WO2009076646A1

WO2009076646A1 - Dry stack block wall systems and methods

Info

Publication number: WO2009076646A1
Application number: PCT/US2008/086697
Authority: WO
Inventors: Brandon James Pratt; John Russel Pratt
Original assignee: Brandon James Pratt; John Russel Pratt
Priority date: 2007-12-12
Filing date: 2008-12-12
Publication date: 2009-06-18

Abstract

System and method for an improved dry stack wall system utilizing novel block designs, wherein adhesive insulative foam material may be optionally be installed. The system, methods and block components of the invention provide increased structural rigidity, superior insulation performance, improved resistance to moisture, wind and rodents, and greater ease and economy of construction.

Description

DRY STACK BLOCK WALL SYSTEMS AND METHODS

Field of Invention

The present invention is directed generally to systems and methods of producing dry stack concrete block walls, to the walls so produced, and to dry stack concrete blocks adapted for use in such systems and methods.

Background of Invention

Dry stack masonry systems pose a number of advantages over conventional concrete masonry unit (CMU) wall systems including that fewer materials are needed and the construction of such systems is less labor intensive. Conventional CMU wall systems require some type of grout or mortar to provide joint support for each modular unit. The process is slow in that it requires skilled masons who have acquired of the necessary skills through long apprenticeships and work experience.

Accordingly, there have been attempts at systems of constructing a CMU wall to reduce the need for a mortar joint between every course of block. Some studies have demonstrated that "all up" installation of dry stack masonry systems are as much as to ten times faster than convention CMU wall construction. However, the use of bonding mortar in conventional block wall construction allows the mason to level and plumb each course of block as it is laid up. A feature of some prior dry stack wall system designs is that they must employ some means of adjusting for plumb and level, which often includes mortaring a course.

Mortaring, of course, means that such prior systems continue to require skilled masons, with the attendant increases in costs and time.

U.S. Pat. No. 4,769,964 ("the '964 patent"), describes a dry stack block wherein preformed insulating cell cores are inserted into hollow cells of the dry stack units used. U.S. Pat. No. 4,748,782 ("the '782 patent"), describes a dry stack wall system which utilizes the dry stack block of the '964 patent. The cell cores are described as situated in such fashion as to provide interlocking alignment with the cell core and an adjacent block within a second running course. The mating and interlocking of the cell cores are noted to maintain the wall level and alignment. Summary of the Invention

In one aspect, the present invention is directed to novel dry stack building blocks used for constructing a dry stack masonry wall. Different types of blocks are presently contemplated and specially adapted for, and may be advantageously employed in, the system according to this aspect of the invention: Regular Insulation Block, Corner Block, U Block, Electrical Block and/or Half Block. In one embodiment, the Regular Insulation Block will connect between Corner Blocks. U-Blocks and/or Electrical Blocks may act as a horizontal bond beam, and provide structural support, and Half Blocks, along with Corner Blocks, may preferably be used around all structural openings.

The Regular Insulation Block utilized in accordance with the invention includes first and second chambers, each of which is open at the top of the block substantially along the length of the block, and which is closed by a web at the bottom. The two chambers are separated from each other by a web or wall that runs the length of the block, and that is preferably centered within the block The first chamber (which may preferably be the inside or inward- facing chamber with reference to the wall in which the block is situated) preferably includes two internal webs which divide the first chamber into three sections; a central section that is enclosed at each end by an internal web, and two adjacent sections, one on each side, that are open at their respective ends, such that when three Regular Insulation Blocks are placed end-to-end, a series of three closed-ended first chamber sections are formed. These closed-ended sections facilitate reinforcing bar or other suitable reinforcing apparatus to be optionally inserted vertically if desired, thereby allowing for rebar to be inserted vertically and to produce a vertical locking system. The second chamber (which may preferably be the outside or outward-facing chamber with reference to the wall in which the block is situated), preferably does not include any internal webs, and may preferably be generally tapered from the top of the block to a point below the top of the block so serves the dual purpose of adding structural support as well as insulative value when filled with an insulating material, which is preferably an adhesive expanding foam, such as adhesive polyurethane foam. In an embodiment, the outside wall chamber may optionally have reinforcing bar or other suitable reinforcing apparatus inserted horizontally, thereby allowing the wall to be locked horizontally to produce a horizontal locking system, horizontally. In one embodiment of the invention, every seventh course may be used for horizontal rebar or a bond beam, and the outside chamber for this course may be filled with grout or mortar rather than with insulation. The bond beam course may also serve the purpose of a leveling course when the bond beam course is mortared. The number and spacing of vertical and horizontal courses containing rebar may be varied as necessary or desirable, depending, for example, upon the structural loading, and/or other loading, which the wall will encounter in service. In another, preferred embodiment, a horizontal rebar or bond beam course is not employed in construction of the dry stack wall system of the invention, with significant savings in time and materials, while equaling or surprisingly exceeding in strength both conventional laid-up block and prior dry stack construction systems. A typical embodiment of the present invention contemplates installation of vertical rebar every two to six feet of construction. This embodiment enables an inside chamber that houses the vertical rebar to be efficiently filled with grout without affecting the insulation value of other inside chambers or of any outside chambers. The unique interior webbings of the block designs of the present invention enable the block to achieve unexpected structural integrity and strength through injection of the adhesive insulation component of the system of the invention into both chambers, which also results in the interlocking of the block horizontally and vertically.

