IP Library Granted Patent US 11,092,010
Granted Patent B2
US 11,092,010 · App. 16/742,505 · Granted Aug 17, 2021

Underground support system and method

Inventors: John M. Mulvoy (Louisville, KY); Andrew J. King (Georgetown, IN)
Assignee: DSI Tunneling LLC
E21D11/107E21D5/11E21D5/12E21D11/08E21D11/385
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Quick Facts
Patent No.
US 11,092,010
App. No.
16/742,505
Granted
Aug 17, 2021
Kind
B2
Abstract

An underground support system having an underground reinforcement system that is at least partially encapsulated with concrete or a cement material. The underground reinforcement system includes a flexible wire mesh having a matrix of longitudinally and transversely extending metal wires. The matrix of longitudinally and transversely extending metal wires has at least one three-dimensional sheet, each sheet having at least one raised corrugation, positioned along the length of an underground space. The raised corrugation acts as a template depth girder for application of concrete or cement material at a defined depth such that the underground reinforcement system is at least partially encapsulated with the concrete or cement material.

Claims (106)

1. An underground support system comprising:

an underground reinforcement system comprising:

a flexible wire mesh comprising a matrix of longitudinally and transversely extending metal wires;

wherein the flexible wire mesh is configured from a plurality of metal wires that are either welded or woven together;

wherein the matrix of longitudinally and transversely extending metal wires comprises a plurality of three-dimensional sheets connected in an overlapping configuration, each said sheet having at least one raised corrugation, positioned along the length of an underground space;

wherein the raised corrugation acts as a template depth girder for application of concrete or cement material at a defined depth such that the underground reinforcement system is at least partially encapsulated with the concrete or cement material;

wherein the spacing and height of the raised corrugation is a design element specific to the application for concrete or cement material depth and intended girder dimensions; and

one or more stabilizing members connected to said flexible wire mesh, or one or more stabilizing members connected to overlapping sheets of said flexible wire mesh, wherein the stabilizing members connected to said flexible wire mesh comprise bolts or hooks, and the stabilizing members connected to overlapping sheets of flexible wire mesh comprise tie rods.

2. The underground support system of claim 1 wherein the flexible wire mesh permits positioning or bending of said sheets along the length and geometry of the underground space.

3. The underground support system of claim 1 wherein the flexible wire mesh comprises at least two said raised corrugations per sheet.

4. The underground support system of claim 1 wherein the underground reinforcement system further comprises at least one rebar interconnecting with the flexible wire mesh.

5. The underground support system of claim 1 comprising an intersection of at least two said underground reinforcement systems.

6. An underground support system comprising:

a first underground reinforcement system; wherein the first underground reinforcement system is at least partially encapsulated with concrete or a cement material;

a second underground reinforcement system; wherein the second underground reinforcement system is at least partially encapsulated with concrete or a cement material; and

a moisture barrier system; wherein the moisture barrier system is positioned between the first underground reinforcement system and the second underground reinforcement system;

wherein the first underground reinforcement system comprises:

a flexible wire mesh comprising a matrix of longitudinally and transversely extending metal wires;

wherein the matrix of longitudinally and transversely extending metal wires of said first underground reinforcement system comprises at least one three-dimensional sheet, said sheet having at least one raised corrugation, positioned along the length of an underground space;

wherein the raised corrugation acts as a template depth girder for application of said concrete or cement material at a defined depth such that the first underground reinforcement system is at least partially encapsulated with the concrete or cement material; and

wherein the second underground reinforcement system comprises: a plurality of structural supports positioned at spaced intervals along the length of an underground space; wherein the structural supports comprise lattice girders.

7. The underground support system of claim 6 wherein the moisture barrier system is at least one barrier selected from the group consisting of: a plastic material, sealant, and foam.

8. An underground support system comprising:

a first underground reinforcement system; wherein the first underground reinforcement system is at least partially encapsulated with concrete or a cement material;

a second underground reinforcement system; wherein the second underground reinforcement system is at least partially encapsulated with concrete or a cement material; and

a moisture barrier system; wherein the moisture barrier system is positioned between the first underground reinforcement system, and the second underground reinforcement system;

wherein at least one of the first underground reinforcement system and the second underground reinforcement system comprises:

a flexible wire mesh comprising a matrix of longitudinally and transversely extending metal wires;

wherein the matrix of longitudinally and transversely extending metal wires comprises at least one three-dimensional sheet, each sheet having at least one raised corrugation, positioned along the length of an underground space; and

wherein the raised corrugation acts as a template depth girder for application of said concrete or cement material at a defined depth.

