The present invention relates to an integrated, post-tensioned, construction system for building structures that utilizes horizontally and vertically interlocking components, which are held in place and strengthened by tensioned internal tendons secured to beams in way of the top and the base of the structure. Connection of the interlocking components with adhesives or mortars is obviated. The system is more resistant to wind storm and seismic damage than conventional structures that use bonding agents for affixing building elements.
A building structure consists of a shell made from different interrelated parts with a fixed location on the ground. Some embodiments of building structures include agricultural barns, airport hangars, churches, clinics, commercial buildings, garages, government offices, greenhouses, hospitals, military barracks, museums, prisons, railway stations, residential houses, schools, silos, and warehouses. In contrast to building structures, civil engineering structures span between, facilitate access to, or protect geographical features. Some embodiments of civil engineering structures include abutments, aqueducts, bridges, dams, highway interchanges, tunnels, and viaducts.
Traditional building construction most often uses concrete-and-aggregate blocks that are held in place with cement mortar. When the mortar cures, it is approximately half the strength of the cured concrete-and-aggregate used in the blocks. Civil engineering structures most often utilize pre-stressed and/or post-tensioned tendons in pre-cast concrete-and-aggregate structures to augment the overall strength of the fabrication by introducing internal compressive stress to partially counteract tensile stresses caused by loads on the structure. This option has not been available for anisotropic, traditionally constructed, building structures, because of the disparity in strength between the concrete-and-aggregate blocks and the cement mortar.
When the walls of the building structure are assembled to the requisite height, the present invention uses a course of interlocking cap blocks above the interlocking blocks forming the walls. On top of the interlocking cap blocks, a structural beam is laid to connect to the top of tendons placed inside the walls. The bottom of the tendons is affixed to the foundation or to a structural beam below a course of interlocking base blocks in way of the foot of the wall. The tendons are tensioned by torquing fasteners in way of the beam above the interlocking cap blocks. The requisite tensioning of the tendons is dependent on the properties of the materials from which the interlocking components and the structural beam(s) are made. The interlocking components of the present invention may be made from virtually any curable or kiln-dried material that is currently being used in building structures; however, concrete-and-aggregate will be the most frequent embodiment. Concrete by itself is a weak binder that is similar to cement mortar. Cured concrete-and-aggregate forms a material that is strongest in compression, and the compression induced by the tensioned tendons augments the strength of the whole structure.
Construction using block, brick, or stone with cement mortar was invented in the late 18th century and has been used since that time with minor changes. Blocks or bricks are laid by skilled tradespeople called masons, who must take care to maintain a uniform thickness of the mortar seams and keep the rows of blocks or bricks level as construction progresses. The time required for construction is determined by the ability of the mason laying the blocks or bricks and the requisite time for the mortar to cure until it will support the weight of the structure. A significant portion of the cost of construction is remuneration of the skilled masons and the construction personnel, whose job time is influenced by the ability of the masons and the curing time of the mortar.
Utilization of the present invention eliminates the need for masons, because the interlocking blocks do not require mortar for assembly and are self-leveling. When the first course of interlocking blocks is placed on the foundation or on the base blocks in the proper orientation, the subsequent rows of interlocking blocks may be laid serially until the building is complete. This task may be done quickly by semi-skilled tradespeople.
In addition to the reduced labor for fabrication, the cost of construction is further reduced relative to traditional construction through reuse of components. If a building structure is to be taken down, the interlocking components may be disassembled for reuse. Similarly, if a building is partially damaged by a windstorm or seismic event, the undamaged components may be reused in a repair or a rebuild. Due to the aging properties of concrete, components taken from pre-existing buildings are significantly stronger than newly cured components, so disassembly is preferable to demolition.
The present invention is pan-global in application. The interlocking components may be made serially in the field or mass-produced through utilization of automation in a factory using engineered tooling in concrete-block-making machines. Do-it-yourself component fabrication and construction avails application of the system to most people in the world. In locations where infrastructure is limited, construction components may be transported utilizing draft animals, carts, boats, or other such conveyances.
The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new system for constructing building structures using post-tensioned, integrated components.
To attain this, the present invention uses interlocking blocks that are laid serially on a foundation to form the shell of a building structure. Some embodiments of the foundation may be reinforced-concrete, structural beams, or compacted-soil. When using a compacted-soil foundation, a bottom course of interlocking base blocks is laid that engages with the full-size and half-size interlocking blocks that form the walls. Full-size and half-size interlocking blocks are laid successively until the wall structure attains the requisite height. The top row of full-size and half-size interlocking blocks is overlaid with a course of interlocking cap blocks that engage with the interlocking features of the blocks forming the wall. Tendons are located inside hollow spaces inside the blocks. Below the base blocks and above the cap blocks are located pultruded, extruded, or composite structural beams that connect to the tendons. The ends of the tendons are mechanically fastened to the beams.
The wall built from of the interlocking blocks with internal tendons mechanically fastened to structural beams above-and-below the wall forms a composite structure that does not require mortar or adhesives to join together individual elements. Proper alignment is achieved through utilization of the interlocking features of the blocks. The tendons hold together the interlocking blocks that form the shell of the building. During construction, build stops are fitted below joints in the tendons to help stabilize the wall and to center the tendon in the openings in the interlocking blocks. When the end fasteners on the tendons are tightened to the structural beam(s) and/or foundation, the interlocking blocks cannot come apart, since the entire structure is mechanically connected.
Post-tensioning of the structure is performed by applying torque to the fasteners in way of the upper ends of the tendons where they connect to the structural beams. The tensioned tendons induce compression in the interlocking blocks between the top and bottom structural beams or between the top structural beam and the foundation. The amount of torque applied to the fasteners on the tendons is dependent on the strength of materials used in the blocks and the beams. The induced compression on the walls forms an internal stress that partially counteracts the tensile stresses caused by external loads on the structure. This improved ability of the structure to support loads beyond its own dead weight enables better performance when external loads are applied, such as by windstorms, seismic events, or settling of the foundation of the structure.
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
In reference to
The cap interlocking block (CIB) 20 is illustrated from the top in
The base interlocking block (BIB) 30 is shown from the top in
The interrelation of the principal components of the present invention is shown in the exploded view in
The corner of a building structure fabricated through utilization of the present invention is illustrated in
The opening shown in
The sides of openings in the building structure are closed with half-size interlocking block (HIB) 10 when necessary. Since the full-size interlocking block (FIB) 1 are laid in staggered courses, gaps in way of the opening will need to be filled with half-size interlocking block (HIB) 10.
With respect to the above description, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function, and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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Number | Date | Country | |
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62621636 | Jan 2018 | US |