Lightweight concrete or masonry fence system with optional concrete footings
10422156 ยท 2019-09-24
Assignee
Inventors
Cpc classification
E04H17/009
FIXED CONSTRUCTIONS
E04H17/1602
FIXED CONSTRUCTIONS
E04H17/1447
FIXED CONSTRUCTIONS
E04H17/1404
FIXED CONSTRUCTIONS
International classification
Abstract
Column and panel concrete fence systems and related methods of construction. Such a method may include placing posts into respective concrete footings, and attaching a 4-arm bracket to each post. The concrete column may be provided in two initially separate portions e.g., each corresponding to a front or back face of the fence. One of the portions (e.g., corresponding to the front or back of the fence) is attached to a given post, supported on one lateral arm of each bracket. The concrete panel may then be advanced into place, and the other portion of the column is attached to the post, over the first column portion that was already attached to the post. The 2.sup.nd portion of the concrete panel is supported on the other lateral arm of the brackets. The panel itself is supported on a middle arm of the bracket, between the lateral column-supporting arms.
Claims
1. A method for constructing a column and panel concrete fence, the method comprising: (i) placing a plurality of posts into a concrete footing; (ii) attaching a bracket to each post, the bracket being positioned above the concrete footing so as not to make contact with the footing; (iii) attaching a first portion of a concrete column to each post; (iv) placing a concrete panel on the brackets of adjacent posts such that a first end of the panel is supported on the bracket of one post and a second end of the panel is supported on the bracket of the adjacent post so that a weight of the panel is completely supported on the brackets; and (v) attaching a second portion of each concrete column to a corresponding post; wherein the bracket is + shaped, with 4 arms, where 3 of the arms are coplanar, all in a horizontal plane, and the 4th arm is disposed at a 90 upward angle relative to the horizontal plane defined by the 3 coplanar arms.
2. A method as recited in claim 1, wherein the first end of the concrete panel overlaps part of the first portion of the concrete column at a given post, and wherein the second end of the concrete panel overlaps part of the first portion of the concrete column at the adjacent post.
3. A method as recited in claim 1, wherein (iii) and (iv) are performed prior to (v).
4. A method as recited in claim 1, wherein the first portion of the column is screwed into the post.
5. A method as recited in claim 1, wherein the second portion of the column is screwed into the post.
6. A method as recited in claim 1, wherein the bracket is screwed into the post.
7. A method as recited in claim 1, wherein each of the concrete panels is monolithic.
8. A method as recited in claim 1, wherein each concrete panel is lightweight, including a foam core.
9. A method as recited in claim 1, wherein the method does not rely on the concrete footings being level or at a particular height to ensure the concrete panel is level.
10. A method for installing a column and panel concrete fence, the method comprising: placing a plurality of posts in a concrete footing; attaching a bracket to each post above the concrete footing so that the bracket does not make contact with the concrete footing, there being a space between a top of the concrete footing and the bottom of the bracket; attaching a first portion of a concrete column to each post, the first portion of the concrete column corresponding to a front or rear face of the fence; placing a lightweight concrete panel on the brackets of adjacent posts such that a first end of the panel is supported on the bracket of one post and a second end of the panel is supported on the bracket of the adjacent post so that a weight of the panel is completely supported by the brackets; and attaching a second portion of each concrete column to a corresponding post at a location on the post opposite the first portion of the concrete column, the second portion of the concrete column corresponding to the other of the front or rear face of the fence; wherein the bracket is + shaped, with 4 arms, where 3 of the arms are coplanar, all in a horizontal plane, and the 4th arm is disposed at a 90 upward angle relative to the horizontal plane defined by the 3 coplanar arms.
11. A method as recited in claim 10, wherein each lightweight concrete panel is configured so that an approximately 9 foot long panel having a height of 6 feet weighs no more than 500 lbs.
12. A method as recited in claim 10, wherein the space between a top of the concrete footing and the bottom of the bracket is at least 1 inch.
