An improved pile

Abstract

A pile for use with a footing or an anchor. The pile may have a cross-sectional profile, an externally presented formation, recess, texture, or a roughened surface, each of which provide for engagement with a substrate. The pile may be fabricated from a polymeric material.

Description

[0001] AN IMPROVED PILE

[0002] FIELD OF THE INVENTION

[0003]

[0001] , The present invention is directed generally to the field of footings and anchors designed to engage with the ground and stabilise a structure such as a building, platforms, bridges, fences, patios and the like; and also the erection of poles. In particular, the invention is directed to improved piles used to engage footing and anchors with the ground.

[0004] BACKGROUND TO THE INVENTION

[0005]

[0002] , For many reasons it may be necessary for a structure to be engaged with the ground, or other some other substrate. For example, a building is provided with footings for support, and so as to prevent the building from sinking, shifting or lifting. As another example, an object may be tethered to a cable, the cable in turn fixed to a ground-engaged anchor so as to prevent movement of the object.

[0006]

[0003] , It is known in the art to engage an object with the ground by way of a series of piles driven through the plate and into the underlying substrate. The piles may be driven using a mallet or a power tool such as a jack hammer. Where the pile is screw-like, the pile is wound into the substrate. The object is typically retained or supported by a plate, socket or other contrivance comprising guide means such as a tube. Each tube functions to guide the piles into the underlying substrate at a predetermined angle. After installation the tubes maintain engagement with the piles so as to limit movement of the object.

[0007]

[0004] , Piles are conventionally fabricated from steel, and are hollow and tubular with a circular cross-section. While prior art piles generally effective problems arise in that the piles are often necessarily of considerable length in order to provide engagement with the substrate down to a sufficient depth. For many applications, the piles must be at least 3 meters in length in order to provide engagement with the substrate down to a sufficient depth. The handling of long and heavy piles may cause difficulties in transportation and also raise occupational health and safety risks for the installer.

[0008]

[0005] , A further problem is that piles are prone to corrosion. Galvanisation may be used to extend the service life of a pile, however the zinc layer may be compromised during installation or degrade after installation. In any event, galvanisation adds significantly to cost and leaching of zinc into the ground presents an environmental concern.

[0009]

[0006] , Another problem in the art is that piles may not be sufficiently engaged with the ground, such that the footing or anchor secured with the pile is not sufficiently stable. Thus, the foot or anchor may be allowed to shift in any of the x, y or z directions, and may even completely dislodge from the ground. It is known in the art that better engagement is provided by increasing the length of the pile, however that approach adds cost, bulk and weight to the pile.

[0010]

[0007] , It is an aspect of the present invention to overcome or alleviate a problem with the prior art by providing a pile which suitable for use with a footing or ground anchor. It is a further aspect to provide a pile which is a useful alternative to piles of the prior art.

[0011]

[0008] , The discussion of documents, acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.

[0012] SUMMARY OF THE INVENTION

[0013]

[0009] , In a first aspect, but not necessarily the broadest aspect, the present invention provides a pile for use with a footing or an anchor, the pile: (i) having a cross-sectional profile, an externally presented formation, recess, texture, roughened surface, each of which provide for engagement with a substrate, and / or

[0014] (ii) being fabricated from a polymeric material.

[0015]

[0010] , In one embodiment of the first aspect, the cross-sectional profile a provides surface area greater than that provided by a pile having a cross-section that is a circle, an oval, a triangle, a square, a rectangle, a pentagon, a hexagon, a septagon, or an octagon.

[0016] [Oi l], In one embodiment of the first aspect, the cross-sectional profile provides one or more radially aligned formations.

[0017]

[0012] , In one embodiment of the first aspect, the radially aligned formations are disposed at regular angular intervals.

[0018]

[0013] , In one embodiment of the first aspect, the pile comprises 3, 4, 5, 6, 7 or 8 radially aligned formations.

[0019]

[0014] , In one embodiment of the first aspect, the one or more radially aligned formations each runs the length of the pile.

