Note: Descriptions are shown in the official language in which they were submitted.
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AN APPARATUS AND METHOD FOR SECURING POSTS TO RETAINING WALLS
FIELD OF INVENTION:
[1] This disclosure generally relates to retaining wall structures. In
particular, the disclosure
relates to an apparatus and method for securing posts, such as fence posts to
a top surface of
retaining wall structures.
BACKGROUND:
[2] Retaining walls are often built by placing a number of interconnected
blocks in courses
upon each other. A course of blocks is also referred to as a row of blocks.
The blocks typically
have interior cavities that hold drainage material. The cavities may also be
referred to as cores
or chambers. The drainage materials are typically drain rocks that are each
about 1 cubic inch
in overall size. Drainage materials are often void of fines so that plugging
of the cavities can be
reduced and flow of water through the retaining wall is substantially
unimpeded.
[31 Retaining walls are structurally supported by the use of a structural
support material, for
example geo grid. Geo grid is a mesh-like material that is often made of
polypropylene or other
polymers with sufficiently high tensile strengths. The geo grid is placed
between one or more
courses of the retaining wall. The geo grid extends away from a back face of
the retaining wall
and into the retained material, such as earth, rocks and soil, which is being
retained by the
retaining wall. The distance that the geo grid extends into the retained
material may vary
based upon a number factors, such as the physical stability of the retained
materials, and
overall mass of the retained materials, the height of the retaining wall and
other factors that
are known to those skilled in the art. The mesh structure of the geo grid
comprises a number of
holes that portions of the retained material can fit within. The weight of the
retained materials
and the presence of the retained materials within the holes of the geo grid
contribute to the
structural integrity of the retaining wall.
[4] Securing posts, such as fence posts, to retaining walls is often
desirable for safety and
security. A builder can secure fence posts to a retaining wall by lag bolting
a post bracket to a
top cap of the retaining wall. The top cap is often adhered to the upper
course of blocks by an
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adhesive. Then the builder will typically secure a fence post into the post
bracket, and build a
fence between a series of secured fence posts. While this is commonly used, it
creates an
unsafe scenario because the adhesive is not designed to maintain adhesion of
the top cap that
includes a fence thereupon. For example, the fence posts can act as a lever
that can, in some
cases easily, disconnect the top cap from the upper course of blocks.
[5] Another known solution to securing fence posts to near to the top of
retaining walls is
to insert sonotubes into the retained material near the back face of the
retaining wall. This
approach includes positioning the sonotubes within the retained material,
inserting the fence
posts and filling the sonotubes with concrete to fix the fence posts within
the sonotubes. While
the use of sonotubes does not pose the same safety concerns as the previously
described
approach, the placement of the sonotubes within the retained material will
often interfere with
the structural support material. For example, the structural support material
is often cut while
digging the holes for the sonotubes. This may impair the structural integrity
of at least a
portion of the retaining wall.
[6] U.S. Patent Publication Document No. 2008/0277543 to Daysh et al.
teaches another
approach for securing fence posts to the top of a retaining wall. Daysh
teaches a fence post
bracket that positions the fence post away from a center portion of the
retaining wall blocks,
when view from above. The post bracket of Daysh comprises a variety of
structures that extend
into the cavities of the blocks. These structures are designed to provide an
increased surface
area for adhering with concrete that is filled within the cavities. This is
how Daysh teaches to
secure the post bracket in place. The post bracket of Daysh makes it difficult
to use a top cap
on the retaining wall. For example, the top cap will have to be cut to provide
recesses that can
accommodate the post brackets and fence posts. This cutting can be meticulous
and labour
intensive work. Additionally, a retaining wall that secures the post brackets
within the block
cavities with concrete could interfere with the use drainage materials within
at least the block
cavities that contain a post bracket.
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SUMMARY:
[7] The present invention provides an apparatus and method for securing a
fence post to
the top of a completed retaining wall that may include a top cap.
[8] One example embodiment of the present invention is a retaining wall
system that
comprises a plurality of interconnected wall blocks that define a wall
structure. The wall
structure includes a front face, a back face, a bottom surface, a top surface
and at least one
internal chamber that is defined between the front and back face. Optionally,
the top surface
of the wall structure includes a top cap, which is also referred to herein as
the top surface. The
retaining wall system may include a support structure that is positioned at
least partially
between one or more of the plurality of interconnected wall blocks. The
retaining wall system
also includes a post bracket that is securable to the top surface of the wall
structure. The post
bracket comprises a shank portion that is extendible through the top surface
of the wall
structure and into the at least one chamber. The post bracket further
comprises a flange
portion that abuts the top surface. The post bracket further comprises a
receptacle that
extends away from the top surface and that is operable for receiving a post
member.
