U.S. patent application number 12/360430 was filed with the patent office on 2009-07-30 for integrated wall system.
This patent application is currently assigned to CMI LIMITED COMPANY. Invention is credited to Steven E. Hargrave, John E. Irvine.
Application Number | 20090188180 12/360430 |
Document ID | / |
Family ID | 40897802 |
Filed Date | 2009-07-30 |
United States Patent
Application |
20090188180 |
Kind Code |
A1 |
Irvine; John E. ; et
al. |
July 30, 2009 |
INTEGRATED WALL SYSTEM
Abstract
A composite wall system includes a foundationless wall
substructure such as a sheet piling wall with a base portion
embedded in the ground and an exposed portion extending above the
ground, and one or more fascia panels or sheets such as synthetic
simulated stonework panels applied over the foundationless wall
substructure. Components of the wall system prevent debris from
entering between the wall substructure and the fascia panels, and
in seawall applications prevent water incursion and resist wave
action.
Inventors: |
Irvine; John E.; (Atlanta,
GA) ; Hargrave; Steven E.; (Roswell, GA) |
Correspondence
Address: |
GARDNER GROFF GREENWALD & VILLANUEVA. PC
2018 POWERS FERRY ROAD, SUITE 800
ATLANTA
GA
30339
US
|
Assignee: |
CMI LIMITED COMPANY
Atlanta
GA
|
Family ID: |
40897802 |
Appl. No.: |
12/360430 |
Filed: |
January 27, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61024395 |
Jan 29, 2008 |
|
|
|
Current U.S.
Class: |
52/169.13 ;
52/300; 52/309.1; 52/630; 52/741.13; 52/745.19 |
Current CPC
Class: |
E02D 29/0233 20130101;
E04D 3/405 20130101 |
Class at
Publication: |
52/169.13 ;
52/630; 52/300; 52/741.13; 52/745.19; 52/309.1 |
International
Class: |
E02D 29/02 20060101
E02D029/02; E04C 2/32 20060101 E04C002/32 |
Claims
1. A composite wall system comprising; a foundationless wall
substructure having a base portion embedded in the ground and an
exposed portion not embedded in the ground; and a panelized fascia
attached to the foundationless wall substructure over at least the
exposed portion thereof.
2. The composite wall system of claim 1, wherein the foundationless
wall substructure comprises a sheet piling wall.
3. The composite wall system of claim 2, wherein the sheet piling
Wall comprises a plurality of vinyl pile members.
4. The composite wall system of claim 2, wherein the sheet piling
wall has a substantially continuous outer surface.
5. The composite wall system of claim 2, wherein the sheet piling
wall comprises metal pile members.
6. The composite wall system of claim 1, wherein the foundationless
wall substructure comprises at least one concrete wall panel.
7. The composite wall system of claim 1, wherein the panelized
fascia comprises a simulated stonework outer surface.
8. The composite wall system of claim 1, wherein the panelized
fascia comprises a simulated brickwork outer surface.
9. The composite wall system of claim 1, wherein the panelized
fascia is applied only to the exposed portion of the foundationless
wall substructure.
10. The composite wall system of claim 1, further comprising a cap
member for attachment over upper edges of the exposed portion of
the foundationless wall substructure and the panelized fascia.
11. The composite wall system of claim 10, wherein the cap member
comprises a simulated stonework outer surface.
12. The composite wall system of claim 10, wherein the cap member
comprises a simulated brickwork outer surface.
13. The composite wall system of claim 1, further comprising a
lug-and-slot coupling system for attaching the panelized fascia to
the foundationless wall substructure.
14. The composite wall system of claim 1, further comprising a
starter strip affixed to the foundationless wall substructure
beneath the panelized fascia.
15. The composite wall system of claim 1, wherein the panelized
fascia comprises a plurality of fascia modules, each fascia module
comprising an upper portion and a lower portion, the upper and
lower portions being partially horizontally offset from one another
and joined at a medial portion, such that adjacent fascia panel
modules combine to form a substantially continuous surface.
