Corrugated Shell Bearing Piles for Soil-Soil Shear Interface
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Solution Overview
Problem
Existing bearing piles face limitations in structural integrity, material efficiency, and installation costs due to their design and installation methods, particularly in subsoil conditions that require deep penetration and high loading capacities.
Innovation Solution
The use of corrugated steel shells with varying lengths and diameters, combined with a segment-by-segment installation methodology, provides enhanced resistance to deformation and increased loading capacity by creating a soil-soil shear interface, reducing material usage, and allowing for adjustable bearing depths and diameters to optimize loading and installation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If smooth-walled pipes with thicker walls are used to achieve the same crush and bending resistance, then the structural strength is improved, but the total weight and material cost increase
Solution Approach 1:
The patent applies corrugations (curved surfaces) to the pipe exterior, creating a structure that efficiently resists radial inward forces from subsoil and compression/tension forces during installation. The curved corrugation profile provides enhanced structural strength with less material compared to straight-walled pipes.
Solution Approach 2:
The patent uses thin-walled corrugated steel shells that rely on the geometric strength of the corrugations rather than thick walls for structural integrity. This flexible shell approach achieves the required crush and bending resistance with significantly reduced material weight.
2Strength
If deeper bearing depths are used to increase loading capacity, then the loading capacity is improved, but the installation time and material costs increase
Solution Approach 1:
The patent divides the bearing pile into multiple corrugated shell segments that can be installed separately and connected together. This segmentation allows for faster installation compared to installing a single long pile, as segments can be prepared and positioned more efficiently, reducing overall installation time while achieving the required bearing depth and loading capacity.
Solution Approach 2:
The patent varies the diameters of corrugated shells at different depths to optimize loading capacity. By changing the diameter parameter along the length of the pile, the structure achieves higher loading capacity without requiring excessive depth, thereby reducing installation time and material costs.
3Ease of manufacture
If smooth-walled pipes are used, then the material usage is simplified, but the loading capacity is reduced due to metal-soil shear interface
Solution Approach 1:
The corrugations create an irregular, curved surface that traps subsoil portions within valleys between flute crests. This geometric feature transforms the metal-soil shear interface into a soil-soil shear interface, significantly increasing friction and loading capacity while maintaining manufacturing feasibility.
4Productivity
If segment-by-segment installation methodology is used, then the installation speed is improved, but the installation process complexity increases
Solution Approach 1:
The patent employs multiple corrugated shell segments with coupling mechanisms that enable rapid assembly. The segmentation allows segments to be installed in sequence using standardized connection procedures, increasing installation speed while keeping the process complexity manageable through repetition of standardized steps.
Solution Approach 2:
The patent varies the diameters of corrugated shells at different depths to optimize loading capacity. By changing the diameter parameter along the length of the pile, the structure achieves higher loading capacity without requiring excessive depth, thereby reducing installation time and material costs.
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 results in lighter, cost-effective bearing piles with improved structural integrity and faster installation times, achieving higher loading capacities with reduced material and labor costs, while ensuring visual confirmation of structural integrity before concreting.
Implementation Method 1
The corrugations in the corrugated shells act to provide an enhanced resistance to radially inward forces from the subsoil and compression and tension forces during installation
Implementation Method 2
The corrugations of the corrugated shells trap portions of the subsoil surrounding the corrugated shells within valleys (e.g., between flute crests). The trapped subsoil portions create a soil-soil shear interface that increases the loading capacity of the bearing pile
Implementation Method 3
The driving force transmits along the mandrel to the first corrugated shell through the cap such that the first corrugated shell is tensioned during driving
Data Source
AI summary
A bearing pile including a plurality of connected corrugated steel shells inserted into a subsoil and installation methodology of the same.