AU677131B2

AU677131B2 - Concrete building block

Info

Publication number: AU677131B2
Application number: AU34542/95A
Authority: AU
Inventors: Caswold Hickson Lee
Original assignee: Individual
Current assignee: Individual
Priority date: 1995-03-03
Filing date: 1995-10-25
Publication date: 1997-04-10
Anticipated expiration: 2015-10-25
Also published as: AU3454295A

Description

THIS INVENTION relates to building blocks, in particular but not limited thereto, to interlocking building blocks made from light weight concrete aggregate.

Current building blocks such as bricks for a wall or floor construction and the like are laid in layers (courses) and adjacent blocks are bonded with a thin layer of mortar. These blocks are normally laid by applying a layer of mortar on surfaces of each block before placing the block on an adjacent block or blocks depending on the wall pattern. Laying blocks this way is time consuming. In addition it requires substantially high skill level in order to apply just sufficient mortar to each block and to align the blocks accurately in each layer. Brick layers can only lay a limited number of blocks per hour because the blocks made from standard materials are relatively heavy. Because of their weight to transportation costs of these blocks are high.

An object of the present invention is to alleviate or at least reduce to a tol 15 certain degree one or more the above disadvantages.

0:04 *o6, In a broad aspect of the present invention therefore there is provided a

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building block for constructing walls, floors, paving or the like. The building block is in the form of a substantially rectangular parallelepipedon having a top

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.5 surface, a bottom surface, a plurality of side surfaces and a pair of opposed end 20 surfaces. A substantially dove-tail shaped central recess is formed in the top and/or bottom surface. The central recess extends transversely across and divides

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the top and/or bottom surface into two separate mirror image surface portions.

Wherein the central recess is configured so that two other such building blocks abutting end to end in an adjacent layer can have their respective adjacent surface

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portions accommodated in the central recess and thereby interlocked therein.

The building block of the present invention is made from lightweight concrete aggregate. lightweight concrete is defined as concrete with a 28 day compressive strength in excess of 2,500 psi (0.36 Mpa) and a air-dry unit weight of 115 lb. per cubic foot (1842.3 Kg/m 3 or less. The aggregate has a predetermined amount of polystyrene granulate which may be coated with a nontoxic chemical compound, and optionally a mixture of cement, sand, flyash and water. The amount of polystyrene granulate and the mixture contents can be varied depending on applications. It is preferred that the granulate is in beads form.

Preferably the building block includes one or more openings extending between the top surface and the bottom surface. More preferably the openings are disposed at the surface portions and/or the recess. Typically the openings are of rectangular cross-section. Alternatively the openings may include one or more s.

square cross-sectioned openings. The openings can also have different cross- .ao* sectioned shapes.

Conveniently the building block of the present invention is dimensioned 200mm in width, 200mm in height and 400mm in length. Alternatively the block may have a width of 150mm, height 200mm and length 400mm. It should be noted 20 that the dimensions of the building block of the present invention can be varied to suit particular applications or preferences.

Typically the dove-tail shaped central recess and its adjoining side portions are configured so that said two other building blocks in the adjacent layer substantially fully fill the volume defined by the recess when accommodated therein. Accordingly there is no need for a bonding agent such as mortar to bond the building blocks. In addition they are aligned automatically by the interlocking arrangement.

Preferably the building block includes a pair of opposed side surface. The building blocks in each layer can be arranged with the opposed side surfaces parallel to a vertical plane or a horizontal plane. When arranged in parallel to a vertical plane, the building blocks in adjacent layers are positioned in the recess from one or the other side surfaces in a horizontal direction. When arranged in parallel to a horizontal plane, the building blocks in adjacent layers are positioned in the recess from one or the other side surface in a vertical direction.

Advantageously the central recess has a base, a mouth, a side extending from each end of the base to the mouth and the respective sides are at a 0%oo °°,predetermined angle towards each other. Corners formed by each side with the base are preferably slightly rounded. More preferably the edge of each side 15 portions joining to the central recess is shaped to match the rounded corners.

In another aspect of the invention there is provided a corner building block for use with the building block described above. The corner block is in the form of a substantially rectangular parallelepipedon having a top surface, a bottom surface, a plurality of side surfaces and a pair of opposed end surfaces. A recess 20 is formed in the top and/or bottom surface adjacent to a surface portion on the top and/or bottom surface. The recess extends transversely across a pair of side surfaces and longitudinally from the surface portion to substantially half the length of the central recess. Wherein the recess is configured so that a surface portion of the building block described in the preceding paragraphs can be accommodated in the recess and interlocked therein.

Preferably the recess has a base, a side extending from one end of the base to the or one side portion at a predetermined inward angle. The base and the side are configured and arranged to accommodate a side portion.

The corner block may be a full sized or half sized corner block. For a full corner block, the recess has a substantially vertical side opposed to the angled side. Said other surface portion has a length substantially half the length of tilhe block. Typically said other surface portion is of a substantially square crosssection. The parts of the corner block where the other surface portion is located may have a height relatively shorter than the part of the corner block where the surface portion is located.

