AU2010201627A1

AU2010201627A1 - Construction block

Info

Publication number: AU2010201627A1
Application number: AU2010201627A
Authority: AU
Inventors: Nicolo Baldi; Antonio Mucci
Original assignee: NUBUILD PRODUCTS Pty Ltd
Current assignee: Casafico Pty Ltd
Priority date: 2009-04-30
Filing date: 2010-04-22
Publication date: 2010-11-18
Anticipated expiration: 2030-04-22
Also published as: AU2010201627B2

Description

P/00/01 1 Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Construction block The following statement is a full description of this invention, including the best method of performing it known to us: 2 Construction block Field of the invention The present invention relates to a construction block and it's manufacture. The construction block being such that it is adapted for interlocking engagement with a 5 further like block. The invention is suitable for use in the construction of walls in buildings. It will be appreciated that the term block refers to any suitable dimensions, including those with generally panel like dimensions, a block usually having one or more flat, or approximately flat, faces. Background of the invention 10 Interlocking blocks of the general kind contemplated here are known in various forms and generally have some form of projection on the top surface, and a complimentary recess in the bottom surface. When in use the projection of one block engages the recess of the block immediately adjacent and interlocks therewith. In the construction industry several problems arise with known interlocking blocks. 15 Firstly, since the blocks are moulded from concrete or clay products, they are brittle and therefore susceptible to damage during handling. Consequently, end projections or protrusions often suffer damage whereby the blocks become unusable or lose some of the strength of the connection due to part of the projection being broken off. Also, because of their proportions, the shape of known interlocking blocks is not uniform and 20 thus the ability to stack some blocks for transportation and storage purposes is considerably reduced compared to conventional rectangular blocks. Furthermore, the shape of the interconnecting parts of conventional blocks in many cases does not provide a firm interconnection enabling the blocks to be used satisfactorily without bonding material. 25 In situations where high fire rating of a brick is required, it is desirable to use an interlocking type block because the bonding material between the more conventional bricks provides a weak point in so far as fire rating is concerned. The abutting surfaces of interlocking blocks provide a much higher fire rating. It is however important with the 3 interlocking blocks that a strong interconnection exists between the blocks so as to provide structural strength to a wall or other structure and not all known interlocking blocks satisfy this requirement. One attempt to address the above-mentioned problems in relation to conventional 5 construction blocks of the interlocking kind is described in International Patent Application No. WO 92/04513. This document describes a construction block in the form of a rectangular block which has uniformly spaced cylindrical apertures or recesses in the top and bottom surfaces thereof. Solid cylindrical locators are provided for insertion into the apertures to fit snugly therein and provide projections for accommodation in a 0 similar manner in the apertures of an adjoining block when two such blocks are laid in closely abutting relationship. The interlocking of the blocks in this manner provides a strong joint without the requirement for conventional mortar joints between the blocks. However, it has been found that such construction blocks, whilst representing a marked improvement over known constructional blocks, nevertheless have a number of 15 deficiencies. Firstly, whilst the strength of a wall made from such constructional blocks is often adequate, it is sometimes necessary to improve the strength of the joints between the joining blocks. To this end, adhesive may be poured onto the ends of a block and into the block recesses prior to the locator being placed therein and an adjacent block being 20 laid on top of the first block. Such a process however, is very time consuming and consequently increases the manufacturing cost of a wall using such constructional blocks. Moreover, the overall strength of a wall made using such constructional blocks is largely dependent upon the material from which the blocks are constructed. For walls required 25 to bear substantial loads, the blocks are generally substantially made from concrete and other heavy material. The considerable weight of such blocks reduces the ease with which they may be handled and adds to the time required to construct walls using such blocks.

4 One attempt to address the above-mentioned problems in relation to the strength of a wall made from such constructional blocks is described in Australian patent 737866. This document describes a constructional block in the form described above, with a cylindrical hole extending vertically there through for communicating with the holes in 5 superposed blocks. When the blocks are stacked in various layers to form the desired construction, a continuous vertical passage is formed extending from an opening in the upper surface of the top most block in the construction to an opening in the under surface of the bottom most block in the construction. Mortar, concrete or other strengthening material is able to be poured into the opening in the upper surface of the 10 top most block and down through the continuous passage formed through each underlying blocks, enhancing the overall strength of the construction. This enables the step of firstly forming an adhesive barrier along all joints of adjoining blocks to be eliminated. While the above-mentioned constructions provide an improvement over known 15 constructional blocks, there is a requirement to optimise the stability and/or strength of the construction when forming large walls. There is also a need to optimise the ease and simplicity of forming large wall constructions. Accordingly, there exists a need to provide an improved construction block that meets the practical and strength requirements of large wall areas. 20 Reference to any prior art in the specification is not, and should not be taken as, an acknowledgment or any form of suggestion that this prior art forms part of the common general knowledge in Australia or any other jurisdiction or that this prior art could reasonably be expected to be ascertained, understood and regarded as relevant by a person skilled in the art.

5 Summary of the invention According to a first aspect, the present invention provides a construction block, including: a polystyrene core dimensioned to have two side faces, an upper surface, an 5 under surface and first and second end surfaces; an outer coating of cementitious material on at least the two side faces; structural elements extending along at least the upper surface and under surface; wherein a plurality of passages extend, in both a first direction and a second direction substantially perpendicular to the first direction, through the construction 0 block to form continuous passages for receiving locators and strengthening elements. According to a second aspect, the present invention provides a construction block, including: an upper surface and an under surface for abutment respectively with the under 5 surface and the upper surface of a like construction block; a first end surface and a second end surface for abutment respectively with the first end surface and the second end surface of a like construction block; a plurality of passages extending in a first direction between a first opening in the upper surface and a second opening in the under surface; 20 a plurality of passages extending in a second direction substantially perpendicular to the first direction between a first opening in the first end surface and a second opening in the second end surface; 6 wherein superposed construction blocks form continuous passages extending in the first and second directions for receiving locators and strengthening elements therethrough in both the first and second directions. The construction block is typically around 2400mm long, but may be up to 6000mm 5 long. The height is typically 600mm and the thickness typically 100mm. The outer coating of cementitious material is preferably applied to both sides of the polystyrene core by laying the core on one side in a mould and applying the coating. Once the coating is dry the core is flipped and a coating is applied to the other side. The coating is typically 12mm thick on both sides. The cementitious coating is preferably a o cement mix formulated from recyclable waste material. A cementitioius coating may be applied to the ends of the core instead of structural elements. The structural elements are preferably galvanised steel channels, with the required holes punched out to line up with corresponding passages cut in the core to create the continuous passages. The steel channels preferably extend along the first and second 5 end surfaces of the core in addition to the upper and lower surfaces. The steel channels are preferably 0.55mm thick, 76mm wide with a 30mm fold extending along either side of the channel. The steel channels may be glued to the polystyrene core. The passages are created through the core, the structural elements and, if applicable, the cementitious material. The passages are preferably 55mm in diameter and are 20 ideally spaced at 100mm centres, although it will be appreciated that these dimensions can vary. The strengthening elements are preferably steel rods. The diameter of the steel rods is preferably less than 27.5mm to allow rods to run in both the first and second directions. The strengthening elements may also be plastic pipes, or a combination of the two. 25 Pipes running in the first direction may include apertures through which rods running in the second direction may project. According to a third aspect, the present invention provides a construction, including: 7 a plurality of construction blocks stacked in layers, the construction blocks having an upper surface and an under surface abutting respectively with the under surface and the upper surface of a like construction block; a first end surface and a second end surface abutting respectively with the first end surface and the 5 second end surface of a like construction block; a plurality of continuous passages extending in a first direction between a first opening in the upper surface of the uppermost construction block and a second opening in the under surface lowermost construction block; a plurality of passages extending in a second direction substantially perpendicular to the first direction between a first 0 opening in the first end surface of a construction block at the first furthermost edge and a second opening in the second end surface of a construction block of the second furthermost edge to form continuous passages extending in the second direction; a plurality of locators inserted into the opening of the upper surface of a first of 5 the plurality of construction blocks and into the opening of the under surface of a second of the plurality of construction blocks; and a plurality of strengthening elements extending through selected passages, in at least the second direction, of abutting construction blocks in the layers to strengthen the construction. 20 The construction may also include a plurality of strengthening elements running through selected passages in the first direction to strengthen the construction. Additional locators may be provided in abutting passages extending in the second direction. According to a fourth aspect, the present invention provides a method of forming a 25 constructions from a plurality of construction blocks according to the first or second aspect, the method including the steps of: 8 positioning one or more first construction blocks on a floor surface to form an initial layer of construction blocks whereby adjacent construction blocks form continuous passages extending in the second direction; inserting one or more locators into openings of the upper surface of the first construction 5 blocks in the initial layer; stacking one or more second construction blocks on top of the first construction blocks so that the locators engage in an opening in the under surface of the second construction blocks to thereby form a continuous passage extending through the first and second construction blocks; 10 repeating steps b) and c) until a construction is formed having a continuous passage extending from an opening in the upper surface of each upper most construction block to an opening in the under surface of each lower most construction block; inserting at least one rod through a continuous passage extending in the second direction formed between adjacent construction blocks to strengthen the construction. [5 Additional strengthening rods may be inserted through the continuous passages extending in the first direction to create a framework or cage. Preferably, the first direction is substantially vertical and the second direction is substantially horizontal. Brief description of the drawings / figures 20 The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a construction block according to the present invention; Figure 2 is an exploded view of the construction block of Figure 1; 9 Figures 3a-3d are respective top views of the polystyrene core, the structural element, the cementitious material and the construction block according to another embodiment of the invention; Figure 4 is a top, side and end view of a polystyrene core; and 5 Figure 5 is a perspective view of a construction according to an aspect of the invention. Detailed description of the embodiments A construction block 10 is shown in Figures 1, 2 and 3d and is formed from a polystyrene core 12, of generally rectangular shape, dimensioned to have two side faces 14, an upper surface 16, an under surface 18 and first and second end surfaces 0 20, 22. In the embodiment illustrated, the core 12 is 2398mm in length, but may be up to 6000mm. The height is 598mm and the thickness is 76mm. Structural elements, in the form of steel channels 26, are positioned to run along the upper surface 16 and the under surface 18. The steel channels 26 have a fold 28 extending along either side, such that when placed on the upper or under surfaces, the 5 folded sections 30 wrap around the side faces 14 reinforcing the corners. The steel channels are usually around 0.55mm thick, 76mm wide with a 30mm folded section. The steel channels 26 are glued to the core 12 using appropriate adhesive. The end faces 20, 22 also have steel channels 27, as shown in Figure 2. However it will be appreciated that the ends faces 20, 22 may be covered by a cementitious coating 20 25, as shown in Figures 3a-3d. The coating may be created in the same manner as the outer coatings on side faces 14, described below, or may be pre-cast sheets, which are then glued to the core 12. The side faces 14 have an outer coating 24 of cementitious material, which would typically be formulated to use recyclable waste material. The core 12 is laid in a mould 25 and the first side is coated with the cementitious material to create a 12mm thick solid sheet. Once the first side is dry, the core 12 is flipped and a 12mm thick coating is applied to the other face 14. The cementitious material is of the appropriate properties 10 for building requirements, such that the constructions blocks 10 could be directly painted, or additional wall decoration or structures can be applied or fixed thereto. The advantage of a construction block of this form is its weight. Large panels, up to 6000mm in length can be easily transported and manually handled, without the need for 5 large and costly cranes, which are typically utilised for similar sized construction elements. As can be seen from the Figures, the construction block 10 includes a plurality of spaced openings 50, 52, typically having 55mm diameters and spaced at 100mm centres. First and second openings 50a, 50b are respectively spaced along the upper 0 surface 16 and under surface 18, extending between them are passages 54 in a first direction, being illustrated as vertical. Additional first and second openings 52a, 52b are respectively spaced along the first end surface 20 and the second end surface 22, with passages 56 extending between them in a second direction substantially perpendicular to the first direction, being illustrated as horiontal. 5 As can be seen in Figure 4, the passages 54, 56 are created in the polystyrene core 12 using a wire cutter to slice from the side of the core. Alternatively, the passages could be drilled through the core 12. The openings 50a, 50b, 52a, 52b in the steel channel 26 are punched out prior to gluing to the core 12 and align with the passages 54, 56 when assembled. 20 As can be seen in Figure 5, a construction 60 can be formed from a plurality of construction blocks 10 stacked in layers. A first, or initial, row 62 of constructions blocks 10 are positioned on the floor surface. Locators (not shown) are inserted in selected openings 50a in the upper surface 16 of the first row 62 of blocks 10. A second row 64 is positioned on top of the first row 62, with the openings 50b in the under surface 18 25 slotting over the locators located in the openings 50a. Additional layers are positioned to create the construction required. Adjacent construction blocks create continuous passages 70 extending in the second direction, or horizontally, the passages 70 extending from the first opening 52a in the 11 first end surface 20 of a construction block 10a at the first furthermost edge and a second opening 52b in the second end surface 22 of a construction block 10b of the second furthermost edge. Similarly, abutting construction blocks create continuous passages 72 extending in the first direction, or vertically, and extend from the first 5 opening 50a in the uppermost construction block 10c to the second opening 50b in the lowermost construction block 10d. Strengthening elements, typically in the form of steel rods 80, 82 are inserted through the continuous horizontal and vertical passages 70, 72. The diameter of the steel rods are preferably less than half of the diameter of the passages, allowing rods to run both 0 vertically and horizontally. The ability to reinforce the construction in both directions allows the creation of a cage after it has been erected. This keeps the blocks light weight during erection of the construction, but creates a reinforced structure after erection. The truss or framework created by the strengthening elements locks the blocks together and assists in flexural and compressive strength of the construction. In 5 selected passages, tubular pipes may be inserted to provide strengthening whilst also allowing cables etc to pass through the wall. A combination of pipes and rods may be used. The ability to insert both vertical and horizontal strengthening elements provides improved stability to the construction and also to the individual construction blocks, 20 particularly in terms of flexural and compressive strength. It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention. 25

Claims

1. A construction block, including: a polystyrene core dimensioned to have two side faces, an upper surface, an under surface and first and second end surfaces; 5 an outer coating of cementitious material on at least the two side faces; structural elements extending along at least the upper surface and under surface; wherein a plurality of passages extend, in both a first direction and a second direction substantially perpendicular to the first direction, through the construction block to form continuous passages for receiving locators and strengthening elements. 10

2. A construction block, including: an upper surface and an under surface for abutment respectively with the under surface and the upper surface of a like construction block; a first end surface and a second end surface for abutment respectively with the first end surface and the second end surface of a like construction block; 15 a plurality of passages extending in a first direction between a first opening in the upper surface and a second opening in the under surface; a plurality of passages extending in a second direction substantially perpendicular to the first direction between a first opening in the first end surface and a second opening in the second end surface; 20 wherein superposed construction blocks form continuous passages extending in the first and second directions for receiving locators and strengthening elements therethrough in both the first and second directions. 13

3. A construction block according to claim 1 or 2, wherein the length of the block is greater than 2400mm long.

4. A construction block according to claim 1, wherein the structural elements are steel channels, with the required holes punched out to line up with corresponding 5 passages cut in the core to create the passages.

5. A construction block according to claim 4, wherein the steel channels are glued to the polystyrene core.

6. A construction block according to any one of claims 1, 4 or 5, wherein the passages are created through the core, the structural elements and, if applicable, the 10 cementitious material.

7. A construction block according to any one of the preceding claims, wherein the strengthening elements are steel rods.

8. A construction block according to claim 7, wherein the diameter of the steel rods is dimensioned to allow rods to run in both the first and second directions. 15

9. A construction, including: a plurality of construction blocks stacked in layers, the construction blocks having an upper surface and an under surface abutting respectively with the under surface and the upper surface of a like construction block; a first end surface and a second end surface abutting respectively with the first end surface and the second end surface of a 20 like construction block; a plurality of continuous passages extending in a first direction between a first opening in the upper surface of the uppermost construction block and a second opening in the under surface lowermost construction block; a plurality of passages extending in a second direction substantially perpendicular to the first direction between a first opening in the first end surface of a construction block at the 25 first furthermost edge and a second opening in the second end surface of a construction block of the second furthermost edge to form continuous passages extending in the second direction; 14 a plurality of locators inserted into the opening of the upper surface of a first of the plurality of construction blocks and into the opening of the under surface of a second of the plurality of construction blocks; and a plurality of strengthening elements extending through selected passages, in at 5 least the second direction, of abutting construction blocks in the layers to strengthen the construction.

10. A construction according to claim 9, wherein the construction also includes a plurality of strengthening elements running through selected passages in the first direction to strengthen the construction. 10

11. A construction according to claim 9 or 10, wherein additional locators are provided in abutting passages extending in the second direction.

12. A method of forming a construction from a plurality of construction blocks according to any one of claims 1 to 8, the method including the steps of: a) positioning one or more first construction blocks on a floor surface to form 15 an initial layer of construction blocks whereby adjacent construction blocks form continuous passages extending in the second direction; b) inserting one or more locators into openings of the upper surface of the first construction blocks in the initial layer; c) stacking one or more second construction blocks on top of the first 20 construction blocks so that the locators engage in an opening in the under surface of the second construction blocks to thereby form a continuous passage extending through the first and second construction blocks; d) repeating steps b) and c) until a construction is formed having a continuous passage extending from an opening in the upper surface of each upper most 25 construction block to an opening in the under surface of each lower most construction block; 15 e) inserting at least one rod through a continuous passage extending in the second direction formed between adjacent construction blocks to strengthen the construction.

13. A method according to claim 12, wherein additional strengthening rods are 5 inserted through the continuous passages extending in the first direction.