13. A column and panel concrete fence comprising: a plurality of posts each positioned in a respective concrete footing; a concrete column attached to each post, each column including two portions which are separated from one another, and correspond to front and rear faces of the fence, respectively; a lightweight concrete panel, a first end of the panel being positioned atop a first bracket attached to one of the plurality of posts at a location such that the first bracket is above its respective concrete footing, with a space between a top of the respective concrete footing and the bottom of the bracket, such that the first end of the panel extends between the portions of the column and a second end of the panel being positioned atop a second bracket attached to an adjacent one of the plurality of posts at a location such that the second bracket is above its respective concrete footing, with a space between a top of the respective concrete footing and the bottom of the second bracket, such that the second end of the panel extends between the portions of the column attached to the adjacent post; wherein the brackets do not make contact with the footing so that the weight of the panel is completely supported by the brackets; wherein the brackets are + shaped, with 4 arms, where 3 of the arms are coplanar, all in a horizontal plane, and the 4th arm is disposed at a 90 upward angle relative to the horizontal plane defined by the 3 coplanar arms.
14. A fence as recited in claim 13, wherein each lightweight concrete panel includes a foam core.
15. A fence as recited in claim 13, wherein each of the concrete panels is precast as a monolithic single piece.
16. A fence as recited in claim 13, wherein the first and second portions of the concrete column are each screwed into the post.
17. A fence as recited in claim 13, wherein each lightweight concrete panel is configured so that an approximately 9 foot long panel having a height of 6 feet weighs no more than 500 lbs.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1) The drawings illustrate several embodiments of the invention, wherein identical reference numerals refer to identical or similar elements or features in different views or embodiments shown in the drawings.
(2)
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(9) I. Introduction
(10) The present invention is directed to concrete panel and column fence systems, as well as methods for installing such fence systems. For example, the fence systems and methods provide for installation of a concrete panel and concrete column fence, which provides desired aesthetic and other benefits. In some embodiments, the present fence system can be installed without requiring the use of any concrete footings, or the excavation typically associated with such footing preparation. In other embodiments, footings may be used, although the light weight panels are not supported on the footing, and do not contact the footing. As such, it is typically not necessary to ensure that such footings are perfectly level or at a particular height. For example, there may be a space between the bottom of the bracket and the top of the footing, e.g., such as at least 1 inch (e.g., from 1 inch to 10 inches, or more).
(11) II. Exemplary Fence Systems and Methods of Installation
(12)
(13) The fence 100 thus includes columns 104 on either side of each panel 106, with adjacent columns being separated by the intervening panel. Where multiple panels are included, the panels are aligned end-to-end, with a column positioned at the respective ends of the two adjacent panels. The ends of the two panels do not need to contact one another, but will typically be spaced apart from one another by at least the width of the post 102. For example, the ends of each panel may abut and contact (or nearly contact) the corresponding post on which the bracket supporting that end of the panel is attached. As seen in
(14) By way of example, where the posts 102 and columns 104 are spaced 9 feet apart from one another, center to center, the panel itself may be somewhat less than 9 feet in width, e.g., about 101 inches, leaving a small gap between the ends of adjacent panels, with the post 102 disposed therebetween.
(15) Posts 102 may be driven into the ground (e.g., dirt) 116, without requiring excavation. In another embodiment, posts may be positioned in footings 117, securing them in place. Each post 102 may include its own discrete footing, as shown. Because the fence panels are not supported or leveled on such footings, it is not required that such footings be particularly level, or at a particular height to ensure that the panel is level. This is so because the panel will be fully supported on a bracket, which will simply be screwed into post 102, at a desired height, and which attachment is forgiving, e.g., if misplacement occurs and replacement of the bracket (to level the panel) is needed.
(16) In conventional construction, concrete footings are needed for such concrete panel and column fences, because of the great weight of the concrete panels, which may easily weigh in excess of 3,000 lbs each. A suitable foundation for supporting such a massive load must be provided, which is provided by the typical concrete footing. Pouring of such concrete footings is particularly time consuming and labor intensive, because of the need to ensure that such footings are level and at the proper height.
(17) For example, the crew may come and form the footings the first day, and leave, returning the next day after the footings have hardened. The second day they can then place the concrete columns and panels and fill the void within the center of each column (e.g., which includes rebar running vertically up from the footing below) with concrete (i.e., grouting the column). Throughout this process, the panels and/or columns may require bracing until the concrete poured within the column has been allowed to harden. As will be apparent, this may typically require the installation crew to return again a third day once the grouted columns have hardened, as only then can the bracing be removed. In some embodiments, no bracing is required with the present embodiments, as grouting of columns is not required (although such is possible, if one so desired).
