SOIL REINFORCING SYSTEMS FOR USE WITH MECHANICALLY STABILIZED EARTH STRUCTURES

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application relates to and claims priority from U.S. Prov. Ser. No. 63/679,583 filed Aug. 5, 2024, the entire contents of which are fully incorporated herein by reference.

TECHNICAL FIELD

The present invention is directed to mechanically stabilized earth structures and, more particularly, to improved soil reinforcing systems, with soil reinforcing elements formed with single or multiple crimping's along one or a plurality of planar orientations and adaptive anchor connector ends with extending or multiple resistance welding points for use, and manufacturing methods of such improved soil reinforcing systems.

BACKGROUND

Modern mechanically stabilized earth (MSE) structures are constructed using soil inclusions that are positioned substantially horizontal in compacted backfill and are a form of ground improvement that is classified as mechanically stabilized earth (MSE) structures. MSE structures are known to be used for retaining wall systems, earthen embankments, bridge abutments that support the bridge substructure, dams that retain water, headwalls for structural plate crossings, mining crusher support structures, among others.

The construction of an MSE structure is a repetitive process that consists of placing compacted backfill and soil reinforcing in regular interval thicknesses until a desired height of the structure is achieved. The soil reinforcing elements are generally the same length from top to bottom and are spaced at regular intervals in both the horizontal and vertical direction. It is known that the soil reinforcing elements are fabricated from metal or plastic. The soil reinforcing can consist of strips or continuous sheets. The strips may consist of elements that are fabricated to form a grid. The soil reinforcing elements can be configured so the soil reinforcing profile is planar or bi-planer. The soil reinforcing can be fabricated to contain different surface configurations, patterns, and profiles along their length.

The soil reinforcing elements may be placed in an embankment with or without a facing element. The soil reinforcing elements are generally placed perpendicular to the face of the embankment however they may be placed in other skewed directions to bypass obstructions. For noncontinuous soil reinforcing elements the adjacent elements are spaced apart and are routinely within the same horizontal plane. The soil reinforcing in combination with the compacted backfill forms a composite structure. The compacted backfill resists compressive forces while the soil reinforcing resists tensile forces.

In instances where the soil reinforcing elements are attached to a facing element, the facing can be concrete, timber, steel, welded wire mesh or the likes thereof. The proximal ends of the soil reinforcing elements are attached to the facing in many different ways. The facing element forms the external surface of the MSE structure or embankment. The facing elements can be positioned vertically, or they can be battered into the earthen formation. The facing element prevents erosion of the backfill at the proximal end of the soil reinforcing between successive rows and columns of the soil reinforcing elements. The facing element may also serve as a decorative veneer.

The embodiments and methods described in this patent pertains to soil reinforcing that is fabricated with metal strips. Metal strip soil reinforcing is known to have surfaces that are fabricated to form a grid, fabricated with a surface that is smooth or that has raised cross ribs. The metal strips are also known to be fabricated with a sinusoidal or other geometric profile in a manner that allows for extension as a force is applied. For metal strip soil reinforcing that utilizes a modified surface, such as a protrusion or raised cross rib, the surface protrusion or raised cross rib is formed during the final phase of the manufacturing process that is known as the hot rolling process.

Hot rolling of rebar or sheet form is a metalworking process that takes place at a temperature above the recrystallization temperature of the material that may be typically between 750° C. to 1200° C. During the metalworking process the grains of the material deform and recrystallize. The metalworking process is designed to so the metal maintains a microstructure where the crystals are approximately the same length and so as to prevent the metal from work hardening. In some operations the material may start at room temperature, then is reheated to the proper temperature. In some cases the material is processed with a series of rollers to produce the end product shape such as strips, rounds, angles, channels, and the likes thereof. The surface of the element can be smooth or configured with raised ribs such as the ribs on concrete reinforcing bars (e.g., re-bar). The raised ribs are placed on the element as a final rolling process while the material is still at or near the original billet temperature. During cooling the material hardens and the crystallization is fixed in form.

ASPECTS AND SUMMARY OF THE INVENTION

The present invention provides an improved soil reinforcing system for use with mechanically stabilized earth (MSE) structures includes a crimped reinforcement element fabricated with a series of crimps and linear portions that may be regularly or irregularly spaced. An anchor connector is positioned at the end thereof and contains anchor contact zones for resistance welding fixing the anchor connector to the end of the crimped reinforcement element. The anchor connectors are formed of bent wire materials with continuous or a series of contact zones or adaptively a shortened plate form with a series of contact zones. The anchor connectors are resistance welded to the end of the reinforcement element and form a unitary soil reinforcing system thereby.

