LIGHTWEIGHT CONCRETE OR MASONRY FENCE SYSTEM WITHOUT CONCRETE FOOTINGS

Abstract

Column and panel concrete fence systems and related methods of construction. Such a method may include placing (e.g., pounding or otherwise driving) a plurality of posts into the ground, attaching a bracket to each post. The concrete column may be provided in two initially separate portions e.g., each corresponding to a “front” or “back” face of the fence. One of the portions (e.g., corresponding to the front or back of the fence) is attached to a given post. The concrete panel may then be advanced into place, and the other of the front or back portions of the column may then be attached to the post, over the first column portion that was already attached to the post.

Description

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present invention is in the field of modular concrete fence systems formed from a plurality of concrete panels and columns.

2. The Relevant Technology

Column and panel concrete fence systems are commonly employed within the field. Such fencing typically includes a plurality of concrete panels oriented end to end, with a column positioned between adjacent panels. Various methods are known for constructing such a fence. For example, typically, a concrete footing is provided for each column, after which the panels and columns may be positioned thereover, so that the load of the panels and columns is supported by the footings. Such footings are typically dug to the needed depth, and then filled with concrete. Once the concrete has hardened sufficiently, the columns and panels may be positioned over the completed concrete footings. Depending on the particular method employed, it may also be necessary to fill or “grout” voids that may be intentionally included within the column with concrete as well, once the columns and panels are in place. Such methods require excavation of the dirt from the footing hole, which dirt must often be hauled away, followed by pouring of concrete into the prepared holes. Placement of the panels and columns cannot be accomplished immediately, and must be postponed until the concrete footing has sufficiently hardened. The time, effort, and expense involved in excavation, concrete pouring, waiting for the concrete to cure, and grouting of columns is significant.

Examples of such existing concrete panel and column fence systems and methods for their construction are described in the inventor's earlier U.S. Pat. Nos. 6,199,832 and 6,609,347, each of which is herein incorporated by reference in its entirety. It would be an advancement in the art to provide concrete panel and column fence systems that could be installed with greater ease, less time, and less expense (e.g., requiring no excavation and requiring no concrete footings).

SUMMARY

In one aspect, the present invention is directed to methods for constructing a column and panel concrete fence. Such a method may include placing (e.g., pounding or otherwise driving) a plurality of posts into the ground, attaching a bracket to each post, attaching a first portion of a concrete column to each post, and placing a concrete panel on the brackets of adjacent posts such that a first end of the panel is supported on the bracket of one post, and a second end of the panel is supported on the bracket of the adjacent post. A second portion of each concrete column may be attached to its corresponding post. For example, the concrete column may be provided in two initially separate portions or halves, e.g., each corresponding to a “front” or “back” face of the fence. One of the portions (e.g., corresponding to the front or back of the fence) is attached to a given post. The concrete panel may then be advanced into place, and the other of the front or back portions of the column may then be attached to the post, over the already attached column portion.

In another embodiment, the method includes placing a plurality of posts in the ground, at least one of the posts being pounded or otherwise driven in the ground, without the use of any concrete footing. For example, such post placement does not require any excavation, as the posts may simply be driven into the ground at the desired spacing. A bracket may be attached to each post, which bracket will be used to support the concrete panel of the fence. A first portion of the concrete column may be attached to each post, with the first portion of the concrete column corresponding to a front or rear face of the fence system. A lightweight concrete panel (e.g., no more than about 500 lbs, e.g., about 250 lbs) may be placed on the brackets of adjacent posts, so that a first end of the panel is supported on the bracket of one post, and a second end of the panel is supported on the bracket of the adjacent post. Because the concrete panel is lightweight (e.g., including a foam core), it is possible to support the weight of the panel on the brackets, which are attached to the posts. It is not necessary to place and support the concrete panel directly on a concrete footing, as is traditionally done. A second portion of the concrete column may be attached to the corresponding post, at a location on the post opposite the first portion of the concrete column. For example, the second portion of the concrete column corresponds to the other of the front or rear face of the fence.

Where the first portion of the concrete column is attached to the post, this may be followed by advancement of the concrete panel into position on the brackets, laterally, from the side (as opposed to from above). Once the panel is in place, the opposite second portion of the concrete column may be attached to the post, which already includes the first portion of the concrete column attached thereto. Such a method is particularly advantageous, as it does not require that the concrete panel be lifted above the columns, and dropped down into a corresponding slot within the columns. Instead, the panel is sandwiched between the facing column portions by placing one column portion, positioning the panel, and then placing the other column portion.

