Abstract
The present invention is directed to a Pre-cast Decorative Retaining Wall consisting of concrete walls constructed on a horizontal surface normally at a manufacturing facility, on rolling platforms, or preferably built on the construction site where after curing to 3000 psi the pre-fabricated walls can be shipped to and installed at a building site. In the flat state the panels can have a wide variety of decorative elements readily applied to both the upper and lower downside reflection surface. A unique feature is the buttress system that is added to the back of the wall system when elevated retention is required. By pouring the buttress portion on top of the footing pier or caisson, and tying into the pre-decorated wall with reinforcement, an eco-friendly, design optional retaining wall system is accomplished which can be rapidly and safely installed.
Claims
1. A pre-cast continuous and horizontal retaining wall three-component system comprising: a) a first system component comprising one or more continuous and horizontal poured concrete footing members including a concrete wall accepting portion capable of supporting a pre-cast concrete wall placed thereon; b) a second system component comprising one or more pre-cast concrete walls having a front wall surface and a wall back side, constructed by casting on a horizontal surface, wherein said pre-cast concrete wall is mounted on said one or more continuous and horizontal poured concrete footing members; c) a plurality of reinforcement bars wherein said reinforcement bars are attached to said concrete wall, and said reinforcement bars are attached to said concrete footing and extending therebetween; and d) a third system component comprising one or more continuous and horizontal concrete buttress support portions poured on top of said one or more continuous and horizontal concrete footing members and adjacent to said wall back side, thereby connecting the wall back side to said footing, by embedding said attached plurality of reinforcement bars, extending between said concrete wall and said concrete footing, within said concrete buttress support portions, when said concrete buttress support portions are poured, to secure the concrete wall and enable retaining wall characteristics throughout the structure of said continuous and horizontal retaining wall system.
2. The pre-cast continuous and horizontal retaining wall three-component system according to claim 1, wherein said one or more pre-cast concrete walls include decorative features integrated on said front wall surface and said wall back side during the construction by casting on a horizontal surface process.
3. The pre-cast continuous and horizontal retaining wall three-component system according to claim 1, wherein said pre-cast concrete walls include electrical conduit and lighting features integrated therein during the casting process.
4. The pre-cast continuous and horizontal retaining wall three-component system according to claim 1, wherein said pre-cast concrete walls include water piping and water features and gas piping and gas features integrated therein during the casting process.
5. The pre-cast continuous and horizontal retaining wall three-component system according to claim 1, wherein said reinforcement bar attached to said pre-cast concrete wall, and said reinforcement bar attached to said concrete footing, are inter-connected to secure said pre-cast concrete wall to said footing.
6. The pre-cast continuous and horizontal retaining wall three-component system according to claim 5, wherein said reinforcement bar attached to said pre-cast concrete wall, and said reinforcement bar attached to said concrete footing, are connected by bending and hooking said reinforcement bar.
7. The pre-cast continuous and horizontal retaining wall three-component system according to claim 5, wherein said reinforcement bar attached to said pre-cast concrete wall, and said reinforcement bar attached to said concrete footing, are connected by bending and lapping said reinforcement bar.
8. The pre-cast continuous and horizontal retaining wall three-component system according to claim 1, wherein said reinforcement bar attached to said pre-cast concrete wall, and said reinforcement bar attached to said concrete footing, are embedded into said concrete buttress support portion poured onto said footing.
9. The pre-cast continuous and horizontal retaining wall three-component system according to claim 1, wherein said one or more continuous and horizontal pre-cast concrete wall is mounted on one continuous and horizontal poured footing and is configured as a non-retaining monument wall and concrete fence.
10. A method for making a continuous and horizontal pre-cast three-component retaining wall system comprising the steps of: a) providing a first system component comprising one or more continuous and horizontal poured concrete footing members including a concrete wall accepting portion capable of supporting a pre-cast concrete wall placed thereon; b) providing a second system component comprising one or more pre-cast concrete walls having a front wall surface and a wall back side, constructed by casting on a horizontal surface, wherein said pre-cast concrete wall is mounted on said one or more continuous and horizontal poured; c) providing a plurality of reinforcement bars wherein said reinforcement bars are attached to said concrete wall, and said reinforcement bars are attached to said concrete footing and extending therebetween; and d) providing a third system component comprising one or more concrete buttress support portions poured on the concrete footing members and adjacent to said wall back side, thereby connecting the wall back side to said footing, by embedding said attached plurality of reinforcement bars, extending between said concrete wall and said concrete footing, within said concrete buttress support portions, when said concrete buttress support portions are poured, to secure the concrete wall and enable retaining wall characteristics throughout the structure of said continuous and horizontal retaining wall system.
