Clamps, grillages and tools used for attaching structures to pile shafts

Abstract

The present disclosure provides grillage assemblies that can be secured to a plurality of helical pile shafts to transfer axial loads, e.g., tension and / or compression loads, to the plurality of helical pile shafts. The present disclosure also provides clamp assemblies that can be secured to helical pile shafts and that support the grillage assemblies. The present disclosure also provides indenting tool assemblies used to make indents in the shafts of helical piles. The indenting tool assembly includes at least one punch drive assembly, at least one punch, a punch ring and an indexing ring or a support ring.

Description

CLAMPS, GRILLAGES AND TOOLS USED FOR ATTACHING STRUCTURES TO PILE SHAFTSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present disclosure is based on and claims benefit from co-pending U.S. Provisional Patent Application No. 63 / 538,678 filed on September 15, 2023 entitled “Clamps and Grillages for Transmitting Loads to Helical Pile Shafts” the contents of which are incorporated herein in their entirety by reference.FIELD

[0002] The present disclosure relates generally to grillage assemblies, clamp assemblies and indenting tools used when attaching the clamp assemblies to helical pile shafts. More particularly to the present disclosure relates generally to grillage assemblies and clamp assemblies that complement the grillage assemblies for transmitting structural loads to helical piles.DESCRIPTION OF THE RELATED ART

[0003] Deep foundations are used to support structures, such as buildings, towers, etc., when the soil underlying the structure would be too weak alone to support the structure. To effectively support a structure, a deep foundation has to penetrate the soil to a depth where competent loadbearing stratum is found. Conventional deep foundations, such as a drilled shaft or a driven pile, require large, specialized equipment to install. These approaches are cumbersome and expensive.

[0004] Helical or screw piles are a cost-effective alternative to conventional deep foundations because of the speed and ease at which a helical pile can be installed as well as requiring smaller more maneuverable installation equipment. Helical piles are rotated such that load bearing helical plates at the lower end of the pile effectively screw the helical pile into the soil to adesired depth. When supporting structures have certain axial loads, more than one helical pile is typically used. Grillages can be used to attach a plurality of helical piles to structure bases or tower legs. Grillages typically consist of welded steel plates and hollow structural steel to attach the helical piles to the structure bases or tower legs. Grillages provide a stable foundation, even in less-than-ideal conditions. One solution to attach grillages to the helical piles includes the use of clamps that deform the shaft of a helical pile when the clamp is attached to the shaft to transfer loads from the grillage to a helical pile. However, there are instances where the helical piles used have shafts with large diameters and / or made of high strength steel to support larger loads such that the clamps that deform the shafts of smaller size helical piles do not deform the larger size shafts. As a result, another methodology is needed to deform the helical pile shafts with large diameters and / or made of high strength steel so that clamps can be deployed.SUMMARY

[0005] The present disclosure provides exemplary embodiments of indenting tool assemblies, grillage assemblies and clamp assemblies used when assembling a support system for a structure. In an exemplary embodiment a clamp assembly includes a first clamp member, a second clamp member, and at least one tensioning member. The first clamp member includes an interior wall and an exterior wall. The interior wall includes an inner wall and at least one mating wall. The inner wall includes at least one rib extending away from the inner wall. The second clamp member includes an interior wall and an exterior wall. The interior wall includes an inner wall and at least one mating wall. The inner wall includes at least one rib extending away from the inner wall. The at least one tensioning member is configured to draw the first clamp member and the second clamp member toward each other. The at least one mating wall of the first clamp member includes at least one aperture extending through to the exterior wall, and the at least one mating wall of the second clamp member includes at least one aperture extending through to the exterior wall. In an exemplary embodiment, the inner wall of the first and second clamp members are substantially arcuate in shape, and the at least one mating wall of the first and second clamp members is substantially flat in shape. In an exemplary embodiment, the at least one tensioning member includes a bolt that is at least partially threaded and a nut.

[0006] In an exemplary embodiment a grillage assembly includes a grillage body, a plurality of retaining members, a plurality of caps and a plurality of clamp assemblies. The grillage body includes a base member, a plurality of arms and a plurality of pile coupling members. Each of the plurality of arms has a first end attached to the base member and a second end that is away from the base member. One of the plurality of pile coupling members is attached to the second end of one of the plurality of arms such that each arm has a pile coupling member attached thereto. Each of the plurality of pile coupling members includes at least one wall and an opening extending from an upper edge of the at least one wall to a lower or bottom edge of the at least one wall. The opening in the pile coupling member is configured and dimensioned to receive a portion of a shaft of a helical pile. The plurality of retaining members are associated with the pile coupling members, where one of the plurality of retaining members is associated with the lower or bottom edge of the at least one wall of the pile coupling member. The plurality of caps are associated with the pile coupling members, where one of the plurality of caps is associated with the upper edge of the at least one wall of the pile coupling member. Each of the plurality of clamp assemblies is configured to be attached to a shaft of a helical pile. In an exemplary embodiments, the at least one tensioning member comprises a bolt that is at least partially threaded and a nut.

[0007] In an exemplary embodiment, each of the plurality of clamp assemblies includes a first clamp member, a second clamp member and at least one tensioning member. The first clamp member has an interior wall and an exterior wall. The interior wall includes an inner wall and at least one mating wall, and the inner wall includes at least one rib extending therefrom. The second clamp member has an interior wall and an exterior wall. The interior wall includes an inner wall and at least one mating wall, and the inner wall includes at least one rib extending therefrom. The at least one tensioning member is configured to draw the first clamp member and the second clamp member toward each other. The at least one mating wall of the first and second clamp members includes at least one aperture extending through to their exterior wall. The inner wall of the first and second clamp members is preferably substantially arcuate in shape. The at least one mating wall of the first and second clamp members is preferably substantially flat in shape.

[0008] In an exemplary embodiment a tool assembly includes a punch drive assembly, a punch, a punch ring and an indexing ring. The punch is coupled to the punch drive assembly and moves with a piston in the punch drive assembly between an at rest position and an extended position where the punch imparts at least one indent in a shaft of a helical pile. The punch has an impacting wall configured to impact the shaft of the helical pile to impart the at least one indent. The punch ring is secured to the punch drive assembly and attachable to the shaft of the helical pile. The indexing ring is attachable to the shaft of the helical pile. In an exemplary embodiment, the punch drive assembly includes a ram assembly and a mounting member. The ram assembly includes a piston that is movable between the at rest position and the extended position. The mounting member is secured to the punch ring. The punch drive assembly may also include a deflection measuring assembly that is used to measure a depth of an indent made in the shaft of the helical pile by the punch drive assembly. The ram assembly includes a housing and the piston positioned within the housing and movable relative to the housing between the at rest position and the extended position.

[0009] In an exemplary embodiment, the punch ring includes a main body and a clamp body that is at least partially removable from the main body. The main body of the punch ring includes an interior wall and an exterior wall. The interior wall includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile. The clamp body of the punch ring includes an interior wall and an exterior wall. The interior wall includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile. The exterior wall of the clamp body includes at least one alignment groove used to align the punch ring with the indexing ring.

[0010] In an exemplary embodiment, the indexing ring includes a main body and a clamp body that is at least partially removable from the main body. The main body of the indexing ring includes an interior wall and an exterior wall. The interior wall of the main body includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile. The exterior wall of the main body includes at least one alignment groove used to align the indexing ring with the punch ring. The exterior wall of the main body includes at least one indicia, e.g., a number, associated with the at least one groove. The at least one indicia is used to identify a sequence for making indents on the shaft of the helical pile. The clamp body of the indexingring includes an interior wall and an exterior wall. The interior wall of the clamp body includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile. The exterior wall of the clamp body includes at least one alignment groove used to align the indexing ring with the punch ring. The exterior wall of the clamp body also includes at least one indicia, e.g., a number, associated with the at least one groove. The at least one indicia is used to identify a sequence for making indents on the shaft of the helical pile.

[0011] In another exemplary embodiment a tool assembly includes a plurality of punch drive assemblies, a plurality of punches and a punch ring. The tool assembly may also include a support ring. Each punch drive assembly includes a ram assembly and a mounting member. The ram assembly has a piston that is movable between an at rest position and an extended position. The ram assembly may also include a housing and the piston may be positioned within the housing and may be movable relative to the housing between the at rest position and the extended position. The mounting member is secured to the punch ring. Each punch drive assembly may also include a deflection measuring assembly used to measure a depth of an indent made in the shaft of the helical pile by the punch drive assembly. In this configuration, one of the plurality of punches is coupled to one of the plurality of punch drive assemblies. Each punch has an impacting wall configured to impact a shaft of a helical pile to impart at least one indent in the shaft. The punch ring is attachable to the shaft of the helical pile, and may include a main body and a clamp body that is at least partially removable from the main body. The main body of the punch ring includes an interior wall and an exterior wall. The interior wall of the main body includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile. Similarly, the clamp body of the punch ring includes an interior wall and an exterior wall. The interior wall of the clamp body includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile. The plurality of punch drive assemblies are attached to punch ring so that the plurality of punches pass through the punch ring when impacting the shaft of the helical pile to impart the indents. The support ring is attachable to the shaft of the helical pile so that the punch ring can rest on the support ring when making indents on the shaft. The support ring may include a main body and a clamp body that is at least partially removable from the main body. The main body of the support ring may include an interior wall and an exterior wall, wherein the interior wall is configured to receive at least aportion of the shaft of the helical pile. The clamp body of the support ring may include an interior wall and an exterior wall. The interior wall is configured to receive at least a portion of the shaft of the helical pile.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] A more complete appreciation of the present disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

[0013] Fig. l is a perspective view of an exemplary embodiment of a tool assembly used when installing load bearing clamps according to the present disclosure, illustrating a punch drive assembly , a punch, a punch ring and an indexing ring;

[0014] Fig. 2 is an exploded perspective view of the tool assembly of Fig. 1;

[0015] Fig. 2A is an enlarged exploded perspective view of a portion of a ram assembly of the punch drive assembly of Fig. 2 taken from detail 2 A, and illustrating a connection of the punch to a piston of the ram assembly;

[0016] Fig. 3 is a perspective view of a main body of the punch ring of the tool assembly of Fig. 1, illustrating a punch opening configured to receive the punch of the tool assembly of Fig. 1;

[0017] Fig. 4 is a rear elevation view of the main body of the punch ring of Fig. 3;

[0018] Fig. 5 is a side elevation view of the main body of the punch ring of Fig. 3;

[0019] Fig. 6 is a cross-sectional view of the main body of the punch ring of Fig. 4 taken along the lines 6-6, illustrating upper and lower edges of the punch opening;

[0020] Fig. 7 is a cross-sectional view of the main body of the punch ring of Fig. 3 taken along the lines 7-7, and illustrating in phantom side edges of the punch opening that can be tapered;

[0021] Fig. 8 is a rear perspective view of a clamp body of the punch ring of the tool assembly of Fig. 1;

[0022] Fig. 9 is a front perspective view of the clamp body of the punch ring of Fig. 8, illustrating an alignment groove extending along an outer wall of the clamp body and an alignment aperture extending through the clamp body;