16. A composite wall system comprising: a sheet-piling substructure
comprising a plurality of elongate pile members, each pile member
having at least one engagement member for connection with an
adjacent pile member; and a fascia panel for application over at
least a portion of the sheet-piling substructure, the fascia panel
having an inner face for attachment to the sheet-piling
substructure, and a decorative outer face.
17. The composite wall system of claim 16, wherein the elongate
pile members comprise a synthetic polymer material.
18. The composite wall system of claim 16, wherein the elongate
pile members comprise metal.
19. The composite wall system of claim 16, wherein the elongate
pile members define a substantially continuous attachment surface
for attachment of the inner face of the fascia panel thereto.
20. The composite wall system of claim 16, wherein the fascia panel
comprises a synthetic molding.
21. The composite wall system of claim 16, further comprising a cap
member for engagement over a top portion of the sheet-piling
substructure and the fascia panel, the cap member having a
decorative outer face.
22. The composite wall system of claim 16, further comprising a
lug-and-slot coupling system for attaching the fascia panel to the
sheet-piling substructure.
23. The composite wall system of claim 16, further comprising a
starter strip for attachment to the sheet-piling substructure below
the fascia panel.
24. The composite wall system of claim 16, wherein the fascia panel
comprises a plurality of modules, each module comprising an upper
portion and a lower portion, the upper and lower portions being
partially horizontally offset from one another and joined at a
medial portion, such that adjacent modules combine to form a
substantially continuous surface.
25. A cap member for a composite wall system, said cap member
comprising an upper panel and a front panel, the upper panel and
the front panel each having an inner portion for engagement with a
substructure, and an outer portion comprising a decorative
surface.
26. The cap member of claim 25, further comprising a back panel,
wherein the front panel, the upper panel and the back panel combine
to form a generally U-shaped profile.
27. The cap member of claim 25, being at least partially formed of
concrete.
28. The cap member of claim 25 further comprising a reinforcing
flange within the concrete.
29. A method of fabricating a composite wall system, said method
comprising: driving at least one substructure member partially into
the ground, whereby the substructure member comprises an embedded
portion within the ground and an exposed portion above the ground;
and applying a panelized fascia over at least the exposed portion
of the at least one substructure member.
30. The method of claim 29, wherein the at least one substructure
member comprises a sheet piling wall.
31. A method of fabricating a composite wall system, said method
comprising: providing at least one substructure member having an
outer attachment surface; providing at least two types of fascia
panel, a first of the at least two types of fascia panel having a
first decorative appearance, and a second of the at least two types
of fascia panel having a second decorative appearance different
from the first decorative appearance; and selecting one of the at
least two types of fascia panel for attachment to the outer
attachment surface of the substructure member.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of U.S.
Provisional Patent Application Ser. No. 61/024,395 filed in the
United States Patent and Trademark Office on Jan. 29, 2008, which
is hereby incorporated herein by reference in its entirety for all
purposes.
TECHNICAL FIELD
[0002] The present invention relates generally to the field of
structural building elements, and more particularly to a composite
wall structure, methods of construction and use thereof, and
components for use therein.
BACKGROUND OF THE INVENTION
[0003] Various wall structures are utilized in the building and
construction trade. For example, retaining walls are often
constructed to resist lateral pressure and prevent movement of
earth behind the wall. Seawalls and dikes may be constructed to
prevent erosion of a shoreline, to break the force of waves, and/or
for aesthetic purposes. Barrier walls are used to restrict ingress
and egress, to mark boundaries, for security, and for various other
functional or decorative purposes. Traditionally, such wall
structures have been constructed of masonry materials including
brick, stone, block, and concrete, of wooden cross-tie members,
and/or of steel or other structural materials.
