US2047648A - Building structure - Google Patents

Description

July-14, 1936. B. .1. POLL'ARD BUILDING STRUCTURE Filed April 1, 1952 INVENTOR. Bernard c/ Foilard ATTORN 25 Y? Patented July 14, 1936 UNI ED srArEs PATENT OFFICE BUILDING; STRUCTURE Bernard J. Pollard, Detroit", Mich.

Application Apri-t l, 1932;. SerialiN-im 6025509 tially the same co-efficient of. contraction and expansion whereby cracking of the: integral structure will. be substantiallyeliminated. In- 0971? rying. out this important object I. contemplate: utilizing 'cinders' of asi'ze: larger than those hitherto utilizedv for aggregate and: associating therewith for bonding? purposes a cinder mortar; In: this way a. substantially homogeneous: integral structure may be builtup whichwilll contract and.

expand. more: or less. as an unit? with changing: temperature, thereby minimizing disintegration: by reason of cracking and subsequent seepage of. moisture.-

it further: obziject oithe: invention is to provide a wall possessing-great. tensile strength. Such. a.

wall' is. particularly adaptedfori use inv conjunc tion with veneer work: and; for garden: wall or' fencing purposes.

Yet another object ofzthe'invention is to provide a decorative: veneerr'wall. of; attractive and unusual appearance which may be: inexpensive 1y built and is; of a; durable nature:

Afurth'er improved featureof the invention resides in. a novel method of pouringwalls: whereby the exterior faces ofi'the. aggregate: utilized are left free. andv clear of thebonding element. In this way the: decorative f eatures; of the. aggregate areretained on the exterior faces oilv the wall structure while at the same:- time the wall. is built in the most inexpensive and rapid fashion known in: the trader Referring now to the drawing wherein like numerals represent similar parts throughout the several figures,

Fig. 1 illustrates in perspective one form of my improved wall, 7

Fig. 2 illustrates a somewhat modified form,

Fig. 3 is a section through a wall during the process of pouring the same, and

Fig. 4 is a section through one of the blocks.

Hitherto cinders have been utilized in building structures in various ways, primarily in the form of cinder blocks wherein aggregate of relatively small size is screened to maintain certain size limits. Such blocks include a relatively large proportion of cement in relation to the cinder aggregate utilized and are necessarily subject to sufficient expansion and contraction with temperature changes to produce cracking. Ginder blocks are a substantial; improvement over concrete: construction insofar ascracking: is con cernedi.

In one form of wall I propose to utilize cin-- ders of relatively large size; the sizebeing com-- 5 parable. to that of the ordinary building brick; andbonding the same: together; in the same man:- ner as. brick. or stone: walls: are bonded, with cinder mortar;

In Figure; J; a wall: wherein the cinder or clinker aggregate Ill: has: been. laid individually, as. bricks would be laid, is' illustrated. The bonding material l'2 is: mortar having: fine'cinder a gregate. for the purpose. of providing. a. co-etficient. of expansion in the: mortar. substantially equal. to that of the large aggregate. used. The wall in: Figure L constitutes a veneer overlying a foundations wall Ht and; as illustrated at. t5; the: outer faces oi. the cinder. aggregate. form a. rough exterior: of rustic appearance", the decorative effeet ofi which canonly be appreciated: by viewing the actual: structure.

As is well! known, cinders or clinkers are: the non-combustible residue of solidi fiuek which. has been completely burned and, depending upongs the type of: fuel utilized, the cinders are. of: varying colors and hues. Theacolorsifoundain such clinker or cinder are; fast and lasting and the peculiar physical characteristics of such; aggre' gaterender it possible for the architect or builder to-produce: a. variety of eficts-a spot of color,

a. mass of color; a. rough castwall, or an. insert which cannotwell be produced in any other Way..

Aniimportant characteristic of awall structure composed of the. material heretofore: described resides in the: great" heat and sound. insulating" qualities derived from: the porous natiufez ofv the. clinker, as well as in the great tensile strength inherent in the wall by reason of the firm bond between the cinder mortar and the porous surfaces of the clinkers. The interior of the individual clinkers or cinders is full of voids that are created by the burning of the fuel from which the clinker was formed. These voids are full of mixed gas and air and constitute a. very effective insulator against heat and sound.