[0023] Fig. 10 is cross-sectional view of the clamp body of the punch ring of Fig. 8 taken along the lines 10-10, and illustrating the alignment groove and the alignment aperture;

[0024] Fig. 11 is a top plan view of the punch of the tool assembly of Fig. 1;

[0025] Fig. 12 is a front elevation view of the punch of Fig. 11;

[0026] Fig. 13 is a side elevation view of the punch of Fig. 11;

[0027] Fig. 14 is a top plan view of the indexing ring of Fig. 1, illustrating a main body and a clamp body that is movably coupled to the main body, and illustrating alignment grooves along an outer wall of the main body and the outer wall of the clamp body and corresponding alignment apertures through the main body and the clamp body;

[0028] Fig. 15 is a top perspective view of another exemplary embodiment of a punch ring according to the present disclosure, illustrating a main body of the punch ring and a clamp body of the punch ring that is movably coupled to the main body, and illustrating an alignment groove along an outer wall of the main body and a corresponding alignment aperture through the main body;

[0029] Fig. 16 is a top plan view of the punch ring of Fig. 15, illustrating the clamp body in phantom lines and in an open position, and the clamp body in solid line in a clamping position;

[0030] Fig. 17 is a perspective view of an exemplary embodiment of a grillage body of a grillage assembly after being staged for marking locations for a plurality of helical piles, illustrating the plurality of helical piles screwed into the soil, and illustrating the indexing ring of the tool assembly of Fig. 1 attached to a shaft of one of the helical piles;

[0031] Fig. 18 is an enlarged perspective view of the indexing ring of the tool assembly attached to the helical pile shaft of Fig. 17 taken from detail 18;

[0032] Fig. 19 is a perspective view of the punch drive assembly , punch and punch ring of the tool assembly of Fig. 1 positioned on the indexing ring and the clamp body of the punch ring staged for clamping the tool assembly to the helical pile shaft;

[0033] Fig. 20 is a top plan view of a portion of the punch drive assembly , punch and the punch ring of Fig. 19, illustrating the clamp body secured to the main body clamping the punch ring to a shaft of a helical pile, and illustrating an arm of a deflection measuring device spaced away from the helical pile shaft;

[0034] Fig. 21 is an enlarged top plan view of a portion of the punch drive assembly , punch and punch ring of Fig. 20 taken from detail 21, and illustrating a gap between the arm of the deflection measuring device and the helical pile shaft;

[0035] Fig. 22 is an enlarged top plan view similar to Fig. 21, illustrating the arm of the deflection measuring device contacting the shaft of the helical pile as the piston of the ram assembly moves toward the extended position;

[0036] Fig. 23 is a top plan view a portion of the punch drive assembly , punch and punch ring of Fig. 20, illustrating the punch impacting the helical pile shaft and the deflection measuring device measuring the deflection of the helical pile shaft caused by the punch;

[0037] Fig. 24 is a cross-sectional view of the main body of the punch ring, the punch and the helical pile shaft of Fig. 23 taken from line 24-24, and illustrating the indent on the helical pile shaft after the punch impacts the shaft of the helical pile;

[0038] Fig. 25 is a top plan view of the punch drive assembly, punch and punch ring of Fig. 20, illustrating rotation of the punch drive assembly, punch and punch ring from a first impact position in phantom lines to a second impact position in solid lines;

[0039] Fig. 26 is a perspective view of a helical pile shaft of Fig. 17 taken from detail 26, illustrating the shaft of a helical pile after the indenting tool assembly has impacted the shaft creating indents in the shaft;

[0040] Fig. 27 is a perspective view of the helical pile shaft of Fig. 26, illustrating an exemplary embodiment of a clamp assembly according to the present disclosure staged for attachment to the helical pile shaft;

[0041] Fig. 28 is a perspective view of the helical pile shaft and clamp assembly of Fig. 27, illustrating a clamp body of the clamp assembly secured to a main body of the clamp assembly;

[0042] Fig. 29 is a cross-sectional view of the shaft of the helical pile shaft of Fig. 28 taken from line 29-29, illustrating ribs of the clamp assembly positioned within the indents in the shaft of the helical pile;

[0043] Fig. 30 is a perspective view of a grillage body of a grillage assembly of Fig. 17 and retaining members of the grillage assembly positioned over the shafts of the plurality of helical piles;

[0044] Fig. 31 is an enlarged perspective view of the grillage body and retaining members of Fig. 30 taken from detail 31, illustrating the grillage body and retaining member being positioned over the shaft of a helical pile and staged to rest on a clamp assembly according to the present disclosure;

[0045] Fig. 32 is a top perspective view of a can of the grillage body of the grillage assembly with a temporary rod holding assembly being removed from a threaded rod of a tensioning system of the grillage assembly within the shaft of the helical pile, and a cap of the grillage assembly staged for installation over the can;

[0046] Fig. 33 is a partial cross-sectional view the portion of the grillage assembly from Fig. 31 prior to tightening the cap of the grillage assembly to the can, illustrating a puck of the tensioning system below the indents made by the indenting tool assembly of the present disclosure;

[0047] Fig. 34 is the partial cross-sectional view of Fig. 33, illustrating the cap of the grillage assembly tightened to the can, and the puck of the tensioning system in contact with the indents;

[0048] Fig. 35 is an enlarged partial cross-sectional view of the portion of the grillage assembly of Fig. 34 taken from detail 35 and illustrating the puck in contact with the indents;

[0049] Fig. 36 is a perspective view of another exemplary embodiment of an indenting tool assembly used when installing load bearing clamps according to the present disclosure, illustrating a plurality of punch drive assemblies, a plurality of punches, a punch ring and a support ring;

[0050] Fig. 37 is a partial cross-sectional view of a portion of a main body of the punch ring of Fig. 36, illustrating an exploded view of one of the plurality of punch drive assemblies where the punch is elongated to fit through the portion of the main body of the punch ring;

[0051] Fig. 38 is a perspective view from the exterior of the main body of the punch ring of Fig- 36;

[0052] Fig. 39 is a perspective view from the interior of a clamp body of the punch ring of Fig. 36;

[0053] Fig. 40 is a cross-sectional view of the clamp body of the punch ring of Fig. 39, illustrating a plurality of punch apertures through which a punch can pass and a plurality of mounting apertures used for mounting multiple punch drive assemblies;

[0054] Fig. 41 is a top plan view of the tool assembly of Fig. 36 secured to a shaft of a helical pile;

[0055] Fig. 42 is a top plan view of a portion of the tool assembly of Fig. 41, illustrating the punch impacting a helical pile shaft and the deflection measuring device measuring the deflection of the helical pile shaft caused by the punch; and

[0056] Fig. 43 is a cross-sectional view of the main body of the punch ring, the punch and the helical pile shaft of Fig. 42 taken from line 42-42, and illustrating the indent on the helical pile shaft after the punch impacts the shaft of the helical pile.DETAILED DESCRIPTION

[0057] A detailed description of examples of preferred embodiments is provided below. While several embodiments are described, the new subject matter described in this patent specificationis not limited to any one embodiment or combination of embodiments described herein, but instead encompasses numerous alternatives, modifications, and equivalents. In addition, while numerous specific details are set forth in the following description to provide a thorough understanding, some embodiments can be practiced without some or all such details. Moreover, for the purpose of clarity, certain technical material that is known in the related art has not been described in detail in order to avoid unnecessarily obscuring the new subject matter described herein. It should be clear that individual features of one or several of the specific embodiments described herein can be used in combination with features of other described embodiments or with other features. Further, the following exemplary embodiments are set forth to aid in an understanding of the subject matter of this disclosure, but are not intended, and may not be construed, to limit in any way the claims which follow thereafter. Therefore, while specific terminology is employed for the sake of clarity in describing some exemplary embodiments, the present disclosure is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents which operate in a similar manner.

[0058] The present disclosure provides exemplary embodiments of indenting tool assemblies used to make indents in the shafts of helical piles. In an exemplary embodiment, the indenting tool assembly includes a punch drive assembly, a punch, a punch ring and an indexing ring. For ease of description, the indenting tool assemblies may also be referred to herein as the “tool assemblies” in the plural and the “tool assembly” in the singular. The present disclosure also provides exemplary embodiments of clamp assemblies that can be secured to helical pile shafts. In an exemplary embodiment, a clamp assembly may include a main body and a clamp body that can be removably secured to the main body using one or more tensioning members. The present disclosure also provides exemplary embodiments of grillage assemblies that can be secured to a plurality of helical pile shafts to transfer axial loads, e.g., tension and / or compression loads, to the plurality of helical pile shafts. Further, like reference numbers and designations in the various drawings indicate like elements.

[0059] In general, the grillage assemblies according to the present disclosure are used with helical piles having shafts having an outer diameter of at least 4.0 inches. For ease of description, helical piles having shafts having an outer diameter of at least 4.0 inches, may alsobe referred to herein as a “larger shaft” or a “shaft” in the singular and as “larger shafts” or the “shafts” in the plural. Helical piles shafts having an outer diameter of at least 4.0 inches also have a thicker wall. Such larger shafts typically have a wall thickness in the range of about 0.3 inches to about 0.6 inches. Helical piles with shafts having a wall thickness in the range of about 0.3 inches to about 0.6 inches are difficult to indent using a clamp alone. The indenting tool assembly of the present disclosure is used to indent the larger shafts in a predefined number of places around the perimeter of the larger shafts. Preferably, such larger shafts are indented in six (6) places around the perimeter of the larger shafts. In addition, the indents in the shaft are preferably made in a predefined pattern so as to limit possible and unintended deformation of the larger shafts. An example of a predefined pattern is to make an indent on one side of a larger shaft and to then make an indent on an opposite side of the larger shaft, similar to the prescribed way to tighten the bolts of a wheel on a vehicle. To assist with the indenting process, the indenting tool assembly includes an indexing system, e.g., an indexing ring, so that the indents are located in the correct positions around the perimeter of the larger shaft. The clamp assembly is then attached in place around the larger shaft where ribs extending from a clamp body align with and rest in the indentations in the larger shaft created during the indenting process. As a result, stronger helical pile shafts can be used with grillage assemblies to support greater loads, such as the loads of larger transmission towers. Another advantage of the grillage assembly of the present disclosure is that the head of the helical pile can be in a fixed end condition when connected to the grillage assembly.

[0060] Referring to the figures, an exemplary embodiment of an indenting tool assembly according to the present disclosure is shown in Figs. 1-16. It is noted that the indenting tool assembly may also be referred to herein as the “tool assembly” in the singular and the “tool assemblies” in the plural. The tool assembly 10 is preferably used when attaching one or more clamp assemblies to a plurality of helical pile shafts, as described herein. In the exemplary embodiment shown, the tool assembly 10 includes a punch drive assembly 20, a punch ring 70, a punch 110 and an indexing ring 130. The punch drive assembly 20 includes a ram assembly 22 and a mounting member 24. The punch drive assembly 20 may also include a deflection measuring assembly 26 used to measure the depth of an indent made in a helical pile shaft by the punch drive assembly 20. Preferably, the ram assembly 22 is a sealed hydraulic unit thatincludes a housing 28 and a piston 30 positioned within the housing 28 and movable relative to the housing 28. In addition, within the housing 28 are internal hydraulic components used to drive the piston 30 between an at rest position, seen in Fig. 2, and an extended position, seen in Fig. 23. In the at rest position, the piston 30 is withdrawn substantially into the housing 28 as shown. The ram assembly 22 is connected to a hydraulic pump (not shown) through a high pressure hose. A non-limiting example of a ram assembly 22 is the RC554 family of General Purpose Hydraulic Cylinders manufactured by Enerpac Tool Group Corp, based in Menomonee Falls, Wisconsin. A non-limiting example of a pump that can be connected to the ram assembly is the P801 family of pumps manufactured by Enerpac Tool Group Corp, based in Menomonee Falls, Wisconsin. The ram assembly 22 and pump may be rated from about 30 tons to about 100 tons with a hydraulic fluid pressure in the range of about 6,000 psi to about 15,000 psi. In the embodiment shown, the ram assembly 22 and the pump are rated for 10,000 psi.

