This invention relates to a masonry block for stacking on other like-shaped blocks in a staggered, interlocking and offset manner to form a wall that is particularly well-suited for use as a vertical seating wall around patios, pool decks, walkways, and the like.
A variety of masonry block designs have been developed for building vertical seating walls. Wall block designs require a mechanism for securing the blocks together to produce a stable wall structure. Conventional interlocking masonry wall blocks are heavy and difficult to handle. In addition, several different block shapes must be combined to form the straight and curved sections of a serpentine wall. The need remains for masonry wall blocks that are cost-efficient to manufacture and easily assembled into a stabile and durable wall.
Each block in an upper course of blocks is laid in a staggered manner relative to a lower course so that the upper block is placed atop two lower blocks. Single block units mate with like units to build straight walls, inside curves, outside curves and angle corners. Laterally adjacent blocks may be similarly aligned. Alternatively, laterally adjacent blocks may be inversely aligned so that the front wall of one block lies adjacent the rear wall of the adjacent block.
According to one aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The core has a width less than 1.25× the width of the projections. The projections are adapted for placement within the core of an underlying block in the retaining wall.
In one embodiment, the core is offset between the front and rear wall outer surfaces. In another embodiment, the core is centered between the front and rear wall outer surfaces.
In one embodiment, the first and second projections are offset between the front and rear wall inside surfaces. In another embodiment, the first and second projections are spaced equidistant between the front and rear wall inside surfaces.
According to another aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The projections are adapted for placement within the cavity of an underlying block in the retaining wall. At least one of the first and second side walls includes a score line between the cavity and the respective first or second projection that extends from the front wall outer surface to the rear wall outer surface.
In one embodiment, the core is offset between the front and rear wall outer surfaces. In another embodiment, the core is centered between the front and rear wall outer surfaces.
In one embodiment, the first and second projections are offset between the front and rear wall inside surfaces. In another embodiment, the first and second projections are spaced equidistant between the front and rear wall inside surfaces.
According another aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The projections are spaced equidistant between the front and rear wall inside surfaces and adapted for placement within the cavity of an underlying block in the retaining wall so as to provide essentially no setback dimension between the block and the underlying block.
In one embodiment, there is essentially no setback dimension when the first and second projections are placed within the cavity of the underlying block in an abutting relation to the front wall inside surface of the underlying block.
In another embodiment, there is essentially no setback dimension when the first and second projections are placed within the cavity of the underlying block in an abutting relation to the rear wall inside surface of the underlying block.
In one embodiment, the core is offset between the front and rear wall outer surfaces. In another embodiment, the core is centered between the front and rear wall outer surfaces.
In one embodiment, the first and second projections are spaced equidistant between the front and rear wall outside surfaces.
According to another aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls that extend from the front wall to the rear wall. The front wall has a length greater than the length of the rear wall such that the first and second side walls converge toward one another as they extend from the front wall toward the rear wall. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The first and second projections are adapted for placement within the cavity of an underlying block in the retaining wall. The front wall of the block is configured to lie adjacent the rear wall of a laterally adjacent block in the retaining wall such that the cavity of the block is positioned to receive the first projection of an overlying block in the retaining wall in an abutting relation to the inside surface of the front wall of the bock and the cavity of the laterally adjacent block is positioned to receive the second projection of the same overlying block in the retaining wall in an abutting relation to the inside surface of the rear wall of the laterally adjacent block.
In one embodiment, the front wall and the rear wall are of equal width.
A masonry wall block for forming a retaining wall comprising a body having a front wall, a rear wall, and first and second side walls that extend from the front wall to the rear wall. The front wall has a length greater than the length of the rear wall such that the first and second side walls converge toward one another as they extend from the front wall toward the rear wall. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The first and second projections are adapted for placement within the cavity of an underlying block in the retaining wall. The front wall of the block is configured to lie adjacent the rear wall of a laterally adjacent block in the retaining wall such that the cavity of the block is positioned to receive the first projection of an overlying block in the retaining wall in an abutting relation to the inside surface of the rear wall of the bock and the cavity of the laterally adjacent block is positioned to receive the second projection of the same overlying block in the retaining wall in an abutting relation to the inside surface of the front wall of the laterally adjacent block.
In one embodiment, the front wall and the rear wall are of equal width.
According to yet another aspect of the invention, a retaining wall comprises a lower tier of individual blocks, each block having a cavity, and an upper tier of individual blocks. Each block in the upper tier comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The projections are spaced equidistant between the front and rear wall inside surfaces and adapted for placement within the cavity of an underlying block in the retaining wall so as to provide essentially no setback dimension between the block and the underlying block.
