U.S. patent application number 11/284151 was filed with the patent office on 2006-05-25 for retaining wall block with face connection.
Invention is credited to William B. Dawson, Robert A. MacDonald.
Application Number | 20060110223 11/284151 |
Document ID | / |
Family ID | 36010442 |
Filed Date | 2006-05-25 |
United States Patent
Application |
20060110223 |
Kind Code |
A1 |
Dawson; William B. ; et
al. |
May 25, 2006 |
Retaining wall block with face connection
Abstract
Single and multiple retaining wall blocks and block systems are
disclosed. The blocks are provided with a face connection system
which includes at least one front lip extending from a top surface
of the block and a bottom channel formed into a front face and
bottom surface of the block. The front lips have a length which is
less than the width of the blocks.
Inventors: |
Dawson; William B.; (Medina,
MN) ; MacDonald; Robert A.; (Plymouth, MN) |
Correspondence
Address: |
POPOVICH, WILES & O'CONNELL, PA;650 THIRD AVENUE SOUTH
SUITE 600
MINNEAPOLIS
MN
55402
US
|
Family ID: |
36010442 |
Appl. No.: |
11/284151 |
Filed: |
November 21, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60630898 |
Nov 24, 2004 |
|
|
|
Current U.S.
Class: |
405/286 ;
405/284; 52/596 |
Current CPC
Class: |
E04B 2002/0206 20130101;
B28B 3/021 20130101; E02D 29/025 20130101; B28B 7/24 20130101; E04C
1/395 20130101; E04B 2002/0269 20130101; B28B 7/0097 20130101 |
Class at
Publication: |
405/286 ;
405/284; 052/596 |
International
Class: |
E02D 17/00 20060101
E02D017/00; E04C 2/04 20060101 E04C002/04 |
Claims
1. A wall block comprising: a block body including a top surface, a
bottom surface and a front face, the front face having a height and
a width; at least one lip extending from the top surface, the at
least one lip having first and second ends, first and second
lateral surfaces and an upper surface, one of the lateral surfaces
forming a part of the front face, the lip having a length measured
between the first and second ends, the length of the lip being less
than the width of the front face; and at least one channel formed
into the bottom surface and front face, the at least one channel
being sized such that when a wall is formed from a plurality of the
blocks stacked in multiple courses the at least one channel will
accommodate a lip from an adjacent block in a lower course.
2. The wall block of claim 1 wherein the block body further
comprises first and second opposing side surfaces and a rear
surface which opposes the front face.
3. The wall block of claim 2 wherein the first and second sides are
nonparallel.
4. The wall block of claim 1 wherein the at least one channel
comprises a first channel and a second channel.
5. The wall block of claim 1 wherein the at least one lip comprises
a first lip and a second lip.
6. A wall block system comprising: a plurality of blocks including
first and second blocks, each block having a block body including a
top surface, a bottom surface and a front face having a height and
a width, each block further having a lip extending from the top
surface and a channel formed into the bottom surface and front
face, the lip having first and second ends, first and second
lateral surfaces and an upper surface, one of the lateral surfaces
forming a part of the front face, the lip having a length as
measured between the first and second ends, the length of the lip
being less than the width of the front face; the channel being
sized such that when a wall is formed from the plurality of blocks
stacked in multiple courses at least a portion of the lip of the
first block positioned in a first course will be accommodated in
the channel of the second block in a second course overlying the
first course.
7. A method of making a retaining wall comprising: providing a
plurality of blocks including first, second and third blocks, each
block having a block body including a top surface, a bottom surface
and a front face having a height and a width, each block further
having a lip extending from the top surface and at least one
channel formed into the bottom surface and front face, the lip
having first and second ends, first and second lateral surfaces and
an upper surface, one of the lateral surfaces forming a part of the
front face, the lip having a length as measured between the first
and second ends, the length of the lip being less than the width of
the front face; laying the blocks in a first lower course including
laying a first block adjacent to a second block; and laying the
blocks in a second upper course in a running bond pattern over the
first course, the third block overlying a portion of the first
block and a portion of the second block, the at least one channel
of the third block accommodating at least a portion of the lip of
the first block and at least a portion of the lip of the second
block.
8. A retaining wall system comprising: a plurality of block types
including a first block type and a second block type, each block
type having a block body including a top surface, a bottom surface
and a front face having a height and a width, each block type
further having a lip extending from the top surface and a channel
formed into the bottom surface and front face, the lip having first
and second ends, first and second lateral surfaces and an upper
surface, one of the lateral surfaces forming a part of the front
face, the lip having a length as measured between the first and
second ends, at least one of the first block type and second block
type including a lip having a length which is less than the width
of the front face.
9. The retaining wall system of claim 8 further comprising a third
block type and a fourth block type.
10. A method of making a retaining wall comprising: providing a
plurality of block types including a first block type and a second
block type, each block type having a block body including a top
surface, a bottom surface and a front face having a height and a
width, each block type further having a lip extending from the top
surface and a channel formed into the bottom surface and front
face, the lip having first and second ends, first and second
lateral surfaces and an upper surface, one of the lateral surfaces
forming a part of the front face, the lip having a length as
measured between the first and second ends, at least one of the
first block type and second block type including a lip having a
length which is less than the width of the front face; and laying a
plurality of first block types and second block types in a random
pattern in multiple courses including a first lower course and a
second upper course such that the channels of first block types and
second block types in the second upper course receive lips of first
block types and second block types in the first lower course.