For a half corner block the base of the recess terminates at the end surface remote from said angled side.

In order that the present invention can be more readily understood and be 15 put into practical effect, reference will now be made to the accompanying drawings which illustrate preferred embodiments of the present invention and S wherein:- Figure 1 illustrates a perspective view of a wall employing the building blocks of the present invention; 20 Figure 2 illustrates a perspective view of another wall employing the building blocks of the present invention; Figure 3 illustrates an isometric view of a first embodiment of the building block of the present invention; Figure 4 illustrates a perspective view of a second embodiment of the 6 building block of the present invention; Figure 5 illustrates a isometric view of a third embodiment of the present invention; Figure 6 illustrates an isometric view of a corner building block of the present invention; and Figure 7 illustrates an isometric view of a half building block of the present invention.

Referring initially to Figure 1 there is shown a wall structure 100 having adjacent walls 102, 104 extending perpendicularly from a corner. As shown each of the walls 102, 104 has 3 layers of lightweight concrete building blocks in end to end abutting relationship. With the exception of a base layer 106 and the uppermost layer 108, each of the intermediate layers 110 between the layer 106 and the layer 108 is interlocked with one or two building blocks in adjacent layers.

15 The walls 102, 104 are formed of building blocks 10, full corner building blocks 12 and base building blocks 14.

:Figure 2 shows a wall structure 100 with a single wall 105. As with the 1. •structure 100 shown in Figure 1 the wall 105 has 3 layers of lightweight concrete building blocks in end to end abutting relationship. The building blocks are laid 20 as for the Figure 1 structure 100 except that half corner blocks 15 are employed in alternate layers at each end of the wall 105.

In Figure 3 the building block 10 as shown has a top surface 20 formed by surface portions 22 and 24 and a dove-tail shaped central recess 26, side surfaces 29 (only one shown), end surfaces 30 (only one shown), a bottom surface 32 formed by a surface portions 34, 36 (not shown) and a dove-tail shaped central recess 26. Each of the dove-tail shaped central recess 26 separates the surface portions 22, 24 and 34, 36 of respective top and bottom surfaces 20, 32. A number of through openings 38 extend between the top and bottom surfaces and 32.

The side portions 22, 24, 34, 36 and the central recesses 26 are dimensioned and arranged so that adjacent surface portions 34, 36) of building blocks 10 or a building block 10 and a corner block 12 or 15 in a layer can be interlocked in a central recess 26) of a block 10 in the adjacent layer.

The building block 10 is made from lightweight concrete aggregate having predetermined portions of polystyrene beads form granulate coated with a suitable non toxic chemical compound and a mixture of cement, sand, flyash and water.

An example of an appropriate lightweight concrete aggregate is BST light weight concrete which has the following technical specification: Density 300 1800 Kg/m 3 Compressive strength 0.5 25 Mpa Flexural strength 0.5 3.55 Mpa Tensile strength 0.5 1.40 Mpa *000 Fire resistance 4 hours (non-toxic, non-combustible) 20 Thermal insulation 2.0 values Acoustic insulation up to 60 STC values As can be seen in Figures 1 and 2, the central recesses 26 are substantially filled by a side portion or adjacent side portions which are interlocked therein.

STherefore there is no need for a bonding agent between the various blocks.

4 8 The building block 10 shown in Figure 4 is substantially similar to the block 10 in Figure 3 except for the shape of the openings 38. In this embodiment the corners of the openings are slightly rounded.

Figure 5 shows a foundation or a topmost building block 14. This building block 14 has a single central recess 26 either in the top surface 20 or the bottom surface 32 depending on whether it is to be used as a foundation or a topmost building block. Where the block 14 is a foundation block the side surfaces 28 and the end surfaces 30 may slope outwardly from the top surface 20. This is useful for a retaining wall construction.

The full corner block 12 shown in Figure 6 has its top 20 and bottom 32 surfaces interrupted by respective recesses 27 which are substantially half of the '-;central recess 26 shown in Figures 3 to 5. The surface portion 24 is as for the block 10 shown in Figures 3 to 5. However the surface portion 23 is substantially square in shape and has a relatively large through hole 39. The parts S 15 of the side surfaces joining to the surface portions 23 are slightly shorter than V. those joining the surface portions 24.

Figure 7 shows a half corner block 15 which is essentially half the size the building block shows in Figures 3 to Whilst the above has been given by way of illustrative example of the 20 present invention, many variations and modifications thereto will be apparent to those skilled in the art without departing from the broad ambit and scope of the invention as herein set forth.

Claims

1. A building block in the form of a substantially parallelepipedon having a top surface, a bottom surface, a plurality of side surfaces and a pair of opposed end surfaces, the block including a substantially dove-tail shaped central recess formed in the top and/or bottom surface, the central recess extending transversely across and dividing the top and/or bottom surface into two separate mirror image surface portions, wherein the central recess being configured so that two other such building blocks abutting end to end in an adjacent layer can have their respective adjacent surface portions accommodated in the central recess and thereby interlocked therein, wherein the building block is made from lightweight concrete (as hereinbefore defined) aggregate having a predetermined amount of polystyrene granulate. o:

2. The building block according to claim 1, wherein the block including one or more openings extending between the top surface and the bottom surface. S 15

3. The building block according to claim 2 wherein the opening(s) being disposed at the surface portions and/or the central recess. S..

4. The building block according to claim 2 or 3 wherein the opening(s) are of rectangular cross-section.

5. The building block according to one of claims 2 to 4 wherein the 90051 opening(s) include one or more square cross-sectioned openings.

6. The building block according to any of claims 1 to 5 wherein the granulate including a predetermined amount of polystyrene granulate coated with a non- toxic chemical compound, and further having a mixture of cement, sand, flyash and water in predetermined proportions. 1 ft

7. The building block according to any one of claims 1 to 6 wherein the polystyrene granulate is in beads form.

8. The building block according to any one of claims 1 to 7 wherein the or each central recess and its adjoining side portions are configured so that said two other building blocks can substantially fill the volume defined by the central recess when accommodated therein.

9. The building block according to claim 8 wherein said two other building blocks are automatically aligned with the building block where the respective adjacent surface portions are interlocked in the central recess.

10. The building block according to any one of claims 1 to 9 wherein the central recess has a base, a mouth and a side extending from each end of the t. base to the mouth, the respective sides being at an angle towards each other. s

11. The building block according to claim 10 wherein corners formed by respective sides with the base have a slightly rounded shape. to 15

12. The building block according to Claim 11 wherein the edge of each side portion joining to the central recess is shaped to match the rounded corners.

13. A corner building block for use with the building block according to any *I *t one of claims 1 to 12, wherein the corner block is in the form of a substantially parallelepipedon having a top surface, a bottom surface, a plurality of side 20 surfaces and a pair of opposed end surfaces, a recess being formed in the top and/or bottom surface, the recess being positioned adjacent to a surface portion on the top and/or bottom surface, the recess extending transversely across a pair of opposed side surfaces and longitudinally from the side portion to substantially half the length of the central recess, wherein the recess is configured so that a Rsurface portion of the building block according to any one of claims to 12 can surface portion of the building block according to any one of claims I to 12 can I- i 11 be accommodated in the recess and interlocked therein, wherein the building block is made from lightweight concrete (as hereinbefore defined) aggregate having a predetermined amount of polystyrene granulate.

14. The corner building block according to claim 13 wherein the corner block including one or more openings extending between the top surface and the bottom surface.

The corner building block according to claim 14 wherein the opening(s) being disposed at one or both surface portions, and/or the recess.

16. The corner block according to claim 14 or 15 wherein the openings are of rectangular cross-section.

17. The corner block according to one of claims 14 to 16 wherein the opening(s) include one or more square cross-sectioned openings.

18. The corner block according to claim 17 wherein the granulate including a predetermined amount of polystyrene granulate coated with a non-toxic S 15 chemical compound, and further having a mixture of cement, sand, flyash and water in predetermined proportions.

19. The corner block according to any one of claims 13 to 18 wherein the polystyrene granulate is in beads form.

20. The corner block according to any one of claims 13 to 19 wherein said l l 20 building block is automatically aligned with the corner block when the surface portion is interlocked in the recess.

21. The corner block according to any one of claims 13 to 20 wherein the recess has a base, a side extending from one end of the base to the or one side portion at of predetermined inward angle, the base and the side being configured 5 and arranged to accommodate a side portion. b 12

22. The corner block according to any one of claims 13 to 21 wherein the corner block is a full sized block.

23. The corner block according to claim 22 wherein the recess of the full sized block has a substantially vertical side opposed to the angled side and said other surface portion has a length substantially half the length of the corner block.

24. The corner block according to clai 23 wherein said other portion is of substantially square cross-section.

The corner block according to any one of claims 22 to 24 wherein the part of corner block where the other surface portion is located has a length relatively shorter than the part of the corner block where the surface portion is located.

26. The corner block according to any one of claims 13 to 21 wherein the corner block is a half sized block.

27. The corner block according to claim 26 wherein the base of the recess terminated at the end surface remote from said angled side. 15

28. A wall comprising a plurality of layers of inter-locked building blocks wherein the building blocks include building blocks according to any one of 000 0e claims 1 to 12 and corner blocks according to any one of claims 13 to 27. *000 0

29. A wall substantially as described with reference to Figure 1 or 2.

30. A building block substantially as described with reference to any one of 0 0 20 Figures 3 to

31. A corner building block substantially as described with Figure 6 or 7. DATED this 2nd day of January 1997 CASWOLD HICKSON LEE TR By his Patent Attorneys INTELLPRO