FIELD OF THE INVENTION
[0001] The present invention relates to concrete blocks, in particular those with a natural
stone appearance, that may be used in walls, columns, steps and other types of structures.
BACKGROUND
[0002] Concrete blocks intended to serve as wall blocks (e.g., retaining wall blocks), column
blocks, step blocks or other types of structural blocks are sometimes provided with
a natural stone appearance over an exposed portion thereof. Such concrete blocks can
then be assembled into walls, columns, steps or other structures that have a natural
and aesthetic look.
[0003] While various configurations, sizes and looks exist, these concrete blocks are conventionally
monolithic elements made of various types of concrete. This monolithic character often
detrimentally affects versatility of existing concrete blocks and their capability
to accommodate design constraints of structures to be constructed.
[0004] Also, depending on their constituent concrete, concrete blocks can be broadly divided
into dry-cast concrete blocks and wet-cast concrete blocks. Different processes are
used to manufacture these two types of concrete blocks and, in particular, to provide
them with a natural stone appearance.
[0005] Wet-cast concrete blocks may have a natural stone appearance realized directly during
casting, but relatively long production times and requirements for numerous molds
typically render impractical their efficient mass-production. For their part, dry-cast
concrete blocks normally have relatively short production times and require only one
or a few molds, which facilitates their mass-production. However, these relatively
short production times impose constraints on a degree of surface irregularity that
may be imparted to dry-cast concrete blocks during casting, thereby preventing realization
of a natural stone appearance during casting. Dry-cast concrete blocks are thus typically
subjected after casting to a mechanical artificial aging/weathering process (e.g.,
tumbling, splitting/breaking, object impacting, etc.) to realize desired natural stone
characteristics, which decreases production efficiency.
[0006] There is therefore a need for improvements in concrete blocks, in particular those
with a natural stone appearance, that may be used in walls, columns, steps and other
types of structures.
SUMMARY OF THE INVENTION
[0007] As embodied and broadly described herein, the invention provides a dry-cast concrete
block system for use in a structure. The dry-cast concrete block system comprises
a support block comprising a first coupling part and a face block comprising a second
coupling part. The first coupling part and the second coupling part enable the face
block to be coupled to the support block. The face block comprises a surface adapted
to be exposed when the face block is coupled to the support block and the dry-cast
concrete block system is positioned in the structure.
[0008] In one embodiment, at least a portion of the surface has a cast texture with a natural
stone appearance.
[0009] In one embodiment, the structure is a wall and the concrete block system is a wall
block system. For example, the wall may be a retaining wall and the wall block system
may be a retaining wall block system.
[0010] In one embodiment, the structure is a column and the concrete block system is a column
block system. In another embodiment, the structure is steps and the concrete block
system is a steps block system.
[0011] As embodied and broadly described herein, the invention provides a dry-cast concrete
block system for use in a retaining wall. The dry-cast concrete block system comprises
a support block comprising a first coupling part, the support block being adapted
to be embedded in material to be retained by the retaining wall. The dry-cast concrete
block system also comprises a face block comprising a second coupling part. The first
coupling part and the second coupling part enable the face block to be coupled to
the support block. The face block comprises a surface adapted to be exposed when the
face block is coupled to the support block and the dry-cast concrete block system
is positioned in the retaining wall.
