U.S. patent application number 12/274963 was filed with the patent office on 2009-06-18 for method of constructing a wall or fence with panels.
This patent application is currently assigned to KEYSTONE RETAINING WALL SYSTEMS, INC.. Invention is credited to Blaine French, David M. LaCroix, Robert A. MacDonald.
Application Number | 20090151281 12/274963 |
Document ID | / |
Family ID | 40751424 |
Filed Date | 2009-06-18 |
United States Patent
Application |
20090151281 |
Kind Code |
A1 |
MacDonald; Robert A. ; et
al. |
June 18, 2009 |
METHOD OF CONSTRUCTING A WALL OR FENCE WITH PANELS
Abstract
This invention relates generally to a method of constructing
walls or fence systems from panels. More particularly, the
invention relates to constructing such walls or fence systems
wherein a back face of one panel connects to a back face of another
panel and further wherein the front faces of the panels have a
desirable texture and further wherein a concrete footing of the
wall or fence system is poured after courses of panels have been
stacked one upon the other.
Inventors: |
MacDonald; Robert A.;
(Plymouth, MN) ; French; Blaine; (Lakeville,
MN) ; LaCroix; David M.; (St. Paul, MN) |
Correspondence
Address: |
POPOVICH, WILES & O'CONNELL, PA;650 THIRD AVENUE SOUTH
SUITE 600
MINNEAPOLIS
MN
55402
US
|
Assignee: |
KEYSTONE RETAINING WALL SYSTEMS,
INC.
Bloomington
MN
|
Family ID: |
40751424 |
Appl. No.: |
12/274963 |
Filed: |
November 20, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60989295 |
Nov 20, 2007 |
|
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|
Current U.S.
Class: |
52/251 ;
52/293.1; 52/309.4; 52/741.1; 52/742.14; 52/745.09; 52/745.21;
52/794.1 |
Current CPC
Class: |
E04H 17/1404 20130101;
E04B 2002/867 20130101; E04B 2/8641 20130101; E04H 17/16 20130101;
E04B 2002/8676 20130101; B29C 44/583 20130101 |
Class at
Publication: |
52/251 ;
52/293.1; 52/745.09; 52/742.14; 52/745.21; 52/741.1; 52/794.1;
52/309.4 |
International
Class: |
E04B 1/04 20060101
E04B001/04; E02D 27/00 20060101 E02D027/00; E04B 1/00 20060101
E04B001/00; E04B 1/16 20060101 E04B001/16; E04B 1/38 20060101
E04B001/38; E04C 2/34 20060101 E04C002/34; E04C 2/20 20060101
E04C002/20 |
Claims
1. A method for constructing a wall or fence comprising: providing
a plurality of connectors and a plurality of panels, each panel
having a front face and an opposed back face, a set of opposed and
substantially parallel upper and lower surfaces and first and
second opposed and substantially parallel side surfaces; preparing
a level base; forming a base layer of panels on the level base by
placing opposed panels on the level base and connecting a back face
of at least one first panel of the base layer to a back face of at
least one opposed second panel of the base layer with at least one
connector, the front faces of the at least one first panel and the
at least one second panel facing outward, the at least one first
panel and at least one second panel each having a knockout cavity;
placing at least one course of opposed panels on the base layer of
panels and connecting a back face of at least one first panel of
the at least one course to a back face of at least one opposed
second panel of the at least one course with at least one
connector, the front faces of the at least one first panel and the
at least one second panel of the at least one course facing
outward, to form a top surface of an uppermost course of panels;
and pouring a flowable material from the top surface between the
opposed panels to form a support footing for the wall or fence, the
support footing encasing at least a portion of the base layer of
panels.
2. The method of claim 1, further comprising: forming a trench; and
adding base material to the trench, wherein the step of preparing a
level base comprises leveling the base material in the trench.
3. The method of claim 2, wherein the base material is compacted
granular material or crushed stone.
4. The method of claim 1, wherein the flowable material is concrete
or cement.
5. The method of claim 1, further comprising: after placing a
plurality of panels and prior to pouring the flowable material,
forming a reinforcing framework between opposed panels, the
reinforcing framework including vertical reinforcement members.
6. The method of claim 5, wherein at least one vertical
reinforcement member is L-shaped and has a vertical portion and a
perpendicular leg portion, the perpendicular leg portion protruding
outwardly through a knockout cavity, the perpendicular leg portion
being encased in the support footing after the flowable material is
poured.
7. The method of claim 6, wherein the reinforcing framework
includes horizontal reinforcement members.
8. The method of claim 1, wherein the panels of the base layer and
the panels of at least one course have the same structure.
9. The method of claim 1, wherein the at least one connector that
connects the at least one first panel and the at least one second
panel of the base layer also connects the at least one first panel
and the at least one second panel of the adjacent course of
panels.
10. The method of claim 1, wherein the panels are made of
polyfoam.
11. The method of claim 1, wherein the support footing encases at
least one half of a vertical height of the base layer of
panels.
12. The method of claim 1, wherein the support footing
substantially encases the base layer of panels.
13. The method of claim 9, wherein the connector has at least four
dovetail projections.
14. The method of claim 1, wherein each set of opposed panel
surfaces has mating tongue and groove attachments, respectively, so
that a respective tongue attachment and groove attachment of
adjacent panels connect the adjacent panels.
15. The method of claim 1, wherein the back faces of the panels
have dovetail channels.
16. The method of claim 1, wherein at least one horizontal
reinforcement member rests on at least one connector.
17. The method of claim 1, wherein at least one vertical
reinforcement member passes through a vertical support ring that is
part of at least one connector.
18. The method of claim 1, wherein the at least one first panel of
the at least one course and the at least one opposed second panel
of the at least one course have a pattern molded into their front
faces.
19. The method of claim 1, wherein the pattern is an ashlar
pattern.
20. The method of claim 1, wherein the pattern is a boulder rock
pattern.
21. The method of claim 1, wherein the pattern is a ledge rock
pattern.
22. The method of claim 1, further comprising attaching a capping
block onto a top of the wall or fence.
23. The method of claim 1, further comprising attaching an end wall
block to some of the plurality of panels before pouring the
flowable material.
24. A wall or fence comprising: a support footing formed from a
hardened flowable material; a base layer of opposed panels, at
least a portion of the base layer of panels being encased within
the support footing, a back face of at least one first panel of the
base layer being connected to a back face of at least one opposed
second panel of the base layer with at least one connector, the
front faces of the at least one first panel and the at least one
second panel facing outward, and the at least one first panel and
at least one second panel each having a knockout cavity, and a
plurality of courses of opposed panels placed on the base layer of
panels, a back face of at least one first panel of the at least one
course being connected to a back face of at least one opposed
second panel of the at least one course with at least one
connector, the front faces of the at least one first panel and the
at least one second panel of the at least one course facing
outward, a volume between the opposed panels containing the
hardened flowable material.
25. The wall or fence of claim 24, wherein the hardened flowable
material is concrete or cement.
26. The wall or fence of claim 24, wherein the wall or fence
further comprises a reinforcing framework between opposed panels,
the reinforcing framework including vertical reinforcement
members.
27. The wall or fence of claim 26, wherein at least one vertical
reinforcement member is L-shaped and has a vertical portion and a
perpendicular leg portion, the perpendicular leg portion protruding
outwardly through a knockout cavity, the perpendicular leg portion
being encased in the support footing.
28. The wall or fence of claim 27, wherein the reinforcing
framework includes horizontal reinforcement members.
29. The wall or fence of claim 24, wherein the panels of the base
layer and the panels of the plurality of courses have the same
structure.
30. The wall or fence of claim 24, wherein the at least one
connector that connects the at least one first panel and the at
least one second panel of the base layer also connects the at least
one first panel and the at least one second panel of an adjacent
course of panels.
31. The wall or fence of claim 24, wherein the panels are made of
polyfoam.
32. The wall or fence of claim 24, wherein the thickness of the
wall or fence terraces from wider to narrower as the wall
heightens.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/989,295, filed Nov. 20, 2007, entitled "Method
of Constructing a Wall or Fence with Panels", the contents of which
are hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] This invention relates generally to a method of constructing
walls or fence systems from panels. More particularly, the
invention relates to constructing such walls or fence systems
wherein a back face of one panel connects to a back face of another
panel and further wherein the front faces of the panels have a
desirable texture and further wherein a concrete footing of the
wall or fence system is poured after courses of panels have been
stacked one upon the other.
BACKGROUND OF THE INVENTION
[0003] Generally, free-standing block walls or fences are
constructed of concrete blocks (or similar material) in running
courses. A trench is usually dug and a concrete footing is prepared
by the placement of batter or screed boards to define the width and
thickness of the footing. Horizontal reinforcing material, such as
steel, running both laterally and transversally is tied together
forming a cage within the screed board framework. The reinforcing
material cage generally has vertical support elements that protrude
above the screed board framework and are used to connect to the
vertical wall structure. Concrete is then poured into the screed
board framework and is leveled off so that it is flush with the
screed surface. This leveling process can be difficult to achieve
when working around the vertical support elements. The concrete is
generally allowed to set for a time and then later a first course
of blocks is laid using mortar to level the blocks on the concrete
footing. Due to the irregularity of the footing with all the
vertical support elements protruding through it, the first course
usually requires the use of mortar at the bed and head joints of
the blocks in order to ensure that it is level. Typically each
subsequent course is placed in such a manner so that the vertical
joints between blocks are staggered in a running bond pattern from
a previous course. Mortar is used as a binding agent between the
courses and between the ends of each of the blocks. Conventional
concrete blocks typically have one or more voids or cores extending
through them in the vertical direction to create open vertical
columns through the walls. The vertical support elements are
accommodated within these vertical columns. The blocks are
installed over the vertical support elements. The cores or voids
are filled with masonry (concrete) grout to connect the wall to the
vertical support elements of the footing to help ensure that the
wall and footing perform as a structure in resisting lateral moment
loads. Additional reinforcing bars may be placed in these columns
for enclosure with concrete grout within the columns, in accordance
with building code standards and are connected to the vertical
support elements of the footing to help ensure wall stability.
[0004] In order for a wall constructed in this manner to be
approved, a building inspector normally will require what is known
as a "knockout". A "knockout" is an inspection opening in a wall
block at or near the base course. This requires that a portion of a
block be removed in order to visibly ensure that the concrete grout
has fully filled the entire vertical column.
[0005] Another widely accepted method of construction of such walls
is to dry stack concrete wall units, or blocks. Mortar is not used
in this method. These blocks are popular because they are mass
produced and, consequently, relatively inexpensive. They are
structurally sound and easy and relatively inexpensive to install.
Because they comprise concrete, they are durable. They can be given
a desired appearance, for example by using coloring and textures to
simulate natural stone and/or adding a real or cultured stone
veneer. Many block systems also use pins that are adapted to fit in
corresponding pin holes in adjacent blocks or may use other
mechanical means to contribute to the alignment and stability of a
wall.
[0006] Typically, retaining wall blocks are manufactured to have
the desired appearance on the front face (i.e., the outer face of a
wall) because only the front is visible after the wall is
constructed. It is highly desirable to have the front face of the
wall system have a natural stone appearance, and many approaches
are used in the art to treat or process concrete to evoke the
appearance of natural stone, including splitting the block,
tumbling the block to weather the face and edges of the face, and
using processing or texturing equipment to impart a weathered look
to the concrete.
[0007] Depending upon their location, the soil type, the amount of
water that can flow through the wall, and the mineral content of
the water, an undesirable appearance (efflorescence) can develop on
the surface of a retaining wall. Efflorescence refers to the
leaching of mineral salts from water and this often occurs on walls
in contact with water. The resultant deposit on a surface creates
an unattractive white stained appearance on a wall. In addition,
due to exposure to the elements and freeze/thaw cycles, concrete
retaining walls may exhibit spalling, that is, chipping and
cracking of concrete, which affects their appearance and can
ultimately affect their utility. Freeze-thaw effects are worsened
when the wall face is exposed to salt spray, which commonly occurs
on roadways where de-icing salts are used to clear the road of ice
and snow.
[0008] There have been prior efforts to veneer segmental retaining
walls with natural stone or concrete that is molded to closely
resemble natural stone. While such veneering produces aesthetically
pleasing walls, it is a laborious and highly expensive process, as
it requires skilled masonry work to tie in the stone or concrete
veneer to the wall using traditional mortared masonry construction
methods. Such veneering can double the cost of the finished wall.
In addition, segmental retaining walls are not rigid structures and
applying a rigid mortared veneer may cause cracking if the
non-rigid underlying segmental wall moves, unless appropriate steps
are taken to provide slip joints.
[0009] High density structural poly foam can be utilized to create
panel forms of accurate dimensions and shape. Poly foam panels are
relatively lightweight (approximately 1 lb/sq foot area, that is 1
to 2 inches thick). The material is easy to handle due to its
lightweight, can be shipped easily long distances, and is durable
and long lasting. The molds to produce the high density structural
poly foam panels can be made to make a wide variety of shapes and
sizes thus offering a wide range of styling and geometry.
SUMMARY OF THE INVENTION
[0010] This invention relates generally to a method of constructing
walls or fence systems from panels. More particularly, the
invention relates to constructing such walls or fence systems
wherein a back face of one panel connects to a back face of another
panel and further wherein the front faces of the panels have a
desirable texture and further wherein a concrete footing of the
wall or fence system is poured after courses of panels have been
stacked one upon the other.
