AU2017100986A4 - Concrete / masonry hollow core clean out block cavity plug - Google Patents

Abstract

Pg 2. Abstract A Block Plug is a device used to plug the wash out hole in a masonry wash out or clean out block so as to allow concrete core filling of a Bessa or other similarly designed hollow core brick or block wall without excess concrete leakage through the washout holes. It works by sealing the internal face of the block cavity exit, with a plate larger than the cavity exit hole. It is pulled into shape and held in position with tension provided by a tension clip. Innovation back ground. Within the commercial and domestic construction industry there is a specially made concrete block that is used to construct heavy load bearing walls. It is a large block with two large cavities side by side creating a rectangular figure 8 shape. (See diagram 1) They are ideal for creating curved walls where tilt panel walls aren't possible. They provide excellent strength as they can be re-enforced with steel rod through the cavities and filled with liquid concrete forming an essentially solid re-enforced concrete mass. With the use of concrete block construction in the commercial and domestic building industry it is often necessary to use a specially formed block for the bottom corse of each section of wall if it is going to be core filled with liquid concrete. This is commonly referred to as a Wash out or Clean out block. (See diagram 2) This block is essentially the same shape with the exception of two sections on one side of the block being removed (or not formed) exposing the cavities and creating an enclosed "E" shape. These openings are to allow the cavities of the wall to be cleaned out of any cement waste that can fall into the cavity during construction. This must be removed as it can cause obstructions, air pockets and other complications during the liquid concrete pouring phase of construction. This can cause potential structural weaknesses to the wall in the end. Pg 3. They are laid by the bricklaying trade as a normal brick would be laid with an overlapping 50% bond so as the two holes in the block align with one hole of each of the blocks in both the corse above and below it. It is then necessary to block these holes prior to the liquid concrete phase. Currently the most common way to do this is to have carpenters or the Brick layers try to secure wooden form work boards to the external face of the wall. This is done by drilling holes into the concrete slab on an angle away from the wall. These holes then have reinforcing bar placed in them. The hole is then covered by a small form board and then wedged in place with another piece of timber against the bars. (see diagram 3). This method of sealing the holes creates un-necessary cost to the builder through the purchase of form boards and hi visibility caps to cover the exposed sharp ends of the bars protruding from the ground, which in itself is an un-necessary safety hazard on the building site. It is excessively time consuming to drill and wedge the boards in this way. It also has destructive consequences to the buildings slab due to the drilling for the bars. Problems can also occur with the unreliability of this method. If the wedge fails under the pressure created by the weight of the wet concrete behind the board, This causes the contents of the cavity to be released onto the jobsite causing waste, time delays and mess. Small leaks past the board mean mess also. Clean up, additional costs and a less than perfect finish if the wall is a feature brick wall. Another problem with this method is if the wall is very high then it must be poured in stages. This means that Clean out blocks must be used at each interval. As the wall gets higher the more awkward sealing the wash out blocks becomes as there is no slab to drill into for the bracing bars. This invention the (BLOCK PLUG) is designed to be cheap, fast to install in any situation, reliable performance, reduce waste, wages and material costs, and provide a superior seal on the inside face of the cavity. Allowing a neat patch piece to be cemented into the block face, post pour to give a superior finish to a feature wall. p 'Ni 2 V.- - -. ~ -NA JC~' 4: V t --. ~-~-w iN - - - ~<~~3 N - ~.- - - o ~ q - -- --- 'S LI) I *-j 9); _ ---Ely-tx

Description

2017100986 20 Μ 2017

Pg 4.

Description

The Block plug is a device constructed of two components. (See diagram 3) 1. The main body of the plug is the flexible seal plate. (See component 1, diagram 3).

This plate is made from sheet steel 0.6mm to 1.2mm in thickness, but could conceivably be made from plastic, wood or another metal. It is wider by 5mm to 10mm than the block hole it is designed to plug. But could conceivably be any width that will still allow manoeuvring into the cavity, and the same height as the cavity hole. Conceivably it could be manufactured taller and be trimmed to correct height, to allow for variance in the brick and mortar placement. It has four locator lugs attached, formed or molded, one in each corner. These perform the function of ensuring the seal plate is positioned correctly in the cavity and ensure that the minimum purchase is achieved at the contact points between the seal plate and the inside surface of the cavity wall either side of the hole. (See diagram 4).

Another feature of the seal plate is the tension clip holder. This part has the function of providing a point at which a pulling force can be applied to the seal plate by the tension clip when installed.

It is attached in the centre of the plate to provide equal distribution of tension over the whole plate. Conceivably there could be more than one of these rings positioned on the plate for use with more than one tension clip if greater tension distribution is required.

It is made from a steel ring attached to, formed with or molded into to the face of the seal plate facing the outside of the brick. Conceivably this does not have to be ring shaped, but could be square triangular or any other shape. It is large enough to allow the passage of the tension clip though its centre but not large enough to protrude past the external face of the wall when the block plug is installed in the cavity.

This is so the tension clip is forced to bend when passed from the brick face on one side of the cavity opening, through the tension clip holder and then out onto the brick face on the opposing side of the cavity opening. This forced bending of the tension clip is what provides the tension required to hold the seal plate firmly in position during the concrete pouring process. 2017100986 20 Μ 2017

Pg 5. 2. The second component is the tension clip, it is made from mild or sprung steel. This could also conceivably be made of plastic or another metal in a sheet or wire configuration and made in any shape so long as it performs the task of holding the seal plate in position and under tension. It could conceivably be supplied separately or as an already attached part of an assembled version.

It is supplied with each block plug and has the function of providing the tension required to hold the seal plate in position once located in the cavity. (See component 2, diagram 3)

Claims (2)

1. Claims

   1. A device made of steel, plastic, wood or any other metal, designed to seal the hole in a concrete/Bessa wash out or clean out block using a square or rectangular plate, positioned on the inside of the block cavity and pulled back against the inside cavity wall and spanning the wash out hole, creating the seal. Held in position by one or more locating lugs, either welded or molded to, or formed with the seal plate and a spring tensioned clip or retainer system that uses the external face of the block outside the clean out hole as a point of bracing and leverage for tension on the seal plate.
2. 2. A device made of steel, plastic, wood or any other metal, designed to seal the hole in a concrete/Bessa wash out or clean out block using a square or rectangular plate, positioned on the inside of the block cavity and pulled back against the inside cavity wall and spanning the wash out hole, creating the seal. Held in position by one or more locating lugs, either welded or molded to, or formed with the seal plate and a mechanical retainer system that uses the external face of the block outside the clean out hole as a point of bracing and leverage for tension on the seal plate.