CA2588112C

CA2588112C - Concrete structure system and apparatus for pre-casting concrete structures

Info

Publication number: CA2588112C
Application number: CA2588112A
Authority: CA
Inventors: Gale J. Stott
Original assignee: Intellectual Property Management LLC
Current assignee: Intellectual Property Management LLC
Priority date: 2004-10-27
Filing date: 2005-10-27
Publication date: 2013-03-05
Anticipated expiration: 2025-10-27
Also published as: CA2588112A1; CR9152A; WO2006047754A9; WO2006047754A3; WO2006047754A2; AU2005299567A1; AU2005299567B2; MX2007006196A; AU2005299567B9; EP1805378A2; EP1805378A4

Abstract

An apparatus for producing one or more pre-cast concrete structures. The apparatus may include partitions that may be positioned in a side by side arrangement. The partitions may be moveable with respect to each other to facilitate installation of reinforcing material and removal of the concrete structures from the apparatus after the concrete has hardened. Cavities may be defined by the partitions for receiving concrete to form structures having panels with integral columns. The columns may include slots for receiving an adjacent panel such that adjacent concrete structures may be joined together to form a continuous wall. The partitions may also include interchangeable liners such that different textures or finishes may be applied to the concrete structures.

Description

CaIVCx'"S17R3 SYSTEM AND APPARATUS FOR PRE-CASTING
CONCRETE STRUCTURES
BACKGROUND
1. The Field of the Invention.
The present disclosure relates generally to devices for forming structures, and more particularly, but not necessarily entirely, to devices for forming precast concrete structures.
The present disclosure also relates generally to structural columns and/or walls, and more particularly, but not necessarily entirely, to pre-cast concrete structures and mechanisms for attaching the structures to footings or other such supports.

2. Description of Related Art.
Precast concrete structures have been used in the building construction industry for many years. Precast concrete structures may include steel reinforced panels for use in constructing fences, walls, sound barriers and the like. Precast concrete structures may also include columns for supporting panels or overhead items. High quality precast concrete structures may be formed efficiently since they may be constructed in a factory with specialized equipment, strict quality standards and controlled conditions not subject to rain, hot or cold temperatures, or builder errors. Moreover, labor savings may be accomplished since precast structures may be formed more efficiently in a factory than constructing a form on site to manufacture the structures in place. Use of precast concrete structures may also reduce construction delays associated with rain or inclement weather since concrete may not be properly poured on site in inclement weather.
In recent years, the use of precast concrete columns and panels with decorative patterns formed on the exterior surface has increased in popularity. The precast concrete panels may have various different patterns such as stone or brick, for example. Such precast concrete panels may be easier to construct than stone or brick walls. Moreover, the precast concrete panels may be durable and provide advantages in that cracking may be reduced as compared to walls formed with grouted natural stone or brick, and no mortar joints are created with precast concrete panels to allow water to seep into the wall.
Various different types of devices are known in the art for forming precast concrete structures. Despite the advantages of known devices for forming concrete structures, improvements are still being sought to improve the efficiency of the manufacturing process and the quality of the concrete structures. Also, improvements are being sought for concrete structures to facilitate installation of the structures at the construction site.
Also, various different types of attaching devices and methods are known in the art for joining concrete structures to footings to support the structures in an upright position.
Despite the advantages of known attaching devices and methods, improvements are still being sought to improve the efficiency of construction and the quality of the concrete structures.
The prior art is thus characterized by several disadvantages that are addressed by the present disclosure.
The present disclosure minimizes, and in some aspects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein.

According to one aspect of the present invention, there is provided an apparatus for simultaneously forming a plurality of concrete structures, said apparatus comprising: a frame; a plurality of partitions mounted on said frame, said plurality of partitions comprising at least three partitions being positioned in a side by side arrangement to form a plurality of cavities, each of said plurality of cavities being separated by a corresponding one of said plurality of partitions, each of said cavities defining: a first portion for receiving wet concrete for forming a panel portion of one of said concrete structures, said panel portion having a first end and an opposing second end, and a second wider portion communicating with said first portion for receiving wet concrete for forming a column portion on said second end of said panel portion, said column portion having a slot formed therein, said first end of said panel portion being sized so that it can be received within said slot; and an end wall mounted on said frame and being disposed adjacent to an end of said plurality of partitions, said end wall being independently moveable relative to said plurality of partitions and relative to said frame, said plurality of partitions being moveable in a first direction, and said end wall being moveable in a second direction substantially perpendicular with respect to said first direction.

According to another aspect of the present invention, there is provided an apparatus for simultaneously forming a plurality of concrete structures, said apparatus comprising: a frame; a plurality of partitions mounted on said frame and having a first end and an opposing second end, said plurality of partitions comprising at least three partitions being positioned in a side by side arrangement to form a plurality of cavities, each of said plurality of cavities being separated by a corresponding one of said plurality of partitions, each of said cavities defining: a first portion for receiving wet concrete for forming a panel portion of a concrete structure, and a second portion in communication with the first portion for receiving wet concrete for forming a column portion on said panel portion; a first end wall mounted on said frame adjacent to said first end of said plurality of partitions so as to bound a portion of said plurality of cavities; and a plurality of first ribs mounted on said first end wall, wherein each of said plurality of first ribs is positioned in a separate one of said second portions for defining slot -2a-.9767-37 extending along the length of said column portion of said concrete structures;
wherein at least one of said plurality of partitions is moveable with respect to said frame and with respect to said first end wall and wherein said first end wall is moveable with respect to said frame in a direction substantially perpendicular to a direction of movement of said at least one of said plurality of partitions.
According to still another aspect of the present invention, there is provided an apparatus for forming a plurality of concrete structures, said apparatus comprising: a frame; a plurality of partitions movably mounted to said frame, each of said plurality of partitions having a first side and an opposing second side that each extend between a first end and an opposing second end, said plurality of partitions comprising at least three partitions and being positionable in a side by side arrangement to form a plurality of cavities therebetween for receiving concrete for forming said concrete structures; and a first end wall movably mounted to said frame and disposed adjacent to said first end of said plurality of partitions so as to partially bound said plurality of cavities, said first end wall being moveable in a direction away from said partitions, wherein said partitions are moveable in a first direction, and said first end wall is moveable in a second direction substantially perpendicular with respect to said first direction.

According to yet another aspect of the present invention, there is provided an apparatus for simultaneously forming a plurality of concrete structures, said apparatus comprising: a frame; a plurality of partitions mounted on said frame, said plurality of partitions comprising at least three partitions being positioned in a side by side arrangement to form a plurality of cavities, each of said plurality of cavities being separated by a corresponding one of said plurality of partitions, each of said cavities defining: a first portion for receiving wet concrete for forming a panel portion of one of said concrete structures, and a second wider portion communicating with said first portion for receiving wet concrete for forming a column portion on said panel portion; wherein the plurality of partitions are arranged so as to be substantially parallel to one another in separate planes and wherein each of the plurality of partitions are independently movable relative to the frame and remain in the substantially parallel planes when -2b-j9767-37 they are moved on said frame; wherein each of said plurality of partitions is movable with respect to the other partitions in a direction substantially orthogonal to the plane of the partition.

According to a further aspect of the present invention, there is provided an apparatus for simultaneously forming a plurality of concrete structures, said apparatus comprising: a frame; a plurality of partitions mounted on said frame and having a first end and an opposing second end, said plurality of partitions comprising at least three partitions being positioned in a side by side arrangement to form a plurality of cavities, each of said plurality of cavities being separated by a corresponding one of said plurality of partitions, each of said cavities defining: a first portion for receiving wet concrete for forming a panel portion of a concrete structure, and a second portion in communication with the first portion for receiving wet concrete for forming a column portion on said panel portion; a first end wall mounted on said frame adjacent to said first end of said plurality of partitions; a second end wall mounted on said frame adjacent to said first end of said plurality of partitions; and a plurality of first ribs mounted on said first end wall, wherein each of said plurality of first ribs is positioned in a separate one of said second portions for defining a slot in said column portions; a plurality of second ribs mounted on said second end wall, wherein each of said plurality of first ribs is positioned in a separate one of said second portions for defining a slot in said column portions; and wheels supporting said plurality of partitions and said first and second walls on said frame so that each of said plurality of partitions and said first and second end walls can move relative to said frame.

