Concrete Section and Method for Constructing a Wall

Abstract

A concrete section and method for constructing a wall includes first and second concrete sections identically configured and dimensioned to allow the entire concrete wall to be constructed via one concrete section design, thereby minimizing labor time and parts. The single design for all concrete sections for constructing a concrete wall is achieved by vertically offsetting corresponding and oppositely disposed first and third locking fingers; and vertically offsetting corresponding and oppositely disposed second and fourth locking fingers. First and second locking finger receiving recesses are also vertically offset to horizontally align a first recess of a second concrete section with a fourth locking finger of a first concrete section; and to horizontally align a second recess of a first concrete section with a first locking finger of a second concrete section. All horizontal alignment occurs when the bottom walls of the first and second concrete sections are coplanar orientated, thereby promoting the snug joining of a locking finger with a cooperating recess.

Claims

1. A method for securing adjacent concrete sections together to construct a wall, said method comprising the steps of: providing a first concrete section comprising: front and back substantially planar walls; a first side portion having a first locking finger with a first vertical aperture; a first side portion having a second locking finger with a second vertical aperture, said first and second locking fingers being vertically separated a predetermined distance that forms a first recess; a second side portion having a third locking finger with a third vertical aperture; and a second side portion having a fourth locking finger with a fourth vertical aperture, said third and fourth locking fingers being vertically separated a predetermined distance that forms a second recess; providing a second concrete section comprising: front and back substantially planar walls; a first side portion having a first locking finger with a first vertical aperture; a first side portion having a second locking finger with a second vertical aperture, said first and second locking fingers of said second concrete section being vertically separated a distance that forms a first recess that promotes the snug insertion of said first locking finger of said second concrete section into said second recess of said first concrete section; a second side portion having a third locking finger with a third vertical aperture; and a second side portion having a fourth locking finger with a fourth vertical aperture; positioning said first and second concrete sections to ultimately form a predetermined configuration for a concrete wall; forcibly urging said first locking finger of said second concrete section into said second recess in said first concrete section, and simultaneously urging said fourth locking finger of said first concrete section into said first recess in said second concrete section; vertically and axially aligning said third and fourth vertical apertures of said first concrete section with said first and second vertical apertures of said second concrete section; inserting a stabilizing rod through said vertically and axially aligned third and fourth apertures of said first concrete section and said vertically and axially aligned first and second apertures of said second concrete section; and injecting a binding agent into said aligned apertures of said second end portion of said first concrete section and said first end portion of said second concrete section with said stabilizing rod inserted through said aligned apertures, whereby, after said binding agent hardens, said stabilizing rod and said second end portion of said first concrete section and said first end portion of said second concrete section are rigidly secured together, thereby maintaining the relative positions of said first and second concrete sections when repeating the method to ultimately secure a quantity of concrete sections together that complete a concrete wall having a predetermined configuration and corresponding dimensions.

2. The method of claim 1 wherein said step of providing a first concrete section comprising a first end portion having a first locking finger with a first vertical aperture includes the step of disposing said first locking finger a predetermined distance below a top planar wall of said first concrete section such that a top planar wall of said first locking finger is parallel with said top planar wall of said first concrete section, and such that a bottom planar wall of said first locking finger is parallel with said top planar wall of said first locking finger, resulting in a substantially square configured first locking finger.

3. The method of claim 2 wherein said bottom planar wall of said first locking finger is parallel with a top planar wall of said second locking finger of said first end portion of said first concrete section, resulting in a substantially square configured first recess.

4. The method of claim 3 wherein said second locking finger includes a planar bottom wall that is coplanar with a bottom wall of said first concrete section, resulting in a substantially square configured second locking finger.

5. The method of claim 4 wherein said step of providing a first concrete section comprising a second end portion having a third locking finger with a third vertical aperture includes the step of disposing said third locking finger such that a top planar wall of said third locking finger is coplanar with said top planar wall of said first concrete section, and such that a bottom planar wall of said third locking finger is parallel with said top planar wall of said third locking finger, resulting in a substantially square configured third locking finger.

6. The method of claim 5 wherein said bottom planar wall of said third locking finger is parallel with a top planar wall of said fourth locking finger of said second end portion of said first concrete section, resulting in a substantially square configured second recess.

7. The method of claim 6 wherein said fourth locking finger includes a planar bottom wall that is parallel with said planar top wall of said fourth locking finger, resulting in a substantially square configured fourth locking finger, said planar bottom wall of said fourth locking finger being parallel with and disposed vertically above said bottom wall of said first concrete section.

8. The method of claim 1 for securing adjacent concrete sections together to construct a wall includes a second wall constructed parallel to and separated from a first wall to allow a binding agent to be disposed between and to engage a back surface of said first wall and a front surface of said second lineal wall to stabilize said first and second lineal walls after said binding agent hardens.

9. The method of claim 1 wherein said front walls of said first and second concrete sections include ornamental designs etched therein.

10. The method of claim 1 wherein said first and second concrete sections can be positioned and secured together from a lineal orientation to an angular orientation.

11. The method of claim 1 wherein said first and second concrete sections include a receiving recess in a top wall of each of said first and second concrete sections.

12. The method of claim 11 wherein said first and second concrete sections include a receiving recess in a top wall and a second locking finger that snugly inserts into said receiving recess in said top wall of a concrete section disposed beneath said second locking finger.

13. The method of claim 12 wherein said second locking finger includes a second vertical aperture that vertically aligns with an aperture in said receiving recess in said top wall of said concrete section, said aperture in said receiving recess extending vertically through said first and second concrete sections, said aperture in said receiving recess being axially aligned with vertically aligned apertures in cooperating fingers of first and/or second concrete sections disposed beneath said aperture in said receiving recess.

