Retaining wall having modular panels

Abstract

A ground retaining wall includes wall panels formed from steel sheet to provide a flat exterior wall surface on a front side and having side flanges on vertically extending edges for joining panels together. The wall includes reinforcement studs and brackets attached to a back side of the panels and extending between a top cap and a base pan of the panels. Each bracket is located along a panel side flange at a seam where two panels are joined together. The wall also includes support brace assemblies each attached to the panels at one of the seams. The brace assembly includes a base plate attached to a bottom strut and a brace rod. The brace rod extends diagonally between the base plate and wall panel. The wall may include a concrete base covering the wall panel base pans and the brace assembly base plates.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, the drawings show a form of the invention that is presently preferred. However, it should be understood that this invention is not limited to the precise arrangements and instrumentalities shown.

FIG. 1 is a quartering from above perspective of a retaining wall frame made from modular wall panels having flat exterior wall surfaces according to the invention.

FIG. 2 shows a base of a wall panel with an optional leveler assembly.

FIG. 3 is a rear view of a section of a wall showing one embodiment of a support brace assembly attached to the wall frame at the seam where two adjacent wall panels are joined together.

FIG. 4 is a cross sectional view of a retaining wall according to the invention.

FIG. 5 is a cross sectional view of a support stud.

FIG. 6 is a cross sectional view of a support bracket.

FIG. 7 is a rear view of a portion of a retaining wall showing a drainage pipe connection venting ground water outside of the wall and showing the wall with a concrete base covering the base pans and lower portions of the support base assembly.

FIG. 8 is a front view of a portion of a retaining wall assembly showing a section of retaining wall being prepared for decorative stucco finish.

FIG. 9 is a top view of a multiple wall assembly creating a step down pathway.

FIG. 10 is a cross sectional view of the multiple wall assembly taken along the line 10-10 in FIG. 9.

DESCRIPTION OF THE INVENTION

FIG. 1 shows a retaining wall assembly 10 including two retaining walls 12, 14 assembled from modular steel wall panels 16 as viewed from the rear prior to fixing the panels in a concrete base, creating drains, and backfilling with soil. The longer wall 12 is set into the ground above the second shorter wall 14. Together they will create a two level terrace to retain the soil behind the walls and prevent the soil from eroding down what would otherwise be a steep slope. The walls can be joined together if desired.

The modular wall panels 16 are formed from steel sheet to provide a flat exterior wall surface 18. Wall panels of this type are commonly used to construct in-ground swimming pools. As shown in FIG. 2, a wall panel 16 of this type has a generally flat sheet portion 20 made by bending the steel sheet to form a flange 22 on each vertically extending side at a right angle in the same direction. These side flanges 22 have matching bolt holes 24 to allow other wall panels to be joined together with it on either side to form a vertical wall. Although the wall panels can be made to any dimensions, a four foot height is about the maximum height typically used.

The wall panel 16 is also bent at the top and base in the same direction to the panel as the side flanges 22. The bending forms a top and bottom surface extending at a right angle to the panel, preferably about five inches wide, then another right angle to make a return flange to form a top cap 26 and a base pan 28 for the panel. The base pan 28 is shown in greater detail in FIG. 2. The sides of the steel sheet are stamp cut before the bending so that a side flap 30 with rounded corner is formed inboard of the side flanges 22 of the sheet. The flaps 30 and the return flange 32 are then bent upward at 90 degrees to form the base pan 28. Then the pan is bent 90 degrees so that the flaps 30 extend inside of the side flanges 22 making the base pan 28 into an enclosed tray at the bottom of the panel. Two toggle locks 34 or other rivet type fasteners are driven through the side flanges and flaps to lock the angle. The top cap 26 is identical to the base pan 28.

The panels 16 can be either straight or curved to a desired radius. Panels of this type used for constructing swimming pools have been available from Cardinal Systems Inc. and are disclosed in published application US 2004/0255544A1. An exemplary wall panel may be made of galvanized or other coated 14 gauge steel.

