Other drawbacks to the conventional pole erection method include: use of pole base plate adds cost to the pole and is foundation-specific, governed by anchor bolt bore spacing, having to refinish the above grade portion of the foundation following pole erection, corrosion exposure requiring periodic inspections and occasional maintenance work.

<CIT> discloses a post footing device that facilitates replacement of broken posts. <CIT> discloses an anchoring system to lock posts into housings mounted in the ground. <CIT> refers to a method of anchoring a post in the ground. <CIT> discloses a pole base which allows retaining of poles of different sizes in position. <CIT> discloses an erection structure which facilitates injection of a filler where the filler can properly spread and ensure erection strength of a steel-pipe column. 3d printing even for large objects is disclosed in <CIT>.

The process of erection of a conventional pole with base plate typically entails the following steps:.

The construction industry has a persistent need for an economical and rapid installation solution for erecting poles eliminating the drawbacks of the conventional means and methods.

The present invention relates to an assembly according to claim <NUM> comprising a pre-fabricated pole foundation and method according to claim <NUM> for installation to reduce pole assembly and erection time. More precisely, according to claim <NUM>, an assembly comprising a pre-fabricated pole foundation to be used for a pole without a base plate is provided, characterized in that the pre-fabricated pole foundation employs polymer molten resin employed by 3D printing. Further, according to claim <NUM>, a method of erecting a pole is provided.

An embodiment, not forming part of the invention, includes a pre-fabricated pole foundation comprising: a cavity section having a pole cavity and a cavity wall having recesses; a core section having core walls; and a base section, wherein: the cavity section includes a tapered structure located on a bottom end of the pole cavity within the within the cavity wall; the tapered structure is configured to support a pole and operates as a pivot point to plumb the pole using alignment devices; and the tapered structure accommodates poles of dissimilar cross-sectional profiles, dimensions and material interchangeably; and cavity walls inner surfaces contain recesses that support pole aligning devices and may have through bores to facilitate anchoring the pole to the foundation.

Another embodiment, not forming part of the invention, includes a pre-fabricated pole foundation comprising: a cavity section having a pole cavity and a cavity wall having recesses; a bridge section located directly below the cavity section, the bridge section comprising an integral tapered structure supporting the pole or a keyed surface onto which a removable keyed tapered structure is coupled; a core section located having core walls, the core section located directly below the bridge section; and a base section located directly below the core section, wherein: tapered structure is configured to support a pole and operates as a pivot point to plumb the pole using alignment devices; and tapered structure accommodates poles of dissimilar cross-sectional profiles, dimensions and material interchangeably; and cavity walls inner surfaces contain recesses that support pole plumbing devices and may have through bores to facilitate anchoring the pole to the foundation; the tapered structure in one embodiment is capable of horizontal rotation for clocking the pole assembly.

Further, another embodiment, not forming part of the invention, includes a method of installing a pre-fabricated pole foundation and a pole assembly, the method comprising: forming bore within a portion of ground soil; hoisting and lowering a pre-fabricated pole foundation within the bore, wherein the pre-fabricated pole foundation comprises: a cavity section having a pole cavity, an cavity wall and a tapered structure located on a bottom end of the pole cavity within the within the cavity wall; a core section having core walls; and a base section; hoisting and lowering a pole assembly within the pole cavity of the cavity section of the pre-fabricated pole foundation; supporting the pole assembly on the tapered structure; pivoting the pole assembly on the tapered structure in response to operation of alignment devices to plumb the pole assembly; and filling open spaces between core walls and the pole cavity with granular or similar structural propertied material and anchoring the pole to the foundation if required and capping the top of pole cavity with grout or similar material as well as lead bores if exist at the exterior walls of pole cavity opening.

Yet another embodiment, not forming part of the invention, includes a pre-fabricated pole foundation comprising: an upper portion having a pole cavity for receiving and retaining a pole and a cavity wall; and a lower portion located below the upper portion, wherein the upper portion includes a tapered structure located at the bottom end of the pole cavity within the cavity wall, wherein the tapered structure is configured to support the pole and operate as a pivot point to plumb the pole using alignment devices wherein the tapered structure accommodates poles of dissimilar cross-sectional profiles, dimensions, and material interchangeably; wherein the tapered structure may be detachable and keyed; and a plurality of recesses in the inside of the pole cavity walls provide anchoring location to at least pole hoisting devices, pole plumb devices and pole anchoring devices, wherein the pole cavity is configured to receive fill material through the pole cavity top end and fill voids between the cavity wall and the pole exterior surface to provide lateral support to embedded pole.

The foregoing and other features and advantages of the present invention will be apparent from the following more detailed description of the particular embodiments of the invention, as illustrated in the accompanying drawings.

A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein like reference numbers refer to similar items throughout the Figures, and:.

As discussed above, embodiments of the present invention relate to pre-fabricated pole foundation and method for installation to reduce pole assembly and erection time.

To mitigate drawbacks associated with the process of conventional pole erection, the present invention includes and employs two pre-fabricated elements, namely a foundation and pole free of base plate notwithstanding the specified device/s assembly on the pole.

Eliminating the pole base plate from the pole, along with its anchor bolts, provides the ability for the foundation to accept a variety of pole cross-sectional profiles, dimensions and materials. In general use, the pre-fabricated foundation arrives on site ready to be lowered into an excavated bore absent of any structural or architectural imperfections. The pre-fabricated foundation construction fabrication is consistent across wide geographical areas, eliminating dependency on local contractor skill level. The two assembly elements, the pre-fabricated pole foundation and the pole joined together operates to remove several steps from the process of erecting a conventional pole. The steps removed include:.

In addition, post-construction steps removed include:.

In addition, pre-fabricated opening/s with or without conduit/s embedded in the pre-fabricated foundation enable the pre-fabricated pole foundation to ground electrical devices as well as to retain related and non-related pole assembly devices. Such devices may include input sensory devices such as accelerometer, noise, pollution, camera and/or input/output or output devices such as a transceiver, surge protector and receptacle for a vehicle charger or a receptacle for a temporary holiday lighting display. Both foundation and pole can easily be removed intact, and be re-used should the need arise. The streamlining of the pole erection process, employing the present innovation, reduces production time from weeks to only a matter of hours and days.

<FIG>, depict an embodiment of a pre-fabricated pole foundation <NUM>. The pre-fabricated pole foundation <NUM> may be divided into four sections along a vertical axis of the pre-fabricated pole foundation <NUM>. The four section include a pole cavity section <NUM> located at a top of the pre-fabricated pole foundation <NUM>, a bridge section <NUM> located directly below the pole cavity section <NUM>, a core section <NUM> located directly below the bridge section <NUM>, and a base section <NUM> located at a bottom of the pre-fabricated pole foundation <NUM>. In these embodiments, the pre-fabricated pole foundation <NUM> includes an upper portion that may include the pole cavity section <NUM> and a bridge section <NUM>, and further may include a lower portion that may include the core section <NUM> and the base section <NUM>. In at least this way the upper portion may include a pole cavity section <NUM> and/or a bridge section <NUM>, and the lower portion may include a core section <NUM> and/or a base section <NUM>.

The pole cavity section <NUM> has a primary purpose to receive and retain an embedded pole <NUM> within a cavity <NUM> (See <FIG>). At a center of the cavity <NUM> bottom, a tapered structure <NUM> provides a support location for a bottom of the pole <NUM>. At the upper regions of the cavity wall <NUM> a plurality of through leader bores <NUM> having a recess <NUM> at the interior surface of cavity wall <NUM>, the recess <NUM> utilized to plumb the pole <NUM> when pole does not require anchoring. When pole <NUM> requires anchoring against rotation and uplift, recess <NUM> and leader bore <NUM> may be utilized to plumb the pole <NUM>. Each through leader bore <NUM> has a horizontal axis that intersects the vertical axis of the pre-fabricated pole foundation <NUM>. These bores <NUM> and corresponding recesses <NUM> may also serve as a hoisting attachment location to lower the foundation into the augured bore in the soil. In another embodiment, a continuous recess at the outside diameter wall <NUM> of the cavity section <NUM> provides an alternate pre-fabricated pole foundation <NUM> hoisting location.