14. The method of claim 13 wherein said aperture in said receiving recess extending vertically through said first and second concrete sections ultimately receives a stabilizing bar and/or binding material that extends through said aperture in said receiving recess and said aligned apertures in said cooperating fingers of first and/or second concrete sections disposed beneath said aperture in said receiving recess, thereby increasing the vertical and horizontal stabilizing of a completed concrete wall after said stabilizing bar and/or said binding material is disposed into said aligned apertures extending from said top wall of a top tier of said concrete sections down to said bottom wall of a bottom tier of said concrete sections.

15. The method of claim 1 wherein said first and second concrete sections include a relatively large recess in said back planar wall of each of said first and second concrete sections, said recess having a depth defined by the transverse dimension of inner side walls of said recess that integrally join with a bottom wall of said recess.

16. The method of claim 15 wherein a mesh material with predetermined openings is secured across substantially the entire surface of a said bottom wall and across all inner side walls of said recess, said mesh material providing a binding element for polyurethane poured into the recess to maintain contact between the polyurethane as it hardens and said side and bottom walls of said recess.

17. A method for constructing a concrete wall, said method comprising the steps of: providing a first concrete section comprising: front and back substantially planar walls, said back planar wall having a relatively large recess therein for receiving a binding agent that ultimately hardens to form a relatively lightweight first concrete section; a first side portion having a first locking finger; a first side portion having a second locking finger, said first and second locking fingers being vertically separated a predetermined distance that forms a first recess; a second side portion having a third locking finger; and a second side portion having a fourth locking finger, said third and fourth locking fingers being vertically separated a predetermined distance that forms a second recess; providing a second concrete section comprising: front and back substantially planar walls, said back planar wall having a relatively large recess therein for receiving a binding agent that ultimately hardens to form a relatively lightweight second concrete section; a first side portion having a first locking finger; a first side portion having a second locking finger, said first and second locking fingers of said second concrete section being vertically separated a distance that forms a first recess that promotes the snug insertion of said first locking finger of said second concrete section into said second recess of said first concrete section; a second side portion having a third locking finger; and a second side portion having a fourth locking finger, said third and fourth locking fingers being vertically separated a predetermined distance that forms a second recess; positioning said first and second concrete sections to ultimately form a predetermined configuration for a concrete wall; and forcibly urging said first locking finger of said second concrete section into said second recess in said first concrete section, and simultaneously urging said fourth locking finger of said first concrete section into said first recess in said second concrete section; whereby, said end portion of said first concrete section and said first end portion of said second concrete section are secured together, thereby maintaining the relative positions of said first and second concrete sections when repeating the method to ultimately secure a quantity of concrete sections together that complete a concrete wall having a predetermined configuration and corresponding dimensions.

18. The method of claim 17 wherein a mesh material with predetermined openings is secured across substantially the entire surface of a said bottom wall and across all inner side walls of said recess, said mesh material providing a binding element for polyurethane poured into the recess to maintain contact between the polyurethane as it hardens and said side and bottom walls of said recess.

19. The method of claim 17 wherein said first and second concrete sections include vertical and/or horizontal stabilizing bars extending through said recesses in said back planar walls of said concrete sections before said polyurethane is poured into said recess, said stabilizing bars cooperating with vertically and horizontally adjacent concrete sections to secure adjacently disposed concrete sections together, thereby stabilizing the concrete wall during construction and after completion of the concrete wall.

20. The method of claim 17 wherein said recesses in said back planar walls of said first and second concrete sections includes multiple metal channels secured inside said recesses via a plurality of screws extending from a countersunk position below a top edge of said channels such that a threaded portion of said screws are disposed into a semi-solid concrete at a bottom portion of said recess, said semi-soled concrete ultimately hardening, thereby anchoring said screws into said concrete and anchoring said channels upon said hardened concrete, said anchored channels promoting the securing of said first and second concrete sections to vertically adjacent concrete sections.

21. The method of claim 17 wherein said front planar walls include horizontal ridges extending from said outer planar wall for receiving a binding material between said ridges such that said binding material applied to said ridges forms a substantially planar deformable wall that allows inner wall portions of concrete blocks to be manually impressed into said deformable wall, thereby displaying predetermined designs in outer walls of said concrete blocks.

22. The method of claim 17 wherein said front planar walls of said first and second concrete sections are precast in a mold by configuring said front planar walls when in a semi-solid state via engagement with a preselected form disposed beneath and in horizontal engagement with said front wall, said method providing an oil based liquid coating upon said preselected form to prevent damage to said front wall when separated from said preselected form after said front wall has hardened with a design impressed into said front wall that corresponds to said design of said preselected form.

23. A method for constructing a concrete wall from lightweight concrete sections, said method comprising the steps of: providing a plurality of rectangular configured concrete section having an outer front wall with a predetermined design, planar outer side walls, planar outer top and outer bottom walls, and an inner planar wall having a relatively large recess therein with a depth defined by the transverse dimension of planar inner side walls; securing a fiberglass mesh with substantially one-quarter inch square configured openings across a bottom wall and across said inner side walls of said recess, said fiberglass mesh providing a binding element for polyurethane poured into said recess to maintain contact between hardening polyurethane and said side and bottom walls of said recess; and installing vertical and/or horizontal stabilizing bars that extend through said concrete section before said polyurethane is poured into said recess in said inner planar wall; whereby, said vertical and/or horizontal stabilizing bars are covered by polyurethane that ultimately hardens to form a substantially planar wall flush with said inner planar wall, thereby providing stability to a constructed concrete wall assembled with a plurality of said concrete sections such that said vertical and/or horizontal stabilizing bars are joined to cooperating vertical and/or horizontal stabilizing bars of vertically and/or horizontally adjacent comparably fabricated lightweight concrete sections.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The foregoing invention and its advantages may be readily appreciated from the following Detailed description of the preferred embodiment, when read in conjunction with the accompanying drawings in which:

[0016] FIG. 1A is a front elevation view of a concrete section with locking side fingers in accordance with the present invention.

