US20110258957A1

US20110258957A1 - Masonry unit for constructing a multi-wythe wall

Info

Publication number: US20110258957A1
Application number: US13/090,371
Authority: US
Inventors: Andrew P. Virnich
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-04-21
Filing date: 2011-04-20
Publication date: 2011-10-27

Abstract

A masonry unit for constructing a wall is disclosed. The masonry unit includes at least three substantially vertical parallel partitions. Each of the partitions connects to an adjacent partition by a web thereby defining a pair of oppositely-facing open-ended recesses on either side of the web. Each of the webs connecting the partitions is offset from any adjacent webs in the masonry unit. A plurality of separated continuous vertical cavities extending through multiple layers of stacked masonry units are formed within the wall when positioning the multiple layers of stacked masonry units on top of each other in a horizontally offset and vertically inverted manner.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 61/326,346 filed Apr. 21, 2010, the disclosure of which is hereby incorporated by reference in its entirety.

STATEMENT CONCERNING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD OF THE INVENTION

This invention generally relates to masonry materials, particularly masonry units for constructing multi-wythe walls.

BACKGROUND OF THE INVENTION

Masonry units (e.g., clay or concrete bricks or blocks) have been used for many years in the construction of building walls. To form a wall, multiple masonry units are typically stacked vertically with cementitious mortar materials placed between them in order to permanently bind the units together. In many cases, the masonry units are stacked in a single-wythe structure (i.e., a structure having a width of one masonry unit). While single-wythe walls are popular and relatively easy to construct, increasingly demanding building codes now require wall systems with greater structural integrity, increased thermal resistance, and improved moisture control.
These requirements have proven difficult to meet, both physically and economically, using single-wythe wall designs. Consequently, the industry has begun to utilize multi-wythe masonry wall systems and cavity wall systems. These systems allow for steel reinforcement within the wall, greater levels of thermal insulation, and air spaces that allow intrusive moisture to be controlled and channeled out of the wall to the building's exterior.
Such wall systems typically include two or more separately-constructed walls that together form the composite wall. Such composite walls are typically constructed by first building a concrete masonry wall, applying a layer of insulating material to the exterior surface of the masonry wall, and then building a second wall (sometimes called a veneer wall) that is spaced from the first wall. The two masonry walls are typically mechanically tied together with metal wires or tabs placed in the horizontal mortar joints of both walls. An air space may be left between the insulation of the first wall and the second wall to define a cavity wall or a rain screen wall that permits the ventilation of air between the two walls. The wall system may also be reinforced with vertical steel rods running through the cores of the masonry units, horizontal steel rods, and/or horizontal ladder wires.
The construction of a composite wall of this type is typically time consuming and labor intensive. Because the two walls are build sequentially, the construction of the veneer wall depends on the completion on the concrete masonry wall. Moreover, when vertical steel reinforcement rods are utilized during construction, masons must typically lift the heavy masonry units to thread their cavities over the top of fixed vertical rods. Because vertical rods are typically four to eight feet in length, this task can be very strenuous.
Hence, there is a need for an improved masonry unit that facilitates construction of a multi-wythe wall.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides a masonry unit for constructing a wall. The masonry unit comprises at least three substantially vertical parallel partitions extending along a lengthwise direction. Each of the partitions connects to an adjacent partition by a web extending in a widthwise direction, thereby defining a pair of oppositely-facing open-ended recesses on either side of the web. Each of the webs connecting the partitions is offset in a lengthwise direction from any adjacent webs in the masonry unit. When a wall is formed from a plurality of the masonry units by positioning multiple rows of stacked masonry units on top of each other in a horizontally offset and vertically inverted manner, a plurality of separated continuous vertical cavities extending through the multiple rows are formed within the wall.
In some forms, the masonry unit may further include a vertically-extending support formed along one at least one of the partitions to provide support for the partition during fabrication of the masonry unit. The vertically-extending support may be aligned with one of the webs in the lengthwise direction. If mortar is applied to the top surface and bonds the unit to the unit above, the vertically-extending support may further lend additional load-bearing capacity to the overall wall system.
In some forms, the masonry units may be configured such that, if a second row of masonry units is stacked on top of a first row of masonry units in a vertically inverted manner and are horizontally offset approximately one-half of an overall length of the masonry unit from the first row, then the webs of the masonry units in the first row and the second row are vertically aligned with one another. Each of the webs may be offset from any adjacent webs in the lengthwise direction of the masonry unit by substantially one half of an overall length of the masonry unit. Moreover, each of the webs may be offset from ends of the partitions in the lengthwise direction of the masonry unit by substantially one quarter of an overall length of the masonry unit. Because some mortar may be inserted between the blocks, the one-half and one-quarter offsets may be approximate.
In some forms, at least one web may include a vertically facing open-ended slot configured to receive a horizontal reinforcement rod.
In some forms, the partitions and the webs may comprise cement and each of the partitions may integrally connect to the adjacent partitions by the webs.
In some forms, the masonry unit is generally rectangular shaped. In this way, when a wall is formed, these masonry units may maintain an aesthetic consistent with conventional masonry units and, moreover, may be made to easily interface with standard corners, end pieces, and other fittings.
A masonry unit of this type offers many advantages over conventional concrete masonry units with closed cavities. With the improved masonry unit, a wall can be constructed with multiple layers in manner that is far easier than the construction of a conventional composite wall. Whereas conventional composite walls require the sequential building of at least two walls with a space there between, by using the disclosed masonry unit the same effect can be achieved with the construction of a single wall. Moreover, because the masonry unit has open-sided cores, the masonry units do not need to be lifted over the top of vertical reinforcement rods during construction. This reduces the amount of lifting necessary to build the wall and eliminates the amount of reinforcement rod material required (as longer continuous lengths of reinforcement material can be utilized).
The masonry units can be used to form a wall with separated continuous vertical cavities. Some of these cavities can serve as a rain screen wall to control moisture and/or provide ventilation to avoid mold and maintain healthy building structures. Additionally, these cavities can receive insulation, receive reinforcement materials to strengthen the wall, and/or house utilities such as plumbing lines, electrical cables, and so forth.
Additionally, this single wall has superior thermal and acoustic transmission properties that are not found in walls constructed with masonry units in which the webs directly connect a front and rear face of the wall.
The foregoing and advantages of the invention will appear in the detailed description which follows. In the description, reference is made to the accompanying drawings which illustrate a preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:

FIG. 1 is a perspective view of a first embodiment of a masonry unit according to the present invention;

FIG. 2 is a bottom view of the masonry unit of a second embodiment similar to the unit of FIG. 1;

FIG. 3 is a perspective view of a third embodiment of a masonry unit according to the present invention;

FIG. 4 is a perspective view of a fourth embodiment of a masonry unit according to the present invention;

FIG. 5 is a perspective view of a fifth embodiment of a masonry unit according to the present invention;

FIG. 6 is a top view of an upper row of masonry units according to the present invention to be placed on a lower row of masonry units according to the present invention;

FIG. 7 is a top view of the upper row of masonry units of FIG. 6 being positioned on the lower row of masonry units;

FIG. 8 is a top view of the upper row of masonry units of FIG. 6 positioned on the lower row of masonry units;

FIG. 9 is a side view of the upper row of masonry units of FIG. 6 positioned on the lower row of masonry units;

FIG. 10 is an exploded perspective view of a wall of masonry units according to the present invention including vertical reinforcement rods;

FIG. 11 is an exploded perspective view of a wall of masonry units according to the present invention including insulation;

FIG. 12 is an exploded perspective view of a wall of masonry units according to the present invention including a horizontal reinforcement rod;

FIG. 13 is an exploded perspective view of a wall of masonry units according to the present invention including two horizontal reinforcement rods;

FIG. 14 is a top view of a wall of masonry units according to the present invention including a horizontal “ladder” reinforcement structure;

FIG. 15 is a top view of a wall of masonry units according to the present invention including a horizontal “truss” reinforcement structure;

