BUILDING ELEMENTS FOR MAKING RETAINING WALLS, AND SYSTEMS AND METHODS OF USING SAME

FIELD

The present disclosure relates generally to building elements for wall structures. More particularly, the present disclosure relates to a plurality of building elements that are operably coupled to each other to erect a retaining wall.

BACKGROUND

It is common practice to use prefabricated building elements and particular masonry works such as walls for retaining slopes along roads, motorways, railways or the like, or for retaining walls for creating drops between urban levels, especially by various types of prefabricated building elements. Such elements usually consist of concrete elements, placed one at the top of the other, and then filled with material such as earth, sand, gravel, and the like. Previous approaches have been developed to building elements for a retaining wall. One example of such an approach is described in U.S. Pat. No. 7,845,885, which is incorporated herein by reference in its entirety.

Currently, building elements require expensive molds and a minimum of one night to rest in the mold to allow time for the material to harden. In addition, the process used to generate a building element results in a building mold with limited variability. Thus, the resulting building element limits the structural variability of the retaining walls that can be constructed using the building element. There is a need in the pertinent art for building elements with increased variability in structure, thereby allowing for increased variability in the structures of retaining walls produced using the building elements.

There is a further need for building elements that provide increased stability and integrity compared to existing building elements. There is still a further need for building elements that provide for increased efficiency in the construction of wall structures.

SUMMARY

The disclosure relates to the building of large and heavily loaded retaining walls by a set of prefabricated building elements. Optionally, the prefabricated building elements can include at least two different types of prefabricated building elements. During installation, the building elements can be operably engaged to build a retaining wall. To solidify the retaining wall, earth fillers such as dirt and the like can be used to support the wall.

Disclosed herein are building elements and systems and methods of using building elements to erect a retaining wall. In some aspects, the disclosed building elements can have a modular construction that simplifies production of the building elements and the retaining walls formed by the building elements. In these aspects, it is contemplated that the modular construction increases the ease in which the dimensions and characteristics of a building element can be selectively varied at a particular location within the wall construction to achieve a particular structural need. It is further contemplated that the modular construction can lower production costs, lower investment costs for molds, and ease transport of building elements.

In other aspects, a building element can be configured to be coupled to at least one other building element to form a retaining wall. The building element can comprise a face panel comprising a top surface, a bottom surface, a front surface, and a rear surface positioned on an opposing side of the face panel from the front surface, wherein the face panel comprises a width dimension oriented along a first axis, a thickness dimension oriented along a second axis that is perpendicular to the first axis, and a height dimension oriented along a third axis that is perpendicular to the first and second axes. A beam member can be coupled to the rear surface of the face panel. The beam member can comprise a main body having a front end portion and a rear end portion. The main body can have an upper surface, a lower surface, and first and second side surfaces that are substantially parallel to the second axis. First and second fork legs can extend between and couple to the face panel and the front end portion of the main body. The first and second fork legs can each define a respective acute angle with a plane that extends parallel to the second and third axes and bisects the beam member. The face panel and the first and second fork legs can cooperate to surround an interior space.

Systems and methods of using and making the disclosed building element are also disclosed.

Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the disclosure will become more apparent in the detailed description in which reference is made to the appended drawings wherein:

FIG. 1 is a front perspective view of an exemplary modular building element as disclosed herein.

FIG. 2 is a rear perspective view of the exemplary building element of FIG. 1.

FIG. 3 is a top plan view of the exemplary building element of FIG. 1.

FIG. 4 is a front perspective view of another exemplary building element as disclosed herein.

FIG. 5 is a top plan view of the exemplary building element of FIG. 4.

FIG. 6 is a rear perspective view of yet another exemplary building element as disclosed herein.

FIG. 7 is a side perspective view of a system comprising exemplary building elements as disclosed herein.

FIG. 8 is a top plan view of the system of FIG. 7.

FIG. 9 is a rear perspective view of another exemplary building element comprising first and second opposing face panels.

FIG. 10 is a cross sectional view of an alignment post as disclosed herein.

FIG. 11 is a top perspective view of another alignment post as disclosed herein.

FIG. 12 is a perspective view of a system comprising a plurality of building elements as disclosed herein.

FIG. 13A illustrates a mesh of reinforcement members that can be integrated within the building elements disclosed herein. FIG. 13B-F illustrate first, second, third, fourth, and fifth portions, respectively of the mesh of FIG. 13A.

FIG. 14 illustrates a system comprising plurality of building elements as disclosed herein.

FIG. 15 illustrates a system comprising plurality of building elements as disclosed herein.

FIG. 16 illustrates a cross section of an exemplary beam with optional profiles and dimensions.

FIG. 17 illustrates a top view of an exemplary structure comprising building elements as disclosed herein.

FIG. 18 illustrates a support structure for a railroad, the support structure comprising building elements as disclosed herein.

FIG. 19 illustrates a support structure for a girder, the support structure comprising building elements as disclosed herein.

FIG. 20A is a graph of cubic feet of concrete per square foot of wall surface area for a building element as disclosed herein and conventional building elements. FIG. 20B is a graph of a ratio of cubic feet of concrete per square foot of wall surface area for a building element as disclosed herein and conventional building elements relative to the cubic feet of concrete of the disclosed building element.

FIG. 21 is a perspective view of an exemplary building element as disclosed herein.

FIG. 22 is another perspective view of the building element of FIG. 21.

FIG. 23 is a top plan view of the building element of FIG. 21.

DETAILED DESCRIPTION

The present invention can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.

As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a beam member” can include two or more such beam members unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. When used herein to precede a dimension, the term “about” can refer to dimensions that are within 15%, within 10%, within 5%, or within 1% (above or below) of the stated dimension.

As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

The word “or” as used herein means any one member of a particular list and also includes any combination of members of that list.

The word “substantially” as used herein can be used to define an angular tolerance of +/−15 degrees with respect to a disclosed (e.g., desired) angular relationship between two geometric entities. For example, “substantially vertical” can indicate that a reference surface or body is oriented vertically or within +/−15 degrees of absolute vertical alignment. Similarly, “substantially collinear” can indicate that two bodies can are collinear or positioned within an alignment divergence of +/−15 degrees of a collinear orientation (with the second body having an angular orientation relative to the first body that is less than or equal to 15 degrees and greater than or equal to −15 degrees). When a term defining a specific angular relationship is preceded by the word “substantially,” it is understood that an embodiment or aspect corresponding to the specific angular relationship is also disclosed. For example, the disclosure of a “substantially parallel” relationship is meant to describe relationships that are within +/−15 degrees of parallel alignment as well as relationships that are, in fact, parallel.

