United States Patent [19J
`Henderson et al.
`
`I IIIII IIIIIIII Ill lllll lllll lllll lllll lllll lllll lllll lllll 111111111111111111
`US005826387 A
`[11] Patent Number:
`[45] Date of Patent:
`
`5,826,387
`*Oct. 27, 1998
`
`[54] PIER FOUNDATION UNDER HIGH UNIT
`COMPRESSION
`
`[76]
`
`Inventors: Allan P. Henderson, 5919 Mohawk
`Dr., Bakersfield, Calif. 93308; Miller B.
`Patrick, 5808 Baywood, Bakersfield,
`Calif. 93309
`
`[ * ] Notice:
`
`The term of this patent shall not extend
`beyond the expiration date of Pat. No.
`5,586,417.
`
`[21] Appl. No.: 773,053
`
`[22] Filed:
`
`Dec. 24, 1996
`
`Related U.S. Application Data
`
`[63]
`
`[51]
`[52]
`
`[58]
`
`Continuation-in-part of Ser. No. 346,935, Nov. 23, 1994,
`Pat. No. 5,586,417.
`Int. Cl.6
`............................... E02D 5/38; E02D 27/32
`U.S. Cl. ............................. 52/295; 52/223.4; 52/296;
`405/249; 405/251; 405/256
`Field of Search ................................ 52/223.4, 223.5,
`52/294, 295, 296, 741.11, 741.14, 741.15,
`742.14; 405/229, 231, 232, 233, 236, 237,
`238,239,242,249,251,255,256
`
`[56]
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`1,048,993
`2,162,108
`2,374,624
`2,706,498
`2,724,261
`3,186,181
`3,382,680
`3,559,412
`3,600,865
`3,839,874
`3,842,608
`3,963,056
`3,963,065
`4,038,827
`4,060,994
`
`12/1912 Meriwether.
`6/1939 Newman ................................. 405/239
`4/1945 Schwendt .
`4/1955 Upson .
`11/1955 Rensaa .
`6/1965 Snow et al. .
`5/1968 Takano .
`2/1971 Fuller .
`8/1971 Vanich.
`10/1974 Wyant .
`10/1974 Turzillo .
`6/1976 Shibuya et al. .
`6/1976 Dauwalder .
`8/1977 Pryke ...................................... 405/239
`12/1977 Chitis . ... ... ... ... .... ... ... ... ... .... ... .. 405 /238
`
`4,228,627
`4,287,691
`4,618,287
`4,842,447
`4,910,940
`5,131,790
`5,228,806
`5,379,563
`5,586,417
`
`10/1980 O'Neill .
`9/1981 Guenther .
`10/1986 Kinnan .
`6/1989 Lin.
`3/1990 Grady, II ............................ 52/223.5 X
`7/1992 Simpson ............................. 405/233 X
`7/1993 De Medieros, Jr. et al. .
`1/1995 Tinsley .
`12/1996 Henderson et al. .
`
`Primary Examiner-Lanna Mai
`Assistant Examiner-Kevin D. Wilken
`Attorney, Agent, or Firm-Jacobson, Price, Holman &
`Stern, PLLC
`
`[57]
`
`ABSTRACT
`
`An upright cylindrical pier foundation is constructed of
`cementitious material. The lower end of the foundation has
`a plate or circumferential ring fully embedded therein and
`long circumferentially spaced rods or bolts have their lower
`ends anchored relative to the ring. The upper ends of the
`long rods project up outwardly of the top of the foundation.
`The rods are shielded over substantially their entire length
`against bonding with the cementitious material to allow the
`rods, when heavily tensioned, to stretch within the cemen(cid:173)
`titious material. A heavy flange, which may comprise the
`base flange of a tubular tower, is positioned downwardly
`upon the upper end of the foundation with the upper ends of
`the bolts projecting through holes provided therefor in the
`base flange. Nuts are threaded downwardly upon the upper
`ends of the bolts and against the base flange under high
`torque in order to place the bolts in heavy tension and
`substantially the entire length of the cylindrical foundation
`under high unit compressive loading. The pier foundation
`may include a diametrically enlarged upper end shoulder
`portion whose outer peripheral portion includes additional
`circumferentiallv spaced heavily tensioned short rods
`anchored between a second anchor plate or ring embedded
`in the shoulder portion and a second flange or ring seated
`downwardly on the shoulder portion upper end. Also, the
`long rods may include shorter rod sections suitably coupled
`together and sections of the foundation may be precast with
`the sheathed rods in place.
`
`19 Claims, 10 Drawing Sheets
`
`174
`
`142
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 1
`
`

