FIELD
The present application relates to examples of a retaining wall system that includes one or more wall blocks.
BACKGROUND
Concrete blocks used for the construction of walls are available in a wide variety of styles for a variety of different applications. A landscaping retaining wall, for instance, typically includes blocks aligned side-by-side in courses, with the courses stacked on top of each other along the height of the wall. Blocks in vertically adjacent courses can be interconnected using pins or other block-connecting elements, or integral features of the blocks that can engage other blocks in the wall. Retaining walls under a few feet high (depending on local building codes) typically do not require any additional structure (other than the blocks themselves and any block-connecting elements) to reinforce the wall. Some known block systems for forming relatively shorter walls, such as for residential landscaping or hardscaping projects, include multiple blocks of different sizes that can be used to form a wall in which the exposed face of the wall is composed of the differently sized faces of the blocks, giving the exposed face of the wall a desired random appearance. In some cases, these block systems can also be used for forming free-standing walls and columns.
Relatively higher walls, such as for large commercial or municipal projects, typically require additional reinforcing, such as the use of geogrid fabric that extends into the earth behind the wall or the inclusion of additional anchor blocks that connect to blocks at the front of the wall and extend rearwardly therefrom into the earth behind the wall. Block systems designed for constructing relatively higher walls typically include blocks of all the same size that form the exposed face of the wall and therefore are not able to form a wall face that has a random appearance, as can be accomplished with shorter walls. Moreover, block systems designed for constructing relatively higher walls typically are further limited in that they cannot be used for forming free-standing walls or columns.
Accordingly, what is needed is a more versatile block system that can be used to construct walls in a wide variety of applications, for example, from relatively shorter retaining walls to relatively taller, and/or structurally reinforced retaining walls to free-standing walls and columns.
SUMMARY
Described herein are block systems comprising a plurality modular blocks for building retaining walls, free-standing walls, columns, and other structures. The walls can be constructed with interconnecting blocks of varying lengths to yield walls of different spans (lengths) and heights having a random, natural appearance. In some examples, a block system can comprise face blocks of different sizes, a depth or trunk block, and a block-connecting element. Each face block can have the same depth and height but can vary in length and numbers of identical female connecting slots for receiving interlocking male projections of trunk blocks.
In some examples, the trunk blocks can each comprise female slots and corresponding male projections. In some examples, the trunk blocks can be adapted to connect adjacent face blocks along a course of blocks in a wall. Additionally or alternatively, the trunk blocks can be arranged to interconnect first and second rows of face blocks in the same course, thus forming a free-standing wall with two exposed surfaces. In some examples, trunk blocks can be connected to other trunk blocks to extend a depth of the wall for improved wall stability.
In some examples, the block systems can further comprise block-connecting elements that can be used for aligning blocks of adjacent courses and/or for vertically connecting blocks in adjacent courses of blocks for increased structural support.
In some examples, a wall block comprises first and second opposing, parallel side walls extending lengthwise of the block; first and second opposing, parallel end walls extending between respective ends of the side walls, wherein the first and second side walls are longer than the first and second end walls; and at least first and second trapezoidal shaped projections extending outwardly from the first side wall, wherein the first and second projections are configured to be received in slots of adjacent blocks in a wall.
In some examples, a wall block comprises a front surface and an opposing rear surface extending lengthwise of the block; first and second opposing, parallel side surfaces extending between respective ends of the front and rear surfaces, wherein the front and rear surfaces are longer than the first and second side surfaces; and wherein the rear surface is formed with three trapezoidal shaped slots configured to receive projections of adjacent blocks in a wall.
In some examples, a wall comprises at least a first course, the first course comprising: a plurality of face blocks arranged in side-by-side relationship with each other and forming a first row of the first course; and a plurality of trunk blocks arranged in side-by-side relationship with each other and forming a second row of the first course, wherein the second row is arranged behind the first row, and wherein a selected trunk block in the second row interconnects two adjacent face blocks in the first row.
In some examples, a block assembly comprises a trunk block and a face block. The trunk block comprises first and second opposing, parallel side walls extending lengthwise of the trunk block and first and second opposing, parallel end walls extending between respective ends of the side walls of the trunk block, wherein the first and second side walls of the trunk block are longer than the first and second end walls of the trunk block; and at least one trapezoidal shaped projection extending outwardly from the first side wall of the trunk block and at least one trapezoidal shaped slot formed in the first end wall of the trunk block. The face block comprises front and rear surfaces extending lengthwise of the face block and first and second side surfaces extending between respective ends of the front and rear surfaces of the face block, wherein the front and rear surfaces of the face block are longer than the first and second side surfaces of the face block, and wherein the rear surface of the face block is formed with at least one trapezoidal shaped slot configured to receive a projection of the trunk block.
The block systems and methods disclosed herein can, among other things, overcome one or more of the deficiencies of typical retaining walls and constructions thereof, thus improving both versatility and aesthetics.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block assembly comprising a plurality of different blocks, according to an example.
FIG. 2 is a top view of a first face block of the block assembly of FIG. 1.
FIG. 3 is top view of a second face block of the block assembly of FIG. 1.
FIG. 4 is top view of an end block of the block assembly of FIG. 1.
FIG. 5 is top view of a trunk block of the block assembly of FIG. 1.
FIG. 6A is a perspective view of a block connecting element for interconnecting and/or aligning adjacent blocks in a course of a wall, according to an example.
FIG. 6B is a side view of the block connecting element of FIG. 6A.
FIG. 6C is a top view of the block connecting element of FIG. 6A.
FIG. 6D is a front view of the block connecting element of FIG. 6A.
FIG. 7A is a side view of a vertical wall formed of multiple courses comprising the face blocks of FIG. 2 and the block connecting elements of FIGS. 6A-6D, according to an example.
FIG. 7B is a back view of the vertical wall of FIG. 7A.
FIG. 8A is a top view of a wall formed of multiple courses comprising the face blocks of FIG. 2 and the block connecting elements of FIGS. 6A-6D, according to an example, where the wall has a negative batter.
FIG. 8B is a perspective view of the wall of FIG. 8A, as viewed from the back and showing the negative batter.
FIG. 9A is a close-up, perspective view of the formation of a wall comprising the face blocks of FIG. 2 and the block connecting elements of FIGS. 6A-6D, according to an example, as viewed from the back and showing a positive batter.
FIG. 9B, is a partial, perspective view of the wall of FIG. 9A comprising additional courses, as viewed from the back, and showing the positive batter.
FIG. 10 is a top view of a corner portion of a wall comprising the face and end blocks of FIG. 1 and block connecting elements of FIGS. 6A-6D, according to an example, where trunk blocks are shown to increase a depth of the wall.
FIG. 11 is a partial, perspective view of the corner portion of the wall of FIG. 10, as viewed from the back.
FIG. 12 is a top view of a double-sided wall comprising the face and end blocks of FIG. 1 and block connecting elements of FIGS. 6A-6D, according to an example.
FIG. 13 is a top view of another double-sided wall comprising the face and end blocks of FIG. 1 and an intermediate wall section comprising trunk blocks, according to an example.
FIG. 14 is a top view showing multiple interconnected trunk blocks for increasing a depth of the wall, according to an example.
FIG. 15 shows a block assembly comprising a plurality of different blocks, according to another example.
FIG. 16A is a perspective view of a first face block of the block assembly of FIG. 15, as viewed from the front.
FIG. 16B is a perspective view of the first face block of FIG. 16A, as viewed from the back.
FIG. 16C is a side view of the first face block of FIG. 16A.
FIG. 16D is a back view of the first face block of FIG. 16A.
FIG. 16E is a front view of the first face block of FIG. 16A.
FIG. 16F is a top view of the first face block of FIG. 16A.
FIG. 17A is a perspective view of a second face block of the block assembly of FIG. 15, as viewed from the front.
FIG. 17B is a perspective view of the second face block of FIG. 17A, as viewed from the back.
FIG. 17C is a side view of the second face block of FIG. 17A.
FIG. 17D is a back view of the second face block of FIG. 17A.
FIG. 17E is a front view of the second face block of FIG. 17A.
FIG. 17F is a top view of the second face block of FIG. 17A.
FIG. 18A is a perspective view of a third face block of the block assembly of FIG. 15, as viewed from the front.
FIG. 18B is a perspective view of the third face block of FIG. 18A, as viewed from the back.
FIG. 18C is a side view of the third face block of FIG. 18A.
FIG. 18D is a back view of the third face block of FIG. 18A.
FIG. 18E is a front view of the third face block of FIG. 18A.
FIG. 18F is a top view of the third face block of FIG. 18A.
FIG. 19A is a perspective view of a trunk block of the block assembly of FIG. 15.
FIG. 19B is a front view of the trunk block of FIG. 19A.
FIG. 19C is a section view of the trunk block taken from the section line in FIG. 19B.
FIG. 19D is a side view of the trunk block of FIG. 19A.
FIG. 19E is a bottom view of the trunk block of FIG. 19A.
FIG. 19F is a top view of the trunk block of FIG. 19A.
FIG. 20 is a top view of a single-sided wall comprising face blocks of FIG. 16A and trunk blocks of FIG. 19A, according to an example.
FIG. 21 is a top view of a double-sided wall comprising faces blocks of FIGS. 16A, 17A, and 18A and trunk blocks of FIG. 19A, according to an example.
FIG. 22A is a perspective view of a block-connecting element, according to an example, as viewed from underneath.
FIG. 22B is a perspective view of the block-connecting element of FIG. 22A, as viewed from above.
FIGS. 23A-23B show the use of the block-connecting element of FIGS. 22A-22B to interconnect vertically adjacent courses, according to an example.
FIG. 24 is a top view of a first course of blocks of a wall, according to an example.
FIG. 25 is a top view of a second course of blocks of a wall, according to an example, where the second course of blocks can be laid on top of the first course of blocks of FIG. 24.
FIG. 26 is a perspective view of a wall with a corner portion, according to an example, as viewed from the front.
FIG. 27 is a perspective view of a block-connecting element, according to another example.
FIG. 28 is a front view of the block-connecting element of FIG. 27.
FIG. 29 is a top view of the block-connecting element of FIG. 27.
FIG. 30 is a bottom view of the block-connecting element of FIG. 27.
FIG. 31 is a side view of the block-connecting element of FIG. 27.
FIG. 32 is a side view of the block-connecting element of FIG. 27.
FIG. 33 shows a method for forming a corner of a wall, according to an example.
FIG. 34 shows a method for finishing an end of a wall, according to an example.
FIG. 35 is a top view of the trunk block of FIG. 19A connected to the face block of FIG. 16A, according to an example.
FIG. 36 is a perspective view of a corner of a double-sided wall, according to an example.
FIG. 37 is a top view of a first course of blocks of the double-sided wall of FIG. 36.
FIG. 38 is a top view of a second course of blocks of the double-sided wall of FIG. 36, where the second course of blocks can be laid on top of the first course of blocks of FIG. 37.
DETAILED DESCRIPTION
General Considerations
For purposes of this description, certain aspects, advantages, and novel features of examples of this disclosure are described herein. The disclosed assemblies, methods, apparatus, and systems should not be construed as being limiting in any way. Instead, the present disclosure is directed toward all novel and nonobvious features and aspects of the various disclosed examples, alone and in various combinations and sub-combinations with one another. The assemblies, methods, apparatus, and systems are not limited to any specific aspect or feature or combination thereof, nor do the disclosed examples require that any one or more specific advantages be present or problems be solved.
Although the operations of some of the disclosed examples are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed methods can be used in conjunction with other methods. Additionally, the description sometimes uses terms like “provide” or “achieve” to describe the disclosed methods. These terms are high-level abstractions of the actual operations that are performed. The actual operations that correspond to these terms may vary depending on the particular implementation and are readily discernible by one of ordinary skill in the art.
As used in this application and in the claims, the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Further, the term “coupled” generally means physically, mechanically, chemically, magnetically, and/or electrically coupled or linked and does not exclude the presence of intermediate elements between the coupled or associated items absent specific contrary language.
Disclosed Technology
A retaining wall system, according to one example, comprises a plurality of concrete blocks that are configured to be used together in forming a wall. FIG. 1 shows a first block assembly 10, according to one example. The block assembly 10 can include one or more of a first face block 12, a second face block 14, a corner or end block 16, and a trunk block 18 (also referred to as a “depth element” or “depth block”). FIGS. 2-5 are top plan views of blocks 12, 14, 16, and 18, respectively. The first face block 12 has a longer first length L1 than the second face block 14 (measured side to side) which has a second length L2; otherwise, the face blocks 12, 14 can have the same overall configuration, height, and depth d1 (measured front to back). The corner block 16 can have a third length L3 that is smaller than the lengths of both the first and second face blocks 12, 14.
Referring to FIG. 2, the first face block 12 can have a front face or front surface 20, a rear face or rear surface 22, and opposing, parallel side surfaces 24. The front and rear surfaces 20, 22 are perpendicular to the side surfaces 24 and to parallel top and bottom surfaces, forming a substantially rectangular prism shape. The rear surface 22 can have a recessed central portion 25. The rear surface 22 can be formed with one or more female connecting slots, including outer slots 26a, 26b and a center slot 28. The outer slots 26a, 26b and the center slot 28 can each extend from an opening on the rear surface 22 toward the front surface 20 of the first face block 12. The outer slots 26a, 26b and the center slot 28 can have identical or substantially identical trapezoidal configurations with non-parallel, opposing vertical side surfaces 27a and 27b that flare away from each other moving in a direction from the rear surface 22 toward the front surface 20. In some examples, the outer slots 26a, 26b and the center slot 28 can extend from the top surface to the bottom surface of the first face block 12, thus extending the entire height of the block.
The slots are adapted to receive a male component of a block connector for interconnecting and/or aligning adjacent blocks in a wall, as further described below. The outer slots 26a, 26b desirably are located at the “quarter points” of the block 12, meaning that centerlines 29 of the slots 26a, 26b are spaced from the closest side surfaces 24 an equal or substantially equal distance S1 equal to one quarter of the overall length L1 of the block (measured from one side surface 24 to the other side surface 24). The center slot 28 desirably is located equidistant from the outer slots 26a, 26b by the distance S1 and the side surfaces 24, and thus is centered about a centerline CL1 of the length L1. Due to the recessed central portion 25 of the rear surface 22, the center slot 28 desirably is offset from the outer slots 26a, 26b toward the front surface 20 in the direction of the block depth, the significance of which is described below.
Referring to FIG. 3, the second face block 14 can have a front face or front surface 30, a rear face or rear surface 32, and opposing, parallel side surfaces 34. The front and rear surfaces 30, 32, are perpendicular to the side surfaces 34 and to parallel top and bottom surfaces, forming a substantially rectangular prism shape. As described above, the length L2 of the second face block 14 can be smaller than the length L1 of the first face block 12. Similar to the first face block 12, the rear surface 32 of the second face block 14 can have a recessed central portion 35 and can be formed with one or more female connecting slots, including outer slots 26a, 26b and a center slot 28. The outer slots 26a, 26b and the center slot 28 can each extend from an opening on the rear surface 32 toward the front surface 30 in the same manner as the outer slots 26a, 26b and the center slot 28 of the first face block 12.
Walls of the outer slots 26a, 26b and the center slot 28 can have identical or substantially identical trapezoidal configurations with non-parallel, opposing vertical side surfaces 27a and 27b as described above. The outer slots 26a, 26b desirably are located at the “quarter points” of the second face block 14, meaning that centerlines 29 of the slots 26a, 26b are spaced from the closest side surfaces 34 an equal or substantially equal distance S2 equal to one quarter of the overall length L2 of the block 14 (measured from one side surface 34 to the other side surface 34). The center slot 28 desirably is located equidistant from the outer slots 26a, 26b by the distance S2 and the side surfaces 34, and thus can be centered about a centerline CL2 of the length L2. As described above, the depth d1 of the second face block 14 is the same as the depth d1 of the first face block 12.
Referring to FIG. 4, the end block 16 can have a front face or front surface 40, a rear face or rear surface 42, parallel, opposing side surfaces 44, and an overall third length L3. The front and rear surfaces 40, 42 are perpendicular to the side surfaces 44 and to parallel top and bottom surfaces, forming a substantially rectangular prism shape. The rear surface 42 can be formed with a female connecting slot 46, which can be located equidistant from the side surfaces 44 and thus is centered about a centerline CL3 of the length L3. The female connecting slot 46 can be shaped in a trapezoidal configuration with non-parallel, opposing vertical side surfaces 27a and 27b as described above for the first and second face blocks 12, 14. The third length L3 can be smaller than both the first and second lengths L1, L2, as described above. The depth d1 of the end block 16 is the same as the depth d1 of the first and second face blocks 12, 14.
When any of the face blocks 12, 14, and 16 are positioned at a corner of a wall, respective side surfaces 24, 34, and 44 can be visible. In some examples, the side surfaces 24, 34, and 44 of the face blocks 12, 14, and 16 can have the same surface finish as their respective front surfaces 20, 30, and 40. In this way, the surface finish of a corner can match the surface finish of adjacent front and side walls on either side of the corner. In some examples, the surface finish of the side surfaces 24, 34, and 44 and the front surfaces 20, 30, and 40 can be smooth. In some examples, the surface finish of any surface can be abraded, textured, or patterned to suit a particular aesthetic. In some examples, the side surfaces and the front surface of a block 12, 14, and/or 16 can be formed with a roughened surface texture as disclosed in U.S. Pat. No. 7,100,886, which is incorporated herein by reference.
Referring to FIG. 5, the trunk block 18 has an overall L-shape that includes a first leg portion 50 and a shorter, second leg portion 52 extending perpendicular to the first leg portion 50. The first leg portion 50 can comprise a first side wall or surface 51 and a second, opposing side wall or surface 53 that is parallel to the first side surface 51. The first leg portion 50 can further comprise an end wall or surface 55 that is perpendicular to and extends between the first and second side surfaces 51, 53 and to top and bottom surfaces of the block 18. The second leg portion 52 can comprise a first side wall or surface 57 and a second side wall or surface 59, where the first side surface 57 extends from and is perpendicular to the second side surface 53 of the first leg portion 50. The second side surface 59 is parallel and opposite to both the first side surface 57 of the second leg portion 52 and the end surface 55 of the first leg portion 50. The second leg portion 52 can further comprise an end wall or surface 60 that is perpendicular to and extends between the first and second side surfaces 57, 59. The end surface 60 is parallel and opposite to the first side surface 51. In this way, the first and second leg portions 50, 52 are disposed at an angle of 90 degrees with respect to each other to form the L-shape described above and seen in FIG. 5. The trunk block 18 can have the same height as the face blocks 12, 14, 16.
The first leg portion 50 can include female connecting slots 54 and 56 each extending from openings on the end surface 55 and the second side surface 59, respectively. The second leg portion 52 can include a female connecting slot 58 extending from an opening on the end surface 60. The female connecting slots 54, 56, 58 can be sized and shaped in the same trapezoidal configuration with non-parallel, opposing vertical sides as described above for slots 26a, 26b, and 28. The slots 54, 56 can be aligned with each other and both centered about a centerline CL4 of the first leg portion 50, where the centerline CL4 bisects the end surface 55 and is disposed equidistant between the first and second side surfaces 51, 53 of the first leg portion 50. The slot 58 can be centered about a centerline CL5 of the second leg portion 52, where the centerline CL5 bisects the end surface 60 and is disposed equidistant between the first and second side surfaces 57, 59 of the second leg portion 52.
In some examples, the depth d1 of the blocks 12, 14, 16 is 4 inches; the height of blocks 12, 14, 16 and the trunk block 18 is 4 inches; the length L1 of the face block 12 is 16 inches; the length L2 of the face block 14 is 12 inches; the length L3 of the face block 16 is 8 inches; an overall length of the trunk block 18 is 8.5 inches; and a depth of the trunk block 18 is 4.5 inches.
FIGS. 6A-6D are various views of a block connecting element 100 that can be used to interconnect and/or align adjacent blocks in a course of a wall. The connecting element 100 includes opposing end portions 102, 104 extending from opposite ends of an intermediate portion 106 and a lip 108 extending perpendicular from the intermediate portion 106. A length of the block connecting element 100 is defined as the distance extending from a first end 103 to a second end 105. The lip 108 can be offset a distance 109 from a centerline CL6 of the connecting element 100 toward the end portion 104 as shown in FIG. 6C, where the centerline CL6 is an imaginary line that bisects the connecting element halfway between the first and second ends 103, 105. Each end portion 102, 104 flares in width from the intermediate portion 106 to the end of the end portion. The flared end portions 102, 104 can be arranged to fit within the female connecting slots of any one of blocks 12, 14, 16, or 18 described above. As best shown in FIG. 6D, each end portion 102, 104 includes a first side surface 110, a second side surface 112, and end surfaces 114 extending between respective ends of the side surfaces 110, 112. As shown, the side surfaces 110, 112 can be flat, while the end surfaces 114 can each have a convex curvature. The connecting element 100, or at least the end portions 102, 104 can be hollow so as to define a void or channel 116 passing therethrough.
FIGS. 7A and 7B show a vertical wall (without a batter) formed from multiple courses of face blocks 12. To form a vertical wall, blocks 12 can be placed in a running bond pattern with respect to blocks in vertically adjacent courses, meaning that each block 12 can overlap two blocks in a vertically adjacent course. Connecting elements 100 can be placed in one or both of the outer slots 26a, 26b of the blocks 12. Each connecting element 100 can be positioned such that the lip 108 extends downwardly and contacts the rear surface 22 of a block in an adjacent lower course. In this manner, the connecting elements 100 function as alignment elements for aligning each block vertically with respect to a block in a lower course without a batter.
A connecting element 100 can be inserted into a slot (e.g., a slot 26a, 26b, or 28) by rotating the connecting element 100 such that the side surfaces 110, 112 are vertical and parallel to the vertical sides of the slot. In this position, an end portion 102 (or end portion 104) is inserted into the slot from the top of the block and slid downwardly toward another block in a lower course. Near the bottom of the slot, the connecting element 100 is rotated 90 degrees such that the end surfaces 114 engage the vertical side surfaces 27a, 27b of the slot and form a friction fit with the side surfaces 27a, 27b of the slot and such that the lip 108 contacts the rear surface 22 of the lower block.
FIGS. 8A and 8B show a wall formed from blocks 12, wherein the wall has a foreword reveal (also referred to as a negative batter). To form such a wall, connecting elements 100 are positioned in the center slots 28 near the top surface of each block such that the lip 108 contacts the rear surface 22 of another block in a course directly above the block with the connecting element. Because the center slot 28 is offset toward the front surface 20 of the block due to the recessed central portions 25, 35, the lip 108 aligns the vertically higher block slightly forward in the wall with respect to the lower block, thereby forming a foreword reveal or negative batter. In other words, a front surface of each subsequently higher course can protrude forward beyond a front surface of an immediately lower course, thus forming a progressively forward projecting wall from bottom to top.
FIGS. 9A and 9B show a wall formed from blocks 12, wherein the wall has a positive batter. To form such a wall, connecting elements are positioned in the center slots 28 near the lower surface of each block such that the lip 108 contacts the rear surface 22 of another block in a course directly below the block with the connecting element. Due to the offset position of the center slot 28 resulting from the recessed central portions 25, 35, the lip 108 aligns the vertically higher block slightly rearward in the wall with respect to the lower block, thereby forming a positive batter (i.e., a progressively recessed wall from bottom to top).
In FIGS. 7A-9B, the walls can be formed with only blocks 12 or blocks 14, or a combination of blocks 12 and 14.
FIGS. 10-11 show an example of a wall formed from blocks 12, 14, 16, and 18. The face blocks 12 and 14 can be used to form the front surface of the wall. The end blocks 16 can be used to form the front surface of the wall at an end of the wall. The trunk blocks 18 can be interconnected to respective blocks 12, 14, and 16 with connecting elements 100 to increase the depth of the wall, thereby increasing the stability of the wall. When interconnecting a trunk block 18 with another block 12, 14 or 16, an end portion (102 or 104) of the connecting element 100 is inserted into a slot (slot 54, 56 or 58) of the trunk block 18 and the other end portion of the connecting element is inserted into a slot of the block 12, 14 or 16. FIG. 10 is a top down view of the wall. Trunk blocks in the uppermost course of the wall are labeled as trunk blocks 18a and trunk blocks in the adjacent lower course are labeled as trunk blocks 18b. As can be seen, a trunk block 18a can be stacked on top of and be at least partially supported by a trunk block 18b in an adjacent lower course. At the corner of the wall, a trunk block 18b′ can be connected to a face block in one side of the wall and to another face block in another side of the wall using block connecting elements 100.
FIG. 12 shows an example of a double-sided wall comprising one or more vertically stacked courses of face blocks 12. Each course comprises a first row 150 of face blocks 12 and a second row 152 of face blocks 12. End blocks 16 can be positioned at the ends of the rows 150, 152. On one side of the wall, a plurality of first rows 150 are stacked on top of each other to form a first vertical wall section. One the other side of the wall, a plurality of second rows 152 are stacked on top of each other to form a second vertical wall section. In each course, the rear surfaces of the blocks 12, 16 in the first row 150 can be connected to the rear surfaces of the blocks 12, 16 in the second row 152 by connecting elements 100, thereby interconnecting the first and second vertical wall sections. The double-sided wall shown in FIG. 12 can be a free-standing wall or fence. In some examples, one or both rows 150, 152 can be formed from face blocks 14 or a combination of face blocks 12, face blocks 14, and end blocks 16.
FIG. 13 shows another example of a double-sided wall comprising one or more vertically stacked courses of face blocks 12 and trunk blocks 18. Each course comprises a first row 150 of face blocks 12, a second row 152 of face blocks 12, and a third row of trunk blocks 18 between the first and second rows 150, 152. End blocks 16 can be positioned at the ends of the rows 150, 152. In FIG. 13, trunk blocks 18a are trunk blocks in the row 154 of the uppermost course and trunk blocks 18b are trunk blocks in a row 154 of an adjacent underlying course. On one side of the wall, a plurality of first rows 150 are stacked on top of each other to form a first vertical wall section. On the other side of the wall, a plurality of second rows 152 are stacked on top of each other to form a second vertical wall section. Between the first and second vertical wall sections, is a third vertical wall section comprising a plurality of third rows 154 stacked on top of each other. The first, second, and third vertical wall sections together form a plurality of courses. In each course, the rear surfaces of blocks 12, 16 in the first row 150 can be connected to adjacent end surfaces of trunk blocks 18 by connecting elements 100, and the rear surfaces of blocks 12, 16 in the second row 152 can be connected to adjacent end surfaces of the trunk blocks 18, thereby interconnecting the first, second, and third vertical wall sections. The double-sided wall shown in FIG. 13 can be a free-standing wall or fence. In some examples, one or both rows 150, 152 can be formed from face blocks 14 or a combination of face blocks 12, face blocks 14, and end blocks 16.
FIG. 14 shows how multiple trunk blocks 18 can be interconnected end-to-end with connecting elements 100 to increase the depth of the wall to a desired depth, depending on the particular engineering requirements of the wall. For example, as shown, a face block 12 or 16 can be connected to a rearwardly extending first trunk block 18c with a connecting element 100, which in turn can be connected to a rearwardly extending second trunk block 18d with a connecting element 100. Additional trunk blocks 18 can be added as needed to further increase the depth of the wall.
FIG. 15 shows a second block assembly 200, according to another example, that can be used to construct walls (e.g., retaining walls and free-standing walls), columns, or other structures. The block assembly 200 can include one or more of a first face block 202, a second face block 204, a third face block 206, and a trunk block 208 (also referred to as a “depth element” or “depth block”). The first face block 202 is longer than the second face block 204 (measured side to side) and the second face block 204 is longer than the third face block 206 (measured side to side). Otherwise, the first, second, and third face blocks 202, 204, 206 can have the same overall configuration, height h1, and depth d2 (measured front to back).
FIGS. 16A-16F are various views of the first face block 202. In some examples, the first face block 202 can have a front face or front surface 210, a rear face of rear surface 212, parallel, opposing side surfaces 214, an upper surface 216, and a lower surface 218, where the upper and lower surfaces 216, 218 are opposing and parallel to each other. The front and rear surfaces 210, 212 are perpendicular to the side surfaces 214 and the upper and lower surfaces 216, 218. In some examples, the rear surface 212 is planar and can be parallel to the front face 210. The rear surface 212 can be formed with one or more female connecting slots, including outer slots 220a, 220b, and a center slot 220c, which can extend the entire height of the block 202. The slots are adapted to receive a male connecting portion of a trunk block 208 (as further described below) or alternatively, a male component of a block connector, such as connecting element 100. The outer slots 220a, 220b desirably are located at the “quarter points” of the block 202, meaning that centerlines 221 of the slots 220a, 220b are spaced from the closest side surfaces 214 a distance S3 which is equal to one quarter of the overall length L4 of the block (measured from one side surface 214 to the other side surface 214). The center slot 220c desirably is located equidistant from the outer slots 220a, 220b and the side surfaces 214 and centered about centerline CL7 of the length L4. The centerline CL7 thus bisects the block 202. The center of the center slot 220c (located on the centerline CL7) is spaced from each centerline 221 by a distance S3.
The outer slots 220a, 220b and the center slot 220c can each extend from an opening on the rear surface 212 toward the front surface 210 of the first face block 202. The outer slots 220a, 220b and the center slot 220c can have identical or substantially identical trapezoidal configurations with non-parallel, opposing vertical sides 222a, 222b that flare outwardly moving in a direction from the rear surface 212 to the front surface 210.
FIGS. 17A-17F are various views of the second face block 204. In some examples, the second face block 204 can have a front face or front surface 230, a rear face of rear surface 232, parallel, opposing side surfaces 234, an upper surface 236, and a lower surface 238, where the upper and lower surfaces 236, 238 are opposing and parallel to each other. The front and rear surfaces 230, 232, are perpendicular to the side surfaces 234 and the upper and lower surfaces 236, 238. In some examples, the rear surface 232 is planar and can be parallel to the front face 210. The rear surface 232 can be formed with one or more female connecting slots, including slots 240a, 240b, which can extend the entire height of the block 202. The slots are adapted to receive a male connecting portion of a trunk block 208 (as further described below) or alternatively, a male component of a block connector, such as connecting element 100. The slots 240a, 240b are equally spaced from the side surfaces 234 a distance S3, where the distance S3 is the same for the second face block 204 as the distance S3 for the first face block 202.
The slots 240a, 240b can each extend from an opening on the rear surface 232 toward the front surface 230 of the second face block 204. The slots 240a, 240b can have identical or substantially identical trapezoidal configurations, and can have the same overall size and shape as the slots 220a, 220b 220c. Centerlines 241 of the slots 240a, 240b are each equidistant from a centerline CL8 of the block 204, where the centerline CL8 bisects the block 204. The distance between the slots 240a, 240b (as measured from one centerline 241 to the other centerline 241) is equal to S3. A length L5 of the second face block 204 is smaller than the length L4 of the first face block 202 while the depth d2 of the block 204 is the same as the depth d2 of the block 202.