[0004] In many seawall and retaining wall applications, the soil is
not conducive to building with heavy stones or bricks. To build a
wall from these materials requires substantial excavation and a
foundational footing in order to support the vertical load. This is
expensive and time consuming in general, and in those applications
involving proximity to water, such as a seawall, it is generally
cost prohibitive. The soils underlying such applications are
typically very soft because of their water saturation. Softer soils
generally require a deeper and wider foundation which can increase
the cost exponentially. Furthermore, excavating and pouring
foundations underwater is an expensive and time-consuming process.
For these reasons, seawalls and retaining walls in the vicinity of
water are rarely constructed of stone, brick or other masonry
materials.
[0005] In the case of retaining walls not in the vicinity of water,
and which are typically supported by harder soils, decorative
materials such as stone or brick are often applied only as an
aesthetic facing on the wall, and are supported by a heavy concrete
sub-wall structure and foundation. Alternatively, simulated stone
molded panels, for example as shown in U.S. Pat. No. 6,726,864, may
be applied over a wall substructure of concrete or other structural
material(s). This manner of construction generally involves
significant labor and material expenses. Such walls typically
require a separate and substantial underlying foundation, commonly
of steel-reinforced poured concrete construction, as well as a high
degree of soil stability and compaction beneath and around the wall
structure to anchor and support the wall's weight.
[0006] Another alternative sometimes used to build retaining walls
is the geogrid and block construction system, wherein the geogrid
reinforces and stabilizes soil behind the wall. This technique
reduces the load on the face of the wall and allows for alternative
decorative surfaces and textures to be used. This construction
technique typically requires a foundation and it can be quite
costly to install the geogrid and blocks.
[0007] Further improvements have been made in the field of wall
structure construction. For example, sheet-piling walls and methods
of construction thereof, as shown for example in U.S. Pat. No.
7,059,807, U.S. Pat. No. 7,056,066, U.S. Pat. No. 7,025,539, U.S.
Pat. No. 6,575,667, U.S. Pat. No. 6,053,666, U.S. Pat. No.
6,033,155 and U.S. Pat. No. 6,000,883, have been developed. These
types of wall systems typically do not require a separate
foundation, as they are not nearly as heavy as walls of masonry or
most other more traditional materials of construction, and as they
derive considerable lateral support and stability from being
partially embedded into the ground. As a result, sheet-piling wall
systems are frequently utilized in seawall construction and other
applications in wet or otherwise unstable soils, and are generally
less expensive to construct as compared with walls of masonry and
many other traditional materials of construction.
[0008] Sheet-piling wall systems typically include a number of
interconnected elongate vertically-driven pile members, which
results in the walls having a corrugated or horizontally segmented
appearance. Consumers in the marketplace have come to accept this
somewhat utilitarian appearance as a necessary characteristic of
the wall's manner of construction. Moreover, the application of any
sort of decorative facing to a sheet-piling; seawall system would
heretofore have been considered counterintuitive to those of skill
in the art, as the corrugations or seams of a standard sheet-piling
wall could permit water and debris to collect in the spaces behind
the facing and could permit wave action to cause detachment of the
facing material.
SUMMARY OF THE INVENTION
[0009] In example embodiments, the present invention provides
improved wall systems and components therefor, and further provides
improved methods of constructing wall systems. Wall systems,
components and construction methods according to the present
invention are adaptable for use in various applications, including
for example, seawalls, dikes, piers, retaining walls, barrier
walls, and the like.
[0010] In one aspect, the present invention is a composite wall
system that includes a foundationless wall substructure having a
base portion embedded in the ground, and an exposed portion not
embedded in the ground. The composite wall system further includes
a panelized fascia attached to the foundationless wall substructure
over at least the exposed portion thereof.
[0011] Optionally, the foundationless wall substructure takes the
form of a sheet piling wall, a driven or jetted-in-place concrete
wall, vinyl pilings, fiberglass reinforced plastic (FRP) pilings,
steel pilings, wood, and/or other form of wall substructure
component(s) not requiring a separately formed foundation. The
fascia optionally takes the form of a synthetic molded panel having
a simulated stone work, simulated brick work, or other
aesthetically appealing outer surface.