FIG. 16 is an exploded perspective view of a wall of masonry units according to the present invention including a vertical reinforcement rod and insulation;

FIG. 17 is a top view of a wall of masonry units according to the present invention including a horizontal “truss” reinforcement structure, insulation, and vertical reinforcement rods and grout proximate an interior surface of the wall;

FIG. 18 is a top view of a wall of masonry units according to the present invention including a horizontal “truss” reinforcement structure, insulation, and vertical reinforcement rods and grout proximate an interior surface and an exterior surface of the wall;

FIG. 19 is a top view of a wall of masonry units according to the present invention including a horizontal “truss” reinforcement structure, vertical reinforcement rods and grout proximate an interior surface of the wall, and insulation that defines air gaps proximate an exterior surface of the wall;

FIG. 20 is a top view of a wall of masonry units according to the present invention including a horizontal “truss” reinforcement structure, vertical reinforcement rods and grout proximate an interior surface and an exterior surface of the wall, and insulation that defines air gaps proximate the exterior surface of the wall; and

FIG. 21 is an exploded perspective view of a wall of masonry units according to the present invention illustrating one of the separated continuous vertical cavities.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring generally to the figures, a masonry unit according to the present invention facilitates improved construction of a wall compared to previous masonry unit designs. Masonry units according to the present invention, when constructed to form a single wall, provide properties and advantages of a multi-wythe and/or a cavity-wall system. In the following paragraphs, the structure of masonry units according to the present invention are first described. Thereafter, walls made from masonry units according to the present invention are described in further detail.
Referring first to FIG. 1, an exemplary masonry unit 10 is illustrated which is generally rectangular in overall form. The masonry unit 10 includes three generally parallel, vertically-extending partitions 12 a, 12 b, and 12 c that span the length and height of the masonry unit 10. The first, second, and third partitions 12 a, 12 b, and 12 c are spaced apart from each other in a width direction of the masonry unit 10 to generally define gaps or spaces there between. To connect the partitions 12 a, 12 b, and 12 c in the width direction, the masonry unit 10 further includes two integral, generally parallel, and vertically-extending connecting webs 14 a and 14 b. A first connecting web 14 a integrally connects the first partition 12 a and the second partition 12 b, and a second connecting web 14 b integrally connects the second partition 12 b and the third partition 12 c. As shown, both of the connecting webs 14 a and 14 b extend from a top face to a bottom face of the masonry unit 10.
The connecting webs 14 a and 14 b are spaced from horizontally-facing ends 16 a, 16 b, and 16 c of the partitions 12 a, 12 b, and 12 c to define, together with the partitions 12 a, 12 b, and 12 c, oppositely facing recesses 18 a, 18 b, 20 a, and 20 b on the ends of the masonry unit 10. These recesses 18 a, 18 b, 20 a, and 20 b are generally U-shaped, extend inwardly from the horizontally-facing ends 16 a, 16 b, and 16 c, and are the fully height of the masonry unit 10. During the construction of a wall, these side-accessible recesses or open-sided cores permit the masonry unit 10 to be moved horizontally relative to a vertical reinforcement rod to receive the rod in one of the recesses 18 a and 18 b. This feature significantly reduces the amount of lifting required for constructing a wall using masonry units 10 compared to traditional masonry units with cavities/cores that are centrally disposed in the masonry unit and which are closed except on the top and bottom faces of the masonry unit.
In addition to the benefit of reduced labor during construction, this open-sided core design also allows for the use of longer vertical supports because overhead lifting is not required. This means that overlaps, ties and couplers do not need to be used to join separate shorter vertical supports and reduces the amount of vertical support material needed.