11. A retaining wall block system comprising: a first block having
a block body including a top surface, a bottom surface and a front
face, the first block further having a lip extending from the top
surface and a channel formed into the bottom surface and front
face, the lip having first and second ends, first and second
lateral surfaces and an upper surface, one of the lateral surfaces
forming a part of the front face; a second block having a block
body including a top surface, a bottom surface and a front face,
the second block further having first and second lips extending
from the top surface and a channel formed into the bottom surface
and front face, the first and second lips each having first and
second ends, first and second lateral surfaces and an upper
surface, one of the lateral surfaces of each of the first and
second lips forming a part of the front face; a third block having
a block body including a top surface, a bottom surface and a front
face, the third block further having a lip extending from the top
surface and a channel formed into the bottom surface and front
face, the lip having first and second ends, first and second
lateral surfaces and an upper surface, one of the lateral surfaces
of the lip forming a part of the front face; and a fourth block
having a block body including a top surface, a bottom surface and a
front face, the fourth block further having first and second lips
extending from the top surface and a channel formed into the bottom
surface and front face, the first and second lips each having first
and second ends, first and second lateral surfaces and an upper
surface, one of the lateral surfaces of each of the first and
second lips forming a part of the front face.
12. A method of making a retaining wall comprising: providing a
plurality of first blocks having a block body including a top
surface, a bottom surface and a front face, the first blocks
further having a lip extending from the top surface and a channel
formed into the bottom surface and front face, the lip having first
and second ends, first and second lateral surfaces and an upper
surface, one of the lateral surfaces forming a part of the front
face; providing a plurality of second blocks having a block body
including a top surface, a bottom surface and a front face, the
second blocks further having first and second lips extending from
the top surface and a channel formed into the bottom surface and
front face, the first and second lips each having first and second
ends, first and second lateral surfaces and an upper surface, one
of the lateral surfaces of each of the first and second lips
forming a part of the front face; providing a plurality of third
blocks having a block body including a top surface, a bottom
surface and a front face, the third blocks further having a lip
extending from the top surface and a channel formed into the bottom
surface and front face, the lip having first and second ends, first
and second lateral surfaces and an upper surface, one of the
lateral surfaces of the lip forming a part of the front face; and
providing a plurality of fourth blocks having a block body
including a top surface, a bottom surface and a front face, the
fourth blocks further having first and second lips extending from
the top surface and a channel formed into the bottom surface and
front face, the first and second lips each having first and second
ends, first and second lateral surfaces and an upper surface, one
of the lateral surfaces of each of the first and second lips
forming a part of the front face; and laying the first, second,
third, and fourth blocks in a random pattern in multiple courses
including a first lower course and a second upper course such that
the channels of blocks in the second upper course receive lips of
blocks in the first lower course.
Description
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 60/630,898, filed Nov. 24, 2004, the
contents of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to retaining wall blocks
having a front face connection system and to retaining walls
constructed from those blocks and to methods of making the blocks
and constructing walls from the blocks.
BACKGROUND OF THE INVENTION
[0003] Numerous methods and materials exist for the construction of
retaining walls. Such methods include the use of natural stone,
pored in place concrete, masonry, and landscape timbers or railroad
ties. In recent years, segmental concrete retaining wall units
which are dry stacked (i.e., built without the use of mortar, have
become a widely accepted product for the construction of retaining
walls. Such products have gained popularity because they are mass
produced, and thus relatively inexpensive. They are structurally
sound, easy and relatively inexpensive to install, and couple the
durability of concrete with the attractiveness of various
architectural finishes.
[0004] When constructing a retaining wall it is desirable to
utilize some form of connection system between the blocks for the
purpose of stabilizing and aligning the wall. For example, the
retaining wall system described in U.S. Pat. No. RE 34,314 includes
a block design that incorporates, among other elements, a system of
pins that interlock and align the retaining wall units, allowing
structural strength and relatively quick installation. The system
may be adapted for the construction of large walls by employing
geogrids which can be hooked over the pins. Such a system is
described in U.S. Pat. No. 4,914,876 (Forsberg).
[0005] Other connection systems make use of the shape of the block
itself for interlock and connection. For example, numerous block
designs have used a sheer connector embodied in the blocks shape to
align the blocks with a setback, or batter. A common form of such
sheer connectors is a rear, downwardly projecting lip or flange. In
forming a multi course wall, the blocks are placed such that the
flanges contact the upper back edge of the blocks located in the
course below. As such, blocks having flanges are caused to become
aligned with the blocks positioned below, while at the same time
providing a degree of resistance against displacement of individual
blocks by earth pressures. In walls formed using blocks of this
type, the rear flanges of the blocks create a setback between block
courses and cause the wall to slope backward at an angle which is
predetermined by the width of the flanges.
