AU2017202174B2 - Modular Cantilever Masonry Block System - Google Patents

Abstract

I Abstract The present invention relates to a system for constructing walls by use of modular blocks preferably consisting of three shaped units, a First shape main block, a Second shape half block, a Third shape corner block which when placed in a plurality of blocks can be used to construct walls. 0 (11 C C (11 I 'I. 4

Description

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Australia

Patents Act 1990

Modular Cantilever Masonry Block System

Inventor: Robert. J. Clarke.

Abstract The present invention relates to a system for constructing walls by use of modular blocks preferably consisting of three shaped units, a First shape main block, a Second shape half block, a Third shape corner block which when placed in a plurality of blocks can be used to construct walls.

Field of Invention The present invention relates to a system of Modular Masonry Blocks for the purpose of constructing retaining walls used in landscaping by means of a plurality of blocks having improved Lateral and Longitudinal locating and improved locking in the Vertical plane by means of a Stiffening Device (SD).

Background/ Problem

[001] In the field of retaining wall construction there are basically four categories for retaining soil and/or altering topographical levels of terrain, these are: anchored; mechanically stabilized; gravity; and cantilever. There are numerous ways in which retaining walls can be constructed from these four basic categories.

[002] Concrete sleepers have become a popular method of constructing retaining walls, but use a great deal of material in their manufacture, making them very heavy and necessitating machinery to install. The concrete sleeper gains strength from its massive size and steel re-bar that is inserted during manufacture used to oppose the lateral forces acting upon it. If cracks appear along its length as a result of transport or being knocked during the installation process, over time any intrusion of air or moisture through such cracks to the re-bar could cause the re-bar to oxidize leading to a condition known as concrete cancer where the steel reinforcement expands as it oxidizes which could eventually break the concrete apart if substantial enough.

[003] A further problem with this particular type of retaining wall method is that it requires a steel support post either side of the sleeper and deep excavations are needed for these steel support posts, being dug at every sleeper end to a depth at least equal to the height of the wall being built, and these must be filled also with large amounts of concrete. By its very nature this type of building method necessitates the use of expensive heavy machinery not only to dig the holes for the steel posts but also to lift and place the sleepers themselves. Another consideration with this type of method is that some grounds may not allow for post holes to be dug due to the inclusion of rock deposits near the surface and the cost associated with digging into or inserting lateral anchoring.

[004] The modular block type of retaining wall relies on either manufactured mass and therefore is heavy to handle and place like concrete sleepers, or obtains extra gained mass after being placed and back filled with material in order to better resist associated loads and this is disclosed in US patent 6010279. US patent 7871223B2 teaches us of the existing problems with other modular blocks when it states that although existing segmental wall blocks have proven versatile they have shown limitations. US patent 6821058B1 teaches that in order to resist loads, it is necessary to lay some block walls with an offset or batter. That is to say they are stepped back by an appreciable amount on each subsequent course and lean against the soil being retained in order to resist the load being applied to them. This set back created in these types of designs will give rise to an appreciable loss of area above in the ground being supported as the wall height increases. Also the use of these types of blocks, although being very popular, if not locked in place adequately, can move out of alignment due to lateral or seismic forces and may eventually lose integrity and cosmetic appearance. Walls of appreciable height using this type of constructing method often require a mechanical means to stabilize them as disclosed in US patent 7390146B2 and also US patent 2009/0185870A by means of geomesh fabric.

[005] When using this type of system another problem might be that, it would not always be feasible to extend geosynthetic or mechanical reinforcement behind a wall due to limiting factors such as the presence of a structure or property line immediately behind the wall. And as most existing modular wall blocks cannot be constructed though the use of grout and re-bar reinforcement there is clearly a need for a retaining wall block that improves on US317048- P. Forsberg's, design, because as blocks are usually placed with manual labour a lighter weight block without compromising performance would be desirable. Another failing of some of these types of dry assembly blocks on the market today is that they do not have adequate shouldering, (where the block above rests across part of the length of the block below to either side), due to their relatively short width. Even though they may be stacked in a staggered running bond in order to share the longitudinal load, as would be occasioned when using long crib type retaining wall structures or by being bonded with mortar as in conventional brick walls, this lack of shoulder support may lead to sagging of the wall over time and gaps forming which could then offer an opportunity for weeds to grow further compromise the structure.

[006] Retaining walls made from modular blocks presently in use can become problematic in other areas such as when movement is caused by expanding water in areas prone to freezing, causing misalignment and eventually possible structural failure.

[007] A further problem posed with most modular blocks is how to erect a fence in newly placed back fill as without complete mechanical compaction of the ground behind, won't support fence posts and many of the blocks themselves are not designed to accept a fence post and so any fence would have to be situated some way in from the wall face giving rise to a further loss of land use.

[008] US patent 4067166 teaches of a precast 'L' shaped section. This reinforced structure which is placed horizontally intermittently throughout the wall to gain stability has to be linked with cables and it can be seen that it would be complicated to build, it can be seen both in this patent and in US patent 3282054 and also in US patent 3464211 the use of a similar mechanical soil intrusion method, where in this design a similar method of intrusion into the soil being stabilized as US patent 4067166 - E. Sheahan's, albeit in a 'T' configuration, but because it teaches of a device that intrudes so much and so often, it can be seen that it would be difficult to back fill around the members adequately and this could cause problems unless compacting is carried out as each wall course is constructed, and the method to achieve this result is not fully explained in either patent, and in US patent 4067166- E. Sheahan alludes to this in his criticism regarding US patent 3282054-I Saginor's design, but in this writers opinion both designs suffer from the same problem. If proper compaction below the intrusion member did not occur it could cause the said member/s to be forced downward by the increasing soil weight above and lever the front face of the wall out of alignment or possibly to destruction. Also, most block retaining wall systems require that back filling occur during the assembly of each course, because of the hollow cavity in them that requires infill of some material to lock them in place, and this must be carried out before the next course is laid which is time consuming and therefore costly, only the more massive modular blocks or those that are filled with concrete slurry after construction would be exempt from this requirement.