According to yet a further aspect of the present invention, there is provided a system comprising: a first concrete structure and a second concrete structure, each comprising a column portion and a panel portion integrally joined with said column portion, said column portion comprising a side face with an elongated slot formed therein, said panel portion having opposing side faces that extend from said column portion to a terminal distal end face, said slot having a width at said side face that is greater than or equal to the width of said panel portion where said panel portion is joined to said column portion; a support having -2c-.,9767-37 said first concrete structure received thereupon; and a substantially rigid member rigidly embedded within said support and received in said slot in said column portion of said first concrete structure for providing lateral support to said first concrete structure, a portion of said panel portion of said second concrete structure being received within said slot in said column portion of said first concrete structure such that said terminal distal end face of said panel portion of said second concrete structure is disposed adjacent to said substantially rigid member within said slot in said first concrete structure.

According to still a further aspect of the present invention, there is provided a system comprising: a first concrete structure comprising: a first column comprising a side face with an elongated slot formed therein, said slot being bounded by two opposing side surfaces extending inward from a mouth at said side face of said first column to an end surface that faces toward said mouth of said slot; and a first panel having opposing side faces that extend from said first column to a first terminal distal end face that faces away from said first column; a support having said first concrete structure received thereupon; and a substantially rigid member attached to said support and received in said slot in said first column for providing lateral support to said first concrete structure, wherein said slot has a width extending between said side surfaces that is substantially constant from said mouth to said rigid member; and a second concrete structure comprising: a second column comprising a side face with an elongated slot formed therein; and a second panel having opposing side faces that extend from said second column to a second terminal distal end face that faces away from said second column, a portion of said second panel being received within said slot in said first column of said first concrete structure such that said second terminal distal end face is disposed adjacent to said substantially rigid member within said slot of said first concrete structure-According to another aspect of the present invention, there is provided a system comprising: a first concrete structure having a height extending from a base end to an opposing upper end, said first concrete structure comprising: a first column portion having a side face that extends along said -2d-height of said first column portion, an elongated slot being formed in said side face and extending along said height of said first column portion, said slot being bounded by two opposing side surfaces extending inward from a mouth at said side face of said first column portion to an end surface that faces toward said mouth of said slot;
and a first panel portion having opposing side faces that extend from said first column portion to a first terminal distal end face, said first panel portion at said first terminal distal end face being sized to fit within said slot on said first column portion; a support having said base end of said first concrete structure received thereupon; a substantially rigid member embedded in or attached to said support and received in said slot in said first column portion toward said end surface for providing lateral support to said first concrete structure, wherein said slot has a width extending between said side surfaces that is substantially constant from said mouth to said rigid member; and a second concrete structure comprising: a second column portion comprising a side face with an elongated slot formed therein; and a second panel portion having opposing side faces that extend from said second column portion to a second terminal distal end face that faces away from said second column portion, a portion of said second panel portion being received within said slot of said first column portion such that said second terminal distal end face is disposed adjacent to said substantially rigid member within said slot of said first column portion.

According to one aspect of the present invention, there is provided a system comprising: a first concrete structure and a second concrete structure, each comprising a column portion and a panel portion integrally joined with said column portion, said column portion comprising a side face with an elongated slot formed therein, said panel portion having opposing side faces that extend from said column portion to a terminal distal end face, said slot having a width at said side face that is greater than or equal to the width of said panel portion where said panel portion is joined to said column portion; a support having said first concrete structure received thereupon; and a substantially rigid member rigidly embedded within said support and received in said slot in said column portion of said first concrete structure for providing lateral support to said first concrete structure, a portion of said panel portion -2e-of said second concrete structure being received within said slot in said column portion of said first concrete structure such that said terminal distal end face of said panel portion of said second concrete structure is disposed adjacent to said substantially rigid member within said slot in said first concrete structure.

According to another aspect of the present invention, there is provided a system comprising: a first concrete structure comprising: a first column comprising a side face with an elongated slot formed therein, said slot being bounded by two opposing side surfaces extending inward from a mouth at said side face of said first column to an end surface that faces toward said mouth of said slot; and a first panel having opposing side faces that extend from said first column to a first terminal distal end face that faces away from said first column; a support having said first concrete structure received thereupon; a substantially rigid member attached to said support and received in said slot in said first column for providing lateral support to said first concrete structure, wherein said slot has a width extending between said side surfaces that is substantially constant from said mouth to said rigid member;
and a second concrete structure comprising: a second column comprising a side face with an elongated slot formed therein; and a second panel having opposing side faces that extend from said second column to a second terminal distal end face that faces away from said second column, a portion of said second panel being received within said slot in said first column of said first concrete structure such that said second terminal distal end face is disposed adjacent to said substantially rigid member within said slot of said first concrete structure.

According to still another aspect of the present invention, there is provided a system comprising: a first concrete structure having a height extending from a base end to an opposing upper end, said first concrete structure comprising: a first column portion having a side face that extends along said height of said first column portion, an elongated slot being formed in said side face and extending along said height of said first column portion, said slot being bounded by two opposing side surfaces extending inward from a mouth at said side face of said first column portion to an end surface that faces toward said mouth of said slot; and a first panel portion - 2f -having opposing side faces that extend from said first column portion to a first terminal distal end face, said first panel portion at said first terminal distal end face being sized to fit within said slot on said first column portion; a support having said base end of said first concrete structure received thereupon; a substantially rigid member embedded in or attached to said support and received in said slot in said first column portion toward said end surface for providing lateral support to said first concrete structure, wherein said slot has a width extending between said side surfaces that is substantially constant from said mouth to said rigid member;
and a second concrete structure comprising: a second column portion comprising a side face with an elongated slot formed therein; and a second panel portion having opposing side faces that extend from said second column portion to a second terminal distal end face that faces away from said second column portion, a portion of said second panel portion being received within said slot of said first column portion such that said second terminal distal end face is disposed adjacent to said substantially rigid member within said slot of said first column portion.
According to yet another aspect of the present invention, there is provided a system comprising: a first concrete structure comprising: a first column comprising a side face with an elongated slot formed therein, said slot being bounded by two opposing side surfaces extending inward from a mouth at said side face of said first column to an end surface that faces toward said mouth of said slot, each of said opposing side surfaces being planar from said side face to said end surface; and a first panel having opposing side faces that extend from said first column to a first terminal distal end face that faces away from said first column; a support having said first concrete structure received thereupon; a substantially rigid member attached to said support and received in said slot in said first column for providing lateral support to said first concrete structure; and a second concrete structure comprising:
a second column comprising a side face with an elongated slot formed therein; and a second panel having opposing side faces that extend from said second column to a second terminal distal end face that faces away from said second column, a portion of said second panel being received within said slot in said first column of said first concrete -2g-structure such that said second terminal distal end face is disposed adjacent to said substantially rigid member within said slot of said first concrete structure.