[0017] FIG. 2A is a top view of FIG. 1A.

[0018] FIG. 3A is a bottom view of FIG. 1A.

[0019] FIG. 4A is a left side view of FIG. 1A.

[0020] FIG. 5A is a right side view of FIG. 1A.

[0021] FIG. 1B is a front elevation view of an alternate concrete section having locking side fingers, a top wall recess and a bottom wall locking finger in accordance with the present invention.

[0022] FIG. 2B is a top view of FIG. 1B.

[0023] FIG. 3B is a bottom view of FIG. 1B.

[0024] FIG. 4B is a left side view of FIG. 1B.

[0025] FIG. 5B is a right side view of FIG. 1B.

[0026] FIG. 1 is a front elevation phantom view of two identical concrete sections adjacently and lineally disposed to promote the engagement of locking fingers extending from each side wall end portion of the concrete sections in accordance with the present invention.

[0027] FIG. 2 is the front elevation phantom view of FIG. 1, but with the locking fingers of the two identical concrete sections lineally disposed and meshed and secured together via a rod vertically extending through each of the locking fingers for both concrete sections in accordance with the present invention.

[0028] FIG. 3 is a top elevation view of FIG. 1.

[0029] FIG. 4 is a top elevation view of FIG. 2.

[0030] FIG. 5 is a right side phantom elevation view of the first section of FIG. 1.

[0031] FIG. 6 is a right side phantom elevation view of stabilizing rod inserted through the aligned apertures in the first and second sections of FIG. 2.

[0032] FIG. 7 is the top elevation view of FIG. 4, but with a second set of concrete sections adjacently and lineally disposed and with a binding material disposed between the two sets of concrete sections in accordance with the present invention.

[0033] FIG. 8 is a front elevation phantom view of two identical concrete sections adjacently and perpendicularly disposed to promote the engagement of locking fingers extending from each end portion of the concrete sections in accordance with the present invention.

[0034] FIG. 9 is the front elevation phantom view of FIG. 8, but with the locking fingers of the two identical concrete sections perpendicularly disposed and meshed and secured together via a rod vertically extending through each of the locking fingers for both concrete sections in accordance with the present invention.

[0035] FIG. 10 is a top elevation view of FIG. 8.

[0036] FIG. 11 is a top elevation view of FIG. 9.

[0037] FIG. 12 is right side phantom elevation view of FIG. 9.

[0038] FIG. 13 is the top elevation view of FIG. 11, but with a second set of concrete sections adjacently and perpendicularly disposed and with a binding material disposed between the two sets of concrete sections in accordance with the present invention.

[0039] FIG. 14 is a front elevation view of an alternate concrete section with phantom apertures in accordance with the present invention.

[0040] FIG. 15 is a top elevation view of the alternate concrete section of FIG. 14.

[0041] FIG. 16 is a left side elevation view of the alternate concrete section with phantom apertures of FIG. 14.

[0042] FIG. 17 is a right side elevation view of the alternate concrete section with phantom apertures of FIG. 14.

[0043] FIG. 18 is a bottom elevation view of the alternate concrete section of FIG. 14.

[0044] FIG. 19 is front elevation view of two concrete sections from FIG. 14, adjacently and lineally joined together via side wall end portion locking fingers to promote the stabilizing of concrete sections that ultimately construct a concrete wall in accordance with the present invention.

[0045] FIG. 20 is the front elevation view of FIG. 19, but with a bottom tier of three identical concrete sections lineally joined together via locking fingers and disposed upon a foundation, and a top tier of two identical concrete sections lineally disposed and secured together via locking fingers and a second locking finger that extends into a cooperating recesses in a top wall of concrete sections in the bottom tier in accordance with the present invention.

[0046] FIG. 21 is a top elevation view of FIG. 20.

[0047] FIG. 22 is a bottom elevation view of FIG. 20.

[0048] FIG. 23 is a left side elevation view of FIG. 20.

[0049] FIG. 24 is a right side elevation view of FIG. 20.

[0050] FIG. 25 is a phantom, front elevation view of FIG. 20, but with a top tier of concrete sections separated from a bottom tier of concrete sections, and the right side of FIG. 20 partially depicted in accordance with the present invention.

[0051] FIG. 26 is a back elevation view of an alternative concrete section configuration that includes a relatively large recess.

[0052] FIG. 27 is a bottom elevation view of the concrete section of FIG. 26.

[0053] FIG. 28 is a back elevation view of a modification of the concrete section depicted in FIG. 1A.

[0054] FIG. 28A is a right side elevation view of the concrete section depicted in FIG. 28, but with ridges added.

[0055] FIG. 28B is a left side elevation view of the concrete section depicted in FIG. 28, but with ridges added.

[0056] FIG. 28C is a bottom elevation view of the concrete section depicted in FIG. 28, but with a ridge added.

[0057] FIG. 28D is a top elevation view of the concrete section depicted in FIG. 28, but with a ridge added.

[0058] FIG. 29 is a section view of FIG. 28 taken along line 29-29.

