The present invention concerns embodiments of construction blocks, connectors and structures made therefrom, and more particularly to retaining wall blocks and retaining walls for retaining slopes of earth.
Conventional retaining walls are used to secure earth embankments against sliding and slumping. Retaining walls are made of various materials such as concrete, solid masonry, wood ties, bricks and blocks of stone and concrete. Typically, blocks are placed in rows overlaying on top of each other to form a wall. One specific approach for building a retaining wall was shown in U.S. Pat. No. 5,350,256 to Hammer. In this approach, the retaining wall comprises vertically-stacked courses, each comprising a series of I-shaped subassemblies placed side-by-side in respective courses. Each subassembly is comprised of face and tail blocks that are connected by a trunk block extending between the face and tail blocks. The chambers defined between adjacent I-shaped subassemblies are filled in with backfill.
Despite such inventions, there exists a continuing need for new and improved systems, block subassemblies and methods for constructing retaining walls.
According to one aspect, the present invention provides a new and improved adjustable connector for use in block subassemblies that are used to construct retaining walls. According to one embodiment, the adjustable connector is configured to interconnect first and second spaced-apart blocks and has an adjustable length to adjust the spacing between the blocks to form block assemblies of different depths. According to another embodiment, the connector is pivotably connected to one or both of the first and second blocks to permit pivoting of the connector in a horizontal plane relative to one or both of the blocks.
According to one representative embodiment, a block subassembly comprises a first block, a second block and an adjustable connector which extends between and is connected to the first and second blocks. The second block is spaced from the first block such that the blocks define a space between them to receive backfill material when constructing the wall. The length of the adjustable connector can be adjusted to adjust the spacing between the first and second blocks. Typically, in prior art systems such as described above, multiple block subassemblies are placed end-to-end in the lower courses of a retaining wall. Advantageously, utilizing a block subassembly with an adjustable length connector can reduce the number of required subassemblies at the base of a wall, thereby reducing the amount of materials and time required for constructing the wall.
In one illustrated embodiment, the adjustable connector comprises an inner tube nested within an outer tube such that the inner tube is telescopically slidable into and out of the outer tube to adjust the length of the connector. The inner and outer tubes can have a plurality of respective longitudinally spaced alignment holes sized to receive a retaining pin. Once the connector is adjusted to its desired length, the pin can be inserted through an alignment hole in each of the inner and outer tubes to restrict relative longitudinal movement between the tubes.
According to another representative embodiment, the present invention provides a building block system for building a retaining wall using a plurality of face blocks each having a rear face, a plurality of tail blocks each having a front face and a rear face, and a plurality of adjustable connectors each having first and second end portions. The length of each adjustable connector between its first and second end portions can be adjusted. The face blocks, tail blocks, and adjustable connectors can be assembled into respective block subassemblies. Each subassembly can be formed by connecting the first end portion of an adjustable connector to the rear face of a face block. The adjustable connector extends rearwardly from the rear face of the face block and is connected at its second end portion to the front face of a tail block. In certain embodiments, the tails block can be adapted to be connected to an adjustable connector at its rear face to allow additional adjustable connectors and tail blocks to be added to the subassembly to extend the subassembly deeper into the slope of the wall for added anchoring strength.
According to another representative embodiment, a retaining wall comprises at least first and second vertically stacked courses or layers. Each course can be constructed by placing several block subassemblies side-by-side along the length of each course. Each block subassembly includes a face block having a front surface exposed in a face of the wall, a tail block positioned behind and spaced from the face block, and an adjustable connector extending between the two blocks and connected to the face and tail blocks. The length of the adjustable connector can be adjusted to adjust the spacing between the face and tail blocks.
According to another representative embodiment, a method of constructing a retaining wall is provided. The method includes forming at least first and second vertically-stacked courses each comprising a plurality of block subassemblies. At least some of the block subassemblies include a face block, a tail block and an adjustable connector, the length of which can be adjusted to adjust the spacing between the face and tail blocks.
According to another representative embodiment, a block subassembly for constructing a retaining wall comprises a first block, a second block spaced from the first block, and a connector comprising an elongated body having first and second opposite end portions. The first end portion is connected to the first block and the second end portion is connected to the second block, and the connector is pivotable relative to at least the first block to permit adjustment of the angle between the connector and the first block.
The foregoing and other features and advantages of the invention will become more apparent from the following detailed description of several embodiments, which proceeds with reference to the accompanying figures.
As used herein, the singular forms “a,” “an,” and “the” refer to one or more than one, unless the context clearly dictates otherwise.
As used herein, the term “includes” means “comprises.”As used herein, a group of individual members stated in the alternative includes embodiments relating to a single member of the group or combinations of multiple members. For example, the term “a, b, or c,” includes embodiments relating to “a,” “b,” “c,” “a and b,” “a and c,” “b and c,” and “a, b, and c.”
Each layer in the illustrated embodiment is formed of a row of side-by-side I-shaped subassemblies 10. Each subassembly typically includes at least two vertically oriented planar blocks and an adjustable connector extending between or connected to the blocks. As shown in
For additional anchoring stability, particularly in the lower layer 4a of walls having several layers, the I-shaped subassemblies 10 can be elongated in the rearward direction A by attaching one or more extension subassemblies 40. The lowest layer desirably extends into the slope a distance approximately equal to one-third of the final wall height. The extension subassembly 40 includes a tail block 18 attached perpendicularly to a nested tube subassembly 68 in a T-shaped arrangement. In each extension subassembly 40, the nested tube subassembly 68 desirably attaches to and extends perpendicularly from the center of the tail block 18 of the standard I-shaped subassembly 10.
In the retaining wall 8 shown in
As further shown in
As shown in
The subassembly components in certain embodiments can be interconnected by dovetail joints so that they may be separated only by vertically sliding one block with respect to the attached block. A dovetail joint may be formed in any of a wide variety of geometries as long as the blocks are connected against lateral separation. Dovetail joints generally have a male key or tongue 50 that mates with a female slot or groove 52. Typically, the tongue is wider at some position toward its free end than at another position closer to its root. The female groove 52 desirably is configured to closely conform to the male shape. In the illustrated embodiment, the face block 24 and tail block 18 define the vertical grooves 52, which are generally trapezoidal, with the face being wider than the aperture at the surface of each block. Compatible male tongues 50 are provided on the ends of the nested tube subassembly 68, with the free end being wider than the root.
In alternative embodiments, the subassembly can be held in place by frictional forces and/or the presence of adjacent unconnected blocks. In such embodiments, flat plates can be attached to the opposite ends of the adjustable connector 68 rather than male tongues 50, which plates are sized and shaped to be inserted into compatible slots or openings in the blocks 18, 24.
In particular embodiments, the length of the connector 68 can be adjusted between 24 inches and 44 inches, which would be desirable for constructing walls having a height of 10 feet or less. For taller walls, the connector 68 can be adapted to have a greater maximum length.
While in the illustrated embodiment the inner and outer tubes 70, 72 are cylindrical, the tubes can have other cross-sectional shapes. For example, the tubes 70, 72 can have a cross-sectional profile that is square, rectangular, triangular, or various combinations thereof, to name a few.
The inner and outer tubes 70, 72 can be made from various materials. For instance, the tubes 70, 72 can be formed from plastic or metal pipe and can have a plate welded or otherwise attached to an end of each pipe for connecting to a block.
The nested tube subassembly 68 can be used to adjust the overall length of the I-shaped subassemblies 10. In particular examples, such an adjustable I-shaped subassembly can enable a retaining wall 8 that can conform to particular contours of the sloped bank 6. In other particular examples, such an adjustable I-shaped subassembly 10 can reduce the number of required extension subassemblies 40 (
The face block 24 can further include alignment channels 58 defining oblong bores 62 passing vertically through the entire block. Each alignment channel 58 can include a rear pocket 60 in communication with the alignment channel 58 and extending to a limited depth. An alignment plug 30 (
The tongues 50 and grooves 52 can be similarly tapered along their vertical lengths so that each dovetail joint is secured against excess motion and slippage by the tongue 50 being wedged into the groove.
In alternative embodiments, the locking pin 84 can extend radially inward from the inner surface of the outer tube 82. The alignment channel 86 and the locking channels 88 can be formed on the outer surface of the inner tube 80. The inner and outer tubes can be positioned into a locked configuration by rotating either tube to insert the locking pin 84 into one of several locking channels 88 extending perpendicularly from the alignment channel 86.
Another embodiment is shown in
In other alternative embodiments, the adjustable connector can comprise any construction configured to interconnect a face and tail block and to adjust the spacing therebetween. For example, the adjustable connector can comprise a first elongated connection member and a second elongated connection member. A first end portion of the first connection member is adapted to be connected to the face block and a second end portion of the second connection member is adapted to be connected to the tail block. The first and second connection members have second end portions that are adapted to be connected to each other at various locations to vary the spacing between the face and tail blocks. For example, the second end portions of each connection member can be formed with a plurality of longitudinally spaced openings adapted to receive a pin or bolt to connect the second end portions to each other at selected locations. The connection members can comprise flat, plate-like members, tubular members, I-shaped members, C-shaped members, or various other shapes.
In another embodiment, a spring-loaded locking pin similar to pin 84 of
In addition, the face and tail blocks 24, 18 can be constructed in various shapes and sizes. For example, the face and tail blocks can be square, rectangular, trapezoidal, diamond-shaped, or various combinations thereof.
In another embodiment, a block subassembly 10 can comprise a face block 24, a tail block 18, and a connector of fixed-length extending between and connecting the face block to the tail block. The connector can be formed from materials that are less expensive than concrete, and in some embodiments, can be fabricated to have a selected length to suit the needs of a particular application. In one example, the connector can comprise a piece of rebar or pipe having plates welded at its ends. The plates are sized to be inserted into the openings 52 in the blocks 24, 18. The openings 52 can be appropriately sized and shaped to complement and readily accept the shape of the plates of the connector.
Block assemblies having such a fixed-length connector can be used for a selected number of courses at the base of the wall where the depth of the wall is greatest and adjustable connectors can be used for courses above the base where the depth of the wall can be reduced.
After the lowermost course of side-by-side block assemblies 10 is formed over the trench 102, the trench can be filled with concrete to form a concrete footing 104 that extends upwardly into the voids between adjacent block subassemblies 10. The anchor 100 helps anchor each block subassembly to the concrete footing 104. The concrete footing 104 is effective to increase the sliding resistance of the wall. This allows the wall to be constructed with a smaller base width than would normally be required, which minimizes excavation and provides more space in the embankment behind the wall, such as for placement of utility easements or other structures. Additional details about forming a retaining wall with the footing 104 can be found in co-pending U.S. application Ser. No. 10/591,736, which is the national stage of PCT Application No. PCT/US2005/008744 (published as WO2005/100700), which is incorporated herein by reference. The block assemblies 10 used to form the remaining courses of the wall need not be provided with anchors 100 connected to the connectors 68.
In other alternative embodiments, the anchor 100 can be connected to the inner tube 70. Similarly, in other alternative embodiments, the connector 68 of each subassembly in the lowermost course could be a fixed-length connector having an anchor 100.
As best shown in
In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. It should be apparent to those skilled in the art that the illustrated embodiments may be modified without departing from the principles described. Rather, the scope of the invention is defined by the following claims. I therefore claim as my invention all that comes within the scope and spirit of these claims.
The present application claims the benefit of U.S. Provisional Application No. 60/964,311, filed Aug. 10, 2007, which is incorporated herein by reference.
Number | Date | Country | |
---|---|---|---|
60964311 | Aug 2007 | US |