It's not necessary to be an experienced builder to climb rocks. In fact, many climbers have never rolled out a set of building plans. But it is necessary to understand both construction systems and rock climbing if you plan to build a climbing wall. Basic considerations are the size and configuration of the wall, the construction system and the climbing holds.
Design
A climbing wall should suit your purposes by affording a complete workout. Plan on the height of the wall to be no less than 16 feet and the width about 12 feet. Your design might consist of a single vertical wall or a four-sided structure that includes an overhanging face. Make a fully dimensioned plan for a permanent structure that's supported in concrete footings. A single wall is supported in footings or with diagonal braces in concrete footings.
Materials and Hardware
Steel pipe uprights for a single wall or a structure offer the best resistance against wet weather. Depending on your mechanical experience and available equipment, you can elect to construct the framework for the face of the wall using steel pipe and welded connections. Another option is treated timbers, such as 6-by-6-inch Douglas fir in concrete footings as uprights. You can assemble a wooden framework made from 2-by-6-inch treated lumber that you attach to the uprights using carriage bolts. With either system, the uprights must be long enough to accomplish the height of your design and extend 36 inches into concrete footings. The wall faces consist of 3/4-inch exterior grade plywood that you attach to the framework with construction adhesive and stainless steel wood screws or full-length bolts. Make a list of the materials and hardware that includes concrete for the footings.
Construction
Refer to the dimensions on your design and lay out the locations for uprights using wood stakes. Dig 36-inch-deep footings that are a minimum of 16 inches in diameter. Rental yards carry gasoline-powered augers that make digging relatively easy. Stand the uprights in the footings and mix the concrete to medium consistency. Pour the footing and plumb the uprights with a long level. Allow the concrete to cure for 48 hours before assembling the framework. Use sawhorses with 2-inch-thick planks or a portable scaffold to build the frame and install the plywood on the faces. Apply construction adhesive on the face of the frame and attach the plywood using a power drill to drive wood screws. Drill pilot holes for bolted attachments. Use full-size pieces of plywood to cover the majority of the frame and cut filler pieces with a circular saw.
Holds
Once the walls are constructed, lay out locations for the climbing holds. You can work from patterns that you find on climbing wall websites or create a layout that suits your purposes. You have the option of purchasing manufactured holds or making your own using sand-cast concrete. Plastic buckets or tubs are filled with clean sand and you create the castings by pressing your fist or rocks into the sand. Embed long machine bolts into each casting and mix the concrete to medium consistency. Drill the faces of the walls at your layout marks and attach the holds using lock washers and nuts on the backside of the plywood at each bolt.
Maintenance
Wood should be protected with several coats of all-weather sealer that you apply with brushes, rollers or a paint sprayer. Sealing treated lumber is recommended. Depending on personal preferences, you can paint the walls to resemble a rocky face or any color of choice. It's a good idea to cover the wall with weather-resistant tarps when it's not in use. Consider installing pulleys and nylon cords to hoist the tarps to the top of the wall and use a pole with a blunt aluminum hook to maneuver the tarps over the face. Secure the bottom edges of the tarps with nylon cord that ties to hooks on the sides of the uprights.
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