Method and apparatus for forming cemented ground support columns

1. An apparatus for constructing a support column, comprising:

a driving mandrel having a top portion, a feed tube, and an expansion head portion that are operatively connected, wherein the expansion head portion comprises an expansion chamber and an egress port within the expansion chamber, the egress port being adapted for crimping wherein the egress port is a tube made of a material, such as concrete hose, Kevlar tubing, or aramid fiber tubing, selected to be sufficiently flexible such that the tube is adapted to compress radially inwards to prevent backflow or infill material upward into the tube.

2. The apparatus as recited in claim 1 , wherein the top portion has an open upper end to the feed tube, and the expansion chamber has an open lower surface.

3. The apparatus as recited in claim 1 , wherein the expansion head portion includes an internal connection ring, and the egress port is affixed to the internal connection ring and extends into the expansion chamber.

4. The apparatus as recited in claim 1 , wherein the top portion has a closed upper end, and the expansion chamber has an open lower surface.

5. The apparatus as recited in claim 4 , further comprising an inlet injection port connected to the feed tube.

6. The apparatus as recited in claim 5 , further comprising a pressure gauge, and a pressure relief valve that are connected to the feed tube.

7. The apparatus as recited in claim 1 , wherein the feed tube has a feed tube inside diameter and a feed tube outside diameter, wherein the expansion chamber has an expansion chamber inside diameter and an expansion chamber outside diameter, the expansion chamber inside diameter being greater than the feed tube outside diameter.

8. A method for constructing a support column, comprising the steps of:

providing a mandrel assembly having a feed tube operatively connected to an expansion head, wherein the expansion head comprises an expansion chamber and an egress port within the expansion chamber, the egress port being adapted for crimping wherein the egress port is a tube made of a material, such as concrete hose, Kevlar tubing, or aramid fiber tubing, selected to be sufficiently flexible such that the tube is adapted to compress radially inwards to prevent backflow or infill material upward into the tube;

driving the mandrel assembly into a ground surface to a prescribed initial depth with respect to the ground surface level;

adding infill material to the feed tube, wherein the infill material has sufficient mobility for advancing within the feed tube and through the egress port;

driving the mandrel assembly further into the ground surface to a prescribed driving termination depth with respect to the ground surface level;

raising the mandrel assembly above the prescribed driving termination depth;

forming a space at the bottom of the mandrel assembly;

allowing a first portion of the infill material to exit through the egress port by gravity into the expansion chamber and into the space; and

forming a first placed infill material at the prescribed driving termination depth.

9. The method as recited in claim 8 , wherein the adding step is done by pumping the infill material into the feed tube.

10. The method as recited in claim 8 , wherein the infill material is mobile medium slump concrete, mobile high slump concrete, sand-cement grout, or neat cement grout.

11. The method as recited in claim 8 , further comprising the step of constructing an expanded diameter of the first placed infill material, the constructing step comprising the step of re-driving the raised mandrel assembly downwards into the first placed infill material.

12. The method as recited in claim 11 , the constructing step further comprising the steps of:

crimping and constricting by the egress port to prevent upward movement into the egress port by the first placed infill material; and

allowing the expansion chamber to push the first placed infill material downward and outward at a prescribed expanded diameter ground depth with respect to the ground surface level.

13. The method as recited in claim 12 , further comprising the step of raising the mandrel assembly above the expanded diameter of the first placed infill material.

14. The method as recited in claim 13 , further comprising the step of allowing a second portion of the infill material to exit through the egress port by gravity into the expansion chamber.

15. The method as recited in claim 14 , further comprising the step of constructing a shaft above the expanded diameter of the first placed infill material.

16. The method as recited in claim 8 , further comprising the step of forming a second placed infill material at a different depth than the prescribed driving termination depth.

17. The method as recited in claim 8 , further comprising the step of forming a second placed infill material having a different diameter than the first placed infill material and at a different depth than the prescribed driving termination depth.

18. The method as recited in claim 8 , further comprising the step of compacting the first placed infill material to have a diameter a larger than the diameter of the expansion chamber.