WO2021217022A1

WO2021217022A1 - Soil reinforcing element and method of manufacturing

Info

Publication number: WO2021217022A1
Application number: PCT/US2021/028877
Authority: WO
Inventors: Thomas P. Taylor
Original assignee: The Taylor IP Group
Priority date: 2020-04-23
Filing date: 2021-04-23
Publication date: 2021-10-28
Also published as: US20210332549A1

Abstract

A soil reinforcing element including a flat elongated strip of material defining an upper planar surface and a bottom planar surface, the bottom planar surface opposing the upper planar surface, and a frictional profile being formed on each of the upper planar surface and the bottom planar surface, as well as a method of manufacturing the same.

Description

SOIL REINFORCING ELEMENT AND METHOD OF MANUFACTURING

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to and the benefit of U.S. Prov. Pat. App. Ser. No. 63/014,292, which was filed on April 23, 2020, and U.S. Non-Provisional Patent Application No.17/238, 719 filed April 23, 2021 which to the extent that it is consistent with the present disclosure is hereby incorporated herein by reference in its entirety and to the extent that it is not inconsistent with the present disclosure.

BACKGROUND

Technical Field

[0002] The invention relates to the configuration, use, and manufacturing of a soil reinforcing element for ground improvement in a mechanically stabilized earth structure using the method of cold forming.

Description of the Related Art

[0003] Earth retaining structures that are constructed using soil inclusions that are positioned substantially horizontal in compacted backfill are a form of ground improvement that is classified as mechanically stabilized earth (MSE) structures. MSE structures are known to be used for retaining wall systems, earthen embankments, bridge abutments that support the bridge substructure, dams that retain water, headwalls for structural plate crossings, mining crusher support structures, among others. Some examples of soil reinforcing devices and methods are shown and described in U.S. Pat. No. 8,632,277, which shares inventorship with the present application and is commonly owned, is fully incorporated herein by reference.

[0004] Referring to FIG. 1A-1C, an exemplary system 100 for securing a facing 102 to an earthen formation or backfill 104 mass. The facing 102 includes an individual precast concrete panel or, alternatively, a plurality of interlocking precast concrete modules or wall members that are assembled into an interlocking relationship. In another embodiment, the facing 102 may be a uniform, unbroken expanse of concrete or the like which may be poured or assembled into an interlocking relationship. In another embodiment, the facing 102 may be a uniform, unbroken expanse of concrete or the like which may be poured or assembled on site. The facing 102 may generally define an exposed face 105 (FIGS. 1 B and 1C) and a back face 106. The exposed face 105 typically includes a decorative architectural facing, while the back face 106 is located adjacent to the backfill 104. Cast into the facing 102, or otherwise attached thereto, and protruding generally from the back face 106, is at least one exemplary facing anchor 108. Instead of being cast into the facing 102, the facing anchor 108 may be mechanically fastened to the back face 106, for example, using bolts (not shown). As will be described below, several variations of the facing anchor 108 may be implemented without departing from the scope of the disclosure.

[0005] The earthen formation or backfill 104 may encompass an MSE structure including a plurality of soil reinforcement elements 110 that extend horizontally into the backfill 104 to add tensile capacity thereto. In an exemplary embodiment, the soil reinforcement elements 110 may serve as tensile resisting elements positioned in the backfill 104 in a substantially horizontal alignment at spaced-apart relationships to one another against the compacted soil. Depending on the application, grid-like steel mats or welded wire mesh may be used as soil reinforcement elements 110, but it is not uncommon to employ “geogrids” made of plastic or other materials to accomplish the same end.

[0006] The earthen formation or backfill 104 may encompass an MSE structure including a plurality of soil reinforcement elements 110 that extend horizontally into the backfill 104 to add tensile capacity thereto. In an exemplary embodiment, the soil reinforcement elements 110 may serve as tensile resisting elements positioned in the backfill 104 in a substantially horizontal alignment at spaced-apart relationships to one another against the compacted soil. Depending on the application, grid-like steel mats or welded wire mesh may be used as soil reinforcement elements 110, but it is not uncommon to employ “geogrids” made of plastic or other materials to accomplish the same end.

