GB2614538A

GB2614538A - Construction block and building element

Info

Publication number: GB2614538A
Application number: GB2200056.6A
Authority: GB
Inventors: William Pittock John
Original assignee: Ecor Ltd
Current assignee: Ecor Ltd
Priority date: 2022-01-05
Filing date: 2022-01-05
Publication date: 2023-07-12
Also published as: GB202200056D0; WO2023131783A1

Abstract

A plant-based construction block (2a,b,c,d) for a building element (1), for example a wall. The plantbased construction block (2a,b,c,d) comprises a uniform recess (3a,b) extending between two opposite faces of the plant-based construction block (2a,b,c,d). The recess comprising first and second interlocking portions (4) disposed on opposite sides of the recess (3a.b) such that an interlocking portion of a further identical plant-based construction block can be received in the recess (3a,b) and engage the first interlocking portion (4), and such that an interlocking portion of a second further identical plant-based construction block can be received in the recess (3a,b) and engage the second interlocking portion (4). The recess may extend vertically between the upper and lower faces of the block. The plant based material may be a hemp or wood based composite, and may include hemp shiv and a lime or silica based binder or wood laminae.

Description

CONSTRUCTION BLOCK AND BUILDING ELEMENT

[0001] This invention relates to a construction block, particularly a plant-based construction block, and a building element comprising the plant-based construction block.

s BACKGROUND

[0002] The construction industry, particularly the cement and concrete industry, is a major contributor to global carbon emissions. Plant-based materials such as wood and crops offer a more sustainable alternative as they capture carbon during growth, which is then trapped in the construction material.

[0003] Hemp is known as a material in the construction industry due to its environmental credentials and high performance for thermal insulation.

[0004] Hemp insulation products are made of the stalk of the hemp plant, otherwise known as 'shiv'. The shiv is mixed with a lime-based binder to form a hemp-composite material. The hemp-composite material can be applied to a building structure as a wet mix, akin to render, poured into a cavity, or formed into blocks. Hemp blocks are used to create a thermal insulation layer on the exterior or interior of a wall, and can be finished with render or cladding.

[0005] Hemp is advantageous over other insulative materials as it can be quickly and sustainably cultivated, it absorbs carbon as it grows, it is lightweight (a hemp block may be around one eighth of the weight of a concrete block), and it is highly thermal insulating.

[0006] Known hemp blocks, for example as available from isohempe, are used to create an insulative layer on a structural frame. Hemp blocks can be mortared together with an adhesive mortar to form a wall.

[0007] The environmental and thermal insulative benefits of hemp make it well suited for improving building thermal insulation in a sustainable manner, and there exists a need for a hemp construction system for new builds and for retrofitting existing buildings.

BRIEF SUMMARY OF THE DISCLOSURE

[0008] According to the present invention there is provided a plant-based construction block for a building element, for example a wall, the plant-based construction block comprising a uniform recess extending between two opposite faces of the plant-based construction block, the recess comprising first and second interlocking portions disposed on opposite sides of the recess such that an interlocking portion of a further identical plant-based construction block can be received in the recess and engage the first interlocking portion, and such that an interlocking portion of a second further identical plant-based construction block can be received in the recess and engage the second interlocking portion.

[0009] As used herein, the term "plant-based material" means a material derived from plant matter, for example wood or crops such as hemp. The plant-based material may be a plant-composite material, including a plant-derived material and a binder, filler, or other bulk material. The term "plant-based" excludes cementifious construction materials, including concrete.

[0010] In examples, the plant-based construction block is generally cuboid and has a top face, a bottom face, opposing side faces, a front face, and a rear face. The recess may extend through the construction block between the top face and the bottom face and opens through the rear face.

[0011] The recess may comprise a uniform profile extending between the top face and the bottom face such that the further identical construction block and the second further identical construction block can be slid into the recess.

[0012] In this manner, the plant-based construction blocks can be interlocked in a horizontal direction, by interlocking adjacent plant-based construction blocks with the recess, and in a vertical direction, by offsetting interlocking plant-based construction blocks within the recess and adding a further course of plant-based construction blocks. Such vertical and horizontal interlocking improves the structural rigidity of a building element formed by the plant-based construction blocks.

[0013] In examples, the first interlocking portion is a mirror image of the second interlocking portion. In particular, the first and second interlocking portions are mirror images of each other about a plane disposed centrally between side faces of the plant-based construction block and extending in the direction of the recess. This allows multiple plant-based construction blocks to be interlocked to form a building element, for example a wall.

[0014] In examples, each of the first interlocking portion and the second interlocking portion comprises a male engaging portion and a female engaging portion arranged to receive a corresponding male engaging portion of the further or second further identical plant-based construction block, respectively. Accordingly, when the interlocking portions interlock with an adjacent plant-based construction block they form a double-interlock, with two male engaging portions and two female engaging portions interlocked with each other. This provides high contact surface area between the interlocking portions and improves structural rigidity.

[0015] In examples, each male engaging portion and each female engaging portion are rounded. In particular, each male engaging portion may comprise a cylindrical sector and each female engaging portion comprises a tubular passage having a cross-section corresponding to the cylindrical sector of the male engaging portion. Rounded engaging portions ensure that loads are spread across a larger surface area as they are transferred between interlocked plant-based construction blocks. Accordingly, rounded engaging portions reduce stress concentrations in the plant-based material, somewhat mitigating the brittleness of the plant-based material.

[0016] In examples, the cylindrical sector of each male engaging portion comprises at least 180 degrees of a cylinder. In particular, the cylindrical sector of each male engaging portion may comprise between about 180 degrees and about 270 degrees of a cylinder.

[0017] In examples, each male engaging portion is disposed adjacent to the corresponding female engaging portion such that a wall of the plant-based construction block has an inflection where the male engaging portion joins the female engaging portion.

Such an inflection ensures no sharp corner or joint in the wall of the plant-based construction block, reducing stress concentrations further as loads will be transferred across the rounded surfaces of the engaging members.

[0018] In other examples, there is a step located between each male engaging portion and each female engaging portion. The step may be substantially parallel to the side faces. The step may provide additional rigidity in the sideways direction when further construction blocks are interlocked in the recess.