[0012] In another aspect, the invention is a composite wall system
including a sheet-piling substructure incorporating a plurality of
elongate pile members, each pile member having at least one
engagement member for connection with an adjacent pile member. The
composite wall system also includes a fascia panel for application
over at least a portion of the sheet-piling substructure. The
fascia panel has an inner face for attachment to the sheet-piling
substructure, and a decorative outer face.
[0013] In still another aspect, the invention is a cap member for a
composite wall system, the cap member including an upper panel and
a front panel, the upper panel and the front panel each having an
inner portion for engagement with a substructure, and an outer
portion including a decorative surface.
[0014] In another aspect, the invention is a method of fabricating
a composite wall system. The method of the invention includes
driving at least one substructure member partially into the ground,
whereby the substructure member defines an embedded portion within
the ground and an exposed portion above the ground. The method of
the invention further includes applying a panelized fascia over at
least the exposed portion of the at least one substructure
member.
[0015] In yet another aspect, the invention is a method of
designing and/or fabricating a composite wall system. The method of
the invention includes providing at least one substructure member
having an outer attachment surface, and providing at least two
types of fascia panel. A first of the at least two types of fascia
panel has a first decorative appearance, and a second of the at
least two types of fascia panel has a second decorative appearance
different from the first decorative appearance. The method of the
invention further includes selecting one of the at least two types
of fascia panel for attachment to the outer attachment surface of
the substructure member.
[0016] These and other aspects, features and advantages of the
invention will be understood with reference to the drawing figures
and detailed description herein, and will be realized by means of
the various elements and combinations particularly pointed out in
the appended claims. It is to be understood that both the foregoing
general description and the following brief description of the
drawings and detailed description of the invention are exemplary
and explanatory of preferred embodiments of the invention, and are
not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view, in partial cutaway, showing a
composite retaining wall system according to an example embodiment
of the present invention.
[0018] FIG. 2 is a cross-sectional view showing a composite seawall
system according to another example embodiment of the present
invention.
[0019] FIG. 3 is a cross-sectional view showing a composite pier
wall and walkway system according to an example embodiment of the
present invention.
[0020] FIGS. 4 and 5 show sectional views of composite wall systems
and wall cap components according to example embodiments of the
present invention.
[0021] FIG. 6 is a cross-sectional view of a composite wall system
according to another example embodiment of the present
invention.
[0022] FIG. 7 is a front view showing the exposed face of a
composite wall system according to another example embodiment of
the present invention.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0023] The present invention may be understood more readily by
reference to the following detailed description of the invention
taken in connection with the accompanying drawing figures, which
form a part of this disclosure. It is to be understood that this
invention is not limited to the specific devices, methods,
conditions or parameters described and/or shown herein, and that
the terminology used herein is for the purpose of describing
particular embodiments by way of example only and is not intended
to be limiting of the claimed invention. Any and all patents and
other publications identified in this specification are
incorporated by reference as though fully set forth herein.
[0024] Also, as used in the specification including the appended
claims, the singular forms "a," "an," and "the" include the plural,
and reference to a particular numerical value includes at least
that particular value, unless the context clearly dictates
otherwise. Ranges may be expressed herein as from "about" or
"approximately" one particular value and/or to "about" or
"approximately" another particular value. When such a range is
expressed, another embodiment includes from the one particular
value and/or to the other particular value. Similarly, when values
are expressed as approximations, by use of the antecedent "about,"
it will be understood that the particular value forms another
embodiment.
