PRE-ENGINEERED NAIL FOUNDATION AND PROCESS OF CONSTRUCTION THEREOF

Abstract

ABSTRACT TITLE : PRE-ENGINEERED NAIL FOUNDATION AND PROCESS OF CONSTRUCTION THEREOF Conventional foundation systems require huge amounts of materials like concrete and steel, excavation of larger areas, heavy machinery, skilled labour as well as a longer period of time for preparatory works such as excavation, formwork, reinforcement, and curing. They also cause environmental disturbance as the extensive excavation disrupts the natural soil terrain, disturbs water tables and impacts drainage patterns. The proposed invention relates to a pre-engineered nail (PEN) foundation (100) which is a portable, easy to implement, low-cost, low- maintenance, modular, sustainable, environment friendly and quick solution to be used for construction of pre- engineered structures. Proposed PEN foundation (100) comprising pre-engineered node head (10) and anchoring nails (30), can be installed in shallow depths quickly. This technology eliminates the need of large excavations, heavy machinery, and longer time periods for installation, functioning and maintenance. The proposed invention also relates to process of construction of PEN foundation for pre-engineered structures. Fig. 1

Specification

Description:FORM 2

The Patents Act, 1970
(39 of 1970)
&
The Patents Rules, 2003

COMPLETE SPECIFICATION
(See sec 10 and rule 13)

PRE-ENGINEERED NAIL FOUNDATION AND PROCESS OF CONSTRUCTION THEREOF
C-DISC TECHNOLOGIES PRIVATE LIMITED,
61/811, VENMARATH BUILDING, R.C ROAD,
KOZHIKODE- 673032, KERALA, INDIA.


The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD OF INVENTION
The present invention relates to a pre- engineered nail foundation and a process of construction thereof. The said foundation is used as a foundation for erecting pre-engineered housing structures. The proposed invention relates to a low-cost, eco-friendly, robust and sustainable solution to the bulky conventional foundations which requires heavy machinery, labour, deeper and larger excavations and potential soil damaging components. The proposed invention also provides an easy to install, versatile and customizable solution for the construction industry. The present invention also relates to a process of construction of Pre-engineered nail foundation and installation of external components over it.

BACKGROUND AND PRIOR ART OF THE INVENTION
In construction of buildings, foundations are essential for transferring loads from a structure to the underlying soil. The conventional technologies include Isolated footings, used to support individual columns by spreading the load over a small area of soil; Strip foundations, that are employed for linear structures like walls, distributing the load evenly across a length of foundation; Raft foundations, which are used for buildings with low soil bearing capacity for distributing the load over the entire building area; and Piled foundations that are adopted in cases where the surface soil lacks the necessary bearing capacity, requiring deep insertion of piles into stronger layers of soil. All these systems primarily use concrete and steel as key materials, necessitating significant excavation and preparation before starting construction.
Existing foundation technologies present several challenges. Conventional foundations require high consumption of materials like concrete and steel, contributing to significant carbon emissions. The conventional foundations are time-intensive since traditional processes involved in construction such as excavation, formwork, reinforcement, and curing are laborious and time-consuming. In addition to that, they pose a risk of environmental disturbance as the extensive excavation disrupts the natural soil terrain, disturbs water tables and impacts drainage patterns. Their construction is high on cost- particularly for small-scale or temporary structures, these foundations can be expensive and resource-inefficient. These structures also have site limitation e.g. deep foundations often require advanced soil studies and heavy machinery, making them unsuitable for difficult or sensitive terrains. Additionally, existing methods frequently block the natural water table, interfering with groundwater flow and environmental stability, and cause disruption to traffic and existing infrastructure when deployed for urban infrastructure works.
The disadvantages of existing conventional construction technology pave its way to the future of construction industry- Pre-engineered Building technology; which comprises use of pre- engineered, light weight building parts laid on pre-engineered foundation.
Reference is taken from US20080276555A1, titled Foundation for modular structures which speaks of an improvement for building perimeter-wall foundations created by attaching galvanized-steel corrugated panels to an in-place structure. The freely hanging bottom edges of the panels, which have continuous deformation specific to the enhancement of bearing and anchorage within concrete, are cast in-situ with footing concrete, so becoming a cast-in-place perimeter-wall foundation, capable of residential-scale bearing and shear loadings. A load bearing pier support is included for load bearing supporting large or multi-unit modular structures. The proposed invention on the other hand provides a foundation which comprises of precast components and require less excavation.
Reference is taken from US5039256A, titled Pinned foundation system which speaks of a pinned foundation system with resiliency under certain loading conditions and requiring minimum excavation, having a cast footing in combination with a plurality of sleeves through which piles may be driven into the soil to create the necessary bearing, uplift and lateral forces to support a structure. The sleeves are retained in fixed position relative to the footing, at predetermined angles corresponding to the specific structure loading characteristics desired for the ensuing foundation. This document deals with a pinned foundation made of metal casing and steel rods; and the said foundation is created at the site of construction. The proposed invention relates to a pre- engineered nail foundation having precast head and precast driving mechanism.
The present invention relates to a Pre-Engineered Nail (PEN) Foundation System addresses these issues through a modular, sustainable, and quick-to-install solution. The PEN system works by using pre-engineered steel nails as load anchors driven into the ground, minimizing the need for deep excavation and large material consumption.
The present invention presents a Pre-Engineered Nail (PEN) foundation to be used for pre -fabricated housing units. Unlike the conventional foundation which requires large area of land to be excavated with deeper excavation, the proposed invention requires only a minimal amount of land excavated to position the foundation at load bearing points. The construction of the proposed pre-engineered nail foundation is with high tensile materials which are ecofriendly, corrosion resistant and strong.
The key benefits include of the proposed invention include
a) Reduction in material use: The proposed system requires far less concrete and steel compared to traditional foundations.
b) Minimal disruption to natural terrain: Since deep excavations are not required, the natural soil and water table remain largely undisturbed.
c) Quick installation: Pre-engineered components allow rapid assembly of the foundation thereby reducing overall project timelines.
d) Reduced transportation impact: Being lightweight and modular, the proposed PEN Foundation is easier to transport, lowering fuel consumption and carbon emissions associated with logistics.
e) Flexibility in various soil conditions: The proposed PEN foundation system is adaptable to different types of soil without the need for specialized equipment or deep foundations.
f) Adaptability to sustainable design: The proposed PEN Foundation is compatible with Net Zero Energy designs, enhancing the sustainability of the entire building lifecycle.
The present invention provides a low cost, energy efficient, reliable and eco-friendly solution that takes less time in constructing a housing unit.
The present invention also relates to a process of construction of the said Pre-engineered nail foundation for installation of external components over the pre- engineered foundation.