The panel 16 shown in FIG. 2 also has an optional threaded rod and expansion box height adjustment assembly 36 attached to the wall panel near each bottom corner. The assembly 36 is useful in leveling swimming pools, where the walls must be accurately level to prevent uneven water height on the wall. Such precise leveling is often unnecessary in ground retaining walls, so the use of levelers is considered optional. If levelers are not used, the holes provided in the base pan 28 for the threaded rods can be used to drive sections of rebar to function as a stake.

When the wall panels 16 are joined together, they create walls 12, 14 having forwardly-facing flat surfaces 18 (which may be straight or curved). On the reverse side of the panels 16 (behind the wall), the panels may be reinforced by one or more vertical reinforcement studs 38 at spaced intervals and vertical reinforcement brackets 40 located along one or both side edges where the panels are joined together. The weight of the soil behind a retaining wall, however, creates a bulging pressure on the wall surface and at the seam where two panels are joined together. The studs 38 and brackets 40 are used to stiffen the panels 16 against this pressure. The studs 38 are preferably spaced at regular intervals (e.g., at 16 inch centers on a 48 inch wide panel). The studs 38 are preferably 14 gauge coated steel having a roughly Z-shaped cross section as shown in FIG. 5. A first flange 42 of the stud 38 is fastened against the flat portion 20 of the wall panel 16. A web 44 of the stud 38 extends inwardly perpendicular to the plane of the wall. The stud 38 is bent again at a right angle to form a second flange 46 in the direction opposite the first flange 42. The studs 38 are made to length to attach to the top cap 26 and the base pan 28 when installed. The flanges 42, 46 may have a short return portion 45, 47 at the ends for increased stiffening. The studs 38 and brackets 40 may have cutouts 54 to allow passage of electrical conduit or plumbing behind the wall.

The vertical reinforcement brackets 40 are substantially C-shaped in cross section as shown in FIG. 6, with bolt holes spaced to match the bolt holes 24 in the side edges 22 of the wall panels 16. A bracket 40 is installed on at least one side of the panel at the seams where adjacent panels are bolted together. A first flange 48 along the flat portion 20 of the wall panel 16. A web 50 of the bracket 40 extends inwardly perpendicular to the plane of the wall then bends at a right angle to form a second flange 52 in the direction opposite the first flange 48. The web 50 has bolt holes arranged to align with the bolt holes 24 in the side flanges 22 of the wall panels 16. The brackets 40 are made to length to contact the top cap 26 and the base pan 28 when installed. The flanges 48, 52 may have a short return portion 49, 53 at the ends for increased stiffening.

The retaining wall assembly 10 also includes support brace assemblies attached to the back side of the panels 16, as shown in more detail in FIG. 3. The brace assembly includes a base structure attached to a side flange adjacent the bottom of the side flange, and a brace rod attached to the base structure away from the panel and attached at its opposite end to an upper section of the side flange of the panel such that the brace rod extends diagonally upward from the base structure to the wall panel. In the depicted embodiment, an “A-frame” type brace assembly 60 has a base structure that includes a base plate 62 with a back flange 64, a drive stake 66 through the plate to anchor the plate 62, and a bottom strut 68 in the form of an angle rod that is bolted at one end to the base plate 62 and extends to and is bolted at its opposite end to a bottom section of a wall panel side flange 22. The brace rod is long diagonal brace 70 that is bolted to the bottom strut 68 over the base plate 62 and at its other end to an upper section of the wall panel side flange 22. The diagonal brace 70 is attached to the side flange 22 at a seam between two adjacent wall panels 16 opposite the reinforcing bracket 40. The diagonal brace 70 is preferably an adjustable-length brace with a threaded rod or a turnbuckle at the top end to adjust the length between the base-plate and the wall panel. The adjustable length for the diagonal brace aids in vertically plumbing the wall. Preferred examples of the diagonal brace are shown in published application US 2004/0255544A1. Other types of base structure and brace rod may be used.

The wall panels 16 may be curved to any radius. Corners of the wall may be formed of corner pieces. The corner pieces can form a right angle corner or, alternatively, could be curved corners of various radii. The corner pieces have side flanges like the wall panels and have bolt holes aligned with those in the wall panels. The corner pieces also have a top cap and base pan like the wall panels 16.

In a method of constructing a retaining wall such as walls 12, 14 from the steel panels 16, the site is first surveyed to locate and mark the line and elevation of the base for the wall or walls. A soil bank is then cut away as necessary to create a generally flat ledge along the full line of the wall at the elevation of the wall base. Preferably, at least 2½ feet should be cleared behind the line of the wall to accommodate the brace assemblies 60. As shown in FIG. 4, the wall base itself may be located below ground level. In climates that experience substantial ground freezing, a trench 80 may be cut to a depth of at least 1 foot underneath the line of the wall. The trench is then filled with rock 82 of various size and shape before the wall is installed. This rock-filled trench 80 will drain water to the soil located beneath the trench and if the water still freezes in the soil, the shifting compaction of the rocks will alleviate frost heaving under the wall.

The wall panels 16 are then assembled with the flat side 18 facing outwardly. The vertical support studs 38 can be fastened onto the wall panels 16 at the proper spacing before the panels are connected together. If the optional leveling assemblies 36 are being used, the base plates, rods and nuts, and leveler brackets are installed at slots in the base pans 28 near each bottom corner. The wall panels 16 can then be connected with a C-shaped reinforcement bracket 40 against at least one (or both) of the panel side flanges 22 at each seam between adjoining panels. The bracket 40 is set into the wall panel such that the web is against the side flange 22 and the bolt holes 24 are aligned. Bolts are inserted through the bracket 40 and the flanges 22 of the adjoining panels and nuts are finger tightened to hold the panels in place. The wall can be generally leveled with shims or the optional threaded leveler assemblies 36 before the nuts are tightened with a wrench.

The A-frame brace assemblies 60 are then attached to the back side of the panels. In this embodiment, a brace assembly includes a base plate 62 with a back flange 64 to act as an anchor in the concrete that will be poured over it. A short angle piece is used as a bottom strut 68. An alternative angle piece may be wider and include a notch (not shown) to pass through a drive stake. The strut 68 is attached to the base plate 62 at one end and the other end is bolted to a lower set of holes through the side flanges 22 and C-bracket 40, preferably at each seam between panels. Then the long diagonal brace 70 is bolted to the bottom strut 68 in a position over the base plate 62 and its other end is bolted to an upper set of holes in the bracket 40 and side flanges 22. The adjustable-length brace with a threaded rod or a turnbuckle at the top end is used to adjust the length between the base plate and the wall panel to vertically plumb the wall. Then the wall can be precisely leveled if desired by adjusting the threaded rods of the assembly 36 or by using shims. When the wall is plumb and level, the base of the wall can be anchored by driving short sections of rebar (10-16 inch) into the ground through holes in the base pan 28 and driving an angle drive stake 66 through a cutout (not shown) in the base plate 62 to anchor the plate prior to pouring concrete.

Long strands of rebar can then be placed along the length of the wall. Preferably, two rebar strands 86 are laid, one against an angle formed by the diagonal brace and the short strut of the brace assembly and the other against an angle formed by the short strut and the side flanges 22 of the wall panels.

A concrete encapsulating base 84 should be poured behind the wall to a depth of a least eight inches, filling and covering the base pans 28 of the wall panels 16, the back flange 64 of the brace assembly base plate 62, the rebar strands 86 and drive stake 66, and a lower portion of the diagonal brace 70. With this encapsulation in the concrete, the wall acts as a light weight, upright, retaining wall. The light weight reduces problems from settling. The upright posture and embedded A-frame support assemblies anchor the wall against overturning torque. The concrete base and A-frame support also anchor the wall against being pushed out from the soil bank by pressure from the backfilled dirt. The rock trench under the wall reduces the likelihood of frost heaving dislodging the wall.

As shown in FIG. 7, a drain is created by running perforated plastic pipe 90 over the concrete base layer 84, preferably outside of the diagonal brace 70, and thereafter covering the pipe with a layer 88 of stone or gravel. At the low point in the drain, a T-fitting 92 may be used to vent the drain through the wall above ground on the outside of the wall. This allows water collected by the pipe and drain to flow out from behind the wall. A landscape cloth (not shown) is placed over the rock layer 88 before backfilling with dirt to keep the fine dirt from interspersing into the rock or gravel and blocking the drainage. The area behind the wall can then be filled with soil 94 up to or just below the top surface of the wall.

If more than one wall is going to be installed to create a terraced effect, the lower wall should be filled first. The terracing effect of multiple walls can also be used to create a step down pathway, as shown by the multiple wall assembly 110 in FIGS. 9 and 10. The long high wall 112 may be a four foot elevation, for example. The next walls could be a three foot wall 114, a two foot wall 116 and a one foot wall 118. The lengths and widths of the shorter walls and their spacing from the main wall could be varied as desired.

Alternatively a steel stairwell box may be placed in the wall between adjoining panels. Such stairwells are well known in the swimming pool industry, and are adapted to bolt into the side flanges of the wall panels. Steel benches or coves, such as a firewood box or storage bin can be placed on or in the wall. The wall panels may also have cutouts for electrical junction boxes 96 for outdoor lighting or utility outlets. The wall panel side flanges have cutout sections through which piping or electrical conduit can be run prior to backfilling.

When used in a decorative landscaping application, a retaining wall can be finished on the open front side using paint or other surface coatings. The retaining wall can also support a stucco finish, as shown in FIG. 8 where a support mesh 102 is fastened onto the panels 16 using tech screws to receive the stucco base coat and the tinted stucco finish 104. Other types of decorative fascia and veneers can also be applied to the flat wall panels.

Claims

1. A ground retaining wall comprising: a plurality of modular steel wall panels of a type formed from steel sheet to provide a flat exterior wall surface on a front side the panel, and on an opposite back side having a side flange on each vertically extending edge with matching bolt holes to allow panels to be joined together, the back side also having a top and bottom surface extending at a right angle to the panel to form a top cap and a base pan for the panel;a plurality of vertical reinforcement studs each attached to the back side of a panel at spaced intervals to stiffen the panel against bulging pressure, the studs extending from the base pan to the top cap;a plurality of vertical reinforcement brackets each located along at least one side flange of a panel at a seam where two panels are joined together, the bracket having bolt holes spaced to match the bolt holes in the side flanges of the wall panels;a plurality of support brace assemblies each attached to a side flange of a panel at the seam where two panels are joined together, the brace assembly including a base structure attached to the side flange adjacent the bottom of the side flange, and a brace rod attached at one end to the base structure at a location away from the panel and attached at its opposite end to an upper section of the side flange of the panel such that the brace rod extends diagonally upward from the base structure to the wall panel.

2. A ground retaining wall as in claim 1, further comprising a concrete base poured behind the wall covering and encapsulating the base pans of the panels and the base structure of the support brace assemblies.

3. A ground retaining wall as in claim 2, wherein the base structure includes a base plate extending generally horizontally way from the wall panel and a flange on the back edge of the plate extending upwardly from the plate, and a drive stake is received through the base plate to anchor the plate, wherein the concrete layer covers and encapsulates the flange and the drive stake.

4. A ground retaining wall as in claim 1, wherein the brace rod is an adjustable-length rod to adjust a length of the brace rod between the base structure and the wall panel.

5. A ground retaining wall as in claim 4, wherein the brace rod has a threaded rod or a turnbuckle to adjust the length of the brace between the base structure and the wall panel.

6. A ground retaining wall as in claim 1, wherein each vertical reinforcement studs is made of steel sheet formed into an elongated member having a substantially Z-shaped cross section in which a first flange of the stud is fastened against a flat portion of the wall panel, a web of the stud extends inwardly perpendicular to the plane of the panel, and a second flange extends in a direction opposite the first flange.

7. A ground retaining wall as in claim 6, wherein each stud includes at least one cutout through the web to allow passage of electrical conduit or plumbing behind the wall.

8. A ground retaining wall as in claim 1, wherein the reinforcement brackets are made of sheet steel formed into an elongated channel member having substantially C-shaped cross section in which a web portion has the bolt holes spaced to match the bolt holes in the side flanges of the wall panels, and a flange at each end of the web contacts the top cap and the base pan respectively when the bracket is installed.

9. A ground retaining wall as in claim 2, wherein the wall panels have a height adjustment leveler assembly attached to the base pan of the wall panel, and wherein the concrete layer covers and encapsulates the leveler assemblies.

10. A ground retaining wall as in claim 9, wherein the leveler assembly includes a threaded rod passing though the base pan near each bottom corner.

11. A method of constructing a ground retaining wall, comprising the steps of: locating and marking the line and elevation of a base for the wall;cutting away as much of any existing soil bank to create a generally flat ledge along the line of the wall at the elevation of the wall base and allowing at least 2½ feet of ledge behind the line of the wall to accommodate brace assemblies;obtaining a plurality of wall panels of a type formed from steel sheet to provide a flat exterior wall surface on a front side the panel, and on an opposite back side having a side flange on each vertically extending edge with matching bolt holes to allow panels to be joined together, the back side also having a top and bottom surface extending at a right angle to the panel to form a top cap and a base pan for the panel;obtaining a plurality of vertical reinforcement studs of sufficient length to extend from the base pan to the top cap of the wall panels;attaching one or more studs to the back side of each wall panel at spaced intervals in a vertical orientation such that a stud extends from the base pan to the top cap;obtaining a plurality of vertical reinforcement brackets having bolt holes spaced to match the bolt holes in the side flanges of the wall panels;assembling the wall panels over the line of the wall by placing adjacent panels side by side with the flat exterior wall surfaces in the same direction such that the bolt holes on the side flanges of adjacent panels are aligned, placing each reinforcing bracket along one side flange of a panel at a seam where two adjacent panels are joined together, inserting bolts though aligned holes in the bracket and the side flanges of adjoining panels, and tightening nuts onto the bolts to secure the panels together;obtaining a plurality of support brace assemblies, a brace assembly including a base structure attachable to the side flange of a wall panel, and a brace rod attachable at one end to the base structure at a location away from the panel and attachable at its opposite end to an upper section of the side flange of the panel;attaching the support brace assemblies to the wall panels by attaching the base structure of each brace assembly to a side flange of a wall panel adjacent the bottom of the side flange, and attaching the brace rod to an upper section of the side flange such that the rod extends diagonally upward from the base structure to the wall panel;pouring a concrete base behind the wall of sufficient height and width to cover and encapsulate the base pans of the panels and the base structure of the support brace assemblies;laying a water collection pipe over the concrete base and venting the pipe through or around the wall to drain water collected in the pipe from behind the wall;covering the pipe with a layer of rock;covering the layer of rock with a landscape cloth; andbackfilling soil behind the wall up to or just below the top of the wall.

12. A method of constructing a ground retaining wall as in claim 11, wherein the brace rods are adjustable-length rods, comprising the further step of adjusting the length of the brace rods as necessary to vertically plum the wall before tightening nuts onto the bolts to secure the panels together.

13. A method of constructing a ground retaining wall as in claim 12, wherein the base structure of the support assembly includes a base pan having a back flange and a slot for passing through a drive stake, comprising the further step of driving a drive stake through each base plate down into the soil ledge beneath the base plates, and wherein the step of pouring a concrete base behind the wall includes pouring the concrete to a sufficient height and width to cover and encapsulate the back flanges and drive stakes of the base plates.

14. A method of constructing a ground retaining wall as in claim 11, wherein the brace rods of the brace assemblies are adjustable-length rods, comprising the further step of using the adjustable length capability to vertically plumbing the wall prior to pouring the concrete layer.

15. A method of constructing a ground retaining wall as in claim 11, comprising the further step of placing strands of rebar across the bottom struts of the brace assemblies and extending along the length of the wall prior to pouring the concrete base.

16. A method of constructing a ground retaining wall as in claim 11, comprising the further steps of providing the reinforcement studs with cutouts through the webs of the studs to allow passage of electrical conduit or plumbing, and stringing such electrical conduit or piping through the cutouts along the back side of the wall before prior to completing the step of backfilling soil behind the wall.

17. A method of constructing a ground retaining wall as in claim 11, comprising the further steps of building a main retaining wall as the highest elevation wall by the steps of claim 11, and then building one or more retaining walls at lower elevations around the main wall.

18. A method of constructing a ground retaining wall as in claim 17, comprising the further steps of building two or more retaining walls at lower elevations around the main wall and graduating the height and length of the additional walls to form a terraced step down pathway from the main wall.

19. A method of constructing a ground retaining wall as in claim 11, further comprising the step of coating the flat exterior wall surface on a front side the panels with a decorative finish.