Because special rollers are required the configurations when forming at billet temperatures, there is a detrimental limit to the roller and sizing that can be purchased by an initial manufacturer. Because special rollers are required the number of fabricators is also limited. It is therefore advantageous to develop a manufacturing process where a metal element can be manipulated into a soil reinforcing element of different formations with adaptive anchors for fixing to fixed points to resist deformation and thereby aid in formation of MSE structures using cross section profiles operable with a cold rolling process and a resistance welding process.

Soil reinforcing is designed to resists tension forces that develop in an earth mass. The soil reinforcement must be strong enough to resist rupture and to resists pullout from the earth mass. The resistance to rupture of a soil reinforcing element is a function of the metal properties and the cross sectional area and is easily calculated. The pullout resistance of a soil reinforcing element is more complicated to calculate and is a function of the surface area and shape. To aid in predicting the pullout resistance of soil reinforcing it is determined through pullout testing. One such pullout test method is governed by the American Society for Testing and Materials (ASTM) specification D6706, Standard Test Method for Measuring Geosynthetic Pullout Resistance in Soil. To determine the pullout resistance of metal soil reinforcing the ASTM D6706 test is modified as required.

When used with soil reinforcing crimped forms, which are divergences-from and returns-to a continuous circular element having a main centerline such as rebar, there is a proposal herein to increase the resistance to pullout from the compacted backfill. A metal soil reinforcing crimped form with higher relief crimps has a higher pullout capacity than that of a smooth and continuously linear circular form with no surface relief and no crimping along a length. It is therefore advantageous to devise an economical method of manufacturing a soil reinforcing element that allows for the use of improved and readily produced metal shapes, that can have surface reliefs and crimped forms and projections that increase the pullout capacity of the soil reinforcing element that is verified and optimized through testing.

It is also advantageous to devise an economical method of manufacturing a soil reinforcing element that allows for the use of commonly produced metal shapes where the cross section can be manipulated by crimping along a single plane or a plurality of plains (one-or-more-planes) so as to increase the pullout capacity of the soil reinforcing element that is verified and optimized through testing.

According to one alternative and adaptive aspect of the present invention there is provided an improved soil reinforcing system for a mechanically stabilized earth structure, comprising: a first crimped metal reinforcement element having an element end, further comprising: a substantially circular cross-section that is selected from the group of round and oval, a plurality of first plane crimps oriented along a common first plane, a plurality of linear portions spacing respective first plane crimps with respective crimp spacings, and respective crimp spacings are regular or irregular crimp spaces, a metal connecting anchor of unitary construction forming a unitary member having spaced apart anchor ends defining an anchor opening shaped to receive the element end along one of a continuous contact zone or a plurality of regular contact zones, and a resistance weld connection at each respective contact zone whereby the connecting anchor and the reinforcement element form a unitary continuous metal improved soil reinforcing system.

According to another alternative and adaptive aspect of the present invention, there is provided an improved soil reinforcing system, wherein: the metal connecting anchor is selected from the group of a bent wire form and a plate form, and the metal connecting anchor spaced apart anchor ends are dimensioned at respective the anchor opening to be in physical contact with an outer surface of the element end of the first crimped metal reinforcement element.

According to another alternative and adaptive aspect of the present invention, there is provided an improved soil reinforcing system, wherein, the first crimped metal reinforcement element further comprises: a plurality of second plane crimps orientated along a common second plane, the common second plane is oriented orthogonally to the common first plane, and the plurality of linear portions space respective second plane crimps from respective first plane crimps by the crimp spacings, whereby the first plane crimps and the second plane crimps are spaced from each other by the regular or irregular crimp spacings.

According to another alternative and adaptive aspect of the present invention, there is provided an improved soil reinforcing system, wherein: the metal connecting anchor is a plate form with the paced apart anchor ends, and a plurality of spaced apart anchor ends having a plurality of contact teeth members contacting the element end whereby the resistance well connection in the respective contact zone is improved.

It will be understood that specific embodiments may include a variety of features in different combinations, and that all of the features described in this disclosure, or any particular set of features, needs to be included in particular embodiments. The specific techniques and structures for implementing particular embodiments of the invention and accomplishing the associated advantages will become apparent from the following detailed description of the embodiments and the appended drawings and claims.