[0019] In examples, the male engaging members of the first and second interlocking portions are disposed at an exterior mouth of the recess opening through a side of the plant-based construction block, and the female engaging members of the first and second interlocking portions are disposed on an internal side of the recess. Accordingly, the female engaging members are formed at internal corners of the recess.

[0020] In examples, each male engaging member extends away from the plant-based construction block, beyond an exterior face (in particular the rear face) of the plant-based construction block.

[0021] In examples, the plant-based construction block comprises a hemp-composite material, for example formed of a hemp shiv and a binder. The binder may comprise a lime-based binder or a silica-based binder. The hemp-composite construction block may comprise at least 50% hemp shiv, for example about 75% hemp shiv. The hemp-composite construction block may further comprise an additive or other bulk material.

[0022] In other examples, the plant-based construction block may comprise a wood-composite construction block. The wood-composite construction block comprises a wood-composite material. The wood-composite material may comprise a wood derivative material and a binder. The wood-composite material may be formed into a lamella, and a plurality of laminae may be attached to each other to form the wood-composite construction block.

[0023] According to a further aspect of the present invention, there is also provided a building element, for example a wall, comprising a first plant-based construction block, a second plant-based construction block and a third plant-based construction block, each of the first, second and third plant-based construction blocks being as described above, and wherein one of the first and second interlocking portions of the second plant-based construction block and one of the first and second interlocking portions of the third plant-based construction block are both received in the recess of the first plant-based construction block so as to engage the first and second interlocking portions of the first plant-based construction block, respectively.

[0024] In examples, the second and/or third plant-based construction block is only partially inserted into the recess of the first plant-based construction block such that the plant-based construction blocks are staggered. In this way, a further course of plant-based construction blocks laid on top of the first plant-based construction block would be vertically interlocked with the second and/or third plant-based construction block. Providing both vertical and horizontal interlocking improves the structural rigidity of the building element.

[0025] In examples, the building element further comprises a foundation supporting the first, second, and third plant-based construction blocks, and wherein the foundation is staggered such that the second and/or third plant-based construction block is only partially inserted into the recess of the first plant-based construction block. The foundation may comprise a slot to receive the first plant-based construction block. The slot may be shaped to interlock with the first plant-based construction block.

[0026] In examples, the foundation further comprises an attachment for a tubular support rod arranged to extend through at least one of the first, second and third plant-based construction blocks. The attachment may comprise a spigot moulded within the foundation or attached thereto. The foundation may comprise a foundation block shaped to match the first plant-based construction block, the foundation block being fixed to the foundation. The foundation block may be concrete. The attachment for the tubular support rod may be provided on the foundation block.

[0027] In examples, the building element further comprises a tubular support rod attachable to the foundation by a threaded connector. The tubular support rod may extend through at least one of the first, second and third plant-based construction blocks. The first, second and third plant-based construction block may comprise a hole to receive the support rod. Alternatively, the first, second and third plant-based construction block may not comprise a male engaging portion, creating a vacant space for the support rod. The support rod preferably extends through multiple courses of plant-based construction blocks to provide structural support to the building element.

[0028] In examples, the building element further comprises a capping plate attachable to ends of the support rod opposite to the foundation, with the plant-based construction blocks disposed between the foundation and the capping plate. The capping plate may be clamped against the plant-based construction blocks so as to tension the support rods and compress the plant-based construction blocks. Tensioning nuts may attach to the ends of the support rods to clamp the capping plate. By tensioning the support rods the structural rigidity provided by the support rods is increased.

[0029] In examples, the building element may further comprise a plurality of load-bearing construction blocks. The load-bearing construction blocks may be shaped to interlock with the at least one of the first, second and third plant-based construction blocks. For example, the load-bearing construction blocks may have the same shape as the first, second, and third plant-based construction blocks. In examples, the load-bearing construction blocks are arranged to provide a load bearing sub-structure of the building element. For example, the load-bearing construction blocks may be interlinked to form a tie line or diagonal that ties two parts of the building element together. In some examples, the tie line may extend between a corner and a support rod of the building element. The load-bearing construction blocks may comprise concrete, polymer or wood-composite material, and may be plant-based or non-plant-based. Providing load-bearing construction blocks may create a load-bearing sub-structure, and plant-based construction blocks may be used to complete the building element.

[0030] In examples, the load-bearing construction blocks comprise side interlocking portions formed of a protrusion in a first side face and a recess in an opposite side face of the load-bearing construction block. In examples, the recess extends from a bottom face of the load-bearing construction block partially to the top face, through the first side face. The protrusion extends from the top face of the load-bearing construction block partially to the bottom face, out of the opposing side face. In this way, when two of the load-bearing construction blocks are arranged in a diagonal arrangement they will interlock. This allows the load-bearing construction blocks to be provided only on the inner or outer layer of the building element and still provide a load-bearing path forming a diagonal fie-line. The other of the inner or outer layer of the building element can be provided with plant-based construction blocks, for example to provide thermal insulation.

[0031] In examples, the building element comprises a corner. The corner may be formed from corner construction blocks arranged on top of each other and shaped to interlock with plant-based construction blocks extending perpendicularly from the corner construction block. The corner construction blocks may be concrete, polymer or wood-composite. The corner may be load-bearing.

[0032] In examples, the building element may comprise a wall, for example an external or internal wall of a building.

[0033] In other examples, the building element may comprise an outer skin attachable to an existing wall of a building. The building element may be a retrofittable insulation system. For example, the building element may further comprise a plurality of mounting brackets attachable to the existing wall, and a plurality of support rods attachable to the brackets. At least one of the first, second and third plant-based construction blocks may be configured to be coupled to at least one of the plurality of support rods. The support rods thereby act to attach the plant-based construction blocks to the existing wall. The support rods may be configured to space the plant-based construction blocks from the existing wall, although the space is not necessary as the thermal insulation provided by the plant-based construction blocks is not dependent on there being an intermediate cavity.

[0034] In examples, the building element may further comprise a bracket arranged to be retained between the first and second plant-based construction blocks and to provide a mounting point for a cladding system, for example a rail of a cladding system. The bracket may extend past the first and second plant-based construction blocks. In examples, the building element further comprises a cladding system attached to the bracket.

