Patent Application
20150354213
This disclosure relates to concrete blocks that can be used as base blocks for a retaining wall or a free-standing wall. This disclosure also relates to methods of arranging the base blocks for constructing the wall.
Concrete blocks can be used to create various structures, including, for example, retaining walls and free-standing walls for landscaping. Example free-standing walls are described in U.S. Pat. No. 8,256,182, incorporated herein by reference. The free-standing walls described in U.S. Pat. No. 8,256,182 use a plurality of base blocks to form the foundation or base of the wall, and then a variety of other blocks are stacked on the base blocks to complete the wall. The free-standing walls of U.S. Pat. No. 8,256,182 can be made curved or serpentine in shape. The base blocks are laid down in the desired curved shape of the resulting wall. The base blocks can also be used to provide the base of a retaining wall.
What is desired is an easier and more convenient way of making curved or serpentine walls, including, e.g., retaining walls or free-standing walls.
In one aspect, a wall base block is provided. The base block comprises opposed top and bottom faces; opposed first and second side faces extending between the top and bottom faces; and opposed first and second end faces extending between the top and bottom faces and between the first and second side faces. The first end face is convex and the second end face is concave and of generally the same curvature as the first end face, so that the convex first end face of one wall base block can closely nest within the concave second end face of an adjacently placed second wall base block. Alignment indicia are provided on the top face adjacent the first and second end faces of the base block to assist in aligning adjacent nested blocks in straight or other predetermined angular relationships.
The alignment indicia can comprise notches adjacent the first and second end faces of the base block.
The alignment indicia notches can be formed in the first and second end faces and extend from the top face to the bottom face of the base block.
The first and second side faces can be oriented generally at right angles to the top and bottom faces.
The first and second end faces can be oriented generally at right angles to the top and bottom faces.
The unit can be formed of concrete having a net compressive strength of at least about 3000 psi.
The unit can be formed of dry cast concrete.
The alignment indicia may include at least one notch in one of the first end face and second end face, and a plurality of notches in the other of the first end face and second end face.
The alignment indicia can include no more than a single notch in one of the first end face and second end face, and a plurality of notches in the other of the first end face and second end face.
The alignment indicia may include at least one notch in one of the first end face and second end face, and a plurality of evenly spaced notches in the other of the first end face and second end face.
The alignment indicia may include at least one notch in the second end face and a plurality of notches in the first end face.
The alignment indicia can include no more than a single notch in one of the first end face and second end face, and at least 5 notches in the other of the first end face and second end face.
The 5 notches can be evenly spaced apart around the curvature of the first end face.
The single notch can be in the second end face, and the 5 notches can be in the first end face.
The radius of curvature of the first end face and second end face can be at least 5 inches.
The radius of curvature of the first end face and second end face can be no greater than 6 inches.
In another aspect, a method of forming a straight or angular base for a wall is provided. The method comprises providing a first wall base block having a first rounded convex end face, an opposite second rounded concave end face having generally the same radius of curvature as the first end face, first and second side faces extending between the first and second end faces; a flat top face and an opposite bottom face between the first and second end faces and the first and second side faces; the first wall base block having alignment indicia on the top face adjacent the first and second end faces. The method comprises orienting the first wall base block on a surface with its bottom face against the surface. The method comprises providing a second wall base block having a first rounded convex end face, an opposite second rounded concave end face having generally the same radius of curvature as the first end face, first and second side faces extending between the first and second end faces; a flat top face and an opposite bottom face between the first and second end faces and the first and second side faces; the second wall base block having alignment indicia in at least the top face adjacent the first and second end faces. The method comprises orienting the second wall base block on the surface with the second wall base block bottom face against the surface and so that the first end face of the first wall base block is received within the second end face of the second wall base block. The method comprises, while orienting the second wall base block, aligning the alignment indicia of the first wall base block relative to the alignment indicia of the second wall base block to achieve a desired straight or predetermined angular shape of the base for the wall.
The method can include providing a third wall base block having a first rounded convex end face, an opposite second rounded concave end face having generally the same radius of curvature as the first end face, first and second side faces extending between the first and second end faces; a flat top face and an opposite bottom face between the first and second end faces and the first and second side faces; the third wall base block having alignment indicia on the top face adjacent the first and second end faces. The method can include orienting the third wall base block on the surface with the third wall base block bottom face against the surface and so that the first end face of the second wall base block is received within the second end face of the third wall base block. The method can include, while orienting the third wall base block, aligning the alignment indicia of the first end face of the second wall base block relative to the alignment indicia of the second end face of the third wall base block to achieve the desired straight or predetermined angular shape of the base for the wall.
A base block constructed in accordance with principles of this disclosure can be used to form a base of walls, including, for example, retaining walls and free-standing walls.