[009] Cantilever retaining walls come under the last category and are often used in large construction projects and usually cast in situ, or prefabricated off site then delivered and installed, but is very labour intensive and necessitates the use of costly machinery and is far beyond the scope of most non commercial retaining wall projects. The present invention has incorporated this readily known engineering principal using it to advantage in a unique way to create a modular block that is practicable for landscaping purposes and can be placed easily by hand.

Summary

[001] It is a device of the present invention to provide an improved wall block satisfying most of the above desires and seeks to provide a solution to the problems mentioned by providing a system that has an improved method for aligning and locking blocks preventing them from moving during construction making it quicker and safer to construct walls with.

[002] The reliability of any retaining wall is dependent on the wall resisting the forces being applied to it and this can only be achieved by having substantial strength or mass in the retaining wall. If a method would be found that does not require such a heavy weight to resist the outward force of the material being retained and yet still retain its ability to resist the loads being applied to it then great savings could be made and the applicant of this application believes the present invention achieves this goal.

[003] One of the problems raised earlier in this document regarding adequate back-filling around the intrusions in US patent 3282054; is not an issue with the present invention as each block sits firmly and squarely upon the one below locked in place by the described embodiment and stabilized further on back filling by the weight of the soil pressing down on each course. Each block rests in a horizontal plane and the back fill, which does not need to be compacted during or after construction, as in most other methods, again saving time and money, rests upon the foot plate keeping it permanently loaded and increasing its coefficient of friction, and the front leg in a state of rotation inward resisting the lateral outward pressure. The naturally occurring settling of the soil is sufficient to stabilize the wall over time as material will fall at its nominal angle of repose, settling against the inner heal of the foot of the block only becoming firmer over time, and as this event occurs at each and every course built, it gives rise to a very stable building method.

[004] It can thus be seen that the present invention provides numerous inventive advantages over existing products in the market and offers a new and compact novel way of constructing a retaining wall using far less material in its construction making it cheaper to manufacture and transport than most other methods and therefore saving greenhouse gasses, and offering far superior stability without resorting to other costly means of soil stabilizing as seen in US patent 7390146 B2 -T. L. Rainey.

[005] As described earlier in this application cantilever designs are usually cast in place on large projects and involve expensive and labour intensive form work to be constructed first or may be prefabricated as large components off site and transported then lifted into place with large cranes. The present invention achieves this same unique stability force in a much smaller compact preformed modular way.

[006] A block at rest needs no coefficient of friction, as no force is acting upon it except gravity, but as lateral load is applied the block will begin to move away from the direction of force once its friction has been overcome.

[007] In an ordinary block wall several basic obstacles must be overcome, such as preventing the wall from leaning forward and falling over or sliding away at the base and collapsing. This would be measured as its ability to resist being pushed outward (coefficient of friction) usually achieved by weight and its ability to stay upright (tipping resistance) usually achieved by mechanical means. In the present invention, the total combined weight of the soil resting on the foot plate of all the blocks gives momentum to resist tipping in as much as the rotating force it generates inward will always be equal to or greater than the lateral outward force being applied so preventing the wall from falling over. But in other block walls the mass can only be a total of the combined weight of all subsequent blocks constructed above, whether they have been filled with back fill or not reaching a final total weight. When the soil load becomes greater than this final total figure other methods are required to prevent the wall moving away from the soil being retained such as in mechanical soil stabilization techniques. With the present invention as soil load is applied to the foot or heal plate it becomes heavier gaining mass as in similar blocks but this mass will continue to increase as more soil is loaded behind and its coefficient of friction will increase, more load, more increase in friction, and the lower down in the wall this happens the greater the friction becomes that must be overcome by the soil load.

[008] The current invention enables construction of a retaining wall without the need for lifting equipment, or digging of holes for support posts or a waterproof membrane being fitted to the rear or resorting to the use of expensive stabilizing methods for the soil due to its design and offers a simple and low cost method of locking the structure together either permanently or temporally with an (SD) the preferred embodiment described herein.

[009] The current invention makes use of standard 9cm plastic pipe as an (SD) which is then inserted into cavities in the protrusions of the retaining wall and either used simply as a locking method on low walls to 80cm height or back filled with cement slurry for higher walls and used with re-bar soil anchor as disclosed herein to form a rigid plug locking method preventing the blocks from ever moving out of alignment but still remaining flexible enough to accommodate soil and ground movement, or the hole can simply be filled with concrete slurry to form a solid permanent plug bonding the blocks together.

[010] Because of the innovative design construction is quicker, cheaper and safer than most other methods, giving reliable results in soil stability. It can be seen that using this type of construction method will result in a cleaner appearance on the outer face because it does not need to be set back on each course. Most importantly, its use would be beneficial should a high wall be required where the ground contains rock preventing the use of sleeper type walls and ordinary block walls would not be able to gain added support from geomesh or other stabilizing methods because of the rock contained therein. The present invention overcomes this problem as placing it and back filling with a course gravel mix would be sufficient to stabilize it making the wall both cost effective and safe. Its design allows it to be assembled by those not skilled in retaining wall construction and a wall can go up quickly. The unique design also prevents material from building up fully against the inside face of the block, due in part to the sloping angle of the foot plate where water is encouraged to run away from the inside block face, but mainly because of the overhanging foot of the block above. Soil falls at its angle of repose from the rearmost edge of the block above and slopes in towards the heal of the foot of the block below leaving a cavity above the sloping material. Thus preventing water or damp soil gathering where freezing expansion might occur in cold climates. As intrusion of water is prevented the need for a damp proof membrane at the rear of the retaining wall is unnecessary unlike in most other wall systems.

The applicant of this patent application has ascertained that the use of a larger but lighter weight and stronger retaining wall block with a distinctly formed shape enabling a much more secure stable wall to be built without recourse to subsidiary stabilisation methods is an advantage from both cost and handling standpoints and safety and together with the described embodiment for locking the blocks together is both new and novel.

