The present disclosure generally relates to masonry block systems for use in forming structures, and more particularly to masonry block systems configured to enable a mason to increase output in building a concrete block wall.
Typically, structures formed from concrete walls are fabricated using concrete masonry units (CMUs), which are also referred to as concrete blocks. Conventional concrete blocks, as shown in
A concrete block wall is typically formed by placing a course, or row, of concrete blocks atop a foundation. Each concrete block may be attached to the foundation and to each other by mortar. Mortar is placed on the concrete block by a mason immediately before the mason places the concrete block in position. Building a concrete block wall is a time consuming procedure that is best under taken by a trained mason. The speed by which a concrete block wall is constructed is limited by the speed of a mason applying mortar to each concrete block via a trowel and placing the concrete block in position while checking whether the concrete block is level and alignment about three axes. Accuracy of the alignment of each concrete block is very important and must be checked constantly, which reduces the speed of the mason in assembling the concrete block wall. After the foundation has been set, the mason is responsible for aligning the concrete block in a level and plumb manner. Building a concrete block wall in this manner is very time consuming and complex because the mason uses mortar to position as well as bond each concrete block to other concrete blocks.
After the primary base course has been laid and properly positioned for alignment and level, each successive course may be laid in a running bond scheme to create maximum strength. The running bond scheme includes offsetting each course of concrete blocks longitudinally along a wall relative to the course of concrete blocks immediately below. A mason must pay close attention to the cells to maintain cell alignment so that reinforcing bars may be added to the aligned cells forming hollow columns within the concrete wall to extend from the base course to the top course.
A masonry block configured to be larger than conventional two cell masonry block yet include cells that align with conventional cells in conventional two cell masonry blocks is disclosed. Thus, the masonry block disclosed herein may be used together with conventional two cell masonry blocks so that the cells are aligned enabling reinforcement bars and concrete to be placed therein. In addition, the masonry block configured to be larger than conventional two cell masonry block may be formed from materials lighter than conventional materials yet possessing similar strength. As such, a mason should be able to assembly a greater amount of a wall area with the masonry block per unit of time using the masonry block disclosed herein than a conventional block. In at least one embodiment, a mason is able to lay about 50% more liner feet of masonry block with the masonry block herein than using conventional two cell masonry block. Thus, the masonry block disclosed herein enables masons to realize substantial labor cost savings per job.
In at least one embodiment, the masonry block may include a first partial cell extending longitudinally from a first end and as second partial cell extending longitudinally from a second end that is generally on an opposite end from the first end. The first partial cell may be configured that when matched up to another masonry block, the first partial cell forms a full cell. The first partial cell may be configured to be anything less than a full volume of a full cell. In at least one embodiment, the first partial cell may be a first half cell whereby the volume of the void created by the first half cell is approximately one half of a volume of a full cell. The volume of the first half cell is not limited to precisely one half of a volume of a full cell but may include variations greater and less than one half. Similarly, the second partial cell may be configured that when matched up to another masonry block, the second partial cell forms a full cell. The second partial cell may be configured to be anything less than a full volume of a full cell. In at least one embodiment, the second partial cell may be a second half cell whereby the volume of the void created by the second half cell is approximately one half of a volume of a full cell. The volume of the second half cell is not limited to precisely one half of a volume of a full cell but may include variations greater and less than one half. The first and second half cells may be configured such that when mated with another block, the first and second half cells form full cells at the first and second ends of the masonry block.
In at least one embodiment, a masonry block may include a first side wall, a second side wall spaced laterally from the first side wall, a first support web extending from the first side wall to the second side wall and a second support web extending from the first side wall to the second side wall and spaced apart from the first support web. The masonry block may include a third support web extending from the first side wall to the second side wall and positioned between the first and second support webs. The third support web may form a first cell defined at least in part by portions of the first and second side walls and the first and third support webs, whereby the first cell includes one or more top openings and one or more bottom openings. The third support web may also form a second cell defined at least in part by portions of the first and second side walls and the second and third support webs, whereby the second cell includes one or more top openings and one or more bottom openings. The first and second side walls may extend longitudinally beyond the first support web to form a first half cell, whereby the first half cell may be formed from portions of the first and second side walls and the first support web. The first and second side walls may extend longitudinally beyond the second support web to form a second half cell, whereby the second half cell is formed from portions of the first and second side walls and the second support web.
The first half cell may be formed from one or more top openings, one or more bottom openings and a side opening. A length of the first half cell in a longitudinal direction of the masonry block may be about one half a length of the first cell defined at least in part by portions of the first and second side walls and the first and third support webs. The second half cell may be formed from one or more top openings, one or more bottom openings and a side opening. A length of the second half cell in a longitudinal direction of the masonry block may be about one half a length of the second cell defined at least in part by portions of the first and second side walls and the second and third support webs.
In at least one embodiment, an overall length of the masonry block may be larger than an overall length of a conventional two cell masonry block. An overall length of the masonry block may be, but is not limited to being, 1.5 times (1.5×) larger than an overall length, 1×, of a conventional two cell masonry block. The masonry block may be configured such that an overall length of the masonry block is greater than a width of the masonry block, and the overall length of the masonry block is greater than a height of the masonry block. The masonry block may be configured such that an overall length of the masonry block is three times greater than a height of the masonry block. In another embodiment, the masonry block may be configured such that an overall length of the masonry block is at least two times greater than a width of the masonry block. In another embodiment, the masonry block may be configured such that an overall length of the masonry block is at least three times greater than a width of the masonry block.
The masonry block may be formed from materials that are lighter per volume than materials used to form conventional masonry blocks. The masonry block may be formed from materials including aggregate that are lighter per volume than materials used to form conventional masonry blocks. The masonry block may be formed from materials including aggregate that are lighter per volume than materials used to form conventional masonry blocks yet retain the same compression strength characteristics.
The masonry block may also include a handhold formed in the third support web and accessible from above the masonry block. The third support web may be centered longitudinally within the masonry block. The handhold may be formed in the third support web and accessible from above the masonry block, thereby forming a centered handhold. In at least one embodiment, the third support web may be formed from a first subthird support web and a second subthird support web. The first and second subthird support webs may be separated by a gap thereby forming a splitable masonry block whereby a first section of the masonry block can be split from the second section of the masonry block.
An advantage of the masonry system is that the masonry block with first and second cells and first and second half cells enables a mason to lay a linear distance of block greater than a conventional block.
Another advantage of the masonry system is that the masonry block with first and second cells and first and second half cells enables a mason to lay a linear distance of block about 1.5 times larger than a conventional block.
Yet another advantage of the masonry system is that the masonry block with first and second cells and first and second half cells enables a mason to lay a linear distance of block about 1.5 times larger than a conventional block with the same effort and energy exertion by the mason when the masonry block is formed from one or more components that are lighter in weight than conventional materials yet possess similar strength characteristics. As such, the a mason may increase his average daily output of linear length of laid concrete block by about 50 percent, thereby greatly reducing labor costs associated with building a concrete block wall.
Another advantage of the masonry system is that the masonry block with first and second cells and first and second half cells reduces the number of end joints needing mortar applied as compared to a conventional 16″ long concrete block.
Still another advantage of the masonry system is that the masonry block includes a center handhold that provides a balanced weight distribution when picked up by the center handhold, thereby providing ease of handling.
Another advantage of the masonry system is that the masonry block with first and second cells and first and second half cells matches cell alignment with conventional concrete block cells and matches itself during installation, thereby providing flexibility and enabling quick adaption by the concrete industry.
These and other embodiments are described in more detail below.
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the presently disclosed invention and, together with the description, disclose the principles of the invention.
As shown in
In at least one embodiment, the masonry block 10 may be include a first partial cell 36 extending longitudinally from a first end and as second partial cell 40 extending longitudinally from a second end that is generally on an opposite end from the first end. The first partial cell 36 may be configured that when matched up to another masonry block 10, the first partial cell 36 forms a full cell. The first partial cell 36 may be configured to be anything less than a full volume of a full cell. In at least one embodiment, the first partial cell 36 may be a first half cell 36 whereby the volume of the void created by the first half cell 36 is approximately one half of a volume of a full cell. The volume of the first half cell 36 is not limited to precisely one half of a volume of a full cell but may include variations greater and less than one half. Similarly, the second partial cell 40 may be configured that when matched up to another masonry block 10, the second partial cell 40 forms a full cell. The second partial cell 40 may be configured to be anything less than a full volume of a full cell. In at least one embodiment, the second partial cell 40 may be a second half cell 40 whereby the volume of the void created by the second half cell 40 is approximately one half of a volume of a full cell. The volume of the second half cell 40 is not limited to precisely one half of a volume of a full cell but may include variations greater and less than one half. The first and second half cells 36, 40 may be configured such that when mated with another block, the first and second half cells 36, 40 form full cells at the first and second ends of the masonry block 10.
In at least one embodiment, as shown in
The first and second side walls 18, 20 may extend longitudinally beyond the first support web 22 to form a first half cell 36, whereby the first half cell 36 may be formed from portions of the first and second side walls 18, 20 and the first support web 22. In at least one embodiment, a volume of the first half cell 36 may be approximately one half of a volume of the first cell 28. In yet another embodiment, volume of the first half cell 36 may be approximately one half of an average volume taken of the volumes of the first and second cells 28, 34. The volume of the first half cell 36 may be determined based upon the three dimensional volume defined by the portions of the first and second side walls 18, 20 and the first support web 22 forming the first half cell and outer surfaces 38 of the first support web 22 and portions of the first and second side walls 18, 20.
The first and second side walls 18, 20 may extend longitudinally beyond the second support web 24 to form a second half cell 40, whereby the second half cell 40 is formed from portions of the first and second side walls 18, 20 and the second support web 24. In at least one embodiment, a volume of the second half cell 40 may be approximately one half of a volume of the second cell 34. In yet another embodiment, volume of the second half cell 40 may be approximately one half of an average volume taken of the volumes of the first and second cells 28, 34. The volume of the second half cell 40 may be determined based upon the three dimensional volume defined by the portions of the first and second side walls 18, 20 and the second support web 24 forming the first half cell and outer surfaces 38 of the second support web 24 and portions of the first and second side walls 18, 20.
In at least one embodiment, the first half cell 36 may be formed from one or more top openings 42, one or more bottom openings 44 and one or more side openings 46. The top opening 42 may be on the same plane as a top outer surface 48 of the first and second side walls 18, 20 and the first support web 22. The bottom opening 44 may be on the same plane as a bottom outer surface 50 of the first and second side walls 18, 20 and the first support web 22. The side opening 46 may be on the same plane as a side outer surface 52 of the first and second side walls 18, 20. In at least one embodiment, the first half cell 36 may have a length in a longitudinal direction 54, such that is aligned with a longitudinal axis 56 of the masonry block 10, that is less than a length in a longitudinal direction 54 of the first cell 28. In at least one embodiment, a length of the first half cell 36 in a longitudinal direction 54 of the masonry block 10 may be about one half a length of the first cell 28 defined at least in part by portions of the first and second side walls 18, 20 and the first and third support webs 22, 26.
In at least one embodiment, the second half cell 40 may be formed from one or more top openings 60, one or more bottom openings 62 and one or more side openings 64, as shown in
The overall length of the masonry block 10 may be larger than an overall length of a conventional two cell masonry block 12, as shown by comparison of
The masonry block 10 may be formed from any appropriate size while enabling the first and second cells 28, 34 to be aligned with other cells in other courses in a concrete block wall. For example, and not limitation, the masonry block 10 may be formed with widths such as, but not limited to, six inches, eight inches, ten inches, and twelve inches. The masonry block 10 may also be formed with a length enabling first and second cells 28, 34 and first and second half cells 36, 40 to be aligned with cells in concrete block courses below the course being laid and may be, but is not limited to being about 24 inches. Such length of the masonry block 10 enables the masonry block 10 with first and second cells 28, 34 and first and second half cells 36, 40 to be laid together with conventional concrete block with only two open cells and typically 16″ in length.
The masonry block 10 may be formed from materials that are lighter per volume than materials used to form conventional masonry blocks 12. One or more components of the materials used to form conventional masonry blocks 12 may be substituted for a lighter material without compromising strength of the masonry block 10. In at least one embodiment, the masonry block 10 may be formed from materials including aggregate that are lighter per volume than materials used to form conventional masonry blocks 12. The masonry block 10 may be formed from materials including aggregate, such as, but not limited to rock, stone and the like, that are lighter per volume than materials used to form conventional masonry blocks yet retain the same strength characteristics, such as, but not limited to, compression strength characteristics. Conventional CMU (concrete) blocks are typically made with aggregates of 125 pound (lb) per cubic foot (PCF). In at least one embodiment, masonry block 10 can be formed with lightweight (LT WT) aggregates not to exceed 105 lb PCF. Masonry block 10 with first partial cell 36 extending longitudinally from a first end and second partial cell 40 extending longitudinally from a second end produced with LT WT aggregates, less than or equal to about 105 lb PCF, are comparable in overall weight to conventional CMU block produced with 125 lb PCF aggregates and classified normal weight. Masonry block 10 with first partial cell 36 extending longitudinally from a first end and second partial cell 40 extending longitudinally from a second end, when produced with LT WT aggregates will allow the mason to place the same amount of masonry block 10 units as conventional CMU's with no additional weight to the mason, which is very important to the mason. Overloading a mason with additional weight severely hinders the mason's productivity by reducing his daily output.
With regard to the density classification of the aggregate used in the masonry block 10, the American Society for Testing and Materials (ASTM) C 90-11b, Standard Specification for Loadbearing Concrete Masonry Units, Table #2 classifies block into three Categories based upon densities PCF: Lightweight (LT WT)—less than 105 lbs; Medium Weight—105 lbs to less than 125 lbs and Normal Weight—125 lbs or more. ASTM C 90-11b provides that each classification have a minimum net area compressive strength equal to 1900 lbs. Thus, the masonry block 10 can be formed with lightweight (LT WT) aggregates not to exceed 105 lb PCF, as defined by ASTM C 90-11b or other applicable building code or regulation. Any aggregate meeting the ASTM C 90-11b or other applicable building code or regulation for weight and strength may be used. Lightweight aggregate may include, but is not limited to, StaLite by Carolina Stalite Company, Salisbury, N.C. and Livelite by Tombigbee Lightweight Aggregate Co. in Livingston, Ala.
The masonry block 10 may include a handhold 68 formed in the third support web 26 and accessible from above the masonry block 10, as shown in
In at least one embodiment, the masonry block 10 may include a third support web 26 formed from a first subthird support web 70 and a second subthird support web 72. The first and second subthird support webs 70, 72 may be separated by a gap 74 thereby forming a splitable masonry block 10 whereby a first section 76 of the masonry block 10 can be split from the second section 78 of the masonry block 10, as shown in
During use, a mason may install masonry block 10 with mortar and may level and align each block 10, as shown in
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of this invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of this invention.
This application is a continuation application of U.S. patent application Ser. No. 15/179,408, filed Jun. 10, 2016, which is a continuation-in-part application of U.S. patent application Ser. No. 14/738,922, filed Jun. 14, 2015, the entireties of which are incorporated herein.
Number | Date | Country | |
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Parent | 15179408 | Jun 2016 | US |
Child | 15967987 | US |
Number | Date | Country | |
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Parent | 14738922 | Jun 2015 | US |
Child | 15179408 | US |