US20160362890A1

US20160362890A1 - Precast concrete wall member and method of erecting the same

Info

Publication number: US20160362890A1
Application number: US15/179,107
Authority: US
Inventors: Andrew Burke
Original assignee: Oldcastle Precast Inc
Current assignee: Oldcastle Precast Inc
Priority date: 2015-06-11
Filing date: 2016-06-10
Publication date: 2016-12-15

Abstract

A free standing wall panel system including a wall panel member and an associated base member for supporting the panel is provided. The system provides versatility for on-site construction and erection of wall panels that may be positioned or erected in various orientations and may comprise temporary, permanent, or semi-permanent wall or barrier features.

Description

This U.S. Non-Provisional Patent Application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 62/174,356, filed Jun. 11, 2015, the entire disclosure of which is hereby incorporated by reference.

FIELD OF THE INVENTION

Embodiments of the present invention relate generally to walls and building panels. More specifically, embodiments of the present invention relate to precast wall members, panels, and sections and methods for erecting the same and forming walls, retaining devices and barriers.

BACKGROUND OF THE INVENTION

Prior art freestanding panel assemblies generally fail to provide wall panels or systems that are quick and efficient to assemble, capable of being erected or assembled on various or varied terrain surfaces, and/or that are of adequate strength to withstand various forces, such as impacts from explosions, vehicles or natural disasters, or to retain soil embankments. In general, existing devices provide either one of ease-of-assembly or adequate strength, wherein systems that are easy to assemble are severely lacking in durability and impact resistance while systems that provide adequate durability and strength are often difficult, expensive, and time consuming to erect.
U.S. Pat. No. 6,854,234 to Gimpel et al., which is hereby incorporated by reference in its entirety, discloses a panel connector system for connecting a plurality of panels and including a clip base plate. Gimpel fails to teach or disclose various novel features of the present invention including, for example, a freestanding panel and corresponding support structure adapted for quick assembly in any number of desired locations, positions, orientations, etc.
U.S. Pat. No. 5,310,063 to Skolasinski, which is hereby incorporated by reference in its entirety, discloses a pallet display apparatus including a platform base with a continuous groove for supporting panels. Skolasinski fails to teach or disclose various novel features of the present invention including, for example, a freestanding panel and corresponding support structure with a channel adapted for quick assembly in any number of desired locations, positions, orientations, etc.
U.S. Pat. No. 5,678,383 to Danielewicz, which is hereby incorporated by reference in its entirety, discloses a construction assembly for attaching thin panels to a support frame with an elongate base strip suitable for attachment to a support frame and walls or panels extending from the elongate base strip. Danielewicz fails to teach or disclose, however, various novel features of the present invention including, for example, a freestanding panel and corresponding support or base structure as shown and described herein that enables quick and efficient construction and wherein the base comprises ballast.
U.S. Pat. No. 3,974,608 to Grearson, which is hereby incorporated by reference in its entirety, discloses a panel wall construction with channel-shaped clips to hold or support panel wall members. Grearson fails to teach or disclose, however, various novel features of the present invention including, for example, a freestanding panel and corresponding support or base structure as shown and described herein that enables quick and efficient construction.
U.S. Patent Application Publication No. 2010/0263807 to Kinder, which is hereby incorporated by reference in its entirety, discloses a freestanding modular wall device with at least two base members and a plurality of panel members to be stacked or arranged to create a wall panel. Kinder fails to teach or disclose various novel features of the present invention including, for example, a wall panel and a base member as shown and described herein.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide one or more freestanding precast concrete wall sections and methods of constructing a barrier or wall structure from a plurality of precast wall sections. Certain embodiments of the present invention also provide a precast concrete wall section and method of building a wall that has many novel features not offered by the prior art, that result in a new and novel freestanding precast concrete wall section and method of building a wall which is not apparent, obvious, or suggested, either directly or indirectly by any of the prior art devices, apparatus, or methods.
In one embodiment, a freestanding precast wall panel system is provided, the system comprising a panel member comprising a substantially planar surface, a base member for supporting the panel member, and the base member comprising a support for supporting the panel member in a substantially vertical position. The base member generally comprises an elongate channel for receiving the panel member. In preferred embodiments, the channel comprises a laterally or horizontally extending channel for receiving the panel member. In alternative embodiments, however, it is contemplated that the channel comprises a vertically extending channel.
In various embodiments, a method of erecting a wall is provided, the method comprising providing at least one wall panel and support member as shown and described herein, positioning the support or base member in a desired position, sliding the wall panel with a channel of the support member, and securing at least one of the wall panel and the support member.
In various embodiments, the present invention provides wall sections as corner, angled, or shaped members. It should be recognized by one of ordinary skill in the art that although wall and panel members shown and described herein comprise flat or planar elements, various alternative shapes and orientations are also contemplated by the present invention. Such shapes include, for example, right-angled members for constructing a corner of a structure. It is to be further understood that the first and second wall panel support footings allow for corner or angled turns while still utilizing the same unmodified support footings.
