GB2458317A

GB2458317A - Improvements in or relating to wall ties

Info

Publication number: GB2458317A
Application number: GB0804752A
Authority: GB
Inventors: Herman Funke
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-03-14
Filing date: 2008-03-14
Publication date: 2009-09-16
Anticipated expiration: 2028-03-14
Also published as: GB0804752D0; GB2458317B

Abstract

A wall-tie comprises a pair of spaced block-engaging bodies 11 linked by an elongate web 12, characterised in that the block-engaging bodies include at least one bore 24 for engaging with a securing means. Also included is a prefabricated foamed plastics block comprising said wall tie; a wall building system comprising the prefabricated foamed plastics block comprising said wall tie; a fixing for use with said wall tie; and finally a method of forming a concrete wall from a plurality of prefabricated foamed plastics block comprising said wall tie.

Description

IMPROVEMENTS IN OR RELATING TO WALL-TIES

The present invention relates to improvements in or relating to wall-ties, in particular to a wall-tic, and a building block and modular building system incorporating a wall-tie.

Modular wall construction systems which comprise a series of stackable blocks formed from expanded foam plastic material, such as polystyrene arc well known.

US 5,570,552 describes a modular system for forming a concrete wall. The system comprises polystyrene blocks and bridge members for spanning two parallel wall sections formed from the blocks, and between which concrete may be poured. The bridge members each have a central aperture which permits the vertical insertion of a steel strengthening rod through a number of vertically adjacent stacked bridge members, prior to the pouring of concrete. In addition, the bridge members each further comprise a series of pins which allow steel strengthening rods to be laid horizontally between adjacent bridge members of the same vertical displacement.

The use of such bridge members in combination with a series of steel strengthening rods provides a much stronger mould structure, prior to and during the concrete pouring process, and also a stronger wall structure once the concrete has set.

US 4,730,422 describes a plastics wall-tie for use in maintaining the positioning of two panels in a spaced opposed relationship, the panels being formed from a series of modular foamed plastic blocks comprising, for example, expanded polystyrene. The ties are arranged to slot into the blocks and wall panels formed therefrom, to hold the panels together and impart structural rigidity in the finished wall structure, either alone or in combination with steel strengthening rods. Further, in this building system, tie locator indicia are provided on outer surfaces of the panels to permit location of the ties and thus enable fasteners to be screwed through a wall covering, the indicia, the panel and the plastic ties to securely anchor an exterior wall covering to the wall structure after concrete has been poured therein and set. This generally removes the need for drilling through the very hard concrete wall, since all but the heaviest of articles will be adequately secured to the wall-tic. Where a more secure anchorage is required, the concrete wall can be drilled and plugged in a conventional manner.

However, an inherent problem associated with this kind of wall-tie is that it can lead to badly aligned and poorly anchored fixings due to excessive unwanted travel of the fixing means during the securing process. Such travel can be difficult to prevent.

Accordingly, it is desirable to provide a wall-tie which does not suffer from these problems.

In a first aspect of the present invention, there is provided a wall-tie comprising a pair of spaced block-engaging bodies linked by an elongate web, characterised in that the block-engaging bodies further comprise at least one securing means engaging bore.

Suitably, each block-engaging body comprises two or more bores.

Advantageously, an internal wall of the bore is provided with grooves along at least a part of its length. Alternatively, the internal wall of the bore is provided with grooves along substantially its entire length.

Suitably, the bore has a substantially uniform diameter along substantially its entire length. Alternatively, the diameter of the bore is tapered along at least part of its length. Suitably, the diameter of the bore is tapered along substantially its entire length.

Suitably, the wall-tie further comprises a first engaging means for a wall-reinforcing member. Preferably, the engaging means comprises a series of teeth. More preferably, the teeth extend outwardly from the elongate web.

Preferably, the wall-tic comprises a second engaging means in the form of one or more channels which extend through the elongate web. In preferred embodiments, the wall-tie comprises both first and second engaging means.

Suitably, the wall-tie further comprises a series of apertures adapted to allow, in use, poured concrete to pass through portions of the wall-tie.

Preferably, each block-engaging body further comprises block-anchoring means.

Preferably, the block-anchoring means is one or more apertures which permit expanded plastics foam to flow thcrcthrough during moulding of a block incorporating the wall-tie. Alternatively, the block-anchoring means is one or more projections which extend from each block-engaging body.

In a second aspect, there is provided a prefabricated foamed plastics block comprising a wall tie; wherein the wall-tie comprises a pair of spaced block-engaging bodies linked by an elongate web, characterised in that the block-engaging bodies further comprise at least one securing means engaging bore.

Suitably, the block comprises a pair of foamed plastics panels, fixed in a spaced relationship by at least one wall-tic according to the first aspect of the invention.

Preferably, the block comprises a pair of foamed plastics panels, fixed in a spaced relationship by a plurality of wall-tics.

Preferably, the blocks further comprise wall-tie locating indicia, formed on outwardly facing side-surfaces thereof, and wherein the indicia each further comprise an indicium which is aligned with the bore of a respective wall-tic, such that a fixing is passable through the indicium and directly into the bore.

Preferably, the blocks are vertically interlockable; more preferably, vertically and horizontally interlockabic. Suitably, the upper and lower surfaces of the blocks comprise primary block-engaging means in the form of a series of interlockable crenellations. Suitably, the ends of the blocks comprise secondary block-engaging means in the form of interlockable tongues and grooves.

Optionally, each outwardly facing side-surface of the block comprises integral batons.

Preferably, the batons perpendicularly traverse the longitudinal span of each side-surface.

In a third aspect, there is provided a fixing for usc with a wall-tie; wherein the wall-tie comprises a pair of spaced block-engaging bodies linked by an elongate web, charactcrised in that the block-engaging bodies further comprise at least one securing means engaging bore.

Suitably, the fixing has a first engaging means for securely engaging with the bore of a wall-tic according to the first aspect of the invention. Suitably, the securing means 1 5 is a screw-thread. Alternatively, the securing means is a barb or series of barbs. In this alternative arrangement the fixing is longer in length than the bore of a wall-tie such that the barb or series of barbs pass through the bore and engage with the outer surface of its mouth.

Suitably, the fixing comprises a block-engaging flange to prevent a portion of the fixing from passing into the block.

Preferably, the fixing further comprises a second engaging means for securing wall coverings such as plasterboard, fascias, rendering, insulation sheets or the like.

Suitably, the fixing further comprises a locking means for use with the second engaging means, wherein a wall covering is engageable with the second engaging means and is securable to the second engaging means with the locking means.

Optionally, the fixing provides an air-gap between the block and the wall covering.

In a fourth aspect there is provided a wall building system comprising a mould and pourablc concrete, wherein the mould comprises: i) a plurality of prefabricated foamed plastic blocks according to the second aspect of the invention; and ii) a plurality of mould end-panels.

Optionally, the system further comprises a plurality of wall-reinforcing members.

Preferably, the wall-reinforcing members arc steel rods.

Suitably, the wall building system further comprises fixings for securing wall coverings such as plasterboard, fascias, rendering, insulation sheets or the like, or anchoring items to a wall formed using the wall building system of the second aspect of the invention. Preferably, the fixings are conventional screws or bolts.

Alternatively, the wall building system comprises fixings according to the third aspect of the invention.

In a fifth aspect of the present invention there is provided a method of forming a concrete wall comprising the steps of: 1) forming a pair of opposed wall structures from a plurality of prefabricated foamed plastic blocks according to the second aspect of the invention; ii) securing closing end-panels between the opposed wall structures to form a mould; and iii) pouring concrete into the mould of step (ii) and allowing the concrete to set.

Suitably, the method further comprises the step of locating a series of wall-reinforcing members between adjacent wall-ties, prior to the concrete pouring process of step (iii). Preferably, the wall-reinforcing members arc steel rods.

In a sixth aspect there is provided a method of securing wall coverings such as plasterboard, fascias, rendering, insulation sheets or the like, or anchoring items to a wall formed according to the fifth aspect, wherein the method comprises the steps of I) locating the indicium of a wall-tic indicia; ii) locating a fixing through one or more indicium and into a respective wall-tie bore and securing said fixing therein; and iii) attaching a wall covering to the fixing.

Optionally, the method further comprises the step of securing the wall covering to the fixing with a locking means.

The above and other aspects of the present invention will now be illustrated in further detail by way of example only, with reference to the accompanying drawings in which: Figure 1 is a perspective view of a wall-tie in accordance with an embodiment of the first aspect of the invention; Figure 2 is a front view of the embodiment of Figure 1; Figure 3 is a top plan view of the embodiment of Figure 1; Figure 4 is a perspective view of a prefabricated block in accordance with an embodiment of the third aspect of the invention, comprising a plurality of wall-ties of Figure 1; Figure 5 is a part perspective view of the embodiment of Figure 4; Figure 6 is a side view of the embodiment of Figure 4 Figure 7 is a part side view of the embodiment of Figure 4; Figure 8A is a top plan view of the embodiment of Figure 4; Figure 8B is an expanded partial schematic view of Figure 8A; Figure 9 is a front view of the embodiment of Figure 4; Figure 10 is a partial section through Figure 10 illustrating a first embodiment of a fixing according to the third aspect of the invention; Figure II is a partial section through Figure 10 illustrating a second embodiment of a fixing according to the third aspect of the invention; Figures 12A & B are perspective views of an embodiment of an end-panel; and Figures 1 3A & B are perspective part views of the end-panel of Figure 12 engaged with a prefabricated block of Figure 4.

Referring to Figures 1 to 3 there is shown a wall-tie 10 for use in maintaining the positioning of two opposed wall panels in a spaced relationship in a building block for a mould for use in the manufacture of a concrete wall. The wall-tie 10 has a generally 11-shaped construction and comprises a pair of block-engaging bodies 11 linked by an elongate web 12.

Elongate web 12 further includes a first engaging means, in the form of series of outwardly extending teeth 13, at its longitudinal edges 14. The teeth 13 permit wall-reinforcing members, typically in the form of steel reinforcing rods, to be rested therebetween and also between corresponding teeth of nearby, horizontally aligned, wall-ties. Additionally, the elongate web 12 also includes a series of apertures 15 which, in usc, allow poured concrete to pass thcrcthrough and embed the wall-tie within a concrete wall thus formed (not shown).

In alternative embodiments (not shown) the wall-tic 10 further includes a second engaging means for engaging wall-reinforcing members. The second engaging means comprises one or more rod-receiving chamiels which pass through a vertical plane of the web, and which provide additional strength and rigidity to a concrete wall formed from a building system utilising wall-tics of the invention.

The use of engaging means in conjunction with a series of correspondingly aligned wall-ties, such as those described above, provide additional strength and rigidity to a mould, prior to and during the pouring of concrete and, more particularly, to the finished wall once the poured concrete has set, by locking a number of adjoining wall-ties together.

Block-engaging bodies 11 are formed at the ends of elongate web 12, and comprise a link 21 and collar 22, interposed between the link 21 and the elongate web 12, and further include an anchor in the form of a foot 23, located distally to the collar 22 on link 21. As is most clearly seen in Figures 1 and 3, the block-engaging bodies 12 have a generally 1-shaped cross-section within the plane of the wall-tie, which permit the wall-tie to be secured within a block during its manufacture.

Additionally, each block-engaging body II includes block-anchoring means in the form of a plurality of apertures 25 which pass through the wall-tie which help to secure the wall-tie within a prefabricated block during the moulding process, described in detail below. In alternative embodiments (not shown), the block-anchoring means are one or more projections which extend from each block-engaging body.

In addition, each block-engaging body 11 of the wall-tie also includes a channel or bore 20 extending through the outwardly facing face of foot 23 and into link 21, the bore 20 being aligned longitudinally with the wall-tic 10. In alternative embodiments, not shown, each block-engaging body includes two or more bores.

In the illustrated embodiment, the bore 20 has a substantially uniform diameter along substantially its entire length. In alternative embodiments, not shown, the bore diameter is tapered along at least a part of its length, and preferably along substantially its entire length.

Furthermore, the entrance to the bore 20 (see Figure 1) includes a countersunk tapered mouth 24 to help guide and accurately locate fixings into the bore.

In use, the bore 20 of the described wall-tie permits the user to conveniently, accurately and securely locate fixings, such as screws, for mounting and anchoring items to a concrete wall which incorporate wall-tie of the present invention. The bore channel may contain a thread for co-operation with threaded fixings of a particular dimension, and will generally have a uniform diameter along its length, although alternative embodiments will be tapered in either direction.

Referring now to Figures 4 to 9, there is shown a pre-fabricated block 30 from which a mould (not shown) for forming a concrete wall can be assembled. The block is formed from a pair of opposed wall panels 31 held in a spaced-apart relationship by a plurality of wall-ties 10 as described above. The blocks arc each comprised of expanded plastics foam and are moulded with a plurality of wall-ties in-situ, to form a very stable and rigid structure.

As is more clearly illustrated in Figure 5, the upper and lower surfaces of each block 32, 33 comprise primary block-engaging means in the form a series of crenellations.

The crenellations are complementary projections 34 and corresponding troughs 35 which permit vertically adjacent blocks to be interlocked when the blocks are stacked.

