RETAINING WALL BLOCK SYSTEM

Abstract

A wall block having a block body having opposed front and rear faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces, one or more pin holes that open onto the top face of the block, and one or more lugs that extend from the bottom face, each lug having a back surface that extends contiguously from the rear face of the block. A corner block for use with the wall block. A retaining wall comprising a plurality of wall blocks including at least one lower course and at least one upper course.

Description

FIELD OF THE INVENTION

This invention relates generally to retaining wall blocks and retaining walls constructed from such blocks. In particular, this invention relates to a retaining wall block system having a dual connection feature that allows the connection of blocks in the wall using a pinning system and/or a lug system. The pinning system is used to interconnect blocks in upper and lower courses and additionally used as a geogrid soil reinforcement connection element. The lug system is used to connect and align blocks by course. The pinning and lug systems prevent block displacement from retaining forces and enhance the structural integrity of the retaining wall constructed.

BACKGROUND OF THE INVENTION

Retaining walls are used in various landscaping projects and are available in a wide variety of styles. Numerous methods and materials exist for the construction of retaining walls. Such methods include the use of natural stone, poured concrete, precast panels, 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 widely accepted in the construction of retaining walls. An example of such a unit is described in U.S. Pat. No. Re 34,314, which issued to Forsberg (Forsberg '314). Such retaining wall units have gained popularity because they are mass produced and, consequently, 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. The retaining wall system described in Forsberg '314 has been particularly successful because of its use of a block design that includes, among other design elements, a unique pinning system that interlocks and aligns the retaining wall units, thereby providing structural strength and allowing efficient installation. This system is advantageous in the construction of larger walls, when combined with the use of geogrids hooked over the pins, as described in U.S. Pat. No. 4,914,876 to Forsberg ('876).

The shape of the block is also an important feature during installation of a retaining wall. Forsberg '876 illustrates a fairly complex shape for a retaining wall block which is particularly advantageous in the construction of curved walls. The block is symmetrical about a vertical plane which bisects the block at a midway point through the front and back faces.

Many commercially available blocks are symmetrical about a plane bisecting the front and back surfaces. Typically such blocks have planes rather than axes of symmetry, as there are differences between the top and bottom surfaces of such blocks. Clearly, blocks that are substantially square or rectangular (i.e., each surface being joined to another at an orthogonal angle) exhibit a great deal of symmetry. Other blocks are more complex in shape and exhibit only one vertical plane of symmetry. For example, U.S. Pat. No. 5,711,130 (Shatley) illustrates a block having substantially parallel front and back faces and non-parallel, mirror-image side wall surfaces. That is, there is a mirror plane of symmetry that vertically bisects the block. U.S. Pat. Nos. 5,598,679 (Orton et al.) and 5,294,216 (Sievert) illustrate a type of block having parallel front and back faces and non-parallel, converging side surfaces. The term “converging side surfaces” means that the side walls of the blocks converge as they approach the rear of the block. Such blocks are also symmetrical about a vertical plane that passes through the front and back surfaces.

There are advantages to having non-parallel surfaces on these blocks when constructing a retaining wall. The angles formed by these side surfaces permits construction of curvilinear walls, and moreover, permit the amount of curvature to vary according to the terrain and desired appearance of the retaining wall.

Retaining wall block systems are generally provided with some means to connect blocks in adjacent courses of the wall, such as the pinning system discussed above in connection with Forsberg '876. Alternatively, numerous block designs have used a shear connector embodied in the block's shape to align the blocks with a setback, or batter. A common form of such shear 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 positioned 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 slope backward at an angle which is predetermined by the width of the flanges.

Retaining walls using blocks having a rear flange are well known in the art. For example, U.S. Pat. No. 2,313,363 (Schmitt) describes an early use of a retaining wall block with a rear flange. More recently, U.S. Pat. No. 5,294,216 (Sievert) describes a geogrid reinforced retaining wall constructed with retaining wall blocks having rear flanges. Such blocks function adequately for small walls where in most cases soil reinforcement is not necessary because they are relatively simple to install and require no special pieces for capping the top course of the wall. In some cases, geogrid may be used to allow these walls to be built to greater heights due to the soil reinforcing principles of geogrid design. Again these walls will be limited in height due to the minimal connection strength of the lip and geogrid and the potential for the lips to abraid and cut the geogrid. These blocks are not generally desirable for use in taller retaining walls where soil reinforcement with a positive connection to the wall is necessary.

It would be desirable to provide a system of blocks for constructing a retaining wall that combines the ease of installation of modern segmental retaining walls with the attractive appearance of a natural stone wall composed of stones of varying sizes. The block system should be efficient to produce, require a minimal number of different block shapes and allow the construction of walls with 90 degree corners, and the construction of freestanding walls with a desirable natural appearance. It would also be desirable to provide a retaining wall system that allowed an aesthetically pleasing randomness of appearance by varying the size of blocks used in the construction of the structure.

It would further be highly desirable to have a wall block system which can be used to build a retaining wall using either a rear flanged block or a pin connection between courses, depending on the requirements of the project. Such a unit would also be desirable from a production and distribution view point, because the same block design could be used in multiple wall applications, thus reducing the need to produce specialty units, as well as the need to maintain separate inventories of pinned and rear flanged products.

In view of the above, a need exists for a wall block system including a retaining wall block having features of both a rear flange for alignment of the units in a wall and connection of the units and a pinning system for positive connection to the geogrid soil reinforcing material. Further a need exists for a retaining wall block that may be constructed using a rear flange connection and a pinning system for use with a geogrid for walls or wall sections where soil reinforcement is required for structural soundness.

SUMMARY OF THE INVENTION

The invention provides a wall block comprising a block body having opposed front and rear faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces, one or more pin holes that open onto the top face of the block, and one or more lugs that extend from the bottom face, each lug having a back surface that extends contiguously from the rear face of the block.

The invention provides a wall block comprising a block body having: opposed front and back faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces; the first and second side walls both having lengths and the length of the second side wall being less than the length of the first side wall, and the first and second side walls being substantially parallel; one or more pin holes that open onto the top face of the block; and a neck that has a shorter width than the width of the block from the front face to the rear face at a main body portion of the block, the neck being formed by a neck surface having a length and being substantially perpendicular to the second side wall and adjacent to the second side wall, the second side wall, and the portion of the front face having the same corresponding length as the neck surface.

The invention provides a retaining wall comprising: a plurality of blocks including at least one lower course and at least one upper course, at least one block comprising a block body having opposed front and rear faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces, one or more pin holes that open onto the top face of the block, and one or more lugs that extend from the bottom face, each lug having a back surface that extends contiguously from the rear face of the block.

The present invention relates to a method of constructing a retaining wall having a dual connection feature that allows the connection of blocks in the wall using a lug system and/or a pinning system. The lug system is used to connect and align blocks by course. The pinning system is used to interconnect blocks in upper and lower courses and is additionally used as a geogrid soil reinforcement connection element. The pinning and lug systems prevent block displacement from retaining forces and enhance the structural integrity of the retaining wall constructed.

The present invention also relates to a wall block that is provided with a lug or multiple lugs to enhance the structural integrity of a structure made with the blocks and to also align the blocks in the structure being constructed. The wall block is also provided with pin holes and a pin receiving channel, the pin holes of a block in a lower course of the wall receive a shaft or base of a pin and the pin receiving channel of a block in an upper course of the wall receive the head or top of the pin thereby interlocking the blocks in the upper and lower courses. When the pinning system is utilized a layer of soil reinforcement material may be laid over the pins and pulled taut. The next course of block is placed on the lower course with the head or top of the pins being received in the pin receiving channel of the upper course providing additional securement of the soil reinforcement material to the retaining wall. Multiple embodiments of the block, lug system and pinning system are disclosed.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings.

FIGS. 1 to 5 are top perspective, side, top, bottom and back views, respectively, of an embodiment of a wall block of the present invention.

FIGS. 6 and 7 are bottom perspective and bottom views, respectively, of a second embodiment of a wall block of the present invention.

FIGS. 8 and 9 are front perspective and bottom views, respectively, of a third embodiment of a wall block of the present invention.

FIGS. 10 to 13 are top perspective, side, back and bottom views, respectively, of an embodiment of a corner block of the present invention.

FIGS. 14 to 16 are front perspective, back perspective and cross-sectional side views, respectively, of a wall constructed with the blocks of the present invention.

FIG. 17 is a cross sectional side view of a wall constructed with the blocks of the present invention

FIGS. 18 and 19 are front perspective and back perspective views, respectively, of a wall constructed with the blocks of the present invention.

FIG. 20 is a front perspective of a curved wall constructed with the blocks of the present invention.

FIGS. 21 and 22 are front perspective and back perspective views, respectively, of a wall constructed with the blocks of the present invention, shown in a 90 degree corner layout.

FIGS. 23 and 24 are front perspective and bottom views, respectively, of an alternative embodiment of a wall block of the present invention.

FIGS. 25 and 26 are top perspective and bottom perspective views, respectively, of an alternative embodiment of a wall block of the present invention.

FIG. 27 is a bottom perspective view of an alternative embodiment of a wall block of the present invention.

FIG. 28 is a front perspective view of a portion of a wall constructed with the blocks of FIGS. 23 and 24.

FIG. 29 is a front perspective view of a portion of a concave wall constructed with the blocks of FIGS. 25 and 26.

FIG. 30 is a front perspective view of a portion of a convex wall constructed with the blocks of FIGS. 25 and 26.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In this application, “upper” and “lower” refer to the placement of the block in a retaining wall. The lower surface faces down, that is, it is placed such that it faces the ground. In forming a retaining wall, one row of blocks is laid down, forming a course. A second course is laid on top of this by positioning the lower surface of one block on the upper surface of another block.

The retaining wall blocks of this invention are symmetrical about a vertical plane of symmetry. The blocks are provided with pin holes, a pin receiving channel, and at least one core which serve to decrease the weight of the block while maintaining its strength while also providing ease of construction of a retaining wall. The blocks are also provided with a lug(s). The location, shape, and size of the pin holes, pin receiving channel, lugs and core are selected to maximize the strength of the block, as described by reference to the drawings. It is also to be understood that the pin holes, pin receiving channels and lugs in addition to pins described below could also be used on different block types and block shapes to form different walls and that the block shown with these features does not limit the scope of the invention.

The invention provides a wall block comprising a block body having opposed front and rear faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces, one or more pin holes that open onto the top face of the block, and one or more lugs that extend from the bottom face, each lug having a back surface that extends contiguously from the rear face of the block. In one embodiment, wherein the front face is substantially parallel to the rear face. In an embodiment, wherein the block has a vertical plane of symmetry. In an embodiment, one or more pin holes are closer to the front face than the back face. In an embodiment, the block comprises a pin receiving channel that opens onto the bottom face of the block. In an embodiment, the pin receiving channel is substantially parallel to the front face. In an embodiment, the pin receiving channel is closer to the front face than to the rear face.

In one embodiment, the front face and the rear face both have lengths and the length of the front face is greater than the length of the rear face. In an embodiment, at least a portion of the side walls are angled back from the front face to the rear face such that the portion of each side wall forms an acute angle with the front face. In one embodiment, the block comprises a core. In an embodiment, no lug extends from the first to the second side wall. In one embodiment, the block is made of concrete. In an embodiment, the block comprises at least one pair of pin holes. In an embodiment, the front face has a compound shape with an angled portion which is non-orthogonal to one or both of the first and second side walls.

In one embodiment, wherein the block comprises two lugs, a first lug being contiguous with the first side wall, and a second lug being contiguous with the second side wall. In an embodiment, the block comprises just one lug, the lug not being contiguous with the first or second side walls. In an embodiment, the lug extends from 0.5 to 0.75 inch (1.27 to 1.91 cm) past the bottom face. In an embodiment, the lug is from 0.75 to 1 inch deep. In one embodiment, the block comprises three lugs. In an embodiment, the first and second side walls have compound shapes and converge back from the front face towards the rear face and then extend outward before meeting the rear face.

The invention provides a wall block comprising a block body having: opposed front and back faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces; the first and second side walls both having lengths and the length of the second side wall being less than the length of the first side wall, and the first and second side walls being substantially parallel; one or more pin holes that open onto the top face of the block; and a neck that has a shorter width than the width of the block from the front face to the rear face at a main body portion of the block, the neck being formed by a neck surface having a length and being substantially perpendicular to the second side wall and adjacent to the second side wall, the second side wall, and the portion of the front face having the same corresponding length as the neck surface. In an embodiment, the block comprises a pin receiving channel that opens onto the bottom face of the block. In an embodiment, the pin receiving channel is substantially parallel to the front face. In one embodiment, the pin receiving channel is closer to the front face than to the rear face. In one embodiment, the block comprises a second pin receiving channel that is substantially parallel to the first side wall. In one embodiment, the pin receiving channel is closer to the first side wall than to the second side wall. In an embodiment, the block comprises two pin holes, one pin hole being closer to the rear face than the front face, and one pin hole being closer to the front face than to the rear face.

The invention provides a retaining wall comprising: a plurality of blocks including at least one lower course and at least one upper course, at least one block comprising a block body having opposed front and rear faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces, one or more pin holes that open onto the top face of the block, and one or more lugs that extend from the bottom face, each lug having a back surface that extends contiguously from the rear face of the block. In one embodiment, the retaining wall further comprises a geogrid. In an embodiment, the retaining wall further comprises one or more pins, which may have a head. In one embodiment, the plurality of blocks includes blocks with differing dimensions.

In an embodiment, the front face of the at least one block is substantially parallel to the rear face. In an embodiment, the at least one block has a vertical plane of symmetry. In an embodiment, the one or more pin holes of the at least one block are closer to the front face than the back face. In an embodiment, the at least one block comprises a pin receiving channel that opens onto the bottom face of the block. In an embodiment, the pin receiving channel is substantially parallel to the front face. In an embodiment, the pin receiving channel is closer to the front face than to the rear face.

In one embodiment, the front face and the rear face of the at least one block both have lengths and the length of the front face is greater than the length of the rear face. In an embodiment, the at least one block comprises a core. In an embodiment, no lug of the at least one block extends from the first to the second side wall. In an embodiment, the at least one block is made of concrete. In an embodiment, the at least one block comprises at least one pair of pin holes.

In one embodiment, the at least one block comprises two lugs, a first lug being contiguous with the first side wall, and a second lug being contiguous with the second side wall. In an embodiment, the at least one block comprises just one lug, the lug not being contiguous with the first or second side walls. In an embodiment, the at least one block comprises three lugs. In an embodiment, the first and second side walls of the at least one block have compound shapes and converge back from the front face towards the rear face and then extend outward before meeting the rear face.

In an embodiment, wherein the retaining wall further comprises at least one block of a second block type, the second block type comprising a block body having: opposed front and back faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces; the first and second side walls both having lengths and the length of the second side wall being less than the length of the first side wall, and the first and second side walls being substantially parallel; one or more pin holes that open onto the top face of the block; and a neck that has a shorter width than the width of the block from the front face to the rear face at a main body portion of the block, the neck being formed by a neck surface having a length and being substantially perpendicular to the second side wall and adjacent to the second side wall, the second side wall, and the portion of the front face having the same corresponding length as the neck surface. In an embodiment, the second block type comprises a pin receiving channel that opens onto the bottom face of the block. In an embodiment, the pin receiving channel of the second block type is substantially parallel to the front face. In an embodiment, the pin receiving channel of the second block type is closer to the front face than to the rear face. In an embodiment, the second block type comprises a second pin receiving channel that is substantially parallel to the first side wall. In an embodiment, the second block type pin receiving channel is closer to the first side wall than to the second side wall. In an embodiment, the second block type block comprises two pin holes, one pin hole being closer to the rear face than the front face, and one pin hole being closer to the front face than to the rear face.

An embodiment of the retaining wall block is shown in FIGS. 1 to 5. Block 100 is made of a rugged, weather resistant material, preferably (and typically) zero-slump molded concrete. Other suitable materials include plastic, reinforced fibers, wood, metal and stone. Block 100 has parallel top face 102 and bottom face 103, front face 104, rear face 105 and first and second side walls 106 and 107. Front face 104 and rear face 105 each extend from top face 102 to bottom face 103. Side walls 106 and 107 extend from top face 102 to bottom face 103, converging from front face 104 toward rear face 105. Front face 104 may be of a compound shape with angled portions 111 which are non-orthogonal to side walls 106 and 107 and to portion 112 which is parallel with rear face 105. Block 100 is generally symmetrical about vertical plane of symmetry S.

Block 100 comprises body portion 108, back portion 109 and neck portions 110 which connect body portion 108 to back portion 109. Front face 104 forms part of body portion 108, while rear face 105 forms part of back portion 109. The body, back and neck portions 108, 109, and 110 each extend between top and bottom faces 102 and 103 and between first and second side walls 106 and 107. Opening or core 114 may extend through neck portion 110 from top surface 102 to bottom face 103, or may only extend part of the way through block 100 (for example, open to top surface 102 but closed at bottom surface 103). Core 114 reduces the weight of block 100; lower block weight is both a manufacturing advantage and a constructional advantage when building a wall from the wall blocks as it reduces cost due to less material and makes lifting of the blocks easier.

First and second pin holes 118 are located in body portion 108 and extend from top face 102 to bottom face 103, i.e., opening onto both top and bottom surfaces. Pin hole depressions 119 located on the bottom face of the body portion 108 are formed from a pin hole forming member or bridge (not shown) which is mounted to a side wall or liner of a mold cavity. During the manufacturing of block 100, concrete or other desired material settles around the pin hole forming member and is allowed to set, the block is then stripped from the mold cavity, forming pin hole 118 and pin hole depression 119. The pin hole interior surfaces may be tapered from narrower to wider from the top surface to the bottom surface or its interior surfaces may be non-tapered or plumb. This taper of the surfaces of the pin holes is used in the manufacturing phase to help ease the removal of the block unit from the mold. The taper creates a draft angle which helps strip the pin hole forming core with greater ease from the block in the mold while helping to maintain the integrity of the shape of the pin hole. The pin holes 118 are positioned away from the line of symmetry S and towards side walls 106 and 107. It should be noted that additional pin holes can be provided, if desired, so as to provide for further choices of predetermined setback when building a wall. Additionally, the location of the pin holes in the body of the block may be varied as desired.

Pin holes are sized to receive pin 50 which is shown in FIG. 3. Pin 50 has a shaft 51 which is placed into a pin hole of the top surface of block 100 in a lower course of blocks when constructing a wall. Pin 50 also has a head 52, and may have a larger diameter than the shaft 51 and may also be tapered, square, round or any other desired shape. Additionally the shaft 51 of the pin may be circular, square or any other desired shape as well. In this manner, the pin inserted into a pinhole on a lower course of blocks in a wall engages a pin receiving channel of a block in an upper course. This results in an interlocking of the blocks with a predetermined setback. It is to be understood that the shape of the pin is not limiting and could be for example uniformly shaped with no head or could have any other number of features.

Bottom surface 103 has pin receiving channel 130 located in body portion 108. Receiving channel 130 may extend the entire length of the body portion as shown in FIG. 4 and open onto the surfaces of side walls 106 and 107. Pin receiving channel 130 may be of sufficient width and depth as to accommodate the head 52 of pin 50. It should be noted that the shape, width and length of the channel can vary depending upon the application and could for example only extend a portion of the length of body portion 108 or may open onto only one of side walls 106 or 107 or may open onto neither side wall.

Block 100 has two lugs 120 located on back portion 109 which extend from the rear surface 105 downward past the bottom face 103 of the block. The lugs have a front surface 122, a bottom surface 123 and a back surface 124 that extends contiguously from the rear face 105 of the block. The lugs provide an earthen retaining structure constructed with blocks 100, and a predetermined amount of setback, thus lugs 120 may have various dimensions, depending on the desired setback for walls constructed of the blocks. In one embodiment of the present invention, lugs 120 extend approximately ½ to ¾ of an inch (1.27 to 1.19 cm) past the bottom face 103 and the lugs are approximately ¾ of an inch to 1 inch deep (1.91 to 2.54 cm). It should be noted that the dimensions of the lug are not limited and can have any dimension as desired.

Lugs 120 also serve to enhance the structural integrity of a retaining structure made with the blocks of the present invention. Front surface 122 of lugs 120 of a block in an upper course of a structure abut the rear face 103 of a block in a lower course of a structure. This abutment helps to prevent retaining forces from displacing a block in an upper course over a block in a lower course. Not only does this abutment help to ensure structural stability it also increases the aesthetic value of the structure by ensuring a more uniform setback for the structure being produced. It should be noted that block 100 may be manufactured with additional lugs as desired (or fewer lugs). Also the size and shape of the lugs are not limiting and may have any desired shape or size depending upon the application.

Block 100 is manufactured in the mold with the bottom surface facing up. A channel forming element is attached at the top stripping shoe of the mold and imparts or presses the pin receiving channel 130 into the bottom face 103 of the block (top surface when sitting inside the mold) as the material inside the mold forms to the channel projecting element. The channel forming element is then removed when the stripping shoe is vertically pulled upward and away from the molded unit and the block is stripped from the mold with the pin receiving channel formed into the bottom surface of the block.

Though the blocks illustrated in the FIGS. 1 to 5 may have various dimensions, block 100 typically has a height (i.e., the distance between surfaces 102 and 103) of about 6 inches (15.2 cm), a body length (i.e., the distance from side wall 106 to side wall 107) of about 10 inches (25.4 cm) and a width (i.e., the distance from front face 104 to rear face 105) of about 10.5 inches (26.7 cm).

An alternative embodiment of the block is shown in FIGS. 6 and 7. Block 200 is substantially similar to block 100 except that the length of block 200, (i.e., the distance from side wall 206 to side wall 207) is less than the length of block 100. Additionally, block 200 has been manufactured with only one lug 220 on bottom face 203. Front face 204 has been provided with an optional pattern. It should be noted that any design or texture may be imparted onto any block surface of the present invention as desired. For example, a roughened surface, such as the appearance of natural stone, is a desirable appearance and can be formed during the molding process with liners as known in the art.

An alternative embodiment of the block is shown in FIGS. 8 and 9. Block 300 is substantially similar to block 100 except that the length of block 300, (i.e., the distance from side wall 306 to side wall 307) is greater than the length of block 100. Additionally, block 300 has been manufactured with three lugs 320 on bottom face 303. Front face 304 has been provided with an optional pattern and is parallel rear face 305. First and second pin holes 318 are located in body portion 308. Bottom surface 303 has pin receiving channel 330 located in body portion 308.

FIGS. 10 to 13 illustrate a corner block of the present invention. Corner block 400 comprises opposing and substantially parallel upper or top and lower or bottom faces 402 and 403 respectively, and opposing front and back faces 404 and 405, respectively. Corner block 400 also comprises opposing side surfaces 410 and 412. Rear face 405 is of a compound shape and includes surface 415 which is parallel with front face 404, surface 414 which is substantially parallel with side surfaces 410 and 412, and surface 413 which is substantially parallel with front face 404. Neck 416 is formed from surface 415 and the corresponding length of surface 415 on front face 404, in addition to side surface 410. Front face 404 and rear face 405 each extend from top surface 402 to bottom surface 403, and side wall surfaces or ends 410 and 412 each extend from top surface 402 to bottom surface 403 and from front face 404 to rear face 405.

Block 400 further comprises core 417 and pin holes 418 which extend the full width of the block. The lower surface of each block has pin hole depressions 419 which result from the attachment of pin hole forming members (not shown) to the division liner of the mold box to form the pin holes in the mold. This may be used instead of a core bar placed across a top plate (not shown) of the mold which may impart a slight groove, channel or indentation along the surface of the corner block. The bottom face of block 400 also has pin receiving channel 430 which is parallel with front face 404 and pin receiving channel 440 which is parallel with side surface 412. Pin receiving channel 430 opens onto side surface 410 and may extend the majority of the length of the front face of the corner block. Pin receiving channel 440 opens onto rear surface 405 and may extend the majority of the length of side face 412.

Corner blocks 400 are manufactured in a mold box which produces two or more corner blocks 400(r) and 400(l) which are mirror images of one another, thus they have a right and left handed orientation, respectively. Front surface 404 and side surface 412 will be visually exposed in the construction of a structure and thus the left handed and right handed orientation is beneficial when constructing a wall with a corner so as to offset each course from another adjacent course in a structure as described below.

Though block 400 may have various dimensions, typical dimensions of this block are about 6 inches (15.2 cm) wide (i.e., the width of side surface 412), 18 inches (45.7 cm) long (i.e., the length of front face 404), and 8 inches (20.3 cm) thick (i.e., the thickness between the opposing upper and lower surfaces). These dimensions are generally smaller than the dimensions of the blocks used to form the retaining wall. Two corner blocks may be formed in a mold box, one with a right handed configuration and one with a left handed configuration.

FIGS. 14 and 15 illustrate perspective views of retaining wall 500 made from block 300 of the present invention. In this illustration, wall block 300 is used to form a wall having a front surface and a rear surface and has been manufactured to have two lugs 320. Generally, when constructing a wall, a trench is excavated to a pre-selected depth and lined with a level base of granular material such as crushed stone. A base layer is then placed and leveled onto the crushed stone. The blocks are placed side to side with front face 304 facing outward and the bottom surface 303 facing downward. Once the base layer is laid, the second layer is built using the rear lugs to connect the upper block to the lower block course. It should be noted that when the block is used in constructing a gravity wall the weight of the blocks and the lugs are sufficient for connection without the use of the pinning system. When a geogrid layer is intended to be built into the wall structure, pins 50 are placed into pin holes 318 of the top surface of the blocks and geogrid soil reinforcement material G is then hooked over pins 50 and pulled taut (towards the backfill embankment). The heads 52 of pins 50 are then received in the pin receiving channels 330 in the bottom surface of the upper adjacent course of blocks. It should be noted that the pinning system may be used without the geogrid as desired. Lugs 320 abut the rear face 305 of the blocks in the lower course as shown in cross-section in FIG. 16. The abutment produces a shear connection and prevents displacement and slippage of the blocks due to forces created by the retained earth behind the structure being constructed. Successive courses are then likewise laid one on top of the other until a desired height is achieved. When the desired height is achieved a cap or finish layer 30, shown in partial view at the top of the wall, may be added. It should further be noted that in some applications where the wall design is more elaborate or the height of the wall is such that the structure needs further stabilization, vertical reinforcing members such as rebar may be threaded through vertical open cores (columnar cavities) created by the cores of blocks as they are stacked one upon the other. It should further be noted that the wall may be constructed with two or more sizes of block as desired for a more random appearance of the wall aesthetic depending upon the application.

FIG. 17 illustrates the wall 550 built with geogrid G as known and used in the art. The wall is built from base course to top course as described above using blocks 100. When geogrid G is used with a course of blocks it is placed upon the top face 102 of block 100. Pin 50 is then inserted through the geogrid and into pin hole 118. The head of the pin securing the geogrid to block 100 is received in the pin receiving channel 130 of the upper course of block 100a. The lug may be removed if desired when incorporating geogrid into the structure. Removal of the lug may help to avoid possible tearing of the geogrid material.

FIGS. 18 and 19 illustrate perspective views of retaining wall 600 made from the multiple block system of this invention. In this illustration, wall blocks 100, 200 and 300, each having a different front face length, are used to form a wall having a front surface and a rear surface. The differing sizes of blocks used in the construction of the wall contribute to the random, natural appearance of the wall. A base layer is placed and leveled onto a crushed stone base. The blocks are placed side to side with front faces 104, 204 and 304 facing outward and the bottom surfaces 103, 203, and 303 facing downward. When constructing a wall without geogrid soil reinforcement material a base layer of blocks is laid and an upper adjacent course is then laid on top of the base layer with lugs 120, 220, and 320 abutting the rear faces of the blocks in the lower course. The abutment prevents displacement and slippage of the blocks due to the forces created by the retained earth the constructed structure holds back. Successive courses are then likewise laid one on top of the other until a desired height is achieved. When the desired height is achieved a cap or finish layer 30, shown in partial view at the top of the wall, may be added.

When constructing a wall with geogrid reinforcement material for walls which need geogrid to add structure to the mechanically stabilized earth, a base layer of blocks is laid and pins 50 are placed into pin hole of top surface of the blocks. Geogrid of a specific design is then placed over the pins or the geogrid is placed on the blocks first, and then the pins are put into the open pin holes on the top surface of the block to connect the geogrid to the blocks. The heads 52 of pins 50 are then received in the pin receiving channels in the bottom surfaces of the upper adjacent course of blocks with lugs 120, 220, and 320 abutting the rear faces of the blocks in the lower course and aligning the blocks in the upper course.

FIG. 20 illustrates a perspective view of retaining wall 650 made from the multiple block system of this invention. In this illustration, wall blocks 100, 200, and 300, each having a different length, are used to form a wall having a front surface and a rear surface. The converging, non-parallel side walls of blocks 100, 200, and 300 allow for a radial curvature of the wall to be achieved in the structure being constructed. The lugs on the back lower surface of blocks 100, 200 and 300 allow for an alignment and setback system of the present invention to follow the radial curvature of the structure as well as giving greater variability. Optionally, geogrid can be added to the structure by using the pinning system as described above. It should be noted that the converging, non-parallel side walls of the blocks of the present invention allow for the structure being constructed to have many different shapes and contours such as linear, curvilinear, serpentine, L-shaped, etc.

FIGS. 21 and 22 illustrate wall 700 built with right hand and left hand corner blocks 400(r), 400(l) and wall blocks 100. A trench is excavated to a pre-selected depth and lined with a level base of granular material such as crushed stone. A base layer is then placed and leveled onto the crushed stone. The blocks of the straight section of the wall are placed end to end with a front face projecting outwardly. The corner of the base layer is formed by the placement of right handed or left handed corner block of the present invention at the desired location for the corner. Base layer 710 is shown with a right handed corner block 400(r) which offsets the base layer of straight wall portion 700b by the length of front face 404 of corner block 400(r), the base layer of straight wall portion 700a is thus offset by the length of side face 412 of corner block 400(r). Pins 50 may be placed into pin holes 418 of corner block 400(r) and additionally into the pin holes of blocks 100 of the base layer. These act as shear connectors for the corner block and points at which geogrid can be introduced for structural purposes.

Once the base layer is laid, first layer 720 of blocks is placed on the base layer and pin receiving channels 430 and 440 of corner block 400(l) and pin receiving channels of blocks 100 of the first course capture the heads of pins 50 in base layer 710. This pin alignment system is thus compatible with both the corner block and the wall block thus adding to the overall stability and structural integrity of the structure being built. First layer 720 is shown with left handed corner block 400(l) which offsets the base layer of straight wall portion 700a by the length of front face 404 of corner block 400(l), the first layer of straight wall portion 700b is thus offset by the length of side face 412 of corner block 400(l). In this embodiment the placement of blocks is vertically offset in adjacent courses in a running bond pattern by the use of the alternating courses of the left and right handed corner blocks 400. It is to be understood that a wall could be formed using only left handed corner blocks or right handed corner blocks but the wall would have a stacked bond configuration.

Subsequent layers of blocks can then be placed one on top of the next with the pin connection system while alternating the left and right handed corner blocks of adjacent layers of the wall until the desired height is reached. The specific dimensions of the corner block ensure that seams between blocks of one course will not be directly vertically adjacent to the same seam between blocks in the adjacent course. The alignment of cores 417 of the alternating courses of left and right handed corner blocks 400 create a vertical columnar cavity at the corner of wall 700. Steel, fiberglass or other suitable rebar can be thread through the columnar cavity and may additionally be filled with concrete grout for additional stability. It should further be noted that reinforcement may be added to the columnar cavities created by the openings of cores 114 of blocks 100 as well. It should be additionally noted that the columnar cavities may be filled with a stabilizing material such as sand, gravel, sheer resistant fill (i.e. crushed stone), concrete, cement or the like with or without the need for rebar depending upon the application. Optionally, construction adhesive may be used to further lock blocks and/or courses together with or without the use of stabilizing materials. A geogrid as known and used in the art is may also be used in the construction of wall 700. Once the desired height is reached a capping layer may be added.

An alternative embodiment of block 100 is shown in FIGS. 23 and 24. Block 800 has parallel top face 802 and bottom face 803, front face 804, rear face 805 and first and second side walls 806 and 807. Front face 804 and rear face 805 each extend from top face 802 to bottom face 803. Side walls 806 and 807 extend from top face 802 to bottom face 803, and have a compound shape converging back from front face 804 toward back portion 809 which extends outward from the converging angle of the side walls 806 and 807. Front face 804 may be of a compound shape. Block 800 comprises body portion 808, back portion 809 and neck portions 810 which connect body portion 808 to back portion 809. Front face 804 forms part of body portion 808, while rear face 805 forms part of back portion 809. The body, back and neck portions 808, 809, and 810 each extend between top and bottom faces 802 and 803 and between first and second side walls 806 and 807. Opening or core 814 may extend through neck portion 810 from top surface 802 to bottom face 803, or may only extend part of the way through block 800 (for example, open to top surface 802 but closed at bottom surface 803).

A set of pin holes 818 are located in back portion 809 and extend from top face 802 to bottom face 803, i.e., opening onto both top and bottom surfaces. Bottom surface 803 has pin receiving channel 830 located in body portion 808, adjacent to back portion 809. Block 800 has three lugs 820 located on back portion 809 which extend from the rear face 805 downward past the bottom face 803 of the block.

An alternative embodiment of the block is shown in FIGS. 25 and 26. Block 900 has parallel top face 902 and bottom face 903, front face 904, rear face 905 and first and second side walls 906 and 907. Front face 904 and rear face 905 each extend from top face 902 to bottom face 903. Side walls 906 and 907 extend from top face 902 to bottom face 903, and have a compound shape. Block 900 comprises body portion 908, back portion 909 and neck portions 910 which connect body portion 908 to back portion 909. Front face 904 forms part of body portion 908, while rear face 905 forms part of back portion 909. The body, back and neck portions 908, 909, and 910 each extend between top and bottom faces 902 and 903 and between first and second side walls 906 and 907. Opening or core 914 may extend through neck portion 910 from top surface 902 to bottom face 903, or may only extend part of the way through block 900 (for example, open to top surface 902 but closed at bottom surface 903).

A set of pin holes 918 are located in neck portion 910 and extend from top face 902 to bottom face 903, i.e., opening onto both top and bottom surfaces. Pin hole depressions 919 located on the bottom face of the neck portion 910 are formed from a pin hole forming member or bridge (not shown) which is mounted to a side wall or liner of a mold cavity. Bottom surface 903 has pin receiving channel 930 located in neck portion 910, adjacent to body portion 908. Block 900 has three lugs 920 located on back portion 909 which extend from the rear face 905 downward past the bottom face 903 of the block.

An alternative embodiment of the block is shown in FIG. 27. Block 900a is similar to block 900. Block 900a has parallel top face 902a and bottom face 903a, front face 904a, rear face 905a and first and second side walls 906a and 907a. Front face 904a and rear face 905a each extend from top face 902a to bottom face 903a. Side walls 906a and 907a extend from top face 902a to bottom face 903a, and have a compound shape. Block 900a comprises body portion 908a, back portion 909a and neck portions 910a which connect body portion 908a to back portion 909a. Front face 904a forms part of body portion 908a, while rear face 905a forms part of back portion 909a. The body, back and neck portions 908a, 909a, and 910a each extend between top and bottom faces 902a and 903a and between first and second side walls 906a and 907a. Opening or core 914a may extend through neck portion 910a from top surface 902a to bottom face 903a, or may only extend part of the way through block 900a (for example, open to top surface 902a but closed at bottom surface 903a).

A set of pin holes 918a are located in neck portion 910a and extend from top face 902a to bottom face 903a, i.e., opening onto both top and bottom surfaces. Pin hole depressions 919a located on the bottom face of the neck portion 910a are formed from a pin hole forming member or bridge (not shown) which is mounted to a side wall or liner of a mold cavity. Bottom surface 903a has pin receiving channel 930a located in neck portion 910a, adjacent to body portion 908a. Block 900a has three lugs 920a located on back portion 909a which extend from the rear face 905a downward past the bottom face 903a of the block.

FIG. 28 illustrates a portion of a wall 850 built with blocks 800 of the present invention. The wall is built from base course to top course as described above.

FIG. 29 illustrates a portion of a concave wall 950 built with blocks 900 of the present invention. The wall is built from base course to top course as described above.

FIG. 30 illustrates a portion of a convex wall 960 built with blocks 900 of the present invention. The wall is built from base course to top course as described above.

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.

Claims

1. A wall block comprising a block body having opposed front and rear faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces, one or more pin holes that open onto the top face of the block, and one or more lugs that extend from the bottom face, each lug having a back surface that extends contiguously from the rear face of the block.

2. The wall block of claim 1, wherein the front face is substantially parallel to the rear face.

3. The wall block of claim 1, wherein the block has a vertical plane of symmetry.

4. The wall block of claim 1, wherein the one or more pin holes are closer to the front face than the back face.

5. The wall block of claim 1, wherein the block comprises a pin receiving channel that opens onto the bottom face of the block.

6. The wall block of claim 5, wherein the pin receiving channel is substantially parallel to the front face.

7. The wall block of claim 6, wherein the pin receiving channel is closer to the front face than to the rear face.

8. The wall block of claim 1, wherein the front face and the rear face both have lengths and the length of the front face is greater than the length of the rear face.

9. The wall block of claim 8, wherein at least a portion of the side walls are angled back from the front face to the rear face such that the portion of each side wall forms an acute angle with the front face.

10. The wall block of claim 1, wherein the block comprises a core.

11. The wall block of claim 1, wherein no lug extends from the first to the second side wall.

12. The wall block of claim 1, wherein the block is made of concrete.

13. The wall block of claim 1, wherein the block comprises at least one pair of pin holes.

14. The wall block of claim 2, wherein the front face has a compound shape with an angled portion which is non-orthogonal to one or both of the first and second side walls.

15. The wall block of claim 1, wherein the block comprises two lugs, a first lug being contiguous with the first side wall, and a second lug being contiguous with the second side wall.

16. The wall block of claim 1, wherein the block comprises just one lug, the lug not being contiguous with the first or second side walls.

17. The wall block of claim 1, wherein the lug extends from 0.5 to 0.75 inch (1.27 to 1.91 cm) past the bottom face.

18. The wall block of claim 17, wherein the lug is from 0.75 to 1 inch deep.

19. The wall block of claim 15, wherein the block comprises three lugs.

20. The wall block of claim 1, wherein the first and second side walls have compound shapes and converge back from the front face towards the rear face and then extend outward before meeting the rear face.

21. A wall block comprising a block body having: opposed front and back faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces;the first and second side walls both having lengths and the length of the second side wall being less than the length of the first side wall, and the first and second side walls being substantially parallel;one or more pin holes that open onto the top face of the block; anda neck that has a shorter width than the width of the block from the front face to the rear face at a main body portion of the block, the neck being formed by a neck surface having a length and being substantially perpendicular to the second side wall and adjacent to the second side wall, the second side wall, and the portion of the front face having the same corresponding length as the neck surface.

22. The wall block of claim 21, wherein the block comprises a pin receiving channel that opens onto the bottom face of the block.

23. The wall block of claim 22, wherein the pin receiving channel is substantially parallel to the front face.

24. The wall block of claim 23, wherein the pin receiving channel is closer to the front face than to the rear face.

25. The wall block of claim 24, wherein the block comprises a second pin receiving channel that is substantially parallel to the first side wall.

26. The wall block of claim 24, wherein the pin receiving channel is closer to the first side wall than to the second side wall.

27. The wall block of claim 21, wherein the block comprises two pin holes, one pin hole being closer to the rear face than the front face, and one pin hole being closer to the front face than to the rear face.

28. A retaining wall comprising: a plurality of blocks including at least one lower course and at least one upper course, at least one block comprising a block body having opposed front and rear faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces, one or more pin holes that open onto the top face of the block, and one or more lugs that extend from the bottom face, each lug having a back surface that extends contiguously from the rear face of the block.

29. The retaining wall of claim 28, wherein the retaining wall further comprises a geogrid.

30. The retaining wall of claim 28, wherein the retaining wall further comprises one or more pins.

31. The retaining wall of claim 30, wherein one or more of the pins has a head.

32. The retaining wall of claim 28, wherein the plurality of blocks includes blocks with differing dimensions.

33. The retaining wall of claim 28, wherein the front face of the at least one block is substantially parallel to the rear face.

34. The retaining wall of claim 28, wherein the at least one block has a vertical plane of symmetry.

35. The retaining wall of claim 28, wherein the one or more pin holes of the at least one block are closer to the front face than the back face.

36. The retaining wall of claim 28, wherein the at least one block comprises a pin receiving channel that opens onto the bottom face of the block.

37. The retaining wall of claim 36, wherein the pin receiving channel is substantially parallel to the front face.

38. The retaining wall of claim 37, wherein the pin receiving channel is closer to the front face than to the rear face.

39. The retaining wall of claim 28, wherein the front face and the rear face of the at least one block both have lengths and the length of the front face is greater than the length of the rear face.

40. The retaining wall of claim 28, wherein the at least one block comprises a core.

41. The retaining wall of claim 28, wherein no lug of the at least one block extends from the first to the second side wall.

42. The retaining wall of claim 28, wherein the at least one block is made of concrete.

43. The retaining wall of claim 28, wherein the at least one block comprises at least one pair of pin holes.

44. The retaining wall of claim 28, wherein the at least one block comprises two lugs, a first lug being contiguous with the first side wall, and a second lug being contiguous with the second side wall.

45. The retaining wall of claim 28, wherein the at least one block comprises just one lug, the lug not being contiguous with the first or second side walls.

46. The retaining wall of claim 44, wherein the at least one block comprises three lugs.

47. The retaining wall of claim 28, wherein the first and second side walls of the at least one block have compound shapes and converge back from the front face towards the rear face and then extend outward before meeting the rear face.

48. The retaining wall of claim 28, wherein the retaining wall further comprises at least one block of a second block type, the second block type comprising a block body having: opposed front and back faces, opposed first and second side walls, and opposed and substantially parallel top and bottom faces;the first and second side walls both having lengths and the length of the second side wall being less than the length of the first side wall, and the first and second side walls being substantially parallel;one or more pin holes that open onto the top face of the block; anda neck that has a shorter width than the width of the block from the front face to the rear face at a main body portion of the block, the neck being formed by a neck surface having a length and being substantially perpendicular to the second side wall and adjacent to the second side wall, the second side wall, and the portion of the front face having the same corresponding length as the neck surface.

49. The retaining wall of claim 48, wherein the second block type comprises a pin receiving channel that opens onto the bottom face of the block.

50. The retaining wall of claim 49, wherein the pin receiving channel of the second block type is substantially parallel to the front face.

51. The retaining wall of claim 50, wherein the pin receiving channel of the second block type is closer to the front face than to the rear face.

52. The retaining wall of claim 51, wherein the second block type comprises a second pin receiving channel that is substantially parallel to the first side wall.

53. The retaining wall of claim 52, wherein the second block type pin receiving channel is closer to the first side wall than to the second side wall.

54. The retaining wall of claim 48, wherein the second block type block comprises two pin holes, one pin hole being closer to the rear face than the front face, and one pin hole being closer to the front face than to the rear face.