Disclosed is a universal mold having removable arm members and socket members that can be configured to fabricate the border blocks, the corner blocks and the interior blocks.

Various embodiments of an adjustable mold are disclosed for forming a precast concrete top panel for a modular earth retaining wall, for example but not limited to, a modular mechanically stabilized earth (MSE) retaining wall. The adjustable mold has a support base with a top surface, bottom surface, and surrounding periphery. A plurality of rails is mounted to the support base and upstand generally perpendicular from the support base. The rails are collectively attached together to form a closed lateral side boundary with an open top designed to receive liquified concrete. The support base and rails are designed to form sides of the precast concrete top panel. The rails can be adjusted to change a geometric shape associated with the closed lateral boundary in order to enable production of different top panels having different lateral boundaries, and therefore geometries.

Various embodiments of an adjustable mold are disclosed for forming a precast concrete top panel for a modular earth retaining wall, for example but not limited to, a modular mechanically stabilized earth (MSE) retaining wall. The adjustable mold has a support base with a top surface, bottom surface, and surrounding periphery. A plurality of rails is mounted to the support base and upstand generally perpendicular from the support base. The rails are collectively attached together to form a closed lateral side boundary with an open top designed to receive liquified concrete. The support base and rails are designed to form sides of the precast concrete top panel. The rails can be adjusted to change a geometric shape associated with the closed lateral boundary in order to enable production of different top panels having different lateral boundaries, and therefore geometries.

Various embodiments of an adjustable mold and method for making precast concrete traffic barrier panels with different geometries are disclosed. The panels are used for creating a continuous traffic barrier by placing the panels in a contiguous side-by-side arrangement adjacent a roadway atop a modular earth retaining wall. Each traffic barrier panel has a body with at least front, back, top, bottom, left, and right sides. The mold body has a plurality of walls that define an interior chamber, a door opening to the interior chamber, and a concrete inlet to the interior chamber. The door is designed to be installed on and to be uninstalled from the mold body to respectively close and open the door opening. The door has left side and right side forming panels that are designed to define respectively a left side two-dimensional geometry and a right side two-dimensional geometry of the left and right sides respectively of a traffic barrier panel to be made. The left side and right side two-dimensional geometries are changeable by interchanging the door with differently oriented forming panels or by adjusting two-dimensional orientations of each of the left side and right side forming panels on the existing door. The interior chamber of the mold body in combination with an interior side of the door define an outer surface geometry of the front, back, top, bottom, left, and right sides of the traffic barrier panel to be made.

Various embodiments of an adjustable mold and method for making precast concrete traffic barrier panels with different geometries are disclosed. The panels are used for creating a continuous traffic barrier by placing the panels in a contiguous side-by-side arrangement adjacent a roadway atop a modular earth retaining wall. Each traffic barrier panel has a body with at least front, back, top, bottom, left, and right sides. The mold body has a plurality of walls that define an interior chamber, a door opening to the interior chamber, and a concrete inlet to the interior chamber. The door is designed to be installed on and to be uninstalled from the mold body to respectively close and open the door opening. The door has left side and right side forming panels that are designed to define respectively a left side two-dimensional geometry and a right side two-dimensional geometry of the left and right sides respectively of a traffic barrier panel to be made. The left side and right side two-dimensional geometries are changeable by interchanging the door with differently oriented forming panels or by adjusting two-dimensional orientations of each of the left side and right side forming panels on the existing door. The interior chamber of the mold body in combination with an interior side of the door define an outer surface geometry of the front, back, top, bottom, left, and right sides of the traffic barrier panel to be made.

A manhole base assembly and a method for making the same employ a non-cylindrical, low-volume concrete base that is fully lined to protect the concrete against chemical and physical attack while in service. This lined concrete manhole base assembly may be readily produced using a modular manhole form assembly which can be configured for a wide variety of geometrical configurations compatible with, e.g., varying pipe angles, elevations and sizes. The form assembly is configurable to provide any desired angle and elevation for the pipe apertures to interface with various underground systems, and can be formed on-site to facilitate compatibility with existing structures. The assembly provides for flexible, modular construction of a wide variety of lined manhole base assemblies at minimal cost, reduced concrete consumption and reduced operational complexity. The modular nature of the production form assembly also facilitates reduced inventory requirements when various manhole base assembly geometries are needed.

A manhole base assembly and a method for making the same employ a non-cylindrical, low-volume concrete base that is fully lined to protect the concrete against chemical and physical attack while in service. This lined concrete manhole base assembly may be readily produced using a modular manhole form assembly which can be configured for a wide variety of geometrical configurations compatible with, e.g., varying pipe angles, elevations and sizes. The form assembly is configurable to provide any desired angle and elevation for the pipe apertures to interface with various underground systems, and can be formed on-site to facilitate compatibility with existing structures. The assembly provides for flexible, modular construction of a wide variety of lined manhole base assemblies at minimal cost, reduced concrete consumption and reduced operational complexity. The modular nature of the production form assembly also facilitates reduced inventory requirements when various manhole base assembly geometries are needed.

A block reinforcement cage made from reinforcing material and adapted for loading within a machine during a block manufacturing process for molding a concrete U-wall construction block structure. The block cage includes an open aperture formed in each of its stem reinforcing portions. During the block manufacturing process, the first and second support members of a support mechanism are inserted within the open apertures formed in the stem reinforcing sections of the block cage, and cooperate with the open apertures of the block cage so as to (i) support the block cage when being loaded into a block manufacturing machine, (ii) define central apertures molded in each stem portion of the concrete U-wall construction block structure, and (iii) lift the molded concrete U-wall construction block when being unloaded from the machine.

A block reinforcement cage made from reinforcing material and adapted for loading within a machine during a block manufacturing process for molding a concrete U-wall construction block structure. The block cage includes an open aperture formed in each of its stem reinforcing portions. During the block manufacturing process, the first and second support members of a support mechanism are inserted within the open apertures formed in the stem reinforcing sections of the block cage, and cooperate with the open apertures of the block cage so as to (i) support the block cage when being loaded into a block manufacturing machine, (ii) define central apertures molded in each stem portion of the concrete U-wall construction block structure, and (iii) lift the molded concrete U-wall construction block when being unloaded from the machine.

An interlocking construction block system comprising a family of blocks that interlock along three axes, including a left/right axis, a front/back axis, and an up/down axis. The family of blocks are self-aligning and do not require skilled labor or mortar to create a structure of any length, width, height, or shape. Each block comprises a specific geometry that allows all blocks in the family to interlock in a woven pattern that not only locks the blocks in place but also allows even distribution of structural weights and stresses. The disclosed blocks can be manufactured in different sizes to conform to any building code requirement and to create wall lengths to a one-inch measurement. The blocks may comprise channel openings to allow for plumbing, electrical, and structural reinforcements in the structure and may each be reinforced with an internal mesh cage.