Patent Publication Number: US-2018030728-A1

Title: Method for casting reinforcement alignment features into concrete wall blocks

Description:
PRIORITY CLAIM 
     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. 62/369,394, titled “METHOD AND FORMS FOR CASTING REINFORCEMENT ALIGNMENT FEATURES INTO CONCRETE WALL BLOCKS,” filed Aug. 1, 2016. The entire disclosure of the aforementioned patent application is incorporated by reference as if fully stated herein. 
    
    
     FIELD 
     This patent application relates to a method for casting reinforcement alignment feature into concrete wall blocks and precast concrete wall blocks configured for assembly into a wall. 
     BACKGROUND 
     It is common in masonry block construction of cast center cores or cast-in-place cantilever walls to use steel reinforcing members embedded inside the structures. These members are typically assembled in the field with a variety of components, such as reinforcement bar (rebar) and welded wire mesh. These components are often secured to each other using plastic clips or lengths of wire twisted around the intersection of the components. 
     The design of wall construction typically defines the type, size, and placement of the reinforcing members. Typically, the correct location of the reinforcing members is specifically determined in order to maximize the stabilizing effects of the reinforcing members and their components. The loading conditions on the wall affect the location of reinforcing members. Improper placement of the reinforcing members compromise the strength and stability of structures, such as walls, and lead to structural deficiencies and/or inadequate performance of the walls. A variety of positioners and aligners exist to maintain the components at the desired position within the block core, while grout, concrete, or other hardening fill material is poured into the block core. Examples of such positioners and aligners include “rebar chair,” “rebar wheels,” and brackets for positioning the rebar. 
     Some commonly used reinforcement alignment techniques for creating structurally stable, cast concrete walls use an insulated concrete form (ICF). In these techniques, polystyrene panels are secured to each other using plastic ribbed connectors, which include grooves or holes for positioning and aligning reinforcing members. Other reinforcement alignment techniques use a rebar chair to retain rebar and to support concrete reinforcement materials and other precast structures. However, the reinforcement alignment features disclosed above are separately integrated (not precast) to the concrete core and to the formwork. As a result, the form and reinforcement alignment features must be constructed at the actual job/construction site, which greatly increases the amount of time and labor spent constructing a wall. In addition, there is a greater likelihood for placing the reinforcement members and/or their components in incorrect or undesired positions when constructing such a wall. 
     Consequently, there is a need to precast reinforcement alignment features on concrete wall blocks using the same forms that cast the concrete wall blocks, while maintaining the strength, stability, and durability walls constructed from the concrete wall blocks. 
     SUMMARY 
     What is provided is a method for casting reinforcement alignment feature into concrete wall blocks and precast concrete wall blocks configured for assembly into a wall. Reinforcement alignment features, such as horizontal reinforcement grooves and/or vertical reinforcement grooves, are precast simultaneously with panels, ribs, and other components of the concrete wall blocks in the forms in which the concrete wall blocks are cast. As a result, reinforcing members, such as rebar and welded wire mesh, may be positioned, either horizontally or vertically, in desired and appropriate locations on the concrete wall blocks. Consequently, there is a significant increase in the convenience and ease of wall construction, while greatly reducing the amount of labor that is needed. In addition, the constructed walls have increased stability, strength, and water resistance. 
     In exemplary embodiments, the concrete wall blocks have heights of about 18 inches or about 36 inches and widths of about 24 inches or about 36 inches. The concrete wall blocks may be manufactured using a steel form and incorporated into the formation of freestanding and retaining blocks used in the construction of a freestanding or retaining wall, respectively. In exemplary embodiments, the concrete wall blocks are trimmed prior to the placement of the concrete wall blocks on a wall in order to accommodate various design features, such as a slope/angle on the wall. The ability to cut upper panels on the concrete wall blocks allows for the addition of coping caps to match any desired grade on the wall. 
     In exemplary embodiments, the precast concrete block configured for assembly into a wall comprises a first inner wall and a second inner wall; a first side panel and a second side panel, wherein the first side panel is substantially parallel to the second side panel and wherein the first side panel and/or the second side panel has a textured surface for imparting a natural stone appearance; at least one connecting rib, wherein the at least one connecting rib extends laterally from the first inner wall to the second inner wall to connect the first side panel with the second side panel and to form a hollow core configured to accept a filling material; and at least one reinforcement alignment feature cast into the first inner wall, the second inner wall, and/or the at least one connecting rib, wherein the at least one reinforcement alignment feature is configured to securely position at least one reinforcing member on the precast concrete block in a substantially horizontal and/or vertical orientation. 
     In an exemplary embodiment, the method for casting at least one reinforcement alignment feature into a concrete block, wherein the reinforcement alignment feature is configured to securely position at least one reinforcing member on the concrete block, comprises providing a form into which the concrete block is cast; casting the concrete block in the form, wherein the concrete block is simultaneously cast with the at least one reinforcement alignment feature, a first side panel, a second side panel, and at least one connecting rib; separating the cast concrete block from the form; and transporting the cast concrete block to an installation site for assembly into a wall. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an exemplary concrete wall block having reinforcement grooves and a height of about 18 inches; 
         FIG. 2  is a perspective view of the exemplary concrete wall block of  FIG. 1 , shown with exemplary reinforcing members positioned within reinforcement grooves; 
         FIG. 3  is a side perspective view of the exemplary concrete wall block of  FIG. 1 ; 
         FIG. 4  is a top perspective view of the exemplary concrete wall block of  FIG. 1 ; 
         FIG. 5  is a perspective view of an exemplary concrete wall block having reinforcement grooves and a height of about 36 inches; 
         FIG. 6  is another perspective view of the exemplary concrete wall block of  FIG. 5 ; 
         FIG. 7  is a perspective view of the exemplary concrete wall block of  FIG. 5  having trimmed side panels at the top of the concrete wall block; 
         FIG. 8  is side perspective view of the exemplary concrete wall block of  FIG. 5 ; 
         FIG. 9  is a top perspective view of the exemplary concrete wall block of  FIG. 5 ; 
         FIG. 10  is a perspective view of the exemplary concrete wall block of  FIG. 5 , shown with exemplary reinforcing members positioned within reinforcement grooves; and 
         FIG. 11  is a perspective view of an exemplary wall comprising a plurality of exemplary concrete wall blocks of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     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. 
     Referring to  FIG. 1 ,  FIG. 1  shows a perspective view of an exemplary concrete wall block  100  having reinforcement grooves and a height of about 18 inches. The concrete wall block  100  may be fabricated from concrete, cement, reinforcing steel, or other functionally equivalent reinforcing materials. The concrete wall block  100  comprises a hollow core  192  in the center of the concrete wall block  100 . The concrete wall block  100  comprises two substantially parallel side panels  110 ,  120  that are connected by two ribs  130 ,  140 . The side panels  110 ,  120  may have any desired shape and texture. In some examples, one or both of the side panels  110 ,  120  may be shaped and textured in a variety of ways, such as to imitate limestone blocks, sandstone blocks, slate, or other natural stone. The concrete wall block  100  also has a top, a bottom, a front, and a back. 
     The concrete wall block  100  may be manufactured using a steel form and incorporated into the formation of freestanding and retaining blocks used in the construction of a freestanding or retaining wall, respectively. The concrete wall block  100  may be cast in forms of known design. For example, the concrete wall block  100  may be cast in a form similar to the form disclosed in U.S. Pat. No. 6,854,702 to Manthei et al., the disclosure of which is incorporated herein. In some examples, side grooves may be formed in the concrete wall block  100  for handling the concrete wall block  100  with a forklift, as shown and described in U.S. Pat. No. 6,835,343 to Manthei et al. In some examples, the concrete wall block  100  is 18 inches high, 46 inches long, and 24 inches wide. In other examples, the concrete wall block  100  may be 36 inches wide or wider to allow for the building of taller walls. 
     The concrete wall block  100  also comprises at least one reinforcement alignment feature. The reinforcement alignment feature is cast in the concrete wall block  100  using the same form that casts the concrete wall block  100 . As a result, the reinforcement alignment feature is precast simultaneously with the form that casts the concrete wall block  100  and at the same precast facility, such as a precast plant. The reinforcement alignment feature is cast into the concrete wall block  100  so that reinforcing members, such as rebar and welded wire mesh, may be positioned, in a substantially horizontal or a substantially vertical orientation, in desired and appropriate locations on the concrete wall block  100 . In some examples, the reinforcement alignment features are horizontal reinforcement grooves  193  and vertical reinforcement grooves  194 . 
     As shown in  FIG. 1 , the horizontal reinforcement grooves  193  and vertical reinforcement grooves  194  are positioned on the concrete wall block  100  such that the vertically-positioned reinforcing members may lock against the concrete wall block  100  and the horizontally-positioned reinforcing members. This type of positioning may eliminate the need to tie or clip the reinforcing members together while constructing the wall. 
     In some examples, the horizontal reinforcement grooves  193  are positioned on each of the two ribs  130 ,  140  in a parallel orientation to the side panels  110 ,  120 . The vertical reinforcement grooves  194  may be positioned along the full-length of the concrete wall block  100  to make it easier for the concrete wall block  100  to better match existing forms and concrete blocks. The vertical reinforcement grooves  194  are positioned along in the inner walls of the concrete wall block  100  to form the side boundaries of the hollow core  192  such that the minimum thickness of poured grout, concrete, or other hardening fill material around the vertical reinforcement grooves  194  meets relevant local, state, and/or federal requirements/code pertaining to the distances between the edge of the concrete and the reinforcing members. 
     Referring to  FIG. 2 ,  FIG. 2  shows a perspective view of the exemplary concrete wall block  100  of  FIG. 1 , shown with exemplary reinforcing members  210  positioned within the horizontal reinforcement grooves  193  and the vertical reinforcement grooves  194 . In some examples, the reinforcing members  210  are rebar. The reinforcing members  210  may be readily positioned within the horizontal reinforcement grooves  193  and vertical reinforcement grooves  194  that were cast into the concrete wall block  100 , as predetermined by the designer. The reinforcing members  210  may simply be installed within the horizontal reinforcement grooves  193  and vertical reinforcement grooves  194  without any additional assembly at the actual job site. As such, the reinforcing members  210  may be easily positioned in their desired and proper locations within the concrete wall block  100 . 
     Referring to  FIG. 3 ,  FIG. 3  shows a side perspective view of the exemplary concrete wall block  100  of  FIG. 1 . In some examples, each horizontal reinforcement groove  193  is spaced between about 3 and 4 inches apart on the ribs  130 ,  140 . In some examples, each horizontal reinforcement groove  193  is spaced about 3.25 inches apart on the ribs  130 ,  140 . In yet other examples, each horizontal reinforcement groove  193  may be spaced at less than 3 inches or greater than 4 inches apart on the ribs  130 ,  140 . In some examples, each horizontal reinforcement groove  193  has a thickness of about ⅝ of an inch, though, other thicknesses are possible in this invention. In some examples, each horizontal reinforcement groove  193  forms an angle between about 45 and 60 degrees with respect to the ribs  130 ,  140 . In yet other examples, each horizontal reinforcement groove  193  may form an angle having less than 45 degrees and greater than 60 degrees with respect to the ribs  130 ,  140 . 
     Referring to  FIG. 4 ,  FIG. 4  shows a top perspective view of the exemplary concrete wall block  100  of  FIG. 1 . In some examples, each vertical reinforcement groove  194  has a length of between about 1 and 1.5 inches. In some examples, each vertical reinforcement groove  194  has a length of about 1 and ⅜ inches, though, other lengths are possible in this invention. In some examples, each vertical reinforcement groove  194  has a thickness of about 1 inch, though, other thicknesses are possible in this invention. In some examples, each vertical reinforcement groove  194  forms an angle between about 45 and 60 degrees with respect to the side panels  110 ,  120 . In other examples, each vertical reinforcement groove  194  may form an angle having other degrees with respect to the side panels  110 ,  120 . 
     Referring to  FIG. 5 ,  FIG. 5  shows a perspective view of an exemplary concrete wall block  500  having reinforcement grooves and a height of about 36 inches. The concrete wall block  500  may be fabricated from concrete, cement, reinforcing steel, or other functionally equivalent reinforcing materials. The concrete wall block  500  comprises a hollow core  510  in the center of the concrete wall block  500 . The concrete wall block  500  comprises two substantially parallel side panels  520 ,  530  that are connected by two ribs  540 ,  550 . The side panels  520 ,  530  may have any desired shape and texture. In some examples, one or both of the side panels  520 ,  530  may be shaped and textured in a variety of ways, such as to imitate limestone blocks, sandstone blocks, slate, or other natural stone. The concrete wall block  500  also has a top, a bottom, a front, and a back. 
     In some embodiments, the side panels  520 ,  530  are cut prior to the placement of the concrete wall block  500  on a wall in order to accommodate various design features, such as a slope/angle on the wall with a reinforced hollow core  510  in the center. In some examples, each of the side panels  520 ,  530  are cut at the top of the concrete wall block  500 , as shown in  FIG. 7 . As a result, the top of the wall constructed using the concrete wall block  500  has a different angle relative to the bottom of the wall. By cutting the side panels  520 ,  530  at the top of the concrete wall block  500 , a coping cap may be added to the concrete wall block  500  in order to match any desired grade on a wall. A coping cap comprises at least one coping block attachable along the top of the wall. The pouring of materials to match the grade of the wall provides a smooth, level surface for coping that can beneficially eliminate the expense and time commitment of on-site coping projects. In other embodiments, only one of the side panels  520 ,  530  is cut prior to the placement of the concrete wall block  500  on a wall. 
     The side panels  520 ,  530  may also be cut at other locations, besides the top of the concrete wall block  500 , such as in the middle of the side panels  520 ,  530  or at the bottom of the concrete wall block  500 . 
     The concrete wall block  500  may be manufactured using a steel form and incorporated into the formation of freestanding and retaining blocks used in the construction of a freestanding or retaining wall, respectively. In some examples, side grooves may be formed in the concrete wall block  500  for handling the concrete wall block  500  with a forklift, as shown and described in U.S. Pat. No. 6,835,343 to Manthei et al. In some examples, the concrete wall block  500  is 36 inches high, 46 inches long, and 24 inches wide. In other examples, the concrete wall block  500  may be manufactured from other forms having different dimensions, 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. 
     The concrete wall block  500  also comprises at least one alignment feature. The alignment feature is cast in the concrete wall block  500  using the same form that casts the concrete wall block  500 . As a result, the alignment feature is precast simultaneously with the form that casts the concrete wall block  500  and at the same precast facility, such as a precast plant. The alignment feature is cast into the concrete wall block  500  so that reinforcing members, such as rebar and welded wire mesh, may be positioned, either horizontally or vertically, in desired and appropriate locations on the concrete wall block  500 . In some examples, the alignment features are horizontal reinforcement grooves  595  and vertical reinforcement grooves  596 . 
     As shown in  FIG. 5 , the horizontal reinforcement grooves  595  and vertical reinforcement grooves  596  are positioned on the concrete wall block  500  such that the vertically-positioned reinforcing members may lock against the concrete wall block  500  and the horizontally-positioned reinforcing members. This type of positioning may eliminate the need to tie or clip the reinforcing members together while constructing the wall. 
     In some examples, the horizontal reinforcement grooves  595  are positioned on each of the two ribs  540 ,  550  in a parallel orientation to the side panels  520 ,  530 . The vertical reinforcement grooves  596  may be positioned along the full-length of the concrete wall block  500  to make it easier for the concrete wall block  500  to match existing forms and concrete blocks. The vertical reinforcement grooves  596  are positioned along in the inner walls of the concrete wall block  500  to form the side boundaries of the hollow core  510  such that the minimum thickness of poured grout, concrete, or other hardening fill material around the vertical reinforcement grooves  596  meets relevant local, state, and/or federal requirements/code pertaining to the distances between the edge of the concrete and the reinforcing members. 
     Referring to  FIG. 8 ,  FIG. 8  shows a side perspective view of the exemplary concrete wall block  500  of  FIG. 5 . In some examples, each horizontal reinforcement groove  595  is spaced between about 3 and 4 inches apart on the ribs  540 ,  550 . In some examples, each horizontal reinforcement groove  595  is spaced about 3.25 inches apart on the ribs  540 ,  550 . In yet other examples, each horizontal reinforcement groove  595  may be spaced at less than 3 inches or greater than 4 inches apart on the ribs  540 ,  550 . In some examples, each horizontal reinforcement groove  595  has a thickness of about ⅝ of an inch, though, other thicknesses are possible in this invention. In some examples, each horizontal reinforcement groove  595  forms an angle between about 45 and 60 degrees with respect to the ribs  540 ,  550 . In other examples, each horizontal reinforcement groove  595  may form an angle less than 45 degrees and greater than 60 degrees with respect to the ribs  540 ,  550 . 
     Referring to  FIG. 9 ,  FIG. 9  shows a top perspective view of the exemplary concrete wall block  500  of  FIG. 5 . In some examples, each vertical reinforcement groove  596  has a length of about 1 and ⅜ inches, though, other lengths are possible in this invention. In some examples, each vertical reinforcement groove  596  has a thickness of about 1 inch, though, other thicknesses are possible in this invention. In some examples, each vertical reinforcement groove  596  forms an angle of about 60 degrees with respect to the side panels  520 ,  530 . In other examples, each vertical reinforcement groove  596  may form an angle having other degrees with respect to the side panels  520 ,  530 . 
     Referring to  FIG. 10 ,  FIG. 10  shows a perspective view of the exemplary concrete wall block  500  of  FIG. 5 , shown with exemplary reinforcing members positioned within the horizontal reinforcement grooves  595  and the vertical reinforcement grooves  596 . Vertical reinforcing members  1000  are positioned within the vertical reinforcement grooves  596  and horizontal reinforcing members  1010 , such as rebar and welded wire mesh, are positioned within the horizontal reinforcement grooves  595 . The vertical reinforcement grooves  596  and the horizontal reinforcement grooves  595  are precast into the concrete wall block  500 . Since the vertical reinforcing members  1000  and the horizontal reinforcing members  1010  may be installed within the vertical reinforcement grooves  596  and the horizontal reinforcement grooves  595 , respectively, without any additional assembly at the actual job site, the vertical reinforcing members  1000  and the horizontal reinforcing members  1010  may be easily positioned in their desired and proper locations within the concrete wall block  500 . 
     Referring to  FIG. 11 ,  FIG. 11  shows a perspective view of an exemplary wall  1100  comprising a plurality of exemplary concrete wall blocks  100  of  FIG. 1 . The concrete wall blocks  100  may be configured to accommodate mounting structures for fences, railings, site lighting, utilities, and functionally equivalent structures. Vertical reinforcing members  1000  and horizontal reinforcing members  1010  are positioned in desired and appropriate locations on the concrete wall blocks of the wall  1100 . By positioning the vertical reinforcing members  1000  and horizontal reinforcing members  1010  in these locations, concrete, grout, or other hardening material may be more easily poured into the hollow cores of the concrete wall blocks  100  in order to provide increase stability, strength, and water resistance to the wall  1100 . 
     There are significant benefits to working with a concrete block that is precast with panels, ribs, vertical reinforcement grooves, and horizontal reinforcement grooves. Specifically, it is easier, less-time consuming, and more efficient for operators to handle the concrete block for assembly into a wall, without sacrificing the strength, stability, or durability of the constructed wall. 
     The forms described herein may be modified with the addition of mold inserts. The mold inserts may be positioned in the forms in which the block is cast and they form a hollow core in the center of the concrete wall blocks. The mold inserts are typically withdrawn from the concrete wall blocks after the concrete has cured. In order to form desired shapes of the hollow core, a plurality of mold inserts may be used. 
     In an exemplary embodiment, the method for casting at least one reinforcement alignment feature into a concrete block, wherein the reinforcement alignment feature is configured to securely position at least one reinforcing member on the concrete block, comprises providing a form into which the concrete block is cast; casting the concrete block in the form, wherein the concrete block is simultaneously cast with the at least one reinforcement alignment feature, a first side panel, a second side panel, and at least one connecting rib; separating the cast concrete block from the form; and transporting the cast concrete block to an installation site for assembly into a wall. 
     In another exemplary embodiment, the method for casting at least one reinforcement alignment feature into a concrete block, wherein the reinforcement alignment feature is configured to securely position at least one reinforcing member on the concrete block, comprises providing a form into which the concrete block is cast; positioning in the form a plurality of mold inserts for forming a hollow core in the center of the concrete block; casting the concrete block in the form, wherein the concrete block is simultaneously cast with the at least one reinforcement alignment feature, a first side panel, a second side panel, and at least one connecting rib; separating the cast concrete block from the form and the mold inserts; and transporting the cast concrete block to an installation site for assembly into a wall. 
     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. 
     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.