ASSEMBLIES AND METHODS FOR ERECTING STRUCTURES

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/681,969, filed Aug. 12, 2024, the entire contents of which are hereby incorporated by reference herein for all purposes.

TECHNICAL FIELD

The present disclosure relates to systems, devices, assemblies, and methods for use in erecting structures. More particularly, the present disclosure relates to precast concrete physical security walls, perimeter walls and screen walls, and associated assembly techniques.

BACKGROUND

Precast concrete structures (e.g., physical security walls, perimeter walls, screen walls, etc.) are an important part of protecting power generating facilities, water treatment plants, gated residential communities, businesses, etc.

Conventional precast walls are time consuming and expensive to build—requiring heavy labor and equipment to excavate, reinforce, inspect, place and finish reinforced concrete

foundations in place under varying site conditions. Site conditions may be volatile and difficult to access due to soil conditions, weather, and availability of the Authority Having Jurisdiction to inspect and approve prior to execution of the cast in place concrete foundations. The conventional laborious process repeats itself at each wall bearing foundation location.

The next step in the conventional process is to qualify the foundation concrete to be cured to the assembly's designed compressive strength by means of destructive testing of sample concrete cylinders obtained at the time of casting. This typically occurs after a minimum of three days per American Concrete Institute standards. When the test result is favorable, the next step is initiated, which is installing the columns on the foundations. A center void in the column is installed over a wide flange beam projecting vertically from the foundation, braced off plumb, true to elevation and in plane, then grouted solid with concrete, resulting in the connection of the column to the foundation. This step also requires access and conveyance of concrete to each foundation and column location and the same validation of cured grout as described with the foundation concrete prior to the next step. This results in a lengthy and cumbersome process that negatively impacts the project schedule.

The next step in the conventional process is to install the wall panels into the slotted columns. This process can be complicated if the cast in place foundations are not dimensionally correct or poured to the correct elevation. The last step in the conventional process of erecting a precast wall assembly is setting the column caps. This process involves building scaffolding to access the top of the column, mixing to specification Type S mortar mix, spreading a “bed” of mortar on top of the column, and setting the cap plumb, true, square, and level, which requires journeyman mason skills.

This conventional process repeats itself in the described sequence to the full length of the wall. After the assembly is complete, the last conventional step is painting the assembly, which requires pressure washing first to prepare the substrate per the paint manufacturer's specifications and includes measuring the moisture content and PH level of the concrete assembly. Painting onsite is subject to damage by wind-borne dust, rain, and construction equipment near the wet paint.

SUMMARY

The disclosure provides, in one aspect, an assembly comprising a precast concrete foundation defining a first surface; a precast concrete column extending from the first surface at a location offset from a center of the first surface; and a beam positioned at least partially within the pre-cast concrete foundation and at least partially within the pre-cast concrete column. The assembly is a unified precast concrete assembly.

In some embodiments, the precast concrete foundation includes a first plurality of rebar.

In some embodiments, the precast concrete column includes a second plurality of rebar.

In some embodiments, the precast concrete column includes a first channel extending along a first side surface and a second channel extending along a second side surface.

In some embodiments, an angle between the first channel and the second channel is within a range of 90 degrees to 180 degrees.

In some embodiments, the angle is 135 degrees.

In some embodiments, the precast concrete foundation defines a second surface; wherein the second surface is spaced from and parallel to the first surface.

In some embodiments, the beam is a steel flange beam.

In some embodiments, the foundation includes a notch formed in the first surface; and wherein the notch is aligned with a first channel in the precast concrete column.

The disclosure provides, in one aspect, a system comprising: a first precast assembly including a first foundation and a first column positioned offset from a center of the first foundation; a second precast assembly including a second foundation and a second column positioned offset from a center of the second foundation; and a wall extending between the first precast assembly and the second precast assembly. At least a portion of the wall is received within a first channel formed in the first column, and at least a portion of the wall is received within a second channel formed in the second column. The first precast assembly, the second precast assembly, and the wall are configured to be installed at a site without the use of in-situ concrete.

In some embodiments, the system further comprises a first notch formed in the first foundation; wherein the first notch is aligned with the first channel.

In some embodiments, at least a portion of the wall is received within the first notch.

In some embodiments, the system further comprises a spacer at least partially received within the first channel.

In some embodiments, the system further comprises a precast concrete cap positioned at a top surface of the first column, wherein the precast concrete cap includes a notch and a portion of the first column is received within the notch.

