U.S. patent application number 11/117077 was filed with the patent office on 2005-11-17 for veneers for walls, retaining walls and the like.
Invention is credited to Dawson, William B., MacDonald, Robert A..
Application Number | 20050252144 11/117077 |
Document ID | / |
Family ID | 34967711 |
Filed Date | 2005-11-17 |
United States Patent
Application |
20050252144 |
Kind Code |
A1 |
MacDonald, Robert A. ; et
al. |
November 17, 2005 |
Veneers for walls, retaining walls and the like
Abstract
A veneer panel system is used with a wall or a retaining wall to
provide a natural stone appearance and/or to improve the appearance
of an existing wall. Panels can be interlocked to form a stable
veneer structure. The structure is attached to a wall by various
attachment means.
Inventors: |
MacDonald, Robert A.;
(Plymouth, MN) ; Dawson, William B.; (Medina,
MN) |
Correspondence
Address: |
POPOVICH, WILES & O'CONNELL, PA
650 THIRD AVENUE SOUTH
SUITE 600
MINNEAPOLIS
MN
55402
US
|
Family ID: |
34967711 |
Appl. No.: |
11/117077 |
Filed: |
April 28, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60566616 |
Apr 29, 2004 |
|
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Current U.S.
Class: |
52/598 ; 405/284;
52/600; 52/745.05; 52/800.1 |
Current CPC
Class: |
B29C 67/243 20130101;
E02D 29/0225 20130101; E04F 13/148 20130101; E02D 29/0266 20130101;
E02D 29/02 20130101; E04F 13/0808 20130101; E02D 29/0241 20130101;
E04F 13/0873 20130101; E04F 13/185 20130101; E04F 13/123
20130101 |
Class at
Publication: |
052/598 ;
052/600; 052/800.1; 052/745.05; 405/284 |
International
Class: |
E02D 005/00 |
Claims
What is claimed is:
1. A wall system comprising: wall components for constructing a
retaining wall; a plurality of rectangular panels, each panel
having a front surface and an opposed back surface defining a panel
thickness, a set of opposed top and bottom edges and a set of
opposed first and second side edges, the front surface comprising a
mineral aggregate embedded in a resin; and means for connecting the
plurality of panels to the retaining wall formed from the wall
components.
2. The wall system of claim 1, wherein the wall components are
selected from natural stone, poured concrete, precast panels,
masonry, landscape timbers, railroad ties, wall blocks, and
combinations thereof.
3. The wall system of claim 1, wherein the wall components are wall
blocks.
4. The wall system of claim 1, wherein the mineral aggregate is
natural stone aggregate.
5. The wall system of claim 1, wherein the resin contains
fiberglass.
6. The wall system of claim 1, wherein the means for connecting the
plurality of panels to the retaining wall are selected from screws
and bolts, hooks, brackets, connection joints, connection channels,
and combinations thereof.
7. The wall system of claim 1, wherein each set of opposed panel
edges has mating tongue and groove attachments, respectively, so
that a respective tongue attachment and groove attachment of
adjacent panels connect the adjacent panels.
8. The wall system of claim 1, wherein the means for connecting the
plurality of panels to the retaining wall is molded into the back
surface of the panel.
9. The wall system of claim 1, wherein the means for connecting the
plurality of panels to the retaining wall include a first
interlocking component on the wall that mates with a second
interlocking component molded into the back surface of the
panel.
10. The wall system of claim 1, wherein the first interlocking
component is a rail.
11. The wall system of claim 10, wherein second interlocking
component is a bracket that attaches to the rail.
12. The wall system of claim 11, wherein the rail is a longitudinal
body with a T-shaped cross-section.
13. The wall system of claim 12, wherein the longitudinal body has
slots to which the bracket attaches.
14. The wall system of claim 13, wherein the bracket has a channel
that matingly fits over the T-shaped cross-section.
15. The wall system of claim 10, wherein the rail has a hanging
bracket formed thereon and the second interlocking component has a
hanging element molded to an edge of a panel.
16. A method of making a retaining wall including a plurality of
wall blocks and geogrid comprising: stacking wall blocks in one or
more courses to form a first portion of the retaining wall, the
first portion having a front wall surface and an upper course of
blocks which forms an upper surface of the first portion; placing
the geogrid over the first portion of the retaining wall such that
a first section of the geogrid extends behind the retaining wall
and a second section of the geogrid extends in front of the
retaining wall; stacking wall blocks in one or more additional
courses over the first portion of the retaining wall to form a
second portion of the retaining wall, the geogrid extending between
the upper surface of the first portion and a lower surface of the
second portion of the retaining wall, the second wall portion
having a front wall surface and an upper course of blocks which
forms an upper surface of the second portion; folding the geogrid
back over the front and upper surfaces of the second portion so
that the second section of the geogrid extends behind the retaining
wall; and stacking wall blocks in one or more additional courses
over the second portion of the retaining wall to form a third
portion of the retaining wall, the geogrid extending between the
upper surface of the second portion and a lower surface of the
third portion of the retaining wall, the third wall portion having
a front wall surface and an upper course of blocks which forms an
upper surface of the third portion.
17. The method of claim 16 further comprising: providing a
plurality of panels; and connecting the panels to the front surface
of the retaining wall.
18. The method of claim 17, wherein the panels are formed of a
mineral aggregate in fiberglass.
19. The method of claim 17, wherein one of adjacent first and
second panels have tongue attachment means and another of adjacent
first and second panels have mating tongue and groove attachment
means, respectively.
20. The method of claim 19, wherein the tongue and groove
attachment means are on opposing panel sides of adjacent first and
second panels, respectively.
21. The method of claim 20, including interconnecting a tongue
attachment means on a first panel with a groove attachment means on
a second panel.
22. The method of claim 16, including placing a protective layer
between the geogrid and an adjacent block.
Description
[0001] This application claims the benefit of provisional
application Ser. No. 60/566,616, filed Apr. 29, 2004, the contents
of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to walls and retaining walls and in
particular relates to a veneer panel system to form a decorative
and protective face for such walls either during construction of
the wall or after the wall has already been installed.
BACKGROUND OF THE INVENTION
[0003] Retaining walls are used in various landscaping projects and
are available in a wide variety of styles. Numerous methods and
materials exist for the construction of retaining walls. Such
methods include the use of natural stone, poured concrete, precast
panels, masonry, and landscape timbers or railroad ties.
[0004] A widely accepted method of construction of such walls is to
dry stack concrete wall units, or blocks. These blocks are popular
because they are mass produced and, consequently, relatively
inexpensive. They are structurally sound, easy and relatively
inexpensive to install. Because they comprise concrete, they are
durable. They can be given a desired appearance, such as, for
example, natural stone. Many block systems also use pins that are
adapted to fit in corresponding pin holes in adjacent blocks or may
use other mechanical means to contribute to the stability of a
wall.
[0005] Typically, retaining wall blocks are manufactured to have
the desired appearance on the front face (i.e., the outer face of a
wall) because only the front is visible after the wall is
constructed. It is highly desirable to have the front face of the
wall system have a natural stone appearance, and many approaches
are used in the art to treat or process concrete to evoke the
appearance of natural stone, including splitting the block,
tumbling the block to weather the face and edges of the face, and
using processing or texturing equipment to impart a weathered look
to the concrete.
[0006] Depending upon their location, the soil type, the amount of
water that can flow through the wall, and the mineral content of
the water, an undesirable appearance can develop on the surface of
a retaining wall. In addition, due to exposure to the elements and
freeze/thaw cycles, concrete retaining walls may exhibit spalling,
that is, chipping and cracking of concrete, which affects their
appearance and can ultimately affect their utility. Freeze-thaw
effects are worsened when the wall face is exposed to salt spray,
which commonly occurs on roadways where de-icing salts are used to
clear the road of ice and snow. Efflorescence refers to the
leaching of mineral salts from water and this often occurs on walls
in contact with water. The resultant deposit on a surface creates
an unattractive white stained appearance on a wall.
[0007] There have been prior efforts to veneer segmental retaining
walls with natural stone or concrete that is molded to closely
resemble natural stone. While such veneering produces aesthetically
pleasing walls, it is a laborious and highly expensive process, as
it requires skilled masonry work to tie in the stone or concrete
veneer to the wall using traditional mortared masonry construction
methods. Such veneering can double the cost of the finished wall.
In addition, segmental retaining walls are not rigid structures and
applying a rigid mortared veneer may cause cracking unless
appropriate steps are taken to provide slip joints.
[0008] Accordingly, it would be desirable to provide a retaining
wall system that would be easy to install, that would possess an
appearance that closely resembles natural stone and that would keep
its desirable appearance indefinitely. Another need in the art is a
way to improve the appearance of surface-damaged or stained
retaining walls.
[0009] Many retaining wall systems described in the art include the
use of reinforcing materials, also referred to as geogrids,
geosynthetic reinforcement, or geogrid soil reinforcement. These
terms sometimes are used interchangeably, and "geogrid" as used
herein is intended as a generic term. Reinforcement materials may
be inextensible, such as steel mesh, or extensible geosynthetic
materials, such as mats and oriented polymeric materials. For
example, flat polymeric sheets are used to form geogrids by forming
holes in the sheets and then drawing them to orient the polymer and
increase the modulus. Such polymeric materials include high density
polyethylene (HDPE) and these materials form relatively stiff
geogrids commercially available under the trade designation
"TENSAR".
[0010] While the HDPE materials are relatively stiff, a second type
of geosynthetic material is composed of a mat typically formed from
polyester fibers that are woven or knitted. These may comprise
rectilinear polymer constructions characterized by large (e.g., 1
inch (2.5 cm) or greater) openings. In these open structure
geogrids, polymeric strands are woven, knitted or "welded" (by
means of adhesives and/or heat) together in a grid. Polymers used
for making relatively flexible geogrids include polyester fibers.
The polyester typically is coated, commonly using a polyvinyl
chloride (PVC) or a latex topcoat. The coating may contain carbon
black for ultraviolet (UV) stabilization. Some open structure
geogrids comprise polyester yarn for the warp fibers and
polypropylene as the fill fibers.
[0011] Another flexible reinforcing geosynthetic material is
fabric, i.e., woven or non-woven constructions without large
openings. These fabrics typically comprise polymers and may be
referred to as geofabrics. The geofabric can be laid between
courses of blocks in a wall, and typically is tied into the wall
and held there. When blocks are configured to have pin connectors,
for example, a hole or slit is formed in the geofabric at the
construction site and the geofabric is held on the blocks by
fitting it over the pins.
[0012] In common use, the geogrid extends behind the retaining wall
and ties into the earth behind the wall, thus creating a cohesive
soil mass tied into the wall facing that resists overturning.
Geogrids are either mechanically connected to a course of blocks or
rely on the friction created by placing the geogrids layer between
courses of blocks. When the mode of connection is friction alone,
the geogrid is placed on top of a course of blocks, and then a
succeeding layer of blocks is placed on top of the geogrid. When
the connection is mechanical, after placement of a course of blocks
to the desired height, geogrid is placed onto a course of blocks
and held in place by means of pins in the block (which may have a
primary function of aligning and holding blocks together) or by
means of special connectors. Flexible geogrid is put under tension
by pulling back and staking the geogrid behind the retaining wall.
Backfill is placed and compacted over the geogrid. Construction of
the wall continues and may include additional layers of
geogrid.
[0013] Such systems have proven reliable in many wall applications.
There are limits to their performance however, particularly at the
upper portions of the wall, where the load of the blocks above the
geogrids layer do not provide as much load on the connection, so
that frictional forces are reduced. The use of frictional
connections forces the wall designer and builder to use more and
higher strength geogrids because connection strength limits the
strength of the system, and this adds expense to the wall.
Mechanical connectors attempt to overcome this limitation by
mechanically connecting the geogrids to the wall facing in a way
that is not load dependent. The difficulty with this approach is
that in order for such connectors to provide high levels of
efficient connection they must add considerable expense to cost of
using the geogrids reinforcement, and add complexity and expense to
the installation process. Thus there are shortcomings to both
approaches.
[0014] There are also many wall applications in seismic zones where
providing an extra measure of protection against loss of connection
between the wall facing and the reinforcing geogrids during a
seismic event would be highly desirable. Thus there is a need for a
geogrid connection system that is not load dependent, that does not
add significant expense to the construction of the wall, and that
is highly reliable and resistant to failure during seismic
conditions.
SUMMARY OF THE INVENTION
[0015] We have invented a veneer panel system that can be used with
a wall or a retaining wall to provide a variety of desired
appearances, including an appearance that closely resembles a
variety of natural stone types and to improve the appearance of the
front face of an existing wall. Individual panels form a veneer for
the wall; the panels preferably are interlocked to form a stable
veneer structure. This structure is attached to a wall by various
attachment means. This system also permits a cost effective maximum
positive connection of geogrid with blocks or units comprising the
retaining wall while providing the desired appearance.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0016] FIG. 1A is a front view of a panel of this invention and
FIG. 1B is a back view of a panel of this invention.
[0017] FIG. 2A is a side view of a panel of this invention with
tongue and groove connectors and FIG. 2B is a partial side view of
two panels showing the detail of the tongue and groove
connection.
[0018] FIG. 3A is a front view of a portion of a veneer panel
system having a running bond pattern and FIG. 3B is a view of a
portion of a veneer panel system having a stacked bond pattern.
[0019] FIG. 4 is a front view of a portion of a veneer panel system
wherein panels have various patterns.
[0020] FIG. 5A is a top view of an adaptor of this invention; FIG.
5B is a top view of the adaptor interlocked with a rail; and FIG.
5C is a partial perspective view of a rail and its attachment.
[0021] FIG. 6A is a side view of a hanging bracket, FIG. 6B is a
side view of hanging element, and FIG. 6C is a perspective view of
a panel hung from a rail.
[0022] FIG. 7A is a partial perspective view of a rail attached to
a wall and FIG. 7B is a partial perspective view showing the
bracket attachment to a wall.
[0023] FIG. 8A is a perspective view of a rail showing attachment
by an L-bracket and FIG. 8B is a top view of a portion of a wall
having a rail attached by an L-bracket.
[0024] FIG. 9 is a sectional view of a retaining wall block system
showing the placement of one layer of geogrid.
[0025] FIG. 10 is a sectional view of a retaining wall block system
with geogrid wrapped around three courses of blocks.
[0026] FIG. 11 is a sectional view of a completed retaining wall
having two geogrid wraps.
[0027] FIG. 12 is a partial perspective view of a veneer panel
system of this invention with one geogrid wrap.
[0028] FIG. 13A is a sectional view of a wire basket retaining wall
with geogrid and FIG. 13B is a perspective view of a wire
basket.
[0029] FIG. 14 is a partial sectional view of a retaining wall with
a veneer panel system of this invention with multiple geogrid
wraps.
[0030] FIG. 15 is a perspective view of a building wall with the
veneer panel system of this invention.
[0031] FIG. 16A is a perspective view of a rail showing attachment
by an angle bracket and FIG. 16B is a top view of a portion of a
wall having a rail attached by an angle bracket.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] In this application, wall refers to structures comprising
natural stone, poured concrete, precast panels, masonry, landscape
timbers or railroad ties, and retaining wall blocks. Panels having
a desired appearance are used as a veneer by attaching the panels
to the exposed surfaces of a wall.
[0033] In a preferred embodiment, the panels of this invention are
used with retaining walls, and in a most preferred embodiment, the
retaining walls comprise blocks. The blocks are made of a rugged,
weather resistant material, preferably (and typically) zero-slump
molded concrete. Other suitable materials include plastic,
reinforced fibers, wood, metal and stone. The blocks may have
various shapes and characteristics, as known in the art, and may be
stacked one upon the other to provide a straight wall, and also may
be stacked so that they are angled from vertical. As known in the
art, the blocks may be connected to each other by a pin attachment
system, or the blocks may be provided with one or more protruding
elements that interlock with one or more corresponding recesses in
an adjacent block.
[0034] "Upper" and "lower" refer to the placement of the block in a
retaining wall. The lower, or bottom, surface is placed such that
it faces the ground. In a retaining wall, one row of blocks is laid
down, forming a course. An upper course is formed on top of this
lower course by positioning the lower surface of one block on the
upper surface of another block.
[0035] Retaining walls may be straight (i.e., substantially linear,
as well as vertically straight), curved (serpentine) or may have
sharp corners (i.e., 90 degree angles). Such walls can be angled
from vertical. In this invention, reinforcing geogrid tie-backs or
geosynthetic fabrics (also referred to generally as geogrids and
geotextiles) may be used with retaining wall blocks. Regardless of
the type of retaining wall, the veneer panel system should be easy
to install, structurally sound, and meet or exceed all ASTM, IBC,
and AASHTO requirements for retaining wall structures.
[0036] The veneer of this invention preferably comprises a mineral
aggregate in fiberglass. This material is produced by mixing stone
particles, sand, or mineral with resin, pouring this into a mold.
Typically, particles of the type of stone that the panel is meant
to resemble are used in the resin mixture, and these particles
provide the color for the panel. For example, if the panel is
intended to resemble natural granite, then granite particles are
used in the mix. If limestone is the desired look, then fine
particles of limestone may be used. Various powdered pigments may
be added to the mix in order to create different colors or shades
of color. The mold is configured to impart a surface texture to the
material that resembles the texture of natural stone. After the
mineral resin mix is added and spread across the mold, a mixture of
glass fibers and resin is added into the mold. At this stage,
structural components used to attach the panels to the surface that
is being veneered may be added. Such components may be formed of
pultruded fiberglass, and may be attached to the panel during the
curing process in order to create a bond between the fiberglass
panel and the structural component. After the resin has cured, the
front surface of the panel preferably is sandblasted to remove
resin from the surface, thus revealing a naturally-appearing
mineral or stone surface. Alternatively, the front surface may by
polished in order to produce a polished stone look.
[0037] It is to be emphasized that the surface of a panel may have
any desired appearance. A natural appearance, such as stone, is
generally most desirable. The panel may have a uniform appearance
or it may have an ashlar pattern formed into it. The panels may
also resemble stone that has been processed or treated as is
commonly known in the natural stone industry. For example, the
panel may resemble a weathered stone, polished stone, or flame
treated stone. In addition, the mold may be configured to produce
panels that resemble stone that has been hand or machine pitched or
tumbled to produce an aesthetically pleasing natural quarried stone
appearance.
[0038] The panels are produced in dimensions that are convenient to
manufacture and handle. The panels may be planar but preferably
have a slight curve molded at the edges so as to be used with
various connecting elements, as described further below. Convenient
panel sizes are about 8.times.18 inches (20.5 cm.times.45.7 cm),
16.times.48 inches (40.6.times.121.9 cm), and 32.times.48 inches
(81.3.times.121.9 cm). The dimensions of the panel may vary from
these stated dimensions in order to meet aesthetic or functional
requirements of particular applications. These panels are
relatively light in weight when compared to panels of granite. For
example, a granite panel may weigh 400 to 500% more than a
similarly sized panel of the present invention.
[0039] The back of the panel is provided with an attachment means
so that the panel can be affixed to a wall. The resin/fiberglass
composition of the panels allows a desired attachment means to be
molded into the panel when it is formed, attached by adhesive, or
attached by mechanical means such as screws and bolts. Attachment
means include hooks, brackets, connection joints, connection
channels, and the like. Preferred attachment mechanisms are
described further below.
[0040] To create a veneer panel, several panels are installed next
to each other over a wall. In a preferred embodiment, the panels
are provided with tongue and groove attachment means so that two
adjacent panels can be connected to each other. Preferably, each
panel has two adjacent sides with a groove adapted to receive a
tongue from corresponding sides of adjacent panels. Preferably, the
attachment means provide a joint that discourages or minimizes
penetration of water from rain or roadway spray. To attach a panel
to the wall, a bracket, hook, connection joint or channel is molded
into the back of the panel when it is manufactured. This then can
be used to attach the panel to the wall by means of screws, bolts,
pins, wire, nylon connectors or strapping or railings.
Alternatively, and preferably, an interlocking element is molded
onto the back of a panel when it is manufactured. This interlocking
element mates with a corresponding interlocking element on the
wall. The attachment means for the veneer panel preferably provides
for flexibility when positioning the panels a distance from the
wall. Because of irregularities in the underlying wall surface, it
may be necessary or desirable to position the panels at various
distances from a wall, and to allow for lateral positioning of the
attachment means to accommodate curvature in the wall.
[0041] The panel of this invention is impervious to water and salt
spray, is resistant to freeze-thaw degradation and UV degradation,
and is relatively light in weight. As a result of these properties,
the panel of this invention provides not only greater beauty, but
enhances the durability of the underlying wall structure, since
most concrete products become more vulnerable to freeze-thaw
deterioration when salt water and freezing conditions are both
present. After a panel wall has been installed, individual panels
can be replaced if desired, which is a cost advantage if a portion
of the surface of a wall has been damaged. The panels also are
formed of a material that discourages graffiti since it has an
irregular surface, and from which graffiti may be removed more
readily since it does not absorb spray paint as readily as
concrete. Use of the panels conceals any aesthetic problems with
the wall, such as staining from red clay soils or from
efflorescence.
[0042] The panels are useful when a wall is constructed from
retaining wall blocks when it is desired to use a geogrid and to
produce a simple, cost-effective and highly efficient connection
between the geogrid and the wall. That is, because the wall surface
will be concealed by the panels, the geogrid can be wrapped around
the blocks, extending behind the blocks into the earth behind the
wall. Thus the geogrid is in contact between the entire surfaces of
adjacent blocks, as shown in FIGS. 9 to 12. Preferably, fabric is
placed where the geogrid exits and re-enters the front face of the
blocks to eliminate abrasion of the geogrid by the edges of the
concrete block. Any cost-effective and suitably durable fabric of
sheet material may be used for this purpose, including woven or
non-woven polyester fabric, vinyl sheeting, or plastic sheeting.
The connection system may use a variety of geogrids or geofabrics
for soil reinforcement.
[0043] Installation of the geogrid reinforcement of the present
invention is accomplished by laying out the geogrid at the desired
height on top of the course of block, but extra geogrid is provided
at the face of the wall in a sufficient quantity that after
succeeding courses of block are placed and backfilled, the geogrid
may be pulled up over the succeeding courses and then laid back
into the reinforced zone. The number of succeeding courses between
geogrid layers is a function of products and the design principles
used, but spacing of two or three courses is common. A protective
fabric or sheet is placed between the geogrid and the block above
and below the geogrid in order to protect the geogrid from
abrasion. The geogrid may be placed in uniform lengths, or may be
in different lengths if the wall design calls for the use of
intermediate reinforcing using shorter reinforcement lengths
between longer lengths.
[0044] As a result of the present invention, the geogrid completely
encloses the blocks. This provides a highly efficient connection
system that adds minimal cost to the wall structure when compared
to existing solutions. It provides greater structural integrity to
the finished wall, which is highly desirable in critical
applications, and certainly in seismic zones.
[0045] Turning now to the Figures, the veneer panel system of this
invention is shown and described.
[0046] FIGS. 1 and 2 illustrate a preferred embodiment of the panel
of this invention, in which the panels are provided with
interlocking tongue and groove elements. The tongue and groove
elements are shown extending the full length of the side to which
they are attached, however, it is to be understood that the tongue
and groove elements could extend over only a portion of the side of
a panel. The tongue and groove elements, as well as adaptors 50,
are molded into the back of the panels during manufacture by
setting the elements into resin before it is cured. FIGS. 1A and 1B
show panel 10a having curvilinear edges with tongues 11 and 12
along two adjacent sides and grooves 13 and 14 (shown in phantom)
along the other two sides. FIG. 2A shows tongue element 11 and
groove element 13 on the back of one panel and FIG. 2B shows how
two of the panels are connected together by these elements.
[0047] FIG. 3A shows veneer panel system 20a wherein panels 10a are
arranged in a running bond pattern over the surface of a wall. FIG.
3B shows veneer panel system 20b wherein panels 10a are stacked.
FIG. 4 shows another veneer panel system 30 wherein some panels
(10b) have an ashlar appearance. The attachment means, shown in
phantom, comprises adaptors 50 molded onto the backs of the panels
and rails 100 attached to the wall by means of brackets. For
simplicity, not all attachment means are shown.
[0048] FIGS. 5A to 5C illustrate how the panel system is attached
to a wall. Rail 100 has a T-shape with body portion 101 and
T-section 102. Adaptor 50 with channel 52 fits over T-section 102
on rail 100. Body portion 101 attaches to wall W by means of a
connector, such as a bracket, though the body portion can be
attached by any suitable means. Rail 100 has one or more slots or
holes 103 to which bracket 110 is attached and held secure through
eyelet 112 by means of nut 120 and bolt 122. Preferably, the
distance of the rail from the wall can be varied. This permits an
installer to produce an even or straight appearance for a wall
which otherwise would have an irregular surface appearance, as
happens occasionally in older walls that have experienced settling.
The preferred way to adjust this distance from the wall is provided
by screw threads 115 on segment 114 of the bracket 110, on which
eyelet 112 is adjustably mounted. Thus eyelet 112 can be positioned
a desired distance away from the wall. Segment 116 is perpendicular
to segment 114 and extends into the wall.
[0049] FIGS. 6A to 6C illustrate that rail 100 with T-section 102
can be used with another style of bracket. Hanging bracket 130 is
formed onto rail 100 and is designed so that it interlocks with
hanging element 140 molded to the top edge of panel 10c.
[0050] FIG. 7A shows a portion of a retaining block wall comprising
retaining wall blocks such as those described in commonly assigned,
co-pending application U.S. Ser. No. 10/754,454, filed Jan. 9,
2004, hereby incorporated herein by reference. Blocks 70 are
provided with channel 72 so that bracket 110 can fit between
blocks. Rail 100 is provided with one or more slots 103, which are
sufficiently long to provide considerable flexibility in the
vertical placement of the rail relative to the wall. Wire 105 feeds
through eyelet 112 of bracket 110 (near the top of FIG. 7A). Bolt
120 and nut 122 attach the bracket to the rail (near the bottom of
FIG. 7A).
[0051] FIG. 7B illustrates further how segment 114 (shown partially
in phantom) of bracket 110 fits between the blocks in channel 72.
Segment 116 of the bracket extends into a cavity or core (such as
core 74) of the block, thus being positioned next to the block and
held securely.
[0052] FIGS. 8A and 8B illustrate that an L-shaped bracket suitable
to attach a rail to masonry wall W. Rail 100 is provided with one
or more slots 103 (two slots are shown in FIG. 8A). L-angle bracket
160 has two sections 161 and 162 provided with a bore through which
can be threaded bolts. Bolt 165 is held secure through section 162
by nut 166 and washer 167. A second bolt 169 threads through the
bore in section 161, thus bolting the rail into the wall. A panel
can then be attached to the rail as described above.
[0053] FIG. 9 shows an exploded side view of three of blocks 80
that use a pin attachment system. Pin 85 has straight portion or
shank 86 that fits into a pin hole (shown in phantom) and head 87
that extends above the surface of the block and into a recess in
the block above. In this way, the pins stabilize the wall.
[0054] Similar blocks are used to form three courses of blocks,
slightly set back from one another. FIG. 9 illustrates the
construction of retaining wall 200 wherein blocks 80 are laid onto
a base leveling pad 202. The bottom block is placed below grade.