[0006] Retaining walls using blocks having a rear flange are well
known in the art. For example, U.S. Pat. No. 2,313,363 (Schmitt)
describes an early use of a retaining wall block with a rear
flange. More recently, U.S. Pat. No. 5,294,216 (Sievert) describes
a geogrid reinforced retaining wall constructed with retaining wall
blocks having rear flanges. Such blocks function adequately for
small walls where soil reinforcement is not necessary because they
are relatively simple to install and require no special pieces for
capping the top course of the wall.
[0007] One disadvantage of using blocks having a rear flange is
that their use naturally creates a setback between courses which
produces a visible line or seam between courses which is noticeable
to an observer. In other words, the visual appearance of the wall
is such that an observer tends to notice not only the vertical
lines between blocks in a course but also the lines at the top and
bottom of blocks in each course. Thus, each block in the wall is
identifiable as a separate unit from the adjacent blocks. In
certain circumstances this may create the desired aesthetic affect.
However, in other situations it is desirable to create a more
random visual appearance where each block is not separately
identifiable.
[0008] Retaining walls using blocks having a continuous front
flange which extend the entire width of the block are also well
known in the art. For Example, U.S. Pat. No. 5,484,236 (Gravier)
describes a block with a continuous front flange or lip located at
the top of the block and a lateral front notch located at the
bottom of the block. The notch is located along the bottom of the
front face of the block and is designed to receive the lip of an
adjacent block in a lower course of the retaining wall. As with
rear flanged blocks, there are disadvantages of prior art
continuous front flanged blocks. First, their use naturally creates
a set back that accentuates the horizontal lines between succeeding
courses of the retaining wall. Second, the continuous flange on
these blocks makes it difficult to form smooth inside or outside
curves in a wall formed from the blocks. Third, because the flange
of a front (or rear) flanged block extends in a straight line
across the entire width of the block, the blocks tend to set back
excessively when a curve in the wall is constructed.
[0009] Thus, a need exists in the art for a retaining wall block
and block system which can be used to construct a retaining wall
having a connection system which provides for the necessary safety
and stability of the wall yet also creates a random or variable
visual appearance for the face of the wall and eases the
construction of curves by maintaining a desired amount of setback
when a curve is constructed.
SUMMARY OF THE INVENTION
[0010] The invention comprises first and second wall block systems
which include face connection systems which allow for construction
of a wall providing safety and stability as well as a desired face
appearance.
[0011] In a first aspect the invention is a wall block comprising a
block body including a top surface, a bottom surface and a front
face. The front face has a height and a width. At least one lip
extends from the top surface, the at least one lip having first and
second ends, first and second lateral surfaces and an upper
surface. One of the lateral surfaces forms a part of the front
face. The lip has a length measured between the first and second
ends, the length of the lip being less than the width of the front
face. At least one channel is formed into the bottom surface and
front face, the at least one channel being sized such that when a
wall is formed from a plurality of the blocks stacked in multiple
courses the at least one channel will accommodate a lip from an
adjacent block in a lower course. The block body may further
comprise first and second opposing side surfaces and a rear surface
which opposes the front face. The first and second sides may be
nonparallel. Further, the at least one channel may comprise a first
channel and a second channel and the at least one lip may comprise
a first lip and a second lip.
[0012] In another aspect the invention comprises a wall block
system having a plurality of blocks including first and second
blocks. Each block has a block body including a top surface, a
bottom surface and a front face having a height and a width. Each
block further has a lip extending from the top surface and a
channel formed into the bottom surface and front face, the lip
having first and second ends, first and second lateral surfaces and
an upper surface. One of the lateral surfaces forms a part of the
front face. The lip has a length as measured between the first and
second ends, the length of the lip being less than the width of the
front face. The channel is sized such that when a wall is formed
from the plurality of blocks stacked in multiple courses at least a
portion of the lip of the first block positioned in a first course
will be accommodated in the channel of the second block in a second
course overlying the first course.
[0013] Another aspect of the invention is directed to a method of
making a retaining wall. The method comprises providing a plurality
of blocks including first, second and third blocks, each block
having a block body including a top surface, a bottom surface and a
front face having a height and a width. Each block further has a
lip extending from the top surface and at least one channel formed
into the bottom surface and front face, the lip having first and
second ends, first and second lateral surfaces and an upper
surface. One of the lateral surfaces forms a part of the front
face. The lip has a length as measured between the first and second
ends, the length of the lip being less than the width of the front
face. The method includes laying the blocks in a first lower course
including laying a first block adjacent to a second block. The
method further includes laying the blocks in a second upper course
in a running bond pattern over the first course, the third block
overlying a portion of the first block and a portion of the second
block, the at least one channel of the third block accommodating at
least a portion of the lip of the first block and at least a
portion of the lip of the second block.
[0014] A further aspect of the invention is a retaining wall system
comprising a plurality of block types including a first block type
and a second block type. Each block type has a block body including
a top surface, a bottom surface and a front face having a height
and a width. Each block type further has a lip extending from the
top surface and a channel formed into the bottom surface and front
face. The lip has first and second ends, first and second lateral
surfaces and an upper surface. One of the lateral surfaces forms a
part of the front face. The lip has a length as measured between
the first and second ends. At least one of the first block type and
second block type include a lip having a length which is less than
the width of the front face. The retaining wall system may further
comprise a third block type and a fourth block type.