[0020]

[0015] , In one embodiment of the first aspect, each of the one or more radially aligned formations is parallel with a central axis of the pile.

[0021]

[0016] , In one embodiment of the first aspect, the cross-sectional profile provides one of more radially aligned recesses.

[0022]

[0017] , In one embodiment of the first aspect, the one or more radially aligned recesses are disposed at regular angular intervals.

[0018] , In one embodiment of the first aspect, the pile comprises 3, 4, 5, 6, 7 or 8 radially aligned recesses.

[0023]

[0019] , In one embodiment of the first aspect, the radially aligned recesses each runs the length of the pile.

[0024]

[0020] , In one embodiment of the first aspect, each of the one or more radially aligned recesses is parallel with a central axis of the pile.

[0025]

[0021] , In one embodiment of the first aspect, the roughed external surface is provided by removing material from an external surface of the pile, including by scoring, abrading, cutting, machining, scratching or ablating the external surface.

[0026]

[0022] , In one embodiment of the first aspect, the roughed external surface is provided by adding material to an external surface of the pile, including by adhering a roughening material to the external surface.

[0027]

[0023] , In one embodiment of the first aspect, the roughed external surface is provided by incorporating a roughening material into the polymeric material, including by adding a roughening material to the polymeric material before the polymeric material has hardened.

[0028]

[0024] , In one embodiment of the first aspect, the polymeric material is a resin.

[0029]

[0025] , In one embodiment of the first aspect, the resin is orthophthalic, isophthalic or vinyl ester.

[0030]

[0026] , In one embodiment of the first aspect, the polymeric material comprises a reinforcing material incorporated therein.

[0031]

[0027] , In one embodiment of the first aspect, the reinforcing material is incorporated into the polymeric material before the polymeric material has hardened.

[0028] , In one embodiment of the first aspect, the reinforcing material is a fibrous material.

[0032]

[0029] , In one embodiment of the first aspect, the reinforcing material is selected from glass, carbon, aramid and basalt.

[0033]

[0030] , In one embodiment of the first aspect, the polymeric material is fibre reinforced polymer.

[0034]

[0031] , In one embodiment of the first aspect, the pile is fabricated from a non-polymeric material.

[0035]

[0032] , In one embodiment of the first aspect, the non-polymeric material is a metal.

[0036]

[0033] , In one embodiment of the first aspect, the metal is formed by an extrusion process, and the cross-sectional profile is formed during the extrusion process.

[0037]

[0034] , In one embodiment of the first aspect, the pile is configured to snugly pass through a tube of circular cross-section.

[0038]

[0035] , In one embodiment of the first aspect, the pile comprises outwardly curved surfaces configured to contact an interior surface of a circular tube into which it is passed.

[0039]

[0036] , In one embodiment of the first aspect, the pile is hollow.

[0040]

[0037] , In one embodiment of the first aspect, the polymeric material or non-polymeric material completely surrounds the hollow

[0041]

[0038] , In one embodiment of the first aspect, the cross-sectional profile of the pile is not round, and has no external corners.

[0039] , In one embodiment of the first aspect, the pile is produced by a method comprising pultrusion, extrusion, moulding, casting, machining, cutting or forming.

[0042]

[0040] , In one embodiment of the first aspect, the pile has a length of at least about 1, 2, 3 or 4 meters.

[0043]

[0041] , In one embodiment of the first aspect, the pile has an external diameter of at least about 20, 30, 40 or 50 mm.

[0044]

[0042] , In a second aspect, the present invention provides a system for engaging an object with a substrate, the system comprising:

[0045] (i) a footing or an anchor configured to support or engage with an object and the pile of any embodiment of the first aspect, and

[0046] (ii) the pile of any embodiment of the first aspect,

[0047]

[0043] , In one embodiment of the second aspect, the footing or anchor comprises a pile guide configured to allow at least a portion of the pile length to pass thereinto and to engage with the structure.

