Retaining wall containing wall blocks with weight bearing pads

Abstract

A retaining wall having a plurality of courses of retaining wall blocks including a first upper course and a second lower course. Each retaining wall block has opposed front and rear faces, opposed first and second side surfaces, and opposed and substantially parallel upper and lower surfaces, and at least one weight bearing pad extends from one of the upper and lower surfaces. The at least one weight bearing pad extends substantially from the rear face to the front face of the block. The weight bearing pads are the only areas of contact between the blocks in the first upper course and the blocks in the second lower course.

Claims

1. A block for forming a portion of an exposed surface of a wall of a structure, the block comprising: a body with a front face opposed to a compound shaped rear face, the front face forming a portion of the exposed surface of the wall, opposed first and second side surfaces, and an upper surface opposed to a lower surface, the compound shape of the rear face of the body having two or more rearmost surfaces and two or more recessed surfaces, the block having two or more weight bearing surfaces extending a height from the upper surface of the body, each weight bearing surface having a planar surface, the planar surface of each weight bearing surface being the uppermost surface of the block; wherein the body has a front portion extending from the front face to the two or more recessed surfaces of the compound shaped rear face and a rear portion extending from the two or more recessed surfaces to the two or more rearmost surfaces of the compound shaped rear face and wherein the two or more weight bearing surfaces extend along the upper surface of the body from the front portion to the rear portion of the body beyond each recessed surface of the compound shaped rear face.

2. The block of claim 1, wherein the two or more rearmost surfaces includes more than two rearmost surfaces, wherein the two or more recessed surfaces includes more than two recessed surfaces, wherein the two or more weight bearing surfaces includes more than two weight bearing surfaces.

3. A wall block system for constructing a wall with one or more exposed surfaces comprising: a plurality of wall blocks having a block body with a front face opposed to a compound shaped rear face, opposed first and second side surfaces, and an upper surface opposed to a lower surface, the compound shape of the rear face of the block body having two or more rearmost surfaces and two or more recessed surfaces, the plurality of wall blocks having two or more weight bearing surfaces extending a height from the upper surface of the block body, each weight bearing surface having a planar surface, the planar surface of each weight bearing surface being the uppermost surface of the wall block; wherein the block body has a front portion extending from the front face to the two or more recessed surfaces of the compound shaped rear face and a rear portion extending from the two or more recessed surfaces to the two or more rearmost surfaces of the compound shaped rear face and wherein each one of the two or more weight bearing surfaces extends along the upper surface of the block body from the front portion to the rear portion of the block body beyond each recessed surface of the compound shaped rear face.

4. The wall block system of claim 3, wherein the two or more rearmost surfaces includes more than two rearmost surfaces, wherein the two or more recessed surfaces includes more than two recessed surfaces, wherein the two or more weight bearing surfaces includes more than two weight bearing surfaces.

5. The wall block system of claim 3, further comprising a plurality of connectors wherein one or more of the plurality of connectors couples one of the plurality of wall blocks to another one of the plurality of wall blocks.

6. The wall block system of claim 3, wherein the wall constructed from the wall block system has at least a first exposed surface and a second exposed surface and wherein the front faces of some of the plurality of wall blocks form the first exposed surface and some of the plurality of wall blocks form the second exposed surface.

7. A wall having one or more exposed surfaces comprising a plurality of courses of wall blocks including at least a first upper course and an adjacent second lower course, a plurality of wall blocks having a block body with a front face opposed to a compound shaped rear face, opposed first and second side surfaces, and an upper surface opposed to a lower surface, the compound shape of the rear face of the block body having two or more rearmost surfaces and two or more recessed surfaces, the plurality of wall blocks having two or more weight bearing surfaces extending a height from the upper surface of the block body, each weight bearing surface having a planar surface, the planar surface of each weight bearing surface being the uppermost surface of the wall block, the block body having a front portion extending from the front face to the two or more recessed surfaces of the compound shaped rear face and a rear portion extending from the two or more recessed surfaces to the two or more rearmost surfaces of the compound shaped rear face, wherein each one of the two or more weight bearing surfaces of the block body extends along the upper surface of the block body from the front portion to the rear portion of the block body beyond each recessed surface of the compound shaped rear face, and wherein the front faces of the plurality of blocks of the at least first upper course and adjacent second lower course form the one or more exposed surfaces of the wall.

8. The wall of claim 7, wherein the wall has at least a first exposed surface having at least a first upper course and an adjacent second lower course of wall blocks and a second exposed surface having at least a first upper course and an adjacent second lower course of wall blocks and wherein the front faces of some of the plurality of wall blocks form the first exposed surface of the wall and the front faces of some of the plurality of wall blocks form the second exposed surface of the wall.

9. The wall of claim 8, wherein the first exposed surface of the wall has a vertical plane formed by the front faces of the wall blocks of the at least first upper course and adjacent second lower course and the second exposed surface of the wall has a vertical plane formed by the front faces of the wall blocks of the at least first upper course and adjacent second lower course, wherein the vertical plane of the first exposed surface is different than the vertical plane of the second exposed surface.

10. The wall of claim 7, wherein two or more rearmost surfaces includes more than two rearmost surfaces, wherein the two or more recessed surfaces includes more than two recessed surfaces, wherein the two or more weight bearing surfaces includes more than two weight bearing surfaces.

11. The wall of claim 10, wherein the wall has at least a first exposed surface having at least a first upper course and an adjacent second lower course of wall blocks and a second exposed surface having at least a first upper course and an adjacent second lower course of wall blocks and wherein the front faces of some of the plurality of wall blocks form the first exposed surface of the wall and the front faces of some of the plurality of wall blocks form the second exposed surface of the wall.

12. The wall of claim 11, wherein the first exposed surface of the wall has a vertical plane formed by the front faces of the wall blocks of the at least first upper course and adjacent second lower course and the second exposed surface of the wall has a vertical plane formed by the front faces of the wall blocks of the at least first upper course and adjacent second lower course, wherein the vertical plane of the first exposed surface is different than the vertical plane of the second exposed surface.

13. The wall of claim 12, further comprising a plurality of connectors wherein one or more of the plurality of connectors couples one of the plurality of wall blocks to another one of the plurality of wall blocks.

14. A block for forming a portion of an exposed surface of a wall of a structure, the block comprising: a body comprising: a planar front face opposed to a compound shaped rear face, the planar front face forming a portion of the exposed surface of the wall, the compound shape of the rear face of the body having first and second rearmost surfaces separated by a recess; opposed first and second side surfaces; and an upper surface opposed to a lower surface, a plurality of weight bearing surfaces formed on the upper surface, wherein a weight bearing surface of the plurality of weight bearing surfaces extends more than half of a distance between the front face to the first rearmost surface and extends a height above the upper surface, wherein the weight bearing surface of the plurality of weight bearing surfaces includes a planar surface that forms an uppermost surface of the body, wherein the weight bearing surface of the plurality of weight bearing surfaces is set back from the planar front surface.

15. The block of claim 14, wherein the weight bearing surface of the plurality of weight bearing surfaces is formed on an area of the upper surface adjacent the first side surface.

16. The block of claim 15, wherein a second weight bearing surface of the plurality of weight bearing surfaces is formed on a second area of the upper surface adjacent the second side surface.

17. The block of claim 14, wherein a second weight bearing surface of the plurality of weight bearing surfaces is formed on a second area of the upper surface adjacent the second side surface.

18. The block of claim 14, wherein the weight bearing surface of the plurality of weight bearing surfaces has a rectangular shape.

19. The block of claim 14, wherein the planar front face includes a smooth texture or a roughened texture that provides a natural stone appearance.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a top plan view of a mold box configuration for Prior Art blocks.

(2) FIG. 2A is a front view of the blocks shown in FIG. 1 curing on a level pallet. FIG. 2B is a front view of the blocks shown in FIG. 1 curing on a sagging pallet.

(3) FIG. 3A is a front view of a portion of a wall constructed with the blocks of FIG. 2A. FIG. 3B is a front view of a portion of a wall constructed with the blocks of FIG. 2B.

(4) FIG. 4 is a perspective view of a compression head assembly having adjustable tamper heads according to a first embodiment of the invention.

(5) FIG. 5A is a bottom plan view of the compression head assembly of FIG. 4.

(6) FIG. 5B is a bottom perspective view of the compression head assembly of FIG. 4.

(7) FIG. 5C is a top perspective view of the compression head of FIG. 4.

(8) FIG. 6 is a front view of the compression head assembly of FIG. 4 positioned over a wall block mold box and production pallet.

(9) FIG. 7 is a top view of wall blocks removed from the mold of FIG. 6 and curing on a pallet.

(10) FIG. 8 is a perspective view of one of the blocks shown in FIG. 7.

(11) FIG. 9 is a front view of a portion of a wall built with blocks shown in FIGS. 7 and 8.

(12) FIG. 10 is a front view of a wall block which has been modified in accordance with a further embodiment of this invention.

(13) FIG. 11 is a plan view of a mold box showing a divider plate.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(14) In this application, “upper” and “lower” refer to the placement of the block in a retaining wall. The lower surface faces down, that is, it is placed such that it faces the ground. In forming a retaining wall, one row of blocks is laid down, forming a course. A second course is laid on top of this by positioning the lower surface of one block on the upper surface of another block.

(15) The blocks of this invention may be made of a rugged, weather resistant material, such as concrete. Other suitable materials include plastic, reinforced fibers, and any other materials suitable for use in molding wall blocks. The surface of the blocks may be smooth or may have a roughened appearance, such as that of natural stone. The blocks are formed in a mold and various textures can be formed on the surface, as is known in the art. Although the embodiments described herein are discussed with reference to a wall block having a front width of 24 inches it should be appreciated that the invention is equally applicable to blocks of all sizes including those whose front faces are either larger or smaller than the ones referenced herein.

(16) As described above due to worn or misaligned equipment used in the block manufacturing process various dimensional intolerances and surface irregularities can be unintentionally imparted to the block. More specifically as described in connection with FIGS. 1 to 3, production pallets which have gone through numerous mold cycles tend to fatigue over time and eventually start to sag. A sagging or otherwise irregular pallet imparts to the blocks the same dimensional intolerances as are present in the pallet. For many block styles and especially blocks which are meant to be used only to construct relatively low walls with few courses of blocks these dimensional intolerances do not create significant problems because the buildup of stress in areas of concentrated stress are not large enough to cause cracks in the wall. However larger blocks, because of their size, are more affected by these dimensional intolerances. Further, blocks used to construct large walls with many courses of blocks are more likely, because of the increased weight of the blocks used, to develop stresses which can cause blocks in the wall to crack. The present invention includes various embodiments that are meant to eliminate or reduce these areas of concentrated stress that are caused by dimensional intolerances which exist in the block molding process by forming on an upper or lower surface of the blocks a weight bearing pad.

(17) FIG. 4 is a perspective view of a compression head assembly in accordance with one embodiment of the present invention. Compression head assembly 100 includes a stripper head plate 102 and a stripper shoe 106 comprising an upper portion 106a and a lower portion 106b. A plurality of stripper plungers 104 are attached between the stripper head plate 102 and the upper portion 106a of the stripper shoe. For purposes of illustration a plurality of tamper heads 108 which may be adjustable in the manner described further below are shown disconnected from the compression head assembly 100. When connected the tamper heads are received within compatible openings in the bottom of the lower portion 106b of the stripper shoe as best seen in FIGS. 5A, 5B and 5C which are a bottom plan view of the stripper shoe and bottom and top perspective views of the compression head assembly, respectively. The tamper heads are provided for the purpose of forming weight bearing pads on a bottom surface of blocks which are formed in a block molding process using the compression head assembly in a manner which will be described in more detail hereafter.

(18) The adjustable tamper heads 108 are attached to threaded shafts 110. Shafts 110 are received in apertures in plates 115. Plates 115 are connected between plungers 104. The depth that the tamper heads are received into lower portion 106b is set by adjusting nuts 112 and 114 to raise or lower shafts 110. Each tamper head 108 pivots with respect to shaft 110 at pivot point 116. The angle at which the tamper heads pivot or tilt is adjustable by using set screws 117 and 119 which are threaded into holes in the upper portion 106a of the stripper shoe. By adjusting the depth by which set screws 117 and 119 extend into and through upper portion 106a the angle of the tamper heads 108 can be adjusted in teeter totter fashion.

(19) FIG. 6 is a front view of compression head assembly 100 positioned over a mold box 20 and pallet 120 during a block forming process. As known in the art the stripper shoe is discontinuous to avoid contact with any core bars or cores that may be used in the block forming process. Once the mold box has been filled with the moldable material and the material has been vibration compacted to hold its shape the compression head assembly is lowered to push the material out of the mold box. The material in the form of wall blocks remains on the pallet and is moved to a curing station.

(20) FIG. 7 is a top view of blocks 200 formed in the process shown in FIG. 6. Blocks 200 are shown resting on the pallet 120 in the curing station. The blocks 200 have front faces 210 that can have any texture and can have a bevel. The blocks also have rear faces 215. The blocks 200 also have pin holes 220 and pin receiving cavities 230. Pins are often placed in the blocks in the process of making a wall. Pin hole mold portions 250 are attached to a divider plate 260, which is attached to the mold box 20 as shown in FIG. 11.

(21) Since the bottom surfaces of the blocks are oriented upwards in the mold, FIG. 7 shows the bottom surfaces of the blocks as they would be used in forming a wall. The adjustable tamper heads which are recessed into lower portion 106b of the shoe impart to the bottom surface of each of the blocks a plurality of raised surfaces 122 which function as weight bearing pads. In this embodiment two weight bearing pads are formed but it should be understood that the number and position of the weight bearing pads can be varied. The amount by which each pad is raised from the bottom surface of the blocks depends on the extent of curvature or other irregularity that is imparted to the block by the pallet or other portion of the mold machinery or equipment. For example, if the pallet is fatigued and sags at each end by from 3/32 to ⅛ of an inch (0.2 to 0.3 cm) the adjustable tamper heads can be set to form the weight bearing pads to extend from the bottom surface of the block by up to ¼ inch (0.64 cm) or more if desired. During the block forming process adjustments to the adjustable tamper heads can be made based on measurements taken from blocks which have been previously made. These measurements may require that the amount that the weight bearing pads extend from the blocks be increased or decreased. This is done by adjusting the amount by which the tamper heads are recessed into lower portion 106b of the stripper shoe. Further, it may be desirable to increase or decrease the amount by which the pads are angled or sloped from the front of the blocks to the back. This angle may be adjusted in the range of from about 0° to 5°. A perspective view of one of the blocks 200 is shown in FIG. 8. Although the compression head assembly is shown in the drawings as including four adjustable tamper heads which form two weight bearing pads 122 on each block it will be apparent to those of skill in the art that more or fewer tamper heads could be used to form more or fewer weight bearing pads on each block depending on how many blocks are formed in the mold box, the size of the blocks, use requirements, and on the desired amount of weight distribution points. Further, although the tamper heads are shown as being adjustable both in the depth they are recessed into lower portion 106b and in their slope it should be understood that the tamper heads could be made adjustable only as to amount of recess or only as to degree of slope. Further, the tamper heads need not be adjustable at all. In fact the tamper heads need not be separate components from the stripper show but may comprise recesses formed into the bottom surface of lower portion 106b to a depth in the range of about ⅛″ to ⅜″ (0.3 to 1 cm). Further, although in the manufacturing process described herein the bottom surfaces of the blocks face upward in the mold box it is also possible to form wall blocks with the upper block surface facing upwards so that the weight bearing pads may be formed on either the upper or lower block surface depending on how the block is oriented in the mold.

(22) FIG. 9 is a front view of a wall constructed in an overlapped or running bond pattern with the blocks of FIGS. 7 and 8. As can be seen each course of blocks contacts an adjacent lower course of blocks only at weight bearing pads 122. Thus, the weight of the blocks from upper courses of blocks is applied only at the locations of the weight bearing pads 122. The pads are positioned on the blocks so that these load or stress areas are formed directly above a weight bearing pad on the underlying block. In other words, when a wall is formed from the blocks 200 in a running bond pattern as shown in FIG. 9 the pads in each course align vertically along lines Y. Since there are no areas of high stress that do not have underlying support, the problem of block cracking is eliminated even if the block thickness is not consistent within an acceptable range as may be caused by worn, misaligned or irregular equipment or machinery used in the block molding process.

(23) FIG. 10 illustrates a further embodiment of the invention which illustrates a method of leveling a portion of a surface of a wall block. In this embodiment a block 300 is provided with weight bearing pads 122. Weight bearing pads 122 are formed in the molding process using a stripper shoe having a recessed tamper head as described above. However, for purposes of this embodiment the tamper heads may be separate components which are adjustable as described above or they may be recesses formed into the bottom surface of lower portion 106b for which no adjustment is possible. They may be recessed by a desired amount, for example, ¼ inch (0.64 cm). Once the blocks have been formed with the weight bearing pads the height of those pads may be adjusted, if necessary, based on measurements taken after the blocks have been formed. The height adjustment is made by grinding, planning or otherwise removing a portion of the weight bearing pads shown as cross-hatched in FIG. 10 so that the block height at those locations is consistent from block to block. This is advantageous since it is not necessary to control the height of the block at all locations but only at the location of the weight bearing pads. In other words, the block need only be formed with standard sized weight bearing pads which are then mechanically adjusted if necessary to maintain correct height tolerance for the block by removing or planning an appropriate amount of material from only the weight bearing pad. Shims could also be used in this process.

(24) Although particular embodiments have been disclosed herein in detail, this has been done for purposes of illustration only, and is not intended to be limiting with respect to the scope of the following appended claims. In particular, it is contemplated by the inventor that various substitutions, alterations, and modifications may be made to the invention without departing from the spirit and scope of the invention as defined by the claims. For instance, the choices of materials or variations in shapes are believed to be a matter of routine for a person of ordinary skill in the art with knowledge of the embodiments disclosed herein. Further, although the invention has been described in connection with blocks having height inconsistencies or intolerances due to forming the blocks on a sagging pallet it should be understood that these inventive concepts and embodiments are also applicable to control height tolerances on any block having height inconsistencies caused by any reason.