To accommodate the formation of separated continuous vertical cavities in a wall constructed from the masonry units 10 in which adjacent rows of masonry units 10 are offset by one-half length, the webs 14 a and 14 b are preferably spaced apart from each other in a length direction of the masonry unit 10 by about one-half of the overall length of the partitions 12 a, 12 b, and 12 c. The webs 14 a and 14 b are also preferably spaced apart from the horizontally-facing ends 16 a, 16 b, and 16 c of the partitions 12 a, 12 b, and 12 c by about one-quarter of the overall length of the partitions 12 a, 12 b, and 12 c. To account for the mortar between the units, the distance between the webs 14 a and 14 b may be slightly greater than one-half of the length of unit 10 and the distance from the webs 14 a and 14 b to the nearest ends 16 a, 16 b, and 16 c may be slightly less than one-quarter length. Such dimensions provide a well-balanced structure about both horizontal axes, which facilitates ease of handling and installation. Such dimensions also provide additional advantages when constructing a wall using multiple masonry units 10 as described in further detail below.
In addition to the partitions 12 a, 12 b, and 12 c and the webs 14 a and 14 b, the masonry unit 10 further includes vertically-extending supports 21 a and 21 b that integrally connect to and are disposed on the first and third partitions 12 a and 12 c, respectively. These supports 21 a and 21 b are positioned along the inwardly facing side of the partitions 12 a and 12 c in the recesses 18 a and 18 b in a region in which the partitions 12 a and 12 c are largely otherwise unsupported (i.e., not disposed near the webs 14 a and 14 b). The supports 21 a and 21 b provide support for the first and third partitions 12 a and 12 c, respectively, when initially fabricating the masonry unit 10. Further, in a wall formed from the masonry units the supports 21 a and 21 b may be respectively aligned with the first and second webs 14 a and 14 b in such a manner that the supports 21 a and 21 b may also be vertically aligned with one another when the units 10 are stacked.
The interfaces or corners between the partitions 12 a, 12 b, and 12 c, webs 14 a and 14 b, and supports 21 a and 21 b are preferably curved or radiused to reduce stress concentrations and cracking at the interfaces. In some embodiments, such as the embodiment depicted in FIG. 2, the partitions 12 a, 12 b, and 12 c may have a greater or increased thickness near the webs 14 a and 14 b. Among other things, this increased thickness may help to strengthen the partition-web connection. However, in some embodiments, such as the embodiment of the masonry unit 110 shown in FIG. 3, the interfaces may have squared corners between the partitions 12 a, 12 b, and 12 c, webs 14 a and 14 b, and supports 21 a and 21 b.
Referring now to FIG. 4, in some embodiments the masonry unit 210 includes horizontally-facing ends 16 a, 16 b, and 16 c with vertically-extending, open-ended notches 22 a, 22 b, and 22 c, respectively. The notches 22 a, 22 b, and 22 c may receive mortar when additional masonry units 210 are positioned adjacent the ends 16 a, 16 b, 16 c of the masonry unit 210 to form a wall. The notches 22 a, 22 b, and 22 c help to ensure good receipt of the mortar by the masonry unit and increases the length of the interface between the mortar and the masonry unit.
In addition to the preferred dimensions and features described above, a masonry unit according to the present invention may have various heights. For example, the masonry units shown in FIGS. 1-4 are approximately half the height of traditional masonry units. In some embodiments, such as the embodiment shown in FIG. 5, the masonry unit 310 may have generally the same height as traditional masonry units. Alternatively, masonry units according to the present invention may have any other appropriate height and various overall length and width dimensions.
Turning to FIGS. 6-9, the construction of two layers of a wall 25 using multiple masonry units 410 according to the present invention will now be described. First, as shown in FIG. 6, several masonry units 410 are positioned in a side-by-side manner (i.e., the horizontally-facing ends 16 of the masonry units 410 are disposed proximate one another) such that a lower row 30 of a wall 25 is formed (shown with no cross-hatching). Mortar is then placed between the masonry units 410 (e.g., within the notches 22 and between the horizontally-facing ends 16) and, in some cases, mortar is placed on the upper surfaces of the masonry units 410.
Next, and as depicted in FIGS. 7-9, an upper row 32 of masonry units 410 is moved into position on top of the lower row 30. However, the masonry units 410 in the upper row 32 are vertically inverted relative to those in the lower row 30 (i.e., the masonry units 410 in the upper row 32 each appear similar to the letter S whereas those in the lower row 30 each appear similar to a backwards letter S). In addition, the masonry units 410 in the upper row 32 are horizontally offset relative to those in the lower row 30 by approximately one half of the overall length of the masonry units 410. Again, this is approximate because of the inclusion of mortar between the masonry units 410 makes the distance between the repeating pattern established by the masonry units 410 slightly greater than the true length of the masonry units 410.
Positioning the masonry units 410 in the lower and upper rows 30 and 32 in the above manner provides several advantages. For example, the webs 14 of the upper row 32 are stacked vertically upon one of the webs 14 of the lower row 32. As such, the webs 14 define a plurality of separated continuous vertical cavities 36 (FIG. 8) that extend through both the lower and upper rows 30 and 32. Referring forward to FIG. 21, a wall 625 is shown in which a volume 60 is illustrated that defines one of the continuous vertical cavities. Notably, the cross section of the volume 60 is generally consistent over the height of the wall 625 and, if further rows of masonry units were laid, these rows would further continue to define this column and would not significantly interrupt this volume 60.
As used herein, the term “continuous” and variations thereof, when used to describe the vertical cavities 36, mean that the shape of the cavities 36 is generally constant as viewed from above as the webs 14 align with one another. It will be appreciated that some limited amount of discontinuity may occur at the interfaces between the masonry units 410 or where other features have been intentionally introduced (e.g., as described below, the vertically facing open-ended slots 42 configured to receive horizontal reinforcement rods 44 which may interrupt the continuity of the wall of the cavity).
Because of the separation of the cavities 36, grout and/or insulation, etc. is prevented from leaking horizontally into other cavities where it is not desired. Similarly, the separation facilitates vertical drainage of intrusive moisture because it has a clear, uninterrupted path downward. There are no webs obstructing the flow as is found with conventional masonry units.
The separated continuous vertical cavities 36 may provide vertical compartmentalization that inhibits horizontal air movement within the wall 25 (i.e., air movement between different cavities 36). When combined with well-known ventilation components (not shown) at the top and bottom of the wall 25, the vertical cavities 36 also facilitate natural convective airflow that may effectively act as a rain screen wall. Additionally, any moisture that passes through the outermost partition 12 c of the masonry unit 410 or through voids in the mortar joints drains down the interior of the vertical cavities 36 and out through weep holes (not shown) at the bottom of the wall 25. In this way, wind-driven moisture is controlled and channeled out of the wall 25 to reduce the potential for moisture-induced problems.
In addition, the serpentine transmission paths through the wall 25 defined by the horizontally offset webs 14 provide thermal and acoustic advantages. In particular, the serpentine paths define relatively long thermal and acoustic paths connecting the interior and exterior of the wall 25 compared to walls constructed using traditional masonry units with single webs that directly connect the front and back walls of the masonry unit. Assuming the material of the masonry unit to be the path of least resistance for sound or heat, the distance through the wall is a length approximately equal to the thickness of the wall plus the lengthwise distance between the webs 14. Such a long thermal path significantly reduces the rate at which heat may be conducted through the wall 25 and, similarly, the long acoustic path significantly reduces sound transmission through the wall 25.
Additionally, the wall 25 advantageously provides additional thermal mass to the temperature stability of a building interior. Thermal mass can also reduce the need for supplemental heat in cold environments when included as part of an overall passive solar heating design.
Moreover, as best seen in FIG. 9, the resultant wall has an aesthetic consistent with conventional masonry design. Accordingly, it is possible if desired to use conventional corners, closed end units, etc. with the improved masonry unit.
Referring now to FIGS. 10-20, walls formed by masonry units according to the present invention may include various additional components and materials to enhance their characteristics. For example and referring to FIG. 10, one or more of the separated continuous vertical cavities 36 of a wall 125 may house one or more vertical reinforcement rods 38 (e.g., steel rods). As described briefly above, when constructing a wall, the masonry units may simply be moved horizontally relative to the reinforcement rods 38 to receive the rods. As such and unlike traditional masonry units, the masonry units according to the present invention do not need to be lifted above and subsequently lowered over the reinforcement rods 38. This provides three distinct advantages over walls constructed using traditional masonry units. First, labor costs are reduced because constructing the wall requires less time. Second, the potential for shoulder and back strains are reduced due to the reduced amount of masonry unit lifting. Third, the total length of reinforcement material is reduced because longer lengths of verticals rods can be used. This minimizes the number of rod overlaps, ties, and/or couplers.
As another example and referring to FIG. 11, one or more of the separated continuous vertical cavities 36, such as the cavities 36 proximate the outermost partition 12 c, may receive insulation 40. Other types of insulation may alternatively be used. Depending on the type that is used, the insulation 40 can be pre-installed into the masonry unit or added after the wall 225 is constructed. The insulation 40 may also be shaped to receive one of the vertically-extending supports 21 of the masonry units. Regardless of the type and specific shape that is used, the insulation further reduces the thermal conductivity through the wall and provides further moisture control.
As yet another example and referring now to FIGS. 12 and 13, in some embodiments, masonry units 510 according to the present invention may further include features to receive horizontally-extending supports. In particular, the webs 14 of the masonry units 510 include vertically facing open-ended slots 42 configured to receive horizontal reinforcement rods 44. The masonry units 510 and horizontal reinforcement rods 44 may be used to construct one or more rows of the wall 325.
A wall formed by masonry units according to the present invention may alternatively have other types of horizontal reinforcements. For example and referring to FIG. 14, the wall 425 may include one or more horizontal “ladder” reinforcement structures 46 between rows of masonry units 410. As another example and referring to FIG. 15, the wall 525 may include one or more horizontal “truss” reinforcement structures 48.
Walls formed by masonry units according to the present invention may include combinations of the above components and materials. For example and referring to FIG. 16, the masonry units 110 may house both the vertical reinforcement rods 38 and the insulation 40. As another example and referring to FIG. 17, the masonry units 410 may support a horizontal “truss” reinforcement structure 48 and house insulation 40 within most of the separated continuous vertical cavities 36. Some of the separated continuous vertical cavities 36 proximate the innermost partitions 12 a also house vertical reinforcement rods 38 and reinforcement grout 50. Referring to FIG. 18, the masonry units 410 may support a horizontal “truss” reinforcement structure 48 and house insulation 40 within most of the separated continuous vertical cavities 36. Some of the separated continuous vertical cavities 36 proximate the innermost partitions 12 a and proximate the outermost partitions 12 c also house vertical reinforcement rods 38 and reinforcement grout 50.
Referring to FIG. 19, the masonry units 410 may support a horizontal “truss” reinforcement structure 48 and house insulation 40 within most of the separated continuous vertical cavities 36. The insulation 40 proximate the outermost partitions 12 c includes protrusions 52 that space the insulation 40 apart from the outermost partitions 12 c and define air gaps 54 within the separated continuous vertical cavities 36 which provide channels for ventilation. In addition, some of the separated continuous vertical cavities 36 proximate the innermost partitions 12 a also house vertical reinforcement rods 38 and reinforcement grout 50. Referring to FIG. 20, the masonry units 410 may support a horizontal “truss” reinforcement structure 48 and house insulation 40 within most of the separated continuous vertical cavities 36. The insulation 40 proximate the outermost partitions 12 c includes protrusions 52 that space the insulation 40 apart from the outermost partitions 12 c and define air gaps 54 within the separated continuous vertical cavities 36. In addition, some of the separated continuous vertical cavities 36 proximate the innermost partition 12 a and proximate the outermost partition 12 c also house vertical reinforcement rods 38 and reinforcement grout 50.
