AU2012216310B2

AU2012216310B2 - Retaining wall system

Info

Publication number: AU2012216310B2
Application number: AU2012216310A
Authority: AU
Inventors: Jason Bassett; Phil Thurlow
Original assignee: Island Block & Paving Pty Ltd
Current assignee: Island Block & Paving Pty Ltd
Priority date: 2011-08-24
Filing date: 2012-08-20
Publication date: 2013-09-26
Anticipated expiration: 2032-08-20
Also published as: AU2012216310A1; NZ602014A

Abstract

There is disclosed a retaining wall system comprising multiple first blocks and second blocks laid in courses to form a retaining wall: wherein each of the first blocks comprises opposed front and rear walls, the block being open from above and below and from each end to receive an infill material, the first blocks being the principal blocks used to form the wall with the first blocks being laid in successive courses with the blocks of each upper course being stacked upon those of a lower course, the block having location means to locate the block of an upper course stacked thereon to permit variable displacement of the upper block relative to the lower block in a forwards/rear direction whereby the upper block is displaceable relative to the lower block between a position in which the front face of the front wall of the upper block is substantially flush with that of the lower block and a position in which the front face of the front wall of the upper block is set back from that of the lower block, the location means defining limits for such movement while permitting the upper block to be set in any selected position between those limits; and wherein the second blocks are corner/end blocks to be laid at the end of a course of the first blocks to close off the open end of an adjacent first block and/or to commence a course of a second wall joined to the first at right angles thereto, each second block comprising opposed front and rear walls and being closed at one end by an end wall, and the block being open from above and below and from the opposite end to receive infill material. 8b 8b 4a 6 8c 8b W 10 6b 8a 8b 8c 8c 8d 8 I ~8a 4

Description

Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT (ORIGINAL) Name of Applicant: Island Block & Paving Pty Ltd Actual Inventor: Phil Thurlow Jason Bassett Address for Service: DAVIES COLLISON CAVE, Patent Attorneys, I Nicholson, Melbourne, Victoria 3000. Invention Title: "Retaining wall system" Details of Associated Provisional Application: No: 2011903407 The following statement is a full description of this invention, including the best method of performing it known to us: C \NK'onhhI)CC\LJI\4545007 1 )OC - 20/8/12 HAplw\1ntenvoven\NRPor1bl\DCC\PLW\5423172 I.doc-27/08/2013 RETAINING WALL SYSTEM The present invention relates to a retaining wall system comprising hollow blocks. 5 The present invention in its preferred embodiment seeks to provide a retaining wall system constructed from blocks having versatility to enable a number of different construction techniques according to requirements. According to the present invention there is provided a retaining wall system comprising 10 multiple first blocks and second blocks laid in courses to form a retaining wall: wherein each of the first blocks comprises opposed front and rear walls, the block being open from above and below and from each end to receive an infill material such that infill material incorporated into the blocks during construction of the wall locks adjacent courses of the wall and locks adjacent blocks within the same course as a consequence of 15 the infill material filling the open ends of the adjacent blocks, the first blocks being the principal blocks used to form the wall with the first blocks being laid in successive courses with the blocks of each upper course being stacked upon those of a lower course, the block having location means to locate the block of an upper course stacked thereon to permit variable displacement of the upper block relative to the lower block in a forwards/rear 20 direction whereby the upper block is displaceable relative to the lower block between a position in which the front face of the front wall of the upper block is substantially flush with that of the lower block and a position in which the front face of the front wall of the upper block is set back from that of the lower block, the location means defining limits for such movement while permitting the upper block to be set in any selected position between 25 those limits; and wherein the second blocks are corner/end blocks to be laid at the end of a course of the first blocks to close off the open end of an adjacent first block and/or to commence a course of a second wall joined to the first at right angles thereto, each second block comprising opposed front and rear walls and being closed at one end by an end wall, and 30 the block being open from above and below and from the opposite end to receive infill material. In a preferred embodiment each of the first blocks includes integral transverse webs interconnecting the front and rear walls, the webs being inwardly of the outer ends of the 35 two walls whereby the block is open at each end, Preferably each of the webs is formed C3NRPorbl\DlCOEJlIM97711_I rX is 1x2 -2 with a recess opening onto an upper edge of the web for optional receipt of horizontal reinforcing bar, cable, or piping during construction of the retaining wall. Advantageously the location means are in the form of lugs optionally engageable with 5 geogrid mesh to extend rearwardly from a course of blocks into backfill during construction of the retaining wall. Advantageously the portion of the rear wall of the first block between the transverse web and the adjacent end of the block constitutes a wing which is selectively removable to 10 provide a connection between a concrete infill and concrete backfill behind the retaining wall. According to another aspect of the invention there is provided a retaining wall constructed using a retaining wall system as specified above, the wall being constructed from the first 15 and second blocks laid in courses on a footing, an infill material incorporated into the blocks during construction whereby the infill locks adjacent courses of the blocks and locks adjacent blocks within the same course as a consequence of the open ends of the adjacent blocks, and a backfill behind the constructed retaining wall. 20 In some embodiments, the footing is of compacted gravel or other material having drainage characteristics, with the infill and backfill being of aggregate or other material having drainage characteristics, or alternatively the infill and backfill can be of no-fines concrete having drainage characteristics. In the latter case the wings of the blocks are removed at selected positions throughout the wall to provide direct connection between the 25 concrete infill and backfill. In another embodiment, the footing is of reinforced concrete and vertical and horizontal reinforcement is within the wall constructed from the blocks, the horizontal reinforcement being laid within the recesses of the transverse webs of the blocks. The infill is of concrete 30 to provide a reinforced retaining block wall which does not require the use of mortar. Embodiments of the invention will now be described by way of example only with C \NR PnblOCC\EJIM.'5U2 1 iDC. M 21 12 -3 reference to the accompanying drawings in which: Figure 1 is a view from the front of a first or principal block of the retaining wall system of the preferred embodiment; Figure 2 is a perspective view of the block of Figure 1; 5 Figure 3 is a plan view of the block of Figure 1; Figure 4 is an end view of the block of Figure 1; Figure 5 is a view from the front of a corner/end block of the retaining wall system of the preferred embodiment; Figure 6 is a perspective view of the block of Figure 5; 10 Figure 7 is a plan view of the block of Figure 5; Figure 8 is an end view of the block of Figure 5; Figure 9 shows schematically a retaining wall constructed using the system of the preferred embodiment wherein the blocks are filled with aggregate or no-fines concrete; and 15 Figure 10 shows schematically a retaining wall constructed using the retaining wall system of the preferred embodiment wherein the infill is of reinforced concrete. The retaining wall system of the preferred embodiment principally comprises blocks I in accordance with Figures 1 to 4 which are laid in courses to form the retaining wall and 20 which are used in conjunction with corner blocks 2 in accordance with Figures 5 to 8 (which may also be used as blocks to finish the end of a course). However it is the block I which constitutes the primary block from which the retaining wall is constructed. Each of the blocks 1, 2 is formed from a mixture of cement, quartz sand aggregate and iron pigments to provide a strong block of the required colour. It is, however, to be understood 25 that the composition of the blocks can differ from that just given as will be readily understood by those skilled in this art. For the primary blocks I, only the front face 4a of the block will be exposed in the finished wall and that face may be smooth, textured, or patterned to provide the required surface finish. For the corner/end blocks 2, the front face and end face are the exposed faces and the same surface finish as that of the primary 30 blocks; if however the block is designed for use as both a right hand and left hand corner/end block, each of its faces could potentially be an exposed face depending on where the block is placed in the wall and thereby all of its faces will then be finished faces.

CXNRPonbDCC\EJLum27711l. DOC.6/X/2012 -4 The primary block I (Figures 1 to 4) has front and rear vertical walls 4, 6 interconnected by parallel transverse webs 8 displaced inwardly from the ends of the walls 4, 6. Each web extends upwardly from the lower edges of the two walls 4, 6 to a position adjacent the 5 upper edges of the two walls 4, 6 which are of the same height. In its forward portion 8a, the upper edge of the web 8 is flush with the upper edge 4b of the front wall 4, while in its rear portion 8b the upper edge of the web 8 projects above the upper edge 6b of the rear wall 6. This projecting portion thereby forms a locating lug having a rear edge 8c which is substantially flush with the inner face of the rear wall 6. Accordingly when an upper 10 course of blocks is laid on a lower course during the construction of a retaining wall, the projecting lugs co-operate with the inner faces of the rear walls of the blocks of the upper course to assist in the location of the blocks of the upper course relative to those of the lower course. In particular, the rear edges of the locating lugs form stops whereby when an upper block is stacked on two adjacent blocks of a lower course (it being understood 15 that in conventional construction the blocks of one course will be offset through half a block length in relation to those of the adjacent lower course), the upper block cannot lie forwardly of the lower blocks, its maximum forwards position being that in which its front face is substantially flush with those of the lower blocks. However, forward edges 8d of the locating lugs are set back by a substantial distance from the inner face of the front wall 20 4. As a consequence of this set back of the forward edges of the lugs, the blocks of the tipper course are able to be set on those of the immediately lower course with a set back of required distance and which is variable up to the maximum determined by the set back of the forward edges 8d of the lugs. In the embodiment shown, the maximum set back could be almost one half of the breadth of the block: although in most circumstances a set back to 25 that extent is unlikely to be needed, nevertheless it is available if required. It is to be noted that the lugs do not act to locate the block laterally (lengthways) relative to those of the lower course when the blocks are laid in the conventional manner in half-length offset relation whereby some side to side movement is possible. 30 Each of the webs 8 is formed with a central void 10 extending downwardly from its upper edge to permit passage of horizontal reinforcement, electrical cable, or pipework along the length of a course of the wall being constructed. The void 10 also, conveniently, acts as a C.\NRPDbl\DCCEJL\537711_ .DOC-(l0V12-2 transition between the forward and rear portions 8a, 8b of the upper edge of the web and which are at different heights as explained above. The corner/end block 2 shown in Figures 5 to 8 is of similar construction to that of the 5 primary block except that it has only a single transverse web 8 at the end portion of the block opposite its end wall 12. Due to the asymmetrical positioning of the projecting locating lug in the embodiment shown and which allows variable, but restricted, set back in one direction and variable but greater set back in the other direction depending on where the block is set within the wall, this corner block cannot, without modification, be used in 10 all situations where a corner/end block is required although it can be used in most situations when the required set back is within the lesser of the two ranges and the block can be designed accordingly. In the relatively rare circumstances where a greater set back is required the locating lug can be removed (a single hammer blow will usually achieve this) to permit the required set back to be achieved. However, it is to be noted that 15 whereas the lugs form a useful function in the primary blocks, they are only of limited value in the corner blocks and an option is to omit the projecting lug from the corner block so that the same corner/end block can be used at any required location in the wall and in any situation without modification. In fact, in some situations where the block is required just to finish a course of the primary blocks it may be convenient to cut the block in half 20 lengthwise and to discard the part of the block including the transverse web. The design of the primary blocks permits significant versatility in construction methods which can be used to build the retaining wall and which will be dependent on wall height, soil conditions, and loading. In this respect it is to be noted that not only are the blocks 25 open from top to bottom to receive infill material following laying to provide a locking action between the blocks of adjacent courses, they are also open at each end so that the filling material will provide a strong interlock between adjacent blocks in the same course. The parts of the rear wall outwardly of the webs 8 in the primary blocks constitute wings W (see Figures 2 and 4) which are able to be removed from the block to permit 30 interconnection between filling within the block and backfill behind the built retaining wall especially in circumstances where no-fines concrete is used for both. In other situations the projecting lugs can be used as locking points for reinforcing mesh material , so catled C NRPartbl\DCC\EJIM45m l. 1 DOC-16I/21 2 -6 geogrids used in soil reinforcement. A retaining wall is built from the blocks on a suitable footing, the construction of which will depend on the height of the wall, soil conditions and load conditions effecting the 5 wall. As such, the footing could be compacted gravel, reinforced concrete or reinforced earth. Although a number of different construction methods will be described subsequently, in general terms a first course of blocks is laid on the footing and is then Filled with a suitable filling material. The next course is laid on the first and similarly filled whereby the two courses are locked together. Subsequent courses are added until the 10 wall of the required height is completed. After backfilling behind the wall has been completed capping blocks are applied over the upper course and are secured by an appropriate adhesive. The special configuration of the locating lugs allows the second and subsequent courses to 15 be laid with a variable set back determined by aesthetic and engineering considerations. However the configuration does allow the courses to be laid with minimal set back whereby the finished wall will have an almost vertical face if engineering considerations permit that. 20 When reinforcement, cabling, or pipework is to be incorporated within the wall. this is done prior to infilling by location within the central voids of the transverse webs. The corner/end blocks are used at the ends of the courses either when a return wall is required or simply as an end block to finish off the end of a course when no return wall is 25 being built, and depending on the specific consideration of the wall it may be necessary to cut the corner block in half so that it fits neatly within the depth of the wall. Specific examples of different construction methods will now be given. 30 As shown schematically in Figure 9, a relatively low non-load-bearing garden wall is constructed on a compacted gravel footing 20. After a course of the blocks is laid the blocks are filled with an aggregate such as blue metal aggregate. An ag-pipe drain 22 is C NRPonbihDCOFJL\ 177J 1_.DOC. I(M 2112 -7 laid at the back of the base of the wall and is backfilled also with aggregate shown at 26. This process is repeated until a wall of the required height is completed and such a wall may perhaps be no more than two or three courses high. The backfill is sealed from above by a compacted clay sealing layer 28, with a geotextile layer 30 being between the 5 aggregate backfill and retained soil 32 behind that. For higher walls, for example up to two metres in height, the aggregate filling and backfill discussed above is replaced with a so-called "no-fines" concrete mix which strengthens and increases the mass of the wall while still allowing water to flow through to the drain at the 10 base of the wall. In this form of construction. the wings W formed by the end portions of the rear walls of some of the blocks I are removed and which can be done quite easily by a hammer blow, to provide direct connection between the concrete filling within the wall and the backfill behind the wall. It is envisaged that at least 25% of the wings would be removed prior to backfilling. 15 In a further variation to produce a higher wall of up to three metres while using an aggregate fill, reinforcing geogrid mesh is locked into each course by engagement with the projecting lugs and is located within compacted gravel backfill. 20 As shown schematically in Figure 10, for walls up to three metres in height the blocks may be laid on a reinforced concrete footing 34. In this construction, starter bars 36 within the reinforcement of the footing are bent upwardly to project from the footing and further vertical bars 38 are wired to them. The blocks are laid by movement over the vertical bars, and horizontal reinforcing bars 40 are incorporated into each course as it is laid by 25 engagement within the central voids of the webs and are wired to the vertical bars. After laying, the blocks are then filled with concrete to form a reinforced block wall without the use of mortar. When cabling or pipework is to be incorporated within the wall, this is laid along the 30 central voids of the webs of selected course prior to filling the course with aggregate or concrete.

