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
FIELD
[0001] 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
100021 It is common practice to use prefabricated building elements and
particular masonry
works such as walls for retaining 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.
[0003] 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.
[0004] 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.
SUMMARY
[0005] 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
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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.
[0006] 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.
[0007] 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 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 width dimension oriented along a first axis, a thickness
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. A beam
member can be
coupled to the rear surface of the face panel. The beam member can comprise a
main body
having a front end portion and a rear end portion. The main body can have an
upper surface,
a lower surface, and first and second side surfaces that are substantially
parallel to the second
axis. First and second fork legs can extend between and couple to the face
panel and the
front end portion of the main body. The first and second fork legs can each
define a
respective acute angle with a plane that extends parallel to the second and
third axes and
bisects the beam member. The face panel and the first and second fork legs can
cooperate to
surround an interior space.
[0008] Systems and methods of using and making the disclosed building element
are also
disclosed.
[0009] 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
of the invention. The advantages of the invention will be realized and
attained by means of
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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
[0010] 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:
[0011] FIG. 1 is a front perspective view of an exemplary modular building
element as
disclosed herein.
[0012] FIG. 2 is a rear perspective view of the exemplary building element of
FIG. 1.
[0013] FIG. 3 is atop plan view of the exemplary building element of FIG. 1.
[0014] FIG. 4 is a front perspective view of another exemplary building
element as
disclosed herein.
[0015] FIG. 5 is a top plan view of the exemplary building element of FIG 4.
100161 FIG. 6 is a rear perspective view of yet another exemplary building
element as
disclosed herein.
100171 FIG. 7 is a side perspective view of a system comprising exemplary
building
elements as disclosed herein.
[0018] FIG. 8 is atop plan view of the system of FIG. 7.
[0019] FIG. 9 is a rear perspective view of another exemplary building element
comprising
first and second opposing face panels.
[0020] FIG. 10 is a cross sectional view of an alignment post as disclosed
herein.
[0021] FIG. 11 is a top perspective view of another alignment post as
disclosed herein.
[0022] FIG. 12 is a perspective view of a system comprising a plurality of
building
elements as disclosed herein.
[0023] FIG. 13A illustrates a mesh of reinforcement members that can be
integrated within
the building elements disclosed herein. FIG. 13B-F illustrate first, second,
third, fourth, and
fifth portions, respectively of the mesh of FIG. 13A.
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[0024] FIG. 14 illustrates a system comprising plurality of building elements
as disclosed
herein.
[0025] FIG. 15 illustrates a system comprising plurality of building elements
as disclosed
herein.
[0026] FIG. 16 illustrates a cross section of an exemplary beam with optional
profiles and
dimensions.
[0027] FIG. 17 illustrates a top view of an exemplary structure comprising
building
elements as disclosed herein.
[0028] FIG. 18 illustrates a support structure for a railroad, the support
structure
comprising building elements as disclosed herein.
[0029] FIG. 19 illustrates a support structure for a girder, the support
structure comprising
building elements as disclosed herein.
[0030] FIG. 20A is a graph of cubic feet of concrete per square foot of wall
surface area for
a building element as disclosed herein and conventional building elements.
FIG. 20B is a
graph of a ratio of cubic feet of concrete per square foot of wall surface
area for a building
element as disclosed herein and conventional building elements relative to the
cubic feet of
concrete of the disclosed building element.
[0031] FIG. 21 is a perspective view of an exemplary building element as
disclosed herein.
[0032] FIG. 22 is another perspective view of the building element of FIG. 21.
[0033] FIG. 23 is a top plan view of the building element of FIG. 21.
DETAILED DESCRIPTION
[0034] 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.
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[0035] 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
[0036] 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.
[0037] 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. When used herein to precede a dimension, the term "about" can
refer to
dimensions that are within 15%, within 10%, within 5%, or within 1% (above or
below) of
the stated dimension.
[0038] 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.
[0039] The word "or" as used herein means any one member of a particular list
and also
includes any combination of members of that list.
[0040] 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
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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). When a term
defining a
specific angular relationship is preceded by the word "substantially," it is
understood that an
embodiment or aspect corresponding to the specific angular relationship is
also disclosed.
For example, the disclosure of a "substantially parallel" relationship is
meant to describe
relationships that are within +/- 15 degrees of parallel alignment as well as
relationships that
are, in fact, parallel.
[0041] 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.
[0042] In various aspects, described herein with reference to FIGS. 1-9 are
building
elements 100A, 100B, 100C, 100D that are configured to be assembled together
with at least
one other building element to form a retaining wall. 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 have 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.