[0012] These and other aspects and features of the invention will now become apparent to
those of ordinary skill in the art upon review of the following description of embodiments
of the invention in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A detailed description of embodiments of the invention is provided below, by way
of example only, with reference to the accompanying drawings, in which:
Figure 1 shows a wall portion comprising a plurality of concrete block systems in
accordance with an embodiment of the invention;
Figure 2 shows a side view of part of the wall portion shown in Figure 1;
Figure 3 shows a cross-sectional view of part of the wall portion shown in Figure
2;
Figure 4 shows a perspective view of a given concrete block system of the wall portion
shown in Figure 1, comprising a face block and a support block;
Figure 5 shows a cross-sectional view of the face block of Figure 4, illustrating
a cast texture of a surface portion of the face block that has a natural stone appearance;
Figure 6 illustrates a cross-sectional view of an embodiment where a surface portion
of a face block that has a natural stone appearance is contiguous to a chamfered,
rounded or otherwise non-natural looking edge portion of the face block;
Figure 7 illustrates a cross-sectional view of an embodiment in which a minimum level
of a surface portion of a face block that has a natural stone appearance is not located
at a boundary of that surface portion; and
Figures 8A and 8B show embodiments in which a face block comprises a plurality of
surface portions with a cast texture that has a natural stone appearance; and
Figures 9A and 9B respectively show a side view and a top view of the support block
of Figure 4;
Figure 10 shows an embodiment in which a wall portion comprises support blocks that
are connected in series;
Figures 11A to 11C respectively show a perspective view, a side view and a top view
of a support block in accordance with another embodiment;
Figure 12 shows an embodiment in which a wall portion has a nonzero setback angle,
illustrating use of alignment keys;
Figures 13A to 13C respectively show a side view, a front view and a top view of an
embodiment of one of the alignment keys of Figure 12;
Figure 14 shows an embodiment in which a wall portion is curved;
Figure 15 to 18 show wall portions comprising a plurality of concrete block systems
in accordance with various embodiments of the invention;
Figure 19 shows a column portion comprising a plurality of concrete block systems
in accordance with another embodiment of the invention;
Figure 20 shows steps comprising a plurality of concrete block systems in accordance
with yet another embodiment of the invention; and
Figure 21 is a flowchart illustrating an example of implementation of a process for
manufacturing face blocks in accordance with an embodiment of the invention.
[0014] It is to be expressly understood that the description and drawings are only for the
purpose of illustrating certain embodiments of the invention and are an aid for understanding.
They are not intended to be a definition of the limits of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0015] Figures 1 to 3 show a wall portion 10 comprising a plurality of concrete block systems
12
1...12
N in accordance with an embodiment of the invention. In this embodiment, the wall portion
10 is part of a retaining wall that holds back material 11 such as soil, drainage
aggregate, etc. The concrete block systems 12
1...12
N can thus be referred to as retaining wall block systems.
[0016] With additional reference to Figure 4, there is shown a given concrete block system
12
j of the concrete block systems 12
1...12
N (1 ≤ j ≤ N). In this embodiment, the concrete block system 12
j comprises a face block 13 adapted to be coupled to a support block 15.
[0017] The face block 13 is intended to be at least partly exposed when the concrete block
system 12
j is positioned in the wall portion 10, i.e., the face block 13 has a surface adapted
to be exposed when the face block 13 is coupled to the support block 15. In this embodiment,
the face block 13 is a dry-cast concrete block, i.e., it is made of no-slump concrete.
No-slump concrete (also known as zero-slump concrete) can be viewed as concrete with
a slump of 6 mm or less. It will be appreciated that various types of no-slump concrete
are possible and may be used. It will also be appreciated that, in other embodiments,
the face block 13 may be made of other types of concrete (e.g., measurable-slump concrete).
[0018] In this embodiment, the face block 13 can be said to have a generally rectangular
prism configuration with six surfaces 14
1...14
6. In other embodiments, the face block 13 may have any desired configuration with
any desired number of surfaces.
[0019] The surface 14
1 is intended to be exposed when the concrete block system 12
j, including the face block 13, is positioned in the wall portion 10. In this embodiment,
at least a portion 16 of the surface 14
1 has a cast texture having a natural stone appearance, i.e., an aged, worn, or weathered
appearance that resembles natural stone. As described later on, the cast texture of
the portion 16 of the surface 14
1 is realized during casting of the face block 13 and may be based on a natural stone's
surface which has been used to produce a mold for casting the face block 13. For ease
of reference, the portion 16 of the surface 14
1 and its cast texture with a natural stone appearance will hereinafter be referred
to as the "natural stone-like surface portion" 16.
[0020] Referring to Figures 4 and 5, the natural stone-like surface portion 16 has a visually
discernible boundary 22. In this embodiment, the natural stone-like surface portion
16 substantially corresponds to the entire surface 14
1 with its boundary 22 substantially corresponding to edges of the surface 14
1. In other embodiments, the natural stone-like surface portion 16 may be only a limited
portion of the surface 14
1 (i.e., not all of that surface). In yet other embodiments, the natural stone-like
surface portion 16 may be one of a plurality of natural stone-like surface portions
of the surface 14
1. For example, Figures 8A and 8B show embodiments in which are provided a plurality
of natural stone-like surface portions 16
1...16
Q separated by a surface portion 80 that does not have a natural stone appearance and
can serve as a false joint (where Q = 2 in Figure 8A and Q = 4 in Figures 8B). Generally,
any number of natural stone-like surface portions may be provided. Such a plurality
of natural stone-like surface portions 16
1...16
Q results in a wall portion seeming to include several blocks of various sizes and
configurations. Also, as shown in Figure 6, in embodiments where the natural stone-like
surface portion 16 is contiguous to a chamfered, rounded, or otherwise non-natural
stone looking edge portion 28 of the face block 13 (e.g., an edge portion serving
as a joint), the boundary 22 of the natural stone-like surface portion 16 is considered
to be configured such that the chamfered, rounded or otherwise non-natural stone looking
edge portion 28 is not part of the natural stone-like surface portion 16.
[0021] Continuing with Figures 4 and 5, in this embodiment, the natural stone-like surface
portion 16 comprises a pattern of cast relief elements 181...18M formed during casting
of the face block 13. This pattern of cast relief elements 181...18M may include a
plurality of bumps or peaks and a plurality of valleys or depressions, which are sized
so as to be visually distinguishable when the concrete block system 12
j, including the face block 13, is positioned in the wall portion 10. It is to be understood
that various other patterns of cast relief elements are possible. For example, the
natural stone-like surface portions 16
1...16
Q in Figures 8A and 8B illustrate various other examples of possible patterns of cast
relief elements.
[0022] The cast texture of the natural stone-like surface portion 16 defines a "surface
level difference" Δ
L, which refers to the normal distance between a maximum level
Lmax of that surface portion and a minimum level
Lmin of that surface portion. As shown in Figure 5, the face block 13 can be viewed as
defining orthogonal X, Y and Z axes, where the X-Y plane is parallel to a plane that
would be formed by the natural stone-like surface portion 16 if that surface portion
was flat, i.e., the plane in which lies the boundary 22 of the natural stone-like
surface portion 16. A level L at a given point of the natural stone-like surface portion
16 can be viewed as a plane parallel to the X-Y plane, and the surface level difference
Δ
L can be viewed as being measured along the Z axis.
[0023] In the embodiment shown in Figure 5, the minimum level
Lmin of the natural stone-like surface portion 16 is located at its boundary 22. Generally,
the minimum level
Lmin of the natural stone-like surface portion 16 may be located anywhere on that surface
portion. For example, Figure 7 illustrates an embodiment in which the minimum level
Lmin of the natural stone-like surface portion 16 is not located at its boundary 22. Similarly,
the maximum level
Lmax of the natural stone-like surface portion 16 may also be located anywhere on that
surface portion, including at its boundary 22.
[0024] In one embodiment, the surface level difference Δ
L may greater than 15 mm, for example, between 15 mm and 25 mm. For instance, in a
particular case, the surface level difference Δ
L may be about 20 mm. This enables the natural stone-like surface portion 16 to exhibit
desired natural stone appearance characteristics. However, it is generally contemplated
that a surface level difference Δ
L of greater than 4 mm achieves satisfactory results in terms of natural stone appearance
of a surface portion of a face block since it enables presence of visually distinguishable
cast texture features mimicking surface texture of natural stone. Also, in embodiments
such as those shown in Figures 8A and 8B, different ones of the natural stone-like
surface portions 16
1...16
Q may define a common or distinct surface level difference Δ
L and may have common or distinct maximum levels
Lmax and minimum levels
Lmin.
[0025] With continued reference to Figures 4 and 5, each of the cast relief elements 18
1... 18
M of the natural stone-like surface portion 16 reaches a respective level L that is
the maximum level
Lmax, the minimum level
Lmin, or a level therebetween. In this embodiment, a plurality of the cast relief elements
18
1... 18
M are seen in Figure 5 as extending to the maximum level
Lmax of the natural stone-like surface portion 16 and separated from each other by other
ones of the cast relief elements 18
1...18
M that only extend to lower levels. More particularly, the natural stone-like surface
portion 16 is configured such that at least three of the cast relief elements 18
1...18
M extend to the maximum level
Lmax and are positioned relative to each other to provide an effective support on which
at least one other face block may be supported. In other words, the maximum level
Lmax of the natural stone-like surface portion 16 provides at least three points that
are located relative to each other such that at least one other face block may be
supported thereon in a stable manner. This facilitates stacking or palletizing of
face blocks for storage or transportation purposes. In embodiments such as those shown
in Figures 8A and 8B, these at least three points may be distributed among the plurality
of natural stone-like surface portions 16
1...16
Q.
[0026] Also, in this embodiment, each of the cast relief 18
1...18
M of the natural stone-like surface portion 16 that is a valley (e.g., the cast relief
element 18
2) can be viewed as having a respective "depth"
D, which refers to the normal distance between the maximum level
Lmax of the surface portion 16 and that valley's deepest point. Depending on the surface
level difference Δ
L, in some embodiments, the respective depth
D of each of one or more valleys of the natural stone-like surface portion 16 may be
greater than 4 mm, for example, between 4 mm and 10 mm. This may further enhance natural
stone appearance characteristics exhibited by the natural stone-like surface portion
16.
[0027] Continuing with Figures 4 and 5, in this embodiment, the natural stone-like surface
portion 16 interacts with ambient light to create shadows that further contribute
to its natural stone appearance. More particularly, as shown in Figure 5, each point
of the cast texture of the natural stone-like surface portion 16 defines a respective
"texture angle"
θ, which refers to the angle between a plane parallel to the X-Y plane and a plane
tangent to the natural stone-like surface portion 16 at that point. In one embodiment,
the respective texture angle θ of each of a plurality of points of the natural stone-like
surface portion 16 may be between about 75 ° and about 90°. This may contribute to
creation of shadows on the natural stone-like surface portion 16 that further enhance
its natural stone appearance. Configuring a dry-cast concrete block with a surface
level difference Δ
L in the above-mentioned ranges has been found to facilitate, if not altogether render
possible, formation of such texture angles
θ during casting.
[0028] It is noted, however, that the above-mentioned values of texture angle θ are presented
for example purposes only and are not to be considered limiting in any respect.
[0029] In the embodiment of Figures 4 and 5, it is recalled that the face block 13 is adapted
to be coupled to the support block 15. This is achieved by providing the face block
13 with a plurality of coupling parts 29 each adapted to interact with a complementary
coupling part of the support block 15 so as to coupled together the face block 13
and the support block 15, as described later on. Each coupling part 29 is integral
with the face block 13 (i.e., not an element distinct from the face block 13). For
example, each coupling part 29 may be formed during casting of the face block 13.
In this embodiment, each coupling part 29 is a respective female part, which, in this
example, is implemented as a respective groove provided on the surface 14
2. In other embodiments, each coupling part 29 may be a respective male part.
[0030] The plurality of coupling parts 29 (in this case, three) allows the face block 13
to be coupled to the support block 15 at different positions relative to the support
block 15 and/or to be coupled to the support block 15 and a support block of an adjacent
one of the concrete block systems 12
1...12
N. In other embodiments, the face block 13 may include one or any other number of coupling
parts.
[0031] Referring now to Figures 4, 9A and 9B, the support block 15 is adapted to be positioned
into the material 11 and its structure and weight, along with that of support blocks
of other ones of the concrete block systems 12
1...12
N, contribute to effecting retention of the material 11 by the wall portion 10. In
this embodiment, the support block 15 is a dry-cast concrete block. In other embodiments,
the support block 15 may be made of other types of concrete (e.g., measurable-slump
concrete).
[0032] The support block 15 comprises a first end portion 34, a second end portion 36, and
a central portion 38 therebetween. In this embodiment, the central portion 38 is configured
as a neck portion that is relatively narrower than the first end portion 34 and the
second end portion 36 such that the support block 15 can be said to have a generally
"I"-shaped configuration. This provides a space 40 on each side of the support block
15 that cooperates with a similar space provided by a support block of an adjacent
one of the concrete block systems 12
1...12
N to receive part of the material 11, thereby enhancing stability of the support block
15 while reducing its weight and cost. In other embodiments, the support block 15
may have various other configurations.
[0033] In this embodiment, the first end portion 34 has a coupling part 41 that is complementary
to each coupling part 29 of the face block 13. This enables the face block 13 to be
coupled to the support block 15 by positioning the face block 13 above or below the
support block 15 such that one of its coupling parts 29 is aligned with the coupling
part 41 of the support block 15 and then fitting the coupling part 41 of the support
block 15 into the coupling part 29 of the face block 13. As mentioned previously,
in some situations, the face block 13 may simultaneously be coupled to a support block
of an adjacent one of the concrete block systems 12
1...12
N via fitting of another one of its coupling parts 29 with a complementary coupling
part of that support block. This may further enhance stability of the wall portion
10. The coupling part 41 is integral with the support block 15 and may be formed during
casting of the support block 15. In this embodiment, the coupling part 41 is a male
part, which, in this example, is implemented as a protrusion provided on the first
end portion 34 and configured to fit into the respective groove forming each coupling
part 29 of the face block 13. In other embodiments, the coupling part 41 may be a
female part.
[0034] Continuing with Figures 4, 9A and 9B, the second end portion 36 has a coupling part
43 that enables the support block 15 to be coupled to another support block. For example,
as shown in Figure 10, it may be useful or necessary in some situations (e.g., relatively
high walls) to connect two or more support blocks in series. In such situations, the
coupling part 43 of the support block 15 may be coupled to a complementary coupling
part of another support block in order to coupled together these two support blocks.
In the embodiment of Figures 4, 9A and 9B, the coupling part 43 is integral with the
support block 15 and may be formed during casting of the support block 15. Also, the
coupling part 43 is a male part, which, in this example, is implemented as a protrusion
provided on the second end portion 36 and configured to fit into a complementary female
part of another support block. In other embodiments, the coupling part 43 may be a
female part. For example, Figures 11A to 11C illustrate an embodiment in which the
support block 15 has a male coupling part 41 and a female coupling part 43.
[0035] In the embodiment shown in Figures 4, 9A and 9B, each of the first end portion 34
and the second end portion 36 is provided with a respective depression 50 on each
of its top and bottom sides. The depression 50 can take the form of a groove or a
recess. The depression 50 can also be an open-ended groove extending from one side
to the other side of the support block 15. As shown in Figure 2, each depression 50
is adapted to receive an alignment key 52 that may be used to adjust an angle θ of
the support block 15 relative to an overlapping support block of the concrete block
systems 12
1...12
N. This enables the wall portion 10 to have a corresponding setback angle or slope.
[0036] More particularly, the alignment key 52 may be placed in different positions in a
given depression 50 to effect the desired angle
θ. For example, in Figure 2, each alignment key 52 is placed in a first position, wherein
it is aligned longitudinally with and entirely lies within the respective depressions
50 in which it is placed. In this case, the angle θ is substantially zero degrees
and it is then possible to erect a wall that is substantially vertical. In Figure
12, each alignment key 52 is placed in a second position different from the first
position, wherein it partly overhangs support block portions contiguous to the respective
depressions 50 in which it is placed. In this case, the angle θ has a nonzero value
such as 7°, 10° or any other permitted value, and it is then possible to erect an
inclined wall.
[0037] Figures 13A to 13C illustrates an example of implementation of the alignment key
52. The alignment key 52 comprises a first portion 54 and a second portion 56 that
respectively define overhang sections 58 and 60. Placing the alignment key 52 in a
given depression 50 of the support block 15 such that both of the overhang sections
58 and 60 lie within the depression 50 achieves a zero degree value for the angle
θ (e.g., Figure 2). When the alignment key 52 is placed such that one of the overhang
sections 58 and 60 overhangs a portion of the support block 15 contiguous to the depression
50, a nonzero degree value for the angle θ is achieved (e.g., Figure 12). In one embodiment,
the alignment key 52 is made of a polymeric material such as polypropylene. In other
embodiments, the alignment key 52 may be made of various other materials.
[0038] While in the embodiment of Figures 4, 9A and 9B each depression 50 is shown as having
a certain configuration and as being located at a certain location on the first end
portion 34 or the second end portion 36, in other embodiments, each depression 50
may have various other configurations and may be located at various other locations
on the support block 15. Also, although in the embodiment of Figures 4, 9A and 9B
the alignment key 52 is an element distinct from the support block 15, in other embodiments,
the support block 15 may be provided with an alignment key that is integral with the
support block 15 (e.g., a male or female key part).
[0039] Continuing with Figures 4, 9A and 9B, the support block 15 has a plurality of fractionation
areas 64
1... 64
p for facilitating controlled fractionating of the support block 15 into separate parts.
In this embodiment, each of the fractionation areas 64
1...64
P is implemented as a respective groove formed on the support block 15 and sized to
facilitate controlled mechanical splitting (e.g., cutting, sawing, etc.) of the support
block 15 at that area. This enables removal of selected portions of the support block
15 such as the first end portion 34, the second end portion 36, the central portion
38, or fractions thereof in order to reconfigure the support block 15 such that it
may accommodate design requirements of the wall portion 10. For example, Figure 14
illustrates an embodiment in which the wall portion 10 is curved and selected portions
of certain support blocks 15 have been removed in order to accommodate the wall portion's
curved aspect. It will be appreciated that removal of selected support block portions
may be effected for various other situations/design requirements.
[0040] It will thus be appreciated that when the concrete block systems 12
1...12
N are positioned in the wall portion 10, the natural stone-like surface portion 16
of the face block 13 of each concrete block system contributes to providing a natural
and aesthetic look to the wall portion 10. For its part, the support block 15 of each
concrete block system contributes to effecting retention of the material 11 by the
wall portion 10, may interact with the alignment key 52 to provide a desired setback
angle θ to the wall portion 10, and may be selectively reconfigured so as to accommodate
design requirements of the wall portion 10. Furthermore, the natural stone appearance
of each face block 13 may be realized during casting thereof, without requiring any
subsequent mechanical artificial aging/weathering process (e.g., tumbling, splitting/breaking,
object impacting, etc.). Moreover, since they may be made of no-slump concrete, production
time for the concrete block systems 12
1...12
N may be significantly less than that required for wet-cast concrete blocks. Concrete
block systems such as the concrete block systems 12
1...12
N may therefore be mass-produced with high efficiency.
[0041] Although the above-described embodiments relate to a retaining wall application,
concrete block systems in accordance with other embodiments of the invention may be
used in various other types of walls. For example, Figure 15 shows an embodiment in
which a freestanding wall portion 70 is constructed with concrete block systems such
as the concrete block systems 12
1...12
N. This example illustrates that, in certain embodiments, the support block 15 of a
concrete block system may be coupled to two face blocks 13 via the coupling part 41
of its first end portion 34 and the coupling part 43 of its second end portion 36.
This example also illustrates that removal of selected support block portions may
be effected to accommodate design requirements of the freestanding wall portion 70.
As another example, Figures 16 to 18 show embodiments in which concrete block systems
such as the concrete block systems 12
1...12
N are used to construct other types of walls (e.g., acoustic walls, etc.).
[0042] In addition, concrete block systems in accordance with embodiments of the invention
are not limited to wall applications but may also be used in various other types of
structures. For example, Figure 19 shows an embodiment in which a column portion 76
is constructed with concrete block systems such as the concrete block systems 12
1...12
N. As another example, Figure 20 shows an embodiment in which steps 78 are constructed
with concrete block systems such as the concrete block systems 12
1...12
N.
[0043] Referring now to Figure 21, there is shown a flowchart illustrating an example of
implementation of a process for manufacturing face blocks of concrete block systems
such as the above-described concrete block systems 12
1...12
N.
[0044] At step 200, no-slump concrete is placed into a mold. To facilitate mass-production,
in one embodiment, the mold has a plurality of cavities. In other embodiments, a plurality
of molds each with a single cavity or each with a respective plurality of cavities
may be used. To further facilitate mass-production, the mold may be located such that
face blocks are placed on a production board when removed therefrom.
[0045] Each cavity of the mold is configured to form a respective face block comprising
a surface that includes a natural stone-like surface portion (e.g., the face block
13 with its natural stone-like surface portion 16). To that end, each cavity is defined
in part by a surface of the mold that comprises a portion with a surface texture corresponding
to the desired natural stone appearance (hereinafter referred to as "the natural stone-like
surface portion of the mold"). This surface portion thus defines a surface level difference
Δ
L' that corresponds to the desired surface level difference Δ
L (Figure 5) of the face block to be formed. Each point of this surface portion also
defines a respective texture angle
θ' corresponding to the desired texture angle θ (Figure 5) of each point of the face
block to be formed.
[0046] It will be appreciated that, in embodiments directed to producing face blocks with
a plurality ofnatural stone-like surface portions (such as those shown in Figures
8A and 8B), each cavity of the mold that is intended to form such face blocks defines
a corresponding plurality of natural stone-like surface portions.
[0047] In order to closely simulate natural stone, in one embodiment, each given natural
stone-like surface portion of the mold, and thus the corresponding natural stone-like
surface portion of face blocks to be formed by the mold, is based on a natural stone's
surface. In one example of implementation, data representative of at least a portion
of the natural stone's surface is obtained, for instance, via three-dimensional scanning
of the natural stone's surface. The obtained data may then be computer processed using
software in order to generate data representative of the given natural stone-like
surface portion of the mold. In some cases, this processing may include modifying
the obtained data representative of at least a portion of the natural stone's surface
to set the desired surface level difference Δ
L' and texture angles
θ' of the given natural stone-like surface portion. This processing may also ensure
that the data representative of the given natural stone-like surface portion of the
mold will result in the corresponding natural stone-like surface portion of face blocks
to be formed by the mold having at least three points that are located relative to
each other such that at least one other concrete block may be supported thereon in
a stable manner.
[0048] As another possible consideration, in embodiments where individual ones of the cavities
of the mold are intended to form concrete blocks of similar overall dimensions (i.e.,
length, width and height) but with natural stone-like surface portions that have different
configurations (e.g., different patterns of cast relief elements), these individual
cavities may be designed to each have a common volume in order to facilitate production.
In other words, a first cavity intended to form concrete blocks with natural stone-like
surface portions having a first configuration may have a first volume, and a second
cavity intended to form concrete blocks with natural stone-like surface portions having
a second configuration different from the first configuration may have a second volume
substantially corresponding to the first volume. This facilitates provision of substantially
the same quantity of concrete into each cavity of the mold, which in turn facilitates
efficient casting of concrete blocks in the mold and subsequent removal of the concrete
blocks therefrom.
[0049] In embodiments where individual ones of the cavities of the mold are intended to
form concrete blocks of significantly different overall dimensions (i.e., length,
width and height) and with natural stone-like surface portions that have different
configurations (e.g., different patterns of cast relief elements), similar production
benefits may be achieved by designing these individual cavities to each have a common
volume per unit area.
[0050] The mold may be manufactured via computer-aided manufacturing based on the data representative
of each given natural stone-like surface portion of the mold. With no-slump concrete
being used, the mold may be made of metal or other rigid material. There is no requirement
for one or more portions of the mold to be made of elastomeric material (e.g., rubber),
which is typically used in molds for casting wet-cast concrete blocks with a natural
stone appearance.
[0051] Thus, during step 200, each cavity of the mold is filled with no-slump concrete in
order to form a face block with at least one natural stone-like surface portion.
[0052] At step 202, the no-slump concrete in the mold is consolidated. Consolidation may
include inducing vibration of the no-slump concrete in the mold so as to cause it
to compact itself and closely conform to each cavity of the mold. A pre-vibration
phase may be effected during step 200 to facilitate filling of the no-slump concrete
in the mold and its eventual consolidation. Consolidation may also include application
of pressure on the concrete in combination with its vibration. It will be appreciated
that consolidation may be effected using various other techniques.
[0053] Upon completion of step 202, the no-slump concrete in each cavity of the mold has
formed into a face block with at least one natural stone-like surface portion.
[0054] At step 204, the face block in each cavity of the mold is removed therefrom and continues
on the production board. The face blocks may be directly stored for curing purposes.
Since provision of a natural stone appearance is effected during casting, the face
blocks do not require a subsequent mechanical artificial aging/weathering process
(e.g., tumbling, splitting/breaking, object impacting, etc.) to impart them with such
an appearance. Also, the face blocks may directly be stacked or palletized in a stable
manner since the at least one natural stone-like surface portion of each face block
has been configured to provide at least three points that are located relative to
each other to ensure such stable supporting. With the face blocks being made of no-slump
concrete, curing times are relatively short such that they are available for use within
a short period of time (e.g., one day).
[0055] At step 206, each cavity of the mold is cleaned such that casting of new face blocks
may be effected. In one embodiment, a cleaning unit uses a fluid to clean each cavity
of the mold. The fluid may be a gas (e.g., compressed air) or a liquid whose flow
relative to each cavity of the mold, and particularly each natural stone-like area
of the mold, removes therefrom substantially any remaining no-slump concrete. Such
a fluid-based cleaning action advantageously enables rapid cleaning of each cavity
of the mold, thereby increasing production efficiency. In some cases, the cleaning
unit may also use, in addition to the fluid, one or more brushes to clean each cavity
of the mold, whereby the fluid-based cleaning action is combined with a brushing cleaning
action. It will be appreciated that other embodiments may employ various other types
of cleaning action.
[0056] As shown in Figure 21, in this example, the process returns to step 200 where a new
production cycle begins. In some embodiments, utilization of no-slump concrete in
combination with rapid cleaning of the mold and other elements of the process may
enable a production cycle to take a relatively short period of time (e.g., 15 to 20
seconds in some cases).
[0057] With respect to manufacturing of support blocks of concrete block systems such as
the above-described concrete block systems 12
1...12
N, it will be appreciated that various conventional casting processes may be used.
[0058] Although various embodiments and examples have been presented, this was for the purpose
of describing, but not limiting, the invention. Various modifications and enhancements
will become apparent to those of ordinary skill in the art and are within the scope
of the present invention, which is defined by the attached claims.
1. A dry-cast concrete block system (12) for use in a structure, said dry-cast concrete
block system being
characterized in that it comprises:
- a support block (15) comprising a first coupling part (41); and
- a face block (13) comprising a second coupling part (29), said first coupling part
and said second coupling part enabling said face block to be coupled to said support
block, said face block comprising a surface (141) adapted to be exposed when said face block is coupled to said support block and
said dry-cast concrete block system is positioned in the structure.
2. A dry-cast concrete block system as claimed in claim 1, wherein said first coupling
part (41) is one of a male coupling part and a female coupling part, and said second
coupling part (29) is the other one the male coupling part and the female coupling
part.
3. A dry-cast concrete block system as claimed in claim 2, wherein said male coupling
part (41) is a protrusion and said female coupling part (29) is a groove configured
to receive said protrusion.
4. A dry-cast concrete block system as claimed in claim 1, wherein each of at least one
of said first coupling part (41) and said second coupling part (29) is a respective
cast coupling part.
5. A dry-cast concrete block system as claimed in claim 1, wherein said support block
(15) comprises a first end portion (34), a second end portion (36), and a central
portion (38) therebetween, said central portion being narrower than said first end
portion and said second end portion.
6. A dry-cast concrete block system as claimed in claim 1, wherein said support block
(15) comprises a first end portion (34) and a second end portion (36), said first
coupling part (41) being located on said first end portion, said support block comprising
a third coupling part (43) located on said second end portion, said third coupling
part enabling said support block to be coupled to one of another support block and
another face block.
7. A dry-cast concrete block system as claimed in claim 1, wherein said support block
(15) comprises a depression (50) for receiving an alignment key (52) adapted to set
an angle of said support block relative to an overlapping support block.
8. A dry-cast concrete block system as claimed in claim 1, wherein said support block
(15) comprises an integral alignment key for connecting said support block with an
overlapping support block.
9. A dry-cast concrete block system as claimed in claim 1, wherein said face block (13)
comprises a third coupling part (29) enabling at least one of: said face block to
be coupled to said support block (15) at a different position relative to said support
block than that enabled by said second coupling part (29); and said face block to
be coupled to another support block (15).
10. A dry-cast concrete block system as claimed in claim 1, wherein at least a portion
(16) of said surface has a cast texture with a natural stone appearance.
11. A dry-cast concrete block system as claimed in claim 10, wherein said cast texture
has a surface level difference of greater than 4 mm.
12. A dry-cast concrete block system as claimed in claim 11, wherein said surface level
difference is between 15 mm and 25 mm.
13. A dry-cast concrete block system as claimed in claim 10, wherein each of a plurality
of points of said cast texture defines a respective texture angle between 75° and
90°.
14. A dry-cast concrete block system as claimed in claim 10, wherein said cast texture
comprises at least one valley each having a respective depth greater than 4 mm.
15. A dry-cast concrete block system as claimed in claim 10, wherein said at least a portion
of said surface is an entirety of said surface.
16. A dry-cast concrete block system as claimed in claim 10, wherein said at least a portion
of said surface is a first portion (161) of said surface and said cast texture is a first cast texture, said surface comprising
(i) a second portion (162) with a second cast texture having a natural stone appearance and (ii) a third portion
(80) without a cast texture having a natural stone appearance and that separates said
first portion and said second portion.