The disclosure provides, in one aspect, a method of erecting a structure. The method comprises: excavating an earthen hole; and positioning a unified precast concrete assembly at least partially within the earthen hole. The unified precast concrete assembly includes a foundation and a column. The method further comprises inserting a portion of a precast concrete wall within a channel formed in the column. The structure is erected without pouring concrete in-situ.

In some embodiments, excavating the earthen hole includes compacting soil within the earthen hole and adding a layer of gravel.

In some embodiments, the unified precast concrete assembly is formed offsite and transported to the earthen hole.

In some embodiments, the method further comprises coupling a cap to a top of the column.

In some embodiments, the method further comprises painting the unified precast concrete assembly before positioning the unified precast concrete assembly within the earthen hole.

The disclosure provides, in one aspect, a method of manufacturing a unified precast concrete assembly. The method comprises casting a concrete foundation with a beam extending from the concrete foundation; casting a concrete column with a cavity; positioning the concrete column on the concrete foundation with the beam at least partially positioned within the cavity; and filling the cavity with concrete to unify the concrete foundation with the concrete column.

In some embodiments, the cavity extends through the concrete column along a longitudinal axis of the concrete column.

In some embodiments, the method further comprises painting the unified precast concrete assembly.

The disclosure provides, in one aspect, an embodiment an embodiment of a complete 6′ high or 8′ high precast concrete wall assembly including plant-cast foundations and columns set true and grouted to the foundation in the precast plant. Wall panels cast and cured, and the column caps cast and cured. The assembly is painted in a purpose-built facility adjacent to the casting facility before shipping the completed components to the site for an expedient assembly. Advantageously, the system is vertically “stackable” in the case where higher walls are required.

The disclosure provides, in one aspect, a method of erecting the structure, the method comprising of locating, excavating, and compacting the soil to set the precast assembly plumb, true to elevation and plane. This process is repeated at each precast assembly location. The precast concrete wall is then inserted in the column slots of two opposing precast assemblies and repeated at each location to the full length of the wall. The column caps are then set by epoxying to the top of the column. This method yields in one day what typically takes weeks to complete: a length of a complete, painted precast physical security, perimeter, or screen wall.

Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

Definitions

As used herein, “about” and “approximately” are used to provide flexibility to a numerical range endpoint by providing that a given value may be “slightly above” or “slightly below” the endpoint without affecting the desired result.

The term “coupled,” as used herein, is defined as “connected,” although not necessarily directly, and not necessarily mechanically. The term coupled is to be understood to mean physically, magnetically, chemically, fluidly, electrically, or otherwise coupled, connected or linked and does not exclude the presence of intermediate elements between the coupled elements absent specific contrary language.

The terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that do not preclude the possibility of additional acts or structures. The singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. The present disclosure also contemplates other embodiments “comprising,” “consisting of” and “consisting essentially of,” the embodiments or elements presented herein, whether explicitly set forth or not.

For the recitation of numeric ranges herein, each intervening number there between with the same degree of precision is explicitly contemplated. For example, for the range of 6-9, the numbers 7 and 8 are contemplated in addition to 6 and 9, and for the range 6.0-7.0, the number 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 are explicitly contemplated.

In the foregoing description of preferred embodiments, specific terminology has been resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “top” and “bottom”, “front” and “rear”, “inner” and “outer”, “above”, “below”, “upper”, “lower”, “vertical”, “horizontal”, “upright” and the like are used as words of convenience to provide reference points.

As used herein, the term “precast concrete” or “pre-cast concrete” refers to a construction product produced by casting concrete in a reusable mold or “form” which is then cured in a controlled environment, transported to the construction site and maneuvered into place.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a precast concrete wall system.

FIG. 2 is a partial cross-sectional view the precast concrete wall system of FIG. 1.

FIG. 3 is a perspective view of a portion of a precast concrete assembly.

FIG. 4 is a perspective view of a portion of a precast concrete assembly.

FIG. 5A is a schematic illustrating manufacturing steps of a precast concrete assembly.

FIG. 5B is a flowchart of a method of manufacturing a precast concrete assembly.

FIGS. 6A-6F are perspective views of precast concrete assemblies with various precast concrete columns.

FIG. 7 is a partial cross-sectional view of a precast concrete column and walls.

FIG. 8A is a perspective view of a precast concrete wall.