[0061] Referring to Figs. 2 and 2A, the piston 30 may include one or more threaded mounting apertures 30a that can be used to attach a punch mounting plate 111 to the piston 30, and to attach the deflection measuring assembly 26 to the piston 30 using fasteners 48 passed through apertures 113 in the punch mounting plate 111. Prior to attaching the punch mounting plate 111 to the piston 30, the punch 110 is attached to the punch mounting plate 111 by passing fastener 115 through aperture 117 in the punch mounting plate 111 into aperture 119 in the punch 110. The housing 28 may include a fluid port 32 located at, for example, a distal end 28a of the housing 28. The fluid port 32 facilitates connection to a hydraulic fluid source, e.g., the pump, so that hydraulic fluid can be pumped into the housing 28 to move the piston 30 from the at rest position, seen in Fig. 2, to the extended position, seen in Fig. 23, preferably with a pressure in a range of about 8,000 psi to about 10,000 psi. The housing 28 has a proximal end 28b that may be threaded to facilitate attaching the housing 28 of the ram assembly 22 to the mounting member 24 as described below.

[0062] Continuing to refer to Figs. 1 and 2, the mounting member 24 may be any type of member that is configured and dimensioned to withstand pressures of at least 10,000 psi and that can be attached to the ram assembly 22 and the punch ring 70. In an exemplary embodiment, the mounting member 24 is made of material having a predefined thickness and sufficient strength to withstand the forces generated by the ram assembly 22 on the punch ring 70 when the punch 110is impacting a shaft of a helical pile. In the embodiment shown, the mounting member 24 is a steel plate having a thickness in the range of about 1.5 inches to about 2.0 inches. The mounting member 24 may be a substantially flat plate having a square, rectangular, circular, elliptical, hexagonal shape or any other suitable shape sufficient to attach the ram assembly 22 to the punch ring 70 as described below. The mounting member 24 includes a mounting aperture 34 that is configured and dimensioned to receive the proximal end 28b of the pump assembly housing 28. The mounting aperture 34 may be threaded so that a threaded proximal end 28b of the housing 28 can be attached to the threaded mounting aperture 34 in the mounting member 24. The mounting member 24 may also include one or more ring attachment apertures 36 that can be used to attach the mounting member 24, and thus the ram assembly 22, to the punch ring 70. More specifically, the mounting member 24 may be attached to the punch ring 70 using one or more tensioning members 38, e.g., mechanical fasteners. A non-limiting example of a tensioning member 38 is the threaded bolts shown in Fig. 2. When attaching the mounting member 24 to the punch ring 70, one or more spacers 40 may be used to create a gap “Gl” between the mounting member 24 and the punch ring 70 as shown in Fig. 1. The gap “Gl” provides a space for the piston 30 to extend from the housing 28 of the ram assembly 22 as the piston 30 moves between the at rest position and the extended position.

[0063] Continuing to refer to Figs. 1 and 2, the optional deflection measuring assembly 26 can be provided to measure a depth of an indent made in a shaft of a helical pile by the punch 110 that is driven by the punch drive assembly 20. In the embodiment shown, the deflection measuring assembly 26 is preferably attached to the piston 30 so that the deflection measuring assembly 26 moves with the motion of the piston 30 between the at rest position and the extended position. For example, the deflection measuring assembly 26 may include a mounting bracket assembly 42 and a deflection measuring device 44. The mounting bracket assembly 42 may include a bracket 46, a fastener 48 and a device holder 50. The mounting bracket assembly 42 can be attached to the piston 30 using the bracket 46 and the fastener 48 that can be screwed into the threaded mounting aperture 30a in the piston 30. The device holder 50 holds the deflection measuring device 44 to the mounting bracket assembly 42 and aligns the deflection measuring device 44 with a shaft of a helical pile. The deflection measuring device 44 includes an indicator 52, e.g., a gauge or digital dial indicator, and a transducer 54 for measuringcompression on a probe 56. Non-limiting examples of deflection measuring devices 44 include compression deflectometers and linear variable differential transformer displacement transducers that measure the displacement of a load on a structure, here a shaft of a helical pile shaft. An example of a suitable deflection measuring device 44 is the Absolute, sold by Mitutoyo America Corporation, Aurora, Illinois.

[0064] Referring again to Figs. 1, 2 and 3-10, an exemplary embodiment of a punch ring 70 according to the present disclosure is shown. The punch ring 70 includes a main body 72 and a clamp body 74. As shown in Figs. 3-7, the main body 72 has a front wall 76 that includes an inner wall 78 and one or more mating walls 80. In the embodiment shown, there are two mating walls identified as walls 80a and 80b. However, there may be less than two mating walls 80 or there may be more than two mating walls 80. The one or more mating walls 80 are preferably substantially flat walls. The inner wall 78 is preferably configured and dimensioned to receive at least a portion of a shaft of a helical pile. In the embodiment shown, the inner wall 78 is an arcuate shaped wall to receive a portion of a round helical pile shaft. However, the shape of the inner wall 78 can be configured to receive square or other shaped helical pile shafts. The main body 72 also includes one or more clamp attachment apertures 82, seen in Fig. 3, one or more mounting apertures 84, seen in Fig. 4, and a punch aperture 86. The one or more clamp attachment apertures 82 are configured and dimensioned to receive a tensioning member 88, e.g., a mechanical fastener, seen in Figs. 1 and 2, used to attach the clamp body 74 to the main body 72. Preferably, the one or more clamp attachment apertures 82 are threaded apertures and the tensioning member 88 is a threaded bolt that can be threaded into the threaded clamp attachment apertures 82 to attach the clamp body 74 to the main body 72. The one or more mounting apertures 84 are configured and dimensioned to receive the tensioning member 38, e.g., a mechanical fastener, seen in Fig. 2, used to attach the mounting member 24 to the main body 72. Preferably, the one or more mounting apertures 84 are threaded apertures and the tensioning member 38 is a threaded bolt that can be threaded into the threaded mounting apertures 84 to attach the mounting member 24 to the main body 72. The punch aperture 86 extends from a rear wall 90, seen in Fig. 4, of the main body 72 through to the inner wall 78 of the front wall 76 of the main body 72. In one exemplary embodiment, the punch aperture 86 is an elongated slot, seen in Fig. 4, that is configured and dimensioned to receive the punch 110. In anotherexemplary embodiment, the punch aperture 86 is a slot, shown in phantom in Figs. 6 and 7, that is configured and dimensioned to receive the punch 110 such that there is snug fit between the punch 110 and the walls of the punch aperture 86 and where the punch 110 is movable within the punch aperture 86. In addition, a portion of the slot forming the punch aperture 110 has tapered walls 87, e.g., top, bottom and side walls. The taper of the tapered walls 87 is configured to mate with a taper in the walls of the punch 110, which is described below.

[0065] Referring to Figs. 1, 2 and 8-10, the clamp body 74 of the punch ring 70 has a front wall 90 that includes an inner wall 92 and one or more mating walls 94. In the embodiment shown, there are two mating walls identified as walls 94a and 94b. However, there may be less than two mating walls 94 or there may be more than two mating walls 94. The one or more mating walls 94 are preferably substantially flat walls so that the one or more mating walls 94 can mate with the one or more mating walls 80 of the main body 72 so that there is a flush fit. The inner wall 92 is preferably configured and dimensioned to receive at least a portion of a shaft of a helical pile. In the embodiment shown, the inner wall 92 is an arcuate shaped wall to receive a portion of a round helical pile shaft. However, the shape of the inner wall 92 can be configured to receive square or other shaped helical pile shafts. The clamp body 74 also includes one or more clamp attachment apertures 96 that extend from a rear wall 98 of the clamp body 74 to the mating walls 94. The one or more clamp attachment apertures 96 are configured and dimensioned to receive the tensioning member 88, e.g., the mechanical fastener, used to attach the clamp body 74 to the main body 72. Preferably, the one or more clamp attachment apertures 96 are smooth bores through the clamp body 74. The clamp body 74 also includes an alignment groove 100 in the rear wall 98 and a corresponding alignment aperture 102. Preferably, the alignment groove 100 extends along the rear wall 98 from a top wall 104 of the clamp body 74 to a bottom wall 106 of the clamp body 74. Preferably, the alignment aperture 102 extends through the clamp body 74 from the top wall 104 to the bottom wall 106. Preferably, the alignment groove 100 is aligned with the alignment aperture 102 such that the alignment groove 100 lies in substantially the same vertical plane as the alignment aperture 102 and is parallel to the alignment aperture 102.

[0066] Referring to Figs. 1, 2 and 11-13, an exemplary embodiment of the punch 110 according to the present disclosure is shown. The punch 110 is attached to the piston 30 so thatthe punch 110 is movable with the piston 30 as the piston moves between the at rest position and the extended position. In the exemplary embodiment shown, the punch 110 includes a first portion 112 and a second portion 114. The first portion 112 includes a top wall 116, a bottom wall 118, a pair of side walls 120 and 122, and a rear wall 124. In the embodiment shown, the walls of the first portion 112 are substantially flat to form a rectangular like structure. However, the present disclosure contemplates first portion walls that encompass different shapes and sizes. The second portion 114 includes a top wall 116a, a bottom wall 118a, a pair of side walls 120a and 122a, and an impacting wall 126. In the embodiment shown, the walls of the second portion 114 are substantially flat and are tapered toward the impacting wall 126 as shown in Figs. 11 and 13. However, the present disclosure contemplates second portion walls that encompass different shapes and sizes. The top and bottom walls 116a and 118a have a taper “Tl” and the side walls 120a and 122a have a taper “T2” The angle of the tapers “Tl” and “T2” may be the same or they may differ. In the exemplary embodiment shown, the angle of the tapers “Tl” and “T2” are the same. A non-limiting example of the angle of the tapers “Tl” and “T2” is ten (10) degrees. However, the angle of the tapers may be in the range of about 5 degrees to about 30 degrees. The punch 110 is preferably made of a metal or metal alloy. Non-limiting examples of such metal or metal alloy include steel, tool steel, stainless steel, or any other suitable alloy to create an indent in the shaft of a helical pile. Preferably, the punch 110 is hardened, e.g., heat treated, in order to withstand repetitive punches or impacts against shafts of helical piles over a period of time.

