Method of constructing a wall or fence with panels

Abstract

This invention relates generally to a method of constructing walls or fence systems from panels. More particularly, the invention relates to constructing such walls or fence systems wherein a back face of one panel connects to a back face of another panel and further wherein the front faces of the panels have a desirable texture and further wherein a concrete footing of the wall or fence system is poured after courses of panels have been stacked one upon the other.

1 . A method for constructing a wall or fence comprising:
 providing a plurality of connectors and a plurality of panels, each panel having a front face and an opposed back face, a set of opposed and substantially parallel upper and lower surfaces and first and second opposed and substantially parallel side surfaces;   preparing a level base;   forming a base layer of panels on the level base by placing opposed panels on the level base and connecting a back face of at least one first panel of the base layer to a back face of at least one opposed second panel of the base layer with at least one connector, the front faces of the at least one first panel and the at least one second panel facing outward, the at least one first panel and at least one second panel each having a knockout cavity;   placing at least one course of opposed panels on the base layer of panels and connecting a back face of at least one first panel of the at least one course to a back face of at least one opposed second panel of the at least one course with at least one connector, the front faces of the at least one first panel and the at least one second panel of the at least one course facing outward, to form a top surface of an uppermost course of panels; and   pouring a flowable material from the top surface between the opposed panels to form a support footing for the wall or fence, the support footing encasing at least a portion of the base layer of panels.   
     
     
         2 . The method of  claim 1 , further comprising:
 forming a trench; and   adding base material to the trench, wherein the step of preparing a level base comprises leveling the base material in the trench.   
     
     
         3 . The method of  claim 2 , wherein the base material is compacted granular material or crushed stone. 
     
     
         4 . The method of  claim 1 , wherein the flowable material is concrete or cement. 
     
     
         5 . The method of  claim 1 , further comprising:
 after placing a plurality of panels and prior to pouring the flowable material, forming a reinforcing framework between opposed panels, the reinforcing framework including vertical reinforcement members.   
     
     
         6 . The method of  claim 5 , wherein at least one vertical reinforcement member is L-shaped and has a vertical portion and a perpendicular leg portion, the perpendicular leg portion protruding outwardly through a knockout cavity, the perpendicular leg portion being encased in the support footing after the flowable material is poured. 
     
     
         7 . The method of  claim 6 , wherein the reinforcing framework includes horizontal reinforcement members. 
     
     
         8 . The method of  claim 1 , wherein the panels of the base layer and the panels of at least one course have the same structure. 
     
     
         9 . The method of  claim 1 , wherein the at least one connector that connects the at least one first panel and the at least one second panel of the base layer also connects the at least one first panel and the at least one second panel of the adjacent course of panels. 
     
     
         10 . The method of  claim 1 , wherein the panels are made of polyfoam. 
     
     
         11 . The method of  claim 1 , wherein the support footing encases at least one half of a vertical height of the base layer of panels. 
     
     
         12 . The method of  claim 1 , wherein the support footing substantially encases the base layer of panels. 
     
     
         13 . The method of  claim 9 , wherein the connector has at least four dovetail projections. 
     
     
         14 . The method of  claim 1 , wherein each set of opposed panel surfaces has mating tongue and groove attachments, respectively, so that a respective tongue attachment and groove attachment of adjacent panels connect the adjacent panels. 
     
     
         15 . The method of  claim 1 , wherein the back faces of the panels have dovetail channels. 
     
     
         16 . The method of  claim 1 , wherein at least one horizontal reinforcement member rests on at least one connector. 
     
     
         17 . The method of  claim 1 , wherein at least one vertical reinforcement member passes through a vertical support ring that is part of at least one connector. 
     
     
         18 . The method of  claim 1 , wherein the at least one first panel of the at least one course and the at least one opposed second panel of the at least one course have a pattern molded into their front faces. 
     
     
         19 . The method of  claim 1 , wherein the pattern is an ashlar pattern. 
     
     
         20 . The method of  claim 1 , wherein the pattern is a boulder rock pattern. 
     
     
         21 . The method of  claim 1 , wherein the pattern is a ledge rock pattern. 
     
     
         22 . The method of  claim 1 , further comprising attaching a capping block onto a top of the wall or fence. 
     
     
         23 . The method of  claim 1 , further comprising attaching an end wall block to some of the plurality of panels before pouring the flowable material. 
     
     
         24 . A wall or fence comprising:
 a support footing formed from a hardened flowable material;   a base layer of opposed panels, at least a portion of the base layer of panels being encased within the support footing, a back face of at least one first panel of the base layer being connected to a back face of at least one opposed second panel of the base layer with at least one connector, the front faces of the at least one first panel and the at least one second panel facing outward, and the at least one first panel and at least one second panel each having a knockout cavity, and   a plurality of courses of opposed panels placed on the base layer of panels, a back face of at least one first panel of the at least one course being connected to a back face of at least one opposed second panel of the at least one course with at least one connector, the front faces of the at least one first panel and the at least one second panel of the at least one course facing outward, a volume between the opposed panels containing the hardened flowable material.   
     
     
         25 . The wall or fence of  claim 24 , wherein the hardened flowable material is concrete or cement. 
     
     
         26 . The wall or fence of  claim 24 , wherein the wall or fence further comprises a reinforcing framework between opposed panels, the reinforcing framework including vertical reinforcement members. 
     
     
         27 . The wall or fence of  claim 26 , wherein at least one vertical reinforcement member is L-shaped and has a vertical portion and a perpendicular leg portion, the perpendicular leg portion protruding outwardly through a knockout cavity, the perpendicular leg portion being encased in the support footing. 
     
     
         28 . The wall or fence of  claim 27 , wherein the reinforcing framework includes horizontal reinforcement members. 
     
     
         29 . The wall or fence of  claim 24 , wherein the panels of the base layer and the panels of the plurality of courses have the same structure. 
     
     
         30 . The wall or fence of  claim 24 , wherein the at least one connector that connects the at least one first panel and the at least one second panel of the base layer also connects the at least one first panel and the at least one second panel of an adjacent course of panels. 
     
     
         31 . The wall or fence of  claim 24 , wherein the panels are made of polyfoam. 
     
     
         32 . The wall or fence of  claim 24 , wherein the thickness of the wall or fence terraces from wider to narrower as the wall heightens.