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US-20260125871-A1 - FOUNDATION REPAIR SYSTEM UTILIZING DISSOLVABLE SPACERS

US20260125871A1US 20260125871 A1US20260125871 A1US 20260125871A1US-20260125871-A1

Abstract

A foundation repair system which employs dissolvable spacers to reduce installation force during pier shimming operations. The system includes concrete piers driven to refusal, topped with pier caps and pier cylinders. A dissolvable spacer is positioned on top of one cylinder, creating a temporary elevation. This allows corrosion-resistant shim plates to be installed on an adjacent pier cylinder with reduced hammering force, decreasing installation impact and preventing pier damage. The dissolvable spacer naturally dissolves when exposed to moisture, leaving little to no residual material. The system may also incorporate galvanized or stainless-steel shim plates for corrosion resistance, and double-stacked pier caps for enhanced load distribution. The method addresses installation force problems that cause pier cracking, while providing long term structural durability.

Inventors

  • Truong Niem Le

Assignees

  • Truong Niem Le

Dates

Publication Date
20260507
Application Date
20250830

Claims (20)

  1. 1 . A system for foundation repair, comprising: a concrete pier driven into soil until refusal is reached or adequate bearing capacity is achieved; a metallic reinforcement inserted into the concrete pier; a pier cap positioned on top of said concrete pier; a first and a second concrete cylinders positioned on said pier cap; a dissolvable spacer positioned on top of said first concrete cylinder; one or more shim plates positioned above said dissolvable spacer; and one or more shim plates positioned on top of said second cylinder.
  2. 2 . The foundation repair system of claim 1 , wherein the dissolvable spacer is allowed to dissolve over time.
  3. 3 . The foundation repair system of claim 1 , wherein said concrete pier is cylindrical with a diameter of 6 or 8 inches and a length of 12 inches.
  4. 4 . The foundation repair system of claim 1 , wherein the metallic reinforcement comprises rebar or rods made of galvanized steel, stainless steel, or plain carbon steel.
  5. 5 . The foundation repair system of claim 1 , wherein said pier cap comprises a double-stacked concrete configuration.
  6. 6 . The foundation repair system of claim 1 , wherein said dissolvable spacer is made from a material selected from the group consisting of carton paper, compressed fiberboard, corrugated cardboard, and biodegradable polymers.
  7. 7 . The foundation repair system of claim 1 , wherein said dissolvable spacer is made of carton paper.
  8. 8 . The foundation repair system of claim 1 , wherein said shim plates are shaped as square, rectangular, or round.
  9. 9 . The foundation repair system of claim 1 , wherein said shim plates are made of galvanized or stainless steel and have a thickness between 0.25 and 1 inch.
  10. 10 . The foundation repair system of claim 9 , wherein said shim plates are shaped as square, rectangular, or round.
  11. 11 . A method for foundation repair, comprising the steps of: installing a concrete pier using a kinetic force until refusal or adequate bearing capacity is reached; inserting metallic reinforcement into the concrete pier; positioning a pier cap on top of said concrete pier; installing a first and a second concrete cylinders on said pier cap; placing a dissolvable spacer on top of said first concrete cylinder; installing one or more shim plates above said dissolvable spacer; and installing one or more shim plates on top of said second cylinder.
  12. 12 . The method of claim 11 , further comprising the step of allowing the dissolvable spacer to dissolve over time.
  13. 13 . The method of claim 11 , wherein said concrete pier is cylindrical with a diameter of 6 or 8 inches and a length of 12 inches.
  14. 14 . The method of claim 11 , wherein the metallic reinforcement comprises rebar or rods made of galvanized steel, stainless steel, or plain carbon steel.
  15. 15 . The method of claim 11 , wherein said pier cap comprises a double-stacked concrete configuration.
  16. 16 . The method of claim 11 , wherein said dissolvable spacer is made of carton paper.
  17. 17 . The method of claim 11 , wherein said shim plates are made of galvanized or stainless steel and have a thickness between 0.25 and 1 inch.
  18. 18 . The method of claim 11 , wherein said shim plates are shaped as square, rectangular, or round.
  19. 19 . The method of claim 17 , wherein said shim plates are shaped as square, rectangular, or round.