[0011] The invention provides a method for constructing a wall or
fence comprising: providing a plurality of connectors and a
plurality of panels, each panel having a front face and an opposed
back face, a set of opposed and substantially parallel upper and
lower surfaces and first and second opposed and substantially
parallel side surfaces; preparing a level base; forming a base
layer of panels on the level base by placing opposed panels on the
level base and connecting a back face of at least one first panel
of the base layer to a back face of at least one opposed second
panel of the base layer with at least one connector, the front
faces of the at least one first panel and the at least one second
panel facing outward, the at least one first panel and at least one
second panel each having a knockout cavity; placing at least one
course of opposed panels on the base layer of panels and connecting
a back face of at least one first panel of the at least one course
to a back face of at least one opposed second panel of the at least
one course with at least one connector, the front faces of the at
least one first panel and the at least one second panel of the at
least one course facing outward, to form a top surface of an
uppermost course of panels; and pouring a flowable material from
the top surface between the opposed panels to form a support
footing for the wall or fence, the support footing encasing at
least a portion of the base layer of panels. In an embodiment, the
method further comprising: forming a trench; and adding base
material to the trench, wherein the step of preparing a level base
comprises leveling the base material in the trench. In an
embodiment, the base material is compacted granular material or
crushed stone. In one embodiment, the flowable material is concrete
or cement.
[0012] In one embodiment, the method further comprises: after
placing a plurality of panels and prior to pouring the flowable
material, forming a reinforcing framework between opposed panels,
the reinforcing framework including vertical reinforcement members.
In an embodiment, at least one vertical reinforcement member is
L-shaped and has a vertical portion and a perpendicular leg
portion, the perpendicular leg portion protruding outwardly through
a knockout cavity, the perpendicular leg portion being encased in
the support footing after the flowable material is poured. In an
embodiment, the reinforcing framework includes horizontal
reinforcement members. In one embodiment, the panels of the base
layer and the panels of at least one course have the same
structure. In an embodiment, the at least one connector that
connects the at least one first panel and the at least one second
panel of the base layer also connects the at least one first panel
and the at least one second panel of the adjacent course of panels.
In an embodiment, the connector has at least four dovetail
projections. In one embodiment, the panels are made of
polyfoam.
[0013] In one embodiment, the support footing encases at least one
half of a vertical height of the base layer of panels, and in
another embodiment, the support footing substantially encases the
base layer of panels. In an embodiment, each set of opposed panel
surfaces has mating tongue and groove attachments, respectively, so
that a respective tongue attachment and groove attachment of
adjacent panels connect the adjacent panels. In one embodiment, the
back faces of the panels have dovetail channels. In an embodiment,
at least one horizontal reinforcement member rests on at least one
connector. In one embodiment, at least one vertical reinforcement
member passes through a vertical support ring that is part of at
least one connector.
[0014] In one embodiment, the at least one first panel of the at
least one course and the at least one opposed second panel of the
at least one course have a pattern molded into their front faces.
In embodiments of the invention, the pattern is an ashlar pattern,
a boulder rock pattern, or a ledge rock pattern.
[0015] In one embodiment, the method further comprises attaching a
capping block onto a top of the wall or fence. In an embodiment,
the method further comprises attaching an end wall block to some of
the plurality of panels before pouring the flowable material.
[0016] The invention provides a wall or fence comprising: a support
footing formed from a hardened flowable material; a base layer of
opposed panels, at least a portion of the base layer of panels
being encased within the support footing, a back face of at least
one first panel of the base layer being connected to a back face of
at least one opposed second panel of the base layer with at least
one connector, the front faces of the at least one first panel and
the at least one second panel facing outward, and the at least one
first panel and at least one second panel each having a knockout
cavity, and a plurality of courses of opposed panels placed on the
base layer of panels, a back face of at least one first panel of
the at least one course being connected to a back face of at least
one opposed second panel of the at least one course with at least
one connector, the front faces of the at least one first panel and
the at least one second panel of the at least one course facing
outward, a volume between the opposed panels containing the
hardened flowable material. In an embodiment, the hardened flowable
material is concrete or cement. In one embodiment, the wall or
fence further comprises a reinforcing framework between opposed
panels, the reinforcing framework including vertical reinforcement
members. In an embodiment, at least one vertical reinforcement
member is L-shaped and has a vertical portion and a perpendicular
leg portion, the perpendicular leg portion protruding outwardly
through a knockout cavity, the perpendicular leg portion being
encased in the support footing. In an embodiment, the reinforcing
framework includes horizontal reinforcement members. In one
embodiment, the panels of the base layer and the panels of the
plurality of courses have the same structure. In an embodiment, the
at least one connector that connects the at least one first panel
and the at least one second panel of the base layer also connects
the at least one first panel and the at least one second panel of
an adjacent course of panels. In one embodiment, the panels are
made of polyfoam. In one embodiment, the thickness of the wall or
fence terraces from wider to narrower as the wall heightens.
[0017] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory and are intended to provide further explanation of
the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A preferred form of the present invention will now be
described by way of example with reference to the accompanying
drawings, wherein:
[0019] FIGS. 1A and 1B illustrate perspective views of a panel mold
embodiment of the present invention.
[0020] FIG. 1C illustrates a perspective view of an alternate panel
mold embodiment of the present invention.
[0021] FIGS. 2A to 2C illustrate back, perspective and front views
of a panel of the present invention.
[0022] FIG. 2D illustrates a back view of an alternate embodiment
of the panel of FIGS. 2A to 2C.
[0023] FIGS. 3A and 3B illustrate perspective views of third and
fourth embodiments of the panel of the present invention.
[0024] FIGS. 4A, 4B and 4C illustrate front views of second, third
and fourth embodiments of front faces of the panel of the present
invention.
[0025] FIG. 5A illustrates a perspective view of a connector of the
present invention.
[0026] FIGS. 5B and 5C illustrate front and top views,
respectively, of a second embodiment of the connector of the
present invention.
[0027] FIG. 5D illustrates a front view of a third embodiment of
the connector of the present invention.
[0028] FIGS. 5E and 5F illustrate perspective and bottom views of a
fourth embodiment of the connector of the present invention.
[0029] FIGS. 6A to 6C illustrate side, front and perspective views
of a wall made from the panel system of the present invention.
[0030] FIGS. 6D and 6E illustrate partial cut-out perspective views
of first and second embodiments of walls formed using the panels
and panel system of the present invention. 6F illustrates a side
view of the tongue and groove connection of the panel wall system
of the present invention.
[0031] FIG. 6G illustrates a top view of the dovetail projection of
a connector attaching to a dovetail channel of a panel for the
panel wall system of the present invention.
[0032] FIG. 6H illustrates a side view of the tongue and groove
connection of an alternate embodiment of the panel of the present
invention.