11. The method for making pre-cast continuous and horizontal retaining wall three-component system according to claim 10, wherein said one or more pre-cast concrete walls include decorative features integrated on said front wall surface and said wall back side during the construction by casting on a horizontal surface process.
12. The method for making pre-cast continuous and horizontal retaining wall three-component system according to claim 10, wherein said pre-cast concrete walls include electrical conduit and lighting features integrated therein during the casting process.
13. The method for making pre-cast continuous and horizontal retaining wall three-component system according to claim 10, wherein said pre-cast concrete walls include water piping and water features and gas piping and gas features integrated therein during the casting process.
14. The method for making pre-cast continuous and horizontal retaining wall three-component system according to claim 10, wherein said reinforcement bar attached to said pre-cast concrete wall, and said reinforcement bar attached to said concrete footing, are inter-connected to secure said pre-cast concrete wall to said footing.
15. The method for making pre-cast continuous and horizontal retaining wall three-component system according to claim 14, wherein said reinforcement bar attached to said pre-cast concrete wall, and said reinforcement bar attached to said concrete footing, are connected by bending and hooking said reinforcement bar.
16. The method for making pre-cast continuous and horizontal retaining wall three-component system according to claim 14, wherein said reinforcement bar attached to said pre-cast concrete wall, and said reinforcement bar attached to said concrete footing, are connected by bending and lapping said reinforcement bar.
17. The method for making pre-cast continuous and horizontal retaining wall three-component system according to claim 10, wherein said reinforcement bar attached to said pre-cast concrete wall, and said reinforcement bar attached to said concrete footing, are embedded into said concrete buttress support portion poured onto said footing.
18. The method for making pre-cast continuous and horizontal retaining wall three-component system according to claim 10, wherein said one or more continuous and horizontal pre-cast concrete wall is mounted on one continuous and horizontal poured footing and is configured as a non-retaining monument wall and concrete fence.
19. A method for installing a concrete pre-cast continuous and horizontal retaining wall three-component system comprising the steps of: a) pre-fabricating one or more concrete walls, having reinforcement bars embedded therein, by casting in place horizontally and allowing said one or more pre-cast concrete walls to cure; b) pouring a continuous and horizontal concrete footing member, having reinforcement bars embedded therein, and allowing said continuous and horizontal concrete footing member to cure; c) mounting said pre-cast concrete wall onto said continuous and horizontal concrete footing member; and d) connecting said pre-cast concrete wall and said concrete footing member using said reinforcement bar extending between said pre-cast concrete wall and said concrete footing member by pouring a continuous and horizontal concrete buttress support portion; thereby connecting said pre-cast concrete wall to said continuous and horizontal concrete footing member, by embedding said reinforcement bars, extending between said concrete wall and said concrete footing, within said concrete buttress support portions, when said concrete buttress support portions are poured, to secure the concrete wall and enable retaining wall characteristics throughout the structure of said continuous and horizontal retaining wall system.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings, which are incorporated, in and form a part of this specification, illustrate embodiments of the Pre-cast Decorative Retaining Wall and together with the description, serve to explain the principles of this application.
(2) FIG. 1A depicts a perspective section view of the Pre-cast Decorative Retaining Wall on a footing with the buttress support.
(3) FIG. 1B depicts a section through the Pre-cast Decorative Retaining Wall illustrating a transparent tesserae segment with a LED light wired through an orifice in the wall connected to an electronic control box embedded in the back side of the wall.
(4) FIG. 2 depicts a perspective view of the back of the Pre-cast Decorative Retaining Wall illustrating the rebar reinforcing between the footing and the back of the wall.
(5) FIG. 3A depicts a cross section through the Pre-cast Decorative Retaining Wall illustrating the connection between the rebar coming from the back of the wall to the rebar in the footing.
(6) FIG. 3B depicts a cross section through the top of the Pre-cast Decorative Retaining Wall with an electric light on top of a wall cap with the electrical conduit running through it.
(7) FIG. 3C depicts a cross section through the top of the Pre-cast Decorative Retaining Wall with an electric light on the front face of the wall with the electrical connection running through an orifice in the wall to an electrical connection box on the back of the wall.
(8) FIG. 4A depicts a cross section through the Pre-cast Decorative Retaining Wall illustrating the connection between the rebar coming from a Richmond Dowel type of concrete anchoring, system in the back of the wall to the rebar in the footing.
