Concrete wall block

Abstract

A stackable concrete wall block is disclosed having a body with an irregular front portion and a prism shaped rear portion, the irregular front portion has a three dimensional surface structure embossed in the front face providing the appearance of natural stone and the regular rear portion facilitating stacking of like blocks. The rear portion has parallel sidewalls perpendicular to a rear wall, which are more easily manufactured by dry casting than tapered sidewalls. A lip protrudes from at least one of the sidewalls of the rear portion and is coplanar with the front face for spacing the body of the block from that of a like block placed adjacent thereto. The lateral lip generates spacing between adjacent blocks at a back terminal edge, thereby allowing the assembly of curved walls. The irregular front face extends over the lip so that the front face is continuous over the lip.

Claims

1. A stackable, dry cast, concrete retaining wall block, comprising a body having a front portion and a rear portion and front and rear terminal edges respectively at the front and rear portion for engagement of a like block placed side by side to the retaining wall block; the rear portion being a prism shaped portion having planar top and bottom faces parallel to one another for placement opposite like blocks located above or below in a stacked condition of the retaining wall block, a planar rear face perpendicularly connecting to the top and bottom faces and two parallel planar side walls extending directly from and perpendicular to the rear face; the front portion including a front face and a continuous multifaceted depending sidewall, the front face having an irregular peripheral edge and a three-dimensional surface structure of projections, depressions, or crevices in the front face, the multifaceted depending sidewall extending from the irregular peripheral edge and connecting to the rear portion and to at least to one of the top face and the bottom face of the rear portion, to provide the front portion the visual appearance of a natural stone face; the front and rear terminal edges being located at the front portion and the rear face respectively; and the rear portion including a lip protruding laterally beyond and extending directly laterally outward from at least one of the two parallel planar side walls of the rear portion for placing the front terminal edge further outward than the rear terminal edge in a direction parallel to the rear face, thereby orienting the block at an angle to the adjacent like block when the front and rear terminal edges are in engagement with the like block, the front face extending over the lip and the lip having a rear wall extending from the at least one of the planar side walls and parallel to the rear face.

2. The wall block of claim 1, wherein: the lip is a first lip protruding laterally beyond and extending outward from one of the two parallel planar sidewalls, and the rear portion includes a second lip that protrudes laterally beyond and extends directly laterally outward from the other of the two parallel planar sidewalls.

3. The wall block of claim 2, wherein the irregular peripheral edge of the front face includes a top edge and a bottom edge respectively oriented towards like blocks stackable above or below the wall block and lateral edges oriented towards like blocks stackable side by side with the wall block, at least one of the lateral edges being oriented at an angle of 45 to 90 degrees to the top or bottom edge and the parallel planar side walls of the rear portion being oriented at an angle of 70 to 110 degrees to the bottom face.

4. The wall block of claim 1, wherein the lip has a depth, which is at the maximum 50% of the overall depth of the wall block as measured from the front face to the back face.

5. The wall block of claim 4, wherein the lip has a depth between 5% and 50% of the overall depth.

6. The wall block of claim 5, wherein the lip has a depth between 25% and 50% of the overall depth.

7. The wall block of claim 1, wherein the lip has at least one step in the rear wall and a depth of the lip increases with each step from the front face edge towards the rear portion.

8. The wall block of claim 7, wherein the lip includes a first step and at least one subsequent step, the first step having a larger depth and smaller protruding length than each of the subsequent steps.

9. The wall block of claim 1, further including a connecting structure for connecting a secondary structure to the rear face of the rear portion.

10. The wall block of claim 1, wherein the three-dimensional surface structure of the front face includes at least one false joint.

11. The wall block of claim 10, wherein the false joint is oriented at an angle of 0 to 45 degrees to the top or bottom face.

12. The wall block of claim 11, wherein the irregular peripheral edge of the front face includes a top edge and a bottom edge respectively oriented towards like blocks stackable above or below the wall block and lateral edges oriented towards like blocks stackable side by side with the wall block, at least one of the lateral edges being oriented at an angle of 45 to 90 degrees to the top or bottom edge.