In the following description, the orientation of the components of the disclosed building elements, retaining walls, and wall systems can be described with reference to a series of axes, including a first axis 114, a second axis 116 that is perpendicular to the first axis, and a third axis 118 that is perpendicular to the first and second axes. A primary plane can be defined by and contain the first axis and the second axis. A secondary plane can be defined by and contain the second axis and the third axis. A tertiary plane can defined by and contain the first axis and the third axis.

In various aspects, described herein with reference to FIGS. 1-9 are building elements 100A, 100B, 100C, 100D that are configured to be assembled together with at least one other building element to form a retaining wall. In these aspects, the building elements can comprise a face panel defining a front surface and a rear surface oriented on an opposing side of the face panel from the front surface. It is contemplated that the face panel can have a length dimension oriented along the first axis 114 and a height dimension oriented along the third axis 118. In additional aspects, and as further disclosed herein, the building elements can further comprise at least one beam member coupled to the rear surface of the face panel. Each beam member can have an upper surface and a lower surface. The beam member can comprise a height dimension oriented along the third axis 118 and a length dimension oriented along the second axis 116. Optionally, in exemplary aspects, at least one surface of the upper surface and the lower surface of at least one beam member can define an alignment void as further disclosed herein.

FIGS. 1-3 depict examples of a building element 100A that can be used to form at least a portion of a retaining wall. In an aspect, building element 100A can comprise a face panel 102 and at least one beam member 104. To provide a framing structure for a retaining wall, the face panel 102 can be coupled (indirectly or directly) or secured to the beam member 104. Optionally, in exemplary aspects, a portion of each beam member 104 can be permanently secured to or integrally formed with a corresponding face panel 102. In an aspect, the face panel 102 can comprise a front surface 102A and a rear surface 102B. The front surface 102A and the rear surface 102B can be defined on opposing sides of the face panel 102.

As depicted in FIG. 1, the face panel 102 can comprise a front surface (optionally, a front rectangular surface) and can have a length dimension, which can extend along the first axis 114. The face panel 102 can further comprise a thickness dimension, which can extend along the second axis 116. The face panel 102 can still further comprise a height dimension, which can extend along the third axis 118. In a further aspect, the face panel can be oriented at an angle with respect to a primary plane (e.g., a horizontal plane), which contains and is defined by the first axis 114 and the second axis 116. Optionally, in this aspect, the face panel 102 can be perpendicular or substantially perpendicular to the primary plane (and the second axis 116). That is, the face panel 102 can be oriented vertically or substantially vertically (approximately 90 degrees) with respect to the primary plane defined by the first and second axes 114, 116 (and parallel or substantially parallel with respect to the third axis 118). In general, the primary plane will be approximately level and can be parallel or substantially parallel to a ground surface on which the retaining wall is erected. In a further aspect, at least a portion of the front surface of the face panel 102 can be coplanar or substantially coplanar with a secondary plane, which contains and is defined by the first axis 114 and the third axis 118.

Although generally described herein in some aspects as having a flat, rectangular construction, it is contemplated that at least a portion of the face panel 102 can have a radius of curvature that defines an arcuate profile (e.g., a convex or concave profile). For example, the face panel can bow with respect to an arcuate path determined by the associated radius. In other configurations, it is contemplated that the face panel can comprise a plurality of adjoining planar surfaces that cooperate to define an overall face profile. Optionally, in these configurations, the adjoining planar surfaces can be angularly orientated relative to one another.

In another optional configuration, the face panel 102 can also comprise at least one projection extending outwardly from one of a top surface or a bottom surface of the face panel. Additionally, or alternatively, the face panel 102 can define at least one inwardly recessed notch or slot. In exemplary aspects, the face panel can comprise a plurality of projections extending outwardly from the top surface and a plurality of notches or slots defined within the bottom surface of the face panel 102. Additionally, or alternatively, the face panel can comprise a plurality of projections extending outwardly from the bottom surface 102D and a plurality of notches or slots defined within the top surface 102C of the face panel 102. In use, each notch or slot can be configured to receive a corresponding projection of an adjacent face panel (upper or lower) when a retaining wall is constructed as disclosed herein. Optionally, when the top or bottom surfaces 102C, 102D of the face panel 102 comprise both projections and notches or slots, it is contemplated that each slot of the face panel can be axially spaced from each projection of the face panel relative to the first axis 114.

In use, it is contemplated that the projections and notches or slots can be used as engagement features to further stabilize the face panel. For example, engaging the face panels 102 of respective panels during retaining wall construction can reduce movement of the face panels along the second axis 116. Optionally, it is contemplated that the projections 120 can be oriented perpendicularly or substantially perpendicularly to the primary plane (and extend parallel or substantially parallel relative to the third axis 118). In a further aspect, a portion of the top or bottom surface of the face panel can be coplanar or substantially coplanar with the primary plane comprising the first axis 114 and the second axis 116. Optionally, in exemplary aspects, and as shown in FIG. 1, the projections can comprise a base surface coupled to the top surface 102C or bottom surface 102D of the panel 102 and an apex or apex surface that is spaced outwardly from the base surface relative to the third axis 118. For example, it is contemplated that the projection can optionally comprise a pyramid or dome type structure, with the apex corresponding to the minimal diameter portion of the projection and the base surface corresponding to the maximal diameter portion of the projection. In yet another example, the projection can define an apex surface as opposed to a true apex, such as a tip. In this example, it is contemplated that a variety of shapes for the projection are possible, including, for example and without limitation, a rhomboid shape, a conical frustum, a rectangular prism, a cylinder, and the like. During the construction of a face panel 102 comprising a projection or a notch or slot that is configured to receive a projection, a mold can be formed to have a corresponding indentation that defines a projection in one or more surfaces of a face panel as disclosed herein. Similarly, it is contemplated that the mold can define a projection or protrusion that is configured to form a notch a slot in one or more surfaces of a face panel as disclosed herein. In use, the projection can be configured to increase the stability of the retaining wall when building elements 100 are stacked upon each other. For example, in another aspect, a notch, slot, or other alignment void can be defined by a top surface 102C or bottom surface 102D of the face panel 102, and each alignment void can be configured to receive a corresponding projection as disclosed herein.

As discussed earlier, the building element 100 can comprise a beam member 104, which can have a length dimension oriented along the second axis 116, a width dimension oriented along the first axis 114, and a height dimension oriented along the third axis 118. In exemplary aspects, the building element 100 can comprise a brace section 106 that is mechanically coupled or secured between the beam member 104 and the rear surface 102B of the face panel 102. Optionally, it is contemplated that at least a portion of the beam member can be integrally formed with the brace section 106 and, optionally, face panel 102. Thus, in some exemplary aspects, the beam member 104, the brace section 106, and the face panel 102 can be integrally formed (optionally, as a single, unitary piece). In exemplary aspects, portions of the building element 100 can include reinforcement (e.g., steel reinforcement) elements 117 (FIG. 13) that are embedded within the concrete of the building element.

