US20250297442A1

US20250297442A1 - System and method for installing pilings using a removable helical tool

Info

Publication number: US20250297442A1
Application number: US19/085,979
Authority: US
Inventors: Warren Davie
Original assignee: Individual
Current assignee: Individual
Priority date: 2024-03-20
Filing date: 2025-03-20
Publication date: 2025-09-25
Also published as: WO2025199362A1

Abstract

A helical tool is driven into a soil mass to a first desired depth with an upper portion of the helical tool remaining accessible. A pile driver can be coupled to the upper portion of the helical tool. Piles can be driven through a bore of the helical tool further into the soil mass to a second desired depth. The helical tool can then be removed from the soil mass. A helical tool is driven to a desired first depth that enables the helical tool to provide the necessary static weight for the pile driver to drive the piles through the bore of the helical tool without needing heaving cranes or drilling rigs. A second desired depth for a completed piling chain can be the depth at which the necessary skin friction and torque is achieved so that the piling chain can be a foundation support for a building structure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a US Non-Provisional Patent Application, which claims priority to and/or the benefit of U.S. Provisional Patent Application Ser. No. 63/710,460, filed on 22 Oct. 2024, and U.S. Provisional Patent Application Ser. No. 63/567,920, filed on 20 Mar. 2024, each of which is hereby incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The apparatus, system and method of the present invention includes a helical tool or pile that can be screwed, rotated, turned or augered into soil to a first depth, e.g., using a helical driving tool, with an upper portion of the helical tool remaining above a soil surface. A helical tool can be driven to a depth that enables the helical tool to provide the necessary static weight to support a pile driver that can be used to drive other pilings through a bore of the helical tool. A pile driver can be coupled to the upper portion of the helical tool after the helical tool is driven into the soil. One or more pilings, e.g., typical concrete or wood pilings or piling sections, can then be driven through a bore of the helical tool to a second depth. The helical tool can be removed from the soil when pile driving is complete and used at another location.

2. General Background of the Invention

Generally, in the prior art when building foundations for a structure, one or more 8-inch (20.31 cm) diameter or width concrete piles (or piles having about a 6 to 14 inch (15.24-35.56 cm) diameter or width) are typically hammered or otherwise driven into the soil about 50 or 60 feet (15.24-18.29 m) or so. In harder or sandy soils, however, hammering or driving in an 8-inch (20.31 cm) width concrete pile, for example, doesn't work as the concrete piling stops driving as if it has hit a wall, and possibly the piling can break or be structurally damaged or compromised. Thus, in the prior art of driving in sandy or harder soils, a helical tool or pile having a plurality of helices or flights can typically be used instead of a concrete piling to drive into the harder soils. A helical tool typically has at least a diameter of about 8 to 14 inches (20.31-35.56 cm) and typically is made of steel. A central bore of a helical pile is typically filled or grouted with concrete after being driven into the soil in the prior art.
As used herein the terms “hard soil” or “harder soil” encompasses soil comprising layers including sand or rocks, encompasses soils which are highly compacted or compressed, and/or encompasses soils that have soil layers that are harder than layers of lightly compressed silt, for example. Harder soils include soils having dirt with sand, or soils with harder dirt or clay. Harder clay or dirt can be compacted clay or dirt, or dry clay or dirt, or denser clay or dirt.
In prior art systems and methods of building foundations in harder soils, a helical tool remains in the ground and is typically filled or grouted in with concrete. A helical tool generally is made of steel and is very expensive. Needing to use helical tools in construction in harder soils then can significantly increase cost for a project compared to projects where concrete or wooden piles can be used to build foundations in other types of soils. Numerous helical tools may be needed for a single building project in harder soils. Reference is made to “Grouted Helical Micropiles from Danbro Distributors” available at: https://www.youtube.com/watch?v=2GbrtsbYDDY, which is incorporated herein by reference.
In use, a helical tool or pile is generally rotated into soil such that helices, or flights, or helical plates engage with the soil to advance the tool therein. This helps to minimize or eliminate vibration. Helices or flights or helical plates on a helical tool generally are configured for soil displacement rather than soil excavation, so little or no spoil is removed during driving. After driving of a helical tool, each helice, flight or helical plate creates a bearing surface to distribute the axial load to the surrounding soil.
In the prior art, auger cast piles are also sometimes used in areas with poor soil conditions, e.g., in New Orleans, Louisiana, US, in a case auger drilling process. With this process, dirt and spoils come out as an auger pile is being driven in. A hollow stem with flights along a continuous length can have a casing or no casing. The hollow stem is driven into soil with spoils coming out of the soil to form a bore in the soil. Concrete or grout is pumped through the hollow stem and/or casing if present to fill a cavity or bore created during driving while the hollow stem with flights is being pulled out of the soil. A reinforcement cage can be cast in the freshly placed concrete. Thus, an auger pile typically has multiple flights and then is removed, or can be cast in place with the bore or hole that is formed during drilling being filled or grouted with concrete. Problems occur because pockets in the soil form due to water or air during drilling and a large amount of unnecessary concrete can be poured in as it fills up the pockets. If drilling to a total depth of about 100 feet (30.48 m), at about 6 to 8 feet (1.83-2.44 m) water and/or a void(s), resulting in pockets, may be hit. Heavy duty cranes or drilling rigs are for case auger drilling.
There is a need in the art for a system and method to drive into hard, sandy soils without requiring use of one or more helical piles or auger cast piles that remain in the ground and/or are grouted or filled with concrete.
The following Patents and Patent Application Publications are incorporated herein by reference:


		Issue Date
		MM/DD/
Patent No.	Title	YYYY

U.S. Pat. No. 3,797,259	Method for Insitu Anchoring Piling	Mar. 19, 1974
U.S. Pat. No. 4,462,716	Pile Driving	Jul. 31, 1984
U.S. Pat. No. 4,626,138	Non-Impacting Pile Driver	Dec. 2, 1986
U.S. Pat. No. 4,708,530	Concrete Foundation Pile a	Nov. 24, 1987
	nd Device for Driving the
	Same into the Ground
U.S. Pat. No. 4,911,581	Pre-Cast Concrete Pile and	Mar. 27, 1990
	Method and Apparatus for Its
	Introduction into the Ground
U.S. Pat. No. 5,137,394	Hollow Steel Pile, Manufacturing	Aug. 11, 1992
	Method and Pile Driving Method
U.S. Pat. No. 6,848,864	Interlocking Slab Leveling System	Feb. 1, 2005
U.S. Pat. No. 7,108,458	Interlocking Slab Leveling System	Sep. 19, 2006
U.S. Pat. No. 7,112,012	Piling Apparatus and Method	Sep. 26, 2006
	of Installation
U.S. Pat. No. 7,914,236	Screw Pile Substructure	Mar. 29, 2011
	Support System
U.S. Pat. No. 8,966,953	Method and Apparatus	Mar. 3, 2015
	for Measuring Helical Pile
	Installation Torque
U.S. Pat. No.	Corrugated Shell Bearing Piles	Jun. 9, 2020
10,676,888	and Installation Methods
U.S. D637,216S	Power Tool Adaptor for a Grease	May 3, 2011
	Fitting Cleaning Tool
U.S. 2007/0110521	Method and Apparatus for	May 17, 2007
	Installing a Helical Pile
U.S. 2022/0341118	Secant Concrete Shoring Using	Oct. 27, 2022
	Helical Piles for Depth
EP 3102741B1	Pile Insertion	Oct. 3, 2018

The following web pages are incorporated herein by reference thereto.

- (https://cementconcrete.org/category/geotechnical/)
- (https://www.davieshoring.com/lockport-shipyard/)