[0043] FIGS. 1-3 depict examples of a building element 100A that can be used
to form at
least a portion of a retaining wall. In an aspect, building element 100A can
comprise a face
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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 (indirectly or directly) 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.
[0044] As depicted in FIG. 1, the face panel 102 can comprise a front surface
(optionally, a
front rectangular surface) and can have a length dimension, which can extend
along the first
axis 114. The face panel 102 can further comprise a 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 a primary plane (e.g., a horizontal 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 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 front surface of the face panel 102 can be
coplanar or
substantially coplanar with a secondary plane, which contains and is defined
by the first axis
114 and the third axis 118.
100451 Although generally described herein in some aspects 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.
In other configurations, it is contemplated that the face panel can comprise a
plurality of
adjoining planar surfaces that cooperate to define an overall face profile.
Optionally, in these
configurations, the adjoining planar surfaces can be angularly orientated
relative to one
another.
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[0046] In another optional configuration, the face panel 102 can also comprise
at least one
projection extending outwardly from one of a top surface or a bottom surface
of the face
panel. Additionally, or alternatively, the face panel 102 can define at least
one inwardly
recessed notch or slot. In exemplary aspects, the face panel can comprise a
plurality of
projections extending outwardly from the top surface and a plurality of
notches or slots
defined within the bottom surface of the face panel 102. Additionally, or
alternatively, the
face panel can comprise a plurality of projections extending outwardly from
the bottom
surface 102D and a plurality of notches or slots defined within the top
surface 102C of the
face panel 102. In use, each notch or slot can be configured to receive a
corresponding
projection of an adjacent face panel (upper or lower) when a retaining wall is
constructed as
disclosed herein. Optionally, when the top or bottom surfaces 102C, 102D of
the face panel
102 comprise both projections and notches or slots, 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.
[0047] In use, it is contemplated that the projections and notches or slots
can be used as
engagement features to further stabilize the face panel. 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 primary
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 or
substantially coplanar with
the primary plane comprising the first axis 114 and the second axis 116.
Optionally, in
exemplary aspects, and as shown in FIG. 1, the projections can comprise a base
surface
coupled to the top surface 102C or bottom surface 102D of the panel 102 and an
apex or apex
surface that is spaced outwardly from the base surface relative to the third
axis 118. For
example, it is contemplated that the projection can optionally comprise a
pyramid or dome
type structure, with the apex corresponding to the minimal diameter portion of
the projection
and the base surface corresponding to the maximal diameter portion of the
projection. In yet
another example, the projection can define an apex surface 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
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comprising a projection 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 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 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, a notch, slot, or other alignment void
can be defined by
a top surface 102C or bottom surface 102D of the face panel 102, and each
alignment void
can be configured to receive a corresponding projection as disclosed herein.
[0048] As discussed earlier, the building element 100 can comprise a beam
member 104,
which can have 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 building element 100 can comprise a brace section 106
that is
mechanically coupled or secured between the beam member 104 and 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 brace section 106 and, optionally, face
panel 102. Thus, in
some exemplary aspects, the beam member 104, the brace section 106, and the
face panel 102
can be integrally formed (optionally, as a single, unitary piece). In
exemplary aspects,
portions of the building element 100 can include reinforcement (e.g., steel
reinforcement)
elements 117 (FIG. 13) that are embedded within the concrete of the building
element.
[0049] In an aspect, the face panel 102 can have a length dimension ranging
from about 9
ft. to about 15 ft., from about 10 ft. to about 14 ft., or from about 11 ft.
to about 13 ft.
Optionally, the face panel can have a length dimension of about 12 ft. In an
aspect, the face
panel can have a height dimension ranging from about 6 ft. to about 10 ft.,
from about 7 ft. to
about 9.5 ft., or from about 8 ft. to about 9 ft. Optionally, the face panel
can have a height
dimension of about 8.5 ft. It is contemplated that the use of face panels
having a length of
about 12 ft. and a height of about 8.5 feet can maximize the dimensions of the
face panels
while still permitting roadway transportation of the face panels (and
associated building
elements) without the need for escort vehicles (using trucks) and without
contacting
overpasses (when the face panels are positioned on a cargo bed of a truck or
trailer).
[0050] 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,
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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. In further aspects, it is contemplated that the face panel
102 can have a length
dimension ranging from about 72 inches to about 144 inches. In further
aspects, it is
contemplated that the face panel 102 can have a height dimension ranging from
about 12
inches to about 110 inches
[0051] 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. In one aspect, the face panel 102 can have dimensions of 8.5 feet tall
(along the third
axis) by 12 feet long, thereby having a total surface area of 102 square feet.