Another aspect of the present invention is directed to a column and panel concrete fence including a plurality of posts (e.g., pounded or otherwise driven into the ground, without excavation), a column attached to each post, each column including two portions which are separate from one another, and which correspond to front and rear faces of the fence, respectively. A lightweight concrete panel is included, with a first end of the panel supported by a bracket attached to one of the plurality of posts such that the first end of the panel extends between the portions of the column and a second end of the panel being supported by a bracket attached to an adjacent one of the plurality of posts, such that the second end of the panel extends between the portions of the column attached to the adjacent post. In other words, the ends of the panel are sandwiched between the column portions.

Such methods and fence systems do not require excavation, as is typically employed in installation of a concrete panel and column fence. Nor do the methods and fence systems require concrete footings, as are also typically employed in installing and supporting concrete panel and column fence systems. This is possible because of the use of relatively lightweight materials in constructing the panels of the fence, while at the same time providing actual exterior surfaces (e.g., veneers) to the panels that are concrete. Normally, a concrete panel fence is very heavy, and it is necessary to include concrete footings in order to support the load associated with typical concrete panel and concrete columns. For example, a typical concrete panel (e.g., about 9 feet long, 6 feet high, and about 4 inches thick) may typically weigh 3,000 to 4,000 lbs. Such massive loads must be supported on a concrete footing.

Because of the need to support such a load on a concrete footing, it is also necessary to excavate the earth under the location of each of the fence columns. For example, in a traditional solid concrete panel fence system, holes are excavated at the spacing of the columns (e.g., about 9 feet apart). Each prepared hole is filled with concrete, which must be allowed to harden. After having hardened, the columns are constructed over the concrete footings, with the ends of the panels resting directly on the concrete footings. Because the ends of the concrete panels rest directly on the concrete footings, it is also important that such concrete footings be prepared so that their top surface is level, and at the desired height. As will be apparent, this can present difficulties, particularly where the fence is being constructed on a sloped surface, where it may be desired to “stair-step” the panels to accommodate the sloping surface. Such requires stair-steps to be incorporated into the top surface of the footings, as well.

Such excavation and pouring of concrete is time and labor intensive, increasing the cost associated with installing such fence systems. Often it is necessary to haul away excavated earth materials, and small amounts of left over concrete often present on the job site represent a further nuisance requiring clean-up. Furthermore, in some areas, the soil is known to undergo variable expansion due to varying levels of water depending on the season, heavy storms, etc. For example, many soils in Texas are expansive in this way, leading to the level of the surface moving up to several inches, depending on the water content in the soil at any given time. As a result, fences constructed under such conditions tend to be unstable, and eventually fall over as a result of the continuous expansion and contraction of the earth into which they are installed, even where concrete footings of typical depth are employed.

In order to prevent or mitigate such effects, it is typically necessary to prepare the footings to a depth which reaches below the expansive soil layer, which can often be at least 3 to 4 feet, or more (e.g., sometimes over 10 feet). It will be readily apparent that the cost to excavate column concrete footings to such depths is impractical and very expensive. For these reasons, installers typically forgo such expensive solutions, and instead simply accept that the fence will eventually collapse. The presently described fence systems and methods of installation are able to overcome many or even all of such problems present within the field associated with concrete fence systems.

Features from any of the disclosed embodiments may be used in combination with one another, without limitation. In addition, other features and advantages of the present disclosure will become apparent to those of ordinary skill in the art through consideration of the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

The drawings illustrate several embodiments of the invention, wherein identical reference numerals refer to identical or similar elements or features in different views or embodiments shown in the drawings.

FIG. 1 is an isometric view of an exemplary fence system according to the present invention.

FIG. 2 shows posts to be driven into the ground, without the need for any excavation or concrete footings.

FIG. 3 shows attachment of a bracket to each post.

FIG. 4 shows the first portion of the two-part fence column being attached to (e.g., screwed into) the post.

FIG. 5 shows placement of the concrete panel so as to be supported on the brackets of each post, between adjacent posts.

FIG. 6 shows the second portion of the two-part fence column being attached to the post, covering the top portion of the post, sandwiching it within the column.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

I. Introduction

The present invention is directed to concrete panel and column fence systems, as well as methods for installing such fence systems. For example, the fence systems and methods provide for installation of a concrete panel and concrete column fence, which provides desired aesthetic and other benefits, without requiring the use of any concrete footings, or the excavation typically associated with such footing preparation.

