The present invention relates generally to retaining wall blocks, retaining wall block systems, retaining walls constructed from such blocks and methods of constructing a retaining wall from the retaining wall block system. In particular, the invention relates to a retaining wall block having a connection system utilizing a flange to secure and set back courses of blocks to adjacent courses of blocks to form walls that are straight, curvilinear, retaining or freestanding and/or that have 90 degree corners.
Numerous methods and materials exist for the construction of retaining walls. Such methods include the use of natural stone, poured in place concrete, masonry, and landscape timbers or railroad ties. In recent years, segmental concrete retaining wall units which are dry stacked (i.e., built without the use of mortar) have become a widely accepted product for the construction of retaining walls. Such products have gained popularity because they are mass produced, and thus relatively inexpensive. They are structurally sound, easy and relatively inexpensive to install, and couple the durability of concrete with the attractiveness of various architectural finishes.
Typically, retaining walls are constructed with multiple courses of blocks. The various courses may be tied together or connected in some manner. For example, numerous block designs have used a sheer connector embodied in the blocks shape to align the blocks with a setback, or batter. A common form of such sheer connectors is a rear, downwardly projecting lip or flange. In forming a multi-course wall, the blocks are placed such that the flanges contact the upper back edge of the blocks located in the course below. As such, blocks having flanges are caused to become aligned with the blocks position below, while at the same time providing a degree of resistance against displacement of individual blocks by earth pressures. In walls formed using blocks of this type, the rear flanges of the blocks cause the wall to have a setback from course to course such that the wall slopes backward at an angle which is predetermined by the width of the flanges. However, blocks with flange connection and setback means are susceptible to having the flange crack or break away from the block due to forces and pressures caused by debris and/or excess material buildup that accumulates between courses of blocks adjacent the flange. The cracking or breaking away of the flange destabilizes the structure and can result in the displacement of blocks within the structure; cracks to form in individual blocks of the structure; and the potential collapse of portions or all of the structure.
It would be desirable to provide a retaining wall block system having a flange connection means that would minimize or eliminate any cracking or breakage caused by debris or excess material buildup adjacent the flange between courses of blocks in a retaining wall. It would be desirable to provide a retaining wall block system having a flange connection means that would minimize or eliminate the ability of retaining forces acting on a block in a course of blocks in a structure to pivot upward (skyward). It would be desirable to provide a retaining wall block system having a flange connection means that would allow for the flange to be more readily broken away cleanly and completely from the block body, eliminating/reducing any excess material that may extend below the bottom face of the block. It would be desirable to provide a method of manufacturing a retaining wall block having a flange connection means that would minimize or eliminate deformation of the flange and to prevent the formation of sharpened edges or burs. It would further be desirable to provide a retaining wall block system having a flange connection means that would form continuous vertical cavities from the uppermost course of retaining wall blocks to the lowermost course of retaining wall blocks to allow stabilizing material to be inserted within the retaining wall to further strengthen the structure.
A wall block that includes a block body having top and bottom faces, a front face, a rear face, first and second side wall faces and a vertical plane of symmetry extending between the front and rear faces. The block body having a front portion including the front face, a rear portion including the rear face, a neck portion connecting the front portion and the rear portion, the front, rear and neck portions each extending between the top and bottom faces and between the first and second side wall faces. The wall block including a core extending through the neck portion from the top face to the bottom face, the core dividing the neck portion into first and second neck wall members extending rearward from the front portion to the rear portion. The wall block including a flange extending downward from the block body beyond the bottom face, the flange extending from the first side wall face to the second side wall face, the flange being positioned on the rear portion of the block body. The flange having a front surface, a back surface and a lower surface. The wall block including a channel positioned in the rear portion of the block body and extending from the first side wall face to the second side wall face and opening onto the bottom face, the first side wall face and the second side wall face. The channel having a front surface, an upper surface and a rear surface, the rear surface of the channel being formed by the front surface of the flange. The neck wall members of the wall block being positioned such that a first plane extending parallel to the plane of symmetry passes through the first neck wall member and a second plane extending parallel to the plane of symmetry passes through the second neck wall member and wherein the first and second planes are located approximately midway between the plane of symmetry and lateral outermost points of the first and second side wall faces, respectively.
