Coupler for helical pile and tieback support systems

A helical pile system comprising:

• a lead section including a first square bar stock and a plurality of helix plates affixed to the first square bar stock;
• an extension section including a second square bar stock;
• and
• a coupler including:
• a first square tube including a first wall defining a first interior recess, a first pair of through holes, and a second pair of through holes, wherein the first interior recess extends through the first square tube, wherein the first interior recess is of a first inner width for receiving the first square bar stock and the second square bar stock;
• and
• a second square tube including a second wall defining a second interior recess, a third pair of through holes, and a fourth pair of through holes, wherein the second interior recess extends through the second square tube, wherein the second interior recess is of a second inner width for receiving the first square tube, the first square tube and the second square tube are a substantially similar length;
• wherein the first square tube is received within the second interior recess and is affixed to the second square tube by a plug weld between the first square tube and the second square tube, the plug weld is located at or near a midpoint of a length of the first square tube and the second square tube, wherein the first pair of through holes and the third pair of through holes are aligned for receiving a first bolt;
• wherein the second pair of through holes and the fourth pair of through holes are aligned for receiving a second bolt;
• wherein the first square bar stock defines a first through hole;
• wherein the first bar stock is received within a first portion of the first interior recess and is coupled to the coupler by the first bolt, the first pair of through holes, the third pair of through holes, and the first through hole;
• wherein the second square bar stock defines a second through hole;
• wherein the second bar stock is received within a second portion of the first interior recess and is coupled to the coupler by the second bolt, the second pair of through holes, the fourth pair of through holes, and the second through hole, wherein the first pair of through holes and the second pair of through holes are disposed on a first face and a second face opposite to the first face, wherein the plug weld is on a face adjacent to the first face and the second face.

An extension section, comprising:

• a square bar stock;
• and
• a coupler including:
• a first square tube including a first wall defining a first interior recess and a first pair of through holes, wherein the first interior recess extends through the first square tube, wherein the first interior recess is of a first inner width for receiving the square bar stock;
• and
• a second square tube including a second wall defining a second interior recess and a second pair of through holes, wherein the second interior recess extends through the second square tube, wherein the second interior recess is of a second inner width for receiving the first square tube, the first square tube and the second square tube are a substantially similar length;
• wherein the first square tube is received within the second interior recess and affixed to the second square tube by a plug weld between the first square tube and the second square tube, the plug weld is located at or near a midpoint of a length of the first square tube and the second square tube, wherein the first pair of through holes and the second pair of through holes are aligned for receiving a bolt;
• wherein the square bar stock is received within a first portion of the first interior recess and is affixed to the coupler by a second permanent joint;
• wherein a second portion of the first interior recess is aligned with the first pair of through holes and the second pair of through holes by which the coupler is configured to receive and couple to a second square bar stock, wherein the first pair of through holes and the second pair of through holes are disposed on a first face and a second face opposite to the first face, wherein the plug weld is on a face adjacent to the first face and the second face.