Steel-Cased Concrete Piers

Abstract

A concrete pier and method of forming include providing a rust-resistant tube of a steel material. The tube is placed in a hole formed in the ground. The workers pour concrete into the tube and allow the concrete to harden. The above-ground structure is then attached to the upper end of the tube, leaving the tube in the ground to serve as a steel reinforcement for the concrete. The mounting structure at the upper end of the tube may be anchor bolts, or it may comprise tapered metal members. In the latter case, the above-ground structure to be supported by the pier has a base with a mating socket that fits over and is welded to the tapered mounting member.

1 . A method of supporting a structure above ground, comprising: 
 (a) placing a rust-resistant tube of a steel material in a hole formed in the ground; then    (b) pouring concrete into the tube and allowing the concrete to harden;    (c) filling any empty portions of an annulus surrounding the tube with a fill material; and    (d) attaching a structure to an upper end of the tube.    
   
   
       2 . The method according to  claim 1 , wherein the tube of step (a) is hollow so that the flow of concrete into the tube is unimpeded.  
   
   
       3 . The method according to  claim 1 , wherein step (a) comprises providing the tube with an open lower end.  
   
   
       4 . The method according to  claim 1 , wherein stop (a) comprises providing the tube with a sidewall having an upper portion that is free of any holes, preventing any concrete from flowing outward from the upper portion of the tube in stop (b).  
   
   
       5 . The method according to  claim 1 , wherein: 
 step (b) comprises embedding a lower portion of an anchor bolt within the concrete at the upper end of the tube prior to the concrete hardening; and step (d) comprises    attaching the structure to the anchor bolt after the concrete has hardened.    
   
   
       6 . The method according to  claim 1 , wherein: 
 step (a) comprises providing the tube with a sidewall having a lower portion containing a plurality of apertures; and    in step (b) some of the concrete flows out of the apertures of the tube into the annulus.    
   
   
       7 . The method according to  claim 1 , wherein: 
 step (a) comprises providing the tube with a tapered mounting section at its upper end and forming the hole to a depth such that the tapered mounting section protrudes from the hole; and    step (b) comprises filling the tapered mounting section with concrete while filling the tube; and    step (d) comprises providing the structure with a base with a tapered interior that mates with the tapered mounting section, placing the base of the structure over the tapered mounting section, then welding the base of the structure to the tapered mounting section.    
   
   
       8 . The method according to  claim 1 , wherein step (a) comprises forming the hole to a depth such that when the tube is placed in the hole, the upper end of the tube protrudes above the ground.  
   
   
       9 . A method of supporting a structure above ground, comprising: 
 (a) providing a hollow tube with open upper and lower ends, the tube being of a rust-resistant steel material;    (b) placing the tube in a hole formed in the ground to a depth such that the upper end of the tube protrudes from the hole; then    (c) pouring concrete into the upper end the tube until the tube is substantially filled with concrete, then allowing the concrete to harden;    (d) filling any empty portions of an annulus surrounding the tube with a fill material; and    (e) mounting the structure to the upper end of the tube.    
   
   
       10 . The method according to  claim 9 , wherein step (a) comprises providing the tube with a cylindrical sidewall having an upper portion that is free of any holes, preventing any concrete from flowing outward from the upper portion of the tube in step (c).  
   
   
       11 . The method according to  claim 9 , wherein: 
 step (c) comprises embedding a lower portion of an anchor bolt within the concrete at the upper end of the tube; and step (e) comprises    attaching the structure to the anchor bolt after the concrete has hardened.    
   
   
       12 . The method according to  claim 9 , wherein: 
 step (a) comprises providing the tube with a sidewall having a lower portion of greater thickness than an upper portion, the lower portion having a plurality of apertures, the upper portion being free of apertures; and    in step (c) some of the concrete flows out of the apertures of the tube into the annulus.    
   
   
       13 . The method according to  claim 9 , wherein: 
 step (a) comprises providing the tube with a tapered mounting section at its upper end, the tapered mounting section having a hole through which the concrete is poured in step (c); and    step (c) comprises filling the tube with concrete by pouring concrete through the hole in the tapered mounting section until the tapered mounting section is filled with concrete; and    step (d) comprises providing the structure with a base with a tapered interior that mates with the tapered mounting section, placing the base of the structure over the tapered mounting section, then welding the base of the structure to the tapered mounting section.    
   
   
       14 . The method according to  claim 13 , wherein the tapered mounting section is conical and the portion of the tube below the tapered mounting section is cylindrical.  
   
   
       15 . A foundation pier, comprising: 
 a rust-resistant tube of a steel material located in a hole formed in the earth, defining an annulus surrounding the tube;    the tube being substantially filled with concrete;    at least part of the annulus surrounding the tube being filled with an earthen fill material;    a metal mounting member at an upper end of the tube;    a base for an above-ground structure connected to the mounting member for supporting the above-ground structure above the tube.    
   
   
       16 . The pier according to  claim 15 , wherein the interior of the tube is free of any reinforcing metal for the concrete.  
   
   
       17 . The pier according to  claim 15 , wherein the tube has a lower portion with a thickened sidewall containing a plurality of apertures and an upper portion that is free of apertures and has a thinner sidewall.  
   
   
       18 . The pier according to  claim 15 , wherein: 
 the mounting member comprises an anchor bolt having a lower portion embedded within the concrete and an upper portion secured to the base of the above-ground structure.    
   
   
       19 . The pier according to  claim 1 , wherein: 
 step (a) comprises providing the tube with a sidewall having a lower portion containing a plurality of holes; and    in step (b) some of the concrete flows out of the apertures of the tube into the annulus.    
   
   
       20 . The pier according to  claim 15 , wherein: 
 the mounting member on the tube comprises a tapered mounting section that is filled with concrete and protrudes from the hole; and    the base of the above-ground structure has a tapered socket that mates with the tapered mounting section and covers any exposed concrete, the base being welded to the tapered mounting section.