A retaining wall block system including a plurality of wall blocks having a block body with top and bottom faces, a front face, a rear face, first and second side wall faces and a vertical plane of symmetry extending between the front and rear faces. The block body having a front portion including the front face, a rear portion including the rear face, a neck portion connecting the front portion and the rear portion, the front, rear and neck portions each extending between the top face and the bottom face and between the first and second side wall faces. The front portion having first and second ears extending laterally beyond the first and second neck wall members, respectively and the rear portion having first and second ears extending laterally beyond the first and second neck wall members, respectively, the laterally extending first ears of the front and rear portions and the inset first neck member of the first side wall face creating a first side wall indentation and the laterally extending second ears of the front and rear portions and the inset second neck member of the second side wall face creating a second side wall indentation. The plurality of retaining wall blocks having a core extending through the neck portion from the top face to the bottom face, the core dividing the neck portion into first and second neck wall members extending rearward from the front portion to the rear portion. The neck wall members being positioned such that a first plane extending parallel to the plane of symmetry passes through the first neck wall member and a second plane extending parallel to the plane of symmetry passes through the second neck wall member, the first and second planes being located approximately midway between the plane of symmetry and lateral outermost points of the first and second side wall faces, respectively. The plurality of retaining wall blocks having a flange extending downward beyond the block body past the horizontal plane of the bottom surface, the flange extending from the first side wall face to the second side wall face, the flange positioned on the rear portion of the block body. The flange having a front surface, a back surface and a lower surface. The plurality of retaining wall blocks having a channel extending upward into the rear portion of the block body and extending from the first side wall face to the second side wall face and opening to the bottom face, the first side wall face and the second side wall face and the flange. The channel having a front surface, an upper surface and a rear surface. The first and second neck wall members of the retaining wall blocks are configured to align, in use, with the neck wall member of a vertically adjacent block in an adjacent course of a wall made from a plurality of courses of the blocks and the core of a block in a course of the wall is configured to align, in use, with the side wall indentations of a vertically adjacent course of blocks to create retaining wall cavities in the retaining wall that are continuously open from the uppermost course of the retaining wall to the lowermost course of the retaining wall.
A method of constructing a retaining wall from a retaining wall block system including providing a plurality of wall blocks having a block body with top and bottom faces, a front face, a rear face, first and second side wall faces and a vertical plane of symmetry extending between the front and rear faces. The block body of the plurality of wall blocks having a front portion including the front face, a rear portion including the rear face, a neck portion connecting the front portion and the rear portion, the front, rear and neck portions each extending between the top face and the bottom face and between the first and second side wall faces. The front portion having first and second ears extending laterally beyond the first and second neck wall members, respectively and the rear portion having first and second ears extending laterally beyond the first and second neck wall members, respectively, the laterally extending first ears of the front and rear portions and the inset first neck member of the first side wall face creating a first side wall indentation and the laterally extending second ears of the front and rear portions and the inset second neck member of the second side wall face creating a second side wall indentation. The plurality of wall blocks having a core extending through the neck portion from the top face to the bottom face, the core dividing the neck portion into first and second neck wall members extending rearward from the front portion to the rear portion, the neck wall members being positioned such that a first plane extending parallel to the plane of symmetry passes through the first neck wall member and a second plane extending parallel to the plane of symmetry passes through the second neck wall member, the first and second planes being located approximately midway between the plane of symmetry and lateral outermost points of the first and second side wall faces, respectively. The plurality of wall blocks having a flange extending downward beyond the block body past a horizontal plane of the bottom surface, the flange extending from the first side wall face to the second side wall face, the flange positioned on the rear portion of the block body, the flange having a front surface, a back surface and a lower surface. The plurality of wall blocks having a channel extending upward into the rear portion of the block body and extending from the first side wall face to the second side wall face and opening to the bottom face, the first side wall face and the second side wall face and the flange, the channel having a front surface, an upper surface and a rear surface. The method including positioning a first plurality of retaining wall blocks to form at least a portion of a first course of blocks. The method including stacking a second plurality of retaining wall blocks to form at least a portion of a second course of blocks, the flange of the blocks of the second course contacting the rear face of the blocks of the second course to secure and connect the first course to the second course. The first and second neck wall members of the retaining wall blocks in each course are configured to align with the neck wall member of retaining wall blocks in an adjacent course and at least some of the cores of the retaining wall blocks in each course are configured to align with at least some of the side wall indentations of the retaining wall blocks in each adjacent course to create retaining wall cavities in the retaining wall that are continuously open from an uppermost course of the retaining wall to a lowermost course of the retaining wall.