[0067] Referring now to Figs. 1, 2 and 14, an exemplary embodiment of the indexing ring 130 according to the present disclosure is shown. The indexing ring 130 is configured and dimensioned to be clamped to a shaft of a helical pile. The indexing ring 130 provides a support structure for the indenting tool assembly 10 and provides alignment grooves and alignment apertures to align the punch ring 70 to the indexing ring 130 in order for the punch 110 to impact a perimeter of the shaft of a helical pile in predefined locations. In the embodiment shown, the indexing ring 130 includes a main body 132 and a clamp body 134. The main body 132 has an exterior wall 136 and an interior wall 138. The exterior wall 136 can be any shape wall, e.g., an arcuate, circular, elliptical, oval, square or any other shaped wall. In the embodiment shown, the exterior wall 136 has an arcuate or circular shape. The interior wall 138 can have any shape,e.g., an arcuate, circular, elliptical, oval or a flat shape. In the embodiment shown, the interior wall 138 has a first portion that has a first shape, a second portion that has a second shape, and a third portion that has a third shape. In the embodiment shown, the interior wall 138 includes an inner wall 140 as the first portion, a mating wall 142 as the second portion and a connecting wall 144 as the third portion. The inner wall 140 is preferably configured and dimensioned to receive at least a portion of a shaft of a helical pile and is arcuate in shape to receive a portion of a round helical pile shaft. However, the shape of the inner wall 140 can be configured to receive square or other shaped helical pile shafts. The mating wall 142 is a flat wall that has an aperture 146 through which a tensioning member 148, e.g., a mechanical fastener, can pass through. The connecting wall 144 is a tongue portion of a tongue and groove connection with the clamp body 134. However, the connecting wall 144 can be any configuration that couples the main body 132 to the clamp body 134. The main body 132 also includes a plurality of alignment grooves 150 in the exterior wall 136 and a plurality of corresponding alignment apertures 152. Preferably, the alignment grooves 150 extend along the exterior wall 136 from a top wall 170 of the main body 132 to a bottom wall 172 of the main body 132. Preferably, the alignment apertures 152 extend through the main body 132 from the top wall 170 to the bottom wall 172. Preferably, the alignment grooves 150 are aligned with their corresponding alignment aperture 152 such that the alignment groove 150 lies in substantially the same vertical plane its corresponding alignment aperture 152 and is parallel to the alignment aperture 152. The plurality of alignment grooves 150 may be equally spaced around the perimeter of the exterior wall 136 or the alignment grooves 150 may be unequally spaced around the perimeter of the exterior wall 136. In the embodiment shown, the alignment grooves 150 are equally spaced around the perimeter of the exterior wall 136. In the exemplary embodiment shown, there are six (6) alignment grooves 150 and six (6) corresponding alignment apertures 152. The six (6) alignment grooves 150 are equally spaced about 60 degrees apart.

[0068] Similarly, the clamp body 134 has an exterior wall 180 and an interior wall 182. The exterior wall 180 can have any shape, e.g., an arcuate, circular, elliptical, oval, square or any other shaped wall. In the embodiment shown, the exterior wall 180 has a circular or arcuate shape. The interior wall 182 can have any shape, e.g., an arcuate, circular, elliptical, oval or a flat shape. In the embodiment shown, the interior wall 182 has a first portion that has a firstshape, a second portion that has a second shape, and a third portion that has a third shape. In the embodiment shown, the interior wall 182 includes an inner wall 184 as the first portion, a mating wall 186 as the second portion and a connecting wall 188 as the third portion. The inner wall 184 is preferably configured and dimensioned to receive at least a portion of a shaft of a helical pile and is arcuate in shape to receive a portion of a round helical pile shaft. However, the shape of the inner wall 184 can be configured to receive square or other shaped helical pile shafts. The mating wall 186 is a flat wall that has an aperture 190 that is preferably a threaded bore that the tensioning member 148 can be threaded into. The connecting wall 188 is a groove portion of a tongue and groove connection with the main body 132. The tongue and groove connection of the clamp body 134 to the main body 132 is by a pin 192 that is passed through apertures in the tongue and the groove. However, the connecting wall 188 can be any configuration that couples the main body 132 to the clamp body 134. The clamp body 134 also includes a plurality of alignment grooves 150 in the exterior wall 180 and a plurality of corresponding alignment apertures 152. Preferably, the alignment grooves 150 extend along the exterior wall 180 from a top wall 194 of the clamp body 134 to a bottom wall 196 of the clamp body 134. Preferably, the alignment apertures 152 extend through the clamp body 134 from the top wall 194 to the bottom wall 196. Preferably, the alignment grooves 150 are aligned with their corresponding alignment apertures 152 such that the alignment groove 150 lies in substantially the same vertical plane its corresponding alignment aperture 152 and is parallel to the alignment aperture 152.

[0069] The exterior wall 136 of the main body 132 and the exterior wall 180 of the clamp body 134 include indicia 200, seen in Figs. 1 and 14, used to identify a sequence for making indents on the shaft of a helical pile in, for example, the predefined sequence set forth above. The indicia 200 are aligned with alignment grooves 150 on the exterior walls 136 and 180 of the main and clamp bodies 132 and 134, respectively, as shown in Fig. 1. It is noted that in Fig. 14 the indicia 200 are shown on the top walls 170 and 194 of the main and clamp bodies 132 and 134, respectively, for illustration purposes so that an exemplary sequence for indenting the shaft of a helical pile is clearly shown.

[0070] Referring now to Figs. 15 and 16, another exemplary embodiment of a punch ring according to the present disclosure is shown. In this embodiment, the punch ring 220 includes a main body 222 and a clamp body 224. In this exemplary embodiment, the clamp body 224 ispivotably attached to the main body 222 using a tongue and groove configuration. However, the present disclosure contemplates other configurations for movably attaching the clamp body 224 to the main body 222. The main body 222 has an interior wall 226. The interior wall 226 can have any shape, e.g., an arcuate, circular, elliptical, oval or a flat shape. In the embodiment shown, the interior wall 226 has a first portion that has a first shape, a second portion that has a second shape, and a third portion that has a third shape. In the embodiment shown, the interior wall 226 includes an inner wall 228 as the first portion, a mating wall 230 as the second portion and a connecting wall 232 as the third portion. The inner wall 228 is preferably configured and dimensioned to receive at least a portion of a shaft of a helical pile and is arcuate in shape to receive a portion of a round helical pile shaft. However, the shape of the inner wall 228 can be configured to receive square or other shaped helical pile shafts. The mating wall 230 is a flat wall that has an aperture 234, which is preferably a threaded bore through which a tensioning member 236 can be threaded into. The connecting wall 232 is a groove portion of the tongue and groove connection with the clamp body 224. The main body 222 also includes a punch aperture 238. The punch aperture 238 is the same as the punch aperture 86 described above so that a description of the punch aperture 86 and thus punch aperture 238 is not repeated.Similarly, the clamp body 224 has an exterior wall 240 and an interior wall 242. The exterior wall 240 can have any shape, e.g., an arcuate, circular, elliptical, oval, square or any other shaped wall. In the embodiment shown, the exterior wall 240 has a circular or arcuate shape. The interior wall 242 can have any shape, e.g., an arcuate, circular, elliptical, oval, square or any other shaped wall. In the embodiment shown, the interior wall 242 has a first portion that has a first shape, a second portion that has a second shape, and a third portion that has a third shape. In the embodiment shown, the interior wall 242 includes an inner wall 244 as the first portion, a mating wall 246 as the second portion and a connecting wall 248 as the third portion. The inner wall 244 is preferably configured and dimensioned to receive at least a portion of a shaft of a helical pile and is arcuate in shape to receive a portion of a round helical pile shaft. However, the shape of the inner wall 244 can be configured to receive square or other shaped helical pile shafts. The mating wall 246 is a flat wall that has an aperture 250 that is preferably a smooth bore so that the tensioning member 236 can pass therethrough and be threaded into the aperture 234 in the main body 222. The connecting wall 248 is a tongue portion of the tongue and groove connection with the main body 222. The tongue and groove connection of the clamp body 224to the main body 222 is by a pin 252 that is passed through apertures in the tongue and groove portions. The clamp body 224 also includes an alignment groove 254 in the exterior wall 240 and a corresponding alignment aperture 256. Preferably, the alignment groove 254 extends along the exterior wall 240 from a top wall 258 of the clamp body 224 to a bottom wall 260 of the clamp body 224. Preferably, the alignment aperture 256 extends through the clamp body 224 from the top wall 258 to the bottom wall 260. Preferably, the alignment groove 254 is aligned with the corresponding alignment aperture 256 such that the alignment groove 254 lies in substantially the same vertical plane as the alignment aperture 256 and is parallel to the alignment aperture 256.

[0071] As noted above, the present disclosure provides embodiments of grillage assemblies that are used to transfer a load of a structure attached thereto to a plurality of load bearing structures, such as helical piles. An exemplary embodiment of a grillage assembly according to the present disclosure will be described with reference to Figs. 17, 27, 30 and 32. A grillage assembly according to the present disclosure includes a grillage body 300, seen in Fig. 17, one or more clamp assemblies 330, seen in Fig. 27, one or more retaining members 370, seen in Fig. 30, one or more caps 372, seen in Fig. 32, and a plurality of tensioning systems 380, seen in Figs. 33 and 34. It is noted that in the embodiment shown, the one or more retaining members 370 may also be referenced with an alpha-numeric reference number, such as retaining member 370a and 370b shown in Figs. 31 and 32. Similarly, the one or more caps 372 may also be referenced with an alpha-numeric reference number, such as caps 372a and 372b shown in Figs. 31 and 32.

[0072] The grillage body 300 is made of a material sufficient to support the intended load. Non-limiting examples of such materials include metal and metal alloys. Non-limiting examples of metals and metal alloys include steel, galvanized steel, stainless steel, or any other suitable alloy to support the intended load. The grillage body 300 includes a base member 302, a plurality of arms 304 and a plurality of pile coupling members 306. The base member 302 includes a body 308 and a mounting plate 310. The body 308 may be in any shape sufficient to permit the arms 304 to extend therefrom and to support the intended load. For example, the body 308 may be an I-beam like structure that may be in a circular, square or other shape. The mounting plate 310 may be integral to or monolithically formed into the body 308, or the mounting plate 310 may be attached to the body 308 using, for example, welds or mechanicalfasteners. The mounting plate 310 may include one or more mounting holes 312 extending through the mounting plate 310 and used when securing a structure (not shown), e.g., a transmission tower, to the base member 302. The mounting holes 312 are sized for fasteners (not shown) used to secure the structure to the base member 302. Each arm 304 includes a first end attached to the base member 302 so that the arms 304 extend from the base member 302, as shown in Fig. 17. The arms 304 may be welded to base member 302, the arms 304 may be integral or monolithically formed into the base member 302 or the arms 304 may be otherwise secured to the base member 302 using, for example, mechanical fasteners or any other suitable method. A second end of each arm 304 has a pile coupling member 306 attached thereto, as shown in Fig. 17. The arms 304 are shaped to support the intended loads and to transfer the load on the base member 302 to the pile coupling members 306. In the embodiment shown, the arms 304 are an I-beam like structures. The pile coupling members 306 are used to couple the grillage assembly to a plurality of helical piles. The pile coupling members 306 may also be referred to herein as “cans” in the plural and as a “can” in the singular. The pile coupling members 306 may be welded to the arms 304, the pile coupling members 306 may be integral or monolithically formed into the arms 304, or the pile coupling members 306 may be otherwise secured to the arms 304 using, for example, mechanical fasteners or any other suitable method. Preferably, the pile coupling members 306 are secured to the arms 304 at an angle as shown in Fig. 17. As a non-limiting example, the angle may be in the range of about 0 degrees to about 30 degrees.