(18) When pouring such conventional concrete footings, it is important that the top of the footing be level (as the panel will be resting thereon), and that it be at the proper height, so that the panels are each at a desired height. While stair stepping of the panels may be desired where installing the fence on a slope, generally, it is desired that the top of each panel be at the same height, so that the fence looks right (i.e., square and plumb). If care is not taken in pouring the concrete footings, the footings may be at different heights, where it is intended that they be at the same height, resulting in the top end of the fence as defined by the panels being uneven from panel to panel (i.e., it goes up and down, where such is not intended). Where the concrete footings are not at the proper height or are not level, this can require shaving or cutting away the top surface of the footing, or build up of a footing that is too short with specially formulated concrete capable of acceptable adhesion between the old and new concrete. Needless to say, such adjustments are time consuming, labor intensive, and add substantially to the cost of a project. Because the present embodiments do no rely on the panel resting on the concrete footing, it does not matter if the footings are not level, or are filled to different heights. Such characteristic greatly simplifies the installation process.
(19) In some embodiments, no concrete footings may be used, but the posts may rather simply be driven into the compacted ground. Even in such an embodiment where one may wish to avoid use of concrete footings, a user may choose to use a concrete footing where the post might require placement at a location where it cannot readily be driven into the ground. An example of such an instance may be where the post must be placed in very rocky ground, where it may not be possible to pound or otherwise drive the post into the ground.
(20) In any case, even if the posts are installed in a concrete footing, the footing is not required for column and panel support in the same way that such is required with a typical concrete panel and column fence. The footing is not required to support any massive load of the fence itself, but merely (in some circumstances) to secure the post itself in place. Even in such instances, the load is supported on the bracket attached to the post, not on the concrete footing. Because the load does not rest directly on the footing, it is not necessary to ensure that the footings are poured to be at a particular level from one footing to the next, nor is it required to ensure that the footings are level or smooth across their top face (e.g., an uneven bumpy surface is fine).
(21) The presently disclosed fence system and method employs an alternative mechanism for supporting the fence structure (columns and panels) that reside above ground. Because the present fence system employs lightweight concrete panels, the panels weight far less than a similarly dimensioned solid concrete panel. For example, as shown in
(22) The columns may be formed from solid precast concrete, as their size is relatively small in comparison to that of the panels. Also, since the column is provided in two halves, the weight is further reduced to approximately 100 lbs. In another embodiment, the columns could be constructed with a lightweight foam core, surrounded by a relatively thin shell of concrete, similar to the panels. The thin shell of concrete and/or the concrete of the columns may be fiber reinforced, so as to provide the desired level of strength. The lightweight concrete fence system provides the aesthetic beauty characteristics of concrete (e.g., mimicking stone), providing weatherability and durability characteristics far greater than those available from plastic and wood fencing systems. Yet, because of the lightweight characteristics, installation and cost is much easier and lower cost as compared to traditional solid precast concrete panels.
(23) Because the concrete panels are lightweight (e.g., showing about a 90% reduction in weight as compared to a similarly sized solid concrete panel), requirements for supporting the load of the panels is significantly different than when working with solid concrete panels. For example, the fence system may have a weight load of only about 400 lbs per post location, as compared to thousands of pounds (e.g., 4,000 lbs or more may be typical) per similar location (i.e., the concrete footing) associated with a traditional concrete fence system. Because of the much lower load characteristics, it is possible to replace the traditionally employed concrete footing support mechanism with a system of posts and brackets attached to the posts, on which the concrete panels and column portions are supported.
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(25) Both the panels and column portions may be precast, monolithic (single piece) in structure, providing for quick, easy, and inexpensive construction or assembly of the fence on site.
(26) Each post 102 may be a rectangular cross-sectioned hollow post, as shown in
(27) As shown in
(28) While bracket 110 is shown as being substantially + shaped, with 4 outwardly extending arms, each about 90 apart, it will be appreciated that any bracket configured to support the panel may be suitable for use. As shown, 3 of the 4 arms may be coplanar, while one of the arms of bracket 110 is shown being disposed at a 90 upward angle relative to the horizontal plane defined by the other arms. As shown in
(29) Arm 110b opposite arm 110a may extend towards the next, adjacent post 102. The panel may be supported on arm 110b of the bracket 110, e.g., with one end 108 of the panel 106 supported on arm 110b of bracket 110 (e.g., attached to the center post seen in
(30) As is apparent from the Figures, brackets 110 are positioned along a height of each post 102, not at an end of post 102. For example, brackets 110 are positioned to be above a top surface of the ground, or the concrete footing 117, so as to provide a space (e.g., at least 0.5, or at least 1 inch) therebetween. In this way the weight of panel 106 and columns 104 are not supported on the footing, but entirely on the arms of bracket 110.