In further
aspects, the face panel 102 can have a height dimension of 8.5 feet, or 100
inches, or 12
inches to 110 inches. In various aspects, the face panel 102 can have a height
dimension of
between about 12 inches, about 24 inches, about 36 inches, about 48 inches,
about 60 inches,
about 72 inches, about 84 inches, about 96 inches, or about 108 inches. In
various aspects,
the face panel can have a length dimension of about 72 inches to about 144
inches. It is
contemplated that a face panel having a height of 8.5 feet can be able to
travel underneath a
standard overpass height. It is further contemplated that a face panel having
a length of 12
feet or less can travel on a highway without the expensive requirement of an
escort vehicle or
other oversized load requirements. Thus, the building element can have a
maximum area for
the front panel (within shipping limitations), thereby allowing for maximum
wall area
installation per crane pick. It is contemplated that a relatively short face
panel (e.g., having a
length of about 74 inches or less than 96 inches) can be used to fomt sharp
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comers or can be used for required end elements of a wall to satisfy
architectural needs. The
beam member can optionally have a length dimension from 4 feet to 40 feet. In
some
aspects, the beam can have a length dimension of between 5 feet and 12 feet,
or between 6
feet and 12 feet. It is contemplated that the beam member with a length
dimension of 12 feet
can be used to form a wall that is about 24 feet tall. In further aspects, the
beam member with
a length dimension of 40 feet fit on the length of a truck bed for
transporting the building
element. The beam member with a length dimension of 40 feet can optionally
form a portion
of a wall that is over 60 feet tall. It is contemplated that the length of the
beam can reach far
back into fill to enhance wall stability.
[0052] Optionally, the panel can be provided with architectural lining.
[0053] It is contemplated that the building elements disclosed herein can be
stable for
transport (e.g., no tilting to the side, back, or front). The building
elements can further be
easy to handle. The stability of a cribwall, comprising one or more building
elements and
filled with earth (e.g., to serve as a retaining wall) can use a minimum
amount of (relatively
expensive) concrete and a maximum amount of (relatively inexpensive) fill
material (e.g.,
gravel, sand, dirt, or a combination thereof). Thus, the cribwall can be made
relatively
inexpensively. In further aspects, the fill can comprise rocks.
[0054] In some aspects, the fill material can comprise, or can consist of,
free waste dust.
Free waste dust can be fine material that is a by-product of crushed rock
fabrication. It is
contemplated that such particles can have high friction. Still further, the
free waste dust can
advantageously compact easily.
[0055] The disclosed building elements can endure maximum weights acting on or
against
the inside surfaces of the building elements, with the fill material holding
the building
elements in position, to prevent overturning or sliding of the building
elements. The large
length dimensions and area dimensions of the building elements disclosed
herein can engage
correspondingly large volumes of fill material.
[0056] It is also further contemplated that the size of the disclosed building
elements 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 as compared
to traditional building elements.
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[0057] In further aspects and with reference to FIGS. 1-5, the beam member 104
can
comprise a main body 222 having a front end portion 224, a rear end portion
226, first and
second side surfaces 230, 232 extending substantially parallel to the second
axis 116, and
upper and lower surfaces 234, 236 spaced relative to the third axis 118. The
main body 222
of the beam member 104 can optionally have a top portion 223 that has a
greater width
dimension than a width of the beam member below the top portion. It is
contemplated that
this greater width dimension can increase the beam member stability,
particularly for long
beam members, thereby inhibiting swinging during transit on rough roads or in
traffic.
[0058] The beam member 104 can further comprise first and second fork legs
160, 162 that
extend between and couple to the face panel and the proximal end portion of
the main body.
Accordingly, the beam member 104 can define split struts. The first and second
fork legs
160, 162 can each define a respective acute angle with a vertical reference
plane 408 that
contains or extends parallel to the second and third axes 116, 118and bisects
the beam
member 104. That is, a respective vertical plane 164, 166 that bisects each of
the first and
second fork legs 160, 162 can form an acute angle with the vertical reference
plane 408. The
acute angle can range from about 15 degrees to about 75 degrees, from about 30
degrees to
about 60 degrees, or be, for example, about 45 degrees. The face panel 102,
the first fork leg
160, and the second fork leg 162 can cooperate to define an interior space
170. It is
contemplated that the fork legs can reduce cantilevering of the front panel
(that carry the
fill/earth pressure of the load from behind). In this way, the fork legs can
greatly enhance the
strength of the front panel, for example, evening out moments on the front
panel. The fork
legs can provide reinforcement forces to the front panel, thereby providing a
front panel with
greater strength and a dramatic reduction of bending moments. In this way the
necessary
amount of steel reinforcement 117 (FIG. 13) can be reduced, which can,
accordingly, reduce
cost of the building element. It is contemplated that the interior space 170
can receive fill.
For example, the interior space 170 can be filled with rocks to add weight to
the building
element.
100591 Optionally, the first and second fork legs 160, 162 can couple to the
face panel at
respective coupling ends 172, 174 opposing the main body 222 of the beam
member 102. In
various aspects, the respective coupling ends can optionally be spaced
relative to the first axis
114 by at least one third of the length of the face panel, or at least one
half of the length of the
face panel, or by substantially the length of the face panel.
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[0060] Optionally, as shown in FIG. 6, the coupling ends 172, 174 can have a
height
dimension relative to the third axis 118 that is greater than the height of
the main body 222 of
the beam 104. In some aspects, the height dimension of the main body 222 of
the beam
member 104 can be less than the height dimension of the face panel 102. For
example, in
some optional aspects, the height dimension of the main body 222 of the beam
member 104
can optionally be between 1 foot and 4 feet or, optionally, half the height
dimension of the
face panel 102. Such a beam member 104 having a shorter height dimension than
that of the
face panel 102 can be advantageous for various applications, including for
building elements
at a top of a wall (FIGS. 14-15), for retaining a thick ballast layer for
railway ballast, for
highway subbase grading and compaction, for utility trenches and rain drains
along a curb,
for traffic barrier anchoring, or for power and utility lines next to a top
building element.
[0061] Referring to FIG 6, in some optional aspects, the face panel can
comprise a first
end portion 176 that extends beyond the coupling end 172 of the first fork leg
160 of the
beam member 104 on a first side of the plane 408 and a second end portion 178
that extends
beyond the coupling end portion 174 of the second fork leg 162 of the beam
member on a
second side of the plane 408. Optionally the first and second end portions of
the face panel
102 can have equal lengths relative to the first axis 114. Accordingly, the
beam member 104
couple to the middle of the face panel 102 relative to the first axis 114. In
further aspects, the
first end portion can have a length that is not equal to the length of the
second end portion.
Accordingly, the beam member 104 can be offset from the middle of the face
panel 102
relative to the first axis 114. Optionally, the length of each of the first
and second end
portions can be less than or equal to 36 inches.
[0062] In still further aspects, and with reference to FIGS. 4-5, the face
panel 102 can have
a length dimension that is equal to the spacing between the coupling end
portions 172, 174 so
that the face panel does not comprise the first end portion 176 that extends
beyond the
coupling end 172 of the first fork leg of the beam member on the first side of
the plane 408 or
the second end portion 178 that extends beyond the coupling end portion 174 of
the second
fork leg of the beam member on the second side of the plane 408. Optionally,
the coupling
end portions 172, 174 can be spaced by about 72 inches, or at least 60 inches.
[0063] Referring to FIGS. 7-8, a system 600 can comprise a plurality of
building elements
100A (FIG. 1). In some aspects, the building elements 100A can comprise
corresponding
slots that align to allow the beam members to cross. For example, the main
body 222 of the
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beam member 104 of a first building element 100B can have a can have a first
slot 602. The
first slot 602 can define a recess that extends upwardly (relative to the
third axis 118) into the
main body 222 of the beam member 104. Accordingly, the first slot 602 can
define a
downward opening. The beam member 102 can define a recessed surface 606 that
is spaced
upwardly (relative to the third axis 118) from the lower surface 236 of the
main body 222 of
the beam member 104. The beam member 104 of a second building element 100C can
have a
second slot 604. The second slot 604 can define a recess that extends
downwardly (relative
to the third axis 118) into the main body 222 of the beam member 104.
Accordingly, the
second slot 604 can define an upward opening. The beam member 102 can define a
recessed
surface 608 that is spaced downwardly (relative to the third axis 118) from
the upper surface
234 of the main body 222 of the beam member 104. The main body 222 of the beam
member
of the first building element 100B at the first slot 604 can be receivable
into the second slot
604 of the main body 222 of the beam member 104 of the second building element
100C.
When the slot 602 of the first building element 100B is received in the slot
604 of the second
building element 100C, the recessed surface 606 can oppose the recessed
surface 608.
Optionally, the recessed surface 606 can bias against the recessed surface
608. In further
aspects, the recessed surface 606 can be spaced from the recessed surface 608.
In some
optional aspects, when the main body 222 of the beam member 104 of the first
building
element 100B at the first slot 604 is received into the second slot 604 of the
main body 222 of
the beam member 104 of the second building element 100C, the upper surface 234
of the
main body 222 of the beam member 102 of the first of building element 100B can
be
coplanar with the upper surface 234 of the main body 222 of the beam member
102 of the
second building element 100C. It is contemplated that the slot 604 can have a
depth that is
half, about half, or at least half the height dimension of the beam. In these
aspects, it is
contemplated that the first and second building elements 100B,C can optionally
be identical,
with the building element 100B inverted 180 degrees relative to the building
element 100C
about an axis that is parallel to the second axis 116.
[0064] It is contemplated that each building element can have respective
first, second, and
third axes that are oriented and described herein relative to the building
element.
Accordingly, the first building element 100B can have reference plane 408a
that is parallel to
a second axis 116a of the first building element 100B, and the second building
element 100C
can have a reference plane 408b that is parallel to a second axis 116b of the
second building
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element 100C. In some aspects, the first and second building elements 100B,C
can be
oriented so that the reference plane 408a is oriented at an angle, a, relative
to the reference
plane 408b of the second building element 100C. In some aspects, the main body
222 of the
beam member of the first building element 100B at the first slot 602 can be
receivable into
the second slot 604 of the main body of the beam member of the second building
element
100C so that the second axis 116a of the first building element defines an
acute angle, a, with
respect to the second axis 116b of the second building element. Such a
configuration can be
used for forming a block-out at an intersection. Further, the building
elements 100B,C can be
configured to enable various angular offsets 13 between the front surface 102A
of the face
panel 102 of the first building element 100B and the front surface 102A of the
face panel 102
of the second building element 100C. The various angular offsets 13 can
optionally be from 0
to 315 degrees. The positioning of the slots 602, 604 along the length of the
respective beam
member 104 can be selected based on the desired angle between the two building
elements.
100651 In some optional aspects, the second end portion 178 of the face panel
102 of the
first building element 100B can be adjacent to the first end portion 176 of
the second building
element 100C. The building elements can be elected to fit the desired wall
configuration.
High walls with a turn can benefit from a detailed study of beam member
crossing
intersections with adjustable visible corners to be flush and angles that can
be custom-tailored
(e.g., based on slot position) to match. Depending on angle, wall height, fill
material type,
and predicted internal lateral earth pressures and earth pressure direction,
the crossed beam
members can use blocking to strengthen the corner stack for internal and
external stability.
Optionally, the geotextiles along backs of adjacent building elements can be
positioned to
prevent material (e.g., fill material) washout.
100661 Referring to FIG. 13, a system 600 can comprise a plurality of building
elements
100A. At least one building element can be oriented at a 90 degree offset
relative to at least
one other building element.
[0067] Referring to FIG. 9, a building element 100D can comprise a first face
panel 102
and a second face panel 610 coupled to the end of the beam member 104 opposite
the first
face panel. In some aspects, third and fourth fork legs 612, 614 can extend
between and
couple to the second face panel 610 and the rear end portion 226 of the main
body 222 of the
beam member. The third and fourth fork legs 612, 614 can each define a
respective acute
angle with a vertical reference plane 408 (FIG. 3) that extends parallel to
the second and third
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axes and bisects the beam member 104. The second face panel 610, the third
fork leg 612,
and the fourth fork leg 614 can cooperate to define an interior space 170b.
The third and
fourth fork legs 614 can optionally be configured as described herein with
reference to the
first and second fork legs. For example, the third and fourth fork legs 614
can couple to the
second face panel 610 at respective coupling ends that are spaced by at least
one third, at least
half, or substantially the entire length of the second face panel 610. It is
contemplated that
such building elements can advantageously be used for separation walls, for
sound walls, and
for barricade walls and other protection walls. Two or more building elements
can be aligned
with their first face panels aligned and with their rear face panels aligned
to form a wall
configuration to be exposed to two sides, thereby forming two exposed (e.g.,
visible) sides.
For protection walls or barricades, vertically stepped interconnections
between the upper and
lower units can be used to resist extraordinary forces like from explosive or
natural (e.g.,
hurricane) effects.
100681 In some optional aspects, the building element 100D can be symmetric
about a
plane 800 that is parallel to the first and third axes and transversely
bisects the beam member
104.