(9) FIG. 4B depicts a cross section through the Pre-cast Decorative Retaining Wall illustrating, the connection between the rebar coming from an additional type of concrete anchoring system in the back of the wall to the rebar in the footing.
(10) FIG. 5 depicts a cross section through the Pre-cast Decorative Retaining Wall illustrating a different style of footing with a shorter toe and an extended back section having a drain line with a gravel covering.
(11) FIG. 6 depicts a cross section through the Pre-cast Decorative Retaining Wall illustrating a tapered wall anchored to the footing without the buttress support system.
(12) FIG. 7A depicts a perspective view of the Pre-cast Decorative Retaining Wall in the form of Pre-cast, or cast in place Monument Wall or Pre-cast, or cast in place Concrete Fencing (a non-retaining wall configuration) resting on numerous separate individual spaced-apart Pre-cast, or cast in place footing blocks each having slots to accept and retain the wall segments.
(13) FIG. 7B depicts a perspective view of the Pre-cast Decorative Retaining Wall in the form of Pre-cast, or cast in place Monument Wall or Pre-cast, or cast in place Concrete Fencing (a non-retaining wall configuration) resting on a continuous Pre-cast, or cast in place footing block having a continuous slot, to retain the wall segments.
(14) FIG. 8 depicts a cross section through the Pre-cast Decorative Non-Retaining Wall in the form of Pre-cast, or cast in place Monument Wall or Pre-cast, or cast in place Concrete Fencing resting on Pre-cast, or cast in place footing blocks having a slots to retain the wall segments along with the rebar reinforcing members.
(15) FIG. 9 depicts a cross section through a short portion of the Pre-cast Decorative Retaining Wall with steel angle or channel inserted into the bottom of the wall conventionally anchored to a concrete slab.
(16) FIG. 10A depicts a cross section through the Pre-cast Decorative Retaining Wall in the form of Pre-cast Monument Wall or Pre-cast Concrete Fencing resting on an existing concrete deck surface.
(17) FIG. 10B depicts a front sectional view of FIG. 10A of the Pre-cast Decorative Retaining Wall in the form of Pre-cast Monument Wall or Pre-cast Concrete Fencing resting on an existing concrete deck surface.
(18) FIG. 11 depicts a cross section through the Pre-cast Decorative Retaining Wall in the form of Pre-cast Monument Wall or Pre-cast Concrete Fencing in a true cantilever configuration on piers or a continuous footing.
(19) FIG. 12 depicts a block diagram describing steps of the footing site preparation.
(20) FIG. 13 depicts a block diagram describing steps of the basic horizontal wall panel preparation on a rolling platform.
(21) FIG. 14A depicts a block diagram describing steps of the decorative horizontal wall panel preparation.
(22) FIG. 14B depicts a block diagram describing steps of the continuation of the decorative horizontal wall panel preparation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(23) Referring now to the drawings, wherein similar parts of the Pre-cast Decorative Retaining Wall 10A, 10B and 10C are identified by like reference numerals, there is seen in FIG. 1A a perspective section view of the Precast Decorative Retaining Wall 10A on a footing 12 with the buttress support 14. The footing 12 will have a toe section 16 in front of the wall 18 and a footing, key 20 on the lower surface. Conventional waterproofing coatings will be applied to the wall back side 26 of the wall 18 and a water transmitting material 32 with a drainage cavity 34 at the bottom on the back side of the buttress support 14. Alternatively, a waterproofing, agent may be added to the concrete mix with only a drainage system required. A tesserae 36 wall design is illustrated on the front wall surface 38 of the wall 18. It should be understood that when constructed, the pre-cast wall may be readily decorated on either the front wall surface 38 or the wall back side 26 as desired.
(24) FIG. 1B depicts a section through the Pre-cast Decorative Retaining Wall 10A illustrating a transparent tesserae 36 segment with a LED light 40 wired through an orifice 42 in the wall 18 connected to junction box 44 and an electronic control panel 46 embedded in the wall back side 26.
(25) FIG. 2 depicts a perspective view of the back of the Pre-cast Decorative Retaining Wall 10A illustrating, the reinforcement bar (hereafter rebar) reinforcing pattern between the footing. 12 and the rebar extending from the wall back side 26. Rebar 24, a breakout bar, is left exposed at the rear of the wall to be lapped connected to rebut 22 extending from the footing 12. Horizontal rebar 28 in the buttress support 14 will extend through the overlapping connection 30 of the rebar 22 exposed at the rear of the footing 12 and the rebar 24 extending from the back side 26 of the wall 18. Shims 48 are inserted to level the each wall 18 segment prior to pouring the buttress support 14.