[0007] The soil reinforcement element 110 may include a welded wire grid having a pair of longitudinal wires 112 that are substantially parallel to each other. The longitudinal wires 112 may be joined to a plurality of transverse wires 114 in a generally perpendicular fashion by welds at their intersections, thus forming a welded wire gridworks. In exemplary embodiments, the spacing between each longitudinal wire 112 may be about 2 in., while spacing between each transverse wire 114 may be about 6 in. As can be appreciated, however, the spacing and configuration may vary depending on the mixture of tensile force requirements that the reinforcement element 110 must resist.

[0008] Lead ends 116 of the longitudinal wires 112 may generally converge toward one another and be welded or otherwise attached to a connection stud 118 of a connector 10 that includes a tab or plate 122 extending from the connection stud 118. The connection stud 118 may include a first end or a stem 120 coupled or otherwise attached to a second end or a tab 122. As will be described below, several variations of the connection stud 118 may be implemented, without departing from the disclosure. In at least one embodiment, the stem 120 may include a cylindrical body having an axial length L. As illustrated, the lead ends 116 may be coupled or otherwise attached to the stem 120 along at least a portion of the axial length L. In one embodiment, the tab 122 may be a substantially planar plate and define at least one centrally-located perforation or hole 124.

[0009] The facing anchor 108 may include a pair of horizontally-disposed connection points or plates 126a, 126b cast into and extending from the back face 106 of the facing 102. As can be appreciated, other embodiments include attaching the facing anchor directly to the back face 106, without departing from the disclosure. Furthermore, as can be appreciated, other embodiments of the disclosure contemplate a facing anchor 108 having a single horizontal plate 126 (not shown), where the tab 122 is coupled only to the single plate 126 via appropriate coupling devices.

[0010] Each plate 126 a, b may include at least one perforation 128 adapted to align with a corresponding perforation 128 on the opposing plate 126 a, b. As illustrated in FIG. 1 B, the plates 126, b may be vertically-offset a distance X, thereby generating a gap 132 configured to receive the tab 122 for connection to the facing anchor 108. In operation, the tab 122 may be inserted into the gap 132 until the hole 124 aligns substantially with the perforations 128 of each plate 126 a, b. A coupling device, such as a nut and bolt assembly 130 or the like, may then be used to secure the connection stud 118 (and thus the soil reinforcement element 110) to the facing anchor 108. In one or more embodiments, the nut and bolt assembly 130 may include a threaded bolt having a nut and washer assembly, but can also include a pin-type connection having an end that prevents it from removal, such as a bent-over portion.

[0011] In this arrangement, the soil reinforcement element 110 (as coupled to the connection stud 118) may be allowed to swivel or rotate about axis Y in a horizontal plane Z (FIG. 1A). Rotation about axis Y may prove advantageous since it allows the system 100 to be employed in locations where a vertical obstruction, such as a drainage pipe, catch basin, bridge pile, bridge pier, or the like may be encountered in the backfill 104. To avoid such obstructions, the soil reinforcement element 110 may be pivoted about axis Y to any angle relative to the back face 106, thereby swiveling to a position where no obstacle exists.

[0012] Moreover, the gap 132 defined between two vertically-offset plates 126a, 126b may also prove significantly advantageous. For example, the gap 132 may compensate or allow for the settling of the MSE structure as the soil reinforcement element 110 settles in the backfill 104. During settling, the tab 122 may be able to shift or slide vertically about the nut and bolt assembly 130 the distance X, thereby compensating for a potential vertical drop of the soil reinforcement element 110 and preventing any buckling of the concrete facing 102. As will be appreciated by those skilled in the art, varying designs of anchors 108 may be used that increase or decrease the distance X to compensate for potential settling or other MSE mechanical phenomena.

[0013] Furthermore, it is not uncommon for concrete facings 102 to shift in reaction to MSE settling or thermal expansion/contraction. In instances where such movement occurs, the soil reinforcement elements 110, which include longitudinal longitudinal wires 112, of the disclosure are capable of correspondingly swiveling about axis Y and shifting the vertical distance X to prevent misalignment, buckling, or damage to the concrete facing 102. [0014] The construction of an MSE structure is a repetitive process that consists of placing compacted backfill and soil reinforcing in regular interval thicknesses until a desired height of the structure is achieved. The soil reinforcing elements are generally the same length from top to bottom and are spaced at regular intervals in both the horizontal and vertical direction. It is known that the soil reinforcing elements are fabricated from metal or plastic. The soil reinforcing can consist of strips or continuous sheets. The strips may consist of elements that are fabricated to form a grid. The soil reinforcing elements can be configured so the soil reinforcing profile is planar or bi- planar. The soil reinforcing can be fabricated to contain different surface configurations, patterns, and profiles along their length.

[0015] The soil reinforcing elements may be placed in an embankment with or without a facing element. The soil reinforcing elements are generally placed perpendicular to the face of the embankment however they may be placed in other skewed directions to bypass obstructions. For noncontinuous soil reinforcing elements the adjacent elements are spaced apart and are routinely within the same horizontal plane. The soil reinforcing in combination with the compacted backfill forms a composite structure. The compacted backfill resists compressive forces while the soil reinforcing resists tensile forces.

[0016] In instances where the soil reinforcing elements are attached to a facing element, the facing can be concrete, timber, steel, welded wire mesh or the likes thereof. The proximal ends of the soil reinforcing elements are attached to the facing in many different ways. The facing element forms the external surface of the MSE structure or embankment. The facing elements can be positioned vertically, or they can be battered into the earthen formation. The facing element prevents erosion of the backfill at the proximal end of the soil reinforcing between successive rows and columns of the soil reinforcing elements. The facing element may also serve as a decorative veneer.

[0017] Flat elongated strips as are conventionally known in the art for use in stabilized earth structures are shown and described in U.S. Pat. No. 4,710,062, the contents of which are incorporated herein by reference. For example, as shown in FIG. 1 D, a piece of material 1 is passed through rollers 11 that define a profile in the material 1 as it is rolled through the pair of opposing rollers 11 which have grooves 12 and other regions 13 defines on the surfaces of the rollers 11 to emboss corresponding features into the material 1 as the material is passed therethrough.

[0018] It should be understood that the background is provided to aid in an understanding of the present disclosure and that nothing in the background section shall be construed as an admission of prior art in relation to the inventions described herein.

SUMMARY

[0019] In an embodiment, a soil reinforcing element may include: a flat elongated strip of material defining an upper planar surface and a bottom planar surface; and a frictional profile formed on each of the upper planar surface and the bottom planar surface. The frictional profile may include a plurality of protuberances. The plurality of protuberances may be spaced apart from one another by a constant interval. The frictional profile may include a plurality of depressions. The plurality of depressions may be spaced apart from one another by a constant interval. The plurality of protuberances may be grouped into a plurality of groups and each of the groups is spaced apart from one another by a constant interval. The flat elongated strip of material may be twisted at intervals to form a plurality of sections, adjacent ones of the plurality of sections being twisted by 180 degrees with respect to one another. The flat elongated strip of material may be formed from metal, e.g., aluminum, stainless steel, or carbon steel.

[0020] In a further embodiment, a method of manufacturing a soil reinforcing element may include: providing a flat elongated strip where all surfaces of the flat elongated strip are smooth; and passing the flat elongated strip through a cold forming embossing roller device to emboss a frictional pattern on opposing surface of the flat elongated strip corresponding to impressions on roller surfaces of the embossing roller. The method may further include twisting the flat elongated strip, about a central axis longitudinally extending along a length of the flat elongated strip, into a plurality of sections, adjacent ones of the sections being twisted 180 degrees relative to one another. [0021] In a still further embodiment, a method of manufacturing a soil reinforcing element using coiled metal may include: placing a coil on an unwinding pedestal to uncoil a strip from the coil; passing the strip through a straightening station to straighten the strip; passing the strip through a punch station to flatten the strip; passing the strip through an embossing station to create a frictional profile on top and bottom surfaces of the strip; passing the strip through a twisting station; passing the strip through a guillotine to cut the strip to a predetermined length; placing the finished strip in a stack; and banding the finished stack of strips. The frictional profile may include a plurality of protuberances. The frictional profile may include a plurality of depressions. The passing the strip through the twisting station may create a plurality of adjacent twisted sections that are twisted 180 degrees relative to one another about an axis extending lengthwise through the strip. The frictional profile may include at least one of a plurality of protuberances and depressions, the plurality of protuberances being grouped into a plurality of groups and each of the groups being spaced apart from one another by a constant interval.

[0022] These and other aspects of the present disclosure are described in greater detail below with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1A is an exploded perspective view of a prior art soil reinforcing system.

[0024] FIG. 1B is a side view of the system shown in FIG. 1A.

[0025] FIG. 1C is a side view of the system shown in FIG. 1A coupled together.

[0026] FIG. 1 D is a schematic view of a rolling process according to the prior art.

[0027] FIG. 2A is an isometric view of an embodiment of a soil reinforcing element in accordance with the present disclosure.

[0028] FIG. 2B is a side view of the soil reinforcing element of FIG. 2A.

[0029] FIG. 3A is an is an isometric view of a further embodiment of a soil reinforcing element in accordance with the present disclosure. [0030] FIG. 3B is an enlarged view of a portion of the soil reinforcing element of FIG. 3A.

[0031] FIG. 3C is a side view of the soil reinforcing element of FIG. 3B.

[0032] FIG. 4 is an is an isometric view of a still further embodiment of a soil reinforcing element in accordance with the present disclosure.

[0033] FIG. 5 is a flowchart depicting a method of manufacturing a soil reinforcing element in accordance with the present disclosure.

DETAILED DESCRIPTION

[0034] Various embodiments and aspects of the present disclosure will be described with reference to the accompanying drawings in which like or similar features are labeled with the same reference number. The following description and drawings are illustrative of the present disclosure and are not to be construed as limiting the disclosure. Numerous specific details are described to provide a thorough understanding of various embodiments of the present disclosure. However, well-known or conventional details are not described in order to provide a concise discussion of embodiments of the present disclosure.

[0035] According to an embodiment of the present disclosure, a soil reinforcing element 150 is described with reference to FIGS. 2A-2B. The soil reinforcing element 150 may include a flat elongated strip 152 of material, e.g., metal such as carbon steel, aluminum, or stainless steel, for example. The flat elongated strip 152 may be configured as a relatively flat rectangular prism having a top surface 152T and a bottom surface 152B. The top surface 152T and the bottom surface 152B are planar surfaces. Preferably, the top surface and the bottom surface of the flat elongated strip 152 is substantially smooth. Raised ribs or raised protuberances 154 may be formed in the top surface 152T and the bottom surface 152B such that a frictional profile may be formed on the respective top and bottom surfaces 152T, 152B. That is, the raised protuberances 154 define a frictional pattern that together define a frictional profile. As shown in FIGS. 2A-2B, the raised protuberances 154 may be ribs that extend at least partially widthwise along a width of respective ones of the top surface 152T and the bottom surface 152B. In the illustrated embodiment, the frictional elements 154 are raised protuberances although other embodiments not shown may use other kinds of frictional elements. For examples, some other embodiments may employ depressions as the frictional elements.

[0036] As shown best in FIG. 1B, which is a side view of the soil reinforcing element 150, raised protuberances 154 may be formed on each of the top surface 152T and the bottom surface 152B. The raised protuberances 154 may be spaced apart from one another at a predetermined interval or spacing and may be grouped within a group 156 of the raised protuberances 154, and may be positioned on opposing sides of the flat elongated strip 152 at the same relative position along the length of the flat elongated strip 152.

