Note: Descriptions are shown in the official language in which they were submitted.
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BUILDING ELEMENTS FOR MAKING RETAINING WALLS, AND
SYSTEMS AND METHODS OF USING SAME
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of the filing date
of U.S.
Provisional Patent Application No. 62/577,451, filed on October 26, 2017,
which is
incorporated herein by reference in its entirety.
FIELD
[0002] The present disclosure relates generally to building elements for wall
structures. More
particularly, the present disclosure relates to a plurality of building
elements that are operably
coupled to each other to erect a retaining wall.
BACKGROUND
[0003] It is common practice to use prefabricated building elements and
particular masonry
works such as walls for retaining slopes and slopes along roads, motorways,
railways or the
like, or for retaining walls for creating drops between urban levels,
especially by various
types of prefabricated building elements. Such elements usually consist of
concrete elements,
placed one at the top of the other, and then filled with material such as
earth, sand, gravel,
and the like. Previous approaches have been developed to building elements for
a retaining
wall. One example of such an approach is described in U.S. Patent No.
7,845,885, which is
incorporated herein by reference in its entirety.
[0004] Currently, building elements require expensive molds and a minimum of
one night
to rest in the mold to allow time for the material to harden. In addition, the
process used to
generate a building element results in a building mold with limited
variability. Thus, the
resulting building element limits the structural variability of the retaining
walls that can be
constructed using the building element. There is a need in the pertinent art
for building
elements with increased variability in structure, thereby allowing for
increased variability in
the structures of retaining walls produced using the building elements.
[0005] There is a further need for building elements that provide increased
stability and
integrity compared to existing building elements. There is still a further
need for building
elements that provide for increased efficiency in the construction of wall
structures.
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SUMMARY
[0006] The disclosure relates to the building of large and heavily loaded
retaining walls by
a set of prefabricated building elements. Optionally, the prefabricated
building elements can
include at least two different types of prefabricated building elements.
During installation, the
building elements can be operably engaged to build a retaining wall. To
solidify the retaining
wall, earth fillers such as dirt and the like can be used to support the wall.
[0007] Disclosed herein are building elements and systems and methods of using
building
elements to erect a retaining wall. In some aspects, the disclosed building
elements can have
a modular construction that simplifies production of the building elements and
the retaining
walls formed by the building elements. In these aspects, it is contemplated
that the modular
construction increases the ease in which the dimensions and characteristics of
a building
element can be selectively varied at a particular location within the wall
construction to
achieve a particular structural need. It is further contemplated that the
modular construction
can lower production costs, lower investment costs for molds, and ease
transport of building
elements.
[0008] In other aspects, a building element can be configured to be coupled to
at least one
other building element to form a retaining wall. The building element can
comprise a face
panel that defines a front surface and a rear surface positioned on an
opposing side of the face
panel from the front surface. The face panel can comprise a length dimension
that is oriented
along a first axis, a width/thickness dimension that is oriented along a
second axis that is
perpendicular to the first axis, and a height dimension that is oriented along
a third axis that is
perpendicular to the first and second axes. The building element can also
comprise at least
one beam member coupled to the rear surface of the face panel. The beam member
can
comprise an upper surface and a lower surface, and at least one surface of the
upper surface
and the lower surface can define an alignment void that is configured to
receive a
complementary portion of an adjacent building element. The beam member can
also
comprise a height dimension oriented along the third axis and a length
dimension oriented
along the second axis (such that the beam member is substantially
perpendicular to the rear
surface of the face panel and extends away from the rear surface of the face
panel relative to
the second axis).
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[0009] Optionally, in various aspects, the building elements can be engaged to
one another
using at least one alignment post. The alignment post can comprise a stem and
a cap. The
stem can have a longitudinal axis and a length dimension along the
longitudinal axis. In use,
it is contemplated that the longitudinal axis of the stem can be parallel or
substantially
parallel to the third axis disclosed herein. The cap can comprise a top
surface and a bottom
surface, wherein the top surface comprises a first cross sectional area and
the bottom surface
comprises a second cross sectional area. The stem can be coupled to the cap
through the
bottom surface. In exemplary aspects, a first portion of the stem can be
embedded within the
cap, with a second portion of the stem extending downwardly and away from the
bottom
surface.
[0010] In other aspects, a plurality of building elements as disclosed herein
can be operably
engaged to erect a retaining wall system. The retaining wall system can
comprise a plurality
of building elements, wherein each building element can comprise a face panel
and at least
one beam member. The face panel can comprise a front surface and a rear
surface positioned
on an opposite side of the face panel from the front surface. At least one
beam member can
be coupled to the rear surface of the face panel. The beam member can comprise
an upper
surface and a lower surface, and at least one surface of the upper surface and
lower surface
can define an alignment void. The retaining wall system can further comprise
an alignment
post, and at least a portion of a stem of the alignment post can be configured
for receipt
within an alignment void of a first building element. Depending upon the
orientation of the
alignment post, the stem of the alignment post can be received within an
alignment void that
extends upwardly from the lower surface of the beam member or an alignment
void that
extends downwardly from the upper surface of the beam member, and a cap
portion of the
alignment post can be configured to extend either (a) above the upper surface
or (b) below the
lower surface. A second building element can define an alignment void that is
configured to
receive the cap of the alignment post when beam members of the first and
second building
elements are positioned in vertical alignment with one another.
[0011] Also disclosed, in further aspects, is a building element for forming a
portion of a
retaining wall, the building element comprising: a face panel comprising a top
surface, a
bottom surface, a front surface, and a rear surface positioned on an opposing
side of the face
panel from the front surface, wherein the face panel comprises a length
dimension oriented
along a first axis, a width dimension oriented along a second axis that is
perpendicular to the
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first axis, and a height dimension oriented along a third axis that is
perpendicular to the first
and second axes; and a beam member coupled to the rear surface of the face
panel, the beam
member comprising a main body and first and second foot portions, the main
body having an
upper surface and first and second side surfaces that are substantially
parallel to the second
axis, wherein the first and second foot portions project, respectively, from
the first and
second side surfaces relative to the first axis, and wherein the first and
second foot portions
have respective lower surfaces that are substantially co-planar with the
bottom surface of the
face panel and respective upper surfaces that are positioned between the
bottom and top
surfaces of the face panel relative to the third axis, wherein the beam member
has a distal end
portion spaced from the front panel relative to the second axis, wherein the
distal end portion
comprises first and second projections that project, respectively, from the
first and second
side surfaces of the main body of the beam member, and wherein the first and
second
projections cooperate with respective portions of the first and second foot
portions, the first
and second side surfaces of the main body, and the rear surface of the face
panel to define
first and second receiving spaces on opposing sides of the beam member.
Systems and
methods of using and making the disclosed building element are also disclosed.
[0012] Further disclosed, in other aspects, is building element for forming a
portion of a
retaining wall, the building element comprising: a panel comprising a top
surface, a bottom
surface, a front surface, and a rear surface positioned on an opposing side of
the face panel
from the front surface, wherein the face panel comprises a length dimension
oriented along a
first axis, a width dimension oriented along a second axis that is
perpendicular to the first
axis, and a height dimension oriented along a third axis that is perpendicular
to the first and
second axes, wherein the panel has opposed first and second side surfaces
extending between
the front surface and the rear surface, wherein the panel comprises: a
plurality of mortar beds
defined within the panel, wherein the plurality of mortar beds are spaced
apart relative to the
first axis; a reinforcing mesh embedded within the panel; and a plurality of
projections
extending upwardly from the top surface and a plurality of receptacles defined
within the
bottom surface, wherein the receptacles are configured to receive the
projections of a second
building element. Systems and methods of using and making the disclosed
building element
are also disclosed.
[0013] Additional advantages of the invention will be set forth in part in the
description
which follows, and in part will be obvious from the description, or may be
learned by practice
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of the invention. The advantages of the invention will be realized and
attained by means of
the elements and combinations particularly pointed out in the appended claims.
It is to be
understood that both the foregoing general description and the following
detailed description
are exemplary and explanatory only and are not restrictive of the invention,
as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] These and other features of the disclosure will become more apparent in
the detailed
description in which reference is made to the appended drawings wherein:
[0015] FIG. 1 is a rear perspective view of an exemplary modular building
element having
a single beam member as disclosed herein.
[0016] FIG. 2 is a rear perspective view of an exemplary modular building
element having
a plurality of beam members as disclosed herein.
[0017] FIG. 3 is a top view of a plurality of building elements with
reinforcement wings of
varying dimensions and varying cross sectional areas.
[0018] FIGS. 4-6 are close-up top views of a plurality of building elements
with
reinforcement wings of varying dimensions and varying cross sectional areas.
FIG. 4 depicts
two building elements having reinforcement wings with straight profiles. FIG.
5 depicts two
building elements having reinforcement wings with curved or arcuate profiles.
FIG. 6 depicts
two building elements having reinforcement wings with different profiles, with
the
reinforcement wings of one building element having curved or arcuate profiles
and the
reinforcement wings of another building element having straight profiles.
[0019] FIG. 7 is a rear perspective view of an exemplary building element
having a
plurality of beam elements that define apertures as disclosed herein.
[0020] FIG. 8 is a rear perspective view of an exemplary extension element
that is
configured for connection to a building element as disclosed herein.
[0021] FIG. 9 is a rear perspective view of an exemplary building element
having beam
elements with securing rods as disclosed herein.
[0022] FIG. 10 is an isometric view of an exemplary alignment post as
disclosed herein.
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[0023] FIG. 11 is a cross-sectional end view of an exemplary engagement
between the
beam elements of two adjacent (vertically stacked) building elements with an
alignment post
as disclosed herein.
[0024] FIG. 12 is a cross-sectional side view of the modular building element
of FIG. 1,
following assembly of the building element.
[0025] FIG. 13 is a rear perspective view of a retaining wall constructed of
exemplary
building elements as disclosed herein. As shown, a portion of the building
elements have
reinforcement wings with curved or arcuate profiles, while a second portion of
the building
elements have reinforcement wings with straight profiles. Additionally, the
building
elements have back sections of various constructions.
[0026] FIG. 14 is a rear perspective view of a retaining wall constructed of
exemplary
building elements.
[0027] FIG. 15 is a cross-sectional side view of the retaining wall depicted
in FIG. 14.
[0028] FIG. 16 is a rear perspective view of a retaining wall constructed of
exemplary
building elements as disclosed herein.
[0029] FIG. 17 is a rear perspective view of a retaining wall constructed of
exemplary
building elements as disclosed herein. As shown, each building element can
include a
securing device as disclosed herein.
[0030] FIG. 18 is a close-up rear perspective view of the lower securing
device depicted in
FIG. 17.
[0031] FIG. 19 is a rear perspective view of a retaining wall having an
exemplary securing
device located at the juncture of two exemplary building elements as disclosed
herein.
[0032] FIG. 20 is a side cross sectional view of an exemplary securing device
located at the
juncture of two exemplary building elements as disclosed herein.
[0033] FIG. 21 is a rear perspective view of an exemplary panel spacer located
at the
juncture of two exemplary building elements as disclosed herein.
[0034] FIG. 22 is a close-up rear perspective view of an exemplary panel
reinforcement
located at the juncture of two exemplary building elements as disclosed
herein.
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[0035] FIGS. 23A, 23B, and 23C are front perspective, rear perspective, and
top plan views
of an exemplary building element having fill receiving spaces as disclosed
herein. FIGS.
23D and 23E are back and front perspective views of an exemplary building
element having a
plurality of vertically spaced elbows that project outwardly from the main
body of the beam
member and extend between the face panel and the distal end portion of the
beam member
(also referred to herein as the "back pillar"). FIGS. 23F-23G are back
perspective views of
exemplary building elements having a plurality of vertically spaced elbows
along the main
body of the beam member and a plurality of vertically spaced elbows along a
rear surface of
the distal end portion of the beam member. FIG. 23F shows a gap between the
side and rear
elbows, while FIG. 23G shows the side and rear elbows as a continuous
structure that extends
along outer surfaces of the beam member.