13. The wall block of claim 12, wherein the parallel planar side walls of the rear portion are oriented at an angle of 70 to 110 degrees to the bottom face.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will now be further described by way of exemplary embodiments and with reference to the attached drawings, wherein,

(2) FIG. 1a to 1d are perspective, bottom plan, front plan and end elevation views of a wall block with a stepped lip;

(3) FIG. 2 is a schematic illustration of a curved wall assembled with the wall blocks of FIGS. 1a to 1d;

(4) FIGS. 3a and 3b are a front and top perspective view and a front plan view of a partial wall including seven (7) stacked blocks in accordance with a variant embodiment of the invention; and

(5) FIG. 4 is an elevational view of the first row of blocks of the partial wall shown in FIGS. 3a and 3b.

DETAILED DESCRIPTION

(6) The present application is directed to a wall block for the assembly of a retaining wall, preferably a dry cast concrete block with a front portion having the visual appearance of natural stone face and a rear portion in the shape of a prism for easy and stable stacking of the stone with like stones into a wall, the front face having an embossed three dimensional surface structure.

(7) In a preferred embodiment as schematically illustrated in FIGS. 1a to 1d and FIG. 2, the wall block 100 includes, a body 110 with a front face 112, a rear face 114, top and bottom faces 116 and 118 and generally parallel side walls 119. The wall block 100 further includes at least one laterally protruding lip 120 on at least one of the side walls 119, which lip 120 protrudes from the side wall 119 and is coplanar with the front face 112, which means the front face 112 extends over the lip 120. The lip 120 can be provided on either one or both of sides of the block 100. The spacing created by the lips 120 allows the assembly of straight walls as shown in FIG. 4 or curved walls as shown in FIG. 2, by arranging the wall blocks in such a way that terminal edges of the block at the lip 120 and the rear face 114 touch the respective edges of an adjacent wall block. The protruding length of the lips 120 determines the radius of curvature which can be achieved by placement of the wall blocks 100 side by side in wall with the lips 120 and the bodies 110 of adjacent blocks touching as shown in FIG. 2. The larger the protruding width of the lips, the smaller the minimum radius achievable. Moreover, the shorter the length of the wall block 100, the smaller the minimum radius achievable.

(8) In the installed condition of the wall block 100, wherein the wall block 100 is stacked with like wall blocks 100 into a wall, the lip 120 provides for spacing between the bodies 110 of adjacent wall blocks 100 placed side by side, while providing the resulting wall with a continuous front surface, as shown in FIG. 3b. The front face 112 of the block, which extends over the lip 120, has an embossed three-dimensional surface structure. Preferably the front face 112 is embossed with a surface structure, which provides the wall block 100 and any wall assembled with such wall blocks with the appearance of natural stone as is apparent from FIG. 3b.

(9) The lip 120 can be provided on either one or both of the side walls 119, preferably both, to create bi-lateral spacing between the bodies 110 of wall blocks 100 stacked side by side in a straight wall (see FIG. 4), while providing the wall with a continuous front surface. As is the case with tapered blocks, this spacing allows the assembly of curved walls, by arranging the wall blocks in such a way that terminal edges of the front and rear faces 112, 114 of adjacent wall blocks 100 are in engagement (see FIG. 2).

(10) A wall block 100 with a body 110 with parallel top and bottom faces parallel side walls 119 is more easily manufactured by dry casting than known, tapered blocks, since no movable mold walls are required.

(11) In another preferred embodiment as illustrated in the Figures, the dry cast wall block 100 further includes a connecting structure 300 for connection of a secondary structure to the rear face 114 of the wall block 100. The secondary structure can be a setback pin, a like block, a different block, or a veneer. The connecting structure 300 includes at least one of a pair of interconnecting protruding and recessed elements, most preferably in the shape of a dovetail arrangement, one of the elements being incorporated into the rear face 114 of the wall block 100 and the other one into the secondary structure (not shown). The connecting structure may include multiple alternating protruding and recessed elements (not shown) in the shape of a repeated dovetail arrangement.

