Building foundation support system with rib and groove interlock drive tool coupler component and piles

Abstract

A building foundation support system includes first and second components having a distal end formed with an outer surface and at least two spaced apart ribs or with at least two spaced apart grooves. When the ribs are respectively inserted into the grooves, a rotationally interlocked mechanical connection is established between the distal ends. One of the first and second components is an elongated pile shaft and the other is a drive tool coupler for driving the elongate pile shaft into the ground proximate the building foundation.

What is claimed is: 
     
         1 . A building foundation support system comprising:
 a first component comprising a first distal end, the first distal end formed with an outer surface and at least two spaced apart ribs projecting outwardly from the outer surface;   a second component comprising a second distal end, the second distal end formed with at least two spaced apart grooves;   wherein when the at least two spaced apart ribs are respectively inserted into the at least two spaced apart grooves, a rotationally interlocked mechanical connection is established between the first distal end and the second distal end; and   wherein one of the first and second components is an elongated pile shaft and wherein the other of the first and second components is a drive tool coupler for driving the elongate pile shaft into the ground proximate the building foundation.   
     
     
         2 . The building foundation support system of  claim 1 , wherein the at least two spaced apart ribs are linear ribs. 
     
     
         3 . The building foundation support system of  claim 1 , wherein the first and second components are configured to be fastened together at a location spaced from the at least two spaced apart ribs and the at least two spaced apart grooves. 
     
     
         4 . The building foundation support system of  claim 1 , wherein the outer surface of the first component is a cylindrically round surface. 
     
     
         5 . The building foundation support system of  claim 1 , wherein the at least two spaced apart ribs are formed integrally on the respective first distal end. 
     
     
         6 . The building foundation support system of  claim 5 , wherein the at least two spaced apart ribs are swaged on the first distal end. 
     
     
         7 . The building foundation support system of  claim 1 , further comprising a first fastener hole formed in the first distal end and a second fastener hole formed in the second distal, wherein when the at least two spaced apart ribs are respectively mated with the at least two spaced apart grooves the first and second fastener holes are self-aligning with one another to receive a first fastener therethrough. 
     
     
         8 . The building foundation support system of  claim 7 , wherein the first fastener is mechanically isolated from rotational torque transmission by the rotationally interlocked mechanical connection. 
     
     
         9 . The building foundation support system of  claim 1 , wherein the elongated pile shaft is one of a primary pile or an extension pile. 
     
     
         10 . The building foundation support system of  claim 9 , wherein at least one of the primary pile or the extension pile includes a helical auger. 
     
     
         11 . A building foundation support system comprising:
 a first component including an outer coupler portion having an inner opening and an inner surface formed with a plurality of inwardly extending torque transmitting edges; and   a second component including an inner coupler portion having an outer surface formed with a plurality of outwardly extending torque transmitting edges;   wherein when the outer surface of the inner coupler portion is received through the inner opening and engaged to the inner surface of the outer coupler portion, an interlocking torque transmission structure is established between the inwardly extending torque transmitting edges and the outwardly extending torque transmitting edges; and   wherein one of the first and second components is a drive tool coupler for driving the other of the first or second components into the ground to support the building foundation.   
     
     
         12 . The building foundation support system of  claim 11 , wherein at least one of the inner coupler portion and the outer coupler portion is swaged on an end portion of the respective first component or the second component. 
     
     
         13 . The building foundation support system of  claim 11 , wherein the outwardly extending torque transmitting edges are defined by linear ribs, and wherein the inwardly extending torque transmitting edges are defined by linear grooves. 
     
     
         14 . The building foundation support system of  claim 11 , wherein the other of the first and second components is an elongated pile shaft. 
     
     
         15 . The building foundation support system of  claim 14  wherein the elongated pile shaft is one of a primary pile or an extension pile. 
     
     
         16 . The building foundation support system of  claim 15 , wherein at least one of the primary pile or the extension pile includes a helical auger. 
     
     
         17 . The building foundation support system of  claim 11 , further comprising at least one bolt extending through the outer coupler portion and the inner coupler portion. 
     
     
         18 . The building foundation support system of  claim 17 , wherein the at least one bolt is mechanically isolated from torque transmitted through the outer coupler portion and the inner coupler portion. 
     
     
         19 . The building foundation support system of  claim 11 , wherein the inner coupler portion is configured to be mated with the outer coupler portion in a self-aligning manner. 
     
     
         20 . The building foundation support system of  claim 11 , wherein the outer coupler portion is provided in the drive tool coupler. 
     
     
         21 . A building foundation support system comprising:
 a primary pile including a first distal end, the first distal end formed with at least two spaced apart ribs projecting outwardly from an outer surface or at least two spaced apart interior grooves;   at least one extension pile including a second distal end, the second distal end formed with at least two spaced apart ribs projecting outwardly from an outer surface or at least two spaced apart interior grooves; and   a drive tool coupler including at least two spaced apart ribs projecting outwardly from an outer surface or at least two spaced apart interior grooves;   wherein the drive tool coupler is configured to establish a rotationally interlocked mechanical connection between the ribs or grooves of the drive tool coupler and the ribs or grooves of the first distal end to drive the primary pile into the ground; and   wherein the drive tool coupler is configured to establish a rotationally interlocked mechanical connection between the ribs or grooves of the drive tool coupler and the ribs or grooves of the second distal end to drive the at least one extension pile and the primary pile into the ground as a combination.   
     
     
         22 . The building foundation support system of  claim 21 , wherein the at least one extension pile includes a third distal end opposite the second distal end, wherein the third distal end is formed with at least two spaced apart ribs projecting outwardly from an outer surface or at least two spaced apart interior grooves, wherein the third distal end is configured to establish a rotationally interlocked mechanical connection between the ribs or grooves of the third distal end and the ribs or grooves of the first distal. 
     
     
         23 . The building foundation support system of  claim 21 , wherein the drive tool coupler includes the at least two spaced apart interior grooves. 
     
     
         24 . The building foundation support system of  claim 23 , wherein the first distal end and the second distal end each includes the at least two spaced apart ribs projecting outwardly from the outer surface. 
     
     
         25 . The building foundation support system of  claim 24 , wherein the at least one extension pile includes a third distal end opposite the second distal end, and wherein the third distal end includes the at least two spaced apart interior grooves. 
     
     
         26 . The building foundation support system of  claim 21 , wherein the drive tool coupler includes a pair of fastener holes for attaching the drive tool coupler to the first distal end or the second distal end. 
     
     
         27 . The building foundation support system of  claim 21 , wherein in each of the primary pile, the extension pile and the drive tool coupler the at least two spaced apart ribs comprise elongated linear ribs and wherein the at least two spaced apart interior grooves comprise elongated linear grooves. 
     
     
         28 . The building foundation support system of  claim 21 , wherein in each of the primary pile, extension pile and drive tool coupler the at least two spaced apart ribs comprise four linear ribs and wherein the at least two spaced apart interior grooves comprise four linear grooves. 
     
     
         29 . The building foundation support system of  claim 21 , wherein the primary pile includes a helical auger. 
     
     
         30 . The building foundation support system of  claim 21 , wherein the primary pile and the extension pile each comprise a hollow steel shaft. 
     
     
         31 . The building foundation support system of  claim 21 , in combination with a cementitious material enhancing a structural strength and capacity of the system to support the building foundation.