In an aspect, the face panel 102 can have a length dimension ranging from about 9 ft. to about 15 ft., from about 10 ft. to about 14 ft., or from about 11 ft. to about 13 ft. Optionally, the face panel can have a length dimension of about 12 ft. In an aspect, the face panel can have a height dimension ranging from about 6 ft. to about 10 ft., from about 7 ft. to about 9.5 ft., or from about 8 ft. to about 9 ft. Optionally, the face panel can have a height dimension of about 8.5 ft. It is contemplated that the use of face panels having a length of about 12 ft. and a height of about 8.5 feet can maximize the dimensions of the face panels while still permitting roadway transportation of the face panels (and associated building elements) without the need for escort vehicles (using trucks) and without contacting overpasses (when the face panels are positioned on a cargo bed of a truck or trailer).

In a further aspect, the face panel can have a width dimension ranging from about 9 in. to about 3 in., from about 8 in. to about 4 in. or from about 7 in. to about 5 in. Optionally, the face panel can have a width of about 6 in. In a further aspect, the face panel can have a surface area defined by the length and height dimension ranging from about 235 sq. ft to about 54 sq. ft, from about 192 sq. ft to about 80 sq. ft, or from about 161 sq. ft to about 105 sq. ft. Optionally, the face panel 102 can have a surface area of about 132 sq. ft. It is further contemplated that the size of the face panel in this disclosure can be about 3.3 to about 16 times larger than traditional building elements where the respective panels range from 8 sq. ft. to 40 sq. ft. In further aspects, it is contemplated that the face panel 102 can have a length dimension ranging from about 72 inches to about 144 inches. In further aspects, it is contemplated that the face panel 102 can have a height dimension ranging from about 12 inches to about 110 inches

In an aspect, the beam member 104 can have a length dimension ranging from about 3 ft. to about 14 ft., from about 4 ft. to about 12 ft., or from about 5 ft. to about 10 ft. Optionally, the beam member can have a length dimension of about 8 ft. In an aspect, the beam member 104 can have a height dimension ranging from about 3 ft. to about 9 ft., from about 4 ft. to about 8 ft., or from about 5 ft. to about 7 ft. Optionally, the beam member 104 can have a height dimension of about 6 ft. In a further aspect, the beam member 104 can have a width dimension ranging from about 3 in. to about 9 in., from about 4 in to about 8 in., or from about 5 in. to about 7 in. Optionally, the beam member 104 can have a width of about 6 in. In one aspect, the face panel 102 can have dimensions of 8.5 feet tall (along the third axis) by 12 feet long, thereby having a total surface area of 102 square feet. In further aspects, the face panel 102 can have a height dimension of 8.5 feet, or 100 inches, or 12 inches to 110 inches. In various aspects, the face panel 102 can have a height dimension of between about 12 inches, about 24 inches, about 36 inches, about 48 inches, about 60 inches, about 72 inches, about 84 inches, about 96 inches, or about 108 inches. In various aspects, the face panel can have a length dimension of about 72 inches to about 144 inches. It is contemplated that a face panel having a height of 8.5 feet can be able to travel underneath a standard overpass height. It is further contemplated that a face panel having a length of 12 feet or less can travel on a highway without the expensive requirement of an escort vehicle or other oversized load requirements. Thus, the building element can have a maximum area for the front panel (within shipping limitations), thereby allowing for maximum wall area installation per crane pick. It is contemplated that a relatively short face panel (e.g., having a length of about 74 inches or less than 96 inches) can be used to form sharp turns around corners or can be used for required end elements of a wall to satisfy architectural needs. The beam member can optionally have a length dimension from 4 feet to 40 feet. In some aspects, the beam can have a length dimension of between 5 feet and 12 feet, or between 6 feet and 12 feet. It is contemplated that the beam member with a length dimension of 12 feet can be used to form a wall that is about 24 feet tall. In further aspects, the beam member with a length dimension of 40 feet fit on the length of a truck bed for transporting the building element. The beam member with a length dimension of 40 feet can optionally form a portion of a wall that is over 60 feet tall. It is contemplated that the length of the beam can reach far back into fill to enhance wall stability.

Optionally, the panel can be provided with architectural lining.

It is contemplated that the building elements disclosed herein can be stable for transport (e.g., no tilting to the side, back, or front). The building elements can further be easy to handle. The stability of a cribwall, comprising one or more building elements and filled with earth (e.g., to serve as a retaining wall) can use a minimum amount of (relatively expensive) concrete and a maximum amount of (relatively inexpensive) fill material (e.g., gravel, sand, dirt, or a combination thereof). Thus, the cribwall can be made relatively inexpensively. In further aspects, the fill can comprise rocks.

In some aspects, the fill material can comprise, or can consist of, free waste dust. Free waste dust can be fine material that is a by-product of crushed rock fabrication. It is contemplated that such particles can have high friction. Still further, the free waste dust can advantageously compact easily.

The disclosed building elements can endure maximum weights acting on or against the inside surfaces of the building elements, with the fill material holding the building elements in position, to prevent overturning or sliding of the building elements. The large length dimensions and area dimensions of the building elements disclosed herein can engage correspondingly large volumes of fill material.

It is also further contemplated that the size of the disclosed building elements can increase the efficiency in building a retaining wall, by allowing for quicker wall construction and a reduction in the number of wall components needed to complete a wall assembly. The size of the building elements can also increase the structural integrity of a wall as compared to traditional building elements.

In further aspects and with reference to FIGS. 1-5, the beam member 104 can comprise a main body 222 having a front end portion 224, a rear end portion 226, first and second side surfaces 230, 232 extending substantially parallel to the second axis 116, and upper and lower surfaces 234, 236 spaced relative to the third axis 118. The main body 222 of the beam member 104 can optionally have a top portion 223 that has a greater width dimension than a width of the beam member below the top portion. It is contemplated that this greater width dimension can increase the beam member stability, particularly for long beam members, thereby inhibiting swinging during transit on rough roads or in traffic.

