U.S. patent application number 12/525491 was filed with the patent office on 2010-01-28 for wall with decorative facing.
This patent application is currently assigned to LES MATERIAUX DE CONSTRUCTION OLDCASTLE CANADA, IN. Invention is credited to Stephane Aube, Bertin Castonguay, Robert Daoust, Marcel Thomassen.
Application Number | 20100018146 12/525491 |
Document ID | / |
Family ID | 39673592 |
Filed Date | 2010-01-28 |
United States Patent
Application |
20100018146 |
Kind Code |
A1 |
Aube; Stephane ; et
al. |
January 28, 2010 |
WALL WITH DECORATIVE FACING
Abstract
A method and system for providing a decorative finish on a wall,
whereby a facing panel is provided to attach to a backing surface
by way of a coupling means Dry cast panels are connected to the
wall by way of a key way connector.
Inventors: |
Aube; Stephane; (Carignan,
CA) ; Castonguay; Bertin; (Magog, CA) ;
Daoust; Robert; (Boucherville, CA) ; Thomassen;
Marcel; (L'Epiphanie, CA) |
Correspondence
Address: |
BORDEN LADNER GERVAIS LLP;Anne Kinsman
WORLD EXCHANGE PLAZA, 100 QUEEN STREET SUITE 1100
OTTAWA
ON
K1P 1J9
CA
|
Assignee: |
LES MATERIAUX DE CONSTRUCTION
OLDCASTLE CANADA, IN
St-John
NB
|
Family ID: |
39673592 |
Appl. No.: |
12/525491 |
Filed: |
December 21, 2007 |
PCT Filed: |
December 21, 2007 |
PCT NO: |
PCT/CA2007/002351 |
371 Date: |
July 31, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60887877 |
Feb 2, 2007 |
|
|
|
Current U.S.
Class: |
52/483.1 ;
52/562; 52/745.13 |
Current CPC
Class: |
E04F 13/147 20130101;
E04C 1/395 20130101; E04B 2002/0269 20130101; E04F 2201/0594
20130101; E04F 13/0862 20130101; E02D 29/0233 20130101; E02D 29/025
20130101; E04F 2201/0505 20130101; E02D 29/0266 20130101 |
Class at
Publication: |
52/483.1 ;
52/745.13; 52/562 |
International
Class: |
E04B 2/32 20060101
E04B002/32; E04F 13/00 20060101 E04F013/00; E04B 2/82 20060101
E04B002/82 |
Claims
1. A method for providing a decorative finish on a wall, preferably
a retaining wall or a freestanding wall, comprising the steps of
obtaining a facing panel having a decorative surface, preferably a
plurality of panels; and mounting the facing panel to the wall for
exposing the decorative surface, preferably, the plurality of
panels are mounted to the wall and arranged to completely cover the
wall, wherein the facing panels are dry cast concrete panels,
preferably with an embossed decorative surface, more preferably
with an embossed, patterned facing surface.
2. The method of claim 1, wherein the mounting step includes
obtaining a connecting means for fastening the facing panel to the
wall, preferably for removably fastening the facing panel.
3. The method of claim 2, wherein the mounting step further
includes attaching the connecting means to the wall and
subsequently attaching the facing panel to the connecting
means.
4. The method of claim 2, wherein the mounting step further
includes attaching the connecting means to the wall and
subsequently suspending the facing panel from the connecting
means.
5. (canceled)
6. (canceled)
7. (canceled)
8. (canceled)
9. A decorative block for a wall, comprising a base block for
forming the wall, a facing panel having an embossed decorative
surface, and a connecting means for mounting the facing panel to
the block for exposing the decorative surface.
10. The decorative block of claim 9, wherein the block has a front
surface and a first retaining recess in the front surface, and the
connecting means is a connector engaging the facing panel and
having a first interlocking member for engaging the first retaining
recess in the block to interconnect the facing panel and the
block.
11. The decorative block of claim 10, wherein the facing panel is
suspended from the block by the interlocking member of the
connector.
12. The decorative block of claim 9, wherein the facing panel has a
rear surface opposite the decorative surface and a second retaining
recess in the rear surface, and the connector has a second
interlocking member for engaging the second retaining recess in the
facing panel to interconnect the facing panel and the
connector.
13. The decorative block of claim 9, wherein the first and second
retaining recesses are first and second keyhole slots and the
connector has a central web with opposite, terminally positioned
enlarged portions forming the first and second interlocking members
respectively, each interlocking member being shaped and constructed
for interlocking engagement with one of the first and second
keyhole slots.
14. The decorative block of claim 13, wherein the first and second
keyhole slots are identical in shape and size and the connector is
of symmetrical construction to permit engagement of the first and
second interlocking members with either one of the first and second
keyhole slots.
15. A decorative wall, comprising a plurality of stacked decorative
blocks as defined in claim 9.
16. A base block for a decorative block in accordance with claim 9,
the base block comprising a body with top and bottom surfaces, a
pair of opposite end surfaces and front and back surfaces, and at
least one retaining recess provided in the front surface for
receiving the connector means for mounting the facing panel to the
base block.
17. The base block of claim 16, having at least one retaining
recess in each of the front and back surfaces, preferably in each
of the front, back and end surfaces, preferably a number of
equidistantly spaced, parallel retaining recesses in each
surface.
18. The base block of claim 17, wherein the retaining recesses are
keyhole slots, preferably of substantially identical shape and
size.
19. (canceled)
20. A modular wall system, comprising individual stackable base
blocks of staggered length, facing panels of equal staggered width,
and connecting means for mounting the facing panels to the base
blocks, the length of the base blocks and facing panels being a
multiple of a preselected base length L (2L, 3L, 4L, 5L, . . .
)
21. The modular wall system of claim 20, wherein a thickness of the
base blocks is equal to a multiple of the base length, preferably
2L.
22. The modular wall system of claim 21, wherein a thickness of the
facing panels is equal to the base length or a multiple of the base
length.
23. The modular wall system of claim 20, wherein the base blocks
are stackable in rows and the connecting means include at least one
retaining groove in each base block and each facing panel and
connectors for mounting the facing panels to the base blocks, each
connector having a body and opposing first and second interlocking
members for engaging a retaining groove in one of the base blocks
and one of the facing panels respectively for interconnecting the
connector with the base block and the facing panel
respectively.
24. The modular wall system of claim 20, wherein the base blocks
have front, back and end surfaces and opposite end surfaces and are
stackable end to end, the connecting means being adapted for
mounting the facing panels to the front or back surfaces of the
blocks.
25. The modular wall system of claim 14, wherein the connecting
means are adapted for mounting the facing panels to the front, back
or end surfaces.
Description
FIELD OF THE INVENTION
[0001] The present invention is generally directed toward
decorative walls such as building walls, retaining walls and
freestanding walls having a decorative surface. In particular, the
invention is directed to modular walls with a decorative facing and
components of such walls. More specifically, the present invention
is directed toward walls, such as building walls, retaining walls
or freestanding walls, which have at least a front decorative
surface.
BACKGROUND OF THE INVENTION
[0002] For reasons of aesthetics, walls are often provided with a
decorative finish. Walls exposed to the elements are normally
provided with a finish able to withstand the effects of weather.
Concrete or masonry blocks or bricks are often used for exterior
weather resistant wall finishes. Those blocks most of the time are
stacked with mortar, using common bricklaying techniques, and
connected to the wall by metal ties. This is an arduous and time
consuming process and requires experienced labour.
[0003] Retaining walls are often used in landscaping around
residential or commercial buildings. Retaining walls can be made of
various materials, but for reasons of durability are most often
either concrete structures cast in situ or walls formed of stacked
courses of natural stone or masonry blocks. Concrete masonry blocks
have become the most popular retaining wall components, due to
their ease of manufacture, transport and handling.
[0004] Freestanding walls are often used as demarcation structures
such as those along roads, walkways or property lines. These walls
can be cast in situ or modular, preferably made of stacked blocks,
for added flexibility in shaping the wall.
[0005] Conventional concrete masonry blocks are generally molded in
a dry cast process in which a concrete mixture is filled into a
mold box and compressed to generate a pre-consolidated block. This
pre-block is removed from the mold box and transported to a setting
location at which the block is stored for setting of the concrete
mixture. The pre-block can be provided with an embossed surface
structure only on the top and bottom surfaces. Thus, this process
does not allow for the molding of a dry cast concrete block with a
front decorative surface. Several methods have been developed to
provide hollow dry cast blocks with a textured front surface.
Molding a slab including several blocks and subsequently braking
the slab into individual blocks allows for the creation of an
irregular, rough front surface similar to the surface of a split
natural stone. Alternatively, the smooth front surface of a
finished molded block cab be subjected to a percussive treatment
which brakes up and roughens the front surface. However, neither
method allows for the manufacture of a hollow block with any
decorative front surface, for example a surface having a regular,
surface structure, such as an embossed surface.
[0006] Thus, an economical and effective method is desired for
providing a decorative finish on any building, retaining or
freestanding wall, or on the building blocks of such walls.
SUMMARY OF THE INVENTION
[0007] It is therefore one object of the invention to provide an
economical and effective way of producing a decorative facing
surface on a wall or on wall components.
[0008] This object is achieved by a method including the steps of
mounting to the retaining wall one or more facing panels having a
decorative face surface. Preferably, the panels are dry cast
concrete panels having a regular surface structure, more preferably
an embossed surface, most preferably a patterned surface.
[0009] The wall can be made of any material and the facing panels
can be mounted by any suitable attachment method. Preferably, the
wall is made of concrete, more preferably of stacked courses of
concrete blocks, most preferably dry cast concrete blocks, as is
often the case with retaining walls. Attachment of the facing
panels to the wall is preferably achieved by one or more connecting
members respectively engaging the wall and the facing panel or
panels. The wall can be an existing wall or a wall which is being
built in situ, for example by using wall components, such as wall
blocks. In the latter case, the wall may be built from decorative
wall components, such as decorative wall blocks in accordance with
the invention.
[0010] It is another object of the invention to provide a block for
a retaining wall or freestanding wall, preferably a dry cast
concrete block, with a decorative facing surface, preferably an
embossed facing surface. This object is achieved by a method of
providing a retaining wall block with a decorative facing surface
including the steps of mounting to the retaining wall block a
facing panel having a decorative face surface. Preferably, the
facing panel is a dry cast concrete panel having an embossed face
surface, most preferably a patterned face surface. Attachment of
the facing panels to the retaining wall is preferably achieved by
one or more connecting members respectively engaging the wall and a
facing panel.