[0069] In some aspects, the beam member 104 can have a distal end portion 150
(e.g., a
vertical pillar) spaced from the face panel 102 relative to the second axis
116. In these
aspects, the distal end portion 150 can comprise first and second projections
152, 154 that
project, respectively, from the first and second side surfaces 230, 232 of the
main body 222
of the beam member 104. As shown in the Figures, the first and second
projections 152, 154
can cooperate with respective portions of the first and second side surfaces
230, 232 of the
main body 222, and the rear surface 102B of the face panel 102 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 100A and, in particular, the structure of the disclosed beam member
104, can
increase the internal arching effect of the fill weight inside the receiving
spaces, thereby
wedging and holding the fill weight in place. The extended width of the distal
end portion
150 can serve as a pillar that helps backfill soil arching. The soil behind
the wall can engage
the distal end portion 150. Because of the structure of the building element,
the receiving
spaces 460, 462 can be accessed from behind the building element for easy and
efficient
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filling. A vibratory roller can further be used to compact the fill within the
receiving spaces.
The fill can inhibit shifting or tilting of the building elements, thereby
inhibiting bulging of a
wall comprising the building elements.
[0070] As depicted in the Figures, the distal end portion 150 of the beam
member 104 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).
[0071] As further depicted in the Figures, the inner surfaces of the first and
second
projections 152, 154 of the distal end portion 150 (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).
[0072] Optionally, the face panel 102 can have a variable width (not shown)
relative to the
second axis 116. In exemplary aspects, the face panel can have a maximum width
within a
vertical reference plane 408 that bisects the length dimension of the face
panel 102. 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 102E,F, where there is no moment.
[0073] In exemplary aspects, as the beam member 104 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. In some
aspects, each of
the fork legs 160, 162 can define a respective pin hole 442. In further
aspects, the main body
222 of the beam member 104 can define at least one pin hole 442.
[0074] 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
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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.
[0075] Optionally, the building element 100A can further comprise at least one
longitudinal
elbow 435 (optionally, a plurality of vertically spaced longitudinal elbows
435) that projects
outwardly from the main body 222 of the beam member 104 and extends between
the face
panel 102 and the distal end portion 150 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 222 (preferably in a symmetrical or
balanced arrangement
with equal numbers of elbows extending from each side surface). Additionally,
or
alternatively, the building element 100A can comprise at least one transverse
elbow 455 that
projects outwardly from a rear surface of the distal end portion 150 of the
beam member 104.
Optionally, as shown in FIGS. 1-6, 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
FIGS. 1-6.
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
104. The
elbows 435, 455 can increase friction against fill to retain the building
element in place.
Accordingly, the weight of the fill can be used to support the building
element. The elbows
435, 455 can further support fill/soil arching on the sides of the beam member
104 and
behind the distal end portion 150.
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[0076] Still further, the rear surface 102B of the face panel 102 can define
one or a plurality
of elbows (not shown).
[0077] In exemplary aspects, the elbows can project by at least one inch, by
between one
inch and four inches, or about two inches. Optionally, the elbows 435, 455 can
comprise
angled portions that extend angularly outwardly (e.g., outwardly at 45 degree
angles) to meet
at planar middle portions. FIG. 16 illustrates a cross-section that includes
exemplary,
optional dimensions of the elbows.
[0078] In use, it is contemplated that the elbows can be configured to provide
horizontal
stiffening of the beam member 104 and/or the distal end portion 150 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.
[0079] 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. It is contemplated that, in addition to, or
alternatively, the
elbows 435, 455, the rear surface 102B of the face panel 102 and/or the side
surfaces 430,
432 of the main body 222 of the beam 104 and/or the distal end portion 150 of
the beam 104
can define a texture that is configured to initiate and positively support and
create substantial
arching of the fill inside the building elements and behind and adjacent the
distal end portion
150 of the beam member 104. For example, the rear surface 102B of the face
panel 102
and/or the side surfaces 430, 432 of the main body 222 and/or the distal end
portion can
define a rough surface (e.g., formed from a rough mold surface). In further
aspects, the side
surfaces 430, 432 of the main body 222 and/or the distal end portion can
define a stepped
surface, a zig-zag surface, or any other surface that increases grip against
the fill. Thus, in
exemplary aspects, the rear surface 102B of the face panel 102 and/or the side
surfaces 430,
432 of the main body 222 and/or the distal end portion 150 can have non-planar
surfaces that
increases surface area engaging the fill. In further aspects, steel and fiber
concrete mix
materials can be provided to increase friction with the fill.
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[0080] 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
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." Accordingly, the building element can have a relatively
small footprint as
compared to other building elements configured for similar purposes.
100811 In still further aspects, the distal end portion 150 (e.g., projections
can be widened
along the first axis 11410 engage a greater amount of fill to inhibit
overturning of the
building element.