[0015] In another aspect the invention is a method of making a
retaining wall comprising providing a plurality of block types
including a first block type and a second block type. Each block
type has a block body including a top surface, a bottom surface and
a front face having a height and a width. Each block type further
has a lip extending from the top surface and a channel formed into
the bottom surface and front face. The lip has first and second
ends, first and second lateral surfaces and an upper surface. One
of the lateral surfaces forms a part of the front face. The lip has
a length as measured between the first and second ends. At least
one of the first block type and second block type include a lip
having a length which is less than the width of the front face. The
method includes laying a plurality of first block types and second
block types in a random pattern in multiple courses including a
first lower course and a second upper course such that the channels
of first block types and second block types in the second upper
course receive lips of first block types and second block types in
the first lower course.
[0016] In a further aspect the invention is a retaining wall block
system comprising multiple blocks which may include first, second,
third and fourth blocks. The first block has a block body including
a top surface, a bottom surface and a front face. The first block
further has a lip extending from the top surface and a channel
formed into the bottom surface and front face, the lip having first
and second ends, first and second lateral surfaces and an upper
surface, one of the lateral surfaces forming a part of the front
face. The second block has a block body including a top surface, a
bottom surface and a front face. The second block further has first
and second lips extending from the top surface and a channel formed
into the bottom surface and front face, the first and second lips
each having first and second ends, first and second lateral
surfaces and an upper surface, one of the lateral surfaces of each
of the first and second lips forming a part of the front face. The
third block has a block body including a top surface, a bottom
surface and a front face. The third block further has a lip
extending from the top surface and a channel formed into the bottom
surface and front face, the lip having first and second ends, first
and second lateral surfaces and an upper surface, one of the
lateral surfaces of the lip forming a part of the front face. The
fourth block has a block body including a top surface, a bottom
surface and a front face. The fourth block further having first and
second lips extending from the top surface and a channel formed
into the bottom surface and front face, the first and second lips
each having first and second ends, first and second lateral
surfaces and an upper surface, one of the lateral surfaces of each
of the first and second lips forming a part of the front face.
[0017] Another aspect of the invention is a method of making a
retaining wall. The method comprises providing a plurality of first
blocks having a block body including a top surface, a bottom
surface and a front face. The first blocks further having a lip
extending from the top surface and a channel formed into the bottom
surface and front face, the lip having first and second ends, first
and second lateral surfaces and an upper surface, one of the
lateral surfaces forming a part of the front face. The method
further comprises providing a plurality of second blocks having a
block body including a top surface, a bottom surface and a front
face, the second blocks further having first and second lips
extending from the top surface and a channel formed into the bottom
surface and front face, the first and second lips each having first
and second ends, first and second lateral surfaces and an upper
surface, one of the lateral surfaces of each of the first and
second lips forming a part of the front face. The method includes
providing a plurality of third blocks having a block body including
a top surface, a bottom surface and a front face, the third blocks
further having a lip extending from the top surface and a channel
formed into the bottom surface and front face, the lip having first
and second ends, first and second lateral surfaces and an upper
surface, one of the lateral surfaces of the lip forming a part of
the front face. Further, the method includes providing a plurality
of fourth blocks having a block body including a top surface, a
bottom surface and a front face, the fourth blocks further having
first and second lips extending from the top surface and a channel
formed into the bottom surface and front face, the first and second
lips each having first and second ends, first and second lateral
surfaces and an upper surface, one of the lateral surfaces of each
of the first and second lips forming a part of the front face. The
wall is formed by laying the first, second, third, and fourth
blocks in a random pattern in multiple courses including a first
lower course and a second upper course such that the channels of
blocks in the second upper course receive lips of blocks in the
first lower course.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1A, 1B, 1C, 1D, 1E, 1F and 1G are perspective, top,
front, right side, back, left side and bottom views, respectively,
of a block according to a first embodiment of a single block system
in accordance with the present invention.
[0019] FIG. 2 is an enlarged perspective view of the front face and
right side of the block of FIG. 1.
[0020] FIG. 3 is a front view of a portion of a retaining wall
constructed with the block of FIG. 1.
[0021] FIGS. 4A, 4B, 4C, 4D, 4E, 4F and 4G are perspective, top,
front, right side, back, left side and bottom views, respectively,
of a block according to a second embodiment of a single block
system in accordance with the present invention.
[0022] FIG. 5 is a front view of a portion of a retaining wall
constructed with the block of FIG. 4.
[0023] FIGS. 6A, 6B, 6C, 6D, 6E, 6F and 6G are perspective, top,
front, right side, back, left side and bottom views, respectively,
of a first block according to a first embodiment of a multiple
block system in accordance with the present invention.
[0024] FIGS. 7A, 7B, 7C, 7D, 7E, 7F and 7G are perspective, top,
front, right side, back, left side and bottom views, respectively,
of a second block according to a first embodiment of a multiple
block system in accordance with the present invention.
[0025] FIGS. 8A, 8B, 8C, 8D, 8E, 8F and 8G are perspective, top,
front, right side, back, left side and bottom views, respectively,
of a third block according to a first embodiment of a multiple
block system in accordance with the present invention.
[0026] FIGS. 9A, 9B, 9C, 9D, 9E, 9F and 9G are perspective, top,
front, right side, back, left side and bottom views, respectively,
of a forth block according to a first embodiment of a multiple
block system in accordance with the present invention.
