CA1258980A - Wall structure for retaining walls and the like - Google Patents
Wall structure for retaining walls and the likeInfo
- Publication number
- CA1258980A CA1258980A CA000567709A CA567709A CA1258980A CA 1258980 A CA1258980 A CA 1258980A CA 000567709 A CA000567709 A CA 000567709A CA 567709 A CA567709 A CA 567709A CA 1258980 A CA1258980 A CA 1258980A
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- module
- modules
- panel
- partition
- partition means
- Prior art date
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Abstract
Abstract of the Invention A prefabricated concrete module and a composite wall structure comprised of an assembly of modules, where the module comprises a generally rectangular front and rear panel, joined by at least one generally trapezoidal partition means. A
cellular wall structure is formed by tacking the modules and aligning the partition means on top of each other, thereby forming bins which contain loose material contributing to the weight of the structure. Provisions can be made for slabs which span longitudinally across partition means to be positioned upon or between partition means of vertically contiguous modules.
These slabs, which capture an additional amount of loose material, can also, where desired, transfer lateral forces between superposed partition means. In a version of the module, useful whether or not the trapezoidal partition means are employed, the longitudinal distance from a partition to the edge of the front panel, is less than half the distance between partitions. By spacing these modules so that their front panels are longitudinally spaced apart, drop-in panels are able to be inserted, and a more economical wall structure can be assembled.
cellular wall structure is formed by tacking the modules and aligning the partition means on top of each other, thereby forming bins which contain loose material contributing to the weight of the structure. Provisions can be made for slabs which span longitudinally across partition means to be positioned upon or between partition means of vertically contiguous modules.
These slabs, which capture an additional amount of loose material, can also, where desired, transfer lateral forces between superposed partition means. In a version of the module, useful whether or not the trapezoidal partition means are employed, the longitudinal distance from a partition to the edge of the front panel, is less than half the distance between partitions. By spacing these modules so that their front panels are longitudinally spaced apart, drop-in panels are able to be inserted, and a more economical wall structure can be assembled.
Description
~25~398() WALL ST~UCTURE FOR RETAINING WALLS AND THE LIKE
s ckqround of the Invention This invention relate~ generally to specially configured prefabricated structural modules for empl4yment in the construction of walls. More particularly this invention relates to that cla~s of wall wherein the structural elements of the module ~orm interior cavities or cells in which granular material is depo~ited. Thi~
enclosed granular material, through ~he action of friction a~ainst the generally upright walls of the cells, adds its own weight to that of the structural parts to form a m~re effective a~sembly.
The structural modules of the present invention are intended to be u~ed in combination with other similar modules arranged in horizontal rows and, accordin~ to the hei~ht required o~ the structure, in additional superposed horizontal rows of modules each properly proportioned to provide adequat~ stability to the as~embled structure.
More particularly the preqent invention relates to an improved prefabricated structural module of the gensral type ~hown in U.S. Pat. No. 3,877,236 and U.S. Pat. No.
4,372,091. These patents show stru~tural modules ~hi~h, 1~5~39&() when assembled in combination laterally and vertically to form a wall structure, create cellular cavities to contain fill material which acts in concert with the wall modules to form a gravity wall. The principal distinction between the referenced patents lies in the method utiliz~d to transfer the lateral components of forces acting upon the walls.
In U.S. Pat. No. 3,877,236 the lateral forces are transmitted by interlocking conto-~rs located in the top and bottom surfaces of the face panels. This detail is effective for small to moderate lateral forces, but the stresses induced in relatively thin face panels by high--lateral stresses in high structures cannot be economically resisted by these methods. U.S. Pat. ~o. 4,372,091 uses a standard rnortise and tenon interlocking key located on the arm connecting the front and rear faces. The lateral forces in a wall constructed with these modules cause very hi~h bending stresses in the connecting arms, since the mortise and tenon keys form couples which are transmitted to the face panels. The connectin~ arms must also resist high vertical shear stresses caused by these couples. The bending and shear stresses so induced must be resisted respectively by heavy longitudinal reinforcing steel and by vertical steel usually in the form o~ stirrups. These requirements add significantly to the cost of the modules and hence to the final cost of the structure.
~s~9~) An object of the present i~vention is to provide an improvement over other prefabricated modules presently used for wall struct~res of this type, since the modules described in this invention are configured in such a manner as to conform more efficiently to the location~, directions and patterns of stresses induced in the wall assembly by the fill material within and by the external loads acting upon the wall. By being positioned in such a manner as to be able to accomodate more efficiently the load~ imposed upon it, the stability of the assembled structure is increased. Moreover, both the intensity of the internal stresses within the module, and the physical size of the individual modules are reduced. This more effective construction results in the u~e of less material in the manufacture of the modules and, when used in a retaining structure, requires less excavation of soil (and consequently, less backfill material to be placed) to place the modules in the field and to complete the structure.
All thesa factors combine to produce a much more economical structure with improved structural integrity.
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Summa~y_o _ he InYention In order to accomplish the objectives of the present invention, a precast structural module i~ configured as follow~: a front panel is provided which typically is of generally rectangular con~iguration when viewed in front elevation. A rear panel is located with its longitudinal axis parallel to that of said front panel, and one or a plurality of partition means connect said front panel ~ith said rear panel. When said modules are placed in lateral contiguity, the front panels and rear panels form t~o opposite longitudinal sides of a cellular chamber, with each partition means ~erving to connect the front panel with the rear panel, and further serving to transversely divide the chamber into smaller individual cells.
In a particularly advantageous form of the present invention, the partition means are of a pronouncad generally trapezoidal hape when view0d along a horizontal line parallel with the longitudinal axis of the ~ront panel. (For the purpose of this application, the term "trapezoidal" includes a parallelogram.) This trap~zoidal shape is such that, when the mod~le is placed in its final erected po~ition within the assembled wall structure, the rear panel o~ a module is situated at an elevatio~
125R~38~) considerably below a plane extending from the upper edge of the front panel at right angles thereto, and the principal axes of the partition means extend in a downward direction, desirably at a~ angle of between 20 and 82 degrees ~rom the plane of the front panel. This results in the axes of the partition means being more nearly perpendicular to the direction of the resultant forces acting on the wall modules. These forces represent the combined effects of (a) the lateral force caused by the material retained behind the wall, and (b) the ver~ical gravity forces ~rom the modules themselves and from the fill enclosed withi the cellular cavities formed by the front and rear panels and the partition means of the assembled modules.
In a wall where modules are stacked vertically, each module beginning with the topmost module i.s acted upon by lts respective overturning and resisting forces and subsequently transmits those forces to the contiguous module(s) below according to the details of the transfer mechanism provided in the design. Such mechanisms have heretofore consisted of commonly used interlocking means such as mortise and tenon ~eys on connecting arms or depended lips on the lower surfaceq of the face panels.
The use of mortise and tenon keys in the partition means results in very heavy bending stres es in the partition means as well as high local shearing stresses in the keys.
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The use of depending lips in the face panel3 results in exces~ively high shearing stresses and bending in the weaker direction of the panel. This factor seriously limits the u~eful height of the de~ign since these stresses when high cannot be resisted by any economically practical ~hickness of face panel or depending lips.
Since concrete, the material commonly used in the manufacture of wall modules, i3 relatively weak in tensile strength, bending in concrete members must be resisted by reinforcing material, usually steel, located longitudinally in the tension face of the member. A very significant aspect of one form of the present invention is the ability of the design to transmit the natural stresses o~ the retained material and those of the resisting material directly as compressive forces, without relocating those forces through exces~ive and inefficient use of expensive reinforcing materials.
- The present invention is not restricted to the use of any particular material of construction, but concrete, either plain or rein~orced by metal embeded therein in the usual way, is very suitable and advantageous. The invention utilizes most effectively and e~onomically the very efficient natural compre~sive strength of concre~e.
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To affect this natural ability of concrete to transmit stresses compressively, one precept of this invention prescribes a variation of configurations of the contact surfaces of vertically contiguous partition means, each embodiment utilizing the advantages of a generally sloped orientation of the contactsurfaces of the partition means. In its simplest form, the contact surface consists of a straight inclined plane oriented in such a way that the total resultant forces, overturning and resisting, exerted by the upper module upon the lower module, occur at such an angle that ordinary frictional ~orces between the surfaces in contact more than compen~ate for any component of the resultant force which may occur in a direction parallel to said contact surface~. Another form of this invention utilizes a more positive engagement of contact surfaces wherein alternate surfaces are angled with respect to each other, presenting surfaces normal to any resulting components of loading.
Description of the Drawl~
Figs. 1 and 2 are perspective views of advantageous forms of structural modules incorporating features of the invention.
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Figs. 3 and 4 are cross sectional and top plan views respectively illustrating a module of the general type shown in Fig. 1, with parallel front and rear panels.
Figs. 5 and 6 are fragmentary cross sectional and plan views, similar to Figs. 3 and 4, illustrating a modification in which the rear panel i5 tilted at an acute angle to the front panel.
Fig. 7 is a fragme~tary perspective view of an assembled retaining wall or the like utilizing structural modulesaccording to the invention.
Fig. 8 is a perspective view of a base of a type which may be used in connection with a wall assembly such as that of Fig. 7.
Fig. 9 is a cross sectional view of a preferred form of base ~odule according to the invention having an extended toe flange for increased resistance to overturn.
Fig. lO illustrates a modified form of structural module, having a notched-out area for reception of a horiæontal, ec~rth-retaining slab.
Figs. 11 and 12 are cross sectional views illustrating d.ifferent advanta~eou~ construction techniques utilizing the structural modules of the invention.
Fig. 13 is a diagrammatic illustration of a structural wall utilizing the modules of the invention, for 2S force analysis purposes.
~L;2589~0 Figs. 14 and lS are cross sectional views taken on lines 14-14 and 15-15 of Fig. 16 illustrating advantageous forms of construction for the tops of retaining walls or the like.
Fig. 16 is a composite cross sectional view illustrating the construction features of Figs. 14, 15.
Fig. 17 is a fragmentary cross sectional view illustrating another form of top structure for a retaining wall or the like.
Fig. 18 is a cross sectional view generally on line 18-18 of Fig. 19.
Fig. 18a is a fragmentary cross sectional detail, illustrating an advantageous form of connector for joining a connecting panel to adjacent structural modules.
Fig. 19 is a top plan view of an arrangement for joining so-called half modules to adjacent structural modules by m~ans of an intermediate connecting panel.
Fig. 20 is a perspective view of a modified form of half module having an integral stabilizing slab.
- Fig. 21 is a front elevational view of a retaining wall or the like constructed with structural modules according to the invention.
Figs. 22 and 22A are front elevational views of modified forms o~ retaining wall assembly or the like 2S incorporating filler panels between adjacent, spaced structural modules.
398~3 Figs. 23-26 are fragmentary cross sectional and top plan views illustrating various arrangements for the mounting and retention of filler panels in a wall assembly of the type shown in Fig. 22.
Fig. 27 is a perspective view of an advantageous form of dro~-in panel, which may be used at the back of the assembly or, more typically, as an intermediate vertical panel.
Figs. 28-30 illustrate various views of an arrangement for mounting of the drop-in panel in an assembly of modules.
Figs. 31 and 32 are fragmentary views in vertical cross section illustrating advantageou~ arrangements for ke~ing together vertically adjacent structural modules for resistanceto shear.
Fig. 33 is a side elevation of an advantageous form of structural module, in which the front and rear panels are generally at the same height, joined by partition elements stepped to provide a plurality of forward facing abutment elements for improved resistance to shear.
Fig. 34 is a cross sectional view of an assembly of structural modules arranged with notched-out partition panels and with adjacent structural modules being joined by special keying blocks or ~labs.
Fig. 35 is a perspective view illustrating a further modified form of the invention.
~5~39~30 Fig. 36 is a cross sectional view of a retaining wall or the like of the general type shown in Fig. 35.
Figs. 37 and 38 are enlarged, fragmentary cross sectional views, ill~strating details of thorou~h retaining/supporting element incorporated in the assembly of Fig. 36.
Figs. 39, 40 are perspective view~ of special configura~ions of base module~, for used in wall as~emblies such as shown in Figs. 35, 36.
Figs. 41 and 42 are cross sectional and top plan views respectively of a modified structural module configuration providing for aligned pairs of mortise notches between vertically adjacent modules, for the reception of keying elements.
Figs. 43 and 44 are cross sectional and top plan viewsrespectively, similar to Figs. 41, 4~, where the module is provided with an inclined rear panel.
Fig. 4$ is an end elevational view of a retaining wall or the like constructed of various modified forms of structural modules having advantageou~ load bearing characteristics.
Figs. 46 and 47, together, constitute a cros~
sectional view of a further modified form of retaininy wall assembly utilizing an advanta~eous form of interlocking means between vertically adjacent modules.
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Fig. 48 is a cross sectional view taken on line 48-48 of Fig. g9.
Fig. 49 is a top plan view of a structural module accordi~g to the invention which is cast in individual components and assembled before installation.
Fig. 50 is an enlarged fragmentary cross sectional view taken on line 50-50 of Fig. 48.
Preferred Embodiment~
Figures 1 through 6 illustrate some of the more preferred embodiments of a module with trapezoidal partition means. The modules comprise rectangular front and rear panels, and trapezoidal partition elements, the upper surfaces 4 and 5, andthe lower surfaces 6 and 7 of which are arranged in matching sawtooth pattern capable of positive unilateral interlocking of one module with another when one of said moduleq is superposed upon another.
Figure 1 is a perspective view of a module 11 with a front panel 1, a rear panel 2, and generally trapezoidal partition elements 3. Usually, but not necessarily, there are two spaced partition elements 3, panel-like in form.
At the intersection of the panels with the partition elements are fillets 9 which are placed according to usual practice.
~S~398() Figure 2 represents a similar module 13, specially designed, however, for use at the base of a wall assembly.
The partition elements 3A, ordinarily trapezoidal, have been, in this particular case, truncated to allow the bottom surfaces thereof to lie along the plane of the wall's foundation. The rear panel 8 is shown in a special configuration more suitable for a base module, where its plane is perpendicular to the plane of the partition means 3A and approximately perpendicular to the plane of the front panel 1. The rear panel 8, as shown, has a marked advantage when used as an element of a base module. Its horizontal orientation forms a shelf which positively -captures the force from the weight of the fill above it, and is located approximately at the center of action of the resultant force combining the vertical gravity loads with the lateral overturning load3. It is capable of behaving as a spread footing distributing the loads from the superposed modulesabove, and from the fill they contain.
The rear panel of any module may be either substantially perpendicular to the ~ront panel, as in Figure 2, substantially parallel with the front panel, as in Fiyures 3 and 4, or inclined at an acute angle with respect to the plane of the front panel, depending upon the particular purpose to which it is to be applied. When a smaller module is to be used below a larger module, at the ~Z589&(~
base of the wall, a rear panel 8 which is substantially perpendicular to the front panel 1 of the module is especially beneficial. When it is desired to use the rear panels to assist in transferring weight between modules, such as in a bridge abutment, it is preferred that the rear panels 10 be parallel with the front panel 1 (Fig. 3) so the rear panels can be readily aligned. When it is desired to increase the forces resisting overturning it is beneficial to tilt the rear panel 2 at an acute angle with the front panel 1, with its upper edge farther away from the front panel, as illustrated in Figures 5 and 6, so as to increase the amount of fill captured, and to reduce-simultaneously the lateral pressure exerted by the retaine~d material behind the module.
Figure 3 clearly shows a cross sectional view of one of many sawtooth patterns made according to the invention.
A plurality of surfaces 4 and 5 form the upper sawtooth edge and a plurality of surfaces 6 and 7 form the lower matching saw~oothedge. In one form of the invention, surfaces 4 and 6 do not come in contact with each other, and the component, parallel to the plane of the front panel, of the resultant of all forces acting upon the module, is carried by the front and rear panels and transmitted to the front and rear panels of the lower module at the panels' respective contact surfaces. The . .
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component, perpendicular to the plane of the front panel, of the resultant of all forces acting upon the superposed module is transmitted from contact surface 7 to contact surface 5 o~ the supporting module and is carried by the partition means 3 of the supporting module. In a preferred form of the invention, all surfaces 6 and 7 come in contact with their respective matching surfaces 4 and 5 and each surface bears a proportionate amount of the component, perpendicular to the contact surface, of the resultant of all forces actin~ upon the module. In a further preferred form of the invention, the modules are constructed to dimensions which prevent the transmission of major forces from one face panel (i.e. front or rear panels 1, 2 or 1, 10) to another. This feature minimizes the occurrence of cracking in said panels.
Fi~ures 5 and 6 show in side view and plan view the rear panel a tilted in a manner which increases the force it receives from the bin-action effect of the fill within the cells of the module while at the same ~ime reducing the lateral force it receives from the retained material. It produces an additionalbenefit when modules o~ the same dimensions are stacked, one upon the other, by creating a protruding top surface which captures the beneficial downward force of retained material locat@d in a zone above the protruding parts of the module. For the tilting to be . ` ' ` ' ' ' ' ' ' !;', ' . `
.' ~ ' ''~' , ,, ~5~
worthwhile, the back panel 2 should be at least about 8 degrees with respect to the front panel.
Figure 7 shows a perspective view of an assembly of modules arranged laterally in horizontal rows with additional horizontal rows o~ module~ superposed above.
The assembly as een in Figure 7 is of a wall -~tructure viewed ~rom the rear. The assembly of front panels 1 form the exterior face of the wall structure. The rear panels 2 are shown at an acute angle with respect to the plane o~
the front panels. With the exception of the base module, each superposed module is shown with its partition means of lesser width than the partition means of the module upon which it is supported. This method of stacking is also shown in cross-sectional view in Figure 11 and represents the standard method of stacking when constructing a modular gravity retaining wall. As shown in Figure 7 the base module is a ~orm of the new module with its bottom portion truncated to conform to the plane of the subgrade. The base module is of smaller width than the module directly superposed on it because the heel o~ the wall is the bottom edge of the rear panel of the module resting on the base unit and is substantially at the elevation of the ba~e module's subgrade.
~2S8~38() Fi~ure 8 shows a solid base. This type of base may be used for smaller walls where the extra material ueed would be less expensive than the cost of forming the empty cells.
Figure 9 shows a base module 14 with the lower exterior edge of its front panel extended a substantial distance. This module, by extendiny the pivot point 48 about which the wall assembly could rotate, increases su~stantially the wall's resistance to such rotation. This improvement is particularly effective for walls with trapezoidal partition mean~ and/or lowered rear panels.
In the analysis of a modular retaining wall for stability ayainst overturning, when the wall ie one in which modules of different size or shape occur in any vertical stack, it is necessary to investigate the stability of the structure above each possible pivot point. It is readily apparent from Figure 11 that the inclined trapezoidal shape of the partition means and lowered position of the rear panel results in several advantages. It subs~antially lower~ the center of gravity of each of the stacked modules and likewise lowers the cen~er of gravity of the granular material enclosed within each of the cells of the modules. In that part of a wall in which the rear face is stepped toward the front face as ;
: .
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the courses progress upward, the trapezoidal shape of the p~rtition means also lowers the center of gravity of the retained material trapped above the protruding rear portion of the modules.
The inclined trapezoidal shape of the partition elements and the lowe~red position of the rear panel has another important effect on the behavior of the modular wall. In the analysis of the complete wall, when investigating the tendency of the bottommost module course to overturn about the toe, or to slide along the base, the lowered position of the rear panel has no effect, either beneficial or detrimental. However, when analyzing the stability of the individual courses above the bottom course, the advantages of the new design are substantial.
Referring to Figure 13, if we perform an overturniny analysis about point 39, the pivot point of a typical module llC, which lies in an arbitrarily chosen upper course of the wall, the improvements become evident. The resultant of those forces causing overturning, as well as the resultant of those forces affecting resistance to overturning, are substantially lowered in elev~tion.
Although the overall magnitude of the overturning force is increased, its effectiveness nevertheless is reduced. At the same time, both the magnitude and the effectiveness of the beneficial resisting forces are increased.
1~898~3 To illustrate in more detail th~ effect of a lowered rear panel on the behavior of th~ force tending to cause o~erturning, refer to Figure 13. In the analysis of a standard wall built according to the present state of the art, the rear panel ~5 is,within the tolerances of usual wall batters and construction accuracies, at the same elevation as the front panel. This condition is illustrated by the dashed lines in Figure 13. Taking the summation of moments about pivot point 39 the lateral overturning force 41 caused by the retained material a~ove the heel 40 acts at an elevation approximately one-third the distance from the elevation of the heel 40 to the surface g4 o~ retained material. In contrast, in the analysis of the wall built according to the teachings of the present invention shown by solid lines in Fisure 13, when we take the summation of moments about the same pivot point 39, the lateral overturning force now consists of the combined effects of the same overturning force 41, plus the overturning ~orce 43 due to the additional volume of retained material between point 40 and the new heel 42.
The additional force 43, although increasing the total horizontal force against the wall, actually has a stabilizing effect since its line of action lies below the elevation of the p~vot point 39. Thus the total effective overturning moment is in fact reduced, and the size and _ ~,9 _ ~eight of the wall structure including module llC and those modules above it may be reduced in size, thereby affecting a more economical construction.
In the analysis of overturning conditions for the entire wall it is necessary to evaluate moments about the base at pivot point 47 (representiny the pivot point location in a standard wall). Since the heel ~6 of the entire wall is at the same elevation as pivot point 47, there is no benefit from the trapezoidal partition means, and the overturning condition is the same for the standard wall and for the wall according to the invention. When the base module is fabricated with its lower edge extended forward from the face, forming the pivot point at 48 (see Figs. 9, 11), overturning moments are reduced, and resisting moments are increased.
Figure 12 illustrates an assembly of modules according to the invention arranged in a more beneficial sequence of sizes. In this type of stacking, the rear panel 2a of module llA, which extends farthe~t away from the front panel, is located a substantial di~tance above the elevation of the base module 14. The rear panel 2A
acts to protect each of the rear panels beneath it from the full effects of the retained material. The overall effect is to reduce substantially the amount of material used to 398(~
collstruct the wall and to require substantially less material (e.g. earth) to be removed prior to construction.
A wall with less required height can be built using the same principle, in which case module llB might be the farthest extending module with all superposed modules of smaller size.
Fi~ures 11 and 12 also show the location of an auxiliary feature which is detailed in Figure 10. This is a prefabricated slab or plank 49 which can be placed between contact surfaces 4 and 6 of superposed partition elements. To incorporate the slab49 in an assembled structure, either or both surfaces 4, 6 must be molded in such a manner that adequate space i5 allowed. If the proper space is allowed, the partition means will behave the same a-q it would without the space, but an additional beneficial action is obtained. The slabs 49, extending into the fill material contained in the cells of the modules, form qhelf-like members which enga~e the weight of fill material above in a more positive ~anner than does the bin-action against vertically extending panels and partitions.