[0011] The connecting members can be in the form of individual
connectors respectively engaging one facing panel and one location
on the wall or on a wall component. Alternatively, a network or
grid of connecting members can be mounted or attached to the wall
either by mechanical interlocking structures of the connecting
members and the wall or by suitable fastening means, such as
screws, bolts, expandable plugs, adhesive, or any other
conventional fastening structure, as well as combinations thereof.
The network or grid can be constructed to support one or more
facing panels.
[0012] It is a further object of the invention to provide a modular
decorative wall system for forming both straight and curved walls
with at least a front decorative facing surface, most preferably a
front and back decorative facing surface. This object is achieved
with a retaining wall block system including blocks, facing panels
and connectors, wherein all blocks are of equal depth and height,
but may have different lengths, and all panels are of equal
thickness but may have different lengths and may have different
widths. The blocks of the wall system all have graduated lengths,
each length being a multiple of a base length L which is equal to
the height of the block. Thus, the blocks have lengths of 2L, 3L,
4L, 5L etc. (2H, 3H, 4H, 5H . . . ). Equally, the panels all have
graduated lengths, each length being a multiple of the base length
L. The panels preferably all have the same base height H as the
blocks, but panels having a height which is a multiple of the base
height may also be used together with the base height panels. The
blocks also preferably have the same base height H, but blocks with
a multiple of the base height can also be used as so-called jumper
blocks. To facilitate the formation of walls with corners, such as
right angled corners, the blocks preferably have a depth which is
equal to a multiple of L, most preferably 2L and the panels have a
thickness which is 1L or a multiple of L, most preferably the
facing panel thickness is 1L.
[0013] In still another embodiment, the invention provides a kit
for forming a retaining wall or freestanding wall having at least
one decorative facing surface. The kit includes base blocks which
are stackable for forming a wall, facing panels having a decorative
surface and connecting means for mounting the facing panels to the
blocks in such a way that the decorative surface of the facing
panels is exposed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Preferred embodiments of the invention will now be further
described by way of example only and with reference to the attached
drawings, wherein
[0015] FIG. 1 illustrates different ways of carrying out the method
in accordance with the invention for providing a decorative finish
on a wall by mounting facing panels to the wall;
[0016] FIG. 2 is a perspective view of a decorative block in
accordance with the invention;
[0017] FIGS. 3a to 3g show different configurations of exemplary
connectors in accordance with the invention;
[0018] FIG. 4 is a perspective view of a base block of the
decorative block in accordance with the invention;
[0019] FIG. 5 is a schematic top view of an exemplary wall in
accordance with the invention having a decorative facing on one
side;
[0020] FIG. 6 is a schematic top view of an exemplary wall in
accordance with the invention having a decorative facing on both
sides and forming a corner;
[0021] FIGS. 7a to 7c illustrate the use of the modular wall system
of the invention for the assembly of walls of different curvature
and having a facing on one or both sides;
[0022] FIG. 8 illustrates a connector panel in accordance with the
invention;
[0023] FIG. 9 a large block for a mass retaining wall including a
facing in accordance with the invention;
[0024] FIG. 10 illustrates a disassembled decorative block in
accordance with the invention having horizontal retaining
recesses;
[0025] FIG. 11 is a perspective view of a connector in accordance
with the invention for mounting facing panels to base blocks
wherein the respective retaining recesses are oriented
perpendicular to one another;
[0026] FIG. 12 is a perspective view of an exemplary snap-in type
connector in accordance with the invention;
[0027] FIG. 13a is a top view of a decorative column block in
accordance with the invention;
[0028] FIGS. 13b and 13c illustrate column or pillar constructions
using wall blocks and facing panels in accordance with the
invention; and
[0029] FIG. 14 is a perspective view of a basket and facing block
combination.
DETAILED DESCRIPTION
[0030] Before explaining the present invention in detail, it is to
be understood that the invention is not limited to the preferred
embodiments contained therein. The invention is capable of other
embodiments and of being practiced or carried out in a variety of
ways. It is to be understood that the phraseology and terminology
employed herein are for the purpose of description and not of
limitation.
[0031] FIG. 1 illustrates the method in accordance with the
invention of providing a decorative finish on a wall 100, such as a
retaining wall or freestanding wall, by mounting a facing panel 110
having a decorative surface 112 to the wall 100. In the preferred
embodiment, the facing panel 110 is connected with the wall 100 by
way of connectors 120, which engage both the wall and the facing
panel. The preferred connector 120, which is also illustrated
separately in FIG. 3a, has a pair of spaced apart parallel,
cylindrical stems 122 connected by an intermediate web 124. The
stems 122 form interlocking members, which engage and are reliably
held in keyhole slots 102, 112 respectively provided in the front
face 104 of the wall and the rear face 114 of the facing panel 110.