[0027] FIG. 10 is a plan view of a mold box used for forming the
first, second, third and fourth blocks of the multiple block
system.
[0028] FIG. 11 is a front view of a portion of a retaining wall
constructed with the blocks of FIGS. 6, 7, 8 and 9.
[0029] FIGS. 12A, 12B, 12C, 12D, 12E, 12F and 12G are perspective,
top, front, right side, back, left side and bottom views,
respectively, of a first block according to a second embodiment of
the multiple block system.
[0030] FIGS. 13A, 13B, 13C, 13D, 13E, 13F and 13G are perspective,
top, front, right side, back, left side and bottom views,
respectively, of a second block according to a second embodiment of
the multiple block system.
[0031] FIGS. 14A, 14B, 14C, 14D, 14E, 14F and 14G are perspective,
top, front, right side, back, left side and bottom views,
respectively, of a third block according to a second embodiment of
the multiple block system.
[0032] FIGS. 15A, 15B, 15C, 15D, 15E, 15F and 15G are perspective,
top, front, right side, back, left side and bottom views,
respectively, of a fourth block according to a second embodiment of
the multiple block system.
[0033] FIG. 16 is a front view of a portion of a retaining wall
constructed with the first, second, third and fourth blocks shown
in FIGS. 12, 13, 14 and 15, respectively.
[0034] FIG. 17 is a side view of first and second blocks according
to the invention which are stacked one over the other to illustrate
the face connection system.
[0035] FIG. 18 is a side view of a multiple course retaining wall
constructed in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] In this application, "upper" and "lower" refer to the
placement of the block in a retaining wall. The lower surface faces
down, that is, it is placed such that it faces the ground. In
forming a retaining wall, one row of blocks is laid down, forming a
course. A second course is laid on top of this by positioning the
lower surface of one block on the upper surface of another
block.
[0037] The blocks of this invention may be made of a rugged,
weather resistant material, such as concrete, especially if the
wall is constructed outdoors. Other suitable materials include
plastic, reinforced fibers, and any other materials suitable for
use in molding wall blocks. The surface of the blocks may be smooth
or may have a roughened appearance, such as that of natural stone.
In some embodiments the front surface or faces of the blocks are
provided with an ashlar pattern and in others a ledgestone pattern.
The blocks may be formed in a mold which is equipped to impart
various textures on the front face of the blocks.
[0038] The figures describe various block embodiments. Many
elements in various block embodiments are identical in shape, size,
relative placement, and function, and therefore the numbers for
these elements do not change. Elements that vary from one block
embodiment to another are identified by suffixes "a", "b", "c",
etc. and may be referred to in a general way by a number without
its suffix.
[0039] The blocks of this invention as illustrated in the drawing
figures are generally symmetrical about a vertical plane of
symmetry. However, it should be understood that the shape of the
block is not critical to the invention. Specifically, any block
shape which can be constructed to utilize the advantages of the
front face connection system disclosed herein will fall within the
scope of this invention. Similarly, although several embodiments of
the surface texture of the front face of the blocks are disclosed
it should be understood that those embodiments are not meant to be
limiting and that any desired front face surface texture can be
utilized within the scope of the present invention. Further,
although the blocks are shown having a solid block body it will be
appreciated that the blocks could be formed with a core, especially
if it is desired to reduce the weight of the blocks or the amount
of material required to make the blocks.
[0040] The novel block connection system of the present invention
can be incorporated into various retaining wall block systems.
Disclosed herein are two block systems incorporating the present
invention, both systems having multiple embodiments. The first
block system shown in FIGS. 1 to 5 comprises a single block which
incorporates the face connection system disclosed herein. The face
connection system comprises one or more upper lips extending from
the top surface of the block (which do not extend across the entire
extent of the width of the face) and one or more lower channels
formed along the bottom of the blocks face, which may, or may not,
extend across the entire extent of the width of the face, depending
on the preferred embodiment. The term "single block system" refers
to the use of a plurality of blocks, each having an identical lip
and channel configuration although the surface texture of the front
face of the block may be varied. A plurality of these blocks are
used to construct a retaining wall. Two embodiments of this block
are disclosed. A first embodiment shown in FIGS. 1A to 1G has a
ledgestone front surface texture. A second embodiment shown in
FIGS. 4A to 4G has an ashlar surface texture. It will be
appreciated that although not disclosed other surface texture
embodiments would work equally well with the present invention such
as smooth surfaces or surface textures that simulate natural stone,
brick, or any other surface texture known to those of skill in the
art.
[0041] A second block system for constructing a retaining wall is
disclosed in FIGS. 6 to 16. This system is a multiple block system
which utilizes more than one version of wall block incorporating
the front face connection system of the present invention. In other
words the multiple block system uses blocks wherein the placement
and/or size of the lips is not identical. Although the system
disclosed illustrates the use of multiples of four such blocks,
each having a different lip configuration, it should be understood
that a multiple block system of this nature could be used in a two
block system, a three block system or any other multiple block
system which incorporates more than one version of a retaining wall
block having the present front face connection system.
