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`US007707797B2
`
`c12) United States Patent
`Henderson
`
`(IO) Patent No.:
`(45) Date of Patent:
`
`US 7,707,797 B2
`May 4, 2010
`
`(54) PILE ANCHOR FOUNDATION
`
`(56)
`
`References Cited
`
`(76)
`
`Inventor: Allan P. Henderson, 2005 Airport Dr.,
`Bakersfield, CA (US) 93308
`
`( *) Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by O days.
`
`(21) Appl. No.: 12/076,904
`
`(22) Filed:
`
`Mar. 25, 2008
`
`(65)
`
`Prior Publication Data
`
`US 2008/0232906 Al
`
`Sep.25,2008
`
`U.S. PATENT DOCUMENTS
`1,164,085 A *
`3,525,224 A *
`4,031,687 A *
`4,060,994 A *
`5,586,417 A *
`6,665,990 Bl *
`7,066,094 B2 *
`
`12/1915 Goldborough .............. 405/244
`8/1970 Bardgette ................... 405/225
`6/1977 Kuntz ...................... 52/741.15
`12/1977 Chitis ......................... 405/238
`12/1996 Henderson et al ............. 52/295
`. .................. 52/295
`12/2003 Cody et al.
`6/2006 Moutsokapas et al.
`...... 104/124
`
`* cited by examiner
`
`Primary Examiner-Jeanette Chapman
`(74) Attorney, Agent, or Firm-Jacobson Holman PLLC
`
`Related U.S. Application Data
`
`(57)
`
`ABSTRACT
`
`(62) Division of application No. 10/734,281, filed on Dec.
`15, 2003.
`
`(51)
`
`Int. Cl.
`E02D 27112
`(2006.01)
`E02D 27142
`(2006.01)
`E02D 27132
`(2006.01)
`(52) U.S. Cl. ........................ 52/745.17; 52/111; 52/153;
`52/155; 52/158; 52/166; 52/169.9; 52/292;
`52/295; 52/745.04; 52/741.17; 52/741.13;
`52/741.14; 52/223.4; 52/223.5; 405/232;
`405/233; 405/244; 405/252.1
`(58) Field of Classification Search ......... 405/228-229,
`405/232-233, 236-239, 242-249, 252.1;
`52/111, 153,155, 156-158, 166,169.9, 292-299,
`52/741.15, 745.04, 745.17, 741.13, 741.14,
`52/223.4, 223.5, 745.15, 741.11, 742.14
`See application file for complete search history.
`
`A circular concrete cap foundation poured in-situ within a
`perimeter forming corrugated metal pipe set atop or within an
`excavated pit and enclosing a series of circumferentially
`spaced pile anchors. The circular concrete cap foundation
`supports sets of inner and outer circumferentially spaced
`tower anchor bolts having their lower ends anchored to an
`embedded anchor ring and their upper ends projecting verti(cid:173)
`cally and upwardly out the top of the circular foundation to
`engage the base flange of a supported tower. The pile anchors
`are formed with perimeter corrugated metal pipes set deep in
`subsurface soils with cementitious material surrounding and
`partially bonding to a centralized steel bolt or tendon which
`extends through the cap foundation. The tower anchor bolts
`and the pile anchor bolts are both partially encased in a PVC
`sleeve so that the bolts can be post-tensioned. The pile
`anchors are in tension only and serve to pull the cap founda(cid:173)
`tion down to compress the underlying ground soils.
`
`16 Claims, 5 Drawing Sheets
`
`13
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`20
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`29
`
`21
`
`Exhibit - 1001
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 1
`
`

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`U.S. Patent
`.-----FIG.
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`May 4, 2010
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`Sheet 1 of 5
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`US 7,707,797 B2
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`50
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`17
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`37
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`46
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`5
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`7
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`9
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`22
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`20
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`21
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`Exhibit - 1001
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 2
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`U.S. Patent
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`May 4, 2010
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`Sheet 2 of 5
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`US 7,707,797 B2
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`0)
`N
`
`N
`•
`(!)
