Apparatus and method of constructing a modular floating retaining wall

Abstract

The invention is a floating natural mortared stone modular wall and method for constructing the same. This natural mortared stone modular wall floats and does not require footings. The modular characteristic of the invention allows each segment to float with the frost conditions and allows each wall segment to be moveable. Each wall segment has an extension piece at one end and a slot of larger dimensions than the extension at the other end, thereby allowing the wall segments to fit together and move independently of one another in a vertical motion and each wall segment is capable of being cable anchored on the back. The invention also discloses a method of making the wall segments, whereby sand is washed around and off of the plurality of stones, thereby creating a concrete impervious base upon which to pour reinforced concrete, and a frame is disclosed whereby the poured concrete creates an extension and a slot at opposite ends of the wall segment.

1 . A modular, floating stone wall segment comprising a plurality of stones embedded in a reinforced concrete mixture, 
 a front face wherein the front face comprises the plurality of stones protruding from the reinforced concrete mixture wherein the front face has the appearance of a stone masonry wall,    a back,    a top comprising a lift ring fixedly embedded within the reinforced concrete mixture,    a bottom,    a slot end side comprising a slot extending along the slot end side from the top to the bottom of the wall segment, and    an extension piece end side comprising an extension piece extending along the extension piece end side from the top to the bottom of the wall segment, whereby the slot end side of one wall segment can fit together with the extension piece end side of another wall segment, thereby allowing each wall segment to form a near seamless stone masonry wall and move upward and downward independently of each other.    
   
   
       2 . The modular, floating wall segment of  claim 1  wherein the top comprises a plurality of lift rings.  
   
   
       3 . The modular, floating wall segment of  claim 1  wherein the lift ring is fixedly embedded within a recess in the reinforced concrete mixture, whereby the lift ring does not protrude above the top of the wall segment.  
   
   
       4 . The modular, floating wall segment of  claim 1  wherein the back comprises an anchor cable fixedly embedded within the reinforced concrete mixture.  
   
   
       5 . The modular, floating wall segment of  claim 4  wherein the back comprises a plurality of anchor cables.  
   
   
       6 . The modular, floating wall segment of  claim 4  wherein the anchor cable is fixedly embedded within a recess in the reinforced concrete mixture.  
   
   
       7 . The modular, floating wall segment of  claim 4  wherein the anchor cable comprises a loop portion and an embedded portion, said embedded portion being fixedly embedded in the reinforced concrete mixture and said loop portion protruding out from the reinforced concrete mixture.  
   
   
       8 . The modular, floating wall segment of  claim 7  wherein the loop portion of the anchor cable attaches to an anchor rod, said anchor rod comprising a rod loop hook end, a metal rod, and an auger end, whereby the anchor cable loop portion is attached to the anchor rod loop hook end, and the metal rod and auger end extend into the earth behind the wall segment, whereby the anchor cable and the anchor rod can move independently of one another.  
   
   
       9 . The modular, floating wall segment of  claim 1  wherein the slot comprises a certain slot depth and a certain slot width, and wherein the extension piece comprises a certain extension depth and a certain extension width, the slot depth being larger than the extension depth and the slot width being larger than the extension width, thereby allowing the extension piece to move within the slot, whereby two connected wall segments may move independently of one another.  
   
   
       10 . The modular, floating wall segment of  claim 9  wherein the slot depth and slot width are sufficiently larger than the extension depth and extension width whereby connected wall segments can be arranged in a non-linear, angled configuration.  
   
   
       11 . The modular, floating wall segment of  claim 1  wherein the plurality of stones protrude from the back of said modular, floating wall segment wherein the back has the appearance of a stone masonry wall.  
   
   
       12 . A method of constructing a modular, floating wall segment comprising a modular wall segment frame, a plurality of stones, sand, water, reinforced concrete, mortar and joint grout, 
 said modular wall segment frame comprising    an extension piece end frame,    a slot end-frame,    a top frame,    a bottom frame, and    a front face frame,    said extension piece end frame, slot end frame, top frame and bottom frame being removably attached to each other to form the shape of a rectangular frame, having the top frame and bottom frame opposite each other, and the extension piece end frame and slot end frame opposite each other,    said front face frame being removably attached to the rectangular frame, thereby forming an inner bottom surface of the wall segment frame,    said plurality of stones are placed within the modular wall segment frame, resting on the inner bottom surface, and the sand is placed over the stones to a sufficient depth,    the sand is then washed off the stones with the water thus ensuring that no sand rests upon the stones, the sand thus becoming evenly packed between each stone and between the stones and the modular wall segment frame and evenly packed onto the inner bottom surface,    said reinforced concrete is then poured between and over the stones, and between the stones and the modular wall segment frame until the reinforced concrete covers the stones and the entire sanded area within the modular wall segment frame, whereby the sand thus forms a layer through which the reinforced concrete cannot flow, thus forming a front face of the modular, floating wall segment,    said reinforced concrete is allowed to cure to a sufficient strength, whereby the front face frame, the top frame, bottom frame, the extension piece end frame and the slot end frame are removed from the wall segment,    excess sand is removed from the front face of the wall segment,    mortar and joint grout are applied between the stones thereby providing for an attractive stone wall appearance.    
   
   
       13 . The method of  claim 12  wherein the extension piece end frame comprises a length, a midline along the length and a protruding rib at the midline and along the length, whereby the reinforced concrete would flow around the protruding rib, thereby creating a slot along the length of the extension piece end frame, and wherein the slot end frame comprises a length, a midline along the length and a recessed furrow at the midline and along the length, whereby the reinforced concrete would flow into the recessed furrow, thereby creating an extension piece along the length of the slot end frame.  
   
   
       14 . The method of  claim 13  further comprising a plurality of wall segments being placed together in a finished stone retaining wall product, said mortar and joint grout being applied between each wall segment to blend each wall segment into each other, thus having the appearance of a solid stone wall unit.  
   
   
       15 . The method of  claim 13  further comprising a base of compacted crushed gravel whereby the modular, floating wall segment is placed upon the compacted crushed gravel, the thickness of the gravel depending upon the height of the wall segment, and further comprising an area immediately behind the wall segment being filled with 1½ inch drainage rock and drain tile.  
   
   
       16 . The method of  claim 15  wherein the crushed gravel comprises class-5 aggregate.  
   
   
       17 . A method of constructing a modular, floating wall segment comprising a modular wall segment frame, a plurality of stones, sand, water, reinforced concrete, mortar and joint grout, 
 said modular wall segment frame comprising    an extension piece end frame,    a slot end frame,    a top frame,    a bottom frame, and    a front face frame,    said extension piece end frame, slot end frame, top frame and bottom frame being removably attached to each other to form the shape of a rectangular frame, having the top frame and bottom frame opposite each other, and the extension piece end frame and slot end frame opposite each other,    said front face frame being removably attached to the rectangular frame, thereby forming an inner bottom surface of the wall segment frame,    said plurality of stones are placed within the modular wall segment frame, resting on the inner bottom surface, and the sand is placed over the stones to a sufficient depth, the sand is then washed off the stones with the water thus ensuring that no sand rests upon the stones, the sand thus becoming evenly packed between each stone and between the stones and the modular wall segment frame and evenly packed onto the inner bottom surface,    said reinforced concrete is then poured between the stones, and between the stones and the modular wall segment frame until the reinforced concrete surrounds the stones and the entire sanded area within the modular wall segment frame, whereby the stones protrude above the reinforced concrete thus forming a back face of the modular, floating wall, and the sand thus forms a layer through which the reinforced concrete cannot flow, thus forming a front face of the modular, floating wall segment,    said reinforced concrete is allowed to cure to a sufficient strength, whereby the front face frame, the top frame, bottom frame, the extension piece end frame and the slot end frame are removed from the wall segment,    excess sand is removed from the front face of the wall segment,    mortar and joint grout are applied between the stones on the front face and the back face of the wall segment thereby providing for an attractive stone wall appearance.    
   
   
       18 . The method of  claim 17  wherein the extension piece end frame comprises a length, a midline along the length and a protruding rib at the midline and along the length, whereby the reinforced concrete would flow around the protruding rib, thereby creating a slot along the length of the extension piece end frame, and wherein the slot end frame comprises a length, a midline along the length and a recessed furrow at the midline and along the length, whereby the reinforced concrete would flow into the recessed furrow, thereby creating an extension piece along the length of the slot end frame.  
   
   
       19 . The method of  claim 18  further comprising a plurality of wall segments being placed together in a finished stone retaining wall product, said mortar and joint grout being applied between each wall segment to blend each wall segment into each other, thus having the appearance of a solid stone wall unit.  
   
   
       20 . The method of  claim 18  further comprising a base of compacted crushed gravel whereby the modular, floating wall segment is placed upon the compacted crushed gravel, the thickness of the gravel depending upon the height of the wall segment, and further comprising an area immediately behind the wall segment being filled with 1½ inch drainage rock and drain tile.  
   
   
       21 . The method of  claim 20  wherein the crushed gravel comprises class-5 aggregate.