According to a further aspect of the present invention, there is provided a method for assembling a wall system, the method comprising: forming a support having a substantially rigid member upstanding therefrom; positioning a first concrete structure having a first column portion and a first panel portion after the step of forming said support having said substantially rigid member upstanding therefrom, said first concrete structure being positioned so that said first column portion is resting on said support and said substantially rigid member is received within an elongated first slot formed on a side face of said first column portion so that the substantially rigid member projects upwardly above said first column portion, said first panel portion having opposing side faces that extend from said first column portion to a terminal distal end face; and positioning a second concrete structure having a second column portion and a second panel portion, said second concrete structure being positioned so that said second column portion rests on top of said first column portion with said substantially rigid member projecting upwardly above said first column portion being received within an elongated second slot formed on a side face of said second column portion, said second panel portion resting on top of said first panel portion, said second panel portion having opposing side faces that extend from said second column portion to a terminal distal end face; a third concrete structure having a third column portion and a third panel portion, a portion of said third panel portion of said third concrete structure being received within said first slot in said first column portion of said first concrete structure such that a terminal distal end face of said third panel portion is disposed adjacent to said substantially rigid member within said first slot in said first concrete structure.

The features and advantages of the disclosure will be set forth in the description that follows, and in part will be apparent from the description, or may be learned by the practice of the disclosure without undue experimentation. The features and advantages of the disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.
-2h-BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the disclosure will become apparent from a consideration of the subsequent detailed -2i-tb~~s'dt StJT np, "s'rcI ed in connection with the accompanying drawings in which:

FIG. 1 is a perspective break-away view of one embodiment of structures made in accordance with the principles of the present disclosure;
FIG. 2 is a perspective view of one embodiment of an apparatus for making the structures of FIG. 1 in accordance with the principles of the present disclosure;
FIG. 3 is a top view of the apparatus of FIG. 2;
FIG. 4 is an exploded top view of adjacent partitions of the apparatus of FIG. 2;
FIG. 5 is an end view of the apparatus of FIG. 2;
FIG. 6 is a side view of the apparatus of FIG. 2;
FIG. 7 is a side view of a partition as shown in FIGS.

3 and 4;

FIG. 8 is a cross-sectional view of the partition of FIG.
7 taken along line A-A;

FIG. 9 is a side view of a panel useful with the partition of FIG. 8;

FIG. 10 is a side view of an upper member of the panel of FIG. 9;

FIG. 11 is a side view of a lower member of the panel of FIG. 9;
FIG. 12 is a side view of a first side member of the panel of FIG. 9;
FIG. 13 is a side view of a second side member of the panel of FIG. 9;
FIG. 14 is an end view of a support on the apparatus of FIG. 2;

FIG. 15 is a perspective break-away view of another embodiment of structures made in accordance with the principles of the present disclosure;
FIG. 16 is a break away top view of an embodiment of structures in accordance with the principles of the present disclosure;

" ": 7 'is"' e cross sectional view of a structure of FIG. 16 taken along line A-A;
FIG. 18 is a break away top view of an alternative embodiment of structures in accordance with the principles of the present disclosure;
FIG. 19 is a break away top view of an additional alternative embodiment structure in accordance with the principles of the present disclosure;
FIG. 20 is a top view of another alternative embodiment structure in accordance with the principles of the present disclosure;
FIG. 21 is a top view of a further alternative embodiment structure in accordance with the principles of the present disclosure;
FIG. 22 is a side view of one embodiment of a member embedded in a footing;

FIG. 23 is a side view of one embodiment of a member attached to a footing;

FIG. 24 is a side view of an alternative embodiment of a member attached to a footing;
FIG. 25 is a side view of one embodiment of a structure attached to a footing;
FIG. 26 is a side view of an alternative embodiment structure attached to a footing; and FIG. 27 is a side view of an additional alternative embodiment structure attached to a footing.
DETAILED DESCRIPTION
For the purposes of promoting an understanding of the principles in accordance with the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the disclosure as illustrated herein, which would normally occur to one s iI "e" in the relevant art and having possession of this disclosure, are to be considered within the scope of the disclosure claimed.
Before the present concrete structure system and apparatus and method for forming one or more concrete structures is disclosed and described, it is to be understood that this disclosure is not limited to the particular configurations, process steps, and materials disclosed herein as such configurations, process steps, and materials may vary somewhat. It is also to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the present disclosure will be limited only by the appended claims and equivalents thereof.
It must be noted that, 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. Similarly, as used herein, the terms "comprising,"
"including," "containing," "characterized by," and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps.
As used herein, the term "concrete" shall be construed broadly to include conglomerate construction materials, including construction materials formed of aggregate and cementitious materials, as well as any other known material that may be placed in a fluid or semi-fluid form and hardened or solidified, including filler materials joined together with a bonding agent or resin.
As used herein, the phrase "substantially rigid" shall be construed broadly to include members that may not be completely rigid, but may have sufficient rigidity to support a structure at the time the structure is installed.
As used herein, the phrase "surface treatment" shall be construed broadly to include any variety of textures or designs or features that may be placed on the exterior of a concrete structure.

I " tzrsd'd Hd &= h.","-'nthe term "attached" shall be construed broadly to include situations in which members are secured or joined together, including situations in which one member is embedded into another member, and situations in which intervening members are used to join one member to another member such that the two members need not physically contact each other.
Referring now to FIG. 1, a break-away perspective view is shown of a plurality of structures, each structure indicated generally at 10. Each structure 10 may be formed of reinforced concrete, and may include a panel portion 12, for forming a wall, such as a fence or sound barrier, for example. The structure 10 may also form part of a retaining wall, building, or any other such construct. The panel portion 12 may include a surface treatment 13 or decorative pattern, such as stone or brick, for example, formed on an exterior surface.
The structure 10 may also include a column portion 14 for supporting the panel portion 12. The column portion 14 may have an increased lateral dimension as compared to the panel portion to allow increased vertical and lateral support of loads as the loads are transferred to a footing, floor, or other support member. The column portion 14 may also include a slot 15 for receiving a panel portion 12 of an adjacent structure 10. Accordingly, a plurality of structures 10 may be joined together to form a wall of a desired length and configuration.
In one embodiment of the present disclosure, the structure 10 may be supported on footings 16. The footings 16 may be formed in any manner known to those skilled in the art, such as cast in place reinforced concrete. A rigid member 17, shown in dashed lines in FIG. 1, such as an "I"
beam, post, or rod, for example, may be fixed into the footing 16. It will be understood that some embodiments of the present disclosure may include a rigid member 17 embedded into the footing 16, or other embodiments may include rigid members tt ~~~~ PCT/US2005/039009 "1 atel o tIri" 1" oEoting 16 by welding, bolts, or any other suitable method known to those skilled in the art. The rigid member 17 may be received in the slot 15 of the column portions 14 to support the structure 10 in an upright position. Some embodiments may also include the placement of concrete within the slot 15 of the column portions 14 to provide additional support to the structure 10.
Other embodiments of the structure 10 may include plates (not shown) attached to the footings 16 and the column portions 14 such that the plates may be attached together to support the structure 10 in an upright position. It will be understood that the plates may be imbedded into the footings 16 and column portions 14, or the plates may be attached to the footings 16 and column portions 14 using any other attachment method known in the art. Moreover, the plates on the footings 16 and column portions 14 may be attached together by welding, bolting, or any other attachment mechanism known to those skilled in the art. Similarly, any other suitable installation technique or device may be used to install the structure 10 within the scope of the present disclosure.
It will be understood that some embodiments of the structure 10 of the present disclosure may not include the column portions 14. Other embodiments of the structure 10 may not include the slots 15 within the column portions 14. Yet other embodiments of the structure 10 may include column portions 14 having upward extending openings in an interior of the column portions 14, such that the openings may be surrounded by concrete. Moreover, the structure 10 may be formed in various different cross-sectional shapes.
Accordingly it will be understood that the structure 10 may have various different configurations within the scope of the present disclosure, and various different attachment mechanisms and methods may be utilized to install the structure 10.