`LI...
`
`n
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`N n
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`0
`N
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`Exhibit - 1001
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 3
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`U.S. Patent
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`May 4, 2010
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`Sheet 3 of 5
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`US 7,707,797 B2
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`FIG. 3
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`20
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`20
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`\ 52
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`FIG. 4
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`16
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`25
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`30 20
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`Exhibit - 1001
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 4
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`

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`U.S. Patent
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`May 4, 2010
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`Sheet 4 of 5
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`US 7,707,797 B2
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`18
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`19
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`FIG. 5
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`43
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`44
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`21
`
`Exhibit - 1001
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 5
`
`

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`U.S. Patent
`
`May 4, 2010
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`Sheet 5 of 5
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`US 7,707,797 B2
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`FIG. 7
`
`FIG. 8
`
`4
`
`39
`
`8
`9
`
`11
`
`Exhibit - 1001
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 6
`
`

`

`US 7,707,797 B2
`
`1
`PILE ANCHOR FOUNDATION
`
`RELATED APPLICATIONS
`
`This application is a divisional of copending application
`Ser. No. 10/734,281, filed Dec. 15, 2003, and hereby claims
`the priority thereof to which it is entitled.
`
`BACKGROUND OF THE INVENTION
`
`10
`
`1. Field of the Invention
`This invention relates in general to concrete support foun(cid:173)
`dations constructed in-situ particularly useful for supporting
`tall, heavy and/or large towers which may be used to support
`wind turbines, power lines, street lighting and signals, bridge
`supports, commercial signs, freeway signs, ski lifts and the
`like. More specifically, the pile anchor foundation of the
`present invention is useful in supporting such towers in clay
`or other fine grain soils which are water bearing and/or too
`weak to stand or maintain the dimensions of an excavation 20
`formed to receive a concrete foundation. Such soils can be
`found in the midwest region of the United States.
`2. Description of Related Art
`My earlier U.S. Pat. Nos. 5,586,417 and 5,826,387, entitled
`Tensionless Pier Foundation and Pier Foundation under High
`Unit Compression, respectively, and my pending U.S. patent
`application Ser. No. 10/067,999, filed Feb. 8, 2002 and
`entitled Perimeter Weighted Foundation for Wind Turbines
`and the like which is a continuation of U.S. patent application
`Ser. No. 09/671,282, now abandoned, disclose post-ten- 30
`sioned concrete tower foundations, the disclosures of which
`are incorporated herein by reference as if fully set forth. The
`prior art cited in these patents and application may also be
`relevant to the pile anchor foundation of this invention.
`
`2
`spaced tower anchor bolts. The tower anchor bolts extend
`through and are nutted atop a circular tower base flange at the
`bottom of the tower and below an embedment, ring near the
`bottom of the concrete cap. The tower anchor bolts are also
`5 sleeved and shielded so as to prevent the concrete from bond(cid:173)
`ing to the anchor bolts. This structure allows the tower anchor
`bolts to be elongated and post-stressed between the tower
`base flange and the embedment ring to alleviate bolt cycling
`and fatigue.
`The tower base flange is set in grout inside a grout trough
`molded by a template bottom ring. Leveling nuts are threaded
`onto several tower anchor bolts spaced around and under(cid:173)
`neath the tower base flange in a blackout void formed by
`blackouts of foam plastic or the like. The leveling nuts allow
`15 the tower to be plumbed vertically and support the base sec(cid:173)
`tion of the tower while grout is poured into the grout trough
`under the tower base flange and cured.
`Electrical and communication conduits are positioned in
`and through the concrete cap to allow wiring and conductors
`to be pulled into the tower. Also, reinforcement rebars are
`provided at the top and bottom of the concrete cap as well as
`lapping vertically near the perimeter thereof which are tied
`and placed radially between the anchor bolts. The rebar rein(cid:173)
`forcement is intended to resist bending forces in the concrete
`25 cap.