`

`U.S. Patent
`
`Oct. 27, 1998
`
`Sheet 1 of 10
`
`5,826,387
`
`FIG. 1
`
`20
`
`FIG. 4
`
`FIG. 8
`
`30
`
`20
`
`38
`
`FIG. 5
`
`50
`
`82
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 2
`
`

`

`U.S. Patent
`
`Oct. 27, 1998
`
`Sheet 2 of 10
`
`5,826,387
`
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`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 3
`
`

`

`U.S. Patent
`
`Oct. 27, 1998
`
`Sheet 3 of 10
`
`5,826,387
`
`FIG. 3
`
`FIG. 6
`58
`
`52
`
`62
`
`52
`
`FIG. 7
`
`60
`
`62
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 4
`
`

`

`U.S. Patent
`
`Oct. 27, 1998
`
`Sheet 4 of 10
`
`5,826,387
`
`FIG. 9
`
`45
`
`49
`
`FIG. 10
`
`38
`
`45
`
`49
`
`FIG. 11
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 5
`
`

`

`U.S. Patent
`
`Oct. 27, 1998
`
`Sheet 5 of 10
`
`5,826,387
`
`FIG. 12
`
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`
`122
`
`120
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 6
`
`

`

`U.S. Patent
`
`Oct. 27, 1998
`
`Sheet 6 of 10
`
`5,826,387
`
`• C) -La...
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 7
`
`

`

`U.S. Patent
`
`Oct. 27, 1998
`
`Sheet 7 of 10
`
`5,826,387
`
`FIG. 14
`
`123
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`
`133
`
`120·
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 8
`
`

`

`U.S. Patent
`
`Oct. 27, 1998
`
`Sheet 8 of 10
`
`5,826,387
`
`FIG. 15
`
`121
`
`174
`
`131
`
`116
`
`169
`
`142
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 9
`
`

`

`U.S. Patent
`
`Oct. 27, 1998
`
`Sheet 9 of 10
`
`5,826,387
`
`FIG. 17
`
`210
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 10
`
`

`

`U.S. Patent
`
`Oct. 27, 1998
`
`Sheet 10 of 10
`
`5,826,387
`
`FIG. 18
`
`310
`
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`·.
`
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`
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`'-;-· - t - - - 3 1 1
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`
`320
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 11
`
`

`

`5,826,387
`
`1
`PIER FOUNDATION UNDER HIGH UNIT
`COMPRESSION
`
`This application is a continuation-in-part of U.S. appli(cid:173)
`cation Ser. No. 08/346,935, for Tensionless Pier Foundation,
`filed Nov. 23, 1994, now U.S. Pat. No. 5,586,417, dated Dec.
`24, 1996.
`
`BACKGROUND OF THE INVENTION
`
`2
`In contrast, the foundation of the instant invention may be
`poured on site monolithically and, therefore, in the case of
`a remote point of use, needs only transportation for the
`ingredients of concrete, corrugated pipe sections and tension
`5 bolts to the construction location and only to the extent
`necessary to construct the foundation in accordance with the
`present invention.
`U.S. Pat. No. 2,724,261 to E. M. Rensaa discloses a
`pre-cast column and means for attaching the column to a
`10 substantially horizontal supporting surface such as a footing
`or wall and which is otherwise not suitable for use as a large
`or tall tower foundation.
`U.S. Pat. No. 3,600,865 to Francesco Vanich discloses a
`single column-borne elevated house unit erected by
`assembling, on a cast in situ foundation pillar, column
`sections provided with means for fastening the same
`together and to the foundation pillar above the pillar and by
`also fastening to the column sections radially arranged
`cantilever beams. The assembled parts are fastened together
`and to the foundation pillar by tendon sections which are
`first coupled together by joints, and then tensioned and
`eventually bonded to the concrete of the assembled parts by
`forcing grout in the clearance fully around the tendon rods.
`The Vanich house foundation is supported either on a
`large diameter pile cast or otherwise forced into the ground
`or inserted with its base portion into a small diameter pit
`whose peripheral walls and bottom are coated with a thick
`layer of preferably reinforced concrete. Sheathed steel rods
`are placed into the pit which is then filled with concrete.
`Before the concrete is completely hardened, a light pre-
`fabricated base is fitted thereon with screw threaded rods
`extending through the base.
`U.S. Pat. No. 3,963,056, to Shibuya et al. discloses piles,
`35 poles or like pillars comprising cylindrical pre-stressed
`concrete tubes or pillar shaped pre-stressed concrete poles
`with an outer shell of steel pipe. While inclusion of the outer
`steel pipe as the outer shell increases the compressive
`strength of the concrete tube or pole by preventing the
`40 generation of lateral stress within the concrete tube or pole
`in a radial direction, the outer steel shell provides little
`resistance to tension stresses imposed upon the concrete due
`to swaying or side-to-side movement of tall towers sup(cid:173)
`ported on the foundation. In contrast, the pier foundation of
`45 the instant invention is post-stressed sufficiently to place the
`entire vertical extent of the concrete portion of the founda(cid:173)
`tion under compression which considerably exceeds any
`expected tension loading thereof.
`U.S. Pat. No. 1,048,993, to C. Meriwether discloses a
`50 reinforced concrete caisson which can be sunk in the usual
`way. Then, if desired, the caisson may be filled with concrete
`to form a pier. The reinforced concrete caisson is pre-cast
`into tubular sections of concrete with heavy large-mesh
`fabric of wire reinforcement and metal rings embedded at
`55 the ends for bolting sections together at a bell and spigot
`joint. Tie-rods extend through the connecting rings on the
`inside of the reinforced concrete tube to connect the section
`together. However, the tensioned tie-rods of Meriwether are
`spaced inward of the inner peripheries of the concrete tubes
`60 and do not pass through the thick wall concrete construction
`itself.
`U.S. Pat. No. 3,382,680, to T. Takano discloses a pre(cid:173)
`stressed concrete pile section, as opposed to a post(cid:173)
`compressed pile construction, and incorporates tensioning
`65 wires which are embedded in the surrounding concrete and
`thus are not capable of stretching relative to the surrounding
`post-cured concrete.
`
`15
`
`1. Field of the Invention
`This invention relates to concrete foundations particularly
`useful for the support of tall, heavy and/or large towers
`which may be used to support power lines, street lighting
`and signals, bridge supports, wind turbines, commercial
`signs, freeway signs, ski lifts and the like.
`2. Description of Related Art in Relation to Present
`Invention
`Various different forms of foundations utilizing some of
`the general structural and operational features of the instant 20
`invention heretofore have been known, such as those dis(cid:173)
`closed in U.S. Pat. Nos. 1,048,993, 2,374,624, 2,706,498,
`2,724,261, 3,186,181, 3,382,680, 3,559,412, 3,600,865,
`3,839,874, 3,842,608, 3,963,056, 4,228,627, 4,287,691,
`4,618,287, 4,842,447, 5,228,806 and 5,379,563. However, 25
`these previously known foundations do not include some of
`the basic features of the instant invention, and the combi(cid:173)
`nation of features incorporated in three of the five disclosed
`forms of the instant invention enable a heavy duty founda(cid:173)
`tion with a slenderness ratio of less than 3 to be formed in 30
`situ and in a manner not requiring the use of large drilling
`rigs or pile drivers, two of the five disclosed forms being
`pre-cast. The combination comprising the present invention,
`all disclosed forms included, results in a foundation capable
`of resisting very high upset loads in various types of soils
`and in a manner independent of the concrete of the foun(cid:173)
`dation experiencing alternating localized compression and
`tension loading.
`U.S. Pat. No. 2,374,624 to P.J. Schwendt discloses a
`foundation intended for supporting signal masts, supply
`cases and signals. The foundation consists of pre-cast sec(cid:173)
`tions of concrete bolted together. The composite foundation
`is embedded in soil. The mounting of a tall mast section for
`signals on this foundation would subject the foundation to
`some overturning moment, and the Schwendt foundation is
`only applicable to relatively small structures, inasmuch as it
`is constructed from pre-cast sections which necessarily
`impose size limitations on the foundation and therefore the
`structure supported thereon.
`In comparison, the pier foundation of the instant invention
`can be poured-on-site monolithically and is of cylindrical
`construction with many post-tensioned anchor bolts which
`maintain the poured portion of the foundation under heavy
`compression, even during periods when the foundation may
`be subject to high overturning moment.
`U.S. Pat. No. 2,706,498 to M.M. Upson discloses a
`pre-stressed tubular concrete structure particularly adapted
`for use as pipe conduits, concrete piles and caissons. The
`pre-stressed tubular concrete structure is pre-cast in sections
`and can be assembled end-to-end. Longitudinal reinforcing
`steel is provided and extends through cavities, is tensioned
`and grouted tight, therefore pre-stressing helical wire wind(cid:173)
`ings which are tensioned providing circumferential pre(cid:173)
`stressing. The Upson structure is pre-stressed and not of a
`size diameter suitable as a foundation for tall support towers
`or columns subject to high upset moment and would be very
`difficult to transport to a remote area of use.
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 12
`
`

