Patent Publication Number: US-2003223824-A1

Title: Wall system

Description:
RELATED APPLICATIONS  
     [0001] This application claims priority of a provisional patent application titled “QUICK SET RETAINING WALL”, Serial No.60/375,611 filed Apr. 24, 2002, hereby incorporated into the present application by reference. 
    
    
     
       BACKGROUND OF THE INVENTION  
       [0002] 1. Field of the Invention  
       [0003] The present invention relates to walls. More particularly, the present invention relates to a concrete wall system that minimizes hydraulic load, can be easily moved, and can be formed into almost any shape.  
       [0004] 2. Description of Prior Art  
       [0005] Current decorative and retaining walls are susceptible to hydraulic load because the walls are typically constructed by trenching for and pouring footings along the wall&#39;s path. Footings provide walls with stability; however, footings extend below grade thereby trapping rain water, irrigation water, and any other water to which they are exposed.  
       [0006] Such trapped water induces hydraulic load on footings and walls which may damage or weaken walls, eventually leading to failure and collapse. Failure can cause flooding from suddenly released water. Collapse can be dangerous to anyone in the vicinity from falling debris.  
       [0007] Furthermore, utility, landscaping, or similar work often requires trenches to be dug under walls. Current decorative and retaining walls are typically damaged or destroyed during such work, since current walls cannot be removed, once installed, without being damaged.  
       [0008] Finally, current decorative and retaining walls are limited in size, shape, and arrangement. Specifically, current decorative and retaining wall components are only available in discrete sizes and wall sections must commonly meet at pre-defined angles, which cannot be altered.  
       [0009] Accordingly, there is a need for an improved wall system that overcomes the limitations of the prior art.  
       SUMMARY OF THE INVENTION  
       [0010] The present invention overcomes the above-identified problems and provides a distinct advance in the art of walls. More particularly, the present invention provides a concrete wall system that minimizes hydraulic load, can be easily moved, and can be formed into almost any shape. The wall system broadly comprises a plurality of pilings and a plurality of slabs supported by the pilings. Both the pilings and slabs are preferably formed of concrete and may be imprinted with one or more patterns.  
       [0011] The pilings are preferably formed at a job site, as will be discussed in greater detail below. The pilings are preferably cylindrical, but may be virtually any shape, and include a bottom section and a top section supported by the bottom section. The bottom section is preferably buried substantially below grade, while the top section is located substantially above grade. While the bottom section is preferably completely solid, the top section includes at least one vertical slot. The vertical slot extends from a ledge located approximately where the bottom section meets the top section to an opening in a top surface of each piling. The ledge supports opposing edges of the slabs, such that lower edges of the slabs are supported substantially at grade.  
       [0012] The slabs may be formed at the job site or may be pre-formed at a manufacturing facility where such work may be done more efficiently. The slabs are preferably substantially flat and may be slid down into the vertical slots.  
       [0013] In use, holes are dug at substantially even intervals along a proposed path for the wall system. Piling forms are placed within the holes, such that a portion of the forms extend above the holes to form the top section of the pilings. Slot blocks are placed within the forms, such that the vertical slots will be formed in the pilings oriented along the proposed path of the wall system. Pattern mats may be placed into the forms, in order to imprint patterns on the pilings. Concrete is then poured into the forms in order to form the pilings. Once the concrete has hardened, the forms may be removed, along with the mats and the blocks.  
       [0014] The slabs are placed between the pilings with the opposing edges of the slabs sliding down into the vertical slots until the lower edges of the slabs rest upon the ledges. In this manner, the lower edges of the slabs are supported substantially at grade. With the lower edges supported substantially at grade, rain and/or flood water may seep under the slabs with little resistance, thereby minimizing hydraulic load on the wall system. Finally, top caps may be placed atop the pilings to cover the vertical slots.  
       [0015] The pilings may be arranged to follow virtually any proposed path for the wall system. For example, the proposed path may comprise a substantially straight line. Alternatively, the proposed path may comprise a curve, compound curve, or serpentine curve. Furthermore, the proposed path may comprise a zig-zag or other jagged abrupt path. The proposed path may even loop back on itself to form a circular or oval containment, such as a holding tank or pond. Finally, the proposed path may comprise any or all of the above elements.  