BRIEF DESCRIPTION OF THE FIGURES

The numerous advantages of the embodiments of the invention may be better understood with reference to the representative embodiments shown in the accompanying figures.

FIG. 1A is an exploded perspective view of an exemplary art soil reinforcing system.

FIG. 1B is a side view of the system shown in FIG. 1A.

FIG. 1C is a side view of the system shown in FIG. 1A coupled together.

FIGS. 2A, 2B, and 2C are illustrative views of exemplary crimped reinforcing elements with crimps formed along a common plane.

FIG. 3 is an illustrative view of a crimped reinforcing element with crimps formed along a plurality of repetitive common plans, shown are crimps on both the vertical plane and a horizontal plane that is ninety degrees (90°) from the other plane relative to a center line (indicated with the dashed line and ‘CL’ overlapped indicator).

FIGS. 4A, 4B, and 4C are illustrative views of exemplary anchor connectors that are formed from a bent wire crimped along a length or a plate form that has a series of serrations or adaptively no serrations (as in FIG. 4A); all formed to receive ends of respective crimped reinforcing elements for resistance welding thereof.

FIGS. 5A, 5B, and 5C are exemplary reviews of anchor connectors assembled with ends of crimped reinforcing elements.

FIGS. 6A through 7 are exemplary reviews of crimped reinforcement elements formed with exemplary anchor connectors.

DETAILED DESCRIPTION OF EMBODIMENTS

Various embodiments and aspects of the present disclosure will be described with reference to the accompanying drawings in which like or similar features are labeled with the same reference number. The following description and drawings are illustrative of the present disclosure and are not to be construed as limiting the disclosure. Numerous specific details are described to provide a thorough understanding of various embodiments of the present disclosure. However, well-known or conventional details are not described in order to provide a concise discussion of embodiments of the present disclosure.

A retaining wall soil reinforcing connector and method, is shown and described in U.S. Pat. No. 8,632,277, which shares inventorship with the present application and is commonly owned, is fully and wholly incorporated herein by reference.

Referring to FIGS. 1A-1C, is an exemplary system 100 for securing a facing 102 to an earthen formation or backfill 104 mass, according to one or more aspects of the disclosure as noted by the Applicant's prior adaptive inventions. The facing 102 may include an individual precast concrete panel or, alternatively, a plurality of interlocking precast concrete modules or wall members that are assembled into an interlocking relationship. In another embodiment, the facing 102 may be a uniform, unbroken expanse of concrete or the like which may be poured or assembled into an interlocking relationship. In another embodiment, the facing 102 may be a uniform, unbroken expanse of concrete or the like which may be poured or assembled on site. The facing 102 may generally define an exposed face 105 (FIGS. 1B and IC) and a back face 106. The exposed face 105 typically includes a decorative architectural facing, while the back face 106 is located adjacent to the backfill 104. Cast into the facing 102, or otherwise attached thereto, and protruding generally from the back face 106, is at least one exemplary anchor 108. Instead of being cast into the facing 102, the facing anchor 108 may be mechanically fastened to the back face 106, for example, using bolts (not shown). As will be described below, several variations of the facing anchor 108 may be implemented without departing from the scope of the disclosure.

The earthen formation or backfill 104 may encompass an MSE structure including a plurality of soil reinforcing elements 110 that extend horizontally into the backfill 104 to add tensile capacity thereto. In an exemplary embodiment, the soil reinforcing elements 110 may serve as tensile resisting elements positioned in the backfill 104 in a substantially horizontal alignment at spaced-apart relationships to one another against the compacted soil. Depending on the application, grid-like steel mats or welded wire mesh may be used as soil reinforcement elements 110, but it is not uncommon to employ “geogrids” made of plastic or other materials to accomplish the same end.

The earthen formation or backfill 104 may encompass an MSE structure including a plurality of soil reinforcing elements 110 that extend horizontally into the backfill 104 to add tensile capacity thereto. In an exemplary embodiment, the soil reinforcing elements 110 may serve as tensile resisting elements positioned in the backfill 104 in a substantially horizontal alignment at spaced-apart relationships to one another against the compacted soil. Depending on the application, grid-like steel mats or welded wire mesh may be used as soil reinforcement elements 110, but it is not uncommon to employ “geogrids” made of plastic or other materials to accomplish the same end.

