The present invention relates to retaining wall blocks having a front face connection system and to retaining walls constructed from those blocks and to methods of making the blocks and constructing walls from the blocks.
Numerous methods and materials exist for the construction of retaining walls. Such methods include the use of natural stone, pored 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.
When constructing a retaining wall it is desirable to utilize some form of connection system between the blocks for the purpose of stabilizing and aligning the wall. For example, the retaining wall system described in U.S. Pat. No. RE 34,314 includes a block design that incorporates, among other elements, a system of pins that interlock and align the retaining wall units, allowing structural strength and relatively quick installation. The system may be adapted for the construction of large walls by employing geogrids which can be hooked over the pins. Such a system is described in U.S. Pat. No. 4,914,876 (Forsberg).
Other connection systems make use of the shape of the block itself for interlock and connection. 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 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 create a setback between block courses and 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 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.
One disadvantage of using blocks having a rear flange is that their use naturally creates a setback between courses which produces a visible line or seam between courses which is noticeable to an observer. In other words, the visual appearance of the wall is such that an observer tends to notice not only the vertical lines between blocks in a course but also the lines at the top and bottom of blocks in each course. Thus, each block in the wall is identifiable as a separate unit from the adjacent blocks. In certain circumstances this may create the desired aesthetic affect. However, in other situations it is desirable to create a more random visual appearance where each block is not separately identifiable.
Retaining walls using blocks having a continuous front flange which extend the entire width of the block are also well known in the art. For Example, U.S. Pat. No. 5,484,236 (Gravier) describes a block with a continuous front flange or lip located at the top of the block and a lateral front notch located at the bottom of the block. The notch is located along the bottom of the front face of the block and is designed to receive the lip of an adjacent block in a lower course of the retaining wall. As with rear flanged blocks, there are disadvantages of prior art continuous front flanged blocks. First, their use naturally creates a set back that accentuates the horizontal lines between succeeding courses of the retaining wall. Second, the continuous flange on these blocks makes it difficult to form smooth inside or outside curves in a wall formed from the blocks. Third, because the flange of a front (or rear) flanged block extends in a straight line across the entire width of the block, the blocks tend to set back excessively when a curve in the wall is constructed.
Thus, a need exists in the art for a retaining wall block and block system which can be used to construct a retaining wall having a connection system which provides for the necessary safety and stability of the wall yet also creates a random or variable visual appearance for the face of the wall and eases the construction of curves by maintaining a desired amount of setback when a curve is constructed.
The invention comprises first and second wall block systems which include face connection systems which allow for construction of a wall providing safety and stability as well as a desired face appearance.
In a first aspect the invention is a wall block comprising a block body including a top surface, a bottom surface and a front face. The front face has a height and a width. At least one lip extends from the top surface, the at least one lip having first and second ends, first and second lateral surfaces and an upper surface. One of the lateral surfaces forms a part of the front face. The lip has a length measured between the first and second ends, the length of the lip being less than the width of the front face. At least one channel is formed into the bottom surface and front face, the at least one channel being sized such that when a wall is formed from a plurality of the blocks stacked in multiple courses the at least one channel will accommodate a lip from an adjacent block in a lower course. The block body may further comprise first and second opposing side surfaces and a rear surface which opposes the front face. The first and second sides may be nonparallel. Further, the at least one channel may comprise a first channel and a second channel and the at least one lip may comprise a first lip and a second lip.
In another aspect the invention comprises a wall block system having a plurality of blocks including first and second blocks. Each block has a block body including a top surface, a bottom surface and a front face having a height and a width. Each block further has a lip extending from the top surface and a channel formed into the bottom surface and front face, the lip having first and second ends, first and second lateral surfaces and an upper surface. One of the lateral surfaces forms a part of the front face. The lip has a length as measured between the first and second ends, the length of the lip being less than the width of the front face. The channel is sized such that when a wall is formed from the plurality of blocks stacked in multiple courses at least a portion of the lip of the first block positioned in a first course will be accommodated in the channel of the second block in a second course overlying the first course.
Another aspect of the invention is directed to a method of making a retaining wall. The method comprises providing a plurality of blocks including first, second and third blocks, each block having a block body including a top surface, a bottom surface and a front face having a height and a width. Each block further has a lip extending from the top surface and at least one channel formed into the bottom surface and front face, the lip having first and second ends, first and second lateral surfaces and an upper surface. One of the lateral surfaces forms a part of the front face. The lip has a length as measured between the first and second ends, the length of the lip being less than the width of the front face. The method includes laying the blocks in a first lower course including laying a first block adjacent to a second block. The method further includes laying the blocks in a second upper course in a running bond pattern over the first course, the third block overlying a portion of the first block and a portion of the second block, the at least one channel of the third block accommodating at least a portion of the lip of the first block and at least a portion of the lip of the second block.
A further aspect of the invention is a retaining wall system comprising a plurality of block types including a first block type and a second block type. Each block type has a block body including a top surface, a bottom surface and a front face having a height and a width. Each block type further has a lip extending from the top surface and a channel formed into the bottom surface and front face. The lip has first and second ends, first and second lateral surfaces and an upper surface. One of the lateral surfaces forms a part of the front face. The lip has a length as measured between the first and second ends. At least one of the first block type and second block type include a lip having a length which is less than the width of the front face. The retaining wall system may further comprise a third block type and a fourth block type.
In another aspect the invention is a method of making a retaining wall comprising providing a plurality of block types including a first block type and a second block type. Each block type has a block body including a top surface, a bottom surface and a front face having a height and a width. Each block type further has a lip extending from the top surface and a channel formed into the bottom surface and front face. The lip has first and second ends, first and second lateral surfaces and an upper surface. One of the lateral surfaces forms a part of the front face. The lip has a length as measured between the first and second ends. At least one of the first block type and second block type include a lip having a length which is less than the width of the front face. The method includes laying a plurality of first block types and second block types in a random pattern in multiple courses including a first lower course and a second upper course such that the channels of first block types and second block types in the second upper course receive lips of first block types and second block types in the first lower course.
In a further aspect the invention is a retaining wall block system comprising multiple blocks which may include first, second, third and fourth blocks. The first block has a block body including a top surface, a bottom surface and a front face. The first block further has a lip extending from the top surface and a channel formed into the bottom surface and front face, the lip having first and second ends, first and second lateral surfaces and an upper surface, one of the lateral surfaces forming a part of the front face. The second block has a block body including a top surface, a bottom surface and a front face. The second block further has first and second lips extending from the top surface and a channel formed into the bottom surface and front face, the first and second lips each having first and second ends, first and second lateral surfaces and an upper surface, one of the lateral surfaces of each of the first and second lips forming a part of the front face. The third block has a block body including a top surface, a bottom surface and a front face. The third block further has a lip extending from the top surface and a channel formed into the bottom surface and front face, the lip having first and second ends, first and second lateral surfaces and an upper surface, one of the lateral surfaces of the lip forming a part of the front face. The fourth block has a block body including a top surface, a bottom surface and a front face. The fourth block further having first and second lips extending from the top surface and a channel formed into the bottom surface and front face, the first and second lips each having first and second ends, first and second lateral surfaces and an upper surface, one of the lateral surfaces of each of the first and second lips forming a part of the front face.
Another aspect of the invention is a method of making a retaining wall. The method comprises providing a plurality of first blocks having a block body including a top surface, a bottom surface and a front face. The first blocks further having a lip extending from the top surface and a channel formed into the bottom surface and front face, the lip having first and second ends, first and second lateral surfaces and an upper surface, one of the lateral surfaces forming a part of the front face. The method further comprises providing a plurality of second blocks having a block body including a top surface, a bottom surface and a front face, the second blocks further having first and second lips extending from the top surface and a channel formed into the bottom surface and front face, the first and second lips each having first and second ends, first and second lateral surfaces and an upper surface, one of the lateral surfaces of each of the first and second lips forming a part of the front face. The method includes providing a plurality of third blocks having a block body including a top surface, a bottom surface and a front face, the third blocks further having a lip extending from the top surface and a channel formed into the bottom surface and front face, the lip having first and second ends, first and second lateral surfaces and an upper surface, one of the lateral surfaces of the lip forming a part of the front face. Further, the method includes providing a plurality of fourth blocks having a block body including a top surface, a bottom surface and a front face, the fourth blocks further having first and second lips extending from the top surface and a channel formed into the bottom surface and front face, the first and second lips each having first and second ends, first and second lateral surfaces and an upper surface, one of the lateral surfaces of each of the first and second lips forming a part of the front face. The wall is formed by laying the first, second, third, and fourth blocks in a random pattern in multiple courses including a first lower course and a second upper course such that the channels of blocks in the second upper course receive lips of blocks in the first lower course.
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 blocks of this invention may be made of a rugged, weather resistant material, such as concrete, especially if the wall is constructed outdoors. Other suitable materials include plastic, reinforced fibers, and any other materials suitable for use in molding wall blocks. The surface of the blocks may be smooth or may have a roughened appearance, such as that of natural stone. In some embodiments the front surface or faces of the blocks are provided with an ashlar pattern and in others a ledgestone pattern. The blocks may be formed in a mold which is equipped to impart various textures on the front face of the blocks.
The figures describe various block embodiments. Many elements in various block embodiments are identical in shape, size, relative placement, and function, and therefore the numbers for these elements do not change. Elements that vary from one block embodiment to another are identified by suffixes “a”, “b”, “c”, etc. and may be referred to in a general way by a number without its suffix.
The blocks of this invention as illustrated in the drawing figures are generally symmetrical about a vertical plane of symmetry. However, it should be understood that the shape of the block is not critical to the invention. Specifically, any block shape which can be constructed to utilize the advantages of the front face connection system disclosed herein will fall within the scope of this invention. Similarly, although several embodiments of the surface texture of the front face of the blocks are disclosed it should be understood that those embodiments are not meant to be limiting and that any desired front face surface texture can be utilized within the scope of the present invention. Further, although the blocks are shown having a solid block body it will be appreciated that the blocks could be formed with a core, especially if it is desired to reduce the weight of the blocks or the amount of material required to make the blocks.
The novel block connection system of the present invention can be incorporated into various retaining wall block systems. Disclosed herein are two block systems incorporating the present invention, both systems having multiple embodiments. The first block system shown in FIGS. 1 to 5 comprises a single block which incorporates the face connection system disclosed herein. The face connection system comprises one or more upper lips extending from the top surface of the block (which do not extend across the entire extent of the width of the face) and one or more lower channels formed along the bottom of the blocks face, which may, or may not, extend across the entire extent of the width of the face, depending on the preferred embodiment. The term “single block system” refers to the use of a plurality of blocks, each having an identical lip and channel configuration although the surface texture of the front face of the block may be varied. A plurality of these blocks are used to construct a retaining wall. Two embodiments of this block are disclosed. A first embodiment shown in
A second block system for constructing a retaining wall is disclosed in FIGS. 6 to 16. This system is a multiple block system which utilizes more than one version of wall block incorporating the front face connection system of the present invention. In other words the multiple block system uses blocks wherein the placement and/or size of the lips is not identical. Although the system disclosed illustrates the use of multiples of four such blocks, each having a different lip configuration, it should be understood that a multiple block system of this nature could be used in a two block system, a three block system or any other multiple block system which incorporates more than one version of a retaining wall block having the present front face connection system.
Single Block System
The single block wall system is shown in FIGS. 1 to 5. A first embodiment of the block is shown in
The front face 6a and rear surface 7 each extend from top surface 2 to bottom surface 3. First and second side surfaces 4 and 5 extend from top surface 2 to bottom surface 3 and from front face 6a to rear surface 7. The top and bottom surfaces, side surfaces, front face and rear surface collectively define a block body. The size of the bocks may be similar to presently used retaining wall blocks. By way of non limiting example the blocks may be between 12-18 inches wide, 7-12 inches deep and 3-8 inches in height. Block 1a is generally symmetrical about a vertical plane of symmetry. As shown block 1a is generally wedge shaped. However, as mentioned previously, other block shapes could be utilized within the scope of the invention including square, rectangular, or shapes characterized by nonparallel side surfaces such as a configuration where one of the side surfaces is orthogonal to the front face.
