Cast wall with modular units

Abstract

A cast wall system comprising at least two modular units, each having a front surface, a back surface, and opposing edge surfaces. A first edge surface (e.g., an upper edge surface) of one modular unit is positioned adjacent to a second edge surface (e.g., a lower edge surface) of another modular unit. A compression system (e.g., a threaded rod under tension) and coupled to elongated beams) provides a force to compress the first edge surface of the one modular unit toward the second edge surface of the other modular unit, and a hardened backing (e.g., concrete) is positioned on the back surface of the at least two modular units. Preferably, the first and second edge surfaces are ground in order to improve the surface contact between those two edge surfaces. When producing the cast wall, the hardened backing is preferably poured onto the back of the modular units. Prior to and during the pouring, it is preferred to support a first end of the one modular unit and a second end of the other modular unit on a common rail. In one embodiment, the common rail includes a base portion and an upright portion (e.g., a T-rail), and the step of supporting includes positioning the base portion on a support surface, and setting the first end of the one modular unit and the second end of the other modular unit on the upright portion. Preferably, the second end of the one modular unit and the first end of the other modular unit are supported on rails different than the common rail.

1 . A cast wall system comprising:
 at least two modular units, each modular unit having a front surface, a back surface, and opposing edge surfaces, wherein a first edge surface of one modular unit is positioned adjacent to a second edge surface of another modular unit;   a compression system providing a force to compress the first edge surface of the one modular unit toward the second edge surface of the other modular unit; and   a hardened backing distributed on the back surface of the at least two modular units.   
   
   
       2 . The cast wall system of  claim 1 , wherein the first edge surface is an upper edge surface and the second edge surface is a lower edge surface. 
   
   
       3 . The cast wall system of  claim 1  wherein the first edge surface is a left side edge surface and the second edge surface is a right side edge surface. 
   
   
       4 . The cast wall system of  claim 1 , wherein the first edge surface comprises a ground surface. 
   
   
       5 . The cast wall system of  claim 1 , wherein both the first and second edge surfaces comprise ground surfaces. 
   
   
       6 . The cast wall system of  claim 1 , wherein the compression system includes a connection bar under tension. 
   
   
       7 . The cast wall system of  claim 6 , wherein the connection bar comprises a threaded rod. 
   
   
       8 . The cast wall system of  claim 6 , wherein the compression system further includes an elongated beam coupled to at least one modular unit and coupled to the connection bar. 
   
   
       9 . The cast wall system of  claim 1 , wherein the hardened backing comprises concrete. 
   
   
       10 . A method of forming a cast wall system, the cast wall system made up of at least two modular units, each modular unit having a front surface, a back surface, an upper edge surface, and a lower edge surface, the method comprising:
 positioning a first edge surface of one modular unit adjacent to a second edge surface of another modular unit;   compressing the first edge surface of one modular unit toward the second edge surface of the other modular unit; and   pouring a backing on the back surface of the at least two modular units.   
   
   
       11 . The method of  claim 10 , further comprising grinding the first edge surface prior to compressing. 
   
   
       12 . The method of  claim 10 , further comprising grinding both the first and second edge surfaces prior to compressing. 
   
   
       13 . The method of  claim 10 , further comprising supporting a portion of each modular unit on a common rail. 
   
   
       14 . The method of  claim 10 , wherein compressing includes forcing the modular units toward each other. 
   
   
       15 . A method of forming a cast wall system, the cast wall system made up of at least two modular units, each modular unit having at least a first end and a second end, each end having an edge surface, the method comprising:
 positioning an edge surface of the first end of one modular unit adjacent an edge surface of the second end of the other modular unit;   supporting the first end of the one modular unit and the second end of the other modular unit on a common rail; and   pouring a backing onto the modular units.   
   
   
       16 . The method of  claim 15 , wherein the common rail includes a base portion and an upright portion, and wherein supporting includes:
 positioning the base portion on a support surface; and   setting the first end of the one modular unit and the second end of the other modular unit on the upright portion.   
   
   
       17 . The method of  claim 15 , wherein the common rail is a first rail, and wherein the method further comprises:
 supporting the second end of the one modular unit on a second rail; and   supporting the first end of the other modular unit on a third rail.   
   
   
       18 . The method of  claim 15 , wherein the backing comprises concrete, and wherein the method further includes hardening the concrete.