[0048]

[0044] , In one embodiment of the second aspect, the pile guide is a tubular structure.

[0049]

[0045] , In one embodiment of the second aspect, the footing or anchor comprises a surface or a structure configured to contact, receive or engage with an object.

[0050]

[0046] , In one embodiment of the second aspect, the surface is a planar surface.

[0051]

[0047] , In one embodiment of the second aspect, the surface or the structure comprises an aperture configured to receive a fastener for fastening the object to the surface or the structure.

[0048] , In one embodiment of the second aspect, the structure is a plate, a bracket or a socket.

[0052]

[0049] , In one embodiment of the second aspect, the footing or anchor is fabricated from a metal.

[0053]

[0050] , In a third aspect, the present invention provides a method for securing an anchor or a footing to a substrate, the method comprising the steps of: positioning an anchor or a footing on, in, or about a substrate; passing the pile of any embodiment of the first aspect through a pile guide of the anchor or the footing, and urging the pile into the substrate such that most or substantially the entire length of the is within the substrate.

[0054] BRIEF DESCRIPTION OF THE DRAWINGS

[0055]

[0051] , FIG. 1 A is a diagram showing a first exemplary cross-sectional profile of a constant cross-section pile of the present invention.

[0056]

[0052] , FIG. IB is a cross-sectional diagram showing the pile of FIG. 1A disposed within a tube of a footing apparatus. A self-tapping screw extends through the tube wall and into the pile so as to secure the pile therein.

[0057]

[0053] , FIG. 2 is a diagram showing a second exemplary cross-sectional profile of a constant cross-section pile of the present invention.

[0058]

[0054] , FIG. 3 shows perspective views of various footings operable with the piles of the present invention.

[0059]

[0055] , Any dimension or other non-structural feature of the drawings is non-limiting on the drawn embodiments. DETAILED DESCRIPTION OF THE INVENTION INCLUDING PREFERRED EMBODIMENTS

[0060]

[0056] , After considering this description it will be apparent to one skilled in the art how the invention is implemented in various alternative embodiments and alternative applications. However, although various embodiments of the present invention will be described herein, it is understood that these embodiments are presented by way of example only, and not limitation. As such, this description of various alternative embodiments should not be construed to limit the scope or breadth of the present invention. Furthermore, statements of advantages or other aspects apply to specific exemplary embodiments, and not necessarily to all embodiments covered by the claims.

[0061]

[0057] , Throughout the description and the claims of this specification the word "comprise" and variations of the word, such as "comprising" and "comprises" is not intended to exclude other additives, components, integers or steps.

[0062]

[0058] , Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may.

[0063]

[0059] , Applicant has discovered that advantage is obtained (or at least a useful prior art alternative is provided) where a pile is fabricated from a polymeric material, such as a synthetic polymer. Such materials are a significant departure from prior art piles which are fabricated from a metal. Polymeric materials are typically resistant to corrosion, do not produce leachates, are light and easy to transport and handle. Polymeric piles may be removed from the ground in virtually unchanged form after years of service, and readily recycled.

[0060] , The construction of the pile and the polymeric material is chosen so as to sufficiently resist damage (such as fracture) when driven into the ground by a hammer, jack hammer, winding or other means. To save materials and weight, the pile is typically hollow and accordingly the wall thickness of the pile should be of sufficient dimension to resist damage. A wall thickness, or an average wall thickness, or a minimum wall thickness of at least about 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm or 10 mm may be selected.

[0064]

[0061] , The polymeric material may be a fibre-reinforced polymer, the reinforcement allowing for the use of less material, or high fracture resistance, or bending moment, or axial resistance to force. Fibre-reinforced polymers (FRPs) are composite materials made of a polymer matrix reinforced with fibres. These composites leverage the strength and stiffness of the fibres with the versatility and ductility of the polymer matrix. The most common types of fibres used in FRPs are glass, carbon, and aramid, each imparting distinct properties to the composite. Further details follow of the different types of fibre-reinforced polymers contemplated to have potential use in the present invention.