1:11 erririg 11ho!w1"'1~t FIG. 2, a perspective view is shown of one embodiment of an apparatus, indicated generally at 20, for forming structures 10 in accordance with the principles of the present disclosure. The apparatus 20 may include a frame 22 and a base 23 for supporting a plurality of partitions 24.
The frame 22 may be formed of an arrangement of columns, beams and/or braces configured to support the partitions 24 and the structures 10 formed by the apparatus 20. The base 23 may form a foundation for the apparatus 20 such that the apparatus 20 may be placed on the ground or any variety of floor surfaces.
As best shown in FIG. 3, which shows a top view of the apparatus 20, the partitions 24 may define one or more cavities 26 for receiving concrete to form the structures 10.
One embodiment of the partitions 24 may be configured to form a cavity 26 having a first portion 28 configured for forming the panel portion 12 of the structure 10, and a second portion 30 configured for forming the column portion 14 of the structure 10. The first portion 28 of the cavity 26 may be contiguous with the second portion 30 of the cavity 26 such that the structure 10 may be formed with the panel portion 12 and the column portion 14 integrally joined as a single piece member. The second portion 30 of the cavity 26 for forming the column portion 14 of the structure 10 may be formed having a wider dimension than the first portion 28 of the cavity 26 for forming the panel portion 12 of the structure 10.
Accordingly, a column portion 14 of the structure 10 may be formed to withstand increased loads transferred from the panel portion 12 to the footing 16 or other'such support member.
In one embodiment of the present disclosure, the partitions 24 may be arranged such that the second portions 30 of the cavities 26 for forming the column portion 14 of the structures 10 may be arranged on opposing ends of the apparatus 20 on adjacent partitions 24. For example, the apparatus may be configured to form six structures 10 at a time, and three of the column portions 14 of the structures 0 may'15d 'formed 's nf"o'he end of the apparatus 20, and the other three column portions 14 may be formed at the opposite end of the apparatus 20, with each adjacent structure 10 being formed with the column portions 14 on opposite ends of the apparatus 20. It will be understood, however, that the apparatus 20 may be configured to form various different quantities of structures 10 at a time, and that the partitions 24 may be configured in various different arrangements.
One or more ribs 31 may be positioned in the second portion 30 of the cavity 26 for forming the slot 15 in the column portion 14 of the structure. The ribs 31 may be sized and shaped corresponding to the desired size and shape of the slot 15 in the column portion 14 of the structure. The ribs 31 may be positioned at any desired location such that the concrete structures 10 may be formed as desired. For example, the rib 31 may be placed to form the slot 15 in the end of the concrete structures 10, such that the panel portion 12 of a concrete structure 10 may be received in the slot 15 of an adjacent concrete structure 10 to form a substantially straight barrier. Also, the rib 31 may be placed in a side of the end of the partition 24 such that the slot 15 may extend substantially perpendicular to the panel portion 12 to allow adjacent concrete structures 10 to form a corner. It will be understood that the ribs 31 may be positioned at any desired angle or location within the scope of the present disclosure. Moreover, some embodiments of the apparatus 20 may include one or more ribs 31 positioned in other parts of the cavity 26 to form slots in the panel portion 12 of the structure 10, or to form openings within an interior of the column portion 14.
One embodiment of the present disclosure may include ribs 31 that may be removably attached using bolts, indicated by dashed lines at 29, such that the ribs 31 may be removed and repositioned as desired. It will be understood that other embodiments of the present disclosure may include other types of attachment mechanisms for the ribs 31, and some embodiments preen' C1 18sure may include ribs that may be fixed in place. Other embodiments may not include any ribs such that the structures may be formed without slots 15.
The partitions 24 may be positioned in a side by side arrangement and at least some of the partitions 24 may be configured to be movable with respect to the frame 22 to facilitate placing reinforcing steel into the cavity 26 as well as to facilitate removing the structure 10 after the concrete has hardened. FIG. 4 shows an exploded top view of adjacent partitions 24. It will be appreciated that the partitions 24 may be separated such that reinforcing steel may be placed between the partitions 24. The partitions 24 may be joined together such that end panels 46 on adjacent partitions 24 come into contact with each other. Accordingly the cavity 26 may thereby be defined by the partitions for receiving concrete for forming the structure 10. Once the concrete has hardened, the partitions 24 may be separated for removing the structure 10. One embodiment of the apparatus may include wheels 32 for supporting the partitions 24 on 20 the frame 22 and allowing the partitions 24 to be easily moved.
In one embodiment of the apparatus 20, the frame 22 may include a support 34 for receiving the wheels 32. The support 34 may extend laterally to provide a space to allow the partitions 24 to be moved apart from each other. An overhang portion 36 of the support 34 may be detachable such that the width of the apparatus 20 may be reduced to facilitate transporting the apparatus 20. Any attachment mechanism known in the art, such as bolts, pins, or clamps, for example, may be used to attach the overhang portion 36 to the remainder of the support 34. Accordingly, the apparatus may be sized to fit on a trailer, rail car or other such transporting device to be transported on rails or highways. It will be understood that other embodiments of the apparatus 20 may include a one piece support 34 that may not be configured to be detached or otherwise retracted to a compact configuration.