Another component of the present invention is referred to as the Electrical Block. The preferred embodiment of the Electrical Block has many of the same attributes as the Regular Insulation Block, and the Electrical Block additionally incorporates a pre-cast knockout that, when knocked out, allows for a proprietary or standard electrical box to be inserted. This enables the present invention to be constructed in a more efficient manner, avoiding the need for field cutting of the block to accommodate electrical boxes in the construction. In addition, it will be appreciated that the dry stack block of the present invention is designed such that electrical conduit or wire (or, indeed, other mechanical and electrical systems) may conveniently be routed through the block cavities during dry stacking of the wall itself, rather than having to be pulled after wall construction, as is the case with many conventional approaches.

Another component of the present invention is referred to as the Half Block. The Half Block, which is approximately half the size of a conventional CMU, is typically used on the sides of open cavities within the constructed wall. In a preferred embodiment, the Half Block is laid up in a stack bond, thereby creating a hollow core, which can be filled with insulative or structural bonding material. Another component of the present invention is referred to as the Corner Block. The preferred embodiment of the Corner Block is spatially matched with the Regular Insulation Block, and when laid in conjunction with a Regular Insulation Block, results in two hollow chambers, in which insulative material may be injected to serve as a horizontal bond between the two blocks. Additionally, a third hollow chamber is created at the corner of the wall system, which can be filled with insulative material and/or a material which can be used to increase structural rigidity.

Another component of the invention is the U Block. In a preferred embodiment, the U Block is incorporated as the top-most course of a constructed wall comprising Regular Insulation Block and Corner Block. Grout or mortar may be poured inside the U Block, which may also conveniently receive horizontal rebar. In addition, the U Block course may optionally be mortared, which provides for leveling of the constructed wall structure. Thus, in the event that a wall constructed according to the systems and methods of the invention varies from level, the addition or elimination of grout applied to the final U Block course can correct for this variance.

Another component of the present invention is the Electrical Block. In a preferred embodiment, the Electrical Block has perforated section, which allows for onsite removal and insertion of an electrical junction box. Electrical wire may be routed in the cavities of the constructed wall system from the site of an electrical junction box to a predetermined location where all electrical wiring will be housed, such as a load center. Preferably, the electrical wire is run through a bond beam course in the wall system. In a preferred embodiment, electrical wiring (which may be any suitable or code -required type, for example, NWM, NM, or BX, or housed within plastic or metal conduit), is inserted through a knockout in a laid-up Electrical Block (for example an Electrical Block laid in the third horizontal course for the purpose of accommodating an electrical outlet in the finished interior wall), and the wire is thereafter pulled through vertically or horizontally as appropriate as each successive block or block course is laid, until a bond beam course is laid, at which point the wire is run along the bond beam course to the site of the load center. Corrugated PVC flexible tubing such as, for example, Flex-Plus Blue ENT (Carlon, Cleveland, Ohio) may be used as a conduit in which the electrical wiring is housed. The present invention contemplates injection of an insulative material, which may preferably comprise expandable foam, injected within the hollow chambers inherent in the various block types and those hollow chambers created as a result of construction of the wall system. In a preferred embodiment, the expandable foam employed is adhesive polyurethane foam. The insulative material in this preferred embodiment not only creates substantial insulation value which, as a result of the design of the bocks of the invention and the manner in which they are laid up, results in substantially continuous and uninterrupted insulation, but also increases structural rigidity by adhering to the blocks, and to the reinforcing bars (or other suitable reinforcement system) within the blocks, interlocking and adhering the blocks and reinforcing bars to one another in both horizontal and vertical planes.

The present invention also contemplates that the entire wall system may be coated with a structural surface coating that provides an advantage over existing dry stack wall systems by enabling decorative use of the exterior of the wall system, increased waterproofing capabilities and increased structural rigidity. A surface coating may be employed on either or both surfaces of the constructed wall according to the invention, including interior drywall-like coating. One presently preferred embodiment of the structural coating of the system of the invention is a cementitious product which also contains fiberglass strands. In an alternative embodiment, application of the structural coat is not employed, because of the substantial structural integrity (as well as the insulation value) provided by the injection of adhesive insulative material into the wall in accordance with the present system. Once the present invention is surface coated, numerous advantages are realized, such as surprisingly reduced air and water infiltration, with the additional advantage of mildew and termite and rodent resistance.

Embodiments of the present invention may have one or more of the following advantages. The present invention provides improved dry stack concrete masonry blocks for constructing masonry load-bearing and non-load bearing wall systems. The present invention provides a substantial increase in insulation value and structural rigidity. For example, walls constructed according to the invention are expected to demonstrate a superior insulation value of at least an R-40 rating, in contrast to lower R values of conventional block construction, even where the same insulative material is employed. The present invention also provides improved cost competitiveness, in that it avoids the need for drywall, furring of interior walls, and the pre- installation of electrical conduit and insulation during the construction of the wall system. The present invention is particularly useful for firewalls including demising firewalls, which, when constructed according to the invention, achieve surprisingly increased burn-through times, as does any wall so constructed, whether or not demising. The improved dry stack masonry block used in the present invention has demonstrated a compressive strength of 3410 psi and a 2.9 hour fire rating. Additionally, the present invention may utilize color coded dry stack masonry blocks. This presents the advantage of using unskilled or foreign speaking laborers to recognize the proper layout of blocks during construction.

Brief Description of the Drawings

The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:

Fig. 1 is a schematic drawing of an embodiment of a dry stackable 8"x8"xl6" Regular Insulation Block according to the invention;

Fig. IA is a photograph of a view of an embodiment of a dry stackable Regular Insulation Block according to the invention;

Figs. IA-E are photographs of views of an embodiment of a dry stackable Right Hand Corner Insulation Block corresponding to Figure 1 ;

Fig. IF is a photograph of a view of an embodiment comprising two adjacent Regular

Insulation Blocks and showing the unique webbing of the blocks and the chambers created during construction of the dry stackable wall system, which, according to the invention, may be injected with insulative, preferably adhesive insulative, material;

Fig. 2 is a schematic drawing of an embodiment of a dry stackable 8"x8"xl6" Right

Hand Corner Insulation Block according to the invention;

Figs. 2A-G are photographs of views of an embodiment of a dry stackable Right Hand Corner Insulation Block corresponding to Figure 2; Figs. 2H-K are photographs of views of an embodiment comprising a dry stackable Right Hand Corner Insulation Block corresponding to Figure 2 adjacent to a Regular Insulation Block corresponding to Figure 1, and showing the manner in which the dimensions of the Right Hand Corner Insulation Block match those of the Regular Insulation Block

Fig. 3 is a schematic drawing of an embodiment of a dry stackable 8"x8"xl6" Left Hand Corner Insulation Block according to the invention;

Fig. 4 is a schematic drawing of an embodiment of an 8"x8"x8" Insulation Block according to the invention;

Fig. 5 is a schematic drawing of an embodiment of a dry stackable 8"x8"xl6" Deep Press Bond Beam Block according to the invention, showing four such blocks;

Figs. 5A-F are photographs of views of an embodiment of a dry stackable 8"x8"xl6"

Deep Press Bond Beam Block corresponding to Figure 5, showing a single such block;

Fig. 6 is a schematic drawing of an embodiment of a dry stackable 8"x8"x8" Half Block according to the invention;

Figs. 6A-B are photographs of views of an embodiment of a dry stackable 8"x8"x8" Half Block corresponding to Figure 6;

Fig. 7 is a schematic drawing of an embodiment of a dry stackable 8"x8"xl6" Electrical Block according to the invention incorporating a two and three eighths inch cutout section suitable for a standard duplex outlet box; Fig. 8 is a schematic drawing of an embodiment of a dry stackable 8"x8"xl6" Electrical Block according to the invention incorporating a four and a quarter inch cutout section suitable for a standard quadraplex outlet box;

Fig. 9A-9F are photographs of constructed walls detailing the color coding of the wall system;

Fig. 10 is a photograph of a constructed wall system with installed vertical rebar;

Fig. 11 is an alternative view of an embodiment of an electrical block; and

Fig. 12 is a photograph demonstrating vertical and horizontal rebar installed in a constructed wall system; and

Fig. 13 is a photograph of a drystack constructed wall with a structure coat layer applied.

Detailed Description of Drawings

Prior to installation of the innovative dry stack block wall system of the invention, it will be understood by those of skill that a blueprint would typically be prepared for the structure being constructed. Accordingly, the various drystack blocks will be temporarily laid on a concrete foundational slab according to plan consistent with such blueprint. This floor plan will not encompass any bonding agent such as mortar, but will serve for purposes of demonstrating features such as placement of vertical rebar within the wall system as depicted in Figure 10. Once these particular areas within the laid out floor plan have been identified, the positioning of the vertical rebar is fixed by conventional means such as drilling, if not previously positioned at the time the slab was poured. The vertical rebar can be set in the floor plan using any bonding material, e.g. epoxy. It is understood that rebar used in accordance with the present invention may be of various sizes, as may be determined according to the static and dynamic loads for which the wall is designed. The next step is the removal of all blocks that had been laid for purposes of determining rebar placement. The vertical rebar is set in those areas predetermined in the previous phase of construction. Typically the rebar is placed in holes which have been drilled approximately six inches deep. However, one of ordinary skill in the art will appreciate that the hole drilled for the vertical rebar placement can vary in depth.

Once the vertical rebar has been set in the vertical slab, the first course of dry stack blocks is again laid consistent with the floor plan. Although it is preferable that the slab used is perfectly level, the present invention can accommodate slight variances in the levelness of the foundational slab. The regular insulation block as shown in Figure 1 is used for those areas in the first course, which are not a corner of the structure or surrounding a door or window casing. According to Figure 1, the dry stackable regular insulation block 100 encompasses various features. The block 100 comprises an outer wall 110, a center wall 120 and an inner wall 130. A first insulating core 140 is created by use of the block's outer wall 110, center wall 120 and vertical webbing 115 and 190. A second insulation core 150 is created between center wall 120 and inner wall 130 and vertical webbing 165 and 180. Additionally, half insulation cores 160 and 170 are created on either side of the second insulation core 150. An alternative insulation block is shown in Figs. 1A-1E. The alternative block 100a is substantially similar to insulation block 100; however, there isn't vertical webbing between center wall 120a and inner wall 130a. Instead, half wall 165a and 180a are used to create second insulation core 150a.

During construction, the insulation block 100 is arranged to fit with various blocks such as shown in Figure IF, which may be described as a running bond. For those corner areas within the floor plan, the corner block 200 as shown in Figure 2 is utilized. The corner block comprises an outer wall 210, an inner wall 220, a corner wall 290 and a center wall 240. A first insulation core 230 is created between outer wall 210, inner wall 220, center wall 240, half wall 272 and adjacent to vertical webbing 273. A second insulation core is created between outer wall 210, center wall 240, half wall 272 and unique webbing 280. A third insulation core is created between center wall 240, inner wall 220 and vertical webbings 271 and 273. A half insulation core 260 is created adjacent to vertical webbing 271 and center wall 240. Figure 3 depicts the a corner block 300 similar to corner block 200 in reverse orientation

Alternatively, the corner block as shown in Figs. 2A-2G may be used in the present invention. This corner block 200a is substantially similar to block 200; however vertical webbings 271 and 273 are replaced by half walls 271a and 272a. Figure 3 depicts the a corner block 300 similar to corner block 200 in reverse orientation

As previously indicated, the system of the present invention is created by the interlocking of various dry stack block components. Figures 2H and 21 are depictions of blocks similar to a corner block 200a and insulation block 100a arranged together. During the construction process, this insulation is inserted into the various insulation cores. Typically, a polyurethane foam material is blown into the insulation cores through the various webbings inside the arranged dry stack blocks.

A wall system constructed in accordance with the present invention will allow laborers to lay at least three courses of block before inputting insulative material. At this point, laborers will install the foam using a nozzle type device and spraying the foam in a downward fashion inside the wall. Additionally the foam will be sprayed around the set vertical rebar.