One aspect of the present disclosure is to provide a precast wall panel and method of use and assembly thereof that prevents the wall panel from sliding or other undesired movement. Another aspect of the present disclosure is to provide a precast wall panel comprising one or more blockouts formed through a base member of the wall panel. The blockouts, which may comprise voids or apertures in the base member are adapted to receive a material. The material, which may comprise various soil or cementitious materials, may be poured or deposited through the blockouts to fill voids between the soil of the subgrade and the wall panel, thereby securing or partially securing the wall panel in a desired location and orientation. The material may be any material that fills the voids and replicates the strength of compacted soil such as grout, cement, concrete, mortar, controlled density fill, adhesives, hydro compacted sand, or any combination thereof.
Various embodiments of the present invention contemplate wall and panel members and associated footings or supports manufactured from precast concrete. It will be recognized, however, that the present invention is not limited to any particular material or combination of materials. For example, metal, wood, composites, plastics, as well as other materials not referred to herein but that will be apparent to one of ordinary skill in the art may be used in various embodiments of the present invention. It is to be understood that the present invention may comprise impact resistant materials including but not limited to KEVLAR®, steel mesh, DUCON®, fabric, composite fibers, carbon, rubber, polymers, as well as others not referred to herein.
In various embodiments, devices of the present invention serve to structurally support cable or wire retention or management apparatus including electrified cable or wire such as that found in substation applications, whereby the apparatus can be attached to the wall panels or the wall panel end cap columns.
In various embodiments, the present invention disclosed herein will also serve to structurally support attached components such as fencing, gates, security equipment, platforms, towers, building structures, signage, as well as other structures not referred to herein. The present invention disclosed herein can be installed below grade resulting in greater structural stability for the assembled wall as well as for any attached structures.
Certain embodiments of the present invention comprise oversized wall panels and/or support members and footings thereby creating impact barriers for resisting and withstanding impacts from vehicles, explosions, natural disasters, etc.
It is to be understood that the present invention may embody refractory capabilities within the wall material. More specifically, certain embodiments of the present invention provide materials comprising refractory concreted to withstand high temperatures without degradation. Such refractory materials include, but are not limited to, cementitious blends with aggregates and other materials intended to withstand high temperature and impact. The commercially available TUFFLOOR offered by Allied Mineral Products, Inc. is one such product that may be used with various embodiments of the present invention.
Embodiments of the present invention may utilize form liners during the production process thereby resulting in a wide variety of patterns and finishes on the wall panels.
Various wall panel members of the present disclosure are contemplated as comprising one or more lifting anchors embedded within the wall panel and operable to contact a lifting device in order to lift and transmit the wall panel(s), for example. Such lifting anchors include, but are not limited, those shown and described in U.S. Pat. No. 8,959,847 to Recker et al., which is hereby incorporated by reference in its entirety.
In one embodiment, a precast wall panel system is provided comprising a plurality of wall panel members, wherein each of the plurality of wall panel member comprise: a height, a width and a depth, a first face comprising a substantially planar surface, a second face provided in opposing relationship from the first face, and a base member extending from the second face for supporting the panel member in a substantially vertical position. The base member comprises an elongate open channel for receiving at least one of a fill material and a ballast material, and the elongate open channel comprises an open channel. A first peripheral edge and a second peripheral edge are provided on lateral sides of the wall panel members and separated by the width, wherein the first peripheral edge comprises a male connection member and the second peripheral edges comprises a female connection member.
In another embodiment, a precast wall panel member is provided comprising: a height, a width and a depth, a first face comprising a substantially planar surface, a second face provided in opposing relationship from the first face, and a base member extending from the second face for supporting the panel member in a substantially vertical position. The base member comprises an elongate open channel for receiving at least one of a fill material and a ballast material, the elongate open channel comprises an open channel extending along an entirety of the width of the panel. The wall panel member comprises a first peripheral edge and a second peripheral edge, the first peripheral edge comprises a male connection member and the second peripheral edge comprises a female connection member.
In one embodiment, a method of installing a precast concrete wall panel system is provided, the method comprising: forming in a precast operation a plurality of wall panel members comprising a height, a width and a depth, a first face comprising a substantially planar surface, a second face provided in opposing relationship from the first face, and a base member extending from the second face for supporting the panel member in a substantially vertical position; preparing a ground surface by excavating a predetermined portion below grade to receive at least one of a bedding member and the base member; placing a base member of a first wall panel member on the prepared ground surface, wherein the base member comprises an elongate open channel; providing at least one of a fill material and a ballast material within the elongate open channel; placing a base member of a second wall panel member on the prepared ground surface and in contact with the first wall panel member; and wherein the first wall panel member and the second wall panel member each comprise a first peripheral edge and a second peripheral edge, wherein the first peripheral edge comprises a male connection member and the second peripheral edges comprises a female connection member, and wherein the step of placing the second wall panel member in contact with the first wall panel member comprises placing the male connection member of the second wall panel member at least partially within the female connection member of the first wall panel member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation view of a wall panel according to one embodiment of the present disclosure.