`The pile anchor tendons or bolts, preferably in plastic
`sleeves or the like, and most preferably in PVC tubes, extend
`through the concrete cap and a pile anchor base plate, and into
`a major extent of the pile anchor cementitious material. The
`upper end of the tendon or bolt is equipped with a post(cid:173)
`tensioning nut threaded thereon to post-tension the pile
`anchor and the concrete cap after the cementitious material
`thereof has hardened.
`The pile anchors are constructed to terminate below the
`foundation concrete cap to form a gap which is preferably
`filled with a compressible material immediately below the
`foundation cap. The pile anchors around the perimeter are
`driven lengths of galvanized CMP filled with cementitious
`material except for the top of the CMP immediately below the
`bottom of the concrete cap. The cementitious material
`encases a centralized anchor bolt or tendon sleeved at the top
`and bare at its bottom with an end nut to facilitate the bottom
`of the bolt bonding with the cementitious material.
`In accordance with the foregoing, it is an object of the
`present invention to provide a concrete foundation for sup(cid:173)
`porting tall, heavy and/or large towers and/or poles which can
`be constructed in situ and is especially useful for supporting
`such towers in clay or other fine grain soils which are water
`bearing or otherwise too weak to stand or maintain the dimen(cid:173)
`sions of an excavation formed to receive a concrete founda-
`tion.
`A further object of the present invention is to provide a
`concrete foundation which includes a generally circular or
`55 cylindrical foundation cap set at or below the ground surface
`to support a tower from the upper surface thereof and a
`plurality of circumferentially spaced post tensioned pile
`anchors which depend a substantial distance into the ground
`below the base of the foundation cap.
`Another object of the present invention is to provide a
`concrete supporting foundation in accordance with the pre(cid:173)
`ceding object in which each pile anchor includes an elongated
`bolt or tendon extending substantially throughout the length
`of the pile anchor, through the concrete cap and above the top
`65 surface thereof, for post tensioning the pile anchors and pull
`the concrete foundation cap downwardly to compress the
`underlying bearing soils.
`
`SUMMARY OF THE INVENTION
`
`35
`
`40
`
`The foundation of this invention resists supported structure
`overturn by a multitude of circumferentially spaced post ten(cid:173)
`sioned pile anchors. Each of the pile anchors includes a cor(cid:173)
`rugated metal pipe (CMP) driven into subsurface soils. The
`CMPs are filled with cementitious material securing a cen(cid:173)
`tralized bolt or tendon to be post-tensioned from a top surface
`of a concrete cap positioned above the pile anchors. The pile
`anchor bolts or tendons are encased, preferably in a plastic 45
`sleeve or the like, so that they do not bond to or bear into the
`upper foundation concrete cap, thus allowing the pile anchor
`to pull upward until skin friction resistance with the surround(cid:173)
`ing soils equaling the required tendon tension is achieved.
`The required bolt or tendon tension exceeds the maximum 50
`structure uplift load determined for each pile anchor. The pile
`anchors of this invention also differ from normal piles in that
`they are tension piles resisting only overturn uplift, and they
`do not serve as load bearing compression piles for supporting
`the structure.
`In a conventional pile foundation, the piles extend
`upwardly through or into an overlying concrete foundation
`and are both compression and tension resisting foundation
`extensions. The piles in such foundations are not post-ten(cid:173)
`sioned. The foundation of this invention allows pole and 60
`tower structure foundations to be constructed at or below
`ground surface in weaker water bearing soils susceptible to
`side wall caving when excavated.
`The pile anchor foundation of the instant invention has a
`circular concrete cap set at or below ground surface which
`supports a tower from the upper surface thereof. The tower is
`attached to the concrete cap by a series of circumferentially
`
`Exhibit - 1001
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 7
`
`

`

`US 7,707,797 B2
`
`3
`Still a further object of the present invention is to provide
`the aforementioned bolts or tendons of the pile anchors with
`plastic sleeves or the like over a major portion of their upper
`extent to prevent bonding with the concrete in the upper
`portion of the pile anchor and the concrete cap, facilitate the 5
`post tensioning of the pile anchors and eliminate stress rever(cid:173)
`sals and fatigue while the bolts are stretched by jacking or
`torquing during the post tensioning.