[0036] FIG. 24 is a perspective view of an exemplary building element having
fill receiving
spaces as disclosed herein.
[0037] FIGS. 25A and 25B are front perspective and side elevational views of
an
exemplary column of building elements having fill receiving spaces as
disclosed herein.
[0038] FIGS. 26A and 26B are front perspective and close-up top views of
spaced columns
of building elements having fill receiving spaces as disclosed herein.
[0039] FIGS. 27A and 27B are top plan views of exemplary building elements
having fill
receiving spaces and reinforcement materials as disclosed herein.
[0040] FIGS. 28A-28B are schematic depictions of an exemplary process for
making a
building element having fill receiving spaces as disclosed herein.
[0041] FIG. 29 is a side view of an exemplary alignment post having a cap
received within
a receptacle of a building element as disclosed herein.
[0042] FIGS. 30-31C are various views of an exemplary enlarged panel as
disclosed herein.
FIG. 30 is a perspective view, while FIGS. 31A, 31B, and 31C respectively show
front, side,
and top views of the enlarged panel.
[0043] FIG. 32 is a close-up partially transparent view of a building element
having a
vertical alignment element as further disclosed herein.
[0044] FIG. 33 is a perspective view of an exemplary layout of panels, with
some columns
of panels having reduced-height panels.
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[0045] FIG. 34 is a top plan view of an exemplary panel having a plurality of
mortar beds
as disclosed herein.
[0046] FIG. 35 is a perspective view of a grid as disclosed herein.
[0047] FIG. 36 is a perspective view of a panel having a plurality of
reinforcement wings
as disclosed herein.
[0048] FIG. 37 is a schematic view of an exemplary assembly process for the
panel of FIG.
36.
[0049] FIGS. 38A-38B are side and perspective views of an exemplary alignment
assembly
as disclosed herein.
[0050] FIG. 39A is a perspective view depicting the connection between hooks
and a grid
as disclosed herein. FIG. 39B is a close-up perspective view depicting the
connection
between the hooks and the grid.
DETAILED DESCRIPTION
[0051] The present invention can be understood more readily by reference to
the following
detailed description, examples, drawings, and claims, and their previous and
following
description. However, before the present devices, systems, and/or methods are
disclosed and
described, it is to be understood that this invention is not limited to the
specific devices,
systems, and/or methods disclosed unless otherwise specified, as such can, of
course, vary. It
is also to be understood that the terminology used herein is for the purpose
of describing
particular aspects only and is not intended to be limiting.
[0052] The following description of the invention is provided as an enabling
teaching of the
invention in its best, currently known embodiment. To this end, those skilled
in the relevant
art will recognize and appreciate that many changes can be made to the various
aspects of the
invention described herein, while still obtaining the beneficial results of
the present invention.
It will also be apparent that some of the desired benefits of the present
invention can be
obtained by selecting some of the features of the present invention without
utilizing other
features. Accordingly, those who work in the art will recognize that many
modifications and
adaptations to the present invention are possible and can even be desirable in
certain
circumstances and are a part of the present invention. Thus, the following
description is
provided as illustrative of the principles of the present invention and not in
limitation thereof
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[0053] As used throughout, the singular forms "a," "an" and "the" include
plural referents
unless the context clearly dictates otherwise. Thus, for example, reference to
"a beam
member" can include two or more such beam members unless the context indicates
otherwise.
[0054] Ranges can be expressed herein as from "about" one particular value,
and/or to
"about" another particular value. When such a range is expressed, another
aspect includes
from the one particular value and/or to the other particular value. Similarly,
when values are
expressed as approximations, by use of the antecedent "about," it will be
understood that the
particular value forms another aspect. It will be further understood that the
endpoints of each
of the ranges are significant both in relation to the other endpoint, and
independently of the
other endpoint.
[0055] As used herein, the terms "optional" or "optionally" mean that the
subsequently
described event or circumstance may or may not occur, and that the description
includes
instances where said event or circumstance occurs and instances where it does
not.
[0056] The word "or" as used herein means any one member of a particular list
and also
includes any combination of members of that list.
[0057] The word "substantially" as used herein can be used to define an
angular tolerance
of +/- 15 degrees with respect to a disclosed (e.g., desired) angular
relationship between two
geometric entities. For example, "substantially vertical" can indicate that a
reference surface
or body is oriented vertically or within +/- 15 degrees of absolute vertical
alignment.
Similarly, "substantially collinear" can indicate that two bodies can are
collinear or
positioned within an alignment divergence of +/- 15 degrees of a collinear
orientation (with
the second body having an angular orientation relative to the first body that
is less than or
equal to 15 degrees and greater than or equal to -15 degrees).
[0058] In the following description, the orientation of the components of the
disclosed
building elements, retaining walls, and wall systems can be described with
reference to a
series of axes, including a first axis 114, a second axis 116 that is
perpendicular to the first
axis, and a third axis 118 that is perpendicular to the first and second axes.
A primary plane
can be defined by and contain the first axis and the second axis. A secondary
plane can be
defined by and contain the second axis and the third axis. A tertiary plane
can defined by and
contain the first axis and the third axis.
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[0059] In various aspects, described herein with reference to FIGS. 1-22 are
building
elements 100, 100A, 100B, 100C, 100D, 100E that are configured to be assembled
together
with at least one other building element to form a retaining wall 300. In
these aspects, the
building elements can comprise a face panel defining a front surface and a
rear surface
oriented on an opposing side of the face panel from the front surface. It is
contemplated that
the face panel can comprise a length dimension oriented along the first axis
114 and a height
dimension oriented along the third axis 118. In additional aspects, and as
further disclosed
herein, the building elements can further comprise at least one beam member
coupled to the
rear surface of the face panel. Each beam member can have an upper surface and
a lower
surface. The beam member can comprise a height dimension oriented along the
third axis
118 and a length dimension oriented along the second axis 116. Optionally, in
exemplary
aspects, at least one surface of the upper surface and the lower surface of at
least one beam
member can define an alignment void as further disclosed herein.
[0060] FIGS. 1-6 depict examples of a building element 100A that can be used
to form at
least a portion of a retaining wall 300. In an aspect, building element 100A
can comprise a
face panel 102 and at least one beam member 104. To provide a framing
structure for a
retaining wall, the face panel 102 can be coupled or secured to the beam
member 104.
Optionally, in exemplary aspects, a portion of each beam member 104 can be
permanently
secured to or integrally formed with a corresponding face panel 102. In an
aspect, the face
panel 102 can comprise a front surface 102A and a rear surface 102B. The front
surface 102A
and the rear surface 102B can be defined on opposing sides of the face panel
102.
[0061] As depicted in FIG. 1, the face panel 102 can comprise a rectangular
surface
comprising a length dimension, which can extend along the first axis 114. The
face panel 102
can further comprise a width/thickness dimension, which can extend along the
second axis
116. The face panel 102 can still further comprise a height dimension, which
can extend
along the third axis 118. In a further aspect, the face panel can be oriented
at an angle with
respect to the primary plane, which contains and is defined by the first axis
114 and the
second axis 116. Optionally, in this aspect, the face panel 102 can be
perpendicular or
substantially perpendicular to the primary plane (and the second axis 116).
That is, the face
panel 102 can be oriented vertically or substantially vertically
(approximately 90 degrees)
with respect to the primary plane defined by the first and second axes 114,
116 (and parallel
or substantially parallel with respect to the third axis 118). In general, the
primary plane will
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be approximately level and can be parallel or substantially parallel to a
ground surface on
which the retaining wall is erected. In a further aspect, at least a portion
of the rectangular
surface of the face panel 102 can be coplanar or substantially coplanar with
the secondary
plane, which contains and is defined by the first axis 114 and the third axis
118.
[0062] Although generally described herein as having a flat, rectangular
construction, it is
contemplated that at least a portion of the face panel 102 can have a radius
of curvature that
defines an arcuate profile (e.g., a convex or concave profile). For example,
the face panel can
bow with respect to an arcuate path determined by the associated radius.
[0063] In another optional configuration, and as shown in Figures 1-6, the
face panel 102
can also comprise at least one projection 120 extending outwardly from one of
a top surface
102C or a bottom surface 102D of the face panel. Additionally, or
alternatively, as shown in
FIG. 12, the face panel 102 can define at least one inwardly recessed notch or
slot 112A. In
exemplary aspects, the face panel can comprise a plurality of projections 120
extending
outwardly from the top surface 102C and a plurality of notches or slots 112A
defined within
the bottom surface 102D of the face panel 102. Additionally, or alternatively,
the face panel
can comprise a plurality of projections 120 extending outwardly from the
bottom surface
102D and a plurality of notches or slots 112A defined within the top surface
102C of the face
panel 102. In use, each notch or slot 112A can be configured to receive a
corresponding
projection of an adjacent face panel (upper or lower) when a retaining wall
300 is constructed
as disclosed herein. Optionally, when the top or bottom surfaces 102C, 102D of
the face
panel 102 comprise both projections 120 and notches or slots 112A, it is
contemplated that
each slot of the face panel can be axially spaced from each projection of the
face panel
relative to the first axis 114.
[0064] In use, it is contemplated that the projections 120 and notches or
slots 112A can be
used as engagement features to further stabilize the face panel 102. For
example, engaging
the face panels 102 of respective panels during retaining wall construction
can reduce
movement of the face panels along the second axis 116. Optionally, it is
contemplated that
the projections 120 can be oriented perpendicularly or substantially
perpendicularly to the
first plane (and extend parallel or substantially parallel relative to the
third axis 118). In a
further aspect, a portion of the top or bottom surface of the face panel can
be coplanar of the
first plane comprising the first axis 114 and the second axis 116. Optionally,
in exemplary
aspects, and as shown in FIG. 1, the projections 120 can comprise a base
surface 120B
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coupled to the top surface 102C or bottom surface 102D of the panel 102 and an
apex or apex
surface 120A that is spaced outwardly from the base surface 120B relative to
the third axis
118. For example, it is contemplated that the projection 120 can optionally
comprise a
pyramid or dome type structure, with the apex 120A corresponding to the
minimal diameter
portion of the projection and the base surface 120B corresponding to the
maximal diameter
portion of the projection. In yet another example, the projection 120 can
define an apex
surface 120A as opposed to a true apex, such as a tip. In this example, it is
contemplated that
a variety of shapes for the projection are possible, including, for example
and without
limitation, a rhomboid shape, a conical frustum, a rectangular prism, a
cylinder, and the like.
During the construction of a face panel 102 comprising a projection 120 or a
notch or slot
that is configured to receive a projection, a mold can be formed to have a
corresponding
indentation that defines a projection 120 in one or more surfaces of a face
panel as disclosed
herein. Similarly, it is contemplated that the mold can define a projection or
protrusion that is
configured to form a notch a slot in one or more surfaces of a face panel as
disclosed herein.
In use, the projection 120 can be configured to increase the stability of the
retaining wall
when building elements 100 are stacked upon each other. For example, in
another aspect, as
shown in FIG. 13, a notch, slot, or other alignment void 112 can be defined by
a top surface
102C or bottom surface 102D of the face panel 102, and each alignment void 112
can be
configured to receive a corresponding projection 120 as disclosed herein.
[0065] As discussed earlier, the building element 100 can comprise a beam
member 104,
which can comprise a length dimension oriented along the second axis 116, a
width
dimension oriented along the first axis 114, and a height dimension oriented
along the third
axis 118. In exemplary aspects, the beam member 104 can comprise a brace
section 106 that
is mechanically coupled or secured to the rear surface 102B of the face panel
102.
Optionally, it is contemplated that at least a portion of the beam member can
be integrally
formed with the face panel 102. In further aspects, the beam member 104 can
comprise a
back section 108 that has a length dimension along the first axis 114 such
that it is
perpendicular or substantially perpendicular to the brace section 106.
Optionally, it is
contemplated that the back section 108 can be integrally formed with a rear
portion of the
brace section 106. Alternatively, it is contemplated that the brace section
106 and the back
section 108 can be formed separately and mechanically coupled or attached.