Another form in which the large cinder aggregate may be utilized is illustrated in Figure 2 wherein the aggregate has been molded into blocks l6, which blocks are subsequently laid either as a wall proper or as a veneer against a background is. These blocks are preferably molded individually and one method of so molding them is to pour a certain amount of cinder mortar in the mold box, and subsequently fill the box with the cinder aggregate prior to hardening of the mortar. It is important that the aggregate utilized be of a greater depth than that of the poured mortar so that the exterior surfaces of the cinder aggregate will project beyond the mortar to expose the decorative faces thereof. The lower left block in Figure 2 illustrates more clearly the internal structure of the block and it will be apparent that the large cinder aggregate is utilized not only for the exterior face of the block but constitutes the major body portion of the block body. The mortar utilized is only for the purpose of bonding the aggregate together and is not designed to form any substantial portion of the block proper.

The block illustrated in Figure 4 utilizes only a single layer ll of clinker aggregate and is adapted primarily for veneer work where no load need be carried by the block.

By reason of the porosity of such aggregate walls may be poured therefrom with great success. An important feature of my improved pouring operation resides in the manner whereby the exterior faces of the clinker are shielded from the bonding material or mortar which is poured along with the aggregate to preserve the decorative effect thereof. In Figure 3 a wooden form comprising a base 20 and side walls 22 and 24 is utilized for the pouring operation. The inner faces of the side walls 22 and 24 are lined with some yieldable substance 26 such as straw prior to the pouring of the material. While straw constitutes one available substance for this purpose, it has been found that mud serves the purpose admirably and will crack when dried, falling off and leaving the exposed aggregate surfaces. A large size cinder aggregate 28 and mortar are poured successively. A layer of mortar follows each layer of aggregate, the preceding layer of mortar being forced down between the voids around the under layer of aggregate as each succeeding layer of aggregate is poured thereon. The outer faces of the aggregate will imbed themselves in the soft yieldable lining 26 of the form walls and this lining will constitute a protective coating preventing the mortar from flowing over the said exterior surfaces.

When the form is removed, after the mortar has set properly, the lining material for the most part will be drawn away with the walls thereof and any portion which sticks to the exterior faces of the cinder aggregate may be easily removed, leaving the decorative body of the aggregate projecting. Such a wall possesses all of the attractive and desirable characteristics of a wall wherein the aggregate is laid individually by hand. The irregularity of the surface contour of the clinkers or cinder aggregate assists materially in providing a strong tensile bond therebetween, such tensile bond being enhanced greatly by virtue also of the porosity of the aggregate. A durable interlocking assembly of substantially homogeneous material results from either the pouring operation, the block formation, or the individually laid clinker.

To secure further decorative effect a slight amount of coloring material may be utilized in the mortar without in any way adversely affecting the bond secured between the clinker aggregate, or a wash of color material may be applied to the exterior surface of the mortar following the bond lines around the outer surfaces of the clinker.

By reason of the porosity inherent in the clinker aggregate the use of air vents in veneer walls for insulation purposes may be substantially eliminated. Furthermore, walls built in the manner hitherto described remain intact over a long period of time without the possibility of individual clinkers falling out, as is almost invariably the case with walls built up from cobblestones or other aggregate having a smooth surface which will not permit as strong a bond as the porous aggregate herein utilize-d.

A very effective structure may be secured for veneer purposes by utilizing a fine graded clinker which produces somewhat the same effect as stucco or pebble-dash without risking the deterioration invariably caused by the contraction and expansion of such stucco work.

While various other forms of structure embodying the principles of my invention may readily be devised, I wish to be limited as to scope only by the appended claim.

I claim:

A decorative structural Wall possessing heat and sound insulative qualities comprising irregular cinder aggregate of a size comparable to that of ordinary building brick bonded together throughout with cinder mortar and constituting substantially over fifty per cent of the total volume of the wall, said cinder aggregate containing a multiplicity of closed and gas filled voids providing heat and sound insulating qualities, said cinder mortar confined within the plane of the exterior surface of the wall so that the exterior surface of the cinder aggregate projects beyond the mortar to expose the decorative surfaces thereof, said irregular exposed protruding portions of the large cinders being uncovered and entirely free of cinder mortar and constituting substantially over fifty per cent of the outer exposed surface of the wall.

BERNARD J. POLLARD.

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