FIG. 2 is a side elevation view of a wall panel according to the embodiment of FIG. 1.

FIG. 3 is a perspective view of a plurality of wall panels provided in an assembled state and according to one embodiment of the present disclosure.

FIG. 4 is a top plan view of a plurality of wall panels in a corner section according to one embodiment of the present disclosure.

FIG. 5 is a top plan view of a plurality of wall panels according to one embodiment of the present disclosure.

FIG. 6 is a top plan view of a plurality of wall panels according to one embodiment of the present disclosure.

FIG. 7a is a top plan view of a plurality of wall panels according to one embodiment of the present disclosure.

FIG. 7b is a detailed top plan view of a plurality of wall panels according to the embodiment of FIG. 7 a.

FIG. 8 is a front elevation view of a plurality of wall panels provided in an assembled state and according to one embodiment of the present disclosure.

FIG. 9 is a perspective view of one embodiment of the present invention showing a wall member and a base member;

FIG. 10 is a perspective view of another embodiment of the present invention showing a wall member and a base member;

FIG. 11 is a perspective view of yet another embodiment of the present invention showing a wall member and a base member; and

FIG. 12 is a perspective view of yet another embodiment of the present invention showing a wall member and a base member.

FIG. 13 is a side elevation view of yet another embodiment of the present invention showing a wall member and a base member.

