MODULAR BLOCK SYSTEM FOR A BEARING BEAM STRUCTURE

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) and the benefit of U.S. Provisional Application No. 63/708,814 entitled MODULAR BLOCK SYSTEM FOR A BEARING BEAM, filed on Oct. 18, 2024, by James Robert Johnson et al., the entire disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

Construction of load bearing structures commonly requires extensive planning, customized or specifically selected components, and construction that extends through several phases. Such processes are time-consuming, expensive, and can have an increasingly adverse impact on the local environment as the required construction time extends. The disclosure provides for a modular structure and bearing support that may improve construction timing and limit delays associated with the design and construction process for load bearing structures, particularly for bridges and support beams.

SUMMARY OF THE INVENTION

A modular construction block system for a bearing beam or an abutment wall includes a plurality of structural blocks combining to form a bearing surface. The structural blocks include a front body section and a rear body section extending between opposing lateral sides and separated by a plurality of connecting partitions. The connecting partitions are separated by a spacing which forms voids extending through the structural blocks between the front panel and the rear panel. The structural blocks further include interlocking features aligning a plurality of courses of the structural blocks in a laterally staggered configuration over a staggered distance. The laterally staggered configuration of the structural blocks aligns the voids in columns extending through successive courses of the plurality of courses.

A method for forming an abutment wall for at least one bearing beam or superstructure includes preparing a structural wall comprising a plurality of courses of structural blocks in a laterally staggered configuration. The laterally staggered configuration of the structural blocks aligns a plurality of voids formed by the structural blocks to align in columns. At least one bearing beam or superstructure is positioned on the structural wall. A binding material (e.g., concrete, aggregates, etc.) is poured into the columns through the plurality of courses formed by the structural blocks through a gap formed between the superstructure and the plurality of voids. The binding material poured in the columns is cured with the superstructure in place supported by the structural wall.

These and other features, objects and advantages of the present invention will become apparent upon reading the following description thereof together with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an environmental view of a bridge supported by an abutment wall;

FIG. 2A is a pictorial process diagram demonstrating a method for bridge construction utilizing a modular construction block system;

FIG. 2B is a pictorial process diagram demonstrating a method for bridge construction continued from 2A;

FIG. 2C is a pictorial process diagram demonstrating a method for bridge construction continued from 2B;

FIG. 2D is a pictorial process diagram demonstrating a method for bridge construction continued from 2C;

FIG. 3 is a projected view demonstrating a plurality of structural blocks for a modular construction block system;

FIG. 4 is a projected view demonstrating a plurality of structural blocks laterally staggered in a plurality of courses demonstrating the alignment of voids in columns among rows of the courses;

FIG. 5 demonstrates a construction block system comprising a bearing block forming a beam seat for a bearing beam or superstructure;

FIG. 6 demonstrates an implementation of a modular construction block system comprising a recessed jig insert configured to support a superstructure;

FIG. 7 is a projected view demonstrating a 90° corner transition of a modular construction block system;

FIG. 8A is a projected view demonstrating a 45° corner transition of a modular construction block system;

FIG. 8B is a top view demonstrating a 45° corner transition of a modular construction block system;

FIG. 9 is a projected view demonstrating a foundation block of the modular construction block system forming a pile cap of a deep foundation; and

FIG. 10 is a projected view demonstrating the modular construction block system implemented as a temporary structural support for a bearing beam or superstructure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the following description, reference is made to the accompanying drawings, which show specific implementations that may be practiced. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. It is to be understood that other implementations may be utilized and structural and functional changes may be made without departing from the scope of this disclosure.

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1. Unless stated otherwise, the term “front” shall refer to the surface of the element closer to an intended viewer of the display mirror, and the term “rear” shall refer to the surface of the element further from the intended viewer of the display mirror. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The terms “including,” “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

Referring generally to FIGS. 1 and 2, a modular construction block system 10 is introduced in reference to an abutment wall 12 supporting a superstructure 14 (e.g., bearing beam, bridge beam, etc.). In the example shown, the superstructure 14 forms a bridge 16 supporting a public road surface 18 including guardrails 20 for vehicle traffic. In this configuration, the bridge 16 may span a gap 22 formed over a valley 24 or terrain variation extending between opposing abutment walls 12. For example, the bridge 16 may extend over the gap 22 to provide for use as a pedestrian crossing, road, wildlife crossing, culvert, or various elevated structures. By implementing the abutment walls 12 with the modular construction block system 10, applications of the bridge 16 extending over valleys 24 corresponding to rivers or water passages may be significantly unencumbered, providing a natural passage for aquatic organisms.

In various implementations, the abutment wall 12 may comprise a bearing wall section 30 that may be flanked on one or more lateral sides by a wing wall section 32. The bearing wall section 30 and wing wall section 32 may be interconnected by a plurality of corner blocks. In this configuration, the abutment wall 12 may serve the dual purpose of supporting the bridge 16 and corresponding structure while also preserving the channel associated with the river 24 or gully to prevent erosion and maintain a grade or structure of opposing banks 36. The abutment walls 12 may provide for a modular system for supporting the bridge 16 or other applications that may require superstructures 14 while also preserving the natural environment associated with the valley 24 or gully. Finally, while discussed in various examples in reference to the bridge 16 extending over a natural landscape in the form of a river or gully, the modular construction block system 10 and related abutment wall 12 may similarly be implemented to provide a bearing support for various structures.

Still referring to FIGS. 1 and 2, the modular construction block system 10 may include a plurality of structural components including a deep foundation (see FIG. 9), foundation blocks 38, wall blocks 40, bearing blocks 42, and corner blocks 44. As demonstrated in step A of FIG. 2, the construction of the abutment wall 12 and the resulting bridge 16 may begin by preparing a foundation base 50, which may correspond to a leveled, graded, and/or filled surface on which the foundation blocks 38 may rest to support the abutment wall 12. In the example shown in step A, the foundation blocks 38 comprise vertical cores 52 that may align with corresponding cores on the wall or abutment blocks 40. As further discussed in reference to FIG. 9, the foundation blocks 38 may further serve as pile caps for optional deep foundations 54 (e.g., formed piles, driven piles, soil anchors, etc.).

As demonstrated in step B of FIG. 2, the modular construction block system 10 may comprise the bearing wall section 30 and wing wall sections 32 formed as a plurality of courses 60 stacked in successively elevated rows on the foundation base 50. The bearing wall sections 30 may be interconnected with the wing wall sections 32 via the corner blocks 44, which may be stacked in the courses 60 aligned with the wall or abutment blocks 40. As further discussed in reference to FIGS. 3-5, the wall blocks 40, bearing blocks 42, and/or the corner blocks 44 may form voids 62 within a perimeter of the corresponding block structures that may extend as columns 64 aligned through the courses 60 with the blocks 40, 42 oriented in a staggered configuration 66. In this way, the blocks 40-44 forming the abutment wall 12 may be structurally interconnected by a binding material (e.g., concrete, aggregates, etc.) placed into the columns 64 formed by the vertically aligned voids 62.

Referring now to FIGS. 3-5, various features of the abutment blocks 40, 42 are described further demonstrating the staggered configuration 66 and the associated alignment of interlocking features 70 formed on or by the corresponding structure of the blocks 40-44. Referring first to FIG. 3, representative examples of the abutment blocks 40, 42 are demonstrated as a wall block 40 or support block and two exemplary variations of bearing blocks 42. In general, each of the blocks 40, 42 may be formed by a front body section 72 and a rear body section 74 interconnected by a plurality of connecting partitions 76. As shown, the front body section 72 and the rear body section 74 may extend between opposing lateral sides 78 from a top surface 80 to a bottom surface 82. As shown, the top surface 80 and bottom surface 82 of each of the abutment blocks 40, 42 may include the interlocking features 70. In the example shown, the interlocking features 70 include protrusions 70a configured to engage corresponding slots or openings 70b on the adjacent top surface 80 or bottom surface 82 of the blocks 40, 42 in the neighboring course 60. In this way, faces 84 of the blocks 40, 42 formed on the front surface of the front body section 72 may be aligned, such that a decorative surface 86 and/or shape 88 is aligned forming an exposed surface 90 of the abutment wall 12.

In addition to the interlocking features 70, the top surfaces 80 of the front body sections 72 of the bearing blocks 42 may form a flat top 92 or a recessed top 94. The recessed top 94 may form a beam seat configured to receive a corresponding connecting protrusion 96 of the superstructure 14 or bridge beam as demonstrated in FIG. 5. In various implementations, the front body segments or sections 72 of the blocks 40-44 may incorporate one or more reinforcement materials or structures that may ensure that the top surface 80 or bearing surface is suitable to support the superstructure 14 or bridge beam and the associated weight of the bridge 16, corresponding structure, and load. For example, the reinforcement structure incorporated in the front body section 72 may include reinforcement bar (rebar), wire mesh, fibers, and/or various structural reinforcement materials. In this way, the modular construction block system 10 may provide for a portable structure, forming the voids 62 and columns 64 as molds between the front body section 72 and the rear body section 74, that may be prefabricated and delivered for rapid construction of various structures.

As shown, multiple examples of the bearing blocks are referenced with numeral 42, including a variation with the flat top 92 and the recessed top 94. In addition to these features, like reference numerals may be utilized to clearly designate similar structures or features described in the detailed description. Though some features may be described in reference to specific examples and combinations, it shall be understood that the scope of the invention is not limited by the examples described in application. Instead, this description provides for non-limiting examples that provide instructions as to how the disclosed subject matter may be implemented.

As best demonstrated in FIG. 4, the staggered configuration 66 of the blocks 40-44 may provide for the alignment of the columns 64 among the voids 62 formed between the front body sections 72 and the rear body sections 74. The staggered configuration 66 may be aligned over a lateral stagger distance D_S based on the corresponding positions of the interlocking features 70 between the top surface 80 and the neighboring bottom surface 82 of each of the successive courses 60 of the blocks 40-42. In the example shown, each of the connecting partitions 76 may be spaced approximately half the stagger distance D_S from the lateral sides 78 of the blocks 40-42. Accordingly, a partial void 62a may be formed between the front body section 72 and the rear body section 74 along each of the lateral sides 78. Additional connecting partitions 76 may be centered and spaced over the stagger distance D_S forming full voids 62b enclosed on four sides between the front body section 72, the rear body section 74, and adjacent connecting partitions 76. In this configuration, the stacked voids 62 formed by the courses 60 of the blocks 40-42 in the staggered configuration 66 may align in interconnected columns 64. In this configuration, binding materials, such as concrete, aggregates, or other materials, may be poured through a top opening 98 of each of the columns 64 and into the vertically aligned voids 62 to secure the blocks 40-44 as a unitary structure.

The partial voids 62a formed on the lateral sides 78 of each of the neighboring blocks 40-44 may combine to form full voids 62b. As a result of the spacing of the connecting partitions 76 spaced from the lateral sides 78, the partial voids 62a may extend over half the stagger distance D_S. In this configuration, the neighboring lateral sides 78 of the blocks 40-44 in each course 60 may be enclosed on four sides to form the full void 62 similar to the successive full voids 62b formed within the individual blocks 40-44. In this way, the columns 64 may consistently extend vertically through the courses 60 between the blocks 40-44 forming the bearing wall section 30, the wing wall section 32, and the interconnecting corners formed by the corner blocks 44.

In addition to the partial voids 62a formed by the adjacent features of the neighboring blocks 40-44, the partitions 76 may form partial openings including a top surface opening 100a and a bottom surface opening 100b recessed from the corresponding top surface 80 and bottom surface 82 of the blocks 40-44. In this configuration, the neighboring top and bottom surfaces 80, 82 of the blocks 40-44 in neighboring courses 60 may form interconnected rows 102 that intersect with the columns 64. In this configuration, the concrete or binding material poured into the columns 64 may flow into the passages formed by the interconnected rows 102 formed by the neighboring stacked partitions 76. In this way, the binding materials poured into the top openings 98 may ensure that interconnected rows 102 and intersecting columns 64 are effectively locked together by the binding materials to form the wall as a reinforced unitary structure.

As demonstrated in FIG. 5, the top opening 98 providing access to the columns 64 of aligned voids 62 may remain accessible after the superstructure 14 (e.g., bearing beams, bridge beams, etc.) is installed or placed on the abutment wall 12. This assembly order may be particularly beneficial by allowing all heavy, large-scale structural segments of the abutment wall 12 and bridge 16 or corresponding superstructure 14 to be assembled without intervening delays that might otherwise be required to allow the concrete or binding material to be poured into the columns 64 and cured. The capability of the abutment wall 12 to support the superstructure 14 or bridge beams without the addition of the concrete or binding materials may be provided by the precision alignment of the interlocking features 70 in combination with the inclusion of the reinforcement structures, for example, rebar, in at least the front body section 72 of the bearing blocks 42. With this structural configuration, the superstructure 14 or bridge beams may be securely supported while leaving the top opening 98 of each of the columns 64 accessible and open to pour the binding material into the voids 62 and corresponding columns 64 to bind the blocks 40-44. In this way, the necessary curing time for the binding material within the voids 62 may occur after the superstructure 14 or bridge beams are installed, such that the heavy equipment required to move both the blocks 40-44 and the superstructure 14 may be utilized over a continuous timeframe without intervening delays.

Referring now to FIG. 6, in some implementations, the bearing blocks 42 may be utilized in combination with a plurality of jig inserts 110 that may be embedded into the top surface 80 of the bearing blocks 42. As shown, the jig inserts 110 may be aligned with the voids 62, such that the resulting support structure extends down through the columns 64 based in the staggered configuration 66 as previously discussed. In various implementations, the jig inserts 110 and resulting columns 64 of binding material (e.g., concrete, aggregates, etc.) may be filled and supplemented with reinforcement structures, for example, reinforcement steel, and cast-in-place following the construction of the abutment wall 12. The resulting columns 64 of reinforced concrete 112 extending into the jig inserts 110 may provide for a readily accessible surface prepared for the connection of various beam structures 114 that may be implemented as the superstructure 14. Accordingly, the modular block system 10 may be utilized to construct the abutment wall 12 to suit a variety of structures and support applications.

As further demonstrated in FIG. 6, the jig inserts 110 may be adjusted or stepped in height relative to the top surface 80 of the bearing blocks 42. For example, in the example shown each of the neighboring jig inserts 110 extends vertically with an increased height relative to the top surface 80 of the bearing blocks 42. In this way, the jig inserts 110 may form an angled or incrementally stepped support structure that may provide the ability to adjust the resulting support structure to be tilted on an angle θ or sloped relative to the top surface 80 of the bearing wall 30. As shown, each of the neighboring jig inserts 110 spaces the superstructure along the slope angle 9. In this way, the disclosure may provide flexibility to tilt, angle, or slope the bridge 16 laterally along a length of the bearing wall 30, referred to as superelevation positioning.

Referring now to FIGS. 7, 8A, and 8B, examples of the corner blocks 44 are demonstrated as a 90° corner block 44a and a 45° corner block 44b interconnecting the bearing wall section 30 with the wing wall section 32. As shown in FIGS. 7 and 8A, each of the corner blocks 44a, 44b may be implemented as partial corner blocks 120 or full corner blocks 122. The partial corner blocks 120 and the full corner blocks 122 may include the partial voids 62a positioned on opposing sides 124 similar to the blocks 40, 42. Additionally, a plurality of the connecting partitions 76 may extend between a front corner body portion 126 and a rear corner body portion 128. The front corner body portion 126 may follow the corresponding angle of the corner block 44 in the 90° configuration 44a or the 45° configuration 44b.

As best illustrated in FIG. 8B, the rear corner body portion 128 may extend diagonally between the adjacent bearing wall section 30 and wing wall section 32 at an angle that bisects the corresponding angle of the corner block 44. For example, the rear corner body portion 128 of the 90° corner block 44a may extend diagonally approximately 45° between the adjacent sections 30, 32. Similarly, the rear corner body portion 128 of the 45° corner block 44b may extend diagonally at an angle of approximately 22.5° between the adjacent sections 30, 32. In this configuration, the corner blocks 44 may structurally tie the adjacent wall sections 30, 32 at the intersection angle allowing the wing wall sections 32 to improve the structural stability of the bearing wall sections 30.

Similar to the alignment of the columns 64 previously discussed in reference to FIG. 4, the formation of the full voids 62b and the partial voids 62a may provide for the alignment of the columns 64 extending through the corner blocks 44a, 44b. For example, the included connecting partitions 76 of the corner blocks 44a, 44b may form full voids 62b. Additionally, adjacent sections of the corner blocks 44a, 44b neighboring the abutment blocks 40, 42 may combine to form the full voids 62b from the neighboring partial voids 62a. The included full voids 62b or full voids 62b formed in combination may align with the spacing of the columns 64 linking the blocks 40-44 together. Accordingly, the columns 64 corresponding to the aligned voids 62 may provide for the corner blocks 44 to receive binding and/or reinforcement materials within the evenly spaced columns 64 over the bearing wall sections 30, the wing wall sections 32, and the interconnected corner sections 130.

Referring now to FIG. 9, an example of a deep foundation 56 is shown comprising a plurality of the deep foundation features 54 driven into or otherwise formed in the earth or a base layer 140 on which the foundation base 50 is set. A base or bottom surface of each of the foundation blocks 38 may include or form a receiving opening 142 that may operate as a pile cap 144 configured to retain an exposed portion of the deep foundation 54 extending outward from the base layer 140 or earth. In this configuration, the even spacing of the openings 142 formed in the foundation blocks 38 may serve to link or interconnect the exposed portions of the deep foundation 54 (e.g., piles) extending upward through the base layer 140 to ensure that the elements of the deep foundation 54 operate in combination to maintain the structural stability of the resulting foundation base 50. Though demonstrated as piles and corresponding pile caps 144, the openings 142 of the foundation blocks 38 may generally provide for the interconnection of various structures for deep foundations 54 that may provide for structural supports including footers, piers, or similar support structures.

Referring to FIG. 10, an example of the block system 10 is shown implemented as a temporary bearing structure 150. As previously discussed in reference to FIG. 5, the design of the modular construction block system 10 may be structurally stable and capable of supporting the bridge beam or superstructure 14 along an elongated bearing surface 152 prior to pouring concrete into the columns 64 or cores. This capability of the block system 10 may primarily be attributed to the depth of the front body 72 and stability afforded by the combination of the interconnected rear body 74 and the interlocking features 70. In practice, the temporary support structure 150 may allow the spans 154 forming the beam structure 114 to be adjusted in position relative to abutment reinforcement bars 156 and a corresponding span-abutment interface 158 while the bearing surface 152 supports the load of the spans 154. Accordingly, the system 10 enables a method of construction for the bridge 16, pedestrian crossing, roadway, wildlife crossing, culvert, or similar structures.

As described in further detail in the following example, utilizing the block system 10 as the temporary support structure 150 may provide considerable benefits primarily associated with the adjustment of the spans 154 and coupling to the span-abutment interface 158 prior to pouring concrete and awaiting the concrete to cure. In conventional bridge construction, the pouring of concrete is required to form corresponding bearing structures or surfaces required to support the bearing beams or superstructure 14. Such delays may require that heavy equipment be maintained or repeatedly transported to construction sites, such that the spans 154 may be moved and placed following the curing of the concrete or binding materials for bridges. In contrast, the provision of the temporary bearing structure 150 enabled by the modular construction block system 10 ensures that the spans 154 may be positioned and coupled to the span-abutment interface 158 prior to pouring concrete. In this way, the modular construction block system 10 may provide considerable improvements in efficiency and cost savings compared to conventional bridge construction.

In the specific example demonstrated in FIG. 10, following the construction of the abutment wall 12 (e.g., FIGS. 2B and 2C), the spans 154 may be positioned on the elongated bearing surface 152 and supported by the bearing structure 150. In various implementations, the spans 154 may be positioned in a spaced-apart configuration elevated over the bearing surface 152 by a spacer 160 over a spacing distance S. In this way, the bearing surface 152 may support the spacer 160 (e.g., a dimensional timber or post) to provide a rough alignment between span plates 158a and bar plates 158b forming the span-abutment interface 158. As shown, the span plates 158a may be fixedly coupled (e.g., welded) to the spans 154 or more generally to the steel beam structure 114, and the bar plates 158b may be coupled to reinforcement bar couplers 162 interconnected to the abutment reinforcement bars 156 incorporated in the columns 64 and between the courses 60 of the abutment wall 12. In this configuration, the spans 154 and reinforcement bar couplers 162 may be incrementally adjusted and aligned while supporting a load (e.g., several tons) of the spans 154 on the bearing surface 152 prior to pouring concrete in the columns 64 or cores and awaiting the requisite cure time for the resulting structure. In this way, the modular construction block system may support the improved method of construction and provide considerable savings downtime and transportation of heavy equipment necessary to place and position the spans 154.

Still referring to FIG. 10, once aligned, the reinforcement couplers 162 may be fastened to the plates 158a, 158b of the span-abutment interface 158 by fixing nuts 166 or fasteners. The structural connection between the spans 154 and the reinforcement bars 156 via the span-abutment interface 158 may ensure that the steel beam structure 114 is effectively aligned and coupled to the abutment wall 12 and the interconnected reinforcement structure 164 formed by abutment reinforcement bars. By coupling the spans 154 to the reinforcement structure 164 prior to the introduction and curing of concrete, the block system 10 may ensure that construction of the span-abutment structure shown in FIG. 10 can be validated and/or inspected and updated before the concrete permanently sets the reinforcement structure 164. In addition to the improvements in adjustment and correction to validate the construction, the bearing structure 150 may further support the spans 154, allowing the corresponding elevated support surface 162 to be utilized for limited transport and conveyance of equipment and/or personnel associated with the construction of the bridge 16 over the length of the spans 154. While it is noted that the spans 154 may be utilized in such a capacity for conveyance, it shall be understood that the structural stability provided by the spans 154 is dependent on the proper execution of the construction of the abutment wall 12 as well as the appropriateness of the steel beam structure 114 and spans for the load conveyed as with any structural assembly.

By allowing the spans 154 to be effectively positioned and coupled to the span-abutment interface 158, the temporary bearing structure 150 provided by the modular construction block system 10 provides various advantages over conventional construction methods. In particular, the operation of setting and mounting the spans 154 to the span-abutment interface 158 prior to pouring concrete provides considerable savings in time and resources, particularly limiting the duration necessary for heavy moving equipment for the spans 154 to be maintained at a job site. Further, the engagement of the spans 154 to the span-abutment interface 158 prior to pouring concrete may allow the reinforcement bar couplers 162 and corresponding bar plates 158b to be corrected or adjusted in position prior setting the reinforcement structure 164 in concrete. In this way, various minor adjustments may be made, and errors may be identified and corrected prior to pouring concrete and awaiting the necessary curing time. Accordingly, the modular construction block system 10 and corresponding methods of construction may provide improved efficiency while also allowing for the identification of corrections and related adjustments to improve the successful construction and validation of the construction of the bridge 16 and similar structures.

According to some aspects of the disclosure, a modular construction block system for a superstructure or an abutment wall includes a plurality of structural blocks combining to form a bearing surface. The structural blocks include a front body section and a rear body section extending between opposing lateral sides and separated by a plurality of connecting partitions. The connecting partitions are separated by a spacing which forms voids extending through the structural blocks between the front panel and the rear panel. The structural blocks further include interlocking features aligning a plurality of courses of the structural blocks in a laterally staggered configuration over a defined stagger distance. The laterally staggered configuration of the structural blocks aligns the voids in columns extending through successive courses of the plurality of courses.

According to various aspects, the disclosure may implement one or more of the following features or configurations in various combinations:

• • the columns formed by the voids receive a binding material comprising concrete or aggregates, thereby permanently affixing the plurality of structural blocks;
  • the front body section of the structural block receives the superstructure leaving an open path to the columns formed by the voids to receive the binding material;
  • the stagger distance aligns the connecting partitions of the plurality of structural block over the plurality of courses;
  • the interlocking features are formed on a top surface and a bottom surface of the front body section;
  • the front body section forms a bearing block section forming a bearing surface configured to support the superstructure;
  • the bearing block section comprises at least one reinforcement structure providing lateral strength between the opposing lateral sides;
  • at least one reinforcement structure comprises rebar;
  • the voids comprise at least one full void enclosed on four sides by the front body section, the rear body section, and the connecting partitions, and at least one partial void enclosed on three sides by the front body section, the rear body section, and one of the partitions;
  • at least one partial void comprises a first partial void and a second partial void on the laterally opposing sides;
  • the partial voids of adjacent blocks formed by the courses of the structural blocks combine to form full voids enclosed by neighboring partitions of the adjacent blocks;
  • the full voids formed by the adjacent blocks are vertically aligned and form the columns extending through successive courses of the plurality of courses;
  • the structural blocks are modular blocks formed of concrete;
  • the plurality of structural blocks comprise a plurality of bearing blocks and a plurality of wall blocks, wherein the bearing blocks are configured to receive the superstructure on a top surface and the wall blocks are configured to receive a wall block or a bearing block on the top surface;
  • the wall blocks comprise the interlocking features formed on a top surface and a bottom surface of the front body section, and the bearing blocks comprise the interlocking features on a bottom surface and form a bearing surface on the top surface;
  • the bearing surface forms a flat top or a recessed top forming a beam seat; and/or
  • the front panel comprises a front face forming a decorative surface texture or shape. According to another aspect of the disclosure, a method for forming an abutment wall for

a superstructure includes preparing a structural wall comprising a plurality of courses of structural blocks in a laterally staggered configuration. The laterally staggered configuration of the structural blocks aligns a plurality of voids formed by the structural blocks to align in columns. The superstructure is positioned on the structural wall. A binding material (e.g., concrete, aggregates, etc.) is poured into the columns through the plurality of courses formed by the structural blocks through a gap formed between the superstructure and the plurality of voids. The concrete poured in the columns is cured with the superstructures in place supported by the structural wall.

According to various aspects, the disclosure may implement one or more of the following features or configurations in various combinations:

• • pouring aggregate material into the columns formed by the voids with the binding material; and/or
  • preparing a foundation from a plurality of foundation blocks, wherein the plurality of structural blocks are stacked in the courses on the foundation blocks.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present device. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present device, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodiments only. Modifications of the device will occur to those skilled in the art and to those who make or use the device. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the device, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents.