Systems and Methods for Supporting a Concrete Slab

Abstract

Systems and methods for supporting a concrete slab are disclosed. The disclosed systems and methods may comprise an array of coupled hollow boxes to support a concrete slab monolithically poured on the array. The array of hollow boxes may be particularly suited for supporting a concrete slab to be emplaced at a construction site on expansive, collapsible, compressible, and/or rocky soils. The disclosed systems and methods may be more economically feasible and more reliable than other methods of preventing damage to a concrete slab in an expansive soil setting.

1 . An apparatus to support a concrete slab, the apparatus comprising:
 a hollow box comprising four side walls, a top wall, and an open bottom, wherein the hollow box is configured to be placed directly on soil of a site oriented such that the open bottom abuts the soil;   a flange extending away from the hollow box, the flange coupled to two of the side walls and adjacent to the open bottom, wherein the flange comprises one or more indentations for placing anchors to secure the hollow box to the soil; and   a plurality of clip holes in the top wall to secure the hollow box to other hollow boxes via clips.   
     
     
         2 . The apparatus of  claim 1 , further comprising a plurality of ribs intersecting along an interior surface of the top wall, each rib of the plurality of ribs coupled to the top wall and two side walls. 
     
     
         3 . The apparatus of  claim 1 , wherein the one or more indentations in the flange comprises three indentations. 
     
     
         4 . The apparatus of  claim 1 , wherein the flange comprises a first straight length and a second straight length coupled by a corner, and wherein the first indentation of the three indentations is located on the corner, a second indentation of the three indentations is located on a first straight length, and a third indentation of the three indentations is located on a second straight length. 
     
     
         5 . The apparatus of  claim 1 , wherein the plurality of clip holes comprise:
 a first clip hole adjacent to a middle portion of a first edge of the top wall; and   a second clip hole adjacent to a middle portion of a second edge of the top wall, wherein the first clip hole and the second clip hole comprise tapered walls.   
     
     
         6 . The apparatus of  claim 5 , wherein the four side walls comprise two vertical sidewalls and two angled sidewalls,
 wherein the two angled sidewalls are angled in an outward direction relative to the top wall, and   wherein a first vertical sidewall is coupled to a second vertical sidewall at a first sidewall edge, the second vertical sidewall is coupled to a first angled sidewall at a second sidewall edge, the first angled sidewall is coupled to a second angled sidewall at a third sidewall edge, and the second angled sidewall is coupled to the first vertical sidewall at a fourth sidewall edge.   
     
     
         7 . The apparatus of  claim 6 , wherein the plurality of clip holes further comprise:
 a third clip hole adjacent to a first corner of the top wall, where the first corner of the top wall is adjacent the second sidewall edge;   a fourth clip hole adjacent to a second corner of the top wall, where the second corner of the top wall is adjacent the third sidewall edge; and   a fifth clip hole adjacent to a third corner of the top wall, where the third corner of the top wall is adjacent the fourth sidewall edge wherein the third, fourth, and fifth clip holes comprise tapered walls.   
     
     
         8 . The apparatus of  claim 7 , wherein the plurality of clip holes further comprise:
 a sixth clip hole generally between a middle portion of a third edge of the top wall and a fourth corner of the top wall, where the fourth corner of the top wall is adjacent the first sidewall edge, wherein the third edge is coupled to the first vertical sidewall; and   a seventh clip hole generally between a middle portion of a fourth edge of the top wall and the fourth corner of the top wall, wherein the fourth edge is coupled to the second vertical sidewall.   
     
     
         9 . The apparatus of  claim 8 , wherein the sixth clip hole and the seventh clip hole are an equal distance away from fourth corner of the top wall. 
     
     
         10 . The apparatus of  claim 7 , wherein the first edge is adjacent to the first angled sidewall and the second edge is adjacent to the second angled sidewall, with the plurality of clip holes further comprising:
 an eighth clip hole adjacent to a middle portion of the third edge of the top wall; and   a ninth clip hole adjacent to a a middle portion of the fourth edge of the top wall.   
     
     
         11 . A system of supports for a concrete slab, the system comprising a plurality of hollow boxes, each hollow box comprising:
 four side walls, a top wall, and an open bottom, wherein the hollow box is configured to be placed directly on soil of a site oriented such that the open bottom abuts the soil; and   a plurality of clip holes in the top wall, the clip holes spaced along and adjacent an exterior perimeter of the top wall, wherein the clip holes comprise tapered walls; and   a plurality of clips comprising two or more posts and a crosspiece coupling the two or more posts together, wherein the two or more posts are configured to be selectively inserted into the clip holes to secure two or more hollow boxes together, wherein the tapered walls of the clip holes are configured to facilitate an interference fit between the clip holes and the posts,   wherein the plurality of hollow boxes are configured to be placed in an array, the array comprising clusters of one or more of the plurality of hollow boxes with each of the clusters spaced apart from other clusters and configured to be coupled with one or more of the plurality of clips to every immediately surrounding cluster via one or more of the plurality of clip holes.   
     
     
         12 . The system of  claim 11 , wherein one or more crosspieces of the plurality of clips configured to be used between the clusters are further configured to receive at least one support member configured to span a plurality of crosspieces. 
     
     
         13 . The system of  claim 11 , wherein the plurality of clip holes are arranged on each hollow box to facilitate coupling between a first cluster comprising two hollow boxes and a cluster comprising four hollow boxes on any side of the first cluster via one or more of the plurality of clips. 
     
     
         14 . The system of  claim 11 , wherein the plurality of clip holes are arranged on each hollow box to facilitate coupling between a first cluster comprising a single hollow boxes and a cluster comprising multiple hollow boxes on any side of the first cluster via one or more of the plurality of clips. 
     
     
         15 . The system of  claim 11 , wherein the plurality of clip holes comprise a clip hole at three corners of the top wall, a clip hole at a middle portion of each of four edges of the top wall, and two clip holes near a fourth corner of the top wall. 
     
     
         16 . The system of  claim 11 , wherein each of the plurality of hollow boxes further comprise a flange extending away from two of the side walls and adjacent to the open bottom, wherein the flange comprises one or more indentations for placing anchors to secure the hollow box to soil. 
     
     
         17 . A method of laying a concrete slab, the method comprising:
 placing a plurality of hollow boxes in an array on the ground of a site, the array comprising clusters of one or more of the plurality of hollow boxes, each of the clusters spaced apart from other clusters and configured to be coupled with one or more clips to immediately surrounding clusters via one or more clip holes on top of each hollow box, wherein each of the hollow boxes comprises a flange extending away from the hollow box and adjacent to a bottom of the box bottom, wherein the flange comprises one or more indentations for placing anchors to secure the hollow box to the soil;   securing the hollow boxes in place by driving one or more anchors through at least one of the one or more indentations of the flange and into the soil; and   placing support member across one or more clips between the clusters of hollow boxes; and   pouring concrete monolithically over the hollow boxes and support members.   
     
     
         18 . The method of  claim 17 , wherein the array comprises a first row of clusters with each cluster comprising two hollow boxes, a second row of clusters where each cluster comprising four hollow boxes, and a third row of clusters where each cluster comprising four hollow boxes, wherein a plurality of clips couple clusters from the second row to clusters from both of the first row and the third row. 
     
     
         19 . The method of  claim 17 , wherein the one or more indentations in the flange comprise three indentations. 
     
     
         20 . The method of  claim 17 , wherein the hollow boxes are left under the concrete after pouring the concrete.