[0073] Continuing to refer to Figs. 17, 27, 30 and 32, the pile coupling members 306 include one or more walls 314 and are open at the top and bottom to form an opening 316 configured and dimensioned to receive a portion of a shaft of a helical pile, e.g., helical piles 700, 704, 708 or 712. As a non-limiting example, each of the one or more walls 314 of the pile coupling members 306 may be about 12 inches in length so that the pile coupling members 306 would be about a 12 inch x 12 inch square pile coupling member 306. However, the pile coupling members 306 may be rectangular in shape, circular in shape or any other shape suitable to receive a portion of a shaft of a helical pile, e.g., helical piles 700, 704, 708 or 712. The one or more caps 372 of the grillage assembly are positioned adjacent a top edge of the pile coupling member 306 to provide a cover over the opening 316. The one or more caps 372 are preferably configured and dimensioned to fit over and cover the top edge of the pile coupling members 306 and to supportat least a portion of the load on the pile coupling member 306. As a non-limiting example, using the example of a 12 inch x 12 inch pile coupling member noted above, and the two caps shown in Fig. 32, the cap 372b may be a square plate in the range of about 18 inches to about 20 inches square. The thickness of the cap 372b may be in the range of about 2 inches thick. It is noted however that the cap 372b may be rectangular in shape, circular in shape or other shape sufficient to fit over and cover the top edge of the pile coupling members 306 and to support at least a portion of the load on the pile coupling member 306. The cap 372a may be a square plate in the range of about 8 inches to about 12 inches square. The thickness of the cap 372a may be in the range of about 2 inches thick. It is noted however that the cap 372a may be rectangular in shape, circular in shape or other shape sufficient to fit over and cover the top edge of the pile coupling members 306 and possibly to support at least a portion of the load on the pile coupling member 306.

[0074] Referring to Figs. 31, 33 and 34, the one or more retaining members 370 of the grillage assembly are positioned adjacent a bottom edge of the pile coupling members 306 to retain grout poured into the opening 316 within the opening 316. Grout is typically poured into the opening 316 before the one or more caps 372 are secured to the pile coupling member 306 of the grillage body 300. The one or more retaining members 370 are preferably configured and dimensioned to fit over and cover the bottom edge of the pile coupling members 306 and to support and transfer at least a portion of the load on the pile coupling member 306 to the one or more clamp assemblies 330. As a non-limiting example, using the example of a 12 inch x 12 inch pile coupling member noted above and the two retaining members 370 shown in Fig. 31, the retaining member 370b may be a square plate in the range of about 18 inches to about 20 inches square. The thickness of the retaining member 370b may be in the range of about 2 inches thick. It is noted however that the retaining member 370b may be rectangular in shape, circular in shape or other shape sufficient to fit over and cover the bottom edge of the pile coupling members 306 and to support and transfer at least a portion of the load on the pile coupling member 306 to the one or more clamp assemblies 330. The retaining member 370a may be a square plate in the range of about 8 inches to about 12 inches square. The thickness of the retaining member 370a may be in the range of about 2 inches thick. It is noted however that the retaining member 370a may be rectangular in shape, circular in shape or other shape sufficient tofit over and cover the bottom edge of the pile coupling members 306 and possibly to support and transfer at least a portion of the load on the pile coupling member 306 to the one or more clamp assemblies 330.

[0075] An exemplary embodiment of a tensioning system 380 is shown in Figs. 33-35. Each tensioning system 380 shown includes a threaded rod 382, a puck 384, nuts 386 and 388, and a nut 390. The puck 384 is secured to one end of the threaded rod 382 using, for example, nuts 386 and 388 positioned on each side of the puck 384 as shown. The nut 390 is used to secure the cap 372 to the first flange 318 of the pile coupling member 306.

[0076] An exemplary operation for impacting shafts of helical piles will be described with reference to Figs. 17-26. In the embodiment shown, the grillage body 300 is first positioned on the ground at a location where the helical piles 700, 704, 708 and 712 are to be located, seen in Fig. 17. The installer then marks the ground to indicate where each helical pile is to be driven, e.g., screwed, into the soil. With the ground marked, the grillage body 300 is removed and the helical piles 700, 704, 708 and 712 are driven into the soil leaving a portion of the final shaft 702, 706, 710 and 714 extending above grade, as shown in Fig. 17. It is noted that the grillage assembly shown is a four pile grillage assembly. However, the grillage assembly may be configured and dimensioned to transfer loads to more than four helical piles. For example, the grillage assembly may be a six pile grillage assembly, an eight pile grillage assembly, a ten pile grillage assembly, or a twelve pile grillage assembly. The shafts 702, 706, 710 and 714 may be hollow or solid and may have any suitable cross-sectional shape including round and square shapes. It is noted that each shaft of the helical pile may include one or more shafts joined together to form the shafts 702, 706, 710 and 714. Typically, the first shaft of a helical pile is called a lead shaft and each subsequent shaft is called an extension shaft. It is the lead shaft and the one or more extension shafts that form the shafts 702, 706, 710 and 714. Each lead shaft has one or more spaced apart shear helical plates arranged along its length as is known. The helical plates may be welded to the lead shaft or may be otherwise secured to the lead shaft using any other suitable methods. When the lead shaft is rotated, each of the one or more helical plates will screw the lead shaft and any extension shafts into the soil with minimal disruption to the surrounding soil. Generally, each shaft 702, 706, 710 and 714 is driven into the soil to an appropriate depth to support the intended load.

[0077] Continuing to refer to Figs. 17-26, with the helical piles 700, 704, 708 and 712 driven into the soil, the tensioning system 380, seen in Fig. 31, is installed in an open end of each helical pile shaft 702, 706, 710 and 714 above grade and temporarily held within the respective shaft 702, 706, 710 and 714 using, for example, a washer or plate 392, seen in Fig. 32, and the nut 390. With a tensioning system 380 installed in each shaft 702, 706, 710 and 714, the pile coupling members 306 of the grillage body 300 are placed over respective shafts 702, 706, 710 and 714, and the shafts are marked at 450 to indicate a position where a clamp assembly 330 is to be attached to each shaft. This mark 450 is intended to level the grillage assembly to provide a level support for the structure (not shown) to be attached to grillage assembly. With the shafts 702, 706, 710 and 714 marked, the indexing ring 130 of the indenting tool assembly 10 is attached to a first shaft, which in this example is shaft 714, so that the mark 450 is aligned with the top wall 170 of the main body 132 of the indexing ring 130 and the top wall 194 of the clamp body 134 of the indexing ring 130, as shown in Figs. 17 and 18. With the indexing ring 130 attached to the shaft 714, the main body 72 of the punch ring 70 is positioned on the indexing ring 130 so that the shaft 714 is within the inner wall 78 of the main body 72, as shown in Fig. 19. At this point, the indexing ring 130 initially provides a support for the tool assembly 10. The clamp body 74 of the punch ring 70 is positioned on the indexing ring 130 so that the tensioning members 88, e.g., bolts, can be threaded into the apertures 82 and loosely tightened around the shaft 714 so that the indenting tool assembly 10 can be rotated relative to the shaft 714. With the indenting tool assembly 10 loosely attached to the shaft 714, the alignment groove 100 on the clamp body 74 of the punch ring 70 is aligned with the alignment groove 150 associated with the sequence 1 indicia 200 on the clamp body 134 of the indexing ring 130, as shown in Fig. 19. With the alignment groove 100 aligned with the alignment groove 150, a locking fastener 73 is passed through the alignment aperture 102 in the clamp body 74 of the punch ring 70 and threaded into the alignment aperture 152 in the clamp body 134 of the indexing ring 130 corresponding to sequence 1 indicia 200. The locking fastener 73 is then tightened so that the punch ring 70 is locked in the sequence 1 position relative to the indexing ring 130, as shown in Fig. 20, and the tensioning members 88 are tightened to secure the indenting tool assembly 10 to the shaft 714.

[0078] With the indenting tool assembly 10 secured to the shaft 714, a tip 56a of the probe 56 of the deflection measuring assembly 26 is spaced away from the shaft 714, seen in Figs. 20 and 21, so that a gap “G2” is between the impacting wall 126 of the punch 110 and the shaft 714 and between the tip 56a of the probe 56 and the shaft 714. The pump (not shown) is activated, e.g., manually activated, to pump hydraulic fluid into the ram assembly 22 causing the piston 30 to begin to move from the at rest position toward the extended position. When the impacting wall 126 of the punch 110 contacts the shaft 714, the tip 56a of the probe 56 also contacts the shaft 714, as shown in Fig. 22. Further activation of the pump moves the piston 30 to the extended position causing the impacting wall 126 of the punch 110 to impact the shaft 714 creating an indent 390 in the shaft 714, seen in Figs. 17, 23 and 24. As the impacting wall 126 of the punch 110 creates the indent 390, the tip 56a of the probe 56 remains in contact with the shaft 714 so that the probe 56 compresses as the shaft 714 is indented by the impacting wall 126. The compression on the probe 56 represents the depth of the indent in the shaft 714, which is measured by the transducer 54 and displayed on the indicator 52 of the deflection measuring assembly 26. The measured depth of the indent is then displayed on the indicator 52, as shown in Fig. 23. When the indicator 52 displays the desired depth of the indent, the pump is deactivated, e.g., the manual pumping is stopped. As a non-limiting example, the depth of the indent may be in the range of about 0.1 inch to about 0.3 inch, and preferably about 0.2 inch. It is noted that the indent 390 has two components, a first component is the indent 390a in the outer wall of the shaft 714 and a second component is a protrusion 390b extending from the inner wall of the shaft 714, as shown in Figs. 23 and 24.

[0079] Referring to Fig. 25, with the sequence 1 indent completed, the locking fastener 73 is removed and the tensioning members 88 of the punch ring 70 are loosened so that the indenting tool assembly 10 can be rotated, e.g., rotated clockwise, until the alignment groove 100 on the clamp body 74 of the punch ring 70 is aligned with the alignment groove 150 associated with the sequence 2 indicia 200 on the clamp body 134 of the indexing ring 130, seen in Figs. 14 and 25. With the alignment groove 100 aligned with the alignment groove 150, the locking fastener 73 is passed through the alignment aperture 102 in the clamp body 74 of the punch ring 70 and threaded into the alignment aperture 152 in the clamp body 134 of the indexing ring 130 corresponding to the sequence 2 indicia 200 and tightened so that the punch ring 70 is locked inthe sequence 2 position relative to the indexing ring 130, as shown in Fig. 25. The tensioning members 88 are then tightened to secure the indenting tool assembly 10 to the shaft 714. With the indenting tool assembly 10 secured to the shaft 714, the pump (not shown) is again activated as described above until the sequence 2 indent 390 is created. This process for aligning the indenting tool assembly 10 with the indexing ring grooves 150 and activating the pump is repeated until all the intended indents 390 are created in the shaft, seen in the shaft 710 of Figs. 17 and 26. Once the indents 390 are created in the shaft 714, the installer can then follow the same indent making process on the shafts 702, 706 and 710 of the other helical piles 700, 704 and 708.