One example embodiment of a free-standing wall using a base block constructed in accordance with the principles of this disclosure is shown in
The free-standing wall 30 includes a plurality of base blocks 42, made in accordance with the principles of this disclosure. The base blocks 42 are provided to form the foundation of the wall 30. In other embodiments, the base blocks 42 form the foundation of other types of structures, including retaining walls. The base blocks 42 are placed on the ground upon which the wall 30 is to be constructed. The base blocks 42 are arranged adjacent to each other, end to end, to form a base course 44 of the wall 30. In the example embodiment of
Cap blocks 110 are depicted at the top of the wall 30, bridging the first plurality of wall blocks 38 and the second plurality of wall blocks 40.
Referring now to
Between the first and second sides 51, 52 are first and second end faces 54, 55. The first end face 54 is a rounded convex end 56, while the second end face 55 is a rounded concave end 57. The convex end 56 and concave end 57 have the same radius of curvature, such that the base blocks 42 can be positioned next to each other with the first rounded convex end 56 of one base block fitting within the second rounded concave end 57 of a second base block. Examples are shown and discussed in connection with
The shape of the first end face 54 and second end face 55 allows for the base blocks 42 to be arranged in a curved or serpentine pattern in a predetermined angular relationship, and in a straight line. In preferred embodiments, the radius of curvature of the convex end 56 and the concave end 57 is at least 5 inches, no greater than 6 inches, and preferably about 5.5 inches.
Between the first and second ends faces 54, 55 and the first and second side faces, 51, 52 are the top face 46 and an opposite bottom face 47. In general, the top face 46 has a contact surface 60, which is flat, to receive the first plurality of wall blocks 38 and the second plurality of wall blocks 40. The bottom face 47 faces and is against the ground.
In the illustrated embodiment, the first and second side faces 51, 52 are at right angles to the top and bottom faces 46, 47. However, the intersection of the first side face 51 with the top and bottom faces 46, 47, and the intersection of the second side face 52 with the top and bottom faces 46, 47 do not necessarily have sharp corners, but can be radiused.
In the illustrated embodiment, the first and second end faces 54, 55 are at right angles to the top and bottom faces 46, 47. The intersection of the first end face 54 with the top and bottom faces 46, 47, and the intersection of the second end face 55 with the top and bottom faces 46, 47 do not necessarily have sharp corners, but can be radiused.
In the preferred embodiment, the bottom face 47 includes a plurality of recessed pockets 62. The pockets 62 permit the ground to be received within the pockets 62 and help to anchor or secure the base block 42 to the ground. While a variety of implementations are possible, in the illustrated embodiment, the pockets 62 include 4 cavities 64, each cavity 64 being in one quadrant of the base block 42. The cavities 64 have a circular shape, but could be any shape. The cavities 64 have a depth of about 0.375 inches, and will generally be greater than 0.25 inch and no greater than 0.5 inch. The cavities 64 allows for sand or gravel used as a leveling pad to embed and help to lock and secure the base block 42 to the ground.
Preferably, the base block 42 further includes a hand hold arrangement 65. The hand hold arrangement 65 can include at least one hand-receiving indent 66 in the bottom face 47. The hand-receiving indent 66 is sized to accommodate at least a few fingers of a human hand and is provided to assist the user in movement and manipulation of the base block 42. While a number of variations are contemplated, in the illustrated embodiment, the hand hold arrangement 65 includes 2 hand receiving indents 66, 67, one located along each of the first and second side faces 51, 52 and generally centered between the first end face 54 and second end face 55. The hand-receiving indents 66, 67 allow a user to insert their fingers underneath the base block 42 when the bottom face 47 is down on the ground. The user's fingers can slide into the space provided by the indents 66, 67 and the user then can move the base block 42 around. The hand-receiving indents 66, 67 may have a height of about 0.625 inches, and be at least 0.5 inches and no greater than 2 inches.
The hand hold arrangement 65 can further include, in addition to or alternative to one or more of the hand receiving indents 66, 67, a through-core arrangement 68 extending completely through the block 42 from the top face 46 to the bottom face 47. The through-core arrangement 68 can provide a structure for a human hand to grip, and it can help to result in a lighter weight block 42.
The core arrangement 68 includes first and second cores 70, 72. The first and second cores 70, 72 are generally centered between the first and second side faces 51, 52 and can be symmetrical with respect to the location between the first and second end faces 54, 55. The first and second cores 70, 72 are sized to accommodate a human hand and form hand holds for the block 42. That is, a user can put one of their hands in one of the first and second cores 70, 72, and their other hand in the other of the cores 70, 72 to grasp the block portion 74 between the first and second cores 70, 72 to move and carry the block.
The core arrangement 68 including the first core 70 and second core 72 have first and second edges 76, 77 that are preferably parallel to the first and second side faces 51, 52, respectively. Between the first and second edges 76, 77 are third and fourth edges 79, 80, such that each of the first core 70 and second core 72 is generally rectangular in shape. The first and second edges 76, 77 being parallel to the first and second side faces 51, 52 is helpful in forming a guide for the arrangement of the first plurality of wall blocks 38 and second plurality of wall blocks 40 on the base blocks 42, as explained in U.S. Pat. No. 8,256,182, incorporated herein by reference.
Referring to
In one preferred embodiment, the base block 42 has a length between the tips 82, 83 and center bight 90 of the concave end 57 of about 17.5 inches, at least 6 inches, and no greater than 38 inches. The width of the base block 42 between first side edge 51 and second side edge 52 is about 11 inches, at least 8 inches and no greater than 36 inches. The width of each of the cores of the through core arrangement 68 between the first and second edges 76 and 77 is about 2 inches, at least about 1 inch, and no greater than 6 inches. The length of each of the cores of the through core arrangement 68 between the third edge 79 and fourth edge 80 is about 3 inches, at least 1 inch, and no greater than 6 inches. Each of the hand receiving indents 66 has an overall length in the direction from the block second end 55 to the block first end 54 of about 4 inches, at least about 2 inches, and no greater than 10 inches. The width of each of the hand receiving indents 66, 67 from each of the respective first and second sides 51, 52 is about 1 inch, at least 0.5 inches, and no greater than 3 inches. In general, the hand receiving indents 66, 67 have a generally rectangular shape in appearance, except where the indents 88, 89 protrude within the hand receiving indents 66, 67.
In the illustrated embodiment, the base block 42 can be divided into 2 regions, 92, 93. The regions 92, 93 are divided by the side indents 88, 89. Region 92 is the region between the side indents 88, 89 and the first end face 54. Region 92 has a general shape from the top or bottom view of a truncated circle; that is, a circle that has been cut off in a region below the diameter. The region 93 is the region between the side indents 88, 89 and the second end 55. Region 93 has an appearance of a rectangle with a pair of jutting tails formed by the tips 82, 83.
The base blocks 42 can be made from concrete. The concrete preferably has a net compressive strength of at least about 3000 psi. The concrete is preferably dry cast concrete, but it may also be wet cast concrete
In accordance with principles of this disclosure, the base blocks 42 include an alignment system 100. The alignment system 100 is used to assist the user in aligning adjacent nested base blocks 42, in straight or other predetermined angular relationships. The alignment system 100 includes alignment indicia 102. The indicia 102 are visual. In the illustrated embodiment, the indicia 102 are part of the top face 46. When the indicia 102 are part of the top face 46, the indicia 102 can be seen by the user when the base block 42 is in place with the bottom face 47 against the ground. The indicia 102 can include, for example a marking system which can include score marks, lines or other similar indicia on at least the top face 46. In the illustrated embodiment, the alignment indicia 102 includes notches in the first and second end faces 54, 55 of the base building block 42 which extend to and can be seen on the top face 46 of the block. In the example shown, at least one notch 104 is in one of the first end face 54 and second end face 55, and a plurality of notches 106 in the other of the first end face 54 and second end face 55.
Referring to
As can be seen in
The notch 104 in the second end face 55 preferably has the same dimensions as the notches 111-115. For example, the notch 104 has a width of at least 0.25 inch, not greater than 0.5 inch, and preferably about 0.035-0.04 inch. The notch 104 has a depth of at least about 0.05 inch, no greater than 0.25 inch, and preferably 0.1-0.15 inch.
The at least one notch 104 in the second end face 55 is preferably located along a central plane P (
In reference again to
The plurality of notches 106 in the first end face 54 are symmetrical with respect to central plane P (
To use the alignment system 100, the first end face 54 of one of the base blocks 42 is oriented adjacent and nested within the second end face 55 of an adjacently placed base block 42. The at least one notch 104 on the second end face 55 is oriented with respect to one of the plurality of notches 106 in the first end face 54 to achieve the desired straight or other predetermined angular relationship between the two adjacent base blocks 42. Example arrangements are discussed in Section D, below.
A method for forming a straight or curved base for a wall, such as wall 30, can include providing a first wall base block 42, having first rounded convex end face 54 and opposite second rounded concave end face 55 having generally the same radius of curvature as the first end face 54. The first block 42 is oriented on a surface with its bottom face 47 against the surface. For example, the surface can be a sand or gravel leveling pad.
A second wall base block 42, having first rounded convex end face 54 and opposite second rounded concave end face 55 with the general same radius of curvature as the first end face 54 is oriented on the surface with its bottom face 47 against the surface and so that the first end face 54 of the first base block 42 is received within the second end face 55 of the second base block 42.
While orienting the second base block 42, the user will align the alignment indicia 102 of the first base block 42 with respect to the alignment indicia 102 of the second base block 42 to achieve a desired straight or predetermined curved shape of the base for the wall.
The base for the wall can continue to be built by providing additional base blocks 42 and using the alignment system 100 as a previously described. For example, a third base block 42, as characterized above, is provided. The third base block 42 is oriented on the surface with its bottom face 47 against the surface so that the first end face 54 of the second base block 42 is received within the second end face 55 of the third base block 42. While orienting the third base block 42, the user aligns the alignment indicia 102 of the first end face 54 of the second base block 42 with respect to the alignment indicia 102 of the second end face 55 of the third base block 42 to achieve the desired straight or predetermined curved shape of the base for the wall.
Example bases are illustrated in
While the examples of bases 120, 122 in
The base 126 shown in
It should be appreciated that many variations are possible. The above are examples. Many embodiments may be made according to the principles provided herein.