Behind the blocks is placed drainage rock. When using retaining
wall blocks with geogrid 250, a concern is that the edges of the
blocks can abrade the geogrid. To prevent this, the edge of a
course of blocks is provided with shield 220 to protect the geogrid
from abrasion. Shield 220 comprises any suitable abrasion resistant
material, such as vinyl, aluminum, steel, and the like, and is
shaped to fit over the edge of course of blocks. Geogrid 250 is
laid over the drainage rock and over the top (i.e., third) course
of blocks.
[0055] Then, as shown in FIG. 10, three more courses of blocks are
laid down. Soil is moved in behind the blocks and compacted. The
geogrid then is laid over the top course of blocks, extending
behind the wall, wrapping around three courses of blocks, thus
forming geogrid wrap 255. The geogrid is securely held in place
after three more courses of blocks are laid down. The placement of
geogrid wrap 255 in front of the retaining wall is exaggerated in
FIG. 10 in order to see it clearly. In use, it would be held close
to the surface of the wall. FIG. 10 also illustrates the
positioning of second geogrid 250 over the topmost course of
blocks.
[0056] FIG. 11 shows the sectional view of a completed retaining
wall with the veneer panel system 20 of this invention in place.
The retaining wall has two geogrid wraps 255 and capping layer 212
that is provided with an overhang 213 under which veneer panel
system 20 of this invention fits. Panels 10 are attached to rail
100 and held by bracket 110. This can be more clearly seen in FIG.
12, in which retaining wall 200 has one geogrid wrap 255. The
veneer panel system is in a running bond pattern and is attached to
rails 100. Rails 100 attach to the wall by brackets 110. For
simplicity, only part of the wall is shown, and only one geogrid
wrap is shown, though it is to be understood that more than one
geogrid wrap can be used.
[0057] The veneer panel system of this invention is also suitable
for use with other types of retaining wall systems. For example, as
illustrated in FIG. 13A, multiple geogrids can be installed in a
system that uses wire baskets filled with soil as retaining wall
elements. A sectional view of a wall shows how geogrids are in
place under each wire basket in wall 400. Wire basket 410 is shown
in FIG. 13B. This type of retaining wall is often intended to be
temporary. The first wire basket is set down over compacted soil or
base layer 402, and geogrid 450 is laid down and attached to the
wire basket. Soil and/or rocks are poured over this and compacted
if necessary. Another wire basket and geogrid is put in place,
filled with soil, and so on. The topmost layer can be a covering
layer, such as plastic, or can be more soil or gravel. The veneer
panel system of this invention is then installed by means of rails
and brackets, as described above. A capping layer 420, with recess
422 to receive the veneer system 20, is used at the top of the
wall.
[0058] Another alternative for temporary retaining wall use is
shown in FIG. 14. In wall 500, geogrid 550 is laid down over
compacted soil or base layer 502, dirt is placed on this, and the
geogrid is laid back over the dirt to form geogrid wrap 555. Veneer
panel system 520 is attached by means of brackets 510 that extend
between geogrid wraps.
[0059] The veneer panel system can also be used with walls in
buildings, such as shown in FIG. 15, wherein the panels 10 form a
partial wall finish, such as wainscoting 600 on the face of a
building. Attachment means are as previously described.
[0060] FIGS. 16A and 16B show an angle bracket suitable to attach a
rail 100 to a wall, such as wood frame WF. The angle bracket can be
installed at one or more slots 103 and positioned as desired. Angle
bracket 170 has base section 171 and a perpendicular section 172
both of which are provided with bores through which can be threaded
bolts or screws. Bolt 175 is held secure through section 172 by nut
176 and washer 177, thus attaching the bracket to the rail. Wood
screws 179 thread through the bores in section 171, thus bolting
the rail into the wall. A panel can then be attached to the rail as
described above.
[0061] Although particular embodiments have been disclosed herein
in detail, this has been done for purposes of illustration only,
and is not intended to be limiting with respect to the scope of the
following appended claims. In particular, it is contemplated by the
inventors that various substitutions, alterations, and
modifications may be made to the invention without departing from
the spirit and scope of the invention as defined by the claims. For
instance, the choices of materials or variations in shapes are
believed to be a matter of routine for a person of ordinary skill
in the art with knowledge of the embodiments disclosed herein.
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