Method of constructing a wall

A method of constructing a wall is shown in which vertical structural columns are erected by mounting vertical, precast concrete panels to a vertical structural member located at each column foundation. The distance between two completed structural columns is spanned by sliding a precast, horizontal structural panel within a pair of column vertical recesses. The height of the horizontal panel is less than the total height of the structural columns and the remaining space is filled with a filler material which can assume a variety of shapes and configurations.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates generally to fence wall construction and, 
more specifically, to a fence wall constructed by combining precast 
concrete elements with other materials to produce a strong and 
aesthetically pleasing structure. 
2. Description of the Prior Art 
In the past, fences and retaining walls have primarily been constructed by 
hand. They were constructed one-piece at a time through a combination of 
mortar and masonry units. The largest single unit of construction was the 
brick, block or stone itself. The prior art process were consequently slow 
and labor intensive, requiring masons and skilled workers with a high 
degree of experience and proficiency. Often the cost of the labor exceeded 
the cost of the raw materials used in building the fence or wall. 
U.S. Pat. No. 4,865,781, issued Sep. 12, 1989, to Stephen R. Jennings, 
represented an improvement over the existing construction techniques and 
disclosed a fence wall structure which could be erected at a substantial 
savings in time and material cost while achieving a permanent, maintenance 
free and aesthetically pleasing fence or wall. The improvement was 
achieved by providing a prefabricated concrete fence made up of precast 
units which were assembled in various combinations. The precast units 
included both components of the structural columns and the panels used to 
span the distance between completed columns. 
The present invention is directed toward improvements in the method and 
structure disclosed in the previously referenced U.S. Pat. No. 4,865,781. 
The present invention provides a fence or wall which can be constructed 
from prefabricated concrete elements in conjunction with various 
manufactured building materials. The components of the fence or wall 
construction are assembled in combinations to give the appearance of 
brick, stone, molded concrete, or other styles; then combine with 
contrasting elements of wood, plastic, stone, brick, concrete block, steel 
or other materials. Using the techniques of the present method, a single 
semi-skilled worker can assemble the vertical structural columns using as 
few as two precast panels of varying widths, thicknesses, heights, and 
styles which are many times larger than the common brick in size. 
Horizontal precast panels of varying widths, lengths, and styles can be 
used to span the distance between completed structural columns. 
The precast panels which are used for the structural columns and 
horizontal, spanning panels can be provided with a finish varying from a 
single side to all sides and edges. These finishes can range from an "as 
cast form" to an infinite number of patterns and colors. The resulting 
fence or wall construction is a structure which can utilize a combination 
of many different materials. These combinations of materials and methods 
achieve savings of time and cost of material. The resulting structure is a 
permanent, maintenance free and aesthetically pleasing fence or wall. 
SUMMARY OF THE INVENTION 
In the method of constructing a wall of the invention, a wall is 
constructed using precast concrete elements in combination with other 
building materials. In the method, a plurality of column foundations made 
of precast or cast-in-place concrete are first installed at various 
locations, elevations and spacings, as dictated by the requirements of the 
particular project at hand. A vertical structural member is erected on at 
least two of the spaced-apart column foundations, each such vertical 
structural member having a front face, a rear face and opposing side 
faces. The vertical structural members can be installed when the column 
foundations are being poured or they can be installed later, as by using 
mounting brackets and either by welding or bolting the structural members 
to the column foundations. 
A structural column for construction is then formed at each selected column 
foundation by mounting at least one precast, vertical concrete panel on 
the respective front and rear faces of each of the vertical structural 
members and by attaching each precast, vertical concrete panel to the 
respective front and rear faces. The precast, vertical panels can be 
connected by any convenient means, such as by welding, bolting or 
connecting of interlocking brackets. The precast, vertical concrete panels 
can be made up of a series of small panels with several pairs of lateral 
edges or as few as two large panels. The vertical structural member 
creates a column vertical recess between the precast, vertical concrete 
panels and each of the opposing side faces of the vertical structural 
members. The width of the recess is determined by the width of the 
structural member utilized. The thickness and external configuration of 
the precast, vertical concrete panels can also vary, depending upon the 
intended application. 
After the structural columns are completed, at least one precast horizontal 
structural panel is installed to span the distance between the vertical 
recesses created between two adjacent columns. Each of the precast 
horizontal panels has lateral edges and vertical edges, the vertical edges 
being adapted to matingly engage the respective column vertical recesses. 
Alternatively, the precast horizontal panels can be installed first and 
braced between the two selected vertical structural members. The vertical, 
precast concrete panels can then be installed to complete the structural 
columns. Most preferably, the structural columns are completed first and 
the precast horizontal panels are lifted to a height that will clear the 
tops of the structural columns and are then lowered into the column 
vertical recesses created by the vertical structural members. The panels 
are lowered until both ends thereof are firmly resting on the column 
foundations. They may be leveled by inserting spacers or shims under each 
end thereof. 
