Abstract:
What is provided is a precast hollow block, a precast wall system incorporating the precast hollow block, and forms for manufacturing a hollow block and a coping cap. Accordingly, the precast hollow block and its incorporation into a precast wall system provide solutions to current “level up” block coping techniques, wall flood protection, wall force protection, and the like. Instead of having mismatched or missing face textures on sloped portions of the wall, the precast wall system allows for easier installation of face-textured blocks directly at the top of the wall. As a result, the precast wall system may readily account for slope transitions of a wall, conform to specific Department of Transportation project requirements, accommodate existing wall construction specifications, and be easily customizable for a variety of applications.

Description:
PRIORITY CLAIM 
       [0001]    This patent application is a Non-Provisional patent application and claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application Ser. No. 62/288,712, titled “PRECAST BLOCK COPING SYSTEM AND FORM FOR MANUFACTURING THE SAME,” filed Jan. 29, 2016; and U.S. Provisional Patent Application Ser. No. 62/431,934, titled “PRECAST BLOCK COPING SYSTEM AND FORM FOR MANUFACTURING THE SAME,” filed Dec. 9, 2016. The entire disclosures of the aforementioned patent applications are incorporated by reference as if fully stated herein. 
     
    
     FIELD 
       [0002]    This patent application generally relates to a precast hollow block, incorporation of the precast hollow block into a wall for a variety of applications, and forms for manufacturing the same. 
       BACKGROUND 
       [0003]    During the construction of a wall, it is generally accepted that a leveling course of concrete is added to the wall prior to setting the precast elements, such as a hollow core block. Coping is commonly used to add a protective cap and to provide a smooth finish to the top of a wall. Coping can be cast-in-place or precast using various elements. A strip of a cast-in-place concrete “level up” is incorporated on the top of a wall to provide a smooth, level surface for the coping. Prior methods that have combined cast-in-place coping on the top of a wall formed by precast elements have been expensive, very time-consuming, and difficult to implement. In particular, some of these methods have resulted in face textures that are either mismatched or entirely absent from sloped portions of finished walls. As such, it is very difficult and time-consuming to install a block that has been cut down to height of only a few inches into a specific location on the wall. 
         [0004]    Typically, wall designers refrain from frequently transitioning the slope from one course to another in a wall and, in particular, from transitioning the courses of the wall in a “stair-step” configuration. In addition to purely aesthetic reasons for not using a “stair-step” configuration, designers are often concerned with specific design limitations, such as matching a road grade or meeting stringent Department of Transportation regulations with regard to stepped elevation changes for surfaces located on top of walls. As a result, it is often necessary to ensure specially shaped coping along the top of these walls. 
         [0005]    Therefore, it is apparent that there is a need for a better precast hollow block that, among other things, can provide a more efficient and cost-effective precast block coping system. Specifically, the precast block coping system should readily account for transitions in the slopes of a wall from one course to another, conform to state and federal Department of Transportation regulations, accommodate existing wall construction specifications, and be readily customizable for a variety of applications in the field. 
       SUMMARY 
       [0006]    What is provided is a precast hollow block, a precast wall system incorporating the precast hollow block, and forms for manufacturing a hollow block and a coping cap. In exemplary embodiments, the precast hollow block comprises a top; a bottom; a front side including a front surface, the front side opposed from a back side including a back surface, each of the front surface and the back surface having a textured surface for imparting a natural stone appearance; and a first connecting rib extending laterally from the front side to the back side and a second connecting rib parallel to the first connecting rib and extending laterally from the front side to the back side to form a hollow interior space configured for accepting a filling material, wherein the distance from the first connecting rib to the center of the hollow block is shorter than the distance from the second connecting rib to the center of the hollow block. 
         [0007]    During the construction of walls, the precast hollow block may be precast at the correct slope or cut in the field and incorporated within a precast hollow block system. The precast hollow block system may be used for a variety of applications, including coping, flood prevention, and force protection. 
         [0008]    In exemplary embodiments, a precast wall system comprises a precast wall system comprising a first set of a plurality of hollow blocks, each of the hollow blocks in the first set comprising a top; a bottom; a front side including a front surface, the front side opposed from a back side including a back surface, each of the front surface and the back surface having a textured surface; and a first connecting rib extending laterally from the front side to the back side and a second connecting rib parallel to the first connecting rib and extending laterally from the front side to the back side to form a hollow interior space configured for accepting a filling material, wherein the first connecting rib is positioned approximately at the center of the hollow block; a second set of a plurality of hollow blocks, wherein the first set of the plurality of hollow blocks is attached to the top of the second set of hollow blocks, each of the hollow blocks in the second set comprising: a top; a bottom; a front side including a front surface, the front side opposed from a back side including a back surface, each of the front surface and the back surface having a textured surface; and a first connecting rib extending laterally from the front side to the back side and a second connecting rib parallel to the first connecting rib and extending laterally from the front side to the back side to form a hollow interior space configured for accepting a filling material, wherein the first connecting rib is positioned approximately at the center of the hollow block; and a plurality of stacked rows of retaining blocks, wherein the second set of hollow blocks is attached to the top of the stacked rows of retaining blocks. 
         [0009]    The precast hollow block may be produced in a form using the same dimensions as existing hollow blocks and from existing standard or custom face texture molds. In exemplary embodiments, a form for manufacturing the hollow block comprises a plurality of doors, wherein at least two of the plurality of doors clamp together to form a hollow interior space configured for accepting a filling material; and a base comprising a plurality of face molds configured for insertion of at least one core insert into the form, wherein the core insert is configured for imparting a shape to the hollow block. In some embodiments, a scoring feature may be precast in the hollow blocks at desired positions using a scoring insert. The scoring insert comprises magnets for positioning the scoring insert inside the form. 