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Aspects of the present invention are described hereinafter with reference to the accompanying drawings, in which: FIG. 1 illustrates a building element formed of plant-based construction blocks with interlocking features, the construction blocks are arranged in an interlocking manner; FIGS. 2A and 23 are top-views of example construction blocks FIG. 3 shows an example wood-composite construction block formed of a plurality of laminae; FIGS. 4A to 4C illustrate example building elements comprising a plurality of the construction blocks of FIGS. 2A, 2B or 3 and a foundation; FIGS. 5A to 50 illustrate example corner construction blocks of the building element; FIG. 6 illustrates an example building element with load-bearing construction blocks and non-load-bearing construction blocks; FIG. 7 illustrates a further example building element with load-bearing construction blocks and non-load-bearing construction blocks; FIGS. 8A to 8B illustrate example load-bearing construction blocks for forming a diagonal tie line of the building element; FIG. 9 illustrates a support rod structure of an example building element; FIG. 10 illustrates a connection between the support rod structure of FIG. 8 and the foundation of a building element; FIG. 11 illustrates an example building element having a support rod structure; FIG. 12 illustrates an example support rod and capping frame arrangement; FIGS. 13A and 13B illustrate a building comprising a building element formed of construction blocks; FIG. 14 illustrates a window opening of the building element of FIGS. 13A and 13B; FIGS. 15A to 150 illustrate a joint block for joining an external building element to an internal building element; FIGS. 16A and 16B illustrate a retrofittable building element having a support rod structure; FIG. 17 illustrates a support rod mounting bracket of the retrofittable building element of FIGS. 16A and 16B; FIGS. 18A to 180 illustrate a construction block and building element having a cladding bracket; FIG. 19 illustrates a cladding system attached to the cladding bracket of FIGS. 18A to 18C; FIGS. 20A and 20B illustrate a manufacturing system for plant-based construction blocks; and FIGS. 21A and 21B illustrate an assembly system for construction of a building element.

DETAILED DESCRIPTION

[0036] As shown in FIG. 1, a building element 1, for example a wall, is formed of a plurality of interlocking construction blocks 2a-2d. The construction blocks 2a-2d are plant-based construction blocks. That is, the construction blocks 2a-2d comprise a plant-derived material.

[0037] As described with reference to FIG. 2, each construction block 2a-2d is identical and has a recess 3 configured to interlock with interlocking portions 4 of two further construction blocks 2a-2d to form the building element 1. In particular, as shown in FIG. 1, a first construction block 2a has a recess 3a configured to interlock with interlocking portions 4 of second and third construction blocks 2b, 2c. In the same manner, the second construction block 2b has a recess 3b configured to interlock with interlocking portions 4 of the first construction block 2a and a fourth construction block 2d. In this way, a plurality of construction blocks 2 can be interlocked together in a generally horizontal direction to form a course, or layer, of a building element 1.

[0038] As shown in FIG. 1, the construction blocks 2 overlap each other in the horizontal direction such that the interlocking portions 4 can engage each other. This creates a front portion formed of construction blocks 2a and 2d as illustrated, and a rear portion formed of construction blocks 2b and 2c as illustrated. The interlocking between the front and rear portions provides a structurally rigid building element 1.

[0039] As also shown in FIG. 1, the front portion 2a, 2d and the rear portion 2b, 2c may be offset in a vertical direction. Accordingly, when a further course of construction blocks 2 are positioned on top of construction blocks 2a and 2d, there is interlocking between courses (i.e., layers) of construction blocks 2 in a vertical direction (i.e., between layered courses) as well as in a horizontal direction (i.e., in the same course). Such vertical and horizontal interlocking between courses further improves the structural rigidity of the building element 1. This arrangement is possible due to the profile of the recess 3 and interlocking portions 4, and in particular how the recess 3 and interlocking portions 4 have a uniform profile extending between the top face 5 and the bottom face allowing any degree of vertical overlap. This is particularly advantageous for the plant-based construction blocks 2a-2d because they will individually have a lower strength and hardness than an equivalent concrete construction block, but the interlocking arrangement provides a structurally rigid building element 1.

[0040] FIGS. 2A and 2B illustrate example plant-based construction blocks 2. In the examples of FIGS. 2A and 2B, the construction block 2 has a uniform cross-sectional form extending between a top face 5 and a bottom face (not illustrated in FIG. 2). The construction block 2 also has a front face 6, a rear face 7, and side faces 8, 9. The construction block 2 has a generally cuboid form, and the top face 5, bottom face, front face 6, and side faces 8, 9 are substantially planar. The rear face 7 comprises the recess 3 and the interlocking portions 4a, 4b.

[0041] As illustrated, the recess 3 is extends through the construction block 2, between the top face 5 and the bottom face. The recess 3 opens through the rear face 7. The recess 3 has a substantially uniform cross-sectional form.

[0042] The first and second interlocking portions 4a, 4b comprise first and second female engaging portions 10a, 10b, respectively. The first and second female engaging portions 10a, 10b are disposed on an interior side of the recess 3 that is spaced from the rear face 7 towards the front face 6.

[0043] The first and second interlocking portions 4a, 4b also comprise first and second male engaging portions 11a, 11b, respectively, that are located on opposing sides of the opening of the recess 3 through the rear face 7.

[0044] As illustrated, the first and second male engaging portions 11a, 11 b are rounded. In particular, the first and second male engaging portions 11a, 11 b comprise a cylindrical sector. In this example, each cylindrical sector comprises approximately 270 degrees of a cylinder. The remaining circumference of the cylinder is joined to the body of the construction block 2. As shown, the first and second male engaging portions 11a, llb extend beyond the rear face 7 of the construction block 2.

[0045] As illustrated, the first and second female engaging portions 10a, 10b are shaped to match the first and second male engaging portions 11a, 11b. That is, each female engaging portion 10a, 10b is rounded. In particular, each female engaging portion 10a, 10b comprises a tubular passage having a cylindrical part that matches the cylindrical sector of the first and second male engaging portions 11a, 11b.

[0046] The rounded form of the male engaging portions 11a, 11 b and female engaging portions 10a, 10b provides for large contact surface area between the interlocking portions 4 of adjacent construction blocks 2 and reduces stress concentrations under side or shear loads. The rounded form reduces stress concentrations within the constriction block 2.

