Patent Application
20170247879
U.S. Pat. No. 5,138,808, issued to Bengtson, et al., teaches a masonry block system that uses blocks formed with minimum webbing to minimize heat flow. Briefly, the patent teaches a wall system that is formed into a unitary structure using blocks. The wall also uses threaded post-tensioning rods tied to reinforcement rods in the wall footer and extending through the voids that contain polyurethane foam in the respective blocks to a top plate positioned on top of the wall.
U.S. Pat. No. 7,033,116, issued to Ward, et al., teaches a method of rammed-earth building construction wherein post-tensioning rods are anchored to a concrete footing so that the wall is post-tensioned to enhance the ability of the wall to receive lateral loading without failing in tension. The wall is then topped with a concrete bond beam and a retaining plate.
U.S. Pat. No. 6,195,955, issued to Kostopoulos, et al., teaches a method and apparatus for constructing a concrete block wall. Briefly, the patent teaches a concrete block wall constructed of concrete blocks each having one or more vertical openings. The patent includes the steps of the layering the blocks to generally align the vertical openings to initiate formation of the wall and placing reinforcement bars through the aligned openings. The wall also utilizes a connector that tightly grips each respective bar to form a frictional engagement of the connector and the bars.
U.S. Pat. No. 6,505,450 issued to Locke, et al., teaches a masonry reinforcement system. The patent teaches a reinforcement system that includes a number of tensioning rods extending from the top to the bottom of a masonry wall structure in spaced columns. In each column, several rod segments are interconnected at each floor diaphragm using a double conical connector assembly. Each type of connector assembly is embedded in a pocket formed in the masonry wall structure using a hardenable grout.
U.S. Pat. No. 6,098,357 issued to Franklin, et al., teaches a modular precast construction block system with a wall subsystem and a foundation subsystem. The wall subsystem has a number of building blocks having cavities and pre-stressed tension cables. The building blocks are aligned to form walls with vertically aligned cavities. Threaded wall bars and extension bars are threaded through the cavities. The foundation subsystem includes a variety of precast foundation members.
U.S. Pat. No. 8,225,578 issued to Ronagh, et al., teaches a method for construction of a wall using flexible interlocking mortarless building blocks. Briefly, the patent teaches a wall foundation, with foundation tendon rods, that is first constructed with a set of mechanical fastenings attached to the foundation tendon rods. A wall structure is created by vertically stacking a plurality of building blocks onto the threaded tendon rods and affixing the building blocks using the mechanical fastening. A plurality of roof connecters and rods are attached to horizontally form a network of roof rods, which interconnect the walls for building a roof.
U.S. Pat. No. 5,899,040 issued to Cerrato, et al., teaches a masonry wall system made of masonry blocks each consisting of interlocking dovetails combined with vertical and horizontal mating surfaces. The main block has two stabilizing holes through the center, and steel reinforcement rods are inserted into these stabilizing holes. The masonry components and loosely placed rods have predetermined tolerances, which permit the wall to have a fluid property. When all of the masonry components reach the peak of their tolerance, the wall locks up as a solid interconnected mass, and the force is then passed on to the stabilizing rods.
According to various implementations, a building block for a wall includes a single face shell, first and second webs, and a pier. The single face shell has an interior surface and an exterior surface, an upper surface and a lower surface, and a first end and a second end. The first and second webs each have a proximal end and a distal end. The webs extend from the interior surface of the face shell. The proximal end of each web is coupled to (e.g., integrally formed with or separately formed and attached to) the interior surface of the face shell. The pier has a proximal surface adjacent the distal ends of the first and second webs and a distal surface opposite the proximal surface and facing away from the interior surface of the face shell. The pier also includes a pier upper surface that is substantially within the same plane as the upper surface of the face shell, a pier lower surface that is substantially within the same plane as the lower surface of the face shell, a first side surface that is coupled to the distal end of the first web, and a second side surface that is coupled to a distal end of the second web. The interior surfaces of the webs, the proximal surface of the pier, and a portion of the interior surface of the face shell between the interior surfaces of the webs together define a pocket. A ledge extends from the distal surface of the pier. The ledge is spaced between the upper and lower surfaces of the pier. In some implementations, at least a portion of the ledge lies in a plane that is parallel to a plane in which at least a portion of the pier upper surface lies. In a further implementation, a plane in which at least a portion of the ledge lies is parallel to a plane in which at least a portion of the pier lower surface lies.