In the illustrated exemplary illustration, the soil reinforcing element 110 may include a welded wire grid having a pair of longitudinal wires 112 that are substantially parallel to each other. The longitudinal wires 112 may be joined to a plurality of transverse wires 114 in a generally perpendicular fashion by welds at their intersections, thus forming a welded wire gridworks. In exemplary embodiments, the spacing between each longitudinal wire 112 may be about 2 in., while spacing between each transverse wire 114 may be about 6 in. As can be appreciated, however, the spacing and configuration may vary depending on the mixture of tensile force requirements that the reinforcing element 110 must resist.

In one or more embodiments, lead ends 116 of the longitudinal wires 112 may generally converge toward one another and be welded or otherwise attached to a connection stud 118 of a connector 10 that includes a tab or plate 122 extending from the connection stud 118. In the example embodiment, the stem 120 has an axial length L. As illustrated, the lead ends 116 may be coupled or otherwise attached to the stem 120 along at least a portion of the axial length L. In one embodiment, the tab 122 may be a substantially planar plate and define at least one centrally-located perforation or hole 124.

In at least one embodiment, the facing anchor 108 may include a pair of horizontally-disposed connection points or plates 126a, 126b cast into and extending from the back face 106 of the panel 102. As can be appreciated, other embodiments include attaching the facing anchor directly to the back face 106, without departing from the disclosure. Furthermore, as can be appreciated, other embodiments of the disclosure contemplate a facing anchor 108 having a single horizontal plate 126 (not shown), where the tab 122 is coupled only to the single plate 126 via appropriate coupling devices.

Each plate 126a, 126b may include at least one perforation 128 adapted to align with a corresponding perforation 128 on the opposing plates 126a, 126b. As illustrated in FIG. 1B, the plates 126a, 126b may be vertically-offset a distance X, thereby generating a gap 132 configured to receive the tab 122 for connection to the anchor 108. In operation, the tab 122 may be inserted into the gap 132 until the hole 124 aligns substantially with the perforations 128 of each plate 126a, 126b. A coupling device, such as a nut and bolt assembly 130 or the like, may then be used to secure the connection stud 118 (and thus the soil reinforcing element 110) to the facing anchor 108. In one or more embodiments, the nut and bolt assembly 130 may include a threaded bolt having a nut and washer assembly, but can also include a pin-type connection having an end that prevents it from removal, such as a bent-over portion.

In this arrangement, the soil reinforcing element 110 (as coupled to the connection stud 118) may be allowed to swivel or rotate about axis Y in a horizontal plane Z (FIG. 1A). Rotation about axis Y may prove advantageous since it allows the system 100 to be employed in locations where a vertical obstruction, such as a drainage pipe, catch basin, bridge pile, bridge pier, or the like may be encountered in the backfill 104. To avoid such obstructions, the soil reinforcing element 110 may be pivoted about axis Y to any angle relative to the back face 106, thereby swiveling to a position where no obstacle exists.

Moreover, the gap 132 defined between two vertically-offset plates 126a, 126b may also prove significantly advantageous. For example, the gap 132 may compensate or allow for the settling of the MSE structure as the soil reinforcing element 110 settles in the backfill 104. During settling, the tab 122 may be able to shift or slide vertically about the nut and bolt assembly 130 the distance X, thereby compensating for a potential vertical drop of the soil reinforcing element 110 and preventing any buckling of the concrete facing 102. As will be appreciated by those skilled in the art, varying designs of anchors 108 may be used that increase or decrease the distance X to compensate for potential settling or other MSE mechanical phenomena.

Furthermore, it is not uncommon for concrete facings 102 to shift in reaction to MSE settling or thermal expansion/contraction. In instances where such movement occurs, the soil reinforcing elements 110, which include longitudinal wires 122, of the disclosure are capable of correspondingly swiveling about axis Y and shifting the vertical distance X to prevent misalignment, buckling, or damage to the concrete facing 102.

As described above, the connector 10, which couples the reinforming element 110 (e.g., wires) to the anchor 108, includes the stem 120 that is coupled to a tab 122 that includes a hole 122 for receiving a fastener (e.g., bolt 130) therethrough and through openings 128 defined in plates 126a, 126b of the anchor 108.

Additionally now referring to FIGS. 2A through FIG. 7 other kinds of reinforcing elements and connector are illustrated.

