Foundation support system and method of installation with self-aligning torque transmitting couplers

Abstract

A foundation support system and method includes support components having mating ends with a pair of fastener holes and a rotational interlock feature configured to partly engage one another while the rotational interlock features are misaligned, and to self-align and fully engage the rotational interlock features via a rotation of one of the ends relative to the other while also automatically aligning the pairs of fastener holes to simplify an insertion of a fastener while avoiding fastener hole deformation when the foundation support components are driven to a desired depth on a building site to support the building foundation.

What is claimed is: 
     
         1 . A support system for a building foundation, the support system comprising:
 a first foundation support component including a first end having a first pair of fastener holes and a first rotational interlock feature spaced from the first pair of fastener holes; and   a second foundation support component including a second end having a second pair of fastener holes and a second rotational interlock feature spaced from the second pair of fastener holes;   wherein the first end and the second end are configured to partly engage while the first and second rotational interlock features are misaligned, and are further configured to self-align and fully engage the first and second rotational interlock features via a rotation of one of the first and second ends about a longitudinal center axis relative to the other of the first and second ends; and   wherein the first end and the second end are configured to automatically align the first pair of fastener holes with the second pair of fastener holes as the first and second rotational interlock features are self-aligned and fully engaged to simplify an insertion of a fastener through the aligned first and second pairs of fastener holes while avoiding a deformation of the first and second pairs of fastener holes when the first and second foundation support components are driven to a desired depth on a building site to support the building foundation.   
     
     
         2 . The support system of  claim 1 , wherein the fastener is a single bolt extending through and between the aligned first pair of fastener holes and the second pair of fastener holes. 
     
     
         3 . The support system of  claim 1 , wherein the first and second rotational interlock feature includes at least one torque transmitting edge extending from each of the first end and the second end. 
     
     
         4 . The support system of  claim 3 , wherein the at least one torque transmitting edge extends linearly or spirally on each of the first end and the second end. 
     
     
         5 . The support system of  claim 4 , wherein the at least one torque transmitting edge extends radially outwardly or radially inwardly from the first end or the second end. 
     
     
         6 . The support system of  claim 4 , wherein the at least one torque transmitting edge is defined by a projecting rib or a depending groove in the first end and the second end. 
     
     
         7 . The support system of  claim 1 , wherein the first end defines a smaller diameter inner coupler portion and wherein the second end defines a larger diameter outer coupler portion. 
     
     
         8 . The support system of  claim 1 , wherein the first foundation support component is a primary foundation support pile. 
     
     
         9 . The support system of  claim 8 , wherein the second foundation support component is an extension foundation support pile or a drive tool coupler. 
     
     
         10 . The support system of  claim 8 , wherein the primary foundation support pile includes a helical auger. 
     
     
         11 . A method of installing a foundation support system on a building site, the method comprising:
 providing at the building site a first foundation support component including a first end formed with a first pair of fastener holes and a second foundation support component including a second end having a second pair of fastener holes;   after driving one of the first and second foundation support components partly below ground on the building site, partly engaging the first end and the second end in a misaligned orientation; and   rotating one of the first and second ends about a longitudinal center axis relative to the other, causing the first and second ends to self-align and fully engage;   whereby the first pair of fastener holes are automatically engaged with the second pair of fastener holes as the first end and second end are fully engaged.   
     
     
         12 . The method of  claim 11 , further comprising extending a fastener through the first pair of fastener holes and the second pair of fastener holes, and driving the first and second foundation support components in combination to a below ground depth on the building site. 
     
     
         13 . The method of  claim 12 , wherein the first end and the second end are each formed with at least one torque transmitting edge, and wherein rotating one of the first and second ends about the longitudinal center axis relative to the other further causes the at least one torque transmitting edge to self-align and fully engage in the first end and the second end. 
     
     
         14 . The method of  claim 13 , further comprising driving the first foundation support component and the second foundation support component below ground via engagement of the least one torque transmitting edge in each of the first end and the second end while the fastener is mechanically isolated from torque transmission. 
     
     
         15 . The method of  claim 13 , wherein the at least one torque transmitting edge extends linearly or spirally on each of the first end and the second end. 
     
     
         16 . The method of  claim 15 , wherein the at least one torque transmitting edge is defined by a radially outwardly projecting rib or an inwardly depending groove in the first end or the second end. 
     
     
         17 . The method of  claim 11 , wherein the first end defines a smaller diameter inner coupler portion and wherein the second end defines a larger diameter outer coupler portion, and wherein partly engaging the first end and the second end comprises partially mating the smaller diameter inner coupler portion and the larger diameter outer coupler portion. 
     
     
         18 . The method of  claim 11 , wherein the first foundation support component is a primary foundation support pile. 
     
     
         19 . The method of  claim 18 , wherein the second foundation support component is an extension foundation support pile or a drive tool coupler. 
     
     
         20 . The method of  claim 18 , wherein the primary foundation support pile includes a helical auger. 
     
     
         21 . A support system for a building foundation, the support system comprising:
 a first foundation support component including a first coupler portion having a first pair of fastener holes and a first rotational interlock feature spaced from the first pair of fastener holes; and   a second foundation support component including a second coupler portion having a second pair of fastener holes and a second rotational interlock feature spaced from the second pair of fastener holes;   wherein the first coupler portion and the second coupler portion are configured to automatically align the first pair of fastener holes with the second pair of fastener holes when the first and second rotational interlock features are aligned.   
     
     
         22 . The support system of  claim 21 , wherein the first interlock features comprise at least two spaced apart outwardly projecting ribs. 
     
     
         23 . The support system of  claim 21 , wherein the second interlock features comprise at least two spaced apart inwardly depending grooves. 
     
     
         24 . The support system of  claim 21 , wherein one of the first foundation support and the second foundation support is a primary pile and wherein the other of the first foundation support and the second foundation support is an extension pile. 
     
     
         25 . The support system of  claim 21 , further comprising a drive tool coupler including a third coupler portion having a third pair of fastener holes and a third rotational interlock feature spaced from the third pair of fastener holes, wherein the third coupler portion is configured to automatically align the first pair of fastener holes with the third pair of fastener holes when the first and third rotational interlock features are aligned. 
     
     
         26 . The support system of  claim 21 , wherein the first and second coupler portions are configured to self-align the first interlock feature and the second interlock feature when one of the first coupler portion and the second coupler portion is rotated about a longitudinal center axis relative to the other. 
     
     
         27 . The support system of  claim 21 , wherein the first and second foundation support components are uniformly round in cross section.