Insulated Concrete Masonry System

Abstract

An insulated masonry wall system comprised of special blocks of 24″×16″×8″ dimension filled with reclaimed rubber crumbs resulting in high R values to resist transmission of heat and cold. Insulation is blown and vibrated into the special concrete blocks as walls are developed. Construction of wall will be similar to standard masonry blocks. Facings attached to the blocks can be vinyl and wood siding, brick, stucco, textured acrylic finish, fiber-cement siding hardboard, photovoltaic siding, and wood shakes.

Description

FIELD OF THE INVENTION

This patent relates to special concrete and other masonry blocks, walls, and other structures and more specially to structures that contain insulation.

BACKGROUND OF THE INVENTION

Masonry walls and similar structures have been made for many years of blocks made of concrete and other materials. Also, masonry walls have been fabricated of poured concrete with and without steel reinforcement bar installations (FIGS. 12 and 13). The field of the invention pertains to structural blocks such as those commonly referred to as “concrete blocks” used for constructing both load bearing and non-load bearing walls of buildings. Such blocks are usually formed with two or three vertical cavities formed therein and made of concrete (FIG. 10). The cavities in the blocks provide a substantial decrease in weight and material without a commensurate decrease in structural strength. The cavities also provide some insulating value as closed airspace in a completed wall. U.S. Pat. Nos. 4,263,765, 4,286,420, and 4,348,845 reflect this approach.

More recently however, attempts have been made to fill those cavities with different materials such as foams, fiberglass and rubber particles to decrease the transfer of thermal convection within the cavities. U.S. Pat. Nos. 5,214,897, 5,507,127, and 5,746,037 address the use of insulation materials in blocks, specifically tire rubber (FIGS. 3 and 11). These methods were at best marginal because the typical 16″×8″×8″ cement block with its 8″ thickness, even blocks whose cavities are filled with insulation, contribute limited resistance to the transmission of heat and cold in the wall assembly.

Also, when introduced, the blocks were a new approach to wall construction (FIG. 2) and where workmen were not trained to use them, the resulting block walls were often of poor quality. Many years later, concrete block walls are considered ubiquitous and workmen are familiar with their use. Since our larger block design (24″×16″×8″) builds on existing wall construction methodology, little re-training is needed. Consequently, the quality of walls made with the special blocks should be comparable to those made with current blocks.

What makes this invention different from previous designs is that while it uses the previous mass produced concrete block design of 16″×8″×8″ the special blocks are enlarged to 24″×16″×8″ and their cavities are filled with reprocessed rubber tires cut into crumbs. This larger block produces an exceptionally high resistance to heat transmission through the final wall application. The end result is that walls designed by this method will have high heat sustainability and consequently will require reduced heat usage to heat and cool the structure, resulting in fewer emissions of the greenhouse gases responsible for climate change and lower costs for the inhabitants.

Structures built with this design will be more rigidly stable, more resistant to hurricane, tornado, and high winds, and seaside salt spray, increased fire protection, more durable, more insect and vermin proof, and quieter for users of the structure. In addition, the blocks will utilize rubber crumb made from new and recycled scrap vehicle tires. Scrap tires are a difficult and expensive to manage and environmentally harmful waste product.

SUMMARY OF THE INVENTION

This invention comprises three parts:

Part 1—Design and Fabrication of the Special Cement Blocks

The special blocks will measure 24″×16″×8″, sixteen inches deeper than typical cement blocks. They will be cast in special molds in a modified block-making machine. Wall dimensions of special blocks will be similar to walls made with 16″×8″×8″ blocks, although they will be 24″ thick (c). The height will remain at 8″ (b). (FIGS. 1, 2, 4, and 10).

Part 2—Manufacture of Rubber Crumb

Rubber crumb (7) is the name given to any material resulting from granulating scrap rubber tires or other rubber into uniform granules with the steel, fiber, dust, glass, and rock removed. Most of this material will come from companies that process scrap tires from landfills or from tire replacement businesses. Historically, scrap tires have been difficult and expensive to manage and their disposal has caused environmental harm. Processing scrap tires into rubber crumb for use as wall insulation material will reduce these challenges.

Part 3—Installation of Special Cement Blocks (2) and Addition of Crumb Rubber (7)

The special cement blocks will be placed on a concrete foundation (1) by a mason with mortar (3) between each block to form a mortar joint. This will be the first course of the block wall. Conduits (4) will be installed in the block cavities for electrical, plumbing, and related needs (FIG. 2). Rubber crumb (7) will be added to the block cavities to a depth level with the top edge of the blocks. Mechanical or physical means (9)(10) with concrete vibrator (9), flex hose (10), and blower (11) will be utilized to eliminate air pockets (FIG. 3). The successive courses of the blocks with conduits and crumbs will be staggered by 8″ (d) and continued until the desired wall height is attained (FIG. 3). To achieve this alternating pattern with the 8″ overlap (d) in the corners, our special 24″ block will be rotated 90 degrees, alternating between 16″ and 24″ as each course of the blocks is laid (FIG. 4). The result is a 24″ thick wall (c) throughout the structure.

All block dimensions must be multiples of 8″ to achieve maximum design efficiency. Going smaller on the 16″ block width (a) not only deviates from the present wall procedure, but also results in the need for additional blocks and increased labor cost to install them. Going larger than 24″ (c) results in additional weight, which can become unwieldy for a single mason and would likely result in a two-mason operation at added cost (FIG. 1).

To accomplish the increased thermal mass of the structure and resulting high R value, the overall width and length of the structure will be increased by 32″. The additional material and labor cost to build this larger structure will be quickly recovered through the reduced heating and cooling costs of the finished building.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1—General Description of the Special Block

FIG. 2—Wall Construction Without Insulation

FIG. 3—Addition of Rubber Insulation

FIG. 4—Corner Wall Construction

FIG. 5—Surface Application-Layers of Stucco on Concrete Blocks

FIG. 6—Surface Application-Layers of Textured Acrylic Finish (TAF) on Concrete Blocks

FIG. 7—Surface Application-Brick Veneer on Concrete Blocks

FIG. 8—Surface Application-Various Siding on Concrete Blocks

FIG. 9—Hurricane and Tornado Proof Building Construction

FIG. 10—Detail Drawing of Special Block

FIG. 11—Detail Drawing of Special Block with Crumb Rubber

FIG. 12—Technique for Locating Reinforcing Rods in Foundation for Insulated Masonry System

FIG. 13—Installation of Reinforcement Rods in an Insulated Masonry System

FIG. 14—Installation of Modified USP 2″×8″ Joist Hanger on Special Cement Blocks

REFERENCED DIMENSIONS

a-Nominal Dim=16″ (Actual 15.63″)

b-Nominal Dim=8″ (Actual 7.63″)

c-Nominal Dim=24″ (Actual 23.63″)

d-8″ Overlap

Typically, the interior wall finish is gypsum wallboard. To attach the wallboard to the special blocks the wallboard installer places a vapor barrier (plastic film) against the inside surface of the blocks. Furring strips are attached with screws to the film and blocks and the wallboard is then glued or screwed to the furring strips.

Different finishes go on to the foundation walls (1) and the course of the building above. The concrete blocks of the foundation and the blocks exposed above ground need to be covered by a material with high impact resistance to avoid damage from landscaping and other equipment. Installers typically use wire mesh covered by a layer of stucco or stucco-like coatings that do not require the mesh.

The most widely used exterior finishes include:

• • a) FIG. 5 describes stucco on concrete blocks utilizing brown coat (12), scratch coat (13), lath (14), and finish coat (15).
  • b) FIG. 6 describes layers of textured acrylic finish (TAF) on concrete blocks utilizing top coat (16), base coat (17), fiberglass mesh (18), and color coat (19).
  • c) FIG. 7 describes brick veneer on concrete blocks utilizing brick (20), on ledge (21), and finishing (22).
  • d) FIG. 8 describes vinyl, beveled wood, fiber-cement, photovoltaic siding, and hardboard wood shakes and shingles which utilizes shingles (23) and tar paper (24). Wood sheathing (6) next to the concrete block is glued to the block and acts as a vehicle to staple, nail, or screw siding (23) to during installation. Also, to install necessary photovoltaic siding wiring, a space is provided between sheathing to utilize tubing (31) for wiring.

Further increases in R-value can be accomplished by the addition of outsulation (EIFS) cadding systems by Dryvit.

An additional feature of our special wall installation (FIG. 9) is the use of USPHW with heavy-duty welded joist brackets (8), which can be slipped in while he walls are erected (FIG. 14). This simplifies the installation of the floor joists (27) in buildings (FIG. 9). Also shown is the ease of installing hurricane straps (26), and roof connectors (25) on roof frame (29) to protect structures from hurricane and tornado damage on insulated concrete masonry systems (28).

Also, to achieve maximum insulated concrete masonry system strength for extreme weather-related conditions, steel reinforcement rods (30) can be added (FIGS. 12 and 13). Layout of reinforcement rods can be simplified by the use of wooden templates (5) (FIG. 12).

Claims

1. A special 24″×16″×8″ concrete block with actual dimensions of 151/2″×71/2″×231/2″ having four smooth sides that can be rotated to produce a smooth sided corner arrangement with alternating joints for wall construction.

2. A special 24″×16×8″ concrete block with admixtures, pigments, or glazers added to give blocks increased compressive strength, decorative effect, or provide protection against deterioration.

3. A special 24″×16″×8″ concrete block with internal slots for reinforcement rod insertion when utilized in residential, institutional, religious, commercial, and industrial building construction to further increase structural strength in earthquake and other severe calamity areas.

4. Rubber crumbs obtained from chopped and granulated new and recycled and recycled tires inserted by air pressure and agitation into hollow block cavities, during construction.

5. Blocks to be offset by 8″ as each row is formed during construction.

6. Blocks to be permanently secured together with mortar premix (comprised of a blend of portland cement, lime and masonry sand) per present cement type construction.

7. Blocks to be positioned so that the 16″ face is exposed to outside wall surface per present block construction. Exception is at corners where alternate 16″ and 8″ surfaces are exposed.

8. Blocks to be positioned to obtain a 24″ thickness of wall, resulting in maximum structural strength and thermal resistance.

9. Outside surface of wall construction modified to include coatings, brick veneer and sidings, including photovoltaic sidings.

10. To simplify and increase building construction strength, steel joist hangers are attached to special blocks during construction to support floor joists.

11. To resist hurricane, tornado, and other weather related conditions, hurricane straps and roof connectors are attached to special blocks to further increase building strength.