[0065] Glass Fibre Reinforced Polymer (GFRP).

[0066]

[0062] , Glass fibres are the most widely used reinforcement in composite materials due to their high tensile strength, relatively low cost, and good chemical resistance. Types of glass fibres include E-glass, being very cost-effective. S-glass offers higher strength and thermal stability compared to E-glass. C-glass provides for superior chemical resistance and may be used in corrosive environments.

[0067] Carbon Fibre Reinforced Polymer (CFRP)

[0068]

[0063] , Carbon fibres provide high stiffness, high tensile strength, low weight, high chemical resistance, high-temperature tolerance, and low thermal expansion. While providing an extremely high strength-to-weight ratio, CRFP piles woul be less preferred given the high cost and brittleness of the material.

[0069] Aramid Fibre Reinforced Polymer (AFRP)

[0064] , Aramid fibres, such as Kevlar, provide exceptional impact resistance and energy absorption capacity. High tensile strength and modulus are provided. Cost is likely to a barrier for widespread use in the context of the present invention.

[0070] Basalt Fibre Reinforced Polymer

[0071]

[0065] , Basalt fibres are produced from basalt rock and offer a combination of high performance and cost-effectiveness. Useful mechanical properties along with corrosion resistance may be provided in piles fabricated from this material.

[0072] Natural Fibre Reinforced Polymer (NFRP)

[0073]

[0066] , Natural fibres, such as flax, hemp, jute, and bamboo, may be used as environmentally friendly alternatives to synthetic fibres. Natural fibres provided for lower mechanical properties and resistance to damage, and accordingly the pile wall thickness may be increased to compensate.

[0074]

[0067] , The polymer matrix in a FRP binds the fibres together, transferring loads between fibres and protecting them from environmental and mechanical damage. The two main types of polymer matrices are thermosetting and thermoplastic resins.

[0075] Thermosetting Resins

[0076]

[0068] , Epoxy resins provide excellent mechanical properties and chemical resistance. -

[0077]

[0069] , Polyester resins are cost-effective, and often used with glass fibres for various applications.

[0078]

[0070] , Vinyl esters combines the benefits of epoxy and polyester resins, providing useful mechanical properties and chemical resistance.

[0079]

[0071] , Phenolic resins are typically used for their fire resistance and low smoke production, and accordingly may not be preferred in the present invention. Thermoplastic Resins

[0080]

[0072] , Polypropylene (PP) is a lightweight and chemically resistant material, often used in automotive parts.

[0081]

[0073] , Polyethylene (PE) provides good impact resistance and may be used in high- performance applications.

[0082]

[0074] , Poly etheretherketone (PEEK) provides high performance, along with excellent thermal, chemical, and mechanical properties.

[0083]

[0075] , A pile of the present invention fabricated from a FRP may be manufactured by a process selected from the following.

[0084]

[0076] , Hand lay-up is a simple and cost-effective method, used for large, low- volume parts.

[0085]

[0077] , Resin transfer moulding (RTM) can be used to produce complex shapes with useful mechanical properties.

[0086]

[0078] , Pultrusion is a continuous process for making constant cross-section parts and is therefore a preferred method for producing piles.

[0087]

[0079] , The type of fibre and polymer matrix chosen for an FRP composite may be determined by reference to properties and suitability for specific applications.

[0088]

[0080] , Some plastics may be useful without any reinforcement. For example, nylon has a tensile strength of 12,400 psi. In addition to its high strength and excellent tensile properties, nylon exhibits excellent abrasion resistance. It has high chemical resistance and is not damaged by oils, solvents or alcohols.

[0081] , PPS (polyphenylene sulfide) has a tensile strength of 12,500 psi providing dimensional stability, and rigidity. PPS does suffer from an inherent brittleness, and so it may be filled to counteract this limitation.

[0089]

[0082] , PEEK (poly etheretherketone) provides a tensile strength of 14,000 psi, has inherently good wear and abrasion resistance as well as a high resistance to biodegradation.

