Building an AB Courtyard with Panels and Posts/Pillars Together
Building Panels and Posts on Existing Patios or Pavement
Step 1: Layout
Determine the location of the first post/pillar. Install the Corner Blocks with the long sides facing out, align and level each course. Make adjustments as needed. See How-to sheet #220: Building A Post for more information on building posts/pillars. Continue building the post/pillar to the desired height. Alternate the blocks to offset the seams from the blocks below.
Step 2: Begin Panel
The first and the last block of every course of wall panel between the posts/pillars will be a cut block. Using a cut block allows the panel to be flush with the post/pillar. If a standard angled block shape is used there will be a gap where the panel meets up with the post/pillar. Cut an AB Dublin Block to achieve a quarter (1/4) and three-quarter (3/4) length piece to start the first course. Place the quarter (1/4) piece with the cut side against the center of the post/pillar to start the first course followed by the next full block. Use the three-quarter (3/4) length piece to complete the end of this course where it will meet up with the next post/pillar. We recommend installing the first two courses of the wall panel at the same time to ensure proper alignment.
Step 3: Second Course
On the next course, cut an AB Dublin Block in half (1/2) to start this course. Place one half of this block with the cut side against the post/pillar. Again, save the other half of this piece for the end of this course. To aid in fitting the cut blocks, try flipping them over so the raised rings are down.
Step 4: Build Panel
With the first two courses started, continue building the wall panel in the chosen pattern. Build to the location of the next post/pillar. At the end of each section place the remaining cut blocks (the 3/4 and 1/2 length pieces) on each course that was used to start the course.
Step 5: Additional Posts/Pillars
At the end of the wall panel, install the next post/pillar as previously done. Place the Corner Blocks with the long sides facing out. Install additional courses until the desired height is achieved. Alternate the blocks to offset the seams from the blocks below.
Step 6: Continue Building
With both posts/pillars built, continue stacking the courses of the wall panel to the desired height. Alternate the type of cut block for each course as you go.
Step 7: Finish
Finish the wall with Wall Caps and Post Caps. Secure the Wall Caps in place with a bead of flexible concrete adhesive along both sides of the raised rings and along the side of each Wall Cap. Place a bead of flexible concrete adhesive along the outside edge of the top course of Corner Blocks and then set the Post Caps in place.
Additional Information:
Taller walls will require some added stability. See How-to sheet #150 Building Taller Wall Panels and How-to sheet #140 Building Taller Posts for more helpful construction techniques.
If building your wall panel with posts/pillars, interlock them together for added stability. See How-to sheet #230 Interlocking Walls & Posts.
For more information on Building with Panels and Posts/Pillars, see How-to sheet #190 Building with Panels and Posts/Pillars.
Modifying Blocks
The AB Courtyard Collection blocks come with a built-in angle. By splitting the blocks at a quarter (1/4), half (1/2) or three-quarter (3/4) length, you create a straight side to the block. See the AB Courtyard product page for detailed information as to where the blocks are to be cut or split to fit properly.
The straight side that is created with splitting is needed when meeting up with a flat surface or when building curves within a wall panel. You can modify the blocks using a hammer and chisel when splitting or a saw with a masonry blade when cutting the block. Some of the blocks are produced with pre-marked splitting notches for ease of locating the cut line, but any of the blocks can be modified.
SAFETY FIRST
Always wear safety glasses when modifying a block. A dust mask and ear protection are also recommended when cutting block as well as following OSHA requirements.
Hammer and Chisel
Use a hammer and chisel, tap around the entire block in the same location where the split is needed to create a quarter (1/4), half (1/2) or three-quarter (3/4) length piece. Then strike the chisel with more force in the score line to break the block.
Saw Option
Use a circular saw to score around the entire block in the same location where the cut is needed to create a score line for the quarter (1/4), half (1/2) or three-quarter (3/4) length pieces. Then with a hammer and chisel, tap around the score line until the block splits. A masonry saw or a metal chop saw can also be used to make a complete cut through the block, eliminating the use of the hammer and chisel.
Corner Blocks
First determine where the corner block will need to be cut/split.
Use a circular saw with a masonry blade to score around the entire block and then with a hammer and chisel score around the block until it breaks. This should yield a nice split. You can also:
- Use a masonry saw with a dry cutting diamond blade. This method makes a complete cut and eliminates the need for a hammer and chisel.
- Use a metal chop saw with a dry cutting diamond blade to cut the block.
For more information on cutting and splitting block, see How-to sheet #210.
NOTE: Masonry saws and metal chop saws are available for rental at most retail centers.
Interlocking Walls and Posts/Pillars
To make strong connections between your patio wall panel and the post/pillar, you can extend the top course of wall panel into the post/pillar to interlock them together. If building a wall panel 5 courses high and taller, we recommend interlocking it into the post/pillar to help stabilize the wall.
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Install Guide
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How-To Sheet #230
Step 1: Build Wall Panel and Post/Pillar
Build the wall panel and the post/pillar to the desired height where they will be interlocked together. We recommend that this occurs within the top 1/3 of the wall to help with stability. See How-to sheet #190: Building Walls and Posts for information.
Step 2: Interlock
On the course to be interlocked, place a Corner Block half on the wall panel and half on the post/pillar. Slide the Corner Block so it meets up with the first raised ring on the wall panel block on the course below.
Step 3: Post/Pillar
Place three more Corner Blocks to build the post/pillar. The last Corner Block will need to be cut to fit. Measure and cut the Corner Block to fit the space. See How-to sheet #210: Cutting Corner Blocks for more information.
Step 4: Adhesive
Remove the interlocking course of blocks and secure with flexible concrete adhesive. Place a bead of adhesive along the outside edge of the Corner Blocks and along the raised ring of the wall panel block where the Corner Block interlocks the wall and post/pillar together. Now replace the blocks and finish the wall panel section for the course.
Step 5: Continue Building Courses
On the top of the interlocking course, again place a bead of flexible concrete adhesive along the outside edge of the Corner Blocks and on top of the Corner Block that interlocks them together. Finish building the post/pillar and wall panel to the desired height as done previously.
Step 6: Finish
Finish the wall with Wall and Post Caps. Secure the Wall Caps in place with a bead of flexible concrete adhesive along both sides of the raised rings and along the side of each Wall Cap. For the Post Caps, place a bead of flexible concrete adhesive along the outside edge of the top course of Corner Blocks and then set the Post Caps in place.
Video: How to Interlock Patio Walls & Posts
Build wall & post to desired height. Interlock will be built on 2nd to last course.
Place corner block to begin the interlock
Finish post with corner blocks. The last corner block will need to be cut to fit.
Glue interlocking course then place last course of post blocks