The connectors 120 are preferably inserted first into the keyhole
slots 102 in the wall. This allows the installer to mount the
facing panel 110 by sliding it onto the already installed
connector. The wall can be of any material, for example concrete,
and can be solid, for example cast in situ, or made of stacked
elements, such as blocks 106. Instead of the continuous keyhole
slots 102, the wall can also be provided with blind slots 108 and a
recessed entry 109 for a connector 120. The wall can be provided
with a plurality of facing panels mounted to the wall for exposing
the decorative surface. Preferably, the plurality of panels are
mounted to the wall and arranged to completely cover the wall. For
ease of use, the connectors 120 are preferably symmetrical, which
means the cylindrical stems 122 are identical in cross-section and
size, but non-symmetrical variants with stems 122 of different
diameter and cross-sectional shape can also be used.
[0032] In a retrofit embodiment of the method in accordance with
the invention, intended for use with existing walls devoid of
keyhole slots, a retrofit connector 130 is fastened to the wall,
which has only one interlocking member 132 for engagement in the
keyhole slot 112 in the facing panel 110. The retrofit connector
130 is fastened to the wall by any suitable fastener, for example
anchor bolts 134. It will be readily apparent that the retrofit
connector 130 can be provided in the form of a grid or network of
interconnected, parallel or intersecting connectors. This
facilitates installation of the retrofit connector on the wall 100
at the exact spacing required for mounting of the facing panels 110
in an abutting relationship.
[0033] In another retrofit embodiment of the method in accordance
with the invention, the facing panel 110 is mounted to the wall 110
by interlocking hook shaped hangers 140 and 142 respectively
fastened to the front surface 104 of the wall 100 and the rear
surface 114 of the panel 110. It will be readily apparent to the
person skilled in the art that numerous other options exist for
mounting the decorative panels 110 to the wall 100. The invention
is not limited to the specific connector options disclosed, the
exact manner of mounting the facing panels 110 to the wall 100
being immaterial, as long as the facing panels are reliably held on
the wall in the orientation respectively desired.
[0034] FIG. 8 illustrates another retrofit embodiment in accordance
with the invention, wherein a connector panel 150 is fastened to an
existing wall 100 for the mounting of decorative facing panels 110
on the wall. The connector panel 150 includes a base panel 152 and
multiple spaced apart parallel connecting ribs 154. The ribs 154
can be integrally molded with the base panel 152 or separately
manufactured and fastened to the panel. The connector panel 150 is
fastened to the wall 100 by way of fasteners 156, such as screws,
bolts, anchors, etc. The connector panel 150 may also be adhesively
fastened, as long as a reliable and durable connection is achieved
and separation of the panel from the wall 100 is prevented. Facing
panels 110 in accordance with the invention are mounted on the
connector panel 150 by inserting the connecting ribs 154 into the
keyhole slots 112 in the rear surface of the facing panels 110 and
sliding the panels along the ribs until the desired installation
location is reached. An aesthetically pleasing appearance of the
decorative finish can be achieved by using facing panels of
different length and height as illustrated.
[0035] Irrespective of the manner of attachment of the decorative
finish, the finish preferably consists of a plurality of facing
panels 110, most preferably a sufficient number of facing panels to
completely cover the entire surface of the wall. The weight of the
facing panels 110 can be supported on a footing of the wall (not
shown), on a separate footing, or by the connectors as will be
described in more detail below.
[0036] FIG. 2 illustrates the method in accordance with the
invention for providing a dry cast concrete block with a decorative
finish, preferably an embossed front facing. FIG. 2 is a
perspective view of a preferred decorative wall block in accordance
with the invention having a decorative finish. Dry cast concrete
blocks are manufactured in molds which allow top to bottom
compression only, which means it is very difficult to emboss the
front surface of such a block. With the method of the invention, a
dry cast concrete block 210 is provided with an embossed decorative
facing by mounting to the block a separately manufactured dry cast
facing panel 220 having an embossed top surface. The facing panel
is mounted to the block in such a way that the embossed surface
becomes the facing surface of the block. As shown in FIG. 2, the
decorative wall block 200 includes a base block 210 and a facing
panel 220 having an embossed decorative surface 222. The base block
210 is a hollow dry cast concrete block, for example a block having
a central through going bore 212 of oval cross-section. The base
block 210 was compressed in the top-to-bottom direction. Face panel
220 is a dry cast concrete block which was also compressed in the
top to bottom direction during manufacture, but is mounted with its
bottom surface 224 against a front surface 214 of the block 210 so
that the top surface 228 of the facing panel 220 is facing away
from the block 210 and thereby forms the new front surface of the
block 200.
[0037] It is readily apparent to the person of skill in the art
that the method in accordance with the invention of providing a
wall block with a decorative finish can be used in connection with
any type of stackable concrete block, even blocks that are not dry
cast. The facing can be mounted to the block irrespective of the
size and shape of the block. The facing can also be mounted
irrespective of the manner in which the block engages or
interlocks, if any, with any adjacent blocks or with any
reinforcing members, such as rods, ties, or netting. In other
words, the method of the invention for providing a concrete block
or wall with a decorative front surface can be employed in
connection with any type of conventional block or wall
component.
[0038] The facing panel 220 preferably has an embossed decorative
surface, more preferably an embossed, patterned surface which
functions as the new front surface of the decorative wall block
200. The facing panel 220 is mounted to the base block 210 by way
of connectors 120 as shown in FIG. 3a and discussed above. The base
block 210 has at least one keyhole slot 216, preferably a pair of
spaced apart parallel keyhole slots 216, in its front surface 214
and the facing panel 220 includes at least one keyhole slot 226,
preferably a pair of equally spaced keyhole slots 226 in its rear
surface 224 (bottom surface during molding of the panel). Each
keyhole slot 216 has a slot portion 216a penetrating the front
surface 214 of the base block 210 and a cylindrical bore portion
216b connected thereto. Each keyhole slot 226 has a slot portion
226a penetrating the front surface 224 of the facing panel 220 and
a cylindrical bore portion 226b connected thereto. The stems 122 of
the connectors 120 are respectively inserted into the keyhole slots
216, 226 to mount the facing panel 220 to the block 210. The facing
panel 220 is preferably sized to completely cover the front surface
214 of the block.
[0039] FIG. 10 shows a variant of the decorative block 200 wherein
the keyhole slots 216 and 226 in the base block 210 and facing
panel 220 respectively are oriented horizontally instead of
vertically. This block design is particularly useful in situations
where installation space is limited in vertical direction, for
example when installing the top rows of facing panels 220 onto a
wall under an overhang or a ceiling. Furthermore, this block design
is also particularly useful for the installation of jumper blocks
and their facings, as discussed in more detail below, which jumper
blocks are installed in a wall in an orientation rotated by
90.degree. relative to that of surrounding blocks. Mounting of the
facing panel 220 to the base block 210 is achieved by connectors
120 as described above.
[0040] Multiple decorative wall blocks 200 as shown in FIGS. 2 and
10 can be used to build a decorative wall. The decorative wall
blocks are thereby stacked in rows, preferably staggered for
additional stability, to form a decorative wall. For maximum
installation flexibility and ease of handling, the decorative
blocks are preferably handled in the disassembled condition, which
means the base blocks 210 are first separately stacked to form the
wall and the facing panels are only subsequently mounted to the
already stacked base blocks. For that purpose, the invention
provides a kit for a decorative wall, which kit includes a number
of base blocks, facing panels for the blocks and connectors for
mounting the facing panels to the blocks. The attachment of the
facing panels is preferably carried out on a row by row basis, as
each row of base blocks is finished, so that the connectors need
not be forced through the keyhole slots of more than one block. In
the alternative, only the insertion of the connectors is done on a
row by row basis. However, this will require moving most facing
panels along several connectors and may increase the time required
for installation of the complete wall. Jumper blocks can be
included in the wall, which are larger in size than the remaining
blocks and rotated by 90.degree.. When jumper blocks of the same
principle construction as the surrounding blocks are used, the
facing panel is preferably installed immediately after placement of
the jumper block and before the rows of blocks around the jumper
block are finished. Sliding of the facing panel onto the connector
in the jumper block may no longer be possible once the connectors
of the adjoining blocks are installed, due to their orientation
perpendicular thereto. However, where jumper blocks are used which
have a principle construction as illustrated in FIG. 10,
installation of the facing panel onto the jumper block can be
carried out in the ordinary course of installation of the
decorative facing, since the slots in the jumper block are then
parallel to those in the surrounding blocks.
[0041] FIG. 4 shows a preferred base block 210 in accordance with
the invention. The base block 210 has a top surface 211, a bottom
surface 213, a pair of opposite end surfaces 215, 217 and front and
back surfaces 214, 219. The block 210 has at least one retaining
groove provided in the front surface 214, which retaining groove is
preferably in the form of a keyhole slot 216 having a slot portion
216a penetrating the front surface 214 of the base block 210 and a
cylindrical bore portion 216b connected thereto. The cylindrical
bore portion 216b is sized and shaped for receiving one of the
interconnecting members of the connectors, the stems 122. The slot
portion 216a is sized and shaped for receiving the web 124 of the
connector 120, the width of the slot portion 216a being less than
the diameter of the stem 122 in order to prevent the connector 120
being pulled out of the keyhole slot 216 by the weight of a facing
panel 220. For maximum flexibility in connecting the facing panels
220 to the base block 210, the base block preferably has a pair of
retaining slots in the front surface. In order to enable the
application of a decorative facing on front and back surfaces of
the block, and even at corners of the wall, the base block 210 is
preferably provided with at least one keyhole slot in each of the
front and back surfaces 214, 219 and most preferably also in the
end surfaces 215, 217. When multiple keyhole slots are provided on
one surface, the slots are preferably parallel and equidistantly
spaced on the respective surface. The slots are preferably oriented
vertical or horizontal and centered on the blocks and panels.
Although other orientations of the slots are possible those
orientations may make assembly of the decorative surface more
challenging. The keyhole slots 216 preferably extend from the top
surface 211 to a bottom surface 213 of the block and the panel.
However, closed end keyhole slots 216c can also be used. The
keyhole slots 216 and 226 preferably extend from a top surface to a
bottom surface of the block and the panel. However, closed end
keyhole slots 216a can also be used.
[0042] FIG. 9 illustrates another decorative block in accordance
with the invention, which is used as a component of a mass
retaining wall. Mass retaining walls, or gravity walls are used in
industrial applications to retain large amounts of material, for
example along recessed highways, around bridge heads, or as
seawalls. The component blocks of mass retaining walls are normally
cast concrete blocks having a volume of 1 m.sup.3 or more and
include a lifting bar for handling of the block with heavy
machinery. The block shown is such a component block 160 for a mass
retaining wall, which block includes a lifting bar 162 and a
plurality of spaced apart parallel keyhole slots 216 on its front
surface. Facing panels 110 in accordance with the invention which
include keyhole slots 112 can be mounted to the component block 160
in the manner described above in relation to FIG. 2, by inserting
one interconnecting member of the connectors 120 (see FIG. 2, FIGS.
3a-e and FIG. 4) into the keyhole slots 216, engaging the other
interconnecting member of the connectors into the keyhole slots 112
in the facing panels and sliding the facing panels to their
respective installation locations. Existing mass retaining wall
blocks 160 without keyhole 216 can also be retrofitted with a
decorative facing by using a connector panel 150 as illustrated in
FIG. 8.
[0043] FIG. 13 illustrates a further variant of a decorative block
in accordance with the invention, a column block 250. The column
block 250 is preferably of square cross-section, but may have any
other cross-section desired, for example hexagonal or octagonal.
Multiple column blocks can be stacked one on top of the other to
form a freestanding column (not shown). The column block 250
includes at least one keyhole slot 216 on each side, preferably a
pair of keyhole slots per side, for the mounting of a decorative
facing to the column. The preferred facing is in the form of facing
panels 220 in accordance with the invention, which are also
provided with keyhole slots 226 for attachment to the column block
250 by way of connectors 120 in accordance with the invention.
Columns, posts or pillars of different dimensions and
cross-sections as shown in FIGS. 13b and 13c can also be
manufactured by using base blocks 210 and having panels 220
designed for the construction of walls. FIG. 13b illustrates a
column made by placement of 3 wall blocks 210 back to back, while
FIG. 13c shows a hollow column achieved by placement of 4 wall
blocks 210 in a square arrangement. It will be readily apparent
that many different columns of different sites and cross-sections
can be produced in this manner.
[0044] FIG. 3b shows a variant of the connector shown in FIG. 3a,
wherein one of the stems 122 is extended beyond the end of the web
124. This connector 120 is particularly suited for use with a base
block 210 having a closed end keyhole slot 216c (see FIG. 4),
whereby the shorter stem 122a is inserted into the closed keyhole
slot 216c and the longer stem 122b is for engagement with the
keyhole slot 226 in a facing panel 220 (see FIG. 2).
[0045] FIG. 3c shows another variant of the connector 120 shown in
FIG. 3a, wherein an end of each stem 122 is provided with a stop in
the form of an enlarged end 125 for limiting movement of the stem
122 in a keyhole slot 216 of the base block 210. The stop is
preferably in the form of a flared end 125 having a rim 127 of
enlarged diameter. The rims 127 are preferably located at opposite
ends of the connector 120 and have a diameter larger than the
diameter of the bore section 216b of the base block 210 or the bore
section 226b of the facing 220 (see FIG. 2). Furthermore, the
overall length of this connector variant, from the widest point of
one rim 127 to the widest point of the other rim 127 is preferably
equal to the overall height of the base block 210 and the facing
220. This connector makes it possible to support the facing 220
from the base block 210 by inserting one of the stems 122 with its
un-enlarged end from the top into the keyhole slot 216 of the base
block 210 (see FIG. 4) until the enlarged end 125 comes to rest
against the top end of the keyhole slot and then sliding the facing
panel 220 from the top onto the other stem 122 until the bottom end
of the keyhole slot 226 in the facing panel comes to rest against
the rim 127 of the other stem. Since the rims 127 are wider than
the respectively associated keyhole slot 216, 226, the facing panel
is then supported on the connector and the connector is supported
on the base block.
[0046] FIG. 3d is a further variant of the connector 120 shown in
FIG. 3a, wherein each stem 122 is provided with a tapered end 128
to facilitate insertion of the stem into a keyhole slot 216, 226
(see FIG. 2). The ends 128 are located at opposite ends of the
connector variant. It would be readily apparent to the person
skilled in the art that the stems 122 may also be provided with a
tapered end 128 at each end in order to maximize the versatility of
the connector.
[0047] Any of the connectors 120 shown in FIGS. 3a to 3f can be
provided with one or more locking ribs 129 on one or both of the
stems 122 as shown in FIG. 3d and FIG. 3e, which is a cross-section
of FIG. 3d taken along line 3e-3e in FIG. 3d. The ribs 129
respectively extend in longitudinal direction of the stem 122 and
are intended to provide a localized enlargement of the stem, which
creates an interference fit of the stem in a bore of a block or
facing into which the stem is inserted. This prevents unwanted
displacement of the connector 120 during assembly of the decorative
block or wall of the invention.
[0048] The connectors 120 can be made of any material sufficiently
strong to reliably mount the facing 220 to the base block 210. The
connectors are preferably made of any material which will be
resistant to deterioration upon exposure to the elements, soil,
gravel and the like. The most preferred material is plastic,
although non-corroding metal alloys or metal connectors with a
non-corroding surface finish can also be used.