Basic description

[001] The present invention relates to a system of rectangular shape masonry modular blocks used as a landscaping element to create walls of varying height. Blocks can be inverted and used as the capping on the last course. It has a large foot area at the rear which when loaded with soil incorporates the principal of cantilever.

[002] The present invention also relates to units made from a plurality of such blocks integrally connected.

[003] The preferred embodiment uses a readily available (SD) Stiffening device made from 90mm diameter P.V.C. pipe to lock groups of blocks together in such a way as to provide substantial improvement in stability.

[004] Furthermore the present invention incorporates a spigot extending up from the top of alternate protrusions which locate with a recess running the length of the underside to help align the wall and prevent forward and rearward motion during construction. Such locking of the blocks against any transversal displacement substantially reinforces the wall in the direction where it is the most subject to deformation.

[005] Furthermore the present invention is represented primarily in three forms, a First shape, Second shape and Third shape block. Each block shape being easily located on the one above by a series of spigots extending up from the top face protrusions of a block mating into a recess of similar dimension located on the underside of each block.

[006] The blocks can be locked firmly into place by means of an (SD) Stiffening Device primarily made from 90mm diameter P.V.C. pipe which is inserted into a cavity in a protrusion and aligns the block either above or below when placed in a plurality of blocks and filled with mortar. When one block is assembled atop another in a staggered fashion as in a plurality of blocks, the block placed above forms a roof over the lower block cavity, this causes any material being retained to be forced to fall at its particular angle of repose from the rear lower edge (60) of the foot of the block above causing it to slope naturally to the inside of the heal (25) plate of the block beneath. Due to this slight amount of material build up against the inner face, pressure buildup against the forward inner face (25) of the lower block is reduced, as would not occur in other types of wall blocks. Refer to (Fig. 21) The bulk of the back fill material is now sitting towards the outer part of the foot the downward force being applied increases and so too does the rotational counter force being experienced by the outer front face now pushing inward, this being limited only by the structural integrity of the block it's self. The shape of the design of the block makes it strong without need for reinforcing steel bars and resists deformation along its length.

The present inventions attributes are: a) It uses no re-bar in its construction and so cannot develop concrete cancer, b) is considerably lighter than other similar blocks for its size therefore easier to handle and making it cheaper to transport to site, c) has great strength to weight ratio, d) needs no support posts drilled in the ground, e) can be placed without machinery, f) needs no compaction of back-fill, g) has a large shoulder area for lateral support preventing movement, h) has a unique inexpensive described locking method enabling accurate alignment and locking of blocks, i) needs no lean in making the area above the retaining wall more useable, j) on low to medium height walls needs no further soil stabilizing method such as geomesh or other soil intrusion to stabilize soil.

k) is able to immediately accept a metal fence post within the structure in order to complete landscaping.

1) A recess located centrally underside of each block along with corresponding spigots on the top of the block offers easy alignment, firmly locating the block preventing it from moving forward during construction, and when used in conjunction with the preferred embodiment of a (SD) located inside the cavity of the protrusions, makes it not only quick and easy to erect but also does not require a great deal of skill to obtain accurate results.

Prior Art

[001] US patent 3430404 - George B Muse; in his Apertured wall construction, teaches us of a brick for constructing a retaining wall incorporating two metal tubes split horizontally along its length and inserted into every brick which has two corresponding holes to accept the metal tubes in order to lock said bricks together and would fall under the latter group.

[002] In this patent and also in US patent 3693307A - George B Muse; 'Variable wall structure', the principal of locking blocks together can be interpreted as having similarity but are obviously not the same. We are show a type of void in the centre of the brick as in this case two holes passing though the brick, It is apparent from the foregoing that the prior art fails to teach about a block utilizing a cantilever principal and though the method of locking the bricks is similar in as much as it is accomplished with a device circular in shape that fits into a circular receiving receptacle/hole, it does not teach us that it can be made from an alternative material such as P.V.C. or if the locking method has to be split along its length as in the prior art or can be completely circular, also if it could extend completely through the structure in one piece or simply reside in one face of each unit as in the prior art, also the prior art does not teach us about any protrusions that reside at either end and also centrally for accepting a locking tube made of plastic.

[003] Further prior art US3464211A-Andresen A Magney. Modular structure for retaining walls, and US3282054A 1966- Irving Sagnor, Block for restraining, US patent 4067166- E. Sheahan, Retaining Wall Block fall into the first category and teach us that although prior art may have a rear protrusion for soil to exert pressure upon they fail to teach of an 'L' shape cross sections in the horizontal plane for the purpose of supporting soil load using a cantilever, and constructed within and running longitudinally the entire length of the body of a modular block itself.

[004] The prior art in US patent 3282054A-Irving Sagnor, teaches us of the use of the cantilever principal where the intrusions at the rear of each block are impressed by the loading of soil at the rear of the wall giving rise to an inward momentum of the top of the block. As mentioned before, this type of block would have difficulty to adequately compact back filled soil around the intrusion and if not done would lead to a disruption in the wall integrity. Also the prior art teaches us of a 'T' shaped cross section that does not exist along the entire length of the block. It does not teach us of a foot being the same length as that of the face of the block and having protrusions to accept a locking method. We are also taught that this particular invention relies upon each block being stepped back upon the one below it to form its primary purpose and is therefore completely dissimilar to the present invention.