The cavity walls <NUM> may also retain electronic devices and/or enclosures and connectivity inside the pole cavity <NUM>, in the pole cavity walls <NUM> and/or the pole cavity walls <NUM> exterior. The bridge section <NUM> top surface forms the tapered structure <NUM> providing support for the pole <NUM> when the pole is received within the cavity <NUM> of the cavity section <NUM>. The tapered structure <NUM> can be made of the same material as the pre-fabricated pole foundation <NUM>, and may be formed with the pre-fabricated pole foundation <NUM> as a unitary piece, as shown in <FIG>. In another embodiment the pre-fabricated manufacturing of the pre-fabricated pole foundation <NUM> may be simplified by removing alternative types of tapered structures <NUM>, wherein the bridge section <NUM> top surface <NUM>, having at its center through conduit/s <NUM> and between its parameter edges and its center, protrusions <NUM> acting as keyed elements to lock a pre-fabricated tapered structure <NUM> in position. This system and method reduces the pre-fabricated pole foundation <NUM> structure to a single product for a given range of pole's profile width and the choice of a keyed tapered structure insert <NUM> to a square (See <FIG>) or a round pole option (See <FIG>). The tapered structure insert <NUM> is made of hardened material and may have internal cavities <NUM> to correspond to the protrusion <NUM>. In some embodiments, the top surface <NUM> may include recesses and the tapered structure inserts <NUM> may include protrusions in order to act as keyed elements to lock the pre-fabricated tapered structure <NUM> in position. In some embodiments, the tapered structure <NUM> may also be constructed of two parts having low friction contact surfaces enabling the top part to horizontally rotate, facilitating easier pole clocking. In one embodiment, guidelines along the pole cavity walls with corresponding profile niches or protrusions at the insert outer parameter facilitate quick insertion.

At a vertical center of the bridge section <NUM>, through conduit/s <NUM> allow a variety of wiring to run from below grade to the cavity section <NUM>. Such wiring may also include ground wire. The bridge section's <NUM> outer walls are an extension of the cavity section wall <NUM>. A through opening(s) <NUM> between the bridge section <NUM> cross-like inner tapered structure <NUM> at its center and the inner surface of the wall <NUM> to allow for granular fill material <NUM> or fill material <NUM> having similar structural properties to reach the core section <NUM> below the bridge section <NUM>. Also, this opening permits moisture from above to seep through and thereby prevent issues caused by accumulated moisture. The vertical depth of the bridge may variable contingent on the axial load and lateral forces acting on the pole <NUM>.

The core section <NUM> provides structural continuity from the cavity section <NUM> and bridge section <NUM> to the base section <NUM>. Further, the core section <NUM> provides frictional and lateral resistance of the pre-fabricated pole foundation <NUM>. The cores section <NUM> comprises a plurality of core walls <NUM> that are spaced annularly around the vertical axis of the pre-fabricated pole foundation <NUM>. The core walls <NUM> may form a cross-shaped cross section, wherein the core walls <NUM> intersect and the through openings <NUM> for the tapered structure <NUM> are located above the intersection of the core walls <NUM> to allow granular or similar in structural properties material to reach the core section <NUM> through the bridge section <NUM>. The fill material <NUM> may be wedged between the core walls <NUM> and the excavated bore <NUM>, as shown in <FIG>. Where forms are needed, the fill material <NUM> is wedged between the core walls <NUM> and the form wall.

The base section <NUM> supports the entire load of the pole <NUM> and its assembly and the pre-fabricated pole foundation <NUM>. In embodiments, the base section <NUM> diameter is the same diameter as the exterior cavity wall <NUM> of the cavity section <NUM>. In special applications, where spread footing is needed, a keyed recess or protrusion at the bottom of the base section <NUM> anchors the pre-fabricated pole foundation <NUM> to a reciprocating key at the top of the spread footing.

Referring to <FIG> and <FIG>, the pre-fabricated pole foundation <NUM> enables both power and data to extend from below grade to one of the pole, the pole cavity, the pole cavity wall, the pole cavity wall exterior or combinations thereof. At the core section <NUM> the core walls <NUM> or recessed inside the core walls are non-corrosive J boxes <NUM> that are sealed to the elements. These J boxes <NUM> are foundation entry portals for power and data. Conduits <NUM> may travel from these portals through the bridge section <NUM> into the pole <NUM>, or travel through the cavity wall <NUM> to electrical/data device enclosures <NUM> embedded in the pole cavity wall <NUM> or to the pole cavity wall <NUM> interior/exterior surfaces. Some embodiments may have a combination of the above and may also have power and/or data enter from below grade directly into the pole cavity <NUM> through the filled granular or similar in structural properties material. The conduit <NUM> rising from below grade through the pole cavity wall <NUM> may employ a splice box or a junction box <NUM> also embedded in the wall <NUM> and may divert power or divert power and data to a plurality of openings and/or enclosures <NUM> in the cavity wall <NUM>. Through the vertical center of the foundation from the pole cavity <NUM> down to the foundation base <NUM> a pre-fabricated bore may house a grounding wire. That grounding wire at the foundation base connects to a grounding spike, grounding the pole <NUM> or the pole <NUM> and pole cavity <NUM> devices.

pre-fabricated pole foundation <NUM> can be made of concrete or any other flame-retardant, structurally-sound, lightweight material. The pre-fabricated pole foundation <NUM> wall design may incorporate impact-absorbing material and/or be constructed to absorb impact, reducing health risks to humans. Some pre-fabricated pole foundation <NUM> material may also be shipped to site, broken down to separate sections with capacity to be quickly assembled onsite. The pre-fabricated pole foundation <NUM> is fabricated by 3D printing.

It has been contemplated that the component of the pre-fabricated pole foundation <NUM> may be formed completely from cement or some type of cement mixture in a cast or the like. It has further been contemplated that the components of the pre-fabricated pole foundation <NUM> may be formed of a polymer material or material having polymer-like structural properties including but not limited to fire-resistant material and/or non-corrosive material. Further, in embodiments of the pre-fabricated pole foundation <NUM> formed of a polymer material, some or all of the components may have a honeycomb structure and/or other cellular structure. For example and without limitation, at least one of the cavity section, the bridge section, the core section, the base section, or combinations thereof comprise a honeycomb structure. Forming the pre-fabricated pole foundation <NUM> of a polymer and further having a honeycomb structure results in a pre-fabricated pole foundation <NUM> having much less weight than cement foundation for supporting the same size pole assembly. The polymer and honeycomb design also provide for shock absorbing characteristics that are improved over cement pole foundations. The polymer with or without the honeycomb structure provides for reduced weight foundation that further does not change the structural integrity required for the support and operation of a pole assembly.

Additionally, the soil type in which the pre-fabricated pole foundation <NUM> is installed provides certain characteristics that determine the size of pre-fabricated pole foundation <NUM>. The soil properties may require that for a certain weight of a pre-fabricated pole foundation <NUM> and pole assembly installed the foundation needs to be a certain size within the soil in order to provide the necessary normal force to support the foundation and pole assembly installed properly. This very much dependent on the weight of the foundation and pole assembly. An easy way to reduce the size of the pre-fabricated pole foundation <NUM> is to form it of polymer and insert honeycomb structure to reduce material and weight. Because of the lighter combined weight of the pre-fabricated pole foundation <NUM> and the pole assembly, the pre-fabricated pole foundation <NUM> may require a smaller foundation base surface area to support the combined weight, thereby allowing for a smaller shaped pre-fabricated pole foundation <NUM> that would be needed in a comparable cement pole foundation, and thereby requiring less material and space for storing and shipping and for easier installation of pre-fabricated pole foundation <NUM>.

The economic feasibility of the pre-fabricated pole foundation <NUM> is to a large degree dependent on the proximity of a fabrication plant to a construction site. The greater the distance, the higher the transportation cost. Granular or similar in structural properties material cost is low and the material is typically readily available in proximity to construction sites. To reduce transportation cost, the pre-fabricated pole foundation <NUM> design cores or removes any excess weight while maintaining full structural integrity.

The key steps to erecting a pole assembly are generally shown in <FIG>, <FIG>, <FIG>, and <FIG>. These steps include for example:.

Auger a bore <NUM> in the soil <NUM> using an auger bit <NUM>. The bore <NUM> may be slightly larger than the pre-fabricated pole foundation <NUM> diameter minimally disturbing the surrounding soil. Where soil <NUM> is unstable, excavation pit width may be wide enough to accommodate a pre-fabricated form slightly larger in diameter of the pre-fabricated pole foundation <NUM>. Both bore <NUM> and excavated pit depth are contingent on structural specification and may include additional depth for bedding <NUM>. When using the excavated method following the insertion of the form in the pit, plumb the form and anchoring it, the gap between the undisturbed soil and the form may be back filled, vibrated and compacted.

In order to insert pre-fabricated pole foundation <NUM> into the bore <NUM>, hoisting harness <NUM> is inserted and secured in pre-fabricated pole foundation <NUM> using pole cavity wall insert plates <NUM> that are inserted within recesses <NUM>. A connector <NUM> may then be used to connect the hoist <NUM> to the insert plates <NUM>. The pre-fabricated pole foundation <NUM> may then be lifted and then lowered into the bore <NUM> or the form.

Once the pre-fabricated pole foundation <NUM> is lowered within the bore <NUM>, the pole <NUM> may be lifted and lowered through the cavity <NUM> until the pole bottom end rests on the tapered structure <NUM> at the bottom center of the cavity.

Plumb devices <NUM> or <NUM> may be utilized to apply multi-directional lateral force at the upper region of the cavity wall <NUM> while having the tapered pole support structure <NUM> as a pivot point to plumb the pole. When there is no need to anchor the pole, removable expandable alignment devices <NUM> can be wedged between the pole and the recesses <NUM> in the foundation cavity wall. In operation, the expandable alignment devices <NUM> may include an actuator that may be manually operated with a tool <NUM>, such as, but not limited to a wrench, to turn the actuator and extend the expandable alignment devices <NUM> laterally between the cavity wall <NUM> and the pole <NUM> in order to apply force to the pole <NUM> to pivot the pole <NUM> about the tapered structure for alignment. Use of three or four expandable alignment devices <NUM> work to plumb the pole by rotating the actuators gradually and in a controlled manner, the pole <NUM> may be made plumb. In another embodiment the expandable and removable plumbing devices can be substituted by the plumb devices <NUM> that may comprise bolts and threaded retainer plates <NUM>. The threaded retainer plates <NUM> are anchored in recesses <NUM> located at the cavity interior surface of wall <NUM>. By rotating the bolts gradually and in a controlled manner, the pole <NUM> may be made plumb. These plumb devices <NUM> may be used for both making the pole plumb and anchoring the pole against rotational and uplift forces.

After pole <NUM> has been made plumb, granular fill material <NUM> or fill material <NUM> similar in structural properties, such as, but not limited to granular fine material may be poured into the pre-fabricated pole foundation <NUM> through the cavity <NUM> through the opening <NUM> of the tapered structure <NUM> and into the core section <NUM> between the core section <NUM> and the bore <NUM> opening to a level just below the alignment devices <NUM>. The alignment or plumb devices <NUM> may be removed and replaced with anchoring bolts if anchoring is needed. Prior to inserting anchoring bolts, a drill bit may be inserted through the leader bore holes <NUM> to drill a bore inside the pole <NUM>. The anchoring bolts may be inserted through the leader bore holes <NUM> and through their respective recesses <NUM>, and then, thread the alignment bolt back through the leader bores until it penetrates the pole <NUM>. In a similar embodiment, the bolt can be inserted through the foundation's wall cavity opening <NUM>. Both methods secure the pole <NUM> against rotation and uplift forces. Following the securing of the bolts to the pole, additional granular fill material <NUM> or fill material <NUM> with similar structural properties may be added above bolts. The fill material <NUM> may be vibrated to assure filling any voids from the bottom of core section <NUM> to top of pole cavity <NUM>.

A grout or similar material cap <NUM> may fill the inner top of the pole cavity <NUM> having a slope away from pole. Elastomeric or similar material properties form a material break between pole and grout-like material to eliminate stress on the grout cap. Further, plugs may be inserted within the leader bore <NUM> (if applicable) at the foundation's cavity exterior walls <NUM>. Prior to plugging the bores <NUM>, insert material break filler may be inserted within the bores <NUM> to avoid grout bonding to bolts. Both the pole <NUM> and the foundation <NUM> are designed to facilitate easy replacement. Replacement only requires breaking the grouted fill seal and removing the plugin of fills at the cavity walls.

According to some embodiments, a method of installing a pre-fabricated pole foundation and a pole assembly includes: forming bore within a portion of ground soil; hoisting and lowering a pre-fabricated pole foundation within the bore, wherein the pre-fabricated pole foundation comprises: a cavity section having a pole cavity, an cavity wall and a tapered structure located on a bottom end of the pole cavity within the cavity wall; a bridge section having an integral or a detachable tapered structure; a core section having core walls; and a base section; hoisting and lowering a pole assembly within the pole cavity of the cavity section of the pre-fabricated pole foundation; supporting the pole assembly on the tapered structure; pivoting the pole assembly on the tapered structure in response to operation of alignment devices to plumb the pole assembly; and filling with fill material open voids from the core section, through the bridge section up to the cavity section, wherein the fill material is level below a top of the cavity section.

The method may further include diverting moisture collection in and around the pole through the fill material; and grounding a pole assembly in response to extending a ground wire through a foundation vertical center opening and connecting the ground wire to a spike mounted to the base section.

The installation of the pole assembly may include bringing power to the foundation and, through embedded conduits in the foundation, and run power to pole-mounted and pole cavity embedded devices. The installation may also include terminating grounding wire, placing, if needed, a surge protector and/or other devices at the pole base and/or pole cavity wall and then power up the assembly and verify proper operation.

The pre-fabricated concrete foundation has significant disadvantages when evaluated against a pre-fabricated foundation with a volumetric enclosure and/or constructed of cellular structure. Truck loads are restricted to an allowable shipping weight. Heavy foundations necessitate the use of additional trucks, thus increasing shipping costs. Heavy foundation may also require the use of costly loading/unloading machinery while exposing workers to higher risk of injury.

Employing new technologies such as 3D printing enables the fabrication of cellular structures and/or large volumetric enclosure inside the foundation structure, overcoming the disadvantage of employing heavy pre-fabricated concrete foundation. As a result, more foundations can be loaded on a single truck, and the foundation installation requires a minimal load capacity machinery or none to drop the foundation into augured bore. Further, lightweight foundations pose lesser risk of bodily injury.

The present innovation cellular and volumetric design structures may include several embodiments:.

The configuration above may include at least one inlet and at least one outlet to fill fluid into the foundation structure. The fluid can be water or any other admixture. The fluid can remain in a liquid state or in coming in contact with air or other fluid can change state and harden. At the inlet spout an anti-tampering cap is installed after filling the foundation with fluid. At the outlet spout, an anti-tampering cap or a cap with a breather or a valve can be installed. Having the additional weight of the fluid or the hardened material adds compressive axial weight to the foundation makes the foundation wall more resistant to impact and adds greater resistance to uplift forces. Granular solid material may also be used to ballast the foundation. The granular material can be poured through the inlet spout and/or through the pole cavity.

As described above, in special applications, where spread footing is needed, a keyed recessed protrusion at the bottom of the base section <NUM> anchors the prefabricated pole foundation <NUM> to a reciprocating key at the top of the spread footing. The present innovation in <FIG> expands on the prior teaching by further describing a keyed foundation. The keyed spread footing or both to retain a volumetric cavity and/or cellular structure, whereas the volumetric cavity or the cellular structure can be filled with fluid (<NUM>). In addition, the entire prefabricated foundation can be made of at least one contiguous element and when two or more contiguous elements are employed, these elements are mechanically keyed, they can employ fastening devices and they are field assembled (not shown).

This innovation can further simplify the pole erection process by eliminating the use of a threaded plate embedded in a recess in the pole cavity inner wall, replacing the threaded plate's functionality with a factory prefabricated threaded through bore, whereas the bore is made of the same material as the foundation wall.

<FIG> show the prefabricated pole foundation placement process inside an augured bore in the soil. In <FIG> the bore is augured. In <FIG> the bottom of the bore is bedded. In <FIG> the pre-casted foundation is lowered inside the bore. In <FIG> a fill material <NUM> is poured through the pole cavity <NUM> top making its way down to the top of the foundation base section <NUM>. Fill material <NUM> occupies all the voids between the foundation's exterior wall <NUM> and the face of the bore in the soil. Within this disclosure it teaches about fill material <NUM> poured into the pole cavity <NUM> of the pre-fabricated foundation to provide lateral stability to the pole <NUM>. Other fill material <NUM> is poured and compacted from the foundation exterior wall <NUM> providing lateral support to the foundation's core <NUM> and base sections <NUM> (not shown).

<FIG> and <FIG> show two elevational embodiments of the pre-fabricated foundation <NUM> placement process inside an augured bore with enclosed bottom pole cavity <NUM>. Innovating both the parent patent and continuation <NUM>, present invention show means to reduce shipping weight of the pre-fabricated foundation by introducing volumetric enclosure/s <NUM> and/or cellular structure <NUM> inside the foundation's structure. <FIG> show the pre-fabricated foundation placement of a cruciform profiled core section <NUM> foundation <NUM> with an elongated volumetric enclosure <NUM> at the vertical center of the foundation extending the length of the core section <NUM>. This embodiment can be filled with fluid <NUM> from an inlet spout <NUM> located at the pole cavity exterior wall <NUM> upper section. In a different embodiment, filled fluid <NUM> can also fill the cellular structure <NUM> inside the foundation's cellular walls <NUM> or the foundation's cellular walls <NUM> and the base core section <NUM> (not shown).

<FIG> show the pre-fabricated foundation placement of a round profiled core section <NUM> foundation <NUM> with an elongated volumetric enclosure <NUM> at the vertical center of the foundation <NUM> extending the length of the core section <NUM>. This embodiment can also be filled with fluid <NUM> as described above and perforate the fluid <NUM> into the cellular structure <NUM> of the foundation's cellular walls <NUM> and the base core section <NUM> (not shown). In a different embodiment, a substantial portion or all the embodiment structure can be fabricated of a cellular structure <NUM> and fluid <NUM> entering the inlet spout <NUM> can reach some or all the cells (not shown).

<FIG> show the elevation of the Figs. described in <FIG> and <FIG>. <FIG> show sections of the cruciform profiled foundation <NUM> at the core section <NUM> with a volumetric enclosure <NUM> extending along the core section's <NUM> vertical axis. <FIG> retains fluid at the volumetric enclosure <NUM> only, while <FIG> permits fluid <NUM> to travel through the foundation's walls cellular structure <NUM> and/or the foundation's walls cellular structure <NUM> and base section <NUM> cells. <FIG> show sections of the round profiled foundation at the top of the core section <NUM> with a volumetric enclosure <NUM> inside the foundation's wall extending along the core section's <NUM> vertical axis. <FIG> retains fluid at the volumetric enclosure <NUM> only while <FIG> permits fluid <NUM> to travel through the foundation's walls cellular structure <NUM> and/or the foundation's walls cellular structure <NUM> and base section <NUM> cells. The sections shown in <FIG> share these common elements: inlet spout <NUM>, fluid outlet <NUM>, valve <NUM>, fluid pipe <NUM>, through opening <NUM>, pole cavity <NUM>, device enclosure <NUM>, power/data conduit <NUM>, and volumetric enclosure <NUM>.

<FIG> show enlargements of the volumetric enclosure <NUM> and the cellular structure <NUM> inside the foundation walls. <FIG> shows the foundation elevation with horizontal section designators. Fig. 15A-A shows a partial horizontal section at the pole cavity <NUM>. Elements enumerated include: the inlet spout <NUM>, fluid pipe <NUM>, cellular structure <NUM>, exterior wall of pole cavity <NUM>, foundation pole, power/data conduit <NUM>, through opening <NUM>, tapered structure <NUM>, and device enclosure <NUM>. <FIG> shows a partial horizontal section at the bottom of the round core foundation above the foundation's base section <NUM>. Elements enumerated include: cellular structure <NUM>, top of foundation base <NUM>, volumetric enclosure <NUM>, cellular wall <NUM> and foundation exterior wall <NUM>. <FIG> shows the horizontal enlarged section of the pole cavity <NUM> at the electrical/data enclosure <NUM> elevation depicting the inlet spout <NUM> opening and the fluid pipe <NUM> riser inside the cellular structure <NUM> wall to enable fluid <NUM> to travel to the volumetric enclosure <NUM> and/or perforate throughout the cellular walls of foundation including the base section <NUM>.

The conventional "pour-in-place" pole foundation construction and erection process entails the following steps:.

The present innovation of pole foundation construction and pole erection process entails the following steps:.

Coupled with the art described in the parent patent and continuation <NUM>, the I-cap enclosure device eliminates <NUM> steps from the conventional foundation construction and pole erection.

The I-Cap is prefabricated using state of the art manufacturing technologies that significantly reduce the pole erection time. This reduction lowers the overall production costs and the likelihood of bad weather having an adverse impact on the construction schedule. The innovation enhances its parent patent and continuation <NUM>, consolidating and streamlining processes and means into an all-in-one device.

The I-Cap is a just-in-time manufactured device located at the foundation's <NUM> top, filling the gap between the pole foundation cavity's <NUM> inner wall and the pole <NUM>, while also providing cavity moisture protection. State of the art technology is capable of producing complex forms in real time. Today, for example, manufacturing by means of 3D printing can produce components at the Space Station by transmitting 3D files from Earth in real time. At the time an order is placed for a prefabricated pole foundation <NUM> and pole <NUM>, both the inner diameter of the pole cavity <NUM> and the outer diameter of the pole <NUM> are known. Both the pole and the foundation are manufactured to precision. A computer program then produces the I-Cap's <NUM> manufacturing data configuring the physical form of the embodiment, the structural design and choice of material.

The present innovation employs the two key elements of the parent patent: a tapered structure <NUM> at the pole cavity's <NUM> bottom center, and at least one anti-rotation bolt <NUM>, <NUM> inserted through the pole cavity's walls <NUM>. The bolt <NUM>, <NUM> can be inserted to engage the pole <NUM> along most of the pole section embedded inside the foundation's pole cavity <NUM> except at the very top and bottom. No bolt <NUM>, <NUM> is needed to plumb the pole as the I-Cap enclosure plumbs the pole. An alternate embodiment with bolts securing the I-cap <NUM> to the foundation structure from above may employ only a single horizontal bolt <NUM>, <NUM> below the I-Cap to prevent the pole from rotation (not shown). In several foundations configuration the I-Cap <NUM> enclosure enables pouring ballasting fill material <NUM> through the pole cavity to the foundation base section <NUM> as well as inserting a vibrator to compact the fill material. The I-Cap eliminate the need to employ fill material <NUM> to transfer lateral pole forces to the foundation's walls <NUM>.