Masonry units and walls constructed therefrom according to the present invention may further vary from those described above. For example, conventional masonry fittings can be used in conjunction with the masonry units. In particular, corner units, closed end units, bond beams, and the like can be utilized with the masonry units in a wall structure. As another example, the separated continuous vertical cavities 36 may additionally or alternatively house components such as plumbing lines, electrical wiring, and data/communication cables.
Materials used to manufacture the invention are typically sand, stone, Portland cement, and water. Cementitious substitutes such as flyash, ground granulated blast furnace slag, cement kiln dust, silica flour and silica fume may alternatively be used. Iron oxides may be used to provide color, and admixtures may be used to aid in manufacturing or provide or enhance certain properties of the masonry units.
Masonry units according to the present invention may be manufactured using a concrete block machine such those manufactured by Besser Co., Columbia Machine, Tiger, or the like, using a concrete paver machine such those manufactured by Columbia Machine, Tiger, Masa, Hess, or the like, or using other similar machines. The masonry units may also be manufactured using a wetcast process in which concrete with a measurable slump is placed into a mold and consolidated prior to curing. As described briefly above, the vertically upright supports 21 a and 21 b connected to the partitions 12 a and 12 c, respectively, provide support for the partitions 12 a and 12 c during fabrication and subsequent transport of the masonry unit.
When the masonry units are manufactured using a block or paver machine, the forming mold can be fabricated in various manners. The complete mold consists of two main assemblies: the mold and the head.
One mold design is consistent with traditional block molds. This design utilizes metal wear partitions of various shapes and dimensions, made of hardened material, that are bolted into position in a rigid metal frame to create the mold.
Another mold design is consistent with traditional paver molds. This design utilizes a one-piece hardened-metal insert that is bolted into the mold. The insert is typically formed from a piece of steel or other wear-resistant material from which material is removed to form cavities of various shapes. These cavities define the shape of the mold. The head assembly consists of a top partition, plungers, and shoes. The various parts can be welded or bolted together.
It should be appreciated that while masonry units have been shown with three parallel partitions and two webs that can be used to form a wall having two rows of separated continuous vertical cavities therein, that masonry units having more than two rows of separated continuous vertical cavities can be made by adding additional partitions and webs. For example, three rows of separated continuous vertical cavities might be formed using a masonry unit having four partitions with three webs. In this instance, the two outermost webs may be co-planar with one another such that the first and third rows have aligned vertical cavities.
From the above description, it should be apparent that the masonry units and walls constructed therefrom according to the present invention provide various advantages over traditional masonry units and walls. In particular, the masonry units facilitate faster and easier construction of masonry walls with vertical reinforcement versus traditional masonry walls with vertical reinforcement. The labor associated with construction of a wall using masonry units according to the present invention is estimated to be less than half of that required for traditional multi-wythe walls. As such, the masonry units provide construction cost advantages through material, time, and labor savings.
Similarly, the masonry units and walls constructed therefrom also perform the functions of traditional multi-wythe walls. In particular, the masonry units provide multiple columns of separated continuous vertical cavities that can be utilized for placement of reinforcing materials, insulation, moisture control mechanisms, plumbing, electrical wiring, ventilation, data/communication cables, and the like.
Preferred embodiments of the invention have been described in considerable detail. Many modifications and variations to the preferred embodiments will be apparent to a person of ordinary skill in the art. Therefore, the invention should not be limited to the embodiments described, but should be defined by the claims that follow.