Related art references discussing subject matter bearing some relations to matters discussed herein include: US. Pat. No. 5,941,042 to Dueck (Dueck), US. Pat. No. Re.37,278 to Forsberg (Forsberg), US. Pat. No. 5,704,183 to Woolford (Woolford), US. Pat. No. 4,964,761 to Rossi (Rossi), US. Pat. No. 5,214,898 to Beretta (Beretta), U.S. Jul. 23, 2009 Pat. No. 5,294,216 to Sievert (Seivert), US. Pat. No. 5,711,130 to Shatley (Shatley), US. Pat. No. 5,484,236 to Gravier (Gravier), German Gebrauschsmuster DE 295 00 694 Ul to Ming Su (Ming Su), US. Pat. No. 5,865,006 to DaWson (DaWson), US. Pat. No. 380,560 to Forsberg, U.S. Design Pat. No. 384,168 to Stevenson, U.S. Design Pat. No. 397,451 to Stevenson, US. Pat. No. 5,540,525 to Miller (Miller), US. Pat. No. 5,800,097 to Martin (Martin), US. Pat. No. 5,487,623 to Anderson et al (Anderson), US. Pat. No. 5,881,511 to Keller, Jr. (Keller), US. Pat. No. 5,524,551 to ScheiWiller (ScheiWiller), US. Pat. No. 6,260,320 BI to Di LorenZo (Di Lorenzo), US. Pat. No. 5,226,275 to Trahan (Trahan), US. Pat. No. 4,824,293 to Brown (Brown), US. Pat. No. 5,522,682 to Eagan (Egan).

In broad terms, and not to be interpreted as comprehensive, the above patents may be said to disclose the following: a) Dueck discloses a retaining wall block with downward extending cylindrical knobs. b) Forsberg discloses pins and pockets for interlocking overlapping blocks. c) Woolford discloses a masonry block which has a centrally-located and dog bone shaped, or two centrally-located circular, protrusions aligned with an opposing inset (or insets) extending partially into the block. d) Rossi discloses dry-mounted construction elements for use in a retaining wall with a series of openings within each block. e) Beretta discloses retraining wall blocks with a cambered front, tapering side walls and an abutment for engagement with an adjacent lower block. f) Sievert discloses a solid composite masonry retaining wall block with a range extending down from the block back surface past the height of the block.

g) Shatley discloses a retaining wall building block with rearward and forward aligning elements extending downward, holes extend through the blocks and pins for interlocking them together. h) Graiver discloses retaining wall blocks with an upward lateral extending front lip and a laterally extending recess. i) Dawson discloses a retaining wall block with a range extending downward from the block's rear surface. j) The Forsberg design patent discloses a three faceted broken front face retaining wall block with a rear edge protrusion from the bottom surface of the block. k) The 384,168 Stevenson design patent discloses a retaining wall block with 2 rear protrusions from the bottom surface of the block. 1) The 397,451 Stevenson design patent discloses a portion of a retaining block wall using the retaining wall blocks of the US. Pat. m) No. 384,168 design patent. Miller discloses a groove in the side of a block. n) Martin discloses an array of projections on the top face of a block that fits into an array of apertures on a bottom fact of a higher block. o) Anderson discloses vertical rods inserted through holes of the blocks in order to form reinforced columns. p) Keller discloses block having a dovetail section for fitting together with adjacent blocks. q) The Schei Willer discloses blocks having holes for attaching with other blocks by filling the holes with concrete. r) Di LorenZo discloses wall flanges held together by rods or cables that are held in each adjacent brick. s) Trahan discloses a block with a lower lip that fits into the block below it. t) Brown discloses a wall using a tieback to connect to a lower member. u) Egan discloses a modular wall block with rearward abscesses for receiving grid connectors. v) Cantarano discloses a wall form panel with interlocking protrusions around the edges which make the panel reversibly symmetric.

The applicant of this application has discovered no prior art that he believes will depose the present invention in either shape, form or function believing the present invention to be a new and novel alternative to what is already known.

Reference US7390146 B2 T. L. Rainey US7645098B1 Thomas L. Rainey/ (Earth Reinforcement Technologies) US6338597B1 Thomas L. Rainey US8246275 Thomas L. Rainey US7775747 B2 T. A. Bott (Block) US7871223B2 Robert. A. MacDonald (Block) US6821058B1 W. B. Dawson (Block) US2009/0185870A Kenneth. L. Shaw US4067166 E. Sheahan's retaining (Block) US3282054 I. Saginor (T shaped intrusion) US3464211 M A Andresen (T shaped intrusion) US3479782 A Muse (Construction blockO US6474036B2 James S. Martin (Block) US4874272 Phillip D Egan (Heavy cantilever cast) US317,048 Forsberg (Block) US6416260 Suheil Rashid Khamis (Block) US4643618 William K. Hilfiker (Cast cantilever) US1762343 Andreas Munster (Cast cantilever) US4619560 Edward V. Crinnion (weird zig zag block) US4186540A Wayne L Mullins (block) US4067166 E. Sheahan's (L shaped insertion)

Brief Drawing Explanation The drawings illustrated are not to scale (unless where stated) and are for explanation purposes of the embodiment's, and a more complete understanding of the method and apparatus of the present improved invention may be obtained by reference to the following when taken in conjunction with the accompanying detailed explanation mentioned later herein:

Fig.1.0 Shows a perspective view of a First shape block as seen from the rear and above. Numbers used: 20, 25, 30, 45, 50, 55, 60, 65,70,75, 80,100,150.

Fig.2.0 Shows a rear view of First shape block with the spigots and recesses. Numbers used: 25,50,55,60,65,70,85,90,97.

Fig.3.0 Shows a plan view of First shape block as seen from underneath, the front being at the top of the drawing and recess along the centre. Numbers used: 20,30,65,75,80,105,230.

Fig. 4.0 Shows an ISO view of First shape block as seen from underneath. Numbers used: 20,60,65,75,80,90,105.

Fig. 5.0 Show's a cross section view of a block showing the 'L' shape section and sloping inner lower face also illustrating the forces acting on a block. Numbers used:

Fig. 6.0 Shows a top view of a Second shape block showing the spigot and recess for locking. Numbers used: 10,25,35,45,50,55,80,85,90,97,150.

Fig. 7.0 Shows a perspective view of Second shape block as seen from above and behind showing an open ended cavity. Numbers used: 25,35,55,60,65,70,80,90,100,150.

Fig.8.0 Shows a Second shape block as seen from the front. Numbers used: 10,35,230.

Fig.9.0 Shows a Second shape block as viewed from the underside illustrating the recess along the centre line of the block, the front being at the top of the drawing.