The beam member 104 can further comprise first and second fork legs 160, 162 that extend between and couple to the face panel and the proximal end portion of the main body. Accordingly, the beam member 104 can define split struts. The first and second fork legs 160, 162 can each define a respective acute angle with a vertical reference plane 408 that contains or extends parallel to the second and third axes 116, 118 and bisects the beam member 104. That is, a respective vertical plane 164, 166 that bisects each of the first and second fork legs 160, 162 can form an acute angle with the vertical reference plane 408. The acute angle can range from about 15 degrees to about 75 degrees, from about 30 degrees to about 60 degrees, or be, for example, about 45 degrees. The face panel 102, the first fork leg 160, and the second fork leg 162 can cooperate to define an interior space 170. It is contemplated that the fork legs can reduce cantilevering of the front panel (that carry the fill/earth pressure of the load from behind). In this way, the fork legs can greatly enhance the strength of the front panel, for example, evening out moments on the front panel. The fork legs can provide reinforcement forces to the front panel, thereby providing a front panel with greater strength and a dramatic reduction of bending moments. In this way the necessary amount of steel reinforcement 117 (FIG. 13) can be reduced, which can, accordingly, reduce cost of the building element. It is contemplated that the interior space 170 can receive fill. For example, the interior space 170 can be filled with rocks to add weight to the building element.

Optionally, the first and second fork legs 160, 162 can couple to the face panel at respective coupling ends 172, 174 opposing the main body 222 of the beam member 102. In various aspects, the respective coupling ends can optionally be spaced relative to the first axis 114 by at least one third of the length of the face panel, or at least one half of the length of the face panel, or by substantially the length of the face panel.

Optionally, as shown in FIG. 6, the coupling ends 172, 174 can have a height dimension relative to the third axis 118 that is greater than the height of the main body 222 of the beam 104. In some aspects, the height dimension of the main body 222 of the beam member 104 can be less than the height dimension of the face panel 102. For example, in some optional aspects, the height dimension of the main body 222 of the beam member 104 can optionally be between 1 foot and 4 feet or, optionally, half the height dimension of the face panel 102. Such a beam member 104 having a shorter height dimension than that of the face panel 102 can be advantageous for various applications, including for building elements at a top of a wall (FIGS. 14-15), for retaining a thick ballast layer for railway ballast, for highway subbase grading and compaction, for utility trenches and rain drains along a curb, for traffic barrier anchoring, or for power and utility lines next to a top building element.

Referring to FIG. 6, in some optional aspects, the face panel can comprise a first end portion 176 that extends beyond the coupling end 172 of the first fork leg 160 of the beam member 104 on a first side of the plane 408 and a second end portion 178 that extends beyond the coupling end portion 174 of the second fork leg 162 of the beam member on a second side of the plane 408. Optionally the first and second end portions of the face panel 102 can have equal lengths relative to the first axis 114. Accordingly, the beam member 104 couple to the middle of the face panel 102 relative to the first axis 114. In further aspects, the first end portion can have a length that is not equal to the length of the second end portion. Accordingly, the beam member 104 can be offset from the middle of the face panel 102 relative to the first axis 114. Optionally, the length of each of the first and second end portions can be less than or equal to 36 inches.

In still further aspects, and with reference to FIGS. 4-5, the face panel 102 can have a length dimension that is equal to the spacing between the coupling end portions 172, 174 so that the face panel does not comprise the first end portion 176 that extends beyond the coupling end 172 of the first fork leg of the beam member on the first side of the plane 408 or the second end portion 178 that extends beyond the coupling end portion 174 of the second fork leg of the beam member on the second side of the plane 408. Optionally, the coupling end portions 172, 174 can be spaced by about 72 inches, or at least 60 inches.

Referring to FIGS. 7-8, a system 600 can comprise a plurality of building elements 100A (FIG. 1). In some aspects, the building elements 100A can comprise corresponding slots that align to allow the beam members to cross. For example, the main body 222 of the beam member 104 of a first building element 100B can have a can have a first slot 602. The first slot 602 can define a recess that extends upwardly (relative to the third axis 118) into the main body 222 of the beam member 104. Accordingly, the first slot 602 can define a downward opening. The beam member 102 can define a recessed surface 606 that is spaced upwardly (relative to the third axis 118) from the lower surface 236 of the main body 222 of the beam member 104. The beam member 104 of a second building element 100C can have a second slot 604. The second slot 604 can define a recess that extends downwardly (relative to the third axis 118) into the main body 222 of the beam member 104. Accordingly, the second slot 604 can define an upward opening. The beam member 102 can define a recessed surface 608 that is spaced downwardly (relative to the third axis 118) from the upper surface 234 of the main body 222 of the beam member 104. The main body 222 of the beam member of the first building element 100B at the first slot 604 can be receivable into the second slot 604 of the main body 222 of the beam member 104 of the second building element 100C. When the slot 602 of the first building element 100B is received in the slot 604 of the second building element 100C, the recessed surface 606 can oppose the recessed surface 608. Optionally, the recessed surface 606 can bias against the recessed surface 608. In further aspects, the recessed surface 606 can be spaced from the recessed surface 608. In some optional aspects, when the main body 222 of the beam member 104 of the first building element 100B at the first slot 604 is received into the second slot 604 of the main body 222 of the beam member 104 of the second building element 100C, the upper surface 234 of the main body 222 of the beam member 102 of the first of building element 100B can be coplanar with the upper surface 234 of the main body 222 of the beam member 102 of the second building element 100C. It is contemplated that the slot 604 can have a depth that is half, about half, or at least half the height dimension of the beam. In these aspects, it is contemplated that the first and second building elements 100B,C can optionally be identical, with the building element 100B inverted 180 degrees relative to the building element 100C about an axis that is parallel to the second axis 116.

It is contemplated that each building element can have respective first, second, and third axes that are oriented and described herein relative to the building element. Accordingly, the first building element 100B can have reference plane 408a that is parallel to a second axis 116a of the first building element 100B, and the second building element 100C can have a reference plane 408b that is parallel to a second axis 116b of the second building element 100C. In some aspects, the first and second building elements 100B,C can be oriented so that the reference plane 408a is oriented at an angle, a, relative to the reference plane 408b of the second building element 100C. In some aspects, the main body 222 of the beam member of the first building element 100B at the first slot 602 can be receivable into the second slot 604 of the main body of the beam member of the second building element 100C so that the second axis 116a of the first building element defines an acute angle, a, with respect to the second axis 116b of the second building element. Such a configuration can be used for forming a block-out at an intersection. Further, the building elements 100B,C can be configured to enable various angular offsets 13 between the front surface 102A of the face panel 102 of the first building element 100B and the front surface 102A of the face panel 102 of the second building element 100C. The various angular offsets 13 can optionally be from 0 to 315 degrees. The positioning of the slots 602, 604 along the length of the respective beam member 104 can be selected based on the desired angle between the two building elements.

In some optional aspects, the second end portion 178 of the face panel 102 of the first building element 100B can be adjacent to the first end portion 176 of the second building element 100C. The building elements can be elected to fit the desired wall configuration. High walls with a turn can benefit from a detailed study of beam member crossing intersections with adjustable visible corners to be flush and angles that can be custom-tailored (e.g., based on slot position) to match. Depending on angle, wall height, fill material type, and predicted internal lateral earth pressures and earth pressure direction, the crossed beam members can use blocking to strengthen the corner stack for internal and external stability. Optionally, the geotextiles along backs of adjacent building elements can be positioned to prevent material (e.g., fill material) washout.

Referring to FIG. 13, a system 600 can comprise a plurality of building elements 100A. At least one building element can be oriented at a 90 degree offset relative to at least one other building element.

Referring to FIG. 9, a building element 100D can comprise a first face panel 102 and a second face panel 610 coupled to the end of the beam member 104 opposite the first face panel. In some aspects, third and fourth fork legs 612, 614 can extend between and couple to the second face panel 610 and the rear end portion 226 of the main body 222 of the beam member. The third and fourth fork legs 612, 614 can each define a respective acute angle with a vertical reference plane 408 (FIG. 3) that extends parallel to the second and third axes and bisects the beam member 104. The second face panel 610, the third fork leg 612, and the fourth fork leg 614 can cooperate to define an interior space 170b. The third and fourth fork legs 614 can optionally be configured as described herein with reference to the first and second fork legs. For example, the third and fourth fork legs 614 can couple to the second face panel 610 at respective coupling ends that are spaced by at least one third, at least half, or substantially the entire length of the second face panel 610. It is contemplated that such building elements can advantageously be used for separation walls, for sound walls, and for barricade walls and other protection walls. Two or more building elements can be aligned with their first face panels aligned and with their rear face panels aligned to form a wall configuration to be exposed to two sides, thereby forming two exposed (e.g., visible) sides. For protection walls or barricades, vertically stepped interconnections between the upper and lower units can be used to resist extraordinary forces like from explosive or natural (e.g., hurricane) effects.

In some optional aspects, the building element 100D can be symmetric about a plane 800 that is parallel to the first and third axes and transversely bisects the beam member 104.

In some aspects, the beam member 104 can have a distal end portion 150 (e.g., a vertical pillar) spaced from the face panel 102 relative to the second axis 116. In these aspects, the distal end portion 150 can comprise first and second projections 152, 154 that project, respectively, from the first and second side surfaces 230, 232 of the main body 222 of the beam member 104. As shown in the Figures, the first and second projections 152, 154 can cooperate with respective portions of the first and second side surfaces 230, 232 of the main body 222, and the rear surface 102B of the face panel 102 to define first and second receiving spaces 460, 462 on opposing sides of the beam member. As further disclosed herein, the receiving spaces 460, 462 can be configured to receive and at least partially enclose fill material. It is further contemplated that the structure of the disclosed building element 100A and, in particular, the structure of the disclosed beam member 104, can increase the internal arching effect of the fill weight inside the receiving spaces, thereby wedging and holding the fill weight in place. The extended width of the distal end portion 150 can serve as a pillar that helps backfill soil arching. The soil behind the wall can engage the distal end portion 150. Because of the structure of the building element, the receiving spaces 460, 462 can be accessed from behind the building element for easy and efficient filling. A vibratory roller can further be used to compact the fill within the receiving spaces. The fill can inhibit shifting or tilting of the building elements, thereby inhibiting bulging of a wall comprising the building elements.

As depicted in the Figures, the distal end portion 150 of the beam member 104 can be widened to form a vertical pillar along the back of the building element for bracing against lateral earth pressures (like a soldier pile) to enhance the arching between such pillars, thereby increasing lateral earth pressure transfer directly from the backfill onto the building element (wall structure).

As further depicted in the Figures, the inner surfaces of the first and second projections 152, 154 of the distal end portion 150 (pillar) close the back of the inside backfill of the building element and thereby enhance the arching effect of internal fill material silo pressures directly onto the building element, which serves to enhance the gravity wall effect (a gravity wall resists against lateral earth pressures by the heavy weight of the wall (which is 20% concrete unit weight and 80% inside cell backfill earth weight).

Optionally, the face panel 102 can have a variable width (not shown) relative to the second axis 116. In exemplary aspects, the face panel can have a maximum width within a vertical reference plane 408 that bisects the length dimension of the face panel 102. It is contemplated that this panel structure (with a maximum thickness at the center) can provide optimal moment resistance against cell-fill earth pressures at the center of the panel. Optionally, in these aspects, the face panel can have a minimum width at the opposing side edges 102E,F, where there is no moment.

In exemplary aspects, as the beam member 104 can define at least one pin hole 442 (optionally, a plurality of pin holes, such as two pin holes) that permit engagement between the building element and a pin and/or lifting cable of a crane or other handling/lifting apparatus. Such pin holes can be formed during the manufacturing process. In use, the pin holes can permit fast and safe installation of the building elements. In some aspects, each of the fork legs 160, 162 can define a respective pin hole 442. In further aspects, the main body 222 of the beam member 104 can define at least one pin hole 442.

As one of skill in the art can appreciate, in some exemplary aspects, the disclosed building elements can be provided as one-piece “cribwall” units that can be cast with a large front panel and a beam member that forms a partially closed backfill cell and is closed at the bottom for “wedging in” the fill such that the fill cannot simply drop out. This “wedging in” of the fill occurs (in part) due to the arching effect (both horizontal and vertical) along the foundations of the face panel and the beam member, including the enlarged distal end portion (pillar), with the fill being wedged between the face panel and the widened portion of the pillar. In use, the fill cannot move out of the cell and must function together with the wall structure to form a cribwall (which is a concrete container structure containing a maximum amount of fill material for creating the weight needed to resist the enormous lateral earth pressures). In use, it is contemplated that such building elements can be easy to fill and compact, while providing easy access (from the back of the building element) to large excavators, vibratory rollers, and compactors, which perform far better than hand tools. Thus, in use, it is contemplated that the disclosed building elements can reduce or eliminate the need for expensive hand-labor work, which is typically unreliable and inefficient.

Optionally, the building element 100A can further comprise at least one longitudinal elbow 435 (optionally, a plurality of vertically spaced longitudinal elbows 435) that projects outwardly from the main body 222 of the beam member 104 and extends between the face panel 102 and the distal end portion 150 of the beam member. In exemplary aspects, it is contemplated that respective longitudinal elbows 435 can extend outwardly from both side surfaces 430, 432 of the main body 222 (preferably in a symmetrical or balanced arrangement with equal numbers of elbows extending from each side surface). Additionally, or alternatively, the building element 100A can comprise at least one transverse elbow 455 that projects outwardly from a rear surface of the distal end portion 150 of the beam member 104. Optionally, as shown in FIGS. 1-6, it is contemplated that respective longitudinal elbows 435 (on both sides of the main body) and a corresponding transverse elbow 455 can extend continuously along the side and rear surfaces of the beam member. Alternatively, a gap between the longitudinal and transverse elbows can be provided as shown in FIGS. 1-6. Optionally, in exemplary aspects, it is contemplated that each elbow 435, 455 can have a pointed or beveled shape. In exemplary aspects, it is contemplated that each elbow 435, 455 can be vertically spaced from the bottom and top surfaces of the beam member 104. The elbows 435, 455 can increase friction against fill to retain the building element in place. Accordingly, the weight of the fill can be used to support the building element. The elbows 435, 455 can further support fill/soil arching on the sides of the beam member 104 and behind the distal end portion 150.

Still further, the rear surface 102B of the face panel 102 can define one or a plurality of elbows (not shown).

In exemplary aspects, the elbows can project by at least one inch, by between one inch and four inches, or about two inches. Optionally, the elbows 435, 455 can comprise angled portions that extend angularly outwardly (e.g., outwardly at 45 degree angles) to meet at planar middle portions. FIG. 16 illustrates a cross-section that includes exemplary, optional dimensions of the elbows.

In use, it is contemplated that the elbows can be configured to provide horizontal stiffening of the beam member 104 and/or the distal end portion 150 of the beam member. This horizontal stiffening is particularly beneficial for longer building elements, which can have a length ranging anywhere from about 5 feet up to about 34 feet. Such stiffening of longer building elements can greatly help with manufacturing, loading, and transporting of the building elements.

It is further contemplated that the elbows can be configured to initiate and positively support and create substantial arching of the fill inside the building elements to function as a real container for the fill. It is contemplated that arches inside the building elements can more effectively transfer the weight of the fill onto the building elements to greatly help stabilize the gravity wall effect. It is contemplated that, in addition to, or alternatively, the elbows 435, 455, the rear surface 102B of the face panel 102 and/or the side surfaces 430, 432 of the main body 222 of the beam 104 and/or the distal end portion 150 of the beam 104 can define a texture that is configured to initiate and positively support and create substantial arching of the fill inside the building elements and behind and adjacent the distal end portion 150 of the beam member 104. For example, the rear surface 102B of the face panel 102 and/or the side surfaces 430, 432 of the main body 222 and/or the distal end portion can define a rough surface (e.g., formed from a rough mold surface). In further aspects, the side surfaces 430, 432 of the main body 222 and/or the distal end portion can define a stepped surface, a zig-zag surface, or any other surface that increases grip against the fill. Thus, in exemplary aspects, the rear surface 102B of the face panel 102 and/or the side surfaces 430, 432 of the main body 222 and/or the distal end portion 150 can have non-planar surfaces that increases surface area engaging the fill. In further aspects, steel and fiber concrete mix materials can be provided to increase friction with the fill.

Additionally, with respect to the transverse elbows 455 along the back of the building elements, these transverse elbows can greatly encourage the support of backfill material behind the wall by increasing the vertical fill weight effect to stabilize the wall against overturning. These transverse elbows can affect the backfill in a number of ways. In particular, the backfill cannot simply slide down along the pillars during compaction; rather, the backfill will at least partially “sit” or rest on the pillar, thereby stabilizing the retaining structure against overturning. Thus, the transverse elbows affect the way the backfill forces are distributed within the area directly behind the wall structure. Therefore, the transverse elbows 455 enlarge and affect the fill material beyond the actual back of the wall structure such that the retaining wall structural “effect” reaches beyond the actual wall footprint. In use, the transverse elbows 455 can increase the vertical loads onto the pillars from outside the wall “footprint.” Accordingly, the building element can have a relatively small footprint as compared to other building elements configured for similar purposes.

In still further aspects, the distal end portion 150 (e.g., projections can be widened along the first axis 114 to engage a greater amount of fill to inhibit overturning of the building element.

In exemplary aspects, a retaining wall system can comprise a plurality of building elements 100A. Optionally, in these aspects, the beam member 104 of each building element 100A can have a length relative to the second axis 116, and at least one beam member can have a length that is less than the length of at least one other beam member. In additional aspects, the plurality of building elements 100A can be arranged in a plurality of columns of vertically secured beam members. In these aspects, a bottom beam member of each column can have a length that is greater than the lengths of the beam members of any other beam member within the column. In further aspects, each column of the plurality of columns can comprise at least three building elements, and the length of the beam member of each building element within each column can be different than the length of each other beam member within the column. It is further contemplated that the building elements can be arranged such that the length of the beam member of each sequential building element within the column decreases moving upwardly relative to the third axis. Optionally, each front panel can have a V-shape that cooperates with the front panels of surrounding building elements to define a corrugated appearance of the retaining wall. Optionally, the columns of building elements do not contact one another.

Optionally, in exemplary aspects, it is contemplated that an entire retaining wall system can be built from the same types of building elements 100A. For example, it is contemplated that each building element of the retaining wall system can have the same front face profile. However, it is contemplated that the length of the beam member of each building element can vary depending upon the level (within the system) in which the building element is positioned. For example, as further described herein, building elements at the base of the system can have a greater length than building elements toward the top of the system. Exemplary sections of a retaining wall system can have a height of about 30 feet (or about 10 m).

In exemplary aspects, it is contemplated that the retaining wall system can comprise a plurality of stacked groups (pillars) of building elements 100A, with each pillar being independent of any other pillar. Thus, on soft ground, each wall pillar can settle independently of any neighboring pillar. Additionally, it is contemplated that it can be impossible to damage laterally spaced panels if the gap to the next pillar is wide enough. During a severe earthquake, it is contemplated that each pillar of wall units must survive from severe horizontal and even vertical shaking; however, because each pillar is independent as disclosed herein, the pillars do not touch each other and can remain intact. The open gaps between the separate pillars can require the use of small concrete slabs loosely set behind the gaps to avoid loss of fill. It is contemplated that occasional water leaking can be acceptable, yet the concrete slabs can avoid erosion and material loss, thereby protecting against damage.

As further explained herein, the disclosed building elements are capable of providing a number of advantages or improvements in comparison to existing retaining wall systems. Such advantages or improvements can include one or more of the following features.

The retaining walls are easy to cast and to transport by fitting onto a truck bed without creating any oversize issues for the trucker or for other drivers.