t i l "i f the support 34 may include tracks 38 for assisting in maintaining the wheels 32 in position. An end view of the support 34 showing one embodiment of the tracks 38 is shown in FIG. 14. The tracks 38 may form ridges for guiding the wheels 32 along a specified path on the support 34. It will be understood that the tracks 38 may be formed in any suitable configuration and manner, and that some embodiments of the present disclosure may not include tracks.
The wheels 32 may be joined to the partitions 24 through arms 40. Adjacent arms 40 may have different lengths, such as a short arm 42 and a long arm 44, such that adjacent partitions 24 may be configured to abut each other without interference from the wheels 32. The arms 40 having different lengths allow the wheels 32 to extend at different locations along the support 34 without contacting each other to thereby allow the partitions 24 to be positioned in an abutting arrangement.
One embodiment of the apparatus 20 may include one or more partitions 24 that may be fixed in place. For example, an end partition 25 on an external side of the apparatus 20 may be attached to the frame 22 so as to be stationary. Other embodiments of the apparatus 20 may include partitions 24 that may all be moveable.
Referring to FIG. 5, an end view of the apparatus 20 is shown. The apparatus 20 may include an end wall or door 48 for enclosing an end of the partitions 24. It will be understood that a door 48 may be positioned on opposing ends of the apparatus 20. Alternatively, it will be understood that the door 48 may be positioned on a single end of the apparatus 20. The door 48 may be supported on door wheels 50 on opposing sides such that the door 48 may be capable of moving in a longitudinal direction of the apparatus away from the partitions 24 in a direction substantially perpendicular to the direction of movement of the partitions 24. As shown most clearly in FIG. 6, which shows a side view of the apparatus 20, the door wheels 50 may be supported on door i Rio ` t;61--2" po I r 1A` d on opposing sides of the apparatus 20 for providing a support surface for the door wheels 50 to roll upon. Accordingly, one embodiment of the present disclosure may provide a door 48 that can be moved in a translational manner for at least a part of its movement path. In other words, every point on the door 48 may move parallel to and the same distance as every other point on the door 48. Similarly, it will be understood that one or more of the partitions 24 may be configured to move in a translational manner, and the direction of movement of the partitions 24 may be substantially perpendicular to the movement of the door 48.
A hinge 53 may also be provided for the door 48 such that when the door 48 is moved a distance away from the partitions 24 into alignment with the hinge 53, the hinge 53 may be engaged to allow the door 48 to swing open. One embodiment of the hinge 53 may include a receiver on the door 48 and the frame 22 for receiving a pin, such that when the door 48 is moved to the point where the receivers are in alignment, a pin may be placed in the receivers to join the door 48 with the frame 22 through the hinge 53, such that the door 48 may swing with respect to the frame 22. It will be understood that other embodiments of the door 48 may be attached by a hinge such that the door may be configured to swing without rolling a distance away from the partitions 24. Yet another embodiment of the apparatus 20 may be provided without a hinge.
In one embodiment of the present disclosure, allowing the door 48 to move away from the partitions 24 before swinging open may allow the ribs 31 to clear the slots 15 in the column portions 14 of the structures 10. Otherwise, swinging motion of the door 48 may be impeded by contact between the ribs 31 and slots 15 to make opening the door 48 difficult in some arrangements of the ribs 31.
Referring now to FIG. 7, a side view of one embodiment of a partition 24 is shown. A cross-sectional view of the partition 24 taken along line A-A is shown in FIG. 8. It will b~~ partition 24 may be sized to form a structure 10 and the partition 24 may include one or more brace members 54. The brace members 54 may be sized and positioned to provide strength to the partition 24 since the forces exerted by concrete in the apparatus 20 may be significant. It will be understood that some of the brace members 54 may be positioned in an upright orientation, and that other embodiments of the brace member 54 may be positioned in a lateral or diagonal orientation.
A panel 56, as best shown in FIG. 9, may be positioned on an exterior surface of the partition 24. The panel 56 may include any variety of shapes or features desired to be applied to the concrete structures 10. One embodiment of the panel 56 may include a plate or liner 58 for placing a surface treatment 13 on the concrete structure 10. The surface treatment may include any variety of textures or designs, such as designs of rock or brick, for example. Other embodiments of the liner 58 may be substantially smooth, without any particular design. Moreover, some embodiments of the liner 58 may include a continuous pattern or texture configured to extend over the entire panel 56, whereas other embodiments of the liner 58 may have multiple patterns, or be configured to cover only a portion of the panel 56.
One embodiment of the panel 56 may include an upper member 60, a lower member 62, a first side member 64 and a second side member 66 for forming a frame or housing 70 around the liner 58 for holding the liner 58 in place. One embodiment of the upper member 60, lower member 62, first side member 64 and second side member 66 may be formed of plate steel, 3/16 inches thick, for example. However, it will be understood that various different materials having different dimensions may be used within the scope of the present disclosure to form the upper member 60, lower member 62, first side member 64 and second side member 66.
As shown most clearly in FIGS. 10-13, which depict side views of the upper member 60, lower member 62, first side rn ",ahc7 ide member 66, respectively, the housing 70 may be formed by an upper lip 72 on the upper member 60, a lower lip 74 on the lower member 62, a first side lip 76 on the first side member 64, and a second side lip 78 on the second side member 66. It will be understood that one embodiment of the upper lip 72, lower lip 74, first side lip 76 and second side lip 78 may be formed of a tri-angular shaped member. However, it will be understood that the housing 70 may be formed of various different shaped members configured to receive the liner 58. It will also be understood that some embodiments of the panel 56 may include a back wall behind the liner 58. Moreover, any variety of seals, adhesives, or attachment mechanisms may be used to maintain the liner 58 within the housing 70 and allow the liner 58 to be removed and interchanged with other liners for providing different surface treatments to the structures 10 to be formed. It will also be appreciated that other embodiments of the panel 56 may be formed without the upper member 60, lower member 62, first side member 64 and second side member 66, such that the panel 56 may be formed in different configurations without a frame or border surrounding the liner 58.
In use, panels 56 may be selected having a surface treatment desired to be placed on structures 10. The doors 48 may be opened and the partitions 24 may be moved to provide access to the partitions 24. The panels 56 may be joined with the partitions 24 and reinforcing steel may be placed in the apparatus for a particular structure 10, if desired. Adjacent partitions 24 may be moved to abut each other and reinforcing material may be placed in a subsequent cavity 26. Once all of the reinforcing material is placed in the apparatus and the partitions 24 are joined together, the partitions 24 may be fastened in place using fasteners 68, as best shown in FIG.
3. One embodiment of the fasteners 68 may include pins receivable in the base 23 for holding the partitions 24 in place. It will also be understood that the fasteners 68 may i c`1it 1 11 e"~ i7 "o :L, I'll I `""" ety of fastening mechanism known in the art, including threaded rods having adjustable blocking members attached thereto. The rods may be pivotally attached to the base 23 or the partitions 24 and the blocking members may be engaged with the other of the base 23 or the partitions 24 for adjustably blocking movement of the partitions 24.
Moreover, it will be understood that additional fasteners 69, as shown in dashed lines in FIGS. 3 and 5, may be used to fasten the partitions 24 in place. The additional fasteners 69 may include bolts extending through the exterior partition 24 on opposing ends of the apparatus 20. It will be understood that the location, configuration and quantity of fasteners 69 may vary within the scope of the present disclosure. Moreover, it will be understood that any other type of bolt, latch, pin, clamp or fastener known in the art may be used to hold the partitions 24 in place within the scope of the present disclosure.
Wet concrete may then be poured into the top of the apparatus 20 from above to thereby fill the cavities 26. Once the concrete has hardened adequately, the partitions 24 may be separated and the structures 10 may be removed. It will be understood that any variety of lifting mechanisms, such as cranes or lifts, may be used to remove the structures from the apparatus 20. Moreover, in some uses of the apparatus 20, it may be beneficial to apply a suitable anti-sticking agent to the apparatus 20 prior to placing concrete in the apparatus 20 to facilitate removing the structure 10 from the apparatus 20. Once the structures are removed from the apparatus 20, the apparatus may be cleaned and used repeatedly to produce additional structures 10 in a controlled environment for shipping to a construction site for installation. The apparatus 20 may also be placed in any location as desired to facilitate construction or shipping of the structures 10.
It will be understood that some embodiments of the present disclosure may include an apparatus that may be configured to form a plurality of structures that do not --- 'Rrtions, such that a plurality of panels may be formed. Other embodiments of the present disclosure may include an apparatus that forms structures in the form of columns. Accordingly, any variety of structures, having different arrangements of columns and/or panels, may be formed in accordance with the principles of the present disclosure.
Moreover, other structures of various different configurations may be formed that may not be considered to be either panels or columns, in accordance with the principles of the present disclosure.

It will be appreciated that the apparatus 20 may be configured to receive concrete of various different varieties known in the art. Moreover, the apparatus 20 may accommodate reinforcing material or steel, commonly referred to as rebar, to construct structures 10 of various different designs and configurations. The arrangement of the cavity 26 may allow for reinforcing steel to be place continuously in the first portion 28 of the cavity 26 for forming the panel portion 12 of the structure 10 and the second portion 30 of the cavity for forming the column portion 14 of the structure 10, such that the panel portion 12 and the column portion 14 of the structure 10 can be tied together with the reinforcing steel.
It will also be understood that the apparatus 20 may also include any variety of vibrating mechanisms integrally or removably attached to the apparatus 20 in various different configurations to facilitate dispersal of wet concrete within the cavities 26.
It will be understood that the apparatus 20 may be formed of any suitable materials known in the art. For example, portions of the apparatus 20 may be formed of steel, and components of the apparatus 20 may be joined together using any suitable method known in the art, such as by welding or bolting, for example. The liner 58 may be formed of any suitable material for placing a texture or design on the concrete without bonding to the concrete such that the if r'uC 9Y, s "='1a- removed from the apparatus 20 without damage.
In accordance with the features and combinations described above, a useful method of forming concrete structures may include the steps of:
(a) placing a plurality of partitions in a side by side arrangement;
(b) defining a plurality of cavities with the plurality of partitions, the plurality of cavities each having a column portion and a panel portion such that the concrete structures include a one piece column and panel. The method may also include selecting liners having a desired surface treatment to be placed on the structures and removably attaching the liners to the partitions.
Those having ordinary skill in the relevant art will appreciate the advantages provided by the features of the present disclosure. For example, it is a feature of the present disclosure to provide an apparatus for forming one or more concrete structures which is simple in design and manufacture. Another feature of the present disclosure is to provide such an apparatus capable of forming concrete structures having walls with integral columns. It is a further feature of the present disclosure, in accordance with one aspect thereof, to provide an apparatus for forming one or more concrete structures in which the apparatus may include interchangeable liners for placing different surface treatments, textures or finishes on the structures. It is an additional feature of the present disclosure to provide an apparatus for forming one or more concrete structures, in which the structures may be efficiently produced and installed. It is an additional feature of the present disclosure to provide an apparatus for forming precast concrete structures in which the structures may be formed in a factory setting with controlled conditions for improved quality of the structures.

