WO2014150222A1 - Precast concrete retaining wall - Google Patents

Precast concrete retaining wall Download PDF

Info

Publication number
WO2014150222A1
WO2014150222A1 PCT/US2014/022625 US2014022625W WO2014150222A1 WO 2014150222 A1 WO2014150222 A1 WO 2014150222A1 US 2014022625 W US2014022625 W US 2014022625W WO 2014150222 A1 WO2014150222 A1 WO 2014150222A1
Authority
WO
WIPO (PCT)
Prior art keywords
module
base
precast concrete
retaining wall
counterfort
Prior art date
Application number
PCT/US2014/022625
Other languages
English (en)
French (fr)
Inventor
Thomas Heraty
Original Assignee
Utility Concrete Products, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Utility Concrete Products, Llc filed Critical Utility Concrete Products, Llc
Priority to EP14718219.0A priority Critical patent/EP2971373A1/en
Priority to JP2016501018A priority patent/JP2016515173A/ja
Priority to AU2014237379A priority patent/AU2014237379B2/en
Priority to CA2906463A priority patent/CA2906463A1/en
Priority to MX2015013095A priority patent/MX2015013095A/es
Publication of WO2014150222A1 publication Critical patent/WO2014150222A1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D29/00—Independent underground or underwater structures; Retaining walls
    • E02D29/02—Retaining or protecting walls
    • E02D29/0258—Retaining or protecting walls characterised by constructional features
    • E02D29/0266—Retaining or protecting walls characterised by constructional features made up of preformed elements

Definitions

  • the present invention pertains generally to retaining walls. Specifically, the invention relates to an apparatus and method of installation for a completely precast concrete retaining wall of the type typically used alongside highways and railways.
  • Various retaining wall systems have been developed for use in retaining soil on an embankment.
  • one of the major design criteria that must be considered is the pressure exerted on the foundation at the front of the base (toe) of the retaining wall system. This becomes particularly limiting in tall vertical walls with sloping baclcfill.
  • Conventionally designed cantilevered walls reduce the pressure at the toe by providing a lever arm perpendicular to and behind the wall face upon which the vertical load of the backfill acts, creating a moment opposite in direction to the moment due to the horizontal force of the backfill material on the wall face. This moment is increased for design purposes by increasing the area of the cantilever arm subject to the vertical loads by increasing the size or length of the moment arm until a suitable toe pressure is reached and a suitable factor of safety against overtiming is reached.
  • Cast-in-place cantilever retaining walls are a proven method of retaining earth. These retaining walls typically consist of a vertical wall on top of a horizontal base.
  • Another prior art product has a precast base and precast wall, but fails to include a counterfort for support. This is disadvantageous as the wall heights grow, since the lever arm to resist the overturning moment is confined within the planes of the base and face. Not only does this lead to unpractical, inefficient reinforcement design and panel tliickness, but it requires a large number of expensive and labor intensive mechanical splice sleeve connections at the critical juncture between the face and base.
  • Another disadvantage to not having a counterfort is that the wall needs to be temporarily braced during installation, which adds both cost and time.
  • T-shaped retaining walls with small scale counterfort ribs.
  • the disadvantage of these walls is that they require specific forms and therefore are not customizable. Also their installation allows for less flexibility due to the fixed connection between the base and face of these T-shaped retaining walls. Further, due to how this system needs to be formed, it makes it difficult to add textured aesthetics to the face of the wall. This system is also limited in retained height due to the challenge of handling such a large, one-piece unit. At a certain height, these retaining walls are also limited in size due to shipping limitations.
  • the present invention provides an apparatus and method for constructing a retaining wall which allows for taller walls and shorter bases by pre-nianufacturing parts of the wall to be transported to and assembled at the site. Using pre-manufactured assembly
  • a precast, substantially solid, rectangular or trapezoidal base is set on grade at the job site, and a face panel with an integral counterfort is set upright on the base with a connection joining them together. Temporary shoring is not required with this assembly. As soon as the face panel and counterfort are set on the base, it can withstand temporary wind loads immediately.
  • the invention is also flexible in that the height or width of any of the individual components can vary over a wide range. All of the pieces of the assembly can easily be made to custom sizes.
  • FIG. 1 represents a perspective view of a prior art retaining wall.
  • FIG. 2 represents a perspective view of a prior art retaining wall.
  • FIG. 3 represents a perspective view of a retaining wall comprising a first embodiment of the present invention.
  • FIG. 4 represents a plan view of the embodiment of Figure 3.
  • FIG. 5 represents a front elevation view of the embodiment of Figure 3.
  • FIG. 6 represents a right elevation view of the embodiment of Figure 3.
  • FIG. 7 represents a close-up view of a connection between a base and face panel with an exposed end of rebar fixed into an opening in a base with grout.
  • FIG. 8a represents a plan view of a retaining wall comprising a second embodiment of the present invention using H-Piles beneath the base.
  • FIG. 8b represents a front view of a retaining wall comprising a second embodiment of the present invention using H-Piles beneath the base.
  • FIG. 8c represents a right side view of a retaining wall comprising a second embodiment of the present invention using H-Piles beneath the base.
  • FIG. 8d represents a perspective view of a retaining wall comprising a second embodiment of the present invention using H-Piles beneath the base.
  • FIG. 9a represents a plan view of a retaining wall comprising a third embodiment of the present invention using H-Piles beneath a pocket in the base.
  • FIG. 9b represents a front view of a retaining wall comprising a third embodiment of the present invention using H-Piles beneath a pocket in the base.
  • FIG. 9c represents a right side view of a retaining wall comprising a third embodiment of the present invention using H-Piles beneath a pocket in the base.
  • FIG. 9d represents a perspective view of a retaining wall comprising a third embodiment of the present invention using H-Piles beneath a pocket in the base.
  • FIG. 10a represents a plan view of a retaining wall comprising a fourth embodiment of the present invention using a barrier located on top of the face panel.
  • FIG. 10b represents a front view of a retaining wall comprising a fourth embodiment of the present invention using a barrier located on top of the face panel.
  • FIG. 10c represents a right side view of a retaining wall comprising a fourth embodiment of the present invention using a barrier located on top of the face panel.
  • FIG. 1 Od represents a perspective view of a retaining wall comprising a fourth embodiment of the present invention using a barrier located on top of the face panel.
  • FIG. 11a represents a plan view of a retaining wall comprising a fifth embodiment of the present invention using a barrier located on the rear side of the face panel.
  • FIG. lib represents a front view of a retaining wall comprising a fifth embodiment of the present invention using a barrier located on the rear side of the face panel.
  • FIG. 11c represents a right side view of a retaining wall comprising a fifth embodiment of the present invention using a barrier located on the rear side of the face panel.
  • FIG. 11 d represents a perspective view of a retaining wall comprising a fifth embodiment of the present invention using a barrier located on the rear side of the face panel.
  • FIGS. 3-7 a preferred embodiment of a retaining wall in accordance with the various aspects of present invention. While retaining wall systems are commonly used in retaining soil, it should be understood that the present invention can be used in many different applications including retaining other materials such as sand, pebbles or rocks. '
  • Figure 3 illustrates a perspective view of an embodiment of wall 10 embodying principles of the present invention.
  • the retaining wall 10 of the present invention is made of precast concrete in two discrete, modular pails.
  • Wall 10 comprises a precast concrete face panel 12 with an integral counterfort piece 14 and a precast base piece 16.
  • a first precast modular part 11 is a generally flat front face panel 12 with an integral counterfort 14 extending from the rear side of the panel 18.
  • the face panel is typically not completely “flat” because it has surface ornamentation so that for example it appears to be a stone or brick or other ornamentation wall.
  • the panel 12 can have a common height of twenty feet.
  • the counterfort 14 which extends from the rear side of the panel 18 is unitary with the face panel 12.
  • the face panel 12 will preferably have at least two counterforts 14 spaced apart evenly from ends of the face 12.
  • the counterfort 14 has a flat bottom, so that in side view, the counterfort 14 is generally a right triangle.
  • the counterfort 14 when viewed from the side, could be a generally rectangular shape or be made of a shape that is generally rectangular and then transitions to a . triangular shape. Many different combinations are claimed and disclosed herein.
  • a side view of an embodiment of the retaining wall 10 is shown in Fig. 6.
  • the wall is designed to retain water, it is important to have proper drainage behind the wall in order to limit the pressure to the wall's design value. Therefore an opening for drainage is preferably provided or the wall can be constructed using the dry stone building method so that the wall can be self-draining. Drainage materials will reduce or eliminate the hydrostatic pressure and improve the stability of the material behind the wall. Therefore, as seen in Fig. 6, the counterfort 14 may also have an opening 20 for drainage near the bottom front corner of the counterfort 14. Face panel 12 may also have a weep hole for drainage towards the bottom.
  • the front face panel 12 may have more than one counterfort 14 providing support.
  • the counterfort 14 extends perpendicularly from the face panel 12, and its base extends rearward (illustratively thirteen feet).
  • the top of the "triangle" may be squared off to have a horizontal top ledge (illustratively of six inches), with a bottom edge (illustratively of ten feet).
  • the bottom edge may also be squared off.
  • Reinforcing bars (rebar) 22 can be cast within the counterfort 14.
  • rebars 22 act as a tensioning device within the concrete helping to meet design loads.
  • the rebars 22 extend through the bottom of the counterfort 14.
  • the rebars 22 can also terrriinate in an "L" or “backwards L” configuration. This helps the exposed portions of the rebars 22 act as anchors.
  • Another option is to utilize a forged foot 24 at the free end, where the bar (illustratively one inch diameter) terrriinates hi a horizontal disk (illustratively two and a half inc diameter).
  • the rebar 22 can terminate in a number of differing configurations.
  • a second precast modular part 15 comprises a base 16 which is illustratively one foot thick.
  • the base 16 is generally a rectangular or trapezoidal shaped platform and typically is set on grade. Because the base 16 is a platform, it is generally solid with no substantial openings other than small openings for grout fill.
  • the base 16 is precast concrete and therefore does not require that the base 16 be cast in-situ at the construction site.
  • a shear key 26 can be made between the face 12 or counterforts 14 and the base 16. This shear key can be a depression in the base 16 and sized to accept the bottom 30 of the front face panel 12. Once the bottom 30 of the face 12 is set into place, the voids between the shear key 26 and bottom 30 of the face panel 12 can be filled with grout to solidify the connection.
  • a shear key 26 can also extend down from the base 16 into the ground. This could be a pre-manufactured shear key or there can be exposed rebar extending down from the base 16 to be later poured with concrete in the field.
  • the base 16 can be precast with a front lip which protrudes from the end of the base 16 near the face panel 12.
  • the base 16 has at least one opening 32 sized to accept the downward- extending rebar 22 ends from the counterfort 14.
  • This opening 32 can be sized to accept more than one rebar 22 end.
  • the base has a single row or multiple rows of openings 32, illustratively four and a half inches in diameter, to receive multiple downward-extending rebar 22 ends from the counterfort 14. This connection point between the counterfort 14 and base 16 is shown more closely in Fig 5.
  • rebar 22 can terminate in forged foot anchor 24.
  • connection between the first module 11 and second module 15 is made by inserting an end of a piece of rebar of one module into an opening in the other module and then sealing the connection with grout.
  • a method of connecting the modules will be described where the first module has protruding rebar and the second module has openings.
  • the connection described herein can be reversed with the second module 15 having rebar extending from its top surface and connecting with openings within the bottom surface of the first module 11.
  • an installer would place the second module 15 into a substantially horizontal position.
  • the installer would then raise the first module 11 above the second module 15 and align the exposed ends of the rebars 22 of the first module 11 with the openings 32 on the second module 15.
  • the installer would then lower the first module 11 on top of the second module 15 such that the exposed ends of the rebar 22 of the selected first module are placed within the openings in the second module.
  • One advantage of this arrangement is that once the first module 11 is placed on the second module 15, no temporary shoring is required to hold the face upright until the grout connection between the first module 11 and second module 15 has cured.
  • the anchor 24 is simultaneously lowered into an opening 32 in the base 16.
  • This opening 32 can be a straight cylindrical shape, tapered or formed using a corrugated pipe. It can extend partially or all the way through the base 16. It shall be understood that those of ordinary skill ill the art can use a number of different sizes and shapes for the opening 32.
  • an installer can use one or more shims 36 to make the front face panel 12 plumb in both the vertical and horizontal directions. An installer can also use shims 36 to rotate the face 12 to any desired angle.
  • the anchor 24 can finally be set into the opening 32.
  • the shims 36 elevate the first module 11 above the second module 15 enough so that an installer can pump a high strength grout 34 into the opening 32.
  • This high strength grout 34 fills the void remaining in the opening 32 and bonds itself to the concrete base 16 and the anchor 24. This results in a shear cone in the base to resist the pullout of the rebar 22, ultimately connecting the two precast modular pieces 11, 15.
  • retaining walls 10 are placed adjacent to one another to form a continuous wall.
  • an installer can place a shear key or use ship laps between adjacent modules. This interface between adjacent walls can either be grouted or not grouted.
  • a product such as butyl mastic joint sealant or wrap can also be used to seal the vertical joint between adjacent faces 12.
  • the base 16 can be textured or roughened to increase friction between the base 16 and subsurface ground beneath the base.
  • the base 16 can be set on shims and have various holes or ports 38 in the base 16 so that flow- able grout can be pumped through the base 16 and into the void created by the sliims underneath. This grout will serve to increase the frictional force between the base 16 and subsurface.
  • H-piles 40 can be driven into the ground and the base 16 set on top of these piles 40 for added stability.
  • Figure 8 shows an embodiment of the present invention with piles 40 driven into the earth underneath the base 16. If desired, a pocket 42 can be created in the base 16 to allow the pile 40 to extend up into the base 16 and then the connection can be filled with grout.
  • Figure 9 shows images of pocket 42 formed in base 16. Alternatively, the piles 40 could extend up into the grouted area between the subsurface and the base 16 and then this void would be filled with grout Still a fourth alternative method would be to utilize a cast-in-place pile cap which can be poured prior to setting the base 16. This pile cap is typically a thick concrete mat that rests on concrete, steel or timber piles that are driven into the unstable ground to provide a suitable stable foundation.
  • a vehicle impact barrier 44 can be formed and cast-in-place on top of the wall 10 or behind the wall 10.
  • Figure 10 shows an embodiment of the retaining wall 10 with a vehicle impact barrier 44 attached on top of the wall 10.
  • Figure 11 shows an alternative embodiment of the retaining wall 10 with a vehicle impact barrier 44 attached to the rear side of the panel 18.
  • To create a cast-in-place impact barrier will use a face panel 12 that has exposed rebar extending out of the face 12. This rebar will extend vertically out of the top surface of the face panel 12 if a user wishes to have the impact barrier 44 formed on top of the face 12.
  • the impact barrier 44 be formed on a rear surface 18 of the face 12, then the rebar will extend horizontally out of the rear surface 18. In either scenario, an installer can cast an impact barrier 44 around the exposed rebar to form the cast-in-place barrier 44 at the desired location.
  • Another embodiment of this impact barrier elirninates the need for in situ casting because a pre-manufactured, pre-cast barrier can also be formed integrally with the face 12 at the factory.
  • the pre-cast concrete barrier can be precast in a number of different desired locations. However, in a preferred embodiment, the pre-cast concrete barrier is located on top of the face 12.
PCT/US2014/022625 2013-03-15 2014-03-10 Precast concrete retaining wall WO2014150222A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
EP14718219.0A EP2971373A1 (en) 2013-03-15 2014-03-10 Precast concrete retaining wall
JP2016501018A JP2016515173A (ja) 2013-03-15 2014-03-10 プレキャストコンクリート擁壁
AU2014237379A AU2014237379B2 (en) 2013-03-15 2014-03-10 Precast concrete retaining wall
CA2906463A CA2906463A1 (en) 2013-03-15 2014-03-10 Precast concrete retaining wall
MX2015013095A MX2015013095A (es) 2013-03-15 2014-03-10 Muro de retencion de concreto precolado.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13/835,100 2013-03-15
US13/835,100 US20140270990A1 (en) 2013-03-15 2013-03-15 Precast concrete retaining wall

Publications (1)

Publication Number Publication Date
WO2014150222A1 true WO2014150222A1 (en) 2014-09-25

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2014/022625 WO2014150222A1 (en) 2013-03-15 2014-03-10 Precast concrete retaining wall

Country Status (7)

Country Link
US (1) US20140270990A1 (es)
EP (1) EP2971373A1 (es)
JP (1) JP2016515173A (es)
AU (1) AU2014237379B2 (es)
CA (1) CA2906463A1 (es)
MX (1) MX2015013095A (es)
WO (1) WO2014150222A1 (es)

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Also Published As

Publication number Publication date
MX2015013095A (es) 2016-06-06
CA2906463A1 (en) 2014-09-25
EP2971373A1 (en) 2016-01-20
JP2016515173A (ja) 2016-05-26
AU2014237379A1 (en) 2015-10-22
US20140270990A1 (en) 2014-09-18
AU2014237379B2 (en) 2017-09-28

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