[0025] With reference now to the drawing figures. Wherein like
reference numbers represent corresponding parts throughout the
several views. FIG. 1 shows a section of a retaining wall system 10
according to an example form of the invention. The wall system 10
comprises a foundationless substructure in the form of a sheet
piling wall wherein a plurality of interconnected elongate pile
members 12 are driven into the ground 14, such that they define a
base portion embedded in the ground and an exposed portion not
embedded in the ground. In the depicted embodiment, the elongate
pile members 12 comprise plastic sheet pile members formed of
polyvinyl chloride, polypropylene, polyethylene and/or other
suitable synthetic or polymeric material(s). In alternate forms,
the foundationless substructure comprises pile members or panels
formed of steel, aluminum or other metal(s), concrete, wood,
fiber-reinforced plastic (FRP), and/or various other substantially
rigid construction material(s).
[0026] In the depicted embodiment, each elongate pile member 12
includes a male connection member or flange along its first lateral
side, and a female connection member or channel along its second
lateral side, for inter-engaging connection with cooperative
connection members of adjacent elongate pile members, to provide
the wall with improved structural integrity. In example forms, the
elongate pile members 12 comprise a generally planar front face,
whereby the interconnected pile members form a sheet piling wall
having a substantially continuous and smooth outer surface 16. In
alternate forms, the pile members define an angulated channel
cross-sectional configuration, forming a corrugated wall surface.
One or more anchor bars 20 optionally extend through the elongate
pile members for engagement with one or more layers of geogrid
sheet(s) through which the anchor bars are interlaced, to reinforce
and anchor the wall substructure.
[0027] The retaining wall 10 further comprises at least one
panelized fascia 30 attached to the outer surface 16 of at least
the exposed portion of the wall substructure. In example forms, the
fascia panel 30 is a sheet-like or strip-like synthetic molding or
extrusion formed of polymeric, ceramic, masonry, and/or composite
material(s), and having a simulated stone, brick, or other
aesthetically appealing outer surface contour and texture. In
example forms, the outer face of each fascia panel 30 presents the
appearance of a plurality of individual stones, bricks, or other
separate building component units. The fascia panel(s) 30 is/are
affixed to the underlying wall substructure in a permanent or
semi-permanent manner, such as for example by adhesive, connection
strips, screws, clips, integrally formed engagement members, and/or
other fasteners or attachment means. In larger applications, a
plurality of fascia panel elements 30 are applied to the underlying
wall substructure in an array of interlaced or adjacently arranged
elements. Optionally, one or more natural or synthetic bumpers or
wale members 40 is/are affixed to the wall substructure, to the
fascia panel 30, or are integrally formed as part of the fascia
panel. A starter strip, flashing, or other sealing means is/are
optionally provided at the upper and/or lower edges of fascia panel
element(s) 30, and/or at interfaces between the fascia panel
element(s) and other components such as bumpers or wales, to
prevent debris and/or wave action from entering between the fascia
panel element(s) and the underlying wall substructure. Additionally
or alternatively, the inner faces of the fascia panel element(s) 30
and/or the sealing means have surface profiles contoured to match
the corrugations or channels of the underlying wall substructure to
prevent debris and/or wave action from entering therebetween.
[0028] The retaining wall 10 optionally further comprises a cap
member 50 overlying and affixed onto the upper end of the wall
substructure 12 and/or the fascia panel 30. In example forms, the
cap member 50 comprises a generally C-shaped or U-shaped molding or
extrusion optionally including a metal or plastic inner reinforcing
flange 52 and having a concrete or composite outer cladding 54
providing a simulated stone or masonry surface appearance. The cap
member 50 can be affixed to the underlying wall elements, such as
for example by adhesive or fasteners, or alternatively can comprise
an internal configuration that mates with cooperatively shaped
components of the underlying wall elements to secure the cap member
in place. Optionally, the cap member 50 functions as a connection
member, engaging portions of the wall substructure 12 and the
fascia panel 30 to connect the two together, and/or to prevent
debris or water from entering therebetween.
[0029] FIG. 2 shows a section of a seawall system 110 according to
another embodiment of the present invention. The seawall system 110
comprises a wall substructure 112, one or more fascia panels 130a ,
130b , and a bumper or wale 140, in similar fashion to those
corresponding elements of the above described embodiment.