FIG. 15, a break-away perspective view is shown of a plurality of structures, each structure indicated generally at 110. One embodiment of each structure 110 may be formed of reinforced concrete, and may include a panel portion 112, for forming a wall, such as a fence or sound barrier, for example. The structure 110 may also form part of a retaining wall, building, or any other such construct. The panel portion 112 may include a surface treatment 113 or decorative pattern, such as stone or brick, for example, formed on an exterior surface.
The structure 110 may also include a column portion 114 for supporting the panel portion 112. The column portion 114 may have an increased lateral dimension as compared to the panel portion to allow increased vertical and lateral support of loads as the loads are transferred to a footing, floor, or other support member. The column portion 114 may also include a slot 115 for receiving a panel portion 112 of an adjacent structure 110. Accordingly, a plurality of structures 110 may be joined together to form a wall of a desired length and configuration. It will also be understood that one embodiment of the present disclosure may include a column portion 114 that does not include a panel portion 112.
In one embodiment of the present disclosure, the structure 110 may be supported on footings 116, also sometimes referred to herein as supports. The footings 116 may be formed in any manner known to those skilled in the art, such as cast in place reinforced concrete. A member 117, shown in dashed lines in FIG. 15, such as a substantially rigid member including an "I" beam, post, pipe, rod, or reinforced concrete member, for example, may be attached to the footing 116. As discussed more fully below, it will be understood that some embodiments of the present disclosure may include a rigid member 117 embedded into the footing 116, or other embodiments may include rigid members 117 attached to the footing 116 by welding, bolts, or any other suitable method known to those skilled in the art. The rigid member 117 may be received in 1j= i o~.Aniilrig x'123{' j 14 with the slot 115 of the column portions 114 to support the structure 110 in an upright position.
Accordingly, it will be understood that one embodiment of the present disclosure may include an opening 120 that may be contiguous with the slot 115 such that there may be no structural separation between the opening 120 and the slot 115. Some embodiments may also include the placement of concrete within the opening 120 of the column portions 114 to provide additional support to the structure 110 once the concrete hardens. It will be understood that some embodiments of the rigid member 117 may make construction of the structure 110 possible without the need for forming a reinforcing cage on site for receiving cast in place concrete to support the structures 110. Accordingly, the labor requirements for installing the structures may be reduced.
A break-away top view of one embodiment of adjacent structures 110 is shown in FIG. 16. It will be understood that the structures 110 may be formed of pre-cast concrete.
The structures 110 may also include reinforcing steel 118, as shown in dashed lines in FIGS. 16 and 17. It will be understood that the configuration of reinforcing steel 118 as well as the concrete formulation may be provided in any suitable manner known to those skilled in the art to provide suitable strength and durability characteristics for the structures 110. It will also be understood that some embodiments of the structure may not include reinforcing steel 118.
The panel portion 112 and the column portion 114 may formed in any manner known to those skilled in the art, such as by placing concrete in forms in a factory condition so as to produce the structures 110 under controlled conditions.
One embodiment of the structure 110 may include the column portion 114 and the panel portion 112 as an integral one piece member of unitary construction without joints. Other embodiments of the present disclosure may be cast in place at a construction site.

WO 2006/047754 (( ~+ ~I PCT/US2005/039009 e "e1r"'ehde'1J I'Y' u"{now to made to FIG. 18 to describe an alternative embodiment of the present disclosure. As previously discussed, the presently disclosed embodiments of the disclosure illustrated herein are merely exemplary of the possible embodiments of the disclosure, including that illustrated in FIG. 18.
It will be appreciated that the alternative embodiment of the disclosure illustrated in FIG. 18 may contain many of the same features represented in FIGS. 15-17 and only the new or different features will be explained to most succinctly describe the embodiments of the disclosure illustrated in FIG.
18.
FIG.18 illustrates a break-away top view of an alternative structure 110a having an opening 120a for receiving a rigid member 117 for supporting the structure 110a in an upright position. The opening 120a may be separated from the slot 115a such that the rigid member 117 may be separated from the panel portion 112a of an adjacent structure 110a. It will be understood that the size, shape and position of the opening 120a may vary in accordance with the principles of the present disclosure.

A break-away top view of an additional alternative embodiment structure 110b is shown in FIG. 19. The alternative embodiment structure 110b may be formed with a panel portion 112b and a column portion 114b. The column portion 114b may also include an opening 120b. However, the alternative embodiment of FIG. 19 may not include a slot.
Accordingly, any adjacent structures 110b, if present, may be joined without being received within the column portion 114b.
Similarly, as shown in FIG. 20, which shows a top view of yet an additional alternative embodiment structure 110c, the column portion 114c may be formed without a panel portion or a slot. The structure 110c may include an opening 120c for receiving a rigid member 117 to support the structure 110c in an upright position.

t'3 -s b understood, that a further alternative embodiment structure 110d may be provided without a panel portion and having a plurality of slots 115d, as shown in FIG.