When block 1a is utilized to construct a retaining wall, a portion of which is shown in
Channels 9 and 10 generally form recesses in front face 6a along bottom surface 3 of block 1a. Channel 9 is defined by a face surface portion 16, a top surface portion 17 and an end surface portion 18. Similarly, channel 10 is defined by face surface portion 19, top surface portion 20 and end surface portion 21. The size of channels 9 and 10 will be selected to receive lip 8 and to produce, in connection with lip 8, the desired setback. By way of non limiting example the height of channels 9 and 10 as measured between bottom surface 3 and top surfaces 17 and 20 may be 5/16 inch. The depth of channels 9 and 10 as measured between front face 6a and face surface portions 16 and 19 may be ½ inch.
The method of constructing a retaining wall with blocks 1a can best be understood with reference to
As best seen in
In order to camouflage any regular pattern which is created by exposed portions 26 of the channels the blocks may be provided with recesses 22a as previously described in connection with
Although this single block wall system can be comprised of the use of a single block 1a having an identical surface texture such as shown in
To further enhance the visual appearance of the retaining wall the exposed surfaces of the lips and channels can be provided with some surface contour. Specifically, the top surface 15 and side surfaces 13 and 14 of the lip can be textured. Additionally, the face surface portion, top surface portion and end surface portion of channels 9 and 10 can be textured. Preferably, the texture of the surface portions of the lip and channel is created with contour formed into the body of the block and not extending from the body of the block so that no interference is created which would affect the manner in which the lip is received by the channels or the amount of block setback.
A second embodiment of the single block system is shown in
A retaining wall constructed with blocks 1b is shown in
An additional benefit of the one block systems is that it facilitates the construction of walls that are curved. Because the wall uses both a lip and recess, the amount of set back is limited. In addition, because the lip only extends across a portion of the center of the block, there is less of a tendency for the succeeding courses to bind and to go into a negative batter during the construction of inside curves.
Multiple Wall Block System
A multiple wall block system is shown in FIGS. 6 to 16. The multiple wall block system is similar to the single wall block system described above except that the system comprises two or more blocks, each having one or more upper lips and one or more lower channels which are dimensioned and/or positioned differently. This difference in the number and/or location of the lips and channels results in several advantages. First, the randomness of the size and spacing of lips and channels insures that when a wall is constructed from the blocks any exposed portions of the channels do not form a regular pattern. Second, additional flexibility with respect to building curved walls with the blocks is provided. Due to the variety of lip sizes and placements, the wall can be built in a fashion that allows the wall builder to select units that allow the construction of curved walls with minimal variation from the pre-designed amount of set back, which enhances the stability and aesthetic characteristics of the finished wall and eases construction. The multiple wall block system comprises a first embodiment of first, second, third and fourth blocks as disclosed in
The first block of the multiple wall block system is shown in
As mentioned previously, block 101a is similar to block 1a except for the details of the face connection system. Specifically, block 101a includes a centrally located lip 150 and a continuous bottom channel 151.
The second block of the multiple wall block system is shown in
The third block of the multiple wall block system is shown in
The fourth block of the multiple wall block system is shown in
The blocks may be formed by any conventional process known in the art. For example, the blocks may be made using dry cast concrete block making equipment or may be formed by use of a wet cast molding process, both of which are known in the art. One manner of making blocks 101a, 101b, 101c and 101d of the multiple wall block system is to form them in a mold as shown in
As mentioned previously, a second embodiment of the multiple wall block system is disclosed in
A retaining wall constructed with blocks 101e, 101f, 101g and 101h is shown in
This application claims the benefit of U.S. Provisional Patent Application No. 60/630,898, filed Nov. 24, 2004, the contents of which are hereby incorporated herein by reference.
Number | Date | Country | |
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60630898 | Nov 2004 | US |