Systems and Methods for In-Situ Manufacturing Wedge-Shaped Retaining Wall Concrete Blocks

Abstract

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Description

Field of the invention Disclosed are systems and methods for in-situ manufacture of large wedge-shaped retaining wall concrete blocks, and more particularly, systems and methods for forming large and heavy concrete blocks in-situ. Background In building concrete retaining walls, various shaped concrete blocks can be used. Wedge-shaped concrete blocks are particularly useful because they can be used to create curved or straight edging without gaps and have a modern aesthetic. These walls not only prevent erosion and hold back the soil. The smooth faces of wedge-shaped concrete blocks are friendlier to Whipper Snipper cords than rough, split stone surfaces. However, transporting premade large wedge-shaped concrete blocks is costly, particularly when the job of building a retaining wall is large. Each concrete block may weigh 500 kilograms, which means that lifting them requires a hoist. The truck carrying the premade concrete blocks therefore must be parked very close to the wall construction position so that the onboard hoist can move the blocks from the truck directly to their final position. Therefore, if there is nowhere for the truck to park close to the final position of a retaining wall, access creates an issue in building retaining walls of wedge-shaped concrete blocks. Additionally, a truck carrying premade large concrete blocks is limited in the number of blocks it can carry as a flat-bed truck which must also include a hoist to move the concrete blocks from the truck. Transporting premade large wedge-shaped concrete blocks long distances to a final position may be costly. Several or many trips may be required depending on the extent of the retaining wall. In worst case scenarios, a truck without access to the final position of the retaining wall must use its hoist to unload each concrete 2026202694   09 Apr 2026 block which must then be moved by a smaller truck close to the final position, requiring a second hoist to move it into its final position. There is a need to address the above, and / or at least provide a useful alternative. Summary Disclosed is a system for manufacturing cement retaining wall blocks in-situ to their final position, the system including a metal polygon comprising an interior surface and an opposite exterior surface and exterior corners, a metal circle enclosing the metal polygon, the metal circle comprising an interior surface and an opposite exterior surface, the metal circle further comprising a plurality of individual metal pieces having lateral ends comprising flanges emanating outwardly from the individual metal pieces’ exterior surface, a plurality of separating metal dividers originating at the exterior corners of the metal polygon some of which emanating past the exterior surface of the metal circle, the separating metal dividers configured with at least one connecting tab to join with the flanges of the individual metal pieces to form places for cement retaining wall blocks to be cured and a concrete mixer comprising a channel for delivering wet concrete in between the separating metal dividers. Also, the disclosed system further includes wedge-shaped metal bases for positioning in between the separating metal dividers, the bases being proximal to the ground. Moreover, disclosed is a system wherein the metal polygon, the metal circle and the separating metal dividers have a height 500 cm from the ground. Additionally, disclosed is a system wherein the metal polygon is approximately four metres across. Furthermore, disclosed is a system wherein the metal circle enclosing the metal polygon is approximately five hundred centimetres from the metal polygon’s outside surface. 2026202694   09 Apr 2026 Yet still, disclosed is a system wherein there are ten places between the separating metal dividers for retaining wall blocks to be formed. Additionally, disclosed is a system wherein the metal circle comprises five individual metal pieces. Furthermore, disclosed is a method for manufacturing a cement retaining wall in-situ to their final position including providing a metal polygon comprising an interior surface and an opposite exterior surface and exterior corners, providing a metal circle enclosing the metal polygon, the metal circle comprising an interior surface and an opposite exterior surface, the metal circle further comprising a plurality of individual metal pieces having lateral ends comprising flanges emanating outwardly from the individual metal pieces’ exterior surface, providing a plurality of separating metal dividers originating at the exterior corners of the metal polygon some of which emanating past the exterior surface of the metal circle, the separating metal dividers configured to with at least one connecting tab to join with the flanges of the individual metal pieces to form places for cement retaining wall blocks to be cured and providing a concrete mixer comprising a channel for delivering wet concrete in between the separating metal dividers. Moreover, disclosed is a method further including providing wedge-shaped metal bases for positioning in between the separating metal dividers, the bases being proximal to the ground. Also, disclosed is a method wherein the metal polygon, the metal circle and the separating metal dividers have a height of 500 cm from the ground. Still yet, disclosed is a method wherein the metal polygon is approximately four metres across. Additionally, disclosed is a method wherein the metal circle enclosing the metal polygon is approximately five hundred centimetres from the metal polygon’s outside surface. 