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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 insure 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 insure 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 insure 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.


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.  


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 US 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.

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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.


Currently designed as 27' above ground with 8' deep continuous foundation.  This concept is easily scaled 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.

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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.
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