Mold system for a modular telescoping barrier and method of construction

A mold system modular telescoping barrier, the system comprising:

• an inner mold subassembly comprising multiple inner panels defined by a pair of lateral edges, an upper edge, and a lower edge, the inner panels joined at the lateral edges, at least one of the pair of lateral edges defined by a recess, the lateral edges further being defined by a tapped hole, or a tapped blind hole, or both;
• at least one inner reinforcing structure abutting the inner panels of the inner mold subassembly, the inner reinforcing structure maintaining the inner mold subassembly in a substantially vertical orientation;
• an outer mold subassembly comprising multiple outer panels defined by a pair of lateral edges, an upper edge, and a lower edge, the outer panels joined at the lateral edges, at least one of the pair of lateral edges defined by a recess, the lateral edges of the outer panels being defined by a tapped hole, or a tapped blind hole, or both,
• the outer mold subassembly disposed to surround the inner mold subassembly in a spaced-apart relationship, whereby a gap forms between the mold subassemblies;
• at least one fastening mechanism operable to pass through the tapped hole and the tapped blind hole;
• at least one outer reinforcing structure abutting the outer panels of the outer mold subassembly, the outer reinforcing structure maintaining the outer mold subassembly in a substantially vertical orientation;
• a platform supporting the inner and outer mold subassemblies, the platform engaging the lower edges of the panels;
• at least one L-bracket fastening the outer reinforcing structure to the platform;
• multiple funnels operable at the top edges of the panels, the funnels comprising a wide receiving end, a sloped sidewall, and a narrow discharge end forming a slot, the discharge end of the funnels comprising a clamp, the clamp operable to press the inner and outer panels towards each other,
• the funnels being operable to pour a mold filling in the gap between the inner and outer mold subassemblies,
• whereby a barrier forms when the mold filling is poured in the gap between the inner and outer mold subassemblies;
• at least one level operable on the outer reinforcing structure, or the platform, or both;
• at least one agitating mechanism operable on the outer reinforcing structure, or in an area surrounded by the inner panels, or both;
• and
• a perimeter element, the perimeter element encasing a portion of perimeter of the outer mold subassembly.

A method of constructing a modular telescoping barrier system, the method comprising:

• providing an inner mold subassembly comprising multiple inner panels;
• providing an outer mold subassembly comprising multiple outer panels, a gap forming between the mold subassemblies;
• interconnecting the lateral edges of the panels, whereby a recess in the panels creates a seamless interconnecting surface;
• fastening the lateral edges of the panels with a fastening mechanism passing through a tapped hole;
• attaching multiple inner and outer reinforcing structures to the panels, the reinforcing structures maintaining the panels in a vertical orientation, the reinforcing structures applying inward pressure to the panels;
• mounting one or more shape-adapted funnel to the top edge of a correspondingly shaped panel, the funnel comprising a pair of clamps pressing the panels inwardly;
• determining evenness of the panels with a level operable on the panels;
• pouring, through the funnels a mold filling into the gap between the mold subassemblies, the mold filling solidifying to form a barrier;
• vibrating, with an agitating mechanism, the panels during pouring to uniformly distribute the mold filling;
• minimizing deformation of the inner panels with the reinforcing structures, and the clamps from the funnel;
• removing the mold subassemblies to access the formed barrier;
• nesting multiple barriers in a telescopic configuration operable between a collapsed position and a deployed position;
• and
• extending the barriers to the deployed position to form a barrier subsystem, the barrier subsystem withstanding inertial and the external forces.