         [0010]    In exemplary embodiments, the form for manufacturing a coping cap comprises a plurality of doors, wherein each of the plurality of doors slide on rails attached to the coping cap form; and a base comprising a plurality of texture molds configured for insertion of at least one removable insert into the form, wherein the removable insert is configured for imparting a shape to the coping cap. 
         [0011]    Accordingly, the precast hollow block and its incorporation into a precast wall system provide solutions to current “level up” block coping techniques, wall flood protection, wall force protection, and the like. Instead of having mismatched or missing face textures on sloped portions of the wall, the precast wall system allows for easier installation of face-textured blocks directly at the top of the wall. As a result, the precast wall system may readily account for slope transitions of a wall, conform to specific Department of Transportation project requirements, accommodate existing wall construction specifications, and be easily customizable for a variety of applications. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1A  is a side perspective view of an exemplary precast hollow block having a height of about 18 inches; 
           [0013]      FIG. 1B  is a top perspective view of the hollow block of  FIG. 1A ; 
           [0014]      FIG. 1C  is a bottom perspective view of the hollow block of  FIG. 1A ; 
           [0015]      FIG. 2  is a side perspective view of an exemplary precast hollow block having a height of about 36 inches; 
           [0016]      FIG. 3  is a side perspective view of the exemplary precast hollow block of  FIG. 2  comprising a scoring feature; 
           [0017]      FIG. 4  is a top view of a scoring insert for creating the scoring feature on the hollow block shown in  FIG. 3 ; 
           [0018]      FIG. 5  is a perspective view of an exemplary precast coping block having a height of about 12 inches; 
           [0019]      FIG. 6  is a perspective view of an exemplary precast coping block having a height of about 24 inches; 
           [0020]      FIG. 7  is a perspective view of an exemplary wall comprising a coping cap affixed along the top of the wall; 
           [0021]      FIG. 8  is a perspective view of an exemplary wall comprising a coping cap with an integrated traffic barrier and cast-in-place moment slab affixed along the top of the wall; 
           [0022]      FIG. 9  is a perspective view of an exemplary form for manufacturing a hollow block having a height of about 18 inches; 
           [0023]      FIG. 10  is a perspective view of an exemplary form for manufacturing a hollow block having a height of about 36 inches; 
           [0024]      FIG. 11  is a perspective view of a scoring insert implemented on the exemplary form disclosed in  FIG. 10 ; 
           [0025]      FIG. 12  is a perspective view of an exemplary wall comprising a textured hollow block having a height of about 36 inches; 
           [0026]      FIG. 13  is a hollow block having about half the length as the hollow block depicted in  FIGS. 1A-1C ; 
           [0027]      FIG. 14A  is a perspective view of an exemplary coping form for manufacturing a coping cap in its open orientation; 
           [0028]      FIG. 14B  is a perspective view of an exemplary coping form for manufacturing the coping cap of  FIG. 14A  in its closed orientation; and 
           [0029]      FIG. 15  is a hollow block having about half the length as the hollow block depicted in  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION 
       [0030]    In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the examples as defined in the claimed subject matter, and as an example of how to make and use the examples described herein. However, it will be understood by those skilled in the art that claimed subject matter is not intended to be limited to such specific details, and may even be practiced without requiring such specific details. In other instances, well-known methods, procedures, and ingredients have not been described in detail so as not to obscure the invention defined by the claimed subject matter. 
         [0031]    Referring to  FIGS. 1A-1C , perspective views of an exemplary precast hollow block  100  having a height of about 18 inches are shown. The hollow block  100  may be used in the construction of retaining walls and free standing walls.  FIG. 1A  shows a side perspective view of the precast hollow block  100 .  FIG. 1B  shows a top perspective view of the precast hollow block  100 .  FIG. 1C  shows a bottom perspective view of the precast hollow block  100 . The hollow block  100  has a top  160 , a bottom  170 , and substantially planar, opposed sides  110  and  120  that include the front surface and back surface of the hollow block  100 , respectively. The front surface and back surface of the sides  110  and  120  are textured such that they may imitate natural stone or other aesthetically pleasing materials. 
         [0032]    The sides  110  and  120  are connected together and spaced apart from one another by one or more lateral connecting ribs  140  and  150 , to form at least one hollow interior space  130  in the center of the hollow block  100 . The first connecting rib  140  and the second connecting rib  150  may be of different lengths, shape, size, and thickness, as well as being in different locations on the hollow block  100 , depending on the particular requirements and specifications of the wall. Also, the first connecting rib  140  and the second connecting rib  150  may be made from a variety of materials, such as plastic, metal, and reinforcing steel. 
         [0033]    The at least one hollow interior space  130  is adapted to receive and hold at least one filling material. In some embodiments, the filling material may be stone, concrete, or other functionally similar filling materials. The pouring of this filling material to match the grade of the wall provides a smooth, level surface for coping that can eliminate the expense and time commitment of on-site coping projects. In addition, the pouring of these filling materials results in the formation of solid walls for flood prevention, force protection, and other related applications. In addition, the pouring of these filling materials results in the formation of solid walls for flood prevention, force protection, and other related applications. In some embodiments, the solid walls can provide these benefits without the addition of a coping cap. 
