Retaining wall block system and method with varying block face sizes

• US 6,447,213 B1
• Filed: 08/31/2000
• Issued: 09/10/2002
• Est. Priority Date: 02/11/1999
• Status: Expired due to Term

• Current Assignee: Keystone Retaining Wall Systems Incorporated (THE QUIKRETE Cos. LLC)
• Original Assignee: Keystone Retaining Wall Systems Incorporated (THE QUIKRETE Cos. LLC)
• Inventors: MacDonald, Robert A.
• Primary Examiner(s): Shackelford, Heather
• Assistant Examiner(s): LEE, JONG SUK
• Application Number:
  US09/652,566
• Time in Patent Office: 740 Days
• Field of Search: 405/284, 405/285, 405/286, 525/96, 526/03, 526/04, 526/06, 526/08, 526/09, 526/10, 526/12, 527/471.2, 404/40, 404/41
• US Class Current: 405/284
• CPC Class Codes: E02D 29/0266 made up of preformed elements
• CPC Class Codes: E04B 2002/0245 Pegs or pins
• CPC Class Codes: E04B 2002/0265 Building elements for making arcuate walls
• CPC Class Codes: E04C 1/395 for claustra, fences, planting walls, e.g. sound-absorbing pots for vertical horticulture A01G9/022

Abstract

A retaining wall block system is described. The block system includes blocks of different sizes that are configured to be compatible with each other in the construction of a retaining wall or free-standing wall. Each block has at least three faces which are textured to produce the appearance of natural stone. The faces have varying sizes based on variations in width.

Claims

1. A wall block for use in forming a wall from multiple wall blocks, the wall having a front surface and a rear surface, the wall block comprising:

an upper surface spaced apart from a substantially parallel lower surface, thereby defining a block thickness,

opposed and substantially parallel first and second faces, the first face having an area greater than the second face;

opposed and non-parallel side surfaces, the first and second faces being orthogonal to one of the side surfaces, the first and second faces together with the upper, lower and side surfaces forming a block body;

the first face, the second face and at least one side surface being textured in a manner resulting in the appearance of natural stone; and

wherein the block body is configured such that when the wall is constructed from the blocks, the front surface of the wall is formed of the first faces of a portion of the multiple wall blocks and the second faces of others of the multiple wall blocks.

2. The wall block of claim 1 wherein the upper surface has first, second, and third pin receiving apt aligned along first second, and third axes which are substantially perpendicular to the upper and lower sits, the third pin receiving aperture being substantially equidistant between the first and second faces, the first pin receiving aperture being between the first face and the third pin receiving aperture and the second pin receiving aperture being between the second face and the third pin receiving aperture, the first, second, and third pin receiving apertures being arranged in a row perpendicular to the first and second faces.

3. The wall block of claim 2 wherein the first and second pin receiving apertures are equidistant from the third pin receiving aperture.

4. The wall block of claim 1 wherein the lower surface of the block comprises a channel that is parallel to and equidistant from the first and second faces.

5. The wall block of claim 1 wherein the block comprises a core extending the thickness of the block.

6. A wall block system having at least three blocks, multiples of the three blocks being suitable for use in constructing a wall from multiple courses of the blocks stacked one upon the other, the wall having a front surface with an irregular block pattern, the wall block system comprising:

first, second, and third blocks, each block having a thickness, width and length, the width of each block being different;

each block having an upper surface spaced apart from a substantially parallel lower surface, thereby defining a block thickness;

each block having opposed and substantially parallel first and second faces, thereby defining the block length, the area of the first face being greater than the area of the second face;

each block having opposed and non-parallel side surfaces, thereby defining the block width;

the first face, the second face, and at least one side surface being textured in a manner resulting in the appearance of natural stone; and

the first, second, and third blocks being configured such that they are capable of being positioned when constructing the wall such that the front surface of the wall is comprised of the first faces of a plurality of the first, second, and third blocks and the second faces of a plurality of the first, second, and third blocks to thereby provide a front wall surface having the irregular block pattern.

7. The wall block system of claim 6 wherein the first and second faces of the block arm orthogonal to one of the side surfaces.

8. The wall block system of claim 6 wherein the upper surface of each of the three blocks has first, second, and third pin receiving apertures aligned along firs, second, and third axes which are substantially perpendicular to the upper and lower surfaces, the third pin receiving aperture being substantially equidistant between the first and second faces, the first pin receiving aperture being between the first face and the third pin receiving aperture and the second pin receiving aperture being between the second face and the third pin receiving aperture, the first, second, and third pin receiving apertures being arranged in a row perpendicular to the first and second faces.

9. The wall block system of claim 8 wherein the lower surface of the block comprises a channel that is parallel to and equidistant from the first and second faces, the wall block system further comprising a plurality of pins, each pin having a head portion and a body portion, the pins being configured such that when the wall is constructed from the wall block system, the head portion is configured to be received within the channel of the lower surface of a block in a first course of the wall and the body portion is configured to be received in one of the pin receiving apertures of the second block in a next lower course of the wall.

10. The wall block system of claim 9 wherein, when no setback between the courses is desired, the body portion of the pin is configured to be received in the third pin receiving aperture.

11. The wall block system of claim 9 wherein, when setback between courses of the wall is desired, the body portion of the pin is configured to be received in the second pin receiving aperture of the second block where the second block is positioned such that its first face is part of the front surface of the wall and in the first pin receiving aperture of the second block where the second block is positioned such that its second face is part of the front surface of the wall.

12. The wall block system of claim 8 wherein the first and second pin receiving apertures are equidistant from the third pin receiving aperture.

13. The wall block system of claim 6 wherein the lower surface of the block comprises a channel that is parallel to and equidistant from the first and second faces.

14. The wall block system of claim 6 wherein the block compries a core extending the thickness of the block.

15. A wall having a front surface and a rear surface, the wall comprising:

at least a first lower course and a second upper course, each course comprising a plurality of first, second, and third blocks;

each block having an upper surface spaced apart from a substantially parallel lower surface, thereby defining a block thickness;

each block having opposed and substantially parallel first and second faces, thereby defining a block length, the area of the first face being greater than the area of the second face;

each block having opposed and non-parallel side surfaces, thereby defining a block width, the width of the first, second, and third blocks being different;

the first face, the second face, and at least one side surface being textured in a manner resulting in the appearance of natural stone; and

the blocks being positioned in the courses such that the front surface of the wall is comprised of the first faces of a plurality of the first, second, and third blocks and of the second of a plurality faces of the first, second, and third blocks to thereby provide an irregular block pattern.

16. The wall of claim 15 wherein the upper surface of each block has first, second, and third pin receiving apertures aligned along first, second, and third axes which are substantially perpendicular to the upper and lower surfaces, the third pin receiving aperture being substantially equidistant between the first and second faces, the first pin receiving aperture being between the first face and the third pin receiving aperture and the second pin receiving aperture being between the second face and the third pin receiving aperture, the first, second, and third pin receiving apertures being arranged in a row perpendicular to the first and second faces.

17. The wall of claim 16 wherein the first and second pin receiving apertures are equidistant from the third pin receiving aperture.

18. The wall of claim 16 further comprising a plurality of pins, each pin having a head portion and a body portion, the head portion being configured to be received within the channel of the lower surface of the block in a first course of the wall and the body portion being configured to be received in a pin receiving aperture of the second block in a next lower course of the wall.

19. The wall of claim 18 wherein the front surface of the wall is substantially vertical and wherein the body portion of the pin is configured to be received in the third pin receiving aperture.

20. The wall of claim 18 wherein the second course is setback from the first course and wherein the body portion of the pin is configured to be received in the second pin receiving aperture of the second block when the second block is positioned such that its first face is part of the front surface of the wall and in the first pin receiving aperture of the second block when the second block is positioned such that its second face is part of the front surface of the wall.

21. The wall of claim 15 wherein the lower surplice of the block comprises a channel that is parallel to and equidistant from the first and second faces.

22. The wall of claim 15 wherein the block comprises a core extending the thickness of the block.

23. A wall block for use in forming a wall from multiple wall blocks, the wall having a front surface and a rear surface, the wall block comprising:

an upper surface spaced apart from a substantially parallel lower surface, thereby defining a block thickness, the upper surface having first, second, and third pin receiving apertures aligned along first, second, and third axes which are substantially perpendicular to the upper and lower surfaces, the third pin receiving aperture being substantially equidistant between the first and second faces, the first pin receiving aperture being between the first face and the third pin receiving aperture and the second pin receiving aperture being between the second face and the third pin receiving aperture, the first, second, and third pin receiving apertures being arranged in a row perpendicular to the first and second faces;

opposed and substantially parallel first and second faces;

opposed and non-parallel side surfaces, the first and second faces together with the upper, lower and side surfaces forming a block body; and

wherein the block body is configured such that when the wall is formed from the wall block, the front surface of the wall is formed of the first faces of a portion of the multiple wall blocks and the second faces of others of the multiple wall blocks.

24. The wall block of claim 23 wherein the first fee of the block has an alma greater team the second face of the block.

25. The wall block of claim 23 wherein the first face, the second face, and at least one side surface are textured in a manner resulting in the a be of natural stone.

26. The wall block of claim 23 wherein the first and second feces are orthogonal to one of the side surfaces.

27. The wall block of claim 23 wherein the lower surface of the block comprises a channel that is parallel to the first and second faces.

28. The wall block of claim 23 wherein the block comprises a core extending the thickness of the block.

29. A method for constructing a wall from wall blocks laid in multiple courses, one upon the other, such that the wall has a front surface with an irregular block pattern, the method comprising:

providing wall blocks, each of the wall blocks having an upper surface spaced apart from a substantially parallel lower surface, thereby defining a block thickness opposed and substantially parallel first and second faces, the first face having an area greater than the second face, opposed and non-parallel side surfaces, the first and second faces being orthogonal to one of the side surfaces, the first and second faces together with the upper, lower and side surfaces forming a block body, the first face, the second face, and at least one side surface being textured in a manner resulting in the appearance of natural stone; and

laying the wall blocks in a first course of the wall and a second course of the wall such that the front surface of the wall is formed of the first faces of a plurality of the wall blocks and the second faces of a plurality of the wall blocks.

30. The method of claim 29 wherein the step of providing the wall blocks includes providing blocks having an attachment system allowing blocks in one course to be attached to blocks in the next lower course.

31. The method of claim 30 further comprising attaching the wall blocks in the second course to the wall blocks in the first course in a manner that results in construction of a substantially vertical wall.

32. The method of claim 30 further comprising attaching the blocks in the second course to the blocks in the first course in a manner that results in a wall having a front surface which is angled from the vertical.

33. A method for constructing a wall from blocks laid in multiple courses, one upon the other, such that the wall has a front surface with an irregular block pattern, the method comprising:

providing a wall block system which includes the blocks of at least three sizes including first, second, and third blocks, each block having a thickness, width and length, the width of each block being different, each block having an upper surface spaced apart from a substantially parallel lower surface, thereby defining the block thickness, each block having opposed and substantially parallel first and second faces, thereby defining the block length, the area of the first face being greater than the area of the second face, each block having opposed and non-parallel side surfaces, thereby defining the block width, the first face, the second face, and at least one side surface of each block being textured in a manner resulting in the appearance of natural stone; and

laying the first, second, and third blocks in the first and second courses such that the front surface of the wall is comprised of the first faces of a plurality of the first, second, and third blocks and the second faces of a plurality of the first, second, and third blocks to thereby provide a front wall surface having the irregular block pattern.

34. The method of claim 33 wherein the step of providing the wall block system includes providing blocks having an attachment system allowing the blocks in one course to be attached to the blocks in the next lower course.

35. The method of claim 34 further comprising attaching the blocks in the second course to the blocks in the first course in a manner that results in construction of a substantially vertical wall.

36. The method of claim 34 further comprising attaching the blocks in few second course to the blocks in the first course in a manner that results in construction of a wall having a front surface which is angled from the vertical.

37. A wall block for use in forming a wall from multiple wall blocks, the wall having a front surface and a rear surface, the wall block comprising:

an upper surface spaced apart from a substantially parallel lower surface, thereby defining a block thickness, the upper surface having at least two pin receiving apertures;

opposed and substantially parallel first and second faces, the first face having an area greater than the second face;

opposed and non-parallel side surfaces, the first and second faces being orthogonal to one of the side surfaces, the first and second faces together with the upper, lower and side surfaces forming a block body; and

wherein the block body is configured such that when the wall is constructed from the blocks, the front surface of the wall is formed of the first faces of a portion of the multiple wall blocks and the second faces of others of the multiple wall blocks.

38. A wall block system having at least three blocks, multiples of the three blocks being suitable for use in constructing a wall from multiple courses of the blocks stacked one upon the other, the wall having a front surface with an irregular block pattern, the wall block system comprising:

first, second, and third blocks, each block having a thickness, width and length, the width of each block being different;

each block having an upper surface spaced apart from a substantially parallel lower surface, thereby defining a block thickness, the upper surface having at least two pin receiving apertures aligned substantially perpendicular to the upper and lower surfaces;

each block having opposed and substantially parallel first and second faces, thereby defining the block length, the area of the first face being greater than the area of the second face;

each block having opposed and non-parallel side surfaces, thereby defining the block width; and

the first, second, and third blocks being configured such that they are capable of being positioned when constructing the wall such that the front surface of the wall is comprised of the first faces of a plurality of the first, second, and third blocks and the second faces of a plurality of the first, second, and third blocks to thereby provide a front wall surface having the irregular block pattern.

39. A wall having a front surface and a rear surface, the wall comprising:

at least a first lower course and a second upper course, each course comprising a plurality of first, second, and third blocks;

each block having an upper surface spaced apart from a substantially parallel lower surface, thereby defining a block thickness, the upper surface having at least two pin receiving apertures aligned substantially perpendicular to the upper and lower surfaces;

each block having opposed and substantially parallel first and second faces, thereby defining a block length, the area of the first face being greater than the area of the second face;

each block having opposed and non-parallel side surfaces, thereby defining a block width, the width of the first, second, and third blocks being different; and

the blocks being positioned in the courses such that the front surface of the wall is comprised of the first faces of a plurality of the first, second, and third blocks and a plurality of the second faces of a plurality of the first, second, and third blocks to thereby provide an irregular block pattern.

40. A method for constructing a wall from wall blocks laid in multiple courses, one upon the other, such that the wall has a front surface with an irregular block pattern, the method comprising:

providing wall blocks, each of the wall blocks having an upper surface spaced apart from a substantially parallel lower surface, thereby defining a block thickness, the upper surface having at least two pin receiving apertures aligned substantially perpendicular to the upper and lower surfaces, the at least two apertures permitting attachment of the wall blocks in one course to the wall blocks in the next lower course;

opposed and substantially parallel first and second faces, the first face having an area greater than the second face, opposed and non-parallel side surfaces, the first and second faces being orthogonal to one of the side surfaces, the first and second faces together with the upper, lower and side surfaces forming a block body; and

laying the wall blocks in a first course of the wall and a second course of the wall such that the front surface of the wall is formed of the first faces of a plurality of the wall blocks and the second faces of a plurality of the wall blocks.

41. A method for constructing a wall from blocks laid in multiple courses, one upon the other, such that the wall has a front surface with an irregular block pattern, the method comprising:

providing a wall block system which includes the blocks of at least three sizes including first, second, and third blocks, each block having a thickness, width and length, the width of each wall block being different, each wall block having an upper surface spaced apart from a substantially parallel lower surface, thereby defining the block thickness, the upper surface having at least two pin receiving apertures aligned substantially perpendicular to the upper and lower surfaces, the at least two apertures permitting attachment of the wall blocks in one course to the wall blocks in the next lower course;

each wall block having opposed and substantially parallel first and second faces, thereby defining the block length, the area of the first face being greater than the area of the second face, each wall block having opposed and non-parallel side surfaces, thereby defining the wall block width; and

laying the first, second, and third wall blocks in the first and second courses such that the front surface of the wall is comprised of the first faces of a plurality of the first, second, and third wall blocks and the second faces of a plurality of the first, second, and third wall blocks to thereby provide a front wall surface having the irregular block pattern.