[0090]

[0083] , PEI (poly etherimide) has similar properties to PEEK, but with a lower impact strength and a lower cost. PEI has excellent mechanical properties, including a tensile strength of 15,200 psi. It is easily machined and fabricated with excellent strength and rigidity.

[0091]

[0084] , PAI (polyamideimide) provides a tensile strength of 21,000 psi and has good wear resistance.

[0092]

[0085] , Applicant further proposes that an improved or alternative pile is provided where the pile has a cross-sectional profile that is convoluted in some way so as to better engage with the ground compared with a pile having a simple profile such as a square or a circle. It is proposed that the convoluted profile present an increased surface area, and thereby increased levels of frictional engagement with the ground. Such piles may be fabricated from a polymeric material (as described elsewhere herein) or a non-polymeric material such as steel.

[0093]

[0086] , Reference is made to FIG. 1A, showing an exemplary cross-sectional profile for a pile of the present invention. The pile (10) has profile comprising 3 lobes (15), (20), and (25) and a hollow central region (30).

[0094]

[0087] , The wall of the pile (10) in FIG. 1 A is of variable thickness, being thickest at the terminus of a lobe and thinnest in the region joining two lobes.

[0088] , FIG. IB shows the pile (10) of FIG. 1A disposed within a tube (105). The tube (105) is part of a footing apparatus, several of which are shown at FIG. 3 (marked 100). The pile (10) extends into the ground underlying the footing, with a terminal portion remaining in the tube (105). A self-tapping screw (108) (such as a Tek screw) is used to secure the pile (10) to the tube (105).

[0095]

[0089] , Reference is made to FIG. 3, showing that the tubes (105) are in each case connected to a main portion (110). An object (not drawn) may be disposed on top of the main portion (110) and secured thereto by a bolt, for example. Any upward, downward or lateral force occasioned by the object is therefore transferred to the main portion (110), to the tubes (105), and then in turn to the piles (10). The piles are well engaged with the surrounding ground, thereby providing resistance to any upward, downward or lateral force occasioned by the object.

[0096]

[0090] , The footing or anchor apparatus with the piles may be configured whether by way of construction or installation provide a combination of shallow and deep ground engagement. The bearing capacity of a shallow foundation, plus the skin friction and toe resistance of a deep foundation in may substrate types may provide a fully certifiable footing or anchor for a particular application. The footing or anchor provides instant bearing capacity and does not disturb the ground, thereby providing efficiencies in labour, material and cost. Pile embodiments of the invention that provide for increased skin friction whether by way of, for example, a convoluted profile or roughening of the surface will assist in either or both of shallow and deep ground engagement. Where improved deep ground engagement only is required, then convolutions or roughening may only be effected in the pile region that is deeply buried.

[0097]

[0091] , A variation to the embodiment of FIG. 1A is shown at FIG. 2. The embodiment of FIG. 2 comprises a central Y-shaped structure (40) providing for 3 hollow regions (30a), (30b), and (30c). The central structure (40) improves the mechanical properties of the pile and may be used in highly compacted ground that provides significant resistance to pile being driven thereinto. In such circumstances significant axial force may be applied to drive the pile into the ground, such force being potentially damaging. The central structure (40) will increase the axial compressive load that can be taken by the pile exerted by a jack hammer, as well as any bending forces that may be occasioned as the pile is being driven.

[0098]

[0092] , The annotated dimensions in FIG. 1A and FIG. 2 are shown in mm, and are nonlimiting on the drawn embodiments.

[0099]

[0093] , The annotated circle surrounding pile (10) in each of FIG. lAand FIG. 2 represents the bounding volume of the pile in cross-section. A tube (such as those marked 105 in FIG. 3) having an inner diameter that is about the same or slightly larger than that of the bounding volume may be incorporated into a footing or an anchor to function as a guide when driving the pile into the ground. The pile remains within the tube after installation, thereby providing engagement between the ground and the footing or anchor. The outer faces of the lobes contact the inner surface of the tube snugly so as to prevent or limit any movement lateral of the tube relative to the pile after installation.