2026202694   09 Apr 2026 Furthermore, disclosed is a method wherein there are ten places between the separating metal dividers for retaining wall blocks to be formed. Moreover, disclosed is a method wherein the metal circle comprises five individual metal pieces. Brief Description of the Drawings In order that the invention may be more easily understood, an embodiment will now be described, by way of example only, with reference to the accompanying drawings, in which: FIG. 1 illustrates an assembled mould system; FIG. 2 depicts mould place from FIG. 1 for a concrete block to be formed; FIG. 3 depicts a perspective view of a disassembled mould system; FIG. 4 depicts a side view of a concrete block; FIG. 5 depicts cement blocks placed to form a retaining wall along a slope; FIG. 6 depicts system components of the disclosed assembled mould system being filled with wet cement delivered by a channel of a cement mixer; and FIG. 7 depicts disassembled mould system components and a concrete block being lifted up by a chain and forklift. Detailed Description 2026202694   09 Apr 2026 Disclosed are systems and methods for in-situ manufacture of large wedge-shaped retaining wall concrete blocks, and more particularly, systems and methods for forming large and heavy concrete blocks in-situ to their final position. By manufacturing large concrete blocks relatively close to their final position, various disadvantages of transporting premade similarly large in size and weight concrete blocks may be avoided. Depending upon where the concrete powder and sand is obtained as supplies for manufacturing large concrete blocks, these supplies may be more easily transported to the location of the final position than would be premade large concrete blocks. For example, if the cement powder, sand and water can be locally obtained, transport costs would be substantially limited. On the other hand, if supplies for making retaining wall blocks being for example, concrete powder, sand and water must be transported, the type of vehicle transporting these ingredients is not an issue. Additionally, a hoist onboard a truck to unload them may not be needed. Bags of cement powder and bags of sand can be stacked up in any type of vehicle, therefore, is no need for a vehicle to include an onboard hoist. Bags of concrete and bags of sand are typically light enough for a worker to pick up and move, for example into a wheelbarrow. Depending upon the circumstances of the final position of the in-situ manufactured retaining wall cement blocks, if need be, the bags of concrete, bags of sand and water may be moved closer to the final position via a wheelbarrow or by being carried. The disclosed methods may include locating or making a flat ground surface relatively close to the retaining wall’s final position. If the final position of a retaining wall is for example, one hundred (100) metres from an assembled mould system, that may be sufficiently close enough in distance to the final position for a forklift to move finished cement blocks into their final position. If there is inadequate space to manufacture the concrete blocks very close to their final position, they may be manufactured in the local neighbourhood maybe in a parking lot or empty lot and then transported by truck such as a Ute to the final position of the intended retaining wall. The cost of transporting the blocks 2026202694   09 Apr 2026 from a manufacturing facility may be substantially more than manufacturing the cement blocks as described here, in-situ to the location of the intended retaining wall. A suitable vehicle to transport bags of cement powder and bags of sand may also transport 5 the components of the disclosed assembled mould system, being a metal polygon, individual metal pieces of a metal circle, metal separating dividers and wedge-shaped metal bases for positioning in between the separating metal dividers proximal to the ground. The metal may be a suitable type of metal, for example steel and for example 4mm-6mm thick. A ground-based hoist to move the finished retaining wall blocks to their final position may 10 also be required to carry out the disclosed methods for forming a retaining wall. While the configuration shown in the figures is a suitable for a retaining wall, the dimensions are exemplar. Other dimensions may be utilised depending upon the particular use. For example, as shown in FIG. 1, the central polygon is ten (10) sided, therefore 15 determining that there are ten places to form full-sized blocks. The metal polygon may be fewer or more than ten sided depending upon the particular use, for example eight (8) sided or twelve (12) sided. The system configuration may be larger or smaller than that disclosed here. 20           FIG. 1 illustrates a metal polygon 101 and five (5) individual metal pieces 103a- 103e of a metal forming a metal circle 103. Additionally illustrated are eleven (11) separating metal dividers and 105a-105k which in this example are welded to the metal polygon 101. Also included are wedge-shaped metal bases 107a-107j (a base being more apparent in FIG. 3). 25 As illustrated in FIG. 1, for edges of a retaining wall, two end concrete blocks in this example, which are half the size of a retaining wall block are formed by adding an extra metal separating divider 105j to form smaller concrete blocks 9a and 9b, hence there are eleven (11) separating metal dividers in the depicted exemplar system. 