BRIEF SUMMARY OF THE INVENTION

The apparatus, system and method of the present invention solves the problems confronted in the art in a simple and straightforward manner. What is provided is a system and method of installing or driving an improved piling apparatus or system. The system and method of the present invention can be used in a wide variety of applications, including in new construction, e.g., using smaller residential type concrete pilings (e.g., about 6 to 8 inch (15.24-20.31 cm) diameter or width concrete pilings). The system and method of the present invention can also be used in commercial or industrial type applications in which larger diameter pilings (e.g., about 8 to 14 inch (20.32-35.56 cm) diameter or width concrete pilings) typically are preferred.
In preferred embodiments of the present invention, a helical tool (which may sometimes also be referred to herein as a helical screw pile or helical pile) can first be used in the system and method of the present invention to dig into soil, e.g., in harder or sandy type soils, where driving a concrete piling by itself is difficult, or sometimes does not work because the concrete piling stops driving or possibly can be damaged when being driven into the soil.
A preferred embodiment of a helical tool of the present invention can be manufactured to include a plurality of helices or flights of different sizes, e.g., three helices or flights of different sizes, with a bottommost flight having a smallest width or diameter, a middle flight having a larger diameter or width than the bottommost flight and a topmost flight having a largest diameter or width. Preferably, the helices or flights are double plated in thickness, at least along a portion of a flight. Each flight can be double plated, or one or more flights can be double plated.
Alternatively, a helical tool of the present invention can also be manufactured to include a plurality of flights, e.g., three flights, that have the same dimensions or substantially the same dimensions, one or more of which can be double plated in thickness at least along a portion of a flight. Each flight can be double plated, or one or more flights can be double plated.
In other embodiments, for example, a helical tool can be used that has three helices or flights of about the same diameter or dimensions and which are not double plated, e.g., an Almita brand helical tool can potentially be used.
Helical tools are typically made from steel and are expensive. A helical tool generally augers into the ground with a spinning motion. As mentioned, in prior art systems and methods, a helical tool remains in the ground and is typically filled or grouted in with concrete.
For example, in the prior art, when building foundations, one or more 8-inch (20.32cm) diameter concrete piles typically may be hammered or otherwise driven into the soil about 50 or 60 feet (15.24-18.29 m) or so. In harder or sandy soils, however, when hammering or driving in an 8-inch (20.32 cm) concrete pile, the piles stop driving as if they hit wall and possibly can be structurally damaged or compromise the piling. Thus, in the prior art, in sandy or harder soils, a helical tool is used instead of a typical concrete piling to drive into the harder soils.
A helical tool typically has a diameter of about 8 to 14 inches (20.32-35.65 cm) in the prior art. A helical tool in the prior art is filled or grouted with concrete in use as a building foundation. In a residential application, of the present invention, a helical tool used can have a diameter or width of about 4 to 10 inches (10.16-25.4 cm), or at least about 4 to 9 inches (10.16-22.86 cm) in diameter, and can have a length of about 6 to 20 feet (1.83-6.1 m), for example.
In a preferred embodiment for a residential application, when driving about 6-inch (15.24 cm) diameter or width concrete pilings through a bore of a helical tool, the helical tool preferably has a diameter of about 6 3/4 inch (17.15 cm) and is about 10 feet (3.05 m) long.
In one or more preferred embodiments of the present invention, a bore of a helical tool is not grouted or filled in place with concrete or other structural material so that one or more pilings can be driven through a bore of the helical tool.
In a preferred embodiment of the method of the present invention, a helical tool is used to start a pile driving process to drive a portion of an overall desired depth into soil and is not driven to a full desired depth that a piling chain or segmental piling will have. A helical tool can be driven into the soil until a desired torque or weight effect is reached, e.g., to about 8 to 10 feet (2.44-3.05 m), or to about 6 to 60 feet (1.83-18.29 m), using a helical pile auger type driving tool, such as one including a torque motor that can measure torque applied while driving the helical tool and rotate the helical tool during driving. Other helical driving tools that are commercially available can also be used if desired. Generally, a desired torque may be reached when the helical tool stops driving or a desired torque can be based on specifications provided by an engineer for the project, for example. In one embodiment, a helical tool can be driven into the soil until 20 kips (or 20,000 pounds-force) (or 20,000 pounds torque) (88,964.43 Newtons) is achieved. A helical tool driver may be coupled onto a tracked or wheeled excavator type vehicle (e.g., a BobCat brand tracked or wheeled vehicle having a boom can be used), which eliminates a need to use heavy cranes or drilling rig machinery in the system and method of the present invention. A helical tool driver can also be attached to a hydraulic power pack. The torque or resistance of force can be calculated with a helical tool driver while driving the helical tool into the ground.
A helical tool can include one or more helical flights, helices or helical plates on an exterior of the helical tool and include a central bore. Preferably a helical tool used in the present invention will have one or more flights that enable the helical tool to drive into the soil with no, or minimal, amounts of soil getting dug out and pushed or pulled onto the soil surface.
An upper portion of a helical tool can remain above a soil surface after driving of the helical tool is complete, e.g., about 4 to 24 inches (10.16-60.96 cm) above a soil surface. Preferably, enough of an upper portion of a helical tool remains above a soil surface to enable a pile driving tool or pile driver, e.g., a hydraulic pile driver, to be coupled to the helical tool. Other types of pile driving tools can also be used in the system and method of the present invention, if desired.
After driving the helical tool into the soil to a desired depth at which a desired torque is achieved, the helical tool driver can be removed from the helical tool. A pile driver, e.g., an hydraulic pile driver, can then be coupled to a portion of the helical tool that remains above the soil surface. A bracket or bolt type connector, for example, can be used to couple a hydraulic pile driver to the helical tool. The depth that a helical tool is driven to can be selected based on the torque or weight effect needed for the helical tool to be able to support a pile driver coupled to the helical tool, while the pile driver is used to drive piles through the central bore of the helical tool. A pile driver coupled to a helical tool can drive pilings or pile sections through the bore of the helical tool and to a depth into a soil mass below the helical tool.
Next, a piling, e.g., a concrete piling or a wood piling, can be driven through a central bore of the helical tool using the pile driver that is coupled to the helical tool and further into the soil mass below the helical tool. A piling driven through a bore of the helical tool can be a concrete piling having a diameter or width of about 6 to 14 inches (15.24-35.56 cm), for example, and of any desired length, e.g., about 6 inches (15.24 cm) to 20 feet (6.1 m) in length. A piling can be a concrete piling with a central bore. A piling can be a concrete piling with rebar. A piling used in the present invention can also be a PermaLock™ piling used by Davie Shoring, Inc. and developed by the present inventor as shown and described in U.S. Pat. Nos. 6,848,864 and 7,108,458, each of which are hereby incorporated herein by reference thereto.
A PermaLock™ piling, or a piling as shown in U.S. Pat. Nos. 6,848,864 and 7,108,458, can be round or substantially round, or can have a substantially rectangular shape or a square shape, or can have another desired block style shape. These pilings can be about 6 to 14 inches (15.24-35.56 cm) in diameter or width and about 6 inches (15.24 cm) to 3 feet (91.44 cm) in height. Preferably these pilings can be connected or locked together along a longitudinal axis, e.g., preferably along a central longitudinal axis, to form a piling chain or segmental piling of a desired overall height, e.g., of a desired height that is capable of supporting a structure to be built thereon. One or more rods along a central longitudinal axis of an overall piling chain length can be used as a coupler for piling sections and torqued while coupling piling sections together.
For residential applications, typically it is preferred to use a round piling or piling section that can have about a 6 to 8 inch (15.24-20.31 cm) diameter or width. After an overall piling chain length is reached and when finished driving the pilings or piling sections through the bore of the helical tool, the pile driver can be removed from the helical tool. The helical pile driving tool can be coupled back onto the helical tool and can be used to remove the helical tool from the soil mass. The helical tool can later be used again at another pile driving site for the same project or for other projects.
The present inventor previously developed a system where a pile driving tool/a pile driver can be coupled to a weighted truck to provide weight needed to drive piles, e.g., concrete pilings or piling sections, in residential areas, and reference is made to (https://www.davieshoring.com/lockport-shipyard/) for more information on this process. Using a weighted truck is beneficial because it is easier to bring a truck onsite in residential areas or in city blocks, for example, than a typical drilling rig or crane. A weighted truck can also be used during pile driving instead of needing to rely on the weight provided by a building foundation. As mentioned, a BobCat brand tracked or wheeled vehicle can also be used in one or more embodiments of the present invention.
In a preferred embodiment of the present invention, a helical tool is preferably driven into ground to a desired torque to provide the necessary weight and support for connecting a pile driving tool/a pile driver to the helical tool so that the pile driving tool/pile driver can then drive piles through a bore of the helical tool and further downward into a soil mass below the helical tool. The helical tool provides the static weight necessary for the pile driver to drive one or more piles further into a soil mass below the helical tool. Using a helical tool to provide the necessary static weight and resistance to drive other pilings through the bore of the helical tool and further downward into a soil mass is an important feature in the system and method of the present invention.
When driving the helical tool into the soil, preferably a user calculates the resistance of force, e.g., using a helical tool driver, to a desired torque. Preferably a helical tool driver includes a pressure gauge and measures pressure while driving. The helical pile system is preferred over using a prior art auger system because when driving a helical tool, the soil, at least for the most part, stays in the soil mass, and it is not pushed out during driving. When pile driving the other piles through the helical tool bore, this further stiffens up the soil because the driving causes the soil to be displaced downward and/or to pack around a pile and provide even more skin friction where the soil or mud “grabs” the outside of the piles or pilings.
In one or more preferred embodiments of the present invention, the system and method of the present invention is quiet and relatively quiet or silent, with very little vibration, which is important in residential areas or in areas with other buildings nearby, e.g., to prevent structural damage in nearby structures.
In one or more preferred embodiments of the present invention, the system and method of the present invention provide benefits of no or minimal noise, no or minimal vibration, and no or minimal contamination, e.g., where soil matter is not brought up to a soil surface but at least substantially remains within the soil mass.
In a preferred embodiment of the present invention, a helical tool can be driven in and pinned or capped off, e.g., to prevent soil from entering its bore. Then it can be driven in further so dirt doesn't get inside it.
In one embodiment, for a piling chain of about 25 tons (22.68 metric tons), with an 8-inch (20.32 cm) diameter (or approximately 8-inch (20.32 cm) diameter, for example), about a 20 to 60 feet (6.1-18.29m) depth for the helical tool is reached to get torque needed to act as a suitable weight for the concrete pile driver that drives pile sections through the bore of a helical pile.
In another embodiment, less than about an eleven foot (3.25 m) depth is reached when driving the helical tool, e.g., when driving a 10 to 11 foot (3.05-3.35 m) long helical tool into the soil mass.
In one or more preferred embodiments of a helical tool, a helical tool has a bore that can receive a piling of a desired width, e.g., a bore that can receive about a 6-inch (15.24 cm) diameter or width piles to be driven therethrough. If about 6-inch (15.24 cm) diameter or width pilings will be used, the bore of the helical tool can be about 6.5 to 7 inches (16.51-17.78 cm) in diameter or width, for example, and preferably about 6¾ inches (17.15 cm) in diameter or width.
In one preferred embodiment of a residential application, an 11-foot (3.35 m) long helical tool or casing that has about a 6 to 7 (15.24-17.78 cm), or 6 and ¾ inch (17.15 cm) inside diameter bore can be used. The helical tool can be made of steel, for example. Prior to driving the helical tool into the soil, the bore of the helical tool is filled with a chain of pile sections, each pile section can be about six inches (15.24 cm) wide by about one foot (30.48 cm) tall, for example.
First a chain of pile sections are connected or interlocked together. Each pile section can have a bore capable of receiving a rod, e.g., a threaded rod. Each rod can be about 12 inches (30.48 cm) when using a piling that has a longitudinal length of 1 foot (30.48 cm) or less. The rod can be placed inside the bore of a bottommost piling section with a portion of the rod extending outside the piling section. A fastener, e.g., a nut, can be screwed onto the rod portion externally extending out of the pile section. A second rod can be coupled with the fastener, e.g., a nut. This second rod then can be pushed through the bore of a second concrete pile section so that a portion of the second rod extends externally to the second pile section. This process can be repeated until a desired length chain is reached, e.g., about a 10-foot (3.05 m) pile chain length is reached if a ten to eleven foot (3.05-3.35 m) helical tool is being used. Between adding each pile section a fastener, e.g., a nut and rod can be torqued down. Alternatively, pile sections with rod connectors already embedded within the pile section can also be used, e.g., as later described and shown herein.
The pile chain can then be pushed into the bore of the helical tool. A portion of the bottommost pile section can extend below and be external to the bottom of the helical tool.
A helical tool driver can then be connected to an upper end of the helical tool, e.g., with a bolted connection or with another desired coupler. The helical tool driver can include a bottom plate having a bore that is capable of receiving a rod extending from the uppermost part of the pile chain.