(31) The bracket 110 may be attached to the respective post 102 as shown, with the bracket not extending about the post, but attached at only one side thereof (e.g., oriented towards the next, adjacent post), to support a panel extending between such posts. The arms between arm 110a and 110b extend laterally outward, orthogonally from the vertical plane defined by the fence panel 106. Such lateral arm extensions support the column portions 104a and 104b, respectively.
(32) As will be apparent from the center post 102 of
(33) As shown in
(34) When placing the post 102, it is desired to ensure that the post does not tilt towards one adjacent post or the other. Small tilting of the post 102 in the front or rear direction of the fence can be accommodated by shimming the column portions when attaching the column portions to the post, should such occur. When placing the first column portion 104a, the installer can ensure that first column portion 104a is plumb, and a shim may be positioned between the post and column portion 104a to make appropriate accommodation, if needed. The second column portions may similarly be shimmed, if desired (or a gap may be present between the second column portion 104b and the corresponding post 102, depending on circumstances). Thus, minor plumb issues may be compensated for by shimming at least one of the column portions as needed, so that the column 104 (which is seen) is plumb, even though the underlying post 102 (which is hidden, and typically embedded in the concrete footing 117) may not be exactly plumb.
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(36) Referring to
(37) The panels 106 may not contact any present concrete footing. Similarly, the columns 104 may not contact any concrete footing. Rather, the entire load is supported by the brackets (e.g., and screws or other attachment mechanism).
(38) Caps 114 may be provided over columns 104 by any suitable mechanism (e.g., they may simply be laid thereover, or may be attached to column 104 by screws or other mechanism, if desired). At an end of a fence line, any gap between column portions 104a, 104b (which would normally be covered by a panel 106) may be filled or otherwise covered, as desired. In an embodiment, concrete fillers are added at the end of a column to replace the panel.
(39) While
(40) Because the posts are positioned in the ground (e.g., footing) before the load of the panels is applied thereto, no bracing of the fence structure, or clamping of the column portions is required, as is normally provided during initial placement of the panel, and during grouting of the columns, and before the grout in the columns has had sufficient time to harden. As described above, once both column portions are attached to the post, the panel is fully supported. The time required to install such a fence system is significantly less than that required to install a similar fence (even a light weight panel one), where concrete footings are relied on for providing proper leveling characteristics to the panel supported thereon.
(41) The fence system may be formed as a single wall structure, as shown, as opposed to the double wall structures described in U.S. Publication No. 2011/0197533. In other words, the entire fence has a thickness defined by the thickness of a single lightweight panel, rather than being a double wall structure as disclosed in the foregoing application.
(42) While described principally in the context of concrete panels and columns, it will be appreciated that other cement or other masonry materials may similarly be employed, while providing similar benefits. In addition, while the panels and columns in an embodiment may both comprise concrete, it will be appreciated that in another embodiment, at least one thereof may comprise a material other than concrete (e.g., masonry). For example, in an embodiment, the fence system could comprise a concrete panel, and the columns may comprise another material (e.g., masonry, another material, etc.). As such, for simplicity, the term concrete as used herein is to be broadly construed to include concrete, as well as other cementitious materials, and masonry, where they provide similar weatherability characteristics.
(43) Numbers, percentages, or other values stated herein are intended to include that value, and also other values that are about or approximately the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing process, and may include values that are within 25%, within 20%, within 10%, within 5%, within 1%, etc. of a stated value. Furthermore, the terms substantially, similarly, about or approximately as used herein represents an amount or state close to the stated amount or state that still performs a desired function or achieves a desired result. For example, the term substantially about or approximately may refer to an amount that is within 25%, within 20%, within 10% of, within 5% of, or within 1% of, a stated amount or value.
(44) Ranges between any values disclosed herein are contemplated and within the scope of the present disclosure (e.g., a range defined between any two values (including end points of a disclosed range) given as exemplary for any given parameter).
(45) As used in this specification and the appended claims, the singular forms a, an and the include plural referents unless the context clearly dictates otherwise.
(46) All publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference.
(47) The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.