Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
  • E04B2/14—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element
  • E04B2/24—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element the walls being characterised by fillings in some of the cavities forming load-bearing pillars or beams
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
  • E04B2002/0202—Details of connections
  • E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
  • E04B2002/023—Non-undercut connections, e.g. tongue and groove connections with rabbets, e.g. stepped
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
  • E04B2002/0202—Details of connections
  • E04B2002/0243—Separate connectors or inserts, e.g. pegs, pins or keys

Definitions

• Patent 4,091,587 a previous patent to applicant will be reviewed later.
• the present and previous inventions concern cement block walls not using mortar between abutting block surfaces.
• Patent 3,325,956 includes inserts interengaging between superposed blocks in mortarless walls.
• the expression "mortarless” does not exclude the use of mortar to grout in reinforcing bars.
• the invention relates to a system for constructing a cement block wall without the use of mortar between the blocks in laying them up into the wall and with the use of interengaging inserts between superposed H-blocks and with interengaging means at the ends of face shell walls.
• the invention does not exclude vertical grouting of aligned cells, with or without vertical reinforcing rods, or the use of grout in installation of horizontal reinforcing rods in a bond beam manner in a cement block wall. It is the use of mortar to form joints between blocks that is eliminated.
• a non-load bearing structure such as a garden wall or fence does not need mortar joints for physical strength, which is better provided by spaced areas that are grouted. It is important to the present invention not only that a cement block wall be provided without mortar joints by also that grouting in of reinforcing rods be facilitated or at least not hampered.
• One common requirement in grouting of vertical reinforcing rods is that mortar droppings be cleaned out of cells to be grouted, and that problem is avoided if mortar isn't used.
• Figure 1 is a perspective view of a cement block wall, with portions broken away, showing various features of a specific embodiment of the invention.
• Figure 2 is an enlarged perspective view of a block interengaging insert.
• Figure 3 is an enlarged fragmentary sectional view taken on line 3-3 of Figure 2.
• Figure 4 is an enlarged sectional view taken on line 4-4 of Figure 1.
• Figure 5 is an enlarged fragmentary plan view taken as indicated by line 5-5 in Figure 1.
• Figure 6 is a perspective view from above a cement block made according to the present invention.
• Figure 7 is like Figure 6 only taken from below.
• Figure 8 is an enlarged fragmentary sectional view taken on line 8-8 of Figure 7 and including a knockout wall.
• Figure 9 is like Figure 8 but with the knockout wall removed.
• Figure 10 is a perspective view from below of a full-length end block.
• Figure 11 is a perspective view from below of a half-length end block.
• Figure 12 is an enlarged detail of the block corner area indicated by line 12-12 in Figure 10.
• Figure 13 is like Figure 2 except of an insert with a horizontal vail.
• Figure 14 is like Figure 3 except of an insert with a horizontal wall.
• Figure 15 is an elevational view, partly in section, of a wall with inserts arranged in one pattern with inserts arranged in every other area of abutting upper and lower cells.
• the inserts are located in the tops of single central cells.
• Figure 16 is like Figure 15 but with inserts disposed in every area of abutting upper and lower cells, which is a different option.
• inserts may be arranged in every cell in a block course is when horizontal reinforcing rods are to be grouted in above that course and the inserts have horizontal walls as in Figures 13 and 14 to hold grout around those rods.
• Patent 4,091 . 587 was to use standard precision blocks. Such use of standard precision blocks suffers from the problem that in a course of blocks the center tie wall were not as wide as the combined widths of two abutted end tie walls. In superposed courses of blocks, cells were not exactly superposed between courses, i.e., Column 4, lines 3-11, of the patent reads: "There is additional reason for offset between the cells 12 of blocks of upper course 22 and lower course 24 in Fig. 10 and that Is, due to half-lapping of blocks, center tie wall 14 of upper course 22 is superposed to two end tie walls 18 of lower course 24 and end tie walls 18 of upper course 22 are superposed to centertie walls 14 of blocks of lower course 24.
