Patent Application
20140150368
The present invention relates to wall blocks, veneer panels and walls made from such blocks. In particular, this invention relates to wall blocks having a connection system that attaches veneer panels to wall blocks and a pinning system that connects courses of blocks with veneer panels to adjacent courses of blocks with veneer panels to form walls that are straight, curvilinear, retaining or freestanding or that have 90 degree corners. Additionally, columns, pilasters and parapets may be constructed with the blocks and veneer panels of the present invention and optionally vertical and horizontal reinforcement members may be utilized in building any structure with the present invention.
Retaining walls are used in various landscaping projects and are available in a wide variety of styles. Numerous methods and materials exist for the construction of retaining walls. Such methods include the use of natural stone, poured concrete, precast panels, masonry, and landscape timbers or railroad ties.
A widely accepted method of construction of such walls is to dry stack concrete wall units, or blocks. These blocks are popular because they are mass produced and, consequently, relatively inexpensive. They are structurally sound and easy and relatively inexpensive to install. Because they comprise concrete, they are durable. They can be given a desired appearance such as a natural stone appearance. Many block systems also use pins that are adapted to fit in corresponding pin holes in adjacent blocks or may use other mechanical means to contribute to the stability of a wall.
Typically, retaining wall blocks are manufactured to have the desired appearance on the front face (i.e., the outer face of a wall) because only the front is typically visible after the wall is constructed. It is highly desirable to have the front face of the wall system have a natural stone appearance, and many approaches are used in the art to treat or process concrete to evoke the appearance of natural stone, including splitting the block, tumbling the block to weather the face and edges of the face, and using processing or texturing equipment to impart a weathered look to the concrete. Colored concrete in various forms and methods also is employed to mimic the look of natural stone.
Depending upon their location, the soil type, the amount of water that can flow through a concrete retaining wall, and the salt content of the concrete, an undesirable appearance can develop on the surface of a retaining wall due to efflorescence. Efflorescence refers to the leaching of mineral salts from concrete by water and this often occurs on walls in contact with water. The resultant deposit on a surface creates an unattractive white, stained appearance on a wall. In addition, due to exposure to the elements and freeze/thaw cycles, concrete retaining walls may exhibit spalling, that is, chipping and cracking of concrete, which affects their appearance and can ultimately affect their utility. Freeze-thaw effects are worsened when the wall face is exposed to salt spray, which commonly occurs on roadways where de-icing salts are used to clear the road of ice and snow.
There have been prior efforts to add a veneer to regular masonry and segmental retaining walls with natural stone or concrete that is pre-cast molded to closely resemble natural stone. While such veneering produces aesthetically pleasing walls, it is a laborious and highly expensive process, as it requires skilled masonry work to tie in the stone or concrete veneer to the wall using traditional mortared masonry construction methods. Such veneering can double the cost of the finished wall. In addition, reinforced soil (also known as mechanically stabilized earth (MSE)) segmental retaining walls are not rigid structures and applying a rigid mortared veneer may cause cracking of the veneer pieces or mortar areas unless appropriate steps are taken to provide slip joints that allow for such movement. Additionally, it has been proposed to attach veneers made from various materials to wall blocks or wall surfaces using a connecting means that does not require mortar. Although such veneers are advantageous in many respects improvements are needed. For example, it would be desirable to provide a block for use with a veneer that has been specifically designed and configured to form a wall that can be interlocked for stability and that can be used with veneers and compatible connectors to provide a wall structure that is both aesthetically pleasing and structurally sound. Further, it would be desirable to improve the connectors with which those veneers are attached to the blocks or wall surface and to improve the manner in which the blocks in the wall are connected and stabilized from course to course.
This invention relates generally to a wall block and veneer panels and a method of constructing walls, retaining walls, free-standing walls or fence systems from the wall blocks and veneer panels. More particularly, the invention relates to constructing such walls or fence systems wherein a veneer panel is attached to a wall block with a connector and further wherein the front faces of the veneer panels have a desirable texture and further wherein the veneer panels can be connected to the wall blocks before, during or after construction of the wall or fence system.
The invention provides a wall block comprising: parallel top and bottom faces, parallel front and rear faces, and first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a receiving pocket for receiving a pin, the receiving pocket located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into the receiving pocket and one of the front or rear faces of the block.
The invention provides a wall block comprising: parallel top and bottom faces, parallel front and rear faces, and first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a pin receiving cavity for receiving a pin, the pin receiving cavity located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into one of the front or rear faces of the block; the front and rear faces having surface areas and the surface area of the front face being greater than the surface area of the rear face; a larger body portion, a smaller body portion, and two neck portions, the neck portions connecting the larger body portion and the smaller body portion, the front face forming a part of the larger body portion and the rear face forming a part of the smaller body portion; a core and two side voids, the core being encompassed by the larger body portion, the smaller body portion and the two neck portions, and the two side voids being formed by the side walls adjacent the two neck portions; and the pin hole extending from the top face of the block to the pin receiving cavity.
The invention provides a wall block comprising: parallel top and bottom faces, parallel front and rear faces, and parallel first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a pin receiving cavity for receiving a pin, the pin receiving cavity located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into one of the front or rear faces of the block; and a single core, the pin hole extending from the top face of the block to the receiving pocket.
The invention provides a combination comprising a wall block, a veneer, and a veneer connector, the wall block having a front face, the front face of the wall block having a connector channel for receiving a veneer connector, the veneer having a connector channel for receiving a veneer connector, and a veneer connector disposed within the wall block connector channel and the veneer connector channel, wherein the veneer comprises parallel top and bottom faces, parallel front and rear faces, and first and second side surfaces, the first side surface having a first surface portion which angles outward from the front face and a second surface portion which angles inward from the first surface portion towards the rear face.
The invention provides a combination comprising a wall block, a veneer, and a veneer connector, the wall block having a front face, the front face of the wall block having a connector channel for receiving a veneer connector, the veneer having a connector channel for receiving a veneer connector, and a veneer connector disposed within the wall block connector channel and the veneer connector channel, wherein the veneer comprises parallel top and bottom faces, front and rear faces, and first and second side surfaces, the rear face of the veneer having projections and valleys, the valleys extending from the top to the bottom faces.
The invention provides a veneer connector comprising: a first shaft and second shaft, the first shaft being attached to the second shaft by a bridge portion, the first and second shafts being parallel to each other; and the first and second shafts each having vertical friction ribs and horizontal friction ribs located at different portions of each shaft.
The invention provides a veneer connector comprising: a first shaft and second shaft, the first shaft being attached to the second shaft by a bridge portion, the first and second shafts being parallel to each other; the first and second shafts each having vertical friction ribs, the first and second shafts not being offset from each other, the first and second shafts being the same length, and the bridge portion being substantially planar.
The invention provides a veneer connector comprising a shaft and bifurcated horizontal prongs that extend from the shaft.
The invention provides a combination comprising a wall block, a veneer, and a veneer connector: the veneer having a connector channel for receiving a veneer connector; the wall block comprising parallel top and bottom faces, parallel front and rear faces, and first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a receiving pocket for receiving a pin, the receiving pocket located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into the receiving pocket and one of the front or rear faces of the block; the veneer connector comprising a first shaft and second shaft, the first shaft being attached to the second shaft by a bridge portion, the first and second shafts being parallel to each other; and the first and second shafts each having vertical friction ribs and horizontal friction ribs located at different portions of each shaft; and the veneer connector being disposed within the wall block connector channel and the veneer connector channel.
The invention provides a combination comprising a wall block, a veneer, and a veneer connector: the veneer having a connector channel for receiving a veneer connector; the wall block comprising parallel top and bottom faces, parallel front and rear faces, and first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a receiving pocket for receiving a pin, the receiving pocket located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into the receiving pocket and one of the front or rear faces of the block; the veneer connector comprising a shaft, and bifurcated horizontal prongs that extend from the shaft; and the veneer connector being disposed within the wall block connector channel and the veneer connector channel.
The invention provides a wall comprising a first course and a second course of wall blocks, a plurality of wall blocks comprising: parallel top and bottom faces, parallel front and rear faces, and first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a receiving pocket for receiving a pin, the receiving pocket located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into the receiving pocket and one of the front or rear faces of the block.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings.
In one embodiment of the invention, veneer panels are used with retaining wall blocks. The retaining wall blocks can be made of a rugged, weather resistant material, preferably (and typically) zero-slump molded concrete. Other suitable materials include polymers, especially high density foam polymers, fiberglass, wood, metal, glass, stone, and composite materials with reinforced fibers, etc. The blocks may have various shapes and characteristics, as known in the art, and may be stacked one upon the other to provide a vertically straight wall, and also may be stacked so that they are angled or set back from vertical. As known in the art, the blocks may be connected to each other by a pin attachment system, or the blocks may be provided with one or more protruding elements that interlock with one or more corresponding recesses in an adjacent block.
“Upper” and “lower” refer to the placement of the block in a retaining wall or fence system. The lower, or bottom, surface is placed such that it faces the ground. In a retaining wall, one row of blocks is laid down, forming a course. An upper course is formed on top of this lower course by positioning the lower surface of one block on the upper surface of another block.
Retaining walls may be straight (i.e., substantially linear, as well as vertically straight or plumb), curved (concave, convex, or serpentine) or may have angled corners (i.e., 90 degree angles, obtuse angles or acute angles of a buildable degree). Such walls can be angled or setback from vertical. Reinforcing geogrid mesh or geosynthetic fabrics (also referred to generally as geogrids and geotextiles) may be used with retaining wall blocks to create a reinforced soil structure where the wall has one exposed face and where the geogrid is attached to the block via the pinning connection and comes out through the back face and into the backfilled soil at desired intervals vertically.
The blocks of this invention are symmetrical about a vertical plane of symmetry. The blocks may optionally be provided with pin holes, pin receiving cavities, and at least one core which serves to decrease the weight of the block while maintaining its strength while also providing ease of construction of a retaining wall. The location, shape, and size of the pin holes and receiving cavities are selected to maximize the strength of the block, as described by reference to the drawings.
The veneer panels of this invention may be comprised of any suitable material such as high strength concrete, polymers, composites, natural stone, metal, wood, glass, porcelain or a mineral aggregate in fiberglass. High strength concrete (6,000 psi and higher) used in the making of the veneer panel may be compacted under vibration and pressure to make the veneer panel extremely durable and strong. Various liquid or dry pigments may be added to the concrete mix in order to create different colors or shades of color. The mold of the veneer panel is configured to impart a surface texture to the material that resembles the texture of natural stone. The high density and strength of the concrete veneer panel make it more resistant to weather and other natural forces.
It is to be emphasized that the surface of a veneer panel may have any desired appearance. A natural appearance, such as stone, is generally most desirable. The panel may have a uniform single stone appearance or it may have an ashlar multi-stone pattern formed into it. The panels may also resemble stone that has been processed or treated as is commonly known in the natural stone industry. For example, the panel may resemble a weathered stone, polished stone, or flame treated stone. In addition, the veneer panels may be molded or configured to produce panels that resemble stone that has been hand or machine pitched or tumbled to produce an aesthetically pleasing natural quarried stone appearance. In addition, the veneer panel can be manufactured to have any desired appearance, whether natural or man made. A combination of geometric forms and shapes, along with natural appearing aesthetics are all possible by adding the veneer panel to the structural support block of this system.
The invention provides a wall block comprising: parallel top and bottom faces, parallel front and rear faces, and first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a receiving pocket for receiving a pin, the receiving pocket located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into the receiving pocket and one of the front or rear faces of the block. In one embodiment, the receiving pocket is located on the bottom face of the block opens into the front face of the block. In an embodiment, the front and rear faces have surface areas and the surface area of the front face is greater than the surface area of the rear face. In an embodiment, the wall block comprises a larger body portion, a smaller body portion, and two neck portions, the neck portions connecting the larger body portion and the smaller body portion, the front face forming a part of the larger body portion and the rear face forming a part of the smaller body portion. In one embodiment, the wall block comprises a core and two side voids, the core being encompassed by the larger body portion, the smaller body portion and the two neck portions, and the two side voids being formed by the side walls adjacent the two neck portions. In one embodiment, the pin hole extends from the top face of the block to the receiving pocket. In an embodiment, the bottom surface of the block in the two neck portions has receiving channels for receiving a reinforcement member.
In an embodiment, the connector channel that is oriented in the direction from the bottom face to the top face of the block and opens onto the front face of the block, opens onto the front face from the bottom face to the top face of the block. In another embodiment, the connector channel that is oriented in the direction from the bottom face to the top face of the block and opens onto the front face of the block, does not open onto the front face for the entire distance from the bottom face to the top face of the block. In an embodiment, the connector channel opens onto the front face of the block from the receiving pocket to a point below the top face of the block.
In an embodiment, the connector channel that is oriented in the direction from the bottom face to the top face of the block and opens onto the front face of the block, opens onto the front face from the receiving pocket to the top face of the block. In one embodiment, the connector channel that is oriented in the direction from the bottom face to the top face of the block and opens onto the front face of the block, does not open onto the front face for the entire distance from the bottom face to the top face of the block. In an embodiment, the connector channel opens onto the front face of the block from the receiving pocket to a point below the top face of the block.
In one embodiment, wherein the bottom face of the block comprises four receiving pockets and the top face of the block comprises four pin holes. In an embodiment, the wall block comprises two connector channels opening onto the front face of the block and two connector channels opening onto the rear face of the block.
In an embodiment, the front and rear faces have surface areas and the surface area of the front face is equal to the surface area of the rear face, and the first and second side walls are parallel. In one embodiment, the bottom face of the block comprises only six receiving pockets and the top face of the block comprises only six pin holes. In an embodiment, the wall block comprises two connector channels opening onto the front face of the block, two connector channels opening onto the rear face of the block, and one connector channel opening onto each of the first and second side walls. In one embodiment, the wall block has only two cores. In an embodiment, the bottom surface of the block has a receiving channel for receiving a reinforcement member.
The invention provides a wall block comprising: parallel top and bottom faces, parallel front and rear faces, and first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a pin receiving cavity for receiving a pin, the pin receiving cavity located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into one of the front or rear faces of the block; the front and rear faces having surface areas and the surface area of the front face being greater than the surface area of the rear face; a larger body portion, a smaller body portion, and two neck portions, the neck portions connecting the larger body portion and the smaller body portion, the front face forming a part of the larger body portion and the rear face forming a part of the smaller body portion; a core and two side voids, the core being encompassed by the larger body portion, the smaller body portion and the two neck portions, and the two side voids being formed by the side walls adjacent the two neck portions; and the pin hole extending from the top face of the block to the pin receiving cavity. In one embodiment, the bottom surface of the block has a receiving channel for receiving a reinforcement member. In an embodiment, the connector channel that is oriented in the direction from the bottom face to the top face of the block and opens onto the front face of the block, opens onto the front face from the bottom face to the top face of the block.
The invention provides a wall block comprising: parallel top and bottom faces, parallel front and rear faces, and parallel first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a pin receiving cavity for receiving a pin, the pin receiving cavity located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into one of the front or rear faces of the block; and a single core, the pin hole extending from the top face of the block to the receiving pocket.
The invention provides a combination comprising a wall block, a veneer, and a veneer connector, the wall block having a front face, the front face of the wall block having a connector channel for receiving a veneer connector, the veneer having a connector channel for receiving a veneer connector, and a veneer connector disposed within the wall block connector channel and the veneer connector channel, wherein the veneer comprises parallel top and bottom faces, parallel front and rear faces, and first and second side surfaces, the first side surface having a first surface portion which angles outward from the front face and a second surface portion which angles inward from the first surface portion towards the rear face.
The invention provides a combination comprising a wall block, a veneer, and a veneer connector, the wall block having a front face, the front face of the wall block having a connector channel for receiving a veneer connector, the veneer having a connector channel for receiving a veneer connector, and a veneer connector disposed within the wall block connector channel and the veneer connector channel, wherein the veneer comprises parallel top and bottom faces, front and rear faces, and first and second side surfaces, the rear face of the veneer having projections and valleys, the valleys extending from the top to the bottom faces.
The invention provides a veneer connector comprising: a first shaft and second shaft, the first shaft being attached to the second shaft by a bridge portion, the first and second shafts being parallel to each other; and the first and second shafts each having vertical friction ribs and horizontal friction ribs located at different portions of each shaft. In an embodiment, the first and second shafts are offset from each other. In one embodiment, the first and second shafts are the same length. In an embodiment, the bridge portion is substantially planar. In one embodiment, the vertical friction ribs of the first shaft point in the opposite direction as the vertical friction ribs of the second shaft. In an embodiment, the first shaft is longer than the second shaft and includes a projection that can function as a pin.
The invention provides a veneer connector comprising: a first shaft and second shaft, the first shaft being attached to the second shaft by a bridge portion, the first and second shafts being parallel to each other; the first and second shafts each having vertical friction ribs, the first and second shafts not being offset from each other, the first and second shafts being the same length, and the bridge portion being substantially planar.
The invention provides a veneer connector comprising a shaft and bifurcated horizontal prongs that extend from the shaft. In an embodiment, the shaft has upper, middle, and lower portions, the upper and lower portions having horizontal friction ribs, and the middle portion having bifurcated horizontal prongs. In one embodiment, the bifurcated horizontal prongs comprise tabs at ends of the prongs. In an embodiment, the bifurcated horizontal prongs comprise tabs at ends of the prongs.
The invention provides a combination comprising a wall block, a veneer, and a veneer connector: the veneer having a connector channel for receiving a veneer connector; the wall block comprising parallel top and bottom faces, parallel front and rear faces, and first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a receiving pocket for receiving a pin, the receiving pocket located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into the receiving pocket and one of the front or rear faces of the block; the veneer connector comprising a first shaft and second shaft, the first shaft being attached to the second shaft by a bridge portion, the first and second shafts being parallel to each other; and the first and second shafts each having vertical friction ribs and horizontal friction ribs located at different portions of each shaft; and the veneer connector being disposed within the wall block connector channel and the veneer connector channel. In an embodiment, the veneer comprises parallel top and bottom faces, parallel front and rear faces, and first and second side surfaces, the first side surface having a first surface portion which angles outward from the front face and a second surface portion which angles inward from the first surface portion towards the rear face. In an embodiment, the veneer comprises parallel top and bottom faces, front and rear faces, and first and second side surfaces, the rear face of the veneer having projections and valleys, the valleys extending from the top to the bottom faces. In one embodiment, the veneer comprises parallel top and bottom faces, front and rear faces, and first and second side surfaces, and the front face of the block is the same size as the rear face of the veneer. In an embodiment, the veneer comprises parallel top and bottom faces, front and rear faces, and first and second side surfaces, and the front face of the block is a smaller size than the rear face of the veneer. In an embodiment, the wall block is a concrete wall block. In an embodiment, the veneer is a pre-cast concrete veneer. In an embodiment, the veneer comprises a polymer. In one embodiment, the veneer is a real stone veneer. In one embodiment, the receiving pocket located on the bottom face of the wall block opens into the front face of the block. In one embodiment, the first and second shafts of the veneer connector are offset from each other.
The invention provides a combination comprising a wall block, a veneer, and a veneer connector: the veneer having a connector channel for receiving a veneer connector; the wall block comprising parallel top and bottom faces, parallel front and rear faces, and first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a receiving pocket for receiving a pin, the receiving pocket located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into the receiving pocket and one of the front or rear faces of the block; the veneer connector comprising a shaft, and bifurcated horizontal prongs that extend from the shaft; and the veneer connector being disposed within the wall block connector channel and the veneer connector channel. In an embodiment, the veneer comprises parallel top and bottom faces, parallel front and rear faces, and first and second side surfaces, the first side surface having a first surface portion which angles outward from the front face and a second surface portion which angles inward from the first surface portion towards the rear face. In one embodiment, the veneer comprises parallel top and bottom faces, front and rear faces, and first and second side surfaces, the rear face of the veneer having projections and valleys, the valleys extending from the top to the bottom faces. In an embodiment, the veneer comprises parallel top and bottom faces, front and rear faces, and first and second side surfaces, and the front face of the block is the same size as the rear face of the veneer. In an embodiment, the receiving pocket located on the bottom face of the wall block opens into the front face of the block. In an embodiment, the shaft of the veneer connector has upper, middle, and lower portions, the upper and lower portions having horizontal friction ribs, and the middle portion having bifurcated horizontal prongs. In one embodiment, the bifurcated horizontal prongs comprise tabs at ends of the prongs.
The invention provides a wall comprising a first course and a second course of wall blocks, a plurality of wall blocks comprising: parallel top and bottom faces, parallel front and rear faces, and first and second side walls, the first and second side walls extending from the top face to the bottom face and from the front face to the rear face; a pin hole located on the top face of the block; a receiving pocket for receiving a pin, the receiving pocket located on the bottom face of the block and opening onto the bottom face of the block; and a connector channel for receiving a veneer connector that is oriented in the direction from the bottom face to the top face of the block, the connector channel opening into the receiving pocket and one of the front or rear faces of the block. In an embodiment, the receiving pocket located on the bottom face of the block opens into the front face of the block. In an embodiment, the wall is a retaining wall. In one embodiment, the wall is a free-standing wall. In an embodiment, the wall comprises a retaining wall and a parapet wall on top of the retaining wall. In an embodiment, veneers are attached to a plurality of the front faces of the blocks. In another embodiment, veneers are attached to a plurality of the front and rear faces of the blocks. In embodiments, the wall is straight or curved. In one embodiment, the wall includes a 90 degree corner. In embodiments, the wall is vertical or has a setback. In an embodiment, the wall is reinforced with geogrid soil reinforcement, internal reinforcement, or a combination of the two.
Though mold boxes 10a may have various dimensions, typical dimensions are about 18.5 inches (47.0 cm) wide (i.e., the width of the first and second end walls), 26.0 inches (66.0 cm) long (i.e., the length of the first and second side walls), and 8 inches (20.4 cm) thick.
The mold boxes of
Block 100a comprises larger body portion 108, smaller body portion 109 and neck portions 110 which connect the larger body portion 108 to the smaller body portion 109. Front face 104 forms part of the larger body portion 108, while rear face 105 forms part of smaller body portion 109. The larger and smaller body and neck portions 108, 109, and 110 each extend between top and bottom faces 102 and 103 and between first and second side walls 106 and 107. Side walls 106 and 107 are thus of a compound shape and have side voids 112 as a result of the reduced width of neck portions 110 compared to that of body portions 108 and 109. Side walls 106 and 107 also have side surface 111 which is part of the larger body portion 108, and side surface 113 which is part of the smaller body portion 109. Side surface 111 angles inward toward the back of the block and side surface 113 angles outward away from the block. Side surfaces 111 and 113 together form a common side angle to block 100a. This common angle preferably is from 5 to 15 degrees and may be 7.5 degrees. Neck portions 110 are generally located at the quarter points of the block to create balance between the space inside core 114 and the side spaces 112 of two adjoining blocks. Quarter points are the midpoints of the two segments produced by dividing the front face of the block at its midpoint.
Opening or core 114 extends through neck portion 110 from top face 102 to bottom face 103. Core 114 and side voids 112 also reduce the weight of block 100a; lower block weight is both a manufacturing advantage and an advantage when constructing a wall from the blocks as it reduces cost due to less material and makes lifting of the blocks easier. Cores 114 and side voids 112 also allow the structure being constructed with the blocks to utilize vertical reinforcing members such as rebar to increase durability and strengthen the structure.
Receiving pockets 120a/b/c/d receive a head of a pin placed in an adjacent lower course of blocks which is described in further detail below. Receiving pockets 120a and 120b are sized to allow for setback/offset from vertical in the construction of a structure while the size of receiving pockets 120c and 120d allow for generally no setback in the construction of a substantially vertical structure.
Front face 104 and back face 105 have connector channels 122 which extend from surface 121a of the upper surface of receiving pockets 120a/b/c/d upward a predetermined distance towards top surface 102. Pin holes 124 are located in body portions 108 and 109 and extend from top surface 102 to surface 121a of the upper surface of receiving pockets 120a/b/c/d. Pin holes open into connector channels 122 of the front face 104 and rear face 105 and together have a predetermined depth specifically sized to receive and secure the veneer connectors/clips which are connected or can be connected to veneer face panels which are described below. It is to be understood that commonly, though not always, the reference to a veneer clip being inserted into the connector channel of a block herewith may refer to a shaft of the veneer clip being received into the pin hole through surface 121a of the receiving pocket and a bridge of the veneer clip being received into the connector channel.
Pin 50, as shown in
Bottom surface 103 has receiving channel 130 located in neck portions 110. Receiving channel 130 extends through the length of the neck as shown and opens onto side surfaces 111 and 113 of side walls 106 and 107 and into the core 114. The receiving channel may be of sufficient width and depth as to accommodate a horizontal reinforcing member such as rebar to help strengthen the wall depending upon the application or may accommodate layers of soil retention material such as geogrid. The receiving channel may specifically have a depth of ¼ of an inch to 1 inch (12.7 to 25.4 mm) but may be wider or narrower depending upon the application.
Though the blocks illustrated in the
An alternative embodiment of the block is shown in
Another embodiment of the block is shown in
Block 200 comprises larger body portion 208, smaller body portion 209 and neck portions 210 which connect the larger body portion 208 to the smaller body portion 209. Front face 204 forms part of the larger body portion 208, while rear face 205 forms part of smaller body portion 209. The larger and smaller body and neck portions 208, 209, and 210 each extend between top and bottom faces 202 and 203 and between first and second side walls 206 and 207. Side walls 206 and 207 are thus of a compound shape and have side voids 212 as a result of the reduced width of neck portions 210 compared to that of body portions 208 and 209. Side walls 206 and 207 also have side surface 211 which is part of the larger body portion 208, and side surface 213 which is part of the smaller body portion 209.
Opening or core 214 extends through neck portion 210 from top face 202 to bottom face 203. Core 214 and side voids 212 also reduce the weight of block 200; lower weight block is both a manufacturing advantage and an advantage when constructing a wall from the blocks as it reduces cost due to less material and makes lifting of the blocks easier. Having a balanced through core 214 with two abutting side voids 212 leads to an effective filling of stone core fill and distribution of frictional connection to geogrid mesh material.
Bottom surface 203 has receiving channel 230 located in neck portions 210. Receiving channel 230 may extend a portion of the length of the neck as shown and may open onto side surfaces 211 of side walls 206 and 207 and into the core 214. The receiving channel may be of sufficient width and depth as to accommodate a horizontal reinforcing member such as rebar to help strengthen the wall depending upon the application or may accommodate layers of soil retention material such as geogrid. The receiving channel may specifically have a depth of ¼ of an inch to one inch (12.7 to 25.4 mm) but may be wider or narrower depending upon the application.
Front face 204 and back face 205 have connector channels 222 which extend from top surface 202 to bottom surface 203. Connector channels have a predetermined depth that is sized to receive and secure the veneer connectors which are connected to the veneer face panels.
Bottom face 203 of block 200 has pin receiving cavities 218 which are located in body portions 208 and 209 and extend a portion of the distance between top and bottom faces 202 and 203, i.e., opening onto the bottom surface but not the top surface. This is not limiting however and the pin receiving cavities may extend the entire distance between the top and bottom faces depending upon the application. Pin receiving cavities 218 may be slot shaped, that is, the cavities are curvilinear, having no sharp angles. The shape and size and location of the cavities are selected to maximize the strength of the block while at the same time reduce the weight of the block. Pin holes 216 and 217, i.e., first and second pin holes respectively, are located in body portions 208 and 209 of the block. The first pin holes 216 are positioned away from pin receiving cavities 218 and slightly set back towards receiving channel 230 of bottom face 203 and towards side walls 206 and 207. Second pin holes 217 are positioned to open into pin receiving cavities 218 of the block and are located towards front and back faces 204 and 205, respectively, of the block relative to pin holes 216. The location of the pin holes forms four pairs of pinholes located around the central core 214 of the block and provides a way to connect courses of block to another course to strengthen the wall and structure being built and also provides a way to offset the stacking of the blocks when constructing a wall depending upon the application.
Pin holes typically extend through to bottom face 203 and are sized to receive pin 50 which is shown in
Though the blocks illustrated in the
Bottom surface 303, front face 304, back face 305 and side faces 306 and 307 of corner block 300a each have receiving cavities or pockets 320 that extend a predetermined depth into the bottom surface 303 and also extend a predetermined depth into one of front face 304, back face 305 and side faces 306 and 307. The receiving pockets 320 receive the head of pin 50 from a course of blocks adjacently below. It should be noted that the receiving pockets could all be the same size or could all have differing sizes depending upon the application. The configuration, structure and function of receiving pockets 320 is similar to that described earlier with respect to receiving pockets 120a/b/c/d of block 100a. The surfaces 321a of the upper surface of receiving pockets 320 are substantially horizontal and extend a predetermined distance while surface 321b of the upper surfaces of receiving pockets 320 have an angular incline from horizontal. The angular incline of receiving pockets 320 is produced as an area of decline in the mold cavity with the bottom face 303 facing upward and is formed by the receiving pocket forming member that is attached to mold box 10 division plate 20 and stationary back and side wall liners 30 and 32.
Front face 304, back face 305 and side walls 306 and 307 have connector channels 322 which extend from surface 321a of the upper surface of receiving pockets 320 upward a predetermined distance towards top surface 302. Connector channels have a predetermined depth specifically sized to receive and secure the veneer clips which are connected or can be connected to veneer face panels which are described below. Corner block 300a also has pinholes 324 which extend from surface 321a to top surface 302. As best seen in
Though the blocks illustrated in the
Bottom surface 303 has receiving channel 330 that may open into one (as shown) or both of block 300a side walls and may be of sufficient width and depth as to accommodate a horizontal reinforcing member such as rebar to help strengthen the wall depending upon the application or may accommodate layers of soil retention material such as geogrid.
An alternative embodiment of corner block 300a is shown in
Back face 505E of veneer panel 500E has two connector channels 522 which extend a predetermined distance into the back face 505E of veneer panel 500E and accept a veneer connector or clip as described in further detail below. The spacing of the two veneer connector channels 522 are designed to align with the connector channels in the front and back faces of the blocks of the present invention. Connector channels 522 typically are oriented at the quarter points along the length of the veneer to optimize connection to the support block and to allow veneers to be sized smaller and larger than the support block face.
Veneer panel 500 is dimensioned to be about the same size as the front face of the blocks of the present invention. Veneer panel 500 typically has a height (i.e., the distance between surfaces 502 and 503) of about 8 inches (200 mm), a body length (i.e., the distance from side face 506 to side face 507) of about 18 inches (450 mm) and a width (i.e., the distance from front face 504 to rear face 505) of about 3 inches (75 mm). If made of materials other than concrete, the veneers typically can have thinner widths of from about 0.75 inch (19 mm) to 3 inches (75 mm). It should be noted that when veneer panels have been attached to a front or rear face of the blocks of the present invention, the combined depth of the veneer panel and the block (front surface to rear surface of assembled unit) is sized to approximate the width of a typical SRW block used in common retaining wall construction (approximately 12 inches (305 mm)). It should be further noted that the body length of the veneer panel may be slightly larger than the body length of the front face of the block for ease in accomplishing construction of a radial structure. It should be noted that the dimensions of the veneer panels and the blocks themselves are not limiting and the veneer panels and blocks can be any size depending upon the application.
Veneer panel 600 is sized to have the same surface area as the back face of the blocks of the present invention. Veneer panel 600 typically has a height (i.e., the distance between surfaces 602 and 603) of about 8 inches (200 mm), a body length (i.e., the distance from side face 606 to side face 607) of about 18 inches (457 mm) and a width (i.e., the distance from front face 604 to rear face 605) of about 3 inches (75 mm). It should be noted that the size and shape of the veneer panels are not limiting and any size or shape could be employed depending upon the application.
Non-bifurcated veneer connectors can be added on to the wall blocks without veneer panels to lighten the weight of the blocks during the wall construction. The veneer panels can then be added on to the wall blocks of the wall by slipping the veneers down over the top ends of the veneer clips at any point during construction.
Horizontal reinforcing member 80 may then be laid upon the base course of blocks and pins 50 may be placed in the pin holes of the top surface 102 of block 100a of the base course. Vertical reinforcing members 90 may be inserted into cores 114 of block 100a or through the side void opening 115 created by the placement of two adjacent blocks 100a. Alternatively, vertical reinforcing members 90 could have been placed into the footer while the concrete was setting, securing the vertical reinforcing members to the footer and adding the ability to resist overturning loads such as wind and impacts. When building an internally reinforced wall the pins could be left out and the concrete and reinforcing members will connect all the blocks together. The receiving channel 130 in the bottom face 103 of blocks 100a of the subsequent adjacent course receive and secure the horizontal reinforcing member 80 giving the structure increased strength and durability. The pin heads 52 from pinholes of the base layer are received and secured in the receiving pockets 120a/b/c and/or 120d of the subsequent adjacent course of blocks 100a. Once the next course is laid the veneer clips 700a and veneer panels 500 are attached and secured to the blocks 100a of the course (if the panels have not already been secured to the desired block face) and then subsequent courses of the wall are laid, including the placement of interlocking pins and horizontal and vertical reinforcing members, until the desired height of the wall is achieved. Once the desired height has been reached concrete may be poured through the core and side void openings to further strengthen the structure and a capping layer may be utilized for a more finished and aesthetically pleasing look. It should be noted that wall blocks 100b and 200 may also be used as described in the construction of such a wall with veneer panels 500.
Parapet wall courses 820b of wall 800b can be laid with front face 104 facing the same way as blocks 100a of retaining wall courses 810b or may be placed with back face 105 facing the same way as the blocks of retaining wall courses 810b because both surfaces are exposed and covered with veneer panels 500. In this manner, the orientation of the blocks in parapet wall courses 820b is not as important as the placement of the pins so that the head 52 of the pin is received into receiving pockets 120c and 120d to allow for no setback. If internally reinforced like the parapet wall shown, the builder can choose to eliminate the course to course connecting pins in the parapet section and rely on the internal reinforcing concrete grout and reinforcing members for block connection. Capping layer 840 gives parapet retaining wall 800b an aesthetically pleasing finished look.
Veneer panels 500 may be attached to the back faces 105 of the inside corner wall in an off-set manner whereby a veneer clip 700a from the back face 105 of one wall block 100a and one veneer clip 700a from the back face 105 of a second adjacent block 100a may each engage the connector channels 522 from the same veneer panel. Back face 305 (which is the same size and area as that of front face 304) of corner block 300a of the inside surface of the corner wall 800c may be attached to corner veneer panel 500A and the same veneer panel 500M may be attached to the back face 105 of an adjacent block 100. It should be noted that the positioning of the veneer panels on the wall is not limiting and that an individual veneer panel may be attached to two adjacent blocks on the outside of wall 800c and that one veneer panel 500 may be utilized for each individual back face 105 of the inside surface of corner wall 800c as well, depending upon the application.
Veneer panels 500 may be attached to the back faces 205 of the inside corner wall in an off-set manner as described whereby a veneer clip 700c from the back face 205 of one wall block 200 and one veneer clip 700c from the back face 205 of a second adjacent block 200 may each engage the receiving channels 522 from the same veneer panel. Corner block 400 may be attached to veneer 500 and the same veneer panel 500 may be attached to the back face 205 of an adjacent block 200. It should be noted that the positioning of the veneer panels on the wall is not limiting and that one veneer panel 500 may be utilized for each individual back face 205 of the inside corner wall 900b and that a veneer panel may be attached to two adjacent blocks on the outside of corner wall 900b as well, depending upon the application.
It should be noted that the veneer panels that are connected to the wall may have varying shapes and sizes depending upon the application. For example, a veneer panel may be sized to encompass the surface area of multiple faces of adjacent blocks, either vertically adjacent, horizontally adjacent or both. Further the veneer panels may be used with random sizes to create a random aesthetically pleasing surface to a wall. Further, it should be noted that the size and shape of the blocks are not limiting either and that any size or shape may be employed depending upon the application.
Although particular embodiments have been disclosed herein in detail, this has been done for purposes of illustration only, and is not intended to be limiting with respect to the scope of the following appended claims. In particular, it is contemplated by the inventors that various substitutions, alterations, and modifications may be made to the invention without departing from the spirit and scope of the invention as defined by the claims. For instance, the choices of materials or variations in shapes are believed to be a matter of routine for a person of ordinary skill in the art with knowledge of the embodiments disclosed herein.
This application is a continuation of U.S. Ser. No. 12/893,308, filed Sep. 29, 2010, which claims the benefit of U.S. Provisional Application No. 61/246,805, filed Sep. 29, 2009, entitled “Wall Blocks, Veneer Panels for Wall Blocks and Method of Construction Walls”, and U.S. Provisional Application No. 61/253,987, filed Oct. 22, 2009, entitled “Wall Blocks, Veneer Panels for Wall Blocks and Method of Construction Walls” the contents of each of which are hereby incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 61253987 | Oct 2009 | US | |
| 61246805 | Sep 2009 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12893308 | Sep 2010 | US |
| Child | 14172157 | US |