FIGS. 18A-18F are various views of the third face block 206. In some examples, the third face block 206 can have a front face or front surface 250, a rear face of rear surface 252, parallel, opposing side surfaces 254, an upper surface 256, a lower surface 258, and a length L6. The upper and lower surfaces 256, 258 are opposing and parallel to each other. The front and rear surfaces 250, 252 are perpendicular to the side surfaces 254 and the upper and lower surfaces 256, 258. The depth d2 of the third face block 206 is the same as the depths of the first and second face blocks 202, 204. In some examples, the rear surface 252 is planar and can be parallel to the front face 210. The rear surface 252 can be formed with one or more female connecting slots 260, which can extend the entire height of the block 202 and which are adapted to receive a male connecting portion of a trunk block 208 (as further described below) or alternatively, a male component of a block connector, such as connecting element 100. In the depicted example, the rear surface is formed with a single slot 260 that is equidistantly spaced between the side surfaces 254, thus centered about a centerline CL9 of the block 206 where the centerline CL9 bisects the block 206.
In one example, the third face block has one slot 260 as shown in FIGS. 18A-18F, which can each extend from an opening on the rear surface 252 toward the front surface 250. The slot 260 can form a trapezoidal configuration with non-parallel, opposing vertical sides 222a, 222b that flare outwardly moving in a direction from the rear surface 252 to the front surface 250 can have the same overall size and shape as the slots 220a, 220b, 220c, 240a, and 240b of the first and second blocks 202, 204.
When any of the face blocks 202, 204, and 206 are positioned at a corner of a wall, respective side surfaces 214, 234, and 254 can be visible. In some examples, the side surfaces 214, 234, and 254 of the face blocks 202, 204, and 206 can have the same surface finish as their respective front surfaces 210, 230, and 250. In this way, the surface finish of a corner can match the surface finish of adjacent front and side walls on either side of the corner. In some examples, the surface finish of the side surfaces 214, 234, and 254 and the front surfaces 210, 230, and 250 can be smooth. In some examples, the surface finish of any surface can be abraded, textured, or patterned to suit a particular aesthetic. In some examples, the side surfaces and the front surface of a block 202, 204, and/or 203 can be formed with a roughened surface texture as disclosed in U.S. Pat. No. 7,100,886. Providing the side surfaces and the front surface of a face block with the same surface finish is advantageous because it allows the face block to be used for constructing corners, columns, jam ends, etc., without the need for specialty corner units or field cutting the face units, which is unappealing as field cut units can separate over time.
FIGS. 19A-19F are various views of the trunk block 208. In some examples, the trunk block 208 comprises opposing and parallel side surfaces (also referred to herein as “side walls”) 270, opposing, parallel end surfaces (also referred to herein as “end walls”) 272, an upper surface 274, and a lower surface 276, where the upper and lower surfaces 274, 276 are parallel to each other. The side surfaces 270 are perpendicular to the end surfaces 272 and the upper and lower surfaces 274, 276. The trunk block 208 can have the same height h1 as the blocks 202, 204, 206, and the same length LA (measured from one end surface 272 to the other end surface 272) as the block 202. The depth d3 of the trunk block 208 is defined as the distance from one side surface 270 to the other side surface 270. The depth d3 can be equal or substantially equal to the depth d2 of the blocks 202, 204, 206. Alternatively, the depth d3 of the trunk block 208 can be different than the depth d2 of the blocks 202, 204, 206 and can be specified to achieve specific depth increments for wall construction.
Extending from each side surface 270 is one or more male connecting portions or projections 280, such as two male connecting portions 280. Each projection 280 is configured with two outwardly flared, vertical opposing walls 281a, 281b and an outer vertical wall 281c extending between ends of the walls 281a, 281b, thus forming a trapezoidal configuration as seen in FIGS. 19A-19F.
In the example shown in FIGS. 19A-19F, each side surface 270 has two male projections 280, where opposing projections 280 on the side surfaces 270 are aligned with each other along respective centerlines 271 of the projections 280. The centerlines 271 can be spaced equidistant from a midpoint or transverse centerline CL10 of the block 208, where the centerline CL10 is an imaginary line located halfway between the end surfaces 272, thus bisecting the block 208. In some examples, the centerlines 271 of the projections 280 can be spaced a distance S3 from the centerline CL10 and a distance S3 from respective end surfaces. In such examples, the distance between adjacent projections 280 on each side of the block can be the same as the distance between the slots 220a, 220b in the block 202, the relevance of which will be described below.
Each end surface 272 can be formed with a female connecting slot 278, where each female connecting slot 278 comprises vertical, non-parallel walls 279a, 279b. The female connecting slots 278 are adapted to receive a male connecting portion 280 of another trunk block 208 (as further described below) or alternatively, a male component of a block connector, such as connecting element 100. The female connecting slots 278 can be the same size and shape as the slots 220a, 220b, 220c, 240a, 240b, and 260 of the first, second, and third blocks 202, 204, 206.
Opposing female connecting slots 278 can be aligned with each other along a longitudinal centerline CL11, where the centerline C11 is an imaginary line extending lengthwise of the block halfway between the side surfaces 270.
The upper surface 274 can be formed with a recess 282 surrounding a vertical slot or core 284 that is elongated in the direction of the length of the block (the length measured from one end surface 272 to the other end surface 272). Both widths of the recess 282 and the slot 284 can be centered about the longitudinal centerline CL11, as shown in FIG. 19F. The slot 284 is adapted to receive a portion of a block-connecting element, as further described below. The slot 284 can extend an entire height of the trunk block 208. That is, the slot 284 can extend from a bottom surface of the recess 282 to the lower surface 276 of the trunk block 208, as seen in the cross section of FIG. 19C.
In some examples, the length L5 of the face block 204 is three-quarters the length LA of the face block 202, and the length L6 of the face block 206 is one-half the length LA of the face block 202. In some examples, the depth d2 of the face blocks 202, 204, 206 is 4 inches; the height h1 of the face blocks 202, 204, 206 and the trunk block is 4 inches; the length L4 of the face block 202 and the trunk block 208 is 16 inches; the length L5 of the face block 204 is 12 inches; the length L6 of the face block 206 is 8 inches; and the depth d3 of the trunk block 208 is 4 inches.
FIG. 20 shows an example of a single-sided wall (e.g., a retaining wall) constructed from multiple blocks 202 and 208. A course of the wall can be constructed by placing blocks 202 side-by-side in a first row 290 along the length of the wall. Blocks 208 are positioned side-by-side in a second row 292 behind the first row of blocks 202 in a staggered arrangement such that each block 208 overlaps with two adjacent blocks 202 with one male connecting portion 280 received within a slot 220 (e.g., slot 220a) of one block 202 and the other male connecting portion 280 received within a slot (e.g., slot 220b) of an adjacent block 202. In other words, a single block 208 can interconnect two adjacent blocks 202 in the same course. An end of the second row 292 can include a block 208′, which is a block 208 with a section of concrete removed (e.g., a partial block 208). Multiple courses of first and second rows 290, 292 of blocks 202, 208, respectively, can be formed on top of each other to extend the height of the wall. In other examples, the blocks 202 in the first row 290 of a course and the trunk blocks 208 in the second row 292 in the same course are not staggered with respect to each other. In such examples, since two male connecting portions 280 can have the same lateral spacing as the slots 220a, 220b, the two male connecting portions 280 of a trunk block 208 can be received in the slots 220a, 220b of the same face block 202, as will be described further below in reference to FIG. 35.
FIG. 21 is an example of a double-sided wall (e.g., a free-standing wall) constructed from blocks 202 and 208. The wall of FIG. 21 is similar to the wall of FIG. 20 except that a third row 294 of blocks 202 is formed behind the second row 292 of blocks 208. Blocks 204 and 206 can be used to finish the ends of the wall. Multiple courses of first, second, and third rows of blocks 202, 208 can be formed on top of each other to extend the height of the wall.
In constructing the walls shown in FIGS. 20-21, the center slots 220c of the face blocks 202 do not receive a projection 280 of a trunk block 208. Thus, when laying a row of face blocks 202 on top of a previously formed row of face blocks 202, the center slots 220c can be utilized as hand holds for grasping a rear of a face block 202 as it is placed over face blocks 202 of a previously laid course.
As shown in FIGS. 22A and 22B, in some examples, a block-connecting element 300 can be used to interconnect trunk blocks 208 in vertically adjacent rows. The block-connecting elements 300 can comprise a lower portion 302, an upper portion 304, and a flange 306 separating the lower portion 302 and the upper portion 304. The lower portion 302 can include axially and radially extending ribs 308. FIGS. 23A-23B show the use of the block-connecting element 300 to interconnect trunk blocks 208 in vertically adjacent rows. In use, a lower portion 302 of a block connecting element 300 is inserted into a slot 284 of a first trunk block 208 such that flange 306 seats within the recess 282, as depicted in FIG. 23A. As the next course of blocks is formed, a second trunk block 208 of the next course is placed over the underlying first trunk block 208 such that the upper portion 304 of the block-connecting element extends upwardly into the slot 284 of the second trunk block 208.
FIG. 24 shows an example of a course 400 of blocks of a wall and FIG. 25 shows another example of a course 402 of blocks of a wall. The course 400 can be a first course and the course 402 can be second course laid on top of the first course 400 in the same wall. The course 400 is constructed of face blocks 202, 206 and trunk blocks 208 and includes a first row 404 of face blocks 202, 206, a second row 406 of trunk blocks 208a behind the first row 404, and a third row 408 of trunk blocks 208b. Each trunk block 208a extends lengthwise of the course and interconnects two adjacent face blocks 202 in the same row 404, in the same manner shown in FIGS. 20-21, or a face block 202 with an adjacent face block 204 or 206. Each trunk block 208b is connected to a respective trunk block 208a and extends rearwardly therefrom in a perpendicular relationship with a male connecting portion 280 of the block 280a received in a connecting slot 278 of the block 280b. The second course 402 similarly includes a first row 410 of face blocks 202, 204, 206, a second row 412 of trunk blocks 208a, and a third row 414 of trunk blocks 208b. Moreover, in some examples, the trunk blocks 208a of row 406 can be interconnected with overlying trunk blocks 208a of row 412 with a plurality of block-connecting elements 300, in the manner shown in FIGS. 23A-23B.
The third row 408 of trunk blocks 208 in each course increases the depth of the wall into the earth or fill material behind the wall, thereby providing increased strength and stability for constructing taller walls. The trunk blocks 208b form a “gravity bin” configuration in which the trunk blocks 208b form “bins” between adjacent blocks 208b that contain earth or fill material. Advantageously, the use of trunk blocks 208b can avoid the need for geofabric positioned between adjacent courses, which is difficult and time-consuming to install due to the fact that geofabric requires extensive excavation behind the wall to lay out the geofabric.
As shown in FIGS. 24 and 25, the rows 406, 412 include voids 416 formed by two adjacent slots 278 where the sides of two adjacent trunk blocks 208a contact each other. These voids 416 can remain empty or can be occupied by backfill material. Alternatively, two adjacent trunk blocks 208a can be interconnected with a block connecting element 100 by inserting an end portion 102 of the block connecting element 100 into a slot 278 of one block 208a and inserting the other end portion 104 of the block connecting element 100 into a slot 278 of an adjacent block 208a. Similarly, block connecting elements 100 can be used to interconnect additional trunk blocks 208b positioned end-to-end (similar to the way trunk blocks 18c, 18d are connected to each other in FIG. 14) to further extend the depth of the wall by positioning the end portion 102 of a block connecting element 100 in an open slot 278 of a trunk block 208b and positioning the end portion 104 in a slot 278 of another trunk block 208b.
In some examples, the trunk blocks 208b shown in FIGS. 24-25 can be omitted, such as when constructing walls that do not require the additional stability provided by the trunk blocks 208b.
When forming a wall, the exposed face(s) of the wall can be formed by any combination of face blocks 202, 204, and 206. FIG. 26 shows one example of a wall comprising multiple courses, each comprising combinations of any of face blocks 202, 204, and 206.
FIG. 33 shows a technique for forming a corner of a wall, according to an example. As shown, near the end of a first side 600 of the wall, a trunk block 208 can be used to interconnect a face block 204 and a face block 204. The face block 204 forms the end of the first side 600 of the wall. A face block 206 is placed perpendicular to the face block 204 to form a corner of the wall with the face block 204. Additional face blocks and trunk blocks can be placed in parallel arrangement with the face block 206 to form a second side 602 of the wall (similar to FIGS. 24-25).
FIG. 34 shows a technique for finishing an end of single-sided wall. This configuration is similar to that shown in FIG. 33, except that the end of the wall is finished with a half face block 206′ placed in perpendicular relationship with the face block 204. This can be referred to as a “jam end finish” for a wall. The half face block 206′ can be formed by splitting a face block 206 in half along centerline CL9.
In some examples, block connecting elements 100 can be used to interconnect vertically adjacent face blocks 202, 204 and/or 206, similar to the way the block connecting elements are used in FIGS. 7-9. For example, an end portion 102 (or end portion 104) can be inserted into a slot 220a, 220b, 220c of a first face block 202 (or a slot 240a, 240b of a face block 204 or a slot 260 of a face block 206) and the lip 108 can engage a second face block 202 (or a face block 204 or a face block 206) that is above or below the first face block. In some examples, a wall can be constructed from only face blocks 202, only face blocks 204, only face blocks 206, or a combination of face blocks 202, 204, 206, without any trunk blocks 208 behind the face blocks.
FIGS. 27-32 are various views of a block-connecting element 500, according to another example. The block-connecting element 500 can be referred to as a “three-way” block-connecting element (or “three-way” alignment plug) because it can be positioned in three different positions within a core of a block to permit vertical, set forward, or set back placement of blocks in a course relative to the blocks in an adjacent lower course. In some examples, the slot 284 in the trunk block 208 can be sized and shaped to receive a block-connecting element 500. In such examples, the trunk blocks 208 in adjacent courses (and therefore the face blocks 202, 204, and/or 206 connected to the trunk blocks 208) can be positioned relative to each other in a vertical, set forward, or set back arrangement.
As shown in FIGS. 27-32, the block-connecting element 500 comprises a lower portion, or projection, 502, an upper portion, or projection, 504, and an intermediate flange portion 506 separating the upper and lower portions. The lower portion 502 can be formed with vertically extending, spaced-apart ribs 508 that extend outwardly from one or more sides of the lower portion (e.g., in the illustrated example, the ribs 508 are formed on three sides of the lower portion). The ribs 508 desirably taper in height extending in a direction from the flange portion 506 to the lower end of the lower portion 502. When inserted into a block, the ribs 508 can contact one or more inner surfaces of a core 284 of the block to assist in frictionally retaining the block-connecting element within the block. Likewise, the upper portion 504 can be formed with vertically extending, spaced-apart ribs 510 that extend outwardly from one or more sides of the upper portion (e.g., in the illustrated example, the ribs 510 are formed on three sides of the upper portion). The ribs 510 desirably taper in height extending in a direction from the flange portion 506 to the upper end of the upper portion 504. When inserted into a block 208, the ribs 510 can contact one or more inner surfaces of a core 284 of the block to assist in frictionally retaining the block-connecting element within the block.
The upper portion 504 is horizontally offset from the lower portion 502; thus, the upper portion 504 is located closer to a forward edge 512 of the flange portion 506 and the lower portion 502 is located closer to a rear edge 514 of the flange portion 506. In the illustrated example, the upper portion 504 is aligned with the forward edge 512 while the lower portion 502 is spaced slightly from the rear edge 514 a distance d.
Further disclosure about using block-connecting elements 500 for constructing walls is disclosed in U.S. Pat. No. 8,667,759, which is incorporated herein by reference.
As described above, FIG. 35 shows an example of a configuration of a block assembly 700 comprising a trunk block 208 and a face block 202 where two male connecting portions 280 of a trunk block 208 are received in the slots 220a, 220b of the same face block 202. In some examples, the assembly 700 of a face block 202 and trunk block 208 connected in this manner form the functional equivalent of a single segmental retaining wall unit, such as disclosed in U.S. Pat. No. 7,328,537, which is incorporated herein by reference. When multiple assemblies 700 are used for forming a wall, assemblies 700 can be placed side-by-side in courses and assemblies 700 in one course can be positioned in a running bond pattern with respect to assemblies 700 in an adjacent course. Also, the trunk block 208 of an assembly 700 in one course can be interconnected to two trunk blocks 208 of two assemblies 700 in an overlying second course using block-connecting elements 300.
Moreover, the trunk block 208 can be paired with a face block 202 having any desired surface finish. A manufacturer can sell trunk blocks 208 for use with face blocks 202 having different surface finishes, such as face blocks 202 with smooth surfaces or face blocks 202 with roughened surfaces. Thus, rather than manufacturing and stocking relatively larger single units having different surface finishes to suit the needs of multiple customers, the manufacturer need only manufacture relatively smaller face blocks with different surface textures.
FIGS. 36-38 show a double-sided wall, according to an example, where an inside, 90-degree corner of the wall is constructed using face blocks. As seen in FIG. 37, a first course of blocks of the double-sided wall can comprise a plurality of face blocks 202, 206 forming both of outer and inner exposed surfaces of the wall with trunk blocks 208 therebetween. The corner of the first course shown in FIG. 37 is formed using a block 208′, which is a block 208 with a section of concrete removed (e.g., a partial block 208), as described above. Additionally, the corner of the first course can be formed using a block 208′″, which is a block 208′ with a projection 280 removed.
FIG. 38 shows a top view of a second course of blocks of the double-sided wall, according to an example, where the second course of blocks can be laid on top of the first course of blocks of FIG. 37. As seen in FIG. 38, the second course of blocks of the double-sided wall can comprise a plurality of face blocks 202, 204, 206 forming outer and inner exposed surfaces of the wall with trunk blocks 208 therebetween. The corner of the second course shown in FIG. 38 is formed using a block 208″, which is a block 208 with a projection 280 removed. Notably, none of the face blocks 202, 204, and 206 need be cut to form the corner of the wall.
In view of the many possible ways in which the principles of the disclosure may be applied, it should be recognized that the illustrated configurations depict examples of the disclosed technology and should not be taken as limiting the scope of the disclosure nor the claims. Rather, the scope of the claimed subject matter is defined by the following claims and their equivalents.
Patent Application
20240426100
