NZ539980A

NZ539980A - Masonry wall system including blocks with tongues which form furring ridges

Info

Publication number: NZ539980A
Application number: NZ539980A
Authority: NZ
Inventors: James Mark Malone
Original assignee: Fletcher Building Holdings Ltd
Priority date: 2005-05-12
Filing date: 2005-05-12
Publication date: 2008-01-31
Also published as: WO2006121356B1; US20080168725A1; AU2006244688A1; WO2006121356A2; CA2608338A1; WO2006121356A3

Abstract

A masonry wall system 40 includes a number of masonry blocks, each block having two external side walls and being adapted for location, in use, adjacent to further said blocks such that the side walls form at least one wall surface of a wall structure. A number of the blocks include a tongue 8 projecting from a sidewall thereof, wherein, in use, said blocks can be arranged such that a number of the tongues 8 combine to form a number of furring ridges on the wall structure. The ridges may be arranged such that a distance between the centres of a furring ridge and an adjacent furring ridge is greater than a length of the longest of the blocks.

Description

PATENTS FORM NO. 5 Our ref: RC505380NZ NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION Complete After Provisional No. 539980 Filed: 12 May 2005 MASONRY WALL SYSTEM We, FLETCHER BUILDING HOLDINGS LIMITED a New Zealand company of 810 Great South Road, Penrose, Auckland, 1006, New Zealand hereby declare the invention, for which we pray that a patent may be granted to me and the method by which it is to be performed, to be particularly described in and by the following statement: Office of NX 1 1 AUG 2086 RECEIVED 300603237_1 ,DOC:RC:jar 300603052_RC505380 2 MASONRY WALL SYSTEM Field of the Invention This invention relates to masonry construction blocks and has particular application to a system of blocks used to create walls to which an interior and/or exterior lining is applied using furring.

Background to the Invention Masonry construction blocks are well known. These blocks are frequently hollow, and are ^ placed adjacent to each other using mortar in between adjacent blocks to form a wall. The cavities within the blocks align with each other in use so that concrete grout may be poured into the wall to create a solid structure. Reinforcing may also be placed through the cavities to add additional strength to the structure.

A difficulty with concrete walls constructed from blocks is that an interior lining is often required to be applied to the wall for interior spaces. In existing constructions, the lining typically comprises gypsum board or rock sheet and may be glued directly on to the concrete wall. However, more often furring is provided on the wall in the form of a series of wooden or metal 20 strips which are glued, nailed, bolted or otherwise fastened on to the interior wall surface. The gypsum board is then affixed using glue or fasteners to the furring to form a cavity separating the gypsum lining board from the block surface. This may provide enhanced acoustic ^ separation and/or a cavity for thermal and/or acoustic insulation. Services such as plumbing or electric wiring may also be provided in the cavity.

Having to provide separate furring results in a number of disadvantages. Firstly, there is the additional cost of sourcing the furring strip material. Secondly, there is the labour cost and additional time in having to affix the furring to the wall before the interior lining can be affixed.

A further difficulty with exterior concrete walls constructed from blocks is that it is difficult to weatherproof them by sealing to prevent penetration by water. In some situations this is overcome by attaching exterior claddings to furring on the block wall which has been sealed, thereby creating a ventilated cavity and drainage plane. intellectual property office of n.z. - 8 DEC 2006 300603052_RC505380 'RECEIVED Other systems of providing furring have been suggested whereby each block is provided with a plurality of projecting tongues. When the blocks are assembled some of the projecting tongues combine to form closely spaced furring ridges. A problem with such systems is that the space between the furring ridges has spare tongues projecting into it, which may increase noise and 5 heat transmission through the wall and may make it inconvenient to install insulation such as fibreglass batts between the furring ridges. In some systems of the prior art the tongues are removable, but it may be extremely time consuming to remove each unwanted tongue in a wall assembly. In addition, the extra, unneeded tongues may add to the cost of the bricks, and to their weight.

Object of the Invention It is an object of the present invention to provide a masonry wall system and/or a method of assembling a masonry wall which will at least ameliorate one or more of the disadvantages referred to above.

Alternatively, it is an object of the present invention to provide a masonry wall system and/or a method of assembling a masonry wall which will at least provide the public with a useful alternative to existing constructions or methods.

Further objects of the invention may become apparent from the following description.

Brief Summary of the Invention According to a first aspect of the present invention there is provided a masonry wall system including a plurality of masonry blocks, each block having two external side walls and being adapted for location, in use, adjacent to further said blocks such that the side walls form at least one wall surface of a wall structure constructed from the blocks, a plurality of said blocks including a tongue projecting from a sidewall thereof, each said block being moulded with no more than one said tongue on each of said external side walls, wherein, in use, said blocks can be arranged such that such that a plurality of said tongues combine to form a plurality of furring ridges on the wall structure such that a distance between centres of at least one of said furring ridges and an adjacent said furring ridge is greater than a length of the longest of said blocks.

Preferably, a distance between centres of each furring ridge and an adjacent furring ridge is greater than a length of the longest of said blocks. 300603052 RC505380 4 Preferably, the tongues are shaped and dimensioned such that a volume of air enclosed between the wall surface and a wailboard which is attached, in use, to the furring, is sufficient to cause attenuation of sound transmitted through the wall.

Preferably, the volume of air is sufficient that an "air-spring" acoustic damping mechanism is active.

Preferably, each said block is moulded with no more than one said tongue on each of said external side walls.

Preferably, the wall structure includes a plurality of rows of said blocks, and each said row of blocks is laterally offset relative to an adjacent row.

Preferably, the masonry wall system includes a first type of masonry block having no tongues, a second type of block having a substantially vertically orientated tongue at or adjacent a first end of the block, and a third type of masonry block having a substantially vertically orientated tongue intermediate a first end and a second end of the block.

Preferably, each said furring ridge is substantially continuous.

Preferably, each said furring ridge is substantially linear.

Preferably, a plurality of said furring ridges are substantially vertical.

Preferably, the distance between centres of adjacent ridges, or every second said ridge, is equal to the width of a standard size of wailboard.

Preferably, the distance between centres of adjacent ridges is substantially 600mm.

Preferably, the wall structure defines an opening, and the blocks adjacent said opening provide furring ridges around an edge of said opening.

Preferably, the wall structure intersects a second masonry wall structure to form a corner assembly including a plurality of interengaged masonry blocks, a plurality of which include a tongue projecting from a sidewall thereof, wherein a plurality of said tongues combine to form a pair of mutually orthogonal, substantially adjacent furring ridges.

According to a second aspect of the present invention a method of assembling a masonry wall includes interengaging a plurality of masonry blocks, a plurality of said blocks including a intellectual property office of n.z. 300603052 RC505380 „ -8 DEC 2006 RECEIVED tongue projecting from a sidewall thereof, such that said blocks are arranged so tnat a plurality of said tongues combine to form a plurality of furring ridges on the wall, wherein a distance between centres of at least one of said furring ridges and an adjacent said furring ridge is greater than a length of the longest of said blocks, and wherein each said block is moulded with 5 no more than one said tongue on each of said external side walls Preferably, the method includes including using a first type of masonry block having no tongues, a second type of block having a substantially vertically orientated tongue at or adjacent a first end of the block, and a third type of masonry block having a substantially vertically orientated tongue intermediate a first end and a second end of the block.

Preferably, the method includes arranging the blocks to define an opening such that the blocks 1 adjacent said opening provide furring ridges around an edge of said opening.

Preferably, the method includes arranging the blocks to form a first masonry wall intersecting a second masonry wall to form a corner assembly which has a plurality of interengaged masonry blocks, a plurality of which include a tongue projecting from a sidewall thereof, wherein a 15 plurality of said tongues combine to form a pair of mutually orthogonal, substantially adjacent furring ridges.