[0033] FIGS. 7A and 7B illustrate top views of a corner of walls
made from first and second embodiments of corner panels of the
panel system of the present invention.
[0034] FIGS. 8A and 8B illustrate top views of pilasters or columns
made from first and second embodiments of pilaster panels of the
panel system of the present invention.
[0035] FIGS. 8C and 8D illustrate top views of pilasters or columns
made from third and fourth embodiments of pilaster panels of the
present invention.
[0036] FIGS. 9A and 9B illustrate top views of ends of walls made
from first and second embodiments of end panels of the panel system
of the present invention.
[0037] FIGS. 10A to 10H illustrate side views of various
embodiments of capping panels of the panel system of the present
invention.
[0038] FIG. 11A illustrates a front view of a finished wall of the
present invention showing a running bond configuration.
[0039] FIG. 11B illustrates a front view of a finished wall of the
present invention showing a stacked bond configuration.
[0040] FIG. 11C illustrates a front view of a wall of the present
invention showing a wall terracing with the slope of the grade.
[0041] FIG. 11D illustrates a side view of a wall of the present
invention showing a partial retaining wall that terraces with the
height of the wall.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] This invention comprises panels that are used together in
the construction of a wall. The panels are configured to be
compatible with each other in the construction of a partial
retaining wall, a parapet wall, a free-standing wall, a sound wall
or a fence system. Such walls may be straight and may have corners
and 90 degree angles. Although not a requirement of this invention,
each panel may have at least one face that is textured in a manner
resulting in the appearance of natural stone. Preferably, there is
a natural-appearing finish on all exposed sides of the wall. The
wall system is designed to be structurally sound and easy to
install.
[0043] It is to be emphasized that the surface of a panel may be
molded to have any desired appearance. A natural appearance, such
as stone, is generally most desirable. The panel may have a uniform
appearance or it may have an ashlar pattern formed into it. The
panels may also resemble stone that has been processed or treated
as is commonly known in the natural stone industry. For example,
the panel may resemble weathered stone, polished stone or flame
treated stone. In addition, the mold may be configured to produce
panels that resemble stone that has been hand or machine pitched or
tumbled to produce an aesthetically pleasing natural quarried stone
appearance.
[0044] The panels are produced in dimensions that are convenient to
manufacture and handle. The panels are substantially planar.
Convenient panel sizes may have a height of 12 inches (30.5 cm) and
a length of 48 inches (121.9 cm), another convenient size are
panels that have a height of 24 inches (61 cm) and a length of 48
inches (121.9 cm). These panels are light weight, relatively large,
durable, weather resistant and easy to handle. The dimensions of
the panel may vary from these stated dimensions in order to meet
aesthetic or functional requirements of particular applications.
The panel can be composed of fiberglass, concrete, wood, particle
board, plastic, etc. but is preferably composed of a high density
structural polymer foam. Some examples of suitable polymers that
may be utilized to create the high density structural polymer foam
are disclosed in U.S. Pat. Nos. 6,607,683 B1 and 7,235,204 B2 both
to Harrington and consist of urethanes, phenolics, epoxies, alkyds,
allylics, aminos, polyesters and silicones. The polymer foam is
usually of a pre-selected color and injected into a mold that may
additionally have a surface oxide coating to give the polyurethane
foam a more visually appealing appearance as well as resistance to
the natural elements of U.V. sunlight deterioration, water, ice,
etc. The polymer foam preferably is durable, weather resistant,
light weight and easy to handle. High density structural
polyurethane foam can be used to create panels of accurate
dimensions and shapes. These panels can be textured by forming in
molds that have been made to simulate true stone and stone
patterns. Color can be added that provides further natural
appearance and resistance to U.V. degradation. The various finishes
and molded textures that can be formed from the polymer foam
visually enhances the panel and makes it look like real stone. The
panel can be made with poly foam that is flame and ignition
resistant. The density of the poly foam can be varied with filler
materials to increase durability and hardness and to further resist
impact damage.
[0045] A back face of the panel preferably is provided with single
or multiple elevated columns which include structure for attaching
a connector. For example the columns may contain dovetail channels
that have been molded or routed into the elevated column. The
dovetail channels of the panel can be affixed to an attachment
means such as a connector as described in more detail below. The
polymer foam composition of the panels allows the channel to be
molded into the panel when it is formed or cut to a precise
location and size (post-forming). In one embodiment the back face
of one panel may be attached to the back face of one or more
opposing panels with the connector. The connector may protrude
vertically from the top of the panel and can engage the back faces
of opposing panels in another course of a wall or fence adding to
the structural integrity and support of the structure. The
subsequent courses of panels may be offset from the previous course
in a running bond pattern or stacked directly on top of the
previous course depending on the desired look of the structure. In
another embodiment, the mirror image back faces of opposing and
non-offsetting first and second panels are attached to one or more
connectors to form a panel block. This panel block can be assembled
at the site of the construction of the structure being built and is
easy to handle and work with. Alternately, panels may be attached
to alternate attachment means and affixed directly to a preexisting
structure such as a wall or fence without the need to form a panel
block. The poly foam panel can be attached to block faces on
existing retaining walls and other structures as well to give the
structure a more desirable appearance. It would also be beneficial
to attach the poly foam panels of the present invention to an
effloresced structure that is still structurally sound in order to
improve the overall aesthetic quality of the structure. Such
alternate methods of attachment are described in detail in U.S.
Patent Application Ser. No. 60/945,457 (Veneers for Walls,
Retaining Walls, Retaining Wall Blocks, and the Like) and U.S.
Patent Application Publication No. 2005/0252144 A1 (Veneers for
Walls, Retaining Walls and the Like), both hereby incorporated
herein by reference. A spacer may be placed between the poly foam
panel and the surface it is being affixed and/or a back surface of
the poly foam panel may be given a corduroyed texture that would be
beneficial by allowing drainage and any efflorescence that occurs
in the structure to flow down open air space cavities and channels
between the back surface of the panel and the surface of the
structure where it would not affect the aesthetic quality of the
panel covered structure.
[0046] In a preferred embodiment, the panels are additionally
provided with tongue and groove attachment means so that two
adjacent panels can be connected to each other. Preferably, each
panel has two adjacent sides with a groove adapted to receive a
tongue from corresponding sides of adjacent panels. Preferably, the
attachment means provide a joint that discourages or minimizes
penetration of water from rain or roadway spray. Optionally the
groove may be molded or routed with a drip edge to further
discourage collection and penetration of water into the
structure.