II. Exemplary Fence Systems and Methods of Installation

FIG. 1 shows an exemplary column and panel concrete fence 100 including a plurality of posts 102, a concrete column 104 attached to each post 102, in which each column 104 includes two initially separate portions 104a and 104b, and a lightweight concrete panel 106. As seen in FIG. 1, the two portions 104a and 104b of column 104 may correspond to front and rear faces of the fence 100, as shown. A first end 108 of concrete panel 106 is positioned and supported on a bracket 110, which bracket is attached to post 102. The brackets 110 are difficult to see in FIG. 1, and are perhaps best seen in FIGS. 3-6, which show progressive views of how the fence may be constructed, according to an embodiment. A second end 112 of panel 106 is also positioned on another bracket 110, so that the panel extends between two adjacent posts 102 of the fence system. The ends 108 and 112 of panel 106 are sandwiched between the two portions 104a, 104b of a given column 104.

The fence 100 thus includes columns 104 on either side of each panel 106, with adjacent columns being separated by the intervening panel. Where multiple panels are included, the panels are aligned end-to-end, with a column positioned at the respective ends of the two adjacent panels. The ends of the two panels do not need to contact one another, but will typically be spaced apart from one another by at least the width of the post 102. For example, the ends of each panel may abut and contact (or nearly contact) the corresponding post on which the bracket supporting that end of the panel is attached. As seen in FIG. 1, to provide a finished appearance, a cap 114 may be attached over each column 104.

By way of example, where the posts 102 and columns 104 are spaced 9 feet apart from one another, center to center, the panel itself may be somewhat less than 9 feet in width, e.g., about 101 inches, leaving a small gap between the ends of adjacent panels, with the post 102 disposed therebetween.

Posts 102 may be driven into the ground (e.g., dirt) 116, without requiring excavation. For example, rather than digging a hole into which each post 102 is then placed, the posts 102 may instead by pounded or otherwise driven into the ground, which can be achieved without disturbing the compacted ground 116. Excavation necessarily disturbs the compacted characteristics of ground 116, which can lead to uneven settling of the excavated and backfilled soil, later. Because no excavation is needed, there is no need to dispose of unwanted dirt removed from the excavated holes (as there are none). Removal of unwanted dirt is often required when installing such concrete panel and column fences, e.g., in residential or commercial retail or other environments where there is no convenient location on-site to spread the unwanted fill dirt. Advantageously, no such issue arises where excavation is not required, as no concrete footings are required.

In addition to no excavation being needed, no concrete footings are needed either. Typically, the hole for a concrete footing is excavated, the excavated dirt must be disposed of, and the hole is filled with concrete, which is allowed to harden. Rebar or other reinforcement may be positioned vertically within the concrete footing to later be secured to the concrete column. Only after the footings have hardened is the remainder of the fence constructed. Concrete footings are needed for such concrete panel and column fences, because of the great weight of the concrete panels, which may easily weigh in excess of 3,000 lbs each. A suitable foundation for supporting such a massive load must be provided, which is provided by the typical concrete footing. Pouring of such concrete footings is messy, time consuming, labor intensive, and represents a substantial fraction of the overall cost of installing a concrete panel and column fence.

Once such footings are poured, they must be allowed to harden (e.g., over a day), which requires the installation crew to be on the job site for more than a single day. For example, the crew may come and form the footings the first day, and leave, returning the next day after the footings have hardened. The second day they can then place the concrete columns and panels and fill the void within the center of each column (e.g., which includes rebar running vertically up from the footing below) with concrete (i.e., “grouting the column”). Throughout this process, the panels and/or columns may require bracing until the concrete poured within the column has been allowed to harden. As will be apparent, this may typically require the installation crew to return again a third day once the grouted columns have hardened, as only then can the bracing be removed.

The pouring of concrete footings, and grouting of the columns is also messy, labor intensive, time consuming, and also represents a substantial fraction of the overall cost of installing a concrete panel and column fence. Often, such fences are to be installed in a location that is not easily accessible by a cement truck, so that the concrete must be hauled by hand (e.g., wheelbarrow), or requiring the use of a concrete pumping truck, which is expensive. In addition, as will be apparent from the above description, it is typically necessary for the cement truck to return twice—once for pouring of the concrete footings (e.g., on day 1), followed by grouting of the concrete columns (e.g., on day 2).

In addition, when pouring the concrete footings, it is important that the top of the footing be level (as the panel will be resting thereon), and that it be at the proper height, so that the panels are each at a desired height. While stair stepping of the panels may be desired where installing the fence on a slope, generally, it is desired that the top of each panel be at the same height, so that the fence looks right. If care is not taken in pouring the concrete footings, the footings may be at different heights, where it is intended that they be at the same height, resulting in the top end of the fence as defined by the panels being uneven from panel to panel (i.e., it goes up and down, where such is not intended). Where the concrete footings are not at the proper height or are not level, this can require shaving or cutting away the top surface of the footing, or build up of a footing that is too short with specially formulated concrete capable of acceptable adhesion between the old and new concrete. Needless to say, such adjustments are time consuming, labor intensive, and add substantially to the cost of a project.