FIG. 8B is a perspective view of the precast concrete wall of FIG. 8A, showing a plurality of embedded rebar.

FIG. 9 is a perspective view of precast concrete caps.

FIG. 10 is a cross-sectional view illustrating installation of a precast concrete assembly into the ground.

FIG. 11A is a perspective view illustrating installation of a precast concrete wall between precast concrete assemblies.

FIG. 11B is a cross-sectional view illustrating installation of a precast concrete wall between precast concrete assemblies.

FIG. 12A is a perspective view illustrating installation of a precast concrete cap.

FIG. 12B is a partial cross-sectional view of a precast concrete cap assembled on a precast concrete assembly.

FIG. 13 is a flowchart of a method of erecting a structure.

FIGS. 14A-14D illustrates manufacturing steps of a precast concrete assembly.

FIG. 15 is a perspective view of a precast concrete wall system installed on an elevation.

FIG. 16A is a perspective view of a portion of the precast concrete wall system of FIG. 15.

FIG. 16B is an enlarged partial view of FIG. 16A.

FIG. 17 is a cross-sectional view of the precast concrete wall system of FIG. 16A.

FIG. 18 is a perspective view illustrating manufacturing steps for a precast concrete assembly.

FIG. 19 is a perspective view of a precast concrete wall system with a taller overall height.

FIG. 20A is a perspective view of a portion of the precast concrete wall system of FIG. 19.

FIG. 20B is an enlarged partial view of FIG. 20A.

FIG. 21 is a perspective view of a precast concrete wall system with a taller overall height installed on an elevation.

Before any embodiments are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

DETAILED DESCRIPTION

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In case of conflict, the present document, including definitions, will control. Preferred methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in practice or testing of the present disclosure. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. The materials, methods, and examples disclosed herein are illustrative only and not intended to be limiting.

Disclosed herein are constructions techniques for use in erecting a precast concrete wall or fence. In one aspect, the present disclosure relates to a unique precast concrete assembly including a foundation and a column, which is cast and assembled off-site. In another aspect, the present disclosure relates to methods and associated techniques for erecting a wall system on site utilizing the module precast concrete assemblies.

The disclosed assemblies and methods achieve the technical aspects and dimensional requirements of the specific fencing requirements and compliance with local building codes, while resulting in a significantly reduced erection duration (e.g., days) when compared to the typical time required to complete a conventional precast concrete fencing assembly, casting the foundations, and fixing the columns to the foundations on-site (e.g., weeks). Advantageously, the systems disclosed herein achieve a turnkey finished precast wall system in one day. This includes delivery of all components, excavation and compaction of soil, installation of precast assembly, installation of precast walls, and installation of precast caps. All components are pre-painted off-site, which facilitates a turnkey assembly as sections are placed per plan on-site. This precast concrete wall system achieves a short turnaround time because there is no concrete poured in-situ. By installing precast concrete assemblies that have been pre-assembled at the manufacturing facility, all on-site cast concrete preparation, inspections, placement and finishing is eliminated from the construction schedule.

With reference to FIG. 1, a precast concrete wall system 10 is illustrated with a plurality of precast assemblies 14, a plurality of precast walls 18, and a plurality of precast caps 22. Each of the plurality of precast assemblies 14 includes a foundation 26 and a column 30. In the illustrated embodiment, the columns 30 are offset from a horizontal center 34 of the corresponding foundation 26. As discussed in greater detail herein, the plurality of precast assemblies 14, the plurality of precast walls 18, and the plurality of precast caps 22 are manufactured offsite to advantageously improve the installation of the wall system 10.

With reference to FIG. 2, a first precast assembly 14A includes a first foundation 26A and a first column 30A positioned offset from a center of the first foundation 26A; and a second precast assembly 14B includes a second foundation 26B and a second column 30B positioned offset from a center of the second foundation 26B. A wall 18 extends between the first precast assembly 14A and the second precast assembly 14B. As detailed further herein, at least a portion of the wall 18 is received within a first channel 46 (FIG. 4) formed in a first column 30A, and at least a portion of the same wall 18 is received within a second channel 54 (FIG. 4) formed in a second column 30B. Advantageously, the first precast assembly 14A, the second precast assembly 14B, and the wall 18 are configured to be installed at a site (e.g., an installation site, “in the field”) without the use of in-situ concrete. In other words, no concrete needs to be poured or cured at the installation site of the wall system 10.