[0047] Panels of the present invention used in the production of a
structure such as a wall or fence may be supported with a concrete
footing. The wall or fence may be further reinforced with vertical
reinforcing members that may be located in vertical cavities
created by the spatial void between the opposing panels of the
wall, and/or horizontal reinforcing members located in horizontal
channels within the connectors attached to the back faces of the
panels of the wall to form a reinforcing framework. In order to
form the footing, concrete may be poured from the top of the
structure into the cavities created by the opposing panels spaced
apart the distance of the connector. The concrete flows down
through the cavities and out through knockout cavities at the
bottom surface of the structure. The concrete covers a footing
framework to a pre-determined depth and encases the vertical and
horizontal reinforcing members to form a support structure for the
wall as described further in U.S. Patent Application Ser. No.
60/928,466 (Method of Constructing a Block Wall) hereby
incorporated herein by reference.
[0048] Turning now to the Figures, the panel wall system of this
invention is shown and described.
[0049] FIGS. 1A and 1B illustrate a first embodiment of a mold used
to form a panel of the present invention. Panel mold 20 has top
plate 22 hinged to bottom plate 23. When in the closed position
shown in FIG. 1A the top and bottom plates form a substantially
enclosed mold cavity. The inner surfaces of top plate 22 and bottom
plate 23 have been designed to imprint a desired surface texture
onto front and back faces of the panel. Groove inserts 28 and 29
can be placed into front 25 and side 27 of the panel mold to form
the groove of the panel. The tongue of the panel on adjacent sides
opposite the groove sides is formed within a channel 24 defined
between the top and bottom plates. Note that for purposes of
illustration a portion of the panel has been removed and one side
of the panel mold is shown in section. Although not shown it will
be understood that the removed portion forms channel 24 between the
top and bottom plates to form a tongue along the side of the panel.
When forming the panel polymer foam in its liquid state is placed
in a metered amount into the mold. Slideable channel inserts 21 are
sprayed with a release agent, along with the groove inserts and the
inner surface of the top plate and then channel inserts 21 are slid
into top plate 22. The release agent functions to lubricate the
surfaces so the panel can be more readily stripped from the mold
after the panel has formed and set in the mold by restricting the
ability of the polymer foam to bond to the surfaces of the mold.
After the polymer form has sufficiently hardened, channel inserts
21 are withdrawn to enable the hardened polymer panel to be removed
from the mold. Alternatively, the dovetail channels of the elevated
column may be routed into the panel after the panel has been
removed from the mold and after the polymer foam has set and
hardened. It should be further understood that only a portion of
the panel mold boxes are shown in FIGS. 1A and 1B. Additional
dovetail channel forming members may be included in the removed
portions. Additionally, any number of dovetail channels may be
formed within each plate. FIG. 1B illustrates a silicone liner 26
which imprints the desired pattern of the front face onto the panel
and functions to give the front face of the panel a more natural
stone appearance as desired.
[0050] FIG. 1C illustrates an alternate embodiment of a panel mold
of the present invention. Panel mold 30 has top plate 32 hinged to
bottom plate 33. The inner surfaces of top plate 32 and bottom
plate 33 have been designed to imprint the desired surface texture
onto front and back faces of the panel. Groove inserts 38 and 39
can be placed into the front 35 and side 37 of the panel mold to
form the groove of the panel. In this embodiment the dovetail
channels are formed by channel inserts 31 which are slideably
accommodated in grooves formed into the top surface of top plate
32. The channel inserts include wedge shaped bars which extend into
the mold cavity. The width of the bars is greater along the surface
closer to the center of the mold cavity. Channel inserts 31 are
coated with a lubricating release agent and placed into the top
plate of the mold when the polymer foam is placed into the mold.
The polymer foam hardens around the channel inserts and when the
foam has set the channel inserts are slid out of the mold box
forming dovetail shaped channels and the panel is stripped from the
mold. The release agent enables the coated channel inserts to be
more readily removed from the mold by restricting the ability of
the polymer foam to bond to the channel inserts.
[0051] The panel molds of FIGS. 1A to 1C can be used in a method of
making a panel as follows. (1) "Clean store" area. The mold is
stored clean and in a ready to use condition. (2) Color stage.
Oxide colors are placed into the silicone liner of the bottom plate
and are then brushed into the silicone liner beds. (3) Spray sealer
stage. This locks in the oxide colors. (4) Temporary drying station
for sealer. (5) Polymer application stage. A metered amount of the
high density structural polyurethane foam is placed in its liquid
state by a manual or robotic method into the mold. (6) The top
plate and the groove inserts of the mold are sprayed with a release
agent and the top plate is then closed. The top and bottom plates
are then clamped together. As the polymer foam expands and hardens,
the top plate does not dislodge from the bottom plate and ruin the
panel as it forms in the mold. Channel inserts are sprayed with a
release agent and slid into the mold. (7) Cure area. The mold is
allowed to cure for approximately 20 minutes and the cure area may
hold up to 60 molds. (8) The molds are pulled out of the cure area
and are prepped for demolding. (9) Channel and groove inserts are
removed. (10) The mold is unclamped and the top plate is opened.
(11) The cured panel is demolded and the silicone liner is stripped
from the panel and re-inserted into the bottom plate. (12) The mold
is cleaned and checked before placing back into the "clean store"
area. (13) De-buffing stage. Any excess flash is removed at panel
edges. (14) Rout out stage. If channel inserts were not used to
create dovetail channels, the dovetail channels can be routed into
the panel. Grooves and other desired features of the panel may also
be routed if not formed into the panel. (15) Color touch up as
required prior to packaging. (16) Packaging station. This station
provides protective wrap to panel or between panels and places
panels in box. (17) Assemble shipping/distribution pallet. Boxes
are placed on a pallet into a complete cube. The pallet is then
stretch wrapped and plastic banded. (18) Completed pallets are then
placed into inventory with clearly labeled boxes and pallet
signs.
[0052] FIGS. 2A to 2C illustrate back, perspective and front views
respectively of panel 100a of this invention. The panel comprises
opposing and substantially parallel upper and lower surfaces 102
and 104 respectively, and opposing and substantially parallel side
surfaces 110 and 112. The panel also comprises front and back faces
106a and 108a, respectively. Front face 106a and rear face 108a
each extend from top surface 102 to bottom surface 104 and side
wall surfaces or ends 110 and 112 each extend from top surface 102
to bottom surface 104 and from front face 106a to rear face 108a.
Back face 108a has elevated vertical columns 120a, 120b, 120c,
120d, 120e, and 120f and elevated horizontal reinforcing ribs 130
forming a grid-like framework which protrudes from back face 108a
and functions to add support and rigidity to the panel and the wall
formed therefrom and also helps to prevent bowing. Elevated columns
120b, 120c, 120d and 120e each contain a dovetail channel or slot
122 which engage and secure to the dovetail projections of
connectors 450a and 450b as described below. Elevated columns 120b,
120c, 120d, and 120e function to strengthen the attachment to the
connectors of the panel wall system. The dovetail channels or slots
122 may be routed into the elevated columns or may be molded during
production. Arched knockout indentations 190 may be molded into the
back face of the panel. Arched knockout indentations 190 provide a
indented guideline on the back face of the panel for the optional
production of knockout cavity 195 described below. Tongues 132 and
134 project outwardly from top surface 102 and side surface 112,
respectively and may be slightly tapered. Grooves 136 and 138,
which can be molded or routed into the poly foam, project inwardly
from bottom surface 104 and side surface 110, respectively. The
tongue of a first panel is designed to engage and secure with the
groove of a second adjacent panel thereby interlocking the panels
and adding to the structural integrity and visual appeal of the
wall or fence. A convenient panel height of 12 inches (31.5 cm) and
a length of 48 inches (121.9 cm) is shown but these dimensions may
vary due to the desired aesthetics or manufacturing and
construction efficiencies.
[0053] FIG. 2D illustrates the back face of panel 100b, a further
embodiment of the invention. Panel 100b has additional reinforcing
ribs 130, no arched knockout indentations and a height of 24 inches
(61 cm) and a length of 48 inches (121.9 cm). It is to be noted
that the dimensions of the panels could vary depending on the
particular application and are not limited to the two dimensions
supplied above.
[0054] FIG. 3A illustrates back face 208 of panel 200 of the
present invention. Panel 200 has two elevated columns 220 which
protrude from back face 208. Each column contains two dovetail
channels or slots 222 which engage and secure to the dovetail
projections of connector 450 or 550 as described below. Elevated
columns 220 add rigidity and support to vertically reinforce the
panel to prevent bowing and also function to strengthen the
attachment to connectors 450 or 550. Reinforcing ribs 230 are
formed during the mold process and protrude horizontally from back
face 208.
[0055] FIG. 3B shows back face 308 of panel 300 of the present
invention. Panel 300 is similar to panel 200 except that elevated
columns 320 each contain a single dovetail channel 322.
[0056] FIGS. 4A to 4C illustrate front views of alternate
embodiments of the front face of the panels of the present
invention. FIG. 4A illustrates an ashlar pattern molded onto front
surface 106b of the panel. FIG. 4B illustrates a boulder rock
pattern molded onto front surface 106c of the panel and FIG. 4C
illustrates a ledge-rock pattern molded onto front surface 106d of
the panel. It should be noted that the patterns shown are not
limiting and that various other patterns could be imprinted onto
the front surface of the panel in order to achieve a desired visual
appearance.
[0057] Connector 450a as shown in perspective in FIG. 5A and
connector 450b as shown in front and top views in FIGS. 5B and 5C,
have dovetail projections 452 configured to engage and secure to a
dovetail channel of the back face of the panels of the present
invention. Dovetail projection 452 may also be formed with a gusset
or web located within the dovetail of the projection for added
stability. Connectors 450a and 450b also have angled truss supports
454 which add stability and rigidity to the connectors and to a
wall formed from the connector and panels attached thereto. The
connectors are provided with a ledge 456 to support the horizontal
reinforcing members 80 as described below. Connector 450a has
reinforcing tab 457 which creates two separate channels on ledge
456 which further help to separate, secure and hold the horizontal
reinforcing members 80 used in the framework of the wall support.
The connector can be made of an injection molded plastic, metal,
wood or other convenient material. The connector may also be sized
to extend the entire height of the panel or may extend the height
of two or more panels in order to additionally interconnect courses
of panels. FIG. 5D illustrates connecter 450c and is similar to
connectors 450a and 450b but has been made to correspond to the
panel height of which it is connecting, thus allowing for the
remote assembly of 2 face panels and a connector to form a panel
block as described previously. These blocks can then be assembled
into a wall or other structure. This connector also allows for the
placement of additional horizontal reinforcing members to further
stabilize and strengthen the structure.
[0058] FIGS. 5E and 5F illustrate an alternate embodiment of a
connector of the present invention. Connector 550 has dovetail
projections 552a, 552b, 552c and 552d which extend outwardly from
side walls 562 and 564. Projections 552a to 552d may contain
vertical friction ribs 590 that help secure the projections into
the dovetail channels of the panels. Vertical friction ribs may
also be used on other variations of connectors as so desired. Side
wall 566 contains horizontal reinforcing channels 556a and 556b and
side wall 568 contains horizontal reinforcing channels 556c and
556d. Vertical support ring 560 which is connected to the inside
corners of each side wall by bridge 570a, 570b, 570c, and 570d is
used to secure, guide and support the vertical reinforcing members
of the framework of the wall support as discussed in detail below.
The connector can be made of an injection molded plastic. The
connectors illustrated in FIGS. 5E and 5F are designed to be used
with a panel having columns formed with two dovetail channels such
as panel 200 with back face 208 as illustrated in FIG. 3A. Dovetail
projection 552 of connectors 550 are received in dovetail channels
222 of back faces 208 of panels 200. The dovetail projections of
each connector 550 engage both dovetail slots for each elevated
column. There may be single or multiple connectors 550 engaged and
secured to the dovetail channels of each elevated column. This
connection secures the two panels to one another while leaving a
predetermined distance the width of connector 550 between the two
faces.
[0059] Referring now to FIGS. 6A to 6H, a method of constructing a
freestanding wall or fence 600 with a wall system which includes a
plurality of panels 100a and a plurality of connectors 450b will be
described. FIG. 6A illustrates a side view of an excavated trench T
of a pre-selected depth, which has been dug into soil S and lined
with a level base B of compacted granular material such as crushed
stone. Depending upon the soil conditions the trench can be dug to
the exact size needed for the footing of the desired structure and
wherein the walls of the trench acts like form boards for the
footing. It should be noted that this is not limiting and that the
trench can be dug to any specification and that form boards can be
used to form the footing to desired specifications. A base layer 10
is formed by attaching the back face 108a of panel 100a to the back
face of an opposing panel 100a with connector 450b whereby the
dovetail projections 452 of connector 450b are received in opposing
dovetail slots 122 of the back faces 108a of panels 100a as shown
in FIG. 6G. This connection secures the two panels to one another
while leaving a predetermined distance the width of connector 450b
between the two faces. This distance is determined by the connector
span between the two opposing panels and is a function of the
structure's strength. The thicker the core of the structure being
built, the more height or lateral load can be subjected on the
structure, allowing the wall to be built taller due to the thicker
wall cross-sections with wider concrete dimensions. It may also be
beneficial to build a structure with varying and terracing widths
from wider to narrower the higher the structure is built especially
if the thicker wall cross-sections are not necessary for structural
stability over the full height of the wall as illustrated in the
partial retaining wall of FIG. 11D. The back face of one panel may
be offset from the back face of an opposing panel thus attaching
the panel to the back faces of two opposing panels. Alternatively,
the back faces of opposing panels may be aligned. The base layer is
leveled onto the granular material of the excavated trench. Arched
knockout indentations 190, which are indentation guides for the
panel assembly and construction crew, are removed from the panels
used to form the base layer, forming knockout cavities 195. It
should be understood that if the panel being used in the formation
of the wall does not have arched knockout indentations 190 for
producing knockout cavities 195, knockout cavities may be cut into
the panel being used on site or the base layer could be laid with
spatial gaps between adjacent panels. The panels 100a of base layer
10 are placed so that the lower surfaces of the panels lay directly
on top of the granular material.
[0060] A first course 20 of panels is then stacked upon the base
layer 10 panels. Panels 100a of first course 20 are placed end to
end upon base layer 10. Connector 450b protrudes vertically from
the base layer and engages opposing back faces 108a of the first
course interlocking the two courses together as shown in FIG. 6D.
It should be noted that the panels may be stacked or offset from
the previous course. The side wall tongue or grooves of each block
secure into the tongue or groove of the next adjacent panel when
placed end to end and also engage the tongue or groove of the panel
of each previous course adding additional support and
interconnecting of the panels as shown in FIG. 6F. FIG. 6H
illustrates a tongue and groove of a panel wall system whereby the
panel has been molded with a drip edge 197 to further discourage
collection and penetration of water into the structure. Subsequent
courses of panels are laid the same way as the base layer and first
course except that the arched knockout indentations are not removed
above any elevation where foundation/footing elements will be
formed. Two rows of horizontal reinforcement members 80 are placed
parallel onto ledge 456 of connector 450b. Horizontal reinforcement
members 80 can be placed onto the first course of panel wall 600
and then added at other locations as desired or in accordance with
the requirements of the wall being built. For example, subsequent
horizontal reinforcement members may be placed on every course,
every other course, or any combination thereof. Additional courses
of panels are stacked one upon another and attached to opposing
panels by connector 450b until the desired height is reached. If
the desired height of the wall is reached and the connector
vertically protrudes from the last course of panels, the connector
may be cut to the desired height. It should be noted that in
courses where the panel wall structure retains earth on one side,
or the wall structure requires being built to code specified frost
depth, then a non-textured (generally smooth), and/or non-colored,
and/or non surface-oxide panel can be used below grade or where
aesthetics are not critical in order to reduce the cost of the
overall structure. An alternate material, such as wood, metal,
plastic, fiberglass concrete etc., may optionally be used in these
circumstances as well to reduce overall cost, as desired.
[0061] Vertical reinforcement members 90 are attached or tied to
connector 450b (or if connector 550 were being used with panel 200,
the vertical reinforcement member would be threaded through the
vertical support ring of connector 550; or if connector 450a were
being used in combination with panel 200, the vertical
reinforcement member would be placed into the cavity created by the
side to side placement of connectors 450a into the double slot
dovetail channels of each elevated column of panel 200). The
vertical reinforcement members are preferably L-shaped, having a
perpendicular leg portion and a vertical portion. The perpendicular
leg of vertical reinforcement member 90 is placed through the
desired opening and protrudes outwardly through knockout cavity 195
in the panels of base layer 10 and is perpendicular to the first
course as shown in FIG. 6B. The vertical reinforcement members can
be inserted through the cavities during the laying of the first
course or can be inserted during a later course, however they must
be inserted before the perpendicular leg of the vertical
reinforcement member can no longer be placed or threaded through
the knockout cavity of the panels of the base layer. The desired
height of the structure may be taller than the vertical reinforcing
members themselves. In this case an additional straight vertical
reinforcement member can be spliced onto or overlapped with the
initial or first stage vertical reinforcement member. The
horizontal reinforcement members (two per course where required)
are used to position and align the vertical reinforcement member in
the open core space or vertical column when placing the vertical
steel into the wall after the wall has been assembled but before
grouting. Thus there can be much variation with the height of the
structure. The 1 foot by 4 foot dimension of one embodiment size of
the panel of the present invention is ideal for creating a pattern
of step down terracing in the length of the structure to follow
changing grade lines as shown in FIG. 11C. Typically a change of 1
foot over 8 feet is average in a reasonable slope.
[0062] FIG. 6C is a perspective view of a wall and support footing
framework for the panel wall system of the present invention. The
support footing framework includes horizontal footing reinforcing
members 96 and transverse footing reinforcing members 95. The
perpendicular leg of the vertical reinforcement member is secured
to the transverse footing reinforcing members 95. The transverse
footing reinforcing members protrude outward on both sides of the
knockout cavity in the panels of base layer 10 and are
perpendicular to the first course of block. Horizontal footing
reinforcing members 96 are secured to the transverse footing
members and run parallel the length of the freestanding wall. The
horizontal footing members and transverse footing members create a
footing support framework that has been elevated above the granular
material by the height of rebar blocks 85 which are attached at
various positions to the footing framework. The size of the rebar
block can be selected to achieve a desired height in order to
ensure proper placement of reinforcing members and footing
specifications for support requirements and functions to help
prevent the framework from corroding. The footing framework can be
completed at anytime during the laying of the wall block courses.
It may sometimes be beneficial to wait until all course layers have
been laid so that block installers will not trip over the framework
during construction of the wall. It may also be beneficial to lay
three or four initial courses and then complete the footing and
support framework. Concrete could then be poured to encase the
footing and support framework and then be allowed to set. This
method would also leave unencumbered access along the wall as the
construction workers are building the remaining structure to the
desired specifications.
[0063] The horizontal and transverse footing reinforcing members
and the vertical and horizontal reinforcing members are selected of
suitable diameter for structural support and integrity and can be
made from suitable materials including but not limited to steel
reinforcing bars (also referred to as "rebar", which may be
deformed, natural and/or galvanized), threaded steel (galvanized)
post-tension rods, fiberglass rods, and other reinforcing members
that are suited for reinforcement in concrete/masonry.
[0064] When a first desired height of the wall has been reached,
typically 3 to 4 panel courses, and the support footing framework
is in place, and the ends of the wall have been fitted with end
wall blocks or end wall panels as described below, concrete is
poured into the top opening of the cavity created by the width of
connector 450b opposing the back faces of panel 100a. The concrete
is poured from the top of the wall and will fill the vertical
cavity created by the vertical alignment of the side wall panels of
the panel blocks. Weights, weighted spacer or connector boards 70
may be placed on top of fittings 71 that are placed on the top
surface of the wall as the concrete is poured into the cavity to
ensure that the concrete does not cause the wall to float or rise.
Additionally or alternatively the wall panels may be tied down to
help prevent any floating and to keep the panels from bowing under
the weight of the wet concrete. The weight 70 may be any suitable
material heavy enough to hold down the wall and the fitting 71 is
designed to protect the top surface and tongue of the last course
of panels from the weight 70. The concrete will flow down through
the wall cavities or voids and out through knockout cavities 195 of
base layer 10 until it fills the trench and covers the footing
framework to a predetermined depth and encases base layer 10 into a
footing support structure as shown in FIG. 6A. After the concrete
has been poured and allowed to set for a predetermined time, more
panel courses fitted with desired end panels or blocks of the
structure may be laid, typically 3 to 4 panel courses, and more
support framework may be placed. Concrete is then poured to fill
the vertical cavity as described above. Again the same weight,
fitting and tie downs may be employed to prevent the wall from
floating or bowing. Additional courses can then be laid and the
same steps repeated until the desired height of the wall has been
reached. After the concrete has been poured, any extra vertical
reinforcing members that extend above the last course of panels may
be cut off (this could be done before the concrete is poured into
the columnar cavities) and capping or coping block 40 (as described
below) may be placed and secured to the top surface of the last
course. It should be understood that the three to four courses
before each concrete pour is not limiting and in fact the whole
structure may be built, or any number of courses may be laid before
the concrete is poured depending upon the specifications of the
structure being built.
[0065] FIG. 6E shows an alternate embodiment of the panel wall
system. In this embodiment the wall panels and connectors are
assembled to form a plurality of panel blocks. The panel blocks are
laid in courses to form a wall in accordance with the previous
discussion. For example, panel wall block 500 has been formed from
opposing and non-offsetting panels 100b whereby the dovetail
projections 452 of connector 450b are received in mirror-image
dovetail slots 122 of the back faces 108b of panels 100b. This
connection secures the two panels to one another while leaving a
predetermined distance the width of connector 450 between the two
faces. This panel block can be used to form a wall by placing the
panel blocks end to end in a course of the wall. The panel block of
an additional course may be offset from the previous course or may
be stacked directly vertical from the previous course. The panel
block system of building the wall can use the same vertical and
horizontal reinforcing framework and footing framework technique
with concrete pour as described herein.
[0066] FIGS. 7A and 7B illustrate top views of alternate
embodiments of panels for the formation of corners for the present
invention. FIG. 7A shows outer corner panel 701 and inner corner
panel 702. Both corner panels have elevated columns with dovetail
channels to receive the connectors of the present invention and
tongue and grooves designed to engage other panels of the present
system and may have horizontal ribbing. It should be noted that
both right handed and left handed inner and outer corner panels may
be built from the same panels. FIG. 7B illustrates an alternate
embodiment of a corner whereby the outer corner is formed from a
first panel 710 having tongue or projection 711 which engages a
groove 722 on the back face 721 of a second panel 720 and further
whereby the inner corner is formed from a first panel 730 having
tongue or projection 731 which engages a groove 742 on the front
face 741 of a second panel 740. Panels 710, 720, 730, and 740 have
elevated columns with dovetail channels to receive the connectors
of the present invention. It should be noted that both right handed
and left handed inner and outer corner panels may be built from
this kit of parts.
[0067] FIGS. 8A to 8D illustrate top views of alternate embodiments
of panels for the formation of pilasters and columns for the
present invention. FIG. 8A shows an embodiment of a pilaster or
column with a wall projecting from both sides. Panel 810 has groove
812 on front face 811 and engages the tongue from panel 100a of
wall 600. Panel 820 has groove 822 on back face 823 and engages
tongue 814 from panel 810. Panel 830 has groove 832 on back face
833 and engages tongue 824 from panel 820. Panel 830 has tongue 834
which engages the groove from panel 100a of wall 600. Panels 810,
820 and 830 have elevated columns with dovetail channels to receive
connectors of the present invention. FIG. 8B shows a second
embodiment of a column or pilaster with panel 840 having groove 842
and tongue 844 and is located on each side of the wall. FIG. 8C
shows a third embodiment wherein panel 100a of wall 600 connects to
panel 810, which connects to a first panel 820, which connects to a
second panel 820 and then to a third panel 820. Third panel 820
connects to panel 830 which connects to panel 100a of wall 600.
Panels 810, 820 and 830 have elevated columns with dovetail
channels to receive connectors of the present invention. The
connectors can be further wired together to add additional support
to the pilaster or column and to prevent the structure from bowing
out when filled with concrete. FIG. 8D shows a fourth embodiment
wherein column or pilaster panel block 850 having groove 852 and
tongue 852 connects to panels 100a of a wall.
[0068] FIGS. 9A and 9B illustrate top views of alternate
embodiments of wall ends for the present invention. FIG. 9A
illustrates end wall block 901 having tongue 902 and groove 903 and
is designed to give the end of the wall a more finished appearance
and to keep the concrete from seeping out the sides of the wall
when it is poured. The end wall block is preferably textured on all
exposed sides. FIG. 9B illustrates an end of a wall finished with
panels. Panel 910 has groove 912 on side 911 and engages the tongue
from panel 100a of wall 600. Panel 920 has groove 922 on back face
923 and engages tongue 914 from panel 910. Panel 930 has groove 932
on back face 933 and engages tongue 924 from panel 920. Panel 930
has tongue 934 which engages the groove from panel 100a of wall
600. Panels 910 and 930 have elevated columns with dovetail
channels to receive connectors of the present invention.
[0069] FIGS. 10A to 10H show various embodiments of capping blocks
or coping pieces for the present invention. FIGS. 10A to 10E show
capping blocks 40a to 40e respectively which have grooves 42
designed to engage the tongue from the panels of the present
invention. These capping blocks can be further anchored to the wall
or additionally attached with use of an adhesive compound. FIGS.
10F to 10H show capping blocks 40f to 40h respectively which have
cavity 44 designed to fit over the tongues of the opposing sides of
the wall. These capping blocks can be further anchored to the wall
or additionally attached with use of an adhesive compound.
[0070] FIG. 11A shows a finished section of the wall 1000a of the
present invention with a running bond pattern. The base layer of
panels and footer is shown in dash and is below grade. It should be
noted that a single course (the base layer) or more may be
positioned below grade depending upon the application. FIG. 11B
shows a finished section of the wall 1000b of the present invention
with a stacked bond pattern. FIG. 11C illustrates a front view of a
wall 1000c of the present invention showing a wall terracing with
the slope of the grade. FIG. 11D illustrates a side view of a wall
1000d of the present invention showing a partial retaining wall
terracing from wider to narrower as the wall heightens.
[0071] Although particular embodiments have been disclosed herein
in detail, this has been done for purposes of illustration only,
and is not intended to be limiting with respect to the scope of the
claims. In particular, it is contemplated that various
substitutions, alterations, and modifications may be made to the
invention without departing from the spirit and scope of the
invention as defined by the claims. For instance, the choice of
materials or variations in the shape or angles at which some of the
surfaces intersect are believed to be a matter of routine for a
person of ordinary skill in the art with knowledge of the
embodiments disclosed herein.
* * * * *