Optionally, a tie rod 144 anchors the wall system 110 into the
ground or to an adjacent anchoring body (unshown). An upper cap
member 150 comprises a back panel 152, a top panel 154, a front
panel 156 and a lower lip 158, to define a generally C-shaped
molding or extrusion of concrete or composite material presenting a
decorative outer surface texture and appearance. Optionally, the
wall substructure includes a top sill plate 160 and/or an
attachment rail 162, formed for example of pressure treated lumber
or composite material, onto which the cap member 150 is
affixed.
[0030] FIG. 3 shows a cross-sectional detail of a pierwall system
210 according to another embodiment of the present invention. The
wall system 210 comprises a wall substructure 212 and one or more
fascia panels 230a , 230b , in similar fashion to those
corresponding elements of the above described embodiments. The wall
system 210 includes front and back top sill plates 260a , 260b and
front and back rails 262a , 262b , formed for example of pressure
treated lumber or composite material. A cap member 250 formed of
concrete or composite material provides a walking surface along the
top of the pier wall system 210.
[0031] FIG. 4 shows a cross-sectional detail of a wall system 310
according to another embodiment of the present invention. The wall
system 310 comprises a wall substructure 312, one or more fascia
panels 330, and a cap member 350 in similar fashion to those
corresponding elements of the above described embodiments. FIG. 5
shows a similar wall system 410 having a wall substructure 412, and
an integrally formed cap member and fascia panel 470.
[0032] FIG. 6 shows a seawall or retaining wall 510 according to
another embodiment of the invention. A foundationless wall
substructure 512 is formed from one or more sheet piling members,
concrete panels, or other structural elements, and one or more
fascia panels are attached thereon (in the depicted embodiment,
upper and lower arrays of fascia panels 530a , 530b are applied
onto the wall substructure). An upper wale 540a and/or a lower (or
dropped) wale 540b are optionally also provided, extending
transversely and generally horizontally along at least a portion of
the wall's length. One or more tie rods 544a , 544b are optionally
installed through the wall substructure 512, the wales 540, the cap
550, and/or other wall component(s), to anchor and brace the wall
system into adjacent ground substrate or structure. In the depicted
embodiment, the cap 550 of the wall takes the form of a flat slab
or block extending transversely and generally horizontally over the
upper end of at least a portion of the wall's length. The cap 550
can be formed of natural stone, concrete, wood, and/or synthetic
material(s). Optionally, a wale fascia strip 575 is applied to
cover underlying wall elements or material transitions, for
decorative purposes and/or for resisting intrusion of debris and
wave action.
[0033] FIG. 7 shows a wall 610 according to another embodiment of
the invention. The underlying wall substructure comprises a
plurality of sheet piling members 616, each defining a retaining
slot 615, and optionally having a series of vertically spaced
receiver openings 617 therein. A starter strip 625 is affixed to
the sheet piling members 616 at about (or just below) the mean low
water level for seawall applications, and at about (or just below)
the soil level for retaining wall applications. A plurality of
fascia panel elements or modules 630 are affixed to the sheet
piling members 616 above the starter strip 625. Each of the fascia
panel modules 630 has a generally S-shaped or Z-shaped profile
comprising an upper rectangular portion and a lower rectangular
portion, the upper and lower rectangular portions being partially
horizontally offset from one another and joined at a medial
portion, such that adjacent fascia panel modules interlock or
combine to form a substantially continuous surface. Each fascia
panel module can include an outer face molded to present the
appearance of one or more stones, bricks, blocks or other building
components, and fascia panel modules having two or more
complementary patterns can be provided to present a more continuous
or evenly distributed visual appearance (i.e., to break up or
disguise the repeating pattern of the fascia modules). The starter
strip may include sealing means for preventing debris and/or water
from entering between the sheet piling members and the fascia panel
modules, can provide a horizontal reference line for alignment of
the first course of fascia panel modules during installation,
and/or can provide attachment between the fascia panel modules and
the sheet piling members. A cap member 650 is optionally provided
along the upper ends of the sheet piling members 616. The fascia
panel modules 630, and optionally also the starter strip 625, are
affixed to the sheet piling members 616 by mounting lugs 635
