Pile coupling

Abstract

The invention includes a coupling for assembling pile sections in series. The pile sections each include transverse flanges at each end. The pile sections are coupled together by fastening a flange of one pile section to a flange of another pile section. This allows the fasteners to be oriented in a direction that is substantially parallel to the longitudinal axis of the pile sections.

1 . A pile assembly comprising: 
 a first pile section and a second pile section, each of the first and second pile sections having a longitudinal axis;    a first flange associated with the first pile section and having an interface surface extending in a plane that is substantially transverse to the longitudinal axis of the first pile section;    a second flange associated with the second pile section and having an interface surface extending in a plane that is substantially transverse to the longitudinal axis of the second pile section; and    the first flange being fastened to the second flange to thereby couple the first pile section to the second pile section.    
   
   
       2 . The pile assembly of  claim 1 , the first and second flanges being fastened together with fasteners that are substantially parallel with the longitudinal axes of the first and second pile sections.  
   
   
       3 . The pile assembly of  claim 1 , the first flange being welded to an end of the first pile section and the second flange being welded to an end of the second pile section.  
   
   
       4 . The pile assembly of  claim 1 , the first flange being welded to an outer surface of the first pile section and the second flange being welded to an outer surface of the second pile section.  
   
   
       5 . The pile assembly of  claim 1 , the first flange being integrally-formed with an end of the first pile section, and the second flange being integrally-formed with an end of the second pile section.  
   
   
       6 . The pile assembly of  claim 5 , further comprising: 
 a first fillet integral with the first pile section and the first flange, the first fillet providing a smooth transition between the first pile section and the first flange; and    a second fillet integral with the second pile section and the second flange, the second fillet providing a smooth transition between the second pile section and the second flange.    
   
   
       7 . The pile assembly of  claim 1 , the first pile section having a first plurality of teeth at an end thereof, and the second pile section having a second plurality of teeth at an end thereof, the second plurality of teeth interlocking with the first plurality of teeth.  
   
   
       8 . The pile assembly of  claim 1 , the first flange having a first plurality of teeth, and the second flange having a second plurality of teeth interlocking with the first plurality of teeth.  
   
   
       9 . The pile assembly of  claim 1 , further comprising rebar positioned within the first and second pile sections and concrete contained within the first and second pile sections.  
   
   
       10 . The pile assembly of  claim 1 , the second pile section having a bedrock end that contacts a bedrock surface, the bedrock surface defining a hole drilled therein, an amount of concrete being contained within the second pile section and the hole.  
   
   
       11 . The pile assembly of  claim 1 , the first and second pile sections being substantially surrounded by a filler material.  
   
   
       12 . The pile assembly of  claim 1 , wherein the filler material is a grout.  
   
   
       13 . A method of forming a pile assembly, the method comprising the steps of: 
 a) providing a first pile section and a second pile section, each of the first and second pile sections having a longitudinal axis, a first flange associated with the first pile section and having an interface surface extending in a direction substantially transverse to the longitudinal axis of the first pile section, and a second flange associated with the second pile section and having an interface surface extending in a direction substantially transverse to the longitudinal axis of the second pile section; and    b) fastening the first flange to the second flange to thereby couple the first pile section to the second pile section.    
   
   
       14 . The method of  claim 13 , further comprising the steps of welding the first flange to an end of the first pile section and welding the second flange to an end of the second pile section prior to said step of fastening the first flange to the second flange.  
   
   
       15 . The method of  claim 13 , further comprising the steps of welding the first flange to an outer surface of the first pile section and welding the second flange to an outer surface of the second pile section prior to said step of fastening the first flange to the second flange.  
   
   
       16 . The method of  claim 13 , further comprising the steps of drilling a hole in a portion of bedrock proximate to an end of the second pile section; and introducing an amount of concrete into the second pile section and the hole.  
   
   
       17 . The method of  claim 13 , further comprising the step of coating the first and second pile sections in a filler material.