Accordingly, the shape of the interlocking portions 4, particularly the rounded form of the male engaging portions 11a, 11b and female engaging portions 10a, 10b, mitigates the brittleness and lack of hardness of the plant-based material forming the construction block 2.

[0047] The cross-sectional form of the construction block 2 is symmetrical about a plane 12 extending through the construction block 2 equidistant from the side faces 8, 9 and in the direction of the recess 3. Accordingly, the first and second interlocking features 4a, 4b are equally spaced from the first side 8 and second side 9, respectively. This allows a plurality of identical construction blocks 2 to be interlocked in a horizontal direction.

[0048] As illustrated, the front face 6, side faces 8, 9 and top face 5 are planar, and so is the bottom face. Accordingly, each construction block 2 has five planar faces, and the recess 3 and interlocking portions 4a, 4b are arranged at the rear face 7. In this way, when a plurality of construction blocks 2 are assembled into a front portion and rear portion, as shown in FIG. 1, the building element 1 has planar front and rear surfaces. Accordingly, the construction blocks 2 can be assembled, as shown in FIG. 1, to provide a flat wall.

[0049] In the example of FIG. 2A, the first male engaging portion 1 la and the first female engaging portion 10a are arranged adjacent to each other such that the wall of the recess 3 has an inflection 65 at the join of the first male engaging portion 1 la and the first female engaging portion 10a. The second male engaging portion 1 lb and the second female engaging portion 10b have the same inflection 65. The inflection may further reduce stress concentrations within the construction block 2, further mitigating the brittleness and lack of hardness of the plant-based material forming the construction block 2.

[0050] In the example of FIG. 2B, there is a step 66 located between the first male engaging portion 11 a and the first female engaging portion 10a (and the same between the second male engaging portion 11 b and the second female engaging portion 10b). The step 66 is substantially parallel to the side faces 8, 9 and provides additional rigidity in the sideways direction when further construction blocks 2 are interlocked in the recess 3.

[0051] Referring to FIGS. 1 and 2, when second and third construction blocks 2b, 2c are interlocked with a first construction block 2a, side faces 8b, 8c of the second and third construction blocks 2b, 2c are facing each other within the recess 3, and the interlocking portions 4 of the first construction block 2a are engaged by interlocking portions 4 of the second and third construction blocks 2b, 2c. Accordingly, the recesses 3 of the construction blocks 2 are filled in by the corresponding parts of the other construction blocks 2, and the outer form of the building element 3 has planar front and rear surfaces 13, 14 as shown in FIG. 1. As the recesses 3 are filled by the interlocking portions 4 of adjacent construction blocks 2 there is no air gap and the building element 1 provides a solid wall.

[0052] The construction blocks 2 described above are plant-based construction blocks 2 formed of a majority plant-derived material and a binder. For example, the plant-derived construction blocks 2 may be hemp-composite construction blocks 2 comprising a hemp material, in particular a hemp shiv, which is made from the stalk of the hemp plant, and a binder. The binder may be lime-based or silica-based. The hemp shiv is cut into an aggregate material and then mixed with the binder then, as described further below, formed into the hemp-composite construction blocks 2. The binder dries or cures to solidify the hemp-composite construction blocks 2. The hemp-composite construction blocks 2 may comprise at least 50% shiv, for example about 75% shiv. The remainder may be binder (e.g., at most 50% or 25%, respectively), or may comprise a binder and other additive or bulk material. In other examples, the plant-based construction blocks 2 may comprise other plant cellulose material and a binder. Examples of plant cellulose material includes, for example, sugar cane, rye, wheat straw, kenaf, or sisal. The source of the plant-based material may be selected based on the location of the building so as to provide a local material source. Different plants are cultivated in different areas, so the choice of plant material may be based on local availability. The binder works in the same way to dry or cure to solidify the plant-based construction blocks 2.

[0053] In some examples, the plant-based construction blocks 2 comprise a wood material, for example a wood-composite material. The wood-composite material may comprise a bonded derivative wood material. As shown in FIG. 3, the wood-composite material may be provided in layers, or laminae 67a-67d. Each lamella may be CNC or laser cut to the profile. A wood-composite construction block 2 may therefore be formed by a plurality of laminae 67a-67d. in the illustrated example the wood-composite construction block 2 is formed of four laminae, but it will be appreciated that any number of laminae may be used, depending on the thickness of each lamella and the desired dimensions of the construction block 2. The laminae 67a-67d may be bonded or glued to each other. Additionally or alternatively, one or more joining rods, for example threaded or bonded joining rods, may pass through each lamella to join them together. As shown, the wood-composite construction block 2 has the same overall form as described with reference to FIGS. 2A and 2B, with the recess 3 and interlocking portions 4a, 4b.

[0054] In examples, each construction block 2 may have a length, between the side faces 8, 9, or between about 30 centimetres and about 100 centimetres, for example about 50 centimetres. In examples, each construction block 2 may have a depth, between the front face 6 and the rear face 7, of between about 10 centimetres and about 30 centimetres, for example about 20 centimetres. The combined depth of two interlocked construction blocks 2, between the front faces 6 of the two construction blocks 2, may be between about 25 centimetres and about 50 centimetres, for example about 30 centimetres. The height of each construction block 2, between the top face 5 and the bottom face, may be between about 10 centimetres and about 50 centimetres, for example about 30 centimetres.

[0055] In some examples, the building element 1 formed from the plant-based construction blocks 2 may be a load-bearing building element, for example a wall of a building. The interlocking between the construction blocks 2, as described above, means that the structural rigidity of the building element 1 is greater than the sum of the structural rigidities of the individual construction blocks 2, meaning that the building element 1 may be somewhat load-bearing.

[0056] Alternatively, as also described hereinafter, the building element 1 formed from the construction blocks 2 may be an internal or external wall insulation system, where the construction blocks 2 are arranged on a surface of an existing building element (e.g., wall) to improve thermal efficiency. In such examples the building element 1 may not be load-bearing other than to bear its own weight.

[0057] The building element 2 may be a new-build building element or a retrofit building 15 element.

[0058] As described in further examples hereinafter, the building element 1 may comprise plant-based construction blocks 2 and other construction blocks, for example concrete or polymer construction blocks. The other construction blocks may have the same shape as the plant-based construction blocks 2 and may be provided within the building element 1 to provide structural rigidity and/or load bearing paths through the building element 1. Additionally or alternatively, the building element 1 may comprise different types of plant-based construction blocks 2. For example, the wood-composite construction blocks of FIG. 3 may be used to provide a load-bearing sub-structure, and hemp-composite construction blocks 2 may be interlocked with the wood-composite construction blocks 2 to form a complete building element.

[0059] As shown in FIG. 4A, a building element 1 may further comprise a foundation 14 on which the construction blocks 2 are supported. The foundation 14 may be a flat concrete foundation on which the construction blocks 2 are placed. Alternatively, as shown in FIG. 4B, the foundation 14 may comprise one or more foundation blocks 15a, 15b having the same form as the construction blocks 2, so that construction blocks 2 can be interlocked with the foundation 14. The foundation blocks 15a, 15b may be formed of concrete, polymer, or other material. The foundation 14 may comprise a slot 16 in which some of the construction blocks 2 and/or foundation blocks 15 are received so as to provide a staggered starting surface on which the construction blocks 2 are placed, creating the vertical overlap described above. In particular, as shown in FIG. 4B, a front row of construction blocks 2 may be received in the slot 16 and a rear row of construction blocks may be placed on a vertically offset surface so that the front and rear rows are vertically offset providing the vertical interlocking between courses. As shown in FIG. 40, the foundation 14 may be formed of a plurality of pre-cast foundation elements 14a-14d. As shown, each foundation element 14a-14d may have a profile of interlocking features to interlock with the first course of construction blocks (2, see FIG. 4A) laid on top of the foundation 14.

[0060] As shown in FIGS. 4A, the building element 1 may comprise more than one wall, in this example four walls 16a-16d. The walls 16a-16d are joined at corners 17a-17d. The corners 17a-17d may comprise corner blocks 18 configured to interlock with the construction blocks 2. Such a corner construction block 18 is shown in FIG. 5A, which shows interlocking portions 19a, 19b corresponding to the shape of the interlocking portions (4, see FIG. 2) of the construction blocks (2, see FIG. 2). The interlocking portions 19a, 19b of the corner construction block 18 are arranged perpendicular to each other to provide a 90 degree corner. It will be appreciated that other angles may be provided. The corner construction blocks 18 may be made from plant-derived material (e.g., hemp-composite or wood-composite material), or may be made from concrete, polymer, or other suitable material. In particular, in some examples the corner construction blocks 18 are load-bearing for the building element 1, in which case concrete, polymer or wood-composite may be used for the corner construction blocks 18. FIG. 5B shows an example wood-composite corner construction block 18 formed of a plurality of laminae 68a-68e, similar to as described with reference to FIG. 3. The laminae 68a-68e of the wood-composite corner construction block 18 are joined by rods provided in holes 69. FIG. 50 illustrates how the corner construction blocks 18 are interlocked with the two walls extending therefrom to form the building element 1.

[0061] As also shown in FIGS. 5A and 5B, the corner construction block 18 may comprise a protrusion 30, in this example a square protrusion, arranged to engage a corresponding recess on the bottom of another corner block 18. In this way the corner blocks 18 laid on top of each other are interlocked with each other, improving the structural rigidity of the corner 17 and therefore also the building element 1. In other examples, the protrusion 30 may be circular, triangular, or other shape. In the example of FIG. 5B, each lamella may comprise a protrusion 30 that engages a recess in the adjacent lamella.

[0062] As shown in FIGS. 6 and 7, some construction blocks 20 of the building element 1 may be load-bearing, and other construction blocks 2 may be non-load-bearing. In particular, the load-bearing construction blocks 20 may be concrete or polymer or wood- composite construction blocks. The non-load-bearing construction blocks 2 may be plant-composite, in particular hemp-composite construction blocks. The load-bearing construction blocks 20 may have an identical shape to the non-load-bearing construction blocks 2, as described with reference to FIGS. 1 and 2, and may be interlocked with the non-load-bearing construction blocks 2 through the building element 1. The load-bearing construction blocks 20 can be provided to improve structural performance, in particular rigidity and/or load-bearing performance. The load-bearing construction blocks 20 can be provided in load-bearing locations.

[00631 As shown in FIG. 6, corner construction blocks 18 provide a corner 17 of the building element 1. The corner construction blocks 18 are load-bearing construction blocks, made of concrete or polymer or wood-composite. In addition, load-bearing construction blocks 18 extend diagonally across the building element 1, partially interlocking with each other and with non-load-bearing construction blocks 2, to form one or more tie lines 28 or diagonals. The tie lines 28, formed of load-bearing construction blocks 20, act to tie parts of the building element 1 to the corners 17 or other structurally rigid features and thereby improve the structural rigidity of the building element 1.

[0064] FIGS. 8A to 8C show example load-bearing construction blocks 20 that form the diagonal tie-lines 28. As shown in FIGS. 8A and 8B, each load-bearing construction block 20 comprises recess 72 formed in the first side face 8. The recess 72 extends from the bottom face 71 partially to the top face 6 and extends through the side face 8. A corresponding protrusion 73 is provided on the second side face 9, extending from the top face 6 partially to the bottom face 71 and out of (protruding away from) the side face 9. In the illustrated example the recess 72 is a cylindrical sector and the protrusion 73 is corresponding cylindrical sector. The cylindrical sectors of the recess 72 and protrusion 73 are at least 180 degrees, for example between 180 degrees and 270 degrees, of a complete cylinder so as to provide interlocking between the protrusion 73 and recess 72.

Accordingly, as shown in FIG. 8C, a diagonal tie line 28 formed of construction blocks 20a, 20b, 20c will be interlocked by the recesses 72 and protrusions 73. Accordingly, the diagonal tie line 28 of load-bearing construction blocks 20 can only be provided on the outer or inner portion of the building element 1 and their interlocking will provide the load-bearing. In particular, the other (outer or inner) portion of construction blocks that are oppositely oriented and interlocking with the load-bearing construction blocks 20a-20c may be non-load-bearing construction blocks, for example plant-based construction blocks as described above.

[0065] In an alternative example, the load-bearing construction blocks 20 may not have the recesses 72 and protrusions 73 and instead additional load-bearing construction blocks 20 may be provided in the opposite orientation, on the other (inner or outer) portion, to provide a load-bearing path between the load-bearing construction blocks 20a-20c illustrated and thereby provide a load-bearing diagonal tie line 28.

[0066] In the example of FIG. 7, load-bearing corner construction blocks 18 are provided at the corner 17, and a support portion 21 (e.g., triangular support portion) of load-bearing construction blocks 20 is formed, extending from and interlocked with the corner construction blocks 18 and with non-load-bearing construction blocks 2. The remainder of the building element 1 may be formed from non-load-bearing construction blocks 2. For example, the corner construction blocks 18 and load-bearing construction blocks forming the support portion 21 may be concrete or polymer or wood-composite construction blocks, and the non-load-bearing construction blocks 2 may be hemp-composite construction blocks 2.

[0067] As shown in FIG. 9, the building element 1 may include a support rod structure 22. In FIG. 9 the construction blocks are omitted for clarity. The support rod structure 22 comprises one or more support rods 23 that extend from the foundation 14 through the construction blocks. The support rod structure 22 may comprise a capping frame 24 connected to the ends of the support rods 23 opposite to the foundation 14, i.e., at the top of the building element 1. The capping frame 24 may be made from metal, polymer, or wood, particularly hardwood.

[0068] As shown in FIG. 4B and in FIG. 10, the foundation 14 may comprise one or more support rod attachments 25. The support rod attachments 25 are spigots extending from the foundation 14 to which the support rods 23 can be attached. The support rod attachments 25 and support rods 23 may be threadedly connected. The support rod attachments 25 may be provided in the foundation 14, as shown in FIG. 10, or in a foundation block 15, as shown in FIG. 4B. In alternative examples the support rod attachments may comprise threaded holes to which an end of the support rod 3 is attached.

[0069] As shown in FIG. 11, the support rod 23 may extend through a hole 26 provided in the non-load-bearing construction blocks 2 and/or the load-bearing construction blocks 20. The support rods 23 thereby extend through the construction blocks that form the building element 1. The support rods 23 can improve structural rigidity of the building element 1.

[0070] Referring to FIGS. 9 and 12, a tensioning system may be provided for the support rods 23. In particular, the ends of the support rods 23 at the capping frame 24 may be threaded, and a tensioning nut 27 may be provided to tension the support rods 23 between the foundation 14 and the capping frame 24, thereby acting to compress the construction blocks. Different parts 24a, 24b of the capping frame 24 may have lap joints where they overlap, particularly at the corners as shown in FIG. 12. After the construction blocks 2 have been positioned on the support rods 23 the capping plate 24 can be positioned and the tensioning nuts 27 tightened to place the support rods 23 in tension and the construction blocks 2 in compression and thereby improve the structural rigidity of the building element 1.

[0071] As shown in FIG. 6, a support rod 23 may extend through the building element 1 and in particular through one or more load-bearing construction blocks 20. The support rod 23 may extend through one of the load-bearing construction blocks 20 of the tie lines 28, thereby tying the support rod 23 to the corner construction blocks 18, further improving the structural rigidity of the building element 1.

[0072] In other examples, one or more construction blocks may not comprise one of the male engaging portions 11a, 11 b illustrated in FIG. 2, and in such an example the support rod 23 may extend through the vacated space. In this example, the support rod 23 acts to interlock adjacent construction blocks to each other.

[0073] As shown in FIGS. 5A and 5B, the corner blocks 18 may include a hole 29 for a support rod 23 such that a support rod 23 can extend through the corners 17.

[0074] In examples, the support rods 23 are provided by a rod or tube that extends through the building element 1 as described above. In other examples, the support rods 23 may be formed by pouring a hardening material, for example concrete or epoxy resin, into holes formed through the building element 1. The holes may be provided by a tube, for example a plastics tube, that extends through the building element 1.

[0075] FIGS. 13A and 13B illustrate a building 31 comprising a building element 1 as described above. In this example the building 31 is a new build building. The building 31 comprises building elements 1, in particular walls 1, formed of the construction blocks described above. The walls 1 comprise non-load-bearing plant-based construction blocks 2 and optionally also load-bearing construction blocks 20 (e.g., concrete, polymer or wood-composite construction blocks), corner blocks 18, tie lines 28, and a support rod structure 22 as described above. Atop of the walls 1 is a roof structure 32. The load of the roof structure 32 may be borne on the corners 17, load-bearing sub-structure, and/or support rod structure as described above.

[0076] As illustrated in FIGS. 13A, 13B and 14, frame members 33 may be provided to create a window and/or door opening for a door 36 or window 37. The frame members 33 may include a lintel 34 and support columns 35. The frame members 33 may comprise the same interlocking shape as the construction blocks for integration into the building element 1. In addition, the frame members 33 may comprise holes for support rods 23 to pass through. The frame members 33, lintel 34 and support columns 35 may be made from concrete, polymer or wood-composite and are load bearing.

[0077] In this way, a new build structure can be provided from the plant-based construction blocks 2, load-bearing construction blocks 20, and other features described above. The corners 17, load-bearing construction blocks 20, and/or support rod structure 22, as described above, can provide a structure and the non-load-bearing plant-based construction blocks 2 are interlocked with that structure to complete the building element 1.

[0078] FIGS. 15A to 150 illustrate a connection between a first building element la, for example an external wall, and a second building element lb, for example a further external wall or an internal wall. The second building element lb can be constructed of the interlocking plant-based construction blocks 2 as previously described. As shown, a joint block 39 may be provided within the first building element la, the joint block 39 having first and second interlocking portions 4a, 4b for interlocking with the first building element la. The joint block 39 has a third interlocking portion 4c for interlocking with the second building element lb. [0079] In the example of FIGS. 15A and 15B, to provide thermal isolation between the first building element la and the second building element lb, an insulating buffer 38 may be provided within the joint block 39. As shown, the joint block 39 may comprise an insulating buffer 38a between the third interlocking portion 4c and the first and second interlocking portions 4a, 4b. The insulating buffer 38a may be a thermally insulating plate bolted between two parts of the joint block 39, thermally isolating the third interlocking portion 4c from the remainder of the joint block 39.

[0080] A further insulating buffer 38b may be provided between the first interlocking portion 4a and the second and third interlocking portions 4b, 4c. The further insulating buffer 38b acts to thermally isolate the two parts of the first building element la on either side of the joint block 39. The further insulating buffer 38b may be a thermally insulating plate bolted between two parts of the joint block 39.

[0081] The joint block 39 may be made from concrete, polymer, or wood composite material. FIG. 150 shows an example joint block 39 formed of wood-composite having a plurality of laminae 70a-70e, similar to as described with reference to FIGS. 3 and 5B. A column of joint blocks 39 stacked on top of each other may provide a load-bearing substructure of the building element 1. In this example the insulating buffers 38a and 38b may not be required as the wood composite material is itself thermally insulating.

[0082] FIGS. 16A and 16B illustrate a retrofittable building element 1 for attachment to an existing building 40. As shown, the retrofittable building element 1 comprises a support rod structure 41 like that described with reference to FIG. 9, except that the support rods 42 are attached to the walls 43 of the existing building 40. FIG. 17 illustrates a thermally-insulated bracket 44 for attaching the supports rods 42 to the existing walls 43. A first portion 45 is attached, for example screwed, onto the existing wall 43. A thermally-insulating member 46 is attached to the first portion 45 and to the support rod 42, thereby holding the support rod 42 spaced from the existing wall 43 and thermally insulating the support rod 42 from the existing wall 43.

[0083] As shown in FIG. 16B, frame members 47, similar to the frame members 33 described with reference to FIGS. 13A, 13B and 14, can be provided to create openings for windows and doors as required.

[0084] The retrofittable building element 1 may include a foundation 14 as previously described. The support rods 42 may connect to the foundation 14 as previously described.

[0085] Construction blocks, in particular plant-based construction blocks 2 and optionally concrete or polymer or wood-composite construction blocks 18, can be assembled in an interlocking manner on the support rods 42 to form an outer layer on the building 40. In this way, a retrofittable external wall insulation system is provided.

[0086] FIGS. 18A to 19 illustrate a cladding system that can be provided on a building element 1 as described above. The cladding system can be provided on a new build building element 1, as shown in FIGS. 13A and 13B, or on a retrofittable building element 1 as shown in FIGS. 16A and 16B.

[0087] As shown in FIGS. 18A to 18C, one or more construction blocks, in particular plant-based construction blocks 2 and/or concrete or polymer construction blocks 20, may comprise a recess 48 to accommodate a cladding bracket 49 between interlocking construction blocks 2, 20. As illustrated, the recess 48 extends within the recess 3 forming the interlocking portions 4a, 4b of the construction block 2, 20, and over the top face 5 of the construction block 2, 20. The recess 48 accommodates an L-shaped bracket 50 for attachment of a cladding structure 49 as shown in FIG. 19. The L-shaped bracket 50 is sandwiched between adjacent interlocking construction blocks 2, 20 and the recess 48 is sized so that the adjacent interlocking construction blocks 2, 20 sit flush against each other. The L-shaped bracket may be attached to the construction block 2, 20, for example by a fastener or bonding agent. The L-shaped bracket 50 extends past the external face 53 of the building element 1 such that a rail 51 can be attached. Cladding panels 52 can be attached to the cladding rail 51. Several L-shaped brackets 50, rails 51, and cladding panels 52 can be provided to cover the external face 53 of the building element 1. The cladding panels 52 may be provided to improve the aesthetics and/or thermal performance of the building element 1.

[0088] FIGS. 20A and 20B illustrate an example block manufacturing system 54 for forming the plant-composite construction blocks 2 described above.

[0089] As mentioned above, the plant-based construction blocks comprise a majority plant-derived material and a binder. In particular, the plant-based construction blocks comprise plant cellulose material (e.g., hemp shiv) and a binder, for example a lime-based or silica-based binder. The plant cellulose material and binder are initially mixed to form a wet mix. The wet mix may comprise at least 50% plant cellulose material, for example about 75% plant cellulose material. The remainder of the wet mix (i.e., at most 50%, for example about 25%) may be the binder. The wet mix may additionally comprise a bulk material or other additive.

[0090] Once the materials are mixed, the wet mix is transferred to the block manufacturing system 54 as shown in FIGS. 20A and 208. The block manufacturing system 54 comprises a mould 55 having a shape corresponding to the final shape of the plant-based construction blocks. A controlled amount (mass and/or volume) of the wet mix is added to the mould. The block manufacturing system 54 comprises a compressing plate 56 on an actuator 57 that is arranged to compress the wet mix within the mould 55. The actuator may be an electric, pneumatic or hydraulic actuator. The compressing plate 56 presses the wet mix into the mould 55, ensuring that the wet mix fills the mould to the correct volume and conforms to the shape of the mould 55.

[0091] As illustrated, the compressing plate 56 may be pivoted out of the way to allow the wet mix to be added to the mould 55, and then pivoted such that the compressing plate 56 engages the mould 55. The compressing plate 56 may extend into the mould 55 and be shaped to correspond to the mould form.

[0092] Once compressed, the plant-based construction block can be removed from the mould by moving a base plate 58 of the mould 55 and using the compressing plate 56 and actuator 57 to push the plant-based construction block through the opposite side of the mould 55.

[0093] The same mould 66 may be used to cast concrete or polymer construction blocks 20.

[0094] FIGS. 20A and 203 show a block manufacturing system 54 for manufacturing one plant-based construction block at a time, but it will be appreciated that further moulds 55 and compression plates 56 may be provided and operated simultaneously.

[0095] In some examples, compression of the wet mix may be sufficient to unify the wet mix into the plant-based construction block and the plant-based construction block can be removed and the binder allowed to cure. In other examples, the mould 55 may be heated to speed up the binder curing process. In other examples, the plant-based construction blocks may be heated, for example in a kiln or by a heated air flow, after being removed from the mould.

[0096] FIGS. 21A and 21B illustrate an assembly system 59 for constructing a building element as described above, comprising plant-based construction blocks 2 and optionally concrete, polymer or wood-composite construction blocks 20, corner construction blocks, a support rod structure, and the other features described here.

[0097] As shown, a height-adjustable platform 60 is provided with a conveyor system 61 for moving pallets 62 of construction blocks 2, 20 along the platform 60. An operator 63 uses a hoist 64 to lift construction blocks 2, 20 from the pallet 62 and then lower them onto the building element 1 such that the construction blocks 2, 20 interlock with construction blocks 2, 20 already on the building element 1. If a support rod structure is used then the construction blocks 2, 20 can be lowered over the support rods. Alternatively, the support rods can be positioned after positioning the construction blocks 2, 20 by feeding the support rods through the openings in the construction blocks 2, 20. The height-adjustable platform 60 increments up as the building element 1 is constructed. A forklift or other machine can be used to lift more pallets 62 of construction blocks 2, 20 onto the height-adjustable platform 60 as required.

[0098] The assembly system 59 provides a safe and efficient method of construction. As no mortar or adhesive is used to bind the construction blocks 2, 20, the building site can be clean and safe from potentially hazardous chemicals.

[0099] Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of them mean "including but not limited to", and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps.

Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

[00100] Features, integers, characteristics, or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

CLAIMS1. A plant-based construction block for a building element, for example a wall, the plant-based construction block comprising a uniform recess extending between two opposite faces of the plant-based construction block, the recess comprising first and second interlocking portions disposed on opposite sides of the recess such that an interlocking portion of a further identical plant-based construction block can be received in the recess and engage the first interlocking portion, and such that an interlocking portion of a second further identical plant-based construction block can be received in the recess and engage the second interlocking portion.
2. The plant-based construction block of claim 1, wherein the plant-based construction block is generally cuboid and has a top face, a bottom face, opposing side faces, a front face, and a rear face, and wherein the recess extends through the plant-based construction block between the top face and the bottom face and opens through the rear face.
3. The plant-based construction block of claim 1 or claim 2, wherein the recess comprises a uniform profile extending between the top face and the bottom face such that the further identical construction block and the second further identical construction block zo can be slid into the recess.
4. The plant-based construction block of any preceding claim, wherein the first interlocking portion is a mirror image of the second interlocking portion.
5. The plant-based construction block of any preceding claim, wherein each of the first interlocking portion and the second interlocking portion comprises a male engaging portion and a female engaging portion arranged to receive a corresponding male engaging portion of the further or second further identical plant-based construction block, respectively.
6. The plant-based construction block of claim 5, wherein each male engaging portion and each female engaging portion are rounded.
7. The plant-based construction block of claim 6, wherein each male engaging portion comprises a cylindrical sector and each female engaging portion comprises a tubular passage having a cross-section corresponding to the cylindrical sector of the male engaging portion.
8. The plant-based construction block of claim 7, wherein the cylindrical sector of each male engaging portion comprises at least 180 degrees of a cylinder.
9. The plant-based construction block of claim 8, wherein the cylindrical sector of each male engaging portion comprises between about 180 degrees and about 270 degrees of a cylinder.
10. The plant-based construction block of any of claims 7 to 9, wherein each male engaging portion is disposed adjacent to the corresponding female engaging portion such that a wall of the plant-based construction block has an inflection where the male engaging portion joins the female engaging portion.
11. The plant-based construction block of any of claims 7 to 10, wherein the male engaging members of the first and second interlocking portions are disposed at an exterior mouth of the recess opening through a side of the plant-based construction block, and wherein the female engaging members of the first and second interlocking portions are disposed on an internal side of the recess.
12. The plant-based construction block of claim 11, wherein each male engaging member extends away from the plant-based construction block, beyond an exterior face of the plant-based construction block.
13. The plant-based construction block of any preceding claim, comprising a hemp-composite material.
14. The plant-based construction block of claim 13, wherein the hemp-composite material comprises a hemp shiv and a binder.
15. The plant-based construction block of claim 14, wherein the binder comprises a lime-based binder or a silica-based binder.
16. The plant-based construction block of any of claims 1 to 12, comprising a wood material.
17. The plant-based construction block of claim 16, wherein the wood material comprises a wood composite material.
18. The plant-based construction block of claim 16 or claim 17, wherein the plant-based construction block comprises a plurality of wood laminae.
19. A building element, for example a wall, comprising a first plant-based construction block, a second plant-based construction block and a third plant-based construction block, is each of the first, second and third plant-based construction blocks being according to any of claims 1 to 14, wherein one of the first and second interlocking portions of the second plant-based construction block and one of the first and second interlocking portions of the third plant-based construction block are both received in the recess of the first plant-based construction block so as to engage the first and second interlocking portions of the first plant-based construction block, respectively.
20. The building element of claim 19, wherein the second and/or third plant-based construction block is only partially inserted into the recess of the first plant-based construction block such that the plant-based construction blocks are staggered.
21. The building element of claim 19 or claim 20, further comprising a foundation supporting the first, second, and third plant-based construction blocks, and wherein the foundation is staggered such that the second and/or third plant-based construction block is only partially inserted into the recess of the first plant-based construction block.
22. The building element of claim 21, wherein the foundation further comprises an attachment for a tubular support rod arranged to extend through at least one of the first, second and third plant-based construction blocks.
23. The building element of claim 22, further comprising a tubular support rod attachable to the foundation by a threaded connector.
24. The building element of any of claims 19 to 23, further comprising a plurality of concrete construction blocks being shaped to interlock with the at least one of the first, second and third plant-based construction blocks.
25. The building element of claim 24, wherein the plurality of concrete construction blocks are arranged to provide a load bearing sub-structure of the building element.
26. The building element of any of claims 19 to 25, wherein the building element comprises a wall, for example an external wall of a building.
27. The building element of any of claims 19 to 25, wherein the building element comprises an outer skin attachable to an existing wall of a building.
28. The building element of claim 27, further comprising a plurality of mounting brackets attachable to the existing wall, and a plurality of support rods attachable to the mounting brackets, and wherein at least one of the first, second and third plant-based construction blocks is configured to be coupled to at least one of the plurality of support rods.
29. The building element of any of claims 19 to 28, further comprising a bracket arranged to be retained between the first and second plant-based construction blocks and to provide a mounting point for a cladding system, for example a rail of a cladding system.