AU2007283441A1

AU2007283441A1 - Insulating building block

Info

Publication number: AU2007283441A1
Application number: AU2007283441A
Authority: AU
Inventors: George Ryder
Original assignee: Global Ryder Holdings Pty Ltd
Current assignee: Global Ryder Holdings Pty Ltd
Priority date: 2006-08-10
Filing date: 2007-07-30
Publication date: 2008-02-14
Also published as: WO2008017105A1

Description

WO 2008/017105 PCT/AU2007/001058 Insulating Building Block Technical Field 5 The invention concerns building blocks for the construction of concrete walls. In particular the invention concerns building blocks for the construction of concrete walls that also provide insulation. Aspects of the invention include a building block, a wall comprised of these building blocks and a method of constructing a wall using these building blocks. 10 Background Art Known hollow building blocks are used to construct reinforced concrete walls. In general these blocks are laid using stagger bond to ensure good connection and to provide sheer strength between blocks. 15 An example of such a known block is shown in Fig. 1(a). The building block 200 is comprised of two side panels 202 and 204 spaced apart by two bridging parts 206 and 208. A pairs of protruding formations 210 and 207 are provided on opposite inner faces of the side panels 202 and 204 to enable a plurality of these building blocks 200 20 to be interconnected with location devices. The first pair 210 is provided at the open ends of the block 200 and the second pair is provided in the middle of the block 200. A suitable plastic location device 250 is shown in Fig. 1(b) and is comprised of two parallel members 252 and 254 spaced apart by cross members 256 and 258. The two members 252 and 254 extend beyond the cross members 256 and 258 to engage with 25 formations 210 and 207of blocks 200. The location device 250 can also support reinforcement rods that rest on the members 252 and 254 at between or adjacent to the vertical tapering projections 260. This arrangement of blocks 200 and location devices 250 is shown in Fig. 1(c) where 30 three blocks 200 are to be laid in two courses 262 and 264 in stagger bond formation. The location device 250 engages the upper ends of the formations 210 of the blocks 200 in the lower course. The dashed lines 226 show how the block 200 of the top course 264 will be aligned when laid in place. The dashed line 268 shows how the location device 250 will receive the lower ends of the formations 207 of the block 20 35 from the top course 264. In this way, the location device 250 interconnects the blocks 200 and holds a lateral reinforcement rod (not shown) in place within the first course WO 2008/017105 PCT/AU2007/001058 2 262. When these blocks 200 are laid in wall, as required vertical steel rods can be placed into the hollow cavities of the wall and then concrete is poured to fill the cavities within the blocks 200. We incorporate here by reference, the detailed description of the block 200 and the location device 250, and how they can be used to 5 construct a wall, as set out in the specification and drawings of the PCT application PCT/AU03/00057 (Publication number WO 03/062549). We note there is some variation in the design of the block 200 however the method of constructing a wall is essentially the same. 10 Constructing energy efficient buildings is increasingly becoming a priority. A wall made using block 200 and poured concrete does not provide good insulation properties. A number of blocks are available that attempt to provide insulation to a wall. These blocks often allow insulation material to be placed within the blocks. For example, US patent No. 4,380,887 is made with special slots that allow foam insulation panels to be 15 inserted into the slots. Another example is US patent No. 5,983,585 where each building unit is comprised of two panels held together by a plastic web. The webs defines two halves of the block where the first half is filled with poured concrete and the second half is filled with poured insulation, such as foam concrete. 20 Summary of the Invention The invention concerns a building block for the construction of walls, the block having a rectangular body comprised of two side walls spaced apart by two end walls and a dividing wall, the end and dividing walls are parallel and span the side walls to define a first and second cavity vertically extending within the block, wherein first parallel 25 grooves are formed in the inner face of at least one side wall or end wall of the first cavity to enable at least part of the wall between the first grooves to be removed so that when the block is in position in a wall the first cavity can be filled with poured concrete that can flow through the removed part of the wall between the first grooves and to a first adjacent block and the second cavity can be filled with insulating material. 30 It is an advantage of the invention that the flow of the concrete from the first cavity of the block to the first adjacent building block provides shear strength to the wall, and this flow of concrete can be controlled by the removal of part of a wall of the block. In a separate cavity of the same block insulation can be placed that is substantially 35 prevented from mixing with the poured concrete by the dividing wall. This allows the wall built using these blocks to be designed to include concrete where structure is WO 2008/017105 PCT/AU2007/001058 3 required and otherwise insulation. This results in both a strong and energy efficient wall without the need for extensive formwork since the block itself provides the formwork for the concrete flow. 5 More specifically, the block may be used for the construction of a structural column in the wall and the concrete poured into the first cavity also forms part of the column. The block may comprise multiple first parallel grooves. 10 Second parallel grooves may be formed in the inner face of at least one side wall or end wall of the second cavity to enable at least part of the wall between the second grooves to be removed so that when the block is in position in the wall, the second cavity can be filled with poured insulating material that can flow through the removed part of the wall between the second groves to a second adjacent block. 15 The block may further comprise a pattern of formations on an upper surface of the block and vertically aligned complementary pattern of recesses on a lower surface of the block. These formations and recesses aid the positioning of the blocks on top of each other in either stagger bond, or perpendicularly. 20 Two slits may also be formed on the dividing wall to enable at least part of the bridging wall between the slits to be removed. Once part of a wall is removed, parts of the side or end wall of the block adjacent to the 25 removed part may provide formations that can be used to interconnect the block to the adjacent block using a location device. The invention further provides a wall having at least one structural column that is comprised of the block as described above. 30 The column may constructed from courses of the block, wherein at least one block of a first course and one block of the second course are laid in stagger bond. Further, the layout of every second course of the blocks of the column may be identical and in vertical alignment. At least one cavity of each block that comprises the column is in 35 vertical alignment with cavities of other blocks that comprise the column. When concrete is poured into the first cavity of the block it also flows vertically to vertically WO 2008/017105 PCT/AU2007/001058 4 aligned cavities of other blocks to create a substantially unitary vertical concrete structure within the blocks. The first adjacent building block may have a rectangular body comprised of two side 5 walls spaced apart by two end walls and a dividing wall, the end and the dividing walls are parallel and span the side walls to define a third and fourth cavity vertically extending within the first adjacent block, wherein third parallel grooves are formed in the inner face of at least one side wall or end wall of the third cavity to enable at least part of the wall between the third grooves to be removed so that when the first adjacent 10 building block is in position in the wall the third cavity can be filled with poured concrete that can flow through the removed part of the wall between the third grooves and into the first cavity of the block. The column may also be comprised of multiple first adjacent building blocks. 