A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings, wherein:
Retaining wall blocks of the present invention can be made of a rugged, weather resistant material, preferably dry cast or wet cast molded concrete. Other suitable materials include polymers, especially high density foam polymers, fiberglass, wood, metal, glass, stone, and composite materials with reinforced fibers, etc. The blocks may have various shapes and characteristics, as known in the art, and may be stacked one upon the other so that they are angled or set back from vertical. The blocks may be provided with one or more protruding elements that interlock with the rear surface of a block in an adjacent course of blocks.
“Upper” and “lower” refer to the placement of the block in a retaining wall or other structure. The lower, or bottom, surface is placed such that it faces the ground. In a retaining wall, one row of blocks is laid down, forming a course. An upper course is formed on top of this lower course by positioning the lower surface of one block on the upper surface of another block, typically in a running or half bond pattern and not in a stacked pattern.
Retaining walls may be straight (i.e., substantially linear), curved (concave, convex, or serpentine) or may have angled corners (i.e., 90 degree angles, obtuse angles or acute angles of a buildable degree). Such walls can be angled or setback from vertical. The blocks of this invention may be symmetrical about a vertical plane of symmetry. The blocks may be provided with cores and side voids which serve to decrease the weight of the block while maintaining its strength and also providing ease of construction when building the structure. The location, shape, and size of the cores and side voids are selected to maximize the strength of the block, as described by reference to the drawings.
Referring to
Block body 20 of block 1 includes front portion 8, rear portion 9 and neck portion 10. Neck portion 10 connects front portion 8 to rear portion 9. Front face 4 forms part of front portion 8, while rear face 5 forms part of rear portion 9. The front, rear and neck portions 8, 9, and 10, respectively, each extend between top and bottom faces 2 and 3 and between first and second side wall faces 6 and 7. Side wall faces 6 and 7 are thus of a compound shape and define side voids 11 and 12 which are located between front and rear portions 8 and 9 and on the exterior facing sides of neck portion 10. Side voids 11 and 12 are a result of the reduced width of neck portion 10 compared to that of front and rear portions 8 and 9. Block body 20 also includes opening or core 13 that extends through neck portion 10 from top face 2 to bottom face 3, separating front portion 8 from rear portion 9. Opening or core 13 divides neck portion 10 into first and second neck wall members 14 and 15 which extend rearward from front portion 8 to rear portion 9. Opening 13 and side voids 11 and 12 reduce the weight of block 1, facilitating handling thereof while also serving to reduce the amount of material necessary for producing the block.
The bottom face of the block along with the flange and channel may be formed facing upward in a mold box during the molding process of the blocks of the present invention. During the molding process, a stripper shoe descends into the mold box from a compression head as known in the art, contacting and compressing the molding material inside the mold box. Forming surfaces of the stripper shoe may mold/form the bottom face 3 of block body 20, the lower surface 28 of the flange, and the angular planar surface 27 of the flange (and depending upon the desired application, the entirety of front surface 26 of flange 24). The angular planar surface 31 and vertical planar surface 32 of back surface 30 of flange 24 may be formed by surfaces and/or liners of the mold cavity, or could be, depending upon the location of the flange relative to the block body, also formed by forming surfaces of the stripper shoe. Additionally, the channel of block 1 may be molded by forming surfaces of the stripper shoe or other processes known in the art. As the stripper shoe compacts the material in the mold box, vertical planar surface 32 may protect the front and back surfaces of the flange from possible over-travel of the stripper shoe as it descends into the mold box during the molding process, also preventing disfiguration of the flange and preventing the formation of any sharp edges or burs that could reduce the functionality of the block in a structure constructed from the block. Specifically, sharp edges or burs formed on the block could shear away, cut or damage a geogrid used with the block in the construction of a retaining structure.
Additionally during the block manufacturing process, blocks of the present invention may exit a kiln on a roller conveyor as known in the art. The blocks exiting the kiln may collide with adjacently positioned blocks on the roller conveyor due to the continual start and stop advancement of blocks on the roller conveyor as the blocks exit the kiln and as the blocks potentially undergo other optional processes. Since the blocks may not be fully cured as they exit the kiln, the collision of blocks on the roller conveyor may damage and deform the flange, particularly rear face to rear face adjacently positioned blocks. Angular planar surface 31 of rear surface 30 of flange 24 and inset lower surface 28 of flange 24, allows for a separation between the flange of a first block and the flange of a second block positioned rear face to rear face adjacent on the roller conveyor. The separation of the flanges will reduce/eliminate any collision between the flanges of adjacently positioned blocks by the start/stop motion of the roller conveyor and will also reduce/eliminate damage and deformation to the flanges during the manufacturing process.
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The configuration also provides overlap between opening 13A of first block 1A and side voids 12B, 11C of second and third blocks 1B, 1C, as well as between the side voids of first block 1A and openings 13B and 13C of second and third blocks 1B, 1C. This overlap provide continuous cavities 38 in the wall which extends through successive courses of blocks, improving the ease with which the cavities can be filled with core fill material such as crushed rock to encourage drainage and add stabilizing mass to the wall or alternatively easing the placement of grout. Continuous cavities 38 may also allow for the placement of guardrail posts or fences at the top of a wall or for the reinforcement of the wall with rebar and concrete grout.
Beyond merely overlapping, first and second neck wall members 14 and 15 are positioned so that they will align (minus the amount of setback due to the flange) with the neck wall members of blocks in adjacent courses when laid in a running bond pattern. Such alignment maximizes the resistance of the blocks against crushing and sheering forces in constructed walls. This will best be achieved if first and second planes P1 and P2 run though first and second neck wall members 14 and 15, respectively. To provide such alignment and to ensure blocks disposed side by side in a given course of blocks are closely adjacent without any significant gap between them, first and second planes P1 and P2 will typically be located approximately midway between plane of symmetry S and laterally outermost points 21 and 22 of first and second side wall faces 6 and 7, respectively, as can be seen in
Neck wall members 14 and 15 may have interior walls 14a and 15a that form surfaces of opening 13 and may run parallel to the line of symmetry S and first and second planes P1 and P2. Additionally, neck wall members 14 and 15 have exterior walls 14b and 15b that from surfaces of side voids 11 and 12, respectively, and may converge from front portion 8 to rear portion 9 of block 1, such that exterior walls 14b and 15b may not be parallel to the line of symmetry S or to first and second planes P1 and P2. As such, neck wall members 14 and 15 do not extend entirely parallel to plane of symmetry S. However, neck wall members 14 and 15 will provide continuous support between vertically adjacent blocks as long as planes P1 and P2 extend the entire length of the neck wall members 14 and 15 at a location between interior walls 14a, 15a and exterior walls 14b, 15b, respectively.
Block 1 of the preferred embodiment is suitable for forming straight, curved or serpentine walls. To provide for convex faced curved walls and serpentine walls, side wall faces 6 and 7 generally taper from front face 4 to rear face 5, such that the block is wider at front portion 8 between outermost points 21 and 22 than at rear portion 9. This enables the blocks to be placed in a convex curve in the usual manner without interference between the rear portions 9 of laterally adjacent blocks.
A retaining wall formed of courses of blocks 1 can be reinforced with the use of rebar and grout. Lengths of rebar can be inserted into at least one of the continuous cavities 38 defined by neck openings 13 and vertically adjacent side voids 11 and 12 of blocks in alternate courses. Cavities 38 can then be filled with grout to encase the rebar. This form of reinforcing is applicable to the setback of the wall created by flange 24, where cavities 38 defined in the wall are continuous but inclined at an angle equal to the setback angle of the wall. Alternatively, the wall may be reinforced by placing threaded rods through the cavities and using conventional post-tension techniques.
Blocks 1 are typically manufactured of concrete and cast in a high-speed masonry block or paver machine. The block may be formed with the bottom face up, to allow for forming of the channel and flange. Opening 13 and optionally side voids 11 and 12 may be formed using a core forming member that extends to the top face (which may form the bottom surface during molding). Alternatively, side voids 11 and 12 may be formed by side liners and other methods known in the art. Blocks 1 may be formed as mirror image pairs joined at the front face 4 which are then subsequently split using a standard block splitter in the usual way to provide a rough front face 4 on the split blocks 1. Alternatively, other methods may be utilized to form a variety of front face surface appearances. Such methods are well known in the art.
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Although particular embodiments have been disclosed herein in detail, this has been done for purposes of illustration only, and is not intended to be limiting with respect to the scope of the appended claims, which follow. In particular, it is contemplated by the inventor that various substitutions, alterations, and modifications may be made to the invention without departing from the spirit and scope of the invention as defined by the claims. For instance, the choice of materials or variations in the shape or angles at which some of the surfaces intersect are believed to be a matter of routine for a person of ordinary skill in the art with knowledge of the embodiments disclosed herein.
Number | Date | Country | |
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62576939 | Oct 2017 | US |