In addition, in some implementations, the interior surfaces of the first and second webs adjacent the proximal ends thereof and the interior surface of the single face shell define first and second grooves, respectively. The first and second grooves extend from the lower surfaces of the first and second webs, respectively, to first and second ledges, respectively, disposed within the pocket. The first and second ledges are spaced between the upper and lower surfaces of the first and second webs, respectively. And, the interior surfaces of the first and second webs adjacent the distal ends of thereof and the proximal surface of the pier define third and fourth grooves, respectively. The third and fourth grooves extend from the lower surfaces of the first and second webs, respectively, to third and fourth ledges, respectively, disposed within the pocket. The third and fourth ledges are spaced between the upper and lower surfaces of the first and second webs, respectively.
In some implementations, the upper surfaces of the first and second webs are substantially within the same plane as the upper surface of the face shell and the pier upper surface. And, in a further or alternative implementation, the lower surface of the first and second webs are substantially within the same plane as the lower surface of the single face shell and the pier lower surface.
In some implementations, a first knock-out portion of the first web is defined between the first and third grooves, the lower surface of the first web, and the first and third ledges, and a second knock-out portion of the second web is defined between the second and fourth grooves, the lower surface of the second web, and the second and fourth ledges. These knock-out portions may be removed from the building block by applying blunt force to the knock-out portions (e.g., with a hammer or mallet) to break off the knock-out portions adjacent the respective ledges and grooves. With the knock out portions removed, the proximal surface of the pier, the lower surfaces of the first and second webs, respectively, with the knock out portions removed, and the interior surface of face shell define a horizontal beam channel, which may receive a beam. In other implementations, removing the knock out portions allows access to the pocket of the building blocks on the lowermost course to remove debris before grouting the pocket and/or to inspect tensioning rods that may be installed in the pocket.
In some implementations, the interior surface of the single face shell comprises a center line that extends between the upper and lower surfaces of the single face shell and is equi-spaced between the first and second ends of the face shell. The proximal ends of the first and second webs are disposed between one of the first and second ends of the single face shell and the center line.
In some implementations, the lower surface of the pier defines a horizontally oriented groove that extends between the first side and the second side of the pier. When blocks are stacked on top of each other in horizontal courses such that the pockets in each course align with the pockets of the adjacent courses, the horizontal groove of a block in one course and the upper or lower surface of the pier of a block in an adjacent course define an opening, which may receive building services (e.g., plumbing, wiring) or horizontal reinforcements that are installed adjacent a wall of a building.
In some implementations, an exterior surface of the first web (and/or second web) defines a lifting ledge adjacent the upper surface of the first web. The lifting ledge extends outwardly from the interior and exterior surfaces of the first web in a direction parallel to a second axis. The second axis extends between the first and second ends of the single face shell. The lifting ledge allows a mason or other user to grasp the building block more easily. In some implementations, the first web is the web closest to a center of gravity of the building block.
To reduce material for the building block without compromising structural stability of the building block, the portion of the single face shell between the proximal ends of the first and second webs has a thickness as measured in a direction parallel to a first axis that is less than a thickness of a remaining portion of the single face shell, according to certain implementations. The first axis extends orthogonal to the interior surface of the face shell.
In addition, according to some implementations, the pier has a width that is less than a width defined between exterior surfaces of the first and second webs, the exterior surfaces being spaced apart and opposite from the interior surfaces of the respective web, and wherein width is measured in a direction parallel to the second axis.
In various other implementations, a masonry wall comprises a plurality of building blocks that are stacked in horizontal courses. Each building block includes a single face shell, a first and a second web, and a pier. The single face shell has an interior surface and an exterior surface, a first end and a second end, and an upper surface and a lower surface. The interior surface and exterior surface extend between the first and second ends and the upper and lower surfaces. The first web and a second web extend from the interior surface of the single face shell. Each of the first web and the second web includes a proximal end and a distal end. The proximal ends of the first and second webs are spaced inwardly from the first and second ends of the single face shell and are coupled to the interior surface of the single face shell. The pier has a proximal surface adjacent the distal ends of the first and second webs, a distal surface opposite the proximal surface and facing away from the interior surface of the single face shell, a pier upper surface that is substantially within the same plane as the upper surface of the single face shell, a pier lower surface that is substantially within the same plane at the lower surface of the single face shell, a first side surface that is coupled to the distal end of the first web, and a second side surface that is coupled to a distal end of the second web. The first and second side surfaces of the pier are spaced apart from each other and extend between the pier upper and pier lower surfaces, and the planes in which the pier upper and pier lower surfaces lie are substantially parallel to each other. Interior surfaces of the webs, the proximal surface of the pier, and a portion of the interior surface of the face shell between the interior surfaces of the first and second webs together define a pocket. In addition, a ledge extends from the distal surface of the pier in the direction away from the interior surface of the single face shell. The ledge is spaced between the upper and lower surfaces of the pier.
The plurality of building blocks of the masonry wall includes a first building block in a first horizontal course and a second building block in a second horizontal course. The first building block is stacked upon the second building block such that the webs and pockets of the first and second building blocks form a column. In addition, a channel is defined by the ledge of the first building block, the pier upper surface of the second building block, and a portion of the distal surface of the pier of the first building block between the ledge and the pier lower surface of the first building block.
In some implementations, a plane in which at least a portion of the ledge lies is substantially parallel to a plane in which at least a portion of the pier upper surface lies. In a further or alternative implementation, the plane in which at least a portion of the ledge lies is substantially parallel to a plane in which at least a portion of the pier lower surface lies.
In some implementations, the masonry wall includes furring channel framing that is disposed horizontally within the channel defined between the first and second building blocks. In other implementations, the furring channel framing is disposed diagonally within the channel defined between the first and second building blocks.
In some implementations, for each building block, the interior surfaces of the first and second webs adjacent the proximal ends thereof and the interior surface of the single face shell define first and second grooves, respectively. The first and second grooves extend from the lower surfaces of the first and second webs, respectively, to first and second interior ledges, respectively, disposed within the pocket. The first and second interior ledges are spaced between the upper and lower surfaces of the first and second webs, respectively. In addition, the interior surfaces of the first and second webs adjacent the distal ends of thereof and the proximal surface of the pier define third and fourth grooves, respectively. The third and fourth grooves extend from the lower surfaces of the first and second webs, respectively, to third and fourth interior ledges, respectively, disposed within the pocket. The third and fourth interior ledges are spaced between the upper and lower surfaces of the first and second webs, respectively.
In a further implementation, a first knock-out portion of the first web is defined between the first and third grooves, the lower surface of the first web, and the first and third ledges, and a second knock-out portion of the second web is defined between the second and fourth grooves, the lower surface of the second web, and the second and fourth ledges. When the first and second knock out portions are removed for the building blocks disposed in a particular course of the masonry wall, the lower surfaces of the webs for those blocks become closer to or continuous with the interior ledges. The proximal surfaces of the piers, the lower surfaces of the webs with the knock out portions removed, and the interior surfaces of the single face shells in the particular course together define a horizontal beam channel along the particular course. The horizontal beam channel may further be defined by the upper surfaces of the webs of the blocks of the course below.
In some implementations, the masonry wall further includes a beam that is disposed within the horizontal beam channel. The particular course may be any course along the height of a wall. For example, the beam channel may be formed in a course that is adjacent to where flooring for a second or higher story is installed or where a roof is installed. Furthermore, the particular course may be formed in more courses in areas in which seismic activity is higher to protect the wall against shear or lateral loads due to seismic activity. And, the beam channel may be formed in an uppermost course to receive a bond beam, for example.
In some implementations, the interior surface of the single face shell of each building block comprises a center line that extends between the upper and lower surfaces of the single face shell and is equi-spaced between the first and second ends. In certain implementations, the proximal ends of the first and second webs of a first set of building blocks are disposed between the first end of the single face shell and the center line, and the proximal ends of the first and second webs of a second set of building blocks are disposed between the second end of the single face shell and the center line. The blocks from the first set are laid in a first horizontal course, and blocks from the second set are laid vertically adjacent the first course in a second horizontal course, which provides a staggering effect for the ends of the blocks in each course.
In a further implementation, the pockets of building blocks in adjacent courses are aligned and stacked to form continuous columns between the adjacent courses.
In some implementations, the masonry wall may also include grout disposed within a column formed by the pockets of adjacently stacked building blocks. And, in further or alternative implementations, a vertical tensioning rod or tendon may be disposed within the column, which may be grouted in place.
In some implementations, the masonry wall may further include a wall foundation on which a lowermost horizontal course of building blocks is laid. According to some implementations, the wall foundation may include a cast-in-place footing made from, e.g., castable cement, concrete, grout, clay, fiberglass, fiber reinforced polymers, polymers, metals, pressure-wood, compacted aggregate, helical piers, pre-cast concrete or aggregate piers, a pier and beam foundation, or other moldable forming materials.
In some implementations, the bond beam may be formed from wood, wood composites, plywood, a reinforced grout bond beam, concrete, cement, iron, iron alloys, metal, nickel, steel, steel alloy, stainless steel alloys, aluminum, aluminum alloys, bronze alloys, brass, brass alloys, chromium, copper, copper alloys, polymers, plastic, reinforced polyester epoxy, fiber reinforced plastic, fiberglass, engineering plastics, Teflon®, lead, natural or synthetic rubber, steel reinforced concrete, any combination thereof, or any other suitable material. Additionally, the bond beam may include one or more openings through which each vertical reinforcement rod or tendon may extend to further provide stabilizing and support for the rods or tendons. The masonry wall may also include a cap disposed on top of the bond beam (or the uppermost layer of building blocks). The cap defines one or more openings through which a respective vertical reinforcement rod or tendon extends to stabilize and support the vertical reinforcement rod or tendon. The cap, according to some implementations, is a single elongated member defining one or more openings. In other implementations, the cap may include separate members that each define one or more openings.
In some implementations, the first and/or second web may define a fastener-receiving groove located on the exterior surface end of the web or a recess in the exterior surface of the web to receive a fastening clip. The face shell and/or the second web may also include one or more lifting ledges that can be used for grasping the building block. In addition, the building block may include one or more ridges extending from the interior surface of the face shell, the interior or exterior surfaces of one or both webs, and/or the side, distal, and/or proximal surfaces of the pier to provide additional mechanical strength and/or to provide mechanical restraining or position control for any number of items that are fitted or fixed with the masonry wall (e.g., insulation, plumbing, wiring, etc.). The interior surface of the face shell may further comprise one or more face shell lugs that each define a groove for receiving a fastener. One or more fasteners may be engaged within the grooves of the lugs to couple adjacently stacked building blocks together.
According to some implementations, the building blocks may be made from various types of materials, including for example, cement, concrete, cinder block, aggregate, clay, polymers, copolymers, metals, fiberglass, forming materials, wood, plywood, oriented strand board, particle board, cement board, engineering composite materials, bamboo, hemp, plastic, nylon, polyester, polypropylene, and polystyrene.
In some implementations, the upper surface and/or the lower surface of the face shell may define one or more horizontal grooves extending from the first end of the face shell to the second end. The horizontal grooves may receive one or more horizontal joint reinforcements between the upper surface of one building block and the lower surface of another building block stacked adjacent to each other. The one or more horizontal joint reinforcements can be made of, e.g., iron, iron alloys, metal, nickel, steel, steel alloy, stainless steel alloys, aluminum, aluminum alloys, bronze alloys, brass, brass alloys, chromium, copper, copper alloys, polymers, plastic, reinforced polyester epoxy, fiber reinforced plastic, fiberglass, fiber reinforced plastic, fiberglass, engineering plastics, Teflon®, lead, natural or synthetic rubber, or some combination thereof, and can provide mechanical and non-mechanical features to the wall. Alternatively, horizontal joint reinforcement may be installed on the mortar bed joint between adjacently stacked building blocks that do not define grooves in the upper or lower surfaces of the face shells. Apart from the horizontal grooves and joint reinforcement design, other designs for the upper and lower surfaces of the face shell include, e.g., a tongue and groove design, dovetail joints, interlocking joints, canal, corrugation, crease, crimp, cut, cutting, depression, ditch, flute, fluting, furrow, gouge, gutter, hollow, incision, notch, pucker, rabbet, rut, scallop, score, scratch, slit, trench, valley, or crenellated joints to provide interlocking capabilities between the surfaces in one or more directions.
In some implementations, the building block may include more than two webs that are coupled to the interior surface of the face shell, extend outwardly from the interior surface of the face shell, and are spaced apart from the other webs. In addition, the building block may further include (or define) one or more brick ties fastened to (or embedded in) the interior or exterior surface of the face shell or one of the webs.
Various implementations also include a method for construction (or assembly) of a wall that includes: (1) coupling one or more vertical reinforcement rods or tendons to one or more anchors embedded in a wall foundation, each of the one or more vertical reinforcement rods or tendons having a first end and a second end, and the first end of each rod being embedded or mechanically attached to a respective one of the one or more anchors, (2) disposing a first layer of one or more building blocks on the wall-foundation, and (3) disposing a second layer of one or more building blocks on the first layer such that the pockets and piers of the building blocks in the second layer align with the building blocks adjacent thereto in the first layer. In some implementations, the vertical reinforcement rods or tendons are spaced such that the one vertical reinforcement rod or tendon extends through a column defined by the pockets of adjacently stacked blocks. In other implementations, the vertical reinforcement rods or tendons are spaced such that the vertical reinforcement rod or tendon is disposed adjacent to at least one web of the building blocks.
In some implementations, the method includes creating a downward tension force in each of the vertical reinforcement rods or tendons to provide support to the wall. Creating the downward tension force may be accomplished by securing a fastener (e.g., a clip, nut, bolt, washer, screw, or other suitable fastener) over a threaded second end of each vertical reinforcement rod or tendon.
The building block and wall assembly and methods may be understood more readily by reference to the following drawings and detailed description, which provide various implementations of the invention.
Various implementations include a building block for assembly into a masonry wall. The building block includes a single face shell with one or more webs attached or integrally formed therewith. A face shell is the outer (or inner) sidewall of a concrete building block, in other words, the face shell can be either on the outside or the inside of the structure. In the examples shown herewith the face shell is an exterior version of the building block. A web is a portion of the building block that extends from the face shell.
The face shell and web can be made from the same material (or different materials), including but not limited to, castable cement, concrete, cinder block, clay, polymers, copolymers metals, forming materials, wood, aggregate, clay, plywood, oriented strand board, particle board, cement board, engineering composite materials, bamboo, hemp, plastic, nylon, polyester, polypropylene, polystyrene, metal, and combinations thereof. The portions of the building block that contact the foundation (or a building block above an existing building block) often include a transition that provides mechanical attachment and/or insulation, e.g., they can include a tongue and groove design, dovetail joints, or crenellated joints to provide interlocking capabilities. Horizontal joint reinforcements (e.g., pencil rods) can be placed in a groove or in a mortar joint between ungrooved blocks, which is just one example of features or methods used to provide, e.g., mechanical strength, attachment, shear stabilization, and/or insulation between one or more layers of building blocks. The horizontal joint reinforcements can be made of iron, iron alloys, metal, nickel, steel, steel alloy, stainless steel alloys, aluminum, aluminum alloys, bronze alloys, brass, brass alloys, chromium, copper, copper alloys, polymers, plastic, reinforced polyester epoxy, fiber reinforced plastic, fiberglass, engineering plastics, coated with Teflon®, lead, natural or synthetic rubber.
Constructing a wall using blocks generally requires a wall-foundation that can support the weight of the wall and/or the strain of one or more vertical reinforcement tendons. The wall-foundation can include, but is not limited to, cast-in-place footing made from castable cement, concrete, grout, clay, fiberglass, fiber reinforced polymers, polymers, metals, pressure-wood, compacted aggregate, helical piers, pre-cast concrete or aggregate piers, a pier and beam foundation, or other moldable forming materials, or it can be a pre-existing surface of, e.g., concrete, ice, rock, dirt, gravel, earth, sand, etc.
The size of each building block is not limited to a certain width, height, and depth. It is possible that an entire wall is made up of only a single sized building block. The building blocks can have a length of about 4 in, about 6 in., about 8 in., about 12 in., about 16 in., about 20 in., about 22 in., about 2 ft., about 3 ft., about 4 ft., about 5 ft., about 6 ft., about 7 ft., about 8 ft., about 9 ft., about 10 ft., about 11 ft., about 12 ft., about 13 ft., about 14 ft., about 15 ft., about 16 ft., about 17 ft., about 18 ft., about 19 ft., about 20 ft., about 21 ft., about 22 ft., about 23 ft., about 24 ft., about 25 ft., about 26 ft., about 27 ft., about 28 ft., about 29 ft., about 30 ft., about 40 ft., about 50 ft., about 60 ft. or more. Likewise with width of the face shell can be about 4 in, about 6 in., about 8 in., about 12 in., about 16 in., about 20 in., about 22 in., about 2 ft., about 3 ft., about 4 ft., about 5 ft., about 6 ft., about 7 ft., about 8 ft., about 9 ft., about 10 ft., about 11 ft., about 12 ft., about 13 ft., about 14 ft., about 15 ft., about 16 ft., about 17 ft., about 18 ft., about 19 ft., about 20 ft., about 21 ft., about 22 ft., about 23 ft., about 24 ft., about 25 ft., about 26 ft., about 27 ft., about 28 ft., about 29 ft, about 30 ft., about 40 ft., about 50 ft., about 60 ft., or more. The length is measured in a direction parallel to a transverse axis that extends orthogonal to and between the upper and lower surfaces of the face shell, and the width is measured in a direction parallel to a transverse axis that extends orthogonal to and between the first and second ends of the face shell. In certain implementations, the length of the webs can be about 4 in., about 6 in., about 8 in., about 10 in., about 12 in., about 16 in., or more. Generally, the size of the building blocks conforms to standards depending on the size of the wall and/or the load of the building, in either metric or imperial units of measure.
In one non-limiting example, a bond beam and/or cap can also placed on top of the wall. The bond beam and/or cap can include but is not limited to reinforced grout bond beam, concrete, cement, iron, iron alloys, metal, nickel, steel, steel alloy, stainless steel alloys, aluminum, aluminum alloys, bronze alloys, brass, brass alloys, chromium, copper, copper alloys, polymers, plastic, reinforced polyester epoxy, fiber reinforced plastic, fiberglass, engineering plastics, metal coated with Teflon®, lead, natural or synthetic rubber, steel reinforced concrete, or any combination thereof.
As shown in
After the final layer of the building block is laid and the optional bond beam and cap placed, a downward tension is created in the vertical reinforcement tendon to enhance the ability of the wall to receive lateral loading without failing in tension. The creating of the downward tension in the vertical reinforcement tendon can be but is not limited to being accomplished with a fastener such as a clip, nut, bolt, washer, or screw that secures over a threaded second end of each vertical reinforcement tendon. Additional methods include but not limited to physically deforming the vertical reinforcement tendon to also create the downward tension and stabilize the vertical reinforcement tendon.
The single face shell provides access to vertical reinforcement tendon members for inspection, maintenance, and replacement, as well as access to wall interior during or after construction for installation of concealed building services, damp proofing, and insulation. Allowing access to wall interior results in decreases in construction time and increases in construction efficiency.
The building block according to various implementations of the present invention provides several distinct advantages: including but not limited to: singlet sided single face shell: access to interior of wall after erection, which: reduces trade scheduling dependencies; allows installation of: vertical reinforcing/post-tensioning tendon, damp proofing, insulation, building services (elec., plumbing, low-voltage, etc.), and allows inspection of building services (elec., plumbing, low-voltage, etc.) after the wall is erected.
The building block according to various implementations also provides an open system, which allows for: modular coursing with standard block; works with installation of conventional non-proprietary (e.g., inexpensive) insulation systems; allows typical or conventional installation for electric, or plumbing), or low-voltage systems; and supports typical interior/exterior finishes other than masonry if desired.
Another advantage of the building block according to various implementations is that is uses less material per square foot of wall area (efficient with material and labor) and more wall area per block (in particular when used as a one-handed block for installation). Another advantage is that the building blocks can be nested together for shipping, pressing and curing, which allows for more efficient manufacturing and palletizing, shipping, and/or staging.
Additional advantages of the building block according to various implementations includes that the building blocks are reversible (integral masonry surface (e.g., the face shell) can be inside or out) allowing an earlier building dry-in for accelerated construction schedules. Other advantages include: reinforcing options/flexibility, such as: conventional grouted rebar; and no-grout post-tensioned reinforcing. The building blocks allow for true back dam flashing in single wythe construction, and it also allows industrial buildings to later be upgraded to more finished uses without supplemental framing.
The first 208 and second webs 209 each have a proximal end 211 and a distal end 213. The webs 208, 209 extend from the interior surface 204 of the face shell 214. The proximal end 211 of each web 208, 209 is coupled to (e.g., integrally formed with or separately formed and attached to) the interior surface 204 of the face shell 214. The webs 208, 209 shown in
The compression pier 240 has a proximal surface 241 adjacent the distal ends 213 of the first 208 and second webs 209 and a distal surface 242 opposite the proximal surface 241 and facing away from the interior surface of the face shell. The pier 240 also includes a pier upper surface 243 that is substantially within the same plane as the upper surface 210 of the face shell 214, a pier lower surface 244 that is substantially within the same plane as the lower surface 212 of the face shell 214, a first side 245 surface that is coupled to the distal end 213 of the first web 208, and a second side surface 246 that is coupled to a distal end 213 of the second web 209. The interior surfaces 247 of the webs 208, 209, the proximal surface 241 of the pier 240, and a portion 249 of the interior surface 204 of the face shell 214 between the interior surfaces 247 of the webs 208, 209 together define a pocket.
Furthermore, the pier 240 balances the load on the face shell 214 on the side of the webs 208, 209, according to some implementations, providing additional structural stability to the building block 200 without blocking the view of the interior surface 204 of the face shell 214 and by reducing the amount of raw materials needed for the block 200.
Like the building blocks described above, building block 200 provides the advantage of being able to view and access the interior surface 204 of the building blocks that are stacked to form a wall assembly, such as is shown in
In addition, the interior surfaces 247 of the first 208 and second webs 209 adjacent the proximal ends 211 thereof and the interior surface 204 of the single face shell 214 define first 260 and second grooves 261, respectively. The first 260 and second grooves 261 extend from the lower surfaces 226 of the first 208 and second webs 209, respectively, to first 264 and second ledges 265, respectively, disposed within the pocket 266. The first 264 and second ledges 265 are spaced between the upper 224 and lower surfaces 226 of the first 208 and second webs 209, respectively. And, the interior surfaces 247 of the first 208 and second webs 209 adjacent the distal ends 213 thereof and the proximal surface 241 of the pier 240 define third 262 and fourth grooves 263, respectively. The third 262 and fourth grooves 263 extend from the lower surfaces 226 of the first 208 and second webs 209, respectively, to third 267 and fourth ledges 268, respectively, disposed within the pocket 266. The third 267 and fourth ledges 268 are spaced between the upper 224 and lower surfaces 226 of the first 208 and second webs 209, respectively.
The upper surfaces 224 of the first 208 and second webs 209 are substantially within the same plane as the upper surface 210 of the face shell 214 and the pier upper surface 243. And, the lower surface 226 of the first 208 and second webs 209 are substantially within the same plane as the lower surface 212 of the single face shell 214 and the pier lower surface 244. In other implementations (not shown), the lower surface 226 of the first 208 and second webs 209 may be in a different plane than the lower surface 212 of the single face shell 214 and the pier lower surface 244.
A first knock-out portion 270 of the first web 208 is defined between the first 260 and third grooves 262, the lower surface 226 of the first web 208, and the first 264 and third ledges 267, and a second knock-out portion 271 of the second web 209 is defined between the second 261 and fourth grooves 263, the lower surface 226 of the second web 209, and the second 265 and fourth ledges 268. These knock-out portions 270, 271 may be removed from the building block by applying blunt force to the knock-out portions 270, 271 (e.g., with a hammer or mallet) to break off the knock-out portions 270, 271 adjacent the respective ledges 264, 267, 265, 268 and grooves 260, 262, 261, 263. With the knock out portions 270, 271 removed, the proximal surface 241 of the pier 240, the new lower surfaces of the first and second webs 208, 209 (which approaches or is continuous with the ledges 264, 265, 267, 268), and the interior surface 204 of face shell 214 define a horizontal channel 275, such as is shown in
In other implementations, the grooves defining the knock out portions 270, 271 may be shaped differently, extend in other directions relative to the interior surface 247 of the webs 208, 209, and/or extend through the width of the webs 208, 209, such as is shown in the implementations in
A ledge 280 extends from the distal surface 242 of the pier 240. The ledge 280 is spaced between the upper 243 and lower surfaces 244 of the pier 240. In some implementations, at least a portion of the ledge 280 lies in a plane that is parallel to a plane in which at least a portion of the pier upper surface 243 lies. In a further implementation, a plane in which at least a portion of the ledge 280 lies is parallel to a plane in which at least a portion of the pier lower surface 244 lies. Due to manufacturing constraints, the ledge 280 may have irregularities in its surface, resulting in a surface that is not within a single plane. In some implementations (not shown), at least a portion of the ledge 280 may be in a plane that is not parallel with a plane in which at least a portion of the pier upper surface 243 and/or lower surface 244 lie.
In some implementations, the first web defines a lifting ledge 215 adjacent the upper surface 224 of the first web 208. The lifting ledge 215 extends outwardly from the interior 247 and exterior surfaces 248 of the first web 208 in the width direction adjacent the upper surface 224 of the web 208. The lifting ledge 215 allows a mason or other user to grasp the building block 200 more easily. The lifting ledge 215 is disposed on the first web 208 because the first web 208 is closest to a center of gravity of the building block 200.
To reduce material for the building block 200 without compromising structural stability of the building block 200, the portion 248 of the single face shell 214 between the proximal ends 211 of the first 208 and second webs 209 has a thickness as measured in a thickness direction that is orthogonal to the length and width directions that is less than a thickness of a remaining portion of the single face shell 214. However, in other implementations, the thickness of the portion 248 of the face shell 214 may be substantially uniform or thicker than the other portions of the face shell 214.
In addition, the pier 240 has a width that is less than a width defined between exterior surfaces 248 of the first 208 and second webs 209. For example, in one implementation, the width of the pier 240 is between about 1.5 and about 3.5 inches (e.g., about 2.25 inches wide), and the external width of the webs 208, 209 is about 4.5 to about 6 inches (e.g., about 5.6 inches wide). As another example, the width of the pier 240 may be 30% to about 60% the external width of the webs, according to some implementations.
However, in other implementations, the width of the pier 240 may be greater than the width of the distance between the exterior surfaces 248 of the first 208 and second webs 209. In such implementations, the interior surface 204 of the face shell 214 remains viewable and accessible when the blocks 200 are stacked relative to each other to form a wall assembly.
In addition, the distance between the proximal surface 241 of the pier and the interior surface 204 of the face shell 214 is between about 2 and about 4 inches (e.g., about 3 inches), according to some implementations.
As shown in
Some courses in the wall 400 may include blocks 200 that have had the knock out portions 270, 271 removed (or are removed after installation). When the blocks 200 that have the knock out portions 270, 271 removed are laid above the webs 208, 209 of a block in a course below, the upper course block 200 and the upper surface 224 of the block 200 below form a horizontal channel 275, which is shown in
In addition, the knock out portions 270, 271 may be removed in a course near the wall foundation 110 to remove debris from the pocket 266 prior to grouting the pocket 266 and/or to inspect tensioning rods or tendons 38 that may be installed within the pocket 266.
In addition, the lower surface 244 of the pier 240 defines a horizontally oriented groove 290 that extends between the first side 245 and the second side 246 of the pier 240. When blocks 200 are stacked on top of each other in horizontal courses as described above, the horizontal groove 290 of a block 200 in an upper course and the upper 243 surface 244 of the pier 240 of adjacent block 200 in a lower course define an opening. The opening is able to receive building services (e.g., plumbing, wiring) or horizontal reinforcements through it. The opening may also receive wire tie attachments for furring channel framing.
To create a staggered effect for adjacent courses in the masonry wall 400, as is shown in
As mentioned above, the building blocks 200 may be nested together for shipping, pressing, and/or curing, which allows for more efficient manufacturing and palletizing, shipping, and/or staging.
In some implementations, the building blocks 200 laid in an upper horizontal course may be oriented 180° from the blocks 200 laid in the adjacent course below. And, in some implementations, the webs 208, 209 and pier 240 are oriented about the central axis 281. Furthermore, in some implementations, the blocks 200 may be stacked in the same orientation.
While the methods and systems have been described in connection with preferred embodiments and specific examples, it is not intended that the scope be limited to the particular embodiments set forth, as the embodiments herein are intended in all respects to be illustrative rather than restrictive.
Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; the number or type of embodiments described in the specification.
It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope or spirit. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit being indicated by the following claims.
Furthermore, it is to be understood that the methods and systems are not limited to specific methods or specific components. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.
As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. “Exemplary” means “an example of” and is not intended to convey an indication of a preferred or ideal embodiment. “Such as” is not used in a restrictive sense, but for explanatory purposes.
Disclosed are components that can be used to practice various implementations of the invention. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutation of these may not be explicitly disclosed, each is specifically contemplated and described herein, for all methods and systems. This applies to all aspects of this application including, but not limited to, steps in disclosed methods. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific embodiment or combination of embodiments of the disclosed methods.
This application claims priority to U.S. Provisional Patent Application No. 62/300,766, entitled “Masonry Wall Assembly,” filed Feb. 26, 2016, the content of which is herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62300766 | Feb 2016 | US |