2026202694   09 Apr 2026 A mould place 10 from FIG. 1 for a cement block 110a to be formed is shown in FIG. 2. The assembled mould system may have exemplar dimensions of a depth of 725 cm, sides lengths of 660 cm, a base width dimension of 800 cm, and an expanse of 1200 cm across from outside corner to outside corner. The metal polygon 101, the metal circle 103a and two individual dividers 105a and 105k shown in FIG. 2 may have a height of 500 cm from the ground. Also shown is a dashed line 117 which indicates where the doglegged base of 100 cm may be provided on a finished cement block 110a (see FIGs. 4 and 5). In FIG. 2, also shown is shown that a connecting tab 109 of the separating metal divider 105k extends past the exterior surface of the individual metal piece 103a of the metal circle 103. The flange 111 on the lateral end of the individual metal piece 103a can be joined to the connecting tab 109 of the separating metal divider 105k by any suitable connecting means for example, a screw and bolt in one or more places along that flange 111. A tight seal at the connection of the connecting tab 109 and the flange 111 keeps the wet cement in place during the curing process. The connecting tab 109 shown inside the circle 113 is provided every other separating metal divider in the disclosed exemplar as an individual metal piece 103a of the metal circle 103 spans two places, for example 10 and 1 (of FIG. 1). Returning to FIG. 1, five (5) individual metal pieces 103a-103e of the metal circle 103, span spaces 10 and 1, 2 and 3, 4 and 5, 6 and 7, 8 and 9 respectively. Therefore, at both lateral ends of the individual metal pieces 103a-103e of the metal circle 103, the individual metal pieces’ 103a-103e flange 111 attaches to the connecting tab 109 of the respective separating metal divider 105a-105k in the manner shown in the dashed line circle 113 of FIG. 2. Any suitable manner in which to devise a configuration of the disclosed system components is within the scope of this discussion. While when arranged, the system components form an assembled mould system, the system disclosed here may be made up of components that are arranged in-situ to the final position of the retaining wall so that the components may be easily transported to that location. The system components shown 2026202694   09 Apr 2026 in the figures and discussed here are provided to the in-situ location so that they may be secured to form an assembled mould system. While forming large wedge-shaped concrete retaining wall blocks for a substantial retaining wall is described here, any process of forming the assembled mould system at an in-situ location is within the scope of this discussion. The disclosed systems and methods may be altered from the described exemplars to suit the particulars of the required cement retaining wall blocks for a retaining wall. FIG. 3 shows a perspective view of a disassembled mould system filled with cured concrete in nine places 1-9 and in one place 10, the place 10 is empty. The individual metal piece 103a is pulled away from its position as part of the metal circle 103, exposing the connecting tab 109. When the individual metal piece 103a is in its position as part of the metal circle 103, the flange 111 on the lateral end of the metal circle’s 103 individual metal piece 103a is secured to at least one connecting tab 109, but preferably more than one connecting tab. In the exemplar, as discussed above, there are two connecting tabs 109 on alternating separating metal dividers 105a-105k. FIG. 4 depicts a side view of a concrete block 10 having a top surface 121 and a base surface 123. Of note on the base surface 123 of the cement block 110a is a dog-legged configuration 125. Briefly returning to FIG. 3, it is shown that the metal base 107 is positioned away from the metal polygon’s 101 exterior surface. The configuration of the metal base 107 leaves a space 117 where the metal base 107 does not meet the exterior surface of the metal polygon 101. When delivering wet cement to the place 10, the wet cement will fill the space 117, forming the dog-legged configuration 125 of the cement block 110a shown in FIG. 4. Line 119 illustrates the overhang of the cement block as shown in FIG. 5 illustrated by dashed lines 119a-119c. Turning to FIG. 5, depicted are cement blocks 110a-110c placed to form a retaining wall along a slope 112. The purpose of the dog-legged configuration 125a-125c may be that when constructing a wall, to secure the cement block 110a with respect to the previously positioned cement block 110b, the dog-legged configuration 125a-125c hangs 2026202694   09 Apr 2026 over the previously positioned cement block 110b, and so on. The depth of the dog-legged cement block configuration 125a-125c may determine the setback 119 of each progressively positioned cement block 110a-110c. 5 FIG. 6 depicts system components of the disclosed assembled mould system which are fixed into position and secured at the connecting tabs 109 and the flange 111 and to form an assembled mould system 115. The metal polygon 101 is on the interior of the assembled mould system 115 and the metal circle 103 is on the exterior of the assembled mould system. Separating metal dividers 105 are positioned to form spaces 1-10 to receive wet 10 cement from the cement mixer 133 via channel 131. FIG. 7 illustrates disassembled mould system components 116, having been disassembled to remove a cured cement block 110a and other cement blocks 110b-110j. As is shown, a post having an eyelet 118 was placed in the wet cement while the cement block 110a was 15 curing. The eyelet 118 may be used with a hook 120 or other connecting device of a hoist 122, here a forklift having a chain 124 wrapped around its fork. The cement block 110a removed from the disassembled system component 116 may be moved from the in-situ manufacturing location to the final position of a retaining wall. The 20 forklift can lift the cement block 110a into its final position as illustrated in FIG. 5. The process of the disclosed in-situ manufacturing methods can be carried out while positioning cement blocks for form a retaining wall. The wet cement usually requires three (3) hours to cure. Therefore, with a few workers constructing a plurality of assembled mould systems 115 that may be filled with wet cement while a few workers places previously cured cement 25 blocks in their final positions, the cement block manufacturing and retaining wall building processes may go on simultaneously. Many modifications of the above embodiments will be apparent to those skilled in the art without departing from the scope of the present invention. 2026202694   09 Apr 2026 Throughout this specification and the claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers 5 or steps. The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or 10 information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Claims

1. A system for manufacturing cement retaining wall blocks in-situ to their final position, comprising:a metal polygon comprising an interior surface and an opposite exterior surface and exterior corners;a metal circle enclosing the metal polygon, the metal circle comprising an interior surface and an opposite exterior surface, the metal circle further comprising a plurality of individual metal pieces having lateral ends comprising flanges emanating outwardly from the individual metal pieces’ exterior surface;a plurality of separating metal dividers originating at the exterior corners of the metal polygon, some of which emanating past the exterior surface of the metal circle, the separating metal dividers configured with at least one connecting tab to join with the flanges of the individual metal pieces to form places for cement retaining wall blocks to be cured; anda concrete mixer comprising a channel for delivering wet concrete in between the separating metal dividers.

2. The system of claim 1 wherein the system further comprises wedge-shaped metal bases for positioning in between the separating metal dividers, the bases being proximal to the ground.

3. The system of claim 1 wherein the metal polygon, the metal circle and the separating metal dividers have a height of 500 cm from the ground.

4. The system of claim 1 wherein the metal polygon is approximately four metres across.

5. The system of claim 1 wherein the metal circle enclosing the metal polygon is approximately five hundred centimetres from the metal polygon’s outside surface.2026202694   09 Apr 2026- 12 -6. The system of claim 1 wherein there are ten places between the separating metal dividers for retaining wall blocks to be formed.

7. The system of claim 1 wherein the metal circle comprises five individual metal pieces.

8. A method for manufacturing a cement retaining wall in-situ to their final position, comprising:providing a metal polygon comprising an interior surface and an opposite exterior surface and exterior corners;providing a metal circle enclosing the metal polygon, the metal circle comprising an interior surface and an opposite exterior surface, the metal circle further comprising a plurality of individual metal pieces having lateral ends comprising flanges emanating outwardly from the individual metal pieces’ exterior surface;providing a plurality of separating metal dividers originating at the exterior corners of the metal polygon some of which emanating past the exterior surface of the metal circle, the separating metal dividers configured to with at least one connecting tab to join with the flanges of the individual metal pieces to form places for cement retaining wall blocks to be cured; andproviding a concrete mixer comprising a channel for delivering wet concrete in between the separating metal dividers.

9. The method of claim 8 wherein the method further comprises providing wedgeshaped metal bases for positioning in between the separating metal dividers, the bases being proximal to the ground.2026202694   09 Apr 2026- 13 -10. The method of claim 8 wherein the metal polygon, the metal circle and the separating metal dividers have a height of 500 cm from the ground.

11. The method of claim 8 wherein the metal polygon is approximately four metres5           across.

12. The method of claim 8 wherein the metal circle enclosing the metal polygon is approximately five hundred centimetres from the metal polygon’s outside surface.10       13. The method of claim 8 wherein there are ten places between the separating metaldividers for retaining wall blocks to be formed.

14. The method of claim 8 wherein the metal circle comprises five individual metal pieces.

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