       [0016] A preferred second embodiment of the present invention is configured as a deck system. The deck system broadly comprises a plurality of pilings and a plurality of slabs supported by the pilings similar to the pilings and slabs of the preferred first embodiment of the present invention.  
       [0017] However, in the second embodiment, the pilings are preferably rectangular. Bottom sections of the pilings are preferably buried substantially below grade, while top sections of the pilings preferably extend less than one foot above grade. The top section includes at least one substantially horizontal slot. The horizontal slot includes a ledge located approximately where the bottom section meets the top section. The ledge supports opposing edges of the slabs, such that lower surfaces of the slabs are supported substantially at grade. The top section may extend above the horizontal slots or may terminate in a top surface flush with upper surfaces of the slabs.  
       [0018] In use, the pilings and the slabs are constructed in a manner similar to that used to construct the pilings and slabs described above, accounting for the differences described herein. For example, slot blocks are placed horizontally within piling forms in order to form the horizontal slots.  
       [0019] It should be noted that the slabs of any of the embodiments may be removed, as desired. For example, should utility or trenching work be required, any affected slabs may be removed, set aside while the work is being conducted, and then reinstalled once the work is completed. This feature prevents damage to the slabs otherwise commonly associated with such work. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0020] A preferred embodiment of the present invention is described in detail below with reference to the attached drawing figures, wherein:  
     [0021]FIG. 1 is a perspective view of a wall system constructed in accordance with a preferred first embodiment of the present invention;  
     [0022]FIG. 2 is a perspective view of a portion of the wall system;  
     [0023]FIG. 3 is a perspective view of a piling of the wall system;  
     [0024]FIG. 4 is a plan view of the piling;  
     [0025]FIG. 5 is a plan view of a deck system constructed in accordance with preferred second embodiment;  
     [0026]FIG. 6 is a vertical section view taken along line  6 - 6  of FIG. 5;  
     [0027]FIG. 7 is the view of FIG. 6 showing inclined slabs; and  
     [0028]FIG. 8 is the view of FIG. 6 showing offset slabs. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT  
     [0029] Referring to FIG. 1, the preferred wall system  10  constructed in accordance with a preferred first embodiment of the present invention is illustrated. The wall system  10  broadly comprises a plurality of pilings  12  and at least one slab  14  supported by the pilings  12 . Both the pilings  12  and slabs  14  are preferably formed of concrete and may be imprinted with one or more patterns. The pilings  12  are preferably formed at a job site, as will be discussed in greater detail below. While the slabs  14  may be formed at the job-site, the slabs may alternatively be preformed at a manufacturing facility where such work may be done more efficiently.  
     [0030] Referring also to FIGS. 2, 3, &amp;  4 , the patterns are preferably imprinted using commonly available pattern mats  16 . Alternatively, the patterns may be imprinted using rubber pattern mats specifically designed for use with the wall system  10 . For example, the rubber mats are reusable and readily accept adhesives in order to line forms, as will be discussed in further detail below. The patterns may be imprinted using a single continuous mat or several individual mats and may be identical for both the pilings  12  and the slabs  14 . Alternatively the pilings  12  may be imprinted with one pattern, while the slabs  14  are imprinted with another pattern. Furthermore, the slabs  14  may be imprinted with a first pattern on a front side  18  and a second pattern on a back side  20 . Finally, the pilings  12 , either of the sides  18 , 20  of the slabs  14 , or all three may be blank with no pattern imprinted thereon.  