Thus, the slab 49 increases the ability Qf the fill ~aterial to act in concert with the cellular wall structure. Slab 49 may be made to span between adjacent 589~() partition means or to cantilever from both sides of a partition means. The most preferred method would be to span between two or more partition means and to cantilever at each end, reaching approximately half the distance to the next partition means.
In Figures 14, 15 and 16 there are shown two methods of constructing the tops of walIs. The top-most front panel shown is a cantilevered panel 17 or 18 with offset arms 20 set vertically behind the front panel 1 of a module. The vertical load from the panel i~ transmitted to the top of the front panel 1 by bottom surface 19 of the offset shoulder. Horizontal loads against the top portion of the cantilevered panel are recisted by cantilever action of the panel with the restraining thrustsupplied by ~hrust blocks. Two forms of thrust blocks are shown. In Figure 14 the thrust block is shown in the form of a plug 21, which may be prefabricated or cast in place, and which extends rearward to the inner face of the rear panel 10.
In Figure 15 the thrust block 16 i8 attached to the partition means 3, either integrally or by connectin~
means.
Figure 16 is a cross-sectional view looking forward-at the rear faces of the cantilevered panel and of t~e front panel. The left portion of Figure 16 shows the ,, ., - ' `~
, constructio~ as in Figure 14, while the right portion of Figure 16 shows the construction as in Figure 15. The rightmost partition means shown in Figure 16 is shown prepared to receive a cantilevered panel. Cantilevered panels are more economical to construct than are cellular modules and may be shaped for special applications such as parapets and may include special shapes as for traffic barriers. Cantilevered panels are able to protrude further above the finished grade and their top edge may be fabricated at an angle with re~p0ct to the horizontal to conform to a specified grade (See Figs. 21, 22).
Cantilevered panels 17 may be used in lieu of a top module in walls whether or not parapets are required.
Figure 17 illustrates a top unit 23 in the form of a V-shaped cantilever. This unit also may be used in lieu of a top module where a parapet is not required, as shown in Figuresll, 12 and ~7, or it may be used as shown in Figure 17 where it is indicated as a parapet with an integral traffic barrier. The vertical and horizontal loads from unit 23 are transmitted to the top module by ribs 26 fabricated along the soffit of the inclined slab 24. Ribs 26 are fabricated with contact sur~aces 6 and 7 which conform to the contour of the tops of partition means 3 of modules 11. Thus these forces are transmitted in the same manner as they are from superposed module to supporting - ~3 -~5~9~
module in a basic wall structure with a ~awtooth pattern in the joints of the partition means. Resistance to overturning is provided to the top unit 23 by the weight of fill supported by slab 24. Whenever it is desired to S provide additional stability to unit 23, the lab 2~ may be extended as indicated by 25. Since extending slab 24 causes the edge to descend deeper into the ~ill as well as rearward, it can be seen that the V-shape o~ unit 23 is more effecti~e than an L-shaped uni~ would be. The V-shaped unit also allows more space for underground structures such as utility structures.
Figure~ 17 and 18 show prefabricated rear slabs 32, 33 and 34. Slab 32 is planar while slab 33 has a depending flange and slab 34 has an ascending flange. Slabs 32, 33 and 34 are able to positively engage the retained material above them in a location which is the most beneficial, tha rear of the module.
Figure 21 shows a front elevation of a wall assemblyusing modules 11 and cantilevered panels 17. The modules are arranged to stagger the vertical joints so that each superposed module, where possible, is supported by two different modules in the course below it. To accomplish this preferred interlocking pattern, the partition means are spaced apart at virtually twice the distance from the
s ckqround of the Invention This invention relate~ generally to specially configured prefabricated structural modules for empl4yment in the construction of walls. More particularly this invention relates to that cla~s of wall wherein the structural elements of the module ~orm interior cavities or cells in which granular material is depo~ited. Thi~
enclosed granular material, through ~he action of friction a~ainst the generally upright walls of the cells, adds its own weight to that of the structural parts to form a m~re effective a~sembly.
The structural modules of the present invention are intended to be u~ed in combination with other similar modules arranged in horizontal rows and, accordin~ to the hei~ht required o~ the structure, in additional superposed horizontal rows of modules each properly proportioned to provide adequat~ stability to the as~embled structure.
More particularly the preqent invention relates to an improved prefabricated structural module of the gensral type ~hown in U.S. Pat. No. 3,877,236 and U.S. Pat. No.
4,372,091. These patents show stru~tural modules ~hi~h, 1~5~39&() when assembled in combination laterally and vertically to form a wall structure, create cellular cavities to contain fill material which acts in concert with the wall modules to form a gravity wall. The principal distinction between the referenced patents lies in the method utiliz~d to transfer the lateral components of forces acting upon the walls.
In U.S. Pat. No. 3,877,236 the lateral forces are transmitted by interlocking conto-~rs located in the top and bottom surfaces of the face panels. This detail is effective for small to moderate lateral forces, but the stresses induced in relatively thin face panels by high--lateral stresses in high structures cannot be economically resisted by these methods. U.S. Pat. ~o. 4,372,091 uses a standard rnortise and tenon interlocking key located on the arm connecting the front and rear faces. The lateral forces in a wall constructed with these modules cause very hi~h bending stresses in the connecting arms, since the mortise and tenon keys form couples which are transmitted to the face panels. The connectin~ arms must also resist high vertical shear stresses caused by these couples. The bending and shear stresses so induced must be resisted respectively by heavy longitudinal reinforcing steel and by vertical steel usually in the form o~ stirrups. These requirements add significantly to the cost of the modules and hence to the final cost of the structure.
~s~9~) An object of the present i~vention is to provide an improvement over other prefabricated modules presently used for wall struct~res of this type, since the modules described in this invention are configured in such a manner as to conform more efficiently to the location~, directions and patterns of stresses induced in the wall assembly by the fill material within and by the external loads acting upon the wall. By being positioned in such a manner as to be able to accomodate more efficiently the load~ imposed upon it, the stability of the assembled structure is increased. Moreover, both the intensity of the internal stresses within the module, and the physical size of the individual modules are reduced. This more effective construction results in the u~e of less material in the manufacture of the modules and, when used in a retaining structure, requires less excavation of soil (and consequently, less backfill material to be placed) to place the modules in the field and to complete the structure.
All thesa factors combine to produce a much more economical structure with improved structural integrity.
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Summa~y_o _ he InYention In order to accomplish the objectives of the present invention, a precast structural module i~ configured as follow~: a front panel is provided which typically is of generally rectangular con~iguration when viewed in front elevation. A rear panel is located with its longitudinal axis parallel to that of said front panel, and one or a plurality of partition means connect said front panel ~ith said rear panel. When said modules are placed in lateral contiguity, the front panels and rear panels form t~o opposite longitudinal sides of a cellular chamber, with each partition means ~erving to connect the front panel with the rear panel, and further serving to transversely divide the chamber into smaller individual cells.
In a particularly advantageous form of the present invention, the partition means are of a pronouncad generally trapezoidal hape when view0d along a horizontal line parallel with the longitudinal axis of the ~ront panel. (For the purpose of this application, the term "trapezoidal" includes a parallelogram.) This trap~zoidal shape is such that, when the mod~le is placed in its final erected po~ition within the assembled wall structure, the rear panel o~ a module is situated at an elevatio~
125R~38~) considerably below a plane extending from the upper edge of the front panel at right angles thereto, and the principal axes of the partition means extend in a downward direction, desirably at a~ angle of between 20 and 82 degrees ~rom the plane of the front panel. This results in the axes of the partition means being more nearly perpendicular to the direction of the resultant forces acting on the wall modules. These forces represent the combined effects of (a) the lateral force caused by the material retained behind the wall, and (b) the ver~ical gravity forces ~rom the modules themselves and from the fill enclosed withi the cellular cavities formed by the front and rear panels and the partition means of the assembled modules.
In a wall where modules are stacked vertically, each module beginning with the topmost module i.s acted upon by lts respective overturning and resisting forces and subsequently transmits those forces to the contiguous module(s) below according to the details of the transfer mechanism provided in the design. Such mechanisms have heretofore consisted of commonly used interlocking means such as mortise and tenon ~eys on connecting arms or depended lips on the lower surfaceq of the face panels.
The use of mortise and tenon keys in the partition means results in very heavy bending stres es in the partition means as well as high local shearing stresses in the keys.
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The use of depending lips in the face panel3 results in exces~ively high shearing stresses and bending in the weaker direction of the panel. This factor seriously limits the u~eful height of the de~ign since these stresses when high cannot be resisted by any economically practical ~hickness of face panel or depending lips.
Since concrete, the material commonly used in the manufacture of wall modules, i3 relatively weak in tensile strength, bending in concrete members must be resisted by reinforcing material, usually steel, located longitudinally in the tension face of the member. A very significant aspect of one form of the present invention is the ability of the design to transmit the natural stresses o~ the retained material and those of the resisting material directly as compressive forces, without relocating those forces through exces~ive and inefficient use of expensive reinforcing materials.
- The present invention is not restricted to the use of any particular material of construction, but concrete, either plain or rein~orced by metal embeded therein in the usual way, is very suitable and advantageous. The invention utilizes most effectively and e~onomically the very efficient natural compre~sive strength of concre~e.
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To affect this natural ability of concrete to transmit stresses compressively, one precept of this invention prescribes a variation of configurations of the contact surfaces of vertically contiguous partition means, each embodiment utilizing the advantages of a generally sloped orientation of the contactsurfaces of the partition means. In its simplest form, the contact surface consists of a straight inclined plane oriented in such a way that the total resultant forces, overturning and resisting, exerted by the upper module upon the lower module, occur at such an angle that ordinary frictional ~orces between the surfaces in contact more than compen~ate for any component of the resultant force which may occur in a direction parallel to said contact surface~. Another form of this invention utilizes a more positive engagement of contact surfaces wherein alternate surfaces are angled with respect to each other, presenting surfaces normal to any resulting components of loading.
Description of the Drawl~
Figs. 1 and 2 are perspective views of advantageous forms of structural modules incorporating features of the invention.
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Figs. 3 and 4 are cross sectional and top plan views respectively illustrating a module of the general type shown in Fig. 1, with parallel front and rear panels.
Figs. 5 and 6 are fragmentary cross sectional and plan views, similar to Figs. 3 and 4, illustrating a modification in which the rear panel i5 tilted at an acute angle to the front panel.
Fig. 7 is a fragme~tary perspective view of an assembled retaining wall or the like utilizing structural modulesaccording to the invention.
Fig. 8 is a perspective view of a base of a type which may be used in connection with a wall assembly such as that of Fig. 7.
Fig. 9 is a cross sectional view of a preferred form of base ~odule according to the invention having an extended toe flange for increased resistance to overturn.
Fig. lO illustrates a modified form of structural module, having a notched-out area for reception of a horiæontal, ec~rth-retaining slab.
Figs. 11 and 12 are cross sectional views illustrating d.ifferent advanta~eou~ construction techniques utilizing the structural modules of the invention.
Fig. 13 is a diagrammatic illustration of a structural wall utilizing the modules of the invention, for 2S force analysis purposes.
