US2052842A

US2052842A - Expanded masonry

Info

Publication number: US2052842A
Application number: US619845A
Authority: US
Inventors: Edward R Powell
Original assignee: Individual
Current assignee: Individual
Priority date: 1932-06-29
Filing date: 1932-06-29
Publication date: 1936-09-01
Anticipated expiration: 1953-09-01

Description

Sept. 1, 1936. I R POWELL 2,052,842

EXPANDING MASONRY Original Filed June 29, 1932 2 Sheets-Sheet 1 i s l7 v 0 OI o n 0 o c 0 oil 0' v INVENTOR.

Sept. 1, 1936. E. R. POWELL EXPANDING MASONRY' Original Filed June 29, 1932 2 Sheets-Sheet 2 INVENTOR.

@W/ Z2 M Patented Sept. 1, I936 2,052,842 EXPANDED MASONRY Edward R. Powell, Alexandria, Ind.

Application June 29, 1932,-Serial N0. 619,8 15

Renewed July 20, 1935 20 Claims.

invention relates to a form of masonry which uses expanded building units as theprincipal material.. 7 I

It relates particularly to a form of masonry a structure in which light-weight ceramic building than common masonry. In this form of masonry,

wall and acts as only a Windbreak will, in genin general,

highest strength. Other functions in the structure maybe performed by units of intermediate strength or density.

Anotherfeature of the invention consists in nent decorative faces and better heat insulating :23. and sound absorbing properties.

is to provide a structure which has minimum weight for its strength, considering the class of materials which it employs.

The full nature-of the invention will be underr stood more readily byreference to the accompanying drawings and the following'description and claims.

In the drawings: Fig. 1 is an elevation of part of a building which embodies the invention, thenature of the mason-- ry in various parts being illustrated by symbols which will be explained hereinafter.

Fig. 2'is an enlarged sectional detail of one means of anchoring masonry. V

Fig. 3 is an enlarged sectional detail of a modi-r fied form or anchor for tie rod or reinforcing rod.

a reinforcing rod in the Another object Fig.4 i sa-sectionof parti'of the structure of Fig. 1 taken on the plane 44and in the direc-: tion of the arrows. r

Fig. 5 is a section of part of the structure of Fig. 1 taken in the plane 5-5 and inthe direction of the arrows.

Fig. 6 is a vertical section of a slab such as a floor or roof slab built of reinforced variably ex-, panded masonry. i

Fig. 7 is an enlarged section taken on line l -1 of Fig. 6 in either direction. 10

In the drawings, the areas rendered in dots only are surfaces of material of maximum strength; those rendered in relatively large cir-. cles only are the weaker and usually much lighter materials. termediate strength or density are indicated by both dots and circles. 7

These expanded building units may be made by expanding clayin the pyro-plastic condition as described in my application Serial No. 522,272 2 now Patent No. 1,963,029, or expanded in wet than the portion 32. Another portion "5 is lighter than M. The panel walls I3 are all about the same density because they carry only themselves between stories. At the top of portion iii, the column portion The rods l9 and 20 take the tension on the lower In Fig.2, the relatively heavy rod 33 is embed- 5Q dad in the masonry. It is embedded more particularly in the. mortar which is thebonding material between the units. The mortar is ordinarily lime, Portland cement and sand. For a very hard mortar, two parts of Portland cement may 55;

The surfaces of materials of in- 15 I4 is lighter joins a typical beam portion. 40

" the rods.

be used to one of lime and nine parts of sand. The proportion of sand will vary with the nature of the sand particle size and how well it packs. Both the sand and the water are usually proportioned on the job to give a mortar of proper working consistency. The mortar may be all Portland cement, it may be gypsum plaster, magnesium oxy-chloride cement, asphaltic mixtures or any other material suitable for bonding building units provided the service which is involved permits the use of these materials.

The rod may be laid in same in the units, it may be laid by notching the units, or the mortar joints may simply be made thick enough to enclose the rods. In any case the final structure consists of units firmly bonded together by means of a mortar'in which a rod is at least partly embedded. The rod 33 is preferably rolled with rough or cleated surfaces sothat it will be firmly gripped by the hardened mortar. The rod. 33 is provided with a nut 23 which bearsagainst the plate 22 so as to distribute the'load over enough of the masonry to avoid local crushing. The platemay be slightly dished or channeled to provide a little spring. This tends to prevent crushing and will take up a little difference in expansion between the rod and the rest of the" structure. The units 29 adjacent to the plate are shown of intermediatestrength.

Fig. 3 shows another form of anchor in which the rod 25-has a hooked portion 3| which connectswith a heavier cross rod 24. The rod 25is preferably a commercial reinforcing rod such as used for concrete reinforcement. It is embedded in the bonding material. The units in Fig. 3

are shown of intermediate strength also.