[0049] A connector 130 for use in retrofitting an existing wall of
stacked, hollow blocks 310 with a decorative facing is shown in
FIG. 3f. This connector 130 is provided with a block engaging
portion 132 having a flat base 131 for laying on top of the block
310 and between adjacent rows of blocks in the wall, and a
depending locking tab 133 for engaging the vertical bore 312 of the
block for locking the connector 130 to the block. The connector 130
further includes a depending facing bridge 134 for laying against a
front face 314 of the block 310 and an integrated stem 138 and web
136 for respectively engaging the bore 226a and slot 226b of a
keyhole slot 226 in a facing panel 220 (see FIG. 2). It will of
course be readily apparent to the person skilled in the art that
more than one connector 130 can be used per hollow block 130 for
added reliability of the facing mount and better alignment and
balancing of the wall blocks.
[0050] Although all the preferred connectors 120, 130 described
herein include interlocking members in the form of the cylindrical
stems 122 intended for being mounted to the base blocks 210 or
facing panels 220 by sliding them along the keyhole slots 216, 226,
connectors with stems of different cross-section can also be used,
the only requirement being that the stems have a shape and
thickness which prevents the weight of the facing panel pulling the
connector out of the keyhole slot in which it is engaged.
Furthermore, connector and retaining groove combinations other than
those particularly exemplified can be used without deviating from
the present invention. For example connectors of the snap in type
can be used. An exemplary snap in connector 170 is shown in FIG.
12. Connector 170 is similar in construction to the connectors 120
shown in FIGS. 3a to 3e and includes a first interconnecting member
171 in the form of a stem 122, a second interconnecting member 172
of the snap-in type and an intermediate web portion 124. The
connector 170 is constructed for insertion into the slot portion
216a or 226a of a keyhole slot 216, 226 (see FIG. 2) in a
compressed condition and for expanding in the bore portion 216b or
226b when fully inserted. The snap-in interconnecting member
includes a pair of spaced apart parallel and resilient retaining
arms 173 defining an intermediate compression gap 174 allowing a
deflection movement of the retaining arms towards one another. The
retaining arms 173 are curved to closely fit the contour of the
bore portion 216b or 226b of a keyhole slot 216 or 226 (see FIG. 2)
when in their at rest position. The retaining arms 173 are made of
sufficiently flexible and resilient material to allow elastic
deformation of the arms and a subsequent return to their original
shape and position. The snap-in connector 170 is installed in a
keyhole slot 216, 226 by forcing the retaining arms 173 through the
slot portion 216a or 226a into the bore portion 216b, 226b. While
the retaining arms 173 are forced through the slot portion 216a,
226a, they are deflected towards one another, which is made
possible by the compression gap 174. When the retaining arms 173
reach the bore portion 216b 226b, they return to their initial at
rest position and thereby lock the connector in the keyhole
slot.
[0051] FIG. 11 illustrates a cross-connector 180, which is a
variant of the connectors 120 shown in FIGS. 3a-3e. The
cross-connector 180 includes a pair of interconnecting members 181,
182, preferably in the form of cylindrical stems 122, and an
intermediate web 184. The stems 122 are principally the same as
those in the connectors of FIGS. 3a to 3e, although they may be of
different length, as illustrated. However, the stems 122 are not
oriented parallel as in the connectors discussed above, but are
oriented at an angle of 90.degree. relative to one another. This
connector allows for the mounting of facing panels to base blocks
having keyhole slots oriented at 90.degree. to those in the facing
panels. For example, when one of the blocks in a wall is rotated by
90.degree. to function as a jumper block, the cross-connector 180
can be used to mount a facing panel to the jumper block in the same
orientation as the facing panels of surrounding blocks.
[0052] Of course, it will be readily apparent to the art skilled
person that a retaining structure other than keyhole slots can be
provided in the blocks 210 and panels 220 as long as a reliable
interlocking engagement between the retaining structure and the
connectors respectively used is ensured. For example, the retaining
structure can be in the form of a slot or bore and the connector
can be a compressible/expandable connector which is insertable into
the slot or bore and locks in the slot or bore when fully inserted
in order to reliably retain the connector in the slot. This can be
of advantage for retrofit applications, wherein, for example, a
retaining slot is cut or a retaining bore is drilled into the front
face of an existing wall and compressible and/or expandable
connectors are used for insertion into and interlocking engagement
in the slot or bore. It is also apparent from the exemplary variant
connector shown in FIG. 3g that connectors can be used which have a
combination of different mounting structures. The variant connector
has a web 124 and a stem 122 for engagement of a keyhole slot 226
in a facing panel 220 and compressible/expandable plugs 180 for
interlocking engagement in a bore drilled into an existing wall
(not shown), or a bore 182 drilled into the front face of an
existing wall block (see FIG. 4), or a keyhole slot 216 in a base
block 210 (FIG. 4) or slots in existing walls or blocks.