The main body of the beam members can include horizontal holes for lifting and transporting the units onto a truck and from the truck to an installation. Thus, the retaining walls are easy to pick up and handle using pins through horizontal holes in the stem (beam)— no need to insert costly tools which might be lost.

The retaining walls are easy to install units with self-aligning keys that direct the unit for precise setting automatically.

The pillars (distal end portions of the beam members) along the back enhance horizontal backfill arching for maximum loading of the concrete structure by vertical earth pressure components to help resisting the wall against overturning earth pressure forces.

The pronounced bottom widening of the beam members further enhances the vertical arching of the earth fill for maximum weight load onto the structure to further increase the wall resistance against overturning and sliding.

The wide front panels provide an ample distance between stems (beams) of adjacent building elements for easy filling.

The wide spacing between pillars (the distal end portions of the beam members) allows for extra-wide vibratory roller compaction from the back, which is known to be more effective and reliable than small compactors.

As further discussed above, the front panels can further show a distinct ‘nose’ like ending along the bottom line for directing rain water running down the face away from the joint onto the next lower panel. This nose can also prevent vertical stains as are frequently seen on vertical walls. The nose can further hide or provide shade for a horizontal joint which conceals local irregularities and possible imperfections. In use, the nose can guide rain water to drip off outside of the front panel, and thereby avoid formation of ugly vertical stripes from smoke and dust washed down the front face. It is contemplated that the nose can cantilever out of the front wall face, causing a distinct shadow falling over the horizontal joint. This shadow can automatically cover small imperfections of units caused by loading, transport, or installation handling. In use, this shadow can create a special aesthetic feature that emphasizes the horizontal wall joints.

In combination, the features of the disclosed building elements maximize efficiency in unit production, transport, and installation. This maximum efficiency goes in line with fabrication features that allow up to three units produced per day from each mold for high capacity production on big projects. The systematic product streamlining eases installation by self-aligning keys resulting in high precision setting, The wide access to equipment from behind easily boosts filling and compaction by providing room for efficient wide vibratory rollers.

FIGS. 12 and 17 show top view of exemplary structure comprising building elements (e.g., building elements 100A,B) as disclosed herein. As shown, the building elements disclosed herein can form walls that intersect at right angles or acute angles (e.g., less than 90 degrees, or less than 80 degrees, or about 70 degrees).

Referring to FIG. 18, the building elements (e.g., building elements 100A) can form a structure for supporting railroads. Referring to FIG. 19, the building elements (e.g., building elements 100A) can form a wall that is configured to receive girder 820 weight. Cast in place concrete 822 can be added (e.g., about one or two inches of pre-cast concrete to adjust exact elevation of the concrete.

Referring to FIGS. 1, 10, and 11, in various aspects, the building element 100A can comprise one or more alignment keys/projections 111 that are receivable into respective recesses 495 of an adjacent building element. For example, the building element can comprise one or more (three shown) projections 111 that extend from an upper surface of the building element, and a building element can define recesses on a lower surface for receiving the respective projections. The recesses can be sized and shaped to allow receipt of the corresponding projections in a predetermined position relative to the first and second axes. For example, the recesses can have complementary surfaces to those of the projections with little or no space for movement therebetween. In this way, vertically stacked adjacent building elements 100A can easily be vertically (and, with two or more projections, angularly) aligned with each other. It is contemplated that the projections and corresponding recesses can enable precise wall installation and very high speed crane operation without any additional cost while cutting installation time and cost (optionally, by half). In some aspects, the projections 111 can be integrally formed with the building element. In further aspects, the projections 111 can be separate components that are coupled to the rest of the building element. The projections 111 can assist in alignment to quickly assemble walls with the building elements. In various aspects, 3000 square feet of a wall can be installed in a single day.

Optionally, the projections 111 can comprise two front projections that are spaced along the first axis and one rear projection that is spaced from the front projections along the second axis. In some optional aspects, the two front projections can be spaced by about 50 inches to about 80 inches, from about 60 inches to about 70 inches, or by about 65.5 inches. In some optional aspects, the rear projection can be spaced from the front surface 102A by about 30 inches to about 50 inches, from about 40 inches to about 45 inches, or by about 42 inches and can be centered between the two front projections along the first axis. In some optional aspects, the front projections can be spaced from the front surface 102A by about 5 inches to about 10 inches or by about 7.5 inches.

FIG. 10-11 depicts exemplary alignment posts 122,700 that can optionally serve as a projection 111. The alignment post 122 can comprise two components, a stem 142 and a cap 140. During construction of the alignment post 122, the stem 142 can be inserted into a mold filled with a setting material to form the cap 140. The setting material can be concrete or the like. The cap 140 can comprise a height dimension H that is associated with the amount of the cap that will be received within an alignment void 495 of another building element 100 during erection of a retaining wall as disclosed herein.

In a further aspect, the cap 140 can be shaped like a frustum (optionally, a conical frustum) having a top surface 144 and a bottom surface 146. The stem 142 can comprise a stem axis 148 oriented along a length dimension L of the stem 142. In another aspect, the stem axis 148 can be perpendicular or substantially perpendicular to a portion of the bottom surface 146 of the cap 142. The bottom surface 146 of the cap 140 can abut the top surface of the beam. In a further aspect, the portion of the stem extending downwardly from the bottom surface of the cap 140 can have a length L ranging from about 3 in. to about 10 in., from about 4 in. to about 8 in. or from about 5 in. to about 7 in. Optionally, the length (L) of the exposed stem portion can be about 5 in. In a further aspect, the width of the stem 142 can range from about 1 in. to about 3 in., from about 1.25 in. to about 2.75 in. or from about 1.5 in. to about 2.5 in. Optionally, the width of the stem can be 2.5 in. In a further aspect, the height H of the cap 140 can range from about 1.75 in. to about 3.25 in., from about 2.0 in. to about 3.0 in. or from about 2.25 in. to about 2.75 in. Optionally, the height of the cap can be about 2.5 in. In a further aspect, the width (outer diameter) of the base 146 of the cap 140 can range from about 1.75 in. to about 3.25 in., from about 2.0 in. to about 3.0 in. or from about 2.25 in. to about 2.75 in. Optionally, the width of the base of the cap can be about 2.8 in.

Optionally, when the alignment post 122 is engaged to the alignment void 495, there can be a clearance space of 0.25 in. between an inner surface that defines the alignment void 495 and the outer surface of the cap 140.

As shown in FIG. 10, in a further aspect, the cap 142 can be strengthened using reinforcement material 149 such as a metal or plastic material embedded within the setting material. During erection of a retaining wall system, the alignment post 122 can be placed in the alignment void 495 defined by a surface of a respective beam member of a building element 100. As the stem 140 is set within the alignment void 495 of the respective beam member 104 the cap 142 will be the portion of the alignment post 122 protruding away from the surface of the beam 104.