C:\NRPonbI\DCOEJL\4317711_l.DOC-1M0g/2012 -8 The embodiments have been described by way of example only and modifications are possible within the scope of the invention.

Claims

1. A retaining wall system comprising multiple first blocks and second blocks laid in courses to form a retaining wall: 5 wherein each of the first blocks comprises opposed front and rear walls, the block being open from above and below and from each end to receive an infill material such that infill material incorporated into the blocks during construction of the wall locks adjacent courses of the wall and locks adjacent blocks within the same course as a consequence of the infill material filling the open ends of the adjacent blocks, the first blocks being the 10 principal blocks used to form the wall with the first blocks being laid in successive courses with the blocks of each upper course being stacked upon those of a lower course, the block having location means to locate the block of an upper course stacked thereon to permit variable displacement of the upper block relative to the lower block in a forwards/rear direction whereby the upper block is displaceable relative to the lower block between a 15 position in which the front face of the front wall of the upper block is substantially flush with that of the lower block and a position in which the front face of the front wall of the upper block is set back from that of the lower block, the location means defining limits for such movement while permitting the upper block to be set in any selected position between those limits; and 20 wherein the second blocks are corner/end blocks to be laid at the end of a course of the first blocks to close off the open end of an adjacent first block and/or to commence a course of a second wall joined to the first at right angles thereto, each second block comprising opposed front and rear walls and being closed at one end by an end wall, and the block being open from above and below and from the opposite end to receive infill 25 material.

