IP Library Granted Patent US 9,091,036
Granted Patent B2
US 9,091,036 · App. 13/822,011 · Granted Jul 28, 2015

Extensible shells and related methods for constructing a support pier

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Quick Facts
Patent No.
US 9,091,036
App. No.
13/822,011
Granted
Jul 28, 2015
Kind
B2
Abstract

Extensible shells and related methods for constructing a support pier are disclosed. A shell can define an interior for holding granular construction material and define an opening for receiving the granular construction material into the interior. The shell can be flexible such that the shell expands when granular construction material is compacted in the interior of the shell. A method may include positioning the shell in the ground and filling at least a portion of the interior of the shell with the granular construction material. The granular construction material may be compacted in the interior of the shell to form a support pier.

Claims (42)

1. An extensible shell for constructing a support pier in ground, the extensible shell defining an interior for holding granular construction material and defining an opening for receiving the granular construction material into the interior, wherein the shell is flexible such that the shell expands laterally outward when granular construction material is compacted in the interior of the shell.

2. The extensible shell of claim 1 , further comprising a first end that defines the opening, and wherein the shell is shaped to taper downward from the first end to an opposing second end of the shell.

3. The extensible shell of claim 2 , wherein the second end defines a substantially flat, blunt surface.

4. The extensible shell of claim 2 , wherein a cross-section of the shell forms one of a substantially hexagonal shape and a substantially octagonal shape along a length of the shell extending between the first and second ends.

5. The extensible shell of claim 2 , wherein a cross-section of the first end is sized larger than a cross-section of the second end.

6. The extensible shell of claim 1 , wherein the shell is comprised of plastic.

7. The extensible shell of claim 1 , wherein the shell defines a plurality of apertures extending between an interior of the shell to an exterior of the shell.

8. The extensible shell of claim 1 , wherein the shell is substantially cylindrical in shape.

9. The extensible shell of claim 1 , wherein the shell is substantially conical in shape.

10. The extensible shell of claim 1 , further comprising a plurality of slots extending between an interior of the shell to an exterior of the shell, the slots being generally transverse to a centerline along the length of the shell.

11. The extensible shell of claim 10 , wherein the slots are discontinuous around a circumference of the shell thereby maintaining portions of continuous material connectivity along the length of the shell.

12. The extensible shell of claim 10 , wherein the slots have a width in the range of ¼ inch (6.35 mm) to ⅜ inch (9.53 mm).

13. The extensible shell of claim 10 , wherein the slots are spaced at a distance of 6 inches (152 mm) from one another.

14. A method for constructing a support pier in ground, the method comprising:

(a) positioning an extensible shell into ground, the shell defining an interior for holding granular construction material and defining an opening for receiving the granular construction material into the interior, wherein the shell is flexible such that the shell expands laterally outward when granular construction material is compacted in the interior of the shell;

(b) filling at least a portion of the interior of the shell with the granular construction material; and

(c) compacting the granular construction material in the interior of the shell to form a support pier.

15. The method of claim 14 , wherein the shell comprises a first end that defines the opening, and wherein the shell is shaped to taper downward from the first end to an opposing second end of the shell.

16. The method of claim 15 , wherein the second end defines a substantially flat, blunt surface.

17. The method of claim 15 , wherein a cross-section of the shell forms one of a substantially hexagonal shape and a substantially octagonal shape along a length of the shell extending between the first and second ends.

18. The method of claim 15 , wherein a cross-section of the first end is sized larger than a cross-section of the second end.

19. The method of claim 14 , wherein the shell is comprised of plastic.

20. The method of claim 14 , wherein the shell defines a plurality of apertures extending between the interior of the shell to an exterior of the shell.

21. The method of claim 20 , further comprising applying vacuum pressure through the shell.

22. The method of claim 14 , wherein the shell is substantially cylindrical in shape.

23. The method of claim 14 , wherein the shell is substantially conical in shape.

24. The method of claim 14 , wherein the positioning in step (a) further comprises partially filling the shell with the granular construction material and driving the shell into the ground subsequent to partially filling the shell.

25. The method of claim 24 , wherein driving the extensible shell comprises applying a force to a mandrel for driving the shell into the ground.

26. The method of claim 14 , wherein the positioning in step (a) further comprises first forming a cavity in the ground and subsequently driving the extensible shell into the cavity.

27. The method of claim 26 , wherein the cavity is at least partially filled with granular construction material after forming and prior to the driving of the extensible shell into the cavity.

28. The method of claim 14 , wherein the compacting in step (c) is performed with a primary mandrel.

29. The method of claim 28 , further comprising an additional compacting step performed with a second mandrel that has a larger cross-sectional area than the primary mandrel.