Single Block System
[0042] The single block wall system is shown in FIGS. 1 to 5. A
first embodiment of the block is shown in FIGS. 1A to 1G which
illustrate perspective, top, front, right side, back, left side and
bottom views, respectively, of block 1a. Block la has a top surface
2 which is substantially parallel to a bottom surface 3,
nonparallel first and second side wall surfaces 4 and 5, and a
front face 6a which is substantially parallel to a rear surface
7.
[0043] The front face 6a and rear surface 7 each extend from top
surface 2 to bottom surface 3. First and second side surfaces 4 and
5 extend from top surface 2 to bottom surface 3 and from front face
6a to rear surface 7. The top and bottom surfaces, side surfaces,
front face and rear surface collectively define a block body. The
size of the bocks may be similar to presently used retaining wall
blocks. By way of non limiting example the blocks may be between
12-18 inches wide, 7-12 inches deep and 3-8 inches in height. Block
1a is generally symmetrical about a vertical plane of symmetry. As
shown block 1a is generally wedge shaped. However, as mentioned
previously, other block shapes could be utilized within the scope
of the invention including square, rectangular, or shapes
characterized by nonparallel side surfaces such as a configuration
where one of the side surfaces is orthogonal to the front face.
[0044] When block 1a is utilized to construct a retaining wall, a
portion of which is shown in FIG. 3, the block is laid in multiple
courses in a running bond pattern. The connection system which
stabilizes the wall comprises a lip 8 extending from the top
surface 2 of the block and channels 9 and 10 formed in the front
face 6a of the block. Lip 8 comprises a front surface portion 11
surface portions 13 and 14 and top surface portion 15 extending
therebetween. The lips will be properly sized to be received in the
channels and create the desired setback between courses. By way of
non limiting example the width of the lip as measured between the
front surface portion and the rear surface portion may be 3/4 inch.
The height of the lip as measured between the top surface 2 of
block 1a and top surface portion 15 may be 1/4 inch.
[0045] Channels 9 and 10 generally form recesses in front face 6a
along bottom surface 3 of block 1a. Channel 9 is defined by a face
surface portion 16, a top surface portion 17 and an end surface
portion 18. Similarly, channel 10 is defined by face surface
portion 19, top surface portion 20 and end surface portion 21. The
size of channels 9 and 10 will be selected to receive lip 8 and to
produce, in connection with lip 8, the desired setback. By way of
non limiting example the height of channels 9 and 10 as measured
between bottom surface 3 and top surfaces 17 and 20 may be 5/16
inch. The depth of channels 9 and 10 as measured between front face
6a and face surface portions 16 and 19 may be 1/2 inch.
[0046] FIG. 2 is an enlarged drawing of block 1a for the purpose of
showing the features of the block in more detail and specifically
the surface contour and texture of front face 6a. From FIG. 2 it is
apparent that front face 6a is provided with a contoured surface
texture which includes ridges which may extend outwardly from front
face 6a as well as indentations or recesses which extend into front
face 6a towards rear surface 7. In particular, front face 6a may be
provided with one or more recesses 22a. In this embodiment recess
22a is formed in the shape of an elongate slot. As will be
described in more detail hereafter the purpose of slot 22a is to
provide a surface contour to the front face of a retaining wall
which is built from blocks 1a which tends to hide or camouflage any
regular pattern which is created by portions of exposed channels 9
and 10.
[0047] The method of constructing a retaining wall with blocks 1a
can best be understood with reference to FIGS. 3, 17 and 18. After
forming a sufficient base leveling pad 23 in a manner well known to
those of skill in the art a first course 24 of blocks is laid.
Thereafter a second course 25 is stacked on the first course in a
running bond pattern. The lips extending from the tops of blocks in
the first course are received within the channels formed in the
lower front surface of the blocks in the second course. Since the
width of the lips as measured between the front surface portion and
rear surface portions is greater than the depth of the channels as
measured between front face 6a and face portions 16 and 19 an
offset is created between courses. This causes the wall to set back
in a rearward direction in an amount determined by the difference
between the width of the lip and the depth of the channels.
[0048] As best seen in FIG. 3 the horizontal length of the combined
channel formed by channels 16 and 19 of adjacent blocks in a course
is greater than the horizontal length of the lip received therein
as measured between the lip side surface portions. This results in
portions of the channels 26 being visually exposed. It is necessary
that the combined length of the channel formed by adjacent blocks
is longer than the length of the lips for at least two reasons.
First, when constructing a wall having an inside curve the channel
formed between adjacent blocks will be pinched or shortened but
must still be large enough in that state to receive a lip. Second,
anytime a curved wall is built having a setback between courses
some misalignment of the running bond pattern between courses is
created. This requires that additional length be available in the
channel to accommodate this misalignment.
[0049] In order to camouflage any regular pattern which is created
by exposed portions 26 of the channels the blocks may be provided
with recesses 22a as previously described in connection with FIG.
2. These recesses may be formed such that their surfaces are
textured to resembled natural stone patterns in order to enhance
the natural look of the finished wall. The single block wall system
can also be made so that the configuration of the side and top
surfaces of the lips and recesses are slightly varied (without
affecting their location or overall dimensions significantly) among
different blocks to create a more random and natural visual
impression These recesses extend into the front face 6a to a depth
sufficient to mimic the visual appearance of a partially exposed
channel 26. Thus, any regular pattern which would be created by the
exposed portions 26 is camouflaged by the random visual appearance
added by recesses 22a.