Typically, there are five courses of block laid before foam is blown into the various insulation cores. In a preferred embodiment, the next course, i.e., the sixth course is the bond beam course. In the present invention, the bond beam block, as well as other blocks within the system, can be color coated for ease of use. The bond beam as shown in Figure 5 is the course wherein any electrical wiring will be ran, as well as horizontal rebar will be installed. Figure 12 demonstrates the bond beam course with horizontal rebar installed. The bond beam 500 consists of walls 510 and 520 and perpendicular walls 530, 540 and 550. Each perpendicular wall incorporates indentations which is approximately halfway down the wall. During the construction process, the bond beam is filled with mortar. The weight of the bond beam is able to be supported by the previous courses which would have been filled with the insulative foam. Once the bond beam course has been laid and the mortar poured therein, additional courses using the insulation block 100 and other blocks may be laid atop the bond beam course.

This process is repeated until the wall has been constructed to a level where floor trusses will be installed. Typically, a floor truss is attached to the wall system utilizing a truss girder connector such as those manufactured by Simpson Strong-Tie®. As previously indicated, the wall system provides that different blocks may be used around door and window openings within a construction plan. The half block 400 as provided in Figure 4 is typically used around door and window openings. These blocks are typically stacked vertically in a similar orientation. This allows a vertical rebar to be put in place and filled with grout. The half block consists of an outer wall 410, an inner wall 420 and a center wall 460. The half block 400 also includes insulation core 430 and half insulation cores 440 and 450. Additionally, the present invention provides for the use of electrical block as shown in Figures 7 and 8. Electrical block has a similar arrangement to that of an insulation block; however the block has a knockout panel, wherein a laborer could easily remove a section of the block and install an electrical junction box. Alternatively, the electrical may be similar to a standard concrete block as shown in Figure 11. Typically, the electrical junction box will be at least three courses of blocks up the wall. However, one skilled in the art would appreciate that this could change according to building code of the particular location of the construction.

Once the entire wall has been constructed a structure coat, comprising fiberglass or similar material is applied to the interior and exterior of the wall system. This increases the moisture resistance of the system as shown in Figure 13. Numerous additional advantages may be realized by those having ordinary skill in the art, for any situation in which one with knowledge of dry stack wall construction requires such construction to achieve substantial structural rigidity and insulation value improvements according to the present invention.

Claims

What is claimed is:

1. A method of constructing a dry stack wall system comprising:

providing a foundation upon which the wall will be erected;

arranging an initial course of cementitious block in a fashion in which the block abut each other in an end to end relationship;

arranging a second course of cementitious block upon said first course of cementitious block, aligning the bottom of said second course with the top of said first course;

arranging at least at the third course rebar to reinforce the concrete laid;

continuing process until the wall of desired length is in place;

injecting insulative foam into the vertical webbings incorporated into each block;

applying smooth mortar product to the completed wall system.

2. The method in claim 1 wherein said foundation comprises a smooth concrete slab.

3. The method of claim 1 wherein said first course is arranged in a manner consistent with a predetermined floor plan.

4. The method of claim 1 wherein said arranging of courses leaves space for doors and windows.

5. The method of claim 1 wherein said third, fourth or fifth course has opposite facing corner blocks.

6. The method of claim 1 wherein said rebar is comprised of a metal bar.

7. The method of claim 1, wherein the injection of insulative foam populates the entire wall system through the various interconnected vertical webbings of each contiguous block.

8. An insulated cementitious block for use in a drystack wall system comprising:

a body portion having a bottom surface, a top surface, a preselected length, width and height, a first outer wall, a second outer wall, and a central wall

said body portion further comprising first and second vertical end cross webs connecting the ends of said first and central walls extending through to the central wall, each of the first and second vertical end cross webs extending a predetermined distance from the top surface toward the bottom surface;

said body portion further comprising a third and fourth vertical end cross webs connecting the ends of said central and second outer walls, each of the third and fourth vertical end cross webs extending a predetermined distance from the top surface toward the bottom surface;

a first insulating core created between the space between the central wall and the first outer wall, said core spanning from the top surface to the bottom surface of said cementitious block and further wherein said first insulating core is adjacent to said first vertical end cross web;

a second insulating core created between said inner wall and said second outer wall, said second insulating core spanning from the top surface to the bottom surface of said cementitious block and further wherein said second insulating core is situated between said third and fourth vertical end cross web; and

a partial insulating core created on at least one side of the second insulating core, wherein an insulated cementitious block of similar layout could be attached to create a full insulating core.

9. The cementitious block according to claim 8, wherein insulative material can be injected through said vertical end cross webs.

10. The cementitious block according to claim 8, wherein knockouts are provided for installation of an electrical junction box.