[0100]

[0094] , The embodiments of FIG. 1A and FIG. 2 are preferably fabricated in continuous lengths by a pultrusion process using fibre-reinforced polymer as the material.

[0101]

[0095] , It will be appreciated that convoluted profiles other than those shown in FIG. 1A and FIG. 2 will be operable to increase the surface area of the pile so an to in turn increase engagement with the ground. A pile may have 2, 4, 5, 6, 7, 8, 9, 10, 11 or 12 lobes, for example.

[0102]

[0096] , It will also be apparent that a lobular structure is not necessary. For example, the lobes may be replaced by apical structures, semi-circular structures, or square structures.

[0103]

[0097] , In other embodiments, the wall of the pile has a zig-zag or a wavy configuration so as to increase the surface area contactable to the surrounding ground.

[0098] , In addition or as an alternative to a convoluted cross-sectional profile, the exterior of the pile may be textured or roughed so as to increase engagement with the surrounding soil. Where the pile is formed from a pultrusion or extrusion process, any texturing will necessarily be oriented longitudinally.

[0104]

[0099] , In addition or as an alternative to a convoluted cross-sectional profile or the texturing, an external surface of the pile may be roughened so as to increase engagement with the surrounding ground. Roughening may be effected after manufacture of the pile structure, and may comprise scoring, abrading, cutting, machining or ablating the pile external surface.

[0105]

[0100] , In another approach, a roughening coating is applied to the pile external surface.

[0106] For example, hard particulate materials such as sand, carborundum and the like may be suspended in an epoxy resin and then applied to the pile. Once cured, a hard and rough coating is provided. In a variation, the pile is formed from a polymeric material which is initially in a flowable form, and subsequently hardening. Immediately after or during formation of the pile, hard particulate materials are applied to the exterior surface. The polymeric material then hardens thereby trapping the particulate material on the surface.

[0107]

[0101] , The piles of the present invention are intended to use in a system with a footing or an anchor. Suitable footings and anchors are offered by Surefoot™ (Australia) including the various Pilecap footing products those including shown in FIG. 3, Mega Building Industries (Australia) including the various Mega Anchor™ and Plate Anchor™ products, All Footings Solutions (Australia) including the various “AF” products, and Advanced Ground Solutions including the Hexplate™ product. Suitable footing an anchor products are also found in Australian patent applications 2023902186, 2022283625, 2012276281, 2024100019, 2021209217, 2020203851, and 2020104507. Given the benefit of the present disclosure the skilled person is able to identify and conceive of other footing and anchors that will be operable with the present piles.

[0102] , Referring now to FIG. 3, there is shown several Surefoot™ footing products being useful in combination with the piles of the present invention. Each footing (100) comprises a plurality of tubes (one marked 105) each of which is sized to snugly receive the pile. As will be noted, the tubes (105) are angled so as to direct a pile into the underlying ground during installation. A terminal region of the pile remains within the tube so as engage footing (100) with the ground. Each footing (100) comprising an upwardly facing planar surface upon the end of a stump, post, pole or other object may be placed. Various apertures are provided to secure the object by a fastener, or to secure a socket or bracket which in turns secures an object.

[0108]

[0103] , With regard to the footing or anchor, either may comprise a planar web through which a plurality of tubes pass, the tubes being adjacent the edges of the planar web, optionally offset from the edges of the planar web, and being disposed at angles to the planar web. In some embodiments none of the angles are 90°. The tubes may be sized to permit (and optionally just permit) the passage therethrough of a pile for fixing thereof into underlying ground, the upper face of the planar web optionally being provided with a plurality of holes to accept bolts for retaining means for receiving a post, pole or upright structural beam. The planar web may be provided with a downwardly extending flange on at least one of the edges of the planar web. Preferably, a downwardly extending flange is provided on each edge of the planar web. The downwardly extending flange or flanges preferably also extend outwardly of the planar web.