Further, the ends of the blocks also comprise secondary block-engaging means in the form of a series of projecting tongues 40 which are engageable with corresponding complementary grooves 41.

In addition, the outwardly facing side-surfaces 42 of the block include wall-tic locating indicia 43 which, as illustrated in Figures 4 and 5, arc aligned with a wall-tie 10. The indicia 43 further include an indicium 44 which arc aligned with the bore of an adjacent wall-tie during the block moulding process such that, in use, the indicium 44 can be used to accurately locate the bore of the wall-tie to allow a lixirig to be pushed through the indicium and directly into the bore.

The outwardly facing side-surfaces 42 of the block also include horizontal and vertical guide marks 45, 50 which facilitate an accurate cuffing of a block in situations where a full block is not required.

In an alternative embodiment, shown schematically in Figure 8B with reference to Figure 8A, each outwardly facing side-surface 42 of the block comprises a series of integral vertically aligned batons 51. In use, the batons 51 provide an air-gap between a wall constructed with blocks according to the invention and a wall covering, held in place by fixings 53.

In use, blocks according to the invention may be stacked in a similar fashion to the way in which conventional building blocks arc laid, and arc interlockablc with adjacent blocks through the primary and secondary block-engaging means.

Referring now to Figure 10, there is shown a section through the embodiment of Figure 9 illustrating the engagement of a fixing 53 with a wall-tie 10. In particular, the block-engaging body 11 of the waIl-tic 10 is shown in which a fixing 53 has been pushed through a respective wall panel 31 and into the bore of wall-tie 10.

Fixing 53 includes a shank 55 connected to a deformable barbed head 54 at a first end, and has a stop-member 60 and wall-covering engaging means 61 at a second end.

The barbed head 54 is larger in diameter than that of the wall-tic bore, and may be compressed to a diameter of less than that of the bore to allow it to be pushed through the bore. Upon exiting the bore, head 54 reverts to its uncompressed form and engages with the outside of the bore to prevent the fixing from being withdrawn therefrom. In this locked arrangement, stop-member 60 abuts against the outwardly facing side-surface to prevent the fixing from travelling further into the wall-tie.

Wall coverings can subsequently be secured to the wall through engagement with the wall-covering engaging means 61 of the fixing 53.

Figure 11 illustrates an alternative fixing 53' comprising an alternative wall-covering engaging means 61' and including a removable lock 62 for securing a wall covering 52 to the fixing 53 and wall. The stop-members 60 of each of the fixings illustrated in Figures 10 and 11 provide an air-gap between the wall-covering and the wall by preventing them from coming directly into contact with each other.

In further alternative embodiments (not shown), the fixings comprise a first fixing part, which pushes through the indicium and securely engages within the wall-tic bore, and a second fixing part which passes through a wall covering and securely engages with a secondary bore in the shank of the first fixing part.

Additionally, conventional fixings such as pins and screws can be used in conjunction with a wall-tie of the invention.

In a building system according to the present invention, a mould for casting a wall is formed by aligning and stacking a plurality of blocks. Referring to Figures 12 and 13, end-panels 63 for closing off the mould prior to the concrete pouring process are also provided. As illustrated in Figures 13A & B, these end-panels 63 extend transversely between opposed wall panels formed from the prefabricated blocks and prevent poured concrete from flowing out of the structure. Similar arrangements may be provided in regions where windows are to be located. For example, the blocks may be cut along cut-lines 64 and bridging panels fitted thcrcbctwecri to confine and contain poured concrete during the setting process. This arrangement is particularly strong and is sufficiently rigid to prevent the mould from buckling and deforming during the concrete pouring process.

Claims

CLAiMS I. A wall-tie comprising a pair of spaced block-engaging bodies linked by an elongate web, wherein the block-engaging bodies further comprise at least oiie securing means engaging bore.
2. A wall-tie as claimed in claim 1, wherein each block-engaging body comprises two or more bores.
3. A wall-tie as claimed in claim I or claim 2, wherein an internal wall of the or each bore is provided with grooves along at least a part of its length.
4. A wall-tie as claimed in claim 1 or claim 2, wherein each bore has an internal wall provided with grooves along substantially its entire length.
5. A wall-tie as claimed in any one of claims I to 4, wherein each bore has a substantially uniform diameter along substantially its entire length.C
6. A wall-tic as claimed in any one of claims Ito 4, wherein the diameter of each bore is tapered along at least part of its length.
7. A wall-tie as claimed in any one of the preceding claims, wherein the wall-tie further comprises a first engaging means for a wall-reinforcing member.
8. A wall-tic as claimed in claim 7, wherein the engaging means comprises a series of teeth, outwardly extending from the elongate web.
9. A wall-tie as claimed in claim 7 or claim 8, wherein the wall-tie comprises a second engaging means in the form of one or more channels which extend through the elongate web.
10. A wall-tie as claimed in any one of the preceding claims, wherein thc wall-tic further comprises a series of apertures adapted to allow, in use, poured concrete to pass through portions of the wall-tie.
11. A wall-tie as claimed in any one of the preceding claims, wherein each block-engaging body further comprises block-anchoring means.
12. A wall-tie as claimed in claim II, wherein the block-anchoring means is one or more apertures which permit expanded plastics foam to flow therethrough during moulding of a block incorporating the wall-tie.
13. A wall-tie as claimed in claim II, wherein the block-anchoring means is one or more projections which extend from each block-engaging body. Co
14. A prefabricated foamed plastics block comprising at least one wall tie as claimed in any one of claims I to 13.
15. A prefabricated foamed plastics block as claimed in claim 14, wherein the block comprises a pair of foamed plastics panels, fixed in a spaced relationship by a plurality of wall-ties.
16. A prefabricated foamed plastics block as claimed in claim 14 or claim IS, wherein the blocks further comprise wall-tie locating indicia, formed on outwardly facing side-surfaces thereof, and wherein the indicia each further comprise an indicium which is aligned with the bore of a respective wall-tie, such that a fixing is passable through the indicium and directly into the bore.
17. A prefabricated foamed plastics block as claimed in any one of claims 14 to 16, wherein the blocks are vertically interlockable; more preferably, vertically and horizontally interlockable.
18. A prefabricated foamed plastics block as claimed in any one of claims 1410 1 7, wherein the upper and lower surfaces of the blocks comprise primary block-engaging means in the form of a series of interlockable crenellat ions.
19. A prefabricated foamed plastics block as claimed in any one of claims 14 to 18, wherein the ends of the blocks comprise secondary block-engaging means in the form of interlockable tongues and grooves.
20. A wall building system comprising a mould for receipt of pourable concrete, wherein the mould comprises: i) a plurality of prefabricated foamed plastic blocks as claimed in any one of claims 14 to 19; and ii) a plurality of mould end-panels. Co
21. A wall building system as claimed in claim 20, wherein the system further comprises a plurality of wall-reinforcing members, preferably in the form of steel rods.
22. A wall building system as claimed in claim 20 or claim 21, wherein the wall building system further comprises fixings for securing wall coverings such as plasterboard, fascias, rendering, insulation sheets or the like, or anchoring items to a wall formed using the wall building system of the second aspect of the invention.
23. A wall building system as claimed in claim 22, wherein the fixings are conventional screws or bolts.
24. A fixing for use with a wall-tie as claimed in any one of claims Ito 13.
25. A fixing as claimed in claim 24, wherein the fixing comprises a first engaging means for securely engaging with the bore of the wall-tie.
26. A fixing as claimed in claim 25, wherein the first engaging means is a screw-thread.
27. A fixing as claimed in claim 25, wherein the first engaging means is a barb or series of barbs, and wherein the fixing is longer in length than the wall-tie bore such that the barb or series of barbs pass through the bore and engage with the outer surface of its mouth.
28. A fixing as claimed in any one of claims 24 to 27, wherein the fixing comprises a block-engaging flange to prevent a portion of the fixing from passing into the block.

CD
29. A fixing as claimed in any one of claims 24 to 28, wherein the fixing further comprises a second engaging means for securing wall coverings such as plasterboard, fascias, rendering, insulation sheets or the like.
30. A fixing as claimed in claim 29, wherein the fixing further comprises a locking means for use with the second engaging means, wherein a wall covering is engageable with the second engaging means and is securable to the second engaging means with the locking means.
3 I. A method of forming a concrete wall comprising the steps of: i) forming a pair of opposed wall structures from a plurality of prefabricated foamed plastic blocks as claimed in any one of claims l4to 19; ii) securing closing end-panels between the opposed wall structures to form a mould; and iii) pouring concrete into the mould of step (ii) and allowing the concrete to set.
32. A method as claimed in claim 3 1, further comprising the step of locating a series of wall-reinforcing members between adjacent wall-tics, prior to the concrete pouring process of step (iii). Co (\J