US3654742A

US3654742A - Method of forming a concrete building component

Info

Publication number: US3654742A
Application number: US5696A
Authority: US
Inventors: John A Wilnau
Original assignee: Individual
Current assignee: Individual
Priority date: 1970-01-26
Filing date: 1970-01-26
Publication date: 1972-04-11
Anticipated expiration: 1989-04-11

Abstract

A building component composed of concrete blocks and a concrete slab with the blocks being recessed along their frontal surfaces for placement within a jig. The concrete receiving surfaces of the blocks are irregular for embedment within the poured concrete. The blocks are in contiguous, surface contact to retain and confine the concrete poured thereon. A method for the face down construction is disclosed.

Description

[151 3,654,742 [451 Apr. 11, 1972 United States Patent Wilnau PTNTEDAPR 11 |912 3, 654, 742

snm 1 nr 2 INVENTOR JOHN A. WILNAU PATENTEDAPR 1 l |972 SHEET 2 UF 2 NVENTR. JOHN A. wlLNAU BY l AGENT METHOD OF FORMING A CONCRETE BUILDING COMPONENT BACKGROUND OF THE INVENTION The present invention relates generally to construction of concrete building components and more particularly to a face down constructed component usable as a wall, floor, or ceiling component of a structure and utilizing a concrete slab in combination with contiguous concrete blocks.

For several years concrete or aggregate blocks have been used successfully in the construction of various types of buildings. Such blocks characteristically provide certain desirable features both functional and aesthetic, in a structure. The blocks are of a size permitting their convenient manual handling for incorporation into the structure. Such concrete block construction typically requires the use of a matrix or other means for block retention with each block being individually set in place. A significant problem with concrete block building construction is the labor cost factor as each worker, is of necessity, a skilled worker.

Other concrete construction has included slab concrete components poured in place or horizontally for subsequent tilt-up" or transfer to the location of the building site. While practical in large structures the concrete slab requires additional efforts, such as the application of a veneer surface material, to render it attractive.

Efforts to produce suitable building components by a face down method of fabrication have not proved acceptable primarily for the reason that fluid concrete will cause cementing of the blocks to a supporting surface or spacer material between the blocks. This cementing of the blocks to a supporting surface results from a flow or bleeding of the fluid concrete between the lower surfaces of the blocks and their supporting surface. Further, such bleeding on the lower face of the blocks severely detracts from the appearance of the finished wall.

SUMMARY OF THE INVENTION The present invention is embodied within a building component and method utilizing both block components and a poured concrete slab the latter integrating the blocks into an integral building component. The component is suitable, functionally and aesthetically, for direct incorporation into a structure. A jig for the building components enables the blocks used to be rapidly set in place to receive the poured concrete.

More specifically, the blocks are configured along their jig contacting surfaces to enable simple, accurate locationing in the jig by workmen unskilled in the masonry art. For example, a pair of unskilled workmen may position, on the present jig, all the block components for an eight foot by twenty foot building component in less than ten minutes. The pouring of concrete for completion of the component is preferably' from a pumped source, either a truck if at the construction site or from a hopper at the plant site. The jig facilitates block placement and retention while the blocks placed along the components edges are desirably of a shape to confine lateral movement of the poured concrete. Alternatively, temporary barriers for the concrete may be utilized.

A novel method is disclosed for the formation of the present building component. The method set forth contributes towards a combined slab-concrete block component of low cost materials and fabrication and a component presenting an attractive exterior requiring no further masonry efforts.

Another important object of the invention is to provide a building component having the appearance of block construction yet fabricated at substantially less cost than conventional block construction. The resulting component, further, has the structural advantages of a poured concrete unit and may be reinforced or pre-stressed similarly to such a unit.

Another object is achieved by the interrelationship of the jig, blocks and poured concrete which respectively serve to accurately locate the blocks with the latter retaining and functioning as a concrete form with the concrete itself, upon curing, interconnecting the multitude of concrete blocks.

Further, the present invention enables the convenient construction of irregular building components i.e., components other than of solid planar configuration. The jig and blocks used permit openings to be accurately formed in the component. Such opening may be for doors, windows, light fixtures, heat vents, etc.

Another object of the invention is to enable the fabrication of a ceiling component of a building with the component embodying an attractive relieved surface.

A still further object of the instant invention is to provide blocks of novel beveled configuration to retain the poured concrete against seeping into contact with the jig which would undesirably retard jig-component separation.

BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings:

FIG. 1 is a perspective view of a building component of the present invention disposed in an upright position for use as a wall in a structure. l

FIG. 2 is a plan view of an angle iron framework constituting a jig for the fabrication of the wall of FIG. l,

FIG. 3 is a sectional, elevational view taken along line 3-3 of FIG. 2 and showing a fragment of the jig with a block elevated therefrom,

FIG. 4 is a view similar to FIG. 3 taken along line 4-4 of FIG. 2 and showing an angle iron barrier for concrete applied to the jig adjacent a concrete block fragment,

FIG. 5 is a perspective view of an intact concrete block usable with the present invention and shown prior to halving of the block,

FIG. 6 is a view similar to FIG. 5 showing a second form of an intact block prior to separation into like halves,

FIG. 7 is an end view of the block of FIG. 5 showing the block after cutting and after beveling of the edges about the frontal perimeters of the resulting blocks,

FIG. 8 is an end view of FIG. 6 showing the block after cutting and after beveling of the edges about the frontal perimeters of the resulting blocks,

FIG. 9 is a perspective view of the concrete slab side of the present component,

FIG. 10 is a fragmentary end view of the component of FIG. 9 with a second component disposed as a wall in place thereon,

FIG. 11 is a fragment of a relief surface attainable with the present building component, and

FIG. 12 is a sectional view taken along line 12-12 of FIG. 2.

DESCRIPTION OF THE PREFERRED EMBODIMENTS With continuing reference to the accompanying drawings wherein applied reference numerals indicate parts similarly identified in the following specification, the reference numeral 1 indicates generally the present building component shown as a wall but as aforesaid may be in the form of a floor or ceiling member.

The component 1 may be of solid planar shapes or formed with openings as at 2 therein to suit the use to which the component is to be put. Comprising one side surface of the component are a multitude of concrete or aggregate blocks disposed in abutting edge-to-edge relationship. A first type of block is indicated at 3, conveniently formed by dividing an intact cast block of the type shown in FIG. 5. A second type of block is indicated at 4. For purposes of economy of manufacture it has been found desirable to cast the blocks as shown in FIGS. 5 and 6 with each block therein shown ultimately separated into two blocks prior to becoming a part of the present component. The planes of separation PS for the blocks in FIGS. 5 and 6 are shown in broken lines with the planes for the latter being offset to provide an extended end portion.

With regard to each block 3, and subsequent to its separation, an exterior or frontal surface is indicated at 5 while on the inner or concrete receiving side at 6 are formed ribs 7 undercut for concrete retention. The ribs 7 have a common bridging portion of reduced size for ease of cutting the intact block. About the perimeter of the blocks exterior frontal surface is a recessed area in the form of a continuous bevel formed as at 8 (broken lines in FIG. 5).

Each of the blocks 4, as formed by separation of the intact block shown in FIG. 6, includes an exterior frontal surface l0. End portions 11 and l2 of the block are each undercut on the blocks side 9 whereat an undercut rib 13 is also formed. The extended end portion 11 of each block 4 serves to confine the poured concrete when in place on the jig as later elaborated upon. In similarity to the first described blocks 3 the perimeter of each block 4 is recessed and is shown as a beveled area at 14.

The separation of the intact blocksin FIGS. 5 and 6 may be done on conventional block cutting equipment prior to sizing of the blocks by grinding to exact size and beveling the surfaces at 8 and 14 all of which is done by conventional block grinding equipment. Since the beveled surfaces of the two

blocks

3 and 4 are used for placement on the jig as later described the grinding of the blocks to size and the beveling grinding must be precisely done. It is desirable to cast the blocks somewhat oversize with reduction to the final dimensions and the bevels being done last by grinding.

The jig, as best shown in FIG. 2, is a latticed framework formed of welded right angle stock having stringers at 16 with interfitting stock sections 17 welded in place coplanar with the stringers 16. By way of example only, the stringers and sections may be assembled on 16 inch centers with the upwardly directed ridges of each stringer and section being so spaced from its adjacent like member. For use in such a jig with such centers the

blocks

3 and 4 would have frontal surfaces at 5 and l respectively of 8 by 16 inches. Such an arrangement permits varous designs to be worked simply by varying block placement as is shown in FIG. l. Obviously single blocks of a larger size or more than two blocks may be used depending on the spacing of the jigs stringers and sections and the block surface dimensions.

The

blocks

3 and 4 rest upon their supporting angle stringers and sections with its longest dimension equal to the distance intermediate the centers of adjacent stringers or sections. The

beveled areas

8 and 14 are of complimentary inclination to that of the supporting flange of the section or stringer. Placement of the

blocks

3 and 4 hence requires no masonry skill to assure accurate, juxtaposed placement of the blocks. Further, each opening at 18 in the jig may be numbered by a subjacent placard on the surface below the jig with a correspondingly numbered diagram being provided to the workman with door and window openings identified thereon which are left desired of blocks.

A further variable is provided for by the use of a positionable barrier, shown in the form of a detachable angle iron 20 in FIGS. 2 and 4. The angle iron is securable to the jig by a clamp 23 to provide a barrier to the poured concrete when the blocks 3 are used along an edge of the component. In the wall shown in FIGS. 1 and 9 the upper and lower edges and opening 2 are defined by the blocks 4 in which case the extended end portions 11 thereof functions as a concrete barrier during pouring. The vertical edges of the component as shown in FIG. l are defined by the ends of blocks 3 with the concrete slab at 19 having been poured and set against one of the detachable barriers 20 as shown in FIG. 4.

The jig is preferably mounted in place horizontally on crosswise and lengthwise extending I-

beams

21,22 to prevent flexing. For fabrication of pre-stressed components the jig may be slightly longitudinally arched. Further the present component lends itself` to pre-tensioning or post-tensioning in the conventional manner as done with poured concrete slabs. Weight reducing voids 23 are applicable as are the reinforcing rods 24.

Further, as shown in FIG. 9,

plates

25,26 may be located in the fluid concrete to facilitate attachment of components l by welding. If desired, for aesthetic purposes, some blocks may be unbeveled and thus will not set into the jig to effect a relieved surface on the complete component as shown in FIG. 10.

Having thus described the invention what I desire to secure under a Letters Patent is:

1. A face down method of constructing a concrete-concrete block building wall component of' rectangular configuration, said method comprising the steps of,

sizing of a multitude of concrete blocks by grinding each of the vertical side surfaces of said blocks, each of the blocks having an irregular upper surface thereon,

' forming inwardly directed beveled surfaces about the lower perimetrical edge of said concrete blocks,

contiguously depositing said blocks upon a rectangular wall sized jig with the irregular upper surface of the block facing upward, said jig comprised of latticed angle iron sections with the blocks placed thereon so as to locate their beveled surfaces in resting contact upon said jig sections with each vertical surface of an interior block being in surfacial abutment with a like surface on another block, said blocks when so positioned forming a composite block assemblage impervious to poured fluid concrete, and

pouring concrete over said blocks to fully cover same to form a monolithic concrete slab which upon curing results in an integral concrete-concrete block building wall component.

2. The face down method of constructing a concreteconcrete block building wall component as claimed in claim 1 including the additional step accomplished prior to pouring of concrete consisting in the mounting of a detachable barrier to the jig in abutment with the aligned surfaces of a row of blocks along an edge of the wall component being constructed to confine the fluid concrete when poured.

3. The face down method of constructing a concreteconcrete block building wall component as claimed in claim 1 wherein the multitude of blocks include those having extended end portions of greater vertical dimension than the remaining concrete blocks, the additional step of depositing the blocks having extended end portions along an edge of the wall component to confine the fluid concrete when poured.

4. The face down method of constructing a concreteconcrete block building wall component as claimed in claim 1 including the additional step of selectively depositing said blocks upon the latticed jig according to a predetermined plan so as to leave areas of the jig devoid of said blocks with the void areas defining door and window openings in the wall component.

5. The face down method of constructing a concreteconcrete bl`ock building wall component as claimed in claim 4 including the additional step accomplished prior to pouring of concrete consisting in the mounting of a detachable barrier to the jig in abutment with the aligned surfaces of a row of rblocks along an edge of the wall component to confine the fluid concrete when poured.

6. The face down method of constructing a concreteconcrete block building wall component as claimed in claim 5 wherein the multitude of blocks include those having extended end portions of greater vertical dimension than the remaining blocks, the additional step of depositing blocks having extended end portions along an edge of the wall component to confine the fluid concrete when poured.

Claims

1. A face down method of constructing a concrete-concrete block building wall component of rectangular configuration, said method comprising the steps of, sizing of a multitude of concrete blocks by grinding each of the vertical side surfaces of said blocks, each of the blocks having an irregular upper surface thereon, forming inwardly directed beveled surfaces about the lower perimetrical edge of said concrete blocks, contiguously depositing said blocks upon a rectangular wall sized jig with the irregular upper surface of the block facing upward, said jig comprised of latticed angle iron sections with the blocks placed thereon so as to locate their beveled surfaces in resting contact upon said jig sections with each vertical surface of an interior block being in surfacial abutment with a like surface on another block, said blocks when so positioned forming a composite block assemblage impervious to poured fluid concrete, and pouring concrete over said blocks to fully cover same to form a monolithic concrete slab which upon curing results in an integral concrete-concrete block building wall component.

2. The face down method of constructing a concrete-concrete block building wall component as claimed in claim 1 including the additional step accomplished prior to pouring of concrete consisting in the mounting of a detachable barrier to the jig in abutment with the aligned surfaces of a row of blocks along an edge of the wall component being constructed to confine the fluid concrete when poured.

3. The face down method of constructing a concrete-concrete block building wall component as claimed in claim 1 wherein the multitude of blocks include those having extended end portions of greater vertical dimension than the remaining concrete blocks, the additional step of depositing the blocks having extended end portions along an edge of the wall component to confine the fluid concrete when poured.

4. The face down method of constructing a concrete-concrete block building wall component as claimed in claim 1 including the additional step of selectively depositing said blocks upon the latticed jig according to a predetermined plan so as to leave areas of the jig devoid of said blocks with the void areas defining door and window openings in the wall component.

5. The face down method of constructing a concrete-concrete block building waLl component as claimed in claim 4 including the additional step accomplished prior to pouring of concrete consisting in the mounting of a detachable barrier to the jig in abutment with the aligned surfaces of a row of blocks along an edge of the wall component to confine the fluid concrete when poured.

6. The face down method of constructing a concrete-concrete block building wall component as claimed in claim 5 wherein the multitude of blocks include those having extended end portions of greater vertical dimension than the remaining blocks, the additional step of depositing blocks having extended end portions along an edge of the wall component to confine the fluid concrete when poured.