Beach stabilizing blocks

[0001] The invention refers to a large fillable shaped device to stabilize beach areas or form walls and protective barriers and a method to employ this device which is water and sand tillable, top vented to allow escape of water, and can have various interlocks to form larger structures.

[0002] The creation of sea walls, breakwaters and similar beach conservation and breakwater devices is well documented and the subject of many patents on stabilization structures and artificial breakwater structures.

[0003] A typical ocean beach is a constantly moving accumulation of sand, mud, and gravel. The action of waves brings sand into the beach area and deposits it from further out (deeper water) at times and at other times the wave action strips the sand accumulation away and re-deposits it elsewhere. Beaches and breakwaters are thus moving objects except where they are fixed by rock deposits or similar retaining walls or manmade barriers which act as anchors around which the deposition and removal of sandy soils continues.

[0004] The earliest and perhaps the best barrier to shifting of beach areas are piles of very large (ton or more) rocks. The rocks break the force of the waves and yet allow the water of the waves to slowly percolate through the rock piles diminishing the hydraulic forces that would exist if water were trapped behind a wall or similar retainer. The shapes of the rocks also diverts the force of the waves in many directions and balances these split forces so that the rocks are not easily moved, even by very large waves and tides. It is common for sand to accumulate behind the stones forming a jetty and to thus reinforce the jetty or barrier formed by the rocks. The accumulation of sand behind barriers is a major factor in the formation of beaches and a factor in stabilization of these beaches. At present there are few practical and easy to install ways to create a barrier around which a beach might form. The closest present way to stabilize uses chained together automobile tires, an unsightly and possibly contaminating method.

[0005] Walls have frequently been used to prevent sand loss from beaches but walls are poor at breaking up the force of waves with relatively large flat areas of (nearly) simultaneous wave impact greatly stressing and eventually cracking the walls. As noted above, walls also retain water and this hinders the free draining of water that is important in beach formation, and walls may allow sand to drain from behind the wall thus actually speeding the errosion that the walls were to prevent.

[0006] Alternates to the walls are logs of cement that have interlocking points that run both parallel to the wave fronts impacting on the beach and also have extended members going perpendicular to the wave fronts that in front break up the waves and behind the wall of logs stabilize and hold sand. The logs are typically built with large gaps between the layers like log houses with alternate logs removed. A similar system is also used in highway construction to stabilize steep soil banks near bridges etc. The logs also allow drainage of soil and sand from behind the barrier.

[0007] The properties of the log style barriers illustrate many of the features desired in beach stabilization or beach area construction. First the barriers are substantial, will not float away, and allow fill behind them. There is a need for a barrier that has similar propertiesi.e. a barrier that would be substantial, would fill, and is easier than cement logs to handle and install.

[0008] Sand and soil retention is also common in flood areas and at shores where sandbags are filled and stacked to form walls of sand that keep water out of that break up wave actions. The bags are fragile and such is useful only for relatively short times and the stacks are easily overturned due to the small size of the sandbags.

[0009] The creation of very large hollow barrier blocks which are either trapezoidal in cross section or are truncated pyramidal shapes or large rectangular boxes which can be filled by water and by sand through natural wave action or by pumped slurry is shown in this device and method to provide a way to stabilize beach areas. Each of the trapezoidal or pyramidal blocks are elements interlocking by one of more of locking stakes or interlocking projections in the shaped elements that provide beach erosion barriers. These-beach barrier blocks have most of the advantages of large rocks but are economical and easier to handle. Since they are filled on site with sand and/or gravel, the blocks are transportable and can be used to form comparatively seamless walls or barriers. In fact any pumpable material could be used as fill within one of the barrier blocks.

[0010] The invention shows a number of shapes including trapezoidal shapes of very large fillable barrier blocks. The trapezoidal shape allows the blocks to be stacked in a variety of patterns which have interlocking sides, make high barriers, or control drainage. Some of the various stacking patterns of the barrier blocks further allow free flow of fluids from behind the barrier blocks while other patterns minimize the fluid flows. While the barrier blocks are first filled with water or sand water slurry after placement, top addition holes allow the sand loaded waves that break over these barrier block assemblies to displace part of the water with sand, eventually by natural wave action filling the barrier blocks with sand through displacement of the water. In a similar manner, blocks filled with slurry settle forming a solid bottom layer and top water layer. As more slurry is added the block fills with solids hydraulically packedthe construction ideal of wet clay fill for stability can thus be formed with this concept. Sand and gravel may also be used as fill.

[0011] The stacking of barrier blocks that are of various shapes allows either a jagged wall upon which the waves impact, or allows a flatter wall with a variety of open spaces for water flow. As the shape is further expanded to pyramidal, both side drain areas and the jagged shapes facing the waves are possible with stacked barrier blocks.

[0012] The stacking and holding of the barrier blocks by gravity forces alone is possible, however it has been shown that interlocking projections and depressions on the surfaces of the blocks add to the utility and makes walls and barriers formed of the blocks more stable. A series of stake wells is further provided so long stakes may be driven through stacks of barrier blocks.

[0013] The most interesting aspect of this concept is the utility as a building element for walls. Barriers, or even sheds and patios where a series of the filled blocks are combined in specific layouts.

[0014] In FIG. 1, the beach barrier block is shown in one embodiment made by the well known process of thermoforming of the components with subsequent assembly and sealing. FIG. 1 shows a cross sectional beach barrier block with trapezoidal shape and the stake wells sectioned with two top vents 9.

[0015] FIG. 2 shows an assembly drawing of a more complex beach barrier block with the top that includes four vent cutouts 9A, five stake wells 5A, which is assembled from a top and a boat like bottom section.

[0016] FIG. 3 shows another view of an assembly, this time for an inverted model with stakes shown and attachments between the modules and side and end attachments.

[0017] FIG. 4 shows an end type of barrier block with alternate round section as a terminal and shapes for specific joining uses such as interlocking fingers.

[0018] FIG. 5 shows a slanted intermediate part which could fit between or act as spacers for other parts.

[0019] FIG. 6 shows a right angled corner part.

[0020] FIG. 7 shows the Beach Barrier concept simplified and with a stake 12A used in well 5C to hold a block. There is a set of 6 blocks shown each attached to each other on sides and top to bottom. The sloped surface is towards waves to dissipate the wave forces and cause the waves to wash over fill vents 9F filling the block.

[0021] FIG. 8 shows an altered form of the barrier block with end grooves 13E, and end projections 61B, vents and stakes for wells. A facia 80 in brick pattern is shown.

[0022] FIG. 9 shows cube shape blocks with side alignment and attachment slots 90 and top projecting X shape 91 which fits within bottom X indention 92. The fill slot is triangular cutout 9G

[0023] FIG. 10 shows a series of barrier blocks where two are joined by joining clips 101 and held to the beach soil by stakes 12C. Cutout 9H is for fill.

[0024] In the most preferred embodiment of this invention as shown in cross section as FIG. 1, a large shaped block 2 which is thermoformed from ultraviolet stabilized high density polyethylene sheet. The shape, in cross section, consists of at least one side 1 sloping at 45 degrees, separated by a 24 inch flat bottom 10. The height of the block is 2.5 feet which makes each sloping side approximately 3.5 feet long and the top 7 feet long. The block has a depth of 2 feet and front and back in this case are straight sides perpendicular to the plane of the bottom. The plane of the top is parallel to the plane of the bottom. The shape of this embodiment is thus a truncated wedge. Fill ports 9 are top cutouts.

[0025] While there will be at least one stake well 5, in this embodiment a total of five stake wells 5 consisting of an 18 inch high conical tube with a top dimension of 2 inches and a bottom dimension of 3.5 inches is thermoformed from the material of the bottom of the shape with one well central in the bottom and the other four wells arranged near (approx. four inches) from the corners of the 2 foot by 2 foot flat bottom in that flat bottom area. As is well known in the art of thermoforming, the wells may be pressure assisted in the process of thermoforming so they retain reasonable wall thickness.

[0026] After thermoforming the bottom, the now shaped sheet is trimmed with minimal edges as shown in FIG. 2 as 11 in a large hydraulic trim stamping) press by a shaped die. This operation leaves extended lips projecting in the plane of the top from all sides.

[0027] As shown in FIG. 2, top 6 is thermoformed from high density polyethylene sheet which is essentially flat except for interlocking edge retainers which fit over and form a snap fit with the extended projecting lip like edges 11 of the truncated wedge shape bottom 1A. The top is also trimmed in a hydraulic trim press. In this embodiment the wells are marked upon the top 8 and the wells project to at least touch the top at the marked depressions for wells. When the wells terminate within less than {fraction (1/8)} inch of the top when the unit is fully assembled, the wells may be joined to the top as noted below. Such joinder of wells and tops is not mandatory in this invention.

[0028] Cutouts 9A which are at least 6 square inches are located on the top within two inches of the edge of the top part.

[0029] The part is assembled by snapping the top onto the bottom. In most uses the top snap fit will be adequate and since it can be assembled on location will provide considerable economies in shipping the units. For sea wall uses subjected to strong impact forces, it will be necessary to thermally weld or to glue or otherwise attach the top to the bottom after assembly.

[0030] Extra stability and strength is available if the wells 5 are then welded or snapped onto the depressions 8. For staking the stakes may be driven through the depressions or the depressions may be cutout.

[0031] In use the top and bottom are snapped into place and units are set into a shallow trench dug into the beach area. The barrier blocks are placed in one of several ways. For maximum dissipation of wave forces the units are stacked with the top upward and filled with water or water and sand slurry as they are located. The top markings show where the stake wells are located and before placing another unit on the top, the stake wells that will be used are drilled open with a hole drill through the top part and the well top material left from thermoforming the wells. A stacked set of blocks is shown in FIG. 7 with stakes 12A and interlocking edges 61A and 13D. In many cases all of the stake wells 5C will be drilled out for maximum staking flexibility. This opening of the wells may also be performed in the die cutting of the mold, but this is not essential and it is usually more convenient to perform the final cutout of holes to be used for stakes at the site.

[0032] FIG. 2 shown the assembly of the parts with the top 6A having depressions marking the location of the staking wells 8A and the top cutouts for draining shown 9A. The overlooking edge going downward is shown as 7. The projecting lip 11 in the bottom 1A interacts with the overlocking edge 7 to close and lock the beach block to the top and make this a single large block, closed on all sides with only the cutouts 9A allowing access to the interior. In the cases where the wells 5A are sealed by welding or mechanical snaps to the cover these wells provide further stability, and even when they are not attached, the wells support the top and prevent collapse, thus allowing thinner walls.

[0033] When the blocks are formed and assembled they can be placed in a number of places and ways for use. The blocks may be filled with only water for a temporary installation and then pumped out when the installation must be moved.

[0034] In permanent or long term uses of the beach blocks, the ideal method to fill is to pump sand or sand and gravel slurries into the top slots of the beach blocks. The sand is allowed time to settle and the water to rise towards the top and then further slurry is added until the blocks are substantially filled with solids, well packed by natural hydraulic settlement processes. These well packed blocks are essentially permanent.

[0035] In use two major goals can be filled with the units. If the flat, non angled sides of the barrier blocks are set toward the waves, a wall is created that could be straight but in the other orientation, rotated 90 degrees, a stepped wall can also be formed. Any type of stake can be applied in the stake wells in the top barrier block staked with stakes to a set of stake holes in the a next lower barrier block unit to create a stepped wall of large blocks that will offer the fastest fill with sand and will have large open holes for water drain.

[0036] For dissipation of the wave front energy while continuing the sand fill feature of the barrier blocks 2C, the sloped sides of the wedge shape are faced into the wave front where each sloped section curls a part of the wave force around and reverses it, thus using the wave force to help dissipate itself, The barrier blocks in both arrangements are staked with stakes into walls and interlocked to form a wall shape of any length. The stakes may also be driven into the ground to stabilize the entire wall unit.

[0037] In a second embodiment the top of the thermoformed barrier block is 6 feet long and two rows of stake wells are arrayed of the width from the outer edge of the block and every 18 inches to allow a wide variety of stacking patterns.

[0038] The shape can also be rectangular and such a large rectangular shape has considerable use as a building element in sheds or as the floors, supporting base of walls surrounding decks and patios.

[0039] In a third embodiment the size of the top is 6 feet by six feet and the bottom is a truncated pyramid with a height of 2 feet and a flat area of two feet square. Rows of stake wells are arrayed from all edges and spacing of holes along the rows is 18 inches.

[0040] In a fourth embodiment shown as FIG. 3, the top of the truncated shape is upward and the larger bottom downward, the staking wells, 5B, whet their stakes 12 are supplemented with interlocking projections 13 and recesses that allow easy stacking in a variety of patterns. The projections may be used for example to join two units end to end or they may be used for other attachments. A series of shaped grooves is also shown which are alternate or supplementary methods of attachment of blocks end to end. The blocks retain the top entry hole for filling 9B.

[0041] In a fifth embodiment the interlocking knobs and matching recesses replace the staking wells on the top and bottom of the truncated wedge or truncated pyramid shape.

[0042] In a sixth embodiment the interlocking knobs and recesses are added to the sloping sides of the barrier blocks of the truncated wedge or truncated pyramid shape.

[0043] In a seventh embodiment the barrier block is deployed after glue or weld seals are formed between the top and bottom parts.

[0044] In an eighth embodiment the barrier block is formed by rotomolding polyolefin or vinyl plastic within a sheet metal mold and the stake holes are thru molded and fill holes are cut after molding.

[0045] In a ninth embodiment the barrier block is formed in one piece by injection blow molding methods in one piece with cutouts for stakes and fill made after the molding.

[0046] In a tenth embodiment shown as FIG. 4, a view of a circular end part 40 for a wall or barrier is shown with attachment grooves 13A and top cutout 9C.

[0047] In an eleventh embodiment shown as FIG. 5, an angled joiner part is shown with end grooves 13B and top hole 9D in part 50.

[0048] In a twelfth embodiment shown as FIG. 6, a right angle top view of a block with end grooves both internally trending as 13C and outwardly projecting as 61 in part 60. The filling cutout is shown as 9E.

[0049] FIG. 7 shows one typical shape with external stakes fitting within shaped grooves and corner stakes 12A fitting into corner wells 5C in part 72. Shaped external stake 71 fits into shaped grooves 13D to hold the part to the ground. A total of 6 blocks is shown with angled sides to a wave front or to sand or other material to be stabilized. If the angles are to waves they act to dissipate and break up the upward forces of the water while in sand or soils the angles hold the blocks from movement.

[0050] FIG. 8 shows the another embodiment, a wall-shaped block with a narrow width, at least one side of which has a decorative surface 80, There is a plethoria of top cutouts 9G and a series of stakes 12B which fit into wells 5D. While not essential, this embodiment also has end shaped grooves 13E and shaped projections 61B which help hold the wall in place and to other wall units.

[0051] FIG. 9 shows blocks with deep edge grooves 90 which can accommodate either surrounding stakes or other projections in different blocks and a top and bottom interlock, in this case in the shape of an X 91,92. A triangular top fill port is shown as 9G

[0052] FIG. 10 shows the final embodiment, in this case a set of two blocks attached with side clips 101 and held down by stakes 12C. The fill hole is shown as 9H.

[0053] It should be understood that the terms and words used herein are specific to this invention and descriptive of it. Any use of the words in a more general context is not anticipated herein. Likewise, this invention shown a number of possible embodiments but cannot show or extrapolate every use of a filled top draining interlockable device but that the basic concepts herein are common to other shapes and attachment methods.