`Yet another object of the present invention is to provide a
`concrete supporting foundation for large and heavy tower 10
`structures including a concrete foundation cap and down(cid:173)
`wardly extending pile anchors which are tension members
`only and serve to pull the concrete foundation cap down(cid:173)
`wardly to compress the underlying soils with such a compres(cid:173)
`sion force that the concrete foundation cap is always bearing 15
`on the underlying soils even under the greatest overturning
`and uplift forces transmitted to the foundation by the sup(cid:173)
`ported structure.
`Other objects and advantages ofthis invention will become
`apparent from the following description, taken in connection 20
`with the accompanying drawings, wherein is set forth by way
`of illustration and example, embodiments of this invention.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`4
`Referring to the drawings, especially FIGS. 1 and 2, the
`foundation of the present invention is generally designated by
`reference numeral 52. The foundation 52 of the present inven(cid:173)
`tion includes a circular or cylindrical foundation cap gener(cid:173)
`ally designated by reference numeral 46 and a series of cir(cid:173)
`cumferentially spaced pile anchor assemblies generally
`designated by reference numeral 47. The foundation cap 46
`preferably includes an outer upstanding corrugated metal
`pipe (CMP) 20 at its perimeter which may, for example, be 24
`feet in diameter and 4 feet in height. The outer CMP 20 is
`placed atop the ground or in an excavation 29 formed in the
`ground and resting upon the bottom of the excavation 29. (See
`FIGS. 2 and 4).
`Referring to FIG. 2, the void between the outer corrugated
`metal pipe 20 at the foundation cap perimeter and the edge of
`the excavation is filled with clean sand or sand cement slurry
`30. The foundation cap 46 includes a series of tower anchor
`bolts 13 spaced circumferentially about the central point of
`the foundation cap 46 (see FIGS. 2 and 3). The tower anchor
`bolts 13 may be positioned in radial pairs forming two anchor
`bolt circles. The inner tower anchor bolt circle has a slightly
`shorter diameter than the outer tower anchor bolt circle. For
`example, the outer tower anchor bolt circle diameter may be
`14 feet and the inner tower anchor bolt circle diameter may be
`25 13 feet. The anchor bolts 13 are sleeved, preferably with PVC
`tubes 18, which cover the anchor bolts 13 except for threaded
`portions at the top and bottom of the bolts (see FIGS. 2 and5).
`The anchor bolt sleeves 18 prevent bonding of the bolts 13 to
`the concrete and grout.
`Referring to FIGS. 2 and 5, the lower ends of the tower
`anchor bolts 13 are anchored near the bottom of the concrete
`cap foundation 46 with an embedment ring 19 which prefer(cid:173)
`ably may be constructed of several circumferential segments
`lap jointed at 45. The embedment ring 19 is preferably about
`the same size as and complementary to the tower base flange
`33. The ring 19 contains bolt holes for each of the anchor bolts
`13. The bolts 13 are secured in the bolt holes by any suitable
`securement, such as hex nuts 44 below the embedment ring 19
`and hex nuts 43 atop the embedment ring as shown in FIG. 5.
`Referring to FIGS. 2, 3, and 4, reinforcing steel rebar 34 is
`positioned radially between the pairs of anchor bolts 13 and
`the pile anchor bolts 16. The radial steel rebar 34 preferably
`are placed both near the top and bottom of the concrete cap
`foundation 46 and are lapped vertically and wire tied near and
`parallel to the outer CMP 20.