Optionally, the retaining wall system may further comprise a drilling guide
for drilling one or
more aligned apertures for securing the post bracket to the top surface.
[9] Another example embodiment of the present invention is a method of
securing a post
member onto a wall. The method comprises the steps of: forming a shank
receiving aperture
on a top surface of the wall; inserting a shank portion of a post bracket into
the shank receiving
aperture; connecting the post bracket to the top surface of the wall; and
securing an end of a
post member to the post bracket. Optionally, the method may further comprise a
step of
aligning the shank-receiving aperture with a second aperture by using a drill
guide and the
second aperture is used to connect the post bracket to the top surface.
[10] Another example embodiment of the present invention is the use of a post
bracket for
securing a post member to a wall structure. The post bracket comprises a shank
portion, a
flange portion and a receptacle portion. The use comprises the steps of
inserting the shank
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portion into an aperture that extends through a top cap surface of the wall
structure;
connecting the flange portion to the top cap surface; and fixing an end of the
post member
within the receptacle portion so that the post member extends away from the
top cap surface.
[11] The present invention allows a user to secure fence posts upon a
completed retaining
wall. The present invention avoids the use of concrete applications and it
does not interfere
with the structural integrity of any structural support material or the
drainage properties of any
drainage material. The use of concrete applications typically necessitates
cutting away portions
of the supporting structural material to allow the concrete to flow into and
through the cavities
of the blocks. Before the wet concrete sets, it can seep between the blocks.
It is known that
wet concrete can degrade the supporting structural material. At least these
two drawbacks of
using concrete applications may be avoided by the present invention.
BRIEF DESCRIPTION OF DRAWINGS:
[12] Various examples of the apparatus are described in detail below, with
reference to the
accompanying drawings. The drawings may not be to scale and some features or
elements of
the depicted examples may purposely be embellished for clarity. Similar
reference numbers
within the drawings refer to similar or identical elements. The drawings are
provided only as
examples and, therefore, the drawings should be considered illustrative of the
present
invention and its various aspects, embodiments and options. The drawings
should not be
considered limiting or restrictive as to the scope of the invention.
[13] Figure 1 is side elevation view of one example embodiment of a
retaining wall system.
[14] Figure 2 is a cross-sectional view of the retaining wall system of
Figure 1, viewed
generally along line 2-2.
[15] Figure 3 is a perspective view of the example post bracket for use
with the retaining wall
system of Figure 1.
[16] Figure 4 is a perspective view of an example embodiment of a drill
guide for use with
the example post bracket of Figure 1.
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DETAILED DESCRIPTION:
[17] As further described herein below, the present invention provides a
system, method
and use of a post bracket for securing a post member to a top surface of a
retaining wall. With
a secured post member, a fence can be built on top of the retaining wall.
Advantageously, the
retaining wall can be completed and the post members can be secured without
the use of
concrete. Furthermore, the present invention may improve the structural
integrity of the
retaining wall while not interfering with any structural support material, for
example geo grid,
that may be used in the building of the retaining wall.
[18] Figure 1 depicts one example embodiment of a wall retaining system 10.
The retaining
wall system 10 comprises a wall structure 12 that is made up of a number of
block courses 14
(with each individual course depicted as 14A to 140) and a top cap 22. Without
intending to be
limiting, Figure 1 depicts four block courses (14A to 14D), however any number
of block courses
may be used in the construction of the wall structure 12. The block courses 14
include
individual blocks, each include a number of faces, such as a front face, a
back face, a lower
surface and an upper surface. Accordingly, the wall structure 12 also
generally includes a front
face 16, a back face 18, a lower surface 20 and an upper surface 22. Each
individual block
defines an internal cavity 24 (as depicted in Figure 2). Optionally, a top cap
22 can be
positioned on top of the upper most upper surface 22 of the wall structure 12.
The top cap 22
may also be referred to as the top surface of the wall structure 12.
[19] The individual blocks each have at least one internal cavity 24. The
internal cavity 24
can be accessed, for example to receive drainage material 120 therein, from
one or more of the
faces of each block. For example, the bottom and top surfaces of each
individual block may
have openings to the internal cavity 24 and the front and back faces may be
closed off to the
internal cavity 24, or vice versa. As one skilled in the art will appreciate,
the definitions of the
faces of the blocks provided herein are not intended to be limiting and,
ultimately, the
definition of a given face depends upon the orientation and final positioning
of each individual
block when the wall structure 12 is being constructed. In other examples of
the retaining wall
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system 10 different types of blocks may be used, preferably the blocks include
one or more
faces that define an internal cavity for receiving drainage material therein.
[20] The wall retaining system 10 may comprise a support structure 112 that is
at least
partially positioned between two individual wall blocks of the plurality of
interconnected wall
blocks. Figure 2, which is not intended to be limiting, depicts the support
structure 112 as
extending away from the back face 18 of the wall structure 12 into retained
material 100. The
support structure 122 may be positioned between two courses of interconnected
wall blocks.
For example, support structure 122A is positioned between courses 14A and 14B,
support
structure 122B is positioned between courses 14B and 14C and support structure
122C is
positioned between courses 14C and 140. The support structures 122 are
positioned between
the courses 14 during the construction of the wall structure 12, as depicted
by the dotted line
in Figure 2. The support structures 122 can be the same length or variable
lengths and extend
into the retained material 100 the same or different distances from the back
face 18. While
Figure 2 depicts support structures 122 A, B and C being positioned between
adjacent courses
14 of blocks, the support structures 122 can be spaced further apart, for
example every 2 or 3
courses 14 of blocks. Between each course 14, the support material 122 can be
positioned as
close to the front face 16 as possible. Alternatively, a particular design of
the wall structure 12
or particular blocks used in a particular wall structure 12 may require that
the support structure
122 is spaced from the front face 16. For example, the support material 122
may be spaced
from the front face 16 to ensure that the support structure 122 is not exposed
and visible at the
front face 16. Preferably, the support structure 122 is a mesh-like sheet of
material made from
a polymer, for example, polypropylene, or other polymers with a sufficiently
high tensile
strength. The mesh-like structure of the support structure 122 defines a
number of holes (not
shown) that can receive a portion of the drainage material 120 and a portion
of the retained
material 100 therewithin. The drainage material 120 and the retained material
100 may also be
referred to as penetrating or impregnating the support structure 122. In this
fashion, the
drainage material 120 and the retained material 100 help maintain the desired
position of the
penetrated support structure 122. In turn, the penetrated support structure
122 helps keep
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the wall structure 12 in the desired position. Preferably, the support
structure 122 is geo grid;
however, other building materials are also suitable.
[21] The drainage material 120 allows water to flow through the internal
cavities 24 of the
wall structure 12. For example, the drainage material may be 1 inch in overall
diameter
drainage rock that has a substantially smooth outer surface. However, other
materials may
also be suitable. Preferably, the drainage material 120 is substantially free
of fine particles to
reduce the formation of plugs that will impair the flow of water through the
wall structure 12.
[22] The wall retaining system 10 further comprises at least one post
bracket 26 that
includes a shank portion 28, a flange portion 30 and a receptacle portion 32.
The flange portion
30 can be positioned on an upper surface of the top cap 22 and the shank
portion 28 is
elongate and extendible through the top cap 22 into the wall structure 12
below (see dotted
lines in Figure 1). The shank portion 28 can be of various lengths (contrast
28 and 28' in Figure
1). Post brackets 26 with shank portions 28 of different, or the same, lengths
may be used in
the same wall system 10. Preferably, the shank portion 28 is long enough to
extend through
the top cap 22 and at least one course of blocks 14. More preferably, the
shank portion 28 is
long enough to extend through the top cap 22 and through more than one course
of blocks, for
example two or three courses of blocks 14. The length of the shank portion 28
may fall within a
range of about 10 cm to about 100 cm. Preferably, the length of the shank
portion 28 is long
enough to extend through the top cap 22 and three courses of blocks and at
least one layer of
structural support 122, for example about 70 cm.
[23] The shank portion 28 may have a shape that reduces or prevents the shank
portion 28
from becoming caught on the drainage material 120 as the shank portion 28 is
inserted into the
wall structure 12. While various shapes may be suitable, preferably the shank
portion 28 has a
smooth outer surface that has a circular cross-sectional shape. The smooth
outer surface
allows the shank portion 28 to pass within the drainage material 120 without
becoming caught
or blocked. Optionally, the shank portion 28 may have a tip 38 that is shaped
to help displace
the drainage material 120 while the shank portion 28 is being inserted
therein. For example, a
frustoconical shaped tip 38 may be preferred over a flat tip.
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[24] The shank portion 28 may also pass through at least one hole of the
support structure
122. In this fashion, the shank portion 28 will also penetrate the support
structure 122 which
may bolster the structural integrity of the support structure 122 and the
overall wall structure
12.
[25] The flange portion 30 is positionable on an upper surface of the top
cap 22. The flange
portion 30 may be any shape. The flange portion 30 may define at least one
aperture 36 for
receiving a connector (not shown). The connector can be inserted into the at
least one
aperture 36 and into another aperture (not shown) in the top cap 22 for
securing the post
bracket to the top cap 22. The connector can be any suitable type of
connector, such as a bolt,
a screw, a pin or a rod.