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[0066] Optionally, as shown in FIGS. 1-2, it is contemplated that the back
section 108 can
have a trapezoidal cross-sectional shape, although alternative shapes are
possible. In general,
the length dimension of the brace section 106 and length dimension of the back
section 108
are perpendicular with respect to one another to provide stability and
balance. In an aspect,
the back section 108 can have a length dimension ranging from about 4 ft. to
about 30 ft.,
from about 6 ft. to about 20 ft., or from about 7 ft. to about 10 ft.
Optionally, the back section
can have a length dimension of about 8 ft. It is further contemplated that the
dimensions of
the face panel 102, beam member 104 and back section 108 can further vary to
accommodate
the mode of transportation. More particularly, it is contemplated that the
length dimensions
of the face panel 102, beam member 104, and back section 108 can be selected
to maximize
efficiency in shipment or transport. For example, during shipment of building
elements 100
on a tractor trailer with a towing bed length of 50 to 55 feet, it is
contemplated that the length
dimensions of the face panel 102, the beam member 104, and the back section
108 can be
selected such that the length dimension of the beam member does not exceed the
width of the
towing bed and the length dimensions of the face panel 102 and the back
section 108 are
sufficiently small that the towing bed can accommodate at least two building
elements along
its length.
[0067] As depicted in FIG. 1, a top surface of the brace section 106 extends
higher along
the third axis 118 than the top surface of the back section 108. In addition,
the trapezoidal
cross section of the back section 108 can comprise a back surface 109 oriented
at an angle
relative to the third axis 118. In a further aspect, this back surface 109 can
be coplanar or
substantially coplanar with a rear surface 106C of the beam member. The angled
orientation
of surfaces 109 and 106C, in addition to the top surface of the back section
108, can define an
engagement surface for engagement with the extension element 200 depicted in
FIG. 8 and
further described herein.
[0068] Referring to Figures 3-6, the length dimension of the back section 108
can be
divided at a coupling junction 111 positioned at the intersection of the back
section and the
brace section 106. As depicted, it is contemplated that the back portion 108
can be
asymmetric relative to the coupling junction 111, with unequal lengths of the
back portion
positioned on opposing sides of the coupling junction. Alternatively, the back
portion 108
can be symmetric relative to the coupling junction 111, with equal or
substantially equal
lengths of the back portion positioned on opposing sides of the coupling
junction. The
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symmetry or asymmetry of the back section 108 relative to the coupling
junction 111 can be
adjusted to account for variations in the underlying earth. Similarly, it is
contemplated that
the front panel of each building element can either be symmetric or asymmetric
relative to the
junction between the beam member and the front panel.
[0069] In an aspect, the beam member 104 can have a length dimension ranging
from about
3 ft. to about 14 ft., from about 4 ft. to about 12 ft., or from about 5 ft.
to about 10 ft.
Optionally, the beam member can have a length dimension of about 8 ft. In an
aspect, the
beam member 104 can have a height dimension ranging from about 3 ft. to about
9 ft., from
about 4 ft. to about 8 ft., or from about 5 ft. to about 7 ft. Optionally, the
beam member 104
can have a height dimension of about 6 ft. In a further aspect, the beam
member 104 can
have a width dimension ranging from about 3 in. to about 9 in., from about 4
in to about 8 in.,
or from about 5 in. to about 7 in. Optionally, the beam member 104 can have a
width of about
6 in.
[0070] In various aspects, and with reference to FIGS. 3-6, each building
element 100 can
further comprise at least one reinforcement wing 110. In these aspects, each
reinforcement
wing 110 can comprise a member that strengthens the coupling between the beam
member
104 and either the face panel 102 or the back portion 108. Functionally, the
reinforcement
wing 110 can increase structural integrity of the building element 100 by
preventing the face
panel 102 or the back portion 108 from being bent by internal earth load
pressures.
Structurally, a reinforcement wing 110 can be operably coupled or secured to
the rear surface
102B of the face panel 102 and a side surface of the brace section 106 of the
beam member
104. Similarly, it is contemplated that a reinforcement wing 110 can be
operably coupled or
secured to a front surface of back portion 108 and a side surface of the brace
section 106 of
the beam member. In exemplary aspects, reinforcement wings can be provided in
pairs, with
a first reinforcement wing 110 positioned on a first side of the beam 104
relative to first axis
114 and a second reinforcement wing 110 positioned on a second, opposite side
of the beam
relative to the first axis, thereby providing additional stability. For
example, the at least one
reinforcement wing can comprise a first pair of reinforcement wings that
extend, respectively,
from opposite sides of the beam 104 to contact portions of the face panel 102
or the back
portion 108 that are positioned on opposing sides of the beam relative to the
first axis 114.
Optionally, it is contemplated that the at least one reinforcement wing 110
can comprise first
and second pairs of reinforcement wings, with a first pair of reinforcement
wings extending,
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respectively, from opposite sides of the beam 104 to contact portions of the
face panel 102
that are positioned on opposing sides of the beam relative to the first axis
114, and with a
second pair of reinforcement wings extending, respectively, from opposite
sides of the beam
104 to contact portions of the back portion 108 that are positioned on
opposing sides of the
beam relative to the first axis 114.
[0071] In exemplary aspects, it is contemplated that the reinforcement wings
of each pair of
reinforcement wings can be symmetrical relative to the beam 104. However, in
other
exemplary aspects and as shown in FIGS. 3-6, it is contemplated that the
reinforcement wings
of each pair of reinforcement wings can be asymmetrical relative to the beam
104. In various
aspects, it is contemplated that each reinforcement wing 110 can have a width
dimension
relative to the first axis 114 and a length dimension relative to the second
axis 116.
Optionally, in these aspects, the reinforcement wings of a pair of
reinforcement wings can
have different width dimensions while maintaining substantially equal length
dimensions. In
further exemplary aspects, when the reinforcement wings of a pair of
reinforcement wings
have curved or arcuate side surfaces that define a curve or arc within the
primary plane, it is
contemplated that each side surface can have a respective radius of curvature.
Optionally, in
these aspects, the side surfaces of the reinforcement wings of the pair of
reinforcement wings
can have an equal radius of curvature; alternatively, in asymmetrical
configurations, it is
contemplated that the side surfaces of the reinforcement wings can have
different radii of
curvature.
[0072] Optionally, each reinforcement wing can have a triangular shape;
however, other
geometric shapes are possible. For example, as shown in FIGS. 1 and 2, the
reinforcement
wings 110 extending between the beam 104 and the face panel 102 can have an
arcuate
profile with a variable cross-sectional area relative to the third axis 118,
such as an arcuate
profile including a curved or arcuate side surface (e.g., a concave side
surface) and a curved
or arcuate upper surface (e.g., a concave upper surface), which can optionally
extend
upwardly from the side surface and taper inwardly until reaching the top
surfaces of the face
panel and the beam at the junction between the face panel and the beam. In
other examples,
it is contemplated that the reinforcement wings 110 can define planar upper
and lower
surfaces and have a side surface that extends between the upper and lower
surfaces and has
either a straight orientation or a curved or arcuate orientation. In another
aspect, as shown in
FIGs. 7 and 9, each reinforcement wing can comprise a triangular prism that
extends along
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the height dimension of the beam and has a uniform cross sectional area along
the third axis
118. As shown in FIGS. 4-6, the respective top views of the reinforcement
wings 110
demonstrate a variety of triangular or arcuate profiles that can be used. In a
further aspect,
when a side surface of a reinforcement member extending from the beam to the
back portion
has a straight orientation (defining a reinforcement member with a generally
triangular
shape), it is contemplated that the side surface can define an angle A
relative to first axis 114.
Similarly, when a side surface of a reinforcement member extending from the
beam to the
face panel has a straight orientation (defining a reinforcement member with a
generally
triangular shape), it is contemplated that the side surface can define an
angle B relative to
first axis 114. For example, the angle A or B of reinforcement wings 110 can
range between
about 30 degrees and about 75 degrees, between about 45 degrees and about 60
degrees, or
between about 50 degrees and about 55 degrees. Optionally, the angles A or B
can be about
45 degrees.
EXEMPLARY BUILDING ELEMENT DIMENSIONS
[0073] In an aspect, the face panel 102 can have a length dimension ranging
from about 26
ft. to about 18 ft., from about 24 ft. to about 20 ft., or from about 23 ft.
to about 21 ft.
Optionally, the face panel can have a length dimension of about 22 ft. In an
aspect, the face
panel can have a height dimension ranging from about 9 ft. to about 3 ft.,
from about 8 ft. to
about 4 ft., or from about 7 ft. to about 5 ft. Optionally, the face panel can
have a height
dimension of about 6 ft. In a further aspect, the face panel can have a width
dimension
ranging from about 9 in. to about 3 in., from about 8 in. to about 4 in. or
from about 7 in. to
about 5 in. Optionally, the face panel can have a width of about 6 in. In a
further aspect, the
face panel can have a surface area defined by the length and height dimension
ranging from
about 235 sq. ft to about 54 sq. ft, from about 192 sq. ft to about 80 sq. ft,
or from about 161
sq. ft to about 105 sq. ft. Optionally, the face panel 102 can have a surface
area of about 132
sq. ft. It is further contemplated that the size of the face panel in this
disclosure can be about
3.3 to about 16 times larger than traditional building elements where the
respective panels
range from 8 sq. ft. to 40 sq. ft. It is also further contemplated that the
size of the disclosed
building elements 100A-C and 200 can increase the efficiency in building a
retaining wall, by
allowing for quicker wall construction and a reduction in the number of wall
components
needed to complete a wall assembly. The size of the building elements can also
increase the
structural integrity of a wall 300 as compared to traditional building
elements.
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BUILDING ELEMENTS HAVING BEAM MEMBERS WITH DETACHABLE BRACE
PORTIONS
[0074] In exemplary aspects, and with reference to FIGS. 1-6, 12, and 15, the
brace section
106 of the beam 104 can comprise a first portion 106A and a second portion
106B that is
selectively attachable and detachable from the first portion 106A. As shown in
FIG. 1, the
first portion 106A of the brace section 106 can be mechanically coupled or
secured to the rear
surface 102B of the face panel 102. Optionally, it is contemplated that the
first portion 106A
can be integrally formed with the face panel 102, such as, for example and
without limitation,
in a single molding process. In use, it is contemplated that the first portion
106A can be used
with a variety of second portions 106B having different features, including,
for example and
without limitation, different lengths relative to the second axis 116,
different constructions,
different reinforcement wing arrangements, different back portion dimensions
or structures,
and the like. Similarly, it is contemplated that the second portion 106B can
be used with a
variety of first portions 106A having different features, including, for
example and without
limitation, different lengths relative to the second axis 116, different
constructions, different
reinforcement wing arrangements, different face panel dimensions or
structures, and the like.
[0075] In erecting a retaining wall, it is contemplated that the modularity
provided by the
detachable portions of the brace section can provide increased variability in
the length
dimension of the beam member 104 and provide a builder with additional
flexibility in
building element configurations to account for variations in the earth. In
exemplary aspects,
as shown in FIGS. 12 and 15, the first and second portions 106A, 106B of a
brace section 106
can be securely attached to each other using at least one alignment post or
securing rod 126
(optionally, a plurality of securing rods) as disclosed herein. Optionally, in
these aspects, a
front portion of the second portion 106B of the brace section 106 can be
configured to overlie
a rear portion of the first portion 106A of the brace section to permit
attachment of the second
portion to the first portion. For example, as shown in FIGS. 1-2 and 12, the
first portion
106A can have a variable height moving along the second axis 116, with the
first portion
having a rear portion with a reduced height that defines a recess for
receiving and engaging
the front portion of the second portion 106B, which in turn can define a
complementary
recess that receives the rear portion of the first portion. When engaged
together, the first and
second portions 106A, 106B can cooperate to define a brace section 106 having
a consistent
height relative to the third axis 118. Optionally, an upper surface of the
rear portion of the
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first portion 106A can define at least one alignment void 112B that is
configured to receive a
portion of an alignment post or securing rod 126 that extends downwardly from
the front
portion of the second portion 106B. In exemplary aspects, a plurality of
securing rods 126
can span between the first and second portions 106A, 106B. In these aspects,
it is
contemplated that the securing rods 126 can be embedded within the second
portion 106B.
