Note: Descriptions are shown in the official language in which they were submitted.
2~903~7
~ The present invention relates to setback type blocks for use in
the construction of a mortarless retaining wall wherein a
plurality of blocks are stacked in rows or courses. The
present invention in particular relates to blocks having block
bodies comprising relatively planar top and bottom surfaces.
The present invention also relates to slabs which are cast on
their sides and which can be broken into a number of blocks
having different shapes and which may be used for the
construction of retaining walls using the (known) rear setback
technique.
It is known to use a capping or crown block having a relatively
flat or planar top surface for the final layer of blocks of a
retaining wall. It is in particular known to make a retaining
wall from molded (concrete) blocks wherein the blocks are
weighted and shaped so as to be stackable in setback fashion so
as to angle the wall to counter the pressure of landfill behind
the wall. It is, for example, known to provide blocks having
opposed planar support surfaces with a block interlock
member(s) for interlocking and setting back successive courses
of blocks; the interlock member may for example comprise a
flange disposed along the rear and bottom of a retaining wall
block; see, for example, U.S. patents nos. 2,313,363 and
5,017,049 Although it is also known to provide flat
topped\bottomed retaining wall blocks for the body of a wall,
2~303~7
such blocks are shaped or configured such that a flat
topped\bottomed capping or crown block may be used as the last
uppermost block layer only in a set back relation with respect
to the underlying block.
Known types of blocks for retaining walls commonly present a
squarish or rectangular aspect such that when used to prepare
convexly curved retaining walls the product wall is pockmarked
or interrupted by cavities between adjacent blocks. In order
to convexly curve the outer wall surface, adjacent rectangular
blocks must be disposed such that the side surfaces adjacent
the front surface are spaced apart although they may abut at
their rear corner edges, i.e. the joint between adjacent blocks
is open. Such cavities are not always desired by the owner of
the wall; the owner may prefer a more or less uniform
uninterrupted wall surface.
It is also known to cast a series of blocks on their sides so
as to facilitate the clean definition of interlocking elements
for a setback type block for a retaining wall; see U.S. patent
no. 5017,049 mentioned above.
At present the user of retaining wall blocks must predetermine
the number and types of blocks needed to make a retaining wall
of given length and height (e.g. of a given number of block
layers). Since the calculations with respect to the number of
2~03~7
blocks may be relatively complicated for a do-it-yourself type
of person, it is not uncommon for such person to either
underestimate or overestimate the number of blocks needed for a
retaining wall of given number of block courses; in the first
case the person is inconvenienced by having to obtain
additional blocks and in the second case by having leftover
blocks for which the person may have no use.
Accordingly, it would be advantageous to have a block
construction or configuration which would facilitate the
preparation of retaining walls having convex as well as concave
curved exposed (i.e. outer) surfaces which present a relatively
uninterrupted continuous surface, i.e. the joint between
adjacent blocks is closed so that an exposed wall surface is
not pockmarked with cavities and presents a relatively
aesthetically pleasing surface.
It would also be advantageous to have blocks for use in the
construction of a mortarless retaining wall wherein the blocks
useful as capping blocks may optionally be used in the body of
the wall as well as for the top covering block layer, i.e.
multi-purpose capping blocks.
It would be advantageous to have block configurations or forms
which would allow a capping block to be offset forwardly or
rearwardly as desired by a wall builder.
2091~8~
It would further be advantageous to have a wall making system
or kit which would exploit a few interchangeable block forms.
It would also be advantageous to have a kit of blocks which may
be structured such that within a given set of parameters the
user is able to exploit all of the blocks to make a retaining
wall.
It would be advantageous to have block configurations which
would facilitate the production or casting of a plurality of
blocks as a set of blocks which, within predetermined set of
parameters, may all be used without any block being leftover.
STATEMENT OF INVENTION
The present invention generally relates to a grooved block for
use in the construction of a mortarless retaining wall wherein
a plurality of blocks are stacked in rows. The grooved block
is provided with an intermediate groove able to engage (e.g.
angularly receive) a block interlock member of another block
for interlocking and offsetting forwardly, if desired, the
other block a predetermined distance with respect to the
underlying block.
Thus, in accordance with an aspect, the present invention thus
provides a grooved block, for use in the construction of a
~903~7
mortarless retaining wall wherein a plurality of blocks are
stacked in successive offset courses,
the grooved block comprising
a block body,
and
a block interlock member,
the block body having
relatively planar top and bottom support surfaces, the top
and bottom surfaces being generally parallel to each
other,
a front surface,
a rear surface, and
two side surfaces,
the block interlock member extending from the planar bottom
surface adjacent the rear surface,
the block interlock member and the block body being configured
such that when the grooved block is disposed on an underlying
retaining wall block having a the block body, the interlock
member is able to engage the rear surface of the underlying
block for offsetting the grooved block rearwardly a
predetermined distance with respect to the underlying block,
the grooved block being characterized in that
the block body has a groove interrupting the planar top surface
adjacent the rear surface,
and
the groove is sized such that when an overlying retaining wall
209D387
block, having a the block body and a the block interlock
member, is disposed on the grooved block, the groove is able to
engage the interlock member of the overlying block for
offsetting the overlying block forwardly a predetermined
distance with respect to the grooved block.
In accordance with the present invention the groove may consist
of a (single) groove which may, for example, extend from one
respective side surface of the block body to the other
respective side surface thereof;
and
the interlock member may consist of a (single) flange disposed
at the rear and bottom of a block, the flange, for example,
extending from one side surface to the other; the interlock
member may of course, if desired, comprise a flange member
comprising a plurality of spaced flange elements rather than a
single continuous flange body.
In accordance with a particular aspect of the present
invention, the groove may, for facilitating the formation of a
curved wall (segment), be sized so as to be able to receive a
flange transversely with respect to the longitudinal axis of
the groove, i.e. the width of a groove may be larger than the
thickness of the flanges such that the flange may be angularly
disposed in the groove (as shall be discussed below).
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The grooved block may, desirably, have a generally tapered
configuration wherein the front and rear surfaces thereof are
generally parallel to each other, the front surface being
larger than the rear surface, ie. to facilitate the
construction of a convex curved wall (segment).
In accordance with a particular aspect of the present
invention, the grooved block may, for example, have a generally
trapezoidal configuration wherein the front and rear surfaces
thereof are generally parallel to each other, one side surface
defines a right angle with the front and rear surfaces thereof,
the other side surface defining a generally acute angle with
the front surface thereof.
A block may if desired be a right hand block or a left hand
block.
In accordance with the present invention, the expressions
"right hand block" and "left hand block" are to be understood
herein as characterizing the configuration of one block as
being the mirror image of the configuration of another block
such that one block cannot be superimposed on the other
notwithstanding their similarity in shape. In accordance with
the present invention a trapezoidally configured block may, for
example, be a right hand block or a left hand block. The
expression "right hand block" as applied to a trapezoidally
2090387
configured block is thus to be understood as characterizing the
block as having a configuration or shape such that when viewed
in perspective from the front toward the front and top surfaces
thereof, the acute angle is on the right side of the block;
similarly, the expression "left hand block" as applied to a
trapezoidally configured block is thus to be understood as
characterizing the block as having a configuration or shape
such that when viewed in perspective from the front toward the
front and top surfaces thereof, the acute angle is on the left
side of the block.
The rear surface of the grooved block may be uninterrupted from
top to bottom surface. However, if desired, the grooved block
may include a rear notch connecting the top and rear surfaces,
i.e. a portion of the rear surface adjacent to the top surface
may be offset toward the front of the block. The notch may be
separated from the groove in the top surface by a projection;
the top of the projection defining the portion of the top
surface adjacent to the rear surface. The notch may extend
from one side surface to the other side surface of the grooved
block. The offset rear surface of the notch may be used for
engagement with the interlock member of an overlying block so
as to offset the overlying block rearwardly with respect the
underlying block.
A grooved block of the present invention may be advantageously
20~0387
used in the body of a retaining wall so as to optionally
provide for offsetting of an overlying (crown) block forwardly
or rearwardly as desired by the wall builder. The grooved
block may in particular be used for the supporting course of
blocks on which a capping or crown course of blocks may rest in
either rearward or forward offset position relative to the
supporting course of blocks; the capping block(s) having
generally uninterrupted planar top surface(s) e.g. generally
flat top surfaces.
Thus in accordance with another aspect the present invention
provides, in a method for the construction of a mortarless
retaining wall wherein a plurality of blocks are laid down one
over the other so as to define a plurality of successive offset
courses of blocks, the wall including an upper crown course of
blocks resting on an underlying lower course of blocks, the
upper crown course and the underlying lower course of blocks
each comprising a plurality of retaining wall blocks, each the
retaining wall block comprising
a block body,
and
a block interlock member,
the block body having
relatively planar top and bottom support surfaces, the top
and bottom surfaces being generally parallel to each
other,
203~387
a front surface,
a rear surface, and
two side surfaces,
the block interlock member extending from the planar bottom
surface adjacent the rear surface,
the block interlock member and the block body of a retaining
wall block being configured such that when the retaining wall
block is disposed on an underlying block having a the block
body, the interlock member of the retaining wall block is able
to engage the rear surface of the underlying block for
offsetting the retaining wall block rearwardly a predetermined
distance with respect to the underlying block,
the improvement
wherein the blocks of the underlying lower course of blocks are
configured relative to the blocks of the crown course so that
blocks of the crown course may be offset forwardly or
rearwardly relative to blocks of the lower course of blocks,
wherein the lower course of blocks comprises a plurality of
grooved retaining wall blocks,
wherein the block body of each grooved retaining wall block has
a groove interrupting the planar top surface adjacent the rear
surface, (- the groove, for example, consisting of a groove
which extends from one side surface of the block body to the
other side surface thereof),
and
wherein the groove of a grooved retaining wall block is sized
2030~87
such that when an overlying block, of the crown course of
blocks, is disposed on the grooved retaining wall block, the
groove thereof is able to engage the interlock member of the
overlying block for setting the overlying block forward a
predetermined distance with respect to the grooved retaining
wall block. The grooved block may take on the forms such as
described herein.
In order to facilitate the construction of a retaining wall
(segment) the present invention also relates to wall kits.
Thus, the present invention in accordance with another aspect
provides a kit for use in the construction of a mortarless
retaining wall wherein a plurality of blocks are stacked in a
predetermined number of successive offset courses of blocks,
the wall, over its length, being relatively straight or having
a relatively straight portion and a relatively curved portion
and the wall including an upper crown course of blocks resting
on an underlying lower course of blocks,
the kit being characterized in that
the kit comprises
a plurality of grooved blocks
and
a plurality of other blocks
5 each of the blocks comprising
a block body,
2~03~7
and
a block interlock member,
the block body having
relatively planar top and bottom support surfaces, the top
and bottom surfaces being generally parallel to each
other,
a front surface,
a rear surface, and
two side surfaces,
the block interlock member extending from the bottom surface
adjacent the rear surface,
the block interlock member and the block body of a the block
being configured such that when a the block is disposed on an
underlying the block, the interlock member thereof is able to
engage the rear surface of the underlying block for offsetting
the block rearwardly a predetermined distance with respect to
the underlying block,
each of the grooved blocks having a groove for receiving a the
block interlock member,
a the groove of a grooved block
interrupting the top surface adjacent the rear surface
thereof, (e.g. the groove may for example consist of a
groove extending from one side surface to the other side
surface thereof), and
2090387
being sized such that a block interlock member of a the
other block is engageable therein for interlocking
therewith,
and
the grooved and other blocks each being configured such that
when a grooved block underlies an overlying other block, the
block interlock member of the overlying other block is
engageable in the groove of the underlying grooved block and
the front surface of the overlying other block is able to be
offset forwardly relative to the front surface of the
underlying grooved block,
the number of the grooved and other blocks in the kit
being such that the crown course of blocks is able to
consist of the other blocks and the immediately underlying
lS lower course of blocks is able to consist of the grooved
blocks.
The grooved blocks of the kit may take on the various forms or
formats such as for example described herein. The other block
may, for example, take on a rectangular configuration or
alternatively, take on the same configuration as the grooved
blocks except for the groove; these latter blocks may be used
in the body of a retaining wall or as a crown block for the
crown course of blocks since the top surface thereof is
relatively planar.
14
2~387
A kit in accordance the present invention may, for example,
comprise
a plurality of first right hand (grooved) blocks
a plurality of second left hand (grooved) blocks
a plurality of third right hand other blocks
and
a plurality of fourth left hand other blocks
each of the blocks comprising the herein described block body
and block interlock member and the first, second, third and
fourth blocks each having the herein mentioned generally
trapezoidal configuration. The configuration of the first
block may for example in particular be a mirror image of the
configuration of the second block; similarly, the configuration
of the third block may be a mirror image of the configuration
of the fourth block.
If it is desired that a wall have a curved longitudinally
extending aspect it is advantageous that the groove of the
grooved blocks be sized (i.e. the width) so as to allow the
interlock member, such as a (straight) flange, to be received
or engaged therein more or less parallel to the longitudinal
length of the groove and optionally also transversely to the
longitudinal axis of the groove. An angular engagement will
allow an overlying block to overlap the junction between two
adjacent underlying blocks such that the flange may be disposed
in a portion of both of the underlying blocks.
20903S7
A kit in accordance with the present invention may, for
example, comprise a plurality of slabs which are splittable
into the blocks described herein. The slabs may be splittable
into any suitable pairs of blocks, i.e. a slab may comprise any
suitable combination of two blocks as described herein.
In accordance with a particular aspect of the present
invention, a kit may be characterized in that it comprises
a plurality of first slabs
a plurality of second slabs
and
a plurality of third slabs
each of the slabs having cleavage groove means for allowing
breakage of each slab into two separate blocks, the front face
of each separate block being exposable on breakage of the
corresponding slab into two separate blocks,
each of the first slabs is breakable along the cleavage groove
means thereof into a the first block and a the second block,
each of the second slabs is breakable along the cleavage groove
means thereof into a the a first block and a the fourth block,
each of the third slabs is breakable along the cleavage groove
means thereof into a the a second block and a the third block,
and
each of the slabs is configured such that prior to breakage
thereof into the respective separate blocks, the side surface
16
20~0387
of one respective block which defines a right angle with the
front surface thereof and the side surface of the other
respective block which defines a right angle with the front
surface thereof are generally disposed in the same plane.
As previously mentioned, each of the above mentioned slabs has
cleavage groove means for allowing breakage of each slab into
two separate blocks. The cleavage means may take any (known)
form. The cleavage means may for example comprise opposed
splitting grooves in the top and bottom surface of a slab;
similar opposed cleavage grooves may also if desired be
disposed on opposed side surfaces such that the splitting
grooves ring the slab. The various slabs referred to herein may
be split in any (known) manner which provides the desired front
surface; i.e. by machines or other methods known in the art.
As mentioned one type of retaining wall block which may be used
in conjunction with the grooved block of the present invention
is a wall block having a rectangular configuration; this type
of wall block may be used in generally straight sections of
wall either as a crown or wall body element; a straight wall
(section) may also include tapered blocks as herein described.
A curved (segment of a) wall associated with straight wall
(segment) is preferably constructed only of tapered blocks as
described herein the grooves being sufficiently wide so as to
allow angular engagement of the interlock member as herein
described. 2 0 9 ~ 3 8~
Thus, in accordance with another particular aspect the present
invention provides a kit for use in the construction of a
mortarless retaining wall wherein a plurality of blocks are
stacked in a predetermined number of successive offset courses
of blocks (for example three such courses), the wall, over its
length, being relatively straight or having a relatively
straight portion and a relatively curved portion and the wall
including an upper crown course of blocks resting on an
underlying lower course of blocks,
the kit being characterized in that
the kit comprises
a plurality of grooved blocks
a plurality of other blocks
and
a plurality of rectangular blocks
each of the blocks comprising
a block body,
and
a block interlock member,
the block body having
relatively planar top and bottom support surfaces, the top
and bottom surfaces being generally parallel to each
other,
a front surface,
209û3~7
a rear surface, and
two side surfaces,
the block interlock member extending from the planar bottom
surface adjacent the rear surface,
the block interlock member and the block body of a the block
being configured such that when the block is disposed on an
underlying the block, the interlock member thereof is able to
engage the rear surface of the underlying block for offsetting
the block rearwardly a predetermined distance with respect to
the underlying block,
each of the grooved and other blocks having a generally
trapezoidal configuration wherein the front and rear surfaces
thereof are generally parallel to each other, one side surface
defines a right angle with the respective front and rear
surfaces thereof, and the other side surface defines a
generally acute angle with the respective front surface
thereof,
each of the rectangular blocks having a generally rectangular
configuration wherein the front and rear surfaces thereof are
generally parallel to each other, the two side surfaces thereof
are generally parallel to each other, and each of the side
surfaces define a generally right angle with the front and rear
surfaces thereof,
19
209~3B7
each of the grooved blocks having a groove for receiving a the
block interlock member,
a the groove of a grooved block ~
interrupting the planar top surface adjacent the rear
surface thereof, (the groove may, for example, consist of
a groove extending from one side surface to the other side
surface thereof),
and
being sized such that a block interlock member of a the
other block or rectangular block may be engaged therein
for interlocking therewith,
and
the grooved, other and rectangular blocks being configured such
that when a grooved block underlies an overlying other or
rectangular block, the block interlock member of the overlying
other or rectangular block is engageable in the groove of the
underlying grooved block and the front surface of the overlying
other or rectangular block is able to be offset forwardly
relative to the front surface of an underlying grooved block,
the number of the grooved, other and rectangular blocks in
the kit being such that the immediately underlying lower
course of blocks is able to consist of the grooved blocks
and the crown course of blocks is able to consist of
blocks selected from the other blocks and the rectangular
blocks provided that the crown course of blocks of the
2090~87
curved portion of the wall is able to consist of the other
blocks,
and
the number of the grooved and other blocks in the kit
being such that all of the courses of blocks below the
crown course of blocks of the curved portion of the wall
are able to consist of blocks selected from the grooved
and other blocks.
If desired the number of the grooved, other and rectangular
blocks in the kit may be such that the crown course of blocks
for a straight wall or straight portion thereof is able to
consist of rectangular blocks and the crown course of blocks of
a curved portion of the wall is able to consist of the other
blocks.
A kit of the present invention may, in particular, be
configured for use in the construction of a retaining wall
comprising 3 courses of bricks or more, e.g. 6, 9, and higher.
In accordance with the present invention the above mentioned
tapered grooved, tapered other and rectangular blocks may be
present in a kit in a proportion of 4:2:3 respectively; the
proportion of various blocks gives the user of the kit the
flexibility of making a straight flat capped (crowned) wall or
a wall having a flat capped straight portion and a flat capped
curved portion. The curved part of a wall may for example make
21
2090387
up about 50% of the longitudinal length of the wall in the case
wherein the kit is configured to make a wall of three courses
and has at least 18 rectangular blocks.
As previously indicated a block may take on a right or left
hand configuration. Thus in accordance with another particular
aspect, the present invention provides a kit for use in the
construction of a mortarless retaining wall wherein a plurality
of blocks are stacked in a predetermined number of successive
offset courses of blocks, the wall, over its length, being
relatively straight or having a relatively straight portion and
a relatively curved portion and the wall including an upper
crown course of blocks resting on an underlying lower course of
blocks,
the kit being characterized in that
the kit comprises
a plurality of first right hand blocks
a plurality of second left hand blocks
a plurality of third right hand blocks
a plurality of fourth left hand blocks
and
a plurality of fifth blocks,
each of the blocks comprising
a block body,
and
a block interlock member,
209038~
the block body having
relatively planar top and bottom support surfaces, the top
and bottom surfaces being generally parallel to each
other,
a front surface,
a rear surface, and
two side surfaces,
the block interlock member extending from the planar bottom
surface adjacent the rear surface,
the block interlock member and the block body of a the block
being configured such that when the block is disposed on an
underlying the block, the interlock member thereof is able to
engage the rear surface of the underlying block for offsetting
the block rearwardly a predetermined distance with respect to
the underlying block,
each of the first, second, third and fourth blocks having a
generally trapezoidal configuration wherein the front and rear
surfaces thereof are generally parallel to each other, one side
surface defines a right angle with the front and rear surfaces
thereof and the other side surface defines a generally acute
angle with the front surface thereof,
the configuration of the first block being a mirror image of
the configuration of the second block,
2090~87
the configuration of the third block being a mirror image of
the configuration of the fourth block,
each of the fifth blocks having a generally rectangular
S configuration wherein the front and rear surfaces thereof are
generally parallel to each other, the two side surfaces thereof
are generally parallel to each other, and each of the side
surfaces define a generally right angle with the front and rear
surfaces thereof,
each of the first and second blocks having a groove for
receiving a the block interlock member,
a the groove of a first or second block
interrupting the planar top surface of a respective block
adjacent the rear surface thereof, (for example, the
groove may consist of a groove extending from one
respective side surface to the other respective side
surface thereof), and
being sized such that a the block interlock member of the
third, fourth or fifth blocks is engageable therein for
interlocking therewith,
and
the first, second, third and fourth blocks being configured
such that when a first or second block underlies an overlying
third, fourth or fifth block, the block interlock member of the
24
209D~8~
overlying third, fourth or fifth block is engageable in a the
groove of the underlying first or second block and the front
surface of the overlying third, fourth or fifth block is able
to be offset forwardly relative to the front surface of an
underlying first or second block
the number of the first, second, third, fourth and fifth
blocks in the kit being such that the underlying lower
course of blocks is able to consist of blocks selected
from the first and second blocks and the crown course of
blocks is able to consist of blocks selected from the
third, fourth and fifth blocks provided that the crown
course of blocks of a curved portion of a wall is able to
consist of blocks selected from the third or fourth
blocks,
15 and
the number of the first, second, third and fourth blocks
in the kit being such that all of the courses of blocks
below the crown course of blocks of a curved portion of
the wall are able to consist of blocks selected from the
first, second, third and fourth blocks.
If desired, the number of the first, second, third, fourth and
fifth blocks in a kit may be such that the crown course of
blocks for a straight wall or straight portion thereof is able
to consist of the fifth blocks and the crown course of blocks
for a curved portion of a wall is able to consist of blocks
20so387
selected from the third and fourth blocks.
As mentioned above a kit of the present invention may, in
particular, be configured to have various proportions of
various blocks so as to give the user of the kit the
flexibility of making a straight capped wall or a wall having a
flat capped straight portion and a flat capped curved portion.
For example, if the retaining wall is to have 3 courses of
bricks, the above mentioned first, second, third fourth and
fifth blocks, may be present in a kit in a proportion of
2:2:1:1:3 respectively such that the curved part of a wall may
for example make up about 50% of the longitudinal length of the
wall in the case wherein the kit has at least 18 rectangular
blocks. On the other hand if the above mentioned first,
second, third fourth and fifth blocks, are present in a kit in
a proportion of 5:5:2:2:4 respectively the curved part of a
wall may for example make up about 2/3 of the longitudinal
length of the wall in the case wherein the kit has at least 12
rectangular blocks.
In accordance with an additional particular aspect of the
present invention, a kit may be characterized in that it may
comprise
a plurality of first slabs
a plurality of fourth slabs
a plurality of fifth slabs
26
2~03~7
a plurality of sixth slabs
and
a plurality of seventh slabs,
each of the slabs having cleavage groove means for allowing
breakage of each slab into two separate blocks,
each of the first slabs is breakable along the cleavage groove
means thereof into a the first block and a the second block,
each of the fourth slabs is breakable along the cleavage groove
means thereof into a the a first block and a the fifth
block,
each of the fifth slabs is breakable along the cleavage groove
means thereof into a the a second block and a the fifth block,
each of the sixth slabs is breakable along the cleavage groove
means thereof into a the a third block and a the fifth block
each of the seventh slabs is breakable along the cleavage
groove means thereof into a the a fourth block and a the fifth
block,
(preferably, for example, each of the slabs is configured such
that prior to breakage thereof into the respective separate
blocks, a side surface of one respective block defining a right
angle with the front surface thereof and a side surface of the
other respective block defining a right angle with the front
surface thereof are generally disposed in the same plane)
and
209~387
the front face of each separate block is exposable on breakage
of the corresponding slab into two separate blocks.
In accordance with another particular aspect the present
invention provides, a kit for use in the construction of a
mortarless retaining wall wherein a plurality of blocks are
stacked in a predetermined number of successive offset courses
of blocks, the wall, over its length, being relatively straight
or having a relatively straight portion and a relatively curved
portion and the wall including an upper crown course of blocks
resting on an underlying lower course of blocks,
the kit being characterized in that
the kit comprises
one or more slabs D
a plurality of slabs E
a plurality of slabs F
and
a plurality of slabs G,
the slabs D, E, F, and G being present in the kit in a
proportion of 1:4:3:2 respectively,
slab D having first and second cleavage groove means for
allowing breakage of slab D into a separate block K, a separate
block Km and a separate block L, a front face of each separate
block K and Km being exposable on breakage of the slab along
the first cleavage groove means to separate the block K
therefrom, a rear face of the block Km and a front face of the
28
20~0387
block L being exposable on breakage of the slab along the
second cleavage groove means to separate the block L therefrom,
slab E having first and second cleavage groove means for
allowing breakage of slab E into a separate block K, a separate
block L and a separate block M, the slab E including a third
cleavage groove means disposed between the first and second
cleavage groove means for allowing breakage of slab E into a
separate block N and a separate block O, a front face of each
of the blocks K and M being exposable on breakage of the slab
along the first cleavage groove means to separate the K block
therefrom, a rear face of the block M and a front face of the
block L being exposable on breakage of the slab along the
second cleavage groove means to separate the block L therefrom,
a front face of each separate block N and 0 being exposable on
breakage of the slab, along the third cleavage groove means,
into the separate blocks N and O,
slab F having first and second cleavage groove means for
allowing breakage of slab E into a separate block L, a separate
block M and a separate block P, the slab F including a third
cleavage groove means disposed between the first and second
cleavage groove means thereof for allowing breakage of slab F
into two separate blocks O and Q, a front face of each separate
block P and M being exposable on breakage of the slab along the
first cleavage groove means to separate the block P therefrom,
29
2~9~387
a rear face of the block M and a front face of the block L
being exposable on breakage of the slab along the second
cleavage groove means to separate the block L therefrom, a
front face of each separate block O and Q being exposable on
S breakage of the slab, along the third cleavage groove means,
into the separate blocks O and Q,
slab G having cleavage groove means for allowing breakage of
slab G into a separate block R and a separate block S, the
block R having another cleavage groove means disposed adjacent
a rear end thereof for allowing breakage thereof into a
separate block T and a block fragment, the block S having
another cleavage groove means disposed adjacent a rear end
thereof for allowing breakage thereof into a separate block U
and a block fragment, a front face of each separate block R and
S being exposable on breakage of the slab, along the cleavage
groove means, into the separate blocks R and S, a rear face of
each respective block T and U being exposable on breakage of a
respective block T and U along a respective other cleavage
groove means to separate a respective block fragment therefrom,
each of the separate blocks comprising
a block body,
and
a block interlock member,
the block body having
2090387
relatively planar top and bottom support surfaces, the top
and bottom surfaces being generally parallel to each
other,
a front surface,
a rear surface, and
two side surfaces,
the block interlock member extending from the planar bottom
surface adjacent the rear surface,
the block interlock member and the block body of a the block
being configured such that when the block is disposed on an
underlying the block, the interlock member thereof is able to
engage an abutment surface of the underlying block for
offsetting the block rearwardly a predetermined distance with
respect to the underlying block,
each of the blocks K, Km~ M and N having a generally
rectangular configuration wherein the front and rear surfaces
thereof are generally parallel to each other, the two side
surfaces thereof are generally parallel to each other, and each
of the side surfaces define a generally right angle with the
front and rear surfaces thereof, each block M comprising a
respective third cleavage groove means, each block N comprising
a respective first cleavage groove means,
each of the blocks R, S, T and U having a generally trapezoidal
configuration wherein the front and rear surfaces thereof are
- 2~80387
generally parallel to each other, one side surface defines a
generally right angle with the front and rear surfaces thereof
and the other side surface defines a generally acute angle with
the front surface thereof,
the block O comprising a respective second cleavage groove
means, the block Q comprising a respective first cleavage
groove means, the blocks O and Q each having a configuration
wherein the front and rear surfaces thereof are generally
parallel to each other, one side surface defines a generally
right angle with the front and rear surfaces thereof and the
other side surface comprises a first surface portion and a
second surface portion, the first surface portion extending
from a respective cleavage groove means to the front surface
such that the first surface portion and the cleavage groove
means define a generally acute angle, the second surface
portion extending from a respective cleavage groove means to
the rear surface generally parallel to the other side surface,
the configuration of block R being a mirror image of the
configuration of block S,
the configuration of block T being a mirror image of the
configuration of block U,
each of the blocks L, T and U having an offsetting groove for
32
2090387
receiving a said block interlock member,
a said offsetting groove of a block L, T and U
interrupting the planar top surface of a respective block
adjacent the rear surface thereof,
and
being sized such that a said block interlock member of a
block K, Km and P is engageable therein for interlocking
therewith,
and
the blocks L, T, U, K, Km and P being configured such that when
a block L, T, or U underlies an overlying block K, Km or P, the
block interlock member of the overlying block K, Km or P is
engageable in a said offsetting groove of the underlying block
L, T or U and the front surface of the overlying block K, Km or
P is able to be offset forwardly relative to the front surface
of an underlying block L, T or U.
As in the case of the previously described kits, the number of
blocks L, T, U, K, Km and P in the above kit is such that the
underlying lower course of blocks is able to consist of blocks
selected from the blocks L, T and U and the crown course of
blocks is able to consist of blocks selected from the blocks K,
Km and P provided that the crown course of blocks of a curved
portion of a wall is able to consist of blocks selected from
the blocks P; additionally, the number of the blocks L, T and U
2090~8~
in the kit is such that all of the courses of blocks below the
crown course of blocks of a curved portion of the wall are able
to consist of blocks selected from the blocks L, T and U.
S In accordance with the present invention, the acute angle of a
block may take any suitable or desired value and is chosen on
the basis of the desired minimum radius of curvature that a
course of blocks is intended to impart to a convexly curved
outer wall surface without pockmarks or cavities. The acute
angle may, for example, range from 60 to 85 degrees (e.g. 75-76
degrees). The acute angle and the length of the front face
will dictate the minimum radius of curvature of a convexly
curved wall segment; a convex wall segment will have a minimum
radius of curvature since the side surfaces of adjacent blocks
will abut at this radius.
It is to be understood herein, that if a "range" is mentioned
with respect to a particular characteristic of the present
invention, the present invention relates to and explicitly
incorporates herein each and every specific member and
combination of sub-ranges or sub-groups therein whatsoever.
Thus, any specified range or group is to be understood as a
shorthand way of referring to each and every member of a range
or group individually as well as each and every possible sub-
ranges or sub-groups encompassed therein. For example, with
respect the acute angle, the mention of the range of 60 to 85
34
2090387
degrees is to be understood as specifically incorporating
herein each and every individual angle as well as sub-range of
angles, such as for example 61 degrees, 75 degrees, 65 to 75
degrees, 80 degrees, 60 to 80 degrees, etc..; similarly with
respect to ranges for length, weight etc...
In drawings which illustrate example embodiments of the present
invention:
Figure 1 is a top view of an embodiment of a (first) slab
comprising first and second block elements;
Figure 2 is a side view of the slab of figure 1 showing the
cleavage groove means;
Figure 3 is a perspective view of the separate blocks
obtainable by splitting of the slab of figure l;
Figure 4 is a top view of an embodiment of a (fourth) slab
comprising first and fifth block elements;
Figure 5 is a side view of the slab of figure 4 showing the
cleavage groove means;
Figure 6 is a perspective view of the separate blocks,
obtainable by splitting of the slab of figure 4,
figure 6 being on the same page of drawings as Figure
3;
Figure 7 is a top view of an embodiment of a (fifth) slab
comprising second and fifth block elements;
Figure 8 is a side view of the slab of figure 7 showing the
cleavage groove means;
209Q387
igure 9 is a perspective view of the separate blocks
obtainable by splitting of the slab of figure 7,
figure 9 being on the same page of drawings as figure
3;
35 a
:
2090387
Figure 10 is a top view of an embodiment of a (seventh) slab
comprising fifth and fourth block elements;
Figure 11 is a side view of the slab of figure 10 showing the
cleavage groove means;
Figure 12 is a top view of an embodiment of a (sixth) slab
comprising third and fifth block elements;
Figure 13 is a side view of the slab of figure 12 showing the
cleavage groove means;
Figure 14 is a top view of an embodiment of a (second) slab
10comprising first and fourth block elements;
Figure 15 is a side view of the slab of figure 14 showing the
cleavage groove means;
Figure 16 is a top view of an embodiment of a (third) slab
comprising second and third block elements;
15Figure 17 is a side view of the slab of figure 16 showing the
cleavage groove means;
Figure 18 is a top view of an embodiment of a (eighth) slab
comprising third and fourth block elements;
Figure 19 is a side view of the slab of figure 18 showing the
20cleavage groove means;
Figure 20 is a top view of an embodiment of a (ninth) slab
comprising two fifth block elements;
Figure 21 is a side view of the slab of figure 20 showing the
cleavage groove means;
25Figure 22 is a schematic side view of stacked first, second and
fifth (or third or fourth) blocks elements, the fifth
36
2~90387
block element being used as a crown element which is
set back;
Figure 23 is a schematic side view of stacked first, second and
fifth (or third or fourth) blocks elements, the fifth
element being used as a crown element which is set
forward;
Figure 24 is a schematic side view of stacked first, second and
fifth (or third or fourth) blocks elements, the fifth
element being used as a wall body element which is
set back;
Figure 25 is a top view of stacked courses of first, second and
fourth block elements;
Figure 26 is a top view of stacked first and second block
elements with the main body of the first block
elements being cut away to expose the disposition of
the flanges thereof in the grooves of the underlying
second block elements;
Figure 27 is a schematic view of a curved retaining wall
constructed with known rectangularly configured
retainer wall blocks;
Figure 28 is a schematic view of a curved retaining wall
constructed with tapered blocks of the present
invention;
Figure 29 is a top plan view of a filled mold for side casting
of slabs in accordance with the present invention.
Figure 30 is a diagrammatic representation of the front of a
20~3~7
wall with three courses of blocks, each block being
identified as to type, the wall being straight;
Figure 31 is a diagrammatic representation of the front of a
wall with three courses of blocks, each block being
identified as to type, the wall having a straight and
a curved segment ;
Figure 32 is a diagrammatic representation of the front of a
wall with three courses of blocks, each block being
identified as to type;
Figure 33 is a diagrammatic representation of the front of a
wall with three course of blocks, each block being
identified as to type; and
Figure 34 is a partially cutaway perspective view of a
retaining wall in accordance with the present
invention.
Figure 35 is a top view of an embodiment of a slab D;
Figure 36 is a side view of the slab of figure 35 showing the
cleavage groove means;
Figure 37 is a top view of an embodiment of a slab E;
Figure 38 is a side view of the slab of figure 37 showing the
cleavage groove means;
Figure 39 is a top view of an embodiment of a slab F;
Figure 40 is a side view of the slab of figure 39 showing the
cleavage groove means;
Figure 41 is a top view of an embodiment of a slab G;
Figure 42 is a side view of the slab of figure 41 showing the
21~03~7
cleavage groove means;
Figure 43 is a perspective view of a slab D shown beside the
three blocks K, Km and L obtainable therefrom;
Figure 44a is a perspective view of a slab E shown beside
5the two blocks N and O obtainable therefrom;
Figure 44b is a perspective view of a slab E shown beside the
three blocks K, M and L obtainable therefrom;
Figure 45a is a perspective view of a slab F shown beside the
two blocks Q and O obtainable therefrom;
10Figure 45b is a perspective view of a slab F shown beside the
three blocks L, M and P obtainable therefrom;
Figure 46a is a perspective view of a slab G shown beside the
two blocks R and S obtainable therefrom;
Figure 46b is a perspective view of a slab G shown beside the
15two blocks T and U obtainable therefrom;
Figure 47 schematically illustrates a side view of a stack of
blocks from slabs D through G;
figure 48 illustrates a one-third block stacked on a one-half
block obtained from blocks D to G;
20Figure 49 is a top plan view of a another filled mold for side
casting of slabs D, E, F and G in accordance with the
present invention;
Figure 50 is a diagrammatic representation of the front of a
wall with four courses of blocks, each block being
25identified as to type;
Figure 51 is a diagrammatic representation of the front of a
39
2090387
wall with eight courses of blocks, each block being
identified as to type, the wall having a straight and
a curved segment; and
Figure 52 is a diagrammatic representation of the front of a
wall with eight courses of blocks, each block being
identified as to type.
In the description which follows surfaces will be described as
being planar. It is to be understood herein that a planar
surface need not be smooth nor necessarily flat; a planar
surface may, for example, be roughened.
Figures 1, 2 and 3 illustrate a slab 1 which may be broken into
a first block and a second block in accordance with the present
invention. The first block element is designated by the
reference numeral 2 and the second block element is designated
by the reference numeral 3; these same numerals will be used
hereinafter with respect to other slabs to designate these same
block elements.
The slab 1 has cleavage groove means which comprises opposed
grooves 4 and 5 which are disposed on opposite sides of the
slab. The grooves 4 and 5 are configured to provide a weak
point or fault which facilitates the splitting of slab 1 along
cleavage line or plane 6 into first and second blocks which are
mirror images of each other. The separated first and second
- 209û~87
blocks correspond in shape to the block elements 2 and 3
respectively; prior to splitting the front faces of the first
and second blocks are joined along the cleavage line 6 such
that the front surfaces of the first and second blocks are only
exposed when the slab 1 is split along the cleavage line 6.
When split from each other the front surfaces of the first and
second blocks are generally planar but may be relatively smooth
or coarse in texture (see U.S. Patent no. 5,017,049).
Each of the block elements 2 and 3 also has a generally
rectangular planar rear surface 7 and 8 respectively. The
block elements 2 and 3 also have generally rectangular planar
side surfaces 9 and 10 respectively which are in the same plane
and which define a right angle with the front faces thereof
joined along cleavage line 6. The generally rectangular planar
side surfaces 11 and 12 which are opposite to sides 9 and 10,
each respectively define an acute angle alpha and beta with the
front faces thereof joined along cleavage line 6; the angle
alpha and beta in the illustrated embodiment have the same
value (i.e. 76 degrees); if desired, the values for the angles
may be different. The rear surfaces 7 and 8 are generally
parallel to the cleavage line 6 such that on splitting of the
slab in two parts the front surface of the first and second
block elements are generally parallel to the rear surfaces 7
and 8 respectively.
41
209~3~7
-
The block elements have respective trapezoidal top surfaces 13
and 14 as well as respective trapezoidal bottom surfaces 15 and
16. The top and bottom surfaces are spaced apart by the body
of each block and are generally planar and generally parallel;
S it is to be understood herein that the expression "generally
parallel" is to include surfaces which while not perfectly
parallel are substantially parallel or do not deviate from
parallelism in any substantial way so as to interfere with the
support role of the surfaces. The surfaces 13 and 15 as well
as 12 and 15 give the first and second blocks a generally
trapezoidal configuration, the side, front and rear surfaces
thereof being of generally of rectangular configuration.
Each block element 2 and 3 has a flange or ridge member 17 and
18 respectively; the ridge members extend downwardly from the
rear surfaces 7 and 8 and bottom surfaces 15 and 16; they also
extend from one side surface 9 (or 10) to the other side
surface 11 (or 12).
The planar top surfaces 13 and 14 are interrupted by grooves 19
and 20 respectively. These grooves are sized wider than the
flanges to be received therein such that the flanges may be
disposed therein in angled relation i.e. the grooves are sized
so as to be able to receive a flange transversely with respect
to the longitudinal axis of the groove. Grooves 19 and 20 are
thus sized so that a flange of the third, fourth or fifth block
42
209C387
(described below) may be received therein so as to facilitate
interlocking of these (crown) blocks so that they may be offset
forwardly (i.e. project forwardly) with respect to the retainer
wall surface rather than be rearwardly offset top.
The blocks 2 and 3 also have a ridge member 21 and 22
respectively which define a side wall of groove 19 and 20 as
well as define a rear edge part of the top surfaces 13 an 14.
The block elements also have a recess designated generally by
the reference numerals 23 and 24. The recesses 23 and 24 are
defined by abutment surfaces 23' and 24' and ledge or shoulder
surfaces 23" and 24" respectively; the abutment surfaces are
intended to engage the flanges of an overlying block for
interlocking of the blocks in set back relation.
Turning to Figure 3, when looking at the separated blocks in
the line of sight shown by the schematic representation of the
respective eye, the first block (i.e. having top surface 13) is
a right hand block and will sometimes be referred to
20 hereinafter as block BR; the acute angle alpha is on the right
side of the exposed front face of the first block. On the
other hand, the second block (i.e. having top surface 14) is a
left hand block and will sometimes be referred to hereinafter
as block B~; the acute angle beta is on the left side of the
25 exposed front face of the second block.
43
2090387
Figures 4, 5 and 6 illustrate a slab 25 which may be broken
into a first block 2 and a fifth block 26 in accordance with
the present invention; the elements of the first block element
are the same as those described above with respect to figures 1
to 3 so the same numerals as used with respect to figures 1 to
3 denote the various parts of block element 2.
The slab 25 has cleavage groove means which comprises opposed
grooves 27 and 28 which are disposed on opposite sides of the
slab. The grooves 27 and 28 are configured to facilitate the
splitting of slab 25 along cleavage line or plane 29 into first
and fifth blocks. The separated first and fifth blocks
correspond in shape to the block elements 2 and 26; prior to
being split apart, the front faces of the first and fifth
blocks are joined along the cleavage line 27 such that the
front surfaces of the first and fifth blocks are only exposed
when the slab 25 is split along the cleavage line 29. When
split from each other the front surfaces of the first and third
blocks are generally planar but may be relatively smooth or
coarse in texture as mentioned above.
The fifth block element 26 also has a generally planar rear
surface 7 and 30 respectively. The block elements 2 and 26
also have planar side surfaces 9 and 31 respectively which are
in the same plane and which define a right angle with the front
faces thereof joined along cleavage line 29. The planar side
~09~3~7
surfaces 11 and 32 are opposite to side surfaces 9 and 31; the
surfaces 31 and 32 are generally parallel to each other whereas
the side surface 30 is generally parallel to the cleavage line
29 such that on splitting of the slab in two parts the front
surface of the fifth block element is generally parallel to the
rear planar surface 30.
The fifth block element 26 has a planar top surface 33 as well
as a planar bottom surface 34 which intersect the other (side
and rear) surfaces; the top and bottom surfaces are spaced
apart by the body of the third block. The front face defined
by cleavage line 29 and the surfaces 30, 31 and 32 give the
third block a generally rectangular configuration; i.e. the
top, the bottom, the sides, and the front and rear surfaces
thereof have a generally rectangular configuration. The fifth
block element is sometimes hereinafter referred to as block C.
The block element 26 has a flange or ridge member 35; the ridge
members extend downwardly from the rear surfaces 31 and the
bottom surface 34; the ridge member 35 also extends from one
side surface 31 to the other side surface 32. This ridge
member 35 is intended to be received in a groove 19 or 20 of
the first and second block elements or in a recess 23 or 24
thereof.
Figure 6 shows the block elements of slab 25 split apart.
.20~q387
Figures 7, 8 and 9 illustrate a slab 36 which may be broken
into a second block and a fifth block in accordance with the
present invention. The second block element is designated with
the numeral 3 and the fifth block element is designated by the
reference numeral 26. These block elements are as described
above so the same reference numerals are used to designate the
same features.
The slab 36 has cleavage groove means which comprises opposed
grooves 37 and 38 which are disposed on opposite sides of the
slab. The grooves 37 and 38 are configured to provide a weak
point or fault which facilitates the splitting of slab 36 along
cleavage line or plane 39 into second and third blocks. As in
the case of slabs 1 and 25, prior to being split apart, the
front faces of the second and third blocks are joined along the
cleavage line 39 such that the front surfaces of the first and
second blocks are only exposed when the slab 36 is split along
the cleavage line 39; as mentioned above when split from each
other the blocks are generally planar but may be relatively
smooth or coarse in surface texture (see U.S. Patent no.
5,017,049).
Figure 9 shows the block elements of slab 36 split apart.
Figures lO and 11 illustrate a slab 40 which may be broken into
a fifth block and a fourth block in accordance with the present
46
20~0387
invention. The fifth block element is designated with the
numeral 26 and the fourth block element is designated by the
reference numeral 41. The fifth block element 26 is as
described above so the same reference numerals are used to
designate the same features. Although somewhat smaller, the
fourth block 41 has generally the same configuration as the
second block element 3 so that the same reference numerals are
used to designate the common features;i.e. it is a left hand
block and is sometimes referred to hereinafter as block CL.
The block element 41 differs, however, from the block element 3
in that it does not have the groove 20, the ridge 22 nor the
recess 24; additionally the width (from front surface to rear
surface) of the block element 41 is smaller (e.g. by 6 mm) than
the corresponding width of the first and second block elements,
the flange 18' is narrower than the flange 18; the angle beta
is the same as mentioned above i.e. 76 degree. The width (from
front surface to rear surface) of the fourth block is the same
as that of the fifth block element.
The slab 40 also has cleavage groove means which comprises
opposed grooves 42 and 44 which are disposed on opposite sides
of the slab; the slab 40 is splittable along cleavage line 45.
Figures 12 and 13 illustrate a slab 46 which may be broken into
a third block and a fifth block in accordance with the present
invention. The fifth block element is designated by the
47
2090387
reference numeral 26 and the third block element is designated
with the reference numeral 47. The fifth block element 26 is
as described above so the same reference numerals are used to
designate the same features. Although somewhat smaller, the
third block 47 has generally the same configuration as the
first block element 2 so that the same reference numerals are
used to designate the common features;i.e. it is a right hand
block and is sometimes referred to hereinafter as block CR.
The block element 47 differs, however, from the block element 2
in that it does not have the groove 19, the ridge 21 nor the
recess 23; additionally the width (from front surface to rear
surface) of the block element 47 is smaller (e.g. by 6 mm) than
the corresponding width of the first and second block elements,
the flange 17' is narrower than the flange 17; the angle alpha
is the same as mentioned above i.e. 76 degrees. The width
(from front surface to rear surface) of the third block is the
same as that of the fifth block element.
The slab 46 has cleavage groove means which comprises opposed
grooves 47 and 48 which are disposed on opposite sides of the
slab; the slab 46 is splittable along cleavage line 49.
The flanges of all of the blocks referred to above are sized
with respect to the recesses 23 and 24 such that, when a block
is placed over a first or second block, a flange will
horizontally abut the underlying first or second blocks but
48
2~90387
will not vertically rest on the shoulder defined by the
recesses 23 and 24 of the underlying first or second blocks.
When in the recess a flange may be considered to be used as set
backward means for interlocking and setting backward the blocks
a predetermined distance with respect to the underlying block.
The predetermined distance may be determined in known manner
and will vary with the relative widths (from front surface to
rear surface) of the blocks as well as the width or thickness
of the flanges, etc.. The predetermined setback distance may
for example be up to 25 mm or less for the above mentioned
blocks.
The flanges of the third, fourth and fifth blocks are sized
smaller than the depth of the grooves 19 and 20 such that when
a flange is disposed in a groove 19 or 20 it does not touch the
bottom of the groove; normally the flange will however, rest up
against (i.e. abut) the front side surface of the groove. When
in the groove the flanges may be considered to be used as set
forward means for interlocking and setting forward of the third
fourth and fifth blocks a predetermined distance with respect
to the underlying block. The predetermined distance may be
determined in known manner and will vary with the position and
width of the grooves, the relative widths (from front surface
to rear surface) of the blocks as well as the width or
thickness of the flanges. The predetermined setforward
distance may for example be from 25 mm to 100 mm for the above
49
2~so3~7
mentioned blocks.
The flanges of the third, fourth and fifth blocks are also
narrower than the flanges 17 and 18 so as to take into account
that these blocks are smaller in width from front surface to
rear surface than the first and second blocks; in the
illustrated embodiments the width of the flanges for the first
and second blocks (e.g. 18 mm) is greater than the width of the
flanges for the third, fourth and fifth blocks (e.g. 12 mm) by
an amount which corresponds to the difference in width (from
the front to rear surface) of the first and second blocks
relative to the other blocks.
Turning to figures 14 and 15, they illustrate a (second) slab
50 which may be broken into a first block and a fourth block in
accordance with the present invention. The first block element
is designated by the reference numeral 2 and the fourth block
element is designated with the reference numeral 41. The first
and fourth block elements are as described above so the same
reference numerals are used to designate the same features.
The slab 50 has a cleavage plane or line 51.
Turning to figures 16 and 17, they illustrate a (third) slab 52
which may be broken into a second block and a third block in
accordance with the present invention. The second block
element is designated by the reference numeral 3 and the third
20~0~87
block element is designated with the reference numeral 47. The
second and third block elements are as described above so the
same reference numerals are used to designate the same
features. The slab 52 has a cleavage plane or line 53.
Turning to figures 18 and 19, they illustrate a (eighth) slab
54 which may be broken into a third block and a fourth block in
accordance with the present invention. The third block element
is designated by the reference numeral 47 and the fourth block
element is designated with the reference numeral 41. The third
and fourth block elements are as described above so the same
reference numerals are used to designate the same features.
The slab 54 has a cleavage plane or line 55. As may be seen
form figure 18, the third and fourth blocks as in the case of
the first and second block elements are mirror images of each
other; the third block being a third right hand block and the
fourth block element being a fourth left hand block.
Turning to figures 20 and 21, they illustrate a (ninth) slab 56
which may be broken into two fifth blocks in accordance with
the present invention. The fifth block elements are designated
by the reference numeral 26. The fifth block elements are as
described above so the same reference numerals are used to
designate the same features. The slab 56 has a cleavage plane
or line 57.
20so~7
The blocks of the present invention may be used to provide a
retaining wall having a more or less continuous surface. The
first and second blocks may be used to build up the body of the
retaining wall (whether curved or straight). The third and
fourth blocks may be used to cap the top of the retaining wall
(whether curved or straight) but may also be used to build up
the body of the retaining wall, i.e. they compliment the first
and second blocks. The fifth block may be used to cap the top
of a (straight) retaining wall but may also be used to build up
the body of the retaining wall.
Figures 22, 23 and 24 show in schematic form the use of the
fifth (or third or fourth) block either as a cap element or as
a part of the body of a retaining wall. The crown block
designated 58 in these figures may be a third, fourth or fifth
block as desired; the other blocks may be selected from the
first and second blocks for a convexly curved surface. For
example, the first and second blocks may be applied in
alternating layers and the wall may finally be capped or
crowned with a layer of third or fourth blocks. The front face
of the retaining wall is indicated generally by the reference
numeral 59. The block 58 is shown in figure 22 in a forward
extending position relative to the underlying block; in figure
23 the block 58 is shown in a rearwardly or set back position
relative to the underlying block.
52
2090387
Figure 25 illustrates a layer of second blocks 59 overlaying a
layer of first blocks 60; the second layer being partly covered
by fourth blocks 61 to cap the stack of blocks, the fourth
blocks being set forward with respect to the underlying second
block layer.
Figure 26 illustrates the angular disposition of the flanges
18' of the fourth blocks 61 in the grooves 20 of the second
blocks; i.e. for curved courses of the blocks. As may be seen
the width of the grooves is sufficient to accommodate this type
of angular positioning of the flanges 18'. Thus, the width of
the grooves is selected with the angular disposition in mind.
The grooves may for example be from 20 mm to 50 mm in width.
Figure 27 schematically illustrates a wall construction using
rectangular shaped retaining wall blocks; the wall is seen from
above so as to expose a layer of blocks in the body of the
wall. The wall has a convex outer surface designated generally
by the numeral 62 and a concave outer surface designated
generally by the reference numeral number 63. As may be seen
the convex outer surface is discontinuous in the sense that
cavities 64 are defined between the blocks. The concave outer
surface on the other hand presents a more or less continuous
outer surface free of such cavities.
Figure 28 schematically illustrates a wall construction using
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blocks in accordance with the present invention; the wall is
seen from above so as to expose a layer of second blocks 59
(only one of which is identified by the reference numeral 59)
in the body of the wall. The wall has a convex outer surface
designated generally by the numeral 65 and a concave outer
surface designated generally by the reference numeral number
66; the wall also has a straight portion 67. As may be seen
the convex outer surface 65 is continuous in the sense that no
cavities are defined between the blocks 59; the concave outer
surface also presents a more or less continuous outer surface
free of such cavities. The radius of curvature for the concave
and convex surfaces are designated by the reference numerals 68
and 69. The minimum value for the radius of curvature 68 will
depend on the angle beta chosen for the second blocks as well
as the size of the face surfaces. Preferably the angles alpha
and beta have the same values.
If a kit is provided with slabs (either exclusively or in
addition to separate blocks), the slabs have to be split into
the two constituent blocks thereof before the blocks may be
incorporated into a retaining wall. A slab may be split in any
(known) manner which provides the desired front surface; i.e.
by methods known in the art.
In order to construct a retaining wall using blocks of the
present invention usual precautions must of course be taken
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with respect to proper preparation of the foundation under the
blocks, etc.
A plurality of slabs in accordance with the present invention
may advantageously be formed by exploiting a (known) molding or
casting technique wherein the slabs are cast on one of their
sides; such a technique is described, for example, in U.S.
patent no. 5,017,049.
In accordance with the side molding process, casting of a slab
may be accomplished by using a compression head in conjunction
with a multi-part mold.
The mold may, for example, comprise a wall part separable from
a bottom part. The wall part may have a plurality of open
ended hollow chambers each having upper and bottom openings.
Each hollow chamber may have a plurality of side walls between
the openings for defining the body of the slab. Two opposed
side walls of each chamber have surfaces configured to provide
the slab with top and bottom surfaces each of which has an
inset groove defining the junction (of the front surfaces) of
the two separate blocks and along which the slab may be split
prior to use.
The mold bottom part during casting closes off the bottom
- 209038 t
openings of the wall mold part so as to provide a plurality of
mold cavities. The mold bottom part has a surface configured
to impart to the slab side along which the slab is cast, a
generally planar surface such that when the wall part is
separated for the cast block, the cast block is able to stand
alone along the side of the slab on the bottom part which may
double as a palate for initial transport and storage of the
cast slabs; i.e. the slab is cast on one of its sides wherein
the surfaces of the separate blocks making up the slab are
generally in the same plane.
The compression head may have a compression surface which
imparts to the side surface of the slab opposite to that on
which the slab is cast, the desired parallel or non-parallel
surface characteristics. Thus for example to form a slab
breakable into a first and second block it may have a surface
split into two parts at the middle thereof; each part may, for
example, extend at a downward angle from the middle of the head
so as to cast first and second blocks having a side surface
defining an acute angle with the front surfaces; alternatively,
for example, one part of the surface of the compression head
may extend from the middle of the head parallel to the opposite
bottom surface whereas the other part may extend from the
middle at an angle so as to form a first block attached along
the cleavage groove to a third block; and so on for the other
blocks.
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2090~387
Figure 29 illustrates a top view of a filled mold 70. The mold
cavities shown allow for the simultaneous preparation of first
(e.g. cavity 71), fourth (e.g. cavity 72), fifth (e.g. cavity
73), sixth (e.g. cavity 74) and seventh (e.g. cavity 75) slabs;
the mold furnishes twelve (120 first, twelve (12) second, six
(6) third, six (6) fourth and eighteen (18) fifth blocks
sufficient for a wall kit for making a wall (segment) having
three courses of blocks with a flat surfaced crown course.
The wet mix in the mold 70 is cast by applying pressure to the
mix at the open upper end of the mold using a compression head
of appropriate surface configuration to obtain the desired two
part slabs. The compression head acts on the exposed surface
of the mix.
Any suitable wet mixture for forming a concrete slab may for
example be used in the casting process; see U.S. patent no.
5,017,049 for example mixtures.
Turning to figures 30 and 31, these figures show
diagrammatically how the 54 blocks obtained from the mold shown
in figure 29 may be used to make a wall having three courses.
For the purposes of illustration the blocks are shown as
resting directly over an underlying block; in use however it is
preferable for the blocks to overlap two underlying blocks as
shown in figure 34.
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For figures 30 and 31, the 54 blocks are given their previously
referred to designations with reference to blocks shown in the
previously described figures, namely
C designates a fifth rectangular block (18 thereof);
CR designates a third right hand block (6 thereof);
CL designates a fourth left hand block (6 thereof);
BR designates a first right hand (grooved) block (12
thereof); and
BL designates a second left hand (grooved) block (12
thereof).
Referring to figure 30 this figure represents a wall made of
the above referred to blocks the wall being straight over its
entire length as indicated by the arrow 80. As may be seen the
crown course of block consists of fifth rectangular blocks; the
middle row comprises a mixture of first and second blocks; and
the third row comprises second, third and fourth blocks. Since
the middle row consists of grooved blocks as described herein
the crown course of blocks may be offset rearwardly or
forwardly as desired.
Figure 31 on the other hand shows a wall made of the same
blocks from the mold shown in figure 29 but so arranged as to
provide a wall having a straight portion 81 and a curved
portion 82. Thus the crown course of blocks for the straight
portion consists of fifth blocks C; the other curved half of
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the wall has a crown course of blocks which comprises third and
fourth blocks. The middle course of blocks comprises first and
second blocks so that the crown course may be offset rearwardly
or forwardly as desired.
Provided that the adjacent blocks of the crown courses of the
walls shown in figures 30 and 31 abut along their side surfaces
the crown courses present a relatively flat uninterrupted top
surface. Although such flat surface is preferred for aesthetic
reasons, a kit may be configured if desired so as to provide a
top surface which may be interrupted by openings.
Turning to figures 32 and 33 in these figures show walls having
three course of blocks. The wall again is made from a kit
comprising 54 blocks which are given their previously referred
to designations with reference to blocks shown in the figures.
The proportion of the blocks is, however, different from that
of the kit used with respect to the wall shown in figures 30
and 31, namely
C designates a fifth rectangular block (12 thereof);
CR designates a third right hand block (6 thereof);
C~ designates a fourth left hand block (6 thereof);
BR designates a first right hand (grooved) block (15
thereof); and
BL designates a second left hand (grooved) block (15
thereof).
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The wall represented by figure 31 has a crown composed of fifth
and third blocks; the middle row comprises first and second
blocks. Accordingly, the wall may be entirely straight as
shown by the arrow 83 or else it may have straight portion 84
and a curved portion 85, the curved portion representing about
one third of the length of the wall. The crown course of the
wall in figure 32 will have rearwardly extending openings or
spaces between adjacent tapered third blocks.
If the fourth blocks of the wall shown in figure 32 are used to
replace the fifth blocks adjacent to the third blocks then as
shown in figure 33 the wall may have a straight portion 86 and
a curved portion 87, the curved portion representing about two
thirds of the length of the wall.
Turning to figure 34, this figure shows a straight portion of
wall made in accordance with the present invention. The crown
row is offset forwardly and comprises tapered and rectangular
blocks, the blocks being identified with the above referred to
designations. Preferably, however, for a predetermined number
of courses of blocks the crown course for straight walls
consists of rectangular fifth blocks, i.e. the number of
rectangular blocks in a kit is sufficient to meet this criteria
(e.g. the kit used for the wall shown in figures 30 and 31).
The portion of the wall comprising the tapered block elements
such as the first, second, third and fourth blocks can be
2090~87
converted into a curved portion by reducing the spaces (some of
which is designated by the reference numeral 88) between the
side surfaces thereof right up to and including the case
wherein the sides abut each other. The larger space 89
represent the space between adjacent first and second blocks
wherein the adjacent faces of the blocks both define an acute
angle.
In order to produce a wall having more than three courses of
blocks a plurality of kits as obtainable from the mold shown in
figure 29 may be used.
Figures 35, and 36 illustrate a slab D indicated generally by
the reference number 90. The slab 90 may be broken into three
blocks K, Km and L, the corresponding block elements of which
are designated respectively by the reference numbers 91, 92 and
93.
The slab 90 has a first cleavage groove means which comprises
opposed grooves 94 and 95 which are disposed on opposite sides
of the slab. The grooves 94 and 95 are configured to provide a
weak point or fault which facilitates the splitting of slab 90
along cleavage line or plane 96 so as to liberate block K
therefrom.
The slab 90 also has a second cleavage groove means which
2~90~87
comprises opposed grooves 97 and 98 which are disposed on
opposite sides of the slab. The grooves 97 and 98 are
configured to provide a weak point or fault which facilitates
the splitting of slab 90 along cleavage line or plane 99 so as
to liberate block L therefrom.
The slab 90 has generally rectangular planar end surfaces 100
and 101 respectively. The slab 90 also has rectangular planar
side surface portions 102, 103 and 104 respectively which are
in the same plane and which define a right angle with the
cleavage lines 96 and 99. The slab further includes generally
rectangular planar side surface portions 105, 106 and 107 which
are opposite to the side surface porions 102, 103 and 104
respectively. The side surface portions 102 and 103 are
generally parallel to the opposed side surface portions 105 and
106. On the other hand the side surface portion 107 defines an
acute angle beta with the second cleavage means. The end
surfaces 100 and 101 are generally parallel to the cleavage
lines 96 and 99 such that on splitting of the slab the
liberated surfaces (front or rear) are generally parallel to
the end surfaces 100 and 101 respectively.
The block elements 91 and 92 have respective rectangular top
and bottom surfaces 108, 109, 110 and 111. The element 93 has
respective trapezoidal top and bottom surfaces 112 and 113.
The top and bottom surfaces are spaced apart by the body of
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each block and are generally planar and generally parallel.
Each block element 91, 92 and 93 has a flange or ridge member
114, 115 and 116 respectively; the ridge members extend
downwardly from the rear surfaces of a corresponding block
(e.g. surfaces 100 and 101) as well as from bottom surfaces
109, 111 and 113; they also extend from one side surface
portion to the other opposed side surface.
The planar top surface of element 93 is interrupted by
offsetting grooves 117 and 119, these grooves being separated
by a projection 120 which defines a part of the top surface of
the element 93. The groove 119 is also bordered by the
projection 121. The groove 119 is for example sized to receive
a flange such as flange 114 so that the flange may be disposed
therein in angled relation i.e. the groove is sized so as to be
able to receive a flange transversely with respect to the
longitudinal axis of the groove. Both of grooves 117 and 119
may, if desired be sized so that a flange of a block K, Km or P
(as described herein) may be received therein so as to
facilitate interlocking of these (crown) blocks so that they
may be offset forwardly (i.e. project forwardly) with respect
to the retainer wall surface rather than be rearwardly offset
with respect to the underlying block.
Turning to figures 37 and 38, these show a slab E indicated
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generally by the reference number 123. Slab 123 is essentially
the same as slab 90 except that it has a third cleavage groove
means. Accordingly, the same reference numerals are used to
designate the common elements.
The third cleavage groove means comprises opposed grooves 124
and 125 which are disposed on opposite sides of the slab 123.
The grooves 124 and 125 are configured to provide a weak point
or fault which facilitates the splitting of slab 123 along
cleavage line or plane 126. As a result the slab 123 comprises
a variety of additional block elements including elements 127,
128 and 129 (i.e. corresponding to blocks M, N and O
respectively).