DETAILED DESCRIPTION

FIG. 1 is a front elevation view of a wall panel 2 according to one embodiment of the present disclosure. As shown, a wall panel 2 is provided as a substantially freestanding wall panel adapted to be provided in combination with one or more additional wall panels or other structures to form a wall of desired dimensions, positions, etc. In various embodiments, it is contemplated that wall panels 2 of the present disclosure are designed and suited for providing perimeter walls. For example, a plurality of wall panels may be provided to form a secure perimeter around various facilities and properties, or to retain soil or other material. It will be recognized, however, that wall panels of the present disclosure are not limited to any particular use or arrangement. Various panels and related features as shown and described herein are useful for and contemplated as being used for walls, barriers, corrals, fences, retaining walls, enclosures and perimeters of various types.
As shown in FIG. 1, a wall panel 2 is provided comprising a height H of between approximately 6 feet and approximately 24 feet, and preferably of approximately 16 feet. The panel 2 comprises a width W of between approximately 3 feet and 15 feet, and preferably of approximately 8 feet. The wall panel 2 preferably comprises a substantially rectangular front face 4. The front face 4 of the panel 2 preferably comprises a planar member. In alternative embodiments, the front face 4 of the wall panel comprises a convex portion, a concave portion, a decorative portion, and various combinations thereof. An upper portion of the wall panel 2 comprises various security and surveillance features including, for example, lighting elements 6 and camera features 8. One or more conduits 10 are provided internally to the wall panel 2 for routing cables, wiring and other elongate features. In certain embodiments, external conduits are provided in addition to or in lieu of the internal conduit 10.
As shown in FIG. 1, the wall panel 2 is provided on a ground surface 12. The ground surface 12 may comprise any number of materials and surfaces including, but not limited to, gravel, dirt, asphalt, concrete, cement, stone and other materials as will be recognized by one of skill in the art. In the depicted embodiment, a wall panel assembly comprises a bedding member 14 provided at least partially beneath a wall panel 2. The bedding member 14 preferably comprises an anti-burrow bedding structure to prevent or minimize burrowing and sinkage of the wall panel 2 into the underlying ground or substrate. The bedding member 14 preferably comprises a porous plastic member to provide enhanced structural support and allowing for fluid drainage through the bedding member 14. The size and spacing of the bedding member 14 may be varied based on the size and weight of the wall panel 2 intended to be provided in connection with the bedding member and the type of substrate underneath the wall panel 2, for example. However, in certain embodiments, the bedding member 14 comprises a depth extending into the ground surface 12 of between approximately 6 inches and approximately 3 feet, and preferably of approximately 1.5 feet.
FIG. 2 is a side elevation view of the wall panel 2 according to the embodiment of FIG. 1. As shown, the wall panel 2 comprises a front face 4 as a portion of a substantially vertical member 16. The substantially vertical member 16 of the embodiment provided in FIG. 2 comprises a tapered feature wherein the base of the member 16 comprises a greater thickness than an upper portion of the member 16. Specifically, in the embodiment provided in FIG. 2, a thickness at the base of the vertical member 16 is between approximately 5 inches and approximately 24 inches, and preferably is approximately 10 inches. A thickness at the top of the vertical member 16 is between approximately 2 inches and approximately 12 inches, and preferably is approximately 6 inches. The depth D of the wall panel 2 includes a base 18 extending away from the vertical member 16. The base 18 and the substantially vertical member 16 combine to provide an overall depth of between approximately 3 feet and 10 feet, and preferably of approximately 6 feet. The base 18 comprises a lower portion 20 that extends substantially perpendicularly away from the vertical member 16. The base 18 further comprises an upstanding member 22 to at least partially define a channel 24. The channel 24 comprises a generally C-shaped open channel that is adapted to receive a fill material 25. The channel 24 in the embodiment of FIG. 2 is provided with a fill material to provide weight, ballast and stability to the wall panel 2. Such fill material 25 may include, for example, gravel, concrete, soil, and other known ballast material.
An interior portion of the channel 24 comprises a depth that is between approximately 3 feet and 6 feet and preferably approximately 4.5 feet. Although the channel 24 comprises an open channel, a height of the channel 24 is between approximately 1 and 3 feet, and more preferably of about 1 foot, 9 inches. It will be recognized that fill material may extend above the height of the channel 24. However, assuming fill material is provided up to and not exceeding the height H, the channel 24 comprises a substantially rectangular cube having a volume of between approximately 50 and approximately 150 cubic feet and preferably of about 95 cubic feet.
