AU692868B2 - Improved wall forming method - Google Patents

Description

P/:00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICAT ION FOR A STANDARD PATENT 0* a.

9e*W C

ORIGINAL

TO BE COMPLETED BY APPLICANT a a S. S b-S.

Name of Applicant: INTERLOCK INTERNATIONAL PTY. LTD.

Actual Inventor(s): Address for Service: Invention title: JOHN R.G. GARDNER PO BOX 443 MUDGEERABA QLD 4213 IMPROVED WALL FORMING METHOD Details of Associated Provisional Applications No: PM 6676 The following statement is a full description of this invention, includ-_g the best method of performing it know to me:- This invention relates to an improved method for constructing walls from constructional blocks particularly masonry blocks and buildings containing such walls constructed therewith.

There have been proposed many different forms of masonry blocks for use in building constructions and these are generally manufactured with a peripheral wall with apertures passing therethrough. The blocks, when built into a wall, are generally laid staggered, that is with the blocks in alternate rows being displaced half a block width from those in the adjacent row and normally are provided with mortar joints.

Such blocks have advantages of lightness in weight and cost relative to bricks but, particularly where 15 skilled tradesman are not readily available, can be difficult to handle and work satisfactorily. Additionally, in staggered block constructions, a level foundation is required for supporting the blocks to ensure correct alignment between the blocks. Furthermore, the blocks are 20 required to be manufactured to stringent tolerances .otherwise staggering of the blocks becomes difficult.

An object of the present invention is to provide a method for manufacturing walls from blocks of masonry or similar materials which minimise the difficulties previously met and which, in particular, enabling walls to be erected from blocks by persons who are unskilled or semi-skilled. A further object of the invention is to provide a wall manufactured using the method of the invention.

The pesn invention thus prv±di ±n a fisLt preferred aspect a method for manufacturing wa -s from masonry blocks, said blocks having at leas at one end, an aperture passing therethrough, said erture opening to the exterior of said block, said hod including the steps of arranging said block in a substantially end to end abutting relat' nhip with a further said block ski that said a ures are adjacent and oppose each other, II _1 i lFconnecting said blocks by a plug or dowel adapted to The present invention thus provides in a first preferred aspect A method of manufacturing walls from blocks, the blocks having opposed ends with apertures formed in the ends and extending to opposed sides of the block, the method including forming adjacent courses of said blocks by arranging the blocks end to end and stacking blocks on top of one another so that an upper most said block in one course overlies only one lower most block in an adjacent course, interconnecting a pair of adjacent said blocks in one course with a pair of adjacent said blocks in an adjacent course by connecting members extending partway only through the apertures in the adjacent pairs of blocks whereby the apertures in adjacent courses are in vertical alignment.

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extend through said opening sp and having poti ns reqjJ-- i in the respective said apertures so old said blocks in a required posit a ive to each other and stacking furt Ig blocks in alignment one abhov the nthpr.

It is preferred that the block has more than one such formed aperture either in the end opposite that described or, alternatively, in a side face so that two blocks can be abutted and held at right angles.

It is preferred that the plug or dowel is of a length sufficient to be received in a pair of adjacent end to end blocks to hold the blocks in end alignment and additionally to extend upwardly from those blocks so as to be receivable in an upper adjacent block or blocks to hold the blocks in a stacked relationship and restrain adjacent 15 courses. A plug or dowel having a length equal to the height of a block is satisfactory to achieve the above result.

In addition to the dowels or plugs holding the block,' in vertical alignment and end to end alignment, the 20 dowels or plugs also hold the blocks in a correct r" horizontal attitude. For this purpose, the dowels or plugs are shaped for a firm fit within the respectiv- apertures.

0* In addition, the axis of the apertures is substantially normal to the longitudinal axis of the block and substantially parallel to the ends of the blocks.

Whilst the ends and faces of the blocks are generally square, the bottom and top surfaces are rarely square to their sides. The plugs or dowels when received in the respective apertures of adjacent upper and lower blocks hold the blocks perpendicular to its sides and horizontally thus eliminating the tendency of the blocks to sit unevenly on each other.

It is also preferred that there be other apertures through the block adapted for alignment with the apertures in blocks above and below and that constructions be made without mortar joints. On completion, some or all of the aligned apertures passing through the various blocks may filled to form columns or they may be left as a dry 4 wall.

Also, if required, re-enforcing rods may pass through some of the aligned apertures to provide additional strength to the wall or to tie top plates or roof supports to the wall. The apertures passing through the wall containing the reinforcing rods may be filled with concrete to form an upright column. A bond beam about the upper edge of the wall may be supported by the columns by for example being integrally formed with the columns.

The apertures in the blocks in one form have walls which diverge Inwardly from the opening and the plugs or dowels have correspondingly divergent walls so as to mate with the aperture walls. In one particilarly preferred arrangement the apertures at least at opposite 15 ends of the block are of dovetail form in section.

"In a further form, the apertures in each end of the block are circular in cross section and extend from one o: side of the block to the other. Openings or slots extend from the apertures to the adjacent end of the block to 20 align in use with a similar opening in an adjacent block.

In this form, the plugs or dowels are of "dumbbell" form in cross section having cylindrical end portions extending substantially parallel to each other and having an external ooe diameter substantially the same as or slightly less than the internal diameter of the openings so as to be firmly receivable therein. The cylindrical end portions are joined through a radially extending wed which is receivable in the respective slots of the blocks. The distance between the cylindrical end portions is substantially the same as the distance between the openings of end to end abutting blocks.

The apertures may, of course, be of many different configurations and preferably of configurations in which the openings through the blocks either at the end or side faces thereof pass into or communicate with enlarged aperture regions passing through the blocks. In such configurations the plugs or dowels may have a complimentary configuration so as to mate with the apertures.

The plugs or dowels may be formed of any suitable material such as concrete or a concrete-like material, metal, wood or plastics, such as a plastics moulding or extrusion.

In a further aspect, the present invention provides a wall formed using the method of the invention.

In yet a further form the invention provides a block for use in forming a wall according to the present invention.

In order that the invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings which illustrate a preferred embodiment of the invention and wherein:- S. Fig. 1 is a perspective view showing two blocks 15 located end to end and showing a plug which can be S.*c associated with the blocks exploded therefrom; Fig. 2 is a plan view of the blocks of Fig. 1 showing the plug position; Fig. 3 is the view of the corner of two walls of 20 a building showing the first course of blocks located; Fig. 4 is a view similar to that to Fig. 3 but showing additional courses; V00' Fig. 5 is a partially broken view showing the arrangement at the top of the walls of the previous figures; Fig. 6 illustrates a portion of a wall constructed using blocks according to a further embodiment of the invention; and Fig. 7 is a plan view of a wall section formed of the blocks shown in Fig. 6.

The blocks 10 of Fig. 1 and 2 can be considered to be relatively conventional masonry blocks of a conventional size and in this embodiment of generally rectangular form. The material of the block, however, may be provided with a reinforcing material, such as fibre glass or other reinforcing.

In plan, each block 10 has, in common with conventional blocks apertures 12 passing therethrough so that the blocks 10 are of somewhat hollow form. The blocks however, differ from more conventional blocks in that, at each end there are relieved portions or recesses 11 which open at 13 to the exterior of the block 10 and are shaped to increase in width inwardly of the opening 13 by virtue of the side walls 14 of the portions or recesses 11 diverging inwardly from the opening 13. The portions 11 or recesses are thus of somewhat dovetail form.

When two of the blocks 10 are abutted end to end, as shown in Figs. 1 2, the two relieved portions or recesses 11 open into each other and they combine to form an aperture 15 which passes through the height of the blocks 10 and which is shaped effectively in the form of a opair of abutting dovetail o: 15 To hold the blocks 10 in this relationship, a shaped plug or dowel 20 is provided, the plug or dowel preferably having a length effectively equal to the height of the blocks 10 and having a cross-sectional shape which is complementary to at least a portion of the aperture 20 formed when two blocks 10 are abutted. The plug or dowel 20 may be inserted into the aperture 15 to connect the blocks 10 in end to end relationship and in alignment longitudinally.

The plug or dowel 20 as shown has side walls 16 which diverge outwardly from a minimum at 17 centrally of the plug or dowel 20 and at a corresponding divergence to the side walls 14 of the portions or recesses 11 so as to allow mating therewith. In the embodiment illustrated however, the walls 16 are shorter than the walls 14 and the opposite ends 18 of the plug or dowel 20 are of rounded form so that the plug 20 is somewhat smaller than the aperture 15. The plug or dowel 20, however, will still serve to hold the blocks 10 in end to end relationship and in addition hold blocks 10 in adjacent courses in a vertical relationship. The plugs or dowels 20 also ensure through mating with the apertures 15 in the blocks 10 that the blocks 10 maintain a substantially horizontal attitude even though upper and lower adjacent surfaces of the blocks may be uneven. It should be appreciated, however, that the plugs or dowels 20 may be made fully complementary to the apertures 15 to be of double dovetail form as shown in Fig. 3. Because of the opposite dovetail shape of the aperture 15, once the plug or dowel 20 is located, the two blocks 10 are restrained against longitudinal or lateral movement relative to each other. This can particularly easily be seen from examination of Fig. 2. The plugs or dowels 20 may be formed at the same time as formation of the blocks 10 being moulded from the material which forms the through apertures 12 in the blocks 10 as shown. This minimises wastage of material. The plugs of dowels however may be made of plastics or other materials.

~The present invention also provides a second form of block, which is illustrated as 30 in Fig. 3 and this "C "block 30 is similar to the blocks 10 of Figs. 1 and 2, but includes a divergent opening 31 which passes through a side 11 .e Cwall 32 of the block 30 to communicate w.th the aperture 12. If a block 10 is abutted agai: he side wall 32, a s. 20 plug 20 can be located in the recess iI and opening 31 to hold the two blocks 10 and 30 together at right angles.

The nature of this opening 31 is more clearly shown in *n* e dotted outlines in Fig. 2 where it will be apparent that the divergence of the side walls of the opening 31 is substantially the same as the divergence of the side walls 16 of the plug 20 so that the opening 31 can matingly receive the plug The recesses 11 and plug 20 can be of many different forms. For example the recesses may be of T-shaped form in cross-section to receive a plug of Ishaped form with opposite ends thereof receivable in the Tshaped sections of the recesses 11. Alternatively, the plugs or dowels 20 may be of dumbbell shape, that is have enlarged generally circular heads at each end joined by a connecting bar and the recesses 11 formed with a corresponding shape, that is with the opening 13 leading into a through aperture or recess of substantially circular shape in cross-section so as to matingly receive the _Ls 8 dumbbell shaped plug 20. It will be appreciated of course that the recesses 11 and corresponding plugs or dowels may be made in other shapes which will ensure interlocking of the blocks in the manner described.

In the construction of a wall, the first course of blocks 10 and 30 as for example shown in Fig. 3 can be bedded onto a poured slab or can be located in or on the ground surface. The alternative is given because the blocks of the present invention are particularly suitable for use by unskilled labour in third world countries where a floor may not be formed. An uneven foundation does not, because of the stack bonding method employed, present particular difficulties in wall construction.

Starter bars 40 may be provided standing upwardly 15 from the ground which bars 40 are adapted to pass through the apertures 12 in the blocks 10 and When the first course is being layed the shaped aperture 15 formed by the abutting ends of the blocks and 30 can be partially filled with sand or concrete so that a plug 20 located therein will extend outwardly or upwardly therefrom as shown, for example at 33.

The plug 20 may extend approximately half its length or a different proportion above the lower block but as will be understood from further description if the plug 20 has a length substantially equal to the height of the block 10 or 30, then the plugs or dowels 20 in adjacent rows will extend effectively the same distance.

Fig. 3 also shows the stacked blocks 10 of part of a second course and where these terminate, show the way in which adjacent plugs or dowels 20 terminate.

Fig. 4 shows a further step in the formation of a building using the blocks 10 and 30 of the invention and in particular shows part of a door frame 40 and a window frame As can be seen the door frame 40 may be provided with galvanised brackets 41 which extend into the open end 42 of the adjacent blocks 10. A number of these brackets 41 can be provided along the length of the door frame Similarly the window frame 45 can be provided with similar brackets 46. Fig. 4 also shows a reinforcing rod 50 which can be passed down the wall through the apertures 12 in the blocks 10 after the wall has been built to height.

When this has been done then a concrete slurry can be passed down the recesses 11 and provided the recesses 11 are filled with concrete the brackets 41, and those 46, will be encased with concrete and will ensure that the door frame 40 and the window frame 45 respectively are positively located relative to the blocks 10 or Also concrete can be passed into the apertures 12 and surround the rods 50 so that the complete building has good structural stability as there is a resistance to any transverse movement because of the blocks 20 and the concrete which fills the apertures, together with the re-enforcing rods 50, gives the walls strength in compression and, to a degree in sheer although this will not be so important because of the interlocking nature of 20 the blocks 10 and It will be seen that provided the first course is satisfactorily layed, the remainder of the building can be built by unskilled workers as the blocks 10 and 30 are rse simply stacked and the plugs or dowels 20 are located therein and final strength may be obtained by pouring o: .concrete into the apertures. Thus, there is no necessity for the worker to be able to handle mortar courses which are difficult to lay as in order to maintain the correct level the courses all have to be of the same width through the building.

Fig. 5 shows the upper portion of the building shown in the earlier figures and in this case the rods are shown as extending upwardly and through a top plate 51, to which they can be connected and, if required, through roof rafters. Any gaps between the tops of the blocks and top plate 51 can be filled with mortar if desired.

Alternatively the timber top plate may be checked out to compensate for any variations in the height of the blocks at the top of the wall.

The rods 50 can, if required be formed on their lower end to co-operate with the starter bars 40 as previously referred to, although this is not essential once the components are placed together and r set in concrete.

As stated above, certain aligned apertures through the courses of blocks when the blocks are layed to the required height, may be filled with concrete and a reinforcing rod or rods or other reinforcing means. This will form vertical concrete columns in the wall which will serve to support a concrete bond beam w ich may be located above the top perimeter of the wall along the top course of blocks. The bond beam may also have reinforcing means such as reinforcing rods for support and may be formed at the 15 same time as the columns. The beam and columns may thus be integrally formed. Where support structures are located along the perimeter beam, the support structures are located above the coiumns which provide the necessary support. The concrete beam along with the concrete columns 20 forms a series of arches around the perimeter of the structure which adds to strength and stability. Any gaps which are left between the blocks may be simply filled with sand and cement whilst the constructed wall may be finished with any suitable surface finish such as by bagging.

Referring now to Figs. 6, there is illustrated a section of a wall 60 formed using a further form of block 61 according to the invention. The block 61 is generally rectangular and may have a hollow central core 62 and openings 63 at each end defined by apertures 64 of substantially circular cross section and extending through the block 61 from one side to the other and arranged along the longitudinal centre line of the block 61. Slots extend from each aperture 64 along the centre line to open to the adjacent end 66 of the block 61.

Plugs or dowels 67 preferably formed of plastics material are adapted for engagement with the openings 63.

The plugs or dowels 67 have opposite end cylindrical portions 68 joined by a radially extending web 69. The cylindrical portions 68 are of a diameter for neat receipt in the apurtures 64 whilst the web 69 is receivable in the slot The plugs of dowels 67 serve to hold the blocks 61 in one course in end to end alignment and in addition hold blocks 61 in adjacent courses in vertical alignment in the manner described previously. Of course, the blocks 61 may also be solid rather than hollow as described.

Fig. 7 illustrates the manner in which the blocks 61 may be modified to allow for joining of dividing, or intersecting walls or right angled walls 70. In this instance, similar openings 63 as used adjacent the ends 66 may be provided to open through the a side wall of the o block 61. Blocks 61 may then be arranged in side to end 15 relationship and joined by the plugs or dowels 67.

0* In the description relating to the drawings we have referred only to two forms of block, those used for 1 the main body of the wall and those used to enable two walls to abut at right angles.

20 These are all that are necessary to produce satisfactory building although we could, if required, provide further forms if necessary to permit, say, three or four walls to abut.

Modifications can also be made into the size and the external appearance of the blocks and in the actual form of the relieved ends, and of course any such variation would necessitate equivalently formed plugs and all such variations are deemed to be part of the invention.

A block wall as formed in accordance with the invention may be finished in any suitable fashion such as by an outer coating of mortar or the like to hide the joins between the blocks.

The dowels or plugs as used in the invention ensure that the blocks are tied in end to end relationship and ensire that the blocks sit vertical irrespective of the undulating nature of the top and bottom faces of the blocks.

Whilst the above has been given by way of 12 illustrative embodiment of the invention, all such modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein defined in the appended claims.

S 0*30 94 .9 *4 0*4 4 4

Claims (7)

1. 2. The method according to Claim 1 wherein said blocks include further apertures adapted for vertical alignment, the method including the step of forming columns through the further apertures.
2. 3. The method according to Claim 2 wherein the aligned further apertures are filled with concrete to form the columns.
3. 4. The method according to Claim 3 wherein the aligned further apertures are provided with reinforcing means. :0 5. The method according to any one of the preceding claims wherein at least some of the blocks having said apertures opening through a side face thereof whereby blocks can be abutted and held at right angles.
4. 6. The method according to any one of Claims 1 to wherein the connecting members have a length substantially equal to the height of the blocks. S wI 7. The method according to any one of the preceding I _1 14 claims wherein the apertures have walls which diverge inwardly from said opening and wherein the connecting members have correspondingly divergent walls so as to mate with the walls of the apertures.
5. 8. The method according to Claim 7 wherein said apertures at least at opposite ends of the block are of dovetail form in section.
6. 9. The method according to any one of Claims 1 to 6 wherein said apertures in each end of said block are circular in cross section and wherein said slots extend from said apertures to open to the adjacent end of said block. The method according to Claim 9 wherein the connecting members have cylindrical end portions extending substantially parallel to each other and are 2 joined through a radially extending web which is receivable in the respective said slots. S.11. A wall formed using the method according to any one of the preceding claims. 25 12. A method of forming a wall substantially as hereinbefore described with reference to the accompanying drawings.
7. 13. A wall formed in accordance with the method 30 substantially as hereinbefore described with reference to the accompanying drawings. DATED THIS 16 TH DAY OF APRIL 1998 INTERLOCK HOLDINGS PTY LTD BY THEIR PATENT ATTORNEYS CULLEN CO. ABSTRACT A method for forming a stack bonded wall using blocks (61) which have openings (64) at each end to receive a plug or dowel (67) which may be received in the opening (64) of adjacent blocks (61) to hold the blocks in an end to end attitude. The plugs (67) also hold the blocks (61) in vertical alignment. a* ooes *o* o** 4 0* S* S. 5500 *°oo