The helical tool filled with the piling chain can then be picked up, e.g., by an arm or boom of a tracked vehicle, and the helical tool, filled with the piling chain, can be driven into a soil mass until the helical tool stops driving or until a desired torque is reached. Preferably enough of an upper portion of the helical tool remains above the soil mass to enable coupling a pile driver to the helical tool.
Next, the helical tool driver is removed from the helical tool. A pile driver can then be coupled to the helical tool. The pile chain positioned within the helical tool bore can then be added to and driven further into the soil mass through the helical tool bore. New pile sections are added in a same or similar method as described above when constructing the first portion of the pile chain. After each new pile section is added, the pile driver that is connected to the helical tool can be used to push the pile chain further into the soil below the helical tool.
The helical tool can be driven into the soil mass until proper torque required for a job is reached, e.g., about 10,000 lbs of pressure (68,948 kPA) when a 10-ton (9.07 metric ton) piling chain is desired. Typically, the helical tool simply stops driving and this is an indicator that a necessary torque is reached. If a helical tool doesn't stop, additional helical tool sections can be added and driven downward until a correct pressure is reached. Helical tool sections can be coupled together with a bolted connection for example. Once driving stops, cylinders (e.g., hydraulic) connected to a helical tool driver head, for example, can be disconnected, e.g., unbolted, and then the helical tool driver can be disconnected from the helical tool and taken off.
Next a pile driver (sometimes referred to as a pressing tool) can be connected to the helical tool. A new pile or piling section can be coupled to the uppermost pile or piling section of the pile or piling chain in the bore of the helical tool. Using friction and with the helices or flights of the helical tool grabbing adjacent soil, it is easier to press the piling chain into the soil than it would be if the helical tool was not used in the process. This enables easily pressing concrete piles into sandy or hard soils, for example. At the beginning of pressing pilings through the bore, pressure measured may be about 1000 psi (6,895 kPa), for example, then pressure may increase to about 1200 psi (8,274 kPa), for example, as more pilings are driven. Using the gauge on the pile driver provides information about what the resistance is to allow knowing when a desired ton capacity for the chain is reached. For example, when resistance on the piling chain is about 2000 psi (13,790 kPa) as shown on a pressure gauge of the pile driver, this provides information that about a 10-ton (9.07 metric ton) piling chain has been driven. When resistance on the piling chain is about 2500 psi (17,237 kPa), this provides information that about a 12.5 ton (11.35 metric ton) piling chain has been driven.
After pressing all the piling sections in and a desired overall length piling chain is driven, (e.g., about 30 feet (9.14 m) long), the pile driver can be disconnected from the helical tool. The helical tool driver can then be connected back onto the helical tool. The helical tool can be removed or unscrewed from the soil mass using the helical tool driver. The piling chain, e.g., which can be about 20 to 50 feet (6.1-15.24 m) long, for example, remains in the ground although the helical tool is removed from the ground.
In preferred embodiments, a pile driver is coupled to the helical tool when driving pilings through a bore of the helical tool. Optionally, a pile driver does not have to be coupled to the helical tool but can be coupled to a tracked vehicle, e.g., a BobCat brand tracked vehicle, or weighted truck or other desired device, vehicle, or structure providing enough weight and resistance for the pile driver to function to drive pilings through the bore of the helical tool. Attaching a pile driver to the helical tool, however, is preferred, for example, to limit machinery and equipment needed on site while pile driving.
In general, no cap or plate on the bottom of helical tool is needed when driving with pilings inside or without pilings inside the bore. It generally doesn't affect the process much if soil is present in the bore of a helical tool. If soil gets in and packed in tight in the helical tool, the soil pushes against the helical tool and can get packed in the bore around the piling chain. When the helical tool is removed from the soil, no or little soil comes to a ground surface.
When driving the piling chain through the bore of a helical tool, if the piling chain doesn't stop, additional pilings can be added through the bore until the piling chain stops driving or until desired torque is reached.
Various driver heads or types of drivers can be used. Driver head pressure and pressure from a pressing tool is determined per job and per engineering recommendations based on the type of soil, for example.
In the prior art, generally for piling jobs, an engineer calculates chain specifications, including length of the chain or piling and torque needed based on one location of land on a job site. However, on a given project site the soil may vary in different locations of the same site. As an example, the Morgan City Welcome Center project in Louisiana encountered several issues. As custom in the prior art, an engineer had specified that certain sized concrete pilings be driven to a certain depth based on soil tested on the property as meeting the required torque needs. But the calculations didn't take into account that parts of the property used to be swamp land and had different soil composition. Contractors did the job to specifications, and it ended up that each piling or piling chain didn't seem to be holding right or to be at the right pressure and the building began to sink. It ended up costing millions in extra materials to fix the overall lengths of the individual piling chains needed based on the different types of soils on the project site.
An advantage of the present invention is that every single piling or piling chain can be tested to its exact pressure when driving each piling chain, and the process also eliminates or greatly lessens friction on piling for the casing. For a particular job, each piling chain can be driven until the engineer tonnage specification is reached with actual tonnage of each chain known. Pressing can be continued until the piling chain reaches desired tonnage or pressure that the engineer is asking for, that is calculated to force, regardless of the length of the chain, given that not all piling chains for one job site need to be the same length to have the necessary tonnage depending on soil composition differences where each chain is driven.
Under prior art methods, each piling chain may be driven to the engineer specified length that met tonnage requirements at a specific location, but each chain is not tested for pressure, so length in one location may have accurate pressure but that same length in another location may not have the accurate pressure.
Under one or more preferred embodiments of the present invention, it is known with specificity during the driving process whether a piling chain may need to be driven further beyond the engineer's length if the desired torque or pressure is not reached yet. Under preferred embodiments of the present invention, the actual force each pile is withstanding as it is being driven into the soil is known and each pile chain is tested to a capacity of weight.
In the muck and mud, under the present invention, once a piling chain sets up for a day or two, everything gets locked and set in the soil and a piling chain then potentially can exponentially hold more than original recorded pressures.
By driving an eleven foot (3.35 m) helical tool in first, for example, the process of the present invention can eliminate about 11 feet (3.35 m) of friction for the overall piling chain. Lessening friction for about the distance of a helical casing or tool, helps driving in sandy or harder soils. An important feature of the present invention is eliminating friction for about the distance that the helical tool is driven into the soil.
For some commercial embodiments, the same process can be utilized but preferably larger diameter pilings are used, e.g., about 12-inch (30.48 cm) diameter (or cross-sectional or lateral width) pilings, or about 10 to 20 inch (25.4-50.8 cm) diameter (or cross-sectional or lateral width) pilings. A larger diameter helical casing or tool can be selected in these embodiments to accommodate a larger diameter piling to be pushed into the soil through the helical casing or tool.
A preferred embodiment of a piling chain of the present invention, e.g., which can be beneficial for use in commercial applications, can include sections that are cast or otherwise manufactured, that can be about 5 to 20 feet (1.52-6.1 m) long and about 8 to 48 inches (20.31 cm-1.22 m) wide. If desired, the sections can also be shorter than about 5 feet (1.52 m). Starter sections having a shorter length are preferably use to start the piling chain used, e.g., 6 inches (15.24 cm) to 10 feet (3.05 m).
To form a piling section, a piling outer tube can be cast using concrete or other structural fill material. A piling outer tube can also be of another material if desired, but for cost efficiency, a concrete outer tube has necessary strength for the intended purpose of this piling chain.
An inner tube having a bore, e.g., a metallic tube or a grout tube with ribs or corrugations, can be positioned, and later cast, about centrally in a bore of the piling outer tube. An inner tube can also be made of another desired material, e.g., a composite or strong plastic material, but preferably concrete or other flowable structural material that can set is able to easily adhere to inner and outer surfaces of the inner tube to encase and cast the inner tube in place. The inner tube can have ribs or corrugations on an interior surface and/or on an exterior surface, which concrete or other desired structural material can adhere to. An inner tube preferably can have a diameter of about 6 inches. An inner tube can also have a diameter of about 4 inches (10.16 cm) to about 8 inches (20.32 cm).
A bar or rod can be positioned, and later integrally cast about centrally, within a bore of the grout tube. For some preferred embodiments using a nut or coupling nut connector, preferably the bar or rod includes exterior threads enabling attachment to a coupler, and preferably the exterior threads are coarse. Concrete or other desired structural material can also adhere to and between the threads during a casting process. The bar or rod can be a rod sold under the brand name Dayton, e.g., a Dayton 25-B rod.
The bar or rod can also be hollow. The bar or rod can be useful to help align pile sections and to be a part of a connection between pile sections. In some embodiments that include a hollow rod with an internal bore along the length of the rod, pressurized water can be flowed through, or blasted through the hollow rod and out the bottom of a piling chain during the driving process to help blast away sand and clay or other harder soils while pile driving. A bar or rod of an upper most pile section can also be used for tension uplift during pile driving.
For a pile chain using piling sections having an inner tube, e.g., a grout tube, preferably a starter pile is a first pile section to start the chain, which can be shorter than other pile sections in the chain and which can have a shape that is different from other pile sections. A starter pile can include a grout tube if desired. A starter pile can include a guide portion if desired. A starter pile can be manufactured without a grout tube. A starter pile can be manufactured without a guide portion. A starter pile can be narrower in width than other pile sections. A hollow bar or rod can extend outside a bottom of a starter pile through which pressurized water, e.g., at 1000 psi (6,895 kPa) or less), can be flowed to help blast away soil during pile driving. A connector, e.g., a nut, can be tightened and/or torqued down on a rod that extends outside of a bottom of a starter pile section, after the pile section is cast, for providing additional tension or uplift during pile driving
For other pile sections that will be used to form a piling chain including an inner tube, e.g., a grout tube, the pile sections can have a longer longitudinal length than the starter pile section and can be wider than a starter section. A guide or guide portion that includes a central tube or a central opening that can be in the shape of a circle or other desired shape having a bore to accommodate a rod or bar, can be positioned at upper and lower portions of an inner tube. A rod can be made from steel, copper, aluminum or other structural material as desired. Preferably a rod or bar has external threads at least at upper and lower ends. A rod or bar can provide some structural support to the piling. A inner tube can have slits or cutouts or notches receptive of one or more plates or support arms of the guide, e.g., four slits or cutouts at upper and lower ends of the inner tube, to accommodate four plates that can extend laterally outward from the central tube or opening of the guide, e.g., with the plates forming the shape of a cross or an “X”. A central tube can preferably be about 1 to 2 inches (2.54-5.08 cm) wide, e.g., about 1.38 inches (3.51 cm) wide to receive a bar or rod and possibly accommodate a fastener, and can be about 2 to 4 inches (5.08-10.16 cm) long, for example. The sizing of the central tube or opening can be selected based on dimensions of the bar or rod used which can be positioned in the central tube or opening. A guide can include 2 plates 523 if desired. A guide can include 3 plates 523 if desired. A guide can include more than 4 plates if desired. A guide can be formed using a metallic material or other desired material of similar strength, e.g., steel or steal coated with a marine grade primer). Plates or arms of a guide can be welded to the central tube when metal is used.
Plates 523 can preferably be closer to a wall 533, e.g., as shown in FIG. 36 , e.g., extending to about 1 inch (2.54 cm) before a wall 533. An end of a plate 523 can also be further from a wall 533, e.g., as shown in other figures.
During manufacture of a pile section including a grout tube and guide portion, plates of a guide can be partially embedded in concrete between an exterior surface of the inner tube and an interior surface of the outer piling tube wall. A guide can be further embedded in concrete during installation of the pile section and/or during pile driving a piling chain when concrete or other structural material that can set, is poured into an interior of a grout tube bore.
An inner tube, e.g., a grout tube, used in one or more embodiments of a pile section of the present invention can be a miniature or smaller galvanized tube with spiral threads on an exterior surface.
An inner tube, e.g., a grout tube, in one or more embodiments of a pile section of the present invention can be a miniature or smaller galvanized tube with spiral threads on an exterior surface and an interior surface.
Use of an inner tube, e.g., a grout tube, within a larger diameter outer piling tube or wall can provide strength and rigidity to a wider diameter piling.
In some embodiments of a piling chain with an inner tube, e.g., a grout tube, pile sections that are about 10 feet (3.05 m) or longer can be used. At the top and bottom of every concrete section a guide can be present, e.g., one or more plates, e.g., ¼ inch (6.35 mm) wide plates standing upright with a bore or tube in the middle of the one or more plates. The guides help to keep the rod or bar centered in the pile section and enables tightening and torqueing down on the rod during installation, e.g., with use of a nut or a coupling nut and optionally a washer.
The apparatus, systems and methods of the present invention are advantageous over the prior art because driving can be done hydraulically with no or minimal vibration, no or minimal noise or pounding, and no or minimal contamination (e.g., removing unknown soil).
In some preferred embodiments, a guide portion can be present on just one end, e.g., in shorter piling section embodiments, e.g., 6 inches (15.24 cm) to 4 feet (121.92 cm).