     [0031] The pilings  12  are preferably cylindrical, but may be virtually any shape, such as rectangular, square, oblong, triangular, hexagon, octagon, or pentagon. The pilings  12  include a bottom section  22  and a top section  24  supported by the bottom section  22 . The bottom section  22  is preferably buried substantially below grade, while the top section  24  is located substantially above grade. While the pilings  12  may be virtually any size, the pilings&#39; diameter and height are dependant up the wall system&#39;s  10  size. For example, a ten foot tall wall system will require larger pilings  12  than a four foot tall wall system. In either case, the bottom section  22  is sized to support the wall system&#39;s  10  weight and the top section  24  is sized to match the wall system&#39;s  10  height. For example, in one embodiment, the pilings  12  are approximately eight foot tall and approximately eighteen inches in diameter. Alternatively, the ten foot tall wall system would include an approximately ten foot tall bottom section, an approximately ten foot tall top section, and the pilings would preferably be approximately thirty inches in diameter.  
     [0032] While the bottom section  22  is preferably completely solid, the top section  24  includes at least one vertical slot  26 . The vertical slot  26  is approximately six inches deep and approximately four inches wide. The vertical slot  26  extends from a ledge  28  located approximately where the bottom section  22  meets the top section  24  to an opening  30  in a top surface  32  of each piling  12 . The ledge  28  supports opposing edges  34  of the slabs  14 , such that lower edges  36  of the slabs  14  are supported substantially at grade.  
     [0033] As discussed above, the pilings  12  may have one or more vertical slots  26 . For example, if an end piling is to be used at an end of the wall system  10  the end piling may include only one vertical slot  26 . Alternatively, if a successive piling is to be used along a proposed path of the wall system  10 , the successive piling preferably includes two vertical slots  26 . Furthermore, if a junction piling is to be used at a junction of wall systems the junction piling may include three or more vertical slots  26 . However, most pilings  12  are expected to be used along the proposed path of the wall system  10  and have two vertical slots  26 .  
     [0034] The vertical slots  26  may be arranged at any angle with respect to each other in order to align the slabs  14  with the proposed path of the wall system  10 . For example, at a ninety degree corner of the wall system  10 , two vertical slots  26  will be arranged at approximately ninety degrees with respect to each other such that corresponding slabs  14  would be aligned at approximately ninety degrees to each other and follow the proposed path of the wall system  10 . This permits the wall system  10  to be formed into almost any shape.  
     [0035] For example, the proposed path may comprise a substantially straight line. Alternatively, the proposed path may comprise a curve, compound curve, or serpentine curve. Furthermore, the proposed path may comprise a zig-zag or other jagged abrupt path. The proposed path may even loop back on itself to form a circular or oval containment. In this case, the wall system  10  may be lined and used as a tank or pond. Finally, the proposed path may comprise any or all of the above elements.  
     [0036] As shown in FIG. 4, the pilings  12  are constructed using commonly available piling forms  38  of appropriate dimensions, as discussed above. The mats  16  may be placed inside the piling forms  38  in order to imprint the pilings  12  with one of the patterns. The vertical slots  26  are formed by placing slot blocks  40  vertically within the piling forms  38 . The blocks  40  may be constructed from foam, wood, plastic, or any other suitable material. Once the piling forms  38  are prepared with the mats  16  and the blocks  40 , as desired, concrete is poured therein. Once the concrete has hardened, the piling forms  38 , the mats  16 , and blocks  40  are removed leaving the pilings  12  with the pattern and the vertical slots  26  therein.  
     [0037] The slabs  14  are preferably substantially flat and approximately four inches thick, and thereby may be slid down into the vertical slots  26 . The slabs  14  are sized to match the wall system  10 . For example, the ten foot tall wall system would include approximately ten foot tall slabs. While the slabs  14  may be designed to virtually any length, the slabs  14  are preferably between six and eighteen feet long. For example, the ten foot tall wall system would include approximately twelve foot long slabs.  
     [0038] The slabs  14  may be formed like a sidewalk. For example, rectangular forms may be constructed along the ground with bulkheads placed between successive slabs. Concrete may be poured into the rectangular forms. Once the concrete has hardened, the rectangular forms may be removed. Then, the slabs  14  may be lifted and set into place between the pilings  12 .  
     [0039] The wall system  10  preferably also includes a plurality of top caps  42  that fit over the top section  24  of the pilings  12  and cover the openings  30  of the vertical slots  26 . The caps  42  may be imprinted with one of the patterns or may be left blank. The caps  42  are preferably between one inch and four inches thick with a diameter sized to match the pilings&#39;  12  diameter. For example, the ten foot tall wall system, with approximately thirty inch diameter pilings, would include approximately thirty inch diameter caps.  