According to third aspect of the present invention there is provided a masonry wall system substantially as herein described with reference to any one of the embodiments of the invention illustrated in the accompanying drawings and/or examples.

According to a fourth aspect of the present invention a masonry wall system includes a plurality of masonry blocks, each block having two external side walls and being adapted for location, in use, adjacent to further said blocks such that the side walls form at least one wall surface of a wall structure constructed from the blocks, a plurality of said blocks including a tongue projecting from a sidewall thereof, wherein, in use, said blocks can be arranged such that each 25 said tongue combines with other said tongues to form a plurality of continuous furring ridges on the wall structure such that a distance between centres of each said furring ridge and an adjacent said furring ridge is greater than a length of the longest of said blocks, and wherein each said block in the system is moulded with no more than one said tongue on each of said external sidewalls.

According to a further aspect of the present invention a masonry wall system includes a plurality of masonry blocks, each block having two external side walls and being adapted for location, in use, adjacent to further said blocks such that the side walls form at least one wall 300503052_RC505380 6 surface of a wall structure constructed from the blocks, a plurality of said blocks including a tongue projecting from a sidewall thereof, wherein, in use, said blocks can be arranged such that a plurality of said tongues combine to form a plurality of furring ridges on the wall structure having a required spacing therebetween, wherein each said block in the system is moulded 5 with no more than one said tongue on each of said external sidewalls.

Further aspects of the invention, which should be considered in all its novel aspects, will become apparent from the following description given by way of example of possible embodiments of the invention.

Brief Description of the Drawings One or more embodiments of the invention will now be described with reference to the accompanying drawings in which: is a perspective view of a block according to a first embodiment of the invention. is a perspective view of a block according to a further embodiment of the invention. is a perspective view of the block of Figure 2 but including a knock out section in the tongue projecting from the block. is a perspective view of the block according to a still further embodiment of the invention in which a tongue projects from the block in a horizontal direction. is a partial perspective view of a wall constructed using blocks of the preceding figures to provide furring means.

Figures 6-9 are perspective views of four blocks according to four further alternative embodiments of the invention.

Figure 10 is a plan view of a pair of blocks forming a corner assembly according to a further alternative embodiment of the invention.

Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 300603052_RC505380 7 is a side elevation of a sill block with a horizontally extending projecting tongue according to a further alternative embodiment of the invention. is a plan view of a rebate block with a vertically extending projecting tongue according to a further alternative embodiment of the invention. is a plan view of a rebate lintel block with a vertically extending projecting tongue according to a further alternative embodiment of the invention. is a plan view of a lintel and half end closure with a vertically extending projecting tongue according to a further alternative embodiment of the invention.

Description of Best Modes for Performing Invention The term "furring" is used herein to describe means for attaching an exterior cladding, such as a weatherboard and/or an internal lining, such as gypsum wailboard, to a wall, which creates a space or cavity between the cladding/lining and the surface of the wall.

Referring to Figure 1, a block is shown according to the first embodiment of the invention being generally referenced 1 and having sidewalls 2 and 3, an end wall 4 and an opposite end 5 which may be provided in the form of a wall, or may be open as shown in Figure 1. The block 1 ^ is constructed from masonry material, and is preferably formed by a moulding process. The ™ block may have hollow or open interior cavities 6 and 7 which may be used in practice to 25 accommodate reinforcing and concrete to provide a solid wall structure such as is described further below.

The block 1 is provided with one or more projecting tongues 8. Typically blocks with tongues 8 on only one side will be used for external walls to which no external cladding is applied, while 30 blocks with tongues 8 on both sides will be used for internal walls, or for external walls where a cladding is applied to the exterior surface of the wall, thereby providing a ventilation cavity and drainage plane, and an interior lining is applied to the interior side of the wall.

In Figure 1, the tongues 8 take the form of elongate ridges provided in a generally vertical 35 direction as shown in the figure. In a preferred embodiment, the tongue 8 is formed as an Figure 11 Figures 12 Figure 13 Figure 14 300603052 RC505380 8 integral part of the block 1 during a moulding manufacturing process. Furthermore, the preferred embodiment includes a rebate 9 provided between one end of the tongue 8 and a side wall 2. This allows the portion of the tongue 8 which is adjacent to the rebate 9 to be removed, for example by use of a hammer, during a wall construction process so that the 5 resultant tongue 8 does not extend along the full height of the side wall 2. The resulting gap allows the reticulation of services such as plumbing or wiring.

Turning to Figure 2, an alternative embodiment is shown, which uses the same reference numerals as those used in respect of Figure 1 to designate like features. As can be seen from 10 the figure, the projecting tongue 8 in Figure 2 is provided at an open end 5 of the block 10 rather than being provided in a position between the two ends 4, 5. In an alternative embodiment the tongue 8 may be provided at the opposite end of the block.

Turning now to Figure 3, a block 20 which is similar to the block 10 of Figure 2 is shown, but 15 further including a rebate 9 provided between a portion of the tongue 8 and side wall 2. Again, this rebate 9 allows the section of the tongue 8 which is immediately adjacent to the rebate to be removed using a hammer, for example, so that the tongue does not extend the full height of the side wall 2.

An alternative embodiment is shown in Figure 4. Again, like reference numerals represent like features of the block 30 shown in Figure 4 and a block described above in the preceding figures. With the block 30 of Figure 4 the projecting tongue 8 extends in a horizontal direction along a base of the sidewall 2. However, those skilled in the art will appreciate that the tongue 8 could also be provided at a portion of the sidewall 2 somewhere between the upper and lower 25 edges of the side wall 2, or along an upper edge of the side wall 2.

Turning now to Figure 5, an example of a wall, generally referenced 40, is constructed using the blocks shown in Figures 1, 2 or 3 as illustrated, in combination with further wall components such as standard blocks 41 which are not provided with tongues. It will be seen that the 30 positioning of the tongue 8 at the positions illustrated in Figures 1 and 2 (or Figure 3) is such that when the wall 40 is constructed, the tongues 8 are provided adjacent to each other so as to provide substantially continuous ridges 42 which extend vertically along a side of the wall 40, even though the blocks have been assembled in the traditional manner, that is, with each row of blocks laterally offset relative to the adjacent row or rows. The preferred arrangement shown 35 in Figure 5 has a spacing between adjacent vertical ridges 42 which is such that the distance 300603052 RC505380 9 between the centres of the adjacent furring ridges is greater than the length of the largest of the blocks in the system. The spacing between some or all of the furring ridges can be increased by adding extra blocks having no tongues between the blocks which do have tongues.

Those skilled in the art will appreciate that the ridges 42 shown in Figure 5 provide furring to thereby allow an appropriate cladding, such as an exterior lining or an exterior wall surface (both not shown), to be affixed to the wall 40 so constructed. In a preferred embodiment the spacing between centres of adjacent furring ridges, or between every second furring ridge is substantially equal to a width of a standard size of wailboard. In a preferred example the 10 distance between centres of adjacent ridges is substantially 600mm, so that 1200mm wide wailboard can be affixed at its centre and edges.

Preferably the tongues are shaped and dimensioned such that the volume of air enclosed between the brick wall surface and the wailboard is sufficient to significantly attenuate noise 15 transmission through the wall, for example through an air-spring acoustic damping mechanism. The conditions necessary for this mechanism of sound attenuation to function are known to those skilled in the art.

In a particularly preferred embodiment acoustic and/or thermal insulation such as fibreglass 20 batts may be placed between the wall surface and the wailboard. This is made particularly convenient by the relatively large spacing between the centres of the furring ridges.

Cladding such as gypsum board may be affixed to the furring provided by the invention by directly gluing the board to the outer surface of the ridges, and/or by using fasteners such as 25 appropriate nails. The provision of the furring as an integral part of the block has the advantage that additional furring does not need to be sourced, nor erected. Therefore there is a significant cost saving. Furthermore, the use of a concrete furring element has advantages of increased noise attenuation and increased thermal resistance due to the resultant insulated cavity.

Those skilled in the art will also appreciate that, if required, some additional blocks with projecting tongues (not shown) may be used between the blocks creating the continuous ridges 42, although this embodiment is less preferred. 300603052 RC505380 It is preferred that each block be moulded with no more than one tongue on each of the sidewalls. If blocks are manufactured with more than one tongue on the sidewall then the additional tongues will need to be removed if a clear space between the furring ridges is required. This may increase the labour cost involved with assembling the wall, and may also 5 increase the cost of the bricks themselves. If blocks with extra tongues do not have the additional tongues removed then those extra tongues may act to increase the noise and heat transmission through the wall, and may also make it more difficult to install insulation in the space between the furring ridges.

In an alternative embodiment the blocks may be stacked directly on top of one another, rather ^ than offset.

The cavities 43 within the blocks may be provided with structural reinforcing and/or concrete so as to increase the structural integrity of the wall.

Although not shown in Figure 5, the rebates 9 may be used to remove a section of the relevant tongue 8 and therefore provide space through which utilities such as plumbing, wiring etc may be provided along the wall.

Figures 6, 7 and 8 show still further embodiments with the projecting tongues 8 provided on both sides of the block. Figure 9 shows a still further embodiment of a block with a tongue 8 on one side only. 9 Although the embodiments described above have at least one end wall, in a still further 25 embodiments (not shown) variants of the above blocks may be open at both ends, or closed at both ends.

Figure 10 shows a plan view of a first corner block 50a and a second corner block 50b combined to form a corner assembly, generally referenced 60, at the intersection of two 30 intersecting masonry walls. The corner blocks are arranged in the usual way, with one end 51 a of the first corner block 50a abutting the side 52b of the second corner block 50b and the end 51b of the second block 50b substantially aligned with the outermost side 52a of the first block 50a. 300603052 RC505380 11 The first corner block 50a has a projecting tongue 8a which is spaced apart from the end 51a of the block 50a by approximately the same distance as the height H2 of the projecting tongue 8b of the second block 50b. The second corner block 50b has a projecting tongue 8b spaced apart from the end 51b of the block 50b by a distance substantially equal to a width W of the 5 first block 50a plus the height H1 of the projecting tongue 8a of the first block 50a. In this way the two projecting tongues 8a, 8b form a pair of mutually orthogonal, substantially adjacent furring ridges. This allows sheets of a suitable lining (not shown) to be secured along the edges which form the interior corner.

Those skilled in the art will appreciate that further layers of blocks will be provided above and ^ below the blocks shown in the figure. In a preferred embodiment each block used for the ^ corner assembly has a protruding tongue, so that continuous furring ridges are formed. In other less preferred embodiments some of the blocks may not have protruding tongues. In these embodiments the furring ridges are discontinuous.

Figure 11 shows a sill block with a horizontally extending projecting tongue 8.

Figure 12 shows a rebate block with a vertically extending projecting tongue 8.

Figure 13 shows a rebate lintel block with a vertically extending projecting tongue 8.

Figure 14 shows a lintel and half end closure with a vertically extending projecting tongue 8.

This skilled in the art will appreciate that suitable combinations of the blocks illustrated above 25 may be used to define an opening in the wall which is provided with furring ridges around the edge of the opening.

Where in the foregoing description, reference has been made to specific components or integers of the invention having known equivalents, then such equivalents are herein 30 incorporated as if individually set forth.

Although this invention has been described by way of example and with reference to possible embodiments thereof, it is to be understood that modifications or improvements may be made thereto without departing from the spirit or scope of the appended claims. 300503052_RC505380 300603052 RC505380 13

Claims

WHAT WE CLAIM IS: intellectual property ofrce of n.2. "8 DEC 2006 RECEIVED

1. A masonry wall system including a plurality of masonry blocks, each block having two external side walls and being adapted for location, in use, adjacent to further said blocks 5 such that the side walls form at least one wall surface of a wall structure constructed from the blocks, a plurality of said blocks including a tongue projecting from a sidewall thereof, each said block being moulded with no more than one said tongue on each of said external side walls, wherein, in use, said blocks can be arranged such that such that a plurality of said tongues combine to form a plurality of furring ridges on the wall 10 structure such that a distance between centres of at least one of said furring ridges and ) an adjacent said furring ridge is greater than a length of the longest of said blocks.

2. The masonry wall system of claim 1 wherein a distance between centres of each furring ridge and an adjacent furring ridge is greater than a length of the longest of said blocks.

3. The masonry wall system of claim 1 or 2 wherein the tongues are shaped and 15 dimensioned such that a volume of air enclosed between the wall surface and a wailboard which is attached, in use, to the furring, is sufficient to cause attenuation of sound transmitted through the wall.

4. The masonry wall system of claim 3 wherein an air-spring acoustic damping mechanism is active. 20

5. The masonry wall system of any one of the previous claims wherein the wall structure includes a plurality of rows of said blocks, and each said row of blocks is laterally offset ^ relative to an adjacent row.

6. The masonry wall system of any one of the previous claims including a first type of masonry block having no tongues, a second type of block having a substantially 25 vertically orientated tongue at or adjacent a first end of the block, and a third type of masonry block having a substantially vertically orientated tongue intermediate a first end and a second end of the block.

7. The masonry wall system of any one of the previous claims wherein each said furring ridge is substantially continuous. 30

8. The masonry wall system of any one of the previous claims wherein each said furring ridge is substantially linear. 300603052_RC505380 14

9. The masonry wall system of any one of the previous claims wherein a plurality of said furring ridges are substantially vertical.

10. The masonry wall system of any one of the previous claims wherein the distance between centres of adjacent ridges, or every second said ridge, is equal to the width of a standard size of wailboard.

11. The masonry wall system of claim 10 wherein the distance between centres of adjacent ridges is substantially 600mm.

12. The masonry wall system of any one of the previous claims wherein the wall structure defines an opening, and the blocks adjacent said opening provide furring ridges around an edge of said opening.

13. The masonry wall system of any one of the previous claims wherein the wall structure intersects a second masonry wall structure to form a corner assembly including a plurality of interengaged masonry blocks, a plurality of which include a tongue projecting from a sidewall thereof, wherein a plurality of said tongues combine to form a pair of mutually orthogonal, substantially adjacent furring ridges.

14. A method of assembling a masonry wall including interengaging a plurality of masonry blocks, a plurality of said blocks including a tongue projecting from a sidewall thereof, such that said blocks are arranged so that a plurality of said tongues combine to form a plurality of furring ridges on the wall, wherein a distance between centres of at least one of said furring ridges and an adjacent said furring ridge is greater than a length of the longest of said blocks, and wherein each said block is moulded with no more than one said tongue on each of said external side walls.

15. The method of claim 14 including using a first type of masonry block having no tongues, a second type of block having a substantially vertically orientated tongue at or adjacent a first end of the block, and a third type of masonry block having a substantially vertically orientated tongue intermediate a first end and a second end of the block.

16. The method of claim 14 or 15 including arranging the blocks to define an opening such that the blocks adjacent said opening provide furring ridges around an edge of said opening.

17. The method of claim 14, 15 or 16 including arranging the blocks to form a first masonry wall intersecting a second masonry wall to form a corner assembly which has a plurality of interengaged masonry blocks, a plurality of which include a tongue projecting from a intellectual property office of n.z. -8 DEC 2006 RECEIVED 300603052 RC505380 15 sidewall thereof, wherein a plurality of said tongues combine to form a pair of mutually orthogonal, substantially adjacent furring ridges.

18. A masonry wall system substantially as herein described with reference to any one of the embodiments of the invention illustrated in the accompanying drawings and/or examples. Intellectual property-office of n.z. -8 DEC 2008 received,