BRIEF DESCRIPTION OF THE SEVERAL VIEW OF THE DRAWINGS

For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote the like elements and wherein:
FIG. 1 is a front view of a first preferred embodiment of a helical tool of the present invention;
FIG. 2 illustrates a step in a first preferred embodiment of the system and method of the present invention illustrating driving a helical tool of FIG. 1 into a soil mass;
FIG. 3 is cutaway view illustrating a helical tool of FIG. 1 after the helical tool is driven into a soil mass;
FIG. 4 illustrates another step in the first preferred embodiment of the system and method of the present invention of driving piling segments or sections through a bore of the helical tool into a soil mass;
FIG. 5 illustrates another step in the first preferred embodiment of the system and method of the present invention illustrating driving of additional pile segments or sections through a bore of the helical tool into a soil mass;
FIG. 6 illustrates another step in the first preferred embodiment of the system and method of the present invention, illustrating removal of the helical tool from the soil mass when pile driving is complete;
FIG. 7 illustrates an alternative type of piling with an exoskeleton that can be driven through a bore of a helical tool in the present invention;
FIG. 8 illustrates that alternatively more than one type of piling can be driven through a bore of a helical tool in the present invention;
FIG. 9 illustrates that alternatively a longer length piling can be driven through a bore of a helical tool in the present invention;
FIG. 10 is a cutaway view of an example piling segment or section, including a first embodiment of an interlocking unit, that can be driven through a bore of a helical tool in one or more preferred embodiments of the system and method of the present invention;
FIG. 11 is a cutaway, exploded view illustrating a connection of one piling segment or section to another piling segment or section, prior to driving in one or more preferred embodiments of the system and method of the present invention;
FIGS. 12-17 illustrate an alternative type of piling with an exoskeleton that can be driven through a bore of a helical tool in one or more preferred embodiments of the present invention;
FIG. 18 illustrates coupling of one type of piling segment or section to another type of piling segment or section to create a chain with different types of pilings that can be driven through a bore of a helical tool in one or more preferred embodiments of the present invention;
FIGS. 19-20 illustrate a second preferred embodiment of a connector or interlocking unit for a piling section that can be included in one or more preferred embodiments of the present invention;
FIGS. 21-22 illustrates a third preferred embodiment of a connector or interlocking unit for a piling section that can be included in one or more preferred embodiments of the present invention;
FIG. 23 illustrates a second preferred embodiment of a helical tool of the present invention, and a first step in a second preferred embodiment of the system and method of the present invention;
FIG. 24 is a sectional view taken along lines 24-24 of FIG. 23 ;
FIG. 25 illustrates another step in the second preferred embodiment of the system and method of the present invention;
FIG. 26 illustrates another step in the second preferred embodiment of the system and method of the present invention;
FIG. 27 is a perspective, cutaway view of the second preferred embodiment of a helical tool of the present invention;
FIG. 28 is a partial detail view of the second preferred embodiment of a helical tool of the present invention;
FIG. 29 is a perspective view of a helical tool driver that can be used in one or more preferred embodiments of the present invention;
FIG. 30 is an exploded view illustrating a connector and the helical tool driver of FIG. 29 ;
FIG. 31 is a perspective view of the connector and helical tool driver shown in FIG. 30 ;
FIG. 32 is a perspective view of one embodiment of a pile driver that can be used in one or more preferred embodiments of the present invention;
FIG. 33 is a perspective view of another embodiment of a pile driver that can be used in one or more preferred embodiments of the present invention.
FIG. 34 illustrates an exploded view of a preferred embodiment of a piling chain of the present invention;
FIG. 35 is a sectional view taken along lines 35-35 of the piling chain shown in FIG. 34 and illustrates a first preferred embodiment of a starter piling section;
FIG. 36 is a sectional view of a preferred embodiment of a piling chain of the present invention illustrating a second preferred embodiment of a starter piling section;
FIG. 37 is a sectional view taken along lines 37-37 of FIG. 35 of the piling chain shown in FIG. 35 ;
FIG. 38 is a sectional view of a preferred embodiment of a piling section that can be used in the piling chain shown in FIG. 34 ;
FIG. 39 is a top view of a preferred embodiment of a guide of the present invention;
FIG. 40 is a side view of a preferred embodiment of a guide of the present invention;
FIG. 41 is a sectional view of a second preferred embodiment of a starter pile section of the present invention;
FIG. 42 is a sectional view of a preferred embodiment of a pile section of the present invention;
FIG. 43 illustrates a preferred embodiment of a piling chain of the present invention within a helical tool of the present invention during pile driving;
FIG. 44 illustrates a sectional view of a third preferred embodiment of a starter pile section of the present invention;
FIG. 45 illustrates a sectional view of a fourth preferred embodiment of a starter pile section of the present invention;
FIG. 46 illustrates a top view of a preferred embodiment of a tube or grout tube of the present invention;
FIG. 47 illustrates a top view of a preferred embodiment of a piling section of the present invention including a tube or grout tube;
FIG. 48 illustrates a top view of a preferred embodiment of a piling section of the present invention including a tube or grout tube and a guide;
FIG. 49 illustrates a sectional view of a preferred embodiment of a piling chain of the present invention;
FIG. 50 illustrates a method step in a preferred embodiment of pile driving a piling chain as shown in FIG. 49 ;
FIG. 51 is a top view of a preferred embodiment of a guide of the present invention; FIG. 52 is a side view of a preferred embodiment of a guide of the present invention; and
FIG. 53 illustrates a method step in a preferred embodiment of pile driving a piling chain.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-6 illustrate a first preferred embodiment of the apparatus, system and method of the present invention. FIGS. 23-28 illustrate a second preferred embodiment of the apparatus, system and method of the present invention. FIGS. 7-22 illustrate alternative preferred embodiments of the present invention of pilings or piling sections, and alternative embodiments of couplers for pilings or piling sections, that can be used in the first and/or second preferred embodiments of the apparatus, system and method of the present invention. FIGS. 29-31 illustrate a third preferred embodiment of an apparatus of the present invention which is sometimes referred to herein as a helical tool driver and connector of the present invention, e.g., as shown in use in FIGS. 23-26 . FIGS. 32-33 optional embodiments for a pile driver that can be used in the first and second preferred embodiments of the system and method of the present invention. FIGS. 34-50 illustrate additional preferred embodiments of apparatuses, systems, and methods of the present invention, with a piling chain designated generally herein by the numeral 500 and which may sometimes be referred to herein as a piling chain 500. A piling chain 500 as illustrated can be used with the first and/or second preferred embodiments of the apparatus, system and method of the present invention.
FIGS. 1-6 and 23-28 illustrate alternative embodiments of the apparatus of the present invention, designated generally by the numerals 10, 70 and sometimes referred to herein as helical tools or helical piles 10, 70. Helical tools or helical piles 10, 70 can be used in one or more preferred embodiments of the system and method of the present invention. A helical pile 10, 70 can include a wall or shaft 49 having outer or exterior surface 46 and bore 13. Wall 49 surrounds bore 13. Bore 13 can be open ended or closed ended at its lower end or lower portion 75 with a plate or cap 63 (see, e.g., FIG. 3 ). Lower end 75 of pile 10, 70 can be tapered if desired as shown in FIGS. 1, 2 , or not tapered as shown in FIGS. 3, 23 .
If bore 13 is closed ended or capped off with a plate or cap 63, then no or minimal soil can be present in bore 13 during and after driving helical tool 10 or 70 into a soil mass. When bore 13 is not closed off at a lower end 75, e.g., as shown in FIGS. 7-9 , some soil can be present inside bore 13 during and after driving helical pile 10 or 70 into a soil mass.
An upper portion 56 of helical pile 10, 70 can also be capped or closed off (not shown) with a plate or cap 63 if desired while driving helical pile 10, 70 into a soil mass.
A piling or piling section or segment 20, 30, 40, 400, 501, 502 for example, can already be inside bore 13 while helical tool 10, 70 is being driven into a soil mass (see e.g., second preferred embodiment shown in FIGS. 23-26 ), or helical tool 10, 70 can be driven into soil mass 16 with bore 13 being empty (see, e.g., see first preferred embodiment shown in FIGS. 2-4 ).
One or more flights or helices 11 can be on exterior surface 46 of wall 49 of a helical tool 10, 70. In the embodiments as shown in the figures three helices or flights 11 are present and spaced apart along wall 49. As illustrated with regard to helical tool 10, all flights or helices 11 can have the same or substantially the same size and dimensions. In a current most preferred embodiment as shown in FIG. 24 , for example, a helical tool 70 includes three helices or flights 11 having different sizes and dimensions with a bottommost flight 11 being the smallest in width, the middle flight 11 being wider and larger than the bottommost flight 11 and uppermost flight 11 being the widest and largest. Although three helices or flights 11 are shown in the figures, fewer or more helices or flights can be on a helical tool 10, 70 if desired.
Preferably at least a portion of a flight 11 is thicker than what is generally in a prior art helical pile, e.g., preferably a flight 11 is at least about 0.5 to 1 inch (1.27-2.54 cm) thick, or at least about 0.4 to 2 inches (1.02-5.08 cm) thick. To form a flight 11, two plates 76, 77 can be welded together, for example, as shown in detail view in FIGS. 27 and 28 , e.g., two plates that are each about 0.5 inches (1.27 cm) can be welded together to form a flight 11 having a thickness of about 1 inch (2.54 cm) at least along a portion of flight 11. As shown in the figures, an upper plate 76 can be welded to a lower plate 77 to form a flight 11. Upper plate 76 can be smaller in width than lower plate 77 but does not have to be. A flight 11 can be coupled to the exterior surface 46 of shaft or wall 49 of a helical tool 10, 70, e.g., via welding.
Alternatively, a flight 11 can be a single plate of a desired thickness, e.g. about 0.5 to 2 inches (1.27-5.08 cm) thick, and can be coupled to the exterior surface 46 of shaft or wall 49 of a helical tool 10, 70, e.g., via welding.
As shown in the embodiment of a helical tool 10 in FIGS. 1 and 2 , one or more openings or holes 62 can be present in wall 49 at upper portion 56 of helical pile 10 to enable connecting helical pile 10 to a helical tool driver 14, e.g., a driving tool that can rotate or turn helical pile 10 into soil mass 16 (e.g., a Digga brand helical tool driver can be used).
An alternative connector is shown with regard to helical tool 70 in FIGS. 23-28 . Optionally, one or more openings or holes 62 can be included on a helical tool 70 if desired. Preferably openings or holes 62 can also be used to connect or couple a helical tool 10, 70 to a pile driver 23 if desired.
An example of a helical tool driver 14 is illustrated in FIG. 29 , wherein when used with helical tool 10 the helical tool driver 14 can be coupled to helical tool 10 using fastener 96, which can be a bolt, at middle portion 84 of helical tool driver 14 to connect to helical tool 10 at one hole or opening 62. A hole or opening 62 can be included on opposing sides of a helical tool 10, 70. Hole or opening 98 can be included on opposing sides of a helical tool driver 14 at middle portion 84. Holes or openings 98 of a helical tool driver 14 can align with holes or openings 62 of helical tool 10, 70 and a fastener 96 can be position through aligned holes or openings 62, 98 and can be tightened, for example.
As illustrated with regards to helical tool 70, instead of using holes or openings 62, an alternative coupler or connector 71 for a helical tool driver is shown in FIGS. 24, 27 . A coupler or connector 71 can be manufactured as an integral part of a helical pile 10, 70 if desired, or can be retrofitted on a helical tool 10, 70. Coupler 71 can be a round or circular plate having a plurality of spaced apart openings 72 able to receive a fastener 73, e.g., a bolt. Coupler 71 and openings or holes 72 can be positioned around bore 13 of helical tool 70 at upper portion 56 of helical tool 70. A connector 71 can enable helical tool 70 to be coupled to a helical tool driver 14. A connector 71 can also enable helical tool 70 to be coupled to a pile driver 23.
Preferably a helical tool driver 14 that can be used in one or more embodiments of the present invention is able to measure and/or calculate torque while helical pile 10, 70 is being driven into soil mass 16. Preferably a pile driver 23 that can be used in one or more embodiments of the present invention is also able to measure and/or calculate torque while driving pile or piling sections 20, 30, 40, 400, 501, 502 into soil mass 16.
FIG. 30 illustrates a connector or coupler 80 that can be fitted onto lower portion 67 of a helical tool driver 14 as shown in FIGS. 29-31 , e.g., using one or more fasteners 96. Lower portion 67 can be retrofitted onto a helical tool driver 14 if necessary to enable connecting with connector 80. One or more holes or openings 95, that can be receptive of a fastener 96, can be included on lower portion 67. If two openings 95 are present, the openings 95 can be on opposing sides of lower portion 67, for example.
Coupler 80 preferably includes a plate 81 with a plurality of openings or holes 83. Plate 81 preferably is adapted so that openings or holes 83 of plate 81 can align with openings 72 of coupler 71 on a helical tool 10, 70. A body 82 having a bore 97 can extend upward from plate 81 and can be positioned about centrally on plate 81, e.g., coupled via welding or other desired connection. Body 82 has a bore 97 that preferably is sized to accommodate and receive lower portion 67 of helical tool driver 14 so that an opening 95 of lower portion 67 can align with opening 99 of body 82, and a fastener 96 can be positioned in openings 95, 99 and tightened, for example. This is shown in exploded view in FIG. 30 . Body 82 can be of any desired shaped, e.g., rectangular or substantially rectangular as shown, or it can be round or circular if desired. Lower portion 67 of helical tool 14 can also be of any desired shape that can be received by bore 97 of connector 80.
Connector 71 can be coupled to a helical tool driver 14 using coupler 80, e.g., wherein the plurality of openings 72 and 83 are aligned and able to receive a fastener 73, e.g., a bolt, that can extend through the aligned openings 72 and 83 and be tightened, for example, to removably secure coupler 80 to coupler 71. As an example, eight openings 72 and 83 can be included with eight fasteners 73, e.g., bolts (see, e.g., FIGS. 23, 27, 31 ). More or less openings 72, 83 can be included as desired, with the number chosen enabling a secure connection of couplers 71, 80.
FIG. 2 illustrates a first step in a first preferred embodiment of the system and method of the present invention of driving a helical tool 10 into soil or soil mass 16. A helical tool driver 14 can be connected to helical tool 10 at openings 62 on helical tool 10 and can also be coupled to a tracked vehicle 15, e.g., a Bobcat brand tracked vehicle, having tracks or wheels 54 and boom 60. Helical tool driver 14 can also be coupled to a truck, e.g., a weighted truck, or to a typical crane or pile driving rig, or to another structure or device if desired that enables helical tool driver 14 to complete the driving process. Use of a smaller tracked vehicle 15, such as a Bobcat brand tracked vehicle, is preferred because it minimizes the footprint of equipment needed at a jobsite, which is especially advantageous in residential areas or cities with other buildings or structures nearby.
As illustrated in FIG. 2 , a helical tool driver 14 mounted on boom 60 turns or spins helical pile 10, e.g., in the direction of arrows 18 into soil mass 16 with no, or with at least minimal, upward soil displacement to a soil surface 55. Helical tool 10 is driven downward in the direction of arrow 17 while being rotated (arrows 18). Helical tool 10 can be driven to a desired depth, e.g., to about 10 to 60 feet (3.05-18.29 m). Preferably a helical tool 10 is driven to a depth that penetrates harder or sandy soil layers. Preferably a helical tool 10 is driven to a depth so that it can support and provide the necessary weight effect for a pile driver 23, that can later be connected to helical tool 10 (see, e.g., FIG. 4 ) to be able to drive one or more piles or pilings, e.g., piles or pilings 20, 30, 40, 400, 501, 502 through bore 13 of helical tool 10.
FIG. 3 is cutaway view illustrating helical tool 10 after helical tool 10 is driven into soil mass 16 in one embodiment of the system and method of the present invention. When driving of helical tool 10 is complete, helical tool driver 14 can be uncoupled from helical tool 10 and tracked vehicle 15 can be removed, e.g., temporarily, from the pile driving location. As shown in FIGS. 3-4 , preferably an upper portion 56 of helical pile 10, including openings 62 (or coupler 71 if used instead), remains above soil surface 55 of soil mass 16 so that a pile driver 23 can be coupled to helical tool 10.
Referring to FIG. 4 , after helical tool driver 14 is removed from helical tool 10, a helical pile driver 23 can be coupled to helical tool 10, e.g., via openings 62 and a connector 12. A connector 12 can be coupled to helical tool 10 using a fastener that can be the same type of fastener 96, for example, e.g., a bolted connection. Preferably connector 12 is adapted to couple a pile driver 23, which can be a hydraulic pile driver, to helical tool 10. A connector 12 can be an integral part of a pile driver 23, or retrofitted on a pile driver 23, or a separate connector able to be removably coupled to both helical tool 10 and pile driver 23. One or more arms or supports 24 can be included that extend between connector 12 and pile driver 23, e.g., arms or supports 24 can be coupled to both connector 12 and pile driver 23.
In one embodiment, a connector 12 can be used to couple both a helical tool driver 14 and a pile driver 23 to a helical tool 10 if desired, e.g., with bolted connections, for example. A connector 12 can also be adapted to hook into existing holes or openings 62 on helical tool 10 and then to also be coupled to a helical tool driver 14 or pile driver 23.
Openings 62 can be included on either a helical tool 10 or 70. A coupler 71 can also be included on either a helical tool 10 or 70. As mentioned, a connector 12 for a pile driver 23 can be the same connector used to connect to a helical tool 14 or can be a different connector that is also adapted to connect at openings 62.
In FIG. 3 , helical tool 10 is preferably driven to a depth and torque that enables helical tool 10 to support and provide the necessary counterweight effect for pile driver 23 to drive one or more pilings 20, 30, 40, 400 into soil mass 16 through bore 13 of helical tool 10 when pile driver 23 is coupled to helical tool 10. This depth is represented by arrow 91 in FIG. 5 . Helical tool 10 can also be driven to a depth that penetrates a harder or sandy soil layer.
Pile or piling sections driven through bore 13 can be a desired type of pile or piling, some embodiments of which are shown herein as piling or pile sections 20, 30, 40, 400, 501, 502.
Pilings or piling segments/sections 20 or 400 can be of a type disclosed in U.S. Pat. Nos. 6,848,864 and 7,108,458 of the same inventor, which are hereby incorporated herein by reference thereto. FIGS. 10, 11, 21 and 22 illustrate sectional views of different embodiments of pilings or piling segments 20, 400 that can be driven through bore 13 of helical tool 10.
Driving a piling 30 through bore 13 is illustrated in FIGS. 7-8 , and piling 30 can be a piling with an exoskeleton 36. Driving a piling 40 through a bore 13 is illustrated in FIG. 9 , and this can be a longer e.g., 5 to 20 foot (1.52-6.1 m) piling, e.g., a wood or concrete piling. A piling 20, 30, 40, 400, 501, 502 can be a smaller width or diameter piling, e.g., for use in residential construction or projects, e.g., about 3 to 11 inches (7.62-27.94 cm) wide. A piling 20, 30, 40, 400, 501, 502 can be a larger width or diameter piling, e.g., for use in commercial construction or projects, e.g., about 12 to 20 inches (30.48-50.8 cm) wide, or about 8 to 24 inches (20.32-60.96 cm) wide.
FIG. 4 illustrates another step in a preferred embodiment of the method of the present invention of driving pilings/piling segments or sections 20 or 400 through bore 13 of helical tool 10 into soil mass 16, as illustrated by arrows 19.
If a bottom of helical pile 10 has a cap 63 or is closed off, preferably it is strong enough to remain in place while driving helical tool 10 into soil mass 16 but can be easily displaced when a piling 20, 30, 40, 400 is driven through bore 13 and further downward into soil mass 16 below bore 13 and below lower portion 75 of helical tool 10. A cap can be tack welded onto a bottom of helical pile 10, for example, and can be a thin metallic material, that can be pushed downward and off helical tool 10 by a piling segment 20, 30, 40, 400, for example, during driving.
FIGS. 10 and 11 illustrate one embodiment of a piling or piling segment/section that is designated by the numeral 20 and how a piling or piling segment/section 20 can be coupled to another piling or piling segment/section 20 with an interlocking unit or coupler 64. Under the method step shown in FIG. 4 , a first piling segment 20, for example, can be driven downward in the direction of arrows 19 (see FIG. 4 ) into soil mass 16 with rod or central longitudinal support 21 at end 57 and coil or connector 22 at end 58 of piling segment 20. Then a rod or central longitudinal support 21 of another piling section 20 can be placed in bore 29, e.g., in the direction of arrows 48 (see FIG. 11 ), of coil or connector 22 of the first piling segment 20 and turned so external threads 28 of rod or central longitudinal support 21 can threadably engage internal threads 27 of coil or connector 22. Then the second pile section 20 and first pile section 20 can be driven further into soil mass 16 in the direction of arrows 19 (see FIGS. 4, 5 ).
This process can be repeated until a desired overall pile segment 20 chain length is achieved (e.g., see FIG. 5 ) and to form a segmented piling or piling chain 59 (see FIG. 5 ). This depth for piling chain 59 is represented by arrow 92 in FIG. 5 . Preferably all longitudinal supports 21 of pilings 20 in a piling chain 59 are situated along a central longitudinal axis, e.g., axis 50 (see FIG. 11 ) (or along a substantially central longitudinal axis), and torqued in place. As shown in FIG. 4 , rod or longitudinal support 21 can face upwards during driving, or rod or longitudinal support 21 can face downward as shown in FIGS. 10-11 , if desired, while driving.
A rod or central longitudinal support 21 and a coil or connector 22 can be coupled to supports 26, e.g., via welding, if desired and embedded in a structural filling material 35, e.g., concrete, of piling section 20 (see, e.g., FIGS. 10-11 ).
An embodiment of an alternative piling section designated generally by the numeral 400 is illustrated in FIGS. 21-22 , including an interlocking unit 480 having a rod or longitudinal support 430, preferably having external threads 431, and with upper fasteners 410, 420 and lower fasteners 440, 450 use to interconnect or lock with another piling section 400. Fasteners 410, 450 can be a nut. Fasteners 420, 440 can be a washer. Rod 430 can be positioned through bore or longitudinal space 470 of piling 400. Lower end 460 of rod 430 of one piling section 400 can be fastened in upper fastener 410 of another piling section 400. Although not shown, if desired, the piling sections 400 can be oriented in the opposite direction during pile driving so that rod end 460 faces upward. A recessed space 401, as shown in piling 400, can be included if desired in any of the piling section embodiments described herein.
Referring to FIGS. 19-20 , another alternative interlocking unit/connector/coupler is shown and designated generally by the numeral 1030. If desired, an interlocking unit 1030 can be included in a piling 20, 30 or 400. Interlocking unit 1030 can include a rod or longitudinal support 1031 and fastener 1035, which can be a coupling nut, for example. Interlocking unit 1030 can be included in a piling 20, 30, 400 to enable interconnecting one piling 20, 400 to another piling 20, 400. Fastener 1035 can be welded at weld 1039 if desired, e.g., in an embodiment when rod 1031 is embedded in a structural filling material 35. A rod or longitudinal support 1031, 430 as shown in FIGS. 20, 22 can be embedded in structural filling material 35, e.g., concrete, of a piling section 20, 30 or 400, but do not need to be. Rods 1031, 430 can also be positioned through a bore, e.g., bore 470, of a piling section 400 if desired during driving, and torqued along a longitudinal axis of a piling chain 59. A similar bore can also be included in piling section 20, if desired, to not have an interlocking unit embedded in concrete.
As shown in FIG. 22 , a piling section 400 can include a bore 470. During driving, a rod 430, 1031 can be inserted through bore 470. A fastener, e.g., a nut, 410 and fastener, e.g., a washer, 420 then can be tightened and torqued into place on rod 430 or 1031. Or a coupling nut 1035 can be tightened and torqued into place on rod 430, 1031. Another rod 430, 1031 can be coupled to a fastener of longitudinal support 430 or 1031 and torqued in position. Then another piling section 400 can be positioned on top of the first piling section 400 with bores 470 aligned around rod 430, 1031. When adding each piling section 400, fasteners used can be tightened and torqued down along the same longitudinal axis.
Referring to FIG. 6 , after pile driving through bore 13 of helical tool 10 is complete and when an overall segmented piling or piling chain 59 is in place in soil mass 16, pile driver 23 can be uncoupled from helical tool 10 and can be removed from helical tool 10. Helical tool driver 14 can then be coupled back onto helical tool 10, and helical tool driver 14 can remove helical tool 10 in the direction of arrows 25 from soil mass 16, leaving segmented piling or piling chain 59 in soil mass 16, which can be used as a foundational support for a building structure, for example.
This process as shown in FIGS. 2-6 can be repeated for each segmented piling or piling chain 59 that is needed for a building structure. The process can also occur simultaneously at different pile driving sites at a project location, e.g., at 2 or more, e.g., at 2 to 20, or more if needed, pile driving sites, to simultaneously install multiple segmented piling or piling chains 59 that may be needed for a building foundation.
FIGS. 7-8 illustrate an alternative method that can include driving of pilings 30, which can be pilings with an exoskeleton 36, through bore 13 of helical tool 10. This embodiment of the system and process can be the same as shown in FIGS. 1-6 but including one or more piles or pilings 30 having an exoskeleton 36 (see FIGS. 12-18 ), which can be driven through bore 13 of helical tool 10 by itself or as a starter pile(s) as shown by arrows 43. Pilings 30, however, are an alternate embodiment of a piling of the present invention that can be driven into soil by themselves as starter piles with larger piles coupled on top of pilings 30 in a chain, without use of a helical tool. The smaller size enable these pilings to be driven in harder soils, e.g., soils including sand. The support provided by exoskeleton 36 also facilitates driving through harder soils. Note that more dirt than desired can be present inside a helical tool if a piling 30 is driven through, due to the smaller diameter. If desired to use pilings 30 to drive through a helical tool, a smaller width helical tool potentially can be selected.
One pile or piling 30 can be used, or more than one pile or piling 30 can be used if desired with each piling 30 to be coupled together during a driving process A total pile or piling 30 can be about 5 inches (12.7 cm) to 60 feet (18.29 m) in length, or as long as is necessary to reach the required torque for a piling chain 59. A pile section 30 can be about 5 to 24 inches (12.7-60.96 cm) long, for example, and preferably is about 8 inches (20.31 cm) long.
Referring to FIGS. 12-18 , piling 30 with an exoskeleton 36 preferably is adapted to be coupled to another piling 30 or to a piling or piling segment 20, 40, 400 (see, e.g., FIGS. 8, 18 ), for example, if desired. Piling 30 can include an exoskeleton 36 having an exoskeleton wall 51 and an exoskeleton bore 52 with structural filling material 35, e.g., concrete or another desired structural material filling bore 52 of exoskeleton wall 51. A rod or support 1031 having external threads 1037 is preferably cast in place about centrally, e.g., along longitudinal axis 53 (see FIG. 18 ), in structural filling material 35 and extends a distance, e.g., about 1 to 2 inches (2.54-5.08 cm) from upper end 39 of piling 30. Connector 1035 having internal threads 1038 and a bore 1036 can be fastened to rod 1031 at lower surface 1049 of lower end 1034 of rod 1031, e.g., when interlocking unit 1030 is cast in place about centrally in structural filling material 35, e.g., along longitudinal axis 53. Connector 1035 can be positioned at lower or bottom end 33 of piling 30.
Preferably exoskeleton 36 is corrugated and/or has spiral or helical coils or threads or corrugations 44 along exterior surface 61 of exoskeleton wall 51 with a series of peaks 38 and valleys 37. Exoskeleton 36 can have a helical or spirally configured corrugation 44 as shown in FIG. 12 . The spiral or helical external corrugation 44 can be included to help increase skin friction with soil during driving.
The embodiment of the system and method as shown in FIGS. 1-6 can be the same, but with a piling 30 with exoskeleton 36 being incorporated in the system and method, e.g., as one or more starter piles to first be driven through bore 13 of helical pile 10 and into soil mass 16 below helical pile 10. An uppermost pile 30 can be coupled to a pile 20 or 400, e.g., see FIG. 8 , if desired during the pile driving process. A piling chain 59 including pilings 30 can include one or more pilings 30 having different diameters or widths, e.g., with a smallest width piling 30 at the bottom.
An interlocking unit or connector 1030 of FIGS. 19, 20 can be included in a piling 30 as shown in FIGS. 12-18 , which includes a rod 1031, which can also be referred to as a stud or longitudinal support. Rod 1031 can have a middle portion 1033 with a smooth or at least relatively smooth outer surface 1044. Rod 1031 also has two ends 1032, 1034 that preferably include external threads 1037. End 1032 has upper surface 1048. End 1034 has lower surface 1049. End 1032 is a male connector of interlocking unit 1030. Interlocking unit 1030 also has a female connector depicted as fastener or coupling nut 1035 in FIG. 20 , for example.
Coupling nut 1035 includes bore 1036, upper end 1061 and lower end 1062. Internal threads 1038 are present in bore 1036. Lower surface 1049 of threaded end 1034 of rod 1031 can be inserted and partially turned or threaded in bore 1036 at end 1061 of coupling nut 1035 to interlock with coupling nut 1035 and wherein a portion of bore 1036 preferably remains open at end 1062, e.g., see FIG. 13 , to enable connecting with another interlocking unit 1030. End 1034 can be fixedly coupled to coupling nut 1035, e.g., welded at weld 1039, but does need to be and can just be fixedly turned and/or tightened in position.
FIGS. 19-20 show that a connector 1030 can be manufactured from rod 1031 and coupling nut 1035. If desired, a similar connector 1030 can also be forged as a single unit.
Connector 1030 can be made of a desired material, e.g., steel, copper, aluminum or other structural material or metal.
Couple nut 1035 is illustrated as having a hexagonal cross-sectional shape. A coupling nut 1035 can also have another desired cross-sectional shape, e.g., circular, square, etc.
FIG. 18 depicts a piling 30 including connector 1030 cast in place within structural material 35 that fills exoskeleton 36. An alternative embodiment of piling 400 is also shown with connector 1030 within a bore 470 and without recess 401.
FIGS. 13-17 are sectional views showing connector 1030 cast in place in structural filing material 35 of piling 30.
Referring to FIG. 8, 12-18 , a first or starter piling 30 can be driven into soil mass 16 with rod or central longitudinal support 1031 at an upper end 39 and coil or connector 1035 at a lower end 33. Piling 400 can be lowered in the direction of arrows 160 so that rod or longitudinal support 1031 of piling 30 can be placed in bore 1036 of coupling nut 1035 of piling 400 and turned so external threads 1037 of rod or central longitudinal support 1031 can threadably engage internal threads 1038 in bore 1036 of coupling nut 1035. Then a piling section 400 coupled to a piling section 30 can be driven further into the soil mass 16 through bore 13. Then rod 1031 of piling 400 can be coupled into a connector 1035 of another piling section 400 and then the piling chain can be driven further into soil mass 16. This process can be repeated to add additional pile segments 400 until a desired length of a piling chain or segmental piling 59 is formed that includes piling(s) 30 and piling(s) 400. Preferably all rods 1031 in a piling chain 59 are situated along a central longitudinal axis 53 (or along a substantially central longitudinal axis) (see FIG. 18 ) and tightened and/or torqued in place. If desired, more than one piling 30 can form a base of segmental piling 59. If desired all pilings 30 can be used to form a segmental piling chain 59.
As discussed, a piling 20 or other type of interlocking unit can be used in the embodiment as shown in FIGS. 8, 12-18 . Also, as discussed, a helical tool 70 can be used instead of a helical tool 10 in any of the embodiments of the system and method as shown in FIGS. 1-9 .
If desired, the orientation of a piling 30 or 400 as shown in FIG. 18 can be the opposite that rod 1031 extends from a bottom of a piling 30, 400 with coupling nut 1035 at a top of piling 30, 400.
FIG. 9 illustrates that alternatively an embodiment of a piling designated by the numeral 40 can be driven through bore 13 in the system and method as shown in FIGS. 1-6 . This embodiment can be the same or similar to what is illustrated in FIGS. 1-6 , except instead of pile or pile segments 20 or 400 being used, a pile 40, which can be a concrete pile or wooden pile, can be driven through bore 13 of helical tool 10 and into soil mass 16 in the direction of arrows 47. Pilings 40 can be driven about a central longitudinal support if desired, but do not need to be driven about a central longitudinal support. A piling 40 can be a longer piling, e.g., about 10 or more feet (3.05 or more meters) long.
Referring to FIGS. 23-28 , a second preferred embodiment of the system and method of the present invention using a helical tool 70 will be discussed.
A helical tool 70 in the embodiment of FIGS. 23-28 can be about 10 to 11 feet (3.05- 3.35 m) long and can be driven into soil 16 less than eleven feet (3.35 m). If desired, a helical tool 70 can be longer, e.g., 12 to 30 feet (3.66-9.14 m) long, or smaller helical tools can be connected together to form a desired length. In a residential application, for example, a helical tool 70 preferably has a bore 13 able to receive about 6-inch (15.24 cm) piles to be driven therethrough, e.g., a bore 13 can be about 6.5 to 7 inches (16.51-17.78 cm), most preferably having about a 6 and ¾ inch (17.15 cm) in diameter bore 13, when receiving about 6 inch (15.24 cm) wide pilings 20, 30, 40, 400 therethrough. A bore 13 can also be about 4 to 12 inches (10.16-30.48 cm) wide, for example, in a residential project, depending on the width of pilings chosen.
As shown in FIG. 23 , prior to driving helical tool 70 into soil 16, bore 13 of helical tool 70 is filled with a chain of pile sections 20 or 400, which can for example each be about six inches (15.24 cm) wide by one foot (30.48 cm) tall, or which can each be about four inches (10.16 cm) wide by two feet (60.96 cm) tall as another example.
First a chain 78 of desired pilings, e.g., piling sections 20, 400, are bolted or fastened together, e.g., as described herein using a desired interlocking unit that is either embedded in a desired piling or positioned through a bore of a desired piling. About a 10-foot (3.05 m) pile chain 78 in length can fill at least a majority of bore 13 of helical tool 70 when using a helical tool 70 that is about ten to eleven feet (3.05-3.35 m) long, for example. Between adding each pile section, e.g., pile sections 20, 400, the pile sections are preferably tightened and torqued in place at each desired interlocking unit along a longitudinal axis of the chain 78, e.g., along a central longitudinal axis.
Pile chain 78 is then pushed into bore 13 of helical tool 70. It is acceptable if a portion of the bottommost pile section, e.g., a pile section 20, 400, extends beyond the bottom or lower end 75 of the helical tool 70 as shown in FIG. 24 , but it does not have to extend beyond bottom 75 of helical tool 70.
FIG. 24 is a sectional view taken along lines 24-24 of FIG. 23 and shows piling chain 78 with multiple piling sections 20, 400 coupled together within bore 13 of helical tool 70 prior to driving helical tool 70 into soil mass 16.
A helical tool driver 14 can then be connected to helical tool 70 via connectors 71, 80, e.g., with fasteners 73, which can be bolts. Connector 80 can include a bottom plate 81 and connector 80 can be coupled on helical tool driver 14. Connector 80 can include a bore 97 that is able to receive a rod or longitudinal support, e.g., rod 1031, if such a rod extends externally from an uppermost piling in a pile chain 78. A helical driver 14 can have one or more hydraulic lines 68, for example. Helical tool 70 filled with piling chain 78 and coupled to helical tool driver 14 can be picked up, e.g., using tracked vehicle 15 and boom 60, and can be driven into soil mass 16 (see FIG. 25 ) until helical tool 70 stops or until a desired torque is reached. Preferably helical tool driver 14 has a gauge 69 to measure pressure during driving to provide information on when desired torque is reached. Gauge 69 on helical tool driver 14 can provide the exact pressures reached during driving. One or more connections 65 can be provided on helical tool driver 14 for attaching a hydraulic line. Referring to FIG. 26 , an upper portion 56 of helical tool 70 preferably remains above soil 16 to enable attaching pile driver 23 to helical tool 70 at coupler 71. A factor in determining depth of helical tool 70 can also be a depth at which harder or sandy soil is penetrated. Preferably pile driver 23 has a gauge 86 to measure pressure during driving to provide information on when desired torque is reached. Gauge 86 on pile driver 23 can provide the exact pressures reached during driving.
Helical tool driver 14 is then removed from helical tool 70 while helical tool 70 and the pile chain 78 remains in soil mass 16. Pile driver 23 is then coupled to helical tool 70. Pile driver 23 can have a plate 93 with a plurality of openings or holes 94 that can align with openings or holes 72 of connector 71. A fastener 73, e.g., bolts, can be inserted through openings 94, 72 and tightened therein to connect pile driver 23 to helical tool 70. The pile chain 78 can be added to as shown in FIG. 26 and driven further into soil 16 through bore 13, and further below lower portion 75 of helical tool 70. A desired new pile section, e.g., a pile section 20, 30, 40, 400 can be added in a same or similar method as previously described with regard to FIGS. 1-8 . After each new pile section 20, 30, 40, 400 is added, pile driver 23 can be used to push the entire chain 59 further into the soil below helical tool 70, until a desired overall chain 59 length is reached.
Helical tool 70 is preferably driven into soil 16 until the proper torque that is required is measured, e.g., until about 10,000 lbs of torque (44,482 Newtons) on helical tool 70 is reached, or until helical tool 70 stops driving when a 10-ton (9.07 metric ton) piling chain 59 is desired. Helical tool sections can be added and coupled together e.g., by incorporating and using additional plate connectors 71, until the desired pressure is reached, if necessary, and pressure is preferably checked by gauges on the helical driver tool 14 head. Once driving of helical tool 70 is completed, helical tool driver 14 can be disconnected and removed. Then pile driver 23, sometimes also referred to as a pressing tool, which can be a hydraulic pile driver, can be connected to helical tool 70 using fasteners 73, e.g., bolts.
A new piling section, e.g., a piling section 20, 400 is coupled to an uppermost piling section of chain 78. With friction present and the flights 11 of helical tool 70 grabbing soil 16, it is easier to press pilings 20, 400 interlocked together through bore 13 of helical tool 70 into the hard soil 16 than if helical tool 70 was not present. When starting to drive, the driver 23 may be pressing pilings 20, 400 at about 1000 psi (6,895 kPa), then pressure may change after a few pilings are added to about 1200 psi (8,274 kPa). Using a pressure gauge on driver 23 allows knowing what the exact resistance is. Pressure can reach about 2000 psi, for example, for about a 10-ton (9.07 metric ton) piling chain. In one example, if about 2500 psi (17,237 kPa) is reached during driving a piling chain 59 will measure about 12.5 tons (11.34 metric tons).
After pressing all desired pilings sections, e.g., piling sections 20, 400 into soil 16, pile driver 23 can be uncoupled and removed from helical tool 70. Helical tool driver 14 can then be reconnected to helical tool 70. Helical tool 70 can be removed from soil mass 16 with the piling chain 59 remaining in soil mass 16. Helical tool driver 14 can then be disconnected from helical tool 70. Helical tool 70 can later be used again in another pile driving application. Piling chain 59 remains in place in the ground, and can be about 30 feet (9.14 m) long, for example.
No cap on bottom of helical tool 70 is needed when driving with cylinders inside. In general, it does not affect the process if soil gets inside helical tool 10 or 70 whether driving helical tool 10 or 70 with or without cylinders inside bore 13. If soil gets in and packed in tight, it is pushing against casing and adds to stability and doesn't negatively affect the process.
If piling chain 59 doesn't stop, it is preferable to keep adding desired pilings and driving in until piling chain 59 stops or reaches the desired torque.
If desired, helical tool 10 can also be used in the process as described and shown with regard to FIGS. 23-28 . If desired, a helical tool 70 along with connector 71 can be used in the method as shown in FIGS. 1-9 .
Various size drivers 14, 23 can be used depending on the size of helical tool 10, 70 and pilings, 20, 30, 40, 400, 500, 501, 502. Helical tool driver 14 pressure and pile driver 23 pressure can be determined per job and per engineering recommendations based on type of soil and structural requirements, for example.
Most preferably, round or cylindrically shaped piles or pilings 20, 30, 40, 400 are driven through bore 13 of helical tool 10, 70. Optionally, other shaped pilings that fit through bore 13 can also be used.
A helical tool 10, 70 preferably can be at least about 6 to 14 inches (15.24-35.56cm) in diameter and about 10 to 60 feet (3.05-18.29 m) long. Preferably bore 13 of helical tool 10 is at least wide enough to push about 3 to 13 inch (7.62-33.02 cm) width or diameter pilings 20, 30, 40, 400 therethrough
If pushing a 5 to 6 inch (12.7-15.24 cm) diameter piling 20, 30, 40, 400 through the bore 13, preferably a helical tool 10, 70 will have a diameter of at least about 5.5 to 7 inches (13.97-17.78 cm).
If pushing an 8-inch (20.31 cm) round piling 20, 30, 40, 400 through bore 13, helical tool 10, 70 preferably will have at least about an 8.5 to 9 inch (21.59-22.86 cm) diameter.
An upper portion of helical tool 10, 70 can extend above soil preferably at least about 6 inches (15.24 cm), or with at least enough of an upper portion 56 extending above the soil to enable coupling a helical tool driver or pile driver, for example, thereto.
Using a helical tool 10, 70 is beneficial to reduce friction for driving the other pilings 20, 30, 40, 400 because they pass downward through bore 13 (e.g., about 10 to 60 feet (3.05-18.29 m)) with no friction in embodiments when a bottom a helical pile 10 is capped off with plate or cap 63 and only have friction for the further driving, e.g., about an additional 10 to 60 feet (3.05-18.29 m) downward below helical tool 10, 70. When not capped off at a bottom, friction when driving is reduced when driving through bore 13 of helical tool 10, 70 compared to driving without use of a helical tool 10, 70.
Length of pilings 20, 30, 40, 400 pushed through bore 13 can be about 8 inches (20.31 cm) or longer, or can be between about 6 inches (15.24 cm) to 20 feet (6.1 m) long.
When driving a helical tool 10, 70 without end cap 63, bore 13 can fill with soil or at least with some soil. The soil should not come above a ground surface and should remain in the ground. Soil remaining in the ground is beneficial because this stiffens the soil around the piling, which helps stabilize the pilings and structure. In San Francisco the Millennium tower was leaning/tilting. They tried to fix it with cast auger techniques that removes the soil. Then the tower started sinking. Using the method of the present invention, the soil compacts and stabilizes around a piling chain 59 so no sinking would occur. With the method of the present invention, the soil all compacts and stabilizes while driving. When you press pilings under the methods of the present invention, it stiffens soil around the piling and helps stabilize further.
When driving a bottom capped helical tool 10, 70 under the method of the present invention, soil will still be stiffened and compacted and stabilized while driving. Driving piles 20, 30, 40, 400 through and downward below bore 13 will also stiffen and stabilize the soil.
A connector 12, 71 can be a connector adapted to utilize bolts or one or more other desired fasteners. An alternative connector can also be configured to hook on and grab a side of a helical tool 10, 70 with enough pressure to enable a pile driver to drive piles through a bore 13 of a helical tool 10, 71.
FIGS. 32-33 illustrate optional embodiments for a pile driver 23 designated by the numerals 152, 153 that can be used in the first and second preferred embodiments of the system and method of the present invention. A pile driver 152, 153 can include a connector 154 or 155 for connecting to a line 85, e.g., a hydraulic line. The embodiment of pile driver 153 shown in FIG. 33 includes a bottom plate 1064 with an opening 1065, which can accommodate an upward facing rod or longitudinal support 1031, 430 for example.
FIGS. 34-50 illustrate additional preferred embodiments of apparatuses, systems, and methods of the present invention, designated generally herein by the numeral 500, and which may sometimes be referred to herein as a piling chain 500.
A piling chain 500 can include a stater pile section 501 and a plurality of pile sections or segments 502. A starter pile section 501 and pile section 502 can have a large diameter or width, e.g., 8 to 48 inches (20.31 cm-1.23 m) wide, and can be beneficial for use in commercial applications. A piling section 502 can be manufactured in sections that are about 5 to 20 feet (1.52-6.1 m) long and about 8 to 48 inches (20.31 cm-1.23 m) wide. A starter piling section 501 preferably can be shorter than a piling section 502, e.g., cast in sections about 6 inches (15.24 cm) to 10 feet (3.05 m) long and 8 to 48 inches (20.31 cm-1.23 m) wide. A starter piling section 501 can also have a narrower width than 8 inches (20.31 cm).
A piling section 502 can be made starting with a pile outer tube 534 of the type having a wall 533 with an exterior surface 514, an interior surface 515, and a bore 511 extending along a longitudinal length of wall 533, see, e.g., FIG. 47 . A wall 533 of a pile outer tube 534 can be cast with concrete 35, or other structural material having good compressive strength that can be cast in place. Other materials can also be used for an outer wall 533 if desired. Concrete is a preferred material for cost efficiency with adequate strength for the intended purpose of a piling section 502.
In preferred embodiments as shown herein, a wall 533 is shown having a round or circular shape. A wall 533 can also have another shape if desired, e.g., square or rectangular.
A tube 506, e.g., which is sometimes referred to herein as a grout tube or an inner tube, and which preferably is preferably made from a metallic material (e.g., galvanized stainless steel), can be positioned within bore 511 of wall 533 as shown in FIGS. 34-36 and 47 . Grout tube or inner tube 506 can have an outer wall 528 that can be corrugated and/or have corrugations, ribs, threads, or spiral or helical coils 535 on an interior surface 508 and on an exterior surface 507, which concrete 35 or other structural material can easily adhere to.
A top view tube of 506 is shown in FIG. 46 . Cuts/notches/slits 529 can be made in tube 506 starting at a top surface 537 and extending downward e.g., between about 1 to 6 inches (2.54-15.24 cm) downward. Cuts/notches/slits 529 can also be made in tube 506 starting at a bottom surface 538 and extending downward e.g., between about 1 to 6 inches (2.54-15.24 cm) downward. A bottom 526 of a grout tube 506 can look the same as the top 527 of grout tube 506 shown in FIG. 46 . The number of notches 529 included can be based on the number plates 523 in a guide 520. A cut/notch/slit can be about 5/16 inch (0.79 cm) to receive a ¼ inch (0.64 cm) wide plate 523, for example.
A guide or guide portion 520 (see FIGS. 39-40 ) can be positioned on grout tube 506 at notches 529 as shown in FIG. 48 . Two guide tubes 520 preferably are included in a piling section 502 at top and bottom notches 529 of inner tube 506 to maximize and enhance the ability of guides 520 to help centrally align all rods or bars 503 of a piling chain 500. Alternatively, if desired, one guide 520 can be included at either a top or bottom of a grout tube 506. Alternatively, it is possible to not include guides 520 and to rely on a connector of rods to align the rods, e.g., in shorter piling sections.
A guide 520 can include a tube or guide tube 521 that can have a bore or opening 522 that is positioned about centrally in a guide 520. Bore or opening 522 of guide tube 521 can be receptive of rod or bar 503. One or more plates or arms 523, e.g., preferably four plates, can extend laterally outward from guide tube 521. Plates or arms 523 can form the shape of a cross or an “X”. Plates or arms 523 can be connected to guide tube 521, e.g., via welding when guide 520 is manufactured using a metallic material. If desired, a guide portion including a guide tube and a plurality of plates can be manufactured as a single unit. Preferably guide arms 523 extend outward from guide tube 521 and can extend so that there is about 1 inch (2.54 cm) between an end of a plate 523 and outer wall 533. There can also be a larger space between a plate 523 and outer wall 533 if desired.
A guide tube 521 can have a same length as a plate 523. Alternatively, a guide tube 521 can have a longer length than a plate 523 and can possibly extend to about the top of a pile section 502 or grout tube 506, or to a bottom of a pile section 502 or grout tube 506, respectively as shown in FIG. 36 . Aternatively, a second tube or guide tube 551 can be coupled to guide 520, e.g., welded, to extend the overall tube 521,551 length. A bore of tube 521/551 can be wide enough to house a nut 524 or 525 if desired, as shown in FIG. 53 .
Although nuts 524 are not shown below a connector 525 between a first piling 502 and starter piling 501 in FIGS. 50, 53 , a nut 524 can be included here as well.
The width or diameter of a guide tube 521 can be selected based on dimensions of a rod or bar 503 and possibly a fastener to be used in the piling chain 500. A guide tube 521 can have a width or diameter of about 1 to 2 inches (2.54-5.08 cm), e.g, about 1.38 to 1.4inches (3.51-3.56 cm) and a longitudinal length of about 3 inches (7.62 cm) as depicted in the figures. Plates 523 can have dimensions of about 1×3×4 to 5 inches (2.54×7.62×10.16 to 12.7 cm) when connected to a guide tube 521 having a width or diameter of about 1 to 2 inches (2.54-5.08 cm) and longitudinal length of about 3 inches (7.62 cm). A lateral width or cross width of a guide 520 can be about 10 to 11 inches (25.4 to 27.9 cm) in this example, when using pile sections 501, 502 that are about 12 inches (30.48 cm) in lateral or cross-width. A longitudinal length and width of a guide tube 521 and plates 523 can also be greater or lesser if desired depending on the diameter of a piling section used in the piling chain.
FIG. 48 depicts how each plate 523 of a guide 520 can be slid into or otherwise positioned within a notch 529 until flush, with guide tube 521 positioned about centrally within bore 509 of grout tube or inner tube 506.
FIG. 46 depicts a top view of a grout tube or inner tube 506 with top surface 537 shown. A bottom view of grout tube or inner tube 506 with a bottom surface 538 (see, e.g., FIG. 38 ) can be the same as shown in FIG. 46 , e.g., when a guide 520 will also be positioned in notches 529 at a bottom of a grout tube or inner tube 506.
FIG. 48 depicts a top view of a grout tube 506 and guide 520 within a pile outer tube 534. A bottom view of a grout tube 506 and guide 520 within a pile outer tube 534 can be the same as shown in FIG. 48 , e.g., when a guide 520 will also be positioned in notches 529 at a bottom of a grout tube 506.
In a most preferred embodiment, concrete 35 or other desired structural material, can be poured into bore 511 of pile outer tube 534 between grout tube 506 exterior surface 507 and an interior surface 515 of wall 533 to partially cast and set grout tube 506 and guide 520 plates 523 in place within pile outer tube 534, and form a starter pile section 502′ that is partially cast. Later as part of a pile driving process, a rod 503 can be positioned through bore(s) 522 of guide tube(s) 521. A connector 525, e.g., a nut, can be positioned around the rod 503 and tightened or torqued down above an uppermost guide 520, see, e.g., FIGS. 34-36, 42, 49 . A connector 525 enables tightening down each pile section 502 that is installed in a piling chain 500 (see, e.g., FIG. 49 ). Although not shown, a washer can also be included below connector 525 if desired. In FIG. 49 , a connector 525 of an upper pile section 502 is shown in sectional view while a connector 525 of a lower pile section is not shown in section view for illustration purposes.
When using connectors 524, 525, preferably bar or rod 503 includes exterior threads 505, and preferably the exterior threads 505 are coarse. Bar or rod 503 can be a rod sold under the brand name Dayton, e.g., a b-25 Dayton rod, or other high strength rod or high strength hollow rod. A bar or rod 503 can also be hollow with a bore 504, e.g., see FIG. 38 .
Bore 504 can have a relatively smooth surface or can include threads. Bar or rod 503 can be useful to help align different pile sections. Bar or rod 503 can also provide structural strength to a piling section and chain. In some embodiments that include a rod 503 that is hollow with bore 504, pressurized water can be blast through the rod 503 and out the bottom of a piling chain 500 during the driving process to help blast away sand and clay or other soil material. Arrow 542 in FIG. 43 represents water or liquid that can be flowed or blast out rod 503 during driving. A bar or rod 503 of an uppermost pile section 502 can also be used for tension uplift during pile driving.
A connector 524 (e.g., a coupling nut or a coupling nut that is a longer nut with rubber grommet seal) can be used to connect a first rod 503 of one starter pile section 502′ with a second rod 503 (see FIG. 49 ; see also FIGS. 34-36 ), as seen with arrows 530. Another second starter pile section 502′ can be aligned with a piling chain 500 so that each guide tube 521 bore 522 of a starter pile section 502′ can receive the second rod 503 and wall 533 of the second starter pile section 502′ can rest on a wall 533 of the first starter pile section 502′. This process can be repeated until a desired piling chain 500 length is reached, e.g., when a desired torque is reached or when the chain stops driving. FIG. 49 depicts how a connection can look between starter pile sections 502′, wherein a coupling nut may be part of two different bores 509 in a chain 500, for example. If a tube 521 is longer than a plate 523, or if a tube 551 is used, connector 524 can be turned and tightened to be about flush with a top of a tube 521 or 551, or to be within a bore of a tube 521, 551.
A partial chain 545 including a starter pile 501 and a plurality of starter pile sections 502′ can be placed within a helical tool 10, 70. A helical tool 10, 70 including said partial chain 545 can be driven into soil mass 16 via arrows 543 in a similar manner as described with regard to FIGS. 23-26 . Additional starter pile sections 502′ can be attached at their rods 503, e.g., as described above and each driven through helical tool 10, 70 and further into soil mass 16 in direction of arrows 541 until a desired pile chain 500 length is reached, e.g., until a desired torque for the chain is reached or until the chain stops driving. In this embodiment, a hydraulic driving attachment, e.g., coupler or connector 80 can be longer and wider as needed to accommodate a pile starter sections 502′ of chain 500.
Alternatively, a helical tool 10, 70 can first be driven into soil mass 16 in a similar manner and shown in described in FIG. 4 , for example. Then a starter pile section 501 can be driven through a bore of helical tool 10, 70. Then a starter pile section 502′ can be connected to starter pile section 501. Then another starter pile section 502′ can be connected to the first starter pile section 502′. This process can be repeated until a desired pile chain 500 length is reached.
Once a desired pile chain 500 length is reached, concrete 35, or other structural material, can be flowed down all the bores 509 of grout tubes 506 in the direction of arrow 550 (see FIGS. 50, 53 ) in the chain 500 to further encase and cast grout tubes 506 and guides 520 including guide tubes 521, and any connectors 524, 525, in concrete 35, or other structural material, as depicted in FIGS. 50, 53 . In this embodiment, each starter pile section 502′ becomes a completed pile section 502 after pile chain 500 is driven and concrete 35 or other structural material is allowed to set in place in bore 509 and within soil mass 16.
The processes described above are the most preferred method of installing and forming a pile chain 500, especially when using very large and heavy pile sections 502.
For illustration purposes, FIGS. 34 to 36 show connectors 524, 525 in exploded view below pile section 502, and shows concrete 35 in bores 511 and 509, and shows connectors 524, 525 above a starter pile 501 that includes concrete in bores 510, 509. If pile chain 500 is formed and driven using the method as described above using starter pile sections 502′ and pouring concrete 35 down bores 509 after pile driving, connectors 524, 525 will also be set in concrete 35, e.g., as shown as shown in FIG. 50 . If an alternative process as described below is used, e.g., using a fully cast section 502 with a recess 401 during pile driving, connectors 524, 525 or another desired connector can be positioned in recess 401 after one pile section 502 is connected to another pile section 502, e.g., in a similar manner as shown in FIG. 21 .
Alternatively, in another preferred embodiment, a pile section 502 can be completed prior to pile driving with a rod 503 positioned through bore(s) 522 of guide tube(s) 521 and then concrete 35 or other structural material filling both bores 511 and 509, prior to attaching one pile section 502 to another pile section 502. In this embodiment, a recess or recessed portion, e.g., similar to recess 401 shown in FIGS. 21, 22 can be included around the upper end of a rod 503 in bore 509 of inner tube 506 to accommodate a connector 524 and/or 525 for another rod 503 of another completed pile section 502, and to enable adjacent pile sections 502 to rest about flush upon one another. In this embodiment, couplers 410, 420 and/or couplers 440, 450 can be used to couple one rod 503 to another rod 503 instead of a coupler 524 or 525. The pile driving process can be similar to using starter pile sections 502′ as described above, except concrete is not poured down any bores 509 at the end of pile driving.
Alternatively, an interlocking unit 1030 can be positioned through bores 522 of guide tube 521 and then concrete or other structural material can be poured into bores 511 and 509 to create a completed pile section 502, prior to attaching one pile section 502 to another pile section 502. In this embodiment a recess 401 is not needed to enable an upper pile section 502 to rest about flush on a lower pile section 502. Sizing of a guide tube bore can be selected to accommodate an interlocking unit 1030. The pile driving process can be similar as described above with the starter pile sections 502′ except concrete is not poured down any bores 509 at the end of pile driving.
As can be seen, different types of interlocking units and connectors can be utilized to connect one pile section 502 to another pile section 502, or to connect one starter pile section 502′ to another starter pile section 502′.
Four different preferred embodiments of a starter pile section 501 are shown in FIGS. 35, 36, 44, 45 and designated generally by the numerals 501A, 501B, 501C, 501D.
A starter pile section 501A preferably includes an inner tube or grout tube 506 positioned about centrally within a bore 510 of starter pile section 501A with a bar or rod 503 positioned about centrally within a bore 509 of grout tube 506. Bar or rod 503 can extend outside a bottom 517 of starter pile section 501A and outside a top 518 of starter pile section 501A. The bottom of bar or rod 503 extending outside a bottom 517 of starter pile section 501A can assist in blasting away soil during pile driving if pressurized water is flowed through rod 503 bore 504.
A pile outer tube 534 of the type having a wall 533 with an exterior surface 512, an interior surface 513, and a bore 510 extending along a longitudinal length of wall 533, can be used to manufacture a starter pile section 501A. A rod or bar 503 can be integrally cast in place about centrally within bore 510 in a base plate 519 made of concrete 35 or other structural material. Another desired base plate can also be used, e.g., a plate with a connector to tighten rod 503 in the connector. A grout tube or inner tube 506 can be positioned around bar or rod 503. Concrete or other structural material can be flowed between exterior wall 507 of grout tube 506 and interior surface 513 of wall 533. As described with regards to starter pile section 502′ at this stage a starter pile section 501A′ is formed. Bore 509 can be left open to be filled with concrete 35 or other structural material after pile driving. Alternatively bore 509 can be filled during manufacture to form a completed starter section 501A, and using an alternative connection and possible a recess 401 if desired.
A starter pile section 501B is similar to a starter pile section 501A but also includes a guide 520. A guide 520 can be placed in notches 529 of grout tube 506 as previously described during manufacture. When pouring concrete 35 or other structural material between wall 533 and grout tube 506, the guide 520 plates 523 can be partially embedded in the concrete 35 or other structural material. Two guides 520 can be included at upper and lower portions of a grout tube 506. Bore 509 can be left open to be filled with concrete 35 or other structural material after pile driving. Alternatively bore 509 can be filled during manufacture to form a completed starter section 501B and using an alternative connection or recess 401 if desired. Water can be blasted out an end of rod 503 through bore 504 to facilitate pile driving if desired.
A starter pile section 501C can have an irregular shape with a plurality of sides that tapers downward to a bottom end 546 as seen in FIG. 44 . Starter pile 501C can be pre-cast with a rod 503 cast about centrally within starter pile 501C extending out bottom 546 and out top 547. The shape of starter pile 501C is beneficial when driving in sand or hard soils. Water can be blasted out an end of rod 503 through bore 504 to facilitate pile driving if desired. Connector 532 can be tightened on rod 503 at the bottom 546 to promote tension uplift during pile driving. If desired a connector 531 can also be used. A width of starter pile 501C can be 12 inches (30.48 cm), or 6 to 12 inches (15.24 to 30.48 cm). the length of a rod extending out a top can be about 6 inches (15.24 cm), for example. A length of a rectangular area of starter pile 501C can be about 6 inches (15.24 cm), for example.
A starter pile section 501C can have an upper width that is the same width of other pile sections 502 in a chain 500 but preferably is shorter, e.g., a length of about 8 inches to 2 feet (20.32-60.96 cm) or less. An upper width can also be narrower than a pile section 502, e.g., it can be about 6 to 12 inches (15.24 to 30.48 cm).
A starter pile section 501D can have a rectangular shape as shown in FIG. 45 . Starter pile section 501D can be cast in the rectangular shape with a rod 503 cast about centrally within starter pile section 501D and extending out a bottom 548 and top 549 of starter pile section 501D. The shape of starter pile 501D is useful for driving in soft or clay soils. Water can be blasted out an end of rod 503 through bore 504 to facilitate pile driving if desired. Connectors 531, 532 can be tightened on rod 503 at the bottom 532 of starter pile section 501D to promote tension uplift during pile driving. If desired, a connector 531 does not have to be used.
A starter pile section 501D can be the same width of the other pile sections 502, e.g., about 12 inches (30.48 cm) wide, in the chain 500 but preferably is shorter, e.g., it can be about 6 inches (15.24 cm) tall. In some embodiments a starter pile section 501D can have a shorter width than a pile section 501, e.g., a width of about 6 inches (15.24 cm) to about 12 inches (30.48 cm). A rod 503 extending out of a starter pile section 501D can be about 6 inches (15.24 cm) exterior to the section.
During manufacture of a starter pile section 501B, or other pile section 502, a guide 520 can be partially embedded in concrete. A guide 520 can be further embedded in concrete during installation of the pile section and a piling chain when concrete 35 or other flowable material that can set, is poured into bore 509 grout tube 506.
Referring to FIG. 37 , a sectional view of a pile section 502 is shown after casting is complete. As shown, cables 516, e.g., prestressed cables can be included in bore 511 between grout tube 506 and wall 533 if desired. A prestressed cable preferably has a galvanized coating.
A piling chain 500 can be driven through a helical tool 10, 70 as described in other embodiments. A piling chain 500 can also be driven into a ground mass without use of a helical tool 10, 70.
A piling chain 500 can be 130 feet (39.6 meters) long, for example. A piling chain 500 can be about 20 to 150 feet (3.05 meters to 45.72 meters) long, for example.
Metallic materials used as parts or components of the present invention can be corrosion resistant.
The following is a list of parts and materials suitable for use in the present invention:

PARTS LIST

	PART NO.	DESCRIPTION

	10	helical tool/helical pile
	11	flight/helices
	12	connector (to pile driver 23)
	13	bore
	14	helical tool driver (e.g., auger
		tool)
	15	tracked vehicle/wheeled
		vehicle/vehicle with boom
	16	soil/soil mass
	17	arrow
	18	arrow
	19	arrow
	20	pile/pile segment or
		section/piling/piling segment or
		section
	21	rod/connector/longitudinal
		support (steel, copper,
		aluminum or other structural
		material)
	22	coil/connector (steel, copper,
		aluminum or other structural
		material)
	23	pile driver (e.g., hydraulic
		hammer/jack)
	24	connector/arms/supports (e.g.,
		for pile driver 23)
	25	arrow
	26	support
	27	thread
	28	thread
	29	bore of coil/connector 22
	30	pile or piling/pile or piling section or
		segment with exoskeleton
	33	bottom end of piling 30
	35	structural filling material, e.g.,
		concrete
	36	exoskeleton (metallic material,
		e.g., galvanized stainless steel)
	37	valley
	38	peak
	39	upper end piling 30
	40	piling (wood or concrete)
	43	arrow
	44	helical/spiral/coil/thread/
		corrugation
	46	outer or exterior surface of helical
		tool 10, 70
	47	arrow
	48	arrow
	49	wall/shaft
	50	axis/longitudinal axis
	51	exoskeleton wall
	52	exoskeleton bore
	53	axis/longitudinal axis
	54	track/wheel
	55	soil surface
	56	upper portion helical tool 10, 70
	57	end/bottom end piling 20
	58	end/upper end piling 20
	59	segmented piling/piling chain
	60	boom
	61	exterior surface piling 30
	62	openings/hole of helical tool
	63	plate/cap
	64	interlocking unit/coupler
	65	connector (e.g., to hydraulic line)
	67	lower end or lower portion of helical tool
		driver 14
	68	line/hydraulic line
	69	gauge/pressure gauge
	70	helical tool/helical pile
	71	connector/coupler/plate
	72	opening/hole
	73	fastener/connector (e.g., bolt)
	75	lower portion/lower end of helical tool
	76	upper plate
	77	lower plate
	78	piling chain (e.g., initial piling chain in
		helical tool 70)
	80	connector/coupler for helical driver tool
	81	plate
	82	body
	83	opening/hole
	84	middle portion of helical tool
		driver
	85	line/hydraulic line
	86	gauge/pressure gauge
	91	arrow (distance helical tool 10 driven
		soil 16)
	92	arrow (distance piling chain 59 driven
		soil 16)
	93	plate
	94	opening/hole
	95	opening/hole
	96	fastener, e.g., bolt
	97	bore
	98	opening/hole
	99	opening/hole
	152	pile driver
	153	pile driver
	154	connector
	155	connector
	160	arrow
	400	piling/piling section
	401	recess/recessed space
	410	fastener/nut
	420	fastener/washer
	430	rod/longitudinal support
	431	thread/external thread
	440	fastener/washer
	450	fastener/nut
	460	lower end rod/longitudinal
		support
	470	bore/longitudinal support of
		piling 400
	480	interlocking unit/connector/coupler
	500	apparatus of the present invention/
		a preferred embodiment of a piling
		chain/commercial piling chain
	501	starter pile/starter pile section
	502	pile section/pile segment
	502′	starter pile section 502′
	503	rod/bar
	504	bore of rod/bar
	505	thread
	506	tube/grout tube
	507	exterior surface grout tube
	508	interior surface grout tube
	509	bore of tube/grout tube
	510	bore of starter pile section
	511	bore of pile section
	512	exterior surface of starter pile section
	513	interior surface of starter pile section
	514	exterior surface of pile section
	515	interior surface of pile section
	516	cable, e.g., pre-stressed cable
	517	bottom
	518	top
	519	base/plate
	520	guide/cross guide (e.g., steel, steel coated
		with a marine grade primer, copper,
		aluminum or other structural
		material)
	521	bore/opening/tube/guide tube
	522	bore of guide tube
	523	plate/guide plate/guide arm
	524	connector/coupling nut
	525	connector/nut
	526	bottom
	527	top
	528	grout tube wall
	529	slit/cut/notch
	530	arrow
	531	connector/washer
	532	connector/ nut
	533	wall
	534	pile outer tube
	535	rib/thead/corrugations/spiral or helical
		coils
	537	top surface of tube 506
	538	bottom surface of tube 506
	541	arrow
	542	arrow
	543	arrow
	544	surface
	545	partial chain 500
	546	bottom of starter pile section 501C
	547	top of starter pile section 501C
	548	bottom of starter pile section 501D
	549	top of starter pile section 501D
	550	arrow
	551	tube/guide tube
	1030	interlocking unit/connector/
		coupler
	1031	rod/stud/longitudinal support
	1032	upper end/threaded end of
		rod 1031/male
		connection of connector 1030
	1033	middle portion of connector rod
		1031
	1034	lower end/threaded ended of rod
		1031
	1035	fastener/coupling nut/female connection
		of connector 1030
	1036	bore
	1037	thread/external thread
	1038	thread/internal thread
	1039	weld/welded portion
	1044	outer surface
	1048	end/upper surface of 1032
	1049	lower surface of end of 1034
	1061	end coupling nut 1035
	1062	end coupling nut 1035
	1064	plate
	1065	opening

All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the claims:

Claims

1. A method of pile driving comprising the steps of:

a) driving a helical tool into a soil mass, said helical tool including a central bore, an upper portion with a connector, and one or more flights on an exterior surface of the helical tool, wherein the upper portion of the helical tool remains accessible above or at a soil surface of said soil mass;

b) coupling a pile driver to the connector of step “a”;

c) driving a first pile through the central bore of the helical tool to a desired depth in the soil mass, wherein at least a portion of a first pile extends into the soil mass below the upper portion of the helical tool; and

d) removing the helical tool from the soil after completing step “c”.

2. The method of claim 1 further comprising driving a second pile through the central bore of the helical tool during step “c” to drive both the first pile and the second pile further downward into the soil mass to form a segmental piling having a desired segmental piling length.

3. (canceled)

4. The method of claim 1 wherein the helical tool is driven into the soil mass to a depth at which the helical tool is operable to provide the necessary static weight and torque effect required by the pile driver, that is connected to the helical tool, to drive the first pile into the soil mass.

5-12. (canceled)

13. The method of claim 2 wherein the first pile and the second pile are connectable along a longitudinal axis prior to driving the second pile into the soil mass.

14-15. (canceled)

16. The method of claim 13 further comprising driving one or more additional piles through the central bore of the helical tool as needed to form a segmental piling and reach a desired segmental piling length, and wherein a first said additional pile is coupled to the second pile along a longitudinal axis prior to driving the first said additional pile, and wherein said second pile is coupled to the first pile along a longitudinal axis prior to driving the second pile into the soil mass.

17. The method of claim 16 wherein some of said additional piles have a larger diameter or cross-sectional width than the first pile.

18-21. (canceled)

22. The method of claim 16 further comprising a step of using the helical tool at another location to repeat the method.

23. A pile driving system comprising:

a) a helical tool having an exterior surface, a central bore, and one or more helical flights on the exterior surface of the helical tool;

b) a helical tool driver operable to drive the helical tool into a soil mass and to remove the helical tool from the soil mass;

c) a pile driver that is operable to drive one or more piling segments into the soil mass;

d) a coupler for coupling the pile driver to the helical tool after the helical tool is driven into the soil mass;

e) wherein the pile driver is operable to drive the one or more piling segments through the central bore of the helical tool and into the soil mass so that at least a portion of the one or more piles is at a depth below the helical tool.

24. The system of claim 23 wherein the helical tool is driven to a depth within the soil mass that enables the helical tool to support the pile driver and provide the necessary static weight for the pile driver to drive the other piles through the bore of the helical tool and further into the soil mass.

25. The system of claim 24 wherein more than one piling segment is driven through the central bore of the helical tool to form a segmental piling.

26. The system of claim 25 wherein the more than one piling segments are coupled together.

27-29. (canceled)

34. The system of claim 23 wherein there is more than one flight on the helical tool that are not the same size.

35. The system of claim 34 wherein a lowermost flight on the helical tool is the smallest.

36-37. (canceled)

41. The method of claim 1 wherein the bore of the helical tool includes a first set of one or more piles when the helical tool is driven into the soil mass.

42. The method of claim 41 wherein in step “c” the first pile is coupled to the first set of one or more piles to drive the first set of one or more piles further into the soil mass.

43-47. (canceled)

48. A pile section comprising:

a) an outer wall having a wall interior surface, a wall exterior surface, and a wall bore;

b) a tube having a tube bore, a tube exterior surface, and a tube interior surface, and a plurality of notches at a first end, and wherein the tube is positioned within the wall bore;

c) a guide portion having a guide tube with a guide bore and having a plurality of plates extending laterally from the guide tube, the plurality of plates positioned within the notches of the tube and the guide tube positioned about centrally in the tube bore;

d) a rod positioned through the guide bore;

e) wherein concrete or other structural material fills the wall bore between the wall interior surface and the tube exterior surface and partially casts the plurality of plates of the guide tube in the concrete or other structural material.

49. The pile section of claim 48 wherein the tube includes a second plurality of notches at a second end and further including a second guide portion.

50. (canceled)

51. The pile section of claim 49 wherein concrete or other structural material fills the tube bore and further casts the plurality of plates of the guide portion and the guide tube in the concrete or other structural material.

52. (canceled)

53. The pile section of claim 49 wherein the rod has a rod bore.

54-60. (canceled)

61. A method of pile driving comprising the following steps:

a) driving a helical tool having a bore into a soil mass;

b) driving a pile section of claim 53 through the bore of the helical tool while flowing pressurized water through the rod bore;

c) repeating step “b” until a desired piling chain length is reached; and

d) filing the tube bores with concrete or other structural material after driving to the desired piling chain length.

62. (canceled)