FIG. 3 is a perspective view of a plurality of wall panels 2 provided in an assembled state. As shown, a wall member 30 is provided and formed by selective placement of a plurality of wall panels 2 in series. FIG. 3 provides a plurality of wall panels 2 provided in contact with one another. It will be recognized, however, that this is merely one example of a wall member 30 that may be formed with features and devices of the present disclosure.
FIG. 4 is a top plan view of first 2 a and second 2 b wall panels. The wall panels 2 a, 2 b of the embodiment of FIG. 4 are operable to be connected, erected or installed in a particular arrangement with respect to one another. Specifically, and as shown in FIG. 4, the wall panels 2 a, 2 b are adapted to provide an internal angle of approximately 90°. Each wall panel 2 a, 2 b comprises at least one male extension 40 extending along a first peripheral edge and at least one female receiving member 42 extending along a second peripheral edge the panel. At least one male extension member 40 b of a second wall panel 2 b is adapted to communicate with or be inserted into a female receiving member 42 a of a first wall panel. In FIG. 4, the first wall panel 2 a and the second wall panel 2 b comprise an interior portion adapted to be connected at an angle, and the interior connection members comprise a male extension member 40 b and a female receiving member 42 a that are provided at an angle corresponding to a connection and relative positioning of the first and second wall panels 2 a, 2 b at the respective angle. Additionally, the first and second wall panels 2 a, 2 b comprise additional connection members 40 a, 42 b. The additional connection members 40 a, 42 b of the embodiment of FIG. 4 are provided and adapted to connect additional wall panels (not shown in FIG. 4) in a manner that creates a flush wall surface with at least one of the first 2 a and second 2 b wall panels.
As shown in FIG. 4, the wall panels 2 a, 2 b each comprise an angled mating surface 25 extending away from a front face 4 of the wall panel 2. In the embodiment provided in FIG. 4, the angled mating surfaces 27 extend at approximately a 45 degree angle with respect to the front face(s) 4. Accordingly, when the angled mating surfaces 27 are brought into contact, the front faces 4 of the wall panels 2 a, 2 b are provided in a substantially perpendicular arrangement as shown to form a corner. The wall panels 2 a, 2 b also comprise an upstanding member 22 to at least partially define a channel 24, the channel adapted to receive a fill material.
In various embodiments, securing features including bracket and fasteners (not shown in FIG. 4) are provided in combination with the wall panels 2 a, 2 b. In certain embodiments, known brackets are used to provide additional securing features between adjacent wall panels that are provided in contact with one other.
The panels 2 a, 2 b of FIG. 4 each comprise at least two mating surfaces 27, 29. An angled mating surface 27 is provided on each of the two panels 2 a, 2 b, and the angled mating surfaces 27 are adapted to contact each other and position the two panels 2 a, 2 b in a relative angular position with respect to one another. The outer mating surfaces 29 of the wall panels 2 a, 2 b are provided at a different angle than the interior mating surfaces 27, at least relative to the front face 4 of the respective wall panels 2. The outer mating surfaces 29 as shown in FIG. 4 are adapted to receive additional wall panels 2 including, but not limited to additional wall panels 2 having front faces 4 that extend substantially parallel to a front face 4 of the wall panel 2 with which they are in direct contact.
FIG. 5 is a top plan view of another embodiment of the present disclosure. As shown in FIG. 5, a plurality of wall panels 2 a, 2 b, 2 c are provided and comprise a wall assembly 30 when interconnected. The wall panels of FIG. 5 comprise a similar construction as shown and described in the embodiment of FIG. 4. However, the wall panels 2 a, 2 b, 2 c of FIG. 5 comprise approximately 45 degree angles provided between adjacent front faces 4 of the wall panels 2, and wherein a more gradual turn or interior corner may be provided. In FIG. 5, three separate wall panels are shown which collectively form a 90 degree turn. It will be recognized, however, that any number of wall panels may be provided and the embodiment of FIG. 5 is not limited to an assembly forming a 90 degree turn (i.e. wherein the first panel 2 a has a front face 4 that is substantially perpendicular to the third panel 2 c). The wall panels comprise male extending members 40 a, 40 b and female receiving members, wherein a male extending member is adapted to communicate with a female receiving member of an adjacent wall panel. Interior mating surfaces 25 of the wall panels extend away from the front faces 4 of the panels, and are provided at an angle to achieve a desired relative arrangement when a wall panel assembly is constructed. In the embodiment provided in FIG. 5, the interior mating surfaces 25 are provided at an angle of approximately 67.5 degrees with respect to a planar surface of the front face 4 of the wall panel, such that an approximately 45 degree internal corner angle is provided when the wall panels 2 are provided in an assembled state.
As shown in FIG. 5, first 2 a, second 2 b and third 2 c panels are provided. The second panel 2 b comprises a panel with first and second angled mating surfaces 27. The first and third 2 a, 2 c wall panels comprise an interior mating surface 27 and an exterior mating surface 29 that extends at a different angle, wherein the angle of the exterior mating surface 29 of the first and third 2 a, 2 c wall panels is substantially perpendicular to the front face 4 of the wall panel 2.
FIG. 6 is a top plan view of another embodiment of the present disclosure comprising a plurality of wall panels 2. As shown in FIG. 6, a plurality of wall panels 2 a, 2 b, 2 c, 2 d are provided. Specifically four wall panels are provided in series to form a gradual interior corner or turn and wherein a first wall panel 2 a comprises a front face 4 that is substantially perpendicular to a front face 4 of a fourth wall panel 2 d. The embodiment of FIG. 6 comprises a first wall panel 2 a, wherein the first wall panel 2 a comprises a first lateral or side surface 27 that is substantially perpendicular to the front face 4 of the wall panel 2 a. Various angled wall panel members are shown and described herein for illustrative purposes. It will be expressly recognized, however, that the present disclosure is not limited to one or more panels of a particular angular or adapted to provide a wall assembly comprising an internal angle. It will further be recognized that the present disclosure contemplates wall panel assemblies comprising various wall panels of different angles and adapted to provide a final assembly of various different geometries. The figures and assembly provided herewith are for illustrative purposes, and no limitation with respect thereto is intended.
FIG. 7a is a top plan view of two wall panels 2 a, 2 b provided adjacent to one another. As shown, the wall panels each comprise a male connection member 40 a, 40 b and a female connection member 42 a, 42 b. Adjacent wall panels 2 a, 2 b are provided with a connection 50. The connection is shown in greater detail in FIG. 7b , wherein a generally trapezoidal male connection member 40 a is shown and is adapted for insertion or connection with substantially inversely shaped female connection member 42 b. The male connection member 40 a is adapted to be received in or nest within the female connection member 42 b such that the interior surfaces 29 of the wall panels 2 a, 2 b are operable to be provided in a substantially flush arrangement. Any number of wall panels may be provided by such features.
FIG. 8 is a front elevation view of a plurality of wall panels 2 a, 2 b, 2 c, 2 d, 2 e provided in series and in a vertically-staggered arrangement. As shown, each successive wall panel is provided at a different elevation at least with respect to an adjacent wall panel. The discrete nature of the wall panels 2 of the present disclosure and predetermined width of the same provides the ability to provide a wall assembly suitable for various uneven or undulating terrains. An upper 24 a and lower limit 24 b of the channel 24 are shown in phantom for illustrative purposes.
It is also contemplated that the wall panels 2 may be offset or staggered in a horizontal direction. For example, the front faces 4 of the wall panel 2 are generally shown as being coplanar and/or sharing at least one peripheral edge that is adjacent or coplanar to a peripheral edge of a sequential wall panel 2. It is also contemplated, however that the wall panels 2 may be staggered such that front faces 4 of adjacent wall panels 2 are offset or non-coplanar with one another.
FIG. 9 is a perspective view of one embodiment of the present disclosure wherein a wall section 102 for use in building or forming a wall or barrier is provided. As shown, the wall section 102 comprises a panel 104 having a first 106 and second face 108. A base member 110 is provided in the form of a wall panel retaining foundation footing. The base member 110 comprises a laterally extending slotted channel 112 or void for receiving and retaining at least one wall panel 104 in a fixed, secure and erect position. In the embodiment shown in FIG. 9, the slotted channel 112 is provided in a raised portion 114, the raised portion 114 extending laterally along the base member 110 and upwardly from the base member. In the depicted embodiment, a bottom of the slotted channel 112 is provided at substantially the same height or elevation as an upper planar surface 116 of the base member 110. In alternative embodiments, the bottom of the slotted channel 112 may be provided in various different locations, including lower than the planar surface 116 of the base member 110, particularly where taller panels 104 are provided and a greater buried depth is required. The embodiment of FIG. 9 provides a raised portion 114 that tapers upwardly from the base member 110 on both sides. In such embodiments, the tapered raised portion 114 provides adequate support for a panel 104 received therein, while reducing the overall mass of the section 102. Alternative embodiments are contemplated wherein the raised portion 114 comprises various shapes and/or angles including, but not limited to, rounded, convex, concave, and rectangular members, for example. The panel 104 shown in FIG. 9 comprises a planar panel member with first 106 and second 108 sides. The embodiment of FIG. 9 provides a precast concrete panel member 102 suitable for forming a wall or barrier. It will be recognized, however, that panels 102 of the present invention may be provided in various different materials, sizes, proportions, etc.
FIG. 10 is a perspective view of another embodiment of the present disclosure wherein a wall section 102 is provided comprising a panel 104 with a first 106 and second 108 face. First and second support footings 118, 120 are provided to support the panel 104 in an erect or assembled position. The first and second support footings 118, 120 comprise upstanding members 124, 122, respectively. The upstanding members 122, 124 extend upwardly from a base or slab member to support a panel 104. In certain embodiments, each support footing 118, 120 and its respective upstanding member 124, 122 are formed of a single precast element. In such embodiments, a panel 104, first support footing 120 with an upstanding member 122, and a second support footing 126 with an upstanding member 124, are provided as modular elements that may be assembled on-site to erect a wall panel. A plurality of wall sections 102 as shown and described herein may be assembled in a preferred orientation to provide a barrier or wall structure of desired shape, length, layout, etc. In alternative embodiments, the support footings 118, 120 of the embodiment of FIG. 10 may be provided as a single precast element adapted to receive a panel 104 in a slot member 126 provided between the support footings 118, 120.
In certain embodiments, first and second wall panel support footings 118, 120 are adjustable in distance from each other and thus capable of receiving and supporting wall panels 104 of various thicknesses. In such embodiments, first and second support footings 118, 120 selectively fasten to each other thereby securing the wall panel in a fixed and secure position. Support footings 118, 120 may be secured to one another by various devices and means as will be recognized by those of skill in the art.
FIG. 11 is a perspective view of yet another embodiment of the present invention comprising a wall section 102 with a panel 104 and an upstanding support member 130. As shown, the panel 104 comprises a planar element suitable for forming a wall or barrier. The panel 104 is supported in an upstanding supporting member 130 comprising slabs 132, 134, a tapered section 133, and a vertically extending elongate portion 138. An elongate and vertically extending channel 140 is provided on at least one side of the support member 130. Preferably, and as shown in FIG. 11, a first and second side of the support member 130 comprises a channel 140 such that the support member 130 is adapted to receive and support a first panel 104 and a second panel (not shown in FIG. 11). The slotted channel 140 may comprise an open or partially open channel member with a rectangular shape, or may comprise other channel shapes. In certain embodiments, the channel 140 comprises a slotted groove member adapted to receive a corresponding tongue member provided on a lateral edge of a panel 104 to be provided in the channel 140. In such embodiments, panels 104 are provided in communication or connection with the support member 130 by sliding the panel 104 into the channel 140, either from above or below the slot. Improved pull out resistance is thus provided.
The embodiment of FIG. 11 provides a generally inverted “Y” shape. In certain embodiments, the slabs 132, 134 comprise cast in foundation support footings with slotted vertical voids disposed to the outside face of each slab wherein the wall panel is inserted and thereby retained in a secure and fixed position. Optional fasteners may be utilized to secure the wall panel to the end caps from the side.
FIG. 12 is a perspective view of yet another embodiment of the present invention wherein a wall section 102 is provided comprising a panel 104 and a support base 140. The support base 140 of FIG. 12 comprises a first base support 142 and a second base support 144 wherein the second base support 144 comprises a laterally extending groove or channel 146. The channel 146 of FIG. 12 comprises a void channel that is recessed in the bottom surface of the second base support 140 and runs the length of the support 140. The first base support 142 comprises a downwardly oriented groove or channel 148 adapted to receive and be provided in force-transmitting communication with an upstanding lip member 150 of the second base support 144. The panel 104 may be secured by providing the panel(s) within the channel 146 and securing the panel 104 by inserting the first base support 142 into the channel 146 such that the lip member 150 is provided in the channel 148 of the first base support 142.
FIG. 13 is a side elevation view of a wall panel member 2 according to another embodiment of the present disclosure. The wall panel member 2 of FIG. 13 comprises at least one and preferably a plurality of apertures 200 extending through the base 18. The apertures 200 may serve various purposes. For example, the apertures 200 may be provided without additional features and serve as weep or drainage holes. Alternatively, the apertures 200 may be provided to receive a grout or similar fill or securing member. In the embodiment of FIG. 13, the apertures are provided with first and second soil nails 202 extending therethrough and extending into a ground or soil surface below the wall panel member 2. The wall panel member(s) 2 are thus secured in place at least in part due to the provision of the soil nails 202 as shown in FIG. 13. In alternative embodiments, at least one soil nail 202 may extend at an angle, either with respect to the base 18 of the wall panel or with respect to the ground surface.
Although various embodiments comprising various features are shown and described herein, it should be understood that the various features of the present disclosure are not exclusive or specific to the embodiment or embodiments they are shown and described in connection with. For example, the illustration and description of one or more features with respect to a specific embodiment should not be interpreted as rendering such a feature or features specific to that embodiment. Features and inventive concepts shown in a given Figure may be combined with or provided with the embodiments of other features, whether or not such combinations are specifically illustrated herein.

Claims

What is claimed is:

1. A precast wall panel system, the system comprising:

a plurality of wall panel members, wherein each of the plurality of wall panel member comprise:

a height, a width and a depth;

a first face comprising a substantially planar surface;

a second face provided in opposing relationship from the first face;

a base member extending from the second face for supporting the panel member in a substantially vertical position;

wherein the base member comprises an elongate open channel for receiving at least one of a fill material and a ballast material, the elongate open channel comprising an open channel;

a first peripheral edge and a second peripheral edge provided on lateral sides of the wall panel members and separated by said width, wherein the first peripheral edge comprises a male connection member and the second peripheral edges comprises a female connection member.

2. The precast wall panel system of claim 1, wherein the wall panel members comprise precast concrete wall panels.

3. The precast wall panel system of claim 1, wherein the male connection member extends along a substantial entirety of the height of the wall panel members.

4. The precast wall panel system of claim 1, wherein the female connection member extends along a substantial entirety of the height of the wall panel members.

5. The precast wall panel system of claim 1, wherein a male connection member of a first wall panel member is inserted into a female connection member of a second wall panel member.

6. The precast wall panel system of claim 1, further comprising a bedding member and wherein at least one wall panel member is provided at least partially on the bedding member.

7. The precast wall panel system of claim 1, wherein the height is between approximately six feet and approximately twenty four feet.

8. A precast wall panel member comprising:

a height, a width and a depth;

a first face comprising a substantially planar surface;

a second face provided in opposing relationship from the first face;

wherein the base member comprises an elongate open channel for receiving at least one of a fill material and a ballast material, the elongate open channel comprising an open channel extending along an entirety of the width of the panel;

a first peripheral edge and a second peripheral edge, wherein the first peripheral edge comprises a male connection member and the second peripheral edge comprises a female connection member.

9. The precast wall panel of claim 8, wherein the wall panel member comprises a precast concrete wall panel.

10. The precast wall panel of claim 8, wherein the male connection member extends along a substantial entirety of the height of the wall panel member.

11. The precast wall panel of claim 8, wherein the female connection member extends along a substantial entirety of the height of the wall panel member.

12. The precast wall panel system of claim 8, further comprising a bedding member and wherein at least a portion of the wall panel member is positioned on the bedding member.

13. The precast wall panel of claim 8, wherein the height is between approximately six feet and approximately twenty four feet.

14. The precast wall panel of claim 8, wherein a ratio of the height of the wall panel member to a height of the base member comprises a ratio of at least approximately 6:1.

15. The precast wall panel of claim 8, wherein an internal volume of the base member is between approximately 50 and approximately 150 cubic feet.

16. A method of installing a precast concrete wall panel system, the method comprising:

forming in a precast operation a plurality of wall panel members comprising a height, a width and a depth, a first face comprising a substantially planar surface, a second face provided in opposing relationship from the first face, and a base member extending from the second face for supporting the panel member in a substantially vertical position;

preparing a ground surface by excavating a predetermined portion below grade to receive at least one of a bedding member and the base member;

placing a base member of a first wall panel member on the prepared ground surface, wherein the base member comprises an elongate open channel;

providing at least one of a fill material and a ballast material within the elongate open channel;

placing a base member of a second wall panel member on the prepared ground surface and in contact with the first wall panel member; and

wherein the first wall panel member and the second wall panel member each comprise a first peripheral edge and a second peripheral edge, wherein the first peripheral edge comprises a male connection member and the second peripheral edges comprises a female connection member, and wherein the step of placing the second wall panel member in contact with the first wall panel member comprises placing the male connection member of the second wall panel member at least partially within the female connection member of the first wall panel member.

17. The method of installing a precast concrete wall panel system of claim 16, further comprising a step of providing a porous plastic bedding member on the prepared ground surface.

18. The method of installing a precast concrete wall panel system of claim 16, wherein the male connection member extends along a substantial entirety of the height of the wall panel members.

19. The method of installing a precast concrete wall panel system of claim 16, wherein the female connection member extends along a substantial entirety of the height of the wall panel members.

20. The method of installing a precast concrete wall panel system of claim 16, further comprising inserting at least one soil nail through said wall panel and into the ground surface.