Foundation Systems and Utility Pole Installations and Methods Including Same

The present application claims the benefit of and priority from U.S. Provisional Patent Application No. 63/647,992, filed May 15, 2024, the disclosure of which is incorporated herein by reference.

The present disclosure relates to foundation systems for utility poles.

Utility poles are commonly used to mount cellular communications antennas in cities. These antennas may form parts of mobile broadband networks. Poles with integrated cellular communications antennas or radio heads and are referred to as small cell poles.

In some instances, it is desired or necessary to replace an existing utility pole (e.g., a light pole) with a small cell pole. It may also be desirable or necessary to provide a foundation for the new small cell pole while leaving in place a foundation of the existing utility pole or other obstacles such as utility cables or pipes.

According to some embodiments, a foundation system for mounting a utility pole includes a foundation base member, a plurality of anchor piles, and a plurality of anchor adapters. The foundation base member is configured to support the utility pole. The foundation base member includes a plurality of preformed holes defining an array of preformed through holes. The plurality of anchor piles is configured to be driven into the ground. The plurality of anchor adapters is configured to secure the foundation base member to the anchor piles. The plurality of preformed through holes are arranged to receive the anchor adapters.

In some embodiments, the foundation base member is a grate.

According to some embodiments, each anchor adapter includes a wedge connector configured to be received in a pile bore of a respective one of the anchor piles and to secure the anchor adapter to the respective anchor pile.

In some embodiments, each wedge connector includes a threaded rod, at least one wedge member, and a drive nut threadedly mounted on the threaded rod and operable to displace the wedge member.

In some embodiments, the at least one wedge member includes an elongate slot, the threaded rod extends into the wedge member through the elongate slot, and the slot permits the wedge member to translate radially relative to the threaded rod.

In some embodiments, each wedge connector includes a first wedge member and a second wedge member each having a sloped bearing face, the sloped bearing face of the first wedge member slidably engages the sloped bearing surface of the second wedge member, and the drive nut is drivable to displace the first wedge member relative to the second wedge member and thereby force at least one of the first and second wedge members radially outward to press against an inner surface of the respective pile bore.

In some embodiments, the foundation system includes: a retainer nut on the thread rod and coupling the thread rod to the second wedge member; and a cage member that prevents rotation of the retainer nut relative to the second wedge member.

According to some embodiments, a method for installing a foundation system for mounting a utility pole includes: providing a foundation base member including preformed through holes; thereafter, driving anchor piles into the earth until a prescribed minimum torque is achieved; installing respective anchor adapters on each anchor pile; positioning a foundation base member over the anchor adapters such that each anchor adapter aligns with a respective one of the preformed through holes of the plurality of preformed holes of the foundation base member, the foundation base member configured to support the utility pole; and, securing the foundation base member to the anchor piles.

In some embodiments, the plurality of preformed holes defines an array of preformed through holes.

According to some embodiments, the foundation base member is a grate.

In some embodiments, the method further includes the step of inserting a wedge connector of an anchor adapter into a respective one of the anchor piles and securing the anchor adapter to the respective anchor pile.

According to some embodiments, each wedge connector includes a threaded rod, at least one wedge member, and a drive nut threadedly mounted on the threaded rod and operable to displace the wedge member.

In some embodiments, the at least one wedge member includes an elongate slot, the threaded rod extends into the wedge member through the elongate slot; and the slot permits the wedge member to translate radially relative to the threaded rod.

In some embodiments, each wedge connector includes a first wedge member and a second wedge member each having a sloped bearing face, the sloped bearing face of the first wedge member slidably engages the sloped bearing surface of the second wedge member, and the drive nut is drivable to displace the first wedge member relative to the second wedge member and thereby force at least one of the first and second wedge members radially outward to press against an inner surface of the respective pile bore.

In some embodiments, the wedge connector includes: a retainer nut on the thread rod and coupling the thread rod to the second wedge member; and a cage member that prevents rotation of the retainer nut relative to the second wedge member.

In some embodiments, each wedge connector includes a tension indicator operative to indicate a tension load on the threaded rod.

According to some embodiments, a foundation system for mounting a utility pole includes a foundation base member, a plurality of anchor piles, and a plurality of anchor adapters. The foundation base member is configured to support the utility pole. The plurality of anchor piles is configured to be driven into the ground. The plurality of anchor adapters is configured to secure the foundation base member to the anchor piles. Each anchor adapter includes a wedge connector configured to be received in a pile bore of a respective one of the anchor piles and to secure the anchor adapter to the respective anchor pile.

In some embodiments, each wedge connector includes a threaded rod, at least one wedge member, and a drive nut threadedly mounted on the threaded rod and operable to displace the wedge member.

According to some embodiments, the at least one wedge member includes an elongate slot, the threaded rod extends into the wedge member through the elongate slot, and the slot permits the wedge member to translate radially relative to the threaded rod.

In some embodiments, each wedge connector includes a first wedge member and a second wedge member each having a sloped bearing face, the sloped bearing face of the first wedge member slidably engages the sloped bearing surface of the second wedge member, and the drive nut is drivable to displace the first wedge member relative to the second wedge member and thereby force at least one of the first and second wedge members radially outward to press against an inner surface of the respective pile bore.

The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the disclosure are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

It is noted that aspects described with respect to one embodiment may be incorporated in different embodiments although not specifically described relative thereto. That is, all embodiments and/or features of any embodiments can be implemented separately or combined in any way and/or combination. Moreover, other apparatus, methods, and systems according to embodiments of the inventive concept will be or become apparent to one with skill in the art upon review of the following drawings and detailed description. It is intended that all such additional apparatus, methods, and/or systems be included within this description, be within the scope of the present inventive subject matter, and be protected by the accompanying claims.

As used herein, “monolithic” means an object that is a single, unitary piece formed or composed of a material without joints or seams. Alternatively, a unitary object can be a composition composed of multiple parts or components secured together at joints or seams.

Embodiments of the present technology are directed to foundation systems for utility poles and methods for using the same. According to some embodiments, the foundation system is configured to mount a small cell pole and the method includes forming a small cell utility pole installation using the foundation system.

As shown in, a utility pole installationaccording to some embodiments includes a utility poleand a structural foundation system. The foundation systemis installed in the ground or earth. In some embodiments, the utility pole installationis connected to underground cabling. The foundation systemmay installed around and between pre-existing obstacles. The pre-existing obstaclesmay be the foundation of utility pole that has been removed, underground cabling or pipes, or the like, for example.

In some embodiments, the utility poleis a small cell utility pole. In some embodiments, the utility poleis a monopole small cell utility pole. The utility poleincludes a pole bodyhaving a lower endA and an opposing upper endB. In some embodiments, the utility poleincludes an integrated radio/antenna unitconfigured to transmit one or more of RF communications signals, cellular communications signals and mobile broadband communications signals. In some embodiments, the utility poleincludes an integral light fixture. The integrated radio/antenna unitand the integral light fixturemay be mounted on or proximate the upper endB. The utility poleincludes a pole baseon its lower endB. The utility polemay be formed of metal or wood, for example.

In some embodiments, the utility polehas a height H() in the range of 15 feet to 50 feet.

With reference to, the foundation systemdefines a structural foundation assembly. The foundation systemincludes a foundation base member, a pole mount system, and an anchor system.

As best shown in, the foundation base memberhas a substantially square or rectangular shape defined by a first set of spaced apart wallsextending along a first axis Dand a second set of spaced apart wallsextending along a second axis Dtransverse (e.g., perpendicular) to the first. It is understood that the substantially square or rectangular shape of the foundation base memberis merely exemplary and is not intended to be limiting. In embodiments, the foundation base membermay be round, oval, triangular or more generally any geometric shape. In embodiments, the foundation base membermay have an irregular non-geometric shape to avoid and be installed around and between pre-existing obstacles. By way of example, the foundation base membermay be U-shaped or L-shaped to avoid an overground or underground pre-existing obstacle.

The foundation base memberis defined by a top sideA and an opposing bottom sideB, where the top sideA and an opposing bottom sideB define thickness T(as best shown in) of the foundation base member. In embodiments, the thickness Tis in the range of 2 inches to 6 inches.

The foundation base memberfurther includes a plurality of preformed through holesextending through the thickness Tand parallel to the walls,, the holescollectively defining an arrayof preformed through holes. In some embodiments, the arraysubstantially covers the surface area of the foundation base member. In some embodiments, the arraycovers a portion of the surface area of the foundation base member. In some embodiments, the arraydefines a first portion of the surface area of the foundation base member, and an opening or plurality of openings define a second portion of the surface area of the foundation base member. The openings may be positioned on the surface area to avoid an overground or underground pre-existing obstacle.

In some embodiments, the holesare arranged in a grid of parallel rows and columns extending along the axes Dand D. The base memberthus takes the form of a grate. Other hole patterns or wall arrangements may be used to form the grate. In embodiments, the holes form an irregular arrayto avoid an overground or underground pre-existing obstacle.

In some embodiments, a length L() and a width W() of the foundation base memberare each in the range of 3 feet to 8 feet.

In some embodiments, each through holehas a hole width W() in the range of 1 inch to 4 inches. In some embodiments, each through holeis rectangular, square or round. In some embodiments, the arrayof preformed through holesis at least a ten (10) by ten (10) array. In some embodiments, the arrayincludes at least fifty (50) preformed through holes. In some embodiments, the number of holesin the arrayis in the range or one hundred (100) to five hundred (500) preformed through holes. In some embodiments, the spacing between centers of adjacent preformed through holesin the arrayis less than 1 inch. The foundation base membermay be formed of any suitable material. In some embodiments, the foundation base member is formed of iron or steel. In some embodiments, the foundation base memberis formed by casting. In some embodiments, the foundation base memberis monolithic. In some embodiments, the foundation base memberis a cast iron grate. In other embodiments, the foundation base membermay be formed using other materials and/or other methods of fabrication.

As best shown in, the pole mount systemdefines a pole mount subassembly. The pole mount systemincludes a first mount plate, a second mount plate, and pole mount fasteners (e.g., boltsand nuts). Each of the first and second mount plates (,) comprises a respectively aligned conduit holefor passing electrical or signal conduits through the first and second mount plates (,). In some embodiments, the mount plates,are formed of a metal or metal alloy (e.g., steel).

The anchor systemdefines at least one anchor subassembly. In embodiments, three or four anchor subassembliesare incorporated in an installation. Each anchor subassemblyincludes a respective anchor pileand an anchor adapter.

As best shown in, in some embodiments and as illustrated, each anchor pileincludes an elongate rodand one or more bearing plates. Each respective rodhas a tubular body defined by a proximal endA and an opposing distal endB with a pile boredefined therein. The boredefines an inner sidewall surfaceA of the rod. In some embodiments and as illustrated, the bearing platesare helical bearing plates. The helical profile of the bearing platesare merely exemplary and are not intended to be limiting. As disclosed herein, according to some embodiments, the anchor piles are helical piles. According to further embodiments, piles of other types and configurations may be used in place of the helical anchor piles. In some embodiments, each anchor pilehas a length in the range of 5 feet to 12 feet.

illustrates an exemplary configuration of an anchor adapter. The anchor adapterhas a proximal endA and an opposing distal endB. In embodiments, the anchor adapterincludes a threaded rod, a clamp nut, an upper clamp washer, a lower clamp washer, and a connector. The clamp nut, the upper clamp washer, and the lower clamp washerdefine a clamping mechanismon the proximal endA.

In the illustrated embodiment, the connectoris an expansion wedge connector. The connectoris located on the distal endB. In embodiments, the connectorhas a proximal endA and an opposing distal endB. The connectorincludes a portion of the threaded rod, a drive nut, a retainer, a stop washer, an upper wedge member, and a lower wedge member. In embodiments, the wedge members,and the stop washerare axially slidably mounted on the threaded rod. In embodiments, the retainermay be a nut and is affixed to the distal end of the threaded rod(e.g., by adhesive or welding). The drive nutis threaded onto the threaded rod. The upper wedge memberand the lower wedge membereach have a sloped bearing faceA,A and a semi-cylindrical anchoring surfaceB.B. The bearing facesA,A engage one another and may be complementary. A lubricant (e.g., wax) may be provided on the bearing facesA,A.

In other embodiments, the connectormay be n expansion connector of a different type, such as a sleeve anchor, a strike anchor, a drop-in anchor or an epoxy connector.

With reference to, an anchor adapteraccording to further embodiments of the disclosure is shown therein. An anchor adaptermay be used in place of each of the anchor adaptersin the anchor systemand the foundation systemto form anchor subassemblies with the anchor piles. The anchor adapterhas a proximal endA and an opposing distal endB. In embodiments, the anchor adapterincludes a threaded rod, a pair of clamp nuts, an upper clamp washer, a lower clamp washer, three intermediate washers, and a connector. The clamp nuts, the upper clamp washer, and the lower clamp washerform a clamping mechanismon the proximal endA.

The connectoris an expansion wedge connector. The connectoris located on the distal endB. In embodiments, the connectorhas a proximal endA and an opposing distal endB. The connectorincludes a portion of the threaded rod, a drive nut, a retainer nut, a washer, a tension indicator, an upper wedge member, and a lower wedge member.

The upper wedge memberincludes a tubular wedge bodyC and an end cap or stop washeraffixed (for example, bonded, welded or adhered) to the upper end of the wedge bodyC. The stop washerincludes an elongate slotA and a peripheral notchB defined therein. The upper wedge memberhas a sloped bearing faceA and a semi-cylindrical anchoring surfaceB. The elongate slotA in the stop washerfacilitates smooth and even movement of the upper wedge memberrelative to the threaded rodso that the semi-cylindrical anchoring surfaceB makes good contact with the inner surface of the bore inner surfaceA. With reference to, in embodiments, the lengthwise axis A-A of the slotA is substantially parallel to the wedge displacement directions DE. The slotA is configured to allow the upper wedge memberto translate radially outward relative to the threaded rod. The notchB enables proper alignment of the stop washerduring a step of securing the stop washerto the wedge bodyC.

The lower wedge memberincludes a tubular wedge bodyC, a U-shaped cage memberD and an end plateE. The lower wedge memberhas a sloped bearing faceA and a semi-cylindrical anchoring surfaceB. The cage memberD and the end plateE are affixed (for example, bonded, welded or adhered) to the lower end of the wedge bodyC. The retainer nutis captured between the cage memberD and the end plateE such that the retainer nutis prevented from rotating relative to the tubular wedge bodyC. In some embodiments, the retainer nutis bonded or otherwise affixed to the lower end of the threaded rod.

The tension indicatoris axially interposed between the stop washerand the washer. In some embodiments, the tension indicatoris a direct tension indicator (DTI) comprised of an annular bodyB and integral, deformable indicator protrusionsA.

In embodiments, the wedge members (,), the annular bodyB of the tension indicator, and the washerare axially slidably mounted on the threaded rod. The drive nutis threaded onto the threaded rod. The bearing facesA,A engage one another and may be complementary. A lubricant (e.g., wax) may be provided on the bearing facesA,A.