[0109]

[0104] , In other embodiments, the footing plate or anchor comprises a planar web from which a plurality of tubes originate and descend, the tubes being adjacent the edges of the planar web, optionally offset from the edges of the planar web, and being disposed at angles to the planar web. In some embodiments, none of the angles are 90°. The tubes may be sized to permit the passage therethrough of a pile for fixing thereof into underlying ground, the upper face of the planar web optionally being provided with a plurality of holes to accept bolts for retaining means for receiving a post, pole or upright structural beam, the planar web being provided with a downwardly extending flange on at least one of the edges of the planar web. Preferably, a downwardly extending flange is provided on each edge of the planar web. The downwardly extending flange or flanges preferably also extend outwardly of the planar web.

[0110]

[0105] , The downwardly extending flange or flanges may be formed by bending the planar web adjacent its edges or by welding of the flanges to the edges of the planar web. Alternatively, the flange or flanges and planar web may be cast or moulded as one piece. The provision of flanges stiffens the planar web to minimize bending or warping thereof. It will be appreciated that the planar web and flanges will be of sufficient thickness to permit the footing plate to be usefully employed in supporting the retaining means for receiving a post, pole or upright structural beam without being distorted appreciably.

[0111]

[0106] , Optionally, the footing or anchor may be provided on the underside of the planar web with at least one rib for strengthening the planar web.

[0112]

[0107] , Preferably, the underside of the planar web is provided with a plurality of such reinforcing ribs which may be welded to the underside and to at least one of the flanges extending downwardly from at least one of the edges of the planar web. Alternatively, the at least one rib for strengthening the planar web or plurality of such reinforcing ribs may be cast or moulded along with the planar web and flange or flanges as one piece.

[0113]

[0108] , More preferably, the plurality of reinforcing ribs meet and are joined to provide further strengthening for the planar web.

[0114]

[0109] , Preferably, the flanges and reinforcing ribs extend to a distance below the planar web that permits the unimpeded passage of pins through the tubes provided in the web into the underlying ground.

[0115]

[0110] , The planar web may have the outline of a circle, oval or ellipse or a square, rectangle, rhombus, trapezium, parallelogram, triangle or other polygon. For ease of use a square outline is preferred.

[0111] , The means for receiving a post, pole or upright structural beam may include a socket which has a cross-section which is either circular, square, rectangular, triangular, hexagonal or prismatic. The dimensions of the socket are usually such as to accommodate one of the known cross-sectional dimensions of a post, pole or structural beam, although specifically dimensioned sockets can be fabricated and used with the footing plate of the invention, so long as the socket can be mounted securely on the footing plate, usually by means of bolts passing through registering holes in the planar web and a plate fixed to the lower end of the socket. The bolts may be welded in position if desired.

[0116]

[0112] , In use a socket may be secured to a footing plate according to the present invention.

[0117] The footing plate is then placed on the ground, preferably levelled off, at the required point. Alternatively the footing plate is placed in a depression in the ground formed by scrapping out dirt to the extent required to have the top face of the planar web of the footing plate level with or slightly lower than the surrounding ground. Piles are then inserted into the plurality of tubes passing through the planar web and hammered or jackhammer ed into the underlying ground until the top ends of the piles are almost level with the top ends of the respective tubes. The length of the piles is such that they are securely fastened in the underlying ground. The "splaying" of the piles in the underlying ground provides a stable and strong anchorage for the footing plate. A post or pole may then be inserted in the socket.

[0118]

[0113] , Footing and anchors that are not generally plate-like are also usable with the present system. For example, a cylinder may be used which is buried or partially buried into the ground, with the piles being driven through opposing apertures of the cylinder wall.

[0119]

[0114] , The combination of pile and footing or anchor may be provided in the form of a vendible kit whereby the system components are sold with the footing or anchor. The system components and footing or anchor may sold in a single package, or be unpackaged but nevertheless sold together,

[0115] , While the invention has been disclosed in connection with the preferred embodiments shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art.

[0120]

[0116] , Accordingly, the spirit and scope of the present invention is not to be limited by the foregoing examples, but is to be understood in the broadest sense allowable by law.

Claims

CLAIMS:

1. A pile for use with a footing or an anchor, the pile:(i) having a cross-sectional profile, an externally presented formation, recess, texture, roughened surface, each of which provide for engagement with a substrate, and / or(ii) being fabricated from a polymeric material.

2. The pile of claim 1, wherein the cross-sectional profile a provides surface area greater than that provided by a pile having a cross-section that is a circle, an oval, a triangle, a square, a rectangle, a pentagon, a hexagon, a septagon, or an octagon.

3. The pile of claim 1 or claim 2, wherein the cross-sectional profile provides one or more radially aligned formations.

4. The pile of claim 3, wherein the radially aligned formations are disposed at regular angular intervals.

5. The pile of any one of claims 1 to 4, wherein the cross-sectional profile provides one of more radially aligned recesses.

6. The pile of claim 5, wherein the one or more radially aligned recesses are disposed at regular angular intervals.

7. The pile of any one of claims 3 to 6, comprising 3, 4, 5, 6, 7 or 8 radially aligned formations or recesses.

8. The pile of any one of claims 3 to 7, wherein the radially aligned formations or recesses each runs the length of the pile.

9. The pile of any of claims 1 to 8, wherein the roughed external surface is provided by (i) removing material from an external surface of the pile, including by scoring, abrading, cutting,machining, scratching or ablating the external surface, (ii) adding material to an external surface of the pile, including by adhering a roughening material to the external surface, or (iii) incorporating a roughening material into the polymeric material, including by adding a roughening material to the polymeric material before the polymeric material has hardened.

10. The pile of any one of claims 1 to 9, wherein the polymeric material is a resin, an orthophthalic resin, an isophthalic resin or a vinyl ester resin.

11. The pile of any one of claims 1 to 10, wherein the polymeric material comprises a reinforcing material incorporated therein.

12. The pile of claim 11 or claim 12, wherein the reinforcing material is a fibrous material, glass, carbon, aramid or basalt.

13. The pile of any one of claims 1 to 12, wherein the polymeric material is fibre reinforced polymer.

14. The pile of any one of claims 1 to 13, fabricated from a non-polymeric material or a metal.

15. The pile of any one of claims 1 to 14, comprising outwardly curved surfaces configured to contact an interior surface of a circular tube into which it is passed.

16. The pile of any one of claims 1 to 15, that is hollow.

17. The pile of any one of claims 1 to 16 having a length of at least about 1, 2, 3 or 4 meters and / or an external diameter of at least about 20, 30, 40 or 50 mm.

18. A system for engaging an object with a substrate, the system comprising:(i) a footing or an anchor configured to support or engage with an object and the pile of any one of claims 1 to 17, and(ii) the pile of any one or claims 1 to 17,19. The system of claim 18, wherein the footing or anchor comprises a pile guide configured to allow at least a portion of the pile length to pass thereinto and to engage with the structure.

20. The system of claim 19, wherein the pile guide is a tubular structure.

21. The system of any one of claims 18 to 20, wherein the footing or anchor comprises a surface or a structure configured to contact, receive or engage with an object.

22. The system of claim 21, wherein the surface is a planar surface.

23. The system of claim 21 or claim 22, wherein the surface or the structure comprises an aperture configured to receive a fastener for fastening the object to the surface or the structure.

24. The system of any one of claims 21 to 23, wherein the structure is a plate, a bracket or a socket.

25. A method for securing an anchor or a footing to a substrate, the method comprising the steps of: positioning an anchor or a footing on, in, or about a substrate; passing the pile of any one of claims 1 to 17 through a pile guide of the anchor or the footing, and urging the pile into the substrate such that most or substantially the entire length of the is within the substrate.

Images