WALL SYSTEM

Abstract

A wall system includes a bracket assembly and at least one block member. The bracket assembly establishes a self-supporting wall frame. The at least one block member is supported on the self-supporting wall frame. The at least one block member includes an outer face, an inner face, and a top face extending between said outer face and said inner face. The top face locates the at least one block member on the self-supporting wall frame.

Description

BACKGROUND OF THE DISCLOSURE

This disclosure generally relates to building components, and more particularly to a wall system.

Modern day building construction, including construction of commercial and residential buildings, often includes the construction of concrete block wall systems. Masonry blocks are stacked in a plurality of rows to construct the wall systems. Typical masonry blocks include masonry face members which are outwardly aligned and parallel and include structural cross members that extend between the parallel faces. Traditional concrete masonry blocks are of unitary construction, with the cross members and face members all formed of a concrete material. Therefore, the masonry blocks must be transported, in finished form, from the point of fabrication, storage, and/or sale, and ultimately to the construction site.

Brick wall systems for commercial and residential buildings are also known. These wall systems utilize studs or furring strips of an existing building frame to construct exterior walls. Therefore, the integrity of wall systems of this type is dependent upon the support of one or more existing surfaces. Sheathing or building wrap (such as a plastic moisture barrier) may be installed over the studs and/or furring strips of the building framework. The brick members are then stacked and mortared to one another and anchors are utilized to attach the brick members to the exterior of the wood sheathing and building wrap.

SUMMARY OF THE DISCLOSURE

A wall system includes a bracket assembly and at least one block member. The bracket assembly establishes a self-supporting wall frame. The at least one block member is supported on the self-supporting wall frame. The at least one block member includes an outer face, an inner face, and a top face extending between said outer face and said inner face. The top face locates the at least one block member on the self-supporting wall frame

A method of constructing a wall system includes positioning stud members at a desired spacing, attaching bracket members to the stud members to establish a self-supporting wall frame independently of any existing surface, and supporting block members on the self-supporting wall frame to construct the wall system.

A block member for a wall system includes an outer face, an inner face and opposing end faces. The outer face extends between the opposing end faces and establishes a first height. The inner face extends between the opposing end faces on an opposite side from the outer face and establishes a second height that is greater than the first height. The top face extends between the outer face and the inner face and includes a ledge at least partially coextensive with the outer face and extending between the outer face and the inner face.

The various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically illustrates an example masonry block;

FIG. 2 schematically illustrates a second example masonry block;

FIG. 3 illustrates a block member for use with the masonry blocks illustrated in FIG. 1 and FIG. 2;

FIG. 4 schematically illustrates example features of the block member shown in FIG. 3;

FIG. 5 illustrates an example wall system;

FIG. 6 illustrates a perspective view of a bracket assembly of the wall system illustrated in FIG. 5;

FIG. 7 illustrates a cross-sectional side view of the example wall system illustrated in FIG. 5;

FIG. 8 illustrates a vertical bar of the bracket assembly illustrated in FIG. 6;

FIG. 9 is a flowchart of an example method for constructing the wall system illustrated in FIG. 5;

FIG. 10 illustrates a top view of the bracket assembly illustrated in FIG. 6;

FIG. 11 illustrates a bracket assembly of another example wall system;

FIGS. 12A, 12B and 12C illustrate a block member for use with the bracket assembly and wall system of FIG. 11;

FIG. 13 illustrates a cross-sectional view of the wall system of FIG. 11;

FIG. 14 illustrates another view of the wall system of FIG. 13; and

FIGS. 15A and 15B illustrate a backer sheet of the wall system of FIGS. 11-14.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS

FIG. 1 illustrates an example masonry block 10 that includes a first block member 12, a second block member 14, and a cross member 16. Each block member 12, 14 includes an outer face 18 and an inner face 20 opposite of the outer face 18. The cross member 16 extends between the inner faces 20 of the block members 12, 14. The cross member 16 may include openings 21 to provide an installer of the masonry blocks 10 with the ability to insulate and vertically reinforce the masonry block 10.

In the illustrated example, the block members 12, 14 and the cross member 16 are formed of concrete as a single-piece construction. However, the first block member 12, the second block member 14 and the cross member 16 may include any other materials known to be suitable by those skilled in the art having the benefit of this description. The masonry blocks 10 are stacked and positioned in a plurality of rows to construct a free-standing wall system.

Each block member 12, 14 of the masonry block 10 includes a depression 44, for example. In another example, each block member 12, 14 includes a plurality of depressions 44. An insert 17 is receivable within the depressions 44. In one example, the insert 17 includes a porous material. In another example, the insert 17 is a Styrofoam rope. The inserts 17 reduce the build up of mortar or other substances within the depressions 44 during installation of the masonry blocks 10, thereby improving water drainage of the masonry blocks.

FIG. 2 illustrates a second example masonry block 24. The masonry block 24 also includes a first block member 26, a second block member 28 and a cross-member 30. The first block member 26 and the second member block member 28 are substantially identical to the first block member 12 and second block member 14 of the masonry block 10. In one example, the cross member 30 is a bracket member 32 which comprises a material different from that of the block members 26, 28. In one example, the bracket member 32 is metal, such as 25 gauge galvanized sheet metal, for example. In another example, the bracket member 32 is plastic. The example block members 12, 14, 26 or 28 of the masonry blocks 10, 24 may be utilized to construct various wall systems, as is further discussed below.

FIG. 3 illustrates the example block member 12. The block member 12 is shown and described as substantially typical of each of the block members 12, 14, 26 and 28. The block member 12 is formed of concrete, brick, or any other suitable material. In one example, the block member 12 includes a water resistant additive that reduces any susceptibility to cracking and water penetration. The example block member 12 includes a length L1. In one example, the length L1 of the block member 12 is approximately 16 inches. In another example, length L1 is approximately 8 inches. However, the block member 12 may be manufactured to the specifications of any desired length.

The length L1 extends between opposing end faces 34, 36. In one example, the block member 12 includes a slot 38. The slot 38 is positioned between the outer face 18 and the inner face 20 of the block member 12.

The slot 38 includes a horizontal portion 40 and a vertical portion 42. The vertical portion 42 is transverse to the horizontal portion 40, in one example. In another example, the vertical portions 42 of the slot 38 are perpendicular to the horizontal portion 40. The horizontal portion 40 of the slot 38 is coextensive with the length L1 of the block member 12. The horizontal portion 40 of the slot 38 extends along a top face 41 (which extends between the end faces 34, 36 and the inner face 20 and the outer face 18) of the block member 12, for example. The vertical portion 42 is coextensive with a height H of the block member 12 and extends along each of the first end face 34 and the second end face 36 of the block member 12. Therefore, the slot 38 extends along each of the first and second end faces 34, 36 and along the entire length L1 of the block member 12. That is, the slot 38 of the block members 12 is continuous and uninterrupted along the height H and length L1 of the block member 12.

The slot 38 is positioned within a plane of the block member 12 which is offset from each plane defined by the outer face 18 and the inner face 20 of the block member 12. That is, no portion of the slot 38 extends into the outer face 18 or the inner face 20. In one example, the outer face 18 is positioned within a first plane 43, the inner face 20 is positioned within a second plane 45 different from the first plane 43, and the slot 38 is positioned within a third plane 47 which is different from both the first plane 43 and the second plane 45 (See FIG. 4).

In one example, the horizontal portion 40 and the vertical portions 42 of the slot 38 are positioned within the same plane. In another example, the vertical portions 42 of the slot 38 are offset from the horizontal portion 40 of the slot 38. The vertical portions 42 may be offset in either direction relative to the horizontal portion 40 (i.e., either towards the outer face 18 or towards the inner face 20 of the block member 12). A person of ordinary skill in the art having the benefit of this disclosure would understand how to design the slot 38 of the block member 12, including the various dimensions associated with the slot 38 such as the offset distance between the vertical portions 42 and the horizontal portion 40 of the slot, the slot depth, and numerous other dimensions.

The block member 12 may also include a plurality of depressions 44 disposed along the length of the block member 12 adjacent to the horizontal portion 40 of the slot 38. The depressions 44 are utilized to divert water into the horizontal portion 40 of the slot 38, which may enter through the joints (i.e., the horizontal and vertical gaps between adjacent block members 12 in a wall system) of a wall system from adjacent block members 12. The horizontal portion 40 communicates the water to the vertical portions 42 of the slot 38. The vertical portions 42 then communicate the water downwardly until the water escapes the wall system. Therefore, the depressions 44 and the slot 38 reduce water penetration and water build-up within the block members 12, as is further discussed below.

The block members 12 may include a beveled edge 35. The beveled edge 35 extends along both the top face 41 and the end faces 34, 36 of the block member 12 (See FIGS. 7 and 10). The beveled edges 35 allow adjacent block members 12 of a wall system to be positioned closer to one another thereby reducing the size of the mortar joints between the block members 12.

The block member 12 (which is typical of block members 12, 14, 26 and 28) may be utilized to construct numerous types of wall systems. In one example, the block members 12 are utilized to assembly a plurality of the masonry blocks 10, which are stacked and positioned in a plurality of rows to build a wall system. In another example, the block members 12 may be utilized with a preexisting wall 46 to establish a block veneer wall system 48, as is illustrated in FIG. 5.

The preexisting wall 46 includes a plurality of stud members 50 that extend adjacent to one another in a vertical manner, in one example. The spacing between the stud members 50 is not significant, and the stud members 50 can be spaced at 8″ on center, 12″ on center, 16″ on center, or any other spacing requirements. Although the preexisting wall 46 is illustrated with stud members 50, it should be understood that the preexisting wall may include any type of wall having any type of wall components. The stud members 50 may include metal studs, for example. In another example, the stud members 50 include wooden studs. In yet another example, the stud members 50 include plastic studs. A person of ordinary skill in the art having the benefit of this disclosure would understand that the block veneer wall system 48 may be utilized with any preexisting wall 46.

The block veneer wall system 48 includes a plurality of ledger clips 52 and a plurality of the block members 12. As is known, the stud members 50 are positioned horizontally adjacent to one another along a length X to establish the pre-existing wall 46. The stud members 50 extend vertically to a desired height Z of the wall system 48.

The ledger clips 52 extend horizontally across the stud members 50 to form a wall frame including a plurality of rows 54A-54n. The wall system 48 may include any number of rows 54. The example ledger clips 52 are manufactured in strips of approximately 10 to 12 feet in length, in one example. However, the ledger clips 52 may be manufactured to any specification. In one example, the stud members 50 are spaced apart a distance of approximately 16 inches and each ledger clip 52 is spaced apart a distance of approximately 8 inches. It should be understood that the spacing and other dimensional relationships that exist between the stud members 50 and the ledger clips 52 may vary to provide a block veneer wall system 48 of any size.

FIG. 6 illustrates a portion of the bracket assembly 51 of the block veneer wall system 48 that includes a ledger clip 52 attached to a stud member 50. In one example, the ledger clip 52 is attached to the stud member 50 with a threaded fastener 56. However, other attachment methods are contemplated as within the scope of this disclosure.

Each ledger clip 52 generally includes a Z-shaped body having a top face 58 and leg members 60, 62 extending transversely from the top face 58. The leg members 60, 62 extend away from the top face 58 in opposite directions relative to the top face 58. The leg member 60 is received against the stud member 50 and is attached to the stud member 50 with the threaded fastener 56, for example. The leg member 62 extends in a downward direction relative to the top face 58 and receives a slot 38 of the block member 12 to support the block member 12 on the block veneer wall system 48. Therefore, the block veneer wall system 48 establishes a wall framework independent of the block members 12. That is, placement of the block members 12 is dictated by the ledger clips 52.

The leg member 62 of each ledger clip 52 includes a flange portion 63. The flange portions 63 push the leg member 62 against a back wall 61 of the horizontal portion 40 of the slot 38 (See FIG. 7) to reduce the amount of “slop” in the wall. That is, the flange portions 63 secure the block members 12 to the ledger clips 52.

In one example, the top face 58 of each ledger clip 52 includes a plurality of teeth 64. The teeth 64 grip a bottom surface of a block member 12 from a vertically adjacent row 54 of the block veneer wall system 48 (see FIG. 7). The top face 58 also includes a plurality of openings 66 for receiving a vertical bar (see FIG. 8) installed between horizontally adjacent block members 12 once positioned onto the block veneer wall system 48. The example ledger clip 52 includes a second set of openings 68 provided on the leg members 62. The openings 68 receive shims to adequately secure the block members 12 to the ledger clips 52 and ensure that the top face 58 is level relative to the ground as the block members 12 are received onto the leg member 62 of the ledger clip 52.

FIG. 9, with continuing reference to FIGS. 1-8, illustrates an example method 100 of constructing a wall system, such as the block veneer wall system 48, for example. At step block 102, the ledger clips 52 are horizontally positioned across the stud members 50 of a pre-existing wall 46 to establish a wall frame including a plurality of rows 54. In one example, wood sheathing, such as plywood for example, is installed over top of the existing stud members 50. In another example, building wrap may be installed to cover the wood sheathing and provide a moisture barrier.

At step block 104, a block member 12 is positioned on the block veneer wall system 48. The top face 41 of the block member 12 is tilted toward the ledger clip 52 and pushed upward such that the horizontal portion 40 of the slot 38 of the block member 12 is received by the lower leg member 62 of the ledger clip 52. The bottom of the block member 12 is next pushed in an inward direction (i.e., toward the stud members 50) until the inner face 20 of the block member 12 rests against the upper leg member 60 of the ledger clip 52 (except for block members 12 of the first row 54A). The block member 12 is then eased slightly downward until a bottom face of the block member 12 is seated on the top face 58 of the ledger clip 52 (or a starting strip where installing the block members 12 of the first row 54A).

Next, at step block 106, an adhesive is applied to the top face 58 of a lowest exposed ledger clip 52 along the portion of the block member 12 which rests against the top face 58. That is, the adhesive is applied to the ledger clip 52 of the first row 54A of the block veneer wall system 48. Any known adhesive may be utilized at this step.

Shims may be inserted into the openings 68 of the bottom leg member 62 to improve the attachment of the block member 12 to the ledger clip 52 and to ensure that the block member 12 is level relative to the ground at step block 108. At step block 110, an additional block member 12 is positioned horizontally adjacent to the block member 12 positioned at step blocks 102 through 108.

At step block 112, and after the block members 12 are positioned side by side, the vertical bar 70 (FIG. 8) is installed downwardly through openings 66 of the ledger clips 52 to maintain the positioning of the adjacent block members 12. The vertical bars 70 are at least partially received within the vertical portions 42 of the slots 38 of the block members 12 (See FIG. 10). Next, at step block 114, step blocks 102 through 112 are repeated to construct the block veneer wall system 48 having a desired width and height. Finally, at step block 116, mortar is applied to each of a plurality of horizontal joints 72 (See FIG. 7) and vertical joints 74 (See FIG. 10) between the block members 12 after a desired number of block member 12 are attached to the ledger clips 52.

FIGS. 11-15 illustrate portions of another example wall system 148. In this example, the wall system 148 is similar to the wall system 48 described in FIGS. 5-10. In this disclosure, like reference numerals designate like elements where appropriate, and reference numerals with the addition of 100 or multiples thereof designate modified elements. It is to be understood that the modified elements incorporate the same features and advantages of the corresponding original elements, except where stated otherwise.

FIG. 11 illustrates a portion of a bracket assembly 151 of the wall system 148 that includes a bracket member 152 attached to a stud member 150 (no block members shown in FIG. 11 for clarity). The bracket assembly 151 establishes a self-supporting wall frame. That is, the bracket assembly 151 can be erected without the assistance of any other existing surface, and the integrity of the wall system 148 is not dependent on other wall systems.

In this example, the bracket member 152 is a ledger clip. Each stud member 150 includes a generally U-shaped body having a face portion 80 and flanges 82, 84 that extend transversely from the face portion 80 at opposite sides 90, 92 of the stud member 150. In the illustrated example, the flanges 82, 84 extend in the same direction away from the face portion 80.

The flanges 82, 84 of each stud member 150 also optionally include a plurality of openings 86. In one example, the openings 86 are punctures that are formed through the flanges 82, 84. Other known methods for forming the openings 86 are known and would be recognized by those of ordinary skill in the art having the benefit of this disclosure.

An adhesive 94 is optionally applied between the stud members 150 and the block members 12. In one example, the adhesive 94 is applied to each flange 82, 84 of the stud members 150 prior to affixing the block members to the bracket assembly 151. The adhesive 94 may also be also applied to portions of the top face 58 and the leg members 60, 62 of the bracket members 152, for example. A worker of ordinary skill in the art would be able to select an appropriate adhesive to bond the block members and the stud members 150 relative to one another.

The bracket member 152 optionally includes a plurality of teeth 64 disposed on the top face 58 and a plurality of punched holes 57 formed on the leg 62. The teeth 64 grip a bottom surface of a block member from a vertically adjacent row of the wall system 148. The punched holes 57 provide a surface for the mortar to adhere to during application of the mortar to the mortar joints 172, 174 (See FIGS. 13, 14) of the wall system 148.

FIGS. 12A-12C illustrate an example block member 112 for use within the wall system 148. The block member 12 includes a length L1. The block member 112 may be manufactured to the specifications of any desired length. The length L1 extends between opposing end faces 134, 136. An outer face 118 and an inner face 120 are disposed on opposite sides of the opposing end faces 134, 136. A top face 141 extends between the outer face 118 and the inner face 120. The opposing end faces 134, 136 include finished surfaces which are free from any indentations, protrusions, slots or other formations.

The outer face 118 defines a first height H1. The inner face 120 defines a second height H2. In this example, the second height H2 is greater than H1. Therefore, a ledge 119 of the top face 141 extends between the outer face 118 and the inner face 120. The ledge 119 extends transversely from the outer face 118 in a direction toward the inner face 120, and includes a height that is substantially equal to the first height H1 of the outer face 118. In this example, the ledge 119 extends between the outer face 118 and an inner surface 121 of the inner face 120. The inner surface 121 of the inner face 120 extends in a direction toward the outer face 118. A portion of the bracket assembly 151 is received against the top face 141, and in one example, directly against the ledge 119, as is further discussed below.

The inner face 120 of the block member 112 includes a plurality of protrusions 123 that protrude from the inner face 120 in a direction away from the outer face 118. A plurality of indentations 125 are disposed between adjacent protrusions 123. The actual number of protrusions 123 and indentations 125 included on the block member 112 will vary depending upon design specific parameters, including but not limited to, the size of the block member 112.

FIG. 12C illustrates two block members 112 connected via connector 127, such as when the block members 112 are molded during a manufacturing molding process. The connector 127 maintains the positioning of the two block members 112 relative to one another within the mold. The connector 127 is detachable at connection points 129 to separate the block members 112 from the connector 127 to prepare the block members 112 for use within the wall system 148.

FIG. 13 illustrates the bracket assembly 151 of the wall system 148 with supported block members 112. Although the wall system 148 is depicted as including block members 112, a person of ordinary skill in the art having the benefit of this disclosure would be able to configure any block member for use with the bracket assembly 151. That is, slight modifications of the block member 112 are contemplated as within the scope of this disclosure. In addition, although only depicted on one side of the bracket assembly 151, a person of ordinary skill in the art would understand that the block members 112 may be positioned on both sides of the stud members 150. FIG. 13 is not shown to the exact scale it would be in practice, and certain details are shown enlarged for clarity.

The bracket members 152 receive the block members 12 in a similar manner as described above with respect to the wall system 48. In addition, other details of the wall system 48 such as the use of shims, the application of mortar joints and the like are applicable to the example wall system 148 where necessary. Like the wall system 48, the wall system 148 establishes a wall framework independent of the block members 112, or any other existing surface of another wall system. That is, placement of the block members 112 is dictated by the bracket assembly 151.

For example, the bracket assembly 151 and the block members 112 are positioned horizontally across each stud member 150 of the wall system 148. The leg 60 of each bracket member 152 is secured relative to the stud members 150 via a fastener 56 to construct the bracket assembly 151. The block members 112 are received by the bracket members 152. The legs 62 of the bracket members 152 can contact the inner surface 121 of the inner face 120 of each block member 112, and the top face 58 of the bracket members 152 generally receives the bottom of the block members 112. In this way, the bracket members 152 maintain the positioning of the block members 112 until the mortar or other adhesive sets and the construction of the wall system 148 is completed. In one example, the legs 62 of the bracket members 152 act as a stop which prevents movement of the block members 112 in a direction D that is away from the stud members 150. Horizontal mortar joints 172 extend between vertically adjacent block members 112.

An additional aspect of the example wall system 148 is illustrated in FIG. 14. Vertical mortar joints 174 extend between horizontally adjacent block members 112. In addition, a backer sheet 75 is disposed between each horizontally adjacent block member 112. The backer sheets 75 reduce the amount of mortar required to fill the vertical mortar joints 174 and provide for moisture drainage. For example, water or other moisture may seep through the mortar joints 172, 174. The backer sheets 75 divert and communicate the moisture downwardly until the moisture can escape the wall system 148. The backer sheets 75 therefore reduce water penetration and moisture build-up within the wall system 148.

FIGS. 15A and 15B illustrate an example backer sheet 75 for use within the wall system 148. The backer sheet 75 is manufactured from a non-corrosive material. In one example, the backer sheet 75 is plastic. The backer sheet 75 includes slots 77 for receiving the legs 62 of the bracket members 152 (See FIG. 15A and FIG. 13 (shown in phantom). The backer sheets 75 can also include a plurality of vertical ribs 81 disposed on an outer surface 83 of the backer sheet 75 to divert and communicate moisture downwardly. The backer sheet 75 is generally flexible such that the backer sheet 75 can be manipulated (such as shown in FIG. 15A) and positioned between adjacent block members 112. When folded, the vertical ribs 81 of the backer sheets 75 face in a direction away from an interior 85 of the backer sheets 75.

The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would recognize that certain modifications would come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.

Claims

1. A wall system, comprising: a bracket assembly which establishes a self-supporting wall frame; andat least one block member supported on said self-supporting wall frame and having an outer face, an inner face, and a top face extending between said outer face and said inner face, wherein said top face locates said at least one block member on said self-supporting wall frame.

2. The wall system as recited in claim 1, wherein said bracket assembly includes a wall component and a plurality of ledger clips attached to said wall component, wherein said plurality of ledger clips extend horizontally across said wall component to establish a plurality of rows of said self-supporting wall frame.

3. The wall system as recited in claim 2, wherein said ledger clips comprise a z-shape, said ledger clips including at least one leg member that is received directly against said top face of said at least one block member to position said at least one block member to said self-supporting wall frame.

4. The wall system as recited in claim 1, comprising a plurality of block members and wherein said bracket assembly includes a plurality of vertical bars positioned between horizontally adjacent block members of said plurality of block members.

5. The wall system as recited in claim 1, comprising a plurality of block members and wherein said bracket assembly includes a plurality of backer sheets positioned between horizontally adjacent block members of said plurality of block members.

6. The wall system as recited in claim 1, wherein said plurality of backer sheets are non-corrosive.

7. The wall system as recited in claim 1, wherein said top face includes a ledge that locates said at least one block member on said self-supporting wall frame.

8. The wall system as recited in claim 7, wherein said ledge extends between said outer face and an inner surface of said inner face.

9. The wall system as recited in claim 7, wherein said ledge extends transverse from said outer face in a direction toward said inner face, wherein at least a portion of said bracket assembly is in direct contact with said at least one block member.

10. The wall system as recited in claim 1, wherein said self-supporting wall frame establishes said wall system independently of any existing surface.

11. A method of constructing a wall system, comprising the steps of: (a) positioning stud members at a desired spacing;(b) attaching bracket members to the stud members to establish a self-supporting wall frame independently of any existing surface; and(c) supporting block members on the self-supporting wall frame to construct the wall system.

12. The method as recited in claim 11, comprising the step of: (d) positioning non-corrosive backer sheets between horizontally adjacent block members.

13. The method as recited in claim 12, comprising the step of: (e) applying mortar in each of a plurality of horizontal joints and vertical joints that extend between the block members.

14. The method as recited in claim 12, comprising the step of: (e) communicating moisture vertically downward relative to the wall system via the non-corrosive backer sheets.

15. A block member for a wall system, comprising: an outer face extending between opposing end faces and establishing a first height;an inner face extending between said opposing end faces on an opposite side from said outer face, wherein said inner face establishes a second height that is greater than said first height; anda top face extending between said outer face and said inner face and including a ledge at least partially coextensive with said outer face and extending between said outer face and said inner face.

16. The block member as recited in claim 15, wherein said inner face includes a plurality of protrusions extending from said inner face in a direction away from said outer face.

17. The block member as recited in claim 16, wherein a plurality of indentations extend between said plurality of protrusions of said inner face.

18. The block member as recited in claim 15, wherein said ledge extends between said outer face and an inner surface of said inner face, and said ledge defines a height that is less than said second height of said inner face.

19. The block member as recited in claim 18, wherein said inner surface extends from said inner face in a direction toward said outer face.

20. The block member as recited in claim 15, wherein said ledge extends transversely from said outer face in a direction toward said inner face.