21. Accordingly, panel portions may be provided separately from the structure 110d, and the panel portions may be joined to the structure 110d through the slots 115d. It will be understood that the quantity, configuration and position of the slots 115d may vary as desired in accordance with the principles of the present disclosure. For example, it will be understood that the slots 115d may be formed on adjacent sides of the structure 110d, as depicted by the dashed lines in FIG. 21, such that the structure 110d may form a corner of a barrier with panel portions extending perpendicular to each other.
Referring now to FIG. 22, a side view is shown of one embodiment of a footing 116 and a rigid member 117. It will be understood that the rigid member 117 may be formed as an "I" shaped member in cross section. Alternatively, it will be understood that the rigid member 117 may be formed of a round pipe member, or a polygonal post member, or any other shaped member known to those skilled in the art. Moreover, the member 117 may have any suitable size within the scope of the present disclosure. The member 117 may be formed of steel or any other suitable material known to those skilled in the art to provide a member 117 that may be substantially rigid.
It will be understood that one embodiment of the member 117 may be formed of a material that may be substantially rigid at the time the structure 110 is installed on the footing 116.
Accordingly, assembly of the structures 110 may occur rapidly without waiting for concrete within the openings 120 to harden, as would be the case if the member 117 were formed of concrete cast within the opening 120.
The footing 116 may be formed of a concrete material, cast in place or precast in a manner known to those skilled in the art. Moreover, the footing 116 may be sized and include steel reinforcement as is known in the art. As shown FM~16-1 id member 117 may be attached to the footing 116 by being embedded within the footing 116. It will be understood that the member 117 may be placed in wet concrete forming the footing 116 such that the concrete may bond with the member 117 to form a substantially fixed connection.
It will be understood that the member 117 may be embedded into the footing 116 at various different depths depending on various factors such as the height of the structure 110, the spacing of the column portions 114, and the type of soil supporting the footing 116, for example. One example of the present disclosure may include a rigid member 117 that may be embedded approximately five feet in the footing 116 and the rigid member 117 may extend another four feet out of the footing 116 for supporting a structure 110 that may be eight feet tall. The footing 116 may be formed approximately two-three feet in diameter for example. Accordingly, it will be understood that the disclosure presented in FIG. 22 is schematic in nature and is not intended to be depicted to scale. Moreover, it will be understood that the features of the present disclosure may vary, including the dimensions of the rigid member 117, the structure 110, and the footing 116,, as well as the depth the rigid member 117 may be embedded into the footing 116.
Alternatively, it will be understood that the footing 116 may be formed with an opening into which the member 117 may be received when the footing is in a hardened condition. The member 117 may thereafter be fixed within the footing 126 in any manner known to those skilled in the art, or the member 117 may be retained in the footing due to gravity and/or friction.
Referring to FIG. 23, a side view is shown of an alternative embodiment for attaching the member 117 to the footing 116. A plurality of fasteners 122 may be embedded in the footing 116 for attaching to a brace member 124 on the rigid member 117. The fasteners 122 may include bolts or WO 2006/047754 PCT/US2005/039009 1 -1 11 ii;;'' i E; ,,;~ it ;I::~ 't;:
t~~ee ' f',"6d8li"a ri4:;,1a'=`t' headed end for receiving a nut 126. It will be understood that any number of fasteners 122 may be utilized to create a suitable connection between the footing 116 and the rigid member 117. The brace 124 may be formed as an angle member or flat member joined to the rigid member 117 in any suitable manner known in the art. For example, the brace member 124 may be welded or bolted to the rigid member 117 such that the brace member 124 may be fixedly attached to the rigid member 117. The brace member 124 may have openings for receiving the fasteners 122 therethrough. Once the fasteners 122 are received through the brace member 124, the nuts 126 may be cinched tight to fixedly attach the rigid member 117 to the footing 116.
Referring to FIG. 24, a side view is shown of an another alternative embodiment for attaching the member 117 to the footing 116. A first plate 127 may be joined to the member 117, such as by welding. A second plate 128 may be joined with the footing 116, such as by being embedded into the footing 116. It will be understood that the second plate 128 may be embedded into the footing 116 so as to protrude above an upper surface of the footing 116, or alternatively, the second plate 128 may be even with the upper surface of the footing 116, or the second plate may be positioned below the upper surface of the footing 116. The first plate 127 may be welded to the second plate 128 to thereby join the member 117 with the footing 116.
Referring now to FIG. 25, a side view is shown of a further embodiment of a connection between a column portion 114e and a footing 116. The column portion 114e may include a slot 115e for receiving a panel portion of an adjacent structure 110 similar to the embodiments previously discussed.
The column portion 114e may also include reinforcing steel 118e, shown in dashed lines, such as rebar. An angle member 129 may be joined to the column portion 114e to assist in supporting the column portion in an upright position. The angle member 129 may be welded to the reinforcing steel 118e, and`or the angle"Lpher 129 may be embedded into the column portion 114e, or the angle member 129 may be joined with the column portion 114e in any other manner known to those skilled in the art. The angle member 129 may extend around a bottom corner of the slot 115e so as to provide a surface for joining with a plate 131 joined with the footing 116. The plate 131 may be embedded in the footing 116, or joined with the footing 116 in any other manner known to those skilled in the art.
It will be understood that the angle member 129 may be welded to the plate 131 to support the column portion 114e in an upright orientation.
Referring now to FIG. 26, a side view is shown of a further embodiment of a connection between a column 130 and a footing 116. It will be understood that the column 130 may form part or all of the structure 110, or the column 130 may be representative of a rigid member for supporting a structure 110 in an upright position. A first plate 132 may be joined to the column 130 and a second plate 134 may be joined to the footing 116. The first plate 132 may then be joined to the second plate 134 by welding, bolting or any other suitable attachment mechanism known to those skilled in the art. It will be understood that the first plate 132 may be joined with the column 130 using anchors 136 embedded into the column 130, or the first plate 132 may itself be embedded into the column 130, or the first plate 132 may be joined with the column 130 in any other suitable manner known to those skilled in the art. Similarly, the second plate 134 may be joined with the footing 116 using anchors 136, or the second plate 134 may be joined with the footing 116 using any other attaching method known to those skilled in the art.
Referring to FIG. 27, an additional alternative embodiment connection mechanism is disclosed in which the first plate 132 may be attached to the footing 116 using fasteners 122. The fasteners 122 may be embedded into the footing 116 similar to the embodiment of FIG. 23 discussed previously. The first plate 132 may include openings for '~'c'erje~~lie s 122 and nuts 126 may be threaded onto the fasteners to attach the column 130 to the footing 116.
One embodiment of construction of a concrete system in accordance with the principles of the present disclosure will now be described. The structure 110 may be constructed on site or precast in a factory setting under controlled conditions. The structure 110 may be formed to include a desired surface treatment such as a brick or stone wall, for example. The footing or support 116 may typically be formed in place at the construction site. The member 117 may be attached to or embedded in the footing 116 in a desired orientation to ensure that the structure may be oriented as desired. The structure 110 may then be lifted such that the member 117 may be received in the opening 120. This may typically take place as the structure 110 is unloaded from a vehicle transporting the structure 110. A crane or other lifting device may be used to lift the structure 110 and lower the structure 110 over the member 117 onto the footing 116.
Welding, bolting, and/or placement of concrete in the opening 120 may be used, for example, to fix the structure 110 to the footing 116. An adjacent structure 110 may be installed in a similar fashion, with the panel portion 112 received in the slot 115. Accordingly, a concrete column, panel and support system may be easily constructed to provide an aesthetically pleasing barrier.
It will also be understood that an alternative embodiment of the present disclosure may include two or more of the structures 110 stacked on top of each other. A rigid member 117 may extend beyond an entire height of the bottom structure 110 up through a portion or all of the height of an upper structure 110. For example, one embodiment of the present disclosure may include a rigid member 117 extending from the footing 116 up to half way through the height of an upper structure 110. Accordingly, the upwardly stacked structures 110 may be supported in various heights and configurations.

1'Ift w's`l'l fib' t NEIL
rstood that the structures disclosed herein may be formed of various materials, including concrete and/or filler materials, such as fiberglass, chopped glass or any other suitable material, that may be bonded or solidified into a hardened material with a cement or bonding agent, such as a resin. Similarly, the apparatus for forming structures as disclosed herein may be configured to be compatible with various such construction materials.
It will be appreciated that the structure and apparatus disclosed herein is merely one example of a means for attaching a concrete structure to a support, and it should be appreciated that any structure, apparatus, or system for attaching a concrete structure to a support that performs, functions the same as, or equivalent to, those disclosed herein are intended to fall within the scope of a means for attaching a concrete structure to a support, including those structures, apparatuses, or systems for attaching that are presently known, or that may become available in the future.
Anything that functions the same as, or equivalently to, a means for attaching a concrete structure to a support falls within the scope of this element.
In accordance with the features and combinations described above, a useful method of attaching a structure to a support includes the steps of:
(a) attaching a substantially rigid member to a support;
(b) providing an opening in said structure for receiving said substantially rigid member; and (c) placing said substantially rigid member in said opening.
Those having ordinary skill in the relevant art will appreciate the advantages provided by the features of the present disclosure. For example, it is a feature of the present disclosure to provide a structural system that is simple in design and manufacture. Another feature of the present disclosure is to provide such a structural system that is easy to install. It is a further feature of the present disclosure, in accordance with one aspect thereof, to provide a structural system that is stable and that has an aesthetically pleasing appearance. It is an additional feature of the present disclosure, in accordance with one aspect thereof, to provide a structural system that may include a column portion integral with a panel portion of the structure. Another feature of one aspect of the present disclosure is to provide a structure that may be supported in an upright orientation by a substantially rigid member.
In the foregoing Detailed Description, various features of the present disclosure are grouped together in a single embodiment for the purpose of streamlining the disclosure.
This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim.
Rather, as the following claims reflect, inventive aspects lie in less than all features, of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description by this reference, with each claim standing on its own as a separate embodiment of the present disclosure.
It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present disclosure. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the scope of the present disclosure and the appended claims are intended to cover such modifications and arrangements. Thus, while the present disclosure has been shown in the drawings and described above with particularity and detail, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein.

Claims

CLAIMS:

1. A system comprising:

a first concrete structure and a second concrete structure, each comprising a column portion and a panel portion integrally joined with said column portion, said column portion comprising a side face with an elongated slot formed therein, said panel portion having opposing side faces that extend from said column portion to a terminal distal end face, said slot having a width at said side face that is greater than or equal to the width of said panel portion where said panel portion is joined to said column portion;

a support having said first concrete structure received thereupon; and a substantially rigid member rigidly embedded within said support and received in said slot in said column portion of said first concrete structure for providing lateral support to said first concrete structure, a portion of said panel portion of said second concrete structure being received within said slot in said column portion of said first concrete structure such that said terminal distal end face of said panel portion of said second concrete structure is disposed adjacent to said substantially rigid member within said slot in said first concrete structure.

2. The system of claim 1, wherein said substantially rigid member is an I
beam.

3. The system of claim 1, wherein said opposing side faces of said panel portion of each concrete structure are substantially parallel to each other along the entire length thereof between said column portion and said terminal distal end face.

4. The system of claim 1, wherein said panel portion of each concrete structure has a width extending between said opposing side faces that is substantially constant along the entire length between said column portion and said terminal distal end face, said width of said panel portion being sized to fit within said slot on said column portion.

5. The system of claim 4, wherein said terminal distal end face of each concrete structure is substantially planar and extends between said opposing side faces.

6. The system of claim 1, wherein for each concrete structure, said terminal distal end face of said panel portion faces away from said column portion.

7. A system comprising:

a first concrete structure comprising:

a first column comprising a side face with an elongated slot formed therein, said slot being bounded by two opposing side surfaces extending inward from a mouth at said side face of said first column to an end surface that faces toward said mouth of said slot; and a first panel having opposing side faces that extend from said first column to a first terminal distal end face that faces away from said first column;

a support having said first concrete structure received thereupon;

a substantially rigid member attached to said support and received in said slot in said first column for providing lateral support to said first concrete structure, wherein said slot has a width extending between said side surfaces that is substantially constant from said mouth to said rigid member; and a second concrete structure comprising:

a second column comprising a side face with an elongated slot formed therein; and a second panel having opposing side faces that extend from said second column to a second terminal distal end face that faces away from said second column, a portion of said second panel being received within said slot in said first column of said first concrete structure such that said second terminal distal end face is disposed adjacent to said substantially rigid member within said slot of said first concrete structure.

8. The system of claim 7, further comprising a brace for attaching said substantially rigid member to said support.

9. The system of claim 8, further comprising fasteners embedded in said support for attaching to said brace.

10. The system of claim 7, further comprising a first plate attached to said first concrete structure and a second plate attached to said support, wherein said first plate is attachable to said second plate.

11. The system of claim 7, further comprising at least one plate attachable to one of said support and said first concrete structure for attaching said first concrete structure to said support.

12. The system of claim 7, wherein a portion of said substantially rigid member is rigidly embedded within said support.

13. The system of claim 7, wherein said first panel has a width extending between said opposing side faces at said first terminal distal end face and the width of said slot of said first column is greater than or equal to the width of said first panel at said first terminal distal end face.

14. A system comprising:

a first concrete structure having a height extending from a base end to an opposing upper end, said first concrete structure comprising:

a first column portion having a side face that extends along said height of said first column portion, an elongated slot being formed in said side face and extending along said height of said first column portion, said slot being bounded by two opposing side surfaces extending inward from a mouth at said side face of said first column portion to an end surface that faces toward said mouth of said slot; and a first panel portion having opposing side faces that extend from said first column portion to a first terminal distal end face, said first panel portion at said first terminal distal end face being sized to fit within said slot on said first column portion;

a support having said base end of said first concrete structure received thereupon;

a substantially rigid member embedded in or attached to said support and received in said slot in said first column portion toward said end surface for providing lateral support to said first concrete structure, wherein said slot has a width extending between said side surfaces that is substantially constant from said mouth to said rigid member; and a second concrete structure comprising:

a second column portion comprising a side face with an elongated slot formed therein; and a second panel portion having opposing side faces that extend from said second column portion to a second terminal distal end face that faces away from said second column portion, a portion of said second panel portion being received within said slot of said first column portion such that said second terminal distal end face is disposed adjacent to said substantially rigid member within said slot of said first column portion.

15. The system of claim 14, wherein said first column portion and said first panel portion are integral such that said first concrete structure is a one piece member, said second concrete structure being separate and discrete from said first concrete structure.

16. The system of claim 14, wherein said substantially rigid member comprises an I beam.

17. The system of claim 14, further comprising a brace for attaching said substantially rigid member to said support.

18. The system of claim 17, further comprising fasteners embedded in said support for attaching to said brace.

19. The system of claim 14, wherein said first column portion comprises an increased lateral dimension as compared to said first panel portion.

20. The system of claim 14, wherein a portion of said substantially rigid member is rigidly embedded within said support.

21. The system of claim 14, wherein said opposing side faces of said first panel portion are substantially parallel to each other along the entire length thereof between said first column portion and said first terminal distal end face.

22. The system of claim 14, wherein said first panel portion has a width extending between said opposing side faces that is substantially constant along the entire length between said first column portion and said first terminal distal end face.

23. The system of claim 14, wherein said width of said slot of said first column portion is substantially constant from said mouth to said end face.

24. The system of claim 14, wherein said rigid member is securely fixed to said support and said second concrete structure is movable relative to said rigid member.

25. A system comprising:

a first concrete structure comprising:

a first column comprising a side face with an elongated slot formed therein, said slot being bounded by two opposing side surfaces extending inward from a mouth at said side face of said first column to an end surface that faces toward said mouth of said slot, each of said opposing side surfaces being planar from said side face to said end surface; and a first panel having opposing side faces that extend from said first column to a first terminal distal end face that faces away from said first column;

a support having said first concrete structure received thereupon;

a substantially rigid member attached to said support and received in said slot in said first column for providing lateral support to said first concrete structure; and a second concrete structure comprising:

a second column comprising a side face with an elongated slot formed therein; and a second panel having opposing side faces that extend from said second column to a second terminal distal end face that faces away from said second column, a portion of said second panel being received within said slot in said first column of said first concrete structure such that said second terminal distal end face is disposed adjacent to said substantially rigid member within said slot of said first concrete structure.

26. A method for assembling a wall system, the method comprising:

forming a support having a substantially rigid member upstanding therefrom;
positioning a first concrete structure having a first column portion and a first panel portion after the step of forming said support having said substantially rigid member upstanding therefrom, said first concrete structure being positioned so that said first column portion is resting on said support and said substantially rigid member is received within an elongated first slot formed on a side face of said first column portion so that the substantially rigid member projects upwardly above said first column portion, said first panel portion having opposing side faces that extend from said first column portion to a terminal distal end face; and positioning a second concrete structure having a second column portion and a second panel portion, said second concrete structure being positioned so that said second column portion rests on top of said first column portion with said substantially rigid member projecting upwardly above said first column portion being received within an elongated second slot formed on a side face of said second column portion, said second panel portion resting on top of said first panel portion, said second panel portion having opposing side faces that extend from said second column portion to a terminal distal end face;

a third concrete structure having a third column portion and a third panel portion, a portion of said third panel portion of said third concrete structure being received within said first slot in said first column portion of said first concrete structure such that a terminal distal end face of said third panel portion is disposed adjacent to said substantially rigid member within said first slot in said first concrete structure.

27. The method as recited in claim 26, wherein the substantially rigid member comprises a unitary I-beam, post, pipe, or rod.

28. The method as recited in claim 26, wherein the step of forming said support comprise embedding the substantially rigid member within the support so that the substantially rigid member upstands therefrom.

29. The method as recited in claim 26, wherein said substantially rigid member has a height greater than a height of said first column prior to the step of positioning said first concrete structure.