Numbers used: 10,80,105,165.

Fig. 10 Shows a Third shape block as seen from above. Numbers used: 15,25,40,55,80,90,97,150.

Fig. 11 Shows a perspective view of a Third shape block as seen from behind with one end face showing. Numbers used: 15, 25, 40, 55, 80,90,97,150.

Fig. 12 Shows a Third shape block as seen from the side. Numbers used: 15,80,165,198.

Fig.13 Shows a perspective view from the top of a preferred embodiment of blocks used with 90mm diameter parallelogram hinge (310) and arm (300) inserted vertically into a cavity (20) wherein said parallelogram acts to give the blocks angular momentum on impact, dissipating the force when used as an aggressive vehicle mitigation system. Numbers used: 05,10,20,300,310.

Fig.14 Shows a perspective view of a preferred embodiment of a setback of blocks showing a Stiffening Device (210) inserted at an angle and filled with concrete to maintain the set back angle. (Stiffening Device / 90mm plastic P.V.C. tube). Numbers used: 05,10, 20, 210, 220.

Fig.15 Shows a perspective view from behind of a preferred embodiment of blocks used with Stiffening Device (200) inserted vertically into a hole made under the foundation wherein re-bar (260) is placed then filled with concrete (250) to form a more stable structure with hidden steel and concrete support posts running throughout the (Stiffening Device / 90mm plastic P.V.C. tube). Numbers used: 25, 30, 50, 80, 200, 250, 260.

Fig.16 Shows a perspective view of a preferred embodiment of blocks showing a Stiffening Device inserted along with steel fence posts fully into cavities. (Stiffening Device / 90mm plastic P.V.C. tube). Numbers used: 05,10,200,270,280.

Fig.17 Shows a perspective view of a preferred embodiment of blocks showing a block inverted and used as a capping and locating with the spigots in the recess. Numbers used: 20,50,90,97,160.

Fig.18 Shows a perspective view of a preferred embodiment of blocks showing inverted capping block and right angle corner blocks and locating with the spigots in the recess. Numbers used: 05,15,80,90,97.

Fig.19 Shows a close up view of a preferred embodiment of locating with the spigots in the recess. Numbers used: 05,90,97.

Fig.20 Shows a perspective view from behind of a preferred embodiment of blocks showing Stiffening Devices inserted into cavities as a preferred locking method and a steel fence post therein inserted. (Stiffening Device / 90mm plastic P.V.C. tube) Numbers used: 20,50,65,70,80,200,270.

Fig.21 Shows a close up view of the characteristic of the design preventing back fill from fully resting against the heal. Numbers used: 05,25,60,230,320.

Fig.22 Shows a view from the front of the preferred embodiment of the comer blocks being used as both positive and negative corners with inverted blocks on top as the preferred embodiment of capping. Numbers used: 05,15,20,30,35,40.

Fig.23 Shows a view from behind of the preferred embodiment of the corner blocks being used as both positive and negative corners with inverted blocks on top as the preferred embodiment of capping.

Numbers used: 15,20,30,35,40.

Fig.24 Shows a view a preferred embodiment of the manufacture of the First and Second shape blocks using a custom made two stage system with the rear mould plate before it has rotated away from the moulding plane during partial filling. Numbers used: 400,410,415,425,440,450.

Fig.25 Shows a view a preferred embodiment of the manufacture of the First and Second shape blocks using a custom made two stage system whereby the rear mould plate has rotated away from the mould box to allow partial filling before returning to the pressing plane and engaging the press head. Numbers used: 400,410,415,425,440,450.

Fig.26 a-d Shows a cross section view a preferred embodiment of the manufacture of the First and Second shape blocks in (fig.a) through (fig.d) using a custom made two stage system whereby the rear mould plate moves from the down pressing position to an up rotated position away from the mould box to allow partial filling before returning again to the pressing plane and engaging the main press head. Numbers used: 400,410,425,440,450,620,675,680,695.

Index of drawing numbers: 165 bottom face of Second shape block front outer face First shape 170 top of front edge of Second shape block block front outer face Second shape block 180 top front edge of Second shape block front outer face Third shape block 190 bottom front edge of First shape block middle cavity First shape block 200 90mm PVC pipe rear front face 210 75mm PVC pipe top face First shape block 220 10mm set back top face Second shape block 230 outer front edge top face Third shape block 240 inside comer Third shape block front inner face bottom edge 250 concrete bottom inner face First shape block 260 re-bar 52 bottom inner face Third shape block 270 steel fence post rear top edge 280 steel fence rail Rear lower edge 290 'L' cross section Rear face 300 parallelogram rear face of protrusion 310 parallelogram hinge end face 320 soil end face cavity 400 mould front face plate inside face of protrusion 410 pallet spigot 415 rear face of mould plate top of middle protrusion 425 rear shape of mould 97 spigot recess 440 pallet extension for recess indent 100 top of end protrusion 450 press plate for foot 105 bottom recess 620 front face of rear mould plate 150 rear top edge of protrusion 675 inner face plate of rear mould plate 160 bottom face of First shape block 680 hinge mechanism for rotating rear mould plate

Components or steps of the invention

[001] The invention principally utilises different shape block types as a method of constructing a retaining wall. Primarily three shape types are shown but should not be considered exhaustive, being primarily the First shape block (the full length block); the Second shape block the (half length block); the Third shape block the (comer block).

[002] A wall would be constructed by first, preparing and leveling a compacted base, then laying out the first course of blocks with a string line. The blocks would be placed in a level manner using the First shape blocks with the front face outward most. At either end of the first course a Third shape block could be used to construct a 90 degree bend and continue the wall or simply used to finish off the course.

[003] To build a uniform length wall; on a subsequent course the Second shape block would be used first placed up alongside a Third shape block which had been placed perpendicular on top of a corresponding Third shape block below at the corner of the first course, lining up the spigots with the recesses underneath each block. Then followed by a First shaped block and continued with First shape blocks until the desired length established finishing with a Second shape block at the end of the course forming a running bond pattern. Each corresponding course placed upon the one below in alternating fashion as described building up the wall height and keeping vertical alignment by inserting an (SD) into cavities at regular spacing as required.

Detailed description of how it works / Essential' aspects

[001] The following is a detailed description of exemplary embodiment's to illustrate the principles of the invention. The embodiment's are provided to illustrate aspects of the invention, but the invention is not limited to any embodiment. The scope of the invention encompasses numerous alternatives, modifications and equivalent; it is limited only by the claims.

[002] Numerous specific details are set forth in the following description in order to provide a thorough understanding of the invention. However, the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured.

[003] The described invention is a mortar less modular wall block system which incorporates the principal of the cantilever. It uses gravity to increase its coefficient of friction propelling it inwards towards the force of the soil being retained by use of its large foot plate. It manages to remain light weight but strong without need for other soil stabilisation methods such as geomesh and soil anchors due to its unique design.

[004] Each block has protrusions that perform the task of both support and for locking the blocks together in the vertical plane through use of cavities that have an (SD) inserted. Further stabilisation is achieved by the use of spigots that extend up from alternating protrusions to locate into a recess located on the underside of each block to make assembly of a wall quick and efficient by preventing blocks from moving forward or backward. The spigots and recesses in the top of the protrusions also allow for alignment of a block that is inverted and used as a capping.

[005] When a plurality of blocks has been assembled, final locking can take place by use of an (SD). A 90mm diameter P.V.C. plastic pipe is suggested as it is readily available and inexpensive. This can later be filled with concrete with or without re-bar inserted.

[006] At the end of each course laid a Third shape block is used to either make a return to continue the build with positive or negative angles or simply as an end finisher. The Third shape blocks must be positioned perpendicularly and locked in place by an (SD) but is also prevented from moving out of alignment by spigots and recesses.

[007] To construct a stable and strong structure a running bond joint is used and this is accomplished by using the Second shape block as the first block on the second course up and alternated with each subsequent course laid, in this way walls of increasing height can be built easily. Should unusual angles be required it is simply a matter of using an angle grinder or such machinery to cut a block as is known. Further clarification is as follows:

[008] A First shape block being the main block having a vertical rectangular outer front face (05) thereof with a corresponding planar inner front face (25) set a distance apart giving rise to a top face (30) and having a bottom outer face (160) thereof with a corresponding planar bottom inner face (50) set a distance apart and being constructed with sufficient angle running down and away from the junction of the inside edge of the front inner face and edge of the bottom inner face (45) so as to prevent water pooling on the surface of the foot of the block. Having faces (75) at each end with protrusions that extend out from the front inner face and up from the bottom inner face through which exists a cavity running though from the upper most face thereof to the bottom most face thereof with the outer end face being open (80) and being of sufficient dimensions to support a subsequent block above and when placed alongside a similar block shape an (SD) (200) be inserted without compromise, and having a further protrusion centrally (95) positioned wherein a cavity (20) runs through from the upper most face thereof to the bottom most face thereof and is of sufficient dimensions to support a similar block above and allow a (SD) (200) to be inserted without compromise.

[009] A Second shape block being similar in description to a First shape block, but having only two protrusions, one at either end and being only half the length.

[010] A Third shape block having four faces 90 degrees planar to each other with corresponding parallel planar inner faces (25) excepting where a part protrusion exists producing a thicker profile and giving rise to a top face (40) and underside face (196) at a determined thickness with recess (97) for aligning with a spigot above and has part of the triangular protrusions (100) at 45 degrees respective with cavities (80) running through from the upper most face (40) thereof to the bottom most face (198). This particular shape block does not use the cantilever principal as it is designed for constructing both negative and positive returns on a wall and has planar faces on all 4 sides.

[011] A cross section through the block illustrating an 'L' shape configuration (Fig.5.0) with an added recess (105) running longitudinally along the block in order to engage spigots (90) of a block below during assembly. The protrusions (100) support subsequent blocks that are placed above and locate the block by means of the spigot jutting out of the top of a protrusion which locate the blocks preventing movement in forward and rearward direction. A recess also exists in the top of the protrusions in alternating positions for accepting the spigot when the block has been inverted and used as capping.

[012] It can be seen from (Fig.16) that it is possible to insert metal fence post into the cavities to enable immediate erecting of fencing in order to complete landscaping of the site.

[013] Also in (Fig.17) and (Figl8) it can be seen that the top course of blocks has been inverted giving a capped appearance with (Fig.20) showing an (SD) inserted into the holes from the top of the wall.

Most important aspect

[001] The object of the present invention is to provide a retaining wall block, which combines the structure and advantages of the interlocking blocks disclosed in the above mentioned patents, but with a new superior means to enable it to be locked together which performs better than what is presently available to date and gives rise to the most important aspect of the described invention the way in which it handles loads.

[002] The forces acting upon a retaining wall block have already been discussed previously in this application as are the ways to address them, most being to create a heavy mass block with which to resist load or by added mechanical means. The described invention tackles the problem in a different simpler way, incorporating the principal of the cantilever in a small modular block that is lighter and easier to handle but has the same potential. Combined with the unique embodiment of locking the blocks together with an (SD), forms another aspect which creates a different product from that already known.

[003] Another object of the present invention is to provide a retaining wall system that can be constructed at a lower cost and still provide all of the advantages of a conventional retaining wall system.

[004] Another object of the present invention is to provide a retaining wall system that can be constructed by persons not skilled in building retaining walls.

[005] Another object of the present invention is to provide a simpler retaining wall system wherein a high strength wall still retains the soil.

[006] Yet another object of the present invention is to provide a retaining wall system capable of supporting a fence extending beyond the grade level of the soil being retained by the retaining wall immediately on completion.

Best and most complete way to make invention

The following steps are commonly used to manufacture a concrete masonry unit (CMU) and are well known to those skilled in the art so this application does not go into too much detail in regards to those facts but three methods mentioned herein are considered the most complete ways to manufacture the described invention.

Mixing * Sand and gravel are transferred into storage bins in the plant by a conveyor belt as they are needed. Portland cement is stored outside in large vertical silos to protect it from moisture.

• As a production run starts, the required amounts of sand, gravel, and cement are transferred by gravity or by mechanical means to a weigh batcher that measures the amounts of each material.

* Dry materials then flows into a stationary mixer where it's blended together for several minutes.

* A small amount of water is added to the mixer and the concrete is then mixed for a short time before it is ready to use.

Molding * Once the load of concrete is thoroughly mixed, it is conveyed to another hopper on top of the block machine at a measured flow rate. In the block machine, the concrete is forced downward into moulds. The mould, consist of an outer mold box containing the negative shapes of the product.

* This is where a deviation from the norm is made because of the unique shape of the invention a two stage method of moulding is needed.

* The rear plate of the mould is hinged to allow it to rotate outwards. This rotation of the plate opens up the rear of the mould above the foot area allowing the first stage of partial filling of conglomerate material to start. This allows the foot section to be filled before the mould is again rotated back into place with assistance of vibration, to ensure complete compression of the material of the foot and before any secondary filling is undertaken.

* This then triggers the secondary filling of the mould which completes the filling process.

* When the mold is full, the concrete is compacted by the weight of the upper mould press head coming down on the mold cavities producing a (CMU). Most block machines also use a short burst of mechanical vibration to further aid compaction.

* The compacted (CMU) blocks are held down by the press head while the outer part of the mould is lifted up first before the press head is also lifted. The finished product sits on either a flat steel or wooden pallet which acts as a pattern, having the positive impression of the recess built on it. The pallet and blocks are pushed out of the machine and onto a chain conveyor for removal. The product is semi-rigid at this stage and will except careful movement as it is transported to a curing area.

Curing * (CMU) blocks can be forced dried in a curing kiln.

* The kiln is an enclosed room with the capacity to hold several racks of blocks at a time. Steam is gradually introduced to raise the temperature at a controlled rate of not more than 60°F per hour (16°C per hour). When the curing temperature has been reached, the steam is shut off, and the blocks are allowed to soak in the hot, moist air for 12-18 hours. The whole curing cycle takes about 24 hours.

Cubing * Cured (CMU) blocks are removed from the kiln.

* If the blocks are to be made into split-face blocks, they are first molded as two blocks joined together. Once these double blocks are cured, they pass through a splitter, which strikes them with a heavy blade along the section between the two halves. This causes the double block to fracture and form a rough, stone-like texture on one face of each piece. Another method of adding a rough face to the blocks would be to simply add some kind of roughing device, ie course mesh, to the mould and as the mould is lifted on completion it would tear at the face of the block causing it to crumble and give the impression of a split block.

A second method that is quite satisfactory to produce a (CMU) is a two stage Wet Cast method. In this method a similar set up to what has already been described for the batching of the material is used.

Wet Cast

• The mixture is made much wetter and then fed into a mould that is sealed at the bottom instead of being hollow.

Moulding

• The mixture is vibrated while in the mould instead of being compressed by a press head, until most of the air has been released and the mixture compacted.

Cubing * When this stage is completed the mould is mechanically inverted and then raised up vertically leaving the product sitting on either the ground or a pallet. The product is usually stiff enough at this stage to support its self but not to be moved. One of the main drawbacks with this method is the large floor area needed to lay out the product for at least 24 hours.

Wet Press * A further suitable method of production of a (CMU) is that of the Wet Pressed system. And again a similar method of batching is employed but in this method a revolving table is used with three moulds at set at equal angles which are moved around in a circle creating three stages.

* The first stage mould is filled with a very wet mixture of mortar from a hopper above after first having a paper inserted into the bottom of the mould to filter the water.

* Then the table moves around to the second stage where a second paper filter is placed on top of the wet mixture and the press head is lowered onto the mould and is then compressed with a very large hydraulic ram with up to 400 tons of pressure. By this means water is driven out of the mould at the bottom through hundreds of tiny holes and drawn away by vacuum to leave a solid product.

* The press head is then withdrawn and the mould then rotated around to the third stage where it is pushed up from underneath the turn table and the finished product lifted away by a vacuum suction arm to be stacked. The product is strong enough to be handled and moved around with this method making it very useful for smaller sized factories where floor space is at a premium as the product needs no kiln drying simply kept dry for a few days to cure.

Most complete ways to use invention

[001] A preferred described embodiment is to use the present invention to retain and remodel landscapes and alter the topography of soil levels.

[002] A described embodiment is to use the present invention to form a circle, square or angled shape to form planter boxes, free standing garden walls or decorative dividing garden walls.

[003] A described embodiment is to use the present invention to form its own capping by inverted on the last course.

[004] A described embodiment is that the invention be set back 10mm on each course during construction and locked with a Stiffening Device at an angle, to create a lean back or battered retaining wall face for taller walls or more unstable soils, or having the foundation for the first course tilted at an angle towards the soil to be retained and the wall built as normal but with back filling after each course for added stability. This last described method will still give a smooth face for either rendering or left natural or coloured.

[005] A described embodiment is that the block be used as a concrete garden edging method by, either burying the foot in the ground to leave a thin edging upwards as a garden border or reversed or tilted, so that the edging has the flat side upwards and the bottom face buried in the ground to leave a flat wider garden edging and the holes simply filled with cement or the front face left at the top without the need to fill any holes. Either of these two other embodiment's could also be used as edging under fencing to prevent rotting of the bottom of the fence, or as an anti digging animal obstruction.

[006] A described embodiment is that the invention when inverted can be used to make steps in a retaining wall by laying two together as the tread and one high as the riser giving a step 200mm high by 500mm deep.

[007] A described embodiment is that the invention could, with slight modification to allow for conduit, be used to construct the walls of a building if the PVC pipe is substituted with re-bar which is included in the foundation pour, as the design would allow insulation to be inserted in the cavities created and offer a stable and robust outer finish which would need to be sealed on each course and could then be rendered if so desired and built by DIY.

[008] A described embodiment is that the holes at the top of a finished course can be used to fit fencing post and back filled with mortar to allow a fence to be constructed immediately the wall is completed.

[009] A described embodiment is that the invention could be made out of reclaimed rubber automobile tires that have been ground up and molded into the shape.

[010] A described embodiment is that the invention be used in a plurality of parallel rows as a crash barrier on roads and race tracks with a parallelogram structure angled at 45 degrees inserted into alternate blocks and allow movement of the structure diagonally to absorb impacts.

[011] The embodiment's described herein should not be considered exhaustive and any similar embodiment that does not detract from the spirit, scope and purpose of the invention which would be considered by reasonable assumption of the design should be assumed to be included.

Citation: US 3479782 A Construction block (brick)

US7645098B1 Thomas L. Rainey/ (Earth Reinforcement, Block with geomesh)

US6338597B1 Thomas L. Rainey

US8246275 Thomas L. Rainey

US7775747 B2 Timothy A Bott (block)

US6474036B2 James S. Martin (block)

US4874272 Phillip D Egan (Large cast cantileverwalls)

US6416260 Suheil Rashid Khamis (blocks with geo)

US4643618 William K. Hilfiker (cast cantilever)

US1762343 Andreas Munster (mechanical stabilized soil)

US4619560 Edward V. Crinnion (modular soil stabilize)

US4186540A Wayne L Mullins (block)

US3282054A Irving Saginor 1966 (T shaped wall block)

Claims (14)

1. Claims (16) The embodiment's of the invention in which an exclusive property or privilege is claimed are as follows:

   1 A modular block system for the purpose of constructing retaining walls comprising:

   a) a first shape block thereof being the full length block of rectangular shape, having a planar outer front face with a corresponding planar inner front face at a set distance apart and at the upper most edges give rise to an upper top face and having a bottom planar outer face with a corresponding bottom planar inner face at set distance apart and at the rear most edges give rise to a rear face and having vertical faces at each end and having protrusions located centrally and at either end that project rearward out from the inner front face and upward from the inner bottom face of suitable dimensions to offer adequate support as a platform for a plurality of blocks assembled above as a wall unit.

   b) a second shape block thereof being the half length block of rectangular shape, having a planar outer front face with a corresponding planar inner front face at a set distance apart and at the upper most edges give rise to an upper top face and having a bottom planar outer face with a corresponding bottom planar inner face at set distance apart and at the rear most edges give rise to a rear face and having vertical faces at each end and having protrusions located at either end that project rearward out from the inner front face and upward from the inner bottom face of suitable dimensions to offer adequate support as a platform for a plurality of blocks assembled above as a wall unit.

   c) a third shape block being the corner block having 4 planar outer faces at 90 degrees to each other respective and having corresponding planar inner faces at a set distance apart and at each outer and inner faces at their respective upper edges form an upper top face and at their respective bottom lower edges form a bottom face and having protrusions extending out from the inner face at two points 90 degrees respective to one another that exist from the upper most face thereof to the bottom most face thereof.
2. 2 As claimed in claim 1 a described embodiment wherein said protrusions having a cavity existing completely through from the upper most face thereof to the bottom most face thereof of suitable dimension to enable a Reinforcing Device (RD) to be inserted as required as the preferred embodiment for locking blocks together in the vertical plane when assembled in a plurality of blocks.
3. 3 As claimed in claim land claim 2 wherein the cavities of said protrusions are open at the ends faces of each block.
4. 4 As claimed in claim 1 each shape block having a spigot extending up from a protrusion and apposing recess extending into a protrusion for accepting a spigot, and each block having at its bottom outer face a recess running the length of the block positioned to accept a spigot.
5. As claimed in claim 1 and claim 3 a further embodiment wherein when the described blocks are laid with set back on the front face of each course a smaller reinforcing device (RD) may be inserted into the cavities at an angle in the protrusions and filled with concrete.
6. 6 As claimed in claim 1 a further embodiment wherein a hole is excavated beneath the first course of described blocks in line with cavities of several alternating blocks and dug to a depth equal to the finished height of the wall to be constructed and either a reinforcing device (RD) inserted into the hole and filled with concrete and re-bar or re-bar inserted and filled with concrete offering a method of forming an enclosed reinforced post support system throughout a plurality of said blocks cavities.
7. 7 As claimed in claim 1 a further embodiment wherein the described blocks can be manufactured at a different scales.
8. 8 As claimed in claim 1 a further embodiment wherein the described blocks are manufactured in a suitable process acceptable for mass producing masonry blocks.
9. 9 As claimed in claim 1 a further embodiment wherein the described blocks are manufactured from reclaimed automotive tire chips for use as an automotive crash barrier.
10. As claimed in claim 1 a described embodiment wherein the described blocks are manufactured from any suitable material.
11. 11 As claimed in claim 1 a further embodiment wherein the described blocks be inverted to form the capping on the last course of a constructed wall.
12. 12 As claimed in claim 1 a described embodiment wherein a plurality of said blocks be constructed in parallel to form two walls at a set distance apart being fitted with steel arm mechanisms placed at intervals into said cavities of corresponding walls and angled at 45 degrees so as to create a parallelogram for dissipating energy when used as an automotive crash barrier or aggressive vehicle mitigation system.
13. 13 As claimed in claim 1 a described embodiment wherein the cavities of the described blocks can be fitted with solar lights for illumination.
14. 14 As claimed in claim 1 a further embodiment wherein the face of said blocks be coloured and/or textured as desired during manufacture.

    As claimed in claim 1 a further embodiment of producing the invention in a two stage press system where the back mould plate being initially rotated away from the pressing mode plane during partial filling of mould rotates back to the plane required for compressing the material of the foot of the block before the head press is engaged.

    While the invention has been shown and described with particular reference to preferred embodiment's it will be understood by those skilled in the art that various changes in details may be made without departing from the spirit and scope of the invention.

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