[0082] In exemplary aspects, a retaining wall system can comprise a plurality
of building
elements 100A. Optionally, in these aspects, the beam member 104 of each
building element
100A can have a length relative to the second axis 116, 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 100A can be arranged in a
plurality of columns 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 sun-ounding
building
elements to define a corrugated appearance of the retaining wall. Optionally,
the columns of
building elements do not contact one another.
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[0083] Optionally, in exemplary aspects, it is contemplated that an entire
retaining wall
system can be built from the same types of building elements 100A. 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).
[0084] In exemplary aspects, it is contemplated that the retaining wall system
can comprise
a plurality of stacked groups (pillars) of building elements 100A, 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
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.
[0085] As further explained herein, the disclosed building elements are
capable of
providing a number of advantages or improvements in comparison to existing
retaining wall
systems. Such advantages or improvements can include one or more of the
following
features.
[0086] 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.
[0087] The main body 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.
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[0088] The retaining walls are easy to install units with self-aligning keys
that direct the
unit for precise setting automatically.
[0089] 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.
[0090] 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.
[0091] The wide front panels provide an ample distance between stems (beams)
of adjacent
building elements for easy filling.
[0092] 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.
[0093] 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
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.
[0094] 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.
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[0095] FIGS. 12 and 17 show top view of exemplary structure comprising
building
elements (e.g., building elements 100A,B) as disclosed herein. As shown, the
building
elements disclosed herein can form walls that intersect at right angles or
acute angles (e.g.,
less than 90 degrees, or less than 80 degrees, or about 70 degrees).
[0096] Referring to FIG. 18, the building elements (e.g., building elements
100A) can form
a structure for supporting railroads. Referring to FIG. 19, the building
elements (e.g.,
building elements 100A) can form a wall that is configured to receive girder
820 weight.
Cast in place concrete 822 can be added (e.g., about one or two inches of pre-
cast concrete to
adjust exact elevation of the concrete.
[0097] Referring to FIGS. 1, 10, and 11, in various aspects, the building
element 100A can
comprise one or more alignment keys/ projections 111 that are receivable into
respective
recesses 495 of an adjacent building element. For example, the building
element can
comprise one or more (three shown) projections 111 that extend from an upper
surface of the
building element, and a building element can define recesses on a lower
surface for receiving
the respective projections. The recesses can be sized and shaped to allow
receipt of the
corresponding projections in a predetermined position relative to the first
and second axes.
For example, the recesses can have complementary surfaces to those of the
projections with
little or no space for movement therebetween. In this way, vertically stacked
adjacent
building elements 100A can easily be vertically (and, with two or more
projections,
angularly) aligned with each other. It is contemplated that the projections
and corresponding
recesses can enable precise wall installation and very high speed crane
operation without any
additional cost while cutting installation time and cost (optionally, by
half). In some aspects,
the projections 1 1 1 can be integrally formed with the building element. In
further aspects,
the projections 111 can be separate components that are coupled to the rest of
the building
element. The projections 111 can assist in alignment to quickly assemble walls
with the
building elements. In various aspects, 3000 square feet of a wall can be
installed in a single
day.
[0098] Optionally, the projections 111 can comprise two front projections that
are spaced
along the first axis and one rear projection that is spaced from the front
projections along the
second axis. In some optional aspects, the two front projections can be spaced
by about 50
inches to about 80 inches, from about 60 inches to about 70 inches, or by
about 65.5 inches.
In some optional aspects, the rear projection can be spaced from the front
surface 102A by
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about 30 inches to about 50 inches, from about 40 inches to about 45 inches,
or by about 42
inches and can be centered between the two front projections along the first
axis. In some
optional aspects, the front projections can be spaced from the front surface
102A by about 5
inches to about 10 inches or by about 7.5 inches.
100991 FIG. 10-11 depicts exemplary alignment posts 122,700 that can
optionally serve as
a projection 111. 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 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 495 of
another building
element 100 during erection of a retaining wall as disclosed herein.
[00100] In a further aspect, the cap 140 can be shaped like a frustum
(optionally, a conical
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 downwardly
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 5 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.
[00101] Optionally, when the alignment post 122 is engaged to the alignment
void 495, there
can be a clearance space of 0.25 in. between an inner surface that defines the
alignment void
495 and the outer surface of the cap 140.
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[00102] 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 495 defined by a surface of a respective beam member of a
building
element 100. As the stem 140 is set within the alignment void 495 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.
[00103] 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.
[00104] Optionally, in further exemplary aspects and with reference to FIG.
10, 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.
[00105] 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 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,
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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.
[00106] Referring to FIGS. 20A and 20B, the disclosed building elements can
use less
concrete per square foot of front surface 102A surface area than wall surface
of conventional
building elements.