[0059] FIG. 30 is a front elevation view of a concrete section having modified dimensions and a plurality of ridges in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0060] Referring to FIGS. 1 A-5A, a concrete section for constructing a wall in accordance with the present invention is denoted by numeral 10. FIGS. 1B-5B depict an alternative embodiment of the concrete section 10 of FIGS. 1A-5A in accordance with the present invention; the alternative embodiment being denoted by numeral 110. Although concrete is the preferred material of construction for the sections 10 and 110, the sections 10 and 110 can be fabricated from a myriad of materials including, but not limited to plastic, wood, aluminum, fiberglass and similar lightweight, rigid materials. The concrete section 10 and 110 can be dimensioned as required by the intended locations of the sections 10 and 110 for the construction of a wall; however, the preferred dimensions for the concrete sections of the present invention includes proximately three feet horizontal and three feet vertical dimensions, and a thickness dimension of proximately nine inches. Further, any surface of the sections 10 and 110 can include any design so long as the design does not obstruct the joining of adjacent concrete sections selected for the construction of a wall. The concrete sections 10 and 110 enable a person to construct a myriad of wall configurations from lightweight concrete with or without using mortar or other binding agents between vertically and/or horizontally disposed adjacent concrete sections 10 (dry stacking). The use or non-use of binding agents is determined via specification parameters that include but are not limited to inside or outdoor installation, temperature ranges, finished wall weight, wind speeds (if outside) and wall support structures.

[0061] Referring now to FIGS. 1-13, a method for constructing a wall via multiple concrete sections 10 in accordance with the present invention is illustrated with the concrete sections denoted as numerals 12 and 13 when joined together. The concrete sections 10 for constructing a concrete wall include front and back walls 14 and 16, a first end portion 18 having a first locking finger 20 with an outer vertical wall 21 and with a first vertical aperture 22, and a second locking finger 24 with an outer vertical wall 25 and with a second vertical aperture 26. The outer vertical walls 21 and 25 are substantially the same length. The first and second locking fingers 20 and 24 are vertically separated substantially the same distance as the length of the outer vertical walls 21 and 25 to form a first recess 28.

[0062] The first locking finger 20 is positioned a distance below a top planar wall 30 (with a longitudinal dimension of proximately twenty-seven inches) of the concrete section 10 to form a vertical wall 23 having the same length as the length of the outer vertical walls 21 and 25. A top planar wall 32 of the first locking finger 20 is parallel to and disposed vertically below the top planar wall 30 of the concrete section 10, and a bottom planar wall 34 of the first locking finger 20 is parallel to and with equal dimensions with the top planar wall 32 of the first locking finger 20, resulting in a substantially square configured (from front, top or side elevation views) first locking finger 20. The bottom planar wall 34 of the first locking finger 20 is parallel to and disposed vertically above a top planar wall 36 of the second locking finger 24 of the first end portion 18 of the concrete section 10. A bottom planar wall 40 of the second locking finger 24 is parallel to and with equal dimensions with the top planar wall 36 of the second locking finger 24, resulting in a vertical wall 27 having the same length as the length of the outer vertical walls 21 and 25 to form a substantially square configured (when viewing from both front, top or side elevation views) first recess 28 and a substantially square configured second locking finger 24. The planar bottom wall 40 of the second locking finger 24 is coplanar with a bottom wall 42 (having a longitudinal dimension of proximately twenty-seven inches) of the concrete section 10.

[0063] The concrete sections 10 further include a second end portion 44 having a third locking finger 46 with an outer vertical wall 47 and with a third vertical aperture 48, and a fourth locking finger 50 with an outer vertical wall 51 and with a fourth vertical aperture 52. The outer vertical walls 47 and 51 are substantially the same length. The third and fourth locking fingers 46 and 50 are vertically separated substantially the same distance as the length of the outer vertical walls 47 and 51 to form a second recess 54. The third locking finger 46 is disposed a distance below the top planar wall 30 of the concrete section 10 to form a vertical wall 49 having the same length as the length of the outer vertical walls 47 and 51. A top planar wall 56 of the third locking finger 46 is coplanar with the top planar wall 30 of the concrete section 10. A bottom planar wall 58 of the third locking finger 46 is parallel to and with equal dimensions with the top planar wall 56 of the third locking finger 46, resulting in a substantially square configured (from front, top or side elevation views) third locking finger 46.

[0064] The bottom planar wall 58 of the third locking finger 46 is parallel to and disposed vertically above a top planar wall 60 of the fourth locking finger 50 of the second end portion 44 of the concrete section 10. A bottom planar wall 62 of the fourth locking finger 50 is parallel to and with equal dimensions with the top planar wall 60 of the fourth locking finger 50, resulting in a vertical wall 53 having the same length as the length of the outer vertical walls 47 and 51 to form a substantially square configured (from front, top or side elevation views) fourth locking finger 50. The square configured planar bottom wall 62 of the fourth locking finger 50 is parallel with and disposed vertically above the bottom wall 42 of the concrete section 10.

[0065] The method for constructing a lineal concrete wall via the concrete sections 10 is illustrated via FIGS. 1-6, and in particular to the joined first and second concrete sections 12 and 13 of FIG. 2. The method for constructing an angular concrete wall via the concrete sections 10 is illustrated via FIGS. 8-13. Irrespective of the concrete wall being lineal or angular, the following description applies to the construction of both wall configurations. The first and second concrete sections 12 and 13 are identically configured and dimensioned to allow the entire concrete wall to be constructed via one concrete section 10 design, thereby minimizing labor time and parts. The single design for all concrete sections 10 for constructing a concrete wall is achieved by vertically offsetting corresponding and oppositely disposed first and third locking fingers 20 and 46; and vertically offsetting corresponding and oppositely disposed second and fourth locking fingers 24 and 50. The first and second recesses 28 and 54 are also vertically offset to horizontally align a first recess 28 of a second concrete section 13 with a fourth locking finger 50 of a first concrete section 12; and to horizontally align a second recess 54 of a first concrete section 12 with a first locking finger 20 of a second concrete section 13. All horizontal alignment occurs when the bottom walls 42 of the first and second concrete section 12 and 13 are coplanar orientated, thereby allowing the snug joining of a locking finger with a respective cooperating recess.

