Barrier Wall and Method of Forming Wall Panels Between Vertical Wall Stiffeners with Support Members Extending Partially Through the Wall Panels

Abstract

A sound barrier wall has a plurality of footings spaced apart and vertical “I” beam wall stiffeners mounted to the footings. Alternatively, the vertical wall stiffeners are mounted to a crash barrier. A horizontal wall stiffener can be disposed between the adjacent vertical wall stiffeners. A plurality of wall panels is vertically stacked between adjacent vertical wall stiffeners. Each wall panel includes a sound insulating block, and plurality of support members disposed on opposite sides of the sound insulating block for providing structural support. Each support member has a head portion in contact with a surface of the sound insulating block and a stem portion extending into the sound insulating block. An “I” beam can be disposed between the vertically stacked wall panels. A top cap is mounted over the vertically stacked wall panels and protective layer is formed over the wall panels and vertical wall stiffeners.

What is claimed is: 
     
         1 . A barrier wall, comprising:
 a first insulating block including a first groove and a second groove formed perpendicularly into a top surface of the first insulating block, wherein the top surface of the first insulating block is substantially planar across an entire length and width of the first insulating block;   a second insulating block including a third groove and a fourth groove formed perpendicularly into a bottom surface of the second insulating block, wherein the bottom surface of the second insulating block is substantially planar across an entire length and width of the second insulating block; and   an I-beam including a first flange of the I-beam disposed in the first groove and third groove and a second flange of the I-beam disposed in the second groove and fourth groove, wherein the I-beam includes a continuous material extending into the first groove, second groove, third groove, and fourth groove.   
     
     
         2 . The barrier wall of  claim 1 , wherein the I-beam further includes a web in contact with the first insulating block and second insulating block. 
     
     
         3 . The barrier wall of  claim 2 , wherein the web of the I-beam extends uninterrupted for a length of the I-beam. 
     
     
         4 . The barrier wall of  claim 1 , further including a first wall stiffener and a second wall stiffener, wherein the first insulating block and second insulating block are disposed within channels of the first wall stiffener and second wall stiffener. 
     
     
         5 . The barrier wall of  claim 4 , further including a crash barrier disposed between the first wall stiffener and second wall stiffener under the first insulating block. 
     
     
         6 . The barrier wall of  claim 5 , wherein a length of the crash barrier is greater than a length between the first wall stiffener and second wall stiffener. 
     
     
         7 . A barrier wall, comprising:
 a first insulating block including a first groove and a second groove formed in a top surface of the first insulating block;   a second insulating block including a third groove and a fourth groove formed in a bottom surface of the second insulating block; and   a horizontal support member disposed in the first groove, second groove, third groove, and fourth groove.   
     
     
         8 . The barrier wall of  claim 7 , wherein the horizontal support member includes a continuous piece of material extending into the first groove, second groove, third groove, and fourth groove. 
     
     
         9 . The barrier wall of  claim 7 , further including a crash barrier disposed under the first insulating block. 
     
     
         10 . The barrier wall of  claim 7 , wherein the first groove and second groove extend perpendicularly into the first insulating block, and the third groove and fourth groove extend perpendicularly into the second insulating block. 
     
     
         11 . The barrier wall of  claim 7 , further including a horizontal base support member disposed under the first insulating block. 
     
     
         12 . The barrier wall of  claim 7 , further including a protective layer formed over the first insulating block and second insulating block. 
     
     
         13 . The barrier wall of  claim 7 , wherein the horizontal support member contacts the first insulating block between the first groove and second groove, and also contacts the second insulating block between the third groove and fourth groove. 
     
     
         14 . A method of making a barrier wall, comprising:
 providing a first insulating block including a first groove and a second groove formed in a top surface of the first insulating block, wherein the top surface of the first insulating block is substantially planar across an entire length and width of the first insulating block;   disposing an I-beam over the first insulating block with a first flange of the I-beam disposed in the first groove and a second flange of the I-beam disposed in the second groove;   providing a second insulating block including a third groove and a fourth groove formed in a bottom surface of the second insulating block, wherein the bottom surface of the second insulating block is substantially planar across an entire length and width of the second insulating block; and   disposing the second insulating block over the first insulating block and I-beam with the first flange of the I-beam disposed in the third groove and the second flange of the I-beam disposed in the fourth groove.   
     
     
         15 . The method of  claim 14 , further including:
 providing a first vertical support member;   providing a second vertical support member;   disposing the first insulating block between the first vertical support member and the second vertical support member; and   disposing the second insulating block between the first vertical support member and the second vertical support member after disposing the first insulating block between the first vertical support member and the second vertical support member.   
     
     
         16 . The method of  claim 15 , further including disposing a crash barrier between the first vertical support member and the second vertical support member before disposing the first insulating block between the first vertical support member and the second vertical support member. 
     
     
         17 . The method of  claim 14 , wherein the first insulating block and second insulating block comprise foam. 
     
     
         18 . The method of  claim 14 , further including inserting a vertical support member into a side of the first insulating block. 
     
     
         19 . The method of  claim 14 , further including depositing an adhesive into the first groove and second groove. 
     
     
         20 . A method of making a barrier wall, comprising:
 providing a first insulating block including a substantially planar top surface;   inserting a horizontal support member into the top surface of the first insulating block;   providing a second insulating block including a substantially planar bottom surface; and   disposing the second insulating block over the first insulating block with the horizontal support member extending into the bottom surface of the second insulating block.   
     
     
         21 . The method of  claim 20 , wherein:
 the horizontal support member includes an I-beam; and   inserting the horizontal support member into the top surface of the first insulating block includes inserting a first flange and a second flange of the horizontal support member into the top surface of the first insulating block.   
     
     
         22 . The method of  claim 21 , wherein disposing the second insulating block over the first insulating block includes inserting the first flange and the second flange of the horizontal support member into the bottom surface of the second insulating block. 
     
     
         23 . The method of  claim 20 , further including:
 providing a first vertical wall support member;   providing a second vertical wall support member; and   disposing the first insulating block and second insulating block in channels of the first vertical wall support member and second vertical wall support member.   
     
     
         24 . The method of  claim 23 , further including disposing a crash barrier between the first vertical wall support member and second vertical wall support member. 
     
     
         25 . The method of  claim 24 , wherein the first insulating block and crash barrier overlap vertically.