(12) The protruding length Y of the lips 120 determines the radius of curvature which can be achieved by placement of the wall blocks 100 side by side in a wall with the lips 120 and the bodies 110 of adjacent blocks 100 being in engagement. The larger the protruding width Y, the smaller the minimum radius achievable. An angle a is enclosed by the side wall 119 of the wall block 100 and an imaginary line 400 connecting the free end 121 of the protruding lip 120 with the terminal edge 115 of the rear wall 114. This angle is the minimum angle at which adjacent wall blocks can be placed without forming a gap between the blocks at the front face 112. Of course, wall blocks 100 can also be placed side by side in straight alignment to form a straight wall, in which case the protruding lips 120 are in engagement, but the blocks do not touch at the rear face 114, resulting in a space between adjacent wall blocks 100 at the rear face 114. To achieve a curved wall, the wall blocks 100 are placed side by side with the lips 120 in engagement, while the lateral edges 115 of the rear faces 114 are placed closer to one another as in the straight orientation. In a curved wall of minimum radius, the lateral edges 115 of the rear faces 114 of adjacent blocks 100 are in engagement and the blocks are placed at the angle a relative to one another (see FIG. 2).

(13) Casting of the lip 120 can be achieved by way of a draw plate (not shown), which is placed in a mold for the wall block (not shown). The draw plate is left in the mold for the filling of the mold and compression of the dry cast mixture in the mold and is pulled from the mold cavity prior to stripping of the block. The use of draw plates in the manufacture of dry cast concrete blocks is known.

(14) The lip 120 preferably has a depth B, measured in a direction parallel to the associated side wall 119, which is a maximum of 50%, preferably between 50% and 5%, most preferably between 50% and 25% of the overall depth A of the wall block 100 as measured from the front face 112 to the back face 114 (see FIGS. 1b and 4). The larger the depth of the lip 120, the wider a gap 117 between the front faces 112 of adjacent stacked blocks 100 in a curved wall (see FIG. 2). Thus, in order to minimize the gap 117, it would be preferable to minimize the depth of the lip 120. Yet, the smaller the depth of the lip 120, the harder it is to manufacture the block 100 by dry casting, since the lip 120 may brake or sag during or after demolding and prior to complete setting of the block. Moreover, the minimum radius achievable with stacked blocks 100 including the lip 120 is determined by the protruding length Y, or overhang, of the lip 120, which is the distance the lip 120 protrudes laterally outward from the sidewall 119 of the block 100 (see FIGS. 1b and 4). The larger the overhang created by the lip 120, the smaller the minimum radius achievable. However, the larger the overhang, the higher the risk of the lip 120 braking or sagging during or after demolding. Consequently, the range of radii achievable by adding a single lip 120 on each side of the block 100 is limited.

(15) In order to address these limitations in relation to the depth and overhang of the lip, the invention also provides a variant of the block 100 in which a larger total protruding length Y or overhang is achieved by providing a stepped lip 120 including two or more steps 120a, 120b, as illustrated in FIGS. 1a to 1d. By dividing the total protruding length or overhang of the lip 120 into multiple, staggered steps 120a, 120b, the chance of the lip braking or sagging during or after demolding is much reduced. Each step 120a, 120b is defined by perpendicular walls respectively parallel to the sidewall 119 and the rear face 114 of the block 100. The protruding length of each step is preferably the same and equal to the total protruding length of the lip divided by the number of steps. The outermost step is coplanar with the front face. Any additional step is located further back towards the rear face 114 and provides a setback or undercut, so that the overall width of the block becomes progressively more narrow with each additional step. By providing the lip with multiple steps, the danger of braking or sagging of the lip during or after demolding is significantly reduced, since the tendency of the lip to brake or sag then becomes directly dependent on the protruding length of the largest step, rather than the overall protruding length of the lip. Since the potential of the lip braking or sagging during or after demolding also directly depends on the depth of the lip, the depth of the outermost step adjacent the front face 112 is preferably larger than the depth of any subsequent step. Moreover, the protruding length of the outermost step is preferably smaller than the protruding length of any subsequent step. When two steps are provided, the protruding length or overhang of the outermost step is preferably less than half the protruding length of the subsequent step.