The I-Cap enclosure device <NUM> is fabricated from organic or inorganic substantially non-corrosive hardened material, resistant to the elements. The device structure can be constructed of one or a series of volumetric enclosures <NUM> or a cellular structure <NUM> with a plurality of small voids. The device manufacturing methods include but are not limited to 3D printing and injection molding. The device form is adaptable to complement the form of the pole foundation cavity's <NUM> inner wall and the form of the pole <NUM>. The I-Cap <NUM> form can be square, round or shaped to take any other form complementing both the structural and architectural requirements. The I-Cap <NUM> can be fabricated from a monolithic embodiment, or made of several embodiments joined together. The monolithic embodiment is typically inserted at the narrow side of the pole <NUM> shaft, and then slides into position at the top of the foundation pole cavity <NUM>. The multi-component embodiment assembly is inserted at the top of the pole foundation cavity <NUM>. Both the monolithic and the multi-component embodiments have a recess <NUM> in their interior wall perimeters. The I-Cap is secured to the foundation from above or from the pole foundation cavity wall using bolts <NUM>, <NUM>, and then, the recess is filled in with an elastomeric compound to prevent moisture from travelling into the foundation pole cavity <NUM>. The top mounted bolt I-Cap <NUM> walls have a keyed lock <NUM> to accommodate a foundation keyed lock <NUM> in the foundation's pole cavity walls. The foundation's keyed lock has a threaded bore <NUM> to which the I-Cap top bolt/s <NUM> mount to. The I-Cap can be removed and re-installed as the pole and the foundation.

The I-Cap possesses the following common properties, regardless of its form:.

<FIG> shows a plan view of a pole assembly employing two luminaires <NUM> resting in a pre-fabricated foundation <NUM> with a monolithic I-cap enclosure <NUM> engaging the pole <NUM> in the foundation's pole cavity <NUM>.

<FIG> shows the assembly of <FIG> in elevation with the monolithic I-cap enclosure <NUM> lowered along the pole <NUM> shaft into position upon resting the pole assembly on the tapered structure <NUM> at the bottom of the pole cavity <NUM>. Also shown is an inlet spout <NUM> to pour fluid <NUM> into the foundation <NUM>. Electrical/data devices enclosure <NUM> and leader bore to facilitate engaging, plumbing and securing the pole <NUM> assembly employing the I-cap <NUM> to the foundation <NUM>.

<FIG> shows a plan view of the pole assembly employing two luminaires <NUM> resting in a pre-fabricated foundation <NUM> with multi-part I-cap enclosure <NUM> engaging the pole in the foundation's pole cavity <NUM>.

<FIG> shows the assembly of <FIG> in elevation with the multi-part I-cap enclosure <NUM> engaging the pole <NUM> and the foundation <NUM> and providing moisture protection to the pole cavity <NUM>. Also shown is an inlet spout <NUM> to pour fluid <NUM> into the foundation <NUM> electrical/data devices enclosure <NUM> and leader bore to facilitate engaging, plumbing and securing the pole <NUM> assembly employing the I-cap <NUM> to the foundation <NUM>.

<FIG> shows an enlarged and exploded perspective of top of foundation <NUM>. Also shown are the compressive filler/elastomeric compound <NUM>, the pole <NUM>, the top of the monolithic I-cap <NUM>, pole anti-rotation/uplift bolt <NUM>, and the top of foundation <NUM>. The monolithic I-cap enclosure <NUM> slides down the pole <NUM> shaft and engages the pole <NUM> by plurality of bolts <NUM>. The bolts <NUM> are inserted through the pole cavity <NUM> wall and the monolithic I-cap enclosure <NUM>. Once the I-cap enclosure <NUM> is secured in place, the compressive filler/elastomeric compound <NUM> is placed in the I-cap recess <NUM> to protect the pole cavity <NUM> against moisture entry.

<FIG> shows an enlarged exploded perspective of top of foundation <NUM>. Also shown are the compressive filler/elastomeric compound <NUM>, the pole <NUM>, the two-part I-cap enclosure top <NUM>, the pole plumbing and anti-rotation/uplift bolt <NUM>, and the top of foundation <NUM>. The two-part I-cap enclosure <NUM> is inserted into the pole cavity <NUM> embracing the pole at their inner walls and the pole cavity <NUM> with their outer walls. Then, bolts <NUM> are inserted through the pole cavity <NUM> wall and through the I-cap enclosure <NUM>, plumbing or securing or plumbing and securing the pole <NUM>. Then, compressive filler/elastomeric compound <NUM> is placed in the I-cap recess <NUM> to protect the pole cavity <NUM> against moisture entry. Bolt <NUM> can be engaged a threaded bore in the pole cavity <NUM> wall, in the I-cap <NUM> or both.

<FIG> show top and bottom perspectives of the I-cap enclosure <NUM> monolithic embodiment. <FIG> shows the I-cap recess <NUM>, the inner wall <NUM>, the top <NUM>, the outer wall <NUM>, and a through bore <NUM>. <FIG> shows the cap's lip <NUM>, the outer wall <NUM>, the inner wall <NUM>, a through bore <NUM>, and a cap's bottom face <NUM>. The I-cap enclosure slides down along the pole <NUM> shaft and is wedged between the pole <NUM> and the pole cavity <NUM> at the top of the pole cavity <NUM>. The through bores <NUM> are aligned with the through bolt port <NUM> in the pole cavity <NUM> wall and bolts <NUM> secure the pole <NUM> and the I-cap to the foundation <NUM>.

<FIG> show bottom and top perspectives of half of a multi-part I-cap enclosure <NUM>. In this embodiment the two parts are joined together after the pole <NUM> shaft rests on the pole cavity <NUM> tapered structure <NUM>. The multi-part I-cap <NUM> is inserted at the top of the pole cavity <NUM> having an overlapping lip <NUM> to direct moisture away from the pole <NUM> toward the exterior edge of the pole cavity top <NUM>. <FIG> shows the cap's lip <NUM>, the outer wall <NUM>, a through bore <NUM>, and the inner wall <NUM>. <FIG> shows the top of the I-cap <NUM> recess <NUM> into which compressive filler/elastomeric compound <NUM> is placed, a through bore <NUM>, and the cap's inner wall <NUM>. Also shown are two enlarged sections designators showing the I-cap's interlocking lips <NUM> in more detail.

<FIG> shows a partial section of the multi-part I-cap <NUM> enclosure interlock at the seam <NUM> and the cap's top lip <NUM> is keyed into the cap's bottom lip <NUM>. The multi-part I-cap enclosure <NUM> cross-section may include voids <NUM> reducing its weight and material without compromising its ability to transfer the pole's <NUM> lateral loads to the foundation <NUM>. The voids may be enclosed by radial spokes originating at the multi-part I-cap's enclosure's <NUM> inner wall <NUM> terminating at the outer wall <NUM>.

<FIG> shows a partial transverse section at the top of the pole cavity <NUM> centered between the pole <NUM> and the pole cavity wall <NUM>. Wedged between them is the I-cap enclosure <NUM> having an overhang over the top of the pole cavity wall <NUM> lip <NUM>. The top of the I-cap <NUM> is sloped outwardly and down from the face of the pole <NUM> and compressive filler/elastomeric compound <NUM> occupies a recess <NUM> in the I-cap enclosure's <NUM> top inner wall <NUM>. Also shown are a bolt <NUM> extending from the pole cavity wall <NUM> through the I-cap enclosure <NUM>, extending into the pole <NUM> wall. This embodiment shows the I-cap enclosure through bore <NUM> threaded. In other embodiments the I-cap enclosure <NUM> bore can be smooth faced.

<FIG> shows a section through the pole cavity <NUM>. At the vertical center of the cavity resting on a tapered structure <NUM> is a pole <NUM> with conduits <NUM> running at its center. Below and away from the tapered structure <NUM> a through opening <NUM> evacuates any trapped moisture inside the pole cavity <NUM>. At the top of the pole cavity, wedged between the pole cavity wall <NUM> and the pole <NUM> is the I-cap enclosure <NUM>. The enclosure caps the top of the foundation <NUM> preventing moisture travel into the pole cavity <NUM>. The enclosure also aligns and secures the pole to the foundation <NUM> employing bolts <NUM>. The bolts are inserted and torqued inside the exterior of the foundation wall through bolt ports <NUM>. Following installation, the ports can be filled and capped.

<FIG> shows a plan view of section 3A (above) employing multi-part I-cap enclosure <NUM>. Also shown are conduits <NUM>, the pole <NUM>, the top of foundation <NUM>, compressive filler/elastomeric compound <NUM>, and in dash line below a plurality of through bolt ports <NUM>.

<FIG> shows a partial enlargement of the top of the pole cavity wall <NUM> with the I-cap enclosure <NUM> wedged between the pole cavity wall <NUM> and the pole <NUM>. This partial enlargement shows a recess <NUM> in the inner wall of the pole cavity <NUM> and a threaded insert plate <NUM> through which the bolt <NUM> is threaded. This fastening method is one example of several methods to plumb and secure the pole. Other methods may include a threaded I-cap enclosure and/or pre-fabricated threads inside the pole cavity wall <NUM>.

<FIG> show the multi-part I-cap enclosure <NUM> in plan and elevation views inside a round pre-fabricated pole foundation <NUM>. <FIG> shows the top of the foundation <NUM>, the pole <NUM>, conduits <NUM>, compressive filler/elastomeric compound <NUM>, multi-part I-cap enclosure <NUM> and through bolt ports <NUM>. <FIG> shows the pole <NUM> inside multi-part I-cap enclosure <NUM> on a round pre-fabricated foundation <NUM> with a through bolt port <NUM>.

<FIG> show a monolithic I-cap enclosure <NUM> in plan and elevation views inside a squared pre-fabricated pole foundation <NUM>. <FIG> shows the top of the foundation <NUM>, the pole <NUM>, conduits <NUM>, compressive filler/elastomeric compound <NUM>, monolithic I-cap enclosure <NUM>, and through bolt ports <NUM>. <FIG> shows the pole <NUM> inside the monolithic I-cap enclosure <NUM> on a square pre-fabricated foundation <NUM> with a through bolt port <NUM>.

<FIG> show the multi-part I-cap enclosure <NUM> in plan and elevation views inside an octagonal pre-fabricated pole foundation <NUM>. <FIG> shows the top of the foundation <NUM>, the pole <NUM>, conduits <NUM>, compressive filler/elastomeric compound <NUM>, multi-part I-cap enclosure <NUM> and through bolt ports <NUM>. <FIG> shows the pole <NUM> inside multi-part I-cap enclosure <NUM> on an octagonal pre-fabricated foundation <NUM> with a through bolt port <NUM>.

<FIG> shows a plan view of a pole assembly employing two luminaire <NUM> resting in a pre-fabricated foundation <NUM> with a monolithic I-cap enclosure <NUM> engaging the pole <NUM> in the foundation's pole cavity <NUM>.

<FIG> shows a plan view of the pole assembly employing two luminaires <NUM> resting in a pre-fabricated foundation <NUM> with multi-part I-cap enclosure <NUM> engaging the pole inside the foundation's pole cavity <NUM>.

<FIG> shows the assembly of <FIG> in elevation with the multi-part I-cap enclosure <NUM> engaging the pole <NUM> and the foundation <NUM> and providing moisture protection to the pole cavity <NUM>. Also shown is an inlet spout <NUM> to pour fluid <NUM> into the foundation <NUM> electrical/data devices enclosure <NUM> and leader bore to facilitate engaging and securing the pole <NUM> assembly and the I-cap <NUM> to the foundation <NUM>.

<FIG> shows an enlarged and exploded perspective of top of foundation <NUM>. Also shown are the compressive filler/elastomeric compound <NUM> (for this illustration purpose higher than its true location at recess <NUM> below), the pole <NUM>, the top of the monolithic I-cap <NUM> and pole anti-rotation/uplift bolt <NUM>. The monolithic I-cap enclosure <NUM> slides down the pole <NUM> shaft and engages the pole <NUM> by at least one bolt <NUM>. The bolt <NUM> is inserted through the pole cavity <NUM> wall and the monolithic I-cap enclosure <NUM>. Once the I-cap enclosure <NUM> is secured in place, the compressive filler/elastomeric compound <NUM> is placed in the I-cap recess <NUM> to protect the pole cavity <NUM> against moisture entry.

<FIG> shows an enlarged exploded perspective of top of foundation <NUM>. Also shown are the compressive filler/elastomeric compound <NUM>, the pole <NUM>, the two-part I-cap enclosure top <NUM>, the pole anti-rotation/uplift bolt <NUM>, and the top of foundation <NUM>. The two-part I-cap enclosure <NUM> is inserted into the pole cavity <NUM> embracing the pole at their inner walls and the pole cavity <NUM> with their outer walls. Then, I-bolts <NUM> are inserted through the pole cavity <NUM> wall and through the I-cap enclosure <NUM>, securing the pole <NUM>. Then, compressive filler/elastomeric compound <NUM> is placed in the I-cap recess <NUM> to protect the pole cavity <NUM> against moisture entry. Bolt <NUM> can be engaged a threaded bore in the pole cavity <NUM> wall, in the I-cap <NUM> or both.

<FIG> show top and bottom perspectives of the I-cap enclosure <NUM> monolithic embodiment. <FIG> shows the I-cap recess <NUM>, the inner wall <NUM>, the top <NUM>, the outer wall <NUM>, and a through bore <NUM>, top bore <NUM> and I-Cap keyed lock <NUM>. <FIG> shows the cap's lip <NUM>, the outer wall <NUM>, the inner wall <NUM>, a through bore <NUM>, the cap's bottom face <NUM> and the I-Cap lock <NUM>. The I-cap enclosure slides down along the pole <NUM> shaft and is wedged between the pole <NUM> and the pole cavity <NUM> at the top of the pole cavity <NUM>. The I-Cap's top bolt/s mounted from above, secure the enclosure to the foundation <NUM>. Bolt/s <NUM> through bolt port <NUM> in the pole cavity exterior wall <NUM> secure the pole <NUM> and the I-Cap <NUM> to the foundation <NUM>.

<FIG> show bottom and top perspectives of half of a multi-part I-cap enclosure <NUM>. In this embodiment the two parts are joined together after the pole <NUM> shaft rests on the pole cavity <NUM> tapered structure <NUM>. The multi-part I-cap <NUM> is inserted at the top of the pole cavity <NUM> having an overlapping lip <NUM> sloped to direct moisture away from the pole <NUM> toward the exterior edge of the pole cavity top <NUM>. <FIG> shows the cap's lip <NUM>, the outer wall <NUM>, a through bore <NUM>, and the inner wall <NUM>. <FIG> shows the top of the I-cap <NUM> recess <NUM> into which compressive filler/elastomeric compound <NUM> is placed, a through bore <NUM>, and the cap's inner wall <NUM>. Also shown are bores <NUM> and the I-Cap keyed lock <NUM>.

<FIG> shows a partial transverse section at the top of the pole cavity <NUM> centered between the pole <NUM> and the pole cavity wall <NUM>. Wedged between them is the I-cap enclosure <NUM> having an overhang over the top of the pole cavity wall <NUM> lip <NUM>. The top of the I-cap <NUM> is sloped outwardly and down from the face of the pole <NUM> and compressive filler/elastomeric compound <NUM> occupies a recess <NUM> in the I-cap enclosure's <NUM> top inner wall <NUM>. Bolt <NUM> inserted at the top of the I-Cap enclosure <NUM> secures the I-Cap to the foundation. The foundation's top lip <NUM> may compress a gasket wedged below the bottom overhung lip of the I-Cap <NUM>. Also shown is bolt <NUM> extending from the pole cavity wall <NUM> through the I-cap enclosure <NUM>, into the pole's <NUM> wall. This embodiment shows the I-cap enclosure through bore <NUM> threaded. In other embodiments the I-cap enclosure <NUM> bore can be smooth faced.

<FIG> shows a section through the pole cavity <NUM>. At the vertical center of the cavity resting on a tapered structure <NUM> is a pole <NUM> with conduits <NUM> running at its center. Below and away from the tapered structure <NUM> a through opening <NUM> evacuates any trapped moisture inside the pole cavity <NUM>. At the top of the pole cavity, wedged between the pole cavity wall <NUM> and the pole <NUM> is the I-cap enclosure <NUM>. The enclosure caps the top of the foundation <NUM> preventing moisture travel into the pole cavity <NUM>. The enclosure also secures the pole to the foundation <NUM> employing bolts <NUM>. The bolts are inserted and torqued inside the exterior of the foundation wall through bolt ports <NUM>. Following installation, the ports can be filled and capped.

<FIG> shows a plan view of section 22A (above) employing multi-part I-cap enclosure <NUM>. Also shown are I-cap top bolts <NUM>, conduits <NUM>, the pole <NUM>, the top of foundation <NUM>, compressive filler/elastomeric compound <NUM>, and in dash line below a through bolt port <NUM>.

<FIG> shows a partial enlargement of the top of the pole cavity wall <NUM> with the I-cap enclosure <NUM> wedged between the pole cavity wall <NUM> and the pole <NUM>. This partial enlargement shows a recess <NUM> in the inner wall of the pole cavity <NUM> and a threaded insert plate <NUM> through which the bolt <NUM> is threaded. This fastening method is one example of several methods to secure the pole. Other methods may include a threaded I-cap enclosure and/or pre-fabricated threads inside the pole cavity wall <NUM>. Also shown is an I-cap top bolt <NUM> fastened into the foundation lock bore <NUM>, securing the I-cap <NUM> to the foundation <NUM>.

<FIG> show the multi-part I-cap enclosure <NUM> in plan and elevation views inside a round pre-fabricated pole foundation <NUM>. <FIG> shows the top of the foundation <NUM>, the pole <NUM>, conduits <NUM>, compressive filler/elastomeric compound <NUM>, multi-part I-cap enclosure <NUM> and through bolt ports <NUM>. <FIG> shows the pole <NUM> inside multi-part I-cap enclosure <NUM> on a round pre-fabricated foundation <NUM> with a through bolt port <NUM>. The I-cap <NUM> in this embodiment is secured to the foundation <NUM> employing four I-cap top bolts <NUM>.

<FIG> show a monolithic I-cap enclosure <NUM> in plan and elevation views inside a squared pre-fabricated pole foundation <NUM>. <FIG> shows the top of the foundation <NUM>, the pole <NUM>, conduits <NUM>, compressive filler/elastomeric compound <NUM>, monolithic I-cap enclosure <NUM>, and through bolt ports <NUM>. <FIG> shows the pole <NUM> inside the monolithic I-cap enclosure <NUM> on a square pre-fabricated foundation <NUM> with a through bolt port <NUM>. The I-cap <NUM> in this embodiment is secured to the foundation <NUM> employing four I-cap top bolts <NUM>.

<FIG> show the multi-part I-cap enclosure <NUM> in plan and elevation views inside an octagonal pre-fabricated pole foundation <NUM>. <FIG> shows the top of the foundation <NUM>, the pole <NUM>, conduits <NUM>, compressive filler/elastomeric compound <NUM>, multi-part I-cap enclosure <NUM> and through bolt ports <NUM>. <FIG> shows the pole <NUM> inside multi-part I-cap enclosure <NUM> on an octagonal pre-fabricated foundation <NUM> with a through bolt port <NUM>. The I-cap <NUM> in this embodiment is secured to the foundation <NUM> employing four I-cap top bolts <NUM>.

The conventional "pour-in-place" pole foundation construction and pole erection process entails the following steps:.

The present innovation of pole foundation construction and pole erection process is rapid requiring fewer steps:.

Coupled with the art described in the parent patent and continuation <NUM>, this innovative foundation construction and pole erection reduce <NUM> steps from the conventional foundation construction and pole erection.

The pre-fabricated foundation employs state of the art manufacturing technologies reducing on-site manual labor. This reduction lowers the overall production costs and the likelihood of bad weather having an adverse impact on the construction schedule. The innovation enhances its parent patent and continuation <NUM>, by streamlining creating an all-in-one foundation streamlining the entire foundation and pole erection process.

The foundation can be manufactured just-in-time having information at hand about the pole shaft dimensions specified. Today's fabrication technology is capable of producing complex forms in real time. For example, 3D components are printed in-real-time at the space station by an uplink from Earth. The pole rests on either a flat or tapered structure at the bottom of the pole cavity with a through opening to enable moisture to evacuate the cavity. The pole is secured to the foundation using at least one through bolts. The bolt is inserted through the pole cavity wall and can penetrate the exterior wall of the pole. A recess at the aperture opening of the pole cavity enables sealing the gap between the pole cavity and pole from moisture penetration. The sealer can be a compressive filler and/or an elastomeric compound.

The present innovation can employ two of the parent patent key elements: a tapered structure at the pole cavity's bottom center, and a pole alignment/anti-rotation/anti-uplift device at the upper portion of the pole cavity's walls.

The foundation is fabricated from substantially non-corrosive hardened material, resistant to the elements including minerals such as salt and common urban/industrial pollutants. The device manufacturing methods include but are not limited to 3D printing and injection molding. Employing 3D printing employing polymer molten resin are similar material, innovate the foundation fabrication process adding design flexibility while reducing production time. For example, the foundation pole cavity opening complements any form the pole's profile may have. Also, the foundation's exterior walls form can be fabricated to complement the pole's cross-sectional profile. Structural calculations can also be executed in real-time by employing design software with predictable material properties stored. The foundation can be fabricated from a single monolithic embodiment, or made of several embodiments joined together by mechanical means.

The foundation possesses the following common properties, regardless of its form:.

The foundation can employ cellular structure and contain volumetric enclosure/s. Both structures and particularly the cellular structure can be easily fabricated today by means of 3D printing. As a result, the foundation to site weight is reduced and the foundations are easier to handle posing lesser risk to injury. Following foundation embedment, if additional weight is needed, through an inlet spout at the exterior face of the foundations' pole cavity wall fluid can enter the cells the foundation's cells and/or the volumetric enclosure.

<FIG> show the pre-fabricated pole foundation placement process inside an augered bore in the soil. In <FIG> the bore is augered. In <FIG> the bottom of the bore is bedded. In <FIG> the pre-fabricated foundation employing external I looped bolts engaged threaded lift bores <NUM> located at the exterior wall of the pole cavity <NUM>. The I loop/s facilitate lifting the foundation/s from the truck and lowering them inside the augered bore <NUM>. The same I loop bores can be used to plumb the foundation (not shown). Since the pole <NUM> is fully aligned inside with the foundation's pole cavity <NUM>, there is no need to align the pole. The alignment is required is for the foundation. <FIG> shows fill material <NUM> around the foundation. The fill is poured and compacted following pulling power/data conductors into the foundation structure. The pole <NUM> then simply lowered into the pole cavity <NUM> and is secured to the foundation <NUM> by at least one pole bolt <NUM>. Other elements shown: the outlet or inlet spout <NUM>, <NUM> and a valve <NUM>.

<FIG> shows an elevation of a pre-fabricated pole foundation employing a cruciform core section <NUM>. At the vertical center of the core section <NUM>, a volumetric enclosure <NUM> reduce the shipping weight of the foundation <NUM> and eases the foundation handling also reducing injury risk. On-site, the volumetric enclosure <NUM> can be filled with fluid <NUM> when additional foundation weight is needed. Fluid <NUM> enters the foundation cellular structure <NUM> and/or the volumetric enclosure <NUM> through an inlet spout <NUM> located at the foundation's exterior wall <NUM>. The spout may also act as an outlet spout <NUM> and a breather valve <NUM>. Also shown are the foundation's exterior walls <NUM> including the pole cavity wall <NUM>, top of foundation's base section <NUM>, base section <NUM> and electrical/data enclosure <NUM>.

<FIG> is a vertical section through the center of the foundation <NUM> for the foundation embodiment shown in <FIG>. At the core section <NUM>, a volumetric enclosure <NUM> may contain fluid <NUM>. The fluid reaches the volumetric enclosure <NUM> through a pipe <NUM> embedder or integral to the pole cavity wall. The pipe <NUM> originates next to the inlet spout <NUM> located at the exterior wall of the pole cavity <NUM>. In different embodiments, the fluid <NUM> can perforate through the cellular structure <NUM> inside the foundation's walls or both the cellular structure <NUM> and the volumetric enclosure <NUM>.

Pole <NUM> is shown slide down the walls (?) of the pole cavity <NUM> and rests on a tapered structure <NUM> at the bottom of the pole cavity <NUM> with through opening <NUM> facilitating a mean for moisture to evacuate the cavity. In another embodiment, the pole rests on a flat surface whereas the through openings <NUM> are depressed. At the top of the cavity, a recess at the aperture of the pole cavity wall <NUM> retains compressive filler/elastomeric compound <NUM> to prevent moisture entering the pole cavity <NUM>. The pole <NUM> is secured to the foundation by engaging pole bolt/s through bolt port/s <NUM> at the foundation's exterior wall <NUM>. <FIG> is like <FIG> except perforated openings inside the volumetric enclosure <NUM> permit fluid <NUM> travel into the foundation's walls cellular structure <NUM> and/or to the foundation's base section <NUM>.

<FIG> shows an elevation of a pre-fabricated pole foundation employing a round core section <NUM>. At the vertical center of the core section <NUM>, a volumetric enclosure <NUM> reduce the shipping weight of the foundation <NUM> and eases the foundation handling also reducing injury risk. On-site, the volumetric enclosure <NUM> can be filled with fluid <NUM> when additional foundation weight is needed. Fluid <NUM> enters the foundation cellular structure <NUM> and/or the volumetric enclosure <NUM> through an inlet spout <NUM> located at the foundation's exterior wall <NUM>. The spout may also act as an outlet spout <NUM> and a breather valve <NUM>. Also shown are the foundation's exterior walls <NUM> including the pole cavity wall <NUM>, top of foundation's base section <NUM>, base section <NUM> and electrical/data enclosure <NUM>.

Pole <NUM> is shown slide down the walls of the pole cavity <NUM> and rests on a tapered structure <NUM> at the bottom of the pole cavity <NUM> with through opening <NUM> facilitating a mean for moisture to evacuate the cavity. In another embodiment, the pole rests on a flat surface whereas the through openings <NUM> are depressed. At the top of the cavity, a recess at the aperture of the pole cavity wall <NUM> retains compressive filler/elastomeric compound <NUM> to prevent moisture entering the pole cavity <NUM>. The pole <NUM> is secured to the foundation by engaging pole bolt/s through bolt port/s <NUM> at the foundation's exterior wall <NUM>. <FIG> is like <FIG> except perforated openings inside the volumetric enclosure <NUM> permit fluid <NUM> travel into the foundation's walls cellular structure <NUM> and/or to the foundation's base section <NUM>.

<FIG> show enlargements of the volumetric enclosure <NUM> and the cellular structure <NUM> inside the foundation walls. <FIG> shows the foundation elevation with horizontal section designators. Fig. 26A-A shows a partial horizontal section at the pole cavity <NUM>. Elements enumerated include: the inlet spout <NUM>, fluid pipe <NUM>, cellular-structure <NUM>, exterior wall of pole cavity <NUM>, foundation pole, power/data conduit <NUM>, through opening <NUM>, tapered structure <NUM>, and device enclosure <NUM>. <FIG> shows a partial horizontal section at the bottom of the round core foundation above the foundation's base section <NUM>. Elements enumerated include: cellular structure <NUM>, top of foundation base <NUM>, volumetric enclosure <NUM>, cellular wall <NUM> and foundation exterior wall <NUM>. <FIG> shows the horizontal enlarged section of the pole cavity <NUM> at the electrical/data enclosure <NUM> elevation depicting the inlet spout <NUM> opening and the fluid pipe <NUM> riser inside the cellular structure <NUM> wall to enable fluid <NUM> to travel to the volumetric enclosure <NUM> and/or perforate throughout the cellular walls of foundation including the base section <NUM>.

<FIG> shows a section of the foundation's pole cavity <NUM> containing a pole <NUM> with power conduits <NUM> rise from the bottom center of the pole. Also located at the bottom of the cavity are through openings <NUM> which facilitate evacuation of trapped moisture at the cavity's bottom. In this embodiment the pole <NUM> is resting on a tapered structure <NUM>. In another embodiment the pole rests on a flat surface with the through openings <NUM> are depressed. Bolt/s <NUM> lodged through the exterior wall of the pole cavity <NUM> secure the pole <NUM> from up-lift and rotation forces. The bolt/s <NUM> also can be used for pole plumbing when the clearance between the pole <NUM> and the pole cavity <NUM> is wide. This use can be when the foundation is adapted to retain a smaller diameter pole <NUM>. Generally, the gap between the pole cavity <NUM> and the pole <NUM> is minimal and the pole <NUM> and the foundation <NUM> assembly plumbing is accomplished by precisely plumbing the foundation <NUM>. The bolt/s <NUM> can engaged threads in the pole cavity wall or by a pole cavity inserted or embedded threaded plate <NUM>. The same threaded bolt bores can retain an I loop lift bolts <NUM> to lift the foundation/s <NUM> off a truck and lower them into an augured bore in the soil. After securing the pole <NUM>, the through bolt port <NUM> at the exterior wall of the pole cavity <NUM> can be plugged with a cap or capped with a sustainable non-shrink compound. At the top of the pole cavity <NUM> a recess at the pole aperture <NUM> opening retains compressive filler/elastomeric compound <NUM> sealing the gap between the pole <NUM> and the walls of the pole cavity <NUM> from moisture travel into the pole cavity.

<FIG> shows a plan view of the above <FIG> section. The elements shown are: through opening <NUM>. Pole <NUM>, compressive filler/elastomeric compound <NUM>, tapered structure <NUM>, conduit <NUM>, top of pole cavity <NUM>, pole cavity aperture recess <NUM>, through bolt port <NUM>, in dashed line at bottom of pole cavity through opening <NUM> and pole bolt <NUM>.

Claim 1:
An assembly comprising a pre-fabricated pole foundation (<NUM>; <NUM>; <NUM>; <NUM>) to be used for a pole without a base plate, the pre-fabricated pole foundation (<NUM>; <NUM>; <NUM>; <NUM>) being formed of one of a cellular structure (<NUM>; <NUM>; <NUM>), a volumetric enclosure (<NUM>; <NUM>; <NUM>) or a combination of a cellular structure (<NUM>; <NUM>; <NUM>) and a volumetric enclosure (<NUM>; <NUM>; <NUM>); and wherein the pre-fabricated pole foundation (<NUM>; <NUM>; <NUM>; <NUM>) is formed by 3D printing and comprises:
a pole cavity section (<NUM>) located at a top of the pre-fabricated pole foundation, a bridge section (<NUM>) located directly below the pole cavity section (<NUM>), a core section (<NUM>) located directly below the pole cavity section (<NUM>) and a base section (<NUM>) located at a bottom of the pre-fabricated pole foundation, wherein
the pole cavity section (<NUM>) comprises a cavity wall (<NUM>) defining a pole cavity (<NUM>; <NUM>; <NUM>; <NUM>) forming a minimal clearance between the cavity wall (<NUM>) and a face of a wall of a pole (<NUM>; <NUM>; <NUM>; <NUM>) to be received in the pole cavity (<NUM>; <NUM>; <NUM>; <NUM>); and
the assembly further comprising a securing device, wherein a pole (<NUM>; <NUM>; <NUM>; <NUM>) is configured to be secured within the pole cavity (<NUM>; <NUM>; <NUM>; <NUM>) of the pre-fabricated pole foundation (<NUM>; <NUM>; <NUM>; <NUM>) by use of the securing device, characterized in that the pre-fabricated pole foundation (<NUM>; <NUM>; <NUM>; <NUM>) employs polymer molten resin employed by 3D printing.