Patent Publication Number: US-2018051436-A1

Title: Systems and methods for use in retaining wall construction

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/376,160 filed on Aug. 17, 2016, and is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present invention relates to a system and methods for use in installation of a retaining wall using cast concrete blocks adapted to be pinned together. 
     BACKGROUND OF THE INVENTION 
     In the formation of retaining walls that require reinforcement to withstand significant pressures from adjacent soil formations, products have been developed which allow individual formed blocks of material to be connected to one another to reinforce the wall formed therefrom. One type of block product, particularly useful for forming retaining walls, uses building blocks formed of a concrete material. The blocks stack one on another in rows or courses. In general, the blocks are slightly offset rearwardly from the row immediately below it. In another style, referred to as the flush mode, the forward ends or faces of the blocks are substantially flush with each other. In either form, the blocks are held together using pins or like structures which are inserted through holes or other structures and lodged in recesses or the like in the blocks. The blocks further include one or more hollow core sections provided for housing a reinforcement material, such as aggregate or gravel, that is backfilled into the hollow cores. The pins or the like will hold the blocks together in the desired configuration along with aggregate or gravel provided in the hollow cores of the blocks. 
     Installation of such retaining wall blocks leads to the problem of the filler, such as aggregate or gravel, used to fill the cores in the blocks tends to fill the channels and/or apertures in the block members used in pinning the blocks together. This requires cleaning out any such aggregate, gravel, or other debris prior to being able to stack another block on top of a laid block for pinning the blocks together. It would be desirable to prevent the aggregate, gravel or other backfill materials or debris from entering the channels and/or apertures in the blocks until another course of blocks are ready to be stacked on a lower course of blocks that have been laid and the cores have been filled with such aggregate, gravel or other backfill materials. 
     SUMMARY OF THE INVENTION 
     In an aspect, the invention relates to a cover system for block members having at least one hollow core and used in construction of a retaining wall. The cover system comprises a cover member having a top section and at least one downwardly depending portion from the top section. The at least one downwardly depending portion is positioned with respect to the top section such that it extends into at least a first structure formed in the top of at least one block, but leaving the at least one hollow core of the block uncovered. The top section may be dimensioned to extend over additional structures formed in the top of the at least one block. The structures covered by the cover system may be used for covering portions of the block used for positively engaging the block member to another block member. 
     In another aspect, the invention relates to a method for installing a retaining wall using block members stacked on one another. The method includes laying of a plurality of block members having at least one hollow core portion in at least one layer on a surface defining the base of the retaining wall. A cover member is positioned to cover channels, apertures or other structure formed in the block members. The at least one hollow core of each block member is not covered and is filled with a predetermined fill material. At least one further layer of a plurality of block members having at least one hollow core portion are laid upon the lower layer of blocks. The steps are repeated to form a retaining wall of predetermined specifications for each layer of block members. The cover members may be removed before the further layer of block members are stacked on a lower block member. 
     Examples are directed to systems and methods for covering the channels and/or apertures or other structure formed in the top surface of the block members used to form a retaining wall. The systems and methods allow for covering of portions of one or more block members before or after laying of the block members. This allows filling of the hollow cores in the block members with filler materials, while preventing the filler materials from entering into channels, apertures or other structures in the block members that may be used for securing blocks together in the wall construction. A cover member has a top section and at least one downwardly depending section or member extending downwardly from the top section. The downwardly depending section may have at least one radially outwardly extending portion which, in use, engages with structure formed in the block members. The at least one radially outwardly extending portion may provide an interference fit of the downwardly depending section or stem in the channel, aperture or other structure in the top portion of the block member. When positioned with one or more block members, the cover member covers the channel, aperture or other structure formed in the blocks to prevent filler materials or other debris from entering into the channel, aperture or other structure in the block members. 
     Other aspects of the invention will become apparent upon reading the following description in conjunction with the figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features and advantages of the present invention will become better understood with regard to the following description, appended claims and accompanying drawings wherein: 
         FIG. 1  is an example of a retaining wall formed from a plurality of block members. 
         FIGS. 2A and 2B  are sectional views of block members in pinned relationship to one another when stacked in the retaining wall of  FIG. 1 . 
         FIGS. 3A and 3B  are end views of embodiments of a cover system for covering predetermined portions of a plurality of block members laid in forming a retaining wall, and  FIG. 3C  is a top view of another embodiment thereof. 
         FIGS. 4A-4C  are top and side views of alternate examples of the invention configured to be left in place after installation with one or more blocks. 
         FIG. 5  is a top view of a plurality of block members with the system of  FIG. 3  positioned therewith. 
         FIGS. 6A-6D  are top views of alternate types of block members usable for forming retaining walls, that the invention may be configured for use with. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is described in detail with reference to examples and to the figures. As shown in  FIG. 1 , there have been developed retaining wall block systems  10  for construction of retaining walls by stacking of the blocks to a desired height and configuration. Such systems are used for commercial and residential retaining walls. For example, various block systems are designed for creating very large retaining walls around road and highway areas for example, or a multitude of other environments. Such systems generally include a plurality of blocks  12  formed into layers stacked on each other. The blocks  12  are generally formed of concrete or other suitable materials, and are engineered to form a retaining wall designed to retain earthen materials (or other materials such as water) behind its height. The height of walls constructed from blocks  12  may be significant, and in order to maintain desired structural integrity, such block members  12  may include designed features to allow the blocks  12  to be positively locked together. In the example of  FIG. 1 , the block members  12  include channels  14  and apertures  16  which allow pinning of the stacked block members together. The block members  12  also include at least one hollow core area  18 . The hollow core area  18  allows for the introduction of predetermined filler materials, such as gravel, which is used to anchor each of the block members  12  in association with pinning or other structures to allow the blocks  12  to be positively locked together. 
     As shown in  FIG. 2 , example block members  12  are stacked on one another and positively locked together using a pin system. The pins  20  are designed to be inserted through apertures  16  in a top block  12  and to extend into a channel  14  of the lower block  12 . The arrangement of channels  14  and apertures  16  in each block  12  allow for stacking in a setback arrangement as shown in  FIG. 2A  or a substantially flush arrangement as shown in  FIG. 2B . To install the pins  20 , the blocks  12  are stacked upon one another at predetermined relative positions to allow the pin  20  to extend through aperture  16  and into a channel  14  of the lower block  12 . If any obstruction or debris is located in the channels  14  or apertures  16 , proper pinning of the blocks  12  to one another is prevented. At the same time, it is necessary to backfill the at least one hollow core area  18  with a fill material once the layer of blocks  12  is laid. The backfill provides further required structural integrity for the retaining wall and also provides drainage regions. This step of backfilling generally results in the filler material getting into the channels  14  and/or apertures  16 , which then prevents proper laying of a next layer of blocks  12  and/or pinning of an upper block  12  to a lower block  12 . To avoid such a problem, at least the channels  14  and/or apertures  16  of the blocks  12  must have any debris from the backfilling step removed prior to laying of a next layer of blocks  12 . This results in the significant extra labor and expense in the installation of the retaining wall, which it would be desirable to avoid. 
     Turning to  FIG. 3A , a first example of a cover system  30  according to the invention is designed to avoid the above problem, and provides at least one cover member  32  for temporary covering of portions of one or more block members  12  after laying of the block members  12 . This allows filling of cores  18  in the block members  12  with filler materials, while preventing the filler materials from entering into the channels  14  or apertures  16  in the block members. A cover or cap member  32  has a top section  34  and a stem section  36  extending downwardly from the top section  34 . The stem  36  may have at least one radially outwardly extending portion  38  which, in use, engages with a channel  14  formed in the block members  12 . The at least one radially outwardly extending retention member(s)  38  may serve to create an interference fit with the channel  14  or other structure in the top of blocks  12  to positively engage the channel  14  (or other structure) in the blocks  12 . The at least one radially outwardly extending retention member(s)  38  may be angled to form a lead-in taper to assist with insertion into the channel  14 , and then to engage and provide an interference fit of the stem  36  in the channel  14 . When positioned with the block members, the cap  32  covers the channels  14  and apertures  16  formed in the blocks to prevent filler materials or other debris from entering into the channels  14 , apertures  16  or other structure in the top of blocks  12  used for positively engaging the blocks  12  together. 
     In the example of  FIG. 3A , the top section  34  has a predetermined width A with first and second edges  40  and  42 . In the block member  12  shown in this example, the width A is approximately 2.35 inches (56.69 mm). In this example, the stem portion  36  extends downwardly at a location approximately 0.80 inches (20.32 mm) from a first edge  40  of the top section  34 , forming a width B between edge  40  and stem  36 . This results in a width C between the stem  36  of top portion  34  and edge  42  being approximately 1.55 inches (39.37 mm), which is designed to extend over the apertures  16  in block members  12  when the stem  36  of cover  32  is engaged in channel  14 . The width B may be of any desired width to allow positive engagement of stem  36  into channel  14 , and for ease of manufacturing. The stem  36  may be dimensioned to correspond to the dimensions of channel  14  or other structures formed in blocks  12 . In this example, the stem  36  extends downwardly from the top section  34  a distance of approximately 0.4-0.6 inches, and in this example extend 0.49 inches (10.80 mm), but any suitable arrangement may be used. The retention member(s)  38  for engaging the sides of the channel  14  for retention of cover member  32  therewith may be formed as outwardly extending members angled toward the top section  34 , with dimensions to slightly engage the sides of channel  14 . In this example, a pair of retention members  38  are provided, and extend a width D from the stem section  36 . In this example, the width D may be slightly greater than the width of channel or aperture in which it is positioned, such as approximately 1.60 inches (12.44 mm) which is slightly greater than the width of channel  14  in this example. The retention members or fins  38  of this example may also have a thickness of approximately between 0.02-0.06 inches, or in this example, 0.037 inches (0.93 mm), to allow deformation to create an interference fit with channel  14 . The distance between the retention members or fins  38  of this example may be approximately 0.1-0.2 in. and in this example are 0.123 inches (3.13 mm), but any suitable arrangement may be used. The stem section  36  may extend from cover member  32  a dimension to substantially fill the channel  14  or other structure, to prevent the possible entrance of debris into the channel  14  or other structure. In many cases, the block members  12  have beveled or tapered edges as seen in  FIG. 1 , and upon backfilling, it may be possible that debris could enter the channel  14  or other structure at the locations between blocks  12 , where these tapered edges are adjacent one another in adjacent blocks  12 . The cover member  32  may be designed to prevent such ingress, such as by downwardly depending portions that cover the bevel or taper in a particular block configuration. Alternatively to the particular example, other dimensions or structures to position the cover member may be suitable and are contemplated as a part of the invention. 
     Any other suitable arrangements to allow temporary engagement with the sides of the channel  14  (or other structure) are contemplated in the invention, such as a deformable boss extending downwardly from the top section  34  or the like. It is also contemplated that the cover system  30  does not have to necessarily be engaged, such as frictionally, with the structure formed in blocks  12 , but simply may include aligning structures extending downwardly that allow proper positioning of the cover system  30  in the desired temporary location in association with and to cover channels  14 , apertures  16  or other structures formed in the top surface of the blocks  12 . The cover system  30  may have any desired length for use in covering the channel(s)  14  and/or apertures  16  in one or more blocks  12 . For example, the cover member  32  may be formed in ten (10) foot lengths, but any desired length is envisioned. 
     In another example of the invention as in  FIG. 3B , the cover  32  may have one or more angled surfaces, such as a peaked or domed top  44  system that tends to cause any filler material used to fill the at least one hollow core  18  to slide off the top section  44 . This angled, peaked or domed top  44  may facilitate prevention of any filler materials getting into the channels  14 , apertures  16  or other structures of blocks  12  upon removal of the cover member  32  after backfilling the hollow core regions  18 . 
     In another example of the invention as in  FIG. 3C , the cover  32  may have a top section  46  having score lines  48  formed therein, to allow the length of the cover  32  to be easily adjusted simply by bending at the score line  48 . Other suitable arrangements to allow simple length adjustment are also contemplated, such as notches formed at different lengths or the like, system that tends to cause any filler material used to fill the at least one hollow core  18  to slide off the top section  44 . As also shown in this example, the top section  46  may have a handle portion  50  to facilitate removal of the cover  32  from its installed position with a one or more blocks  12  by simply pulling up on the handle  50 . As another alternative, one or more of the ends of the cover member  32  may have an interconnecting structure  52  provided to allow lengths of cover members  32  to be interconnected together in the installed position with a one or more blocks  12 . Any suitable interconnecting arrangements  52  to allow connection of lengths of the cover members  32  to one another are contemplated, such as a dovetail type connection as shown using male/female structure that mates together, a hook and loop fastening section at each end or other suitable connection. 
     Turning to  FIGS. 4A-4C , alternate examples of the cover system of the invention are shown. In this example, the cover system  300  is configured to be installed in position with one or more blocks  12  prior to backfilling. After backfilling, the cover system  300  is left in place and a further layer or course of blocks  12  is laid on top of the cover system  300  in its installed position with one or more blocks  12 . In this configuration, the cover system  300  may include one or more punch out portions  305  formed in the top  304  of the cover member  302 . The punch out portions  305  may be formed using score lines, the material may allow for punching out a portion or portions  305  may be formed in any other suitable manner, to allow a pin  20  (or other like member) used to secure stacked blocks  12  together as previously described. The pin  20  (or other like member) breaks through the top  304  and into a locking position within channel  14  of the lower block  12 , or in association with other structure to allow blocks to be secured together. The position of the portions  305  corresponds to the location of the channel  14  other structure to allow blocks to be secured together. Alternatively, instead of punch out portions  305 , the cover member  302  may be made of a material that allows a pin  20  or the like to be punched through it relatively simply, while still providing the structural integrity to allow backfilling without debris entering the channel  14  or other structure. For example, the cover member  302  may be formed of a hard paper material, thin plastic material, or any other suitable material that allows a pin or the like to be punched through it relatively simply. The cover member  302  may also be formed of a biodegradable material that will degrade after installation of the retaining wall  10 . As seen in  FIG. 4B , the cover system  300  may have downwardly depending stem portions  307 , which may be similar to the stem portions  36  previously described, but only positioned adjacent or at the ends of the cover system  300  or intermittently along the length of cover system  300 , leaving the punch out portions  305  without any structure beneath them. Alternatively, as seen in  FIG. 4C , the cover system  300  may have downwardly depending end portions  309 , designed to extend over the side edge of a block  12  to be retained in place. The cover system may be made to correspond to a single block  12  or a plurality of blocks  12 . 
     In an example, the system  30  or  300  may be fabricated of a material that has good durability, but also some amount of flexibility. As shown in  FIG. 5 , many times a retaining wall  10  has concave or convex curvatures. The cover system  30  or  300  of the invention may be designed to allow lengths to be flexed to accommodate such curvatures. For example, the material used to make cover system  30  or  300  may be a semi-rigid polyethylene that is extruded to form the system  30  or  300  in desired lengths. The cover system  30  or  300  may be formed of any suitable material, such as a plastic or paper material as noted, or alternatively, the material may be an elastomeric material. It may also be desirable to form the system  30  or  300  from a material that allows lengths to be rolled to facilitate cost-effective packaging and shipping. As described above, the cover system  30  or  300  may also be formed to fit an individual block  12 , allowing pre-assembly of the cover system  30  or  300  with each block  12  separately before the block is laid. 
     Other examples of blocks  12  having at least one core region, used in forming retaining walls are shown in  FIGS. 6A-6D . In the prior example of  FIGS. 1 and 2 , the blocks  12  are commercially produced and sold under the Versa-Lok brand by Kiltie Corporation, and referred to as the Square Foot block. This manufacturer also makes other block products using as least one hollow core region designed to be filled with particular filler materials, such as shown in  FIG. 6A , referred to as an Ultra unit. In this type of block, similar channels  14  and apertures  16  are provided to positively couple the stacked blocks  12  together, by pinning. Or, in the block of  FIG. 6B  from the same manufacturer, referred to as the Nexus block unit, the block  12  includes channels  60  and extending bosses  62  around the core  18 . The block  12  shown in the example of  FIG. 6C  is produced by Tensar International Corporation under the brand name Mesa Retaining Wall Systems, and this particular product is referred to as the Mesa Standard Unit. In this block, the structures formed on the top of block  12  include a channel  64  to accommodate a Mesa Standard Connector (not shown) as well as channel  66  along with channel  64  for accommodating an end of a geosynthetic reinforcing fabric/sheet used in constructing a retaining wall  10 . A further block product  12  using as least one hollow core region designed to be filled with particular filler materials, is shown in  FIG. 6D , being manufactured by Keystone Retaining Wall Systems, a Contech company, and is referred to as the Keystone Compac. In this example of a block  12 , there is provided apertures  68  for pinning of the stacked blocks  12  together, and cavities  70  to accept pins when stacked on a block below. As seen in each of these different examples of  FIGS. 6A-6D , the blocks  12  have at least one hollow core region designed to be filled with particular filler materials. Each block  12  also includes structures formed on the top surface thereof to allow positive coupling between stacked blocks, just as in the example described above with reference to  FIGS. 1 and 2 . Alternatively or in addition, as noted with other block configurations above, the blocks  12  may include structure on the top faces of the blocks for engaging and retaining geosynthetic reinforcing fabric/sheet or like products or with other materials used in constructing a retaining wall as will be appreciated by persons skilled in the art. As in the example of  FIGS. 1-2 , for each of these or other block configurations, the cover system  30  of the invention will be configured to cover the structures for positive coupling between stacked blocks to allow backfilling of the hollow core regions without debris getting into the structures for positive coupling or retention of materials between stacked blocks  12 . Though not shown in detail with respect to each of these examples of blocks  12 , a person skilled in the art would easily configure the cover system to operate in the manner as described, and such different configurations of the cover system  30  or  300  of the invention are contemplated within the invention. For example, the cover system  30  or  300  described with reference to  FIGS. 1-5  above include a downwardly depending portion that would be configured to fit into the channels  14 ,  60 ,  64  and/or  66  in the examples above, with the top portion then configured to cover other structures on the top surface of blocks  12  while leaving the core  18  open for backfilling. Similarly, the downwardly depending portion could be configured to fit into the apertures  68  or cavities  70  of the example block  12  shown in  FIG. 6D . It should also be recognized that these examples of blocks  12  are only examples, and there are a variety of other manufacturers and blocks  12  for which the cover system of the invention could be used. Further, in addition or in the alternative, the cover system  30  or  300  may include a downwardly depending portion that is dimensioned to extend into the hollow core  18  adjacent structures to be covered thereby, as a means to retain cover system  30  in a desired position in relation to the structures for positive coupling of stacked blocks, while still allowing backfilling of the hollow core regions  18  without debris getting into or around the structures. 
     In use, the cover system  30  or  300  is used in construction of a retaining wall  10 . The method relates to installing a retaining wall  10  using block members  12  stacked on one another in layers to a predetermined height and configuration. The method includes laying of a plurality of block members  12 , having at least one hollow core portion, in at least one layer on a surface defining the base of the retaining wall  10 . A cover member  32  is positioned to cover channels  14 , apertures  16  or other structure formed in the block members. The cover member  32  does not cover the hollow core  18 . The at least one hollow core(s)  18  of each block member  12  are filled with a predetermined fill material. The cover member of the cover system  30  or  300  is then removed or left in place as described in examples, and at least one further layer of a plurality of block members  12  having at least one hollow core portion  18  are laid upon the lower layer of blocks and the blocks  12  are positively engaged to one another. These steps are repeated to form a retaining wall of predetermined specifications. The positioning of cover member  32  with a one or more blocks  12  simply requires snapping or inserting the stem section  36  into a channel  14  or other structure of blocks  12 , with extension(s)  38  engaging the sides of the channel  14  or other structure of blocks  12  for retention of cover member  32  therewith. Thereafter, for the cover system  30 , the cover member  32  is simply removed by pulling the cover member  32  out of the frictional engagement with channel  14  or other structure formed in the top surface of the blocks  12 . Alternatively, the stem  36  may not be frictionally engaged but simply positioned in the channel  14 . For a cover system  300 , the cover member is left in place and the at least one further layer of a plurality of block members  12  having at least one hollow core portion  18  are laid upon the lower layer of blocks and the blocks  12  are positively engaged to one another. In another example, the cover system  30  or  300  is pre-installed on one or more blocks  12  to allow positioning of the blocks  12  in a retaining wall with the system in place, to allow immediate backfilling after installation. 
     The invention has been described with reference to examples presented above. Only examples have been presented and described in detail, it is to be understood that the invention is not limited thereto or thereby. It is therefore intended that the invention not be limited to the particular embodiments disclosed as examples of invention, but that the instant invention will include all embodiments falling within the scope of the appended claims.