Claims

1. A masonry unit for constructing a wall, the masonry unit comprising:

at least three substantially vertical parallel partitions extending along a lengthwise direction, each of the partitions being connected to an adjacent partition by a web extending in a widthwise direction, thereby defining a pair of oppositely-facing open-ended recesses on either side of the web, each of the webs connecting the partitions being offset in the lengthwise direction from any adjacent web in the masonry unit;

wherein, when the wall is formed from a plurality of the masonry units by positioning multiple rows of stacked masonry units on top of each other in a horizontally offset and vertically inverted manner, a plurality of separated continuous vertical cavities extending through the multiple rows are formed within the wall.

2. The masonry unit of claim 1, further comprising a vertically-extending support formed along one at least one of the partitions to provide support for the partition during fabrication of the masonry unit.

3. The masonry unit of claim 2, wherein the vertically-extending support is aligned with one of the webs in the lengthwise direction.

4. The masonry unit of claim 1, wherein the masonry units are configured such that, if a second row of masonry units is stacked on top of a first row of masonry units in a vertically inverted manner and are horizontally offset approximately one-half an overall length of the masonry unit from the first row, then the webs of the masonry units in the first row and the second row are vertically aligned with one another.

5. The masonry unit of claim 4, wherein each of the webs is offset from any adjacent webs in the lengthwise direction of the masonry unit by substantially one half of the overall length of the masonry unit.

6. The masonry unit of claim 4, wherein each of the webs is offset from ends of the partitions in the lengthwise direction of the masonry unit by substantially one quarter of the overall length of the masonry unit.

7. The masonry unit of claim 1, wherein at least one web includes a vertically facing open-ended slot configured to receive a horizontal reinforcement rod.

8. The masonry unit of claim 1, wherein the partitions and the webs comprise cement.

9. The masonry unit of claim 1, wherein each of the partitions integrally connects to the adjacent partitions by the webs.

10. The masonry unit of claim 1, wherein the masonry unit is generally rectangular shaped.

11. A masonry unit for constructing a wall, the masonry unit comprising:

a first vertical partition;

a second vertical partition substantially parallel to the first vertical partition and offset from the first vertical partition in a first horizontal direction;

a third vertical partition substantially parallel to the first vertical partition and the second vertical partition and offset from the second vertical partition in the first horizontal direction;

a first web connecting the first vertical partition and the second vertical partition and thereby defining open-ended recesses on both sides of the first web facing away from each other along a second horizontal direction substantially perpendicular to the first horizontal direction;

a second web connecting the second vertical partition and the third vertical partition and thereby defining open-ended recesses on both sides of the second web facing away from each other along the second horizontal direction; and

wherein the masonry unit has an overall length in the second horizontal direction, the first web is offset from the second web in the second horizontal direction by a web offset distance, and the web offset distance is substantially one half of the overall length such that, when the wall is formed using the masonry units by positioning multiple layers of stacked masonry units together in a horizontally offset and inverted manner, a plurality of separated continuous vertical cavities extending through the multiple layers are formed within the wall.

12. The masonry unit of claim 11, wherein the first vertical partition includes a vertically-extending support disposed in one of the open-ended recesses defined by the first web to provide support for the first vertical partition during fabrication of the masonry unit.

13. The masonry unit of claim 12, wherein the vertically-extending support is aligned with the second web in the second horizontal direction.

14. The masonry unit of claim 11, wherein horizontally-facing ends of the first vertical partition include open-ended notches facing away from each other along the second horizontal direction and being configured to receive mortar to connect the masonry units in the wall.

15. The masonry unit of claim 11, wherein the first web includes a vertically facing open-ended slot configured to receive a horizontal reinforcement rod.

16. The masonry unit of claim 11, wherein the first web is offset from an end of the first vertical partition facing in the second horizontal direction by a horizontal offset distance, the second web is offset from an end of the third vertical partition facing in the second horizontal direction by the horizontal offset distance, and the horizontal offset distance is substantially one quarter of the overall length.

17. A masonry unit for constructing a wall, the masonry unit comprising:

a first vertical partition;

wherein the masonry unit has an overall length in the second horizontal direction, the first web is offset from an end of the first vertical partition facing in the second horizontal direction by a horizontal offset distance, the second web is offset from an end of the third vertical partition facing in the second horizontal direction by the horizontal offset distance, and the horizontal offset distance is substantially one quarter of the overall length such that when wall is formed using the masonry units by positioning multiple layers of stacked masonry units together in a horizontally offset and inverted manner, a plurality of separated continuous vertical cavities extending through the multiple layers are formed within the wall.

18. The masonry unit of claim 17, wherein the first vertical partition includes a vertically-extending support disposed in one of the open-ended recesses defined by the first web to provide support for the first vertical partition during fabrication of the masonry unit.

19. The masonry unit of claim 18, wherein the vertically-extending support is aligned with the second web in the second horizontal direction.