[0066] The method for constructing a wall using concrete sections 10 begins by providing two concrete sections 10 and disposing the sections 10 relatively close together as illustrated in FIG. 1. Referring to FIG. 2, the two sections 10 are then joined together by forcibly urged the first locking finger 20 of the second concrete section 13 into the second recess 54 in the first concrete section 12, and simultaneously urging the fourth locking finger 50 of the first concrete section 12 into the first recess 28 in the second concrete section 13. The first and second recesses 28 and 54 are identically configured and dimensioned, and the first and fourth locking fingers 20 and 50 are identically configured and dimensioned to snugly insert into the respective first and second recess 28 and 54.

[0067] The next step is to vertically and axially align the third and fourth vertical apertures 48 and 52 of the first concrete section 12 with the first and second vertical apertures 22 and 26 of the second concrete section 13, resulting in all four apertures being in vertical axial alignment to receive a stabilizing rod 64 that completely inserts through all four apertures. The preferred stabilizing rod 64 is a section of metal rebar having a diameter of about one-half times the diameter of the vertically aligned apertures, which are cylindrically configured and identically dimensioned. The stabilizing rod 64 has a length substantially equal to the cylindrical axis of the four apertures. The stabilizing rod 64 includes a relatively small plate 66 secured to a top end of the rebar 64. The plate 66 is dimensioned to maintain the position of the stabilizing bar 64 relative to the concrete section 10 after the stabilizing bar 64 is inserted into the aligned apertures.

[0068] The first and second concrete sections 12 and 13 are then lineally aligned for forming a straight portion of the concrete wall, or angularly joined to form a ninety degree angle to construct a corner portion of a concrete wall (see FIGS. 8-12). The formed angle can be set to any degree, which is generally between a straight run and ninety degrees depending upon the wall configuration selected by the user. The front walls 14 of the first and second concrete sections 12 and 13 can include ornamental designs that are etched into the front walls 14.

[0069] A relatively liquid binding agent (such as polyurethane foam) is then injected into the aligned apertures of the joined second end portion 44 of the first concrete section 12 and the first end portion 18 of the second concrete section 13 with the stabilizing rod 64 inserted through the aligned apertures. After the binding agent hardens, the stabilizing rod 64 and the second end portion 44 of the first concrete section 12 and the first end portion 18 of the second concrete section 13 are rigidly secured together, thereby maintaining the relative positions of the first and second concrete sections 12 and 13 when repeating the method of joining concrete sections 10 together to ultimately construct a concrete wall, irrespective of the completed wall being lineally or angularly configured.

[0070] The method of the present invention can be used to construct a second lineal wall 68 adjacent and parallel to a first lineal wall 70 (see FIG. 7) to allow a binding agent 71 to be disposed between the walls 68 and 70 such that the binding agent engages a back surface 72 of the first lineal wall 70 and a front surface 74 of the second lineal wall 68 to stabilize the first and second lineal walls 70 and 68 after the binding agent hardens. Further, irrespective of the number of wall configurations constructed via the method of the present invention, the first and second concrete sections 12 and 13 can include greater or lesser numbers of locking fingers on each side portion of each concrete section 12 and 13 as required for corresponding greater or lesser dimensioned concrete sections 12 and 13, and as required for relatively high or short wall dimensions. Also, the method of the present invention need not include the aligned apertures or the stabilizing rods 64 inserted through the aligned apertures when the predetermined wall includes one tier of concrete sections 10. In place of the stabilizing rods 64, mortar or other well known binding agent can be used to secured the concrete sections 10 together as the predetermined wall is assembled.

[0071] The method of the present invention can be used to construct a second angular wall 76 adjacent to and with the same angular configuration as a first wall 78 (see FIG. 13) to allow a binding agent to be disposed between the walls 76 and 78 such that the binding agent 79 engages a back surface 80 of the first angular wall 78 and a front surface 82 of the second angular wall 76 to stabilize the first and second angular walls 78 and 76 after the binding agent hardens.

[0072] Referring now to FIGS. 14-18, an alternative concrete section 110 for constructing a wall in accordance with the present invention is illustrated. The alternative concrete section 110 includes substantially the same dimensions as the above described concrete section 10. A method for constructing a wall via multiple alternative concrete sections 110 in accordance with the present invention is illustrated in FIG. 19, which includes two joined first and second concrete sections denoted as 112 and 113.

[0073] Referring to FIG. 20, a first tier 111 of concrete sections 110a for constructing a concrete wall include front and back walls 114 and 116, a first end portion 118 having a first locking finger 120 with a first vertical aperture 122, and a second locking finger 124 with a second vertical aperture 126. The first and second locking fingers 120 and 124 are vertically separated a predetermined distance that forms a first recess 128. The first locking finger 120 is positioned a predetermined distance below a top planar wall 130 of the concrete section 110a such that a top planar wall 132 of the first locking finger 120 is parallel with the top planar wall 130 of the concrete section 110a, and such that a bottom planar wall 134 of the first locking finger 120 is parallel with the top planar wall 132 of the first locking finger 120, resulting in a substantially square configured (from front, top or side elevation views) first locking finger 120. The top planar wall 132 of the first locking finger 120 is parallel with and disposed vertically below the top planar wall 130 of the concrete section 110a. The bottom planar wall 134 of the first locking finger 120 is parallel with a top planar wall 136 of the second locking finger 124 of the first end portion 118 of the concrete section 110a, resulting in a substantially square configured (when viewing from both front, top or side elevation views) first recess 128.

[0074] The second locking finger 124 of the concrete sections 110a in the first tier 111, include a planar bottom wall 140 that is coplanar with a bottom wall 142 of the concrete section 110. For a second tier 115 of concrete sections 110 and for every tier of concrete sections above the second tier 115, the concrete sections 110 include a second locking finger 125 that extends below the bottom wall 142 such that a planar bottom wall 141 of the second locking finger 125 is disposed below the bottom wall 142 of the concrete section 110. The second locking finger 125 in the second tier 114 of concrete sections 110a is dimensioned and configured to snugly insert a lower portion of the second locking finger 125 into a second locking finger receiving recess 117 in the top wall 130 of a cooperating concrete section 110 in the first tier 111 of concrete sections 110, thereby preventing the sliding or horizontal movement of concrete sections 110 as the sections 110 are disposed upon a lower tier of concrete sections. This horizontal locking cooperates with the locking fingers of the side wall portions of the concrete sections 110 to maintain the horizontal position of each concrete section 110 as the section 110 assembles a dry staked concrete wall or a concrete wall that uses binding agents between adjacent sections 110. Each concrete section 110 of every tier includes the second locking finger receiving recess 117 in the top wall 130.

[0075] The second locking finger 125 of the concrete sections 110 in all tiers above the first tier 111 includes the same second vertical aperture 126 that is in the second locking fingers 124 in the concrete sections 110 of the first tier 111. After the first tier 111 of concrete sections 110 have been positioned on a foundation 149, the second tier 114 of concrete sections 110 are disposed upon the first tier 111 such that the first and second vertical apertures 122 and 126 in the first and second locking fingers 120 and 125 align with an aperture 127 in the bottom wall 129 of the receiving recess 117. The bottom wall aperture 127 extends vertically through the respective concrete section 110 to allow a stabilizing and/or reinforcement bar 64 to extend completely through two vertically adjacent concrete section 110 in two vertically adjacent first and second tiers 111 and 115, thereby increasing the vertical and horizontal stabilizing of a completed concrete wall after a stabilizing material or binding agent such as grout or mortar is injected into the apertures with the stabilizing rods 64 already disposed therein.

[0076] The concrete sections 110 further include a second end portion 144 having a third locking finger 146 with a third vertical aperture 148 and a fourth locking finger 150 with a fourth vertical aperture 152. The third and fourth locking fingers 146 and 150 are vertically separated a predetermined distance that forms a second recess 154. The third locking finger 146 is disposed such that a top planar wall 156 of the third locking finger 146 is coplanar with the top planar wall 30 of the concrete section 110, and such that a bottom planar wall 158 of the third locking finger 46 is parallel with the top planar wall 130 of the third locking finger 146, resulting in a substantially square configured (from front, top or side elevation views) third locking finger 146. The bottom planar wall 158 of the third locking finger 146 is parallel with a top planar wall 160 of the fourth locking finger 150 of the second end portion 144 of the concrete section 110, resulting in a substantially square configured second recess 154 when taking front, top or side elevation views of the second recess 154. The fourth locking finger 150 includes a planar bottom wall 162 that is parallel with the planar top wall 160 of the fourth locking finger 150, resulting in a substantially square configured (from front, top or side elevation views) fourth locking finger 150. The planar bottom wall 162 of the fourth locking finger 150 is parallel with and disposed vertically above the bottom wall 142 of the concrete section 110.

[0077] The method for constructing a lineal concrete wall via the concrete sections 110 and 110a illustrated in FIGS. 18-25 can be used to construct an angular concrete wall using concrete sections 110 and 110a by using the same angling technique illustrated in FIGS. 8-13. Irrespective of the concrete wall being lineal or angular, the first and second concrete sections 112 and 113 are identically configured and dimensioned to allow the entire concrete wall to be constructed via one concrete section 110 design (with the exception of the first tier 111, which requires a concrete section 110 having a second locking finger 124 with a bottom wall 140 coplanar with an adjacent bottom wall 142 of the same concrete section 110), thereby minimizing labor time and parts. The single design for all concrete sections 110 for constructing a concrete wall is achieved by vertically offsetting corresponding and oppositely disposed first and third locking fingers 120 and 146; and vertically offsetting corresponding and oppositely disposed second and fourth locking fingers 124 and 150. The first and second recesses 128 and 154 are also vertically offset to horizontally align a first recess 128 of a second concrete section 113 with a fourth locking finger 150 of a first concrete section 112; and to horizontally align a second recess 154 of a first concrete section 112 with a first locking finger 120 of a second concrete section 113. All horizontal alignment occurs when the bottom walls 142 of the first and second concrete section 112 and 113 are coplanar orientated, thereby allowing the snug joining of a locking finger with a respective cooperating recess.

[0078] Referring to FIG. 25, after the assembly of the first and second tiers 111 and 115 of the concrete sections 110 and 110a, a first stabilizing rod 164a is inserted through aligned apertures that include the first and second vertical apertures 122 and 126 in the first and second locking fingers 120 and 125 of the second concrete section 110 in the second tier 115; the first stabilizing rod 164a vertically extending through the aperture 127 in the first concrete section 112 in the first tier 111 until the first stabilizing rod 164a extends completely through both tiers 111 and 115. A second stabilizing rod 164b is inserted through an aperture 127 in a bottom wall 129 of a recess 117 and through aligned apertures 148 in a third finger 146 of the first section 112, aperture 122 in a first finger 120 of the second section 113, aperture 152 in a fourth finger 150 of the first section 112 and aperture 126 in a second finger 124 of the second section 113 until stabilizing rod 164b extends completely through both tiers 111 and 115. A third stabilizing rod 164c is inserted through aligned apertures 148 in a third finger 146 of section 112 in the second tier 115, aperture 122 in first finger 120 of section 113 in the second tier 115, aperture 152 in fourth finger 150 of section 112 in the second tier 115 and aperture 126 in locking finger 125 of section 113 in the second tier 115; the third stabilizing rod 164c vertically extending through the aperture 137 in the second concrete section 113 in the first tier 111 until stabilizing rod 164c extends completely through both tiers 111 and 115.

[0079] After inserting stabilizing rods 164a, 164b and 164c through each aligned group of apertures through both the second and first tiers 115 and 111, a binding agent such as grout, mortar or polyurethane is injected into the apertures and around the stabilizing bar 164 to horizontally and vertically secure all concrete sections 110 in first and second tiers 111 and 115. The method of assembly for the concrete sections 110 can be repeated for a third tier (not depicted) upon the second tier 115 by snugly inserting a second locking finger 125 of the third tier into a receiving recess 117 in a top wall 130 of a concrete section 110 in the second tier 115, then inserting stabilizing rods 164 through respective aligned apertures in the third, second tier 115 and first tier 111, followed by injecting the grout, mortar or polyurethane into the aligned apertures.

[0080] Referring now to FIGS. 26 and 27, another alternative configuration for a precast concrete section in accordance with the present invention is denoted as numeral 200. The precast concrete section 200 is a rectangular configured (when taking front, top or side views of the section 200) building block fabricated from lightweight concrete and includes an outer front wall 202 having predetermined design or configuration, planar outer side walls 203, and planar outer top and outer bottom walls 205 and 207. The precast concrete section 200 further includes an inner planar wall 204 having a relatively large recess 206 therein with a depth defined by the transverse dimension of planar inner side walls 209. A fiberglass mesh 208 with one-quarter inch square configured openings is secured across substantially the entire surface of a bottom wall 210 and across all inner side walls 209 of the recess 206. The fiberglass mesh 208 provides a binding element for polyurethane poured into the recess 206 to maintain contact between the polyurethane as it hardens and the side and bottom walls 209 and 210 of the recess 206.

[0081] To construct a preselected wall, a predetermined number of concrete sections 200 dimensioned as required to form the wall are filled with polyurethane to ultimately form a planar polyurethane wall flush with the inner planar wall 204 of the concrete section 200. After the polyurethane has hardened, predetermined number of concrete sections 200 can be assembled using polyurethane, mortar or similar bonding material to construct the preselected wall. If the dimensions or use of the preselected wall require stability above that provided by a typical bonding agent, a vertical stabilizing bar 212 can be included in the construction of the preselected wall.

[0082] The stabilizing bar 212 can be a standard rebar or similar metal material that extends through the concrete section 200 via vertical apertures 214 through the top and bottom outer walls 205 and 207, and corresponding top and bottom inner side walls 209. The stabilizing bar 212 is ultimately rigidly secured to the concrete section 200 via a polyurethane foam (or similar material that sets-up or otherwise hardens) that has solidified after being deposited into the recess 206 in the horizontally positioned concrete section 200. The deposited polyurethane ultimately fills the recess 206 until the level of the polyurethane is flush with the inner wall 204, thereby covering the stabilizing bar 212 with end portions snugly extending through the vertical apertures 214 in the top and bottom outer walls 205 and 207 a predetermined distance. The stabilizing bar 212 can protrude from the top and/or bottom outer walls 205 a distance that promotes securing a first tier of sections 200 to a foundation, or securing a first tier of sections 200 to a second tier. The liquid polyurethane engages both the bottom wall 210 of the recess 206 and the fiberglass mesh 208, thereby increasing the grip of the hardening polyurethane upon the bottom wall 210 of the recess 206. After the polyurethane completely hardens, the precast concrete section 200 is capable of being vertically positioned at a location selected by the user to complete a predetermined lightweight concrete wall having a preselected designs or configurations.

[0083] As an alternative to the stabilizing bar 212 remaining in the polyurethane, as the polyurethane hardens and becomes semi-rigid, the stabilizing bar 212 is slidably removed from the precast concrete section 200 and the concrete section 200 is manually disposed at a position that cooperates with adjacent concrete sections 200; whereby, the aperture (not depicted) formed by the removal of the stabilizing bar 212 is lineally aligned with similarly formed apertures in vertically adjacent concrete sections 200 to enable polyurethane to pour into aligned apertures of the vertically adjacent concrete sections 200. The polyurethane vertically deposited into an upper concrete section 200 flows into a lower concrete section 200 and ultimately hardens, thereby replacing the removed vertical stabilizing bars 212 to provide a vertical stabilizing member for the resulting concrete wall.

[0084] To horizontally stabilize horizontally adjacent precast concrete sections 200, a horizontal stabilizing bar 216 can be installed through the recess 206 in the inner wall 204 via horizontal apertures 218 in the outer side walls 203 and through corresponding inner walls 204 such that the placement of the apertures 218 disposes the horizontal stabilizing bar 216 under the vertical stabilizing bar 212. To horizontally position one stabilizing bar 216 through a predetermined number of concrete sections 200, the sections 200 are adjacently and horizontally disposed such that horizontal apertures 218 through all of the sections 200 are axially aligned; whereupon, a stabilizing bar 216 is snugly inserted though all of the aligned apertures 218 such that adjacent planar side walls 203 are in congruent engagement. Polyurethane is then poured into the recess 206 and allowed to harden; whereupon, all the horizontally joined concrete sections 200 are vertically positioned upon a foundation that allows for insertion of any vertical bars 212 protruding from an outer bottom wall 207 of the joined concrete sections 200. Alternatively, the horizontally joined concrete sections 200 can be disposed upon a first tier of vertically disposed concrete sections 200 such that all protruding vertical bars 212 from either tier have been removed or otherwise adjusted to promote the cooperative vertical joining of the two tiers.

[0085] Similarly to the vertical stabilizing bar 212, the horizontal stabilizing bar 218 can remain in the polyurethane and after the polyurethane hardens, the horizontal stabilizing bar 218 horizontally stabilizes horizontally adjacent precast concrete sections 200. As with the vertical bar 212, the horizontal bar 218 can be slidably removed from the concrete section 200 when the polyurethane is in a semi-hardened state, which results in a horizontal aperture extending through the polyurethane after it hardens. After multiple concrete sections 200 are adjacently positioned such that all horizontal apertures are lineally aligned, polyurethane in a liquid state can be pumped or otherwise urged into the horizontal aperture, thereby horizontally stabilizing the aligned concrete sections 200 to promote the construction of a predetermined lightweight concrete wall. Also, the method of the present invention pertaining to aligned concrete sections 200 need not include the vertical or horizontal stabilizing bars 212 and 218 inserted through the polyurethane when the predetermined wall includes one tier of concrete sections 200. In place of the stabilizing bars 212 and 281, mortar or other well known binding agent can be used to secured the concrete sections 200 together as the predetermined wall is assembled.

[0086] Referring to FIGS. 28 and 29, a modification to the concrete section depicted in FIG. 1A is illustrated with multiple metal cross bars in accordance with the present invention and denoted as numeral 230. The concrete section 230 is precast in a mold such that an outer planar wall 232 of a bottom portion 231 of the concrete section 230 is configured while in a semi-solid, malleable state via engagement with a preselected form 234 disposed beneath and in horizontal engagement with the outer wall 232. An oil based liquid coats the preselected form 234 so that the hardened concrete section 230 is separated from the form 234 without damage or disfigurement. The concrete section 230 further includes a relatively thin vertical concrete wall 233 integrally joined to a peripheral edge portion of an inner wall 235 of the concrete section 230 such that a relatively large recess 237 is formed. When the concrete section requires added structural strength and/or members that promote the assembly of a plurality of concrete sections 230 to form a concrete wall having more than one tier, multiple metal crossbars, studs or channels 236 are secured inside the recess 237 via a plurality of screws 238 extending from a countersunk position below a top edge 240 of the channels 236 to dispose a threaded portion 242 of the screws 238 into the semi-solid concrete 231 at the bottom portion of the recess 237.

[0087] Once the bottom portion 231 has solidified, the screws 238 and the channels 236 are integrally secured to the bottom portion 231, such that the channels 236 perpendicularly engage opposing inner side wall portions 254 of the vertical concrete wall 233, each channel 236 being displaced an equal distance from a center point 244 of a top wall 235 of the bottom portion 231. The top edge 240 of the channels 236 and the top edge 246 of the vertical concrete wall 233 are vertically spaced the same distance from the top wall 235 of the bottom portion 231. A self-leveling polyurethane liquid or polyurethane foam is disposed in the recess 237 and in between the metal channels 236 such that when the polyurethane has hardened a polyurethane planar wall is formed that is coplanar with the top edge 246 of the vertical wall 233 and the top edge 240 of the channels 236, thereby providing a solid, stackable, lightweight concrete section 230 that can be elevated and secured proximate to adjacent vertically orientated sections 230 via the now vertically orientated channels 236 with fasteners well known to those of ordinary skill in the art to ultimately form a lightweight wall having an outer configuration defined by the impression formed into the outer wall 232 of each concrete section 230.

[0088] In the event that a vertical portion of the wall formed by the concrete sections 232 requires a stabilizing member, one or more stabilizing rods 64 as described above and in FIGS. 26 and 27, can be installed parallel to the channels 236 such that the rods 64 are covered with polyurethane and penetrate a portion of the peripheral wall 233 via apertures (not depicted) through opposing wall portions 254, thereby enabling the rods 64 to vertically engage concrete sections 230 above and/or below a preselected concrete section 230. A simplified concrete section 230 can be formed by replacing the channels 236 with concrete that is integrally joined to the opposing wall portions 254 and to the inner wall 235 of the bottom portion 231. However, the trade-off is that the resulting concrete section 230 will be relatively heavier than a section 230 that uses the metal channels 236, thereby requiring stabilizing members as upper portions of a concrete wall is assembled using the heavier sections 230.

[0089] Irrespective of the configuration of any of the concrete sections described above, multiple rows of horizontal ridges 250 (see FIGS. 28A-28D and 30) can be molded into the outer planar wall 232 via the preselected form 234 described above or the ridges 250 can be added to any outer planar wall during the fabrication process of the selected concrete section. be secured to hardened outer planar walls 232 of selected concrete sections 230, for example. The ridges 250 are included to receive and maintain a binding agent across the entire surface of an outer planar wall 232 of the selected concrete section 230. The binding agent (well known to those of ordinary skill in the art) during its hardening process receives decorative lightweight concrete blocks (not depicted) with designs illustrated on a front wall and a planar back wall for maximum engagement of the binding agent. The front wall designs of the decorative lightweight concrete blocks provide an artistic depiction across the entire wall constructed by the selected concrete sections. The recesses 252 between each ridge 250 are about three-eighths of an inch deep, and about one-quarter inch wide between the bases of adjacent ridges 250. As an alternative to using horizontal ridges 250, a polyurethane binding agent can be disposed upon outer planar walls 232 of the selected concrete sections 230 and after the polyurethane has substantially hardened, multiple decorative light weight concrete blocks can be impressed into the substantially hardened polyurethane to ultimately construct a wall with a predetermined design on the viewing areas of the wall.

[0090] The foregoing description is for purpose of illustration only and is not intended to limit the scope of protection accorded this invention. The scope of protection is to be measured by the following claims, which should be interpreted as broadly as the inventive contribution permits.