~L;2589~0 Figs. 14 and lS are cross sectional views taken on lines 14-14 and 15-15 of Fig. 16 illustrating advantageous forms of construction for the tops of retaining walls or the like.
Fig. 16 is a composite cross sectional view illustrating the construction features of Figs. 14, 15.
Fig. 17 is a fragmentary cross sectional view illustrating another form of top structure for a retaining wall or the like.
Fig. 18 is a cross sectional view generally on line 18-18 of Fig. 19.
Fig. 18a is a fragmentary cross sectional detail, illustrating an advantageous form of connector for joining a connecting panel to adjacent structural modules.
Fig. 19 is a top plan view of an arrangement for joining so-called half modules to adjacent structural modules by m~ans of an intermediate connecting panel.
Fig. 20 is a perspective view of a modified form of half module having an integral stabilizing slab.
- Fig. 21 is a front elevational view of a retaining wall or the like constructed with structural modules according to the invention.
Figs. 22 and 22A are front elevational views of modified forms o~ retaining wall assembly or the like 2S incorporating filler panels between adjacent, spaced structural modules.
398~3 Figs. 23-26 are fragmentary cross sectional and top plan views illustrating various arrangements for the mounting and retention of filler panels in a wall assembly of the type shown in Fig. 22.
Fig. 27 is a perspective view of an advantageous form of dro~-in panel, which may be used at the back of the assembly or, more typically, as an intermediate vertical panel.
Figs. 28-30 illustrate various views of an arrangement for mounting of the drop-in panel in an assembly of modules.
Figs. 31 and 32 are fragmentary views in vertical cross section illustrating advantageou~ arrangements for ke~ing together vertically adjacent structural modules for resistanceto shear.
Fig. 33 is a side elevation of an advantageous form of structural module, in which the front and rear panels are generally at the same height, joined by partition elements stepped to provide a plurality of forward facing abutment elements for improved resistance to shear.
Fig. 34 is a cross sectional view of an assembly of structural modules arranged with notched-out partition panels and with adjacent structural modules being joined by special keying blocks or ~labs.
Fig. 35 is a perspective view illustrating a further modified form of the invention.
~5~39~30 Fig. 36 is a cross sectional view of a retaining wall or the like of the general type shown in Fig. 35.
Figs. 37 and 38 are enlarged, fragmentary cross sectional views, ill~strating details of thorou~h retaining/supporting element incorporated in the assembly of Fig. 36.
Figs. 39, 40 are perspective view~ of special configura~ions of base module~, for used in wall as~emblies such as shown in Figs. 35, 36.
Figs. 41 and 42 are cross sectional and top plan views respectively of a modified structural module configuration providing for aligned pairs of mortise notches between vertically adjacent modules, for the reception of keying elements.
Figs. 43 and 44 are cross sectional and top plan viewsrespectively, similar to Figs. 41, 4~, where the module is provided with an inclined rear panel.
Fig. 4$ is an end elevational view of a retaining wall or the like constructed of various modified forms of structural modules having advantageou~ load bearing characteristics.
Figs. 46 and 47, together, constitute a cros~
sectional view of a further modified form of retaininy wall assembly utilizing an advanta~eous form of interlocking means between vertically adjacent modules.
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Fig. 48 is a cross sectional view taken on line 48-48 of Fig. g9.
Fig. 49 is a top plan view of a structural module accordi~g to the invention which is cast in individual components and assembled before installation.
Fig. 50 is an enlarged fragmentary cross sectional view taken on line 50-50 of Fig. 48.
Preferred Embodiment~
Figures 1 through 6 illustrate some of the more preferred embodiments of a module with trapezoidal partition means. The modules comprise rectangular front and rear panels, and trapezoidal partition elements, the upper surfaces 4 and 5, andthe lower surfaces 6 and 7 of which are arranged in matching sawtooth pattern capable of positive unilateral interlocking of one module with another when one of said moduleq is superposed upon another.
Figure 1 is a perspective view of a module 11 with a front panel 1, a rear panel 2, and generally trapezoidal partition elements 3. Usually, but not necessarily, there are two spaced partition elements 3, panel-like in form.
At the intersection of the panels with the partition elements are fillets 9 which are placed according to usual practice.
~S~398() Figure 2 represents a similar module 13, specially designed, however, for use at the base of a wall assembly.
The partition elements 3A, ordinarily trapezoidal, have been, in this particular case, truncated to allow the bottom surfaces thereof to lie along the plane of the wall's foundation. The rear panel 8 is shown in a special configuration more suitable for a base module, where its plane is perpendicular to the plane of the partition means 3A and approximately perpendicular to the plane of the front panel 1. The rear panel 8, as shown, has a marked advantage when used as an element of a base module. Its horizontal orientation forms a shelf which positively -captures the force from the weight of the fill above it, and is located approximately at the center of action of the resultant force combining the vertical gravity loads with the lateral overturning load3. It is capable of behaving as a spread footing distributing the loads from the superposed modulesabove, and from the fill they contain.
The rear panel of any module may be either substantially perpendicular to the ~ront panel, as in Figure 2, substantially parallel with the front panel, as in Fiyures 3 and 4, or inclined at an acute angle with respect to the plane of the front panel, depending upon the particular purpose to which it is to be applied. When a smaller module is to be used below a larger module, at the ~Z589&(~
base of the wall, a rear panel 8 which is substantially perpendicular to the front panel 1 of the module is especially beneficial. When it is desired to use the rear panels to assist in transferring weight between modules, such as in a bridge abutment, it is preferred that the rear panels 10 be parallel with the front panel 1 (Fig. 3) so the rear panels can be readily aligned. When it is desired to increase the forces resisting overturning it is beneficial to tilt the rear panel 2 at an acute angle with the front panel 1, with its upper edge farther away from the front panel, as illustrated in Figures 5 and 6, so as to increase the amount of fill captured, and to reduce-simultaneously the lateral pressure exerted by the retaine~d material behind the module.
Figure 3 clearly shows a cross sectional view of one of many sawtooth patterns made according to the invention.
A plurality of surfaces 4 and 5 form the upper sawtooth edge and a plurality of surfaces 6 and 7 form the lower matching saw~oothedge. In one form of the invention, surfaces 4 and 6 do not come in contact with each other, and the component, parallel to the plane of the front panel, of the resultant of all forces acting upon the module, is carried by the front and rear panels and transmitted to the front and rear panels of the lower module at the panels' respective contact surfaces. The . .
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component, perpendicular to the plane of the front panel, of the resultant of all forces acting upon the superposed module is transmitted from contact surface 7 to contact surface 5 o~ the supporting module and is carried by the partition means 3 of the supporting module. In a preferred form of the invention, all surfaces 6 and 7 come in contact with their respective matching surfaces 4 and 5 and each surface bears a proportionate amount of the component, perpendicular to the contact surface, of the resultant of all forces actin~ upon the module. In a further preferred form of the invention, the modules are constructed to dimensions which prevent the transmission of major forces from one face panel (i.e. front or rear panels 1, 2 or 1, 10) to another. This feature minimizes the occurrence of cracking in said panels.
Fi~ures 5 and 6 show in side view and plan view the rear panel a tilted in a manner which increases the force it receives from the bin-action effect of the fill within the cells of the module while at the same ~ime reducing the lateral force it receives from the retained material. It produces an additionalbenefit when modules o~ the same dimensions are stacked, one upon the other, by creating a protruding top surface which captures the beneficial downward force of retained material locat@d in a zone above the protruding parts of the module. For the tilting to be . ` ' ` ' ' ' ' ' ' !;', ' . `
.' ~ ' ''~' , ,, ~5~
worthwhile, the back panel 2 should be at least about 8 degrees with respect to the front panel.
Figure 7 shows a perspective view of an assembly of modules arranged laterally in horizontal rows with additional horizontal rows o~ module~ superposed above.
The assembly as een in Figure 7 is of a wall -~tructure viewed ~rom the rear. The assembly of front panels 1 form the exterior face of the wall structure. The rear panels 2 are shown at an acute angle with respect to the plane o~
the front panels. With the exception of the base module, each superposed module is shown with its partition means of lesser width than the partition means of the module upon which it is supported. This method of stacking is also shown in cross-sectional view in Figure 11 and represents the standard method of stacking when constructing a modular gravity retaining wall. As shown in Figure 7 the base module is a ~orm of the new module with its bottom portion truncated to conform to the plane of the subgrade. The base module is of smaller width than the module directly superposed on it because the heel o~ the wall is the bottom edge of the rear panel of the module resting on the base unit and is substantially at the elevation of the ba~e module's subgrade.
~2S8~38() Fi~ure 8 shows a solid base. This type of base may be used for smaller walls where the extra material ueed would be less expensive than the cost of forming the empty cells.
Figure 9 shows a base module 14 with the lower exterior edge of its front panel extended a substantial distance. This module, by extendiny the pivot point 48 about which the wall assembly could rotate, increases su~stantially the wall's resistance to such rotation. This improvement is particularly effective for walls with trapezoidal partition mean~ and/or lowered rear panels.
In the analysis of a modular retaining wall for stability ayainst overturning, when the wall ie one in which modules of different size or shape occur in any vertical stack, it is necessary to investigate the stability of the structure above each possible pivot point. It is readily apparent from Figure 11 that the inclined trapezoidal shape of the partition means and lowered position of the rear panel results in several advantages. It subs~antially lower~ the center of gravity of each of the stacked modules and likewise lowers the cen~er of gravity of the granular material enclosed within each of the cells of the modules. In that part of a wall in which the rear face is stepped toward the front face as ;
: .
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the courses progress upward, the trapezoidal shape of the p~rtition means also lowers the center of gravity of the retained material trapped above the protruding rear portion of the modules.
The inclined trapezoidal shape of the partition elements and the lowe~red position of the rear panel has another important effect on the behavior of the modular wall. In the analysis of the complete wall, when investigating the tendency of the bottommost module course to overturn about the toe, or to slide along the base, the lowered position of the rear panel has no effect, either beneficial or detrimental. However, when analyzing the stability of the individual courses above the bottom course, the advantages of the new design are substantial.
Referring to Figure 13, if we perform an overturniny analysis about point 39, the pivot point of a typical module llC, which lies in an arbitrarily chosen upper course of the wall, the improvements become evident. The resultant of those forces causing overturning, as well as the resultant of those forces affecting resistance to overturning, are substantially lowered in elev~tion.
Although the overall magnitude of the overturning force is increased, its effectiveness nevertheless is reduced. At the same time, both the magnitude and the effectiveness of the beneficial resisting forces are increased.
1~898~3 To illustrate in more detail th~ effect of a lowered rear panel on the behavior of th~ force tending to cause o~erturning, refer to Figure 13. In the analysis of a standard wall built according to the present state of the art, the rear panel ~5 is,within the tolerances of usual wall batters and construction accuracies, at the same elevation as the front panel. This condition is illustrated by the dashed lines in Figure 13. Taking the summation of moments about pivot point 39 the lateral overturning force 41 caused by the retained material a~ove the heel 40 acts at an elevation approximately one-third the distance from the elevation of the heel 40 to the surface g4 o~ retained material. In contrast, in the analysis of the wall built according to the teachings of the present invention shown by solid lines in Fisure 13, when we take the summation of moments about the same pivot point 39, the lateral overturning force now consists of the combined effects of the same overturning force 41, plus the overturning ~orce 43 due to the additional volume of retained material between point 40 and the new heel 42.
The additional force 43, although increasing the total horizontal force against the wall, actually has a stabilizing effect since its line of action lies below the elevation of the p~vot point 39. Thus the total effective overturning moment is in fact reduced, and the size and _ ~,9 _ ~eight of the wall structure including module llC and those modules above it may be reduced in size, thereby affecting a more economical construction.
In the analysis of overturning conditions for the entire wall it is necessary to evaluate moments about the base at pivot point 47 (representiny the pivot point location in a standard wall). Since the heel ~6 of the entire wall is at the same elevation as pivot point 47, there is no benefit from the trapezoidal partition means, and the overturning condition is the same for the standard wall and for the wall according to the invention. When the base module is fabricated with its lower edge extended forward from the face, forming the pivot point at 48 (see Figs. 9, 11), overturning moments are reduced, and resisting moments are increased.
Figure 12 illustrates an assembly of modules according to the invention arranged in a more beneficial sequence of sizes. In this type of stacking, the rear panel 2a of module llA, which extends farthe~t away from the front panel, is located a substantial di~tance above the elevation of the base module 14. The rear panel 2A
acts to protect each of the rear panels beneath it from the full effects of the retained material. The overall effect is to reduce substantially the amount of material used to 398(~
collstruct the wall and to require substantially less material (e.g. earth) to be removed prior to construction.
A wall with less required height can be built using the same principle, in which case module llB might be the farthest extending module with all superposed modules of smaller size.
Fi~ures 11 and 12 also show the location of an auxiliary feature which is detailed in Figure 10. This is a prefabricated slab or plank 49 which can be placed between contact surfaces 4 and 6 of superposed partition elements. To incorporate the slab49 in an assembled structure, either or both surfaces 4, 6 must be molded in such a manner that adequate space i5 allowed. If the proper space is allowed, the partition means will behave the same a-q it would without the space, but an additional beneficial action is obtained. The slabs 49, extending into the fill material contained in the cells of the modules, form qhelf-like members which enga~e the weight of fill material above in a more positive ~anner than does the bin-action against vertically extending panels and partitions.
Thus, the slab 49 increases the ability Qf the fill ~aterial to act in concert with the cellular wall structure. Slab 49 may be made to span between adjacent 589~() partition means or to cantilever from both sides of a partition means. The most preferred method would be to span between two or more partition means and to cantilever at each end, reaching approximately half the distance to the next partition means.
In Figures 14, 15 and 16 there are shown two methods of constructing the tops of walIs. The top-most front panel shown is a cantilevered panel 17 or 18 with offset arms 20 set vertically behind the front panel 1 of a module. The vertical load from the panel i~ transmitted to the top of the front panel 1 by bottom surface 19 of the offset shoulder. Horizontal loads against the top portion of the cantilevered panel are recisted by cantilever action of the panel with the restraining thrustsupplied by ~hrust blocks. Two forms of thrust blocks are shown. In Figure 14 the thrust block is shown in the form of a plug 21, which may be prefabricated or cast in place, and which extends rearward to the inner face of the rear panel 10.
In Figure 15 the thrust block 16 i8 attached to the partition means 3, either integrally or by connectin~
means.
Figure 16 is a cross-sectional view looking forward-at the rear faces of the cantilevered panel and of t~e front panel. The left portion of Figure 16 shows the ,, ., - ' `~
, constructio~ as in Figure 14, while the right portion of Figure 16 shows the construction as in Figure 15. The rightmost partition means shown in Figure 16 is shown prepared to receive a cantilevered panel. Cantilevered panels are more economical to construct than are cellular modules and may be shaped for special applications such as parapets and may include special shapes as for traffic barriers. Cantilevered panels are able to protrude further above the finished grade and their top edge may be fabricated at an angle with re~p0ct to the horizontal to conform to a specified grade (See Figs. 21, 22).
Cantilevered panels 17 may be used in lieu of a top module in walls whether or not parapets are required.
Figure 17 illustrates a top unit 23 in the form of a V-shaped cantilever. This unit also may be used in lieu of a top module where a parapet is not required, as shown in Figuresll, 12 and ~7, or it may be used as shown in Figure 17 where it is indicated as a parapet with an integral traffic barrier. The vertical and horizontal loads from unit 23 are transmitted to the top module by ribs 26 fabricated along the soffit of the inclined slab 24. Ribs 26 are fabricated with contact sur~aces 6 and 7 which conform to the contour of the tops of partition means 3 of modules 11. Thus these forces are transmitted in the same manner as they are from superposed module to supporting - ~3 -~5~9~
module in a basic wall structure with a ~awtooth pattern in the joints of the partition means. Resistance to overturning is provided to the top unit 23 by the weight of fill supported by slab 24. Whenever it is desired to S provide additional stability to unit 23, the lab 2~ may be extended as indicated by 25. Since extending slab 24 causes the edge to descend deeper into the ~ill as well as rearward, it can be seen that the V-shape o~ unit 23 is more effecti~e than an L-shaped uni~ would be. The V-shaped unit also allows more space for underground structures such as utility structures.
Figure~ 17 and 18 show prefabricated rear slabs 32, 33 and 34. Slab 32 is planar while slab 33 has a depending flange and slab 34 has an ascending flange. Slabs 32, 33 and 34 are able to positively engage the retained material above them in a location which is the most beneficial, tha rear of the module.
Figure 21 shows a front elevation of a wall assemblyusing modules 11 and cantilevered panels 17. The modules are arranged to stagger the vertical joints so that each superposed module, where possible, is supported by two different modules in the course below it. To accomplish this preferred interlocking pattern, the partition means are spaced apart at virtually twice the distance from the
- 2~ -, ~L~58~38() partition means to the lateral edge of the front panel 1 of modules 11. The center lines 35 of a few adjacent partition means are shown. As can be seen, this spacing allows all the partition means to occur in continuous planes from top to base as required in the invention, and also allows the lateral edges of the front panels essentially to touch.
It is often necessary in the construction of a wali to provide continuous vertical joints at certain locations such as: expansion joints, turning points where the direction of the wall changes, locations where it is desirable to change horizontal joint elevations, and settlement joints where there is a significant change in the expected settlement of a foundation. Such a joint 60 is shown in Figure 21. Because of the pattern where each module overhangs half of a module immediately below it, it i-s necessary to provide half-modules 12 adjacent to the joint in alternating courses as indicated.
Figure 20 shows a half-module 12. Since the module possesses only one partition mean~, it iq necessary to provide alaterally stabili~ing mechanism. One such mechanism is shown in Figure 20. A slab 30 dimensioned to bear on a contact surface 4 is cantilevered from the half-module's partition means 3. A gusset panel 31 is 3L~5~3~38(~
provided for rigidity and strength. In the full size module 11 adjacent to the half-module 12, one o~ the contact surfaces 6 is cast at a higher elevation than is normal to provide for the thickness of slab 30. When slab 30 is locked between the partition means of two modules, half-module 12 is laterally stabilized against rotation.
An alternate method of lateral stabilization is illustrated in Figures 18 and 19 where a lateral diaphragm panel 27, generally vertically disposed, is provided to span betweeD the partition means of the half-module to the nearest partition means o~ the adjacent module. The diaphragm panel 27 is connected to the partition means by threaded inserts 28 and connectors 2g, of a type similar to those shown in Figure 18A.
Figure 22 shows a new and improved arrangement i~
the assembly of cellular modules llS. Partition means are spaced as shown by center lines 35, except that, in the ~rrangement in Figure 22, the spa~ing between the partition elements is substantially greater than twice the distance from the partition elements to the lateral edge of the front panels lS~ This pattern results in significant benefits. When the partition means are erected in vertical alignment with the left partitionmeans of each superposed module llS supported by the right partition means of the 1~5~3"3~() module below it, and the right partition means supported by the left partition mean~ below it, a substantial space is left between adjacent front panels lS and adjacent rear panels. This space is filled by a drop-in face panel 36 between front panels and a drop-in panel 51 at the rear of the space between modules. Panel 51 may be parallel to the front panels or set at an angle thereto. The rear drop-in panel ~ay be secured by a device such as the detail of bearing surface and ribs shown in Figures 28, 29 and 30.
The ribs 54 shown in Figure 29 may be tilted to accomodate an inclined drop-in panel 51. This unique arrangment increases the face area of the wall approximately 50 percent per module. The improved arrangement of modules shown in Figure 22 may also be used with equal advantage in the assembly of modules with non-trapezoidal partition means.
Since it is more economical to fabricate and place the planar panels 36 and to strengthen the modules for the ~additional loading, than to construct additional modules for the equivalent area, the cost savings realized are substantial. Planar panels have an additional advantage in that they may be cast flat and therefore are less expensive to mold, easier to cast with t~xtured sltr~ace 36~ or in bas-relief as are panelq lT of modules llS. The panels may be recessed behind the front panels lS as are drop-in ~s~
panels 36R or may protrude forward of the front panels lS
as do drop-in panels 36P. These treatments produce decorative shadows on the face of the wall and improve the appearance of the stru~ture, especially in the case of large face areas. Shadow effects may also be produced by texturing or casting three dimensional patterns on the front panels lS of the modules llS as shown in Figure 22.
A similar effect may be obtained in front panels 1 of modules 11 (Fig. 21~.
Figure 22 show~ various aesthetic improvements which may be used to interrupt the monotony of a wall surface, especially one of relatively large area. The pattern of front panels shown in Figure 22 may be changed in various other ways to improve appearance. One such method, shown in Fig. 22A, would be to cast the front panels 101 in the form of parallelograms (as seen when viewed in front elevation) preserving horizontal top and bottom edges. If alternate front panels were first right-leaning and then left-leaning, the space created betw~en them would be in the form of a trapezoid in the plane of the front panels.
Figure 22A shows a front elevation of a wall with parallelogram-shaped front panels 101 and trape20idal filler panels 102 secured in a manner similar to that holding drop-in panels 36F, 36P, 36R and 36T in Figures 2 through 26.
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Methods of securing the drop-in panels are shown in Figures 23, 24, 25 and 26. A recessed drop-in panel 36R is shown in ~ross sectional view in Figure 23 and in sectional planview Figure 24. It is supported vertically on the top sur~ace of front panel lS, is restrained from moving rearward during erection by lugs 37, and is further supported laterally before and after the ~ill is placed inside the cell, by the shear-transfer joints 50. Figures 25 and 26 show a similar method of securing a drop-in panel. In the example shown a flush drop-in panel 36F, is temporarily secured rearwardly by loose dowels 38 placed in matching holes cast in the partition means. --In certain large modules, it may be desirable to include one or more dividing intermediate panels behind thefront panel to improve the ability of the cellular structure to capture the weight of the fill material. Such panels may be either parallel to or inclined with respect to the front panel and may be either cast integrally with the modules or of drop-in design. An improved form of drop-in panel 51 is shown in Fig. 27 and is provided with tapered bearing surfaces 52 which rest on matching tapered bearing surfaces 53 loca~ed in notched brack~ts on the sides of the partition means of selected modules. The panel S1 is restrained laterally by the ribs 54 which extend almost the full height of the panels. The detail , ~5~981) shown provides ~or efficient lateral restraint and transfer of vertical loading. Drop-in panel 51 may also be used as a drop-in rear panel in walls assembled as ~hown in Figure 22.