         [0034]    In the illustrated embodiment, the first connecting rib  140  and the second connecting rib  150  extend laterally parallel to one another along the hollow block  100 . The first connecting rib  140  is positioned approximately at the center of the hollow block  100  and the second connecting rib  150  is positioned approximately at one end of the hollow block  100 . As a result, two substantially parallel legs  181  and  182  are defined on a first end  180  of the hollow block  100 . By positioning the first connecting rib  150  at approximately the center of the hollow block  100 , the hollow interior space  130  of the hollow block  100  can better vertically align when the hollow block  100  is stacked with other hollow blocks on a running bond (i.e., a half-block offset). As a result, the hollow interior spaces  130  vertically align through the resulting wall formed from the hollow blocks  100 . 
         [0035]    In other embodiments, both connecting ribs  140  and  150  may be positioned towards the center of the hollow block  100  in order to define four substantially parallel legs on a second end  190  of the hollow block  100 . At least one of the first end  180  and the second end  190  of the hollow block  100  may be cut in order to accommodate various wall construction requirements and allow for the formation of non-planar walls. 
         [0036]    During the construction of a wall, some blocks may need to be cut shorter prior to their placement on the wall due to various design features or to accommodate a slope or angle on the wall. When a portion of the wall is placed at an angle to the rest of the wall or when the wall follows an arc or free-form curve, blocks are cut vertically to construct non-planar walls where one face of the wall is shorter than another. In some embodiments, the hollow block  100  may be cut in the field such that the top  160  is at a different angle relative to the bottom  170 . The ability to cut the hollow block  100  in the field allows a coping cap to match any grade behind the wall. Instead of cutting the sides  110  and  120  in the field, in an alternative embodiment, the sides  110  and  120  may be poured at an angle to match the grade in the field. 
         [0037]    The hollow block  100  may be securely connected to other blocks of different sizes, shapes, and orientations; wall components; wall panels; concrete footings; earthen anchorages, and the like. Each hollow block  100  may be configured to connect with other blocks when the blocks are stacked atop one another or arranged side-by-side to form a wall. This connection can increase wall stability by restricting the movement between adjacent blocks. The hollow block  100  may also be adapted to align with known locking and alignment elements, such as knobs and grooves, tabs, or nodes, to match existing wall batters. 
         [0038]    Referring to  FIG. 2 ,  FIG. 2  shows a side perspective view of an exemplary precast hollow block  200  having a height of about 36 inches. In this embodiment, the height is about twice the height of commonly used hollow blocks, including the hollow block  100  shown in  FIGS. 1 a   - 1   c.  The hollow block  200  has a length of about 46 inches, which is about equal to the length of commonly used blocks, including the hollow block  100  shown in  FIGS. 1 a   - 1   c.  In some embodiments, the hollow block  200  has a height of about 36 inches and length of about 92 inches, both the height and the length are about twice the height and length of commonly used blocks, including the hollow block  100  shown in  FIGS. 1 a   - 1   c.  In another embodiment, the hollow block  200  has a height that is about 18 inches, which is equal to the height of commonly used blocks, including the hollow block  100  shown in  FIGS. 1 a -1 c    and a length of about 92 inches, which is about twice the length of commonly used blocks, including the hollow block  100  shown in  FIGS. 1 a   - 1   c.    
         [0039]    The hollow block  200  has a top  210 , a bottom (not shown), and substantially planar, opposed sides  230  and  240  that include the front surface and back surface of the hollow block  200 . The front surface and back surface of the sides  230  and  240  are textured such that they may imitate natural stone or other aesthetically pleasing materials. 
         [0040]    The opposed sides  230  and  240  are connected together and spaced apart from one another by one or more lateral connecting members, such as connecting ribs  260  and  270 , to form at least one hollow interior space (not shown) in the center of the hollow block  200 . The connecting ribs  260  and  270  may be of different lengths, shape, size, and thickness, as well as being in different locations on the hollow block  200 , depending on the particular requirements and specifications of the wall. Also, the connecting ribs  260  and  270  may be made from a variety of materials, such as plastic, metal, and reinforcing steel. 
         [0041]    In an exemplary embodiment, the at least one hollow interior space may be adapted to receive and hold at least one filling material, such as stone and concrete, after the hollow block  200  is positioned on a wall. The pouring of these filling materials to match the grade of the wall provides a smooth, level surface for coping that can eliminate the expense and time commitment of on-site coping projects. In addition, the pouring of these filling materials results in the formation of solid walls for flood prevention, force protection, and other related applications. In some embodiments, the solid walls can provide these benefits without the addition of a coping cap. 
         [0042]    In the illustrated embodiment, the connecting ribs  260  and  270  can extend parallel to one another and the first connecting rib  260  is positioned at approximately the center of the hollow block  200  and the second connecting rib  270  is positioned at approximately one end of the hollow block  200 . As a result, two substantially parallel legs  281  and  282  form on a first end of the hollow block  200 . By positioning the first connecting rib  260  at approximately the center of the hollow block  100 , the hollow interior space  130  of the hollow block  200  can better vertically align when the hollow block  200  is stacked with other hollow blocks on a running bond (i.e., a half-block offset). As a result, the hollow interior spaces  130  vertically align through the resulting wall formed from the hollow blocks  200 . 
         [0043]    In other embodiments, both connecting ribs  260  and  270  may be set further towards the center of the hollow block  200  in order to form four substantially parallel legs on a second end  280  of the hollow block  200 . At least one of the first end and the second end  280  of the hollow block  200  may be cut in order to accommodate various wall construction requirements and allow for the formation of non-planar walls. 