An individual masonry block 10 for use in constructing vertical seating walls around patios, pool decks, walkways, etc. is shown in
The upper surfaces of walls 14, 20, and 26 define an upper surface 34 of the body 12. The lower surfaces of walls 14, 20, and 26 define a lower surface 36 of the body 12. The upper and lower surfaces 34 and 36 are generally parallel to each other. When laid in place on a horizontal supporting surface, the upper and lower surfaces 34 and 36 are horizontal as well.
The front wall 14 has a length LF and the rear wall 20 has a length LR. Each side wall 26 converges toward the other at an angle A as it extends toward the rear wall 20 such that LF>LR, thereby providing the block 10 a generally trapezoidal shape. The front and rear walls 14 and 20 are generally parallel (i.e., both walls 14 and 20 are of an essentially straight or linear configuration), and generally perpendicular to upper and lower surfaces 34 and 36. It is contemplated, however, that either or both of front and rear walls 14 and 20 may be of a curvilinear configuration, e.g., convex, arcuate, or serpentine configuration (not shown). Front and rear walls 14 and 20 are desirably both finished (split, soft split or textured). The block 10 has a width WB.
Desirably, at least one score line 38 is provided. In a preferred embodiment, a pair of opposing score lines 38 are provided. In the illustrated embodiment, the score lines 38 take the form of a V-shaped grooves G. The score lines 38 are generally parallel and extend from the front wall 14 to the rear wall 20. A block 10 may be split along a score line 38 to form an end block 40 presenting a flat end surface 42, as will be explained in detail later (see
Two opposing integral lug projections 44 extend from the lower surface 36 of the block 10. In the illustrated and preferred embodiment, a first projection 44 extends from the lower surface 36 of the first side wall 26 and the second projection 44 extends from the lower surface 36 of the second side wall 26. Each projection 44 is desirably positioned between the score line 38 and the outside surface 28 of the respective side wall 26. The projections 44 are generally rounded or convex, having a radius RL, a height HL, and a width WL. It is contemplated that the projections 44 may take on a variety of other configurations, e.g., rectangular or square, to accommodate specific needs. In a preferred embodiment, each lug projection 44 is generally centered equidistant between the front wall inside surface 18 and the rear wall inside surface 24 such that distance D1 and distance D2 are essentially equal.
The open interior or core 32 extends completely through the block 10 from the upper surface 34 to the lower surface 36. The open core 32 does not present a trapezoidal shape as does the block body 12, but instead has a generally elongated, rounded shape having a length LC, width WC and radius RC. Desirably, the width of the core 32 is only slightly larger than the width of the projection 44, such that WC is only slightly greater than WL. This arrangement allows for easy placement of the projections 44 within the core 32 of an adjacent-tiered block 10 and provides a tolerance allowing for expansion, contraction, or settling movement of the blocks 10. This arrangement also provides sufficient tolerance for orientating the blocks 10 in various configurations, e.g., curved walls, as will be described later. In addition, this arrangement permits minimal forward or reverse movement of the blocks 10 within the retaining wall, thus providing additional stability to the wall. For example, the core 32 may have a width WC that is less than twice the width of the projections WL (WC<2×WL), and preferably WC is less than 1.25 times WL (WC=1.25×WL). In a preferred embodiment, the core 32 has a width of 1½ inches and each lug projection 44 has a width of 1⅜ inch.
With reference to
In an alternative embodiment, the core 32 is not offset, i.e., the front and rear walls 14 and 20 are of equal width, such that D3=D4. In this embodiment, there is no or zero setback when the projections 44 are placed equidistant between the front and rear inside wall surfaces 18 and 24 within the core 32 of a similarly-aligned adjacent-tiered block 10. In this case, it may be desirable to slightly offset the projections 44 with respect to the core 32 (i.e., such that D1≠D2) so as to provide zero offset when the projections 44 abut the front wall inside surface 18 or the rear wall inside surface 24 of an adjacent-tiered block 10.
One of ordinary skill in the art should readily appreciate that the volume of the core 32 can vary, but is preferably maximized to decrease the weight and material cost of the block 10 without impairing the strength, integrity and manufacturability of the block 10. Similarly, the actual shape and dimensions of the core 32 can vary, provided the core 32 maintains the ability to receive the lug-shaped projections 44 of another block 10, as will be described later.