(26) FIG. 3A depicts a cross section through the Pre-cast Decorative Retaining Wall 10A illustrating the lap connection between the rebar 24 coming from the back of the wall to the rebar 22 in the footing. Back fill material 50 extends to the top of the wall 18.
(27) FIG. 3B depicts a cross section through the top of the Pre-cast Decorative Retaining Wall 10A with an electric light (or gas fixture) 52 on top of a wall cap 54 with the electrical conduit (or gas piping) 56 running through it.
(28) FIG. 3C depicts a cross section through the top of the Pre-cast Decorative Retaining Wall 10A with a wall mount electric light 58 on the front face of the wall 18 with the electrical connection running through an orifice 42 in the wall 18 to an electrical junction box 44 on the wall back side 26. An option is to have a gas fixture utilizing the piping, orifice and gas fixture feature, in place of the electrical set-up shown here.
(29) FIG. 4A depicts a cross section through the Pre-cast Decorative Retaining Wall 10A illustrating the connection between the rebar 60 on the inside of the wall 18 to the imbedded Richmond Dowel 62 (or other rebar splicing) type of concrete anchoring system in the wall back side 26. Pryor to pouring the concrete for the buttress system 14 rebar 64 extends over and around horizontal rebar 28 and down to be connected to the rebar 22 left exposed at the rear of the footing 12.
(30) FIG. 4B depicts a cross section through the Pre-cast Decorative Retaining Wall 10A illustrating the connection between the rebar 64 coming from an additional type of concrete anchoring system 66 in the wall back side 26 to the rebar 22 in the footing.
(31) FIG. 5 depicts a cross section through the Pre-cast Decorative Retaining Wall 10A illustrating a different style of footing 70 with a shorter toe 72 and an extended footing back section 74 having, a drain line 76 with a gravel covering 78.
(32) FIG. 6 depicts a cross section through the Pre-cast Decorative Retaining Tapered Wall 10B illustrating a tapered wall 82 anchored to the footing 12 without the buttress support system 14. The tapered wall 82 is anchored to the footing 12 by the means of the wall internal rebar 84 welded to a steel angle 86 and a jacking plate 88 running the length of the tapered wall 82. Jacking nuts 90 on a threaded rod (or threaded bent rebar) 92 will establish the vertical aspect of the tapered wall 82 and shims 48 will establish the level position.
(33) FIG. 7A depicts a perspective view of a short Pre-cast Decorative Non-Retaining Wall 10C in the form of Pre-cast, or cast in place Monument Wall 98 or Pre-cast Concrete Fencing 100 resting on Pre-cast, or cast in place footing blocks 102 having a wall slot 104 to retain the decorative wall segment 106.
(34) FIG. 7B depicts a perspective view of the Pre-cast Decorative Non-Retaining Wall 10C in the form of Pre-cast Monument Wall or Pre-cast Concrete Fencing resting on a continuous Pre-cast, or cast in place footing block 103 having; a continuous slot to retain the wall segments.
(35) FIG. 8 depicts a cross section through a of Pre-cast Decorative Non-Retaining Wall 10C in the form of Pre-cast, or cast in place Monument Wall 98 or Pre-cast Concrete Fencing 100 resting on Pre-cast, or cast in place footing blocks 102 having a wall 104 slot to retain the wall segments 106 along with the rebar reinforcing members 108.
(36) FIG. 9 depicts a cross section through a short use of the Pre-cast Decorative Retaining Wall 10C with the wall internal rebar 84 welded to the steel angle or channel 112 welded to the jacking plate 88. Jacking nuts 90 on a threaded rod 92 will establish the vertical aspect of the tapered wall 98, 100 conventionally anchored to a concrete slab.
(37) FIG. 10A depicts a cross section through the Pre-cast Decorative Retaining Wall 10D in the form of Pre-cast Monument Wall or Pre-cast Concrete Fencing resting on an existing concrete deck surface 110. This configuration can be used to construct planter boxes and the like. Waterproof barrier 115 in the soil 50 side is used to allow water to run down to buttress support system 14 and out existing drains (not shown). Rebar 114 runs from the buttress support system 14 an into a drill hole within the existing podium deck 110, to secure the Pre-cast Monument Wall or Pre-east Concrete Fencing resting on the existing concrete deck surface 110.