Alternatively, it is contemplated that the second portion 106B can define
respective
alignment voids that receive portions of the securing rods such that a portion
of each securing
rod is received within respective alignment voids of both the first and second
portions 106A,
106B. In a further aspect, a reinforcement bar 169 can be embedded within the
second
portion 106B of the brace section 106 and coupled to the securing rods 126.
The
reinforcement bar 169 can increase the alignment and stability of the securing
rods when the
securing rods 126 are engaged to alignment voids 112B located at the joint 107
between the
brace sections 106A, 106B.
BUILDING ELEMENTS HAVING BEAM MEMBERS THAT DEFINE HORIZONTAL
APERTURES
[0076] In another aspect, as depicted in FIG. 7, a surface of the brace
section 106 can
define an aperture 124 that surrounds an axis that is parallel to the first
axis 114. The aperture
124 can be used as a conduit to allow backfill comprising filler materials to
pass through the
beam member and allow for more consistent filling during erection of the wall.
In
exemplary non-limiting aspects, the aperture can have a cross-sectional area
ranging from
about 1 sq. ft. to about 10 sq. ft., from about 2 sq. ft. to about 9 sq. ft.
or from about 3 sq. ft.
to about 8 sq. ft. Optionally, the cross sectional area can be about 5 sq. ft.
The aperture 124
can also reduce cost and weight of the building element by reducing the amount
of concrete
needed to form the respective elements. The aperture can further provide
additional
engagement features to allow a crane or moving apparatus to grab the building
element for
transport. During erection of the wall, the apertures 124 can serve as
conduits to pass utilities
or communications lines and also allow for movement of workers among different
sections of
the wall assembly before filler materials have been delivered. The filler
materials 166 can
comprise earthen materials such as dirt, sand, gravel, rocks, sand, or the
like. In use, the
apertures 124 can help the building element maintain consistent contact with
the filler
material 166, thereby providing increased stability.
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[0077] As shown in FIG. 7, the building element 100B can also comprise an
alignment
post 122, which can extend downwardly from the building element 100B and
function in a
similar manner to projections 120.
EXTENSION ELEMENTS
[0078] As shown in FIG. 8, an extension element 200 can be configured to be
coupled to
the exemplary building element 100B in FIG. 7. The extension element 200 can
be
configured to align and reinforce the stability of building element 100B. In
particular, the
beam members 204 can be aligned with the beam members 104 of the building
element 100.
In addition, a front surface 202A of the face panel 202 of the extension
element 200 can serve
as a mating panel to the rear surface 109 of building element 100B. Abutting
the extension
element 200 with the building element 100B can increase the stability of the
resulting wall by
increasing the distance from the face panel 102 along the second axis 116. In
a further
aspect, the beam member 204 can overlap the face panel 202 along the length
dimension of
the beam member 204 (relative to the second axis 116). The overlap portion 211
of the beam
member 204 can rest on a top surface of the back member 108 of building
element 100B
while the front surface 202A can abut against the slanted surface defined by
the rear surfaces
106C of the brace section and the rear surface 109 of the back section. In a
further aspect, the
beam member 104 and the beam member 204 can be collinear or substantially
collinear along
the length dimension along the second axis 114. In yet a further aspect, the
extension
element 200 can also have alignment posts 112 and corresponding alignment
voids, which
can be configured to extend along the third axis 118 when in use. In an
aspect, the extension
member 200 can have a length dimension relative to the second axis 116 ranging
from about
2 ft. to about 8 ft., from about 3 ft. to about 7ft., or from about 4 ft. to
about 6 ft. Optionally,
the extension member 200 can have a length dimension of about 4 ft.
[0079] In exemplary aspects, it is contemplated that the extension beam
elements 204 can
define apertures 210 that function in the same way as, and are similarly
dimensioned to, the
apertures 124 of the beam members 104 of building element 100B.
ALIGNMENT POSTS
[0080] FIG. 10 depicts an exemplary aspect of an alignment post 122. The
alignment post
122 can comprise two components, a stem 142 and a cap 140. During construction
of the
alignment post 122, the stem 142 can be inserted into a mold filled with a
setting material to
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form the cap 140. The setting material can be concrete or the like. The cap
140 can comprise
a height dimension H that is associated with the amount of the cap that will
be received
within an alignment void 112 of another building element 100 during erection
of a retaining
wall as disclosed herein.
[0081] In a further aspect, the cap 140 can be shaped like a frustum having a
top surface
144 and a bottom surface 146. The stem 142 can comprise a stem axis 148
oriented along a
length dimension L of the stem 142. In another aspect, the stem axis 148 can
be perpendicular
or substantially perpendicular to a portion of the bottom surface 146 of the
cap 142. The
bottom surface 146 of the cap 140 can abut the top surface of the beam. In a
further aspect,
the portion of the stem extending downardly from the bottom surface of the cap
140 can have
a length L ranging from about 3 in. to about 10 in., from about 4 in. to about
8 in. or from
about 5 in. to about 7 in. Optionally, the length (L) of the exposed stem
portion can be about
in. In a further aspect, the width of the stem 142 can range from about 1 in.
to about 3 in.,
from about 1.25 in. to about 2.75 in. or from about 1.5 in. to about 2.5 in.
Optionally, the
width of the stem can be 2.5 in. In a further aspect, the height H of the cap
140 can range
from about 1.75 in. to about 3.25 in., from about 2.0 in. to about 3.0 in. or
from about 2.25 in.
to about 2.75 in. Optionally, the height of the cap can be about 2.5 in. In a
further aspect, the
width (outer diameter) of the base 146 of the cap 140 can range from about
1.75 in. to about
3.25 in., from about 2.0 in. to about 3.0 in. or from about 2.25 in. to about
2.75 in. Optionally,
the width of the base of the cap can be about 2.8 in.
[0082] Optionally, when the alignment post 122 is engaged to the alignment
void, there can
be a clearance space of 0.25 in. between an inner surface 102E that defines
the alignment
void 112 and the outer surface of the cap 140.
[0083] As shown in FIG. 10, in a further aspect, the cap 142 can be
strengthened using
reinforcement material 149 such as a metal or plastic material embedded within
the setting
material. During erection of a retaining wall system, the alignment post 122
can be placed in
the alignment void 112 defined by a surface of a respective beam member of a
building
element 100. As the stem 140 is set within the alignment void 112 of the
respective beam
member 104 the cap 142 will be the portion of the alignment post 122
protruding away from
the surface of the beam 104.
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[0084] In an alternative aspect, the stem 140 can comprise multiple materials.
For
example, an outer layer that circumscribes the stem axis 148 can comprise a
plastic material
such as polyethylene. An inner material for the stem 148 can be a metal bar
that serves as a
reinforcement of the plastic outer layer.
SECURING RODS
[0085] FIG. 9 depicts another exemplary embodiment of a building element 100C,
which
comprises a securing rod 126 extending away from a top or bottom surface 102C,
102D of
the building element. The beam member can also comprise an alignment void 112.
As
shown in FIG. 16, the securing rod 126 as well as the alignment void 112 can
be configured
to be engaged as further disclosed herein such that a plurality of building
elements 100C can
be stacked upon each other. Again, the engagement between the securing rod 126
(and
alignment posts) and their corresponding alignment voids 112 can allow the
building element
100C to have increased stability by securing a connection between the two
respective
building elements. In a further aspect, building element 100C can serve as the
top building
element in a retaining wall as further disclosed herein. In a further aspect,
the height
dimension of the face panel 102 is less than the height dimension of the beam
member 104.
RETAINING WALL SYSTEMS
[0086] As shown in FIG. 12, depicts a side view of building element 100A. As
further
disclosed herein, the brace section can be detachable into first portion 106A
and second
portion 106B. In a further aspect, the first portion 106A can be coupled
(e.g., secured) to the
face panel 102 and the second portion 106B can be detachably coupled to the
first portion at a
joint 107. In a further aspect, as disclosed herein, the first portion 106A
and the second
portion 106B can be coupled using securing rods 126. For example, a securing
rod 126 can
be a dowel, pin, or piece of rebar that is inserted to properly align the
first and second
portions 106A, 106B of the brace section of the beam member 104. In another
exemplary
aspect, the upper surfaces of the first and second portions 106A, 106B can
define respective
slots or recesses (alignment voids) that are configured to receive opposing
end portions of a
U-bar 150 as shown in FIG. 12. In this aspect, the respective alignment voids
can be axially
spaced relative to the second axis 116.
[0087] Figures 13-15 depict an exemplary retaining wall 300 structure
comprising a
plurality of building elements. In an aspect, the retaining wall can comprise
a combination of
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various types of building elements disclosed herein. It is contemplated that
the retaining
walls 300 can comprise a combination of one or more building elements 100A-E
and/or an
extension element 200 as disclosed herein. In a further aspect, as shown in
FIG 15, upon
assembly of a plurality of building elements 100A as disclosed herein to form
a retaining
wall, it is contemplated that the joints 107 of adjacent building elements
100A are not
vertically aligned. Optionally, in some exemplary aspects, it is contemplated
that no joint
107 of any building element 100A will be vertically aligned with the joint 107
of any other
building element 100A. For example, the joints 107 that occur at the
intersection between the
first and second portions 106A, 106B of the brace sections can be offset by at
least 1 foot
along the second axis 116. Offsetting the joint 107 across different layers of
the wall can
produce a staggered configuration that reduces the stress points in the wall.
In a further
aspect, staggering the joint 107 locations can reduce the potential of a fault
line that runs
through the layers of the wall. As also depicted, alignment voids can be
located at different
sections of the beam member 104 and face panel 102 to insure that the variable
configurations of the building elements can still be secured together. As
depicted, the top
layer of a retaining wall can comprise a building element 100C.
[0088] As shown in FIG 16, the securing rod 126 as well as the alignment void
112 can be
configured to be engaged such that a plurality of building elements 100C can
be stacked upon
each other. Again, the combination of engagement between the securing rod 126
and
alignment notches 120 with the alignment void 112 allows the building elements
100 to have
increased stability by securing a connection between the two respective
building elements. In
a further aspect, building element 100C can serve as the top building element
in a retaining
wall. In a further aspect, the height dimension of the face panel 102 is less
than the height
dimension of the beam member 104.
[0089] An additional aspect adding to the versatility of building elements
100A-E is that
they can be produced from a single mold. During the casting of a building
element, a
manufacturer can transition between respective building elements by adjusting
the internal
molding structure (e.g., by filling in receptacles or emptying receptacles to
modify the shape
to be created by the mold). The adjustments to the internal molding structure
allow alternate
components of a building element to be formed with a differing shape or
orientation.
[0090] Although generally described herein as having a substantially vertical
orientation, it
is contemplated that the retaining walls produced as disclosed herein can have
any desired
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orientation relative to the a horizontal plane, including for example and
without limitation, a
wall batter producing an angular orientation ranging from about 70 degrees to
about 90
degrees relative to the horizontal plane.
SECURING DEVICES
[0091] FIG. 17 depicts another exemplary building element 100E comprising a
face panel
102, a beam member 104, and a back section 108. In a further aspect, the
building element
100D can comprise a securing device 152 for coupling two building elements
100D. The
securing device 152 can comprise fixtures that can lock two respective
building elements
100D to each other. For example, the securing device 152 can comprise securing
rod 126 and
securing bracket 154. In a further aspect, the securing rod 126 can be affixed
to the bracket
154 by a nut/washer 156 combination. The securing rod 126 and the securing
bracket 154
can be oriented such that the securing rod 126 can pass through a void in the
alignment
bracket 154.
[0092] FIG. 17 depicts another exemplary building element 100E comprising a
face panel
102 and a beam member 104. In a further aspect, the building element 100D can
comprise a
securing device 152 for coupling two building elements 100D. The securing
device 152 can
comprise fixtures that can lock two respective building elements 100D to each
other. The
securing device 152 can prevent an upper building element from leaning over
during the
erection of the retaining wall. For example, the securing device 152 can
comprise securing
rod 126 and securing bracket 154. In a further aspect, the securing rod 126
can be affixed to
the bracket 154 by a nut/washer 156 combination. The securing rod 126 and the
securing
bracket 154 can be oriented such that the securing rod 126 can pass through a
void in the
alignment bracket 154. FIGs. 18 and 19 depict alternative configurations of
the securing
device 152 and their respective attachment to a building element 100E. FIG. 20
depicts
another embodiment of the securing device, wherein the securing bracket 154 is
not oriented
at an angle and only lies in a single plane. In a further aspect, the securing
bracket 154 can be
attached to the rear surface 102B.
SPACERS
[0093] In an alternative aspect, as depicted in FIG. 21, two building elements
can be
oriented in a wall without being physically coupled (i.e., the spacers are not
mechanically
fixed in any way to the building elements). For example, a spacer 160 can be
used to
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maintain a space 162 between two respective face panels 102. For example, the
space 162
allows building elements 100 to settle independently in a vertical or
substantially vertical
orientation without touching each other. The size of the space may be
evaluated based on
any determined irregularities in the settlement of backfill. During erection,
the spacer 160
can be covered with a geotextile fabric to prevent erosion. In as aspect, the
spacer 160 can
comprise weather resisting materials such as roof shingles, slate rocks,
galvanized stretch
metal pieces covered with geotextile fabric. The spacer can also be placed on
the rear surface
102B that faces the earth (filler material) 166. In a further aspect, the
space 162 can range
from about 0.25 in. to about 4 in., from about 1.5 in. to about 3.0 in, or
from about 2.0 in. to
about 2.5 in. Optionally, the space 162 can be about 2.5 in. In exemplary
aspects, the spacer
can have a dimension relative to the first axis 114 that is at least 2 to 3
times the size of space
162. In operation, the spacer 160 can provide a cantilevering function to the
front panels
toward the open joint, with the spacer cooperating with the common fill behind
the panels to
provide tolerance and stability in case of an earthquake or irregular
settlement.
[0094] It is contemplated that the spacer 160 can work with any combination of
building
elements disclosed herein.
JOINT STIFFENERS
[0095] In an aspect of the retaining wall, a joint 163 between face panels 102
can be
strengthened using a joint stiffener 164 as depicted in FIG. 22. In a further
aspect, the joint
stiffener 164 can be oriented along the height dimension of the face panel 102
along the third
axis 118. To facilitate the insert of the circular joint stiffener 164, the
surfaces along the third
axis 118 of the face panel 102 can define a semicircular channel 102E. It also
further
contemplates that the joint stiffener can have another geometric cross
sectional shape.
Similarly, the surface of the face panel can define a channel that mates with
the alternative
geometric cross sectional shape. In another aspect the joint stiffener 164 can
be annular
configuration wherein the joint stiffener is filled with a filler material
166. The filler material
can comprise earthen material such as dirt, sand, or gravel. In a further
aspect, the joint
stiffener can comprise polyethylene which is flexible and UV resistant.
BUILDING ELEMENTS HAVING FILL RECEIVING SPACES
[0096] Disclosed herein with reference to FIGS. 23A-28B is a building element
400 for
forming a portion of a retaining wall. In exemplary aspects, the building
element 400 can
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comprise a face panel 410 comprising a top surface 412, a bottom surface 414,
a front surface
416, and a rear surface 418 positioned on an opposing side of the face panel
from the front
surface. In these aspects, the face panel 410 can comprise a length dimension
oriented along
a first axis 402, a width dimension oriented along a second axis 404 that is
perpendicular to
the first axis, and a height dimension oriented along a third axis 406 that is
perpendicular to
the first and second axes.
[0097] In additional aspects, the building element 400 can comprise a beam
member 420
coupled to (e.g., secured to or integrally formed with) the rear surface 418
of the face panel
410. In these aspects, the beam member 420 can comprise a main body 422 and
first and
second foot portions 424, 426. In some aspects, the main body 422 can have an
upper surface
428 and first and second side surfaces 430, 432 that are parallel or
substantially parallel to the
second axis 404. In further aspects, the first and second foot portions 424,
426 can project,
respectively, from the first and second side surfaces 430, 432 relative to the
first axis 402. In
these aspects, the first and second foot portions 424, 426 can have respective
lower surfaces
434 that are co-planar or substantially co-planar with the bottom surface 414
of the face panel
410 and respective upper surfaces 436 that are positioned between the bottom
and top
surfaces of the face panel relative to the third axis 406.
[0098] Optionally, the beam member 420 can be integrally formed with the face
panel 410
as a monolithic structure.
[0099] In additional aspects, the beam member 420 can have a distal end
portion 450 (e.g.,
a vertical pillar) spaced from the front panel 410 relative to the second axis
404. In these
aspects, the distal end portion 450 can comprise first and second projections
452, 454 that
project, respectively, from the first and second side surfaces 430, 432 of the
main body 422
of the beam member 420. As shown in the Figures, the first and second
projections 452, 454
can cooperate with respective portions of the first and second foot portions
424, 426, the first
and second side surfaces 430, 432 of the main body 422, and the rear surface
418 of the face
panel 410 to define first and second receiving spaces 460, 462 on opposing
sides of the beam
member. As further disclosed herein, the receiving spaces 460, 462 can be
configured to
receive and at least partially enclose fill material. It is further
contemplated that the structure
of the disclosed building element 400 and, in particular, the structure of the
disclosed beam
member 420, can increase the internal arching effect of the fill weight inside
the receiving
spaces, thereby wedging and holding the fill weight in place.
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[00100] As depicted in the Figures, the distal end portion 450 of the beam
member 420 can
be widened to form a vertical pillar along the back of the building element
for bracing against
lateral earth pressures (like a soldier pile) to enhance the arching between
such pillars,
thereby increasing lateral earth pressure transfer directly from the backfill
onto the building
element (wall structure).
[00101] As further depicted in the Figures, the inner surfaces of the first
and second
projections 452, 454 of the distal end portion 450 (pillar) close the back of
the inside backfill
of the building element and thereby enhance the arching effect of internal
fill material silo
pressures directly onto the building element, which serves to enhance the
gravity wall effect
(a gravity wall resists against lateral earth pressures by the heavy weight of
the wall (which is
20% concrete unit weight and 80% inside cell backfill earth weight).
[00102] In exemplary aspects, the distal end portion 450 of the beam member
420 can have
a width that is significantly greater than is present in conventional
retaining wall structures.
For example, in some aspects, it is contemplated that the width of the distal
end portion 450
can range from about 2.5 feet to about 5 feet and, optionally, be at least 3
feet. It is
contemplated that this increased width can increase the internal arching
effect of the fill
weight inside the receiving spaces and against the distal end portion, thereby
increasing the
stability of the building element. In further exemplary aspects, it is
contemplated that the
face panel can have a width ranging from about 6 feet to about 12 feet and,
optionally, be at
least 7 feet or at least 8 feet. In these aspects, it is contemplated that an
increased width of
the face panel can further increase the arching effect of the cell fill along
the front panel.
[00103] In further exemplary aspects, the face panel 410 can have opposed
first and second
side edges 470, 472 that are spaced apart relative to the first axis 402. In
these aspects, the
front surface 416 of the face panel 410 can comprise first and second portions
474, 476 that
extend, respectively, from the first and second side edges 470, 472 to a
center point 478 that
is intersected by the vertical reference plane 408. It is contemplated that
the first and second
portions 474, 476 of the front surface 416 can be angularly oriented relative
to each other.
Optionally, the first and second portions 474, 476 of the front surface
together define a V-
shape.
[00104] Optionally, the face panel 410 can have a variable width relative to
the second axis
404. In exemplary aspects, the face panel can have a maximum width within a
vertical
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reference plane 408 that bisects the length dimension of the face panel 410.
It is
contemplated that this panel structure (with a maximum thickness at the
center) can provide
optimal moment resistance against cell-fill earth pressures at the center of
the panel.
Optionally, in these aspects, the face panel can have a minimum width at the
opposing side
edges 470, 472, where there is no moment.
[00105] In addition to providing the disclosed performance advantage, it is
contemplated
that the variation in panel thickness and the V-shaped profile of the front
surface 416 of the
face panel 410 can provide a desired front-face appearance and visual effect,
which can
optionally produce variation in the appearance of shadows during the day.
[00106] In exemplary aspects, as the beam member 420 can define at least one
pin hole 442
(optionally, a plurality of pin holes, such as two pin holes) that permit
engagement between
the building element and a pin and/or lifting cable of a crane or other
handling/lifting
apparatus. Such pin holes can be formed during the manufacturing process. In
use, the pin
holes can permit fast and safe installation of the building elements.
[00107] As one of skill in the art can appreciate, in some exemplary aspects,
the disclosed
building elements can be provided as one-piece "cribwall" units that can be
cast with a large
front panel and a beam member that forms a partially closed backfill cell and
is closed at the
bottom for "wedging in" the fill such that the fill cannot simply drop out.
This "wedging in"
of the fill occurs (in part) due to the arching effect (both horizontal and
vertical) along the
foundations of the face panel and the beam member, including the enlarged
distal end portion
(pillar), with the fill being wedged between the face panel and the widened
portion of the
pillar. In use, the fill cannot move out of the cell and must function
together with the wall
structure to form a cribwall (which is a concrete container structure
containing a maximum
amount of fill material for creating the weight needed to resist the enormous
lateral earth
pressures). In use, it is contemplated that such building elements can be easy
to fill and
compact, while providing easy access (from the back of the building element)
to large
excavators, vibratory rollers, and compactors, which perform far better than
hand tools.
Thus, in use, it is contemplated that the disclosed building elements can
reduce or eliminate
the need for expensive hand-labor work, which is typically unreliable and
inefficient.
[00108] Optionally, as shown in FIGS. 23D-23G, the building element 400 can
further
comprise at least one longitudinal elbow 435 (optionally, a plurality of
vertically spaced
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longitudinal elbows 435) that projects outwardly from the main body 422 of the
beam
member 420 and extends between the face panel 410 and the distal end portion
450 of the
beam member. In exemplary aspects, it is contemplated that respective
longitudinal elbows
435 can extend outwardly from both side surfaces 430, 432 of the main body 422
(preferably
in a symmetrical or balanced arrangement with equal numbers of elbows
extending from each
side surface). Additionally, or alternatively, the building element 400 can
comprise at least
one transverse elbow 455 that projects outwardly from a rear surface of the
distal end portion
450 of the beam member 420. Optionally, as shown in FIG. 23G, it is
contemplated that
respective longitudinal elbows 435 (on both sides of the main body) and a
corresponding
transverse elbow 455 can extend continuously along the side and rear surfaces
of the beam
member. Alternatively, a gap between the longitudinal and transverse elbows
can be
provided as shown in FIG. 23F. Optionally, in exemplary aspects, it is
contemplated that
each elbow 435, 455 can have a pointed or beveled shape. In exemplary aspects,
it is
contemplated that each elbow 435, 455 can be vertically spaced from the bottom
and top
surfaces of the beam member 420.
[00109] In use, it is contemplated that the elbows can be configured to
provide horizontal
stiffening of the beam member 420 and/or the distal end portion 450 of the
beam member.
This horizontal stiffening is particularly beneficial for longer building
elements, which can
have a length ranging anywhere from about 5 feet up to about 34 feet. Such
stiffening of
longer building elements can greatly help with manufacturing, loading, and
transporting of
the building elements.
[00110] It is further contemplated that the elbows can be configured to
initiate and positively
support and create substantial arching of the fill inside the building
elements to function as a
real container for the fill. It is contemplated that arches inside the
building elements can
more effectively transfer the weight of the fill onto the building elements to
greatly help
stabilize the gravity wall effect.
[00111] Additionally, with respect to the transverse elbows 455 along the back
of the
building elements, these transverse elbows can greatly encourage the support
of backfill
material behind the wall by increasing the vertical fill weight effect to
stabilize the wall
against overturning. These transverse elbows can affect the backfill in a
number of ways. In
particular, the backfill cannot simply slide down along the pillars during
compaction; rather,
the backfill will at least partially "sit" or rest on the pillar, thereby
stabilizing the retaining
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structure against overturning. Thus, the transverse elbows affect the way the
backfill forces
are distributed within the area directly behind the wall structure. Therefore,
the transverse
elbows 455 enlarge and affect the fill material beyond the actual back of the
wall structure
such that the retaining wall structural "effect" reaches beyond the actual
wall footprint. In
use, the transverse elbows 455 can increase the vertical loads onto the
pillars from outside the
wall "footprint."
[00112] Additionally, or alternatively, as shown in FIG. 24, the building
element 400 can
further comprise a base projection 465 extending away from a base portion of
the rear surface
418 of the front panel 410. Optionally, the base projection 465 can have a
bottom surface
that is flush with a bottom surface of the face panel 410. As shown, the base
projection 465
can have a downward slope moving away from the upper surface of the building
element
(and toward the bottom surface of the building element) such that the width of
the base
projection (measured relative to axis 116) increases moving away from the
upper surface of
the building element. In use, it is contemplated that the base projection can
function in a
manner similar to the elbows 435, 455. That is, the base projection can be
configured to
initiate and positively support and create substantial arching of the fill
inside the building
elements to function as a real container for the fill, thereby allowing for
more effective
transfer of the weight of the fill onto the building elements to improve
stability. In use, it is
contemplated that backfill will at least partially "sit" or rest on the base
projection, thereby
stabilizing the retaining structure against overturning.
[00113] Overall, the disclosed elbows 435, 455 and base projection 465
effectively change
and challenge the internal earth pressures to act differently and enhance the
wall stability with
minimal additional cost.
[00114] In exemplary aspects, it is contemplated that the elbows can be formed
using the
molding process described herein. In these aspects, it is contemplated that
the elbows can
optionally be formed integrally with the remainder of the beam member as a
monolithic
structure.
[00115] Optionally, in further aspects, and as shown in FIG. 26B, the beam
member 420 can
have a proximal end portion 480 having first and second portions 482, 484 that
extend,
respectively, from the first and second side surfaces 430, 432 of the beam
member to the rear
surface 418 of the front panel 410. In these aspects, each of the first and
second portions 482,
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484 of the proximal end portion 480 can extend at an obtuse angle relative to
adjoining
portions of the first and second side surfaces 430, 432 of the beam member.
Optionally, in
further aspects, the rear surface 418 of the front panel 410 can comprise
first and second end
sections 490, 492 positioned on opposing sides of the proximal end portion 480
of the beam
member 420. In these aspects, the first and second end sections 490, 492 of
the rear surface
418 of the front panel 410 can be parallel or substantially parallel to the
first axis 402.
[00116] In another aspect, the upper surfaces 436 of the first and second foot
portions 424,
426 of the beam member 420 can slope downwardly from the respective side
surfaces 430,
432 of the main body 422 of the beam member.
[00117] In still another aspect, the front surface 416 of the face panel 410
can comprise an
upper portion 475 and a base portion 477 that extends between the upper
portion and the
bottom surface 414 of the face panel relative to the third axis 406. In this
aspect, the base
portion 477 can be angularly oriented to extend outwardly relative to the
upper portion 475 of
the front surface 416 of the face panel 410.
[00118] Optionally, in exemplary aspects, the base portion 477 of the panel
410 can have an
outwardly sloped profile with an increase thickness than the upper portion 475
of the panel.
Optionally, the panel can have a continuously sloped profile, with the base
portion
corresponding to the thickest sections of the panel. Alternatively, the base
portion 477 can
project from the upper portion 475 and define a visible "nose." Some purposes
of such a
"nose" along the bottom of the panel include creating a shade along the bottom
joint that
covers up small imperfections of an underlying panel (resulting from
manufacturing or
handling) and to emphasize the horizontal joint visually for an additional
architectural effect.
[00119] Optionally, in further aspects, the face panel 410 can comprise a
reinforcing
material 500 (e.g., at least one steel bar, a steel plate, or a wire mesh)
that is embedded within
the face panel and oriented parallel or substantially parallel to the first
axis 402. In these
aspects, it is contemplated that the parallel or substantially parallel
orientation of the rear
surface 418 of the face panel 410 can allow for positioning of the
reinforcement material 500
without the need for bending, thereby maximizing efficiency in the assembly
process.
[00120] In exemplary aspects, the reinforcement material 500 can be provided
as one or
more wire mesh sections 405, as shown in FIGS. 27A-27B. Optionally, as shown
in FIG.
27A, the face panel 410 can comprise at least a first wire mesh section 405
that extends
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parallel or substantially parallel to the first axis 114. A corresponding wire
mesh section
405a is depicted in FIG. 27B. These wire mesh sections extend along the back
face of the
panel with a straight mesh. As shown in FIG. 27B, it is contemplated that
additional wire
meshes 405b, 405c, 405d can optionally be positioned within the panel and/or
beam member.
As shown in FIG. 27B, it is contemplated that the provision of wire mesh
section 405b can be
possible due to the increased and variable panel thickness further discussed
herein, which
leads to efficient reinforcement.
[00121] Optionally, in still further aspects, the face panel 410 can comprise
a plurality of
steel bars 510 that are embedded within the face panel. Optionally, in
exemplary aspects, and
as shown in FIG. 27A, the face panel 410 can comprise at least first and
second steel bodies
510 (e.g., steel bars) that are embedded within the face panel. In these
aspects, the first and
second steel bodies 510 have respective first and second ends, wherein the
first ends of the
first and second steel bodies are positioned proximate the center point 478 of
the center
section of the rear surface. It is further contemplated that the first steel
body can be oriented
parallel or substantially parallel to the first portion of the center section
of the rear surface of
the face panel, and wherein the second steel body is oriented substantially
parallel to the
second portion of the center section of the rear surface of the face panel.
[00122] In further aspects, at least one surface of the top surface 412 and
the bottom surface
414 can define an alignment void 495 configured to receive a portion of an
adjacent building
element during formation of the retaining wall. Optionally, the top surfaces
of the front panel
and or the beam member can comprise alignment posts 700 (as further described
herein) that
are configured to permit self-alignment of building elements during
installation, by matching
the alignment posts with corresponding alignment voids along the bottom of the
building
elements.
[00123] Optionally, in still further aspects, the front surface of the face
panel 410 can have a
surface area of greater than 40 square feet, such as, for example and without
limitation,
greater than or equal to 41 square feet, greater than or equal to 42 square
feet, greater than or
equal to 43 square feet, greater than or equal to 44 square feet, greater than
or equal to 45
square feet, or greater than or equal to 50 square feet.
[00124] In exemplary aspects, a retaining wall system 600 can comprise a
plurality of
building elements 400. Optionally, in these aspects, the beam member 420 of
each building
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element 400 can have a length relative to the second axis 404, and at least
one beam member
can have a length that is less than the length of at least one other beam
member. In additional
aspects, the plurality of building elements 400 can be arranged in a plurality
of columns 600
of vertically secured beam members. In these aspects, a bottom beam member of
each
column can have a length that is greater than the lengths of the beam members
of any other
beam member within the column. In further aspects, each column of the
plurality of columns
can comprise at least three building elements, and the length of the beam
member of each
building element within each column can be different than the length of each
other beam
member within the column. It is further contemplated that the building
elements can be
arranged such that the length of the beam member of each sequential building
element within
the column decreases moving upwardly relative to the third axis. Optionally,
each front
panel can have a V-shape that cooperates with the front panels of surrounding
building
elements to define a corrugated appearance of the retaining wall. Optionally,
the columns of
building elements do not contact one another.
[00125] Optionally, in exemplary aspects, it is contemplated that an entire
retaining wall
system can be built from the same types of building elements 400. For example,
it is
contemplated that each building element of the retaining wall system can have
the same front
face profile. However, it is contemplated that the length of the beam member
of each
building element can vary depending upon the level (within the system) in
which the building
element is positioned. For example, as further described herein, building
elements at the base
of the system can have a greater length than building elements toward the top
of the system.
Exemplary sections of a retaining wall system can have a height of about 30
feet (or about 10
m).
[00126] In exemplary aspects, it is contemplated that the retaining wall
system 600 can
comprise a plurality of stacked groups (pillars) of building elements 400,
with each pillar
being independent of any other pillar. Thus, on soft ground, each wall pillar
can settle
independently of any neighboring pillar. Additionally, it is contemplated that
it can be
impossible to damage laterally spaced panels if the gap to the next pillar is
wide enough.
During a severe earthquake, it is contemplated that each pillar of wall units
must survive from
severe horizontal and even vertical shaking; however, because each pillar is
independent as
disclosed herein, the pillars do not touch each other and can remain intact.
The open gaps
between the separate pillars can require the use of small concrete slabs
loosely set behind the
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gaps to avoid loss of fill. It is contemplated that occasional water leaking
can be acceptable,
yet the concrete slabs can avoid erosion and material loss, thereby protecting
against damage.
[00127] Optionally, in further exemplary aspects and with reference to FIG.
29, the system
can further comprise an alignment post 700 having a stem 710 comprising first
and second
portions that cooperatively define an axial length dimension of the stem. The
alignment post
700 can further comprise a cap 720 comprising a top surface and a bottom
surface, wherein
the top surface comprises a first cross sectional area and the bottom surface
comprises a
second cross sectional area greater than the first cross sectional area. In
further aspects, the
first portion of the stem can be embedded within the cap, and the second
portion of the stem
can extend downwardly from the bottom surface of the cap. In additional
aspects, the top
surface of the front panel of a first building element of the plurality of
building elements can
define an alignment void that receives the second portion of the stem of the
alignment post,
and the bottom surface of the front panel of a second building element of the
plurality of
building elements can define an alignment void 495 that receives the cap of
the alignment
post. In this exemplary configuration, the first and second building elements
can cooperate to
define at least a portion of a column of the retaining wall. In use, it is
contemplated that the
disclosed alignment posts and alignment voids can be used to assemble a
retaining wall as
further disclosed herein.
[00128] In use, it is contemplated that self-alignment keys (e.g., the
alignment posts
disclosed herein) can ensure the perfect alignment of precast units onto the
wall face. As
discussed generally above, the alignment posts 700 can comprise a vertical
steel bar and a
mushroom-like head on top. It is further contemplated that the alignment posts
can be
fabricated upside down in cups and inserted into the fresh concrete of the
precast units,
preferably directly after concrete work is complete. It is contemplated that
the self-aligning
posts can provide exact guidance for the units to be installed on top of the
other while
avoiding the need for special molding on the units, which is difficult to
adjust precisely.
Instead of mounting molds every time before casting, the only required
finishing of concrete
is the smoothing of the concrete surface with a tool. Then, the alignment
posts can be
inserted at the precise location.
[00129] As further explained herein, the disclosed building elements are
capable of
providing a number of advantages or improvements in comparison to existing
retaining wall
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systems. Such advantages or improvements can include one or more of the
following
features.
[00130] The retaining walls are easy to cast and to transport by fitting onto
a truck bed
without creating any oversize issues for the trucker or for other drivers.
[00131] The main body portions of the beam members can include horizontal
holes for
lifting and transporting the units onto a truck and from the truck to an
installation. Thus, the
retaining walls are easy to pick up and handle using pins through horizontal
holes in the stem
(beam)¨no need to insert costly tools which might be lost.
[00132] The retaining walls are easy to install units with self-aligning keys
that direct the
unit for precise setting automatically.
[00133] The pillars (distal end portions of the beam members) along the back
enhance
horizontal backfill arching for maximum loading of the concrete structure by
vertical earth
pressure components to help resisting the wall against overturning earth
pressure forces.
[00134] The pronounced bottom widening of the beam members further enhances
the
vertical arching of the earth fill for maximum weight load onto the structure
to further
increase the wall resistance against overturning and sliding.
[00135] The wide front panels provide an ample distance between stems (beams)
of adjacent
building elements for easy filling.
[00136] The wide spacing between pillars (the distal end portions of the beam
members)
allows for extra-wide vibratory roller compaction from the back, which is
known to be more
effective and reliable than small compactors.
[00137] The front face of the panels shows a vertical centerline edge required
by the earth
fill load resulting in a peak moment in the front panels. This peculiar
structural function can
also achieve a characteristic architectural effect along the front panels.
[00138] The vertical centerline edge of the front face further creates and
adds an ever-
changing sun and shade pattern every day.
[00139] As further discussed above, the front panels can further show a
distinct 'nose' like
ending along the bottom line for directing rain water running down the face
away from the
joint onto the next lower panel. This nose can also prevent vertical stains as
are frequently
seen on vertical walls. The nose can further hide or provide shade for a
horizontal joint
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which conceals local irregularities and possible imperfections. In use, the
nose can guide rain
water to drip off outside of the front panel, and thereby avoid formation of
ugly vertical
stripes from smoke and dust washed down the front face. It is contemplated
that the nose can
cantilever out of the front wall face, causing a distinct shadow falling over
the horizontal
joint. This shadow can automatically cover small imperfections of units caused
by loading,
transport, or installation handling. In use, this shadow can create a special
aesthetic feature
that emphasizes the horizontal wall joints.
[00140] In combination, the features of the disclosed building elements
maximize efficiency
in unit production, transport, and installation. This maximum efficiency goes
in line with
fabrication features that allow up to three units produced per day from each
mold for high
capacity production on big projects. The systematic product streamlining eases
installation
by self-aligning keys resulting in high precision setting, The wide access to
equipment from
behind easily boosts filling and compaction by providing room for efficient
wide vibratory
rollers.
METHODS OF MAKING THE BUILDING ELEMENTS
[00141] In exemplary aspects, and with reference to FIGS. 28A-28B, it is
contemplated that
the disclosed building elements can be cast without an expanding mold. In
these aspects, it is
contemplated that a mold assembly 1000 can comprise a plurality of mold
components,
including a face mold component 1010, a wire mesh 1020 (or other reinforcement
material),
first and second side mold components 1030, 1040, a rear mold component 1050,
and a
support platform 1060. In use, the plurality of mold components can be
selectively
positioned in a mold-ready position to define a three-dimensional profile of a
building
element as disclosed herein, with the face mold component defining the shape
of the front
surface of the building element, the side and rear mold components defining
the shape of the
beam member, and the support platform defining a flat bottom surface of the
building
element. With the mold components positioned in the mold-ready position,
concrete can be
received within the receiving space defined by the mold components, thereby
encasing the
wire mesh 1020 within the panel portion of the building element. Optionally, a
plurality of
support platforms 1060 (e.g., at least three platforms) can be provided in
close proximity to
each other. In use, it is contemplated that the plurality of mold components
can be
disassembled and separated from a first support platform after a few hours
without the need
for touching the concrete, thereby allowing a first building element to
continue to cure on the
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first support platform. It is further contemplated that the mold components
can be
reassembled with a second support platform to permit formation of a second
building
element. After concrete is provided within the mold over the second support
platform, the
remaining mold components can again be disassembled and the process repeated
as needed to
form a plurality of building elements. In contrast to conventional
molding/casting methods
which typically produce only a single unit per day, the disclosed methods can
allow for
production of a plurality of units in a single day, thereby greatly speeding
up wall production
while avoiding the need for multiple mold assemblies.
[00142] The vertical front edge and the horizontal wide 'nose' along the
bottom line provide
architectural features based on technical functions and a vivid change of
shades of the
otherwise overly flat front face.
ENLARGED PANELS
[00143] Disclosed herein with reference to FIGS. 30-39 is building element 800
for forming
a portion of a retaining wall, the building element comprising: a panel
comprising a top
surface, a bottom surface, a front surface, and a rear surface positioned on
an opposing side
of the face panel from the front surface, wherein the face panel comprises a
length dimension
oriented along a first axis, a width dimension oriented along a second axis
that is
perpendicular to the first axis, and a height dimension oriented along a third
axis that is
perpendicular to the first and second axes, wherein the panel has opposed
first and second
side surfaces extending between the front surface and the rear surface. In
exemplary aspects,
the panel 800 can comprise a plurality of mortar beds 805 defined within the
panel. In these
aspects, the plurality of mortar beds 805 can be spaced apart relative to the
first axis 402. In
further aspects, the panel 800 can comprise a reinforcing material, such as,
for example and
without limitation, a reinforcing mesh, that is embedded within the panel. In
still further
aspects, the panel 800 can comprise a plurality of projections 810 extending
upwardly from
the top surface and a plurality of receptacles 812 defined within the bottom
surface, wherein
the receptacles are configured to receive the projections of a second building
element.
[00144] Optionally, the length dimension of the panel can be at least 11 feet,
at least 12 feet,
at least 13 feet, at least 14 feet, at least 15 feet, at least 16 feet, at
least 17 feet, at least 18 feet,
at least 19 feet, or at least 20 feet.
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[00145] Optionally, the height dimension of the panel can be at least 5.5
feet, at least six
feet, at least 7 feet, at least 8 feet, at least 9 feet, or at least 10 feet.
[00146] In use, it is contemplated that the large panels can allow for the use
of a significant
reduction in the number of struts required to assemble a wall structure,
thereby opening the
construction site for big excavators for efficient filling and giving access
to big vibratory
rollers to eliminate hand compactors, hand-labor, and inefficient "gardener
work." As further
disclosed herein, it is contemplated that the large panels can comprise
alignment posts and
corresponding receptacles or openings to permit precise setting of the panels
in a desired
orientation and location.
[00147] Enlarged struts can be designed to hold the enlarged panels disclosed
herein. In
particular, the strut length must fit the panel size and the topography to
anchor the bottom
into firm ground. Standard practice is to use helix-type ground anchors
screwed in with a
small tractor gear connection, and unscrew the ground anchor after use for the
next
application. In comparison, it is contemplated that the disclosed enlarged
panels can require
as few as two struts only, thereby speeding up installation by providing a
larger work space
and providing improved access for filling and compaction. In exemplary
aspects, backfill
with crushed rock at a minimum of 2 ft. for verticality can be used, without
the need for
compaction (it is self-compacting backfill). Self-aligning keys (e.g.,
alignment posts) as
disclosed herein can be used along the top and joints.
[00148] In exemplary aspects, and with reference to FIG. 32, simple 'half -
pipe boxouts can
be used for casting panels on flat tables. In these aspects, vertical flexible
plastic pipes can
be used for simplified and 'flexible' tongue and groove connection.
Polyethylene(PE) UV-
resistant and flexible pipe can be used for vertical alignment control. It is
contemplated that
flexible pipes can serve as absorbers for irregular settlement and avoid
earthquake damages.
In settlement-prone and earthquake-prone areas, it is contemplated that the
gap between
panels can be widened to prevent damage to adjacent panels. In exemplary
aspects, small
concrete pavers can be placed behind such wide-open gaps to allow for lateral
deformations
and to avoid fill material erosion or loss.
[00149] In further exemplary aspects, and with reference to FIG. 33, it is
contemplated that a
wall face layout using half height (or other reduced height) panels 800b along
a bottom
leveling pad can allow for easier vertical alignment. Optionally, in these
aspects, it is
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contemplated that reduced-height panels 800b can cooperate with at least one
other reduced-
height panel to form a column of panels. It is further contemplated that other
columns of
panels can be formed by full-height panels 800a in combination with reduced-
height panels.
Optionally, in one example, columns formed from reduced-height panels 800b and
columns
formed from a combination of reduced-height and full-height panels 800a, 800b
can be
positioned in an alternating arrangement as shown in FIG. 33. As shown, wooden
crosses
with tie bars can also be used to straighten verticality of panels the
conventional way.
[00150] As shown in FIG. 34, mortar beds 805 can be positioned at the ends of
panels and
along a center part of the panel for avoiding excessive contact pressures and
spalling for high
walls. Gaps between mortar beds can be kept open to drain excessive water and
prevent frost
damage in winter.
[00151] In additional aspects, and with reference to FIGS. 39A-39B, the
building element
800 can further comprise a plurality of hooks 820 that are partially embedded
within the
panel and that partially extend rearwardly from the rear surface. In these
aspects, the
building element 800 can further comprise a support grid 830 positioned in
secure
engagement with the plurality of hooks 820 such that the support grid is
parallel or
substantially parallel to the rear surface of the panel. Optionally, it is
contemplated that the
support grid 830 can be secured to the hooks 820 using a bar 825 that is
engaged by or
coupled to both the hooks and the support grid.
[00152] Optionally, the plurality of hooks 820 can comprise galvanized steel.
In use, the
hooks 820 can extend out of the back of the enlarged panel for connecting the
support grid
830. A galvanized straight bar 825 can be placed onto the support grid next to
the panel. The
end of the support grid can be positioned over the steel bar, and the bar can
be pushed down
over and behind the hooks so that the support grid is firmly locked onto the
hooks and
secured to the frong panel. The support grid can then be stretched from the
very end to avoid
any slack. A small trench can be dug along and near the back end of the
support grid. The
support grid can then be stretched, and fill can be placed at the back end of
the support grid to
lock the support grid in place. Tension to the support grid can be added by
placing additional
fill along or within the small trench.
[00153] As shown in FIGS. 35-37, panel reinforcement can be achieved using
standard flat,
reinforcing mesh and a few additional bars along the center area of the panel.
A 2 ft. wide
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volume of crushed pea gravel size crushed rock can be positioned onto a mesh
grid 830 next
to panel to get started (crushed rock does not need compaction and is self-
stabilizing). Filling
of the backfill can continue onto the mesh grid all the way to the end. Before
starting
compaction, the roller must not be in vibration mode. After confirming the
roller is not in
vibration mode, the front panel can be approached as close as allowed. Rolling
can occur
moving backward away from the front panel; simultaneously, vibration can
begin. The
compacted soil can now move slightly away from the front panel by the
compaction process,
leading to straightening and tensioning of the mesh grid and keeping the
connection without
any slack. It is contemplated that this process can initiate grid tensioning
and avoid fill
settlement and related repositioning of front panels in awkward angles.
[00154] In still further aspects, and with reference to FIGS. 36-37, the
building element 800
can further comprise at least one reinforcement wing 840 secured to the rear
surface of the
panel. In these aspects, the at least one reinforcement wing 840 can extend
outwardly from
the rear surface of the panel relative to the second axis 404.
[00155] Reinforcement wings 840 along the back of the front panels can help to
set the first
base unit vertical on the leveling pad Wings along the back of panels provide
for an easier
start-up on the leveling pad to build stacks of wall elements. First, using
separate molds,
wings should be prepared for the back of the lowest panels in each stack.
These wings should
be set onto the panels ready for casting. The connecting reinforcement
panels/materials
should match with the panel positions. By casting wings separately, the
enlarged panels can
be cast face down without the need for complicated formwork. These base units
can then be
set onto widened leveling pads. Mortar beds and wooden wedges can be used to
adjust the
base units for proper verticality and line-up. In use, it is contemplated that
reinforcement
wings can be eliminated after a user becomes experienced with the particular
setting and
installation characteristics of the enlarged panels.
[00156] In exemplary aspects, a retaining wall system can comprise a plurality
of building
elements 800, wherein the plurality of building elements are arranged in a
plurality of
columns of vertically secured building elements. Optionally, the columns of
building
elements do not contact one another.
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[00157] In one exemplary aspect, a first column of building elements comprises
a first
building element and a second building element, and the projections of the
first building
element are at least partially received within the receptacles of the second
building element.
[00158] In a further exemplary aspect, the plurality of building elements can
comprise a
column of at least first and second vertically secured building elements. In
this aspect, and
with reference to FIGS. 38A-38B, the system can further comprise an alignment
assembly
900 having a first transverse opening 920 extending partially through the
width dimension of
the first building element; a second transverse opening 910 extending
partially through the
width dimension of the second building element, wherein the second transverse
opening 910
is positioned in alignment with the first transverse opening 920 relative to
the third axis. The
alignment assembly 900 can further include first and second dowels 940, 930
received within
the respective first and second transverse openings 920, 910. It is further
contemplated that
the alignment assembly 900 can comprise a threaded fastener that is
threadingly coupled to
the first and second dowels 940, 930 to permit selective adjustment of a
distance or
orientation between the first and second dowels relative to the third axis.
[00159] In exemplary aspects, the alignment assembly 900 can comprise steel or
brass
aligning screws along the back of the panels for fine tuning of verticality.
Optionally, two
round dowels can be inserted into holes drilled after one day of concrete
curing. It is
contemplated that the dowels can have a vertically oriented opening near the
outside end. A
threaded bar, for tying and adjusting verticality, can be inserted through the
opening of the
dowels. Nuts at the ends of the threaded bar can allow for adjustment of the
relative
positioning of the panels. Nuts at the inside of the threaded bar (between the
dowels) allow
for relative translation of the next panel.
EXEMPLARY ASPECTS
[00160] In view of the described devices, systems, and methods and
variations thereof,
herein below are described certain more particularly described aspects of the
invention.
These particularly recited aspects should not however be interpreted to have
any limiting
effect on any different claims containing different or more general teachings
described
herein, or that the "particular" aspects are somehow limited in some way other
than the
inherent meanings of the language literally used therein.
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[00161] Aspect 1: A building element for forming a portion of a retaining
wall, the
building element comprising: a face panel comprising a top surface, a bottom
surface, a front
surface, and a rear surface positioned on an opposing side of the face panel
from the front
surface, wherein the face panel comprises a length dimension oriented along a
first axis, a
width dimension oriented along a second axis that is perpendicular to the
first axis, and a
height dimension oriented along a third axis that is perpendicular to the
first and second axes;
and a beam member coupled to the rear surface of the face panel, the beam
member
comprising a main body and first and second foot portions, the main body
having an upper
surface and first and second side surfaces that are substantially parallel to
the second axis,
wherein the first and second foot portions project, respectively, from the
first and second side
surfaces relative to the first axis, and wherein the first and second foot
portions have
respective lower surfaces that are substantially co-planar with the bottom
surface of the face
panel and respective upper surfaces that are positioned between the bottom and
top surfaces
of the face panel relative to the third axis, wherein the beam member has a
distal end portion
spaced from the front panel relative to the second axis, wherein the distal
end portion
comprises first and second projections that project, respectively, from the
first and second
side surfaces of the main body of the beam member, and wherein the first and
second
projections cooperate with respective portions of the first and second foot
portions, the first
and second side surfaces of the main body, and the rear surface of the face
panel to define
first and second receiving spaces on opposing sides of the beam member.
[00162] Aspect 2: The building element of aspect 1, wherein the beam member
is
integrally formed with the face panel as a monolithic structure.
[00163] Aspect 3: The building element of aspect 1 or aspect 2, wherein the
face panel
has a variable width relative to the second axis, and wherein the face panel
has a maximum
width within a vertical reference plane that bisects the length dimension of
the face panel.
[00164] Aspect 4: The building element of aspect 3, wherein the face panel
has opposed
first and second side edges that are spaced apart relative to the first axis,
wherein the front
surface of the face panel comprises first and second portions that extend,
respectively, from
the first and second side edges to a center point that is intersected by the
vertical reference
plane, and wherein the first and second portions of the front surface are
angularly oriented
relative to each other.
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[00165] Aspect 5: The building element of aspect 4, wherein the first and
second portions
of the front surface together define a V-shape.
[00166] Aspect 6: The building element of aspect 4, wherein the beam member
has a
proximal end portion having first and second portions that extend,
respectively, from the first
and second side surfaces of the beam member to the rear surface of the front
panel, and
wherein each of the first and second portions of the proximal end portion
extends at an obtuse
angle relative to adjoining portions of the first and second side surfaces of
the beam member.
[00167] Aspect 7: The building element of aspect 6, wherein the rear
surface of the front
panel comprises first and second end sections positioned on opposing sides of
the proximal
end portion of the beam member, wherein the first and second end sections of
the rear surface
of the front panel are substantially parallel to the first axis.
[00168] Aspect 8: The building element of aspect 1 or aspect 2, wherein the
upper
surfaces of the first and second foot portions of the beam member slope
downwardly from the
respective side surfaces of the main body of the beam member.
[00169] Aspect 9: The building element of aspect 1 or aspect 2, wherein the
front surface
of face panel comprises an upper portion and a base portion that extends
between the upper
portion and the bottom surface of the face panel relative to the third axis,
wherein the base
portion is angularly oriented to extend outwardly relative to the upper
portion of the front
surface of the face panel.
[00170] Aspect 10: The building element of aspect 1 or aspect 2, wherein
the face
panel comprises a reinforcing material that is embedded within the face panel
and oriented
substantially parallel to the first axis.
[00171] Aspect 11: The building element of aspect 1 or aspect 2, wherein
the face
panel comprises a plurality of steel bars that are embedded within the face
panel.
[00172] Aspect 12: The building element of aspect 6, wherein the face
panel
comprises at least first and second steel bodies that are embedded within the
face panel,
wherein the first and second steel bodies have respective first and second
ends, wherein the
first ends of the first and second steel bodies are positioned proximate the
center point of the
center section of the rear surface, wherein the first steel body is oriented
substantially parallel
to the first portion of the center section of the rear surface of the face
panel, and wherein the
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second steel body is oriented substantially parallel to the second portion of
the center section
of the rear surface of the face panel.
[00173] Aspect 13: The building element of aspect 1 or aspect 2, wherein
at least
one surface of the top surface and the bottom surface defines an alignment
void configured to
receive a portion of an adjacent building element during formation of the
retaining wall.
[00174] Aspect 14: The building element of aspect 1 or aspect 2, wherein
the front
surface of the face panel has a surface area of greater than 40 square feet.
[00175] Aspect 15: A retaining wall system comprising: a plurality of
building
elements of any one of aspects 1-14, wherein the beam member of each building
element has
a length relative to the second axis, and wherein at least one beam member has
a length that
is less than the length of at least one other beam member.
[00176] Aspect 16: The system of aspect 15, wherein the plurality of
building
elements are arranged in a plurality of columns of vertically secured beam
members, wherein
a bottom beam member of each column has a length that is greater than the
lengths of the
beam members of any other beam member within the column.
[00177] Aspect 17: The system of aspect 16, wherein each column of the
plurality
of columns comprises at least three building elements, wherein the length of
the beam
member of each building element within each column is different than the
length of each
other beam member within the column, and wherein the building elements are
arranged such
that the length of the beam member of each sequential building element within
the column
decreases moving upwardly relative to the third axis.
[00178] Aspect 18: The system of aspect 16, wherein each front panel has
a V-
shape that cooperates with the front panels of surrounding building elements
to define a
corrugated appearance of the retaining wall.
[00179] Aspect 19: The system of aspect 16, wherein the columns of
building
elements do not contact one another.
[00180] Aspect 20: The system of aspect 16, further comprising an
alignment post
having:a stem comprising first and second portions that cooperatively define
an axial length
dimension of the stem; and a cap comprising a top surface and a bottom
surface, wherein the
top surface comprises a first cross sectional area and the bottom surface
comprises a second
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cross sectional area greater than the first cross sectional area, wherein the
first portion of the
stem is embedded within the cap, and wherein the second portion of the stem
extends
downwardly from the bottom surface of the cap, wherein the top surface of the
front panel of
a first building element of the plurality of building elements defines an
alignment void that
receives the second portion of the stem of the alignment post, and wherein the
bottom surface
of the front panel of a second building element of the plurality of building
elements defines
an alignment void that receives the cap of the alignment post, and wherein the
first and
second building elements cooperate to define at least a portion of a column of
the retaining
wall.
[00181] Aspect 21: A method of assembling a retaining wall using a
system of any
one of aspects 15-20.
[00182] Aspect 22: A method of molding a building element of any one of
aspects
1-14.
[00183] Aspect 23: A building element for forming a portion of a
retaining wall,
the building element comprising: a panel comprising a top surface, a bottom
surface, a front
surface, and a rear surface positioned on an opposing side of the face panel
from the front
surface, wherein the face panel comprises a length dimension oriented along a
first axis, a
width dimension oriented along a second axis that is perpendicular to the
first axis, and a
height dimension oriented along a third axis that is perpendicular to the
first and second axes,
wherein the panel has opposed first and second side surfaces extending between
the front
surface and the rear surface, wherein the panel comprises: a plurality of
mortar beds defined
within the panel, wherein the plurality of mortar beds are spaced apart
relative to the first
axis; a reinforcing mesh embedded within the panel; and a plurality of
projections extending
upwardly from the top surface and a plurality of receptacles defined within
the bottom
surface, wherein the receptacles are configured to receive the projections of
a second building
element.
[00184] Aspect 24: The building element of aspect 23, wherein the length
dimension of the panel is at least 11 feet.
[00185] Aspect 25: The building element of aspect 24, wherein the height
dimension of the panel is at least six feet.
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[00186] Aspect 26: The building element of aspect 23, further
comprising: a
plurality of hooks that are partially embedded within the panel and that
partially extend
rearwardly from the rear surface; and a support grid positioned in secure
engagement with the
plurality of hooks such that the support grid is substantially parallel to the
rear surface of the
panel.
[00187] Aspect 27: The building element of aspect 23, further comprising
at least
one reinforcement wing secured to the rear surface of the panel, wherein the
at least one
reinforcement wing extends outwardly from the rear surface of the panel
relative to the
second axis.
[00188] Aspect 28: A retaining wall system comprising: a plurality of
building
elements of any one of aspects 23-27, wherein the plurality of building
elements are arranged
in a plurality of columns of vertically secured building elements.
[00189] Aspect 29: The system of aspect 28, wherein the columns of
building
elements do not contact one another.
[00190] Aspect 30: The system of aspect 28, wherein a first column of
building
elements comprises a first building element and a second building element,
wherein the
projections of the first building element are at least partially received
within the receptacles
of the second building element.
[00191] Aspect 31: The system of aspect 23, wherein the plurality of
building
elements comprise a column of at least first and second vertically secured
building elements,
the system further comprising an alignment assembly having: a first transverse
opening
extending partially through the width dimension of the first building element;
a second
transverse opening extending partially through the width dimension of the
second building
element, wherein the second transverse opening is positioned in alignment with
the first
transverse opening relative to the third axis; first and second dowels
received within the
respective first and second transverse openings; and a threaded fastener that
is threadingly
coupled to the first and second dowels to permit selective adjustment of a
distance or
orientation between the first and second dowels relative to the third axis.
[00192] Aspect 32: A method of assembling a retaining wall using a
system of any
one of aspects 28-31.
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[00193] Aspect 33: A method of forming a building element of any one of
aspects
23-27.
[00194] Aspect 34: The building element of any one of aspects 1-14, further
comprising
at least one longitudinal elbow that projects outwardly from the main body of
the beam
member and extends between the face panel and the distal end portion of the
beam member.
[00195] Aspect 35: The building element of any one of aspects 1-14 or
aspect 34, further
comprising at least one transverse elbow that projects outwardly from a rear
surface of the
distal end portion of the beam member.
[00196] Aspect 36: The method of aspect 32, wherein at least a first
building element
comprises: a plurality of hooks that are partially embedded within the panel
and that partially
extend rearwardly from the rear surface; and a support grid positioned in
secure engagement
with the plurality of hooks such that the support grid is substantially
parallel to the rear
surface of the panel, and wherein the method comprises backfilling the support
grid with
crushed rock.
[00197] Several embodiments of the invention have been disclosed in the
foregoing
specification. It is understood by those skilled in the art that many
modifications and other
embodiments of the invention will come to mind to which the invention
pertains, having the
benefit of the teaching presented in the foregoing description and associated
drawings. It is
thus understood that the invention is not limited to the specific embodiments
disclosed
hereinabove, and that many modifications and other embodiments are intended to
be included
within the scope of the appended claims. Moreover, although specific terms are
employed
herein, as well as in the claims which follow, they are used only in a generic
and descriptive
sense, and not for the purposes of limiting the described invention, nor the
claims which
follow.
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