I IIIII IIIIIIII Ill lllll lllll lllll lllll lllll lllll lllll lllll 111111111111111111
`US007533505B2
`
`c12) United States Patent
`Henderson
`
`(IO) Patent No.:
`(45) Date of Patent:
`
`US 7,533,505 B2
`May 19, 2009
`
`(54) PILE ANCHOR FOUNDATION
`
`(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 611 days.
`
`(21) Appl. No.: 10/734,281
`
`(22) Filed:
`
`Dec. 15, 2003
`
`(65)
`
`Prior Publication Data
`
`US 2004/0131428 Al
`
`Jul. 8, 2004
`
`(51)
`
`Int. Cl.
`E02D 27/00
`(2006.01)
`(52) U.S. Cl. ............................. 52/292; 52/294; 52/295;
`52/296; 52/155; 52/156; 405/228; 405/244;
`405/232; 405/252.1; 405/229; 405/239
`(58) Field of Classification Search ................... 52/111,
`52/153, 156-158, 166, 169.9, 292-299, 741.15,
`52/745.04, 745.17; 405/228-229, 232-233,
`405/236-239, 242, 244, 249, 252.1
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`1,048,993 A
`12/1912 Meriwether
`6/1939 Newman ....................... 61/57
`2,162,108 A
`4/1945 Schwendt ...................... 72/77
`2,374,624 A
`4/1955 Upson ......................... 138/84
`2,706,498 A
`11/1955 Rensaa ........................ 72/107
`2,724,261 A
`3,186,181 A
`6/1965 Snow et al. .................. 61/53.5
`5/1968 Takano .......................... 61/56
`3,382,680 A
`2/1971 Fuller ......................... 61/53.6
`3,559,412 A
`8/1971 Vanich .......................... 52/73
`3,600,865 A
`3,793,794 A
`2/1974 Archer et al.
`................. 52/632
`3,839,874 A
`10/1974 Wyant ....................... 61/53.52
`3,842,608 A
`10/1974 Turzillo ..................... 61/53.52
`3,916,635 A * 11/1975 Lynch et al.
`................ 405/253
`
`3,963,056 A
`3,963,065 A
`
`6/1976 Shibuya et al. .............. 138/175
`6/1976 Dauwalder ............... 151/41.76
`
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`DE
`
`27 58 489
`
`11/1978
`
`(Continued)
`
`OTHER PUBLICATIONS
`
`Patent Abstracts of Japan, 55122916, Sep. 22, 1980, Keizo.
`
`(Continued)
`
`Primary Examiner-Jeanette Chapman
`(74) Attorney, Agent, or Firm-Jacobson Holman PLLC
`
`(57)
`
`ABSTRACT
`
`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 .
`
`25 Claims, 4 Drawing Sheets
`
`Exhibit - 1017
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 1
`
`

`

`US 7,533,505 B2
`Page 2
`
`U.S. PATENT DOCUMENTS
`
`4,038,827 A
`4,060,994 A *
`4,217,738 A
`4,228,627 A
`4,232,846 A
`4,287,691 A
`4,618,287 A
`4,842,447 A
`4,910,940 A
`5,131,790 A
`5,228,806 A
`5,231,808 A
`5,289,626 A *
`5,379,563 A
`5,474,399 A *
`5,586,417 A *
`5,625,988 A
`5,678,382 A
`5,761,875 A
`
`8/1977 Pryke ........................ 61/53.62
`12/1977 Chitis ......................... 405/238
`8/1980 Smith ............................ 52/40
`10/1980 O'Neill ....................... 52/295
`11/1980 Bressani ..................... 248/158
`9/1981 Guenther ....................... 52/97
`10/ 1986 Kinnan ....................... 405/232
`6/ 1989 Lin ............................ 405/243
`3/ 1990 Grady, II . ... .. ... ... ... ... .. . 52/726
`7 I 1992 Simpson ..................... 405/236
`7/1993 De Medieros, Jr. et al .. 405/231
`8/1993 Angelette .................. 52/122.1
`3/1994 Mochida et al. ............... 29/452
`1/1995 Tinsley ........................ 52/295
`12/1995 Chia-Hsiung ............... 405/229
`12/1996 Henderson et al. ............ 52/295
`5/ 1997 Killick . ... ... .. ... ... ... ... .. . 52/298
`10/1997 Naito
`...................... 52/745.21
`6/ 1998 Oliphant et al. ............ 52/721.2
`
`5,826,387 A
`5,878,540 A
`5,960,597 A
`6,119,425 A
`6,216,414 Bl
`6,270,308 Bl
`6,665,990 Bl *
`6,672,023 B2
`
`10/1998 Henderson et al ............. 52/295
`3/1999 Morstein ..................... 52/296
`10/1999 Schwager .................. 52/223.4
`9/2000 Shimonohara . ... .. ... ... ... 52/439
`4/2001 Feldberg .................... 52/736.1
`8/2001 Groppel ...................... 415/4.3
`12/2003 Cody et al.
`. .................. 52/295
`1/2004 Henderson .. ... ... .. ... ... ... 52/296
`
`FOREIGN PATENT DOCUMENTS
`
`FR
`FR
`JP
`JP
`
`1463696
`2030478
`58 166195
`6 316942
`
`1/1966
`11/1970
`10/1983
`11/1994
`
`OTHER PUBLICATIONS
`
`Patent Abstracts of Japan, 59150830, Aug. 29, 1984, Asso.
`Patent Abstracts of Japan, 61233131, Oct. 17, 1986, Kazuichi.
`
`* cited by examiner
`
`Exhibit - 1017
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 2
`
`

