US20080095584A1

US20080095584A1 - Natural stone simulated surface retaining wall systems

Info

Publication number: US20080095584A1
Application number: US11/964,385
Authority: US
Inventors: Todd Strand; Peter Stroh
Original assignee: Kiltie Corp
Current assignee: Kiltie Corp
Priority date: 2006-04-24
Filing date: 2007-12-26
Publication date: 2008-04-24

Abstract

A mortar-less retaining wall apparatus is built from of a plurality of masonry blocks, each masonry block having four side walls and two end walls, two or more masonry blocks being abutted on respective side walls, at least one of the end walls of each masonry block having a split texture surface and a plurality of recesses creating a natural stone simulated surface. One or more of the masonry blocks each has a side wall that tapers from one end wall to the other end wall, thus allowing either straight or curved walls to be built by changing the relative orientation of the tapers of adjoining blocks.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No. 11/409,669, filed Apr. 24, 2006, entitled RETAINING WALL SYSTEMS, which is co-pending. Priority is claimed thereto, and the content thereof is hereby incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates to segmented retaining wall systems for soil retention or other environmental or aesthetic uses. In particular, the invention relates to retaining wall systems using masonry blocks to create modules resulting in a random appearance of the face of a retaining wall. While the application primarily is described as a retaining wall, it can also be used as a freestanding seat wall, courtyard garden wall, garden borders and edging, low fencing walls and also as a retaining wall for low wall applications.
Segmented retaining wall systems are commonly used for residential, commercial and government projects. Transportation departments and the U.S. Army Corps of Engineers routinely use retaining wall systems to retain soil and other structures. These systems can create straight or curved walls and can even be used along shore lines where embankment control is desired.
Segmented retaining wall systems can be comprised of poured slabs, bricks, natural stone, masonry blocks or other components. Individual units can be held together by mortar, other adhesives, gravity, pins, or other fasteners.
Uniform bricks or masonry blocks can provide a stable, durable and attractive retaining wall. However, these walls tend to have a very homogenous and uniform appearance that may not be suitable for every project. Sometimes a more unique randomized retaining wall or landscape is desired.
Natural stone can be used to provide a unique random appearance to a landscape. However, without the use of mortar or some other adhesive/sealant, natural stone retaining walls have poor soil retention properties. Additionally, natural stone retaining walls are expensive and cumbersome to construct. It is therefore desired to create a retaining wall system that maintains the unique random look of a natural stone wall surface with the structural and soil retention properties, as well as the economic efficiencies, of man-made masonry block walls. It is also desired to create a retaining wall system without using mortar.
Working with masonry blocks of different sizes affects the securing methods typically used during construction. A mortar-less wall that uses pins to secure masonry blocks would require numerous pins of different sizes corresponding to the size of the particular masonry block. Installers have the burden of keeping track of the appropriate pins and using them accordingly. It is desirable to have a pin-less method or apparatus that could be used with different sized masonry blocks.

SUMMARY OF THE INVENTION

A mortar-less retaining wall apparatus having a unique random quality of a natural stone wall surface is built from of a plurality of masonry blocks, each masonry block having four side walls and two end walls, two or more masonry blocks being abutted on respective side walls, and at least one of the end walls of each masonry block having a split texture surface and a plurality of recesses creating a natural stone simulated portion. One or more of the masonry blocks each has a side wall that tapers from one end wall to the other end wall, thus allowing either straight or curved walls to be built by changing the relative orientation of the tapers of adjoining blocks.
An object and advantage of the present invention is that no mortar is needed to construct the wall, the blocks being held together by adhesive.

BRIEF DESCRIPTION OF DRAWINGS

FIGS. 1 a, 2 a, 3 a, and 4 a are perspective views of masonry blocks of the present invention.
FIGS. 1 b, 2 b, 3 b, and 4 b are end views of masonry blocks of the present invention.
FIGS. 1 c, 2 c, 3 c, and 4 c are plan views of masonry blocks of the present invention.
FIGS. 1 d, 2 d, 3 d, and 4 d are opposite end views of masonry blocks of the present invention.
FIG. 5 is an elevational view of a retaining wall constructed from the masonry blocks.
FIGS. 6 a, 6 d; 7 a, 7 d; 8 a, 8 d; and 9 a, 9 d are elevational views of a panel constructed from the masonry blocks, showing each side of the panel.
FIGS. 6 c, 7 c , 8 c, and 9 c are plan views of the top course of two courses of masonry blocks in the panels.
FIGS. 6 b, 7 b, 8 b, and 9 b are cross-sections through the assembled panel taken at the indicated lines.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is shown in the drawings by reference numeral 10.
The mortar-less retaining wall apparatus 10 (best seen in FIG. 5) comprises a plurality of masonry blocks 12. As best seen in FIGS. 1 a-1 c, 2 a-2 c, 3 a-3 c, and 4 a-4 c, each masonry block 12 has four side walls 14 and two end walls 16. Two or more of the masonry blocks 12 are abutted on respective side walls 14. At least one of the end walls of each masonry block having a split texture surface and a plurality of recesses creating a natural stone simulated surface 18. The simulated surface 18 in the finished wall (FIG. 5) gives the appearance of a natural stone retaining wall without the use of mortar. It is preferred that each of the two end walls 16 have a natural stone simulated surface 18.
As best seen in the drawings, the end walls 16 are preferably generally quadrilateral in shape.
As best seen if FIGS. 1 c, 2 c, and 3 c, one or more of the masonry blocks 12 has a side wall 14 a that tapers from one end wall 16 to the other end wall 16. One of the blocks, as shown in FIG. 3 c, has two tapering side walls 14 a, 14 b.
As shown in FIG. 6 a and 6 b, two of the masonry blocks 12 with tapered sides 14 a can be abutted along the tapered sides, with the tapered sides having opposed tapers, to create a straight wall.
Alternatively, as seen in FIGS. 7 a and 7 b, two of the masonry blocks 12 with tapered sides 14 a can be abutted along the tapered sides, with the tapered sides having matched tapers, to form a curved wall.
FIGS. 1 a-1 d, 2 a-2 d, 3 a-3 d, and 4 a-4 d show four different types of masonry blocks 12 used in the present invention. Three of the four types (FIGS. 1 a-1 d, 2 a-2 d, and 3 a-3 d have a first height H1 (height being defined as the dimension of the masonry block that, when laid in the wall 10, is substantially perpendicular to the top 11 of the wall 10). The fourth masonry block (FIGS. 4 a-4 d) has a second height H2 twice that of the first height H1 (the block shown in FIGS. 4 a-4 d would be rotated 90 degrees clockwise or counterclockwise for insertion in the wall 10). See FIG. 5.
Looking at FIG. 7 a as an example, the apparatus may further comprise a panel 30 of two rows 32, 34 of blocks. Each of the two rows has blocks S and M, for example, of the first height H1 and an end block V of the second height H2. It will be appreciated that many different combinations of the masonry blocks may be used to form such panels 30, as illustrated, without exclusion, in FIGS. 8 a-8 d and 9 a-9 d. For example, as shown in FIG. 5, larger panels using six blocks per panel between vertical units is one combination. Another combination, not shown, uses four blocks per panel between vertical units. Yet, another combination, not shown, is a running bond using small, medium and large blocks only.
Use of various panels can create a random appearance using natural stone simulated surface as shown in FIG. 5. The user can flip and re-position the blocks to place the natural stone simulated surface in different orientations to further generate a natural stone appearance of randomness. This advantage is even more pronounced when both end walls of the block have natural stone simulated surfaces, thereby providing greater variability. Also, the radius of curved walls can be varied depending on the use of the particular blocks, as can be seen by comparing FIGS. 7 c, 8 c, and 9 c. It may be necessary to split or cut various blocks to obtain the desired radius for a curved wall.
The various blocks are attached to each other by adhesive. The appropriate types of adhesive are known to one of skill in the art. For example, Versa-Lok® brand of Concrete Adhesive, trademark owned by Kiltie Corporation, Oakdale, Minn., can be used to attach the blocks, and is a preferred adhesive. Versa-Lok® Concrete Adhesive remains flexible and retains its adhesive properties to tolerate minor earth movement.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar to or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety to the extent allowed by applicable law and regulations. In case of conflict, the present specification, including definitions, will control.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.

Claims

1. A mortar-less retaining wall apparatus, comprised of a plurality of masonry blocks, each masonry block having four side walls and two end walls, two or more masonry blocks being abutted on respective side walls, and at least one of the end walls of each masonry block having a split texture surface and a plurality of recesses creating a natural stone simulated surface.

2. The apparatus of claim 1, wherein the two end walls of each masonry block having a natural stone simulated surface.

3. The apparatus of claim 2, wherein the two end walls are generally quadrilateral in shape.

4. The apparatus of claim 1, wherein one or more of the masonry blocks each has a side wall that tapers from one end wall to the other end wall.

5. The apparatus of claim 4, wherein two of the masonry blocks with tapered side walls are abutted along the tapered sides, with the tapered sides having opposed tapers, thereby forming a straight wall.

6. The apparatus of claim 4, wherein two of the masonry blocks with tapered side walls are abutted along the tapered sides, with the tapered sides having matched tapers, thereby forming a curved wall.

7. The apparatus of claim 1, further comprising masonry blocks of four different types.

8. The apparatus of claim 7, wherein three of the four types each has a first height and the fourth type has a second height twice that of the first height.

9. The apparatus of claim 8, further comprising a panel of two rows of blocks, each of the two rows having blocks of the first height and an end block of the second height.

10. A mortar-less retaining wall apparatus, comprised of a plurality of masonry blocks, each masonry block having four side walls and two end walls, each end wall having a split texture surface and a plurality of recesses creating a natural stone simulated surface creating a natural stone simulated surface, each end wall being generally quadrilateral in shape, two or more masonry blocks being abutted on respective side walls, and wherein one or more of the masonry blocks each has a side wall that tapers from one end wall to the other end wall.

11. The apparatus of claim 10, wherein two of the masonry blocks with tapered side walls are abutted along the tapered sides, with the tapered sides having opposed tapers, thereby forming a straight wall.

12. The apparatus of claim 11, wherein two of the masonry blocks with tapered side walls are abutted along the tapered sides, with the tapered sides having matched tapers, thereby forming a curved wall.

13. The apparatus of claim 10, further comprising masonry blocks of four different types.

14. The apparatus of claim 13, wherein three of the four types each has a first height and the fourth type has a second height twice that of the first height.

15. The apparatus of claim 14, further comprising a panel of two rows of blocks, each of the two rows having blocks of the first height and an end block of the second height.

16. A mortar-less and pin-less retaining wall apparatus, comprised of a plurality of masonry blocks, each masonry block having four side walls and two end walls, at least one of the end walls of each masonry block having a split texture surface and a plurality of recesses creating a natural stone simulated surface, two or more masonry blocks being abutted on respective side walls, one of the end walls of each masonry block having a natural rock simulating portion.

17. The apparatus of claim 16, wherein the two end walls of each masonry block having a natural rock simulating portion.

18. The apparatus of claim 17, wherein the end walls are generally quadrilateral in shape.

19. The apparatus of claim 17, wherein one or more of the masonry blocks each has a side wall that tapers from one end wall to the other end wall.

20. The apparatus of claim 19, wherein two of the masonry blocks with tapered side walls are abutted along the tapered sides, with the tapered sides having opposed tapers, thereby forming a straight wall.

21. The apparatus of claim 17, wherein two of the masonry blocks with tapered side walls are abutted along the tapered sides, with the tapered sides having matched tapers, thereby forming a curved wall.

22. The apparatus of claim 16, further comprising masonry blocks of four different types.

23. The apparatus of claim 22, wherein three of the four types each has a first height and the fourth type has a second height twice that of the first height.

24. The apparatus of claim 23, further comprising a panel of two rows of blocks, each of the two rows having blocks of the first height and an end block of the second height.