Alternative Pile Structures Using Helical Lead Sections

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Solution Overview

Problem

In areas where bedrock is not accessible or requires additional stabilization, existing methods for constructing foundations on soil are costly and inefficient, as they often necessitate the use of high-strength steel piles that remain in the ground.

Innovation Solution

The method involves driving a lead section with helical screws into the soil, forming a hole, and then replacing the high-strength steel pile with a lower-cost material while using a reinforcing structure and grout to achieve similar performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If high-strength steel piles are used to support structures on soil, then the structural strength and stability are improved, but the construction cost increases significantly

Engineering Contradiction:

Improvepile shaft strengthVSAvoidconstruction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The pile system is divided into two functional segments: a lead section with helical screws that remains in the ground to provide anchoring, and a shaft section that can be made of lower-cost materials. This segmentation allows the expensive high-strength steel to be used only where absolutely necessary (in the lead section for driving and initial anchoring) while cheaper materials suffice for the remaining shaft length.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the material parameter along the pile length rather than using uniform high-strength steel throughout. The lead section uses high-strength steel to withstand driving forces, while the shaft section uses lower-cost materials since it experiences different stress conditions after installation.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If high-strength steel piles are driven into the ground, then the pile can be installed and provide support, but the entire pile shaft must remain in the ground increasing material cost

Engineering Contradiction:

Improvepile support performanceVSAvoidamount of high-strength steel required

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The invention extracts the high-strength steel lead section from the ground after installation, retaining only the essential helical screw anchors. This allows the system to maintain reliable support performance through the combination of helical anchors and grout-reinforced shaft while removing the unnecessary high-strength steel shaft material.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The lead section with helical screws is driven into the ground to create the pile foundation, then the shaft portion is removed or replaced with lower-cost materials, while the helical screw anchors remain in the ground to provide continued support. This discards the expensive material after it has served its primary installation function.

Inventive Principle:

Principle #34Discarding and recovering

3Ease of operation

If conventional piles are used without removal, then the installation process is simple, but the device complexity increases when considering material optimization

Engineering Contradiction:

Improveinstallation simplicityVSAvoidpile structure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The pile system transitions from a static, fixed-configuration structure to a dynamic, multi-stage installation process. The lead section is driven in first, then the shaft is removed or replaced, allowing the system to adapt its configuration during installation to optimize both simplicity and material efficiency.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces construction costs by using lower-cost materials for the pile shaft while maintaining or improving performance through the use of a reinforcing structure and grout, which provides adequate support and stability for structures.

Implementation Method 1

a lead section disposed in the soil, comprising a flight of helical screws between a top end and a bottom end

Methodology Applied

Scientific EffectHelical screw mechanism: Screw

Implementation Method 2

grout in contact with the reinforcing structure

Methodology Applied

Scientific EffectGrout hardening: Phase Change

Data Source

PatentUS20250109563A1Alternative pile structures

Publication Date: 2025.04.03 FULLER ANDREW CORBIN

AI summary

Piles and methods for installing them appear. An alternative pile has a lead section driven a depth below the soil surface, and then a reinforcing structure such as a rebar cage is placed above the lead section. Liquid grout is allowed to harden in contact with the reinforcing structure, thereby forming the pile. Reinforcing structure extending above the surface of the soil can tie in supported structure, such as pile caps, reinforced columns, and cmu columns, for example.