     [0040] In use, holes are dug at substantially even intervals along the proposed path for the wall system  10 . For example, the ten foot tall wall system would require the holes to be spaced at approximately twelve feet and eighteen inches on center. The intervals are determined by the pilings&#39;  12  diameter, the slots&#39;  26  depth, and the slabs&#39; length  14 . For instance, the above eighteen inches represents a measurement from either opposing edge  34  of the slabs  14  to a center of the pilings  12 , multiplied by two in order to account for both pilings  12  upon which each slab  14  will rest. More specifically, the above eighteen inches is calculated as the pilings&#39;  12  fifteen inch radius minus the slot&#39;s  26  six inch depth multiplied by two.  
     [0041] The piling forms  38  are placed within the holes, such that a portion of the piling forms  38  extend above the holes to form the top section  24  of the pilings  12 . The mats  16  are placed into the piling forms  38 , in order to imprint the pilings  12  with one or more of the patterns, if desired. The blocks  40  are placed within the piling forms  38 , such that the vertical slots  26  will be formed in the pilings  12  oriented along the proposed path of the wall system  10 . Concrete is then poured into the piling forms  38  in order to form the pilings  12 . Once the concrete has hardened, the piling forms  38  may be removed, along with the mats  16  and the blocks  40 . Some minor trimming or shaping may be required around the vertical slots  26 , since concrete may seep around the blocks  40 .  
     [0042] At this point, the pilings  12  are substantially finished. The holes are preferably filled in and the job site may be brought to final grade. Alternatively, the job site may be left ungraded until after the slabs  14  have been installed.  
     [0043] The slabs  14  are placed between the pilings  12  with the opposing edges  34  of the slabs  14  sliding down into the vertical slots  26  until the lower edges  36  of the slabs  14  rest upon the ledges  28 . In this manner, the lower edges  36  of the slabs  14  are supported substantially at grade, since the ledges  28  are located where the bottom section  22  meets the top section  24  and substantially at grade. With the lower edges  36  supported substantially at grade, rain and/or flood water may seep under the slabs  14  with little resistance, thereby minimizing hydraulic load on the wall system  10 . Finally, the caps  42  are placed atop the top surfaces  32  of the pilings  12  to cover the openings  30  of the vertical slots  26 .  
     [0044] As shown in FIG. 2, the wall system  10  is preferably backfilled with drainage rock  52  in order to facilitate water drainage. The drainage rock  52  is preferably placed behind the slabs  14 , below the slabs  14 , or both. Such a configuration allows the wall system  10  to act as a sea wall holding back soil and/or other material while allowing a relatively free flow of water. For example, when configured as a sea wall, the wall system  10  may prevent erosion by holding the drainage rock  52  in place, which in turn holds the soil.  
     [0045] Furthermore, the wall system  10  may be used as a retaining wall. For example, the proposed path may encircle an elevated area. Once the wall system  10  is in place, any space between the wall system  10  and the elevated area may be back filled with the drainage rock  52  in order to buttress the elevated area and provide proper drainage from the elevated area.  
     [0046] Alternatively, the wall system  10  may be used as a holding tank, such as those found at sewage treatment facilities. In this case, the proposed path preferably forms either the circle or the oval discussed above. Once the wall system  10  is in place, a liner is preferably installed. In this case, the liner acts to retain water, or whatever is intended to be held in the holding tank, while the wall system  10  reinforces and holds the liner.  
     [0047] Referring to FIGS.  5 - 6 , a deck system  110  in accordance with a preferred second embodiment of the present invention is illustrated. The deck system  110  broadly comprises a plurality of pilings  112  and a plurality of slabs  114  supported by the pilings  112 . The pilings  112  and the slabs  114  are similar to the pilings  12  and slabs  14  of the preferred first embodiment of the present invention.  