[0037] Another embodiment of a soil reinforcing element 200 is shown and described with respect to FIGS. 3A-3C. The soil reinforcing element 200 is substantially similar to the soil reinforcing element 150 except that the soil reinforcing element 200 defines a different frictional profile and includes depressions 204a that are formed in each of its upper surface 202T and bottom surface 202B. In particular, along opposing edges of the upper surface 202T and the bottom surface 202B, depressions 204a and 204b may be formed. The depressions 204a and 204b may be spaced at an interval and may also be grouped into groupings 206 and each of the groupings 206 may be spaced apart from one another by an interval. FIG. 3C depicts a side of the soil reinforcing element 200. The grouping 206 may also be referred to as a frictional profile as it provides friction or grip with soil when the soil reinforcing element 200 is used that would not otherwise be provided as the top surface 202T and the bottom surface 202B, which are planar, are otherwise smooth.

[0038] As shown in FIG. 3C, the depressions 204a may be formed on both the upper surface 202T and the bottom surface 202B. Similarly, on the opposing side of the soil reinforcing element 200, the depressions 204a may be formed on both the upper surface 202T and the bottom surface 202B. It should be understood that in other embodiments, that the upper surface 202T and the bottom surface 202B may include a combination of protuberances and depressions and that such protuberances and depressions may have other arrangements, patterns, and/or configurations without departing from the scope and spirit of the present disclosure.

[0039] A method of manufacturing the soil reinforcing elements 150 and 200 may include providing a relatively flat elongated strip of metal that has a smooth surface on the top and bottom surfaces 152T, 152B and forming depressions or protuberances (i.e. , raised elements) in the top and bottom surfaces 152T, 152B. The manipulation of the surface profile is fabricated by the method of cold form embossing. It is also economically advantageous to fabricate the soil reinforcing using stock metal material that is contained on a coil. Where the cold formed rolled raised and depressed profile is intermittently spaced along the flat elongated strip surface, where the spacing and shape of the raised and depressed profile is optimized and verified by using the method of pullout testing.

[0040] A further embodiment of a soil reinforcing element 300 is shown and described with respect to FIG. 4. The soil reinforcing element 300 may be a flat elongated strip 302 including protuberances 304 formed on respective opposing surfaces thereof in a similar fashion to that of strips 152 and 152, except that the flat elongated strip 302 has been twisted to form a plurality of sections 306 that are twisted relative to one another. It should be noted that instead of protuberances 304 that depressions forming a frictional profile similar to that of the soil reinforcing element 200 may be utilized instead.

[0041] Each of the reinforcing elements 300 may include a through bore (not shown) to facilitate coupling of the reinforcing element to an MSE.

[0042] A method of manufacturing the soil reinforcing element 300 may include providing a flat elongated strip 302 of material, e.g., metal. The flat elongated strip 302 may be substantially similar to the flat elongated strips 150, 200 described above except that the flat elongated strip 302 has been twisted about an axis longitudinally extending along its length by intermittently twisting the flat elongated strip 302 by 180 degrees such each of the sections 306 have their respective top and bottom surfaces remaining substantially planar with respect to the top and bottom surfaces of adjacent ones of the sections 306. As shown in FIG. 4, the flat elongated strip 302 has been twisted such that what was the bottom surface B of one of the sections 306 is twisted to be coplanar with the top surface T of an adjacent one of the sections 306.

[0043] FIG. 5 depicts a flowchart outlining steps in a method of manufacturing the above-described soil reinforcing elements. In particular, at step 502, a determination is made as to whether the strip of material is on a coil. If the strip of material, e.g., metal, is on a coil, the coil is unwound at step 506. Otherwise, if the strip is not on a coil, i.e. , it is already unwound, the strip is fed into the rollers, which may be performed according to a similar process as described with respect to FIG. 1D. At step 508, the strip of material is straightened by passing the material through a straightening station. At step 510, a determination is made as to whether the material requires punch to further smooth and flatten the material. At step 512, if the strip of material needs to be punched such that is has substantially smooth top and bottom surfaces, the strip of material may be further flattened by passing through a punch station. If the strip does not require a punch, at step 514, a determination is made as to whether the surface requires profiling. If the strip of material, at step 514, was determined not to require profiling, a determination is made at step 516 as to whether the strip of material requires a twist, at step 518, the strip is twisted. If the step 514 a determination was made that the surface requires profiling, at step 520, a query is made as to whether the strip at a predetermined or desired thickness, and if yes, at step 522, induction heating is performed, and if not, at step 524, surface profiling is performed. If induction heating was performed at step 522, after the induction heating is performed, the surface profiling at step 524 is performed and thereafter, the strip is sheared to a desired length at step 526. If at step 516, the strip did not require twisting, the next step may been shearing the strip to a desired length at step 526, and the finished strip may then be stacked at step 528 and banded at step 530.

[0044] A particular frictional profile may be formed on respective ones of the top and bottom surfaces of the flat elongated strip of material by passing the flat elongated strip through an embossing station, such that as discussed above with respect to FIG. 1A- 2D, a desired arrangement of protuberance (e.g., protuberances 154) and/or depressions 204a, 204b may be formed. After a desired frictional profile has been formed in the top and bottom surfaces of the flat elongated strip, the flat elongated strip may be passed through a twisting station, cut to a particular size by passing through a guillotine, and then placed in a stack and banded. Other orderings of these steps may be utilized without departing from the scope and spirit of the present disclosure.

[0045] Where the process method of manufacturing shown in FIG. 5 may be manipulated to included using stock metal that is: 1. Placed on in a feeding station; 2. Passed through a straightening station; 3. Passed through a punch station; 4. Passed through an induction heating station; 5. Passed through an embossing station; 6. Passed through a twisting station; 7. Passed through a guillotine; 8. Placed in a stack; 9. Banded. It should be noted that other orderings of these steps may be utilized without departing from the scope and spirit of the present disclosure.

[0046] The embodiments and methods described in this patent pertains to soil reinforcing that is fabricated with flat elongated strips. Flat elongated strip soil reinforcing is known to have surfaces that are fabricated to form a grid, fabricated with a surface that is smooth or that has raised cross ribs. The flat elongated strips are also known to be fabricated with a sinusoidal or other geometric profile in a manner that allows for extension as a force is applied. For flat elongated strip soil reinforcing that utilizes a modified surface, such as a protrusion or raised cross rib, the surface protrusion or raised cross rib is formed during the final phase of the manufacturing process that is known as the hot rolling process.

[0047] Hot rolling is a metalworking process that takes place at a temperature above the recrystallization temperature of the material that may be between 850 °C to 1200 °C. During the metalworking process the grains of the material deform and recrystallize. The metalworking process is designed so the metal maintains a microstructure where the crystals are approximately the same length and so as to prevent the metal from work hardening. The starting material typically consists of large pieces of metal that may be classified as slabs, blooms, and billets. In instances where the casting operation is continuous the material is fed directly into rolling mills at the predefined temperature. In some operations the material may start at room temperature, then is reheated to the proper temperature. In both cases the material is processed with a series of rollers to produce the end product shape such as strips, rounds, angles, channels, and the likes thereof. The surface of the element can be configured with raised ribs such as the ribs on concrete reinforcing bars. The raised ribs are placed on the element as a final rolling process while the material is still at or near the original billet temperature.

[0048] The placement of the raised protuberances (e.g., protuberances 154) requires sets of special rollers, e.g., embossing rollers, to produce elements, e.g., depressions or protuberances on the material that is passed through the rollers. Because special rollers are required the thickness, width, and configuration of the element is limited by the roller and limited in sizes that can be purchased by the consumer. Because special rollers are required the number of fabricators is also limited. It is therefore advantageous to develop a manufacturing process where a metal element can be manipulated into a soil reinforcing element of different widths and thicknesses and with different surface and cross section profiles using a cold rolling process.

[0049] A metalworking process that can manipulate the surface of metal is called embossing. Metal embossing is a stamping process that produces raised or sunken reliefs in the metal. The stamping process is typically made by means of matched male and female dies. In one process the metal is passed between male and female rollers that contain impressions of the desired pattern. The pattern is formed in the metal when it is cold. This is advantageous as it allows for the fabrication using different metal stock such as strips, plates, and bars. It also allows for the use of bars with different cross sections such as rectangular, square, round, hexagonal or any desired pattern placed on the surfaces or edges.

[0050] Soil reinforcing is designed to resists tension forces that develop in an earth mass. The soil reinforcing must be strong enough to resist rupture and to resists pullout from the earth mass. The resistance to rupture of a soil reinforcing element is a function of the metal properties and the cross-sectional area and is easily calculated. The pullout resistance of a soil reinforcing element is more complicated to calculate and is a function of the surface area and shape. To aid in predicting the pullout resistance of soil reinforcing it is determined through pullout testing. One such pullout test method is governed by the American Society for Testing and Materials (ASTM) specification D6706, Standard Test Method for Measuring Geosynthetic Pullout Resistance in Soil. To determine the pullout resistance of metal soil reinforcing the ASTM D6706 test is modified as required. [0051] When used with soil reinforcing the raised reliefs that are hot-rolled on the surface of flat flat elongated strip is known to increase the resistance to pullout from the compacted backfill. A flat elongated strip with surface reliefs has a higher pullout capacity than that of a flat elongated strip with no surface relief. It is therefore advantageous to devise an economical method of manufacturing a soil reinforcing element that allows for the use of commonly produced metal shapes, that can have surface reliefs or projections, and, or, edge relief or projections, that increase the pullout capacity of the soil reinforcing element that is verified and optimized through testing.

[0052] It is also advantageous to devise an economical method of manufacturing a soil reinforcing element that allows for the use of commonly produced metal shapes where the cross section can manipulated by twisting the element so as to increase the pullout capacity of the soil reinforcing element that is verified and optimized through testing.

[0053] A system for constructing a mechanically stabilized earth structure may include a soil reinforcing element, e.g., the reinforcing element 150, 200, or 300, consisting of a flat elongated strip fabricated with cold formed embossed elements along the surface and a through bore at the proximal end; a facing anchor having first and second connection plates extending from the back face of an earth structure and being vertically-offset from each other at predetermined distances that accepts the proximal end of the soil reinforcing, each connection plate defining a horizontally-disposed through bore; and a coupling device extendable through each horizontally-disposed through bore and the central opening of the connection element to secure to the soil reinforcing to the facing anchor, wherein the combination of the through bore, central opening and the coupling device prevent the element from uncoupling. The combined connection element and soil reinforcing element 150, 200, or 300 may be configured to swivel in a horizontal plane. In an embodiment, the soil reinforcing element 150, 200, or 300 may replace the reinforcement elements 110 of the MSE structure that was described above with reference to FIGS. 1A-1C

[0054] The system may include: a soil reinforcing element 150, 200, or 300 consisting of a flat elongated strip fabricated with cold formed embossed elements along the surface and a through bore may be formed in a proximal section of the of the flat elongated strip to facilitate coupling of the soil reinforcing element to a facing element such as those described above with respect to FIGS. 1A-1C, for example. The system may further include a facing that includes welded wire mesh with horizontal and vertical wires, where the vertical wires extend as prongs at the top edge. The proximal section of the soil reinforcing may be coupled to the wire facing element by passing the through bore of the proximal end of the soil reinforcing element over the vertical prongs of the facing element.

[0055] A system for constructing a mechanically stabilized earth structure may include: a soil reinforcing element a flat elongated strip fabricated with cold formed twists along the central axis and a through bore at the proximal end (e.g., the soil reinforcing element 300); a facing anchor having first and second connection plates extending from the back face of an earth structure and being vertically-offset from each other at predetermined distances that accepts the proximal end of the soil reinforcing, each connection plate defining a horizontally-disposed through bore; and a coupling device extendable through each horizontally-disposed through bore and the central opening of the connection element to secure to the soil reinforcing to the facing anchor, wherein the combination of the through bore, central opening and the coupling device prevent the element from uncoupling. The combined connection element and soil reinforcing element may be configured to swivel in a horizontal plane.

[0056] In a further embodiment, a system for constructing a mechanically stabilized earth structure may include: a soil reinforcing element consisting of a flat elongated strip fabricated with cold formed twists along the central axis and a through bore at the proximal end; a facing consisting of welded wire mesh with horizontal and vertical wires, where the vertical wires extend as prongs at the top edge; and connecting the proximal end of the soil reinforcing to the wire facing element by passing the through bore of the proximal end of the soil reinforcing element over the vertical prongs of the facing element.