(38) FIG. 10B depicts a front sectional view of FIG. 10A of the Pre-cast Decorative Retaining Wall 100 in the form of Pre-cast Monument Wall or Pre-cast Concrete Fencing resting on an existing concrete deck surface 110. Rebar 84 is bent inside, buttress support system 14, as is rebar 114 which extends down from buttress support system 14 into the existing podium deck 110 inside a drill hole, to secure the planer box or the like constructed in this fashion.
(39) FIG. 11 depicts a cross section through the Pre-cast Decorative Retaining Wall. 101 in the form of Pre-cast Monument Wall or Pre-cast Concrete Fencing, in a true cantilever configuration on piers or a continuous footing 123. This configuration includes a backfill of gravel 119 behind the wall 38 and above the buttress support system 14 for efficient drainage.
(40) FIG. 12 depicts a block diagram describing steps of the footing site preparation 114 where the first step 116 is to prepare the earthwork for panel installation as required by wall size and local building codes. The second step 118 is to compact the soil as required by the soils tests. The third step 120 is to place the required reinforcement per the design requirements. The fourth step 122 is to perform the inspections of the footing system as required by governing agency or geotechnical report. The fifth step 124 is to place the concrete per the requirements and details.
(41) FIG. 13 depicts a block diagram describing steps of the basic horizontal wall panel preparation 128 where the first step 130 is to prepare the reflection surface per panel design requirements. The second step 132 is to setup concrete forms to the desired size on the reflection surface. The third step 134 is to install the miscellaneous hardware i.e. lift inserts, weld plates and reinforcing rebar. The fourth step 136 is to pour proprietary concrete mix. The fifth step 138 is to screed and float the surface. The sixth step 140 is to apply the applicable retarder. The seventh step 142 is after the concrete surface reaches desired strength strip and wash aggregate surface by certified ECS technicians to predetermined desired effect. The eighth step 144 is to apply applicable curing compound if required on all surfaces and remove from factory and store or ship. The ninth step 146 is after a minimum of 14 days and after the panels are installed on site, power wash (acid when required) apply densifying sealer to all exposed surfaces.
(42) FIG. 14A depicts a block diagram describing steps of the decorative horizontal wall panel preparation 150 where the first step 152 is to prepare the reflection surface per panel design requirements. The second step 154 is to up concrete forms to the desired size on the reflection surface. The third step 156 is to install miscellaneous hardware i.e. lift inserts weld plates, etc. The fourth step 158 is to establish decorative computer graphic design. The fifth step 160 is to project layout down onto reflection surface. The sixth step 162 is to cut decorative Styrofoam shapes to proposed layout design if required. The seventh step 164 is to install Styrofoam shapes into concrete form if required. The eighth step 166 is to install optional downside/backside wall elements i.e. form liner, tesserae, impressions, etc. The ninth step 168 is to imbed tesserae into emulsified sand or Styrofoam on the reflection surface to establish desired relief. The tenth step 170 is to finish emulsified sand and tesserae to desired reflection. The eleventh step 172 is to place or implant reinforcing and accessory decorative components so as not to interfere with decorative features on either side.
(43) FIG. 14B depicts a block diagram describing steps of the continuation of the decorative horizontal wall panel preparation 176 where the twelfth step 178 is to place concrete in a manner so as not to disturb down side design. The thirteenth step 180 is to screed and float the concrete surface. The fourteenth step 182 is to install upside front side wall elements using the wide variety of decorative features listed. The fifteenth step 184 is to install tesserae, glass, metal, incandescent lights, fluorescent lights, rope lighting, fiber optic lighting and water or gas feature plumbing. The sixteenth step 186 is after concrete surface reaches desired strength strip and wash aggregate surface by certified ECS technicians to predetermined desired effect. The seventeenth step 188 is to apply applicable curing compound if required on all surfaces and remove from factory and store or ship. The eighteenth step 190 after a minimum of 14 days and after panels are installed on site, power wash (acid when required) and apply densifying sealer to all exposed surfaces. It should be emphasized that following this method result in substantial time savings over conventional retaining wall installation methods and construction techniques.
(44) The Pre-cast Decorative Retaining Wall 10A, 10B, 10, 10D and 10E shown in the drawings and described in detail herein disclose arrangements of elements of particular construction and configuration for illustrating preferred embodiments of structure and method of operation of the present application. It is to be understood, however, that elements of different construction and configuration and other arrangements thereof, other than those illustrated and described may be employed for providing the Pre-cast Decorative Retaining Wall 10A, 10B, 10C, 10D and 10E in accordance with the spirit of this disclosure, and such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this design as broadly defined in the appended claims.
(45) Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are familiar with patent or legal terms and phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
