United States Patent [19]
`Henderson et al.
`
`I IIIII IIIIIIII Ill lllll lllll lllll lllll lllll lllll lllll lllll 111111111111111111
`5,586,417
`Dec. 24, 1996
`
`US005586417A
`[11] Patent Number:
`[45] Date of Patent:
`
`[54] TENSIONLESS PIER FOUNDATION
`
`[76]
`
`Inventors: Allan P. Henderson, 5919 Mohawk
`Dr., Bakersfield, Calif. 93308; Miller B.
`Patrick, 5808 Baywood, Bakersfield,
`Calif. 93309
`
`[21] Appl. No.: 346,935
`
`[22] Filed:
`
`Nov. 23, 1994
`
`Int. Cl.6
`.......................•....... E02D 5/38; E02D 27/32
`[51]
`[52] U.S. CI . ........................ 52/295; 52/223.4; 52/741.15;
`52/742.14; 405/233; 405/236; 405/239;
`405/249
`[58] Field of Search .............................. 52/294, 295, 296,
`52/741.11, 741.14, 741.15, 742.14, 223.4,
`223.5; 405/229, 232, 233, 236, 237, 238,
`239,242,249
`
`[56]
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`274,261 11/1895 Rensaa.
`1,048,993 12/1912 Meriwether ......................... 405/239 X
`2,374,624
`4/1945 Schwendt.
`2,706,498
`4/1955 Upson.
`3,186,181
`6/1965 Snow et al .............................. 405/233
`3,382,680
`5/1968 Talcano ............................... 52/223.5 X
`3,559,412
`2/1971 Fuller ...................................... 405/237
`3,600,865
`8/1971 Vanich.
`3,839,874 10/1974 Wyant ..................................... 405/233
`3,842,608 10/1974 Turzillo ................................... 405/236
`3,963,056
`6/1976 Shibuya et al. ......................... 138/175
`3,963,065
`6/1976 Dauwalder .
`4,228,627 10/1980 O'Neill ..................................... 52/295
`
`4,287,691
`4,618,287
`4,842,447
`5,228,806
`5,379,563
`
`9/1981 Guenther ............................... 52/294 X
`10/1986 Kinnan .................................. 52/296 X
`6/1989 Lin ...................................... 405/233 X
`7/1993 De Medieros, Jr. et al ....... 405/232 X
`1/1995 Tinsley ...................................... 52/295
`
`Primary Examiner-Wynn E. Wood
`Assistant Examiner-Kevin D. Wilkens
`Attorney, Agent, or Firm-Jacobson, Price, Holman & Stern,
`PLLC
`
`[57]
`
`ABSTRACT
`
`A hollow, cylindrical pier foundation is constructed of
`cementitious material poured in situ between inner and outer
`cylindrical corrugated metal pipe shells. The foundation is
`formed within a ground pit and externally and internally
`back filled. The lower end of the foundation has a circum(cid:173)
`ferential ring fully embedded therein and sets of inner and
`outer circumferentially spaced bolts have their lower ends
`anchored to the anchor ring, their upper ends projecting up
`outwardly of the top of the foundation and a majority of the
`midportions thereof free of connection with the cementitious
`material of which the foundation is constructed. The base
`flange of a tubular tower is positioned downwardly upon the
`upper end of the foundation with the upper ends of the inner
`and outer sets of bolts projecting upwardly through holes
`provided therefor in the base flange and nuts are threaded
`downwardly upon the upper ends of the bolts and against the
`base flange. The nuts are highly torqued in order to place the
`bolts in heavy tension and to thus place substantially the
`entire length of the cylindrical foundation in heavy axial
`compression.
`
`13 Claims, 4 Drawing Sheets
`
`Exhibit - 1009
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 1
`
`

`

`U.S. Patent
`
`Dec. 24, 1996
`
`Sheet 1 of 4
`
`5,586,417
`
`FIG. 1
`
`20
`
`FIG. 4
`
`36
`
`30
`
`FIG. 8
`
`10
`
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`•
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`
`12
`
`88
`
`14
`
`-38
`
`FIG. 5
`
`50
`
`Exhibit - 1009
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 2
`
`

`

`U.S. Patent
`
`Dec. 24, 1996
`
`Sheet 2 of 4
`
`5,586,417
`
`0
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`N
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`CD
`
`Exhibit - 1009
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 3
`
`

`

`U.S. Patent
`
`Dec. 24, 1996
`
`Sheet 3 of 4
`
`5,586,417
`
`FIG. 3
`
`FIG. 6
`58
`
`52
`
`FIG. 7
`
`62
`
`52
`
`62
`
`Exhibit - 1009
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 4
`
`

`

`U.S. Patent
`
`Dec. 24, 1996
`
`Sheet 4 of 4
`
`5,586,417
`
`FIG. 9
`
`47-0
`
`11:
`,·1
`
`111
`
`i
`
`51
`
`iii
`I:
`
`iii'
`
`45
`
`49
`
`FIG. 10
`
`49
`
`FIG. 11
`
`12
`
`/~ -===
`
`Exhibit - 1009
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 5
`
`

`

`5,586,417
`
`1
`TENSIONLESS PIER FOUNDATION
`
`BACKGROUND OF THE INVENTION
`
`5
`
`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
`invention heretofore have been known, such as those dis- 15
`closed in U.S. Pat. Nos. 2,374,624, 2,706,498, 2,724,261,
`3,600,865 and 3,963,056. However, these previously known
`foundations do not include some of the basic features of the
`instant invention, and the combination of features incorpo(cid:173)
`rated in the instant invention enable a heavy duty foundation 20
`with a slenderness ratio of less than 3 to be formed in situ
`and in a manner not requiring the use of large drilling rigs
`or pile drivers. The combination comprising the present
`invention results in a foundation capable of resisting very
`high upset loads in various types of soils and in a manner 25
`independent of the concrete of the foundation 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- 30
`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 35
`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
`is poured-on-site monolithically and is of cylindrical con(cid:173)
`struction 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 50
`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.
`In contrast, the foundation of the instant invention is
`poured on site monolithically and, therefore, in the case of
`a remote point of use, needs only transportation for the 60
`ingredients of concrete, corrugated pipe sections arid tension
`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 65
`pre-cast column and means for attaching the column t~ a
`substantially horizontal supporting surface such as a footing
`
`2
`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 assem(cid:173)
`bling, 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 foun-
`10 dation 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(cid:173)
`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,
`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
`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
`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.
`Finally, U.S. Pat. No. 1,048,993, to C. Meriwether dis(cid:173)
`closes a 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(cid:173)
`mesh fabric of wire reinforcement and metal rings embed-
`ded at 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 Meri(cid:173)
`wether are spaced inward of the inner peripheries of the
`concrete tubes and do not pass through the thick wall
`concrete construction itself.
`
`40
`
`45
`
`55
`
`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 foun(cid:173)
`dation, 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.
`In a normal concrete pier foundation the concrete bears
`the compressive loads and the contained reinforcing bars
`
`Exhibit - 1009
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 6
`
`

`

`5,586,417
`
`10
`
`35
`
`3
`(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,
`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
`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
`amount of concrete to encase the reinforcing steel. Extensive 15
`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 a concrete
`cylinder. The outer boundary shell of the concrete is formed
`by corrugated metal pipe. The inner boundary, preferably in
`large hollow cylinder foundations, is also formed by corru(cid:173)
`gated metal pipe of lesser diameter. Elongated high strength
`steel bolts then run from an anchor flange near the bottom of 25
`the cylinder vertically up through "hollow tubes" extending
`vertically through the concrete portion of the foundation to
`a connecting flange of the supported structure. The bolt
`pattern is determined by the bolt pattern on the mounting
`flange of the supported structure. That pattern is established
`in the construction of the foundation by a removable tem(cid:173)
`plate. The "hollow tubes" are preferably in long plastic tubes
`which encase the bolts substantially through the entire
`vertical extent of the concrete and allow the bolts to be
`tensioned thereby post-tensioning the entire concrete foun(cid:173)
`dation. 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 no typical 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 45
`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 50
`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
`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 60
`reinforcing bar matrix, and by reducing the amount of
`concrete required and excess excavating costs such as those
`required for typical cylindrical foundations.
`When the structure to be supported by the foundation is
`placed thereon, the bolts are tightened to provide tension on 65
`the bolts from the structure flange to the anchor plate at the
`bottom of the foundation, thereby post-stressing the concrete
`
`4
`in great compression. The bolts are tightened so as to exceed
`the maximum expected overturning force of the tower
`structure on the foundation. Therefore, the entire foundation
`withstands the various loads with the concrete thereof
`5 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, expe(cid:173)
`rience alternating tensile and compressive loads on the
`foundation concrete, reinforcing bars and anchor bolts,
`thereby producing loci for failure.
`The main object of this invention is to provide a pier
`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(cid:173)
`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
`20 remote locations.
`A still further object of this invention is to provide a pier
`foundation in which the concrete is heavily post-stressed in
`the vertical direction to thereby stabilize tension and com(cid:173)
`pression forces.
`Another object in conjunction with the foregoing objects
`is to post-stress 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
`30 foundation which may be formed in remote locations inde(cid:173)
`pendent of the use of heavy drilling or pile driving equip(cid:173)
`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
`40 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
`55 upper portion for containment of equipment associated with
`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
`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
`chambers to contain blasting material.
`A final object of this invention to be specifically enumer(cid:173)
`ated herein is to provide a pier foundation in accordance
`
`Exhibit - 1009
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 7
`
`

`

`5,586,417
`
`5
`with the preceding objects and which will conform to
`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.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a fragmentary vertical sectional view of the
`upper portion of a completed pier foundation constructed in
`accordance with the 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(cid:173)
`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
`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
`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
`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; and
`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.
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`Referring now more specifically to the drawings, espe(cid:173)
`cially FIGS. 1 and 2, the numeral 10 generally designates the
`pier foundation of the instant invention. The foundation 10
`preferably includes inner and outer upstanding corrugated
`
`5
`
`10
`
`15
`
`30
`
`35
`
`40
`
`45
`
`6
`pipe sections 12 and 14 which may, for example, be ten feet
`and eighteen feet, respectively, in diameter and generally
`twenty feet in length. The outer pipe 14 is initially placed
`within a hole or excavation 16 formed in the ground 18 and
`resting upon the bottom of the excavation 16. The inner
`corrugated pipe is then placed and positioned within the
`excavation 16 and the interior of the inner corrugated pipe
`12 is partially back filled and the excavation 16 outwardly of
`the outer corrugated pipe 14 being initially partially back
`filled to stabilize the pipe sections generally in position
`within the excavation and relative to each other.
`The foundation 10 additionally includes a series of ten(cid:173)
`sioning bolts 20 and 21 spaced circumferentially about the
`annulus defined between pipe sections 12 and 14. Preferably,
`the tensioning bolts are in side-by-side pairs which extend
`radially from the center of the foundation. The inner ring of
`bolts 20 has a slightly shorter diameter than the outer ring of
`bolts 21. In the embodiment shown with the dimensions
`described in the preceding paragraph forty-eight tensioning
`bolts 20 and forty-eight tensioning bolts 21, or a total of
`20 ninety-six, are provided. The rings of bolts have diameters
`which are several inches apart and diameters generally about
`12 feet. However, it will be understood by those skilled in
`the art that the number of tensioning bolts and their circum(cid:173)
`ferential positioning will depend upon the number and
`25 position of the holes of the anchoring feet of the tower or
`other structure to be supported on the foundation.
`The lower ends of the bolts 20 and 21 are anchored
`relative to a lower anchor ring 22, which preferably may be
`constructed of several circumferentially butted and joined
`sections, and the anchor ring 22 is radially spaced relative to
`the inner corrugated pipe 12 preferably by utilization of
`circumferentially spaced horizonal and radially extending
`positioning bolts 24 threaded through nuts 26 secured rela-
`tive to the under side of the anchor ring 22 at points spaced
`circumferentially thereabout. Further, the bolts 20 and 21
`have all but their opposite ends slidingly received through
`hollow tubes, preferably PVC pipes which are sized to
`receive and loosely grip to bolts 20 and 21 but still permit
`free movement therethrough. As shown in the drawings, the
`hollow tubes C>r PVC tubing need not extend through the
`entire vertical height of concrete 68, only through as much
`of the central portions and extending as 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
`50 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(cid:173)
`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
`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
`bolts 20 and 21. The inner ends of the radial channel
`
`55
`
`60
`
`65
`
`Exhibit - 1009
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 8
`
`

`

`5,586,417
`
`7
`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 10
`feet 50 abutingly engageable with the ground 18.
`Further, a cylindrical formplate 52 is clamped about the
`upper end of the outer pipe 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 15
`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 20
`58 carrying the mounting lug 56.
`As may be seen from FIG. 4, the ring 36 is slightly
`downwardly tapered and at each radial channel member 38
`a blackout body 64 is provided for a purpose to be herein(cid:173)
`after more fully described. Further, each of the six radial 25
`channel members receive the corresponding pair of inner
`and outer bolts 20 and 21 therethrough and each of the
`blackout bodies 64 extends inwardly to the outer periphery
`of the inner corrugated pipe 12, and encloses the correspond(cid:173)
`ing nuts 44 as may be seen in FIG. 4. Preferably, the 30
`blackout bodies 64 are constructed of any suitable readily
`removable material, such as wood or styrofoam.
`After the template 32, the bolts 20 and 21 with their
`associated tubing 30, wraps 28 if necessary and the lower 35
`anchor ring 22 have been assembled, the bolts 24 are
`adjusted inwardly until the caps 66 carried by the bolt inner
`ends approximate the outer periphery of the inner pipe 12
`with the inner set of bolts 20 generally equally spaced from
`the inner corrugated pipe 12. A crane is then utilized to lower 40
`the assembly down into the space between the inner and
`outer pipes 12 and 14 after the form plate 52 has been placed
`in position. Then, the feet 50 are adjusted in order to insure
`that the template 32 is level.
`Thereafter, concrete 68 may be poured to the bottom of
`each of the radial channel members 38 and to the top of each
`of the blackout bodies 64. After the concrete 68 has hard(cid:173)
`ened, the upper nuts 42 are removed and the entire template
`32 including the upper and lower rings 34 and 36 the channel
`members 38 and attached feet 50 are lifted up from the bolts
`20 and 21 and the form plate 52, the blackout bodies 64
`being exposed from above by removal of the template 32 to
`then allow removal of the blackout bodies 64.
`When the concrete 68 has sufficiently hardened and it has
`been determined that the groove 70 is level, the nuts 44 are
`removed or threaded downwardly on the bolts 20 and 21 at
`least % inch and the tower 74 to be supported from the
`foundation 10 is thereafter lowered into position with the
`upper exposed ends of the bolts 20 and 21 upwardly received
`through suitable bores 76 and 78 formed in the inner and
`outer peripheries of the base flange 80 of the tower 74 and
`the lower lug defining portion of the base flange 80 seated
`in the groove 70, a coating of high compression hardenable
`grout 82 preferably having been placed within the groove 70
`prior to positioning of the lower end of the tower 74 65
`downwardly upon the foundation 10. Initially, the upper nuts
`42 are again threaded down onto the upper ends of the bolts
`
`8
`20 and 21 and preferably torqued to 50 foot pounds. The nuts
`42 are thereafter sequentially torqued (in a predetermined
`pattern of tightening) preferably to about 600 foot pounds
`which places each of the bolts 20 and 21 under approxi-
`5 mately 40,000 pounds tension at approximately VJ the
`stretch limit of the bolts 20 and 21.
`If, on the other hand it has been found, after the concrete
`has sufficiently hardened, and the blackout bodies 64 have
`been removed that the groove 70 is not level, the nuts 44 are
`adjusted to define a level plane co-incident with the highest
`portion of the groove 70. Then, high strength grout 82 is
`poured into the groove 70 and the tower 74 is lowered into
`position seated within the groove 70 on the high side thereof
`and supported by the nuts 44 at the other locations about the
`foundation 10, the nuts 42 then being installed and only
`initially tightened. After the grout 82 has hardened, nuts 42
`are sequentially torqued in the same manner as set forth
`hereinbefore.
`By placing the bolts 20 and 21 under high tension, the
`cylindrical structure comprising the concrete 68 is placed
`under heavy compressive loading from the upper end thereof
`downwardly to a level adjacent the lower end of the cylin(cid:173)
`drical structure and the compressive loading is considerably
`greater than any upset tensional forces which must be
`overcome to prevent upset of the tower 74 and foundation
`10. As a result, the concrete 68 is always under compression
`and never subject to alternating compression and tension
`forces.
`As may be seen from FIG. 2, the back fill within the inner
`pipe 12 may be completed considerably below the surface of
`the ground 18. In such instance, the interior of the upper
`portion of the pipe 12 may be used to store maintenance
`equipment, electrical control equipment or other equipment,
`in which case the lower end of the tower 74 will be provided
`with a door opening (not shown).
`On the other hand, the back fill within the inner pipe 12
`may be completed to substantially ground level and pro(cid:173)
`vided with a poured concrete cap 86, as shown in FIG. 1.
`The cap 86 may be sloped toward the center thereof and
`provided with a drainage conduit 88 and a conduit 90 for
`electri