OBJECT OF THE INVENTION
The main objective of the invention is to provide a pre-engineered nail foundation to be used in construction.
Another objective of the invention is to provide pre-engineered foundation that can be used in any type of soil condition.
Another objective of the present invention is to provide an eco-friendly and low-cost solution to construction of foundation.
Another object of the present invention is to provide an alternative solution to the requirement of deep excavations and larger area excavations as required by the conventional construction methodology.
Another object of the present invention is to provide a foundation that uses less materials than the conventional foundations.
Another objective is to provide a reliable and eco-friendly foundation for construction.
Another objective is to provide a foundation system which is faster to deploy than the conventional foundation system which requires longer periods of time for construction.
Another objective is to provide a novel foundation system that works without damaging or altering the moisture content, drainage characteristics, chemical make-up or structural integrity of the soil on which it is engaged.
Another objective of the proposed invention is to provide a foundation system that can be easily altered the need of the changes in plan of the constructional project.
Another objective of the proposed invention is to provide a foundation system which is easily removable and re-usable.
Another objective of the proposed invention is to provide a foundation system which is resilient to a certain degree of prolonged or sudden soil movement due to environmental conditions such as rains or earthquake.
Another objective is to provide a robust foundation that can be customized according to soil conditions or specification or requirement of the construction project.
Another object of the proposed invention is to provide a process of constructing a Pre-engineered nail foundation for installation of external components over the pre-engineered foundation.
Yet another object of the proposed invention is to provide a process of constructing a pre-engineered nail foundation according to different load requirements.
Yet another object of the proposed invention is to provide a process of construction of a pre-engineered foundation and installation of external components over the foundation.

SUMMARY OF THE INVENTION
The present invention relates to a pre- engineered nail foundation unit comprising a node head and a plurality of anchoring nails with a top arm portion and a grounding member portion in which,
- the node head has a geometrical shape, is made of a material with high compressive strength and high tensile strength; and has plurality of oblique holes to house the anchoring nails; and the holes run from anterior end to posterior end of the node head; and the top of the node head includes plurality of threaded galvanized bolts to accommodate a base plate of a connector, the said connector comprising a bottom base plate, a stump and a top base plate and where the bottom base plate of the connector is connected to the threaded bolts such that the center-to-center distance is in the range of 100-200 mm between the bolts; and where the top base plate of the connector is attached to the lower portion of a super structure of external pre-engineered component;
- the plurality of anchoring nails are to be embedded inside the node head; where the nails enters from the anterior end of the node head towards the posterior end through the oblique holes; and wherein
-the top arm portion of the anchoring nail is hammered into the node head and the vertex of top arm portion is covered with rubber caps;
-the grounding member portion of the anchoring nail is nailed to the ground and secured.
In an embodiment of the pre- engineered nail foundation, the node head is made of materials selected from reinforced concrete, metal reinforced concrete, fibre reinforced concrete, pre-treated bamboo, pre-treated hempcrete, ferrock, ashcrete, timbercrete.
In yet another embodiment of the pre-engineered nail foundation, the node head is precast to attain high compressive strength.
In yet another embodiment of the pre-engineered nail foundation, the anchoring nails are made up of high-grade galvanized steel bars.
In yet another embodiment of the pre-engineered nail foundation, the anchoring nails are made up of materials selected from stainless steel, copper, brass, carbon steel, pre-treated bamboo.
In another embodiment of the pre-engineered nail foundation unit, the threaded bolts are 4.6 grade galvanized bolts and are spaced to accommodate the base plate of a connector between the plurality of arms.
In an embodiment of the pre-engineered nail foundation, the anchoring nails, made up of materials such as galvanized steel, stainless steel, copper, brass, carbon steel, pre-treated bamboo are hollow.
In another embodiment of the pre-engineered nail foundation, the anchoring nails are filled with inert substances or are solid pipes.
In another embodiment of the pre-engineered foundation, the anchoring nail is made of 2-4 mm thick steel pipe with a diameter in the range of 40-60mm.
In yet another embodiment of the pre-engineered nail foundation, the end of the grounding member portion of anchoring nails is tipped with tungsten.
In another embodiment of the pre-engineered nail foundation, the length of the anchoring nails is in the range of 100-170 cm.
The present invention also relates to a process of construction of a pre-engineered nail foundation comprising of
- creating a pre-cast node head by pouring high tensile strength cementitious moulding material in a pre-casting mould and firing the casted node head; and wherein
the moulding material is selected from reinforced concrete, metal reinforced concrete, fibre reinforced concrete, pre-treated bamboo, pre-treated hempcrete, ferrock, ashcrete, timbercrete; where the said node head has plurality of oblique holes to house plurality of anchoring nails; and the top of the node head includes plurality of threaded galvanized bolts to accommodate the base plate of a connector with a center-to-center distance in the range of 100-200 mm between the bolts; and
- creating anchoring nails comprising a top arm portion and a grounding member portion; wherein the said anchoring nail is made of materials with high compression strength, selected from galvanized steel, high-grade galvanized steel bars, stainless steel, copper, brass, carbon steel, pre-treated bamboo; with dimensions in the range of 2-4 mm thickness, 40-60mm diameter, 100-170cm length; and wherein the threaded bolts are positioned to house a base plate of a connector between them; and the vertex of top arm portion is covered with rubber caps; and the tip of the grounding member portion of anchoring nails is coated with tungsten;
- driving the anchoring nails through the node head by hammering the vertex of top arm portion such that the grounding member of the plurality of anchoring nails penetrates the ground and are fixed to the ground; and
- fixing the bottom base plate of the connector on the plurality of threaded galvanized bolts
and securing with nuts; wherein the said connector comprises a bottom base plate, a stump portion and a top base plate;
- fixing the top base plate to the posterior part of the super structure of a pre-engineered exterior component with threaded bolts and nuts and welding.
In yet another embodiment of the proposed invention the dimensions of the precast node head and plurality of anchoring nails is customized according to load bearing capacity, soil conditions and plan of construction project.

BRIEF DESCRIPTION OF THE DRAWINGS
Fig.1 shows an embodiment of the Pre-engineered nail foundation (100) in its isometric view. The Pre-engineered nail foundation comprises of a node head (10) and plurality of anchoring nails (30). The node head (10) has plurality of oblique holes (40) running from anterior/top end to posterior/bottom end. These oblique holes (40) house the anchoring nails (30). The node head (10) also comprises of plurality of embedded threaded bolts (50) to connect to the base plate of a connector. The top portion of anchoring nails (30) is the top arm portion (20) and the lower portion of the anchoring nail (30) is the grounding member portion (60). The top arm portion is capped at the top/vertex (21) with a rubber cap (80). The lower end of the grounding member portion is tungsten tipped (70). The lower portion of the pre-engineered nail foundation is embedded below the foundation ground level.
Fig 2 shows the plan (200) of the pre-engineered nail foundation. The node head (10) has plurality of embedded threaded bolts (50) to which the base plate of connecter is secured with the help of nuts. The top of anchoring nails is the top arm portion (20) which is capped with a rubber cap (80) at the vertex (21). The grounding member portion (60) of the anchoring nails is tungsten tipped (70) and lies below the ground level of installation of the foundation unit.
Fig.3 shows the elevation (300) of an embodiment of the pre- engineered nail foundation. The top portion of the pre-engineered nail foundation (100) that is above the foundation ground level is depicted in this figure. The node head (10) houses plurality of the anchoring nails in the oblique holes (40). The top arm portion (20) of the anchoring nail is covered with a rubber cap (80) on the vertex/top. The head node (10) has plurality of embedded threaded bolts (50) for connecting with the base plate of connector, and the base plate is secured by nuts (52).
Fig.4 shows an embodiment of the complete structural construction of a functional pre-engineered nail foundation unit. The geometrical node head (10) having oblique holes (40) to house the plurality of anchoring nails (30). The grounding member portions (60) of the anchoring nails are embedded inside the ground. The top portion of the anchoring nails, the top arm portion (20) is capped with rubber caps (80) at the top/vertex (21). The head node (10) also consists of plurality of embedded threaded bolts (50) which hold the bottom base plate (51) of the connector (55) secured by the nuts for threaded bolts (52). The connector (55) has a top base plate (54) , a stump (53) and a bottom base plate (51). The top base plate (54) is attached to the posterior part of super structure /exterior pre-engineered component or welded component (83) of the super structure (90) through threaded bolts (81) and nuts (82).
Fig.5 shows another embodiment of the pre-engineered nail foundation made of cementitious material node head (10) and galvanized steel anchoring nails (30). A rubber cap (80) is provided at the top of the anchoring nail, top arm portion (20). The tip of the grounding member portion (60) of the anchoring nail (30) is tungsten tipped (70). The node head has plurality of embedded galvanized threaded bolts (50) which secure the base plate with nuts (52) is spaced such as to hold the base plate.

DETAILED DESCRIPTION OF THE INVENTION
The invention relates to a pre-engineered nail foundation (100) for pre-engineered buildings and a process of construction thereof.
The present invention relates to a pre- engineered nail foundation (100) comprising a node head (10) and a plurality of anchoring nails (30) with a top arm portion (30) and a grounding member portion (60) wherein
the node head (10) has a geometrical shape.
In one embodiment the shape resembles two chiselled pyramids, one of which is upside down, stuck at the bases. In another embodiment, the head node has a shape of a 3D trapezoidal prism on either sides (top & bottom). Depending on the load requirements the shape of the node head and number of anchoring nails is changed.
The node head (10) is made up of a material with high compressive strength and high tensile strength. It has a plurality of oblique holes (40) to house the plurality of anchoring nails (30). The holes run from anterior end to posterior end of the node head (10). In one embodiment, the oblique holes run from the side of the trapezoidal prism structure. The top of the node head includes plurality of threaded galvanized bolts (50) to accommodate a base plate (51) of a connector (55). The connector (55) comprises of a bottom base pate (51), a stump (53) and a top base plate (54). The bottom base plate (51) of the connector (55) is connected to the threaded bolts (50). The threaded bolts are spaced such with a center-to-center distance in the range of 100-200 mm between the bolts.
The plurality of anchoring nails (30) is embedded inside the node head. It enters from the anterior end of the node head towards the posterior end through the oblique holes (40). The top arm portion (20) of the anchoring nail (30) is attached to the lower portion of the exterior pre- engineered modular components (90) and vertex (21) of top arm portion (20) is covered with rubber caps (80). The grounding member portion (60) is nailed to the ground and secured.
The node head (10) is made of materials selected from reinforced concrete, metal reinforced concrete, fibre reinforced concrete, pre-treated bamboo, pre treated hempcrete, ferrock, ashcrete, timbercrete.
The node head (10) is precast to attain high compressive strength. The node head can be any geometric shape. It can be triangular, square, rectangular, cuboid, hexagonal, pentagonal, octagonal, trapezoidal, spherical or any combination of geometrical shapes.
In an embodiment the node head (10) is chiselled icosahedral shaped and is made of M50 grade (7250 psi) precast concrete which is capable of taking a load of 15 MT capacity.
The anchoring nails (30) are made up materials selected from galvanized steel, high-grade galvanized steel bars, stainless steel, copper, brass, carbon steel, pre-treated bamboo. In an embodiment the anchoring nails are made of 2-4 mm thick steel pipe with a diameter in the range of 40-60mm. The anchoring nail may or may not be hollow. The anchoring nails can be filled with concrete while grounding. The end of the grounding member of anchoring nails are tipped with tungsten so that they easily penetrate the earth. The end of the grounding member portion (60) of the anchoring nail (30) may or maynot be tipped with tungsten. The length of the anchoring nails is in the range of 100-170 cm.
The node head (10) also has embedded threaded bolts (50). These threaded bolts (50) are at least 4.6 grade galvanized bolts spaced to accommodate the base plate (51) of a connector between the plurality of threaded bolts.
In an embodiment, these threaded bolts are M12 metric threaded galvanized 4.6 grade bolts. An embodiment of the pre-engineered nail foundation made of cementitious material node head (10) and galvanized steel anchoring nails (30) is shown in fig 5.
The pre-engineered nail foundation has a node head (10) has plurality of embedded threaded bolts (50) to which the base plate of connecter is secured with the help of nuts. The top of anchoring nails is the top arm portion (20) which is capped with a rubber cap (80) at the vertex (21). The grounding member portion (60) of the anchoring nails is tungsten tipped (70) and lies below the ground level of installation of the foundation unit. Fig 2 shows the plan of the pre-engineered nail foundation.
The elevation (300) of an embodiment of the pre- engineered nail foundation is shown in Fig 3. The top portion of the pre-engineered nail foundation (100) that is above the foundation ground level is depicted in this figure. The head node (10) has plurality of embedded threaded bolts (50) for connecting with the base plate of connector, and the base plate is secured by nuts (52).
The complete structural construction of a functional pre-engineered nail foundation unit is shown in Fig 4. The geometrical node head (10) having oblique holes (40) to house the plurality of anchoring nails. The grounding member portions (60) of the anchoring nails are embedded inside the ground. The top portion of the anchoring nails, the top arm portion (20) is capped with rubber caps (80) at the top/vertex (21). The head node also consists of plurality of embedded threaded bolts (50) which hold the bottom base plate (51) of the connector (55) secured by the nuts for threaded bolts (52). The connector (55) has a top base plate (54), a stump (53) and a bottom base plate (51). The top base plate (54) is attached to the posterior part of super structure /exterior pre-engineered component or welded component (83) of the super structure (90) through threaded bolts (81) and nuts (82). In an embodiment, multiple PEN foundations are clubbed together to lay stronger foundation for heavier load requirements.
The proposed invention also relates to a process of construction of a pre-engineered nail foundation comprising of
a) creating a pre-cast node head (10) by pouring high tensile strength cementitious moulding material in a pre-casting mould and firing the casted node head; where the moulding material is selected from reinforced concrete, metal reinforced concrete, fibre reinforced concrete, pre-treated bamboo, pre-treated hempcrete, ferrock, ashcrete, timbercrete. The node head (10) has plurality of oblique holes (40) to house plurality of anchoring nails (30); and the top of the node head includes plurality of threaded galvanized bolts (50) to accommodate a base plate (51) of a connector (55) with a center-to-center distance of about 100-200 mm between the bolts;
b) creating anchoring nails (30) comprising a top arm portion (20) and grounding member portion (60), where the anchoring nail (30) is made of materials with high compression strength, selected from galvanized steel, high-grade galvanized steel bars, stainless steel, copper, brass, carbon steel, pre-treated bamboo; with dimensions in the range of 2-4 mm thickness, 40-60mm diameter, 100-170cm length; and wherein the vertex (21) of top arm portion (20) of the anchoring nails (30) and is covered with rubber caps (80); and the tip of the grounding member (60) of anchoring nails (30) is coated with tungsten (70);
c) driving the anchoring nails (30) through the node head (10) by hammering the vertex (21) of the top arm portion (20) such that the grounding member portion (60) of the plurality of anchoring nails (30) penetrates the ground and are fixed to the ground.
d) fixing the bottom base plate (51) of the connector (55) on the plurality of threaded galvanized bolts (50) and securing with nuts (52). The connector (55) comprises a bottom base plate (51), a stump portion (53) and a top base plate (54); and
e) fixing the top base plate (54) to the posterior part of the super structure (90) of pre-engineered exterior component with threaded bolts (81) and nuts (82) and welding (83).
The dimensions of the precast node head and plurality of anchoring nails (30) is customized according to the required load bearing capacity, soil conditions and plan of construction project.
The proposed Pre- Engineered Nail (PEN) foundation is novel in many aspects. It involves a modular approach in construction. Unlike traditional foundations, which require heavy machinery and extended timelines, the PEN foundation uses pre-engineered steel nails that are lightweight, easy to transport, and quick to install. It requires a reduced need for excavation. Since anchoring of the structure is at shallow depths using distributed load points, the proposed foundation avoids the need for deep installations, minimizing site disruption and reducing project time. The proposed pre-engineered nail foundation uses prefabricated components. The use of prefabricated elements ensures consistency, accuracy, and efficiency in construction, unlike conventional methods where much of the work is done on-site. Additionally, this feature provides quicker and easier reinstallation of PEN foundation on disturbed terrains (disrupted due to rain or earthquake). The pre-engineered nail foundation unit can be reused and replaced according to change in plan of pre- engineered structure.
The proposed pre-engineered nail foundation (PEN foundation) incorporates several advanced materials, like :
-High-strength steel: These are used for the anchoring nails and anchors, ensuring durability and the ability to withstand significant loads.
-High-strength modified concrete: These are used for certain structural components that require additional support or reinforcement.
-Tungsten carbide bits: These are incorporated in the driving mechanisms, or simply the ends of grounding members of anchoring nails, for penetrating tougher soils and ensuring that the foundation system can be used across a variety of terrains.
-Corrosion-resistant coatings: These are used to protect the steel components from environmental degradation, particularly in high-moisture or saline environments.
Before employing the proposed Pre-engineered nail foundation in any construction project, there are certain pre-requisites that are mandatory to be adhered to according to the construction standards of the country.
a) IS Code Compliance: The design and installation of the construction is envisioned so as to comply with the relevant Indian Standards (IS) for foundations, particularly with respect to load distribution and structural safety.
b) Design Procedure: A formalized design procedure is developed, including detailed calculations for load-bearing capacities, to ensure that the Pre- Engineered Nail Foundation system /PEN system is correctly specified for each project.
c) Soil Investigation: Basic soil analysis is performed to determine the appropriate nail configuration and load distribution for the specific terrain.
d) Worker Training: Construction teams are extensively trained in the correct assembly and installation techniques, to ensure that the foundation system performs as expected.
The introduction of the PEN foundation has several significant impacts in every aspect of construction technology.
a) Environmental aspect : The proposed foundation system has a low reliance on concrete and steel, which helps reduce the carbon footprint of construction projects, while its minimal excavation requirements preserve the natural landscape and soil structure.
b) Economic aspect : The PEN foundation technology reduces project costs by lowering material and labour requirements, offering a more affordable solution for both temporary and permanent structures.
c) Speed of infrastructure deployment: The proposed technology significantly accelerates infrastructure work, particularly for projects like electrical posts, telephone posts, camera poles, signage, and hoardings etc. without disrupting existing roads or blocking traffic.
d) Technological advancement: The proposed PEN foundation system encourages innovation in low-impact construction methods, which may lead to new applications in modular and sustainable building technologies.
By integrating advanced engineering with a commitment to sustainability, the proposed PEN Foundation offers a transformative step toward greener construction practices, helping reduce the industry's carbon footprint while promoting efficiency and innovation.
The proposed invention provides a plethora of applications in the construction sector. The Pre-Engineered Nail foundation or PEN foundation system is highly versatile and can be applied across a broad spectrum of industries and uses, including
i) Residential and modular homes: The pre-engineered nail foundation technology is suitable for both temporary and permanent structures, especially in areas with challenging soil conditions.
ii) Infrastructure projects: Ideal for the rapid and non-intrusive installation of electric poles, telephone poles, camera poles, hoardings, and signages, ensuring minimal disruption to existing infrastructure
iii) Security and traffic systems: Deployment for security kiosks, traffic barriers, and acoustic dampers without interfering with road networks.
iv) Agriculture and animal husbandry: Applicable in the construction of animal husbandry structures, vertical farming installations, or small agricultural buildings.
v) Temporary and emergency structures: The quick assembly and minimal site preparation make the system ideal for disaster relief shelters and other temporary installations.

EXAMPLES :
An embodiment of the proposed invention shows a pre-engineered nail foundation designed for both residential and commercial applications in mild, moderate, and severe soil conditions, utilizing advanced soil nailing technology with high point load bearing capacity. This model features a high strength concrete node head made of M50 grade (7250 psi) precast concrete, conforming to IS 456:2000 and IS 10262:2009 standards. The foundation is secured using four bearing nails made of galvanized steel pipes as per IS 4923/IS 3601/IS 1161 with a 40mm outer diameter and 2mm wall thickness to resist lateral and uplift forces. The ends of these nails are tipped with tungsten carbide bits to facilitate easy driving into the ground, and the tops are covered with rubber caps for protection. Additionally, the top of the CD-PEN-40.2.150 foundation includes four M12 metric threaded galvanized 4.6 grade bolts as per IS 5624 to accommodate a base plate, with a center-to-center distance of 100 mm between the bolt. The load bearing for 15 MT capacity was tested. The anchoring nails used in this embodiment were 120 cm long.

In certain embodiment the load bearing capacity of the pre-engineered foundation is increased by placing many units of the PEN foundation.

In certain embodiments the load bearing capacity of the pre-engineered foundation is increased by changing the dimensions of the node head (10) or angle of inclination of anchoring nails or length of anchoring nails or any combination thereof.

In an embodiment the anchoring nails are driven into the ground using jack hammer. The anchoring nails (30) can be driven into the ground using any means e.g. drilling machine, earth auger, drill bit, jack hammer, post-haul auger, post- hole digger etc. or any other mechanism.
In an embodiment the pre-engineered foundation is installed at shallow depths.

Certain variations in components are done so as to customize according to the requirement of construction project.
1. Foundation Bolt Configuration: The quantity and design of hot-dip galvanized foundation bolts is tailored to match the column sizes and their respective load-carrying capacities.
2. PEN Foundation Grouping: PEN foundation groups (e.g., double or triple units) are created to enhance both load-bearing and moment-carrying capacities of the foundation.
3. Micro Concrete Filling: In certain conditions, hollow pins (anchoring nails) may be filled with micro concrete, which in turn forms an under reamed bulb and provides more load bearing capacity, thus improving structural integrity.
4. Hollow Pipe Filling Under Pressure: In specific soil conditions, hollow pipes of the anchoring nails may be filled with micro concrete under pressure, forming under-reamed bulbs that significantly increase load-bearing capacity.
5. Tungsten Carbide End Cap Modification: In certain soil conditions, the absence of a tungsten carbide end cap, can double the contact surface area between anchoring arms and the surrounding soil. This modification enhances skin friction and improves the foundation's bearing capacity.
6. Node Head Dimension and Strength: The dimensions and strength of the node heads may also be adjusted based on soil conditions and loading parameters. The size of concrete head needs to be increased if the load carrying capacity of the PEN Foundation has to be increased. E.g. if the load carrying capacity is increased to 25 MT the dimension of concrete and size of arms also increases.
The performance of any foundation is significantly influenced by the characteristics of the underlying soil. Soils such as soft clayey, loose sands, and organic soils present unique challenges, including excessive settlement and instability especially to conventional foundation systems. Conventional foundations have difficulty distributing loads effectively in some soil conditions especially in expansive clays and loose sands, leading to uneven settlement and an increased risk of structural failure.

The pre-engineered nail foundation effectively takes the load at shallow depths. The proposed pre-engineered nail foundation technology eliminates the need for extensive excavation thereby preserving soil structure and groundwater flow.
A structural parametric study for ascertaining the change in dimensions of the node head and anchoring nails of the proposed PEN foundation is being conducted for further investigation. The load bearing capacities of the pre-engineered nail foundation for different soil conditions is also being conducted for further consideration.

The proposed Pre-Engineered nail foundation, an embodiment as depicted in Fig. 5 is a registered design of C-DISC Technologies (Design No. 408951-001). The product is under evaluation for various certifications by certifying agencies (IGBC, GRIHA) in India.

An embodiment of the proposed design was presented at Convergence India 2024 exhibition (9th Smart Cities India Expo, a collaboration of Smart Cities Mission and Ministry of Housing & Urban Affairs (MoHUA), Govt. of India) in January 2024 at Pragati Maidan, New Delhi.

The description, drawings and examples only illustrate embodiments of the present invention and should not be construed in limiting the scope of the invention.

ADVANTAGES
The proposed PEN foundation system provides multiple advantages over traditional foundation methods:
1. Sustainability: The proposed invention provides significant reduction in material consumption, leading to a lower environmental impact and carbon footprint.
2. Cost-efficiency: The reduced material and labour costs involved in employing the proposed invention makes it ideal for budget-conscious projects.
3. Fast installation: Prefabricated components, used in the proposed invention, can be quickly assembled on-site, cutting down on construction time.
4. Environmental protection: The proposed system avoids disturbing the natural soil structure and does not interfere with groundwater flows.
5. Versatility: The proposed system can be deployed in various soil types and topographies, offering a wide range of applications from small-scale projects to larger commercial development.
6. The proposed invention of Pre-engineered foundation and the process of construction, is a low-cost, eco-friendly, time saving, efficient and futuristic solution for the construction industry.

, Claims:We Claim :
1. A pre- engineered nail foundation (100) comprising a node head (10) and plurality of anchoring nails (30) with a top arm portion (20) and a grounding member portion (60); wherein
- the node head (10)
-has a geometrical shape;
-is made up of a material with high compressive strength and high tensile strength; and
-has plurality of oblique holes (40) to house the anchoring nails (30); wherein
the holes (40) run from anterior end to posterior end of the node head (10); and
-comprises of plurality of threaded galvanized bolts (50) on the top of the node head (10) to accommodate base plate (51) of a connector (55) ; wherein the connector (55) comprises a bottom base plate (51), a stump (53) and a top base plate (54);
wherein the bottom base plate (51) of the connector (55) is connected to the threaded bolts (50); and
the threaded bolts are spaced such that the center-to-center distance is in the range of 100-200 mm between the bolts;
the top base plate (54) of the connector (55) is attached to the lower portion of a super structure (90); wherein, the super structure is an external pre-engineered component;
- the plurality of anchoring nails (30)
-are to be embedded inside the node head;
-enter from the anterior end of the node head towards the posterior end through the oblique holes; and wherein
-the top arm portion (20) of the anchoring nail (30) is hammered into the node head (10); and vertex of top arm portion is covered with rubber caps (80);
-the grounding member portion (60) of the anchoring nail (30) is nailed to the ground and secured.
2. The pre-engineered nail foundation (100), as claimed in claim 1, wherein the node head (10) is made of materials selected from reinforced concrete, metal reinforced concrete, fibre reinforced concrete, pre-treated bamboo, pre-treated hempcrete, ferrock, ashcrete, timbercrete.
3. The pre-engineered nail foundation (100), as claimed in claim 1, wherein the node head (10) is precast to attain high compressive strength.
4. The pre-engineered nail foundation (100) , as claimed in claim 1, wherein the anchoring nails (30) are made up materials selected from galvanized steel, high-grade galvanized steel bars, stainless steel, copper, brass, carbon steel, pre-treated bamboo.
5. The pre-engineered nail foundation (100), as claimed in claim 1, wherein the threaded bolts (50) are 4.6 grade galvanized bolts and are spaced to accommodate the base plate (51) of a connector (55), between the plurality of threaded bolts.
6. The pre-engineered nail foundation (100), as claimed in claim 1, wherein the anchoring nail (30) is made of 2-4 mm thick steel pipe with a diameter in the range of 40-60mm.
7. The pre-engineered nail foundation, as claimed in claim 1, wherein the end of the grounding member portion (60) of anchoring nails (30) are tipped with tungsten (70).
8. The pre-engineered nail foundation, as claimed in claim 1, wherein the length of the anchoring nails (30) is in the range of 100-170 cm.

9. A process of construction of a pre-engineered nail foundation comprising of
a) creating a pre-cast node head (10) by pouring high tensile strength cementitious moulding material in a pre-casting mould and firing the casted node head; wherein
-the moulding material is selected from reinforced concrete, metal reinforced concrete, fibre reinforced concrete, pre-treated bamboo, pre-treated hempcrete, ferrock, ashcrete, timbercrete;
-the said node head (10) has plurality of oblique holes (40) to house plurality of anchoring nails (30); and
-the top of the node head (10) includes plurality of threaded galvanized bolts (50) to accommodate base plate (51) of a connector (55), with a center-to-center distance in the range of 100-200 mm between the bolts; and
b) creating anchoring nails (30) comprising a top arm portion (20) and a grounding member portion (60); wherein,
-the said anchoring nail (30) is made of materials with high compression strength, selected from galvanized steel, high-grade galvanized steel bars, stainless steel, copper, brass, carbon steel, pre-treated bamboo; with dimensions in the range of 2-4 mm thickness, 40-60mm diameter, 100-170cm length; and wherein
-vertex (21) of top arm portion (20) is covered with rubber caps (80); and
-the tip of the grounding member (60) of anchoring nails (30) is coated with tungsten (70);
c) driving the anchoring nails (30) through the node head (10) by hammering the vertex (21) of the top arm portion (20), such that the grounding member portion (60) of the plurality of anchoring nails (30) penetrates the ground and are fixed to the ground; and
d) fixing the bottom base plate (51) of the connector (55) on the plurality of threaded galvanized bolts (50) and securing with nuts (52); wherein the said connector (55) comprises a bottom base plate (51), a stump portion (53) and a top base plate (54); and
e) fixing the top base plate (54) to the posterior part of the super structure (90) of pre-engineered exterior component with threaded bolts (81) and nuts (82) and welding (83).
10. The process of construction of a pre-engineered nail foundation, as claimed in claim 9, wherein the dimensions of the precast node head (10) and plurality of anchoring nails (30) is customized according to the required load bearing capacity, soil conditions and plan of construction project.


Dated this 22nd day of November, 2024.



Anjali Menon (IN/PA-2696)
IPRGENIE LLP
(AGENT FOR APPLICANT)

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