`

`U.S. Patent
`
`May 19, 2009
`
`Sheet 1 of 4
`
`US 7,533,505 B2
`
`S'o
`
`.•• t"
`.... f\
`·j t,
`·ii-Ji
`~-
`~'tr.~
`.. -..
`
`RGURE1
`
`Exhibit - 1017
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 3
`
`

`

`U.S. Patent
`
`May 19, 2009
`
`Sheet 2 of 4
`
`US 7,533,505 B2
`
`('I
`
`w
`a:
`=>
`CJ
`lL
`
`Exhibit - 1017
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 4
`
`

`

`U.S. Patent
`
`May 19, 2009
`
`Sheet 3 of 4
`
`US 7,533,505 B2
`
`TOP VIEW
`FIGURE 3
`
`FIGURE 4
`
`Exhibit - 1017
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 5
`
`

`

`U.S. Patent
`
`May 19, 2009
`
`Sheet 4 of 4
`
`US 7,533,505 B2
`
`FIGURE 5
`
`FIGURE 6
`
`FIGURE 7
`
`FIGURE 8
`
`Exhibit - 1017
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 6
`
`

`

`US 7,533,505 B2
`
`1
`PILE ANCHOR FOUNDATION
`
`BACKGROUND OF THE INVENTION
`
`2
`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
`5 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
`the tower to be plumbed vertically and support the base sec-
`10 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
`15 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
`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-
`25 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
`30 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
`35 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-
`sions of an excavation formed to receive a concrete founda(cid:173)
`tion.
`A further object of the present invention is to provide a
`concrete foundation which includes a generally circular or
`cylindrical foundation cap set at or below the ground surface
`50 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
`surface thereof, for post tensioning the pile anchors and pull
`60 the concrete foundation cap downwardly to compress the
`underlying bearing soils.
`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
`post tensioning of the pile anchors and eliminate stress rever-
`
`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
`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 20
`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(cid:173)
`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.
`
`SUMMARY OF THE INVENTION
`
`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 cementious material securing a central(cid:173)
`ized 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
`sleeve or the like, so that they do not bond to or bear into the 40
`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
`structure uplift load determined for each pile anchor. The pile 45
`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
`tower structure foundations to be constructed at or below 55
`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
`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 65
`sleeved and shielded so as to prevent the concrete from bond(cid:173)
`ing to the anchor bolts. This structure allows the tower anchor
`
`Exhibit - 1017
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 7
`
`

`

`US 7,533,505 B2
`
`3
`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
`structures including a concrete foundation cap and down-
`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
`on the underlying soils even under the greatest overturning 10
`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
`with the accompanying drawings, wherein is set forth by way 15
`of illustration and example, embodiments of this invention.
`
`5
`
`4
`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
`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
`a major upper portion 21 of their length to prevent bonding
`with the concrete foundation cap 46 and pile anchor grout 24
`50 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(cid:173)
`titious grout or concrete 24 pumped to fill the interior of the
`pile anchor CMP 23. The grout or concrete 24 fills the interior
`55 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
`the foundation cap 46, the pile anchor base plates 17 are
`installed over the pile anchor bolts 16 atop the concrete foun-
`60 dation cap, and the post-tensioning nuts 28 are torqued or
`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-
`65 erally designated by reference numeral 37. The template
`assembly 37 is a temporary structure securing and positioning
`the anchor bolts 13 and Styrofoam blackouts 12 while form-
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is an exploded perspective view, partially in section, 20
`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
`the tower base section flange set in the grout trough, with the 25
`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 30
`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 35
`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
`a post tensioned pile anchor with the compressible material
`filling the skin friction development gap between the top of 40
`the cementitious material of the pile anchor and the bottom of
`the foundation cap.
`FIG. 7 is an enlarged fragmental view illustrating the bot(cid:173)
`tom of the pile anchor with terminating nut and centralizer.
`FIG. 8 is an enlarged fragmental view illustrating the tern- 45
`plate assembly.
`
`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.
`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
`
`Exhibit - 1017
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 8
`
`