The expanded ceramic material'wh'ich has been developed for such service may'have nearly as much strength as solid'masonry and still be considerably lighter. The expanded material usually has much better bonding properties than regular brick or hollow as a whole may conventional type.

tile so that'the structure The better bonding proper- :ties of the expanded units resultprincipally from the enclosed gas-formed cells which are partly exposed on the surface so that trates an appreciable distance into the unitsin places and keys itself thereto.

Fig. 4 shows a portion of the beam and adjacent panel walls. The portion of the beam shown is under mainly shearing stress which the intermediate strength material will stand. It is under some compression stress also from the tension of In Fig. 5, however,;which is near the middle of the span, the upper is under considerable compression stress while the lower portion is under tension. 'Ihe'rods, of j I that the masonry proper is under very little stress. Lighter mate-.

course take the tension so rial is therefore used in this portion of the beam. The units of which the beam is built are shown. specially designed to interlock and provide-channels for the rods l9 and 20.

standardized size and shape units by using a little more mortar and bonding it well to the units. Most water-mixed mortarswill bond better to the units if the unit surface is wet. An additional load which may be carried by the beam is shown in dotted lines. have a decorative coating of some sort,

Fig. 6 shows a slabsuitable for a. floor or roo The'units 34 are understood to be of different a channel provided for this case, the rods of strength,- the density be stronger than masonry of the mortar pene part of the beam 7 There is asloping sill 26. Similar results may be obtained by using The innerwall I! may" That is they have a variation in the degree or character of the expansion within themselves. For example, the upper part may reach a maximum density of '75 lb. per cu. it. while the lower part may have a minimum density of 25 lb. per cu. ft. The units as shown are provided with channels 36 which admit the reinforcing rods 38. The rods 38 terminate preferably in plates 31 which may be welded on orheld with nuts or threads. For large areas, the slabs are sometimes supported on 1 steel T-irons 35 or other structural members. In may be secured to the web of the T-iron instead of to separate plates.

'A sub-floor of Portland cement mortar may be poured-on the slab and a composition floor laid 1 over this. For roof service a built up roofing may be used and composition service floor over the roofing. The sub-fioor 39 should be well bonded tothe units 34, wetting the units if necessary. The lower surface of the units 34 may be decorative and be of open structure so as -to have acoustical properties; The construction ofa slab" of this sort usually requires false work which should be left'in place until the mortar has set andhardened. Thefalse work -may,-if desired be supported from the-T-irons V P r .In general the pyro-plastically expanded ceramic material permits lower 'density without sacrifice of strength. That is brick of practically full strength'have been made by pyro-plastic expan- 3 sion at 35 lb. per cu. ftadensity. At a sacrif ce may be as low as 18 to 29 lbs-per cu. ft. The wet plasticmaterial usually has less strength for a given density but is easier to produce by certain processes in special shapes 3 and textures. Typical densities for the various parts of-the structure of Fig. 1 for the wet expanded materialmay beas follows: Part 11, lbs. per cu. ft.;'part 32, '75 lbs; part 14, 65 lbs; part 16, 55 lbs.;

part

13, 35 lbs.

Expanded'masonrymay be of constant density or it may not be reinforced. While a specific group of structures is illustrated, it should be understood that any masonry structure where the listed advantagesare desired may ordinarily be designed o n thesarne principles. In general, the invention'is involved in any structure in which the density of the structural units is reduced in places to lighten the structure and. improve its properties, the difierence in density being secured by cellular expansion of the material. The above examples should therefore be taken' as illustrations and not in a limiting-sense. r Structural ceramic material is intended to include preformed structures which are formed by theapplication of heat to clayey material of plentiful grade. These mayor maynot be of refractory type but must be load bearing'wher'e" loads are imposed and weather resistant where exposed. Usually refractory materials are resistant tohigh temperatures but, if expanded atall, will not carry loads or stand the weather. The invention claimed is: I V 5 1. In a composite building. structure, the com-' bination. of a relatively hard and'relatively high. bonding strength mortar in continuous frame work arrangement, relatively hightensilestrength; reenforcing material imbedded in said frame work, and a pluralityof independent structural units united by said frame work and each includ-i 7 pendent,.cellular expanded'masonry units, jointing mortar in unitary frame work arrangement for securing the units together, reenforcing meansifor-the wallstructure and included in the jointing mortar, substantially all units .having a cellular portion of relatively high thermal insulating value, certain of said cellular masonry units having another and relatively denser portion resistant to high compression stress, said units being so arranged in said wall that the denser portionwill be positioned to prevent rupture inthe cellular portions as a wall when subjected to high compression strength, the thermal resistance of the entire wall being approximately the same as that of the individual units when measured inthe same direction. 1

3; A structure as defined by claim 2, characterized by each cellular unit having its cellular portion provided-with an open type surface for. acoustical lating thermal resistance.

4. A building structure of expanded character,

including in. combination a plurality of building units each of expanded character and having relatively low mechanical strength and high thermal insulating value compared with standard building units of like dimension and like original material, said expanded units being arranged in unitary formation, relatively hard bonding material between said units for securing the same in said formation and constituting a unitary frame work, and relatively high tensile strength reenforcing material imbedded in the bonding material frame work, said relatively hard bonding material having a relatively high bonding relation with the low mechanical strength units to supplement the strength of said units when in structural formation.

