# US 5,702,208 A · Grid-locked block panel system

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- Number: US 5,702,208 A
- Document ID: US5702208A
- Status: Granted
- Kind: A
- Application number: 08/585,568
- Filed: 1996-01-16
- Granted: 1997-12-30
- Earliest claimed: 1994-06-02
- Inventors: William K. Hilfiker; Thomas P. Taylor
- Web page: https://patentgrep.com/patent/US5702208A

## CPC

- E02D 17/205: {with modular blocks, e.g. pre-fabricated}
- E02D 29/0225: {comprising retention means in the backfill}
- E02D 29/025: {made up of similar modular elements stacked without mortar}
- E02D: FOUNDATIONS; EXCAVATIONS; EMBANKMENTS (specially adapted for hydraulic engineering E02B); UNDERGROUND OR UNDERWATER STRUCTURES {(tunnels, tunnelling, mining E21)}

## Abstract

Concrete blocks are formed with intersecting grooves in the underside thereof which assume aligned condition when the blocks are assembled into side by side relationship to form panels. Polymer or welded wire grids are received within the aligned grooves to hold the blocks in the panel configuration. The grids are held in elevated seated condition within the grooves during assembly of the blocks into the panel configuration. Stands or wire connectors may be provided for the latter purpose. In the preferred embodiment the blocks are L-shaped and formed with passages extending therethrough and the grooves intersect these passages. Grout or fill may be placed within the passages of the assembled panels. In certain embodiments, the blocks may be disposed in side-by-side relationship and stacked to form retaining walls for earthen formations, with rods received within the grooves of the blocks to hold the blocks in alignment and the grids extending from the blocks to serve as soil reinforcements.

## Claims

### Claim 1

A block for use in combination with a gridwork of intersecting elements which are engageable with the block to secure like blocks together in the construction of panels, said block comprising:
a) a body having at least one open cell extending therethrough from top to bottom; and
b) grooves formed in the bottom of said body and extending upwardly into the block, said grooves intersecting the open cell of the block and being proportioned for receipt of the intersecting elements whereby the elements may extend across and intersect within the open cell of the block.

### Claim 2 (depends on 1)

A block according to claim 1 wherein:
a) the block is of an L-shape viewed in plan and a plurality of open cells extend therethrough from top to bottom;
b) the cells are separated by webs of the block; and,
c) certain of the grooves extend across webs.

### Claim 3 (depends on 1)

A block according to claim 1 wherein the grooves are of a depth extending approximately one-half the distance between the top and bottom of the block.

### Claim 4

An assembly for forming concrete panels, said assembly comprising:
a) a plurality of concrete blocks each having at least one open cell extending therethrough from top to bottom, grooves formed thereacross in intersecting relationship to said cell and a side wall complementally engageable with the side walk of another of said blocks; and,
b) a gridwork having intersecting elements proportioned for receipt in said grooves and spaced to be received within the intersecting grooves of adjacent blocks when complementally engaged and to intersect within the open cells of the blocks to hold the blocks in such engagement.

### Claim 5 (depends on 4)

An assembly according to claim 4 wherein the grooves are formed in the bottom of and extend upwardly into the blocks.

### Claim 6 (depends on 5)

An assembly according to claim 5, wherein the grooves are of a depth extending approximately one-half the distance between the top and bottom of the blocks.

### Claim 7 (depends on 5)

An assembly according to claim 5, wherein:
a) at least certain of the blocks are of an L-shape viewed in plan and a plurality of open cells extend therethrough from top to bottom;
b) the cells are separated by webs of the block; and,
c) certain of the grooves extend across the webs.

### Claim 8 (depends on 5)

An assembly according to claim 5 further comprising a hanger engagable over the blocks and under the gridwork to hold the gridwork within the grooves of the blocks.

### Claim 9

A method of forming a panel comprised of concrete blocks, said method comprising:
a) providing a gridwork comprised of intersecting elements;
b) providing a plurality of concrete blocks having voids extending therethrough from top to bottom and grooves formed in the bottom thereof in intersecting relationship to the voids, said grooves being proportioned and arranged for complemental receipt of intersecting elements of the gridwork to hold the blocks in side-by-side relationship;
c) supporting the gridwork in an elevated condition; and,
d) assembling the blocks over the gridwork in side-by-side relationship to engage the intersecting elements of the gridwork within the grooves of the blocks with the elements intersecting within the voids.

### Claim 10 (depends on 9)

A method according to claim 9 further comprising extending a hanger over at least one of the blocks and into a cell to engage an intersecting element of the gridwork and hold the gridwork in elevated condition within the grooves of the blocks.