9. An underground support system comprising:

a first underground reinforcement system; wherein the first underground reinforcement system is at least partially encapsulated with concrete or a cement material;

a second underground reinforcement system; wherein the second underground reinforcement system is at least partially encapsulated with concrete or a cement material; and

a moisture barrier system; wherein the moisture barrier system is positioned between the first underground reinforcement system, and the second underground reinforcement system;

wherein the first underground reinforcement system and the second underground reinforcement system comprise:

a flexible wire mesh comprising a matrix of longitudinally and transversely extending metal wires;

wherein the matrix of longitudinally and transversely extending metal wires comprises at least one three-dimensional sheet, said sheet having at least one raised corrugation, positioned along the length of an underground space; and

wherein the raised corrugation acts as a template depth girder for application of concrete or cement material at a defined depth such that the underground reinforcement system is at least partially encapsulated with the concrete or cement material.

10. A method of supporting an underground space, said method comprising:

positioning an underground support system against an underground substrate; and

maintaining the underground support system in contact with the underground substrate;

wherein the underground support system comprises:

an underground reinforcement system comprising:

a flexible wire mesh comprising a matrix of longitudinally and transversely extending metal wires;

wherein the flexible wire mesh is configured from a plurality of metal wires that are either welded or woven together;

wherein the matrix of longitudinally and transversely extending metal wires comprises a plurality of three-dimensional sheets connected in an overlapping configuration, each said sheet having at least one raised corrugation, positioned along the length of an underground space;

wherein the raised corrugation acts as a template depth girder for application of concrete or cement material at a defined depth such that the underground reinforcement system is at least partially encapsulated with the concrete or cement material;

wherein the spacing and height of the raised corrugation is a design element specific to the application for concrete or cement material depth and intended girder dimensions; and

one or more stabilizing members connected to said flexible wire mesh, or one or more stabilizing members connected to overlapping sheets of said flexible wire mesh, wherein the stabilizing members connected to said flexible wire mesh comprise bolts or hooks, and the stabilizing members connected to overlapping sheets of flexible wire mesh comprise tie rods.

11. The method of claim 10 wherein the underground support system is installed in an underground excavation that is vertically or horizontally oriented.

12. The method of claim 10 wherein the underground reinforcement system is prefabricated and installed on site.

13. The method of claim 10 wherein the underground support system comprises an intersection of two or more underground reinforcement systems.

14. A method of supporting an underground space, said method comprising:

positioning an underground support system against an underground substrate; and

maintaining the underground support system in contact with the underground substrate;

wherein the underground support system comprises:

a first underground reinforcement system; wherein the first underground reinforcement system is at least partially encapsulated with concrete or a cement material;

a second underground reinforcement system; wherein the second underground reinforcement system is at least partially encapsulated with concrete or a cement material; and

a moisture barrier system; wherein the moisture barrier system is positioned between the first underground reinforcement system, and the second underground reinforcement system;

wherein the first underground reinforcement system comprises:

a flexible wire mesh comprising a matrix of longitudinally and transversely extending metal wires;

wherein the matrix of longitudinally and transversely extending metal wires comprises at least one three-dimensional sheet, said sheet having at least one raised corrugation, positioned along the length of an underground space;

wherein the raised corrugation acts as a template depth girder for application of concrete or cement material at a defined depth such that the underground reinforcement system is at least partially encapsulated with the concrete or cement material;

wherein the second underground reinforcement system comprises:

a plurality of structural supports positioned at spaced intervals along the length of the underground; wherein the structural supports comprise lattice girders.

15. The method of claim 14 wherein the substrate comprises rock, soil, or an existing structure.

16. The method of claim 14 wherein the moisture barrier system is at least one barrier selected from the group consisting of: a plastic material, sealant, and foam.

17. The method of claim 14 wherein the flexible wire mesh comprises a plurality of sheets connected in an overlapping configuration.

18. The method of claim 14 wherein the flexible wire mesh permits positioning or bending of said sheets along the length and geometry of the underground.

19. The method of claim 14 wherein the flexible wire mesh has two or more raised corrugations per said three-dimensional sheet.

20. The method of claim 14 wherein the underground support system is installed in an underground excavation that is vertically or horizontally oriented.

21. The method of claim 14 wherein at least one of the first underground reinforcement system and the second underground reinforcement system is prefabricated and installed on site.

22. The method of claim 14 wherein the underground support system comprises an intersection of two or more underground reinforcement systems.

23. A method of supporting an underground space, said method comprising:

positioning an underground support system against an underground substrate; and

maintaining the underground support system in contact with the underground substrate;

wherein the underground support system comprises:

a first underground reinforcement system; wherein the first underground reinforcement system is at least partially encapsulated with concrete or a cement material;

a second underground reinforcement system; wherein the second underground reinforcement system is at least partially encapsulated with concrete or a cement material; and

a moisture barrier system; wherein the moisture barrier system is positioned between the first underground reinforcement system, and the second underground reinforcement system;

wherein the first underground reinforcement system and/or the second underground reinforcement system comprise:

a flexible wire mesh comprising a matrix of longitudinally and transversely extending metal wires;

wherein the matrix of longitudinally and transversely extending metal wires comprises at least one three-dimensional sheet, said sheet having at least one raised corrugation, positioned along the length of an underground space; and

wherein the raised corrugation acts as a template depth girder for application of concrete or cement material at a defined depth such that the underground reinforcement system is at least partially encapsulated with the concrete or cement material.

24. A method of supporting an underground space said method comprising:

positioning an underground support system against an underground substrate; and

maintaining the underground support system in contact with the underground substrate;

wherein the underground support system comprises:

a first underground reinforcement system; wherein the first underground reinforcement system is at least partially encapsulated with concrete or a cement material;

a second underground reinforcement system; wherein the second underground reinforcement system is at least partially encapsulated with concrete or a cement material; and

a moisture barrier system; wherein the moisture barrier system is positioned between the first underground reinforcement system, and the second underground reinforcement system;

wherein the first underground reinforcement system and the second underground reinforcement system comprise:

a flexible wire mesh comprising a matrix of longitudinally and transversely extending metal wires;

wherein the matrix of longitudinally and transversely extending metal wires comprises at least one three-dimensional sheet, said sheet having at least one raised corrugation, positioned along the length of an underground space; and

wherein the raised corrugation acts as a template depth girder for application of concrete or cement material at a defined depth such that the underground reinforcement system is at least partially encapsulated with the concrete or cement material.

25. An underground reinforcement system comprising:

a flexible wire mesh comprising a matrix of longitudinally and transversely extending metal wires;

wherein the flexible wire mesh is configured from a plurality of metal wires that are either welded or woven together;

wherein the matrix of longitudinally and transversely extending metal wires comprises a plurality of three-dimensional sheets connected in an overlapping configuration, each sheet having at least one raised corrugation, positioned along the length of an underground space;

wherein the raised corrugation acts as a template depth girder for application of concrete or cement material at a defined depth such that the underground reinforcement system is at least partially encapsulated with the concrete or cement material;

wherein the spacing and height of the raised corrugation is a design element specific to the application for concrete or cement material depth and intended girder dimensions; and

one or more stabilizing members connected to said flexible wire mesh, or one or more stabilizing members connected to overlapping sheets of said flexible wire mesh, wherein the stabilizing members connected to said flexible wire mesh comprise bolts or hooks, and the stabilizing members connected to overlapping sheets of flexible wire mesh comprise tie rods.

26. The underground reinforcement system of claim 25 wherein the flexible wire mesh has two or more raised corrugations per sheet.

27. The underground reinforcement system of claim 25 installed in an underground excavation that is vertically or horizontally oriented.

28. The underground reinforcement system of claim 25 which is prefabricated and installed on site.

29. The underground reinforcement system of claim 25 comprising an intersection of two or more underground reinforcement systems.

Assignments (6)
SECURITY INTEREST Recorded May 29, 2026
From: FCI HOLDINGS DELAWARE, LLC; J-LOK CO.; JM STEEL - PENNSYLVANIA, LLC; XCAL TOOLS - BECKLEY, LLC; XCAL TOOLS - SOUTH POINT, LLC
To: PNC BANK, NATIONAL ASSOCIATION
Reel/Frame 075651/0136 →
SECURITY INTEREST Recorded Dec 17, 2025
From: XCAL TOOLS – BRISTOL, LLC; JM STEEL – PENNSYLVANIA, LLC; J-LOK CO.; FCI HOLDINGS DELAWARE, LLC
To: JEFFERIES FINANCE LLC, AS COLLATERAL AGENT
Reel/Frame 074005/0650 →
CHANGE OF NAME Recorded May 16, 2025
From: FCI HOLDINGS DELAWARE, INC.
To: FCI HOLDINGS DELAWARE, LLC
Reel/Frame 071297/0130 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 17, 2024
From: JENNMAR SPECIALTY PRODUCTS - LOUISVILLE, LLC
To: FCI HOLDINGS DELAWARE, INC.
Reel/Frame 066141/0661 →
CHANGE OF NAME Recorded Jan 11, 2024
From: DSI TUNNELING LLC
To: JENNMAR SPECIALTY PRODUCTS - LOUISVILLE, LLC
Reel/Frame 066270/0461 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 14, 2020
From: MULVOY, JOHN M.; KING, ANDREW J.
To: DSI TUNNELING LLC
Reel/Frame 051511/0913 →
Continuity (3)
Provisional Application 62823286 · Mar 25, 2019
Provisional Application 62807796 · Feb 20, 2019
Related Publication 20200263542A1 · Aug 20, 2020