Patent Publication Number: US-11661737-B2

Title: Modular concrete building block and methods

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 16/919,732, filed Jul. 2, 2020, issued as U.S. Pat. No. 11,326,343; application Ser. No. 16/919,732 is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     This disclosure relates to modular concrete building blocks with decorative faces that can be used in many different ways, including, for example, to build walls, such as landscaping walls or freestanding walls, or to build columns and at-grade or above-grade edging strips. This disclosure also relates to methods for making the blocks and methods for using them. 
     BACKGROUND 
     Modular concrete building blocks can be used to build walls, including free-standing walls, retaining walls, and landscaping walls. These blocks can be used either by contractors or by individuals in the “do it yourself” market. 
     Improvements in building blocks, including the ease of assembling the blocks into various structures, and with a visually attractive result, are desirable. 
     SUMMARY 
     In one aspect, a first block is provided comprising first, second, third, fourth, fifth, and sixth planar faces, wherein; the first and second faces are generally parallel, and the distance between the first and second faces define a thickness of the first block; the third and fourth faces are parallel to each other and perpendicular to the first and second faces; the fifth face is perpendicular to the first, second, third, and fourth faces; the sixth face extends perpendicular to the third face, extends toward the fourth face and ends at a non-planar remainder section, is parallel to the fifth face, and is contained in a plane that intersects a plane containing the third face; a distance from the intersection to the remainder section being at as least as long as the thickness of the first block; and the remainder section extends between the sixth face and the fourth face and has a shape such that when a second block of the same construction as the first block has its remainder section engaged against the remainder section of first block, the remainder sections of the first and second blocks mate. 
     In examples, the length from the third face to the remainder section is equal to the thickness of the first block. 
     In examples, the remainder section includes a plurality of planar faces angled relative to each other at non-straight and non-zero angles. 
     In examples, the plurality of planar faces of the remainder section includes at least three planar faces. 
     In some examples, the plurality of planar faces of the remainder section includes at least five planar faces. 
     The remainder section includes a curved surface, in some examples. 
     In some examples, the curved surface includes at least one convexly curved surface and at least one concavely curved surface. 
     Some examples include at least the first face having false joint lines thereon. 
     In some embodiments, the third and fourth faces have false joint lines thereon. 
     In another aspect, a free-standing wall comprising a plurality of the first blocks as variously characterized above is provided. The wall comprises a first wall section including a base layer of the first blocks arranged side by side such that the first faces of the blocks are generally co-planar, the fifth face is against a base surface, and the sixth face and remainder section are facing up; and a first layer of second blocks, having the same construction as the first blocks, stacked on the base layer so that the sixth face of most of the second blocks is engaged against the sixth face of the first blocks in the base layer, and the remainder section of most of the second blocks is in mating engagement with the remainder section of the first blocks in the base layer. 
     The wall can further include a second wall section perpendicular to the first wall section; the second wall section having a base layer of the first blocks arranged side by side such that the first faces of the blocks in the second wall section are generally co-planar with each other and perpendicular to a plane containing the first faces of the first wall section; the second wall section having a first layer of the second blocks stacked on the second wall section base layer so that the sixth face of most of the second blocks in the second wall section is engaged against the sixth face of the first blocks in the base layer of the second wall section, and the remainder section of most of the second blocks in the second wall section is in mating engagement with the remainder section of the first blocks in the base layer in the second wall section; and wherein the sixth face one of the second blocks at a first end of the second wall section first layer is engaged against the sixth face of one of the first blocks at a first end of the first wall section base layer. 
     The wall can further include a third wall section perpendicular to the first wall section; the third wall section having a base layer of the blocks arranged side by side such that the first faces of the blocks in the third wall section are generally co-planar with each other and perpendicular to a plane containing the first faces of the first wall section; the third wall section having a first layer of the blocks stacked on the third wall section base layer so that the sixth face of each of the blocks in the third wall section first layer is engaged against the sixth face of the blocks in the third wall section base layer, and the remainder section of the third wall section first layer of blocks is in mating engagement with the remainder section of the third wall section base layer of blocks; and wherein the sixth face of one of the first blocks at a first end of the third wall section base layer is engaged against the sixth face of one of the second blocks at a second end of the first wall section first layer. 
     In another aspect, a first body piece is provided including planar first and second faces that are parallel, the distance between those faces defining the thickness of the first body piece; third and fourth planar side faces that are parallel to each other and perpendicular to the first and second faces; opposite fifth and sixth surfaces, with the first and second faces and third and fourth faces extending between the fifth and sixth surfaces; each of the fifth and sixth surfaces having an identical profile shape including: a planar section and a non-planar remainder section; the planar section extending from one of the third and fourth side faces and extending perpendicular to that side face toward the other side face ending at the remainder section; the planar section having a length as least as long as the thickness of the first body piece; the remainder section extending between the planar section and the other side face; the remainder section being formed such that when a second body piece of the same construction has its remainder section engaged against the remainder section of the first body piece, the remainder sections of the first and second body pieces mate. 
     In some examples, the planar section having a length equal to the thickness of the first body piece. 
     In some examples, the remainder section includes a plurality of planar faces angled relative to each other at non-straight and non-zero angles. 
     Some embodiments have the plurality of planar faces of the remainder section including at least three planar faces. 
     In some examples, there are at least the first and second faces with false joint lines thereon. 
     In another aspect, a free-standing wall is provided comprising: a first wall section including a base layer of first blocks as variously characterized herein, arranged side by side such that the first faces of the first blocks are generally co-planar; a first layer of body pieces as variously characterized herein stacked on the base layer so that the planar section of the sixth surface of each of the body pieces in the first layer is engaged against the sixth face of the first blocks in the base layer, and wherein the remainder section of the sixth surface of the first layer of body pieces is in mating engagement with the remainder section of the sixth face of the base layer of first blocks; and a second layer of body pieces stacked on the first layer so that the planar section of the fifth surface of each of the body pieces in the second layer is engaged against the planar section of the fifth surface of the body pieces in the first layer, and wherein the remainder section of the fifth surface of the second layer of body pieces is in mating engagement with the remainder section of the fifth surface of the first layer of body pieces. 
     Example embodiments further include a third layer of the first blocks of claim  1  stacked on the second layer of body pieces so that the sixth face of each of the first blocks in the third layer is engaged against the planar section of the sixth surface of the body pieces in the second layer, and wherein the remainder section of the third layer of first blocks is in mating engagement with the remainder section of the sixth surface of the second layer of body pieces. 
     In another aspect, a method of constructing a free-standing wall comprising a plurality of the first blocks as variously characterized herein; the method comprising: laying a base course of the first blocks arranged side by side such that the first faces of the blocks are generally co-planar, and the fifth face is against a base surface, and the sixth face and remainder section are facing up to create a first wall section; and laying a first layer of second blocks, having the same construction as the first blocks, stacked on the base course so that the sixth face of most of the second blocks is engaged against the sixth face of the first blocks in the base course, and the remainder section of most of the second blocks is in mating engagement with the remainder section the first blocks in the base course. 
     In examples, there is further a step of constructing a second wall section perpendicular to the first wall section by laying a base course of the first blocks arranged side by side such that the first faces of the blocks in the second wall section are generally co-planar with each other and perpendicular to a plane containing the first faces of the first wall section; and laying a first layer of the second blocks on the second wall section base course so that the sixth face of most of the second blocks in the second wall section is engaged against the sixth face of the first blocks in the base course of the second wall section, and the remainder section of most of the second blocks in the second wall section is in mating engagement with the remainder section the first blocks in the base layer in the second wall section; and wherein the sixth face one of the second blocks at a first end of the second wall section first course is engaged against the sixth face of one of the first blocks at a first end of the first wall section base course. 
     Example methods further includes steps of constructing a third wall section perpendicular to the first wall section by laying a base course of the blocks arranged side by side such that the first faces of the blocks in the third wall section are generally co-planar with each other and perpendicular to a plane containing the first faces of the first wall section; laying a first course of the blocks on the third wall section base course so that the sixth face of each of the blocks in the third wall section first course is engaged against the sixth face of the blocks in the third wall section base course, and the remainder section of the third wall section first course of blocks is in mating engagement with the remainder section of the third wall section base course of blocks; and wherein the sixth face of one of the first blocks at a first end of the third wall section base course is engaged against the sixth face of one of the second blocks at a second end of the first wall section first course. 
     In another aspect, a concrete construction block is provided comprising: a first face; a second face generally parallel to the first face; the block having a uniform thickness defined by a distance between the first face and second face; a third face extending between and perpendicular to the first and second faces; a fourth face parallel to the third face; the fourth face extending between and perpendicular to the first and second faces; a fifth planar face extending between and perpendicular to the first face, second face, third face, and fourth face; a sixth planar face, parallel to the fifth face; the sixth face extending perpendicular to the first face, second face, and third face and being contained within a plane extending from a plane containing the third face a distance as least as long as said thickness; an irregular section extending from the sixth face to the fourth face and perpendicular to the first face and second face; the irregular section including at least a first cavity and a first projection; the first cavity being recessed from an imaginary plane in a direction toward the fifth face; said plane being co-planar with the sixth face; the first projection extending from said plane in a direction away from a remainder of the block; and the first cavity and the first projection have the same first perimeter shape. 
     In some embodiments, the irregular section further includes a second cavity and second projection; the second cavity being recessed from the imaginary plane in a direction toward the fifth face; the second projection extending from said imaginary plane in a direction away from a remainder of the block; and the second cavity and the second projection have the same second perimeter shape. 
     In some examples, the sixth face extends from the third face a distance equal to the thickness. 
     In some examples, the second projection is between the first cavity and second cavity. 
     In some embodiments, the first and second cavities alternate with the first and second projections along the irregular section. 
     In some examples, the perimeter first shape is curved. 
     In some examples, the perimeter first shape is polyhedral. 
     In some examples, the perimeter first shape is polyhedral; and the perimeter second shape is polyhedral. 
     Some embodiments include at least the first and second faces having false joint lines thereon. 
     For some examples, the third and fourth faces have false joint lines thereon. 
     In another aspect, a free-standing wall comprising a plurality of the blocks as variously characterized herein is provided. The wall comprises a first wall section including a base layer of the blocks arranged side by side such that the first faces of the blocks are generally co-planar, the fifth faces are facing down against a base surface, and the sixth faces and irregular sections are facing up; and a first layer of the blocks stacked on the base layer so that the sixth face of most of the blocks in the first layer is engaged against the sixth face of the blocks in the base layer, and the irregular section of most of the blocks in the first layer is in mating engagement with the irregular sections of the blocks in the base layer. 
     A variety of examples of desirable product features or methods are set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practicing various aspects of this disclosure. The aspects of the disclosure may relate to individual features as well as combinations of features. It is to be understood that both the foregoing general description and the following detailed description are explanatory only, and are not restrictive of the claimed invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view of an embodiment of a concrete block, constructed in accordance with the principles of this disclosure; 
         FIG.  2    is a front, elevation view of an embodiment of a block similar to the block of  FIG.  1    and showing the general outer perimeter shape; 
         FIG.  3    is a top, plan view of the blocks of  FIG.  2    as laid out on a pallet for shipping, in which the blocks are laid on their back face; 
         FIG.  4    is a front, elevation view of four of the blocks of  FIG.  2    connected together; 
         FIG.  5    is a perspective view of an example embodiment of structures that can be constructed from the block of  FIG.  2   , the example shown in  FIG.  5    as columns, landscaping walls, and a planter; 
         FIG.  6    is a perspective view of a back-to-back wall with columns constructed from the block of  FIG.  2   ; 
         FIG.  7    is a front elevation view of another embodiment of a concrete block, constructed in accordance with principles of this disclosure; 
         FIG.  8    is a front elevation view of the embodiment of  FIG.  7    but showing only the outer perimeter shape; 
         FIG.  9    is a top plan view of the block of  FIG.  7    arranged on a pallet with other like blocks, and laid on the back face of the block; 
         FIG.  10    is a front elevation view of the blocks of  FIG.  7    arranged in a wall construction; 
         FIG.  11    is another wall construction using the blocks of  FIG.  2   , and also with a body piece, shown in  FIGS.  12  and  13   ; 
         FIG.  12    is a front elevation view of a body piece usable with the block of  FIG.  2    in constructing the wall of  FIG.  11   ; 
         FIG.  13    is a front elevation view of the body piece of  FIG.  12    and shown only the outline perimeter shape; 
         FIG.  14    is a perspective view of another embodiment of a concrete block, constructed in accordance with principles of this disclosure; 
         FIG.  15    is a perspective view of an embodiment of a wall with a corner construction using the block of  FIG.  14   ; 
         FIG.  16    is a perspective view of another embodiment of a concrete block, constructed in accordance with principles of this disclosure; 
         FIG.  17    is a perspective view of an embodiment of a wall with a corner construction made from the blocks of  FIG.  16   ; 
         FIG.  18    is a front elevation view of the block of  FIG.  2    showing the perimeter shape and additional definitions; 
         FIG.  19    is a front elevation view of the block of  FIG.  14    showing the outer perimeter shape and with additional definitions; 
         FIG.  20    is a front elevation view of the block of  FIG.  16    showing an outer perimeter shape and additional definitions; 
         FIG.  21    is a perspective view of the body piece of  FIG.  12   ; 
         FIG.  22    is an end view of the body piece of  FIGS.  12  and  21   ; and 
         FIG.  23    is a perspective view of an assembly of blocks according to another embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     A. Molded Concrete Blocks—Generally 
     While the techniques described herein were particularly developed for use with concrete blocks made by a dry-cast process, various ones of the techniques described can be applied to concrete blocks formed by wet cast processes, concrete press processes, concrete extrusion processes, 3D concrete printing processes, and other processes. 
     The concrete blocks of particular interest here are generally ones that are mass-produced, and are molded having at least one face or face section molded into a configuration such that the block can be used, together with other such blocks, to create a structure that simulates a wall or wall section made from stone masonry, i.e. to simulate the appearance of many discrete and differentiated stone pieces secured to one another with mortar or similar material. To facilitate this, the blocks are molded with a face or face section that has: visually distinct section(s) with features emulating stone pieces (false stone sections); and, various grooves between those distinct sections that simulate the appearance of joints and/or mortar sections between individual stones (false joints), in spite of the blocks actually having an integral structure and not comprising individual pieces. The blocks can also have a face or face section with various other types of topology to give a craggy appearance, or other types of three-dimensional (positive/negative topology) features, molded in to create a visually attractive appearance. Techniques applicable to mold such blocks are known. In the context of dry-cast concrete blocks, the molding techniques are described, for example, in U.S. Pat. No. 8,128,851, incorporated herein by reference. 
     Herein, the terms “molded block”, “molded block unit” and variants thereof, are meant to refer to a single unitary molded block structure, without specific regard to the method of manufacture (other than molding having been used). The term “dry-cast concrete block” and variants thereof, is meant to specifically reference a block that has been made from a dry-cast concrete process as opposed to a wet-cast concrete process. 
     B. Example Block Types and Features—FIGS.  1 - 6 ,  10 - 13 ,  18 ,  21  and  22   
     It is noted that a concrete block can be characterized by its features “as made”—that is, as the block is oriented within the mold and when removed from the “mold” on a standard dry-cast production line-; or “as installed”—that is, as the block is oriented when installed in a wall or other structure in use. 
       FIG.  1    generally indicates an example concrete block constructed in accord with the present disclosure. Slight variations between what is depicted in  FIG.  1    and  FIG.  2    can be seen, but  FIG.  1    is similar to what is shown in  FIGS.  2 - 6 ,  10 - 13 ,  18 ,  21  and  22   , such that the same reference numerals are used for similar parts. The concrete block  20  includes a first face  22  referenced herein as the “first face, or a front, decorative, face” or by similar terms. This is the face of the block  20  that, when the block is used to form a structure such as a wall, decorative feature, or retaining wall, primarily faces a viewer in front of the wall. It is also preferably a face that is visually enhanced in accord with the present techniques. 
     Opposite the first face  22  is a second face  24 , which is generally referred to herein alternatively as a “back or rear” face. When the block  1  is made in a “dry-cast” mold process, it is typically constructed with front face  22  being directed upwardly and rear face  24  being a bottom surface or downwardly directed surface. When removed from the mold, as a green block for transportation to a curing station, the block is typically oriented resting on the machine pallet with surface  24  down (against the pallet) and face  22  up. 
     Blocks, such as block  20 , generally include third and fourth opposite faces  26 ,  28  that, in use in a wall or other structure, are the left and right sides extending between the first face  22  and second face  24 . The block  20  also includes a fifth (bottom) face  30  and sixth (top or upper) face  32  each extending between surfaces  22 ,  24  and surfaces  26 ,  28 . 
     Still referring to  FIG.  1   , the first face  22  is decorative and can be seen as having visually distinct false stone sections  22   a ,  22   b ,  22   c ,  22   d  and  22   e  separated by groove or false joint sections  22   f . These groove sections  22   f  are molded sections that cause the appearance of the separate sections  22   a - 22   e , to simulate an appearance in the face  22  of a resulting construction from a masonry process in which separate stones (the appearance of which is created by the sections  22   a - 22   e ) are joined together by mortar to form the resulting structure. Techniques for creating such sections and grooves are described for example in such references as U.S. Pat. No. 8,128,851. 
     Herein, visually distinct sections such as  22   a - 22   e  will sometimes referred to as “false stone sections.” By this term it is not meant to be suggested that the sections are actually separate, but rather they are sections that create the appearance of separate stones having been used in the resulting wall or other structure. Sections such as  22   f  will be sometimes referred to as “false mortar sections” or “false joints.” By such terms it is not meant that the sections actually include mortar, but rather the molded sections that create the appearance of mortar between the false stone sections. The decorative face  22  can also have a face that does not include the visually distinct false stone sections and/or false joints; such alternative decorative faces  22  can be any of a variety of appearances including non-limiting flat faces, bumpy faces, or a combination of flat and bumpy faces with or without the use of false joints. 
     It is noted that in some instances portions of the third and fourth faces  26 ,  28  can be provided with molded decorative features to facilitate the appearance of stone sections and/or mortar sections around a corner. This may be particularly desirable in blocks that are to be used as corner blocks in a wall or other construction. 
     In  FIG.  2   , a schematic front elevation view of an embodiment of the block  20  is depicted, with the first face  22  being shown, but without the decorative nature of the face  22  depicted. When the block  20  is a dry-cast block, generated in a mold and removed therefrom on a pallet, in a typical dry-cast process, the first face  22  is upwardly directed, i.e., as an upper (“as made”) face in the uncured or green block. However, when the block is used in a wall, first face  22  is generally a lateral face, with sixth face/upper face  32  directed upwardly and fifth face/bottom face  30  directed downwardly. Since first face  22  is the decorative face, it is generally oriented in the resulting wall or other structure toward the viewer. 
     In  FIG.  2   , the block  20  is depicted having an outer perimeter shape in which the third and fourth faces  26 ,  28  are parallel; and the fifth (bottom) face  30  is perpendicular to the third and fourth faces  26 ,  28 . In general, the first face  22  is generally parallel to the second face  24 . That is, by “generally parallel”, it is meant that even though the first face  22  can be decorative with false stone sections or other non-flat shapes, a plane from which the decorative face projections project in the first face  22  is parallel to the second face  24 , and the distance  34  ( FIG.  1   ) between the first face  22  and second face  24  defines the thickness of the block  20 . 
     The first face  22 , second face  24 , third face  26 , fourth face  28 , fifth face  30 , and sixth face  32  are planar faces. In this context, the term “planar” means that the faces can have some projections and/or recesses, but the overall visual impression is generally planar in that most of the outermost projections are contained within the same general plane. For example, even though the first face  22  can be decorative with false stone sections, it is considered planar since most of the outermost projections are contained within the same plane. As can be seen in  FIG.  2   , the sixth face  32  is contained in a plane that intersects a plane containing the third face  26 . 
     Still in reference to  FIG.  2   , the sixth/upper face  32  has a first section  36  that extends from and is perpendicular to the third face  26 . The first section  36  is parallel to the fifth (bottom) face  30  and extends from the third face  26  toward the fourth face  28  and ends at a remainder section  38 . The remainder section  38  is also referred to herein as an “irregular section  38 ”, as it can have a perimeter with an irregular shape. The first section  36  has a length  40  from the third face  26  to the remainder section  38  that is as least as long as the distance  34  defining the thickness of the block  20 . In  FIG.  2   , the length  40  is equal to a distance from an intersection of the planes containing the sixth face  32  and third face  26  to the remainder section  38 . In many arrangements, the length  40  is equal to the thickness. This relationship leads to advantages when constructing structures (e.g. walls, columns, etc.) with corners, as described further below. 
     The remainder section  38  extends between the first section  36  of the sixth face  32  and the fourth face  28  and is perpendicular to the first (front) face  22  and second (back) face  24 . The perimeter surface of the remainder section  38  is shaped such that when a second block of the same construction as the block  20  has its remainder section  38  engaged against the remainder section  38  of the original block  20 , the remainder sections  38  of the two blocks mate or mateably engage one another. 
     Attention is directed to  FIG.  18   .  FIG.  18    shows the block  20  of  FIG.  2    in front elevation view with false stones and false joints. The remainder section/irregular section  38  can be seen extending from the first section  36  of the top face  32 . Also depicted in  FIG.  18    is the broken line of a plane at  46 . The plane  46  is parallel to the fifth face/bottom  30  and perpendicular to planes containing the third face  26  and fourth face  28 . The plane  46  contains within it (i.e., is co-planar with) the first section  36  of the sixth/top face  32 . 
     The remainder/irregular section  38  includes at least a first cavity  48  that is recessed from the plane  46 . The first cavity  48  forms a depression or recess from the plane  46  in a direction toward the fifth face/bottom  30 . While many different embodiments are possible, in the example shown, the first cavity  48  has a perimeter shape of a trapezoid  50 . The parallel portions of the trapezoid  50  include section  51  of the irregular section  38  of the block  20  and the plane  46 . Extending between the parallel section  51  and plane  46  are inclines or ramps  52 ,  53 . The ramp is slanted downward and away from the first section  36  ending at the section  51 . The section  51  is generally parallel to the fifth face/bottom  30 . The ramp  53  is slanted or angled upward and away from the section  51  to the plane  46 . 
     The remainder or irregular section  38  further includes at least a first projection  54 . The first projection  54  extends or projects from the plane  46  in a direction away from the rest of the block  20 . The first projection  54  has a perimeter shape  55 . The perimeter shape  55  is the same shape as perimeter shape  50  of the first cavity  48 . In this example embodiment, the perimeter shape  55  of the first projection is trapezoidal, as described above with respect to perimeter shape  50 . The perimeter shape  55  in the form of a trapezoid includes parallel section  56 , which is parallel to the fifth/bottom face  30  and the plane  46 . It is also parallel to the section  51  and section  36  along the top face  32 . Extending between parallel section  56  and plane  46  is ramp  57 . Ramp  57  forms a continuous planar surface with the ramp  53 . Extending from the parallel section  56  is ramp  58 , which extends downward and away from parallel section  56  to the fourth face  28 . 
     Because of the shape of the irregular section  38 , including the symmetry between the perimeter shape  50  of first cavity  48  and perimeter shape  55  of the first projection  54 , the block  20  can be mateably engaged or fitted together with a second block  20  of the same construction. 
     In other embodiments, as will be explained further below, there can be additional cavities and projections along the irregular section  38 , and the perimeter shapes of the projections and cavities can be alternatively shaped including polyhedral shapes, curved shapes, and combinations of polyhedral and curved shapes. 
     In  FIG.  2   , it can be seen how in this embodiment, the remainder/irregular section  38  includes a plurality of planar faces relative to each other at non-straight and non-zero angles. The plurality of planar faces can include at least three planar faces, and in the embodiment shown in  FIG.  2   , at least five planar faces. In  FIG.  2   , the planar faces include, starting at the end of the first section  36 : ramp  52 , parallel section  51 , ramp  53  together with ramp  57 , parallel section  56 , and ramp  58 . Ramp  58  ends at fourth face  28 . In other embodiments, there can be more or fewer faces in the remainder section  38 , or the parts of the remainder section can be curved. 
     The block  20  of  FIG.  2    can be many different sizes. In  FIG.  2   , example dimensions are indicated. An example length of the block  20  from third face  26  to the fourth face  28  shown at reference numeral  60  is at least 10 inches, not greater than 20 inches, and about 14 inches. The distance  60   a  from the third face  26  to the section  51  is about 5-6 inches, while the distance  60   b  between the fourth face  28  to the section  51  is greater than 60a, at about 6-7 inches. The height of the block  20  at  61  between the bottom face  30  and first section  36  of the top face  32  is at least 5 inches, no greater than 15 inches, and in one example about 9 inches. The height  62  between the bottom face  30  and section  56  of the first projection  54  is at least 6 inches, no greater than 16 inches, and in one example about 10-11 inches. The thickness  34  shown in  FIG.  1   , which is the same as length  40  of the first section  36  of the top face  32  is at least 3 inches, no greater than 10 inches, and in one example about 4 inches. The depth of the first cavity  48  shown at  62  is at least 0.5 inch, no greater than 3 inches, and one example about 1-2 inches. The depth  63  is the same as the height of the first projection  54 . The distance  64  along the plane  46  from where the first section  36  ends to where the plane  46  intersects the end of the ramp  53  and the beginning of the ramp  57  is at least 3 inches, no greater than 7 inches, and in one example about 5 inches. This distance  64  is also the same as distance  65 , which is the distance of the plane  46  from where the ramp  53  ends and ramp  57  begins to where the ramp  58  ends at the fourth face  28 . A length  66  of the section  51  between ramps  52  and  53  is at least 0.5 inch, no greater than three inches, and in one example about 1 inch. 
       FIG.  3    illustrates the blocks  20  as laid out on a pallet, for example after molding and curing. The blocks  20  are shown as they would be arranged on the pallet, resting on their back faces  24  with the front faces  22  facing upward. In this example, the pallet has a size of about 42 inches by 36 inches and holds four rows of 3 blocks  20  each. 
     It can be see how the bottom row  68  of blocks  20  are arranged end to end, with the fourth face  28  against the third face  26  of the next adjacent block. In the second row  69 , the blocks  20  are also end to end, but the remainder sections  38  of the blocks  20  in the second row are engaged against the remainder sections of  38  of the first row. The projections  54  in the remainder sections  38  of the first row  68 . The third row  70  is shown oriented in the same configuration as the first row  68 , and the fifth face/bottom  30  of the blocks  20  in the third row  70  are against the bottoms  30  of the second row  69 . The fourth row  70  is oriented in the same way as the second row  69 , with the remainder sections  38  of the fourth row  71  mateably engaging the remainder sections  38  of the third row  70 . 
       FIG.  4    is a front elevation view of four of the blocks  20  of  FIG.  2    mated together. As can be seen, the shape of the remainder section/irregular section  38  is such that when block  20  of the same construction has its remainder section/irregular section  38  engaged against the remainder section/irregular section  38  of the first block, the two remainder sections  38  mateably engage. By mateably engaged, in this example, it means that the first projection  54  of the blocks  20  in the upper layer are received by the first cavities  48  of the blocks  20  in the lower layer; and the first projections  54  of the blocks  20  in the lower layer are received by the first cavities  48  of the blocks  20  in the upper layer. The first section  36  of the sixth face  32  of the end block  74  in the bottom layer is open and exposed. It is available for receiving a block  20  in the upper layer either oriented 90° to it, to form a corner, or straight alongside, to form another length in the wall. Because the length  40  of the first section  36  is the same as the thickness  34  of the block  20 , the block  20  is advantageously shaped for forming corners. 
       FIGS.  5  and  6    show some example structures that can be made from the block  20 . A variety of structures are possible including free standing walls, walls with inside and outside corners, benches, garden walls, planters, tables, bars, fencing, columns, outdoor living areas, mailbox inserts, fire pits, benches with columns, planters and columns, decking over short columns, etc. In  FIG.  5    is a construction  76  made from the blocks  20  having three columns  77 ,  78 ,  79 . A pair of parallel facing walls extend between columns  77  and  78 , and between the walls is a section  80  which can hold plants. A pair of parallel walls capped with cap blocks  82  extend between columns  78  and  79 , and can form a seating area. 
     In  FIG.  6   , is a back-to-back wall  84  between two columns  85 ,  86 . Each of the columns  85 ,  86  and wall  84  are constructed from the blocks  20 . 
     In reference to  FIG.  5   , the construction  76  includes the planted section  80 , which is a pair of parallel facing walls, one of which is shown at  88 . In between the walls  88  plants may be placed. The wall  88  is constructed by forming a base course/layer  90  along the ground, with the blocks  20  arranged side by side, such that the first faces  22  of the blocks  20  are generally co-planar, the fifth face  30  is against the ground, and the sixth face  32  with the remainder section  38  is facing up. A first course/layer  91  of the blocks  20  (referred to herein as “second blocks  20 ) are stacked on the base course  90  so that the sixth face  32  of most of the second blocks  20  in the first course  91  are engaged against the sixth face  32  of the blocks  20  in the base course  90 . The remainder section  38  of most of the second blocks  20  is in mating engagement with the remainder section  38  of the blocks in the base course  90 . 
     Still in reference to  FIG.  5   , the construction  76  has a corner  77 , in which there is a second wall section  94  perpendicular to the wall  88 . The second wall section  94  has a base course  95  of the blocks  20  arranged side by side such that the first faces  22  of the blocks  20  in the second wall section  94  are generally co-planar and perpendicular to a plane containing the first faces  22  of the wall  88 . 
     The second wall section  94  has a first course  96  of the blocks  20  (called “second blocks  20 ”) stacked on the second wall section  94  base layer  95  so that the sixth face  32  of most of the second blocks  20  in the second wall section  94  is engaged against the sixth face  32  of the first blocks  20  in the base layer  95  of the second wall section  94 , and the remainder section  38  of most of the second blocks  20  in the second wall section  94  is in mating engagement with the remainder section  38  of the blocks  20  in the base layer  95  of the second wall section  94 . The sixth face  32  of one of the blocks  20  at a first end  98  of the second wall section  94  first layer  96  is engaged against the sixth face  32  of one of the blocks  20  at the first end  98  of the base layer  90  of the first wall section  88 . 
     In the embodiment of  FIG.  5   , the wall sections  88  and  94  are shown as having only a base course and first course of the blocks  20 , but in other embodiments, there can be further layers, as further shown in  FIG.  10   , described below. The columns  77 ,  78 , and  79  have two additional courses arranged in the same manner as the base course and first course. 
     In  FIG.  6   , the back-to-back wall  84  is constructed like the wall  88  of  FIG.  5   , except that there is no space between the parallel walls; rather the parallel walls  101 ,  102  are engaged back-to-back between the columns  85 ,  86 . 
       FIG.  10    is the front view of a wall section  114  that can be constructed of the blocks  20 . In the embodiment of  FIG.  10   , there are six layers of the blocks  20 , shown at courses or layers  115 ,  116 ,  117 ,  118 ,  119 , and  120 . 
       FIG.  11    is another wall section  122  constructed with the blocks  20 . The difference between wall section  122  and wall section  114  is the existence of seams in the wall section  114 . In the wall section  114 , there are seams  123 ,  124  between every two layers of the wall section  114 . For example, there is a seam  123  between layer  116  and  117 , and there is a seam  124  between layers  118 , and  119 . In the wall section of  122  of  FIG.  11   , there are no seams. This is because the wall section  122  is made with the blocks  20  in addition to the use of body pieces  126  ( FIGS.  12 ,  13 ,  21  and  22   ). In  FIG.  11   , the perimeters of some of the blocks  20  and body pieces  126  are bolded so that they can be more easily seen. 
     In  FIGS.  12 ,  13 ,  21 , and  22   , the body piece  126  includes first and second faces  127 ,  128 . The faces  127 ,  128  are parallel and can be generally planar. By “generally planar,” it is meant that any crags, indents, projections, or cavities, do not project or recess greatly, such as no more than 1 inch. 
     In  FIG.  21   , the first face  127  is shown to have false joint lines  130 , dividing the first face  127  into visually distinct false sections  127   a ,  127   b ,  127   c ,  127   d ,  127   e ,  127   f , and  127   g . These false stone sections  127   a - 127   g  are separated by the false joint lines  130  to cause the appearance of separate sections  127   a - 127   g , to simulate an appearance in the face  127  of a resulting construction from a masonry process in which separate stones are joined together by mortar to form the resulting structure. 
     The distance between the first and second faces  127 ,  128 , defines the thickness of the body piece  126 . The body piece  126  further includes third and fourth planar side faces  132 ,  133  that are parallel to each other and perpendicular to the first end second faces  127 ,  128 . 
     Fifth and sixth faces  134 ,  135  are opposite to each other. The first and second faces  127 ,  128  and third and fourth faces  132 ,  133  extend between the fifth and sixth faces  134 ,  135 . Each of the fifth and sixth faces  134 ,  135  have an identical profile shape to each other. The profile shape for each of the faces  134 ,  135  is described below using the same reference numbers. 
     In the example embodiment, the profile shape of faces  134 ,  135  includes at least a planar section  138  and a non-planar remainder section  139 . The planar section  138  extends from fourth side face  133  and extends perpendicular to side face  133  toward the third side face  132  ending at the remainder section  139 . 
     The planar section  138  has a length that is as least as long as the thickness of the first body piece  126 , and can be equal to the thickness. The non-planar remainder section  139  is formed such that when a second body piece  126  of the same construction has its non-planar remainder section  139  engaged against the non-planar remainder section  139  of the first body piece  126 , the non-remainder sections  139  of the first and second body pieces  126  mateably engage. 
     In the example shown, which is designed for use with blocks  20 , the non-planar remainder section  139  of the body piece  126  includes a plurality of planar faces/surfaces angled relative to each other to form ramps at non-straight and non-zero angles. There can be at least three planar faces, and in the example shown in  FIG.  12   , there are five ramps  141 ,  142 ,  143 ,  144 ,  145 . Still in reference to  FIG.  12   , the non-planar remainder section  139  of each of the fifth and sixth faces  134 ,  135  includes a first cavity  146  and a first projection  147 . The first cavity  146  is recessed from a plane  148  that is co-planar with the planar section  138 , and the first cavity  146  is recessed in a direction toward the opposite face. That is, in the fifth face  134 , the first cavity  146  is recessed toward the sixth face  135 , while in the sixth face  135 , the first cavity  146  is recessed toward the fifth face  134 . 
     The first projection  147  extends from the plane  148  that is co-planar with the planar section  138  in a direction away from a remainder of the body piece  126 . Each of the first cavity  146  and first projection  147  have the same perimeter shape. In the example shown in  FIG.  12   , the perimeter shape is a trapezoid. The trapezoid of the first cavity  146  is defined by ramps  141 ,  142 , and a portion of  143 . The trapezoid of the first projection  147  is defined by ramps  144 ,  145 , and a remainder of  143  that projects from the plane  148 . 
       FIG.  13    shows the perimeter outline of body piece  126  with example dimensions. A length of the body piece  126  between the third face  132  and fourth face  133  is shown at  155  and can be at least 10 inches, no greater than 20 inches, and about 13-15 inches. The lengths  155   a ,  155   b  of the projection  147  and recess  146  respectively are at least 3 inches, no more than 7 inches, and typically about 4-6 inches. The length  155   c  of the planar section  138  will often be less than the lengths of  155   a  and  155   b , and will be at least 2 inches, no more than 6 inches, and typically about 3-5 inches. A greatest height  156  of the body piece  126  between the peaks of the projections  147  is at least 8 inches, no greater than 22 inches, and typically about 11-12 inches. A height  157  between the planar sections is at least 6 inches, no greater than 12 inches, and typically about 8-10 inches. The thickness  158  ( FIG.  22   ) of the body piece  126  will be as least as long as the length  155   c  of the planar section  138  and may be equal to the length  155   c  in preferred arrangements. Many alternatives are possible. 
     Turning again to the wall section  122  of  FIG.  11   , it can be seen how the wall section  122  includes base course/layer  150  of the blocks  20  arranged side by side, such that the first faces  22  are generally co-planar. Stacked on top of the base course  150  is a first course  151  of the body pieces  126 . The body pieces are stacked on the base course  150  so that the planar section  138  of the sixth surface  135  of each of the body pieces  126  in the first course  151  is engaged against the sixth face  32  of the blocks  20  in the base course  150 . The non-planar remainder section  139  of the sixth surface  135  of the first course  151  of body pieces  126  is in mating engagement with the remainder section  38  of the sixth face  32  of the base course  150  of the blocks  20 ′. 
     A second course  152  of the body pieces  126  is stacked on the first course  151  so that the planar section  138  of the fifth surface  134  of each of the body pieces  126  in the second course  152  is engaged against the planar section  138  of the fifth surface  134  of the body pieces  126  in the first course  151 . The non-planar remainder section  139  of the fifth surface  134  of the second course  152  of body pieces  126  is in mating engagement with the non-planar remainder section  139  of the fifth surface  134  of the first course  151  of body pieces  126 . 
     Still in reference to  FIG.  11   , the wall section  122  further includes a third course  154  of the blocks  20  stacked on the second course  152  of body pieces  126  so that the sixth face  32  of each of the blocks  20  in the third course  154  is engaged against the planar section  138  of the sixth surface  135  of the body pieces  126  in the second course  152 . The remainder section  38  of the third course  154  of the blocks  20 ′ is in mating engagement with the non-remainder section  139  of the sixth surface  135  of the second course  152  of body pieces  126 . 
     It should be understood that body pieces  126  can be shaped to work with the blocks  20  of any of the various embodiments described herein and other variations within the scope of this disclosure. 
     C. Example Block Type and Features, FIGS.  7 - 9   
       FIG.  7    illustrates another embodiment of the block, shown here as block  20 ′. The same reference numerals are used for the same parts, although it should be understood that the outer perimeter has a different shape from that of the block of  FIG.  2   , as further described. 
     In this embodiment, the first cavity  48  has a perimeter shape of a triangle  110 . The first projection  54  has a perimeter shape of a triangle  112 . The remainder/irregular section  38  has, from left to right starting at the first section  36  of the sixth face  32 : ramp  104  extending downward and away from the first section  36 ; ramp  105  extending upward and away from ramp  104 ; ramp  106  which is continuous with ramp  105 ; and ramp  107  extending downward and away from ramp  106  to end at fourth face  28 . The first cavity  48  is defined by ramps  104 ,  105 . The first projection  54  is defined by ramps  106 ,  107 . 
     In  FIG.  8   , the dimensions of the block  20 ′ are illustrated. The dimensions are about the same as the dimensions shown in the  FIG.  2    embodiment. 
     In  FIG.  9   , the blocks  20 ′ are illustrated as they would be laid out on a pallet, laying on their backs  24  with the first face  22  facing up. The pallet can accommodate four layers of three blocks  20 ′ each. It can be seen how the remainder sections  38  mateably engage each other. 
     D. Example Block Types FIGS.  14 ,  15 , and  19   
       FIG.  14    illustrates another embodiment of the block, shown here as block  20 ″. The same reference numerals are used for the same parts, although it should be understood that the outer perimeter of block  20 ″ has a different shape from that of the block  20  of  FIG.  2    and block  20 ′ of  FIG.  7   , as further described. 
     In this embodiment, the remainder section  38  includes seven planar faces  161 ,  162 ,  163 ,  164 ,  165 ,  166 , and  167 . In  FIG.  19   , it can be seen how the remainder/irregular section  38  has first cavity  48  with a perimeter shape of a triangle  170 , while the first projection  54  also includes a triangle perimeter shape  171 . 
     The block  20 ″ further includes a second cavity  174 . The second cavity  174  is recessed in a direction toward the fifth face  30 . There is a second projection  175  extending in a direction away from the rest of the block  20 ″. The second cavity  174  and the second projection  175  have the same perimeter shape. In this example, the perimeter shape of the second cavity  174  and second projection  175  is trapezoidal. 
     The planar faces  161 ,  162  are angled relative to each other to form the first cavity  48 . The planar faces  162 ,  163 , and  164  form the trapezoidal shape of the second projection  175 . The planar faces of  164 ,  165 , and  166  form the trapezoid of the second cavity  174 . The planar faces  166  and  167  form the perimeter shape of the first projection  54 . 
     As can be seen in  FIG.  14   , the second projection  175  is between the first cavity  48  and the second cavity  174 . Furthermore, the first cavity  48  and second cavity  174  alternate with the second projection  175  and first projection  54  along the irregular section  38 . 
       FIG.  15    shows a wall construction  178 , including wall section  178   a  and wall section  178   b  joined at a corner  180  assembled from the blocks  20 ″. In the example shown in  FIG.  15   , the wall construction  178  has four layers or courses of blocks  20 ″. It can be seen how the base course  181  is laid with the fifth/bottom face  30  against the ground surface, and the first course  182  is assembled on top of the base course  181  with the sixth face  32  pointed downwardly to mateably engage with the base course  181 . The remainder sections  38  of the blocks  20 ″ mateably engage with each other. 
     The second course  183  is assembled with its fifth face/bottom face  30  engaged against the fifth face/bottom  30  of the first course  182 . The third course  184  is assembled on top of the second course  183  with the fifth face  30  pointed downwardly so that the remainder sections  38  mateably engage between the second course  183  and third course  184 . 
     At the corner  180 , one of the blocks  20 ″ a  at the corner  180  is in the base course in part of the wall construction  178   a  and is perpendicular to the wall construction  178   b . The block  20 ″ a  has its sixth face  32  engaged against the sixth face  32  of block  20 ″ b  in the first course  182  in the wall construction  178   b . A similar construction of the corner  180  is made between the second course  183  and third course  184 . 
     E. Example Block Types, FIGS.  16 ,  17 , and  20   
       FIGS.  16 ,  17 , and  20    illustrate another embodiment of the block shown here as block  220 . The same reference numerals are used for the same parts, although it should be understood that the outer perimeter of block  220  has a different shape from that of the block  20  of  FIG.  2   , as further described. 
     In the previous embodiments, in general, the shape of the remainder section/irregular section  38  is polyhedral. In contrast, in the embodiment of  FIGS.  16 ,  17 , and  20   , the perimeter shape of the remainder section  38  is curved. Some embodiments can also include a combination of both polyhedral and curved shapes for the remainder section  38 . 
     In  FIG.  16   , the first cavity  48  has a perimeter that is curved, while the first projection  54  has the same shape, which is curved. The curved section of the first cavity  48  is defined by at least one concavely curved surface  222 , while the first projection  54  is defined by at least one convexly curved surface  224 . 
     Many different perimeter shapes are possible, and in the example shown, the first cavity  48  and first projection  54  are generally in the shape of semi-circles. Other shapes can includes sine-wave shapes, or any of a variety of shapes. There can be multiple curved surfaces resulting in multiple cavities and projections. 
     In  FIG.  16   , example dimensions are shown and many variations are possible. The thickness of the block  220  is shown at  240  and will be as least as long as the length  241  of the first section  36 , preferably equal to the length  241 , with a value of at least 4 inches, no greater than 10 inches, and typically about 5-7 inches or about 6 inches. The length  243  of the recess  48  and length  242  of the projection  54  will be equal and at least 6 inches, no greater than 12 inches, and typically about 8-10 inches or about 9 inches. The depth  243  of the recess  48  and the height  244  of the projection  54  will be equal and at least 2 inches, no greater than 8 inches, typically about 3-5 inches or about 4 inches. 
     In  FIG.  17    is a wall construction  226  made from the blocks  220 . The wall construction includes a first segment  226   a  and a second segment  226   b  joined at a corner  228 . 
     The wall construction  226  has two courses, shown as base course  230 , which is against the ground and first course or layer  231  which is against the base layer  230 . The base layer  230  is made from the blocks  220  by orienting the blocks  220  with the fifth face  30  against the ground. The blocks  220  in the first section  226   a  have their first faces  22  co-planar with each other, while the blocks  220  in the second wall section  226   b  are oriented so that their first faces  22  are 90° to the first faces  22  of the blocks  220  in the first section  226   a.    
     The blocks  220  in the first layer  231  are oriented upside down from the blocks in the base layer  230 , so that the sixth face  32  and remainder section  38  of the blocks  220  in the first layer  231  mateably engage and are received by the remainder section  38  of the blocks  220  in the base layer  230 . 
     At the corner  228 , the sixth face  32  of the block  220   a  in the first layer  231  is engaged against the sixth face  32  of the block  220   b  in the base layer  230 . The block  220   b  is in the wall construction section  226   b , while the block  220   a  is in the wall construction section  226   a . As such they are perpendicular to each other. 
     F. Example Block, FIG.  23   
       FIG.  23    illustrates another embodiment of the block, shown here as block  320 . The same reference numerals are used for the same parts, although it should be understood that the outer perimeter of block  320  has a different shape from that of the block  20  of  FIG.  2   , block  20 ′ of  FIG.  7   , block  20 ″, and block  220 , as further described. 
     In this embodiment, the remainder section  38  includes four planar faces  361 ,  362 ,  363 ,  364 . In  FIG.  23   , it can be seen how the remainder/irregular section  38  has first cavity  48  with a perimeter shape of a triangle  370 , while the first projection  54  also includes a triangle perimeter shape  371 . 
     The planar faces  361 ,  362  are angled relative to each other to form the first cavity  48 . The planar faces  362 ,  363  form a triangular perimeter shape of the first projection  54 . Extending from a base of the first projection  54 , at an end of the face  363  is the planar face  364  extending to the fourth face  28 . The planar face  364  is generally parallel to the fifth (bottom) face  30 . In preferred embodiments, the planar face  364  is co-planar with the first section  36  of the sixth (upper) face  32 . 
     In this embodiment, the first section  36  has a length  40  from the third face  36  to the remainder section  38  at least as long as the thickness  34  of the block  320 . In the example shown in this embodiment, the length  40  of the first section  36  is greater than the thickness  34  of the block  320 . 
       FIG.  23    shows a wall construction  378 , including wall section  378   a  and wall section  378   b  joined at a corner  380  assembled from the blocks  320 . In the example shown in  FIG.  23   , the wall construction  378  has two layers or courses of blocks  320 . It can be seen how the base course  381  is laid with the fifth/bottom face  30  against the ground surface, and the first course  382  is assembled on top of the base course  381  with the sixth face  32  pointed downwardly to mateably engage with the base course  381 . The remainder sections  38  of the blocks  320  mateably engage with each other. 
     At the corner  380 , one of the blocks  320   b  at the corner  380  is in the base course in part of the wall construction  378   b  and is perpendicular to the wall construction  378   a . The block  320   b  has its sixth face  32  engaged against the sixth face  32  of block  320   a  in the first course  382  in the wall construction  378   a.    
     G. Example Methods 
     A variety of structures can be constructed from the blocks described herein with methods as generally described above. The methods generally include laying out the base course of the blocks, and arranging a first course on top of the base course in such a way that the first course is oriented so that the remainder section of the first course is against and mateably engaged with the remainder section of the base course. Corners can be constructed due to the length of the first section of the sixth face being as least as long as the thickness of the block as defined by the distance between the front and back faces. The result of this geometry is that a corner is made by the sixth face of one of the blocks in the first course and at the end of a wall section perpendicular to a first wall section is engaged against the sixth face of one of the blocks at the corner section and of the wall perpendicular to it in the base layer. 
     The above represents example principles. Many embodiments can be made using these principles.