`FIGS. 1 and 2 show complete views of the pile anchor
`assemblies 47. Each pile anchor assembly 47 consists of a
`pipe, preferably a corrugated metal pipe (CMP) 23, driven
`into the ground sands, silts, clays, or combinations thereof by
`a mandrel pile driver. Post-tensioning pile anchor bolts or
`tendons, preferably all-thread bolts 16 with a nut 22 at the
`bottom, are centralized in the center of the pile anchor CMP
`23 by pile anchor centralizers 32 (see FIGS. 2 and 7). The pile
`anchor bolts 16 are sleeved, preferably by PVC tubing along
`55 a major upper portion 21 of their length to prevent bonding
`with the concrete foundation cap 46 and pile anchor grout 24
`and to allow for post-tension stretching. The portion of the
`pile anchor bolts 16 below the PVC no bond zone and the
`bottom nut 22 are encased and secured in position by cemen-
`60 titious grout or concrete 24 pumped to fill the interior of the
`pile anchor CMP 23. The grout or concrete 24 fills the interior
`of the pile anchor CMP 23 to within about two (2) feet of the
`bottom of the concrete foundation cap 46, leaving an unfilled
`spaced 31 (see FIG. 6). Following concrete pour and cure of
`65 the foundation cap 46, the pile anchor base plates 17 are
`installed over the pile anchor bolts 16 atop the concrete foun(cid:173)
`dation cap, and the post-tensioning nuts 28 are torqued or
`
`35
`
`FIG. 1 is an exploded perspective view, partially in section,
`of the completed cap and pile anchor foundation constructed
`in accordance with a preferred embodiment of the present
`invention.
`FIG. 2 is a sectional view of the completed foundation with 30
`the tower base section flange set in the grout trough, with the
`concrete cap and pile anchors in accordance with preferred
`embodiments.
`FIG. 3 is a top plan view of the foundation under the
`template, prior to concrete being poured.
`FIG. 4 is an enlarged fragmental view, partly in section, of
`the completed foundation illustrating the upper pile anchor,
`the tower anchor bolts and foundation cap with the tower base
`flange positioned atop the foundation.
`FIG. 5 is an enlarged fragmentary sectional view of the
`embedment ring at the bottom of the tower anchor bolts
`illustrating two nuts, PVC sleeve and a splice plate for con(cid:173)
`necting segments of the embedment ring.
`FIG. 6 is an enlarged fragmental view illustrating the top of 45
`a post tensioned pile anchor with the compressible material
`filling the skin friction development gap between the top of
`the cementitious material of the pile anchor and the bottom of
`the foundation cap.
`FIG. 7 is an enlarged fragmental view illustrating the bot- 50
`tom of the pile anchor with terminating nut and centralizer.
`FIG. 8 is an enlarged fragmental view illustrating the tem(cid:173)
`plate assembly.
`
`40
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENT
`
`Although one preferred embodiment of the invention is
`explained in detail, it is to be understood that the invention is
`not limited in its scope to the details of construction and
`arrangement of components of this specific embodiment. The
`invention is capable of other embodiments and of being prac(cid:173)
`ticed or carried out in various ways. Also, in describing the
`preferred embodiment, specific terminology will be resorted
`to for the sake of clarity. It is to be understood that each
`specific term includes all technical equivalents which operate
`in a similar manner to accomplish a similar purpose.
`
`Exhibit - 1001
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 8
`
`

`

`US 7,707,797 B2
`
`10
`
`5
`threaded snugly against the pile anchor plates 17 during the
`post-tensioning jacking of the pile anchor bolts 16 (see FIG.
`4).
`Referring to FIGS. 1 and 8, the template assembly is gen(cid:173)
`erally designated by reference numeral 37. The template 5
`assembly 37 is a temporary structure securing and positioning
`the anchor bolts 13 and Styrofoam blackouts 12 while form(cid:173)
`ing a recessed tower grout trough 14 during pouring of the
`concrete for the foundation cap 46 and until the concrete
`ini ti ally sets.