2. A retaining wall system according to claim 1, wherein each second block includes location means for locating a first block stacked thereon in a forwards/rear direction to provide a variable set back of the outer face of the forward wall of the first block relative 30 to that of the second block.

3. A retaining wall system according to claim 1 or claim 2, wherein the location means of the first block defines a stop position in which the front face of an upper block stacked upon a lower block cannot lie forwardly of the front face of the lower block. C NR I orbl\DCCEJ A;!'711_ lx)C.I 6I-1/2 - 10

4. A retaining wall system according to any one of claims I to 3, wherein each of the first blocks includes integral transverse webs interconnecting the front and rear walls, the webs being inwardly of the outer ends of the two walls whereby the block is open at each end. 5

5. A retaining wall system according to claim 4, wherein each of the webs is formed with a recess opening onto an upper edge of the web for optional receipt of horizontal reinforcing bar, cable, or piping during construction of the wall. 10

6. A retaining wall system according to claim 4 or claim 5, wherein the location means of the first block is formed by extension of the webs beyond upper edges of the forward and rear walls of the block for co-operation with lower edge portion of a block stacked thereon. 15

7. A retaining wall system according to claim 2 or any claim dependent on claim 2, wherein each of the second blocks includes an integral transverse web interconnecting the front and rear walls, the web being set inwardly from the said opposite end of the block whereby that end is open. 20

8. A retaining wall system according to claim 7, wherein the transverse web of the second block includes a recess opening onto its upper edge for optional receipt of horizontal reinforcing bar, cabling, or piping during construction of the wall.

9. A retaining wall system according to claim 8 or claim 9. wherein the location 25 means of the second block is formed by extension of the transverse web beyond upper edges of the front and rear walls for co-operation with the lower edge portion of a block stacked thereon.

10. A retaining wall system according to any one of claims I to 9, wherein the location 30 means are in the form of lugs optionally engageable with geogrid mesh to extend rearwardly from a course of blocks into backfill during construction of the retaining wall. C:\NRioobl\DCC\EJIlMl7 711 DOC-W(0121 12 - 11

11 A retaining wall system according to claim 4 or any claim dependent on claim 4, wherein the portion of the rear wall of the first block between the transverse web and the adjacent end of the block constitutes a wing which is selectively removable to provide a connection between a concrete infill and concrete backfill behind the retaining wall. 5

12. A retaining wall constructed using a retaining wall system according to any one of the preceding claims, the wall being constructed from the first and second blocks laid in courses on a footing, an infill material incorporated into the blocks during construction whereby the infill locks adjacent courses of the blocks and locks adjacent blocks within the 10 same course as a consequence of the open ends of the adjacent blocks, and a backfill behind the constructed retaining wall.

13. A retaining wall according to claim 12, wherein the footing is of compacted gravel or other material having drainage capability and the infill and backfill are of an aggregate 15 or other material having drainage capability.

14. A retaining wall according to claim 13, wherein the wall is constructed using first blocks according to claim 10, the retaining wall further comprising reinforcing geogrid mesh locked into at least some of the courses by engagement with the projecting lugs and 20 located within a compacted backfill.

15. A retaining wall according to claim 12 or claim 13, wherein the wall is constructed using first blocks according to claim 11, wherein the infill and backfill is of a no-fines concrete having drainage characteristics and some of the wings are removed to provide 25 direct connection between the concrete infill and concrete backfill.

16. A retaining wall according to claim 12, wherein the wall is constructed using first blocks according to claim 5, the footing is of reinforced concrete and vertical starter bars extend upwardly from the reinforced concrete footing for location within the blocks of the 30 courses, with further vertical bars being tied into the starter bars as required, and horizontal reinforcing bars are located within the recesses in the transverse webs of the respective courses during laying, and the infill is concrete whereby the retaining wall thus formed is a C \NRi' bNI)COEII.\45177II 1.I 6/0I/2012 - 12 reinforced block wall without the use of mortar.