Table 1 lists dimensions for a representative embodiment:
The block 10 configuration enables a fastening system that provides simple construction and automatic wall alignment. The like-shaped blocks 10 are sized and configured to be laterally aligned in an abutting side-by-side engagement, and vertically aligned in a staggered, stacked manner so that one block 10 rests atop two other blocks 10.
When arranged in this manner, the blocks form a multi-tiered wall (W), such as the wall W shown in
An interlocking fit is achieved between the like-shaped blocks 10 in adjacent upper and lower courses 48 and 46. Each block 10 in the upper course 48 is laid in a staggered manner relative to the lower course 46 so that the upper block 10 is placed atop two lower blocks 10. Each block 10 is also placed such that one of its lug projections 44 extends into and is received by the open core 32 of an adjacent block 10 in an adjacent course 46 or 48. This interlock limits forward or backward movement of blocks 10 in one course 46 or 48 relative to the blocks 10 of an adjacent course 46 or 48. This arrangement also limits sideways or lateral movement of blocks 10 in one course 46 or 48 relative to the blocks 10 of the adjacent course 46 or 48.
The first course may be laid such that the lower surface 36 and projections 44 are positioned facing upward (i.e., with upper surface 34 facing downward). Upward positioning of the projections 44 may be desirable if the first course is to be laid on a hard or finished surface, e.g., on a patio or deck 50, as shown in
Alternatively, subsequent courses may all be laid with the projections 44 facing downward, such that each projection 44 extends into and is received by the open core 32 of an adjacent lower block 10. That is, the lower surface 36 of each block 10 in each stacked, upper course 48 is placed on and rests on the upper surfaces 34 of the blocks 10 in the lower course 46 upon which it is placed. The final course is desirably laid with the projections 44 facing downward regardless of whether the previous courses were laid with the projections 44 facing upward or downward to present the flat or smooth upper surfaces 34 of the blocks 10 forming the top course, thereby eliminating the need to cut or otherwise remove the projections 44 from the blocks 10 forming the top course.
Alternatively, the first course may be laid with the lower surface 36 and projections 44 positioned facing downward (i.e., with upper surface 34 facing upward). Downward positioning of the projections 44 may be desirable if the first course is to be laid on soil or other surface in which the projections 44 may be extended to further anchor the first course blocks 10. If the first course is laid with the projections 44 facing downward, the subsequent courses are preferably all laid with the projections 44 facing downward. This arrangement also presents the flat or smooth upper surfaces 34 of the blocks 10 forming the top course.
With reference again to
When the core 32 is spaced essentially equidistant between the front and rear wall outside surfaces 22 and 28, the core 32 of a block 10 is positioned to receive the first projection 44 of an overlying block 10 in the retaining wall W in an abutting relation to the inside surface 24 of the front wall 14 of the bock 10 and the core 32 of an inversely-aligned and laterally-adjacent block 10 is positioned to receive the second projection 44 of the same overlying block 10 in an abutting relation to the inside surface 24 of the rear wall 20 of the laterally adjacent block 10. Alternatively, when the core 32 is spaced essentially equidistant between the front and rear wall outside surfaces 22 and 28, the core 32 of the block 10 is positioned to receive the first projection 44 of an overlying block 10 in the retaining wall W in an abutting relation to the inside surface 24 of the rear wall 20 of the bock 10 and the core 32 of an inversely-aligned and laterally-adjacent block 10 is positioned to receive the second projection 44 of the same overlying block 10 in an abutting relation to the inside surface 18 of the front wall 14 of the laterally adjacent block 10.
As seen in
As shown in
To accommodate a variety of landscapes and individual design plans, it is often desirable to construct a wall W in which at least a portion is of a curved or arcuate configuration. As seen in
Alternatively, as illustrated in
Curved portions WC may be arranged in either a convex or a concave manner. The degree of curvature may also be selected to provide a low radius curve, a medium radius curve, or a high radius curve. In addition, the blocks 10 can be arranged to gradually or rapidly increase or decrease the radius of the curvature to accommodate a specific setting, landscape or purpose. It is contemplated that blocks 10 may be aligned to form a wall W having both straight portions and curved portions WL and WC (see
With reference again to
This application claims the benefit of provisional U.S. Patent Application Ser. No. 60/500,492, filed Sep. 5, 2003, and entitled “Interlocking Masonry Wall Block.”
Number | Date | Country | |
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60500492 | Sep 2003 | US |