5. A reenforced masonry structure adapted to resist bending moment which includes a plurality V of cellular expanded units, mortar for securing insulating value, said last mentioned portion not being subjected to the principal compressive stresses, said units being arranged in the structural formation so that the said portions have the accommodation value specified, and reenforcing means for the structure and enclosed in the mortar frame work.

6. A multiple course reinforced masonry structure adapted to resist bending moment which includes a plurality of cellular expanded units arranged in courses, mortar for securing said units together, said mortar forming a unitary frame work for said units and having relatively high strength and hard bonding power with said units, most of the units in different courses having different degrees of expansion, some units having a relatively great crushing strength for accommodating principal compressive stresses, and other units having less crushing strength and of higher thermal insulating value, said last mentioned units not being subject to the principal compressive stresses, said units being arranged in the structural formation so that the said units have the accommodation value specipurposes in addition to the insufied, and reinforcing means for the structure and enclosed in the mortar frame work.

'7. A structure as defined by claim 1 which has, when 'subjected to bending moment, certain regions of high compressive stress and certain regions of high tensile stress, the high compressive stress regions consisting of the hard mortar and the dense portions of the units; and. the high tensile stress portions consisting of the hard mortar, and the reinforcement of the cellular portions of the units.

8. In a composite building structure, the combination of a relatively hard and relatively high bonding strength mortarin continuous frame work arrangement, relatively high tensile strength reinforcing material imbedded in said frame work, and a plurality of independent structural units united by said frame woik'and each including a portion structure being approximately equal tothat of the individual units when measured in the same direction.

9. A ceramic structural unit comprising a true ceramic material of relatively high density and a light weight cellular layer inseparably united with one of the surfaces of said body portion, the relative thickness of the dense and cellular bodies being varied in accordance with conditions or service to which the material is placed, said cellular material being of substantially uniform composition throughout and characterized by the inclusion throughout its body of separate and closed cells separated by thin cell walls of true ceramic material.

10. As a new article of manufacture, a structural unit comprising a body portion of relatively high density, and a heat insulating portion composed of a cellular argillaceous material inseparably united with said body portion, said cellular material comprising a heat-treated argillaceous body of substantially uniform composition throughout and of predetermined shape and dimensions, and characterized by the inclusion throughout its body of separate and closed cells separated by relatively thin cell walls of firedclay material having in its unit form a density of less than one-half the density of the firstnamed body portion of said unit.

11. A ceramic or refractory unit comprising a structural material of relatively high density and a light weight cellular layer inseparably united with one of the surfaces of said refractory material of high density, the relative thickness of the dense and cellular materials being varied in accordance with conditions of service to which said cellular material being of substantially uniform composition throughout and characterized by the inclusion throughout its body of separate and closed cells separated by thin cell walls of true ceramic material.

12. A ceramic structure comprising a ceramic material of relatively high density and an integrally attached adjoining layer of heat-insulating ceramic material, said heat-insulating material being of substantially uniform composition and characterized by inclusion throughout its body of separate cells separated by thin walls of ceramic material.

13. As a new article of manufacture, a structural unit comprising a body portion of relatively high density, and a heat insulating portion composed of a cellular material inseparably united with said body portion, said cellular material comprising a body of substantially uniform comof relatively high thermal resistance, the thermal resistance of the whole positionthroughout and of predetermined shape and dimensions, and characterized by the inclusion throughout its body of separate-and closed cells separated by relatively thin cell walls of material havingin its unit form a density of less than one-half the density of the first-named body portion-of said unit. 1

14. As a new article of manufacture," 'a structural ceramic unit comprising a body portion'of relatively high density, portion composed of a cellularmaterial inseparably united with said body portion, said cellular material comprising a body of substantially uni-, form composition throughout and'of predeter- 'mined shape and'dimensions, and characterized by the inclusion throughout its body of separate and closed cells separated by relatively thin cell walls-of material having in its-unit form a densityof less than one-half the density of the firstnamed body portion of said unit.

-15. A structural unit as defined characterized by the inseparable union being an and a heat insulating by claim 9,?

integral formationwith-the remainder of the unit, :1: t

1*163Awstructuralsunit as defined by claim 10, characterized thy: the inseparable union being an integral" formation' with. the remainder of the '5 unitpi :1, 1:, Y 7

17;- A structural unit as defined by claim 11,- characterized by-:the inseparable union being an integralf-formation with the remainder of the l 18. A structuralunit as defined by claim 12', characterized by the inseparable union being an integral formation :With the remainder of the 19'." A 'structura1 unit as: defined by claim 13, characterized by the inseparable union being an integral formation with thexremainder of the 20.-A- structural unitlas defined by claim 14,

characterized by the-inseparable union being an 203- integral formation with:the remainder of the unitprr 1 EDWARD R. POWELL