[00107] Referring to FIGS. 21-23, in various aspects, the face panel of any
one of the
disclosed building elements can be omitted. For example, in further aspects,
the face panel
102 (FIG. 1) can be replaced with one or more shelves 350. The shelves 350 can
be
configured to support soil and trees/plants/greenery, planted therein.
[00108] The shelves 350 can have a length dimension oriented along the first
axis, a width
dimension oriented along the second axis that is perpendicular to the first
axis, and a height
dimension oriented along the third axis that is perpendicular to the first and
second axes.
[00109] A building element 100E can comprise one or more shelves 350 and a
beam
member 104 that is coupled to the shelves 350. In various aspects, the
building element can
comprise one, two, three, four, five, six, or more shelves 350. In exemplary
aspects, a
plurality of shelves 350 can be spaced relative to the third axis, which can
optionally be
vertically oriented.
[00110] The beam member can comprise a main body 222 having a front end
portion 224, a
rear end portion 226 and first and second side surfaces 230, 232 extending
substantially
parallel to the second axis 116.
[00111] The beam member 104 can further comprise first and second fork legs
160, 162 that
extend between and couple to the shelves 350 and the proximal end portion of
the main body.
Accordingly, the beam member 104 can define split struts. The first and second
fork legs
160, 162 can each define a respective acute angle with a vertical reference
plane 408 (FIG.
23) that contains or extends parallel to the second and third axes 116, 118
and bisects the
beam member 104. That is, a respective vertical plane that bisects each of the
first and
second fork legs 160, 162 can form an acute angle with the vertical reference
plane 408. The
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acute angle can range from about 15 degrees to about 75 degrees, from about 30
degrees to
about 60 degrees, or be, for example, about 45 degrees. The face panel 102,
the first fork leg
160, and the second fork leg 162 can cooperate to define an interior space
170.
[00112] The beam 104 can further be configured in accordance with various
further aspects
disclosed herein.
[00113] In exemplary aspects, the shelves 350 can have a top surface 352 that
is angled
upwardly from a rear of the beam to a front of the beam along the second axis
106. In this
way, the shelf can retain dirt, soil, or other infill so that the dirt, soil,
or infill does not spill
forwardly over the front of the shelf Still further, with the top surface 352
angled upwardly
as illustrated, water (e.g., from heavy rain) can be directed away from the
front of the shelf
(e.g., toward a mountainside against which the building element is
positioned.) The shelves
350 can have a thickness measured along the third axis 118. In some aspects,
the thickness
can taper at the front of the shelf A front portion 359 of the top surface 352
can be
horizontal and flat. In some optional aspects, the shelves can each have a
bottom surface 356
that is parallel to the top surface 352 along at least a portion of the width
of the shelf
[00114] The shelves can have opposed longitudinal ends 354. In some aspects,
the beam
can coupled to the shelves 350 at locations between the longitudinal ends 354.
Optionally,
the beam 104 can be centered between the opposed longitudinal ends. In further
aspects, the
beam 104 can be offset from centered.
[00115] In some aspects, the shelves 350 can have a length between the opposed
longitudinal ends 354. In some aspects, outer portions 358 of the shelves that
extend
outwardly from the first and second fork legs 160, 162 can be supported in a
cantilevered
fashion. The outer portions 358 can have a length along the first axis 114
that is less than
1/3, less than 'A, or about 1/6, or less than 1/6 of the length of the
shelves. Accordingly, the
portion of the shelves 350 that are supported in a cantilevered fashion can be
less with the
beam 104 having fork legs than a narrow beam coupling to the shelves in a
single location
(e.g., wherein about half of the beam is held in cantilevered fashion on each
side of the
beam).
[00116] The shelves 350 can have cross sections in planes perpendicular to the
first axis 116.
In various aspects, the cross sections can be rectangular, L-shaped, or
trapezoidal. In some
aspects, the top surface 352 can be flat, L-shaped (e.g., having a lower
surface and a front
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surface that at the forward edge of the lower surface along the second axis
116), or
trapezoidal (e.g., with a lower surface and opposed sloping surfaces that
slope downwardly to
the lower surface along the second axis 116).
[00117] The shelves 350 can be filled with topsoil, and greenery can be
planted therein, such
as plants, shrubs, or trees. It is contemplated that the greenery can be
selected based on the
amount of maintenance or irrigation needed. For example, in environments in
which
irrigation is limited or not possible, greenery can be selected based on its
ability to survive.
With the building element 100E installed, the shelves can be horizontal to
inhibit water from
running to one side and washing out soil.
[00118] 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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