15 The fourth cavity of the first adjacent building block may be filled with concrete. Two slits or grooves are provided in the dividing wall of the first adjacent building block to enable at least part of the wall between the slits or grooves to be removed so 20 that when the first adjacent building block is in position in the wall and the third cavity is filled with concrete, the poured concrete can flow between the two slits or grooves of the dividing wall and into the fourth cavity. Alternatively, the fourth cavity of the first adjacent building block may be filled with 25 insulating material. Fourth parallel grooves may be formed in the inner face of at least one side wall or end wall of the fourth cavity to enable at least part of the wall between the fourth grooves to be removed so that when the first adjacent building block is in position in the wall the fourth cavity can be filled with poured insulating material that can flow through the removed part of the wall between the fourth grooves and into a 30 third adjacent building block. The second and or third adjacent block may form part of a linear segment of the wall. Substantially all of the building blocks of the linear segment of the wall may be insulated building blocks that are laid in stagger bond. In this way, the blocks that 35 comprise the column are connected with the linear segment of the wall as the blocks that comprise the column will also form part of the linear segment of the wall. This WO 2008/017105 PCT/AU2007/001058 5 integrates the linear segment of the wall with the column and provides the resulting wall with increased shear strength. Since this entire structure is built by simply laying a combination of blocks and without 5 the need for extensive formwork, the wall can be built using relatively unskilled labour which saves costs. The second and third adjacent building blocks may be the building block described in the published PCT application PCT/AU03/00057 (WO 03/062549). The insulation 10 may flow through an open end of the block shown in Fig. 9 of WO 03/062549 (or as reproduced in Fig. 1(a) of this specification). The plan of the course of blocks that comprise a column may be symmetrical, that is, the combined shape of the blocks that comprise the column may be square or 15 rectangular. In this way, a column having any symmetrical plan for a cross section of the column can be constructed using the blocks of the invention. In a further aspect the concerns a method for constructing a wall described above, wherein the method comprises the steps of: 20 (a) selecting a block for laying in a course of the wall, wherein if the block is a block according to claim 1 removing part of the wall between the first grooves as appropriate; (b) laying the block in a course of the wall; (c) repeating steps (a) and (b) until the course is laid; 25 (d) placing location devices and reinforcement rods into the course as appropriate; (e) pouring the concrete and insulation into the course as appropriate; and (f) repeating steps (a) to (e) until the desired number of courses is laid. 30 Brief Description of the Drawings Examples of the present invention will now be described with reference to the accompanying drawings, in which: Fig. 1(a) shows a perspective view of a known concrete building block; Fig. 1(b) shows a perspective view of a known plastic location device; 35 Fig. 1(c) shows a perspective view of a wall comprised of three blocks of Fig. 1(a) laid in two stagger bond courses and using a location device of Fig. 1(b); WO 2008/017105 PCT/AU2007/001058 6 Fig. 2 shows a perspective view of a concrete building block of the present invention; Fig. 3 shows a plan view of the block of Fig. 2; Fig. 4 shows a perspective view of the concrete building block of Fig. 2 where 5 two parts of the walls are removed; Figs. 5(a) shows a plan view of a first course of a wall constructed using the blocks of Fig. 1(a) and Fig. 2; Figs. 5(b) shows a simplified plan view of a second course of the wall of Fig. 5(a) using the blocks of Fig. 1(a) and Fig. 2; 10 Fig. 6(a) is an enlarged view of part of the wall of Fig. 5(a); Fig. 6(b) is an enlarged view of part of the wall of Fig. 5(b); and Fig. 7 is a side view of a wall constructed with twelve courses and constructed according to the course plans similar to those shown in Figs. 5(a) and 5(b). 15 Best Modes of the Invention Figs. 2 and 3 shows a first building 20 block for use in constructing walls that form part of a building. The block 20 is formed from a concrete mixture using a mould. It has a rectangular 20 shaped body comprised of two parallel side walls 22 and 24 spaced apart by end walls 26 and 28 and a dividing wall 30. The inner surface 26a of the end wall 26, together with an inner surface 30a of the dividing wall 30 and part of the inner surface 22a and 24a of the side walls 22 and 24 25 define a first vertical cavity 34 extending the height of the block 20. Similarly on the other side of the block 20, the inner surface 28a of the end wall 28, together with an inner surface 30b of the dividing wall 30 and part of inner surfaces 22b and 24b of the side walls 22 and 24 define a second vertical extending cavity 38. The inner sides of the side walls 22 and 24 and end walls 26 and 28 are tapered slightly so that the 30 openings to the cavities 34 and 38 are larger on the upper end than at the lower end of the block 20. The edge of the inner walls is shown in Fig. 3 by the dashed line 98. This tapering helps release the block 20 from the mould. Pairs parallel grooves 40a and 40b are formed on the each inner surface 22a, 22b, 24a, 35 24b, 26a and 28a of each of the sides 22 and 24 and end walls 26 and 28. These grooves 40a and 40b extend from the upper surface 44 of the block 20 approximately WO 2008/017105 PCT/AU2007/001058 7 the top third of the vertical height of the block 20. Since the grooves 40a and 40b provide a structural weakness in the walls, each pair of grooves 40a and 40b enable the part of the wall between the grooves 40a and 40b to be knocked out when force is applied to the that part of the wall. This makes a total number of six parts of the side 5 and end walls that can be removed. These six parts of the wall are numbered 51 to 56 on Figs. 2 and 3. The dividing wall 30 is formed with two slits 48 at the ends of the dividing wall 30 adjacent the side walls 22 and 24. The slits 48 extend from the upper surface 44 of the 10 block 20 approximately the top third of the vertical height of the block 20. Since the slits 48 provide a structural weakness in the dividing wall 30, the part 58 of the dividing wall 30 between the slits 48 can be knocked out when force is applied to that part 58 of the dividing wall 30. 15 If the parts of the wall 53, 58 and 56 are all knocked out, a lateral reinforcement rod can be positioned within and along the length of the block 20. If parts 55 and 51 are knocked out then a lateral reinforcement rod can be positioned within the block that extends through the removed parts 55 and 51. Similarly if parts 54 and 52 are removed, a lateral reinforcement rod can extend through those removed parts 54 and 20 52. The block 20 can be laid in a wall in stagger bond. To aid the alignment of the blocks 20, the upper surface 44 of each block 20 is provided with a pattern of protrusions. The side walls 22 and 24 each have two protrusions 60 that extend between a pair of groves 25 40a and 40b. A further similarly sized protrusion 62 is formed on each side wall 22 and 24 equally spaced between the pair of protrusions 60 on the same side wall. Each end of the side walls 22 and 24 also comprises a smaller formation 64 that is about half the size of protrusions 60 and 62. The end walls 26 and 28 each have a protrusion that extend between a pair of groves 40a and 40b. In this way the pattern of protrusions on 30 each side wall 22 and 24 are substantially the same and the pattern of protrusions on the end walls 26 and 28 are identical. For every protrusion 60, 62, 64 and 66 a complementary recess (not shown) is formed on the lower surface 68 of the building block 20 in vertical alignment with the 35 corresponding protrusion on the upper surface 44. This means that when the blocks 20 are placed on each other, in say stagger bond, the recesses of a block above WO 2008/017105 PCT/AU2007/001058 8 complement a protrusion. For example, the recess corresponding to protrusion 64 on side wall 22 near the end wall 28 would receive part of the protrusion 62 on the side wall 22. The recess directly below protrusion 60 of the side wall 22 near the end wall 26 would receive protrusion 60 on the side wall 22 near the end wall 28 of the block 20 5 directly beneath. In this way the protrusions and recesses help aid the alignment of blocks when laying a wall of blocks 20. Fig. 4 shows block 20 with part 53 of the end wall 26 removed. The rest of the upper part of the end wall 26 remains to provide formations 90. These formation 90 are 10 shaped, sized and spaced apart similarly to the upper part of a pair of formations 210 of the block 200. When part 53 is removed, this allows the end wall 26 of block 20 and either end of block 200 to be interconnected using a location device 250 to form a straight wall. The location device 250 is able to engage with an opposing pair of formations 210 of the block 200 and the opposing pair of formations 90. Similar 15 formations 90 (not shown) are formed on the end wall 28 if part 56 is removed to enable that end of the block 20 to be interconnected with a block 200 using a location device 250. Fig. 4 also shows part 55 of the side walls 24 removed. The side wall 24 on either side 20 of the removed part 55 remains to provide formations 92. These are also shaped, sized and spaced apart similarly to the upper part of a pair of formations 210 of the block 200. When part 55 is removed, this allows the side wall 24 of the block 20 and either end of block 200 to be interconnected using a location device 250 to create a corner in a wall. The location device 250 is able to engage with an opposing pair of formations 25 210 of the block 200 and the opposing pair of formations 92. Similar opposing pairs of formations 92 (not shown) are created when parts of the wall 51, 52 or 54 are removed to enable other or further interconnections to be made using a location device 250. Further, formations 90 or 92 can be used to interconnect two or more blocks 20 using a 30 location device 250 that engages with two opposing pairs of formations from two blocks 20 to form a straight line or corner. This is particularly useful when forming a column structure from the blocks 20. Possible combinations are pairs of formations 90 from both blocks 20, pairs of formations 92 from both blocks 20, and a pair of formations 90 from a first block 20 and a pair of formations 92 from a second block 20. 35 The different type of interconnections are better shown in Fig. 6(a) and (b) and will be discussed further below.

WO 2008/017105 PCT/AU2007/001058 9 A method of constructing a wall will now be described with reference to Figs. 5(a) and (b). Please note that these diagrams simply show the plan of the wall and do not show detail such as removed parts of walls of the blocks 20. This wall will have a 5 combination of insulation and concrete poured filling. The design of the wall, including the selection, arrangement and modification of the blocks (i.e. knocking our parts of the walls of the block) is predetermined to meet the desired insulation and strength combination in the wall. 10 First, the job site is laid out and positions for the blocks, doors and windows are marked and profiles installed in each corner for accurate height. Then a first course of blocks is laid as shown in Fig. 5(a) to form a wall having three linear segments 70, 72 and 74. Wall 70 is comprised of the concrete blocks 200 as 15 shown in Fig. 1 and concrete blocks 20. Referring first to wall 70, a block 20 is selected to begin the line. For ease of reference this block will be referred to as 20a. This block 20a will be used to form a first column filled with concrete to provide strength to the wall. Depending on the shape of the 20 column, parts of the side 22 and 24 and end 26 and 28 walls will be knocked out between the grooves 40a and 40b to allow the poured concrete to flow through the removed part into the adjacent block or within the block. In this case, part 55 of the side wall 24 is knocked out before laying. The part 55 can be removed by applying force to either the inner surface or the outer surface of this part 55 of the wall 24, with 25 say a hammer. This block 20a is then laid according to the positions laid out. Next, three blocks 200 are laid adjacent to block 20a and end to end to form a straight wall without the use of mortar. Between each pair of blocks 200 a gap is left to allow for tolerance. This part of the wall comprised of blocks 200 will be filled with 30 insulation. Parts of walls 206 and 208 can be removed from these blocks 200 as required to encourage the flow of insulation material within these blocks 200 or blocks 200 can be fabricated with these parts already removed. Then, a block 20 is selected for placement at the end of this line (for ease of reference 35 this block will be referred to as 20b) that will form part of a second column. In this case part 53 of the end wall 26 is removed. Also the part 54 of the side wall 24 is WO 2008/017105 PCT/AU2007/001058 10 removed. These removed portions 53 and 54 will allow the concrete mixture to flow through the removed parts to or from two adjacent blocks. Also it allows lateral reinforcement rods to be placed in the block. By not removing part 58 of the dividing wall 30 we can substantially separate the concrete that will be placed in the cavity 34 5 from mixing with the insulation that will be placed in cavity 38 of the block. Part 56 of the end wall 28 is also removed to allow insulation placed into the cavity 38 to flow to the adjacent block 200. This block 20b is then laid end to end at the end of the line. This is better shown in the enlarged view of Fig. 6(a). 10 A further block 20 is selected for placement at the end of the line (for ease of reference this block will be referred to as 20c). Before laying this block 20c, the part 56 of the end wall 28 is knocked out. Also, the part 55 of the side wall 24 is removed. The non removal of part 58 serves to separate the poured concrete and insulation that will both be poured into this block 20c. Further, part 53 of the end wall 26 is also removed to 15 allow insulation placed in the cavity 34 of block 20c to flow to a block 200 adjacent to this end. This block 20c is then laid end to end at the end of line 70. Next, four blocks 200 are laid adjacent to block 20c and end to end to form the straight wall 70 without the use of mortar. Between each pair of blocks 200 a gap is left to 20 allow for tolerance. Again, parts of walls 206 and 208 can be removed if appropriate. This part of the wall comprised of blocks 200 will be filled with insulation. The wall 70 ends in a third structural column that will be made out of blocks 20 and then filled with concrete. Accordingly, a further block 20 (referred to as 20d) is 25 selected and in this case part 54 of the side wall 24 is removed. This block is then laid in line at the end of the wall 70. Side of the wall 72 is laid perpendicular to the wall 70. A block 20 is selected (referred to as block 20e) and part 56 of the end wall 28 is removed. Block 20e is then laid 30 perpendicular with block 20a with the end wall 28 of block 20e adjacent block 20a. Wall 72 is then continued with one further blocks 200. Similarly, side 74 of the wall is also laid. First with block 20f having part 56 of the end wall 28 removed, then one further blocks 200. 35 WO 2008/017105 PCT/AU2007/001058 11 Next, further blocks 20 are selected to complete the second column. Block 20 is selected (referred to here as 20g) and part 53 of the end wall 26, part 58 of the bridging wall 30 and parts 54 and 55 of the side 24 wall are removed. The block 20g is laid perpendicularly to block 20b with the side wall 24 of block 20g aligned with the end 5 wall 26 of block 20b. Parallel to block 20g, block 20h is laid. Block 20h has removed parts 53, 51, 52 and 58. The block 20h is laid perpendicularly to block 20c with the side wall 22 of block 20h aligned with the end wall 28 of block 20c. This completes the first course of blocks. The first course is laid to a line forming a 10 bed joint to bring the blocks to accurate alignment and length. Next location devices 250 are inserted (as required) so as to interconnect any two blocks, being the two blocks 20 and 20, 20 and 200, or 200 and 200. The placement of the location devices is shown best in Fig. 6(a). For example, location device 250a engages with formations 210 of block 200 and formations 90 of block 20c. 15 Further lateral reinforcement rods may be installed along the lengths of the wall 70, 72 and 74 as required (not shown) and may rest on the location devices 250. Vertical reinforcement rods 80 and lateral reinforcement rods 82 are also positioned with the second column as shown in Fig. 6(a). As required, lateral or vertical reinforcement 20 rods may be position with the first and third column (not shown). Then the second course as shown in Fig. 5(b) is laid similarly to the first course (Fig. 5(a)) but in a stagger bond. 25 A block 20 is selected for placement at the end of the line 70 (for ease of reference this block will be referred to as 20j) to form part of the first column. Before laying this block 20j, the part 58 of the dividing wall 30 is knocked out to allow concrete to flow between cavities 34 and 38 of block 20j. This block 20j is then laid perpendicular to line 70 and parallel with line 72. In this way the cavity 34 is aligned with the cavity 38 30 of the block 20a underneath so that the poured concrete can flow between courses to form the first column. Next, four blocks 200 are laid adjacent to block 20j end to end to form a straight wall 70. Again this part of the wall comprised of blocks 200 will be filled with insulation 35 and the parts of walls 206 and 208 are removed if appropriate to allow for lateral reinforcement rods.

WO 2008/017105 PCT/AU2007/001058 12 Then, a block 20 is selected for placement at the end of this line (for ease of reference this block will be referred to as 20k) that will form part of a second column. In this case part of the parts 53, 54, 55, 56 and 58 are removed. These removed portions will 5 allow the concrete mixture to flow through the block and to other blocks that comprise the second column and the placement of a lateral reinforcement rod within this course of the second column. This block 20k is then laid end to end at the end of the line 70 already laid. This is better shown in the enlarged view of Fig. 6(b). In this way, the cavity 38 of block 20k is vertically aligned with the cavity 34 of block 20b of the first 10 course. Also cavity 34 of block 20k is vertically aligned with the cavity 38 of the block 20c underneath. This will allow the poured concrete to flow between courses to form the second column. Next, five blocks 200 are laid adjacent to block 20k and end to end to form a straight 15 wall 70 without the use of mortar. Again, this part of the wall comprised of blocks 200 will be filled with insulation. A further block 20 (referred to as 201) is selected to form part of the third column. Similarly to block 20j, part 58 is removed and block 201 is placed perpendicular to wall 20 70 and parallel with wall 74. In this way the cavity 34 of block 201 is aligned with the cavity 34 of the block 20d underneath so that the poured concrete can flow between courses to form the third column. Side 74 of the wall is also laid with two further blocks 200 laid end to end with block 25 201. Next, further blocks 20 are selected to complete the second course of the second column. Block 20 is selected (referred to here as 20m) and parts 51, 52, 54, 55 and 58 are removed. The block 20m is laid parallel to block 20k. Parallel to block 20m, block 30 20n is laid. Block 20n has parts 51, 52 and 58 also removed. By this arrangement the cavity 34 of block 20g is vertically aligned with the cavity 34 of block 20m. Also cavity 34 of block 20h is vertically aligned with the cavity 34 of block 20m. For block 20n, cavity 38 is aligned with cavity 38 of block 20g and cavity 34 is aligned with cavity 38 of block 20h. By way of this alignment, when the concrete is poured it can 35 flow between courses to form the second column.

WO 2008/017105 PCT/AU2007/001058 13 This completes the second course of blocks. Next, location devices 250 are inserted (as required) at the interconnection between any two blocks, being the two blocks 20 and 20, 20 and 200, or 200 and 200. The placement of the location devices is shown best in Fig. 6(b). For example, location device 250b engages with formations 90 of block 20k 5 and formations 210 of the adjacent block 200. Further, location device 250c engages with formations 92 of block 20m and a similar opposing formation of block 20n formed when part of wall 51 of block 20n is removed. Further lateral reinforcement rods (not shown) may be installed along the lengths of the 10 wall 70, 72 and 74 within the second course as required. Vertical reinforcement rods 80 and lateral reinforcement rods 82 are also positioned with the second column as shown in Fig. 6(b). This method is repeated to create further courses. The course in Fig. 5(a) is repeated 15 for odd numbered courses and the course shown in Fig. 5(b) is repeated for all even numbered courses until the desired number of courses is reached. For every say three courses that are laid, concrete and insulation is poured into the wall. A side view of the wall 70 is shown in Fig. 7 where halves of blocks 20 that are marked 20 with an "X" correspond to cavities 34 and 38 that are filled with concrete to form columns. All cavities of blocks 20g, 20h, 20m and 20n are also filled with concrete. The remaining halves of blocks that are not marked with an "X" are filled with insulation. For the final course 90, all the blocks 20 are filled with concrete. Please note that this side view shows more blocks 200 laid between columns than shown in 25 Figs. 5 and 6. Firstly a concrete mixture is poured into primarily the blocks 20 to form the three columns. The vertical alignment of the cavities 34 and 38 of blocks 20 allows the concrete to flow down as it is poured. The removal of parts of the walls of blocks 20 30 that comprise the columns allows the concrete to flow laterally. In some cases concrete may flow from a block 20 to a block 200, such as between block 20k and the adjacent blocks 200 due to the removal of parts 53 and 56. The result is a group of blocks 20 are interconnected to using concrete as well as reinforcement rods to make a sound structural support for the wall. Since the concrete is able to flow, a substantially 35 unitary concrete structure is formed within the blocks 20.

WO 2008/017105 PCT/AU2007/001058 14 Then the lines of blocks 200 are filed with poured insulation concrete. Again the insulation is allowed to flow vertically and between open ends of adjacent blocks. The insulation is also able to flow into the cavities of blocks 20 that form part of a column that are not otherwise filled with concrete. This helps to ensure that there are no 5 insulations gaps in the wall and helps maximise the amount of insulation used. This structure means that the wall is filled with both cement to meet structural requirements and insulation to meet energy requirements. The insulation is prevented from substantially mixing in with the concrete. Also, the walls are tied into the 10 columns as parts of some blocks 20 that form the columns also extend into the wall and are interconnected with blocks 200. It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments 15 without departing from the spirit or scope of the invention as broadly described. For example, any column shape could be made from any combination of blocks 20. The slits on the dividing wall could easily be formed as grooves. 20 Further, layout of the concrete and insulation could easily be changed to meet specific requirements. Also, the order of steps of the method of constructing the wall can be re-ordered as 25 appropriate or suitable for the particular building. The blocks may be preformed with parts of the wall 51 to 56 already removed. For example, a proportion of the blocks provided to a building site may require the same combination of parts of the walls to be removed, such as parts 53 and 54. In this case, 30 this proportion of blocks can be provided with parts of walls 53 and 54 not formed in the moulding process. This helps to reduce the weight of these blocks for shipping and avoids wasting the concrete material used to form these parts. Grooves 40a and 40b are provided on the remaining inner sides of the side and end walls and can be removed onsite as appropriate. 35 WO 2008/017105 PCT/AU2007/001058 15 The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

1. A building block for the construction of walls, the block having a rectangular body comprised of two side walls spaced apart by two end walls and a dividing wall, the side and dividing walls are parallel and span the side walls to define a first and second cavity vertically extending within the block, wherein first parallel grooves are 5 formed in the inner face of at least one side wall or end wall of the first cavity to enable at least part of the wall between the first grooves to be removed so that when the block is in position in a wall the first cavity can be filled with poured concrete that can flow through the removed part of the wall between the first grooves and to a first adjacent block and the second cavity can be filled with insulating material. 10

2. A block according to claim 1, wherein the block comprises further first parallel grooves formed on the inner face of side or end walls of the first cavity.

3. A block according to claim 1 or 2, wherein second parallel grooves are formed 15 in the inner face of at least one side wall or end wall of the second cavity to enable at least part of the wall between the second grooves to be removed so that when the block is in position in the wall, the second cavity can be filled with poured insulating material that can flow through the removed part of the wall between the second groves to a second adjacent block. 20

4. A block according to any one of claims 1, 2 or 3, wherein the block further comprises a pattern of formations on an upper surface of the block and vertically aligned complementary pattern of recesses on a lower surface of the block. 25

5. A block according to any one of the preceding claims, wherein two slits are formed on the dividing wall to enable at least part of the bridging wall between the slits to be removed.

6. A block according to any one of the preceding claims, wherein once part of a 30 wall is removed, parts of the side or end wall adjacent to the removed part can be engage with formations of a location device to interconnect the block to the adjacent block.

7. A wall having at least one structural column that is comprised of at least one 35 block according to any one of claims 1 to 6. WO 2008/017105 PCT/AU2007/001058 17

8. A wall according to claim 7, wherein the column is constructed from courses of the block, wherein at least one block of a first course and one block of the second course are laid in stagger bond. 5

9. A wall according to claims 7 or 8, wherein at least one cavity of each block that comprises the column is in vertical alignment with cavities of other blocks that comprise the column.

10 10. A wall according to claim 9, wherein when concrete is poured into the first cavity of the block it also flows vertically to vertically aligned cavities of other blocks to create a substantially unitary vertical concrete structure within the blocks.

11. A wall according to any one of claims 7 to 10, wherein the first adjacent 15 building block may have a rectangular body comprised of two side walls spaced apart by two end walls and a dividing wall, the end and dividing walls are parallel and span the side walls to define a third and fourth cavity vertically extending within the first adjacent block, wherein third parallel grooves are formed in the inner face of at least one side wall or end wall of the third cavity to enable at least part of the wall between 20 the third grooves to be removed so that when the first adjacent building block is in position in the wall the third cavity can be filled with poured concrete that can flow through the removed part of the wall between the third grooves and into the first cavity of the block. 25

12. A wall according to claim 11, wherein the column is further comprised of multiple first adjacent building blocks.

13. A wall according to claim 11 or 12, wherein the fourth cavity of the first adjacent building block is filled with concrete. 30

14. A wall according to claim 11, 12, or 13, wherein two slits or grooves are provided in the dividing wall of the first adjacent building block to enable at least part of the wall between the slits or grooves to be removed so that when the first adjacent building block is in position in the wall and the third cavity is filled with concrete, the 35 poured concrete can flow between the two slits or grooves of the dividing wall and into the fourth cavity. WO 2008/017105 PCT/AU2007/001058 18

15. A wall according to claim 11 or 12, wherein the fourth cavity of the first adjacent building block is filled with insulating material. 5

16. A wall according to claim 15, wherein fourth parallel grooves are formed in the inner face of at least one side wall or end wall of the fourth cavity to enable at least part of the wall between the fourth grooves to be removed so that when the first adjacent building block is in position in the wall the fourth cavity can be filled with poured insulating material that can flow through the removed part of the wall between the 10 fourth grooves and into a third adjacent building block.

17. A wall according to any one of claims 7 to 16 but limited by claim 3, wherein the second adjacent block forms part of a linear segment of the wall. 15

18. A wall according to any one of claims 7 to 17 but limited by claim 16, wherein the third adjacent building block forms part of a linear segment of the wall.

19. A wall according to any one of claim 7 to 18, wherein parts of the wall not part of a column are insulated building blocks that are laid in stagger bond. 20

20. A wall according to any one of claims 7 to 19 but limited by claim 3, wherein the second adjacent building blocks is a building block described in the published PCT application PCT/AU03/00057 (WO 03/062549). 25

21. A wall according to any one of claims 7 to 20 but limited by claim 16, wherein the third adjacent building blocks is a building block described in the published PCT application PCT/AU03/00057 (WO 03/062549).

22. A wall according to any one of claims 7 to 21, wherein the plan of the course of 30 blocks that comprise a column is symmetrical so that the combined shape of the blocks that comprise the column may be square or rectangular.

23. A method for constructing a wall according to any one of claims 7 to 23, wherein the method comprises the steps of: WO 2008/017105 PCT/AU2007/001058 19 (a) selecting a block for laying in a course of the wall, wherein if the block is a block according to claim 1 removing part of the wall between the first grooves as appropriate; (b) laying the block in a course of the wall; 5 (c) repeating steps (a) and (b) until the course is substantially laid; (d) placing location devices and reinforcement rods into the course as appropriate; (e) pouring the concrete and insulation into the course as appropriate; and (f) repeating steps (a) to (e) until the desired number of courses is laid. 10