Preferably, the length of the opposing vertical edges of the horizontal, 
precast panels define a vertical height of the panel which is less than 
the height of the adjacent structural columns. At least a portion of the 
remaining vertical height between the panel top lateral edge and the 
height of the adjacent columns and spanning the distance between adjacent 
columns is filled with a filler material. These materials can include 
brick, block, stone, precast panels, wood, plastic, steel and the like. 
The filler materials can be installed singularly or in combination of any 
two, three or more. The filler material provides an aesthetically pleasing 
contrast in color and texture. 
The patterns, design and size of the horizontal precast panels can vary 
from one set of structural columns to the next. The tops of the structural 
columns can also be treated with a variety of treatments including 
cast-in-place concrete, precast concrete units, cast stone units, brick, 
stone, metals, plastic or wood. Similar treatments can be provided for the 
top lateral edges of the horizontal precast panels. 
Additional objects, features and advantages will be apparent in the written 
description which follows.

DETAILED DESCRIPTION OF THE INVENTION 
The method of the invention is applicable to all types of ornamental and 
utilitarian walls and fences including retaining walls, privacy walls, 
sound barrier walls, and fences, and the like. The term "wall" and "fence" 
are therefore used interchangeably in the discussion which follows. The 
wall is first located with reference to building property or lines set out 
to determine the location of the wall. Using conventional practice, points 
are located for the foundations of the vertical, structural columns. The 
column locations are separated by predetermined distances according to, 
e.g., the property lines, length of the wall, etc. The earth is then 
excavated to comply with engineering specifications for the vertical 
structural columns in accordance with local building codes and 
manufacturer's requirements. The column foundations can be either round, 
square, polygonal, or piers. The elevation of each foundation is 
determined and noted and reinforcement is placed in the excavation and 
stabilized. The reinforcement reaches from the approximate bottom of the 
excavation to within a few inches of what will become the top surface of 
the column foundation, or can extend to the height of the column. A 
completed column foundation is indicated at 11 in FIG. 1. 
Each column foundation has an associated vertical structural member 13. In 
the embodiment of FIG. 1, the vertical structural member 13 is a length of 
square, tubular shape or combination of shapes to create a box shape of 
steel having a hollow interior 15. The member 13 is placed in the 
excavated foundation location in the approximate center thereof or as 
close to center as possible, still remaining within the line of the other 
portions of the wall or fence to be constructed. Concrete can then be 
poured into the excavation and brought to the level of the desired top 
surface of the pier or column foundation. The structural member 13 is 
brought to plumb, in all directions, while the concrete is in the plastic 
state. 
It will be understood that although the previously described method steps 
are preferred, that the vertical structural member 13 can be installed 
after the completion of pouring of the column foundation 11, as by welding 
on attachment brackets and bolting the attachment brackets to the poured 
foundation 11. 
As shown in FIG. 1, the vertical structural member 13 preferably has 
associated therewith mounting brackets 17, 19 which are welded to the 
front and rear faces 21, 23 of the member 13, respectively. The mounting 
brackets can assume various configurations and can include side flanges, 
e.g., flange 25 which engage the opposing side faces 27, 29 of the 
structural member 13. 
In the next step of the method, a structural column is formed at the 
selected column foundations (see for example, structural columns 31, 33 in 
FIG. 2) by mounting at least one precast, vertical concrete panel (35 in 
FIG. 1) on the respective front and rear faces 21, 23 of each of the 
vertical structural members 13 and attaching each precast, vertical 
concrete panel 35 to the respective front and rear faces. This can be 
accomplished, as by utilizing bolts 37 and engaging the bolts with the 
mounting brackets 17, 19. In this way, a column vertical recess 37, 39 is 
formed between the precast, vertical concrete panels (35, 36 in FIG. 2) 
and each of the opposing side faces 27, 29 of the vertical structural 
member 13. 
Although the vertical, precast concrete panels 35 can comprise two or more 
precast concrete blocks of square or rectangular shape, stacked upon one 
another and having open interiors to receive re-bar rods and the like, the 
precast, vertical concrete panels are preferably provided as unitary 
plates. A typical plate or panel, such as panel 35, will be, as an 
example, 18 inches wide, 3 1/2 inches thick and, for example, 75 inches in 
height. The sizes and shapes of the vertical, precast concrete panels can 
vary to meet the requirements of the particular project. The plates can be 
precast in forms in the controlled environment of a manufacturing plant or 
molded in a variety of plain or decorative appearances, such as brick, 
stone, wood, rock, fractured fins and other patterns and be provided in an 
infinite number of variations. 
FIG. 3 is a side, cross-sectional view of the structural column 33 showing 
the column foundation 11 including pier 41 and top surface 12 and showing 
various types of mounting brackets 43, 45, 47 used to erect the precast, 
vertical concrete panels 35, 36. 
FIG. 5 is a close-up, isolated view of a vertical structural member 13 with 
associated mounting brackets 17, 19 each of which carries mounting bolts 
49, 51 used to erect the vertical, precast, concrete panels 35, 36. This 
can also be accomplished by imbedded weld plates in the back of the 
vertical panels, which are simply welded onto the vertical structural 
member 13. 
Preferably, the distance between at least two of the adjacent structural 
columns (e.g., columns 33, 51 in FIG. 2) is spanned by at least one 
horizontal, precast panel 53. Preferably, the horizontal panel 53 is 
installed by sliding the horizontal panel within the vertical column 
recesses (39, 55 in FIG. 2) created by the two adjacent columns 33, 51. 
The panel 53 has top and bottom lateral edges 57, 59 and opposing vertical 
edges 61, 63 which are received within the respective vertical column 
recesses 39, 55. 
The horizontal, precast panel 53 is preferably lifted so as to clear the 
tops of the structural columns 33, 51 and is lowered through the column 
recesses to the position shown in FIG. 2. In this position, the horizontal 
panel 53 rests on the top surfaces (12 in FIG. 3) of the column 
foundations 11. If the panel requires leveling, it can be leveled through 
the use of mortar, concrete, plastic, steel or appropriate shims. The 
leveling material would be placed between the bottom lateral edge of the 
panel 53 and the top of the column foundation. Wedge shaped spacers can 
also be used to locate the horizontal, precast panels within the vertical, 
column recesses. 
The length of the opposing vertical edges 61, 63 of the horizontal, precast 
panel 53 defines a vertical height ("h" in FIG. 2) which is preferably 
less than the total height of the adjacent structural column 65. The 
remaining height above each horizontal panel 53 is preferably filled with 
a filler material. This filler material can be brick, stone, wood, steel, 
wrought-iron, screening materials, concrete, etc. There are also an 
infinite number of panel treatments which can be used to fill the space 
occupied by the filler material 67. The wall can then be completed by 
finishing the top of the wall with a suitable treatment ranging from a 
single row of brick to an elaborate cast stone piece. The column tops can 
also be finished in similar fashion. 
It will also be understood that the horizontal, precast panel 53 can be 
installed by first erecting a pair of vertical structural members 13 on at 
least two of the spaced-apart column foundations 11 and thereafter 
spanning the distance between th respective side faces (e.g. face 29 in 
FIG. 1) of two adjacent vertical structural members by bracing the 
horizontal panel therebetween. The structural column would then be 
completed by mounting precast, vertical concrete panels (35 and 36 in FIG. 
1) on the respective front and rear faces of each of the vertical 
structural members. The remaining steps in the construction technique 
would be identical to those previously described. 
The construction method o the invention is exceedingly versatile, and is 
well adapted for use in a variety of specific job applications. For 
example, FIG. 4 shows a corner construction of the wall of FIG. 2 in 
close-up, isolated fashion. Mounting brackets 71, 73, 75 are used to mount 
the vertical, precast concrete panels 77, 79, 81, 83, thereby provided 
vertical column recesses 85, 87 for receiving horizontal, precast panels 
(e.g., 53, 89 in FIG. 2). 
FIG. 6 shows a structural column 95 having a vertical structural member 97 
joined to vertical precast concrete panels 99, 101, 103 by mounting 
brackets 105, 107, 109. In this manner, a vertical recess 111 is created 
for receiving an intermediate horizontal, precast panel (shown in dotted 
lines as 113 in FIG. 6) which might serve as an intermediate connecting 
wall in the completed wall system. 
FIG. 7 is a partial, isolated view of the mounting brackets 105, 107, 109 
and vertical structural member 97 used in forming the structural column of 
FIG. 6. 
FIG. 8 is an isolated view of a portion of a completed fence wall, 
constructed according to the method of the invention. In the embodiment of 
FIG. 8, the vertical, precast concrete panels 113, 115 are joined by a 
vertical structural member 117 of greater width than the member 13 in FIG. 
1. The horizontal, precast panels 119, 121 are also of greater relative 
width ("w" in FIG. 8), allowing the panels 119, 121 to support double 
walls 123, 125 of brick filler material laid to fill the remaining 
vertical space to the approximate vertical height of the adjacent 
structural columns. 
FIG. 9 is a view similar to FIG. 8 but with a pair of horizontal precast 
panels 127, 129 installed between the vertical, precast concrete panels 
113, 115 in the vertical column recess 131. The pair of panels 127, 129 
support double walls 133, 135 of brick filler material. 
An invention has been provided with several advantages. A single, 
semi-skilled worker can assemble the structural columns of the invention 
utilizing two vertical, precast concrete panels and an internal, vertical 
structural member. The intermediate wall or horizontal panels can be 
easily installed with a small tractor or mechanical lift. The horizontal 
panels can be removed and replaced if damaged. By using precast units, a 
fence or wall can be quickly and easily erected with a minimum labor 
expense using semi-skilled workers under varying weather conditions. 
While the invention has been shown in only one of its forms, it is not thus 
limited but is susceptible to various changes and modifications without 
departing from the spirit thereof.