[0080] Referring now to Figs. 27-29, an exemplary embodiment of a clamp assembly according to the present disclosure is shown. The clamp assembly 330 includes a first clamp body 332 and a second clamp body 334. The first clamp body 332 has a front wall 336 that includes an inner wall 338 and one or more mating walls 340. In the embodiment shown, the inner wall 338 is preferably configured and dimensioned to receive at least a portion of a shaft of a helical pile, e.g., shaft 710, and is arcuate in shape. However, the inner wall 338 can have any shape suitable to contact the shaft of a helical pile. The inner wall 338 includes one or more ribs or detents 342 that extend away from the inner wall 338. Each of the one or more ribs 342 is configured and dimensioned to fit within one of the indents 390 around the perimeter of the shaft 710. The ribs 342 have a thickness “T” that is substantially the same as the depth of the indent 390. For example, the thickness “T” of the ribs 342 may be in the range of about 0.1 inch to about 0.3 inch, and preferably about 0.2 inch. Each of the one or more mating walls 340 of the first clamp body 332 includes one or more clamp attachment apertures 344, seen in Fig. 27. Each of the one or more clamp attachment apertures 344 is configured and dimensioned to receive a tensioning member 346, e.g., a mechanical fastener, used to attach the first clamp body 332 to the second clamp body 334. Preferably, the one or more clamp attachment apertures 344 are smooth bore apertures. In the exemplary embodiment shown, the tensioning members 346 is a mechanical fastener, such as threaded bolt 348 and nut 350, where the threaded bolt 348 can be passed through the clamp attachment apertures 344.

[0081] Continuing to refer to Figs. 27-29, the second clamp body 334 has a front wall 352 that includes an inner wall 354 and one or more mating walls 356. In the embodiment shown, theinner wall 354 is preferably configured and dimensioned to receive at least a portion of a shaft of a helical pile, e.g., shaft 710, and is arcuate in shape. However, the inner wall 354 can have any shape suitable to contact the shaft of a helical pile. The inner wall 354 includes one or more ribs or detents 358, which are substantially the same as ribs or detents 342, that extend away from the inner wall 354. Each of the one or more ribs 358 is configured and dimensioned to fit within one of the indents 390 around the perimeter of the shaft 710. The ribs 358 have a thickness “T” that is substantially the same as the depth of the indent 390. For example, the thickness “T” of the ribs 358 may be in the range of about 0.1 inch to about 0.3 inch, and preferably about 0.2 inch. Each of the one or more mating walls 356 of the second clamp body 334 includes one or more clamp attachment apertures 360, seen in Fig. 27. Each of the one or more clamp attachment apertures 360 is configured and dimensioned to receive the tensioning member 346, e.g., a mechanical fastener, used to attach the first clamp body 332 to the second clamp body 334. Preferably, the one or more clamp attachment apertures 360 are smooth bore apertures. In the exemplary embodiment shown, each tensioning member 346 includes a threaded bolt 348 and nut 350, where the threaded bolt 348 can be passed through the clamp attachment aperture 344 in the first clamp body 332, as noted above, and through clamp attachment aperture 360 in the second clamp body 334 and the nut 350 is threaded to the bolt 348 and tightened to secure the first clamp body 332 and the second clamp body 334 to the shaft of the helical pile, here shaft 710. More specifically, the first clamp body 332 can be positioned on one side of the shaft 710 and the second clamp body 334 can be positioned on an opposite side of the shaft 710, so that the ribs 342 of the first clamp body 332 and the ribs 358 of the second clamp body 334 are positioned in the indents 390 in the shaft of the helical piles, here shaft 710. The first clamp body 332 can then be secured to the second clamp body 334 with the shaft 710 therebetween using the one or more tensioning members 346, as shown in Figs. 28.

[0082] Generally, clamp assemblies 330 are secured to the shafts, e g., shafts 702, 706, 710 and 714 of the helical piles, e.g., helical piles 700, 704, 708 and 712, at a point where the ribs 342 and 358 of the clamp assemblies fit within the indents 390 around a perimeter of the shafts, e.g., shafts 702, 706, 710 and 714, as shown in Fig. 29. When the clamp assemblies 330 are secured to the shafts of the helical piles, the clamp assemblies provide both a friction and mechanical connection to the shafts of the helical piles sufficient to transfer the load, an axialload, from the grillage assembly to the helical piles. The tensioning members 346 used to secure the first clamp body 332 to the second clamp body 334 may be tensioned using, for example, a hydraulic or pneumatic driver. According to embodiments of the present disclosure, the clamp assemblies 330 and the tensioning members 346 may be made of metallic materials. Nonlimiting examples of such metallic materials include grade 8 steel, steel, galvanized steel, stainless steel, or any other suitable alloy.

[0083] Referring now to Figs. 30-35, an exemplary operation for attaching the grillage body 300 of Fig. 30 to the shafts 702, 706, 710 and 714 of the helical piles 700, 704, 708 and 712 is shown and described. With the clamp assemblies 330 secured to the shafts 702, 706, 710 and 714 as described above, two retaining members 370a and 370b, seen in Fig. 30, are positioned over each shaft 702, 706, 710 and 714 so that retaining member 370a rests on the respective clamp assembly 330, seen in Fig. 31, and the retaining member 370b rests on the respective retaining member 370a. The retaining members 370a and 370b are positioned over each shaft 702, 706, 710 and 714 such that the respective shaft passes through mounting apertures (not shown) in the retaining members 370a and 370b. The mounting apertures in the retaining members 370a and 370b may be centered on the retaining members 370a and 370b. However, the present disclosure contemplates that the mounting apertures in the retaining members 370a and 370b may be offset from the center of the retaining members 370a and 370b to compensate for the positioning of the shafts 702, 706, 710 and 714 relative to the center of the pile coupling members 306. The pile coupling members 306 of the grillage body 300 are then positioned over each shaft 702, 706, 710 and 714, respectively, so that the bottom edge of the pile coupling member 306 is in contact with a respective retaining member 370b, as shown in Figs. 31 and 33. With the pile coupling members 306 positioned on respective shafts 702, 706, 710 and 714, grout 400, seen in Fig. 33, may be poured into the pile coupling members 306 and possibly into the shafts 702, 706, 710 and 714 of the helical piles 700, 704, 708 and 712 as is known. With the grout 400 poured into the pile coupling members 306 and possibly into the shafts, the temporary washer or plate 392 and nut 390 holding the tensioning systems 380 in place within each shaft 702, 706, 710 and 714 are removed, as shown in Fig. 32, so that a the one or more caps 372 can be positioned onto pile coupling members 306 where the threaded rod 382 of the tensioning systems 380 is passed through mounting apertures 374 in the one or more caps 372. In theexemplary embodiment shown, the cap 372b is positioned on the top edge of the pile coupling member 306, and the cap 372a is positioned on the cap 372b, as shown in Fig. 32. It is also noted that the mounting apertures 374 are shown as being centered on the caps 372. However, the present disclosure contemplates that the mounting apertures 374 may be offset from the center of the caps 372 to compensate for the positioning of the threaded rod 382 relative to the center of the pile coupling member 306. The nut 390 is then threaded onto the threaded rod 382, as shown in Figs. 32 and 33. As shown in Fig. 33, the length of the threaded rod 382 is such that the puck 384 of the tensioning systems 380 is below the indents 390 within the shaft of the respective helical pile, here shaft 710. As a non-limiting example, the threaded rod 382 may have an outside diameter of about 2 inches and a length of about 36 inches. As the nut 390 is tightened, the threaded rod 382 and puck 384 move upward toward the open end of the shaft, e.g., shaft 710, as shown in Fig. 34. It is noted that the puck 384 has an outer diameter “DI” that is slightly smaller than the inner diameter “D2” of the shaft of the helical pile, here shaft 710, so that the puck 384 can move within the shaft, e.g., shaft 710, and engage the protrusions 390b of the indents 390 within the shaft. As a result, when the nut 390 is tightened to a point where the puck 384 engages the protrusions 390b of the indents 390, as shown in Fig. 35, the one or more retaining members 370, pile coupling member 306 and one or more caps 372 are tightened against the clamp assembly 330. With the one or more retaining members 370, pile coupling member 306 and one or more caps 372 tightened against the clamp assembly 330, axial loads, e.g., compression and / or tension loads, exerted by the structure onto the grillage assembly supporting the structure are transferred to the helical piles. More specifically, the grillage assemblies and clamp assemblies described herein effectively transfer axial loads, e.g., tension and / or compression loads, on the grillage assemblies to helical piles attached to the grillage assemblies.

[0084] Turning to Figs. 36-43, another exemplary embodiment of a tool assembly according to the present disclosure is shown. In this exemplary embodiment, the tool assembly 500 includes a plurality of punch drive assemblies 20, a plurality of punches 110, a punch ring 510 and a support ring 570. Each punch drive assembly 20 is substantially the same as the punch drive assemblies described above with reference to Fig. 1-35 so that a more detailed description of the punch drive assemblies is not repeated. Each of the plurality of punches 110 are substantially thesame as the punches described herein above, except the length of the first portion 112 and the second portion 114 may be larger than the length in the embodiments described above. Therefore, a more detailed description of the punches 110 is not repeated.

[0085] Referring to Figs. 36-40, another exemplary embodiment of a punch ring 510 according to the present disclosure is shown. Punch ring 510 is configured and dimensioned to support a plurality of punch drive assemblies 20 so that the punch drive assemblies 20 can be activated in unison or sequentially without having to reposition the punch drive assemblies 20. In the exemplary embodiment shown, punch ring 510 is configured and dimensioned to support six punch drive assemblies 20. However, punch ring 510 can be configured and dimensioned to support less than six punch drive assemblies 20 or more than six punch drive assemblies 20.

[0086] The punch ring 510 includes a main body 512 and a clamp body 514. As shown in Fig. 38, the main body 512 has a front wall 516 and a plurality of punch drive assembly walls 518.For ease of description, the punch drive assembly walls 518 may also be referred to herein as the “punch walls” in the plural and the “punch wall” in the singular. The front wall 516 includes an inner wall 520 and one or more mating walls 522. Preferably, the one or more mating walls 522 are substantially flat walls configured to align with mating walls of the clamp body 514 described below. In this exemplary embodiment, there are two mating walls identified as walls 522a and 522b. The inner wall 520 is preferably configured and dimensioned to receive at least a portion of a shaft, e.g., shaft 702, 706, 710 or 714, of a helical pile, e.g., helical pile 700, 704, 708 or 712, seen in Fig. 17. In the embodiment shown, the inner wall 520 is an arcuate shaped wall configured to receive a portion of a round helical pile shaft. However, the shape of the inner wall 520 can be configured to receive square or other shaped helical pile shafts.

[0087] Continuing to refer to Figs. 36-40, each punch wall 518 of the main body 512 is a generally flat wall that is configured and dimensioned to support a punch drive assembly 20 so that the punch 110 of the tool assembly 500 is properly aligned to strike or impact the helical pile shaft. Punch wall 518a includes a clamp attachment aperture 524 extending through the main body 512 and exiting the mating wall 522a, and punch wall 518c includes a clamp attachment clamp attachment aperture 524 extending through the main body 512 and exiting the mating wall 522b, as shown in Fig. 38. The clamp attachment apertures 524 are preferably smooth bores sothat tensioning members 88, e.g., the mechanical fasteners, used to attach the main body 512 to the clamp body 514 can pass through the apertures. Each punch wall 518, which in this exemplary embodiment is punch walls 518a, 518b and 518c, includes a plurality of mounting apertures 526 and a plurality of punch apertures 528, seen in Figs. 37 and 38. The plurality of mounting apertures 526 are configured and dimensioned to receive the tensioning members 38, e.g., mechanical fasteners seen in Figs. 2 and 37, used to attach the mounting members 24 of the punch drive assemblies 20 to the main body 512. Preferably, each of the plurality of mounting apertures 526 are threaded apertures and the tensioning member 38 are threaded bolts that can be threaded into the threaded mounting apertures 526 to attach the mounting member 24 to the main body 512 of the punch ring 510. Each punch aperture 528 extends from punch wall 518, seen in Fig. 38, of the main body 512 through the main body and exiting the inner wall 520 of the front wall 516 of the main body 512, as shown in Fig. 37. The punch apertures 528 are substantially the same as the punch apertures 86 described above. In one exemplary embodiment, each punch aperture 528 is an elongated slot, seen in Fig. 37, that is configured and dimensioned to receive the punch 110. In another exemplary embodiment, the punch aperture 528 may be a slot, similar to that shown in phantom in Figs. 6 and 7, that is configured and dimensioned to receive the punch 110 such that there is snug fit between the punch 110 and the walls of the respective punch aperture 528 and where the punch 110 is movable within the punch aperture 528. In addition, a portion of the slot forming punch aperture 110 has tapered walls, e.g., top, bottom and side walls, similar to tapered walls 87 seen in Figs. 6 and 7. The taper of tapered walls, similar to tapered walls 87, is configured to mate with a taper in the walls of the punch 110, which is described above.

[0088] Referring to Figs. 36, 39 and 40, the clamp body 514 has a front wall 530 and a plurality of punch drive assembly walls 532. For ease of description, the punch drive assembly walls 532 may also be referred to herein as the “punch walls” in the plural and the “punch wall” in the singular. The front wall 530 includes an inner wall 534 and one or more mating walls 536. In the embodiment shown, there are two mating walls identified as walls 536a and 536b. However, there may be less than two mating walls 536 or there may be more than two mating walls 536. The one or more mating walls 536 are preferably substantially flat walls so that the one or more mating walls 536 can mate with the one or more mating walls 522 of the main body512 so that there is a flush fit. Inner wall 534 is preferably configured and dimensioned to receive at least a portion of a shaft, e.g., shaft 702, 706, 710 or 714, of a helical pile, e.g., helical pile 700, 704, 708 or 712, seen in Fig. 17. In the embodiment shown, the inner wall 534 is an arcuate shaped wall configured to receive a portion of a round helical pile shaft. However, the shape of the inner wall 534 can be configured to receive square or other shaped helical pile shafts. The front wall 530 of the clamp body 514 also includes a plurality of clamp attachment apertures 538 that extend at least partially into the clamp body 514. Each clamp attachment aperture 538 is configured and dimensioned to receive the tensioning member 88, e.g., the mechanical fastener, used to attach the clamp body 514 to the main body 512. Preferably, the clamp attachment apertures 538 are threaded apertures and, as noted, the tensioning members 88 are threaded bolts that can be threaded into the threaded clamp attachment apertures 538 to attach the clamp body 514 to the main body 512.

[0089] Continuing to refer to Figs. 39 and 40, each punch wall 532 of the clamp body 514 is a generally flat wall that is configured and dimensioned to support a punch drive assembly 20 so that the punch 110 of the tool assembly 500 is properly aligned to strike or impact the helical pile shaft. Each punch wall 532, which in this exemplary embodiment is punch walls 532a, 532b and 532c, includes a plurality of mounting apertures 540 and a plurality of punch apertures 542. The plurality of mounting apertures 540 are configured and dimensioned to receive the tensioning members 38, e.g., mechanical fasteners, seen in Figs. 2 and 37, used to attach the mounting members 24 of the punch drive assemblies 20 to the clamp body 514. Preferably, each of the plurality of mounting apertures 540 are threaded apertures and the tensioning members 38 are threaded bolts that can be threaded into the threaded mounting apertures 540 to attach the mounting member 24 to the clamp body 514 of the punch ring 510. Each punch aperture 542 extends from punch wall 532 of the clamp body 514 through the clamp body and exiting the inner wall 534 of the front wall 530 of the main body 512, as shown in Fig. 40. The punch apertures 542 are substantially the same as the punch apertures 86 described above. In one exemplary embodiment, each punch aperture 542 is an elongated slot, seen in Fig. 40, that is configured and dimensioned to receive the punch 110. In another exemplary embodiment, each punch aperture 542 may be a slot, similar to that shown in phantom in Figs. 6 and 7, that is configured and dimensioned to receive the punch 110 such that there is snug fit between thepunch 110 and the walls of the respective punch aperture 542 and where the punch 110 is movable within the punch aperture 542. In addition, a portion of the slot forming punch aperture 110 has tapered walls, e.g., top, bottom and side walls, similar to tapered walls 87 seen in Figs. 6 and 7. The taper of tapered walls, similar to tapered walls 87, is configured to mate with a taper in the walls of the punch 110, which is described above.

[0090] Referring again to Fig. 36, an exemplary embodiment of the support ring 570 according to the present disclosure is shown. The support ring 570 is configured and dimensioned to be clamped to a shaft of a helical pile. The support ring 570 provides a support structure for the tool assembly 500. In the embodiment shown, the support ring 570 includes a main body 572 and a clamp body 574. The main body 572 is a substantially solid shaped member having an exterior wall 576, an interior wall 578, a mating wall 580 and a connecting wall 582. The exterior wall 576 can be any shape wall, e.g., an arcuate, circular, elliptical, oval, square or any other shaped wall. In the embodiment shown, the exterior wall 576 has an arcuate shape. The interior wall 578 can have any shape that is sufficient to contact and engage the shaft of a helical pile when the support ring 570 is attached to a helical pile. Non-limiting examples of the shape of the interior wall 578 include arcuate, circular, elliptical, oval and square shapes. In the embodiment shown, the mating wall 580 is a substantially flat wall configured to align with a mating wall of the clamp body 574 described below. The main body 572 includes an aperture 584 extending therethrough from the exterior wall 576 to the mating wall 580. In the embodiment shown, the aperture 584 is a smooth bore aperture configured and dimensioned to receive a tensioning member 586, e.g., a mechanical fastener. The tensioning member 586 is substantially similar to the tensioning member 148 shown in Fig. 14 and described above. The connecting wall 582 defines a tongue portion of a tongue and groove connection with the clamp body 574. However, the connecting wall 582 can be any configuration that couples the main body 572 to the clamp body 574.

[0091] Similarly, the clamp body 574 is a substantially solid shaped member having an exterior wall 590, an interior wall 592, a mating wall 594 and a connecting wall 596. The exterior wall 590 can be any shaped wall, e.g., an arcuate, circular, elliptical, oval, square or any other shaped wall. In the embodiment shown, the exterior wall 590 has an arcuate shape. The interior wall 592 can have any shape that is sufficient to contact and engage the shaft of a helicalpile when the support ring 570 is attached to a helical pile. Non-limiting examples of the shape of the interior wall 592 include arcuate, circular, elliptical, oval and square shapes. In the embodiment shown, the mating wall 594 is a substantially flat wall configured to align with the mating wall 580 of the main body 572. The clamp body 574 includes an aperture 598 extending from the mating wall 594 into the clamp body 574. In the embodiment shown, the aperture 598 is a threaded aperture configured and dimensioned to receive a threaded portion of the tensioning member 586, e.g., a mechanical fastener, when securing the clamp body 574 to the main body 572. The connecting wall 596 defines a groove portion of a tongue and groove connection with the main body 572. The tongue and groove connection of the clamp body 574 to the main body 572 is by a pin 600 that is passed through apertures in the tongue and the groove. However, the connecting wall 596 can be any configuration that couples the main body 572 to the clamp body 574.

[0092] Referring now to Figs. 17-22 and 41-43, the installation of a grillage assembly using the tool assembly 500 will be described. As described above, with the helical piles 700, 704, 708 and 712 driven into the soil, the tensioning system 380, seen in Fig. 31, is installed in an open end of each helical pile shaft 702, 706, 710 and 714 above grade and temporarily held within the respective shaft 702, 706, 710 and 714 using, for example, a washer or plate 392, seen in Fig. 32, and the nut 390. With a tensioning system 380 installed in each shaft 702, 706, 710 and 714, the pile coupling members 306 of the grillage body 300 are placed over respective shafts 702, 706, 710 and 714, and the shafts are marked at 450 to indicate a position where a clamp assembly 330 is to be attached to each shaft, as shown in Fig. 17. This mark 450 is intended to level the grillage assembly to provide a level support for the structure (not shown) to be attached to grillage assembly. With the shafts 702, 706, 710 and 714 marked, the support ring 570 of the indenting tool assembly 500 is attached to a first shaft, which in this example is shaft 714, so that the mark 450 is aligned with a top wall 602 of the main body 572 of the support ring 570 and a top wall 604 of the clamp body 574 of the support ring 570, as shown in Figs. 17 and 18. With the support ring 570 attached to the shaft 714, the main body 512 and the punch drive assemblies 20 attached to the main body 512 are positioned on the support ring 570 so that the shaft 714 is within the interior wall 520 of the main body 512, similar to how the main body 72 is shown in Fig. 19. At this point, the support ring 570 initially provides support for the tool assembly 500.The clamp body 514 and the punch drive assemblies 20 attached to the clamp body 514 are positioned on the support ring 570 so that the tensioning members 88, e.g., bolts, can be threaded into the apertures 538 of the clamp body 514 and tightened around the shaft 714.

[0093] With the indenting tool assembly 500 secured to the shaft 714, there are now a predefined number of punch drive assemblies 20 attached to the tool assembly 500, which in this exemplary embodiment is six. However, as previously mentioned, there may be more than six or less than six punch drive assemblies 20 attached to the tool assembly 500. For each punch drive assembly 20 attached to the tool assembly 500, the tip 56a of the probe 56 of the deflection measuring assembly 26 is spaced away from the shaft 714, similar to what is shown in Figs. 20 and 21, so that a gap “G2” is between the impacting wall 126 of the punch 110 and the shaft 714 and between the tip 56a of the probe 56 and the shaft 714. The pump or pumps (not shown) attached to each punch drive assembly 20 is activated, e.g., manually activated or electrically activated or activated via an electronic controller, to pump hydraulic fluid into the ram assembly 22, seen in Fig. 37, causing the piston 30 to begin to move from the at rest position toward the extended position. It is noted that the pump or pumps (not shown) may be activated at the same time or in pairs or sequentially or in predefined sequences. When the impacting wall 126 of punch 110 contacts shaft 714, the tip 56a of the probe 56 also contacts shaft 714, similar to what is shown in Fig. 22. Further activation of the pump (or pumps) moves the piston 30 to the extended position causing the impacting wall 126 of the punch 110 to impact the shaft 714 creating an indent 390 in the shaft 714, seen in Figs. 17, 42 and 43. As the impacting wall 126 of the punch 110 creates the indent 390, the tip 56a of the probe 56 remains in contact with the exterior of the shaft 714 so that the probe 56 compresses as the shaft 714 is indented by the impacting wall 126. The compression on probe 56 represents the depth of the indent in the shaft 714, which is measured by the transducer 54 and displayed on the indicator 52 of the deflection measuring assembly 26. The measured depth of the indent is then displayed on indicator 52, as shown in Fig. 42. When the indicator 52 displays the desired depth of the indent, the pump (or pumps) is deactivated, e.g., the manual pumping or electrically activated pumping or pumping activated via an electronic controller, is stopped. As a non-limiting example, the depth of the indent may be in the range of about 0.1 inch to about 0.3 inch, and preferably about 0.2 inch. It is noted that indent 390 has two components, a first component is the indent 390a in the outerwall of the shaft 714 and a second component is a protrusion 390b extending from the inner wall of the shaft 714, as shown in Figs. 42 and 43.

[0094] Thus, in this exemplary embodiment, the with the six punch drive assemblies 20 activated, either at the same time or in pairs or sequentially or in predefined sequences, and without moving the tool assembly 500, the six indents 390 are made. This reduces the installation time for technicians in the field to install grillage assemblies. With the indents 390 made, as shown in Fig. 26, the exemplary operation for attaching the clamp assemblies 330 to the shafts 702, 706, 710 and 714 of the helical piles 700, 704, 708 and 712 is shown and described above with reference to Figs. 26-29 and, for ease of description, is not repeated. In addition, the exemplary operation for attaching the grillage body 300 of Fig. 30 to the shafts 702, 706, 710 and 714 of the helical piles 700, 704, 708 and 712 is shown and described above with reference to Figs. 30-35 and, for ease of description, is not repeated.

[0095] Utilizing the indenting tool assemblies, clamps assemblies and grillage assemblies described herein, large structures can be more effectively and efficiently erected in remote locations. The grillage assemblies described herein complement the clamp assemblies described herein providing a secure base for large structures erected in remote locations. The clamp assemblies and grillage assemblies described herein are particularly suited for the construction of remote structures utilizing helical pile shafts. The particular configuration of the clamp assemblies and grillage assemblies, etc. as well as the dimensions of each may depend upon the particular helical piles being utilized which will generally depend on the load the helical piles are to bear and the soil conditions. Accordingly, it will be understood that various modifications can be made to the embodiments of the present disclosure herein without departing from the spirit and scope thereof. Therefore, the above description should not be construed as limiting the disclosure, but merely as embodiments thereof. Those skilled in the art will envision other modifications within the scope and spirit of the disclosure as defined by the claims appended hereto.

Claims

CLAIMSWhat is claimed is:

1. An indenting tool assembly for imparting at least one indent to a shaft of a helical pile, the indenting tool assembly comprising: a punch drive assembly; a punch coupled to the punch drive assembly, the punch having an impacting wall configured to impact the shaft of the helical pile to impart the at least one indent; a punch ring secured to the punch drive assembly and attachable to the shaft of the helical pile; and an indexing ring attachable to the shaft of the helical pile.

2. The indenting tool assembly according to claim 1, wherein the punch drive assembly comprises: a ram assembly having a piston that is movable between an at rest position and an extended position; and a mounting member, the mounting member being secured to the punch ring.

3. The indenting tool assembly according to claim 2, wherein the punch drive assembly further comprises a deflection measuring assembly used to measure a depth of an indent made in the shaft of the helical pile by the punch drive assembly.

4. The indenting tool assembly according to claim 2, wherein the ram assembly comprises a housing and the is piston positioned within the housing and movable relative to the housing between the at rest position and the extended position.

5. The indenting tool assembly according to claim 1, wherein the punch ring comprises a main body and a clamp body that is at least partially removable from the main body.

6. The indenting tool assembly according to claim 5, wherein the main body of the punch ring includes an interior wall and an exterior wall, wherein the interior wall includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile.

7. The indenting tool assembly according to claim 5, wherein the clamp body of the punch ring includes an interior wall and an exterior wall, wherein the interior wall includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile, and wherein the exterior wall includes at least one alignment groove used to align the punch ring relative the indexing ring.

8. The indenting tool assembly according to claim 1, wherein the indexing ring comprises a main body and a clamp body that is at least partially removable from the main body.

9. The indenting tool assembly according to claim 8, wherein the main body of the indexing ring includes an interior wall and an exterior wall, wherein the interior wall includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile, wherein the exterior wall includes at least one alignment groove used to align the indexing ring relative the punch ring, and wherein the exterior wall includes at least one indicia associated with the at least one groove, the at least one indicia being used to identify a sequence for making indents on the shaft of the helical pile.

10. The indenting tool assembly according to claim 8, wherein the clamp body of the indexing ring includes an interior wall and an exterior wall, wherein the interior wall includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile, wherein the exterior wall includes at least one alignment groove used to align the indexing ring relative the punch ring, and wherein the exterior wall includes at least one indicia associated with the at least one groove, the at least one indicia being used to identify a sequence for making indents on the shaft of the helical pile.

11. An indenting tool assembly for imparting a plurality of indents to a shaft of a helical pile, the indenting tool assembly comprising:a plurality of punch drive assemblies; a plurality of punches, wherein one of the plurality of punches is coupled to one of the plurality of punch drive assemblies, each punch having an impacting wall configured to impact the shaft of the helical pile to impart the at least one indent; a punch ring attachable to the shaft of the helical pile and having the plurality of punch drive assemblies attached thereto such that the plurality of punches pass through the punch ring when impacting the shaft of the helical pile to impart the indents; and an support ring attachable to the shaft of the helical pile.

12. The indenting tool assembly according to claim 11, wherein each punch drive assembly comprises: a ram assembly having a piston that is movable between an at rest position and an extended position; and a mounting member, the mounting member being secured to the punch ring.

13. The indenting tool assembly according to claim 12, wherein each punch drive assembly further comprises a deflection measuring assembly used to measure a depth of an indent made in the shaft of the helical pile by the punch drive assembly.

14. The indenting tool assembly according to claim 12, wherein the ram assembly comprises a housing and the piston is positioned within the housing and movable relative to the housing between the at rest position and the extended position.

15. The indenting tool assembly according to claim 11, wherein the punch ring comprises a main body and a clamp body that is at least partially removable from the main body.

16. The indenting tool assembly according to claim 15, wherein the main body of the punch ring includes an interior wall and an exterior wall, wherein the interior wall includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile.

17. The indenting tool assembly according to claim 15, wherein the clamp body of the punch ring includes an interior wall and an exterior wall, wherein the interior wall includes an inner wall that is configured to receive at least a portion of the shaft of the helical pile.

18. The indenting tool assembly according to claim 1, wherein the support ring comprises a main body and a clamp body that is at least partially removable from the main body.

19. The indenting tool assembly according to claim 18, wherein the main body of the support ring includes an interior wall and an exterior wall, wherein the interior wall is configured to receive at least a portion of the shaft of the helical pile.

20. The indenting tool assembly according to claim 18, wherein the clamp body of the support ring includes an interior wall and an exterior wall, wherein the interior wall is configured to receive at least a portion of the shaft of the helical pile.

21. A clamp assembly comprising: a first clamp member having an interior wall and an exterior wall, wherein the interior wall includes an inner wall and at least one mating wall, and wherein the inner wall includes at least one rib extending therefrom; a second clamp member having an interior wall and an exterior wall, wherein the interior wall includes an inner wall and at least one mating wall, and wherein the inner wall includes at least one rib extending therefrom; and at least one tensioning member configured to draw the first clamp member and the second clamp member toward each other.

22. The clamp assembly according to claim 21, wherein the at least one mating wall of the first clamp member includes at least one aperture extending through to the exterior wall.

23. The clamp assembly according to claim 21, wherein the at least one mating wall of the second clamp member includes at least one aperture extending through to the exterior wall.

24. The clamp assembly according to claim 21, wherein the inner wall of the first clamp member is substantially arcuate in shape.

25. The clamp assembly according to claim 21, wherein the inner wall of the second clamp is arcuate in shape.

26. The clamp assembly according to claim 21, wherein the at least one mating wall of the first clamp member is substantially flat in shape.

27. The clamp assembly according to claim 21, wherein the at least one mating wall of the second clamp member is substantially flat in shape.

28. The clamp assembly according to claim 21, wherein the at least one tensioning member comprises a bolt that is at least partially threaded and a nut.

29. A grillage assembly for attachment to a plurality of helical piles, the grillage assembly comprising: a grillage body having a base member, a plurality of arms and a plurality of pile coupling members, wherein each of the plurality of arms has a first end attached to the base member and a second end that is away from the base member, wherein one of the plurality of pile coupling members is attached to the second end of one of the plurality of arms, and wherein each of the plurality of pile coupling members includes at least one wall and an opening extending from an upper edge of the at least one wall to a bottom edge of the at least one wall, the opening being configured and dimensioned to receive a portion of a shaft of a helical pile; a plurality of retaining members, where one of the plurality of retaining members is associated with the bottom edge of the at least one wall; a plurality of caps, where one of the plurality of caps is associated with the upper edge of the at least one wall; and a plurality of clamp assemblies, each of the plurality of clamp assemblies is configured to be attached to a shaft of a helical pile.

30. The grillage assembly according to claim 29, wherein each of the plurality of clamp assemblies comprises: a first clamp member having an interior wall and an exterior wall, wherein the interior wall includes an inner wall and at least one mating wall, and wherein the inner wall includes at least one rib extending therefrom; a second clamp member having an interior wall and an exterior wall, wherein the interior wall includes an inner wall and at least one mating wall, and wherein the inner wall includes at least one rib extending therefrom; and at least one tensioning member configured to draw the first clamp member and the second clamp member toward each other.

31. The grillage assembly according to claim 30, wherein the at least one mating wall of the first clamp member includes at least one aperture extending through to the exterior wall.

32. The grillage assembly according to claim 30, wherein the at least one mating wall of the second clamp member includes at least one aperture extending through to the exterior wall.

33. The grillage assembly according to claim 30, wherein the inner wall of the first clamp member is substantially arcuate in shape.

34. The grillage assembly according to claim 30, wherein the inner wall of the second clamp is arcuate in shape.

35. The grillage assembly according to claim 30, wherein the at least one mating wall of the first clamp member is substantially flat in shape.

36. The grillage assembly according to claim 30, wherein the at least one mating wall of the second clamp member is substantially flat in shape.

37. The grillage assembly according to claim 30, wherein the at least one tensioning member comprises a bolt that is at least partially threaded and a nut.

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