In an alternative aspect, the stem 140 can comprise multiple materials. For example, an outer layer that circumscribes the stem axis 148 can comprise a plastic material such as polyethylene. An inner material for the stem 148 can be a metal bar that serves as a reinforcement of the plastic outer layer.

Optionally, in further exemplary aspects and with reference to FIG. 10, the system can further comprise an alignment post 700 having a stem 710 comprising first and second portions that cooperatively define an axial length dimension of the stem. The alignment post 700 can further comprise a cap 720 comprising a top surface and a bottom surface, wherein the top surface comprises a first cross sectional area and the bottom surface comprises a second cross sectional area greater than the first cross sectional area. In further aspects, the first portion of the stem can be embedded within the cap, and the second portion of the stem can extend downwardly from the bottom surface of the cap. In additional aspects, the top surface of the front panel of a first building element of the plurality of building elements can define an alignment void that receives the second portion of the stem of the alignment post, and the bottom surface of the front panel of a second building element of the plurality of building elements can define an alignment void 495 that receives the cap of the alignment post. In this exemplary configuration, the first and second building elements can cooperate to define at least a portion of a column of the retaining wall. In use, it is contemplated that the disclosed alignment posts and alignment voids can be used to assemble a retaining wall as further disclosed herein.

In use, it is contemplated that self-alignment keys (e.g., the alignment posts disclosed herein) can ensure the perfect alignment of precast units onto the wall face. As discussed generally above, the alignment posts can comprise a vertical steel bar and a mushroom-like head on top. It is further contemplated that the alignment posts can be fabricated upside down in cups and inserted into the fresh concrete of the precast units, preferably directly after concrete work is complete. It is contemplated that the self-aligning posts can provide exact guidance for the units to be installed on top of the other while avoiding the need for special molding on the units, which is difficult to adjust precisely. Instead of mounting molds every time before casting, the only required finishing of concrete is the smoothing of the concrete surface with a tool. Then, the alignment posts can be inserted at the precise location.

Referring to FIGS. 20A and 20B, the disclosed building elements can use less concrete per square foot of front surface 102A surface area than wall surface of conventional building elements.

Referring to FIGS. 21-23, in various aspects, the face panel of any one of the disclosed building elements can be omitted. For example, in further aspects, the face panel 102 (FIG. 1) can be replaced with one or more shelves 350. The shelves 350 can be configured to support soil and trees/plants/greenery planted therein.

The shelves 350 can have a length dimension oriented along the first axis, a width dimension oriented along the second axis that is perpendicular to the first axis, and a height dimension oriented along the third axis that is perpendicular to the first and second axes.

A building element 100E can comprise one or more shelves 350 and a beam member 104 that is coupled to the shelves 350. In various aspects, the building element can comprise one, two, three, four, five, six, or more shelves 350. In exemplary aspects, a plurality of shelves 350 can be spaced relative to the third axis, which can optionally be vertically oriented.

The beam member can comprise a main body 222 having a front end portion 224, a rear end portion 226 and first and second side surfaces 230, 232 extending substantially parallel to the second axis 116.

The beam member 104 can further comprise first and second fork legs 160, 162 that extend between and couple to the shelves 350 and the proximal end portion of the main body. Accordingly, the beam member 104 can define split struts. The first and second fork legs 160, 162 can each define a respective acute angle with a vertical reference plane 408 (FIG. 23) that contains or extends parallel to the second and third axes 116, 118 and bisects the beam member 104. That is, a respective vertical plane that bisects each of the first and second fork legs 160, 162 can form an acute angle with the vertical reference plane 408. The acute angle can range from about 15 degrees to about 75 degrees, from about 30 degrees to about 60 degrees, or be, for example, about 45 degrees. The face panel 102, the first fork leg 160, and the second fork leg 162 can cooperate to define an interior space 170.

The beam 104 can further be configured in accordance with various further aspects disclosed herein.

In exemplary aspects, the shelves 350 can have a top surface 352 that is angled upwardly from a rear of the beam to a front of the beam along the second axis 106. In this way, the shelf can retain dirt, soil, or other infill so that the dirt, soil, or infill does not spill forwardly over the front of the shelf. Still further, with the top surface 352 angled upwardly as illustrated, water (e.g., from heavy rain) can be directed away from the front of the shelf (e.g., toward a mountainside against which the building element is positioned.) The shelves 350 can have a thickness measured along the third axis 118. In some aspects, the thickness can taper at the front of the shelf. A front portion 359 of the top surface 352 can be horizontal and flat. In some optional aspects, the shelves can each have a bottom surface 356 that is parallel to the top surface 352 along at least a portion of the width of the shelf.

The shelves can have opposed longitudinal ends 354. In some aspects, the beam can coupled to the shelves 350 at locations between the longitudinal ends 354. Optionally, the beam 104 can be centered between the opposed longitudinal ends. In further aspects, the beam 104 can be offset from centered.

In some aspects, the shelves 350 can have a length between the opposed longitudinal ends 354. In some aspects, outer portions 358 of the shelves that extend outwardly from the first and second fork legs 160, 162 can be supported in a cantilevered fashion. The outer portions 358 can have a length along the first axis 114 that is less than ⅓, less than ¼, or about ⅙, or less than ⅙ of the length of the shelves. Accordingly, the portion of the shelves 350 that are supported in a cantilevered fashion can be less with the beam 104 having fork legs than a narrow beam coupling to the shelves in a single location (e.g., wherein about half of the beam is held in cantilevered fashion on each side of the beam).

The shelves 350 can have cross sections in planes perpendicular to the first axis 116. In various aspects, the cross sections can be rectangular, L-shaped, or trapezoidal. In some aspects, the top surface 352 can be flat, L-shaped (e.g., having a lower surface and a front surface that at the forward edge of the lower surface along the second axis 116), or trapezoidal (e.g., with a lower surface and opposed sloping surfaces that slope downwardly to the lower surface along the second axis 116).

The shelves 350 can be filled with topsoil, and greenery can be planted therein, such as plants, shrubs, or trees. It is contemplated that the greenery can be selected based on the amount of maintenance or irrigation needed. For example, in environments in which irrigation is limited or not possible, greenery can be selected based on its ability to survive. With the building element 100E installed, the shelves can be horizontal to inhibit water from running to one side and washing out soil.

Several embodiments of the invention have been disclosed in the foregoing specification. It is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed hereinabove, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.

BUILDING ELEMENTS FOR MAKING RETAINING WALLS, AND SYSTEMS AND METHODS OF USING SAME

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CPC

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