With reference to FIGS. 3-5A, the manufacture of a precast assembly 14 is illustrated. With reference to FIG. 3, the assembly 14 includes a precast concrete foundation 26 defining a first surface 27 (e.g., a top surface) and a second surface 28 (e.g., a bottom surface). In the illustrated embodiment, the second surface 28 is spaced from and parallel to the first surface 27. In the illustrated embodiment, the precast concrete foundation 26 includes a plurality of rebar 38. A beam 42 is positioned at least partially within the pre-cast concrete foundation 26. In the illustrated embodiment, the beam 42 is offset from a horizontal center 34 of the foundation 26, which is aligned with a center of the first surface 27 and the second surface 28. In some embodiments, the beam 42 is steel flange beam. The foundation 26 is cast with both the rebar 38 and the beam 42 set in place.

With reference to FIG. 4, a precast concrete column 30 includes a first channel 46 extending along a first side surface 50 and a second channel 54 extending along a second side surface 58. The column 30 of FIG. 4 may be referred to as an “H-column” or “H-shaped.” An angle 62 is defined between the first channel 46 and the second channel 54. In the illustrated embodiment, the angle 62 is approximately 180 degrees. In the illustrated embodiment, the precast concrete column 30 includes a plurality of rebar 66 embedded therein. The column 30 includes a cavity 70 that is configured to receive the beam 42. In some embodiments, the cavity 70 extends through the concrete column 30 along a longitudinal axis 74 of the concrete column 30.

With reference to FIG. 5A, the joining of the precast foundation 26, the beam 42, and the precast column 30 is illustrated. The precast concrete column 30 is initially separate, but is then positioned onto the beam 42. In particular, the cavity 70 at least partially receives the beam 42. The column 30 then contacts the foundation 26 plumb, true and square. The cavity 70 is then filled solid with concrete 78 (e.g., high strength concrete). The end result is a precast assembly 14 with the beam 42 positioned at least partially within the pre-cast concrete foundation 26 and at least partially within the precast concrete column 30. Advantageously, the precast assembly 14 is a unified precast concrete assembly. In other words, the assembly 14 is a singular, unitary, or monolithic structure that is manufactured entirely off-site (e.g., no concrete poured at the installation site of the wall system 10).

With continued reference to FIG. 5A, the precast concrete column 30 extends from the first surface 27 of the foundation 26 at a location offset from a horizontal center 34 of the first surface 27. Advantageously, positioning the column 30 offset on the foundation 26 improves the ability to position the installed wall system 10 closer to a property line without needing to dig or disturb an adjacent property.

With reference to FIG. 5B, a method 300 of manufacturing a unified precast concrete assembly (e.g., the assembly 14) is shown. The method 300 includes (STEP 301) casting a concrete foundation (e.g., the foundation 26) with a beam (e.g., the beam 42) extending from the concrete foundation. The method 300 further includes (STEP 302) casting a concrete column with a cavity (e.g., the column 30 of FIG. 4). The method 300 further includes (STEP 303) positioning the concrete column on the concrete foundation with the beam at least partially positioned within the cavity; and (STEP 304) filing the cavity with concrete (e.g., the concrete 78) to unify the concrete foundation with the concrete column (e.g., FIG. 5A). In some embodiments, the method 300 further includes painting the unified precast concrete assembly. As discussed herein, the method 300 advantageously is completed entirely off-site (e.g., away from wall system installation site).

With reference to FIGS. 6A-6F, the precast concrete assemblies 14 may include various column embodiments. FIG. 6A illustrates an assembly 14 with a column 30 having two channels 46, 54 with an angle 62 of approximately 180 degrees defined therebetween (e.g., the assembly 14 of FIG. 5A). In other embodiments, the angle 62 between the two channels 46, 54 is within a range of approximately 90 degrees to approximately 180 degrees. The column 30 of FIG. 6A may be referred to as an “H Column” or “H shaped.” The assembly 14 is utilized as the connection between two precast walls 18 that extend along a common line.

FIG. 6B illustrates an assembly 100 with a column 102 having no channels (e.g., a “stand-along column”), which does not interact with a wall. The assembly 100 of FIG. 6B may serve as a decorative column or a connection point of a conventional fence system.

FIG. 6C illustrates an assembly 110 with a column 112 having three channels 114 with an angle of approximately 90 degrees defined between circumferentially adjacent channels 114. The column 112 of FIG. 6C may be referred to as a “T Intersection Column” or “T-shaped,” and can act as a connection between three intersecting walls that meet at two 90 degree angles.

FIG. 6D illustrates an assembly 120 with a column 122 having one channel 124 (e.g., an End Column), which may be utilized as a singular end point in the wall system-allowing one precast wall to interact on one side of the column 122.

FIG. 6E illustrates an assembly 130 with a column 132 having two channels 134 with an angle of approximately 90 degrees defined therebetween. The column 132 of FIG. 6E may be referred to as a “Corner Column,” and may serve as a connection point for two walls that meet at one 90 degree angle—thereby forming a corner section in the wall system.

FIGS. 6F and 7 illustrate an assembly 140 with a column 142 having two channels 144, 145 with an angle 146 of approximately 135 degrees defined therebetween. With reference to FIG. 7, the column 142 of FIG. 6F serves as an angled connection point for two precast walls 18 that intersect at an approximately 135 degree angle. A portion 150 of the first wall 18 is received within the first channel 144 and a portion 151 of the second wall 18 is received within the second channel 145. References made through the disclosure to a precast assembly 14 may refer to any one of the precast assemblies (e.g., assemblies 100, 110, 120, 500, 600, 700, etc.) detailed herein.

With reference to FIGS. 8A and 8B, the precast wall 18 (also referred to as concrete wall panel) is illustrated and includes a first end portion 19 of reduced thickness and a second end portion 20, opposite the first end portion 19, of reduced thickness. As detailed herein, the end portions 19, 20 are received within corresponding channels (e.g., channels 46, 54) formed in the assemblies (e.g., assembly 14, 100, 110, etc.). In the illustrated embodiment, the precast wall 18 includes a plurality of rebar 21. In the illustrated embodiment, both sides 23A, 23B of the precast wall 18 includes corbel banding 24 and a specified texture to be chosen by the end user.

With reference to FIG. 9, precast concrete caps 22A, 22B are illustrated. The cap 22A has a flat top 25A. The cap 22B has a pointed top 25B.

With reference to FIGS. 10-11B, various steps of installing the wall system 10 are illustrated. With reference to FIG. 10, installation of the precast assemblies 14 is illustrated. Upon excavating an earthen hole 200 where the precast assemblies 14 will be inserted, the soil 202 at the foundation location is compacted, followed by approximately 8 inches of gravel 204 (e.g., #57 limestone gravel). The precast assembly 14 is then placed into the hole 200 on top of the compacted soil 202, and set plumb, true, square, and in alignment with the desired wall trajectory.

With reference to FIG. 11A, once the precast assemblies 14 are set, precast walls 18 are installed between adjacent precast assemblies 14. With reference to FIG. 11B, a precast wall 18 is being set between the installed precast assemblies 14 and illustrates the end portions 19, 20 of the wall 18 being positioned within corresponding channels 46, 54 in the columns 30. The interface between the wall 18 and the assembly 14 may be referred to as a tongue and groove connection.

With reference to FIGS. 12A and 12B, a precast cap 22 is positioned at a top surface 79 of the column 30. In the illustrated embodiment, the precast cap 22 includes a notch 27 and a portion 81 of the column 30 is received within the notch 27.

With reference to FIG. 13, a method 400 of erecting a structure (e.g., the wall system 10) is shown. The method 400 includes (STEP 401) excavating an earthen hole (e.g., hole 200) and (STEP 402) positioning a unified precast concrete assembly (e.g., assembly 14) at least partially within the earthen hole (see FIG. 10). In some embodiments, excavating the earthen hole includes compacting soil (e.g., soil 202) within the earthen hole and adding a layer of gravel (e.g., gravel 204). As detailed herein, the unified precast concrete assembly includes a foundation and a column and is formed offsite and transported to the earthen hole ready for installation. In some embodiments, the method 400 further comprises painting the unified precast concrete assembly before positioning the unified precast concrete assembly within the earthen hole.

The method 400 further includes (STEP 403) inserting a portion of a precast concrete wall within a channel formed in the column (FIGS. 11A and 11B). In some embodiments, the method 400 further includes coupling a precast concrete cap to a top of the column. Advantageously, with the method 400, the structure is erected without pouring concrete in-situ. In other words, pouring concrete is not required or necessary at the installation site of the wall system with the method 400.

With reference to FIGS. 14A-14D, in some embodiments, a precast assembly 500 includes a notch 504 formed in a first surface 508 (e.g., the upper surface) of a foundation 512. Such footings may be referred to as a “dropped footing,” and are utilized for installation of the wall system along a sloped elevation. In other words, precast assemblies with a dropped footing are used where the installation site requires elevation changes in the wall system. In the illustrated embodiments, the notch 504 is aligned with a channel 516 formed in a precast concrete column 520. Advantageously, the precast assembly 500 can serve as a connection point for two intersecting wall panels that will reach differing elevations. One side of the column foundation reaches the typical elevation (e.g., approximately 4 inches below grade), and the other side of the column foundation includes the notch 504.

With reference to FIGS. 14B-14D, the notch 504 may have a varied depth dimension 524. FIG. 14B illustrates a notch 504 approximately 4 inches deep. FIG. 14C illustrates a notch 504 approximately 8 inches deep. FIG. 14D illustrates a notch 504 approximately 12 inches deep. In some embodiments, the depth of the notch 504 is within a range of approximately 4 inches to approximately 12 inches. As the depth of the notch 504 increases, the depth of the foundation 512 also increases.

With reference to FIG. 15, a wall system 510 shown utilizing precast assemblies 500 with dropped footings to facilitate a descending wall elevation.

With reference to FIGS. 16A and 16B, a precast wall 18 is inserted into the corresponding notch 504 formed in the foundation 512. At least a portion of the wall 18 is received within the notch 504. Since the wall 18 is set lower on one side of the column 520, a visible gap 528 is left in the channel 516 at the top of the column 520 (FIG. 16B). In some embodiments, a precast concrete spacer 532 is positioned and secured (e.g., with an epoxy adhesive) within the gap 528 after the precast wall 18 has been inserted, but prior to installation of the precast cap 22. FIG. 17 illustrates how the dropped footings are set on a descending elevation, and the spacers 532 are positioned in the channels after the precast walls 18 have been set into position. In the illustrated embodiment, the spacers 532 are at least partially received within the channels 516 formed in the columns 520.

With reference to FIG. 18, a precast assembly 600 is illustrated with a taller beam 604 extending from a foundation 608 and stacked precast columns 612, 616. In other words, a second precast column 616 is positioned around the beam 604 and onto a first precast column 612. In the illustrated embodiment, the beam 604 extends from the foundation 608 to approximately half the vertical distance of the second lift of columns. The precast assembly 600 may be manufactured utilizing the method 300 described herein, with differences detailed herein. Before setting the second precast column 616 onto the first precast column 612, at least one bearing pad 620 is positioned between the two columns 616, 620. With the bearing pad 620 in place, the second precast column 616 is set onto the first column 612 with the beam 604 extending into a cavity of the second column 616, which is then filled with concrete.

With reference to FIG. 19, a wall system 610 is illustrated utilizing the precast assembly 600 of FIG. 18 and at least two vertically stacked precast walls 18 extending therebetween. In some embodiments, the wall system 610 has a height within a range of approximately 6 feet to approximately 16 feet.

With reference to FIGS. 20A and 20B, illustrates installation of the wall system 610 of FIG. 19. Precast columns 616 are vertically stacked on top of precast columns 616, and precast walls 18 are vertically stacked on top of precast walls 18 to extend the overall height of the wall system 610. Before setting the second wall 18 onto the first wall 18, at least one bearing pad 622 is positioned between the two walls 18.

With reference to FIG. 21, a stacked precast wall system 710 is shown installed on a sloped elevation. This utilizes assemblies 700 with dropped footings in combination with the vertically stacked walls and columns. Assembly techniques described herein would also be utilized in this situation. In some embodiments, the method includes casting an enlarged dropped footing at the plant; casting the appropriate column; inserting the column over the elongated wide flange beam; pouring high strength concrete or grout into the cavity; allowing the high strength grout or concrete to cure (at the plant); excavating and compacting the soil; setting the precast assemblies in their final specified locations; inserting precast wall panels into the column slots (horizontal and vertical; setting bearing pads; inserting a second vertical level of columns onto the extended wide flange beam, pouring cavity of second level columns with high strength concrete; allowing the second level columns to cure; setting a second level of wall panels; installing any necessary precast inserts; and finally installing the precast caps.

The systems and methods disclosed herein provide for wall systems advantageously capable of withstanding approximately 192 mph wind loads, and also meet Ballistic Resistant Design (BRD) level 10 (UL 752).

Various features and advantages are set forth in the following claims.