`The template assembly 37 consists of a generally square
`frame structure 50 comprising channels or I-beams 1 and 4
`welded or bolted together. The frame structure 50 supports
`the top ring 7 and bottom ring 9 steel template rings unified
`and separated by several pieces of angle iron 8 which are 15
`welded between the steel template rings 7 and 9. The template
`rings 7 and 9 have bolt holes in exact vertical alignment to
`match with the bolt holes in the tower base flange 33. The steel
`template rings 7 and 9 are suspended below the frame struc(cid:173)
`ture 50 by all thread bolts 3 nutted atop the channels or 20
`I-beams 1 or 4 by nuts 38 and connected to the top template
`ring 7 by nuts 39 welded thereto. The nuts 38 can be turned to
`lengthen or shortened the spaced between the frame structure
`50 and the top of the unified template rings 7 and 9 to allow the
`unified template rings to be leveled. The frame structure 50 is 25
`supported around the perimeter of the excavation 29 by any
`suitable support structure, such as wooden timbers 5 atop the
`surrounding ground. The wooden timbers 5 are stacked atop
`each other to the required height so the template assembly 37
`is near level when placed atop the wooden timbers 5 by using 30
`a crane.
`The blackouts 12 of"Styrofoam" or the like are duct taped
`underneath the bottom template ring 9 in at least three (3)
`positions to create voids in the concrete below the bottom of
`the grout trough 14. These voids allow placement of the tower
`leveling nuts 11 which support the tower underneath the
`tower base flange and above the bottom of the grout trough
`14. The tower leveling nuts 11 are adjusted by turning in order
`to plumb the tower to a true vertical position prior to grouting
`the tower base flange 33 in position. The voids below the 40
`grout trough 14 created by the blackouts 12 also provide a
`space for lowering the leveling nuts 11 after the tower base
`flange 33 has been grouted into position and the grout has
`hardened sufficiently to support the tower. Lowering the lev(cid:173)
`eling nuts into their respective blackout void provides a space
`between the top of the leveling nuts 11 turned down into the
`blackout void and the underneath side of the base flange 33.
`This space allows those anchor bolts 13 with the leveling nuts
`11 to be elongated by post-tensioning in the same manner as
`all other anchor bolts 13.
`Construction Sequence and Special Features
`1. Drive pile anchor CMPs 23 with mandrel pile driver (not
`shown). The CMPs 23 will initially extend above the ground
`surface.
`2. The pile anchor bolts or tendons 16 with PVC sleeves 18
`and centralizers 32 are placed inside the CMPs 23.
`3. The pile anchor bolts or tendons 16 are grouted in place
`by pumping grout or concrete 24 into the pile anchor CMPs
`23. The top of the grout 24 should be at least two (2) feet
`below the bottom of the concrete foundation cap to be con(cid:173)
`structed, leaving gap 31.
`4. The grout 24 of pile anchors 47 is allowed to cure a
`minimum of twelve (12) hours before excavation (ifrequired)
`for concrete foundation cap 46.
`5. Excavate for concrete foundation cap 46. Hand work 65
`required around pile anchor CMPs 23.
`6. Place outer CMP 29 in excavation.
`
`6
`7. Cut off pile anchor CMPs 23 at bottom of concrete
`foundation cap and fill the two (2) feet of each pile anchor
`CMP with foam or other equivalent compressive filler.
`8. Place bolts 13 with thread nuts 43 through holes in
`segments in embedment ring 19 and thread nuts 44 under
`embedment ring; install lap joints connecting embedment
`ring segments.
`9. Place reinforcing rebars 34 top and bottom, tie wire rebar
`to anchor bolts and circular hoops near ends and bend.
`10. Pour concrete and finish concrete foundation cap 46.
`11. Post-tension pile anchor bolts 16.
`12. Pour sand/cement slurry in arnmlar space 30 between
`the concrete foundation cap 46 and edge of foundation.
`13. After seven (7) days, install tower atop concrete foun-
`dation cap 46 and post-tension tower anchor bolts 13.
`The pile anchor foundation 52 of the present invention
`provides significant structural and operational advantages as
`follows:
`1. The pile anchors 47 of the pile anchor foundation 52 are
`tension members only which pull the concrete foundation cap
`46 downward compressing the underlying bearing soils with
`such a compression force that the concrete foundation cap is
`always bearing on the underlying soils even under the greatest
`overturning and uplift forces transferred to the concrete foun(cid:173)
`dation cap from the tower structure by the tower anchor bolts
`13 atop the foundation cap.
`2. The pile anchor bolts or tendons 16 are sleeved to elimi(cid:173)
`nate stress reversals and fatigue while the bolt is stretched by
`jacking or torquing (post-tensioning).
`3. The post-tensioned pile anchor bolts 16 are shielded
`from bonding with the reinforced concrete of the concrete
`foundation cap 46 allowing the bolts or tendons 16 to elongate
`when pulled upward by jacks to the required post-tension.
`The post-tensioned bolts or tendons 16 are secured in tension
`35 by nuts 28 which are threaded atop the pile anchor base plates
`17 against the top of the concrete foundation cap 46, thus
`pulling the cap 46 downward with great compression against
`the underlying soils. Pile anchor bolts or tendons 16 may be
`re-tensioned as necessary using thread nuts 28.
`4. The pull down/hold down force of the pile anchors 47
`results from the post-tensioning of the pile anchor bolts 16
`against the pile anchor base plates 17 atop the concrete foun(cid:173)
`dation cap 46. Each pile anchor 47 is pulled upwardly toward
`the bottom of the concrete foundation cap 46 until the resist-
`45 ing skin friction along the sides of the CMP 23 equals the
`post-tension of the tension bolt 16 centered in the CMP and
`restrained by the grout 24. The post-tension downward force
`atop the concrete foundation cap 46 by each pile anchor 47
`should exceed the determined maximum uplift of the pile
`50 anchor by a factor of 1.5 or greater.
`5. The pile anchors 47 include compressible voids or foam
`filled spaces 31 between the bottom of the concrete founda(cid:173)
`tion cap 46 and the top of the grout filled pile. The compress(cid:173)
`ible space 31 allows the concrete cap foundation 46 to be
`55 pulled downward compressing and consolidating the under(cid:173)
`lying soils to the required bearing strengths and allowing the
`pile anchors 47 to pull upward developing the skin friction
`resistance equal to the pile anchor bolt or tendon post-tension.
`6. The pile anchors 47 preferably have corrugated metal
`60 pipes 23 around their perimeter to maximize the skin friction
`resistance with the contacting exterior soils.
`7. The pile anchor bolts or tendons 16 are preferably fitted
`with centralizers 32 to maintain their position in the center of
`the corrugated metal pipe 23.
`8. The pile anchors 47 are filled with cementitious grout or
`concrete to bond and secure all-thread bolts or tendons 16 as
`a structural unit with the perimeter corrugated metal pipe 23.
`
`Exhibit - 1001
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 9
`
`

`

`US 7,707,797 B2
`
`7
`The foregoing is considered as illustrative only of the prin(cid:173)
`ciples of the invention. Further, since numerous modifica(cid:173)
`tions and changes will readily occur to those skilled in the art,
`it is not desired to limit the invention to the exact construction
`and operation shown and described, and, accordingly, all 5
`suitable modifications and equivalents may be resorted to,
`falling within the scope of the invention.
`What is claimed is:
`1. A method of forming a pile anchor foundation for sup(cid:173)
`porting a heavy load from a ground surface comprising the 10
`steps of:
`inserting pile anchor pipes into a ground surface;
`placing pile anchor bolts having sleeves thereon longitudi(cid:173)
`nally in said pipes with the pile anchor bolts extending
`above an upper end of said pipes;
`filling the pipes with cementitious material and allowing
`said cementitious material to cure to form pile anchors;
`placing load anchor bolts generally parallel to said pile
`anchor bolts;
`pouring a concrete cap foundation above the upper ends of
`said pile anchor pipes and in contact with the upper ends
`of said sleeved pile anchor bolts and said load anchor
`bolts while leaving an unfilled space between a bottom
`surface of the cap foundation and an upper end of said
`pile anchors and allowing said cap foundation to cure;
`post tensioning said pile anchor bolts; and
`placing a support flange of a heavy load onto the upper ends
`of said load anchor bolts and post tensioning said load
`anchor bolts with said support flange attached thereto.