         [0044]    During the construction of a wall, some blocks may need to be cut shorter prior to their placement on the wall due to various design features or to accommodate a curve or angle on the wall. When a portion of the wall is placed at an angle to the rest of the wall or when the wall follows an arc or free-form curve, blocks are cut vertically to construct non-planar walls where one face of the wall is shorter than another. In some embodiments, the hollow block  200  may be cut in the field such that the top  210  is at a different angle relative to the bottom. The ability to cut the hollow block  200  in the field allows a coping cap to match any grade behind the wall. Instead of cutting the sides  230  and  240  in the field, in an alternative embodiment, the sides  230  and  240  may be poured at an angle to match the grade in the field. 
         [0045]    In some embodiments, a full 18-inch cut may be made through the hollow block  200  without having the hollow block  200  lose any of its support. Typically, transitioning the slope from one course to another results in the last block having a height that is only a fraction of the height (about 2-3 inches or less) of blocks having their full height. Consequently, the face textures are difficult to support or missing entirely from the finished wall. However, in the hollow block  200 , the texture is integrated into the row of blocks located below it, which results in a well-supported texture and allows for a designer or installer to more easily and quickly accommodate the grade as it transitions from one row of blocks to another (as shown in  FIG. 12 ). 
         [0046]    The hollow block  200  may be securely connected to other blocks of different sizes, shapes, and orientations; wall components; wall panels; concrete footings; earthen anchorages, and the like. Each hollow block  200  may be configured to connect with other blocks when the blocks are stacked atop one another or arranged side-by-side to form a wall. This connection can increase wall stability by restricting the movement between adjacent blocks. The hollow block  200  may also be adapted to align with known locking and alignment elements, such as knobs and grooves, tabs, or nodes, to match existing wall batters. 
         [0047]    In order to make it easier and quicker for an operator to cut hollow blocks in the field, some embodiments involve the formation of hollow blocks that are precast with at least one scoring feature. Referring to  FIG. 3 ,  FIG. 3  shows a side perspective view of the exemplary precast hollow block  200  of  FIG. 2  comprising a scoring feature  310 . Even though the exemplary precast hollow block  200  shown in  FIG. 3  has one scoring feature  310  precast on the side  230  at a substantially horizontal angle with respect to the hollow block  200 , a plurality of scoring features may be precast in the same precast hollow block  200  at various locations and angles. The scoring feature  310  is a groove or marking created in the concrete of the hollow block  200  using a scoring insert (shown in  FIG. 4 ) to allow the hollow block  200  to be cut to desired grades. As a result, the hollow block  200  can be easily used during the formation of a wall that provides a smooth, level surface for on-site coping projects. 
         [0048]    Referring to  FIG. 4 ,  FIG. 4  shows a top view of a scoring insert  410  for creating the scoring feature  310  on the hollow block  200  shown in  FIG. 3 . The scoring insert  410  comprises at least one magnet  420  attached/embedded into the scoring insert  410  and a substantially triangular end point  430 .  FIG. 4  shows the scoring insert  410  having three magnets  420  attached/embedded into the scoring insert  410 . The scoring insert  410  may be made from a variety of resilient, durable materials, such as, but not limited to steel. The magnets  420  allow the scoring insert  410 , to be easily positioned in desired locations within the form used for manufacturing the hollow block  200 . The magnets  420  may be any size, strength, type, or material, depending on the type of scoring feature  310  to be created in the hollow block  200 . Due to the permanent attachment of the magnets  420  to the scoring insert  410 , the scoring insert  410  remains attached to the hollow block  200  during removal of the hollow block  200 . As a result, the hollow block  200  can be easily removed, and the scoring insert  410  can be easily replaced or repositioned in the form during setup for a new concrete pour. 
         [0049]    Each scoring insert  410  can be positioned at any angle on the hollow block  200  relative to the position of hollow block  200  on a fully assembled wall. In some embodiments, the substantially triangular end point  430  on the scoring insert  410  may serve as a guide for cutting the precast hollow block  200  at specific locations since it provides an easier access point/guide. Since there is less concrete material at the substantially triangular end point  430  than at other locations on the hollow block  200 , an operator will have an easier time cutting into or fracturing the hollow block  200  along the scoring feature  310  and removing more material from the hollow block  200 . This is particularly the case if the operator does not have the appropriate tools (concrete saws) to cut hollow blocks that do not have a scoring feature. 
         [0050]    Alternative embodiments of the hollow blocks  100  and  200 , as shown in  FIGS. 1A-1C, 2, and 3 , can include hollow blocks of different sizes, shapes and orientations. In one embodiment, a hollow block may form a horizontal corner with angles of varying degrees, such as, but not limited to 90 degrees. In another embodiment, the hollow block may be installed on a wall in a vertical orientation and may have textured faces on its ends. Some other embodiments of the hollow block may have other dimensions combinations, such as, but not limited to a height from about 6 inches to about 45 inches and a length of about 10 inches to about 120 inches. For example,  FIG. 13  shows a hollow block having about half the length as the hollow block having a height of about 18 inches depicted in  FIGS. 1A-1C . Similarly,  FIG. 14  shows a hollow block having about half the length as the hollow block having a height of about 36 inches depicted in  FIG. 2 . In addition, the thickness and texture of the sides may vary between embodiments. In some embodiments, the hollow blocks  100  and  200  may be known as MAGIC™ blocks. 
         [0051]    A coping cap comprises at least one coping block attachable along the top of a wall. Referring to  FIG. 5 ,  FIG. 5  shows a perspective view of an exemplary precast coping block  500  having a height of about 12 inches. In this particular example, the coping block  500  has a height of about 12 inches and a length up to about 120 inches. The coping block  500  may be fabricated from a particular type of concrete, cement, reinforcing steel, or other functionally equivalent reinforcing materials. The coping block  500  has a top  510 , a bottom (not shown), substantially planar, opposed sides  520  and  530  having a rectangular shape that include the front surface and back surface of the coping block  500 , and ends  540  and  550 . In addition to the front surface and back surface of the sides  520  and  530  being textured, one or both of the ends  540  and  550  also may be textured, particularly when they are visible in a finished wall. 
         [0052]    At least one of the ends  540  and  550  of the coping block  500  may be cut in order to accommodate various wall construction requirements, ensure accurate joints, and allow for the formation of non-planar walls. During the construction of a wall, some blocks may need to be cut shorter prior to their placement on the wall due to various design features or to accommodate a curve or angle on the wall. When a portion of the wall is placed at an angle to the rest of the wall or when the wall follows an arc or free-form curve, blocks are cut vertically to construct non-planar walls where one face of the wall is shorter than another. In some embodiments, the coping block  500  may be configured to match any grade behind the wall by casting the ends  540  and  550  at an angle other than one that is perpendicular to the top  510  and the bottom. In other embodiments, the coping block  500  may be configured to match any grade behind the wall by cutting the ends  540  and  550  at an angle other than one that is perpendicular to the top  510  and the bottom. 
         [0053]    The coping block  500  may be securely affixed and positioned along the top of a wall that includes precast hollow blocks, as depicted in  FIGS. 1A-1C, 2, and 3  in order to provide a flat surface on top of the wall and to provide a desired aesthetic component to the wall. The coping block  500  may also be securely affixed and positioned to other blocks of different sizes, shapes, and orientations; wall components; wall panels; concrete footings; and the like. The coping block  500 , along with other coping blocks, may also be configured to accommodate mounting structures for fences, railings, site lighting, utilities, traffic barriers, and functionally equivalent structures on the top of the coping block  500 . 
         [0054]    In exemplary embodiments, the traffic barrier may be precast into the coping block  500 , as illustrated in  FIG. 8 . In an alternative embodiment, the coping block  500  may be fabricated with reinforcing rods (rebar) to allow for incorporation with a cast-in-place moment slab and/or a cast-in-place traffic barrier. This allows for a secure connection with the traffic barrier in order to help prevent its tipping and overturning when impacted by a moving vehicle. 
         [0055]    Referring to  FIG. 6 ,  FIG. 6  shows a perspective view of an exemplary precast coping block  600  having a height of about 24 inches. In this particular example, the coping block  600  has a height of about 24 inches and a length up to about 120 inches. The coping block  600  may be fabricated from a particular type of concrete, cement, reinforcing steel, or other functionally equivalent reinforcing materials. The coping block  600  has a top  610 , a bottom (not shown), a substantially planar, rectangular-shaped front side  620  including a front surface, a substantially planar, rectangular-shaped back side  630  including a back surface, and ends  640  and  650 . In addition to the top  610  and the surfaces of the front side  620  and the back side  630  being textured, one or both of the ends  640  and  650  also may be textured, particularly when they are visible in a finished wall. 
         [0056]    In one embodiment, the front side  620  is about 12 inches taller than the back side  630  due to a void on the back side  630 . As a result, fencing, railings, or other functionally equivalent barriers, such as a traffic barrier, may be installed in the void of the coping block  600 . At least one of the ends  640  and  650  of the coping block  600  may be cut in order to accommodate various wall construction requirements, ensure accurate joints, and allow for the formation of non-planar walls. During the construction of a wall, some blocks may need to be cut shorter prior to their placement on the wall due to various design features or to accommodate a curve or angle on the wall. When a portion of the wall is placed at an angle to the rest of the wall or when the wall follows an arc or free-form curve, blocks are cut vertically to construct non-planar walls where one face of the wall is shorter than another. In some embodiments, the coping block  600  may be configured to match any grade behind the wall by casting the ends  640  and  650  at an angle other than one that is perpendicular to the top  610  and the bottom. In other embodiments, the coping block  600  may be configured to match any slope of the wall by cutting the ends  640  and  650  at an angle other than one that is perpendicular to the top  610  and the bottom. 
         [0057]    The coping block  600  may be securely affixed and positioned along the top of a wall that includes precast hollow blocks, as depicted in  FIGS. 1A-1C, 2, and 3 , in order to provide a flat surface on top of the wall. The coping block  600  may also be securely affixed and positioned to other blocks of different sizes, shapes, and orientations; wall components; wall panels; concrete footings; and the like. The coping block  600 , along with other coping blocks, may also be configured to accommodate mounting structures for fences, railings, site lighting, utilities, traffic barriers, and functionally equivalent structures on the top of the coping block  600 . 
         [0058]    In exemplary embodiments, the traffic barrier may be integrated into the coping block  600  in a precast manner, as illustrated in  FIG. 8 . In an alternative embodiment, the coping block  600  may be fabricated with reinforcing rods (rebar) to allow for incorporation with a cast-in-place moment slab and/or a cast-in-place traffic barrier. This allows for a secure connection with the traffic barrier in order to help prevent its tipping and overturning when impacted by a moving vehicle. 
         [0059]    The pouring of filling materials into the hollow interior space  130  of the hollow block  100  and the coping block  600  increase the total height of any resulting wall. The result is that the coping block  600  becomes part of the formed retaining wall. This creates a more efficient wall system that requires fewer hollow blocks and much fewer concrete to create a wall having the same height. In some embodiments, landscaping, soil, concrete, asphalt, and functionally similar materials may be placed within close proximity of the front side  620  of the coping block  600  to provide additional support for the wall in order to limit overturning and sliding. Further, the coping block  600  may be configured to accommodate at least one vertical face panel that may extend above and/or below relative the horizontal portion(s) of the coping block  600 . The vertical face panel may be supported by the other blocks surrounding the coping block  600 . 
         [0060]    Alternative embodiments of the coping blocks  500  and  600 , as shown in  FIGS. 5 and 6 , respectively, can include coping blocks of different sizes, shapes and orientations. For example, a coping block may form a horizontal corner with angles of varying degrees, such as, but not limited to 90 degrees. Further, in another example, the hollow block may be installed on a wall in a vertical orientation and may have textured faces on its ends. Other embodiments of the hollow block may have other dimensions combinations, such as, but not limited to a height from about 12 inches to about 24 inches and a length of up to about 120 inches. In addition, the thickness and texture of the sides may vary between embodiments. 
         [0061]    Referring to  FIG. 7 ,  FIG. 7  shows a perspective view of an exemplary wall  700  comprising a coping cap  710  affixed along the top of the wall  700 . In the illustrated embodiment, the coping cap  710  comprises at least one coping block  720  installed on top of a first set of a plurality of hollow blocks  730 . Each coping block  720  has a height of about 12 inches and is used to protect the wall  700  from degradation and to provide a finished surface on top of the wall  700 . Each of the hollow blocks  730  in the first set is has a height of about 18 inches. The wall  700  also comprises a plurality of stacked rows of retaining blocks  740 , which are stacked to a predetermined height at the desired batter and a second set of a plurality of hollow blocks  750 . Each of the hollow blocks  750  in the second set has a height about twice the height of each of the hollow blocks  730  in the first set. In one embodiment, each of the hollow blocks  750  in the second set has a height of about 36 inches. In the finished wall  700 , the first set of hollow blocks  730  are stacked on top of the second set of hollow blocks  750 , which are stacked on top of the retaining blocks  740 . 
         [0062]    The at least one coping block  720  is configured to allow for secure structural connections with the first set of hollow blocks  730 , the retaining blocks  740 , and the second set of hollow blocks  750 . In addition, the at least one coping block  720 , the first set of hollow blocks  730 , the retaining blocks  740 , and the second set of hollow blocks  750  are configured to securely connect with wall components; wall panels; concrete footings; earthen anchorages, and the like. The wall components; wall panels; concrete footings; and earthen anchorages may be added on top of or around the coping cap  710 . These connections can increase wall stability by restricting the movement between adjacent blocks. 
         [0063]    In some embodiments, the at least one coping block  720 , the first set of hollow blocks  730 , and the second set of hollow blocks  750  may be precast at the desired grade and labeled according to their orientation on the wall  700 . In alternative embodiments, the at least one coping block  720 , the first set of hollow blocks  730 , and the second set of hollow blocks  750  may be cut to the desired grade at the construction site of the wall  700 . In some embodiments, fencing, railings, or other functionally equivalent barriers, such as a traffic barrier, may be installed on top of the coping cap  710 . 
         [0064]    Referring to  FIG. 8 ,  FIG. 8  shows a perspective view of an exemplary wall  800  comprising a coping cap  810  with an integrated traffic barrier  820  and cast-in-place moment slab  830  affixed along the top of the wall  800 . In the illustrated embodiment, the coping cap  810  comprises a coping block  840  that has a height of about 24 inches and is used to protect the wall  800  from degradation and to provide a finished surface on top of the wall  800 . The wall  800  also comprises a first set of a plurality of hollow blocks  850  on its top row. Each of the hollow blocks  850  in the first set has a height of about 18 inches. Further, the wall  800  comprises a plurality of stacked rows of retaining blocks  860 , which are stacked to a predetermined height at the desired batter and a second set of a plurality of hollow blocks  870 . Each of the hollow blocks  870  in the second set has a height about twice the height of the hollow blocks  850  in the first set. In one embodiment, each of the hollow blocks  870  in the second set has a height of about 36 inches. 
         [0065]    The coping block  840  is configured to allow for secure structural connections with the first set of hollow blocks  850 , the retaining blocks  860 , and the second set of hollow blocks  870 . In addition, the coping block  840 , the first set of hollow blocks  850 , the retaining blocks  860 , and the second set of hollow blocks  870  are configured to securely connect with wall components; wall panels; concrete footings; earthen anchorages, and the like. These connections can increase wall stability by restricting the movement between adjacent blocks. 
         [0066]    In some embodiments, the coping block  840 , the first set of hollow blocks  850 , and the second set of hollow blocks  870  may be precast at the desired grade and labeled according to their orientation on the wall  800 . In alternative embodiments, the coping block  840 , the first set of hollow blocks  850 , and the second set of hollow blocks  870  may be cut to the desired grade at the construction site of the wall  800 . 
         [0067]    In some embodiments, fencing, railings, landscaping, soil, plants, or other functionally equivalent materials may be installed on top of the coping cap  810 . Traffic barriers, moment slabs, sidewalks, or other functionally equivalent materials may be cast-in-place on top of the coping cap  810 . 
         [0068]    Alternative embodiments of the walls  700  and  800 , respectively shown in  FIGS. 7 and 8 , can include walls that form a horizontal corner with angles of varying degrees, such as, but not limited to 90 degrees. When a portion of the wall is placed at an angle to the rest of the wall or when the wall follows an arc or free-form curve, blocks are cut to construct non-planar walls where one face of the wall is shorter than another. 
         [0069]    As disclosed above, the hollow block provides a smooth, level surface for coping that can eliminate the expense and time commitment of on-site coping project. Additionally, in alternative embodiments, the system disclosed herein may be used for other types of applications involving walls and non-wall structures. Specifically, the precast hollow block wall system disclosed herein may be used for flood management walls with a watertight cast-in-place center core, rail bed ballast retention, bridge abutments, barrier walls with a cast-in-place center core, parapet walls, sound attenuation walls, visual screen walls, force protection structures, blast mitigation structures, and the like. 
         [0070]    In an exemplary embodiment, the precast wall provides a solid core across the entire wall for flood protection. The precast wall comprises the first set of hollow blocks  730  stacked on top of the second set of hollow blocks  750 , which are stacked on top of the retaining blocks  740 . In some examples, the precast wall does not include the retaining blocks  740 . The precast wall also comprises reinforcing steel, such as rebar, and poured-in-place concrete, but no coping cap. The blocks used for this precast wall may be assembled and positioned in areas known to have potential for flooding. The reinforcing steel is placed in prescribed locations on the blocks while the wall is being constructed. Concrete is then poured into the core hollow interior spaces of the wall to create a solid core across the entire wall. The result is the creation of an effectively water-tight wall with greater structural stability. Thus, no separate framework or parts are needed to create the wall. As a result, there are great cost-savings on labor as compared with existing wall construction techniques. In addition, the hollow core block adds mass to the wall cross-section. The result is a more robust and stable wall that can be used as a formwork that can be integrated into the wall. Unlike cast-in-place techniques for wall construction, no post-processing is needed to the wall after concrete is poured. 
         [0071]    In another exemplary embodiment, the precast wall provides a solid core across the entire wall for the formation of a barrier. The precast wall comprises the first set of hollow blocks  730  stacked on top of the second set of hollow blocks  750 , which are stacked on top of the retaining blocks  740 . In some examples, the precast wall does not include the retaining blocks  740 . The precast wall also comprises reinforcing steel, such as rebar, and poured-in-place concrete, but no coping cap. The blocks used for this precast wall may be assembled and positioned in areas in need of a barrier. The reinforcing steel is placed in prescribed locations on the blocks while the wall is being constructed. Additional anchoring and/or reinforcement structures may be added to the wall at this time. Concrete is then poured into the core hollow interior spaces of the wall to create a solid core across the entire wall, effectively tying all the wall blocks into a single mass. As a result, any impact to the wall blocks would be distributed across the wall. 
         [0072]    Referring to  FIG. 9 ,  FIG. 9  shows a perspective view of an exemplary form  900  for manufacturing a hollow block  910  having a height of about 18 inches. In the illustrated embodiment, the form  900  has a height of about 18 inches and comprises a plurality of doors  950  and a base comprising one or more face molds  960  used for insertion of one or more core inserts  920 . The one or more face molds  960  create simulated rock faces on the hollow block  910 , while the one or more core inserts  920  impart a desired configuration to the hollow block  910 . The one or more face molds  960  and one or more core inserts  920  may be fabricated into a variety of shapes and sizes and from a variety of materials, such as, but not limited to rubber, steel, and plastic. 
         [0073]    At least two doors  950  clamp to each other to form at least one hollow interior space  930  in the center of the hollow block  910  into which the concrete is poured. The doors  950  swing or slide out of the way after the hollow block  910  is cured. In some embodiments, the doors  950  may open and close on a sliding rail system, hinges, or a combination of both. 
         [0074]    The form  900  is configured to locate and support any necessary concrete reinforcement materials for the manufacturing of the hollow block  910 . The form  900  is also configured to locate and support lateral connecting members, such as connecting ribs  940 , located in the hollow block  910 . 
         [0075]    Referring to  FIG. 10 ,  FIG. 10  shows a perspective view of an exemplary form  1000  for manufacturing a hollow block  1010  having a height of about 36 inches. In the illustrated embodiment, the form  1000  has a height of about 36 inches and comprises a plurality of doors  1040  and a base comprising one or more face molds  1050  used for insertion of one or more core inserts  1020 . The one or more face molds  1050  create simulated rock faces on the hollow block  1010 , while the one or more core inserts  1020  impart a desired configuration to the hollow block  1010 . The one or more face molds  1050  and one or more core inserts  1020  may be fabricated into a variety of shapes and sizes and from a variety of materials, such as, but not limited to rubber, steel, and plastic. 
         [0076]    At least two doors  1040  clamp to each other to form at least one hollow interior space  1030  in the center of the hollow block  1010  into which the concrete is poured. The doors  1040  swing or slide out of the way after the hollow block  1010  is cured. In some embodiments, the doors  1040  may open and close on a sliding rail system, hinges, or a combination of both. 
         [0077]    The form  1000  is configured to locate and support any necessary concrete reinforcement materials for the manufacturing of the hollow block  1010 . The form  1000  is also configured to locate and support lateral connecting members, such as connecting ribs (not shown), located in the hollow block  1010 . In some embodiments, the form  1000  comprises doors or side walls that open and close on a sliding rail system, hinges, or a combination of both. 
         [0078]    Referring to  FIG. 11 ,  FIG. 11  shows a perspective view of the scoring insert  410  of  FIG. 4  implemented on the exemplary form  1000  disclosed in  FIG. 10 . The scoring insert  410  is attached to sides of the core insert  1020  using magnets embedded in the scoring insert  410 . However, the scoring insert  410  is readily removable from the core insert  1020  to prevent the core insert  1020  from being trapped inside hollow blocks. The magnets allow the scoring insert  410  to be easily positioned in desired locations within the form  1000 . Due to the permanent attachment of the magnets to the scoring insert  410 , the scoring insert  410  remains attached to a hollow block (shown as  1010  in  FIG. 10 ) during removal of the hollow block  1010  from the form  1000 . In some cases, the extra or unneeded scoring inserts  410  may be readily removed from the form  1000  when the doors  1040  are removed. As a result, the scoring insert  410  can be easily replaced or repositioned in the form during setup for a new concrete pour. 
         [0079]    In some embodiments, a coping cap including coping blocks  500  and  600 , as shown in  FIGS. 5 and 6 , respectively, may be manufactured with a coping cap form, as shown in  FIGS. 14A and 14B .  FIG. 14A  shows a perspective view of an exemplary coping form  1400  for manufacturing a coping cap  1410  in its open orientation. In this illustrated embodiment, the coping form  1400  includes a plurality of doors  1420  that may open and close on a sliding rail system, hinges, or a combination of both attached to the base of the coping form  1400 . In some embodiments, the coping form  1400  comprises four doors. The base comprises a plurality of texture molds  1430  that create simulated rock faces on the coping blocks of the coping cap  1410 . Each of the plurality of texture molds  1430  comprises a rubber mat that can be interchanged to create different textures on the coping blocks. 
         [0080]    The plurality of texture molds  1430  are configured for insertion of at least one removable insert  1440  that imparts a desired configuration to the coping blocks of the coping cap  1410 . Each removable insert  1440  may be fabricated from a variety of materials, such rubber, steel, and plastic and may be fabricated into a variety of shapes and sizes. Thus, each removable insert  1440  can be readily interchanged to create different coping blocks. Each removable insert  1440  comprises an integrated lifting insert  1450  having a removable cover in order to allow for easier removal and replacement of the removable insert  1440 . In the illustrated embodiment, the height of the coping cap  1410  manufactured by the coping form  1400  is about 12 inches. In other embodiments, the removable insert  1440  may be removed and replaced with a different removable insert to allow for the creation of a coping cap having a height of about 24 inches. 
         [0081]    Each lifting insert  1450  is integrated within a removable insert  1440  and includes a removable cover. In some embodiments, the removable cover is made from molded rubber. As a result, concrete or other types of filling material can cover the lifting insert  1450  without creating problems with leaking or stripping. 
         [0082]    The coping form  1400  further comprises a plurality of clamps  1460 , each of the clamps  1460  is positioned at about a 45 degree angle on a plurality of doors  1420 . In some embodiments, each of the clamps  1460  is positioned on two doors  1420  in the open orientation of the coping form  1400 . Due to the angle of each of the clamps  1460  with respect to the doors  1420 , each clamp  1460  may readily interlock with a door  1420  adjacent to the door  1420  where the clamp  1460  is positioned. This allows the clamp  1460  to pull two doors  1420  simultaneously shut, causing the coping form  1400  to enter a closed orientation, as illustrated in  FIG. 14B . 
         [0083]    Referring to  FIG. 14B ,  FIG. 14B  shows a perspective view of an exemplary coping form  1400  for manufacturing the coping cap  1410  of  FIG. 14A  in its closed orientation. In its closed orientation, the coping form  1400  comprises a door jack assembly  1470  that includes a jack screw  1471  and a post  1472 . The door jack assembly  1470  is attached to at least one door  1420 . Once the coping cap  1410  is cured, the jack screw  1471  reacts against the post  1472  to pull the door  1420  out of the concrete. As a result, nothing is required from the operator of the coping form  1400 , besides a standard impact driver. If the door  1420  needs to be opened further or removed altogether, the post  1472  can be readily removed from the base. 
         [0084]    The coping cap form  1400  may be configured to locate and support any necessary concrete reinforcement materials and mounting structures for fences, railings, site lighting, utilities, and functionally equivalent structures on the top of the coping block. Also, the coping cap form  1400  may be configured to incorporate a traffic barrier into a coping block or wall and to incorporate voids for landscaping, soil, concrete, and other functionally equivalent materials. Further, the coping cap form  1400  may be configured to locate and support reinforcement for cast-in-place traffic barriers, cast-in-place moment slabs, and connectors to other wall components. 
         [0085]    Referring to  FIG. 15 ,  FIG. 15  shows a perspective view of an exemplary wall comprising a textured hollow block having a height of about 36 inches. In this embodiment, the textured hollow block is integrated into the wall in order to essentially mimic the appearance of two hollow blocks, each having a height of about 18 inches, stacked on top of each other. As a result, the textured faces are integrated into the row of blocks located below where it would ordinarily appear. This allows for easier and quicker accommodation of the grade in the wall as it transitions from one row of blocks to another. 
         [0086]    It will, of course, be understood that, although particular examples have just been described, the claimed subject matter is not limited in scope to a particular example or limitation. Likewise, an example may be implemented in any combination of compositions of matter, apparatuses, methods or products made by a process, for example. 
         [0087]    In the preceding description, various aspects of claimed subject matter have been described. For purposes of explanation, specific numbers, percentages, components, ingredients and/or configurations were set forth to provide a thorough understanding of claimed subject matter. However, it should be apparent to one skilled in the art having the benefit of this disclosure that claimed subject matter may be practiced without the specific details. In other instances, features that would be understood by one of ordinary skill were omitted or simplified so as not to obscure claimed subject matter. While certain features and examples have been illustrated or described herein, many modifications, substitutions, changes or equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications or changes as fall within the true spirit of claimed subject matter.