[0053] FIGS. 5 to 7 schematically illustrate the modular wall
system in accordance with the invention. Conventional retaining or
decorative walls are erected by simply stacking a multitude of
identical blocks. Equally, a retaining or decorative wall in
accordance with the invention can be erected by using a multitude
of equal stackable decorative blocks 200 (see FIG. 2) each
including a base block 210 and facing panel 220. However, the range
of possible wall designs using only blocks of equal height and
length is limited. Unless the length of the wall is exactly a
multiple of the block length, at least one block must be cut for
each row of blocks in the wall. Furthermore, although the blocks
can be aligned along a curved path, the range of curvature shapes
and radii achievable is limited. The inventors of the present
invention have now discovered, that the design possibilities can be
vastly improved when base blocks 210 and facings 220 of different
length are used. Furthermore, the inventors have surprisingly
discovered that the design possibilities can be vastly improved, in
particular for curved walls and walls having a decorative surface
on both sides, when blocks and facings of staggered length are
used. In a preferred embodiment of the modular wall system of the
invention as illustrated in FIG. 5, the system includes a
combination of individual stackable base blocks 210 having a length
which is a multiple of a pre-selected base length L. Thus, the
blocks are graduated in length and have lengths of 2L, 3L, 4L, 5L
etc. Equally, the facing panels 220 all have graduated lengths,
each length being a multiple of the base length L. The blocks
preferably all have the same base thickness or depth T and
preferably also the same base height H. Maximum design flexibility
is achieved with blocks wherein the base length L is equal to the
base height H and the base thickness is 2L. Preferably, the
thickness PT of the facing panels 220 is 1L. Panels having a height
which is a multiple of the base height may also be used together
with panels having the base height H. Blocks with a multiple of the
base height can also be used as so called jumper blocks which are
installed in a the wall in an orientation rotated by 90.degree.
relative to the other blocks.
[0054] In order to further improve the design flexibility, the base
blocks 210 preferably have keyhole slots 216 in their front, back
and end surfaces. It is of course readily understood by the art
skilled person that for alignment of the facing panels 220 with the
base blocks 210 the placement of the keyhole slots 216 in the base
blocks 210 of one length must be coordinated with the placement of
the keyhole slots 226 in the facing panels 220 of equal length.
[0055] An even higher design flexibility and vastly facilitated
assembly of the wall is achieved with a particularly preferred
variant of the modular wall system of the invention, wherein each
keyhole slot 216 in the base block 210 is placed at a distance from
an end of the block, which is equal to the base length L. Blocks
with a length of 3L or higher preferably have two keyhole slots 216
respectively spaced at the distance L from the ends of the block.
Blocks of length 4L or higher may be provided with additional
keyhole slots 216, which are evenly spaced from one another,
preferably at the distance L. The number and placement of the
keyhole slots 226 in the facing panels is preferably selected in
the same manner. Placement of the keyhole slots in this manner
allows a mixing and matching of the base blocks and facing panels
and the mounting of a facing panel of one length to a base block of
a different length. It also allows the mounting of facing panels to
a wall of stacked blocks in a staggered manner in which the facing
panels overlap the vertical or horizontal joints of the base
blocks.
[0056] Placement of keyhole slots 216 in the ends of the base
blocks 210 allows the forming of walls with corners and even
provides the flexibility of mounting a decorative facing surface on
both sides and at ends of the wall as shown in FIG. 6.
[0057] As illustrated in FIGS. 7a to 7c, the base blocks 210 may
have a tapered cross-section with angled side walls 215, 217,
resulting in blocks having a rear face which is more narrow than
the front face. This facilitates the assembly of curved walls. Most
preferably, the base blocks are not only tapered front to back, but
further include lateral ears 230 as extensions of the rear face 219
(see FIG. 7c), which ears are of sufficient width to bring the rear
face back to the same width as the front face 214, but can be
broken off by the user for assembly of a curved wall as shown. The
facing panels 220 are also preferably provided with a bevel 229 at
their lateral ends in order to allow for a closer fit of the facing
panels in curved wall applications. As is readily apparent from
FIGS. 7a to 7c, the curvature of the wall can be adjusted by using
base blocks and facings of different length. Generally, the shorter
the blocks, the tighter the radius that can be created.
[0058] FIG. 14 shows a retaining wall member 300 consisting of a
combination of a facing panel 210 in accordance with the invention
with a retaining basket 310 to be filled with loose material. This
wall member can be used for assembling a retaining wall by
attaching the facing panel 210 to the retaining basket 310 to form
the wall member 300, aligning a row of the relating members at the
desired wall location and fitting the retaining baskets 310 with
loose material, preferably gravel. Subsequent rows of retaining
members 300 can be successively stacked on top of an existing row
of retaining members, whereby the retaining baskets 310 of the
members 300 in each row are preferably filled prior to the stacking
of a subsequent row therein, for added stability of the retaining
wall during assembly. The person skilled in the art will readily
appreciate that many different types of material can be used for
filling the retaining basket 310, including settable materials such
as concrete. Filling the baskets of the bottom row of a retaining
wall made of retaining members 300 may provide additional stability
to the base of the wall. Of course, filling all baskets of the
retaining members 300 in a wall with concrete will result in a
concrete retaining wall with decorative facing.
[0059] While the invention has been described with a certain degree
of particularity, it is understood that the invention is not
limited to the embodiments set forth herein for purposes of
exemplification, but is to be limited only by the scope of the
attached claims, including the full range of equivalency to which
each element thereof is entitled.
[0060] The above-described embodiments of the present invention are
intended to be examples only. Alterations, modifications and
variations may be effected to the particular embodiments by those
of skill in the art without departing from the scope of the
invention, which is defined solely by the claims appended
hereto.
* * * * *