US20120057939A1

US20120057939A1 - Retaining wall block

Info

Publication number: US20120057939A1
Application number: US12/877,029
Authority: US
Inventors: Ernest E. Bone
Original assignee: Pacific Coast Building Products Inc
Current assignee: Pacific Coast Building Products Inc
Priority date: 2010-09-07
Filing date: 2010-09-07
Publication date: 2012-03-08
Also published as: CA2714683A1; CA2714683C

Abstract

A retaining wall block including a body having a front face, a rear face, opposing side faces, a top face, and a bottom face, and an elongated channel located in a surface of the bottom face preferably extending substantially between the opposing side faces. At least one pin aperture is located in a surface of the top face. A retaining pin is located in the pin aperture, extending vertically a predetermined distance above the surface of the top face. The block includes a cut-out portion defining a hollow extending from the top face through the body to the bottom face. The cut-out is located in the top face between the pin aperture and the front face and in the bottom face between the channel and the front face. A hand grip is provided within the forward upper portion of the cut-out.

Description

CROSS-REFERENCE TO RELATED APPLICATION

Applicant herein is the inventor of co-pending U.S. application Ser. No. 29/367,217, for an ornamental design of a Retaining Wall Block, filed Aug. 4, 2010.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The invention relates generally to blocks used for the construction of retaining walls for landscaping and construction projects. More specifically, the invention pertains to a relatively lightweight cementitious block including a unique retaining pin system to form a secure block wall assembly.
2. Description of the Prior Art
Retaining walls comprised of a plurality of blocks have become a very popular feature for both residential and commercial construction projects. The blocks are typically manufactured from concrete material having different colors and textures. Owing to their significant weight, when the blocks are assembled to form a wall, they effectively perform the function of retaining soil, while aesthetically defining walkways, property lines, and other landscaping features.
Some efforts have been made to provide an interlocking feature between and among blocks. By interlocking the blocks, their ability to resist displacing lateral forces is increased. Also, assembled interlocked blocks look more professional, as they are more uniformly and consistently arranged.
One of the most basic interlocking features is a lip or protrusion extending along the lower rear edge of each block. As each successive course is laid over an underlying course, the lips of the blocks in the new course are fitted over the rear upper edge of the underlying course of blocks. This effects an interlocking feature while uniformly setting the new course back from lower course a predetermined distance.
Other arrangements include providing pins which extend between the blocks to resist lateral shifting or movement between adjacent blocks and courses. Pins also provide a registry function, by assuring that the front faces of the blocks are aligned and assembled into a vertical wall. Exemplary of this approach are U.S. Pat. Nos. 6,615,561 and 6,536,994. One of the problems with the pin registration system stems from trying to align a pin with a bore or cavity in a very heavy concrete block.

SUMMARY OF THE INVENTION

The retaining wall block disclosed herein includes a number of features that facilitate the relatively easy assembly of a plurality of blocks into a retaining wall. One of the features includes an improved retaining pin system adapted to align and secure the blocks together. This system facilitates easier alignment and assembly of the blocks than known prior art systems.
At least one retaining pin extends vertically from the upper surface of each block. Instead of relying upon a singular bore or a relatively small cavity into which the pin is to be located, a longitudinal channel is provided in the bottom face of each of the blocks. This enables an upper block to be slid into a proper position over a lower block, where the pin in the lower block merely enters the channel in the upper block, rather than having to be located with a discrete bore or cavity.
Two or more retaining pins may also be employed, for additional interlocking strength, with each pin easily being accommodated within the groove or grooves of overlying blocks. In one embodiment, the pins are axially coincident with the center line of the longitudinal channel, and located an identical distance from the rear face of each block. This arrangement effects a co-planar alignment for the front faces of the blocks. Alternatively, the pins may be located closer to the rear face of each block than the longitudinal channel, effecting setbacks for the front faces of each successively higher course of blocks.
For the purpose of significantly lowering the weight of the concrete blocks, a generally centrally positioned cut-out portion is provided. This cut-out portion lowers the weight of the block for much easier handling by the installer. It also saves cementitious material without compromising the strength and structural integrity of the block.
Also, to assist in easier and more accurate assembly of the blocks, a hand grip is conveniently provided in the upper, forward edge of the cut-out portion. The hand grip includes an inclined shelf on its lower side, adapted for comfortable gripping by the installer.
A number of different embodiments of the invention are also disclosed, each including different front face configurations. Each of these embodiments when assembled into a wall, presents a different overall appearance to suit the individual tastes of the consumer.
These and other features are included in the retaining wall block of the present invention, as will become apparent from the drawings and the detailed written specification to follow.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a partially assembled retaining wall, incorporating the blocks of the present invention;

FIG. 2 is a front perspective view of a retaining wall block;

FIG. 3 is a perspective view of a typical retaining pin;

FIG. 4 is rear perspective view of a retaining wall block;

FIG. 5 is a rear perspective view of the bottom face of a retaining wall block, showing the longitudinal channel and the bottom of the hand grip in the block cutout portion;

FIG. 6 is a top plan view of a retaining wall block, showing the cutout portion and pin apertures in the upper face thereof;

FIG. 7 is cross-sectional view taken on the line 7-7 in FIG. 6, showing profiles of the hand grip and the channel;

FIG. 8 is an exploded front perspective view, showing the retaining pins being installed in a lower course of blocks and an upper block being installed in horizontally offset relation;

FIG. 9 is a cross-sectional view taken on the lines 9-9 in FIG. 8, after the upper block has been installed, showing a retaining pin in the channel of the upper block;

FIG. 10 is a cross-sectional view taken on the lines 10-10 in FIG. 8, after the upper block has been installed, showing two retaining pins in the channel of the upper block;

FIG. 11 is a cross-sectional view of an alternative construction for the block, in which the pin aperture extends from the upper face to the lower face of the block;

FIG. 12 is a front perspective view of an alternative construction for the block, including facets across the front corners of the block;

FIG. 13 is a top plan view of the block shown in FIG. 12;

FIG. 14 is a front perspective of an alternative construction for the block, including an arcuate front face;

FIG. 15 is a top plan view of the block shown in FIG. 14;

FIG. 16 is an exploded front perspective view, showing the lower course of blocks arranged to present a convex block face curvature;

FIG. 17 is a top plan view, showing the lower course of blocks and the upper block in FIG. 16 assembled,

FIG. 18 is a top plan view, showing the lower course of blocks and the upper block arranged to present a concave block face curvature; and,

FIG. 19 is a top plan view, showing blocks provided with two sets of retaining pin apertures, with the retaining pins being located in a second rear set of apertures to effect a rearward offset of the front face of the upper block with respect to the front faces of the lower course of blocks.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to the drawings, FIG. 2 shows the first embodiment of a retainer wall block 11. Block 11 comprises a body 12, including: a front face 13; a rear face 14; opposing side faces 16; a top face 17; and, a bottom face 18. Front face 13 is generally parallel to rear face 14, and top face 17 is generally parallel to bottom face 18. However, side faces 16 are angled to converge rearwardly. This allows adjacent blocks to be arranged in a curve, as will be explained in more detail below. As additional benefits, angling the side faces 16 in this manner saves concrete material and lightens the blocks, without compromising the apparent width and frontal presentation of the block 11.
In one commercial example, block 11 is approximately 18″ across its front face 13, approximately 12″ across its rear face 14, approximately 12″ deep, and approximately 8″ high. Block 11 is preferably made from concrete, although alternative moldable materials capable of hardening may also be used. Concrete is an inexpensive construction material that provides substantial flexibility in both color and texture. Most consumers desire concrete color and texture that resemble natural stone, although other choices are available for block 11. If manufactured from concrete into the general dimensions mentioned above, including the structural features discussed below, block 11 will weigh approximately 77 lbs.
As is shown particularly in FIGS. 5 and 10, an elongated channel 19 is located in the surface of bottom face 18, preferably extending between opposing side faces 16 and oriented parallel both to front face 13 and to rear face 14. There is nothing critical about the depth and width of channel 19, and a depth of 1″ or so and a width of ¾″ have proven satisfactory. Channel 19 is elongated, so as to present a more flexible and easier found recess for accommodating a retaining pin 21. This aspect of the pin retaining system will be described below when the assembly of a retaining wall 22 is explained in greater detail.
At least one pin aperture 23 is located in the surface of top face 17. The depth of pin aperture 23 may vary from several inches or so, to the entire thickness of the block, depending upon the particular molding technique employed. FIG. 11 shows a pin aperture 24 of alternative construction, which extends from the top face 17 into the top side of the channel 19. The axes of both pin apertures 23 and 24, shown respectively in FIGS. 9 and 11, are such that they intersect a center line 26 of channel 19 (See, FIGS. 4 and 5). Put another way, the distance from the axes of apertures 23 and 24 to the rear face 14 is identical to the distance from the center line 26 of channel 19 to the rear face 14.
Block 11 further includes a cut-out portion 27 defining a hollow 28 extending from top face 17 through the block body 13 to the bottom face. Cut-out portion 27 is positioned in the top face 17 between the pin apertures 23 and the front face 13, and between the opposing side faces 16. As shown particularly in FIG. 5, cut-out portion 27 is located the bottom face 18 between the channel 19 and the front face 13, and between the opposing side faces 16.
Cut-out portion 27 is generally trapezoidal in plan because this configuration mimics the trapezoidal configuration of block 11. This maximizes the size and volume of the cut-out portion 27, while maintaining substantial wall thickness around the hollow 28. It has been determined that maintaining the wall thickness within the range of 2″ to 2½″ or so, minimizes breakage of the blocks during manufacture, transport, and assembly. Other configurations of blocks may call for corresponding modifications to the configuration of the cut-out portion to achieve these same objectives. For example, if the front face of the block is arcuate in configuration, the front of the cut-out portion could also assume an arcuate configuration, maximizing the volume of the cut-out portion and keeping the wall thickness within target dimensions.
The cut-out portion 27 effectively reduces the weight of the 18″ wide concrete version of the block 11 from approximately 113 pounds for a solid volume block to approximately 77 pounds with the cut-out portion, making it substantially lighter without compromising its strength or durability. It has been determined that the volume of the hollow 28 should be approximately within the range of 25% to 35% of the entire volume of the block 11, to ensure that the dual objectives of providing a substantial weight reduction and maintaining adequate strength of the block will be met.
In accordance with standard practice, after or during assembly of the individual blocks into a retaining wall 22, the hollows 28 can be filled either with crushed rock or a combination of mortar and rebar for additional strength and mass. It should also be noted that for particular applications, hollows 28 could also be filled with expandable foam for higher insulating qualities.
To facilitate easier lifting and handling of blocks 11 during loading, unloading, and assembly, a hand grip 29 is provided in the forward, upper edge of the cut-out portion 27. The hand grip 29 includes an inclined shelf 31 below the top face 17, which is adapted for easy gripping by the installer. See, FIGS. 5 and 7.
Retaining pin 21 has a sidewall 32 defining an upper end 33 and a lower end 34. Preferably, an enlarged diameter portion is provided in the sidewall 32, between upper end 33 and lower end 34. This enlarged diameter portion is larger than the diameter of aperture 23, allowing the lower end 34 of the pin to fit easily within aperture 23 while preventing the upper end of the pin from dropping into the aperture. In the retaining pin 21 shown in FIG. 3, upper end 33 constitutes both the enlarged diameter portion and the portion of the retaining pin that extends vertically above the top face 17 of the block 11 a predetermined height. The predetermined height of the retaining pin 21 above face 17 is equal to or preferably slightly less than the depth of the channel 19, so that the former can easily and fully be inserted into the latter during the process of block assembly.
It is apparent that other equivalent structures could perform the function of the enlarged diameter portion. For example, a plurality of radially extending nubs or protuberances on the sidewall of the pin would provide the same function of maintaining the vertical portion of the pin 21 above the top face 17 of the block. In another example, the pin itself could be tapered somewhere between the upper end and the lower end, so the enlarged diameter portion would be somewhere between the ends. Retaining pin 21 can be manufactured from a wide variety of materials capable of sustaining stresses encountered both during assembly and while interlocking a plurality of blocks retaining soil. These materials would include fiberglass, plastic, and metal.
In comparing FIGS. 9 and 11, it will be apparent that aperture 23 may be of variable depth without affecting the ability of retaining pin 21 to perform its function. In FIG. 9, pin aperture 23 is slightly deeper than the terminus of lower end 34. In FIG. 11 however, pin aperture 23 extends entirely from top face 17 to bottom face 18. In either case, retaining pin 23 performs the identical function in the same way and provides the same result. The depth of aperture 23 is simply dependent upon the molding technique employed, which is a matter of choice of the manufacturer.
Turning now to FIG. 8, the assembly of a small portion of an entire retaining wall 22 is depicted. Typically, a ground excavation 35 is made in advance of laying the base course 36 of blocks. See, FIG. 1. The excavation is laid out for the same length and configuration for the planned retaining wall, and it may include a floor layer of sand or aggregate for leveling and drainage. In this example shown in FIG. 8, the base course 36 includes two of the blocks 11 arranged in lineal fashion, with only the proximal edges of their front faces 13 in contingent relation. A retaining pin 21 is placed into a respective aperture 23 in each of the blocks 11, in preparation for laying the first block 11 of the first course 37.
The first block of the first course is located and centered over the conjunction of the two blocks in the base course. This ensures that the first course blocks will be arranged in horizontally offset, overlapping relation with respect to the base course blocks. In lowering this first block over the base course blocks, the installer locates the retaining pins 21 into the channel 19. If the block is not exactly centered upon initial installation, the longitudinal channel 19 allows the block to be adjusted or slid horizontally to the extent required. FIG. 10 shows the pins 21 located in the channel 19, with the block of the first course 37 arranged in centered relation over the blocks of the base course 36. This assembly process is simply continued, as the wall is extended to its full length and height, with additional blocks added to the base course 36 and additional courses added over the first course 37 of blocks. As a finishing touch, a plurality of top caps 40 are cut to size and adhesively applied over the top faces of the upper course of blocks 11.
Additional embodiments of the retaining wall blocks of the present invention are shown in FIGS. 12-15. A faceted retaining wall block 38 includes a front face 39, and side facets 41. Side facets 41 may be manufactured by breaking off corners of retainer wall block 11 after molding, or they may be formed through the molding process itself. In all other structural and functional respects, retaining wall block 38 is identical to retainer wall block 11. Another embodiment, shown in FIGS. 14 and 15, is arcuate retaining wall block 42, including arcuate front face 43. The curved component of this block is more readily manufactured through the molding process, although a rough or exposed aggregate finish to the face may be effected through mechanical abrasion after the basic molding process is completed. With the exception of its different front face 43, the retaining wall block 42 includes all of the other structural and functional features described in connection with retainer wall block 11, so they will not be repeated here.
As indicated in FIG. 1, the retaining wall can be configured to have both concave and convex curved portions. FIGS. 16 and 17 illustrate the relationship and positions of the blocks and the retaining pins, where a convex wall curvature is made. As to the blocks in the base course 36, it is evident that the proximate side faces 16 are in contingent abutting relation. This also brings the retaining pins 21 in the blocks closer together. When the block in the first course 37 is lowered over the base course blocks, longitudinal channel 19 easily accommodates the new, relatively close spacing for the retaining pins.
FIG. 18 shows the relationship and positions of the blocks and the retaining pins, where a concave wall curvature is made. In this configuration, the proximate side faces 16 of the blocks in the base course 36 are angled away from each other, in rearwardly diverging relation. As a consequence, the retaining pins 21 in each block are now remote from each other. Owing to the length of the elongated channel 19, the pins 21 are still able to register within the channel, and maintain the blocks securely together.
There are also circumstances where an offset in the front faces of successive courses the blocks is desired, either for functional or for aesthetic reasons. For that purpose, a second set of pin apertures 44 may be provided. The location of each of the pin apertures 44 is between a respective pin aperture 23 and the rear face 14. Effectively, the distance between apertures 23 and 44 determines the measure or extent of the offset. As shown in FIG. 19, after the base course 36 has been laid, and retaining pins 21 have been installed in pin apertures 44 in each block, the block of the first course 37 is lowered into position so that the pins 21 register within channel 19. Owing to the rearward offset in the relative position of pins 21, the block in the first course is offset rearwardly. As successive courses of blocks are laid, the faces of the blocks within each course are accordingly offset rearwardly from the adjacent lower course of blocks.

Claims

What is claimed is:

1. A retaining wall block comprising: a body, said body having a front face, a rear face, opposing side faces, a top face, and a bottom face; a channel located in a surface of said bottom face extending substantially between said opposing side faces; and, at least one pin aperture located in a surface of said top face.

2. A block as in claim 1 including a cut-out portion, said cut-out portion defining a hollow extending from said top face through said body to said bottom face, said cut-out portion being located in said top face between said pin aperture and said front face and said opposing side faces, and said cut-out portion being located in said bottom face between said channel and said front face and said opposing side faces.

3. A block as in claim 2 in which a volume for said cut-out portion comprises approximately 25% to 35% of the volume of said block, defined by said front, rear, side, top and bottom faces.

4. A block as in claim 1 including a retaining pin located in said pin aperture, and extending vertically therefrom.

5. A block as in claim 4 in which said retaining pin has a sidewall and an upper end and a lower end, and includes an enlarged diameter portion in said sidewall between said upper and lower ends maintaining said pin at a predetermined height above said top face.

6. A block as in claim 1 in which said channel has a center line and said aperture has an axis, and said axis of said aperture intersects said center line of said channel.

7. A block as in claim 1 in which said channel has a center line and said aperture has an axis, and said axis of said aperture is located between said center line of said channel and said rear face.

8. A block as in claim 1 in which said front face includes a pair of opposing front edge facets extending rearwardly at an angle to meet a respective said side face.

9. A block as in claim 1 which said front face is arcuate.

10. A block as in claim 2 further including a hand grip located in forward edge of said cut-out portion, said hand grip including a shelf below said top face adapted for gripping.

11. A retaining wall block comprising:

a. a body, said body having a front face, a rear face, opposing side faces, a top face, and a bottom face, a channel located in a surface of said bottom face extending substantially between said opposing side faces, and at least one pin aperture located in a surface of said top face;

b. a retaining pin, said pin being located in said pin aperture, and extending vertically a predetermined distance above a surface of said top face;

c. a cut-out portion, said cut-out portion defining a hollow extending from said top face through said body to said bottom face, said cut-out being located in said top face between said pin aperture and said front face and said opposing side faces, and said cut-out being located in said bottom face between said channel and said front face and said opposing side faces.

12. A block as in claim 11 in which a volume of said cut-out portion comprises approximately 25% to 35% of the volume of said block, defined by said front, rear, side, top and bottom faces.

13. An apparatus as in claim 11 further including a hand grip located in forward edge of said cut-out portion, said hand grip including a shelf below said top face adapted for gripping.

14. A block as in claim 11 in which said front face includes a pair of opposing front edge facets extending rearwardly at an angle to meet a respective said side face.

15. A block as in claim 11 which said front face is arcuate.

16. A retaining wall comprising:

a. first and second base course blocks, each of said base course blocks comprising: a body, said body having a front face, a rear face, opposing side faces, a top face, and a bottom face, and at least one pin aperture located in a surface of said top face; a retaining pin, said pin being located in said pin aperture, and extending vertically a predetermined distance above a surface of said top face; a cut-out portion, said cut-out portion defining a hollow extending from said top face through said body to said bottom face, said cut-out being located in said top face between said pin aperture and said front face and said opposing side faces, and said cut-out being located in said bottom face between said rear face and said front face and said opposing side faces; said base course blocks being elongated, having a longitudinal axis extending from said side face to said side face, and being arranged in side to side relation with respect to each other so that said pins of said blocks are relatively close to the side face of the adjacent block;

b. a first course block, said first course block comprising: a body, said body having a front face, a rear face, opposing side faces, a top face, and a bottom face, a channel located in a surface of said bottom face extending substantially between said opposing side faces; a cut-out portion, said cut-out portion defining a hollow extending from said top face through said body to said bottom face, said cut-out being located in said top face between said rear face and said front face and said opposing side faces, and said cut-out being located in said bottom face between said channel and said front face and said opposing side faces; said first course block being located on and straddling said first and second base course blocks, said bottom face of said first course block resting in contingent relation over a respective portion of said top faces of said first and second base course blocks, with a respective said retaining pin of each of said first and second base course blocks being located within said channel of said first course block.

17. A retaining wall as in claim 16 in which a volume of said cut-out portions of said first and second base course blocks and said first course block comprises approximately 25% to 35% of the volume of said blocks, defined by said front, rear, side, top and bottom faces.

18. A retaining wall as in claim 16 further including a hand grip located in forward edge of said cut-out portions of each of said first and second base course blocks and said first course block, said hand grip including a shelf below said top face adapted for gripping.

19. A retaining wall as in claim 16 in which said front face of each of said first and second base course blocks and said first course block includes a pair of opposing front edge facets extending rearwardly at an angle to meet a respective said side face.

20. A retaining wall as in claim 16 which said front face of each of said first and second base course blocks and said first course block is arcuate.