### Claim 11 (depends on 9)

A method according to claim 9 further comprising grouting certain of the cells to hold the gridwork in elevated condition within the grooves of the blocks.

### Claim 12

A method of covering the surface of an earthen formation, said method comprising:
a) providing a gridwork comprised of intersecting elements;
b) providing a plurality of blocks having intersecting grooves formed in and opening through one side thereof, said grooves extending across the blocks and being proportioned and arranged for complemental receipt of intersecting elements of the gridwork to hold blocks in side-by-side relationship;
c) supporting the gridwork in spaced relationship to the surface of the earthen formation; and,
d) assembling said blocks over the gridwork in side-by-side relationship to engage the intersecting grooves of the blocks with intersecting elements of the gridwork.

### Claim 13 (depends on 12)

A method according to claim 12 further comprising:
a) covering the surface of the earthen formation with drain material before supporting the gridwork in spaced relationship thereto; and,
b) supporting the blocks on said drain material upon assembly of the blocks over the gridwork.

### Claim 14 (depends on 12)

A method according to claim 12 wherein:
a) the surface of the earthen formation takes the form of a channel having a generally flat bottom portion and an outwardly divergent generally flat side portion;
b) the gridwork is comprised of bottom and side portions which are supported, respectively, in spaced generally parallel relationship to the bottom and side portions of the channel; and,
c) the blocks are assembled over the bottom and side portions of the gridwork to line the channel.

### Claim 15 (depends on 14)

A method according to claim 14 further comprising:
a) covering the bottom and side portions of the channel with drain material before supporting the gridwork in spaced relationship thereto; and,
b) supporting the blocks on said drain material upon assembly of the blocks over the gridwork.

### Claim 16

A method of covering the surface of an earthen formation, said method comprising:
a) providing a gridwork comprised of intersecting elements;
b) providing a plurality of blocks having intersecting grooves formed in and opening through one side thereof, said grooves extending across the blocks and being proportioned and arranged for complemental receipt of intersecting elements of the gridwork to hold blocks in side-by-side relationship;
c) supporting the gridwork in an elevated condition;
d) assembling said blocks over the gridwork in side-by-side relationship to engage the intersecting grooves of the blocks with intersecting elements of the gridwork and form a panel comprised of blocks held together by the gridwork;
e) lifting the panel to an elevated condition by engaging spaced portions of the gridwork with hoisting elements and elevating said elements; and,
f) moving the panel while in the elevated condition to the situs of the earthen formation and depositing the panel to support the blocks on the formation with the gridwork disposed in spaced generally parallel relationship to the surface of the formation.

### Claim 17

A concrete block panel comprising:
a) a gridwork having intersecting elements;
b) means supporting said gridwork in a suspended condition;
c) a plurality of concrete blocks supported on the gridwork, said blocks having intersecting grooves opening through and extending across one side thereof, said intersecting grooves being engaged over the intersecting elements of the gridwork to hold blocks in side-by-side relationship.

### Claim 18 (depends on 17)

A panel according to claim 17, wherein:
a) the blocks have cells extending therethrough from top to bottom and the grooves extend across the blocks in intersecting relationship to the cells; and,
b) elements of the gridwork intersect within the cells.

### Claim 19 (depends on 18)

A panel according to claim 18, further comprising a hanger extending over at least one of the blocks and into a cell and engagement with an intersecting element of the gridwork to hold the gridwork in elevated condition within the grooves of the blocks.

### Claim 20 (depends on 17)

A panel according to claim 17 wherein:
a) at least certain of the blocks are of an L-shape viewed in plan and a plurality of open cells extend therethrough from top to bottom;
b) the cells are separated by webs of the block; and,
c) certain of the grooves extend across the webs.

### Claim 21 (depends on 17)

A panel according to claim 17 wherein the grooves are formed in the bottom of and extend upwardly into the blocks.

### Claim 22 (depends on 21)

A panel according to claim 21 wherein the grooves are of a depth extending approximately one-half the distance between the top and bottom of the blocks.

### Claim 23 (depends on 17)

A panel according to claim 17 wherein reinforcing bars are secured to and extend upwardly from the panel, the panel further comprising subpanels stacked on top of said panel and received over said reinforcing bars, each sub-panel comprising:
a) a second gridwork having intersecting elements;
b) means supporting second gridwork in a suspended condition;
c) a plurality of second concrete blocks supported on the second gridwork, said blocks having intersecting grooves engaged over the intersecting elements of the gridwork to hold blocks in side-by-side relationship.

### Claim 24

An assembly for lining an earthen formation, said assembly comprising:,
a) a gridwork of intersecting elements, said gridwork being supported in spaced generally parallel relationship to the earthen formation; and,
b) a plurality of concrete blocks supported on the earthen formation, said blocks having intersecting grooves engaged over the intersecting elements of the gridwork to hold blocks in side-by-side relationship.

### Claim 25 (depends on 24)

An assembly according to claim 24, wherein:
a) the blocks have cells extending therethrough from top to bottom and the grooves extend across the blocks in intersecting relationship to the cells; and,
b) elements of the gridwork intersect within the cells.

### Claim 26 (depends on 25)

An assembly according to claim 25, further comprising a hanger extending over at least one of the blocks and into a cell and engagement with an intersecting element of the gridwork to hold the gridwork in elevated condition within the grooves of the blocks.

### Claim 27 (depends on 24)

An assembly according to claim 24, wherein:
a) at least certain of the blocks are of an L-shape viewed in plan and a plurality of open cells extend therethrough from top to bottom;
b) the cells are separated by webs of the block; and,
c) certain of the grooves extend across the webs.

### Claim 28 (depends on 24)

An assembly according to claim 24 wherein the grooves are formed in the bottom of and extend upwardly into the blocks.

### Claim 29 (depends on 28)

An assembly according to claim 28, wherein the grooves are of a depth extending approximately one-half the distance between the top and bottom of the blocks.

### Claim 30

An assembly for retaining an upstanding portion of an earthen formation and covering a base portion of the formation at the foot of the upstanding portion, said assembly comprising:
a) a gridwork of intersecting elements, said gridwork being supported in spaced generally parallel relationship to the base portion of the earthen formation; and,
b) a first plurality of concrete blocks supported on the base portion of the earthen formation, said blocks having intersecting grooves engaged over the intersecting elements of the gridwork to hold blocks in side-by-side relationship;
c) a second plurality of concrete blocks stacked upon one another and extending over the upstanding portion of the earthen formation, said second plurality of blocks being supported on the first plurality of blocks; and,
d) means securing the second plurality of blocks against displacement relative to the upstanding portion of the formation.

### Claim 31 (depends on 30)

An assembly according to claim 30 wherein:
a) the second plurality of blocks have intersecting grooves formed therein; and,
b) the means securing the second plurality of blocks against displacement relative to the formation comprise reinforcing mats having intersecting elements complemental with the intersecting grooves of the second plurality of blocks, said mats having proximal portions with intersecting elements engaged within the intersecting grooves of the second plurality of blocks and distal portions extending toward the earthen formation.

### Claim 32 (depends on 30)

An assembly according to claim 30 further comprising drain material disposed between the earthen formation and the first and second plurality of blocks, said first plurality of blocks resting on the drain material therebeneath.

### Claim 33 (depends on 30)

An assembly according to claim 30 wherein the upstanding portion of the earthen formation terminates in a surface and is capped with an assembly comprising:
a) a gridwork of intersecting elements, said gridwork being supported in spaced generally parallel relationship to said surface of the earthen formation; and,
b) a third plurality of concrete blocks supported on said surface of the earthen formation, said blocks having intersecting grooves engaged over the intersecting elements of the gridwork to hold blocks in side-by-side relationship.

### Claim 34

A method of constructing a retaining wall for an earthen formation, said method comprising:
a) providing a plurality of concrete blocks having first grooves extending thereacross and second grooves extending through one side thereof in intersecting relationship to said first grooves;
b) assembling said blocks in front of the formation in side-by-side relationship with the first grooves of adjacent blocks aligned;
c) providing gridworks having paired longitudinal elements engageable within the second grooves of adjacent blocks disposed in side-by-side relationship and a cross-element engageable within the first grooves of said adjacent blocks;
d) engaging said gridworks with the assembled blocks so as to extend from said one side thereof into the earthen formation with the paired longitudinal elements engaged-within the second grooves of adjacent blocks and the cross-element engaged within the first grooves of said adjacent blocks.

### Claim 35 (depends on 34)

A method according to claim 34, further comprising extending a bar across the first grooves of adjacent blocks to span the blocks.

### Claim 36 (depends on 35)

A method according to claim 35 wherein the concrete blocks have open cells extending therethrough from top to bottom and the first and second grooves intersect the cells, said method further comprising filling at least certain of the cells with a medium to hold the gridworks and bar in place within the first grooves.

### Claim 37 (depends on 35)

A method according to claim 35 wherein the bar is disposed to engage the gridwork and resist pullout of the gridwork from the blocks.

### Claim 38 (depends on 34)

A method according to claim 34 wherein the longitudinal elements define a plane therebetween and are formed with bent-up end portions which carry the cross-element and extend out of said plane.

### Claim 39 (depends on 38)

A method according to claim 38 further comprising extending a bar across the first grooves of adjacent blocks to one side of said bent-up ends to resist pull-out of the gridwork from the blocks and span the blocks.

### Claim 40

A retaining wall for an earthen formation, said wall comprising:
a) a plurality of concrete blocks having first grooves extending thereacross and second grooves extending through one side thereof in intersecting relationship to said first grooves, said blocks being assembled in front of the formation in side-by-side relationship with the first grooves of adjacent blocks aligned and said one side facing the formation; and,
b) gridworks having paired longitudinal elements engaged within the second grooves of adjacent blocks disposed in side-by-side relationship and a cross-element fixed between said longitudinal elements and engaged within the first grooves of said adjacent blocks to span the blocks, said gridworks extending from said one side of the blocks and into the earthen formation.

### Claim 41 (depends on 40)

A retaining wall according to claim 40, further comprising a bar extending across the first grooves of adjacent blocks to span the blocks.

### Claim 42 (depends on 41)

A retaining wall according to claim 41 wherein the concrete blocks have open cells extending therethrough from top to bottom and the first and second grooves intersect the cells, said wall further comprising a fill means disposed within at least certain of the cells to hold the gridwork and bar in place within the first grooves.

### Claim 43 (depends on 41)

A retaining wall according to claim 41 wherein the bar is disposed to engage the gridwork and resist pullout of the gridwork from the blocks.

### Claim 44 (depends on 40)

A retaining wall according to claim 40 wherein the longitudinal elements define a plane therebetween and are formed with bent-up end portions which carry the cross-element and extend out of said plane.

### Claim 45 (depends on 44)

A retaining wall according to claim 44 further comprising a bar extending across the first grooves of adjacent blocks to one side of said bent-up ends to resist pull-out of the gridwork from the blocks and span the blocks.

### Claim 46

A retaining wall for an earthen formation, said wall comprising:
a) a plurality of concrete blocks having first grooves extending thereacross and second grooves extending through one side thereof in intersecting relationship to said first grooves, said blocks being assembled in front of the formation in side-by-side relationship with the first grooves of adjacent blocks aligned and said one side facing the formation;
b) a gridwork having paired longitudinal elements engaged within the second grooves of one of the blocks and a cross-element fixed between said longitudinal elements and engaged within the first groove of said one block, said gridwork extending into the earthen formation; and,
c) a bar received within and extending across the first grooves of adjacent blocks to span the blocks.

### Claim 47 (depends on 46)

A retaining wall according to claim 46 wherein the bar is disposed to engage the gridwork and resist pullout of the gridwork from the blocks.

### Claim 48 (depends on 46)

A retaining wall according to claim 46 wherein the longitudinal elements define a plane therebetween and are formed with bent-up end portions which carry the cross-element and extend out of said plane.

### Claim 49 (depends on 48)

A retaining wall according to claim 48 wherein the bar engages the bent up portions to resist pullout of the gridwork from the blocks.

### Claim 50 (depends on 46)

A retaining wall according to claim 46 wherein the concrete blocks have open cells extending therethrough from top to bottom and the first and second grooves intersect the cells, said wall further comprising a fill means disposed within at least certain of the cells to hold the gridwork and bar in place within the first grooves.

### Claim 51

A method of retaining an earthen formation, said method comprising:
a) providing a plurality of concrete blocks having first grooves extending thereacross and second grooves extending through one side thereof in intersecting relationship to said first grooves,
b) assembling said blocks in front of the formation in side-by-side relationship with the first grooves of adjacent blocks aligned and said one side facing the formation;
c) providing a gridwork having paired longitudinal elements engageable within the second grooves of the blocks and a cross-element fixed between said longitudinal elements and engageable within the first grooves of said blocks;
d) engaging the gridwork with one of the assembled blocks so as to extend from said one side thereof into the earthen formation with the paired longitudinal elements engaged within the second grooves of said one block and the cross-element engaged within the first groove of said one block;
c) extending a bar across the first grooves of adjacent blocks to span the blocks.

### Claim 52 (depends on 51)

A method according to claim 51 wherein the bar is disposed to engage the gridwork and resist pullout of the gridwork from the blocks.

### Claim 53 (depends on 51)

A method according to claim 51 wherein the longitudinal elements define a plane therebetween and are formed with bent-up end portions which carry the cross-element and extend out of said plane.

### Claim 54 (depends on 53)

A method according to claim 53 wherein the bar engages the bent up portions to resist pullout of the gridwork from the blocks.

### Claim 55 (depends on 51)

A method according to claim 51 wherein the concrete blocks have open cells extending therethrough from top to bottom and the first and second grooves intersect the cells, said method further comprising filling at least certain of the cells with a medium to hold the gridwork and bar in place within the first grooves.