`

`5,826,387
`
`10
`
`3
`U.S. Pat. No. 3,559,412, to F. M. Fuller discloses a
`reinforced concrete pile whose reinforcement comprises
`static reinforcement only and which is in intimate contact
`with the surrounding concrete and is not capable of stretch(cid:173)
`ing relative to the surrounding post-cured concrete.
`U.S. Pat. No. 3,842,608, to L. Turzillo discloses a pile
`including outer spiral flutes enabling it to be screwed into the
`ground. Further, the Turzillo pile does not include an open
`top and an open bottom and further does not include
`structure whereby the pile is post-compressed.
`U.S. Pat. No. 4,228,627, to J. O'Neill discloses a rein(cid:173)
`forced foundation structure incorporating vertical rods or
`bolts, but these rods or bolts include lower ends anchored
`relative to radial reinforcing rods as opposed to a peripher(cid:173)
`ally continuous anchor ring embedded in the lower end of 15
`the concrete structure and, accordingly, the O'Neil structure
`is not capable of being placed under high unit compressive
`loading.
`Finally, U.S. Pat. No. 5,379,563, to C. Tinsley discloses
`an anchoring assembly by which heavy machinery may be 20
`anchored to a foundation. However, no continuous lower
`anchor ring is provided and there is no peripherally con(cid:173)
`tinuous upper ring through which the anchoring bolts
`extend. Accordingly, although peripherally spaced portions
`of the Tinsley foundation can be placed under compression, 25
`there is no structure by which the Tinsley foundation may be
`placed under high unit compressive loading.
`SUMMARY OF THE INVENTION
`The foundation of the instant invention is unique because
`it eliminates the necessity for reinforcing steel bars (rebar
`tension bars), substantially reduces the amount of concrete
`used, and therefore the cost of the foundation compared to
`conventional designs, simplifies the placement of the sup(cid:173)
`ported structure on the foundation, and eliminates alternat(cid:173)
`ing cyclical compression and tension loading on the
`foundation, thereby substantially reducing fatigue. Also, the
`foundation construction of the present invention allows for
`the replacement of the tower anchor bolts in the unlikely
`event of bolt failure and, in three of the disclosed forms, 40
`allows removal of the upper four to five feet of the foun(cid:173)
`dation in the event such action is desired for decommission(cid:173)
`ing purposes.
`In a normal concrete pier foundation the concrete bears
`the compressive loads and the contained reinforcing bars 45
`(rebar) bear the tensile loads. The anchor bolts are typically
`placed within the reinforcing bar matrix using a removable
`template at the top and a separate anchor plate at the bottom
`of each bolt. The entire module is poured in concrete. As the
`foundation is loaded by the structure supported therefrom, 50
`the unit is subjected to varying tensile and compressive
`loads with there being a boundary at the bolt anchor plates
`where the loading on the concrete alternates from a com(cid:173)
`pressive load to a tensile load depending upon the various
`forces on the supported structure. The tensile load from the 55
`overturning moment of the supported structure is applied
`near the top of the foundation by the anchor bolts and
`subjects the large portion of the foundation below the point
`of application to tension. The large foundation typically
`requires a great amount of reinforcing steel and a large 60
`amount of concrete to encase the reinforcing steel. Extensive
`labor is also necessary to assemble the reinforcing steel
`matrix and fill the volume of the foundation with concrete
`and fix the anchor bolts. A typical cylindrical foundation also
`requires the use of a large drill to excavate the hole.
`The foundation of the instant invention is preferably in the
`shape of a concrete cylinder. The outer boundary shell of the
`
`4
`concrete may be formed by corrugated metal pipe. The inner
`boundary, preferably in large hollow cylinder foundations,
`also may be formed by corrugated metal pipe of lesser
`diameter. Elongated high strength steel bolts then run from
`5 a peripheral anchor plate or ring near the bottom of the
`cylinder vertically up through "hollow tubes" extending
`vertically through the concrete portion of the foundation to
`a peripheral connecting plate or flange adjacent the upper
`end of the structure. The bolt pattern may be determined by
`the bolt pattern on the plates or flanges. That pattern may
`also be engineered in the construction of the foundation by
`a removable template. The "hollow tubes" are preferably
`elongated plastic tubes which encase the bolts substantially
`through the entire vertical extent of the concrete and allow
`the bolts to be tensioned after the concrete has hardened and
`cured, thereby post-tensioning the entire concrete founda(cid:173)
`tion. Alternatively, the elongated bolts can be wrapped in
`plastic tape, or coated with a suitable lubrication, which will
`allow the bolts to stretch under tension over the entire
`operating length of the bolt through the vertical extent of the
`concrete. There is typically no rebar reinforcing steel in the
`foundation, except perhaps in large foundations where a
`small amount of incidental steel may be used to stabilize the
`bolts during construction. The costs of the elongated bolts
`and nuts is significantly less than the cost of reinforcing
`steel, the placement of the steel and necessary anchor bolts
`associated with conventional foundations.
`The center of a large hollow cylindrical foundation is filed
`with excavated soil and then capped. Excavation for the
`foundation may be done using widely available, fast, low
`30 cost excavating machines instead of relatively rare, slow,
`costly drills necessary for conventional cylindrical founda(cid:173)
`tions.
`The design of the foundation of the instant invention uses
`the mechanical interaction with the earth to prevent over
`35 turning instead of the mass of the foundation typically used
`by other foundations for tubular towers. The foundation of
`the instant invention thus greatly reduces the costs by
`eliminating the need to fabricate reinforcing steel matrices
`and to locate and connect the anchor bolts within the
`reinforcing bar matrix, and by reducing the amount of
`concrete required and excess excavating costs such as those
`required for typical cylindrical foundations.
`The high strength bolts are tightened to provide heavy
`tension on the foundation from a heavy top flange through
`which the bolts pass to the anchor flange or plate at the
`bottom of the foundation, thereby post-stressing the concrete
`in great compression and placing the entire foundation,
`between the heavy top plate or flange and lower anchor plate
`or flange, under high unit compression loading. The bolts are
`tightened so as to exceed the maximum expected overturn(cid:173)
`ing force of the tower structure on the foundation. Therefore,
`the entire foundation withstands the various loads with the
`concrete thereof always in compression and the bolts always
`in static tension. In contrast, conventional foundations, in
`which the bolt pattern is set in concrete in a reinforcing bar
`matrix, experience alternating tensile and compressive loads
`on the foundation concrete, reinforcing bars and anchor
`bolts, thereby Producing loci for failure. The heavy top place
`or flange in the present construction may comprise the base
`flange of the tower structure to be supported from the
`foundation, or a separate set of bolts, suitably anchored
`relative to the upper portion of the foundation, may be used
`to anchor the tower structure base flange to the foundation.
`The main object of this invention is to provide a pier
`65 foundation which will exert maximum resistance to upset.
`Another object of this invention is to provide a concrete
`pier foundation which is maintained under heavy compres-
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 13
`
`

`

`5,826,387
`
`6
`conventional forms of manufacture, be of simple construc(cid:173)
`tion and easy to erect so as to provide a structure that will
`be economically feasible, long lasting and relatively inex(cid:173)
`pensive.
`These together with other objects and advantages which
`will become subsequentially apparent reside in the details of
`construction and operation as more fully hereinafter
`described and claimed, reference being had to the accom(cid:173)
`panying drawings forming a part hereof, wherein like
`numerals refer to like parts throughout.
`
`10
`
`25
`
`5
`sion considerably in excess of expected tension forces when
`resisting upset of a supported tower, especially tall towers
`and structures.
`Another important object of this invention is to provide a
`concrete pier foundation which may be formed in situ in 5
`remote locations.
`A further object is to provide a pier foundation which can
`be formed from pre-cast concrete sections placed under
`heavy compression.
`A still further object of this invention is to provide a pier
`foundation in which the concrete is heavily post-tensioned in
`the vertical direction after the concrete has hardened and
`cured to thereby stabilize tension and compression forces.
`Another object in conjunction with the foregoing objects
`is to post-tension the concrete in a manner which avoids
`formation of failure loci at the upper surface of the concrete
`where the supported structure is attached.
`A further object of this invention is to provide a pier
`foundation which may be formed in remote locations inde- 20
`pendent of the use of heavy drilling or pile driving equip-
`ment.
`Still another important object of this invention is to
`provide a pier foundation which may be formed in situ
`independent of the use of reinforcing materials.
`Another object of this invention is to provide a pier
`foundation whose components may be trucked to remote
`locations without excessive difficulty.
`A further important object of this invention is to provide
`a pier foundation which is not restricted by soil conditions
`or ground water.
`Still another object of this invention is to provide a pier
`foundation which will incorporate a minimum amount of
`concrete.
`A further important object of this invention is to provide
`a pier foundation which may be readily adaptable to a
`pedestal configuration for elevation of the associated tower
`above high water level in flood zones.
`Yet a further object of this invention is to provide a pier
`foundation that is resistant to erosion, scouring and sedi(cid:173)
`mentation.
`Another object of this invention is to provide a pier
`foundation which may be constructed to include a hollow
`upper portion for containment of equipment associated with 45
`the corresponding tower such as switch gear, transformers,
`etc. secure from the elements and vandalism.
`Yet another important object of this invention is to pro(cid:173)
`vide a pier foundation including tensioned compression 50
`bolts incorporated into the foundation in a manner such that
`they may be periodically retorqued and substantially fully
`removed from the bores in which they are received in the
`event it becomes necessary to remove the foundation, in
`which instance the bolt receiving bores may be used as 55
`chambers to contain blasting material.
`Still another object of this invention is to provide a pier
`foundation including a heavy top plate or ring as well as a
`heavy lower plate or ring and with each of the plates or rings
`being at least substantially continuous about an upstanding
`center axis of the foundation and with the concrete of the
`foundation between the plates or rings permanently placed
`under high unit compressive loading in excess of expected
`tension forces placed on the foundation.
`A final object of this invention to be specifically enumer(cid:173)
`ated herein is to provide a pier foundation in accordance
`with the preceding objects and which will conform to
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a fragmentary vertical sectional view of the
`upper portion of a completed pier foundation constructed in
`15 accordance with a preferred embodiment of the present
`invention and ready to have the base of a tower to be
`supported therefrom anchored to the foundation and utilized,
`in conjunction with tension bolts, to place the pier founda-
`tion in heavy compression;
`FIG. 2 is a fragmentary vertical sectional view illustrating
`the pier foundation of FIG. 1 immediately after pouring of
`the concrete thereof;
`FIG. 3 is a top plan view of the assemblage illustrated in
`FIG. 2;
`FIG. 4 is an enlarged fragmentary vertical sectional view
`illustrating the manner in which the upper template is used
`during the construction of the pier foundation in accordance
`with the present invention to maintain the upper ends of the
`30 tension bolts properly positioned;
`FIG. 5 is a fragmentary enlarged side elevational view of
`the outer end portion of one of the template radials illus(cid:173)
`trating the manner in which it may be adjusted relative to
`ground level outwardly of the outer periphery of the pier
`35 foundation;
`FIG. 6 is a fragmentary enlarged top plan view illustrating
`the manner in which the opposite ends of the upper periph(cid:173)
`eral form plate are lap-secured relative to each other;
`FIG. 7 is an elevational view of the assemblage illustrated
`40 in FIG. 6;
`FIG. 8 is an enlarged fragmentary vertical sectional view
`illustrating the manner in which the tower lower end and
`base flange may be bolted to the upper end of the pier
`foundation in accordance with the present invention, while
`at the same time tensioning the tension bolts and placing the
`concrete of the foundation under heavy compression;
`FIG. 9 is a side elevational view of a stabilizer channel for
`stabilizing the radial channel members, laterally, relative to
`the inner corrugated pipe;
`FIG. 10 is a vertical sectional view illustrating the stabi(cid:173)
`lizer channel as mounted on one of the radial channel
`members;
`FIG. 11 is a side elevational view of the assembly of FIG.
`10 as engaged with an upper edge portion of the inner
`corrugated pipe, the latter being fragmentarily illustrated in
`vertical section;
`FIG. 12 is a fragmentary isometric view of a modified
`form of pier foundation incorporating a lower portion with
`60 a radially thinner wall and an upper portion with a radially
`thicker wall defining a shouldered upper end of said pier
`foundation, with portions of the foundation being broken
`away and illustrated in vertical section;
`FIG. 13 is a top plan view of the pier foundation illus-
`65 trated in FIG. 12;
`FIG. 14 is an enlarged fragmentary vertical sectional view
`illustrating the manner in which a lower mounting flange of
`
`Exhibit - 1010
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 14
`
`

`

`5,826,387
`
`7
`a tower structure or the like may be mounted from the outer
`set of bolts of the foundation illustrated in FIGS. 12 and 13;
`FIG. 15 is a vertical sectional view of the pier foundation
`illustrated in FIGS. 12 and 13 and with the lower end
`mounting flange of a tower structure or the like mounted 5
`therefrom in the manner illustrated in FIG. 14;
`FIG. 16 is an enlarged fragmentary vertical sectional view
`illustrating the manner in which the inner set of tension bolts
`or rods used in the foundation illustrated in FIGS. 12 and 13
`each may include a pair of releasably joined rod or bolt 10
`sections;
`FIG. 17 is a vertical sectional view similar to FIG. 15, but
`illustrating a second modified form of pier foundation; and
`FIG. 18 is a vertical sectional view similar to FIGS. 15 15
`and 17, but illustrating a third modified form of pier foun-
`dation.
`
`8
`close to the top and bottom as to allow tensioning bolts to
`extend evenly through the concrete during post-tensioning.
`In lieu of the PVC pipes 30 and other suitable tubing
`which may be used or any other suitable method such as a
`lubricant coating or plastic wrap may be used to prevent
`bonding between the bolts 20 and 21 and the concrete to be
`subsequentially poured. It should be understood that tubes
`30 serve to allow bolts 20 and 21 to move relatively freely
`through the concrete after curing so as to allow post-
`tensioning of the elongated rods. Any mechanism which
`allows the movement for post-tensioning is contemplated for
`this invention. In addition, rebar wraps 28 are preferably
`used and secured to the tubes 30 associated with outer bolts
`21 at approximately five foot intervals along the vertical
`extent of the bolts 21 in order to maintain the bolts longi(cid:173)
`tudinally straight during the pour of concrete.
`The upper ends of the bolts 20 are supported from a
`template referred to generally by the reference numeral 32
`and consisting of upper and lower rings (ring sections
`20 secured together) 34 and 36 between which upwardly open(cid:173)
`ing radial channel members 38 and mounting blocks 40
`received in the channel members 38 are clamped through the
`utilization of upper and lower nuts 42 and 44 threaded on the
`Dolts 20 and 21. The inner ends of the radial channel
`members 38 are joined by a center circular plate 46 and the
`inner portions of the channel members 38 include lateral
`stabilizers 45 in the form of inverted channel members
`downwardly embracingly engaged thereover and equipped
`with opposite side set screws 47 clamp engaged with the
`corresponding channel members 38. The depending flanges
`49 of the channel members 45 are slotted as at 51 for
`stabilizing engagement with adjacent upper edge portions of
`the inner pipe 12 while the outer ends of the channel
`members 38 include threadingly adjustable channel member
`35 feet 50 abutingly engageable with the ground 18.
`Further, a cylindrical form plate 52 is clamped about the
`upper end of the outer pine 14 and has its opposite ends
`secured together in overlapped relation as illustrated in
`FIGS. 6 and 7. The form plate ends are joined together by
`40 a pair of threaded bolts 54 rotatably received through a
`mounting lug 56 carried by one end 58 of the form plate 52
`and threadedly secured through bolts 60 carried by the other
`end of the plate 52. A lap plate 62 is carried by the last
`mentioned form plate end and lapped over the form plate end
`45 58 carrying the mounting lug 56.
`As may be seen from FIG. 4, the ring 36 is slightly
`downwardly tapered and a: each radial channel member 38
`a blackout body 64 is provided