[0057] While the present disclosure may have been shown and described with reference to various embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope and spirit of the present disclosure as defined by the appended claims and their equivalents. In other words, the various exemplary embodiments disclosed in the present specification and drawings are merely specific embodiments to facilitate an understanding of the various aspects of the present disclosure and are not intended to limit the scope of the present disclosure. For example, the particular ordering of the steps may be modified or changed without departing from the scope and spirit of the present disclosure. Therefore, the scope of the present disclosure is defined not by the detailed description of the disclosure but by the appended claimed, and all differences in the scope should be construed as being included in the present disclosure.

Claims

CLAIMS What is claimed is:

1. A soil reinforcing element, comprising: a flat elongated strip of material defining an upper planar surface and a bottom planar surface; and a frictional profile formed on each of the upper planar surface and the bottom planar surface.

2. The soil reinforcing element of claim 1 , wherein: the frictional profile includes a plurality of protuberances.

3. The soil reinforcing element of claim 2, wherein: the plurality of protuberances are spaced apart from one another by a constant interval.

4. The soil reinforcing element of claim 1 , wherein: the frictional profile includes a plurality of depressions.

5. The soil reinforcing element of claim 4, wherein: the plurality of depressions are spaced apart from one another by a constant interval.

6. The soil reinforcing element of claim 2, wherein: the plurality of protuberances are grouped into a plurality of groups and each of the groups is spaced apart from one another by a constant interval.

7. The soil reinforcing element of claim 1 , wherein: the flat elongated strip of material is twisted at intervals to form a plurality of sections, adjacent ones of the plurality of sections being twisted by 180 degrees with respect to one another.

8. The soil reinforcing element of claim 1 , wherein: the flat elongated strip of material is formed from aluminum.

9. The soil reinforcing element of claim 1 , wherein: the flat elongated strip of material is formed from stainless steel.

10. The soil reinforcing element of claim 1 , wherein: the flat elongated strip of material is formed from carbon steel.

11. A method of manufacturing a soil reinforcing element, comprising: providing a flat elongated strip where all surfaces of the flat elongated strip are smooth; and passing the flat elongated strip through a cold forming embossing roller device to emboss a frictional pattern on opposing surface of the flat elongated strip corresponding to impressions on roller surfaces of the embossing roller.

12. The method of claim 11 , further comprising: twisting the flat elongated strip, about a central axis longitudinally extending along a length of the flat elongated strip, into a plurality of sections, adjacent ones of the sections being twisted 180 degrees relative to one another.

13. The soil reinforcing element of claim 11 , wherein: the flat elongated strip is formed from aluminum.

14. The soil reinforcing element of claim 11 , wherein: the flat elongated strip is formed from stainless steel.

15. The soil reinforcing element of claim 11 , wherein: the flat elongated strip is formed from carbon steel.

16. A method of manufacturing a soil reinforcing element using coiled metal comprising: placing a coil on an unwinding pedestal to uncoil a strip from the coil; passing the strip through a straightening station to straighten the strip; passing the strip through a punch station to flatten the strip; passing the strip through an embossing station to create a frictional profile on top and bottom surfaces of the strip; passing the strip through a twisting station; passing the strip through a guillotine to cut the strip to a predetermined length; placing the finished strip in a stack; and banding the finished stack of strips.

17. The method of claim 16, wherein: the frictional profile includes a plurality of protuberances.

18. The method of claim 16, wherein: the frictional profile includes a plurality of depressions.

19. The method of claim 16, wherein: passing the strip through the twisting station creates a plurality of adjacent twisted sections that are twisted 180 degrees relative to one another about an axis extending lengthwise through the strip.

20. The method of claim 16, wherein: the frictional profile includes at least one of a plurality of protuberances and depressions, the plurality of protuberances being grouped into a plurality of groups and each of the groups being spaced apart from one another by a constant interval.