As such, it would be a great advantage to provide a concrete panel and concrete column fence that does not require any concrete footings. While concrete footings are not required, under certain circumstances, a user employing the present inventive concepts may wish to include a concrete footing for one or more of the posts (e.g., where the post might require placement at a location where it cannot readily be driven into the ground. An example of such an instance may be where the post must be placed in very rocky ground, where it may not be possible to pound or otherwise drive the post into the ground. Thus, while some post locations of a fence installation may conceivably include a concrete footing, most of the post locations typically will not so require, and can be pounded or otherwise driven into the ground. Furthermore, even if the posts are installed in a concrete footing, the footing is not required for column and panel support in the same way that such is required with a typical concrete panel and column fence. The footing is not required to support any massive load of the fence itself, but merely (in some circumstances) to secure the post itself in place. Even in such instances, the load is supported on the bracket attached to the post, not on any rarely installed concrete footing that might sometimes be included within the contemplated fence systems. In such instances, because the load does not rest directly on the footing, the same level of care in achieving the proper level, etc., is not required.

Rather than excavating holes for footings, and pouring concrete footings, the presently disclosed fence system and method employs an alternative mechanism for supporting the fence structure (columns and panels) that reside above ground. Because the present fence system employs lightweight concrete panels, the panels weight far less than a similarly dimensioned solid concrete panel. For example, each panel may include a foam core (e.g., about 2.5 inches thick), with a relatively thin concrete shell or veneer that surrounds the foam core. For example, the concrete shell may be about ⅜ inch thick, providing the concrete panel with an overall thickness of about 3 to about 4 inches. The foam core may comprise any suitable lightweight material, e.g., such as expanded polystyrene. Rather than weighing in excess of 3,000 lbs (for an approximately 9 foot long, 6 foot high panel), such a concrete panel may weigh no more than 500 lbs, no more than 400 lbs, no more than 300 lbs, e.g., from 200 to 300 lbs. Such a typical panel weighs about 250 lbs.

The columns may be formed from solid precast concrete, as their size is relatively small in comparison to that of the panels. Also, since the column is provided in two halves, the weight is further reduced to approximately 100 lbs. In another embodiment, the columns could be constructed with a lightweight foam core, surrounded by a relatively thin shell of concrete, similar to the panels. The thin shell of concrete and/or the concrete of the columns may be fiber reinforced, so as to provide the desired level of strength. The lightweight concrete fence system provides the aesthetic beauty characteristics of concrete (e.g., mimicking stone), providing weatherability and durability characteristics far greater than those available from plastic and wood fencing systems. Yet, because of the lightweight characteristics, installation and cost is much easier and lower cost as compared to traditional solid precast concrete panels.

Because the concrete panels are lightweight (e.g., showing about a 90% reduction in weight as compared to a similarly sized solid concrete panel), requirements for supporting the load of the panels is significantly different than when working with solid concrete panels. For example, the fence system may have a weight load of only about 400 lbs per post location, as compared to thousands of pounds (e.g., 4,000 lbs or more may be typical) per similar location (i.e., the concrete footing) associated with a traditional concrete fence system. Because of the much lower load characteristics, it is possible to replace the traditionally employed concrete footing support mechanism with a system of posts and brackets attached to the posts, on which the concrete panels and column portions are supported.

As described above, elimination of the need for concrete footings and the associated excavation represents a significant advantage over existing fence systems and installation methods. FIGS. 2-6 illustrate steps of an exemplary method of installation. As seen in FIG. 2, the posts 102 may be placed into the ground (e.g., by pounding or otherwise driving them to the desired depth). The posts 102 may be spaced apart from one another an appropriate distance (e.g., 9 feet), depending on the particular length characteristics of the precast lightweight concrete panels. It will be apparent that other spacings may be provided, depending on the particular length dimension of the panels.

Both the panels and column portions may be precast, monolithic (single piece) in structure, providing for quick, easy, and inexpensive construction or assembly of the fence on site.