  20. 20 . The method of claim 11 , further comprising the step of applying water to said dissolvable spacer to accelerate dissolution.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a Non-Provisional Patent Application which claims the benefit of U.S. Provisional Ser. No. 63/715,116, filed on Nov. 1, 2024, and Design Ser. No. 30/013,904, filed on Jul. 18, 2025, the entire specifications of which are incorporated herein by reference in their entirety. BACKGROUND Field of the Invention The disclosure relates to the field of foundation repair systems, and more particularly to the field of pier and shim installation techniques. Discussion of the State of the Art Foundations are crucial for building stability, yet they frequently experience settling, cracking, or shifting due to variations in soil composition, moisture levels, and construction practices. Certain soil types, such as clay, expand and contract with moisture, while others, like sand, may erode or compact under load, leading to uneven foundation support. These conditions cause foundations to shift, sink, or crack, compromising the structural integrity of buildings and necessitating repair to restore stability and safety. The current process of foundation repair, particularly involving concrete pier installation and shimming, is a force-intensive and damage-prone endeavor. It involves hydraulically installing concrete piers beneath existing foundations and using shim plates to level and support the structure. During installation, a substantial amount of hammering force must be used to drive the shim plates into precise alignment, particularly when positioning shims under the second pier once the hydraulic jack is removed. This excessive force and high-impact hammering frequently results in cracking, structural damage, or decreased stability to the concrete piers, pier caps, or surrounding structure, which can lead to immediate or gradual pier failure and potential instability in the foundation. Traditional repair techniques utilize plain square or rectangular carbon steel shim plates positioned beneath foundation structures to provide load-bearing support and height adjustment. While these plates initially meet basic structural requirements, they are highly susceptible to corrosion, particularly in moist environments. This corrosion weakens the load bearing capacity of the shim plates and requires more frequent replacement. Galvanized steel loses its structural integrity at a much lower rate than carbon steel. A round shim plate design has been adapted more recently by some foundation contractors. The circular configuration provides better conformity to cylindrical pier tops. However, the installation force is not consistently reduced, as the hammering force used in installation remains substantial, limiting the effectiveness for preventing pier damage. Conventional pier cap configurations, typically comprising single concrete blocks, and are designed to provide load transfer surfaces between pier assemblies and foundation structures. The single block single cap design provides limited load distribution area and are vulnerable when hydraulic jacks are not perfectly aligned during installation. The eccentric loading from off-center jack placement can compromise cap performance. What is needed is a system and method to reduce installation force during shim placement while preventing damage to pier assemblies and ensuring long-term structural integrity. BRIEF SUMMARY Accordingly, the inventor has conceived and reduced to practice, a system and method for foundation repair utilizing dissolvable spacers and corrosion resistant shim plates to significantly reduce installation force during installation and preventing structural damage while ensuring long term durability. The system and method employ temporary dissolvable spacers placed during the installation process to reduce hammering force by approximately 30-40%, allowing shim plates to be installed with reduced impact on pier assemblies. The dissolvable spacers, typically made from carton paper, are designed to naturally dissolve over time when exposed to environmental moisture, leaving little to no residual material that could interfere with permanent structural alignment or load distribution. The system and method also incorporate corrosion-resistant galvanized or stainless-steel shim plates to maintain structural integrity over extended periods, and double-stacked pier caps that provide enhanced load distribution and can counteract eccentric alignment during hydraulic lifting operations. With the combination of the force reduction techniques, corrosion-resistant materials, and improved pier cap configuration, this system and method offers a practical and technical improvement over existing foundation repair techniques, impacting both immediate installation challenges and long-term structural performance requirements. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional side view illustrating a foundation repair system with the dissolvable spacer installed on the right pier to reduce installation force required