Method for casting reinforcement alignment features into concrete wall blocks

Abstract

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.

1 . A precast concrete block configured for assembly into a wall, the precast concrete block comprising:
 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.   
     
     
         2 . The precast concrete block of  claim 1 , wherein the first inner wall, the second inner wall, the first side panel, the second side panel, the at least one connecting rib, and the at least one reinforcement alignment feature are simultaneously precast in a form adapted for making the concrete block. 
     
     
         3 . The precast concrete block of  claim 1 , wherein the first side panel and/or the second side panel is cut prior to placement of the precast concrete block on the wall. 
     
     
         4 . The precast concrete block of  claim 3 , wherein the wall comprises a top and a bottom and the top of the wall has a different angle than the bottom of the wall. 
     
     
         5 . The precast concrete block of  claim 1 , wherein the at least one reinforcement alignment feature is a plurality of horizontal reinforcement grooves and/or a plurality of vertical reinforcement grooves. 
     
     
         6 . The precast concrete block of  claim 5 , wherein the horizontal reinforcement grooves are parallel to each of the first side panel and the second side panel when cast into the at least one connecting rib. 
     
     
         7 . The precast concrete block of  claim 5 , wherein the vertical reinforcement grooves are cast into the first inner wall and/or the second inner wall to form side boundaries of the hollow core. 
     
     
         8 . The precast concrete block of  claim 6 , wherein each of the horizontal reinforcement grooves forms an angle between about 45 and 60 degrees with respect to the at least one connecting rib. 
     
     
         9 . The precast concrete block of  claim 8 , wherein each of the horizontal reinforcement grooves is spaced between about 3 and 4 inches apart on the at least one connecting rib. 
     
     
         10 . The precast concrete block of  claim 7 , wherein each of the vertical reinforcement grooves forms an angle between about 45 and 60 degrees with respect to the first side panel and the second side panel. 
     
     
         11 . The precast concrete block of  claim 10 , wherein each of the vertical reinforcement grooves has a length of between about 1 and 1.5 inches. 
     
     
         12 . The precast concrete block of  claim 1 , wherein the at least one reinforcing member is rebar or wire mesh. 
     
     
         13 . A 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, the method comprising:
 (i) providing a form into which the concrete block is cast;   (ii) 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   (iii) transporting the cast concrete block to an installation site for assembly into a wall.   
     
     
         14 . The method of  claim 13 , wherein the at least one reinforcement alignment feature is a plurality of horizontal reinforcement grooves and/or a plurality of vertical reinforcement grooves. 
     
     
         15 . The method of  claim 14 , wherein each of the horizontal reinforcement grooves forms an angle between about 45 and 60 degrees with respect to the at least one connecting rib. 
     
     
         16 . The method of  claim 14 , wherein each of the vertical reinforcement grooves forms an angle between about 45 and 60 degrees with respect to the first side panel and the second side panel. 
     
     
         17 . The method of  claim 13 , wherein the at least one reinforcing member is rebar or wire mesh. 
     
     
         18 . The method of  claim 13 , the method further comprising, prior to step (ii), positioning in the form a plurality of mold inserts for forming a hollow core in the center of the concrete block.