Each post 102 may be a rectangular cross-sectioned hollow post, as shown in FIG. 2, although other configurations might alternatively be employed while still providing a foundation on which to support the columns and panels. For example, a circular cross-sectioned post, or other polygonal shaped cross-section post may alternatively be employed. It is preferred that the posts 102 be hollow, including open ends at each end, as this facilitates easy driving of the posts into the ground. In another embodiment a pointed end could be provided at the end being driven into the ground. Posts 102 may be driven into the ground manually, or any other suitable mechanism may be employed. For example, a front end loader, “Bobcat” or similar earth moving equipment could be used, e.g., with a specially configured post driving attachment (e.g., a plate compactor with a sleeve for pounding/driving), to quickly drive the posts 102 into the ground to a desired depth. Such post driving attachments (any of which may be suitable) are commercially available for use with various earth moving equipment.

Such a method of driving a post 102 into the ground (e.g., every 9 feet) is far faster, less labor intensive, etc. than excavating a hole for a footing, and pouring a concrete footing into each hole, particularly where care must be taken to ensure that the footing is correctly leveled, and accommodations for stair stepping in the footing provided where the ground slopes. In addition, this avoids all of the issues described herein associated with disposal of the unwanted excavated dirt, disposal and clean up of concrete, etc. For example, under typical soil conditions, a 4 inch square metal post can be pounded to a depth of 4 feet penetration (typically all that is needed) in about 30 seconds, using a front end loader or other earth moving equipment with appropriate attachment. It will be readily apparent what an enormous advantage this is over the traditional excavation and concrete footings.

Furthermore, such a post foundation to the fence system is particularly advantageous in areas where the ground is made up of soils exhibiting severe moisture expandability, such as the expandable clays common in Texas. Such soils routinely result in surface uplift of concrete footings prepared in such soils. Where a traditional concrete fence is constructed in such an environment, the constant uplift and subsequent shrinking as the soil dries out causes such fences to collapse relatively quickly. The post foundation construction as contemplated herein is not nearly as susceptible (if at all) to such problems caused by expansive soils. This is particularly so where the posts 102 are hollow, with an open end at the bottom, as will be appreciated from FIG. 2.

For example, the post may comprise a 4 inch square steel (e.g., galvanized) or other metal (e.g., aluminum) post. Where the post is open at the end driven into the ground, it includes only a very small surface area in “plan view” against which hydraulic pressure (i.e., uplift) may be applied by the soil. As a result, of the post's low applicable surface area, the surface uplift force applied by such soil against the small post surface area is small, and is in fact offset by surface friction along the sides of the post, between the post sides and the ground, which relationship prevents the post from being uplifted even when the ground around the post undergoes surface uplift due to moisture absorption and associated soil expansion.

In other words, the surface area of the post (and the associated surface uplift force applied thereto) is sufficiently small so that the post remains in place, as the friction resisting uplift is greater than any such surface uplift force. This is so, so long as the post is driven into the ground sufficiently deep so that the friction force opposing pull out (or uplift) is greater than any hydraulic surface uplift force applied against the bottom surface of the post. Typically, a 4 foot penetration will be sufficient to achieve this result. Even if more penetration is required, the post can easily and quickly be driven to the needed depth (e.g., 6 feet, 8 feet, 10 feet, or more). Thus, it is not necessary to drive the post so as to actually reach below any such expansive soil layer, but just to ensure that the frictional forces opposing uplift of the post are greater than the applicable surface uplift force.

If desired, a smaller dimensioned post could be positioned within the post driven into the ground, and the column portions and panels supported on such a telescoping post. For simplicity, the present disclosure refers to a “post”, although it will be appreciated that a telescoping arrangement of posts is contemplated, and within the scope of the present invention.

Once the posts 102 are positioned within the ground, it can easily be verified that the post will provide the desired load rating. For example, a hydraulic ram and certified load cell can be used to verify in real time, on site, that the post will support the needed load. This is advantageous as it does not require building of the entire fence, just pounding of the post, at which point the load characteristics can be easily and quickly verified. This represents a particular improvement over load verification as it currently exists for traditional concrete column and panel fence systems, where there is a significant degree of uncertainty in the calculations, so much so that such systems must be over-engineered to accommodate such uncertainty. For example, there is typically a 3-5 times safety factor applied to such fence systems, to ensure that they really will meet the desired minimum load rating. With the present post fence systems where the load is supported on a pounded or otherwise driven post, an engineer is much more confident of the load rating, which can be verified on site, in real time, as the post is being driven, using a certified load cell and a hydraulic ram. If the testing shows the load rating to be too low, this is easily remedied, immediately, in real time, by driving the post in a bit deeper. As a result of this greater degree of confidence, the safety factor applied under such circumstances is much lower, e.g., about 1.6.