[26] The receptacle portion 32 can extend away from the flange portion 30 for
receiving a
post member 110 within a receiving hole 40. The receptacle portion 32 can be
any cross-
sectional shape and any dimension to receive the post member 110 of any
desired shape or
size. The receptacle portion 32 can include one or more apertures 38 for
receiving connectors
(not shown) for securing the post member 110 within the receiving hole 40. The
connectors
can be any suitable type of connector, for example, a screw, a nail, a bolt, a
pin or a staple.
Figure 1, which is not intended to be limiting, depicts a fence 114 that
comprises a number of
post members 110 and cross-rails 112. Other types of fences 114, for example
chain-link fences
or picket fences, are also contemplated. The type of fence 114 to be built on
top of the wall
structure 12 and, therefore, the type of post member 110 will generally
dictate the shape and
dimensions of the receptacle portion 32.
[27] The post bracket 26 may be composed of a number of different materials,
such as
metal, metal alloys, rigid polymers, composite materials and combinations
thereof. The post
bracket 26 may be constructed as a single, monolithic structure.
Alternatively, the post bracket
26 may be an aggregated structure with the shank portion 28, the flange
portion 30 and the
receptacle portion 32 all manufactured as individual components that are
assembled and
connected together. For example, if the post bracket is made of mostly metal
or metal alloy
individual components, then welding may be used to connect them together.
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[28] Figure 4, without intending to be limiting, depicts an example
embodiment of a drill
guide 200. The drill guide 200 comprises a planar portion 210 and a guide arm
220. The guide
arm 220 has a primary guide hole 222. The planar portion 210 has one or more
secondary
guide holes 230. The drill guide 200 can also be referred to as a jig, a
template or a stencil. The
drill guide 200 allows a user to drill apertures in the top cap 22 so that the
shank portion 28 can
be inserted into the top cap 22 and so that connectors can be used to secure
the flange portion
30 to the top cap 22. For example, the primary guide hole 222 may be spaced
from the
secondary guide holes 230 substantially the same distance that the outer edge
of the shank
portion 28 is distanced from apertures 36 on the flange portion 30.
Additionally, the drill guide
200 and, in particular, the primary guide hole 222 is substantially
perpendicular to the flange
portion 30. In this manner, the drilling of the shank-receiving hole may be
substantially
perpendicular to the top surface of the top cap 22.
[29] The present invention also provides a method of securing a post member
110 onto a
wall structure 12. The method comprises the steps of drilling a shank-
receiving aperture on a
top surface of the wall structure 12 and inserting the shank portion 28 of the
post bracket 28
into the shank-receiving aperture. Optionally, the method further comprises a
step of levelling
the top cap 22 so that the shank-receiving aperture is substantially
perpendicular to the top cap
22 and, therefore, the shank-receiving aperture may be substantially vertical.
The next step of
the method is connecting the post bracket 26 to the top surface of the wall
structure 12, which
is followed by securing the post member 110 to the post bracket 26. The
inventor has observed
that this method may be advantageous for securing post members 110 onto
already completed
wall structures 12.
[30] The step of drilling the shank-receiving aperture through the top cap
22 is most typically
performed using a masonry drill bit. The shank-receiving aperture has a
diameter that is large
enough to receive the shank portion 28 and that is deep enough to penetrate
through at least
the top cap 22. Preferably, the diameter of the shank-receiving aperture is
closely matched
with the cross-sectional area of the shank portion 28 so that the shank
portion 28 fits within the
shank-receiving aperture with a minimal space between the shank portion 28 and
the inner
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diameter of the shank-receiving aperture. Optionally, the diameter of the
shank-receiving
aperture may be slightly smaller than the cross-sectional area of the shank
portion 28 so that a
friction fit is formed to help maintain the position of the shank portion 28
within the shank-
receiving aperture. Optionally, the user can use the drill guide 200 to drill
through the top cap
22 to form the shank-receiving aperture and another set of apertures that
align with the
apertures 36 of the flange portion 30.
[31] The user then inserts the shank portion 28 into the shank-receiving
aperture and
connects the post bracket 28 to the top cap 22. As described above, the post
bracket 28 can be
connected to the top cap 22 via connectors that are inserted through the one
or more
apertures 36 of the flange portion 30. Alternatively, the post bracket 28 may
be connected to
the top cap 22 by other means, such as adhesives, concrete or other brackets
and connectors.
[32] The user then secures an end of the post member 110 to the post bracket
28. For
example, a connector may be inserted through aperture 38 into the end of the
post member
110 that is positioned within the receiving hole 40. If the post member 110 is
made of wood,
then nails or screws may be preferred. If the post member 110 is made of
metal, or a metal
alloy, pins or bolts may be preferred.
[33] While
the above disclosure describes certain examples of the present invention,
various
modifications to the described examples will also be apparent to those skilled
in the art. The
scope of the claims should not be limited by the examples provided above;
rather, the scope of
the claims should be given the broadest interpretation that is consistent with
the disclosure as
a whole.
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