• a multiplicity of frame-like inserts or block interengaging members 30 are provided.
• a primary objective of the invention is to provide a mortarless cement block wall, i.e., a cement block wall with no mortar between blocks and therefore with no mortar joints.
• Mortar is used in grouting cells or grouting reinforcing rods in cells but mortar isn't used between blocks. They are simply abutted.
• Members 30 are used to facilitate laying up the cement block walls 24, i.e., inserts 30 provide the basic guide to the worker who puts inserts 30 into a lower block course 22 and orients blocks 10 in the next upper course 22 merely by engaging them with inserts 30.
• inserts 30 have limited strength and may be slightly pliable, which means that the upper blocks 10 are properly engaged with inserts 30 rather than forced into place too roughly, as inserts 30 might give or break if they were subjected to excessive force. Of course it would be possible to make inserts 30 heavier or to make them of stronger material, to withstand more abusive treatment, but that is not necessary.
• inserts 30 are molded out of plastic, such as polythylene. They could be fabricated from metal or molded from a different material.
• inserts 30 are not primarily for sealing of joints and sealing does not have to be a function at all.
• the inserts 30 are used only in alternate cells, as shown in Figures 1 and 15, i.e., the inserts preferably are only in stalled in the upper ends of single central cells 16 and not in the upper ends of combined end cells 20, so inserts 30 inthat configuration would only seal every other cell area.
• One purpose of sealing would be to confine grout in cells and that function can be taken care of by block abutments if suitable tolerances are maintained in block manufacture.
• how many inserts 30 are used is the decision of the builder and some builders may want to use inserts 30 at every cell joint for sealing or other purposes. As later will be described, use of inserts 30 in every cell of a course, as in Figure l6, is the preferred construction especially in a bond beam situation when a horizontal rein forcing bar is to be grouted in place.
• Inserts 30 have a limited function in wall strength, i.e., strength against removal of a block from a wall, although if strength were a primary objective, inserts 30 could be used in every cell joint and inserts 30 could be made of heavier, stronger material.
• Blocks 10 are installed in a wall in inverted positions to their orientations when made. What is bottom during manufacture is top when installed in a wall. When manufactured, the block is supported on a flat metal plate, which means that edges on the bottom of the block when manufactured are especially true and sharp. Molds used in molding the cement block descend and abut the flat metal plate, and the molds are raised after molding while shoes strip the blocks from the molds. The blocks remain supported on the plates until sufficiently cured.
• Horizontal mortar joints are simulated in each block 10 by a horizontal corner recess 32 extending from end to end of block 10 and from the face of each face shell wall inwardly at the top of the block as made.
• the inner recess wall should be upwardly tapered at about fifteen degrees to avoid a problem in upward mold release.
• the top of each block 10 as made (bottom of block in wall) should be radiused at 34 adjacent to each recess 32 to reduce mold suction when the mold moves upwardly from the molded block. Radiuses 34 have proven to be important in reducing block imperfections in that area.
• Horizontal corner recesses 32 are at the bottoms of blocks 10 as they are laid into a wall.
• each block 10 vertical mortar joints are simulated in each block 10 by a vertical corner recess 40 extending from top to bottom of block 10 and from the face of each face shell wall inwardly at one end of the block.
• Each single central cell 16 and each combined end cell 20 have walls tapered from bottom to top in the positions thereof in wall 24.
• blocks 10 are installed in wall 24 in inverted positions to their orientations when made. The upward tapers of the cells when installed is downward tapers of the cells when made which means that the mold portions used to make cells 16, 20 will be released as they move upwardly after making blocks 10.
• Ledge 42 forms a generally rectangular and symmetrical outline in plan view.
• Each frame-like insert 30 has end and side portions forming a generally rectangular outline in plan view.
• Each insert 30 has a larger upper wall 50 fitting in the larger lower portion of the upper cell of superposed cells 16, 20 and each insert 30 has a smaller lower wall 52 fitting in the smaller upper portion of the lower cell.
• a lower horizontal medial surface 54 is formed extending generally horizontally inwardly from the lower margin of upper wall 50 to the upper margin of lower wall 52.
• Lower horizontal medial surface 54 forms a gen erally rectangular and symmetrical outline in bottom view.
• Lower hori zontal medial surface 54 rests on and generally fits ledge 42.
• Inserts 30 locate blocks 10 in upper and lower courses 22 of blocks in wall 24 by engaging adjacent superimposed upper and lower cells 20, 16.
• the exterior surface of larger upper wall 50 of each insert 30 tapers upwardly to provide a wedging, camming action in inserting in the larger lower portion of the upper cell of superposed cells.
• the exterior surface of smaller lower wall 52 of each insert 30 tapers down wardly to provide a wedging camming action in inserting in the smaller upper portion of the lower cell of superposed cells.
• the lower portion 56 of the exterior surface of the larger upper wall 50 adjacent to lower horizontal medial surface 54 is substantiall vertical to form a seat to engage in the larger lower portion of the up per cell of superposed cells.
• the upper portion 58 of the exterior sur face of the smaller lower wall 54 adjacent to lower medial surface 54 is substantially vertical to form a seat to engage in the smaller upper portion of the lower cell of superposed cells.
• Flattened vertical por tions 56, 58 adds to the stability of inserts 30 when originally set in the lower cell, during the process of engaging the upper cell on the insert, and after the insert is interengaged in upper and lower cells 20, 16. The importance of this feature was discovered after walls 50, 52 were tapered, which helped in engaging inserts 30 in blocks but also made them more unstable.
• Figure 1 shows grouting of vertically aligned cells 16, 20 with mortar 60 and often with vertical reinforcing rods 62.
• the spacing of vertical grouting 60 and vertical rods 62 will depend on needed strength for the particular wall 24 which will vary between load bearing walls and non-load bearing walls and also will vary as to special conditions such as earthquake-prone areas.
• every line of vertically superposed cells 16, 20 will be grouted and reinforced, and, in other walls, grouting or reinforcing may be spaced or even widely spaced.
• Horizontal grouting and reinforcement likewise will vary depending on needed strength in an application and related building codes.
• Such bond beam installations require bond beam blocks 10, meaning tie walls
• H-blocks 10 can be provided with regular blocks without recesses 64 and bond beam blocks with recesses 64.
• Another alternative is to provide blocks with spaced slots 68 forming recesses 64 when the wall between slots 68 is knocked out as shown in Figure 9.
• the wall between slots 68 can be termed "knockout wall”. The narrowness of slots 68 and their considerable relative depths will not pass mortar even if slotted blocks are used in place of regular blocks, as the mortar will plug slots 68.
• Horizontal grouting 70 is used to embed horizontal rods 66 as shown in Figure 4. Although Figures 1 and 4 show use of two horizontal rods 66, use of only one horizontal rod 66 is more common.
• the grouting 70 must be supported in vertically aligned cells 16, 20 in which vertical grouting 60 is not used. Such support of grouting 70 could be accomplished in a number of ways, such as use of a sheet of plastic or mesh or other material to hold up the mortar until it Is set.
• the use of a thin horizontal wall on floor 72 in inserts 30 is illustrated bridging the space between end portions and side portions of inserts 30. Horizontal wall 72 is located medially of insert 30 vertically, at near the level of horizontal surface 54.
• Wall 72 is thin enough to be knocked out or otherwise opened to pass vertical rods 62 or inserts 30 without walls 72 could be used.
• a series of inserts 16 with horizontal walls 72 supporting horizontal grouting 70 is preferred located side by side in the same course in adjacent central cells 16 and combined end cells 20. Whereas inserts 30 may be only set in the tops of single central cells 16 and may not be set in the tops of combined end cells 20 in many installations, if horizontal grouting 70 is to be supported then, in that case, the inserts 30 must be used in every cell whether central cell 16 or combined cell 20.
• Figure 1 shows horizontal rods 66 In a course in which in serts 30 are illustrated only used in the tops of single central cells 16, to demonstrate that condition, but ordinarily a full series of inserts 30 in the tops of both cells l6 and 20 would be used under horizontal rods 66,
• the upper end portions of upper walls 50 of inserts 30 have upwardly open notches 74 under recesses 64 forming rests to receive and position horizontal rods 66.
• each end portion of upper walls 50 of inserts 30 have three spaced notches to accommodate either two spaced horizontal rods 66 or one cen trally located rod 66.
• notches 74 are wider than the diameters of rods 66 normally used, so the minimum spacing is from the positions of rods 66 in notches 74 and not from the walls of notches 74 themselves. Hotches 74 are made wider than rods 66 so that rods 66 merely can be dropped into notches 74 rather than fitted into notches 74, in order to save labor.
• Special blocks are needed where walls end and where walls turn corners. Examples of a wall end include a doorway, a window opening, and the end of a building or garden wall.
• Blocks 10 normally are half-lapped in adjacent courses 22 in a wall 24.
• One way to end a wall 24 is to provide special full-length and half-length closed. end blocks 80, 82.
• full-length closed end blocks 80 and half-length closed end blocks 82 have one flush end tie wall 84, 86 which is at the very ends of the blocks and provide generally planar end surfaces on the blocks. If at the end of a wall, full-length closed end blocks 80 and half-length closed end blocks 82 were superimposed, the wall would end with a generally planar surface, as demonstrated at the right hand end in Figure 1. Also, the full-length end blocks 80 can be used to form a right-rectangular corner with a first end block 80 on a first level having its flush end tie wall 84 facing one direction and a second block 80 above or below having its flush end tie wall 8. facing in another direction, as demonstrated at tne left hand corner of Figure 1.
• Face shell walls 12 have vertical end walls or surfaces 110, 114 that are provided with mating surfaces on the abutting vertical end walls of adjacent blocks 10, 80, 82 in the same course 22 in wall 24, as particularly shown in Figure 5.
• a first vertical end wall 110 has a tongue 112 outstanding from the remainder 122 of first wall 110 extending inwardly from the adjacent face of the block.
• the second type of vertical end wall 114 of face shell walls 12 has a vertical corner recess ko extending inwardly from the adjacent face of the block, so that when tongue 112 abuts end wall 114 they only abut in a relatively narrow area.
• Tongue 112 extends from the remainder 122 of the first wall 110 and second wall 114 has a second tongue 116 spaced inwardly from tongue 112 and extending only part way toward the remainder 122 of the first end surface 110, whereby the plane of abutment between tongue 112 and second end surface 114 in side view is intersected and shielded by second tongue 116 and whereby there is provided a space 118 for grout between second tongue 116 and tongue 112 and there is provided a space 120 for grout between second tongue 116 and the remainder 122 of first wall 110.
• Grout will flow into spaces 118 and 120 when the adjacent cellular space is being grouted, i.e., a vertical reinforcing rod 62 or a horizontal reinforcing rod 66 is being grouted in the adjacent space.
• the invention can be used in manufacturing cement blocks and in manufacturing plastic or other block interengaging inserts for cement block walls and the invention can be used in the actual construction of cement block walls.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Retaining Walls (AREA)

Applications Claiming Priority (1)

Publications (1)

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• 1982
  • 1982-06-07 EP EP19820902388 patent/EP0111484A1/de not_active Withdrawn
  • 1982-06-07 WO PCT/US1982/000779 patent/WO1983004423A1/en unknown
  • 1982-06-08 AU AU87660/82A patent/AU8766082A/en not_active Abandoned

Non-Patent Citations (1)

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