It is more beneficial to capture the weight of the fillmaterial at the rear of a module than to capture an equivalent weight of fill material at the front of the module because of the dif~erence in moment arm. By moving a drop-in panel located between the front panel and rear panel of a module rearwardly or by tilting it so ~hat its top i5 closest to the front panel and its bottom is closest to the rear of the module, the bin-action of the rear cell formed by the panel is improved while the bin-action of the cell forward of the panel is reduced. Hence overall stability of a module can be improved by proper placing and tilting o~ the drop-in panels.
When the rear panel of a module is located sufficiently forward of the rear panels of modules below so that the tilting of the rear panel has no effect on the magnitude or direction of the overturning ~orce exerted by the retained material against the entire wall structure, then it is appropriate to tilt the panel forward so a~ to cause the direction of ~he force exerted by the retained material against the rear panel of this module to be 125~98~
located at a more vertical angle and to be greater in magnitude. Th~se Eorces can be translated into improved resisti~g ~oments for the overall wall structure. Further, the forward tilting of the rear panel of a module superposed above a module of a longer partition means improves the bin-action at the rear of the larger module below.
Figure 33 shows a further embodiment of the inventionwhere the partition means 3 is predominantly trapezoidal, with its upper and lower surface~ arrar a sawtooth pattern, but the rear panel 10 i~ approximately at the same level as the front panel 1. Its contact surfaces 5 and 7 are positioned to engage mutually with similar modules above and below. Surfaces 4A and 6A may be located to bear against matching surfaces of similar modules above and below, or they may be located, so as to avoid contact with each other when it is desired that the vertical load be transferred from front panel to front panel and from rear panel to rear panel. Any module constructed according to the detail shown is able to interlock with and above any other module of the same or larger front-to-rear width. This ability will markedly decrease the variations in models and significantly reduce inventory requirements for stock piling and adju3tments to molds during manufacture compared with ordinary mortise and ~ ~58'38() tenon interlocked modules in use. Since the resultant force acting upon a module is always directed toward the front panel, it is not necessary to have two-wa~
interlocking keys, This condition of a one-direction lateral loading allows the use of the sawtooth pattern shown in Figure 33 and also the pattern shown in Figures 1 through 9, etc. The uses of these and similar patterns results in improved bearing and shear behavior because significantly more area for bearin~ and shear resistance can be furnished, when compared with existiny mortise and tenon, depending lip, or tongue and groove intexlocks for wall modules.
Figure 34 shows three cellular modules with generally rectangular partition mean~ 55, one superposed upon another. It is not material to the invention whether the modules transmit vertical load~ from panel to panel or from partition means to partition means. What is provided is a system for the transference of lateral forces between modules which allows any size module to be superposed above a~y similar module regardless of the supporting module's relative size (smaller or larger) without any change in the location of the mortises 56. This ability permits a type of stacking arrangement, similar to that shown in Figs. 36 and 46, where module ~izes increa3e and then decrea~
progressively at each superposed course. The lateral ~5~3~
forces are transferred by keys 57 which engage a single opposing pair of mortises 56 as shown also in Figure 32, or by elongated slab-like keys 58 which span from one partition means to an adjacent one, performing the additional function of capturing the fill material more posi~ively. Figure 31 shows a detail of one embodiment of such a member. Wherever a rsar panel 10 occurs over or under a mortise in the vertically contiguous module, bearin~ blocks 59 can be provided in the ca~e of panel-bearing modules.
Figures 35 throuyh 47 illustrate modules and assemblies of modules which utilize th0 principles set forth in the invention. The trapezoidal partition means is represented inits simplest form, an inclined bearing surface. In Figure 35 an assembly of modules 61 is shown.
Module 61 comprises a front panel 1, and a non-parallel rear panel 2 connected by a plurality of trapezoidal partition elements 63. As set forth in the teachings of the invention the longitudinal (principal) axes of the partition elements 63 are inclined at an acute angle from the plane of t~e front panel such that the upper contact surface 64 and the lower contact surface 65 ar0 disposed at an angle ~hich is substantially normal to the line of action of the resultant force representin~ all loads bein~
transferred from superposed module to supportiny module.
~5~9~
Specifically, the principal axes of the partition elements extend downward and rearward at an angle of between 20 and 82 degrees from the plane of the front panel 1, such that the upper edge of the rear panel 2 lies substantially below a plane extending from the upper edge of the fro~t panel, and at right angles thereto. As represented in Figure~ 41, 42, ~3 and 44, the superposed module is held in place during erection of the assembly by a surface 66 perpendicular to the front panel in the æone of the intersection of the partition elements 63 with the front panel 1. As soon as a course of modules is loaded with f ill material inside it~ cellQ and a commensurate ~uantity of retained material, the resultant loading i5 substantially normal (within the angle of friction between surfaces 64 and 65) to the resultant load being transferred from module to module.
Figure 36 i~lustrates an end view in cross-section of a wall assembl~ o~ modules 61. The assembly uses the beneficial pattern of module sizes described earlier in this specification where module size vary, starting at the base of the wall, from small to larger to smaller as the courses progress upwardly. This pattern is shown here to illustrate the facility with which different sizes of modules 61 fit one above the other in any sequsnce without special fabrication. This greatly simplifies the number of
It is often necessary in the construction of a wali to provide continuous vertical joints at certain locations such as: expansion joints, turning points where the direction of the wall changes, locations where it is desirable to change horizontal joint elevations, and settlement joints where there is a significant change in the expected settlement of a foundation. Such a joint 60 is shown in Figure 21. Because of the pattern where each module overhangs half of a module immediately below it, it i-s necessary to provide half-modules 12 adjacent to the joint in alternating courses as indicated.
Figure 20 shows a half-module 12. Since the module possesses only one partition mean~, it iq necessary to provide alaterally stabili~ing mechanism. One such mechanism is shown in Figure 20. A slab 30 dimensioned to bear on a contact surface 4 is cantilevered from the half-module's partition means 3. A gusset panel 31 is 3L~5~3~38(~
provided for rigidity and strength. In the full size module 11 adjacent to the half-module 12, one o~ the contact surfaces 6 is cast at a higher elevation than is normal to provide for the thickness of slab 30. When slab 30 is locked between the partition means of two modules, half-module 12 is laterally stabilized against rotation.
An alternate method of lateral stabilization is illustrated in Figures 18 and 19 where a lateral diaphragm panel 27, generally vertically disposed, is provided to span betweeD the partition means of the half-module to the nearest partition means o~ the adjacent module. The diaphragm panel 27 is connected to the partition means by threaded inserts 28 and connectors 2g, of a type similar to those shown in Figure 18A.
Figure 22 shows a new and improved arrangement i~
the assembly of cellular modules llS. Partition means are spaced as shown by center lines 35, except that, in the ~rrangement in Figure 22, the spa~ing between the partition elements is substantially greater than twice the distance from the partition elements to the lateral edge of the front panels lS~ This pattern results in significant benefits. When the partition means are erected in vertical alignment with the left partitionmeans of each superposed module llS supported by the right partition means of the 1~5~3"3~() module below it, and the right partition means supported by the left partition mean~ below it, a substantial space is left between adjacent front panels lS and adjacent rear panels. This space is filled by a drop-in face panel 36 between front panels and a drop-in panel 51 at the rear of the space between modules. Panel 51 may be parallel to the front panels or set at an angle thereto. The rear drop-in panel ~ay be secured by a device such as the detail of bearing surface and ribs shown in Figures 28, 29 and 30.
The ribs 54 shown in Figure 29 may be tilted to accomodate an inclined drop-in panel 51. This unique arrangment increases the face area of the wall approximately 50 percent per module. The improved arrangement of modules shown in Figure 22 may also be used with equal advantage in the assembly of modules with non-trapezoidal partition means.
Since it is more economical to fabricate and place the planar panels 36 and to strengthen the modules for the ~additional loading, than to construct additional modules for the equivalent area, the cost savings realized are substantial. Planar panels have an additional advantage in that they may be cast flat and therefore are less expensive to mold, easier to cast with t~xtured sltr~ace 36~ or in bas-relief as are panelq lT of modules llS. The panels may be recessed behind the front panels lS as are drop-in ~s~
panels 36R or may protrude forward of the front panels lS
as do drop-in panels 36P. These treatments produce decorative shadows on the face of the wall and improve the appearance of the stru~ture, especially in the case of large face areas. Shadow effects may also be produced by texturing or casting three dimensional patterns on the front panels lS of the modules llS as shown in Figure 22.
A similar effect may be obtained in front panels 1 of modules 11 (Fig. 21~.
Figure 22 show~ various aesthetic improvements which may be used to interrupt the monotony of a wall surface, especially one of relatively large area. The pattern of front panels shown in Figure 22 may be changed in various other ways to improve appearance. One such method, shown in Fig. 22A, would be to cast the front panels 101 in the form of parallelograms (as seen when viewed in front elevation) preserving horizontal top and bottom edges. If alternate front panels were first right-leaning and then left-leaning, the space created betw~en them would be in the form of a trapezoid in the plane of the front panels.
Figure 22A shows a front elevation of a wall with parallelogram-shaped front panels 101 and trape20idal filler panels 102 secured in a manner similar to that holding drop-in panels 36F, 36P, 36R and 36T in Figures 2 through 26.
~S~398~
Methods of securing the drop-in panels are shown in Figures 23, 24, 25 and 26. A recessed drop-in panel 36R is shown in ~ross sectional view in Figure 23 and in sectional planview Figure 24. It is supported vertically on the top sur~ace of front panel lS, is restrained from moving rearward during erection by lugs 37, and is further supported laterally before and after the ~ill is placed inside the cell, by the shear-transfer joints 50. Figures 25 and 26 show a similar method of securing a drop-in panel. In the example shown a flush drop-in panel 36F, is temporarily secured rearwardly by loose dowels 38 placed in matching holes cast in the partition means. --In certain large modules, it may be desirable to include one or more dividing intermediate panels behind thefront panel to improve the ability of the cellular structure to capture the weight of the fill material. Such panels may be either parallel to or inclined with respect to the front panel and may be either cast integrally with the modules or of drop-in design. An improved form of drop-in panel 51 is shown in Fig. 27 and is provided with tapered bearing surfaces 52 which rest on matching tapered bearing surfaces 53 loca~ed in notched brack~ts on the sides of the partition means of selected modules. The panel S1 is restrained laterally by the ribs 54 which extend almost the full height of the panels. The detail , ~5~981) shown provides ~or efficient lateral restraint and transfer of vertical loading. Drop-in panel 51 may also be used as a drop-in rear panel in walls assembled as ~hown in Figure 22.
It is more beneficial to capture the weight of the fillmaterial at the rear of a module than to capture an equivalent weight of fill material at the front of the module because of the dif~erence in moment arm. By moving a drop-in panel located between the front panel and rear panel of a module rearwardly or by tilting it so ~hat its top i5 closest to the front panel and its bottom is closest to the rear of the module, the bin-action of the rear cell formed by the panel is improved while the bin-action of the cell forward of the panel is reduced. Hence overall stability of a module can be improved by proper placing and tilting o~ the drop-in panels.
When the rear panel of a module is located sufficiently forward of the rear panels of modules below so that the tilting of the rear panel has no effect on the magnitude or direction of the overturning ~orce exerted by the retained material against the entire wall structure, then it is appropriate to tilt the panel forward so a~ to cause the direction of ~he force exerted by the retained material against the rear panel of this module to be 125~98~
located at a more vertical angle and to be greater in magnitude. Th~se Eorces can be translated into improved resisti~g ~oments for the overall wall structure. Further, the forward tilting of the rear panel of a module superposed above a module of a longer partition means improves the bin-action at the rear of the larger module below.
Figure 33 shows a further embodiment of the inventionwhere the partition means 3 is predominantly trapezoidal, with its upper and lower surface~ arrar a sawtooth pattern, but the rear panel 10 i~ approximately at the same level as the front panel 1. Its contact surfaces 5 and 7 are positioned to engage mutually with similar modules above and below. Surfaces 4A and 6A may be located to bear against matching surfaces of similar modules above and below, or they may be located, so as to avoid contact with each other when it is desired that the vertical load be transferred from front panel to front panel and from rear panel to rear panel. Any module constructed according to the detail shown is able to interlock with and above any other module of the same or larger front-to-rear width. This ability will markedly decrease the variations in models and significantly reduce inventory requirements for stock piling and adju3tments to molds during manufacture compared with ordinary mortise and ~ ~58'38() tenon interlocked modules in use. Since the resultant force acting upon a module is always directed toward the front panel, it is not necessary to have two-wa~
interlocking keys, This condition of a one-direction lateral loading allows the use of the sawtooth pattern shown in Figure 33 and also the pattern shown in Figures 1 through 9, etc. The uses of these and similar patterns results in improved bearing and shear behavior because significantly more area for bearin~ and shear resistance can be furnished, when compared with existiny mortise and tenon, depending lip, or tongue and groove intexlocks for wall modules.
Figure 34 shows three cellular modules with generally rectangular partition mean~ 55, one superposed upon another. It is not material to the invention whether the modules transmit vertical load~ from panel to panel or from partition means to partition means. What is provided is a system for the transference of lateral forces between modules which allows any size module to be superposed above a~y similar module regardless of the supporting module's relative size (smaller or larger) without any change in the location of the mortises 56. This ability permits a type of stacking arrangement, similar to that shown in Figs. 36 and 46, where module ~izes increa3e and then decrea~
progressively at each superposed course. The lateral ~5~3~
forces are transferred by keys 57 which engage a single opposing pair of mortises 56 as shown also in Figure 32, or by elongated slab-like keys 58 which span from one partition means to an adjacent one, performing the additional function of capturing the fill material more posi~ively. Figure 31 shows a detail of one embodiment of such a member. Wherever a rsar panel 10 occurs over or under a mortise in the vertically contiguous module, bearin~ blocks 59 can be provided in the ca~e of panel-bearing modules.
Figures 35 throuyh 47 illustrate modules and assemblies of modules which utilize th0 principles set forth in the invention. The trapezoidal partition means is represented inits simplest form, an inclined bearing surface. In Figure 35 an assembly of modules 61 is shown.
Module 61 comprises a front panel 1, and a non-parallel rear panel 2 connected by a plurality of trapezoidal partition elements 63. As set forth in the teachings of the invention the longitudinal (principal) axes of the partition elements 63 are inclined at an acute angle from the plane of t~e front panel such that the upper contact surface 64 and the lower contact surface 65 ar0 disposed at an angle ~hich is substantially normal to the line of action of the resultant force representin~ all loads bein~
transferred from superposed module to supportiny module.
~5~9~
Specifically, the principal axes of the partition elements extend downward and rearward at an angle of between 20 and 82 degrees from the plane of the front panel 1, such that the upper edge of the rear panel 2 lies substantially below a plane extending from the upper edge of the fro~t panel, and at right angles thereto. As represented in Figure~ 41, 42, ~3 and 44, the superposed module is held in place during erection of the assembly by a surface 66 perpendicular to the front panel in the æone of the intersection of the partition elements 63 with the front panel 1. As soon as a course of modules is loaded with f ill material inside it~ cellQ and a commensurate ~uantity of retained material, the resultant loading i5 substantially normal (within the angle of friction between surfaces 64 and 65) to the resultant load being transferred from module to module.
Figure 36 i~lustrates an end view in cross-section of a wall assembl~ o~ modules 61. The assembly uses the beneficial pattern of module sizes described earlier in this specification where module size vary, starting at the base of the wall, from small to larger to smaller as the courses progress upwardly. This pattern is shown here to illustrate the facility with which different sizes of modules 61 fit one above the other in any sequsnce without special fabrication. This greatly simplifies the number of
- 3~ -8~3 differ~nt shape variations which must be fabric~ted or carri~d in in~entory.
Figures 37 and 38 show special closure slabs which may be incorporated in a wall assembly constructed of modules similar to module 61. On the top surfac~ of a module which does not support a larger module, the exposed top of the cells containing fill material may be, if desired, cov~red by a closure slab 67. I~ a smaller module 0 i5 superpo ed, the additional width exposed may be covered by adding one or a plurality of closure .~lab~ 68. Closure slab 67 is formed to contain a depending portion 67A which fits between adjacent partition elements and which enga~es the surface of the rear panel which faces the inside of the module. Closure slab 68 may be rectangular in cross-section.
In some cases it may be desirable to close the open space at the bottom of a module which overhangs its s~upporting module. Closure slab ~9, shown in Figure 38, fits between adjacent partition element-~ at the bottom of a module and accomplishes this task~ A recessed keyway 70 is provided in rear panel 2A to support the rearmost ed~e 69A
of the slab while the opposite edge 69B is supported on the top eurface of the lower module's rear panel.
~5~9~(1 Figures 39 and 40 show two possible configurations of base modules 62, 72 for wall as~emblies using module 61. The base module 62 is simply a module 61 truncated at the bottom to lie along the subgrade of the wall. Base module 72 shown in Figure 40 is similar to base module 62 but the exterior bottom surface of the ~ront panel has been extended substantially forward to move the pivot point, about which an entire wall assembly tends to rotate, to a more beneficial location.
Figures 41 and 42 show a module 61 ~ith a vertical rear panel 10 and with mortise~ 56 provided in the upper and lower edges of the partition elements 63A. These mortises are dimensioned to accept a keying block 57 or slab 58 similar to those illustrated in Fiyures 31, 32 and 34. ~ey 57 is shown in Figure 41 but a slab 58 may be used with equal f acility. .T~e purpose of the key is to secu~e the position of the blocks during assembly and until the lateral force ~rom the retained material is allowed to act. Figure~ 43 and 44 show a similar type of module but with an inclined rear panel.
Figure 45 illustrates several keying mechanisms which may be used to secure a superposed mo~ul~. Joint 73A
is secured by depending keys in the front and rear panels which mate with keyways in the top of the front panel and ~1~5~98~:) in the tops of the generally trapesoidal partition means of the lo~er module. Joint 73B is ~ecured by a wedge-shaped protrusion and matching recess. Joint 73C i~ ~ecured by one or a plurality of key locks (may be a shelf-like member 58) which fit in recesses (such as mortises) placed in contraposition in the contact surfaces of vertically contiguous modules. Joint 73D and 73E are secured by standard mortise and tenon keys. In joint 73D the tenons extend upward while in 73E the tenon extend downward into their mating mortises~ Joints 73F are planer contact surfaces which are secured during erection by a reversal in the direction o~ inclination of the contact surfaces in the zone of the intersection of th~ partition meanC with the ~ront panel. This reversal of the incline of the surfaces at the face of the wall (downward toward the front) would provide the additional benefit o~ decreasing the quantity of water likely to seep through the joint from the exterior surface of the wall. Figure 45 is intended only as a composite drawing of representative means to secure the module~.
Figures 46 and 47 show an assembly of wall modul~s 71 which are keyed in a manner which provides additional benefits. Each module 71 has the rearmost portion of its partition means displaced upwardly to form a pair of interlocking surfaces when the module is placed in vertical 1~58980 contiguity with a similar module 71. Interlocking surface 74 is on the top of each partition means 77, and interlocking surface 75 is on the bottom of each partition means 77 except the partition means of the smallest module, which is too small to contain surface 75. The interlocking surfaces 74 for the top edge all occur at the same distance from the front panel 1 for each size module 71, except the smallest. Likewise the interlocking surfaces 75 on the bottom edge all occur at the same distance from the front panel 1 for each size module 71, except the smallest. The interlocking surfaces 74 and 75 could be placed at the same distance from the front panel 1 allowing them to mate directly, but in the as~embly illustrated in Figures 46 and 47, surface 75 is placed a substantial distance ~orward (toward front panel 1) of surface 74. This separation of the mating surfaces allows the placement of a slab 76 which spans between adjacent partition means, and which produces substantial benefits to the wall structure. The slabs 76 impart additional overturning resistance to the wall. ~hen slab~ 76 occur behind a superposed module they direct the overturning ~orce in a more downward direction which is beneficial in effectO
When slabs 76 occur within the cells of a wall assembly they very efficiently enga~e the forces present in the fillmaterial and transfer these forces to the partition ~ 5 ~3~
means upon which they are supported. Since the slabs 76 are oriented in the same direction as the joints between partition m2ans, they are subqtantially normal to the direction of the forces in the fill material and therefore very effective. Figure 47 shows how top unit 23, shown also in Figure 17, may be used effectively in combination with modules 71.
Figures 48 through 50 show a module 88, substantially the same as module 11 or 71, wherein each element of the module, front panel 81, rear panel 82, and partition means 83, is fabricated separately and subsequently assembled using a plurality of fastening means which, in the example illustrated, are interengaging threaded elements. In the method illustrated a female threaded insert 78 is cast integrally in one of the module's main elements, and the element with which it is to be connected is cast with a cylindrical hole to receive the male threaded fastener 79. The threaded elements 78 and 79 are positioned to align correctly with each other when the module's main elements are properly positioned with respect to each other. ~hen desired, pockets 80 can b@ provided in one or both of the module's elemen~s to allo~ acces~ in securing the threaded fastening meansO It is desirable to restrict stresses in fasteners o~ the type illu-~trated to tensile stress. Therefore, other means must be provided to 1~589~
transfer shear in any direction in which is may pos~ibly occur. In the example showna mortise and tenon shear transfer interlock is designed to function in two plane~.
Shear may be transferred laterally in either direction by the compression of the edse of partition means against the ribs 84, cast on the inside of the front and rear panels.
Shear, in a direction parallel with the ribs 84, is ~ransferred by a mortise 86 and tenon 87 cast between the position of the ribs 84.
Some of the advantages of càstiny the module elements separately are: simpler and more economical mold re~uirements (most elements may be cast in a horizontal plane), better adaptability to mas~ production methods, less waste when one of the elements is damaged during fabrication, in shipping, or in erection, and simpler and smaller inventory of useable elements since the elements can be mutually interchanged. A cosmetically damaged front panel may be substituted for a rear panel if the connecting threaded elements and shear transfer keys are kept in matching locations. A structurally damaged element can be discarded with relatively little financial loss.
It will usually be economically advantageous to assemble the segmental module 88 away from the erection site. In order to be able to handle safely a non-integral '.` ' '. . . "
.
3~30 module it is advisable to provide a stiffening diaphragm to prevent lataral warping of the unit such as would occur if a change were allowed to occur in the angle, measured in a horizontal plane, betweenthe partltion elements and the front and rear panels. One method of stiffening i8 shown in Figures 48 and 49 wherein a slab 89 is placed between the partition means during assembly of the module. In the example illustrated, vertical and horizontal shear is transferred through a tenon 90 cast at the end of ~lab 89.
Tenon 90 fits with minimal clearances into a mortise 91 cas~ in the body of the partition means 83. ~ plurality of fastening means, threaded connectors are shown, hold ~he shoulders 92 at the ends of slab 89 firmly ayainst the sides of parti~ion means 83 and affect a riyid diaphragm action. An alternative method of stiffening is to attach gussets at the intersections of the partition means 83 with front panel 81 and rear panel 82. One gusset in each o~
two diagonally opposite corners would be the minimum requirement. The gussets should be connected by threaded connectors and shear transfer keys in a manner similar to the connection of slab 89.
Modules, whose partition means carr~ the ~rincipal wall loads and which transfer these loads directly to partition means upon which they bear, are more readily constructed of separately cast element~ becau~e the 5~3~38~
stresses required to be transferred at the connecting joints are minimal and the joint is therefore simpler and more economical. For this reason embodiments of this invention which have partition means which bear directly upon one another are particularly advantageous.
It should be understood, o~ course, that the specific forms of the invention herein illustrated and described are intended to be repre en~ative only, as many modifications thereof may be made without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention.
, '~
Figures 37 and 38 show special closure slabs which may be incorporated in a wall assembly constructed of modules similar to module 61. On the top surfac~ of a module which does not support a larger module, the exposed top of the cells containing fill material may be, if desired, cov~red by a closure slab 67. I~ a smaller module 0 i5 superpo ed, the additional width exposed may be covered by adding one or a plurality of closure .~lab~ 68. Closure slab 67 is formed to contain a depending portion 67A which fits between adjacent partition elements and which enga~es the surface of the rear panel which faces the inside of the module. Closure slab 68 may be rectangular in cross-section.
In some cases it may be desirable to close the open space at the bottom of a module which overhangs its s~upporting module. Closure slab ~9, shown in Figure 38, fits between adjacent partition element-~ at the bottom of a module and accomplishes this task~ A recessed keyway 70 is provided in rear panel 2A to support the rearmost ed~e 69A
of the slab while the opposite edge 69B is supported on the top eurface of the lower module's rear panel.
~5~9~(1 Figures 39 and 40 show two possible configurations of base modules 62, 72 for wall as~emblies using module 61. The base module 62 is simply a module 61 truncated at the bottom to lie along the subgrade of the wall. Base module 72 shown in Figure 40 is similar to base module 62 but the exterior bottom surface of the ~ront panel has been extended substantially forward to move the pivot point, about which an entire wall assembly tends to rotate, to a more beneficial location.
Figures 41 and 42 show a module 61 ~ith a vertical rear panel 10 and with mortise~ 56 provided in the upper and lower edges of the partition elements 63A. These mortises are dimensioned to accept a keying block 57 or slab 58 similar to those illustrated in Fiyures 31, 32 and 34. ~ey 57 is shown in Figure 41 but a slab 58 may be used with equal f acility. .T~e purpose of the key is to secu~e the position of the blocks during assembly and until the lateral force ~rom the retained material is allowed to act. Figure~ 43 and 44 show a similar type of module but with an inclined rear panel.
Figure 45 illustrates several keying mechanisms which may be used to secure a superposed mo~ul~. Joint 73A
is secured by depending keys in the front and rear panels which mate with keyways in the top of the front panel and ~1~5~98~:) in the tops of the generally trapesoidal partition means of the lo~er module. Joint 73B is ~ecured by a wedge-shaped protrusion and matching recess. Joint 73C i~ ~ecured by one or a plurality of key locks (may be a shelf-like member 58) which fit in recesses (such as mortises) placed in contraposition in the contact surfaces of vertically contiguous modules. Joint 73D and 73E are secured by standard mortise and tenon keys. In joint 73D the tenons extend upward while in 73E the tenon extend downward into their mating mortises~ Joints 73F are planer contact surfaces which are secured during erection by a reversal in the direction o~ inclination of the contact surfaces in the zone of the intersection of th~ partition meanC with the ~ront panel. This reversal of the incline of the surfaces at the face of the wall (downward toward the front) would provide the additional benefit o~ decreasing the quantity of water likely to seep through the joint from the exterior surface of the wall. Figure 45 is intended only as a composite drawing of representative means to secure the module~.
Figures 46 and 47 show an assembly of wall modul~s 71 which are keyed in a manner which provides additional benefits. Each module 71 has the rearmost portion of its partition means displaced upwardly to form a pair of interlocking surfaces when the module is placed in vertical 1~58980 contiguity with a similar module 71. Interlocking surface 74 is on the top of each partition means 77, and interlocking surface 75 is on the bottom of each partition means 77 except the partition means of the smallest module, which is too small to contain surface 75. The interlocking surfaces 74 for the top edge all occur at the same distance from the front panel 1 for each size module 71, except the smallest. Likewise the interlocking surfaces 75 on the bottom edge all occur at the same distance from the front panel 1 for each size module 71, except the smallest. The interlocking surfaces 74 and 75 could be placed at the same distance from the front panel 1 allowing them to mate directly, but in the as~embly illustrated in Figures 46 and 47, surface 75 is placed a substantial distance ~orward (toward front panel 1) of surface 74. This separation of the mating surfaces allows the placement of a slab 76 which spans between adjacent partition means, and which produces substantial benefits to the wall structure. The slabs 76 impart additional overturning resistance to the wall. ~hen slab~ 76 occur behind a superposed module they direct the overturning ~orce in a more downward direction which is beneficial in effectO
When slabs 76 occur within the cells of a wall assembly they very efficiently enga~e the forces present in the fillmaterial and transfer these forces to the partition ~ 5 ~3~
means upon which they are supported. Since the slabs 76 are oriented in the same direction as the joints between partition m2ans, they are subqtantially normal to the direction of the forces in the fill material and therefore very effective. Figure 47 shows how top unit 23, shown also in Figure 17, may be used effectively in combination with modules 71.
Figures 48 through 50 show a module 88, substantially the same as module 11 or 71, wherein each element of the module, front panel 81, rear panel 82, and partition means 83, is fabricated separately and subsequently assembled using a plurality of fastening means which, in the example illustrated, are interengaging threaded elements. In the method illustrated a female threaded insert 78 is cast integrally in one of the module's main elements, and the element with which it is to be connected is cast with a cylindrical hole to receive the male threaded fastener 79. The threaded elements 78 and 79 are positioned to align correctly with each other when the module's main elements are properly positioned with respect to each other. ~hen desired, pockets 80 can b@ provided in one or both of the module's elemen~s to allo~ acces~ in securing the threaded fastening meansO It is desirable to restrict stresses in fasteners o~ the type illu-~trated to tensile stress. Therefore, other means must be provided to 1~589~
transfer shear in any direction in which is may pos~ibly occur. In the example showna mortise and tenon shear transfer interlock is designed to function in two plane~.
Shear may be transferred laterally in either direction by the compression of the edse of partition means against the ribs 84, cast on the inside of the front and rear panels.
Shear, in a direction parallel with the ribs 84, is ~ransferred by a mortise 86 and tenon 87 cast between the position of the ribs 84.
Some of the advantages of càstiny the module elements separately are: simpler and more economical mold re~uirements (most elements may be cast in a horizontal plane), better adaptability to mas~ production methods, less waste when one of the elements is damaged during fabrication, in shipping, or in erection, and simpler and smaller inventory of useable elements since the elements can be mutually interchanged. A cosmetically damaged front panel may be substituted for a rear panel if the connecting threaded elements and shear transfer keys are kept in matching locations. A structurally damaged element can be discarded with relatively little financial loss.
It will usually be economically advantageous to assemble the segmental module 88 away from the erection site. In order to be able to handle safely a non-integral '.` ' '. . . "
.
3~30 module it is advisable to provide a stiffening diaphragm to prevent lataral warping of the unit such as would occur if a change were allowed to occur in the angle, measured in a horizontal plane, betweenthe partltion elements and the front and rear panels. One method of stiffening i8 shown in Figures 48 and 49 wherein a slab 89 is placed between the partition means during assembly of the module. In the example illustrated, vertical and horizontal shear is transferred through a tenon 90 cast at the end of ~lab 89.
Tenon 90 fits with minimal clearances into a mortise 91 cas~ in the body of the partition means 83. ~ plurality of fastening means, threaded connectors are shown, hold ~he shoulders 92 at the ends of slab 89 firmly ayainst the sides of parti~ion means 83 and affect a riyid diaphragm action. An alternative method of stiffening is to attach gussets at the intersections of the partition means 83 with front panel 81 and rear panel 82. One gusset in each o~
two diagonally opposite corners would be the minimum requirement. The gussets should be connected by threaded connectors and shear transfer keys in a manner similar to the connection of slab 89.
Modules, whose partition means carr~ the ~rincipal wall loads and which transfer these loads directly to partition means upon which they bear, are more readily constructed of separately cast element~ becau~e the 5~3~38~
stresses required to be transferred at the connecting joints are minimal and the joint is therefore simpler and more economical. For this reason embodiments of this invention which have partition means which bear directly upon one another are particularly advantageous.
It should be understood, o~ course, that the specific forms of the invention herein illustrated and described are intended to be repre en~ative only, as many modifications thereof may be made without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention.
, '~
Claims (5)
1. A wall structure comprising an assembly of prefabricated structural modules, said modules comprising a front panel, a rear panel and partition means rigidly interconnecting said panels, said partitions means being so arranged that adjacent upper and lower edges thereof on respective vertically stacked modules are closely spaced or in contact, said partition means being provided on their respective adjacent upper and lower edges with oppositely facing, aligned mortise notches, and keying means positioned in an opposed pair of said mortise notches and serving to key adjacent modules against lateral forces.
2. An assembly according to claim 1, wherein said keying means is a slab-like member, portions of said slab-like member extending laterally from said partition means and providing a material retaining surface.
3. An assembly according to claim 2, wherein vertically adjacent modules include a plurality of laterally spaced partition elements aligned with a partition element of a module above or below, and said slab-like members span the space between at least two adjacent partition elements.
4. An assembly according to claim 1, wherein said partition elements are of generally trapezoidal shape.
5. An assembly according to claim 4, wherein the upper edge of said rear panel lies substantially below a plane extending from the upper edge of said front panel at right angles thereto.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000567709A CA1258980A (en) | 1984-02-08 | 1988-05-25 | Wall structure for retaining walls and the like |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US06/578,352 US4619560A (en) | 1984-02-08 | 1984-02-08 | Structural module for retaining walls and the like |
| US578,352 | 1984-02-08 | ||
| CA000473891A CA1237288A (en) | 1984-02-08 | 1985-02-08 | Structural module for retaining walls and the like |
| CA000567709A CA1258980A (en) | 1984-02-08 | 1988-05-25 | Wall structure for retaining walls and the like |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000473891A Division CA1237288A (en) | 1984-02-08 | 1985-02-08 | Structural module for retaining walls and the like |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1258980A true CA1258980A (en) | 1989-09-05 |
Family
ID=25670583
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000567717A Expired CA1262053A (en) | 1984-02-08 | 1985-02-08 | Assembly of structural modules for retaining walls and the like |
| CA000567709A Expired CA1258980A (en) | 1984-02-08 | 1988-05-25 | Wall structure for retaining walls and the like |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000567717A Expired CA1262053A (en) | 1984-02-08 | 1985-02-08 | Assembly of structural modules for retaining walls and the like |
Country Status (1)
| Country | Link |
|---|---|
| CA (2) | CA1262053A (en) |
-
1985
- 1985-02-08 CA CA000567717A patent/CA1262053A/en not_active Expired
-
1988
- 1988-05-25 CA CA000567709A patent/CA1258980A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| CA1262053C (en) | 1989-10-03 |
| CA1262053A (en) | 1989-10-03 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |