Masonry block retaining wall with attached keylock facing panels and method of constructing the same

• US 5,788,423 A
• Filed: 08/09/1995
• Issued: 08/04/1998
• Est. Priority Date: 09/08/1995
• Status: Expired due to Fees

• Current Assignee: Surebond, Inc.
• Original Assignee: GP Industries (Linde Plc)
• Inventors: Perkins, Garry R.
• Primary Examiner(s): Graysay, Tamara L.
• Assistant Examiner(s): MAYO-PINNOCK, TARA LEIGH
• Application Number:
  US08/524,202
• Time in Patent Office: 1,091 Days
• Field of Search: 405/284, 405/286, 52/570, 52/426, 52/599, 52/604, 52/605, 52/606, 52/612, 52/311.1
• US Class Current: 405/284
• CPC Class Codes: E02D 29/025 made up of similar modular elements stacked without mortar
• CPC Class Codes: E04B 2002/0252 Dovetail keys
• CPC Class Codes: E04B 2002/0269 Building elements with a natural stone facing
• CPC Class Codes: E04C 1/395 for claustra, fences, planting walls, e.g. sound-absorbing pots for vertical horticulture A01G9/022

Abstract

An inexpensive, yet beautiful retaining wall may be formed with architecturally pleasing, coordinating or matching materials such as marble, granite or the like. Architecturally pleasing, thin decorative facing panels are attached to masonry blocks. The retaining wall is formed from several rows of such masonry blocks with the blocks each including a top edge and a bottom edge and a front face having a masonry appearance extending between the top and bottom edges. The blocks in an upper row are stacked upon the blocks in an adjacent lower row below the upper row, with the bottom edges of the upper row blocks supported on adjacent lower row blocks. Decorative facing panels are provided which are substantially smaller in size than the masonry blocks and include a rear face attached to the front face of the masonry blocks to change the outward appearance of the front faces of the masonry blocks. A keyway and key are formed in the front faces of the blocks and rear faces of the decorative facing panels for mounting the decorative facing panels flush against the front faces of the blocks.

Claims

1. An outside masonry retaining wall for retaining earth and made with an outer decorative surface other than the masonry of the wall, comprising:

a plurality of rows of masonry blocks for retaining the earth and with the blocks each including a top edge and a bottom edge and a front face being made from a masonry material and having a masonry appearance extending between the top edge and the bottom edge, the blocks in an upper row being stacked upon the blocks in an adjacent lower row below the upper row with the bottom edges of the upper row blocks supported on adjacent lower row blocks;

the masonry blocks each having a unitary body formed with an integral front portion having the front face for facing outwardly toward the front of the retaining wall and having an exposed masonry surface;

the adjacent front portions of adjacent masonry blocks forming the front of the retaining wall;

a rearwardly extending web portion integrally joined to the integral front portion of each the unitary masonry blocks and extending rearwardly therefrom;

a rear leg portion integrally joined to the web portion and being spaced from the front portion by hollow spaces in each masonry block;

discrete and separate decorative facing panels substantially smaller in size than the masonry blocks and made of a decorative material selected from marble, granite, glass, tile or metal and having rear faces attached to the front faces of the masonry blocks to cover the exposed masonry surfaces of the front faces of the masonry blocks and to change the outward appearance of the front faces of the masonry blocks;

the decorative facing panels being made of different material than the masonry block material;

the decorative panels being substantially thinner in thickness than the blocks forming the retaining wall; and

a keyway and key connection being formed in each the front faces of the blocks and rear faces of the decorative facing panels for mounting the decorative facing panels, respectively, flush against the front faces of the blocks to cover the masonry front faces of the masonry blocks to provide the outer decorative surface for the retaining wall.

2. The retaining wall of claim 1 wherein the keyway connection comprises a vertical keyway extending between the top and bottom edges of each of the blocks.

3. The retaining wall of claim 1 wherein the keyway connection comprises a plurality of keyways formed in each of the front faces of the blocks.

4. The retaining wall of claim 1 wherein the blocks each have a back face and a keyway is formed in the back faces of the blocks for mounting facing panels flush against the back faces of the blocks.

5. The retaining wall of claim 1 wherein the blocks are made from a concrete material.

6. The retaining wall of claim 1 wherein the facing panels have tongue keys which are sized to fit into the keyways on the blocks;

and

an adhesive is applied between the facing panels and the front faces of the blocks to secure the panels to their corresponding blocks.

7. A retaining wall comprising:

a plurality of rows of masonry blocks with the blocks each including a top edge and a bottom edge and a front face having a masonry appearance extending between the top edge and the bottom edge and the blocks in an upper row being stacked upon the blocks in an adjacent lower row below the upper row with the bottom edges of the upper row blocks supported on adjacent lower row blocks;

decorative facing panels substantially smaller in size than the masonry blocks having a rear face attached to the front face of each the masonry blocks to change the outward appearance of the front faces of the masonry blocks;

a keyway and key formed in the front faces of the blocks and rear faces of the decorative facing panels for mounting the decorative facing panels flush against the front faces of the blocks; and

the blocks each include a top and a bottom with the bottom of the blocks each having a tab protruding therefrom and the blocks being configured to form openings between adjacent blocks in a row such that with the tabs of the upper blocks inserted in the openings between corresponding lower blocks the tabs and openings cooperate to substantially fix the stacked blocks in adjacent upper and lower rows in offset relation to each other.

8. A method for forming a masonry retaining wall for retaining earth and having an outer decorative surface providing an appearance of being other than being made of masonry material, the method comprising the steps of:

providing a plurality of masonry blocks made of masonry material having keyways with a first cross-sectional shape formed in their faces;

providing masonry blocks each having a unitary body formed with an integral front portion having the front face, the adjacent front portions of adjacent masonry blocks forming the front of the retaining wall, a rearwardly extending web portion integrally joined to the integral front portion of each the unitary masonry blocks and extending rearwardly therefrom, a rear leg portion integrally joined to the web portion and being spaced from the front portion by hollow spaces in each masonry block;

providing a plurality of decorative facing panels having elongate locating members with a second cross-sectional shape substantially the same as the first cross-sectional shape of the keyways, the decorative facing panels being made of different material than the masonry block material and made of a decorative material, the decorative panels being substantially thinner in thickness than the front block portions forming the outer sides of the retaining wall;

stacking the blocks in rows with each row being set upon the row below it to form a wall having a front side with outwardly exposed, front side, masonry surfaces and offsetting the masonry blocks in rows with each row offset from the row below it to engage and support a portion of a decorative panel on a masonry block thereabove; and

after forming the masonry retaining wall, covering the outwardly exposed, front side, masonry surfaces of the masonry blocks by attaching the decorative facing panels to the blocks by sliding the locating members of the facing panels down into the keyways of the blocks; and

resting portions of each lower edge of the decorative facing panel on portions of the offset block below it with the decorative panels flush against the front faces of the blocks to which they are attached to provide the previously formed masonry wall with the outer appearance of the decorative material of the decorative panels.

9. The method of claim 8 wherein the step of attaching the decorative facing panels further includes the step of applying adhesive to the blocks to fix the decorative facing panels to the blocks.

10. A method for forming a retaining wall, the method comprising the steps of:

providing a plurality of masonry blocks having keyways with a first cross-sectional shape formed in their faces;

providing a plurality of decorative facing panels having elongate locating members with a second cross-sectional shape substantially the same as the first cross-sectional shape of the keyways;

stacking the blocks in offset rows with each row being set back from the row below it; and

attaching the decorative facing panels to the blocks by sliding the locating members of the facing panels down into the keyways of the blocks so that the facing panels rest on the blocks below it and are flush against the blocks to which they are attached;

the blocks being provided with tabs and the step of stacking the blocks in offset rows includes the inserting of the tabs in openings formed between adjacent blocks immediately therebelow to produce a uniform set back from one row to the next.

11. A decorative retaining wall block for earth having an appearance on a front exterior side thereof of being other than being made of masonry material comprising:

a body made of a masonry material having the appearance of a masonry product on a front face of the block;

a first portion of a keyway interlock on the front face of the masonry body adjacent the front exterior side of the block;

a discrete-and separate decorative facing panel substantially smaller in size than the masonry body and made of a decorative material selected from marble, granite, glass, tile, or metal and attached to the front face of the masonry product to cover the exposed surface of the front face of the masonry body to change the outward face appearance of the block;

a second portion of the keyway interlock on the decorative facing panel to interlock the decorative facing panel to the masonry body;

the masonry block having a unitary body formed with an integral front portion having the front face for facing outwardly to the front of the retaining wall and having an exposed masonry surface until covered by the decorative facing panel;

a rearwardly extending web portion integrally joined to the integral front portion and extending rearwardly therefrom;

a rear leg portion integrally joined to the web portion and being spaced from the front portion by hollow spaces in the masonry block;

the decorative facing panel being made of different material than the masonry body material; and

the decorative panel being substantially thinner in thickness than the block body.

12. The decorative retaining wall block of claim 11 wherein the first portion comprises an elongate keyway having a first cross-sectional shape and the second portion includes a tongue key having a second cross-sectional shape substantially the same as the first cross-sectional shape of the keyway.

13. The decorative retaining wall block of claim 12 wherein the keyway and key have complementary trapezoidal cross-sectional shapes.

14. A decorative retaining wall block comprising:

a body made of a masonry material having the appearance of a masonry product on a front face of the block;

a first portion of a keyway interlock on the front face of the masonry block;

a decorative facing panel substantially smaller in size than the masonry body attached to the front face of the masonry product to change the outward face appearance of the block;

a second portion of the keyway interlock on the decorative facing panel to interlock the decorative facing panel to the masonry body; and

the block body having an H-shape in cross-section defined by a pair of spaced elongate legs spanned by an intermediate web with the block face and interlock first portion on at least one of the spaced legs, the web and one of the legs including a tab protruding from the bottom thereof which fits in openings formed between blocks immediately therebelow in a retaining wall with the ends of said legs abutting each other such that with blocks stacked in rows the tabs uniformly set back the blocks in one row from the row therebelow.