`

`US 7,533,505 B2
`
`10
`
`5
`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
`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
`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 shorten the space 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
`supported around the perimeter of the excavation 29 by any 20
`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
`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 30
`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 35
`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 40
`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.
`
`25
`
`45
`
`6
`8. Place bolts 13 with thread nuts 43 through holes in seg(cid:173)
`ments in embedment ring 19 and thread nuts 44 under
`embedment ring; install lap joints connecting embedment
`ring segments.
`5 9. Place reinforcing re bars 34 top and bottom, tie wire rebarto
`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 annular space 30 between the
`concrete foundation cap 46 and edge of foundation.
`13. After seven (7) days, install tower atop concrete founda(cid:173)
`tion cap 46 and post-tension tower anchor bolts 13.
`The pile anchor foundation 52 of the present invention
`15 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 founda(cid:173)
`tion cap 46 downward compressing the underlying bear(cid:173)
`ing 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 foundation 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 con(cid:173)
`crete 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 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 nec(cid:173)
`essary 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 con(cid:173)
`crete foundation cap 46. Each pile anchor 47 is pulled
`upwardly toward the bottom of the concrete foundation
`cap 46 until the resisting 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 founda(cid:173)
`tion cap 46 by each pile anchor 47 should exceed the
`determined maximum uplift of the pile 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
`foundation cap 46 and the top of the grout filled pile. The
`compressible space 31 allows the concrete cap founda(cid:173)
`tion 46 to be pulled downward compressing and consoli(cid:173)
`dating the underlying 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
`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.
`
`50
`
`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 55
`below the bottom of the concrete foundation cap to be
`constructed, leaving gap 31.
`4. The grout 24 of pile anchors 47 is allowed to cure a mini(cid:173)
`mum of twelve (12) hours before excavation (ifrequired)
`for concrete foundation cap 46.
`5. Excavate for concrete foundation cap 46. Hand work
`required around pile anchor CMPs 23.
`6. Place outer CMP 29 in excavation.
`7. Cut off pile anchor CMPs 23 at bottom of concrete faun-
`dation cap and fill the two (2) feet of each pile anchor CMP
`with foam or other equivalent compressive filler.
`
`60
`
`65
`
`Exhibit - 1017
`NV5, Inc. v. Terracon Consultants, Inc.
`Page 9
`
`

`

`US 7,533,505 B2
`
`7
`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.
`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
`suitable modifications and equivalents may be resorted to,
`falling within the scope of the invention.
`
`What is claimed is:
`1. A pile anchor foundation for supporting a heavy load
`from a ground surface comprising a concrete foundation cap
`having a bottom surface engaged with said ground surface
`and an upper surface supporting a heavy load connected
`rigidly thereto and a plurality of elongated pile anchors
`depending from said cap, each of said pile anchors including
`cementitious material extending into underlying soil a sub(cid:173)
`stantial vertical depth below said foundation cap, a void or a
`gap at an upper end of each pile anchor between said cemen(cid:173)
`titious material of each said pile anchor and a bottom surface
`of said cap, each of said pile anchors further including a
`tension member anchored thereto and extending upwardly
`through said respective void or gap and said cap, a lower end
`of each tension member being anchored in said pile anchor, an
`upper end of each tension member including a post tensioning
`assembly which engages an upper surface of said cap to pull
`said cap downwardly, an upper portion of each tension mem(cid:173)
`ber being movable in relation to said pile anchor and said cap
`to enable stretching of said tension member when the post
`tensioning assembly on the upper end thereof is tightened
`downwardly against the cap so that said upper end of the pile
`anchor moves upwardly into said void or gap and said cap is
`pulled downwardly and compresses underlying soil forming
`said ground surface, said cap bearing on the underlying com(cid:173)
`pressed soil to withstand overturning and uplifting forces
`exerted on said cap by said heavy load connected to said cap.
`2. The foundation as claimed in claim 1 wherein each of
`said tension members includes a bolt having a sleeve enclos(cid:173)
`ing a substantial length thereof to prevent the portion of the
`bolt covered by said sleeve from bonding to said pile anchor
`and cap and facilitating said post tensioning.
`3. The foundation as claimed in claim 1 wherein said foun(cid:173)
`dation cap is generally cylindrical and said elongated pile
`anchors are circumferentially spaced around said foundation
`cap.
`4. The foundation as claimed in claim 1 wherein a periph(cid:173)
`ery of each said pile anchor is defined by a corrugated metal
`pipe for a substantial length thereof.
`5. The foundation as claimed in claim 1 wherein a periph(cid:173)
`ery of said concrete foundation cap is defined by a corrugated
`metal pipe.
`6. The foundation as claimed in claim 4 wherein said block(cid:173)
`out element is said uppermost section of said corrugated pipe.
`7. The foundation as claimed in claim 1 wherein said block(cid:173)
`out element is made of foam.
`8. The foundation as claimed in claim 1 wherein said black(cid:173)
`out element has a height of less than about two feet.
`9. The foundation as claimed in claim 6 wherein said block(cid:173)
`out element has a height of less than about two feet.
`10. The foundation as claimed in claim 1 wherein an upper
`end of each tensioning member is threaded and said post
`tensioning assembly includes a base plate on the upper sur(cid:173)
`face of said cap and a nut that is received on said threaded end
`which engages an upper surface of the base plate.
`
`8
`11. A foundation for supporting a tower subject to high
`overturn loads which comprises a concrete cap defined by
`vertically spaced top and bottom surfaces and a peripheral
`wall, said cap adapted to be supported on an upwardly facing
`5 soil surface, fastening members rigidly securing said tower to
`said cap upper surface, a plurality of pi