For example, as shown in FIGS. 2A through 3 a reinforcing element may be formed from a circular element having a center line (CL) for example from rebar or a thickened wire, as in crimped reinforcement elements 200, 300, each respectively having relative plurality of crimps that are formed diverting from the centerline through the element. Crimped reinforcement element 200 includes a plurality of single plane crimps 201, as shown, spaced by a series of linear portions 202; which may be of common repetitive spacing or irregular spacing without departing from the scope and spirit of the present invention. Crimped reinforcement element 200 shows the respective single plane crimps 201 arrayed along a common designated single plane (in this case represented by the horizontal plane). Adaptive alternatives are noted in FIG. 3 wherein crimped reinforcement element 300 is provided with a plurality of first plane crimps 301A, arrayed along a common plane (the horizontal plane) and a series of second plane crimps 301B, arrayed along a common plane (the vertical plane); wherein the horizontal plane and vertical plane are orientated ninety (90) degrees relative to each other (e.g., orthogonal to each other). Respective linear portions 302 interspace respective crimps 301A, 301B and the spacing between respective linear portions 302 and crimps 301A, 301B may be of a common repetitive spacing or an irregular spacing without departing from the scope and spirit of the present invention.

As illustrated in FIGS. 4A through 7, a connective anchor 400, 500, 600 may be formed as shown, and be of a bent wire form in anchors 400, 500 or in a cut plate form 600 each having respective anchor ends 405, 505, 605 and respective anchor openings 406, 506, and 606. As shown in connective anchors 400, 500 the pair of legs may be shown in linear form (anchor 400) or in an undulating form (anchor 500) forming respective contact portions when assembled with respective ends of crimped reinforcement elements 200, 300. It will be understood that the spacing between respective legs are sized to contact the respective reinforcing elements to be received therein. Where linear legs are provided (anchor 400) there is a continuous or near continuous contact with the sides of a linear portion 302 of crimped reinforcement elements 200, 300 allowing for an extended contact zone 410, 410 (shown in FIGS. 4A, 5A) or a series of contact zones 510 (shown in FIGS. 4B, 5B). Similarly, anchor 600 may be of a plate form with slot legs (as shown) and a series of gripping teeth 610 (shown) each forming, upon assembly with one of the crimped reinforcement elements 200, 300 a series of contact zones for direct contact (shown in FIGS. 4C, 5C).

It will be understood by those of skill in the art that upon assembly with respective connective anchors 400, 500, 600 with respective crimped reinforcement elements 200, 300 that respective contact zones form respective resistance welding zones 411 (continuous, see FIG. 5A), 511 (spaced, See FIG. 5B), or either spaced 611A and/or continuous 611B (see FIG. 5C). As noted in FIG. 6C, the respective anchor contact zones 610 are designed and spaced sufficiently to allow a resistance welding (based on respective voltage (V) and time (t)) to form one continuous resistance weld or a series of resistance welds.

As will accordingly be understood by understood by those of skill in the art having fully considered, understood, and appreciated the disclosure herein, adaptive reinforcing assemblies may be arranged between the elements herein. Nonlimiting examples are noted in FIGS. 6A through 7, wherein crimped reinforcement elements 200, with respective single plane crimps 201 and linear portions 202 may be use with any anchor 400, 500, 600 without departing from the scope and spirit of the present invention. Similarly, crimped reinforcing element 300, with respective first and second plane crips 301A, 301B, may also be used with any anchor 400, 500, 600 without departing from the scope and spirit of the present invention. In this manner, those of sill in the art will recognize that the adaptive anchors noted herein ma be assembled with respective crimped reinforcing elements such as rebar or bent wire and joined by resistance welding in a fixed manner.

The present disclosure provides a substantive advantageous improvement over the convention art in that resistance welding of a dual-legged connector with a continuous or a series of anchor contact zones may be used by a larger number of manufacturers with crimped reinforcement elements such as rebar or wire.

The inventors intend that only those claims which use the specific and exact phrase “means for” are intended to be interpreted under 35 USC 112. The structure herein is noted and well supported in the entire disclosure. Moreover, no limitations from the specification are intended to be read into any claims, unless those limitations are expressly included in the claims.

Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it will be apparent to those skills that the invention is not limited to those precise embodiments, and that various modifications and variations can be made in the presently disclosed system without departing from the scope or spirit of the invention. Thus, it is intended that the present disclosure covers modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents.