Wall construction and installation method

Abstract

To install a wall, a placement area for a set of prefabricated wall sections is determined. The placement area includes a starting end and a terminating end. A wall section of the set of prefabricated wall sections includes a first layer of urethane foam, a second layer of urethane foam, an extension and depression to mate with a corresponding depression and extension of another wall section of the set of prefabricated wall sections, and a through bore extending from an upper face of the extension, passing through the extension and exiting a lower face of the extension. During installation, surface vegetation is removed from the placement area in response to surface vegetation being present on the placement area, the soil is compacted in the placement area, and a first wall section of the set of prefabricated wall sections is placed at the starting end. In addition, the first wall section is secured to the starting end, a next wall section of the set of prefabricated wall sections is placed at the placement area, and the next wall section is affixed to a previously secured wall section of the set of prefabricated wall sections. Furthermore, the next wall section is secured to the placement area, the steps of placing, affixing, and securing next wall section are continued until the terminating end is reached. Moreover, a last wall section of the set of prefabricated wall sections is placed at the terminating end and the last wall section is affixed to the previously secured wall section.

1 . A method of installing a wall, the method comprising the steps of:
 determining a placement area for a set of prefabricated wall sections, the placement area having a starting end and a terminating end, a wall section of the set of prefabricated wall sections comprises:
 a first layer of foamed plastic; 
 a second layer of foamed plastic; 
 an extension and depression to mate with a corresponding depression and extension of another wall section of the set of prefabricated wall sections; and 
 a through bore extending from an upper face of the extension, passing through the extension and exiting a lower face of the extension; 
   removing surface vegetation from the placement area in response to surface vegetation being present on the placement area;   compacting soil in the placement area;   placing a first wall section of the set of prefabricated wall sections at the starting end;   securing the first wall section to the starting end;   placing a next wall section of the set of prefabricated wall sections at the placement area;   affixing the next wall section to a previously secured wall section of the set of prefabricated wall sections;   securing the next wall section to the placement area;   continuing the steps of placing, affixing, and securing next wall section until the terminating end is reached;   placing a last wall section of the set of prefabricated wall sections at the terminating end; and   affixing the last wall section to the previously secured wall section.   
   
   
       2 . The method according to  claim 1 , wherein the first layer is a urethane foam. 
   
   
       3 . The method according to  claim 1 , wherein the second layer is a urethane foam. 
   
   
       4 . The method according to  claim 1 , wherein the wall is a retaining wall and the method further comprises:
 back filling the wall.   
   
   
       5 . The method according to  claim 1 , further comprising:
 removing soil from the placement area to a predetermined depth.   
   
   
       6 . The method according to  claim 5 , wherein the predetermined depth is about 1 inch to about 12 inches. 
   
   
       7 . The method according to  claim 5 , wherein the predetermined depth is about 3 inch to about 6 inches. 
   
   
       8 . The method according to  claim 1 , further comprising:
 disposing a layer of gravel on the placement area.   
   
   
       9 . The method according to  claim 8 , further comprising:
 compacting the layer of gravel.   
   
   
       10 . The method according to  claim 1 , further comprising:
 driving a rod through the through bore and into soil disposed below the placement area.   
   
   
       11 . The method according to  claim 1 , further comprising:
 applying an adhesive to the extension and depression to affix same to the corresponding depression and extension.   
   
   
       12 . A wall section comprising:
 a first layer of urethane foam;   a second layer of urethane foam;   an extension and depression to mate with a corresponding depression and extension of another wall section of the set of prefabricated wall sections; and   a through bore extending from an upper face of the extension, passing through the extension and exiting a lower face of the extension.   
   
   
       13 . The wall section according to  claim 12 , wherein the first layer has a density of about 80 kilograms per cubic meter (“Kg/m 3 ”) to about 320 Kg/m 3 . 
   
   
       14 . The wall section according to  claim 12 , wherein the first layer has a compressive strength of greater than about 4.5 kilogram per square centimeter (“Kg/cm 2 ”). 
   
   
       15 . The wall section according to  claim 12 , wherein the second layer has a density of about 1.5 Kg/m 3  to about 15 Kg/m 3 . 
   
   
       16 . The wall section according to  claim 12 , wherein the first layer has a compressive strength of less than about 1.5 Kg/cm 2 . 
   
   
       17 . The wall section according to  claim 12 , further comprising an exterior surface having an appearance mimicking stone. 
   
   
       18 . The wall section according to  claim 12 , further comprising a plurality of mating surfaces disposed on the extension and depression. 
   
   
       19 . The wall section according to  claim 18 , wherein the plurality of mating surfaces are configured to receive an adhesive. 
   
   
       20 . A column comprising:
 a first layer of urethane foam, wherein the first layer has a density of about 80 kilograms per cubic meter (“Kg/m 3 ”) to about 320 Kg/m 3 ; and   a second layer of urethane foam, wherein the second layer has a density of about 1.5 Kg/m 3  to about 15 Kg/m 3 .