     [0048] However, the pilings  112  of the second embodiment are preferably rectangular having a length substantially equal to the deck system&#39;s  110  width. A bottom section  122  of each piling  112  is preferably buried substantially below grade, while a top section  124  of each piling  112  preferably extends less than one foot above grade. The top section  124  includes at least one substantially horizontal slot  126 , instead of the vertical slot  26  of the preferred first embodiment. The horizontal slot  126  includes a ledge  128  located approximately where the bottom section  122  meets the top section  124 . The ledge  128  supports opposing edges  134  of the slabs  114 , such that lower surfaces  136  of the slabs  114  are supported substantially at grade. The top section  124  may extend above the horizontal slots  126  or may terminate in a top surface  132  flush with upper surfaces  150  of the slabs  114 .  
     [0049] In use, the pilings  112  and the slabs  114  are constructed in a manner similar to that used to construct the pilings  12  and slabs  14  described above, accounting for the differences described herein. For example, slot blocks are placed horizontally within piling forms in order to form the horizontal slots  126 .  
     [0050] Referring also to FIG. 7, the deck system  110  may be used as a culvert. For example, slabs  114  may be installed at an incline with respect to other slabs. In this manner, the deck system  110  may form a channel to direct water flow. The patterns may be especially useful in this case. For example, the patterns may be particularly abrupt, and thereby act to slow the flow of water. Referring to FIG. 8, slabs of the deck system  110  may be offset with respect to other slabs. In this case, the deck system  110  may take on a stair-step appearance. Such a configuration may also be used to control the flow of water.  
     [0051] While the deck system  110  has been described as being configured substantially horizontally, the entire deck system  110  may be constructed at an angle. For example, the deck system  110  may be used as part of an abutment for overpasses or other bridges. In this case, the pilings  112 , are preferably aligned down a face of the abutment, such that the slabs  114  may be slid into place down the face and between the pilings  112 . Alternatively, the pilings may be aligned across the face of the abutment, such that the slabs  114  are slid into place across the face and between the pilings  112 .  
     [0052] The pilings  12 , 112  and/or the slabs  14 , 114  are preferably reinforced with re-bar, as required. For example, as shown in FIGS. 3 and 4, vertical re-bar  54  preferably extends substantially the entire height of the pilings  12 , 112  to structurally tie the bottom section  22 , 122  to the top section  24 , 124 . Additional re-bar  56 , may be used to tie the vertical re-bar  54  together, further adding to the structural integrity of the pilings  12 , 112 . Similar re-bar techniques may be used for the slabs  14 , 114 . With the re-bar  54 , 56 , the wall system  10  and the deck system  110  may be designed to withstand significant structural load, such as that associated with holding tanks, sea walls, retaining walls, culverts, and abutments, while still allowing proper drainage in order to minimize hydraulic load on the wall system  10  or the deck system  110 .  
     [0053] It should be noted that the slabs  14 , 114  may be removed, as desired. For example, should utility or trenching work be required, any affected slabs may be removed, set aside while the work is being conducted, and then reinstalled once the work is completed. This feature prevents damage to the slabs  14 , 114  otherwise commonly associated with such work.  
     [0054] While the present invention has been described above, it is understood that other materials and/or dimensions can be substituted. For example, the wall system  10  may be installed between two areas with two significantly different grades, thereby acting as the retaining wall. In this case, the lower edges  36  of the slabs  14  are preferably supported substantially at a lowest one of the two grades. Alternatively, the wall system  10  may be installed between two areas with substantially identical grades, thereby acting as a decorative or privacy wall. Additionally, the pilings  12 , 112  may be tapered such that the bottom section  22 , 122  is wider than the top section  24 , 124 . The concrete may also be tinted using commonly available concrete coloring products. Furthermore, concrete or mortar may be poured into the slots  26 , 126  after the slabs  14 , 114  have been installed in order to hold the slabs  14 , 114  firmly in place. Concrete or mortar may similarly be used to hold the caps  42  in place. Finally, the slots  26 , 126  may include tapered sidewalls, as shown in FIG. 3, or squared sidewalls, as shown in FIG. 4. These and other minor modifications are within the scope of the present invention.