As shown in FIG. 3, once the posts 102 are driven to a desired depth into the ground (e.g., about 4 feet, or more, depending on the soil characteristics, desired load rating, etc.), brackets 110 may be attached to each post 102. While shown screwed to posts 102, it will be appreciated that any other attachment mechanism for attaching the posts may be employed (e.g., welding, riveting, gluing with an adhesive, etc.). Care is taken to ensure that the brackets are attached at the appropriate height along each post 102, as the lightweight concrete panels will rest thereon. Nevertheless, it will be apparent that if a mistake is made in attaching a bracket too high or too low, this is easily remedied by removing the bracket and reattaching it at the appropriate height. It will be apparent that such corrective measures are far simpler and easier than correcting mistakes made in the height or leveling of the concrete footing in traditional concrete fence systems.

While bracket 110 is shown as being substantially+shaped, with 4 outwardly extending arms, each about 90° apart, it will be appreciated that any bracket configured to support the panel may be suitable for use. As shown, 3 of the 4 arms may be coplanar, while one of the arms of bracket 110 is shown being disposed at a 90° upward angle relative to the horizontal plane defined by the other arms. As shown in FIG. 3, this vertical arm 110a of bracket 110 may be screwed into or otherwise attached to post 102. Arm 110a, and/or each of the other arms of bracket 110 may be of a width approximately equal to that of the post 102, as shown. For example, where the post is about 4 inches in width, bracket arm 110a may also be about 4 inches in width.

Arm 110b opposite arm 110a may extend towards the next, adjacent post 102. The panel may be supported on arm 110b of the bracket 110, e.g., with one end 108 of the panel 106 supported on arm 110b of bracket 110 (e.g., attached to the center post seen in FIG. 3), while the other end 112 of panel 106 may be supported on arm 110b of the other bracket 110, attached to the adjacent post (e.g., the right most post seen in FIG. 3). The arms defined between arms 110a and 110b, which extend in a direction corresponding to the “front” and “rear” faces of the fence may also aid in supporting the ends 108 and 112 respectively, although more typically they may support or interface with the column portions 104a and 104b, respectively. Brackets 110 are generally hid from view once the fence is fully constructed (e.g., see FIG. 1), as arm 110b may be under the bottom of panel end 108 or 112, arm 110a is hidden within column 104, and the front and rear arms are also generally hidden by column portions 104a and 104b. This is so particularly where the brackets 110 are installed near ground level 116, so as to not be readily seen by a person standing up.

As will be apparent from the center post 102 of FIG. 3, the brackets 110 attached on either side of post 102 may be attached at different heights to accommodate a step in the fence, where the ground is sloped. Where the ground is generally level, the brackets on either side of a given post 102 may be at the same height. At the end of a fence, the brackets 110 may only be installed on one side of the post. Where the fence forms a corner, the brackets may be attached on adjacent sides (e.g., 90° apart, rather than the 180° seen on the center post of FIG. 3). Other configurations to accommodate a desired fence design will be apparent from the present disclosure.

As shown in FIG. 4, a first portion 104a of each column 104 may be attached to the corresponding post 102. Each column portion may be attached using any suitable mechanism. It may be attached by screwing, welding, riveting, gluing with an adhesive, combinations thereof, etc. In an embodiment, attachment may be by structural self-tapping screws, e.g., including a hardened tip and more ductile threads, which provides for excellent shear strength. For example, pilot holes may be drilled through the column portions, and the structural self-tapping screws may be screwed through the pilot holes, which self-tap into the metal post 102. Other suitable attachment mechanisms will be apparent to those of skill in the art.

When driving the post 102, it is desired to ensure that the post does not tilt towards one adjacent post or the other. Small tilting of the post 102 in the front or rear direction of the fence can be accommodated by shimming the column portions when attaching the column portions to the post. When placing the first column portion 104a, the installer can ensure that first column portion 104a is plumb, and a shim may be positioned between the post and column portion 104a to make appropriate accommodation. The second column portions may similarly be shimmed, if desired (or a gap may be present between the second column portion 104b and the corresponding post 102, depending on circumstances). Thus, minor plumb issues may be compensated for by shimming at least one of the column portions as needed, so that the column 104 (which is seen) is plumb, even though the underlying post 102 (which is hidden) may not be exactly plumb.

When driving a post 102, if it is not quite plumb, rather than applying corrective force to the post 102 directly (which would cause disruption of the compacted soil on the opposite side of the post from where the force is applied), force may be applied to the ground adjacent the post, to cause it to tilt. In other words, if the post is not quite plumb, a corrective force may be applied using a compaction post or tamper (e.g., by swapping out the plate compactor and sleeve used to drive the post), to compact the soil on one side of the post, indirectly pushing the post back up to the straight, vertical, plumb orientation desired. Such a corrective measure is preferred over applying the force directly to the post 102 to correct a plumb issue, as such a directly applied force loosens the soil, compromising the load bearing capacity provided by the post.