projecting from the back faces of the fascia panel modules. The
lugs 635 are engaged and retained in the retaining slot 615 by
means of interengaging male and female profiles. In alternate
forms, the lug-and-slot coupling system is reversed, with the lugs
comprising projections from the sheet piling members or other wall
substructure, and the slots being formed in the fascia panel(s). In
assembling the wall 610, the sheet piling members 616 are driven
into the ground in typical fashion. The starter strip 625 is
installed onto the sheet piling members at the desired level, for
example at a true horizontal. The fascia panel modules 630 are
attached by inserting the lugs 635 into the slots 615, as by
sliding the fascia panel modules down from the top of the sheet
piling members, or by insertion of the lugs into receiver openings
617 (if provided) near the desired point of attachment and sliding
them up or down in the slots for final placement. Additional
attachment may optionally be provided between the fascia panel
modules and the sheet piling members, for example by means of
adhesive, screws or other fasteners, clips, integral snap
couplings, or the like. The cap member 650 may be engaged by one or
more couplings or other attachment means, to prevent upward
movement and possible detachment of the fascia panel modules.
[0034] In its various example embodiments, the composite wall
system of the present invention may be fabricated by driving one or
more substructure members partially into the ground. In example
forms, the substructure members take the form of sheet piling
members or wall panel components. An embedded portion of the wall
substructure serves to anchor the wall in the ground and resist
lateral forces. An exposed portion of the wall substructure extends
a distance above the ground. Anchor bars and/or tie rods may be
installed to reinforce the wall substructure. One or more panelized
fascia members are then applied over at least the exposed portion
of the wall substructure. In example forms, the panelized fascia
members take the form of sheet-like or strip-like synthetic
moldings or extrusions formed of polymeric, ceramic, masonry,
and/or composite material(s), and having a simulated stone, brick,
or other aesthetically appealing outer surface contour and texture.
The fascia members can be affixed to the underlying wall
substructure by adhesive, connection strips, screws, clips,
integrally formed engagement members, and/or other permanent or
semi-permanent fasteners or attachment means. Optionally, one or
more bumpers or wale members are affixed to the wall substructure,
to the fascia panel, or are integrally formed as part of the fascia
panel. A cap member is optionally installed over the top of the
wall substructure and panelized fascia members, and in example
embodiments serves as an attachment mechanism to join the
substructure and fascia and/or serves to prevent water or debris
from entering therebetween.
[0035] The invention also includes methods of designing and
fabricating composite wall systems, wherein multiple different
types of fascia panels are provided for attachment to an outer
attachment surface of underlying substructure members. For example,
a first type of fascia panel can comprise an outer surface having a
first decorative appearance in the form of simulated stonework, and
a second type of fascia panel can comprise an outer surface having
a second decorative appearance in the form of simulated brickwork.
Alternatively, the first and second decorative appearances can be
stonework or brickwork of differing colors, differing tones,
differing geometric configurations or sizes, differing textures, or
various other differing decorative appearances. The first and
second types of fascia panels, however, will both be compatible for
attachment to the common shared form of underlying wall
substructure elements. A designer will then specify or select one
or more of the multiple different types of fascia panels for
attachment to the wall substructure. The design and fabrication
methods according to the present invention can optionally further
comprise the provision of different types of cap members, each type
having a differing outer surface appearance; the provision of
different types of bumper or wale members, each type having a
differing outer surface appearance; and/or the provision of
different types of other wall system components, each type having a
differing outer surface appearance, whereby the designer specifies
or select one or more of the different types of wall system
components for attachment to the wall substructure.
[0036] While the invention has been described with reference to
preferred and example embodiments, it will be understood by those
skilled in the art that a variety of modifications, additions and
deletions are within the scope of the invention, as defined by the
following claims.
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