`2. The method as claimed in claim 1 wherein the step of 30
`pouring the concrete cap foundation includes the steps of:
`forming a grout trough in a top surface of said concrete cap
`foundation with said load anchor bolts extending
`through said trough;
`supporting said support flange on said load anchor bolts 35
`above a bottom of said grout trough;
`placing grout in said trough below said support flange;
`lowering said support flange into engagement with said
`grout in said trough after said grout cures; and
`post tensioning said load anchor bolts by nuts threaded 40
`thereon and engaging an upper surface of said support
`flange.
`3. Themethodasclaimedinclaiml whereinadepthofsaid
`unfilled space is at least about two feet.
`4. The method as claimed in claim 1 wherein the step of 45
`pouring said cap foundation includes the step of placing
`crushable or compressive material in said space between said
`cap foundation bottom surface and the upper end of the pile
`anchors to enable downward movement of said cap founda(cid:173)
`tion after curing by tensioning the pile anchor bolts and mov- 50
`ing said cap foundation downwardly, thereby compressing
`underlying soils.
`5. The method as claimed in claim 4 wherein the step of
`placing crushable or compressive material includes placing
`Styrofoam blackouts in said space.
`6. The method as claimed in claim 1 wherein said step of
`placing said pile anchor bolts in said pile anchor pipes
`includes fitting said pile anchor bolts with centralizers to
`maintain their position in a center of said pipes.
`7. A method of forming a pile anchor foundation for sup- 60
`porting a heavy load from a ground surface comprising the
`steps of:
`forming a plurality of generally vertical pile anchors in a
`ground surface each of which includes placing a pile
`anchor bolt having a sleeve thereon longitudinally 65
`therein with the pile anchor bolts extending above an
`upper end of the pile anchor;
`
`8
`placing load anchor bolts generally parallel to said pile
`anchor bolts;
`forming a cap foundation above said upper ends of said pile
`anchors and in contact with upper ends of said sleeved
`pile anchor bolts and said load anchor bolts while leav(cid:173)
`ing a space between said pile anchor upper ends and a
`bottom surface of said cap foundation, with said pile
`anchor bolts extending through said space;
`post tensioning said pile anchor bolts; and
`placing a support flange of a heavy load onto the upper ends
`of said load anchor bolts and post tensioning said load
`anchor bolts with said support flange attached thereto.
`8. The method as claimed in claim 7 wherein the step of
`15 forming said cap foundation includes the step of placing
`crushable material in said space between the bottom surface
`of said cap foundation and the upper ends of the pile anchors
`to enable downward movement of said cap foundation by
`tensioning the pile anchor bolts and moving said cap founda-
`20 tion downwardly, thereby compressing underlying soils.
`9. The method as claimed in claim 7 wherein the step of
`forming said cap foundation includes leaving an unfilled
`space having a depth of at least about two feet between the
`bottom surface of the cap foundation and said pile anchor
`25 upper ends.
`10. The method as claimed in claim 9 wherein the step of
`forming said cap foundation includes the step of placing
`crushable material in said space between said cap foundation
`bottom surface and said pile anchor upper ends to enable
`downward movement of said cap foundation by tensioning
`the pile anchor bolts and moving said cap foundation down-
`wardly, thereby compressing underlying soils.
`11. The method as claimed in claim 10 wherein the step of
`placing crushable material includes placing Styrofoam block(cid:173)
`outs in said space.
`12. The method as claimed in claim 7 wherein the step of
`forming the concrete cap foundation includes the steps of:
`forming a g