FIG. 5 shows panels 106 being advanced into place, from the open side on which column portions 104b have not yet been placed, e.g., against column portions 104a, on brackets 110. Panels 106 are advantageously lightweight, so that they can be completely supported on brackets 110 (e.g., on bracket arms 110b), attached to posts 102. Because panels 106 are lightweight, the load on each post (through brackets 110) is much smaller than is traditionally applied to the concrete footings of a traditional concrete fence system, where the panels are laid directly on the footings themselves. Where each concrete footing may bear a load of 4,000 lbs or more, the posts in the present configuration typically only bear a load of about 400 lbs each (e.g., where the panel weighs about 250 lbs). Because the panels are lightweight, two crew members can easily lift and place the panel in position on brackets 110.

Referring to FIG. 6, with panels 106 in place, the remaining column portion 104b may be attached to the corresponding post 102. Attachment may be by a similar mechanism as described above relative to the first column portion 104a (e.g., structural self-tapping screws). It will be apparent that the panel 106 may thus simply rest on the brackets 110, rather than being fixedly attached to the posts 102 or columns 104. For example, even once the second column portion 104b is positioned and attached over the corresponding post 102, the panels 106 may simply rest within the cavity defined between column portions 104a, 104b, on brackets 110. Of course, in other embodiments, the panel could be attached to the columns, if desired. There is no need to grout the column voids, as is typically done. Thus, the assembly mechanism does not require the use of any concrete at all, and the various component parts of the fence system may easily be disassembled and reassembled, should it be necessary to replace a damaged panel, column, etc. In other words, the fence system is easily reversible, particularly where nothing is cemented in place. One crew member may steady panel 106 in place, while another crew member secures the second column portion 104b in place. Once both column portions 104a and 104b are in place, sandwiching panel 106, the panel is fully supported, so that no bracing or other temporary support is needed.

The panels 106 may not contact any concrete footing, as typically no concrete footings are present at all. Similarly, the columns 104 may not contact any concrete footing. Rather, typically no footings are needed, and the entire load is supported on the post, through the brackets (e.g., and screws or other attachment mechanism).

Caps 114 may be provided over columns 104 by any suitable mechanism (e.g., they may simply be laid thereover, or may be attached to column 104 by screws or other mechanism, if desired). At an end of a fence line, any gap between column portions 104a, 104b (which would normally be covered by a panel 106) may be filled or otherwise covered, as desired. In an embodiment, concrete fillers are added at the end of a column to replace the panel.

While FIGS. 2-6 illustrate a particular order of steps (e.g., driving posts 102, attaching brackets 110, attaching column portions 104a, positioning panels 106, and attaching the remaining column portions 104b), it will be appreciated that the steps of the disclosed method do not necessarily have to proceed in this order, although there may be advantages associated with at least some of the steps being in a particular order For example, brackets 110 may be attached to posts 102 after pounding of post 102, as it may not be known exactly to what depth to pound the post prior to pounding. Similarly, placement of the panel 106 after one panel portion (e.g., 104a), but before the second panel portion (e.g., 104b) may be preferred, as the panel 106 does not have to be hoisted above the column and dropped into the slot defined between portions 104a, 104b.

Because the posts are driven into the ground before the load of the panels is applied thereto, no bracing of the fence structure, or clamping of the column portions is required, as is normally provided during initial placement of the panel, and during grouting of the columns, and before the grout in the columns has had sufficient time to harden. As described above, once both column portions are attached to the post, the panel is fully supported. The time required to install such a fence system is significantly less than that required to install a similar fence (even a light weight panel one), where excavation and concrete footings are employed. For example, even a well-trained installation crew may average about 15 minutes per column location, to excavate the hole, pour the footing, and level the footing.

A similar crew has been able to install the presently disclosed fence system averaging about 1 to 2 minutes per post location, which is far faster, as typically there is no excavation, no concrete pour, no grouting of columns, no dirt disposal, and no clean-up of concrete required. Overall installation time, including placement of the panels, is cut to half the time or less, relative to what it was using the previous system based on excavation and concrete footings, even with lightweight panels. Furthermore, there is no need to wait a day between preparation of the foundation (i.e., the footing) and placement of the panels. Rather, the entire procedure can be performed in a single day, as there is no need to wait for concrete to cure (either in the footings, or when grouting the columns with concrete).

While described principally in the context of concrete panels and columns, it will be appreciated that other cement or other masonry materials may similarly be employed, while providing similar benefits. In addition, while the panels and columns in an embodiment may both comprise concrete, it will be appreciated that in another embodiment, at least one thereof may comprise a material other than concrete (e.g., masonry). For example, in an embodiment, the fence system could comprise a concrete panel, and the columns may comprise another material (e.g., masonry, another material, etc.). As such, for simplicity, the term “concrete” as used herein is to be broadly construed to include concrete, as well as other cementitious materials, and masonry, where they provide similar weatherability characteristics.

Numbers, percentages, or other values stated herein are intended to include that value, and also other values that are about or approximately the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing process, and may include values that are within 25%, within 20%, within 10%, within 5%, within 1%, etc. of a stated value. Furthermore, the terms “substantially”, “similarly”, “about” or “approximately” as used herein represents an amount or state close to the stated amount or state that still performs a desired function or achieves a desired result. For example, the term “substantially” “about” or “approximately” may refer to an amount that is within 25%, within 20%, within 10% of, within 5% of, or within 1% of, a stated amount or value.

Ranges between any values disclosed herein are contemplated and within the scope of the present disclosure (e.g., a range defined between any two values (including end points of a disclosed range) given as exemplary for any given parameter).

As used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A method for constructing a column and panel concrete fence, the method comprising:

placing a plurality of posts in the ground;

attaching a bracket to each post;

attaching a first portion of a concrete column to each post;

placing a concrete panel on the brackets of adjacent posts such that a first end of the panel is supported on the bracket of one post and a second end of the panel is supported on the bracket of the adjacent post;

attaching a second portion of each concrete column to a corresponding post.

2. A method as recited in claim 1, wherein the first end of the concrete panel overlaps part of the first portion of the concrete column at a given post, and wherein the second end of the concrete panel overlaps part of the first portion of the concrete column at the adjacent post.

3. A method as recited in claim 1, wherein at least one post of the plurality of posts is pounded in the ground.

4. A method as recited in claim 1, wherein the first portion of the column is screwed into the post.

5. A method as recited in claim 1, wherein the second portion of the column is screwed into the post.

6. A method as recited in claim 1, wherein the bracket is screwed into the post.

7. A method as recited in claim 1, wherein each of the concrete panels is monolithic.

8. A method as recited in claim 1, wherein each concrete panel is lightweight, including a foam core.

9. A method as recited in claim 1, wherein the method requires no excavation.

10. A method as recited in claim 1, wherein the method requires no concrete footings.

11. A method for constructing a column and panel concrete fence, the method comprising:

placing a plurality of posts in the ground, at least one of the posts being driven into the ground, without the use of any concrete footing;

attaching a bracket to each post;

attaching a first portion of a concrete column to each post, the first portion of the concrete column corresponding to a front or rear face of the fence;

placing a lightweight concrete panel on the brackets of adjacent posts such that a first end of the panel is supported on the bracket of one post and a second end of the panel is supported on the bracket of the adjacent post; and

attaching a second portion of each concrete column to a corresponding post at a location on the post opposite the first portion of the concrete column, the second portion of the concrete column corresponding to the other of the front or rear face of the fence.

12. A method as recited in claim 11, wherein each lightweight concrete panel is configured so that an approximately 9 foot long panel having a height of 6 feet weighs no more than 500 lbs.

13. A column and panel concrete fence comprising:

a plurality of posts;

a concrete column attached to each post, each column including two portions which are separated from one another, and correspond to front and rear faces of the fence, respectively;

a lightweight concrete panel, a first end of the panel being positioned atop a bracket attached to one of the plurality of posts such that the first end of the panel extends between the portions of the column and a second end of the panel being positioned atop a bracket attached to an adjacent one of the plurality of posts such that the second end of the panel extends between the portions of the column attached to the adjacent post.

14. A fence as recited in claim 13, wherein each lightweight concrete panel includes a foam core.

15. A fence as recited in claim 13, wherein each of the concrete panels is precast as a monolithic single piece.

16. A fence as recited in claim 13, wherein at least one post of the plurality of posts is secured in the ground without any concrete footing.

17. A fence as recited in claim 13, wherein at least one post of the plurality of posts is driven in the ground.

18. A fence as recited in claim 13, wherein the first and second portions of the concrete column are each screwed into the post.

19. A fence as recited in claim 13, wherein the fence includes no concrete footings.

20. A fence as recited in claim 13, wherein each lightweight concrete panel is configured so that an approximately 9 foot long panel having a height of 6 feet weighs no more than 500 lbs.