This application is the U.S. national phase of PCT Application No. PCT/MX2011/000057 filed on May 13, 2011, which claims priority to Mexican Patent Application No. MX/a/2010/013375 filed on Dec. 6, 2010, the disclosures of which are incorporated in their entirety by reference herein.
The system for constructing walls using blocks equipped with coupling means allows for the construction of walls in less time and with a cleaner, flatter and more homogeneous finish, since the mortar joints are avoided and replaced with very slightly visible seams, also achieving a more solid structure than that of traditional blocks or bricks, while saving adhesive material or mortar and avoiding the need for skilled labor to build the wall. All the above, considering also the channeling inside the wall for electrical installations or any kind of piping, without weakening the structure of the wall. This system also considers the construction of piers by stacking quoin blocks equipped with coupling means, on a rib previously set in the foundation. The system allows for the construction of walls without the need for skilled labor. The features of the blocks equipped with coupling means of the present system can reduce the volume of material used for its manufacture and can reduce its weight, without compromising its strength. The blocks equipped with coupling means have thermal characteristics due to the design of their cavities. The system is provided with blocks equipped with coupling means with different characteristics suitable for different purposes in the construction of a wall, which include the plinth courses, housing of ducting and reinforcement of the wall. The system also comprises attaching and fastening elements to the plinth surface, as well as longitudinal reinforcements making walls particularly resistant in seismic zones.
Walls are traditionally built with blocks, by aligning them to form rows, called courses, inserting adhesive between one block and the next. The first course called plinth course, requires the placement of a layer of mortar on the plinth surface to bond the blocks to the plinth surface, each block requiring to be leveled and aligned, while assuring the correct thickness of the mortar joint. Courses are stacked one on top of another to the desired height, inserting adhesive between one course and the next one. The blocks used are hexahedral whose sides are comprise rectangular polygons and are called bricks. Some of the blocks used in the construction industry have holes from side to side to reduce their weight. Construction of walls requires each course to be fully aligned and leveled, both horizontally and vertically, so that each consecutive course, resting on the previous one, is aligned and leveled as well, therefore, adhesive or mortar must be applied carefully so that each block is leveled with the previous one. This requires the person building the wall to develop the ability to do it properly so that the wall remains aligned and leveled.
Once the wall is built, a crack is made on one or both sides to make a channel to house the ducting for electrical, water or gas installations, therefore weakening the structure of the wall and increasing the investment on time of skilled labor for its implementation. Next, it is needed to apply a finish to the wall to provide it with an even surface, which is accomplished by spreading a mixture of plaster, for the case of interior walls, or concrete for the case of exterior walls or facades. Achieving this even finish requires as of investment on time of skilled labor well.
There are designs for construction blocks as described in patent application WO 2010124345, which discloses a block for the construction of contention walls which can be assembled with a front panel for aesthetic purposes.
Patent US20100236179 shows a block for construction that serves as a template for the engineering and construction works.
The patent application FR2939817 discloses assembly blocks provided with protective outer coverings to keep uniform spacing between blocks.
Patent application WO 2007080182 shows a pair of blocks for construction that are assembled one on top of another with a rotational movement of their coupling means.
The present invention consists of a wall construction system comprising a set of blocks equipped with coupling means, having some features common to all of these and other features that complement each other, and a wall building method using said blocks equipped with coupling means.
The blocks equipped with coupling means may be made of lightweight concrete or plastic or other man-made material. Preferably, the body of the block equipped with coupling means is made of cast material, extruded material or natural stone. The cast material is selected from the group comprising concrete, clay, mud, adobe, foamed concrete, reconstituted stone or sand, polymers, recycled materials, or a combination thereof.
The first type of block equipped with coupling means is called plinth block (950), which consists of four elements. Two of said elements are rectangular prisms (100), being parallel to each other. Their front faces (101) correspond to the inner and outer sides, respectively, of the wall being built. Said front faces (101) are proportionately greater in area than its top, bottom and sides, which form its upper edge (120), lower edge (121) and side edges (122) respectively. Said rectangular prisms (100) form the inner and outer sides of the wall being built with the blocks equipped with coupling means. For the plinth block (950), said rectangular prisms (100) are separated by two trapezoidal prisms (200) whose cross section is a rectangular trapezoid (201), this being its profile, with the face of said trapezoidal prism (200) corresponding to the angled side (202) of the rectangular trapezoid (201) profile facing downwards. Trapezoidal prisms (200) are arranged opposite to each other on one of their faces, said faces corresponding to the minor base (203) of the rectangular trapezoid (202) profile of each trapezoidal prism (200). Between said faces there is a cavity (204). In the central part of the bottom surface of the plinth block (950), corresponding to the lower faces of the trapezoidal prisms (200), two slopes (205) are formed, at an angle that opens and rises from the ends of the plinth block (950) towards its center, where the cavity (204) is, said slopes (205) not crossing with the top surfaces of the trapezoidal prisms (200). The lowest point of the slopes (205) is elevated relative to the lower edge (121) of the two rectangular prisms (100), so that when placing the plinth block (950) on the plinth surface (800), the lower edge (121) of the two rectangular prisms (100) is laid directly on said plinth surface (800) without any intermediate space but leaving a space between said plinth surface (800) and the surface of the slopes (205). Thereby forming a cavity (300) between the plinth surface and the slopes (205) where the adhesive (301) will be accommodated.
Rectangular trapezoid (201) surfaces corresponding to the profile of the trapezoidal prisms (200) being the central part of the plinth block (950) are attached to the rectangular prisms (100). The upper edge (120) of both trapezoidal prisms (200) is elevated relative to the top surfaces of said trapezoidal prisms (200), which correspond to the perpendicular side of the rectangular trapezoid (201) profile. This forms a channel (302) on the top of the plinth block (950) with a cavity (204) in the center of said plinth block (950). The side surface of the trapezoidal prisms (200), opposite to the cavity (204) is recessed relative to the side edges (122) of both rectangular prisms (100), forming a vertical cavity (303). When placing two adjacent plinth blocks (950), said vertical cavity (303) serves to accommodate adhesive (301) and thereby sticking both plinth blocks (950). All visible surfaces of the trapezoidal prisms (200) have a roughened or textured finish, as they will come into contact with the adhesive (301). The side surfaces of the rectangular prisms (100) corresponding to the walls (304) of the channel (302) have an inclination (305) preferably between 5° and 45°, beginning from the border of the upper edge (120) of each trapezoidal prism (200) and opening towards the center of the plinth block (950).
Placement of the plinth block (950) on the plinth surface (800) is done before applying the adhesive (301). Once the course is placed, the adhesive is poured through the cavities (204) to get them filled and therefore sticking the plinth blocks (950) to the plinth surface (800). The plinth surface (800) may have a plurality of fixings (810) protruding from the plinth surface (800) in order to place plinth blocks (950) on said fixings (810) so that they are inserted into the cavity (204) of the plinth blocks (950), to provide greater strength to the wall, particularly in seismic zones. In one of its embodiments, the plinth block (950) has a groove (130) disposed vertically on one of the side edges (122) of each of the rectangular prisms (100), preferably centrally placed on said side edges (122), while its opposite side edge (122) has a ridge (131) disposed vertically, oriented correspondingly with the orientation of the groove (130) in the former side edge (122), so that by placing a plurality of adjacent plinth blocks (950), the ridges (131) of the rectangular prisms (100) from one plinth block (950) fit in the grooves (130) of the rectangular prisms (100) from the adjacent plinth block (950).
The second type of block equipped with coupling means is called lightened block (951). Said lightened block (951) is similar to the plinth block (950), except for the following differences that characterize said lightened block (951): a) both trapezoidal prisms (200) are joined at the center of lightened block (951) by a bridge (206), removing the cavity (204) from the plinth block (950) forming a channel (302) without a cavity (204) in the center of the lightened block (951), b) each one of the trapezoidal prisms (200) has, on the bottom side and near the ends of the lightened block (951), a base (207) whose lower surface (208) is horizontal and protruding relative to the lower edge (121) of the rectangular prisms (100). The height of the protrusion forming said base (207), is less than the height of the walls (304) of the channel (302) on the top face of all kinds of blocks equipped with coupling means of the present invention, except for the ending block (952), which has no channel (302) whatsoever, c) the slope (205) of the trapezoidal prisms (200) is steeper for the lightened block (951) than for the plinth block (950), starting from the bottom base of the bridge (206) towards the lower edge (121) of the rectangular prisms (100), thereby forming the cavity (300).
The protruding bases (207) allow the lightened block (951) to be placed on a previous course of plinth blocks (950), or on a previous course of lightened blocks (951), or a previous course of a combination of any of the blocks equipped with coupling means except for the ending block (952), while automatically aligning itself with said previous course. Prior to its placement, it is necessary to fill the channel (302) of said previous course with adhesive (301). By placing the lightened block (951), the bases (207) displace the adhesive (301) horizontally on the channel (302), distributing it along the cavity (300).
The side faces of the bases (207) placed adjacent to the channel (302) walls of the blocks equipped with coupling means from a previous course, have an inclination from the lower edge (121) of the rectangular prisms (100) and towards the center, wherein said inclination is equal to the inclination of the walls (304) of the channel (302) allowing the blocks equipped with coupling means from one course to fit in the channel (302) of the blocks equipped with coupling means from the course immediately below.
In another embodiment of the lightened block (951), cavity (300) is not present so that the base (207) is unique and extends longitudinally along the bottom of the block equipped with coupling means, having the block (957) a uniform profile.
A third embodiment of the block equipped with coupling means is called ducting block (953). This block equipped with coupling means is similar to the lightened block (951), except that the base (207) is unique to each ducting block (953) extending from end to end thereof.
In a first embodiment of said ducting block (953), the channel (302) has a longitudinal notch (306), preferably through its center, its cross section being preferably semicircular, crossing through the channel (302) from one end of the ducting block (953) to the opposite end, denominated ducting block (953) with a notch in the channel (302).
In a second embodiment of the ducting block (953), the base (207) has a longitudinal notch (306), preferably in its center, its cross section being preferably semicircular, crossing through the base (207) from one end of the ducting block to the opposite end, denominated ducting block (953) with a notch (306) in the base (207).
In a third embodiment of the ducting block (953), the channel (302) has a longitudinal notch (306), preferably in its center, its cross section being preferably semicircular, crossing through the channel (302) from one end of said ducting block to the opposite end and the base (207) has a longitudinal notch (306), preferably in its center, its cross section being preferably semicircular, crossing through the base (207) from one end of the ducting block to the opposite end, denominated ducting block (953) with notches (306) both in the channel (302) and in the base (207).
Said ducting block (953) in its various embodiments allows inserting pipes between a pair of course, at the time of building the wall, avoiding the process of cracking the wall once it is finished to make room for ducting.
A fourth embodiment of the block equipped with coupling means is the reinforcement block (954) which is similar to the ducting block (953), except that it does not have a notch (306) neither in the channel (302) nor in the base (207), but has a longitudinal perforation (209) instead, crossing through the reinforcement block (954) from side to side through its central portion. This reinforcement block (954) is used to structurally reinforce the wall. By laying one or more courses of reinforcement blocks (954), a post-tension cable or a rebar can be installed to horizontally join the piers (820) or columns.
A fifth embodiment of the block equipped with coupling means is called the quoin block (955), which is similar to any of the blocks equipped with coupling means, since their characteristics are complementary to those of any of the previously described blocks equipped with coupling means, substituting one end section of the block equipped with coupling means for the following features: in said end section, the quoin block (955) has a vertical tunnel (307) crossing the quoin block (955) from top to bottom. The vertical tunnel (307) preferably has an octagonal profile, to provide it with strength and it is surrounded by four walls. Two of these walls are formed by the rectangular prisms (100). A third wall corresponds to the outer wall (210) of the quoin block (955) so that said outer wall (210), together with the side edge (122) of both rectangular prisms (100) correspond to one of the sides of the quoin block (955) altogether. In this embodiment, the side edges (122) of the rectangular prisms (100) have neither a ridge (131) nor a groove (130), so that the outer wall (210) is completely smooth on its outer side to achieve the same apparent finish that the visible faces of the rectangular prisms (100) have. An intermediate wall (211) stands in the way between the vertical tunnel (307) and the rest of the block equipped with coupling means. Thus, the quoin block (955) has neither bottom bases (207) nor upper channels (302) in the section corresponding to said vertical tunnel (307), a section that is bounded by said rectangular prisms (100), said outer wall (210) and said intermediate wall (211). Said quoin block (955) allows to finish the wall's side ends, achieving quoins with an apparent finish, considering its coupling into the piers (820), which pass through the quoin blocks (955) across their vertical tunnel (307).
When the corner block (955) complements with a ducting block (953) with a notch (306) in the channel (302), the intermediate wall (211), in its top surface, has a cutout (308) in the material, which is attached to the notch (306) in the longitudinal channel (302). This allows for the ducting to be placed vertically through the vertical tunnel (307) of the quoin blocks (955) and allows said ducting to have an elbow joint so that the ducting can horizontally enter into the wall, through a course of ducting blocks (953).
When the quoin block (955) complements a plinth block (950), the intermediate wall (211) is separated from the channel (302) by the cavity (204), allowing the adhesive (301) to be poured through it.
A second embodiment of said quoin blocks (955) corresponds to a continuation block (956), the only difference being that the side edges (122) of the rectangular prisms (100), corresponding to its outer wall (210), have notches (130), or in another embodiment, ridges (131). This allows putting a pier (820) or ducting in an intermediate section of the wall being built, while adjacent blocks equipped with coupling means at both sides are able to be coupled to said continuation block (956).
In one embodiment of the continuation block (956), one or both rectangular prisms (100) have an opening (123) preferably rectangular either in the lower edge (121) or in the upper edge (120), at the height of the vertical tunnel (307), crossing through the rectangular prism (100) from its front face (101) to said vertical tunnel (307). This allows to horizontally take a ducting (830) installed through the vertical tunnel (307) out of the wall, by placing a block equipped with coupling means having an opening (123) on the lower edge (121) on a block equipped with coupling means having an opening (123) in the upper edge (120). Said opening (123) may also be present in any block equipped with coupling means having a vertical tunnel (307), as in the ending block (952) or quoin block (955). With these designs of blocks equipped with coupling means, unnecessary volumes present in the building blocks are eliminated, so that their weight is reduced and savings are achieved in their manufacture. The different embodiments of blocks equipped with coupling means correspond to specific needs in the construction of walls: a) plinth, b) ducting installations, c) uniform apparent finish, d) reinforcement, f) ease of construction due to its coupling features.
A sixth embodiment of the block equipped with coupling means is the ending block (952), which consists of the end section of the quoin block (955) containing the vertical tunnel (307). Said ending block (952) has either ridges (131) or grooves (130) in one or more of its sides. This allows for the use of the ending block (952) to finish the endings where two, three or four walls join together, leaving an apparent finish without the need to split quoin blocks (955) in half.
The method of building walls using the blocks equipped with coupling means consists of, first of all, achieving a perfectly leveled plinth surface (800), since the evenness of the courses depends on the leveling of this surface. The plinth surface (800) must have its piers (820) or ribs prepared for the construction of the wall. Likewise, places must be spotted in the plinth surface where vertical ducting (830) for installations is to be arranged. Also, fixings (810) might be secured on the plinth surface to further enhance the wall's strength, particularly in seismic zones. The separation distance between one fixing (810) and another must correspond to twice the distance between the cavity (204) of the plinth block (950) and its side edge (122). Then, quoin blocks (955) for course of plinth blocks (950) are placed, inserting the piers (820) or the ribs through the vertical tunnel (307) of the quoin block (955). Next, a plinth block (950) is placed adjacent to the quoin blocks (955) by coupling the ridges (131) of a block equipped with coupling means into the grooves (130) of the adjacent block equipped with coupling means. After that, a plurality of plinth blocks (950) are placed along the plinth surface (800) so that the fixings (810) fit into the cavities of the plinth blocks (950) and coupling the ridges (131) from one plinth block (950) into the grooves (130) from the adjacent plinth block (950). In places of the plinth course where vertical ducting (830) is to be arranged, a continuation block (956) for plinth course is placed, so that the ducting (830) is inserted into the vertical tunnel (307), and the ridges (131) of the continuation block (956) fit into the grooves of the adjacent plinth block (950) and vice versa.
Once the placement of the plinth course is done, adhesive (301) is poured on the channel (302) of the plinth course and introduced through the cavities (204) and vertical cavities (303) of the plinth blocks (950), and the channel (302) is completely covered by the adhesive (301). Immediately after that, before the adhesive sets, quoin blocks (955) for course are placed in the piers (820), oriented at 90° relative to the quoin blocks (955) of the previous course, alternating its orientation from one course to another to achieve the fabric of the courses. Also, lightened blocks (951) are placed over the channel (302) that has already been filled with adhesive (301), so that the ridges (131) of a block equipped with coupling means fit into the grooves (130) of the adjacent block equipped with coupling means. The bases (207) of the lightened blocks (951) displace the adhesive (301) still unset in the channel (302) to bring it to the surfaces of the cavity (300). Where there are continuation blocks (956) in the plinth course, there is also a continuation block (956) placed in the next course, but turning it by 180° on its vertical tunnel (307). Thus, the vertical tunnel (307) of a continuation block (956) is exactly aligned with the vertical tunnel (307) of the continuation block (956) from the previous course, but the ends of the continuation blocks (956) not containing the vertical tunnels (307) are oriented in opposite directions to achieve the fabric of the courses. Then, several courses are placed on top in the same manner until the desired height is achieved.
At the height of the wall where ducting (830) is to be arranged horizontally, lightened blocks (951) adjacent to a continuation block (956) in a course, are replaced with ducting blocks (953) with a notch (306) in the channel (302), as many as required for the ducting (830) to reach the required distance in the wall. Likewise, quoin blocks (955) and continuation blocks (956) containing the cutout (308) in their intermediate wall (211) are used. At the end of a ducting (830), whether it is arranged horizontally or vertically, a continuation block (956) with opening (123) in its upper edge (120) is placed. After that, ducting (830) is placed and the adhesive (301) is poured in the channel (302), introducing it into the vertical cavities (303).
In the course immediately above, ducting blocks (953) with a notch (306) in the base (207) are placed on the ducting blocks (953) with a notch (306) in the channel (302). Another option is to place ducting blocks (953) with notches (306) both in the channel (302) and in the base (207), to place ducting (830) in two consecutive courses.
Where it is required to build a window or door frame, as many blocks equipped with coupling means as required are replaced with a beam. At the ends of the beam, piers (320) are placed and on top of said piers (320), quoin blocks (955) and ending blocks (952) are alternately placed to build the side posts of the frame. In courses where the piers (320) of the frame end, blocks equipped with coupling means are replaced by a beam (840). In some courses, reinforcement blocks (954) can be placed from one pier (820) to another to install a post-tension cable or rebar to join the two piers (208) for added structural strength to the wall.
Number | Date | Country | Kind |
---|---|---|---|
MX/a/2010/013375 | Dec 2010 | MX | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/MX2011/000057 | 5/13/2011 | WO | 00 | 6/4/2013 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2012/078017 | 6/14/2012 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
2655032 | Zagray | Oct 1953 | A |
3478482 | Weir | Nov 1969 | A |
4124961 | Habegger | Nov 1978 | A |
4314431 | Rabassa | Feb 1982 | A |
4426815 | Brown | Jan 1984 | A |
4485604 | Palamara et al. | Dec 1984 | A |
5191744 | Bowes | Mar 1993 | A |
5485703 | Nordahl | Jan 1996 | A |
5623797 | Gravier et al. | Apr 1997 | A |
6065265 | Stenekes | May 2000 | A |
6082067 | Bott | Jul 2000 | A |
6105330 | Nanayakkara | Aug 2000 | A |
6223493 | Ruggeri | May 2001 | B1 |
6298632 | Sherwood | Oct 2001 | B1 |
7305803 | Correa et al. | Dec 2007 | B2 |
8074419 | Humphress et al. | Dec 2011 | B1 |
20050108972 | Banova | May 2005 | A1 |
20100018150 | Azar | Jan 2010 | A1 |
20100236179 | Kim et al. | Sep 2010 | A1 |
20120102868 | Janssens et al. | May 2012 | A1 |
Number | Date | Country |
---|---|---|
3013520 | Apr 1980 | DE |
3013520 | Oct 1981 | DE |
202007016365 | Jan 2008 | DE |
472250 | Mar 1979 | ES |
263907 | Nov 1982 | ES |
2237890 | Aug 2005 | ES |
1454026 | Jul 1966 | FR |
2939817 | Jun 2010 | FR |
2219315 | Sep 2002 | RU |
2219315 | Dec 2003 | RU |
2004055287 | Jul 2004 | WO |
2007080182 | Jul 2007 | WO |
2010013991 | Feb 2010 | WO |
2010124345 | Nov 2010 | WO |
Entry |
---|
International Search Report for PCT/MX2011/000057, English translation attached to original, Both completed by the Spanish Patent Office on Oct. 19, 2011, All together 11 Pages. |
Number | Date | Country | |
---|---|---|---|
20140007529 A1 | Jan 2014 | US |