Concrete Building Systems , Global Technology Building Systems, Waffle-Crete inventor

 BORDER WALLS

   CONCRETE PANEL PRODUCTION
  
   Molds are built on lowboy trailer frames for portable bases with aluminum extrusions for beams running
   perpendicular to the trailer frame. The complex waffled and slotted mold bodies are large Thermoformed
   plastic supported and framed by custom aluminum extrusions. These molds on wheels can be readily
   moved along the wall and grouped as needed for remote casting operations near the wall, reducing
   shipping costs. Sand and Gravel can be sourced near the wall, in most cases. Mass production of the
   mold bodies facilitates rapid deployment of the forming system to the sites. Molds are Pressure washed
   each day after panels are removed from the forms, to ensure clean molds each day.

   Outriggers on each trailer provide for leveling each form before casting of concrete into the molds.
   Heavy duty electric vibrator motors mounted on the trailer frames consolidate the self leveling concrete
   to ensure void free panels and the self leveling and vibration process eliminates the need for screeding
   and finishing the top surface. Tops of panels are relatively smooth and flat and as soon as initial set is
   achieved, the insulated curing cover blankets are rolled out over the forms to ensure over night curing
   so the molds can be reused daily without the use of external heat for rapid curing.

   Panels are removed each morning from the molds and
   either stacked near the wall for erection or placed on
   flatbed trailers for hauling short distances to the erection
   areas.  Heavy duty electric vibrator motors mounted on
   the trailer frames can also be use to help facilitate panel
   removal from the forms.

   EXCAVATION OF FOOTING/FOUNDATION

   As panels are being cast for the walls,
   large pipeline type trenching excavators
   crawl along the wall line which has been
   surveyed earlier. Digging continuous trench
   footings of approx. 3’ wide x 8.5’ deep, the
   excavated dirt is conveyed onto dump
   trucks for hauling a short distance away.

   ERECTION OF THE WALL

   Precast shim pads for each panel joint have been cast
   using excess concrete from the panel casting. These
   precast pads are roughly 30" sq. x 18" high and are
   accurately prepositioned with survey instruments along
   the trench so that center of each pad is the joint
   between two adjacent wall panels, and the height is
   pre-adjusted to provide level pads for panels to set on.
   Slots, or troughs, in the top of each leveling pad serve 
   as alignment for the panels to keep them in a straight
   line. Panels are also stair-stepped for hills and slopes.
   Panels are erected on the leveling pads and braced back
   to temporary dead man anchors on the USA side of the
   wall. Each panel is plumbed (leveled) perfectly vertical
   with adjusting screws on the braces.  Nearly all work
   can be accomplished on the USA side of the wall. Simple
   bolted connection at the top corners of each panel are
   connected as each panel is aligned with the last panel,
   using galvanized bolt hardware.

   POURING THE FOOTING/FOUNDATION

   Pouring of the foundation/footing follows some distance
   behind the erection crew and uses self-leveling flowable
   concrete poured into one side of the trench, flowing
   under and through the precast wall panels (between the
   Precast shim pads) and filling both sides. Within a day or
   two the foundation concrete will have cured adequately
   so that the braces can be removed and the walls are
   freestanding. Braces and dead man anchors are now
   free to be moved ahead for use as the wall progresses.

            

          "SMART" BORDER WALL SYSTEM

        Currently designed as 27' above ground with 8' deep
        continuous foundation.  This concept is easilyscaled
        up or down to the size required/specified.
        The “Smart” Border Wall system also includes
        optional integrated Solar Powered detection and
        motion activated cameras for tunneling or breaching
        attempts, as needed or as called for.

BENEFITS
Patent Number: US 10,683,656 B1 and Other Patents Pending

Practical and proven lower cost system for the border wall.
Very efficient use of materials and labor.
Relatively low cost molds to set up portable production and move production as wall construction progresses on lowboy drop-deck trailer mounted molds.
Overnight curing without external heat for daily production and mold reuse.
Remote production readily set up at convenient sites along the wall - less shipping costs.
Ventilated design of the wall is much more attractive and friendly "fencing" than solid walls.
Aesthetically pleasing "Picket Fence" design allows sunshine, sight, water, and air through.
Vents reduce wind load on the wall and therefore less steel rebar and concrete in the wall and foundation.
Vents allow sand in desert areas to blow through the wall instead of piling up and needing removal.
Vents allow border agents to see what is happening on the other side.
Vents allow small animals and reptiles more ability to pass thru the wall so less environmental concerns.
Option of solid areas or no vents at lower levels where needed for special conditions.

Custom designed foundation system easily adjustable for various soil conditions.
Adjustable height and width of wall panels as needed, for special conditions.
Scalable wall can be made taller, if needed.
3' wide trench foundation is efficient and disturbs less land - less rights of way and less environmental concern.
Space between panel bottom and bottom of trench (18") allows flow-able self leveling concrete foundation.
Most all the work, including poured foundation, can be done on US side of the wall.
Waffle shaped panel, in the foundation zone, allows for good load transfer from the precast wall to the foundation concrete fill, so wall and foundation are locked together.
Proven technology over the last 40 years has been demonstrated all over the globe for security walls, sound barrier walls, fences, affordable housing, water tanks, etc.
Maintenance-free for a lifetime with high quality, high strength precast concrete.
"Smart" Border Wall system also includes optional integrated Solar Powered detection and motion activated cameras for tunneling or breaching attempts, as needed or as called for.