30. The method of claim 14 , wherein the shell further comprises a plurality of slots extending between an interior of the shell to an exterior of the shell, the slots being generally transverse to a centerline along the length of the shell.

31. The method of claim 30 , wherein the slots are discontinuous around a circumference of the shell thereby maintaining portions of continuous material connectivity along the length of the shell.

32. The method of claim 30 , wherein the slots have a width in the range of ¼ inch (6.35 mm) to ⅜ inch (9.53 mm).

33. The method of claim 30 , wherein the slots are spaced at a distance of 6 inches (152 mm) from one another.

34. A method for constructing a support pier in ground, the method comprising:

(a) forming a cavity in the ground;

(b) partially backfilling the cavity with an aggregate construction material;

(c) positioning an extensible shell into the cavity, the shell defining an interior for holding granular construction material and defining an opening for receiving the granular construction material into the interior, wherein the shell is flexible such that the shell expands laterally outward when granular construction material is compacted in the interior of the shell;

(d) filling at least a portion of the interior of the shell with the granular construction material; and

(e) compacting the granular construction material in the interior of the shell to form a support pier.

Assignments (8)
RELEASE OF SECURITY INTEREST Recorded Apr 26, 2022
From: WHITEHORSE CAPITAL MANAGEMENT, LLC
To: TENSAR CORPORATION, LLC; TENSAR CORPORATION; TENSAR INTERNATIONAL CORPORATION; GEOPIER FOUNDATION COMPANY, INC.; GEOTECHNICAL REINFORCEMENT COMPANY, INC.; TENSAR TECHNOLOGIES LIMITED
Reel/Frame 059804/0298 →
RELEASE OF SECURITY INTEREST Recorded Apr 26, 2022
From: ALTER DOMUS (US) LLC
To: TENSAR CORPORATION, LLC; TENSAR CORPORATION; TENSAR INTERNATIONAL CORPORATION; GEOPIER FOUNDATION COMPANY, INC.; GEOTECHNICAL REINFORCEMENT COMPANY, INC.; TENSAR TECHNOLOGIES LIMITED
Reel/Frame 059804/0380 →
RELEASE OF SECURITY INTEREST IN PATENT RIGHTS (FIRST LIEN) Recorded Nov 23, 2020
From: WILMINGTON TRUST, NATIONAL ASSOCIATION
To: GEOPIER FOUNDATION COMPANY, INC.; NORTH AMERICAN GREEN INC.; TENSAR CORPORATION; TENSAR CORPORATION, LLC (FORMERLY KNOWN AS THE TENSAR CORPORATION); TENSAR HOLDINGS, LLC (FORMERLY KNOWN AS TENSAR HOLDINGS CORPORATION); TENSAR INTERNATIONAL CORPORATION; GEOTECHNICAL REINFORCEMENT INC.
Reel/Frame 055354/0098 →
PATENT SECURITY AGREEMENT (SECOND LIEN) Recorded Nov 23, 2020
From: GEOPIER FOUNDATION COMPANY, INC.; GEOTECHNICAL REINFORCEMENT COMPANY INC.; TENSAR CORPORATION, LLC; TENSAR INTERNATIONAL CORPORATION; TENSAR CORPORATION
To: ALTER DOMUS (US) LLC, AS COLLATERAL AGENT
Reel/Frame 054504/0843 →
RELEASE OF SECURITY INTEREST IN PATENT RIGHTS (SECOND LIEN) Recorded Nov 23, 2020
From: WILMINGTON TRUST, NATIONAL ASSOCIATION
To: GEOPIER FOUNDATION COMPANY, INC.; NORTH AMERICAN GREEN INC.; TENSAR CORPORATION; TENSAR CORPORATION, LLC (FORMERLY KNOWN AS THE TENSAR CORPORATION); TENSAR HOLDINGS, LLC (FORMERLY KNOWN AS TENSAR HOLDINGS CORPORATION); TENSAR INTERNATIONAL CORPORATION; GEOTECHNICAL REINFORCEMENT INC.
Reel/Frame 055354/0341 →
SECURITY INTEREST Recorded Nov 20, 2020
From: GEOPIER FOUNDATION COMPANY, INC.
To: WHITEHORSE CAPITAL MANAGEMENT, LLC, AS COLLATERAL AGENT
Reel/Frame 054427/0621 →
FIRST LIEN PATENT SECURITY AGREEMENT Recorded Aug 13, 2014
From: GEOPIER FOUNDATION COMPANY INC.
To: UBS AG, STAMFORD BRANCH
Reel/Frame 033532/0807 →
SECOND LIEN PATENT SECURITY AGREEMENT Recorded Aug 13, 2014
From: GEOPIER FOUNDATION COMPANY INC.
To: UBS AG, STAMFORD BRANCH
Reel/Frame 033532/0699 →