Slab 123 also includes an elongated notch 130 extending the
length of flange 115 for facilitating removal of the flange if
a block O is desired; i.e. by breaking off the flange 115 in
any suitable manner.
Turning to figures 39 and 40, these show a slab F indicated
generally by the reference number 131. Slab 131 is essentially
the same as slab 123 except that it has a second trapezoidally
shaped element 132 instead of a rectangularly shaped element
91. Accordingly, the same reference numerals are used to
designate the common elements.
The side surface portion 105 for element 132 defines an angle
64
~ .
2090387
alpha with the cleavage line 96; i.e. the top and bottom
surfaces 108 and 109 have a trapezoidal aspect. As a result
the slab 132 comprises an additional block element 133 (i.e.
corresponding to blocks Q).
Figures 41 and 42 illustrate a slab G which is designated by
the numeral 135 which may be broken into a block R and a second
block S, the corresponding block elements are designated by the
reference numbers 136 and 137. The blocks R and S may also be
subdivided into blocks T and U and respective block fragments,
the corresponding block elements are designated by the
reference numerals 138, 139, 140 and 141.
The slab 135 has cleavage groove means which comprises opposed
grooves 142 and 143 which are disposed on opposite sides of the
slab. The grooves 142 and 143 are configured to provide a weak
point or fault which facilitates the splitting of slab 135
along cleavage line or plane 144 into blocks R and S which are
mirror images of each other. The separated blocks R and S
correspond in shape to the block elements 136 and 137
respectively; prior to splitting the front faces of the blocks
R and S are joined along the cleavage line 144 such that the
front surfaces blocks R and S are only exposed when the slab
135 is split along the cleavage line 144. When split from each
other the front surfaces of the blocks are generally planar but
as mentioned above may be relatively smooth or coarse in
209~387
texture.
Each of the block elements 136 and 137 also has a generally
rectangular planar rear surface 145 and 146 respectively. The
block elements 136 and 137 also have generally rectangular
planar side surfaces 138 ' and 139 ' respectively which are in
the same plane and which define a right angle with the front
faces thereof joined along cleavage line 144. The generally
rectangular planar side surfaces 140 and 141 which are opposite
to sides 138 ' and 139 ', each respectively define an acute angle
alpha and beta with the front faces thereof joined along
cleavage line 144; the angle alpha and beta in the illustrated
embodiment have the same value (e.g. 75 degrees); if desired,
the values for the angles may be different. The rear surfaces
145 and 146 are generally parallel to the cleavage line 144
such that on splitting of the slab in two parts the front
surface of the blocks R and S are generally parallel to the
rear surfaces 145 and 146 respectively.
The block elements have respective trapezoidal top surfaces 147
and 148 as well as respective trapezoidal bottom surfaces 149
and 150. The top and bottom surfaces are spaced apart by the
body of each block and are generally planar and generally
parallel. The top and bottom surfaces give the blocks R and S
a generally trapezoidal configuration, the side, front and rear
surfaces thereof being of generally of rectangular
2û90387
configuration.
Each block element 138 and 139 has a flange or ridge member 149
and 150 respectively; the ridge members extend downwardly from
the rear surfaces 145 and 146 and bottom surfaces 149 and 150;
they also extend from side surface to opposite side surface.
The bottom surfaces of the elements 136 and 137 are also
interrupted by flanges 151 and 152. Elongated notches 153 and
154 extend the length of the flanges 151 and 152; these notches
as in the case of similar notches referred to above are sized
to facilitate the removal of the flanges 151 and 152 if blocks
R and S are desired.
The flanges 151 and 152 may serve as the analogous end flanges
for the blocks T and U, i.e. when the block fragment elements
are removed. In this respect the block elements 136 and 137
are each provided with additional cleavage group means for
allowing the terminal elements 140 and 141 to be split away so
as to expose the rear surfaces of the blocks T and U, these
blocks are also mirror image of each other. The additional
cleavage groove means for the block element 136 comprises
opposed elongated notches 153 and 155 which are configured to
provide a weak point or fault which facilitates the splitting
away of the fragment along cleavage line or plane 156. The
additional cleavage groove means for the block element 137
209û387
comprises opposed elongated notches 154 and 157 which are
configured to provide a weak point or fault which facilitates
the splitting away of the respective fragment along cleavage
line or plane 158.
The planar top surfaces 147 and 148 are each interrupted by two
grooves adjacent the rear surfaces 145 and 146, namely grooves
159 and 160 on one hand and on the other hand grooves 161 and
162. Grooves 160 and 162 are sized wider than the flanges to
be received therein such that the flanges may be disposed
therein in angled relation i.e. the grooves are sized so as to
be able to receive a flange transversely with respect to the
longitudinal axis of the groove. Grooves 160 and 161 are thus
sized so that a flange of a block (e.g. block P or K) may be
received therein so as to facilitate interlocking of these
(crown) blocks so that they may be offset forwardly (i.e.
project forwardly) with respect to the retainer wall surface
rather than be rearwardly offset top. The grooves 159 and 161
may if desired be likewise so sized but are to be at least
sized so as to longitudinally receive a flange. The elements
136 and 137 also have projections 163 and 164 respectively
which each define a portion of the top surfaces thereof.
For the blocks obtainavble from the slabs D to G, the
predeteremined setback may, for example, be up to 50 mm or
less; hte predetermined setforward distance may, for example,
68
20903~7
be 25 mm to 100 mm; and the width of the setforward groove may,
for example, be 22 mm to 100 mm.
Turning to figures 43 to 46b, these illustrate various
combinations of blocks that may be obtained from slabs D
through G by the user of a kit comprising such slabs.
Figure 43 shows the exposed front surfaces 165 and 166 of
blocks K and Km; as well as the exposed rear surface 167 of
block Km and the exposed front surface 168 of block L.
Figure 44a shows the exposed front surfaces 169 and 170 of
blocks N and O.
Figure 44b shows the exposed front surfaces 171 and 172 of
blocks K and M; as well as the exposed rear surface 173 of
block M and the exposed front surface 174 of block L.
Figure 45a shows the exposed front surfaces 175 and 176 of
blocks Q and O.
Figure 45b shows the exposed front surfaces 177 and 178 of
blocks P and M; as well as the exposed rear surface 179 of
block M and the exposed front surface 1$0 of block L.
Figure 46a shows the exposed front surfaces 181 and 182 of
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blocks R and S.
Figure 46b shows the exposed front surfaces 183 and 184 of
blocks T and U; as well as the exposed rear surfaces 185 and
186 of blocks T and U.
The blocks K, Km~ L, M, P, T and U may each represent one third
of the overall length of a respective slab from which the
blocks are separated; they may for example all be of the same
length. The blocks N, O, Q, R and S may each represent one
half of the length of a respective slab from which they are
separated; they may for example all be of the same length.
Turning to figures 47 and 48, these illustrate the advantageous
stacking of the one-third and one-half blocks obtainable from
the slabs D through G. As may be seen the lower most courses
of blocks may comprise long blocks such as block O (i.e.
heavier one -half blocks) while upper courses of blocks may
comprise shorter blocks such as blocks K and L (i.e. lighter
one-third blocks); in this manner the heavier blocks support
the greater weight of earth at the foot of the retainer wall
whereas the lighter blocks can be placed at upper levels where
less weight is to be applied to the retainer wall.
The abutment surface (of a lower block) engaging the rear
flange of an upper block may, for setback purposes, comprise
2~903~7
the rear surface of a block; alternatively, if a one-third
block (e.g. block L) is placed over a one-half block (e.g.
block 0 or R), the flange of the one-third block may be
received in a rear groove of the lower block and abut an
opposed surface thereof. The stack of blocks shown in figure
47 show a crown block, setback relative to the underlying
block. The flange 114 of block K abuts against the rear
surface 101 of the block L. If desired the block K could be
set forward by disposing the flange 114 in the groove 119 of
block L.
Figure 49 illustrates a top view of a filled mold 187. The
mold cavities shown allow for the simultaneous preparation of
slabs D (e.g. 1 cavity 188), slab E (e.g. 4 cavities 189), slab
F (e.g. 3 cavities 190) and slab G (e.g. 2 cavities 191); the
mold furnishes sufficient slabs for a wall kit for making a
wall (segment) having four courses of blocks with a flat
surfaced crown course.
Figure S0 schematically shows a wall built with a kit produced
from the mold of figure 49. The various blocks are designated
using the reference letters referred to above; see for example
figures 43 to 46b. The reference numeral 192 shows the wall as
straight whereas the other reference numerals designate a wall
portion which may be straight (193) and wall portion which may
be curved (194), the latter exploiting trapezoidal like blocks.
2~90387
Figure 51 and 52 each schematically show a wall built with 3
kits produced from the mold of figure 49. The various blocks
are again designated using the reference letters referred to
above; see for example figures 43 to 46b.
Turning to figure 52 the reference numerals designate a wall
portion which may be straight (196) and wall portion which may
be curved (197), the latter exploiting trapezoidal like blocks.
The remaining (unused) blocks after the wall is made consist of
2 blocks L and one block K.
Turning to figure 53 the reference numeral 197 designates a
straight wall. The remaining (unused) blocks after the wall is
made consists of 4 blocks P.