[0050] Although this single block wall system can be comprised of
the use of a single block 1a having an identical surface texture
such as shown in FIG. 2 the randomness of the wall surface
appearance is further enhanced by providing block 1a with a number
of surface texture variations which can include varying the
location and number of recesses 22a per block. Such variation in
the surface contour and texture is efficiently created at the time
the blocks are manufactured. One efficient manner of forming blocks
1a is with the use of a mold similar to that shown in FIG. 10 and
described hereafter with respect to the multiple block wall system.
If the blocks are manufactured according to this method each one of
the four blocks in the mold can be formed with a different surface
pattern or texture, all in the ledgestone style. Alternatively two
could have a first surface texture and two could have a second
surface texture. The result is that the single block wall system
described herein can be formed with up to 4 (or more) surface
variations which can be laid randomly to construct a retaining wall
having a varied and random surface texture in which any regular
pattern formed by exposed channel portions is effectively
camouflaged.
[0051] To further enhance the visual appearance of the retaining
wall the exposed surfaces of the lips and channels can be provided
with some surface contour. Specifically, the top surface 15 and
side surfaces 13 and 14 of the lip can be textured. Additionally,
the face surface portion, top surface portion and end surface
portion of channels 9 and 10 can be textured. Preferably, the
texture of the surface portions of the lip and channel is created
with contour formed into the body of the block and not extending
from the body of the block so that no interference is created which
would affect the manner in which the lip is received by the
channels or the amount of block setback.
[0052] A second embodiment of the single block system is shown in
FIGS. 4 and 5. Block 1b is similar in all respects to block 1a
except that the front face 6b is provided with an ashlar surface
pattern instead of the ledgestone pattern of front face 6a. The
description of the various features of block 1a and the
construction of a retaining wall therefrom are applicable with
respect to block 1b and will not be repeated. The only significant
difference between blocks 1a and 1b is the front face contour and
the appearance which is created when the blocks are used to
construct a retaining wall.
[0053] A retaining wall constructed with blocks 1b is shown in FIG.
5. In accordance with the discussion regarding the manufacture of
block 1a with up to four different surface configurations FIG. 5,
for purposes of illustration, shows a partial retaining wall
constructed from blocks 1b showing only the surface configurations
of four potential surface contours of block 1b. Construction of the
wall in its intended manner results in portions 26 of the channels
of block 1b being exposed. In this embodiment in order to
camouflage any regular pattern of exposed portions 26 the front
faces 6b of the blocks are provided with recesses 22b. These
recesses can be either horizontal or vertical or both and are
provided at a depth which mimics the appearance of exposed portions
26. This effectively camouflages any regular pattern formed by
exposed portions 26 and provides a pleasing variable or random
appearance to the surface of the wall.
[0054] An additional benefit of the one block systems is that it
facilitates the construction of walls that are curved. Because the
wall uses both a lip and recess, the amount of set back is limited.
In addition, because the lip only extends across a portion of the
center of the block, there is less of a tendency for the succeeding
courses to bind and to go into a negative batter during the
construction of inside curves.
Multiple Wall Block System
[0055] A multiple wall block system is shown in FIGS. 6 to 16. The
multiple wall block system is similar to the single wall block
system described above except that the system comprises two or more
blocks, each having one or more upper lips and one or more lower
channels which are dimensioned and/or positioned differently. This
difference in the number and/or location of the lips and channels
results in several advantages. First, the randomness of the size
and spacing of lips and channels insures that when a wall is
constructed from the blocks any exposed portions of the channels do
not form a regular pattern. Second, additional flexibility with
respect to building curved walls with the blocks is provided. Due
to the variety of lip sizes and placements, the wall can be built
in a fashion that allows the wall builder to select units that
allow the construction of curved walls with minimal variation from
the pre-designed amount of set back, which enhances the stability
and aesthetic characteristics of the finished wall and eases
construction. The multiple wall block system comprises a first
embodiment of first, second, third and fourth blocks as disclosed
in FIGS. 6A-6G, 7A-7G, 8A-8G, and 9A-9G, respectively in a
ledgestone pattern. A second embodiment of those blocks is shown in
FIGS. 12A-12G, FIGS. 13A-13G, FIGS. 14A-14G, and FIGS. 15A-15G in
an ashlar pattern. Each of these block embodiments is similar to
the block embodiments described with respect to the single block
wall system except for the variation in placement and location of
the lips and the provision of a single continuous channel which
comprise the face connection system. Therefore this description
will focus primarily on the varying aspects of the front face
connection system.
[0056] The first block of the multiple wall block system is shown
in FIGS. 6A-6G. Block 101a has a top surface 102 which is
substantially parallel to a bottom surface 103, nonparallel first
and second side wall surfaces 104 and 105 and a front face 106a
which is substantially parallel to a rear surface 107. The front
face 106a and rear surface 107 each extent from top surface 102 to
bottom surface 103. First and second side surfaces 104 and 105
extend from top surface 102 to bottom surface 103 and from front
face 106a to rear surface 107. The top and bottom surfaces, side
surfaces, front face and rear surface collectively define a block
body. Block 101a is generally symmetrical about a vertical plane of
symmetry. As discussed with respect to block 1a the size and shape
of block 101a may be varied considerably within the scope of the
invention.
[0057] As mentioned previously, block 101a is similar to block 1a
except for the details of the face connection system. Specifically,
block 101a includes a centrally located lip 150 and a continuous
bottom channel 151.
[0058] The second block of the multiple wall block system is shown
in FIGS. 7A-7G. Block 101b is similar to block 101a in all respects
except that instead of a single centrally located lip the block of
101b comprises lips 152 and 153 which are spaced apart and located
adjacent the sides of block 101b.
[0059] The third block of the multiple wall block system is shown
in FIGS. 8A-8G. This block is similar to block 101a in all respects
except that it has a single continuous lip 154 which extends the
width of the block along front face 106c.
[0060] The fourth block of the multiple wall block system is shown
in FIGS. 9A-9G. Block 101d is similar to block 101a except that it
has randomly spaced lips 155 and 156.
[0061] The blocks may be formed by any conventional process known
in the art. For example, the blocks may be made using dry cast
concrete block making equipment or may be formed by use of a wet
cast molding process, both of which are known in the art. One
manner of making blocks 101a, 101b, 101c and 101d of the multiple
wall block system is to form them in a mold as shown in FIG. 10.
The mold will allow multiple units to be made. There can be any
combination of different units. A commonly known concrete block
manufacturing machine is used to produce the blocks. Typical
machines are manufactured by Besser, Columbia or Tiger. A mold
(open at both top and bottom) is placed in the machine at the
beginning of a production run of the blocks of the present
invention. A manufacturing pallet is placed underneath the mold,
and forms the bottom of the block. The top of the block is formed
by a stripper shoe. In one cycle of a continuous process, the mold
is filled with concrete, the concrete is compacted and vibrated,
and the blocks are stripped from the mold onto the manufacturing
pallet that forms the bottom of the block. The top of the block is
formed by an indented portion of the stripper shoe that compacts
the concrete mix, and at the appropriate stage, strips the blocks
from the mold down onto the manufacturing pallet. The blocks are
then delivered to a curing area, cured, and then cubed onto
delivery pallets. The method of constructing a retaining wall with
blocks 101a, 101b, 101c and 101d is similar to that described with
respect to the single block system except that the various block
styles are utilized randomly to achieve a varied and visually
appealing surface texture for the wall. As is well known in the
art, a trench is excavated to allow the placement of a base
leveling pad of well compacted gravel or road base. The base course
of the wall units is placed and leveled along the desired contour
of the wall. Typically, varying the type of wall unit so that a
variety of patterns are adjacent to one another is desirable to
enhance the random, natural stone appearance of the wall. A second
course is place above the base course by placing the wall blocks so
that the lips of the first course blocks engage the recesses of the
second course blocks, and again by selecting a random pattern of
block types to enhance the natural appearance of the wall.
Succeeding courses are placed in the same manner until the desired
wall height is reached. If a curve is constructed, the wall builder
may elect to choose blocks with center lips to minimize set back
variation. If the wall is tall enough, reinforcement with geogrid,
as is well known in the art, may be employed. Construction of a
wall with the multiple wall block system as with the single wall
block system results in exposing portions 126 of channels. However,
because the connection system comprises blocks with a continuous
bottom channel but varied lip placement and size the net effect is
that no regular pattern of exposed portions 126 is formed. In
addition, texturing the back wall of the recesses enhances the
natural appearance of these joints in the wall. The random effect
of exposed portions 126 is even further enhanced and camouflaged by
providing in the block surfaces recesses 122a which are designed to
resemble the appearance of the recesses that receive the connector
lips.
[0062] As mentioned previously, a second embodiment of the multiple
wall block system is disclosed in FIGS. 12-16. In this embodiment
blocks 101e (FIGS. 12A-12G), 101f (FIGS. 13A-13G), 101g (FIGS.
14A-14G) and 101h (FIGS. 15A-15G) correspond to blocks 101a-d,
respectively, except that the front surface of the blocks has an
ashlar surface pattern instead of a ledgestone pattern. In all
other respects the blocks are the same and the description set
forth previously is equally applicable to these blocks.
[0063] A retaining wall constructed with blocks 101e, 101f, 101g
and 101h is shown in FIG. 16. The construction is similar to that
described with respect to FIG. 11 except that the irregular pattern
of exposed portions 126 are further camouflaged by providing
recesses 122b in the front faces of the blocks. These recesses can
either be horizontal or vertical or both and are provided at a
depth which mimics the appearance of exposed portions 126. The
recesses would be in the areas where grout joints would be found in
a traditional ashlar wall. The combination of eliminating regular
horizontal lines between succeeding courses of the blocks,
providing irregularly spaced lips on the top of each block, and
mimicking the irregular appearance of the horizontal joints on the
main face of the blocks all contribute to camouflage the horizontal
joints and create a visual impression of a true ashlar wall, while
using wall blocks that lay out in continuous horizontal layers, as
opposed to the varying levels of an ashlar wall, which greatly
complicates construction, since the builder must make individual
pieces fit.
* * * * *