(16) As illustrated in FIG. 1a, the block 100 in one embodiment includes an irregularly shaped front portion 190 with the simulated appearance of natural stone and a regularly shaped rear portion 195 in the shape of a prism for reliable and easy stacking of the block with like blocks. The front portion includes the embossed front face 112 with an irregular peripheral edge 112a with lateral edges 113 and a multifaceted depending sidewall 130 following the irregular peripheral edge 112a, which provides the front portion 190 with an irregularly shaped face and outline or contour, to simulate the appearance of a natural rock face. The front face has a three-dimensional surface structure of projections 112b, depressions 112c, or crevices 112d, or ridges 112e embossed into the front face. The multifaceted depending sidewall 130 follows the irregular peripheral edge 112a, providing the front portion the visual appearance of a natural stone face. The rear portion 195 is in the shape of a prism having planar top and bottom faces 116, 118 parallel to one another for placement opposite like blocks located above or below in a stacked condition of the retaining wall block. The rear portion 195 further includes a planar rear face 114 perpendicular to the top and bottom faces 116, 118 and a pair of parallel planar side walls 119 perpendicular to the rear face 114. The front and rear terminal edges 121, 115 are located at the front portion 190 and the rear face 114 respectively. The front portion 190 includes a lip 120 protruding laterally beyond, and extending outward from, at least one of the side walls 119 of the rear portion 195 for placing the front terminal edge 121 further outward than the rear terminal edge 115 in a direction parallel to the rear face 114, thereby orienting the block at an angle to the adjacent like block when the front and rear terminal edges are in engagement with the like block (see FIG. 2). The front face 112 extends over the lip 120 and the lip has a rear wall 122 parallel to the rear face 114.

(17) The block of FIG. 10a further includes an interconnecting structure 300 for the connection of a secondary structure (not shown), such as a setback pin, a like concrete block, a veneer block, or a filler block, to the rear face 114 of the concrete block. The connecting structure is preferably a dovetail type connection with one or more female connector members 350 provided in the back face 114 of the wall block and a corresponding number of complementary male connector members (not shown) provided on, or connected with the secondary structure to be connected to the back surface 114. A back to back attachment of a pair of like blocks by way of the interconnecting structure 300 allows for the assembly of a two sided wall. The connecting structure may be a separate connector (not shown) insertable into the connector member 350 and a receiving recess in the secondary structure (not shown).

(18) As shown in FIGS. 1a to 1d and 2, a facing surface 112 resembling a rock face or quarry face is produced by embossing the facing surface during dry casting of the stone with a three-dimensional surface structure including randomly dispersed projections 112b, depressions 112c, crevices 112d, ridges 112e, or the like to mimic the appearance of natural stone. Furthermore, the facing surface has an irregular contour, periphery or outer edge 112a, with a depending multifaceted sidewall 130, which imparts the front portion the visual appearance of a natural stone face.

(19) In another embodiment of the block 100, illustrated in FIGS. 3a, 3b and 4 as block 100a, the block is provided with an embossed front face 112, which includes at least one crevice, here a false joint 180, which may extend at an angle to the top and bottom faces 116, 118. This makes the appearance of the block even more similar to the appearance of a natural stone, for example a quarry stone with ashlar dimensions. In the particular embodiment illustrated, the crevice 112d or false joint 180 extends at an angle of about 45 degrees to the top and bottom faces, but other orientations of the false joint 180 at any angle from 0 to 45 degrees are possible. Of course, the front face 112 may include multiple false joints 180 respectively oriented at different angles to the top and bottom faces 116, 118.

(20) As illustrated in FIGS. 3a, 3b and 4, the block 100 or 100a can also be provided with irregularly shaped front faces 112 where at least one lateral edge 113 of the front face extends at an angle of up to 45 degrees to the sidewall 119. Thus, in this embodiment of the block, the lateral edges 113 of the front face are oriented at an angle of 0 to 45 degrees to the sidewall in order to give the block the appearance of a natural stone with slanted sidewalls. The sidewalls 119 can also be oriented at an angle other than perpendicular to the top and bottom faces 116, 118, for example at an angle of 70 to 110 degrees to the top or bottom face. However, if maximum structural stability of a wall of stacked blocks 100a is desired, it is preferred that the angled sides of the block be limited to only the front portion 190 of the block, with the rear portion 195 of the block having parallel sidewalls 119 perpendicular to the top and bottom faces 116, 118.

(21) As shown in FIG. 2, the blocks 100 with multiple steps 120a, 120b can also be used to build a curved wall, whereby the radius of the curvature achievable is determined by the combined protruding length of all the lips 120a, 120b at each end of the block.