GB2272462A

GB2272462A - Masonry block

Info

Publication number: GB2272462A
Application number: GB9223886A
Authority: GB
Inventors: Philip Lever
Original assignee: Boral Edenhall Concrete Products Ltd
Current assignee: Boral Edenhall Concrete Products Ltd
Priority date: 1992-11-13
Filing date: 1992-11-13
Publication date: 1994-05-18
Anticipated expiration: 2012-11-13
Also published as: GB9223886D0; GB2272462B

Abstract

A masonry block 2, comprises keying formations 16, 18, adapted to engage complementary keying formations provided on a block situated adjacent the block, in such a manner as to obviate the need for a mortar joint between the two. The blocks may be of different depths, allowing staggered blocks horizontally, and the blocks have an insulating facing layer 6. Apertures 22, 24 allow some vertical columns of blocks to be filled with, e.g. concrete, and solid blocks are employed, e.g. adjacent openings in walls formed from the blocks. <IMAGE>

Description

MASONRY BLOCK This invention relates to a masonry block. More particularly, the invention relates to a block suitable for use in a cavity wall construction.

Conventional masonry blocks are bonded together to form a wall by the use of mortar joints. The mortar joints have a lower resistance to heat transfer than most known masonry blocks. The transmission of heat via the mortar joints will therefore lower the overall thermal insulation properties of the wall. This heat loss through the mortar joints represents a highly undesirable problem and is particularly disadvantageous in cavity wall constructions, where thermal insulation is of paramount importance.

The present invention sets out to obviate the need for mortar joints, thereby allowing the thermal insulation qualities of a wall to be improved.

According to a first aspect of the invention there is provided a masonry block comprising a keying formation, the said keying formation being adapted to engage a complementary keying formation provided on a block situated adjacent to the said block and in such a manner as to obviate or mitigate the need for a mortar joint between the said block and a block situated adjacent the said block.

Preferably, the keying formation will be in the form of a dovetail projection or a dovetail recess. The dovetail projection should be shaped to fit into a dovetail recess in another block; the dovetail recess should be shaped to receive a dovetail projection from another block. A block can comprise a dovetail projection on one end face and a dovetail recess in another end face. Alternatively, the block could be provided with a dove tail projection on one end face and a dovetail recess in one side face. Such a block can be used to connect with another block or blocks arranged at right angles, so as to form a corner. The respective positions of the recess and projection could be reversed.

The block can also be provided with a layer of thermally insulative material on one or more of its side and/or end faces.

The block may be completely solid, or may be perforated and comprise openings extending partially or completely from one to the other of its top and bottom faces.

Alternatively, the dovetail projection and/or recess provided on the block could be replaced with a keying projection and/or a keying recess which has some other cross-sectional profile such as, for example, a part circular cross-sectional profile.

According to a second aspect of the invention there is provided a wall comprising a plurality of masonry blocks, a first one of the said masonry blocks comprising a keying projection and a second one of the said masonry blocks being situated directly adjacent the said first masonry block and comprising a keying recess, the said keying projection being keyed with the said keying recess; the two blocks being connected together without the assistance of mortar.

Preferably, the blocks forming the wall will be aligned in vertical columns, with blocks from adjacent columns being staggered, in a vertical direction, with respect to each other. In such an arrangement, blocks having a reduced height can be provided in alternate columns of blocks, in order to effect the staggering arrangement.

Preferably, each block will be provided with a layer of thermally insulative material on one surface thereof.

Preferably, each block of at least one column of blocks of the wall will comprise at least one opening which extends from an upper surface thereof to a lower surface thereof, thereby defining an open column extending from the bottom of the wall to the top of the wall. In a preferred embodiment, the open column will be filled with means for stabilising the wall, such as concrete, foamed concrete mortar, or grout, for example.

The column situated at each end of the wall is preferably formed from solid blocks which are secured one on top of another by means of an adhesive.

Preferably, the adhesive will be in the form of an epoxy glue. The blocks are solid, because they may need to be cut down in length to fit opening dimensions, for example, whilst still providing a solid end. Hollow blocks would be less suitable for such a purpose.

Additionally, the solid form presents greater areas to receive adhesive than would be the case with hollow blocks.

According to a third aspect of the invention there is provided a method of constructing a wall comprising arranging a plurality of blocks in vertical columns whilst causing blocks from adjacent columns to interengage by means of complementary keying formations, the method being such that the blocks do not require interadhesion by means of mortar.

The wall can define the inner leaf of a cavity wall structure.

Embodiments of the present invention will now be described by way of example and with reference to the accompanying drawings in which Figures la to 11 are perspective views of twelve embodiments of a masonry block according to a first aspect of the invention; Figure 2 is a perspective view of an embodiment of a wall constructed in accordance with a second aspect of this invention; and Figure 3 is a plan view of a second embodiment of a wall constructed in accordance with the second aspect of the invention.

Figure la shows a first embodiment of a block in accordance with the first aspect of this invention. The block comprises two side faces 4, 6; two end faces 8, 10; an upper face 12 and a lower face 14. The block is generally cuboidal in shape.

One end face 8 is provided with a projection 16, which is dovetail-shaped in cross section. The projection 16 extends from the upper face 12 of the block 2 to the lower face 14 of the block 2 and is generally elongate and aligned with its longitudinal axis parallel to each of the side faces 4,6 of the block 2.

End face 10 of the block 2 is provided with a recess 18 which is dovetail-shaped in cross section. The recess 18 extends from the upper face 12 of the block to the lower face 14 of the block. The recess 18 is elongate and is aligned with its longitudinal axis parallel to each of the side faces 4,6 of the block.

The recess 18 is shaped so as to comfortably house a projection having identical dimensions to projection 16.

The projection 16 and the recess 18 are each positioned the same distance from the side face 4 and the same distance from the side face 6.

The block 2 is perforated by two openings 22 and 24.

The openings extend in a vertical direction from the upper face 12 of the block to the lower face 14 of the block. Each of the openings is rectangular in cross section. The two openings 22, 24 are separated by a web 26.

Side face 6 of the block is covered with a thermally insulating layer 20, which is bonded to the side face 6 of the block.

Figure 1b shows a block 2 which is generally similar to the block 2 shown in Figure la. The block 2 shown in Figure 1b differs from the block shown in Figure la only in that it is only half as high as the block 2 of Figure la.

Figure lc shows a block 102 having a similar general shape to the block 2 shown in Figure la. However, this block does not include the openings 22 and 24 and does not include the dovetail-shaped recess 18. The block 102 shown in Figure 1d is the same as the block 102 shown in Figure lc, but is only half as high as the block of Figure lc.

These blocks are solid because they are intended to be used in an end part of a wall and may need to be cut down, to fit opening dimensions, for example, whilst still presenting a solid end. This would not be possible with hollow blocks. Additionally, the solid form presents a greater area to receive adhesive than would be the case with hollow blocks.

Figure le shows a block 202 similar to the block 102 shown in Figure lc. However, the dovetail-shaped projection 116 of block 102 is replaced by a dovetail-shaped recess 218. Block 202 could also be considered to be the same as the block 2 shown in la, but with the openings 22 and 24 and the dovetail-shaped projection 16 omitted.

The block shown in Figure if is generally similar to the block of Figure le, but is only half as high.

Figure ig shows a block 302 generally similar to the block of Figure la, but the recess 18 provided in end face 10 of block 2 is not included in block 302.

Instead, block 302 is provided with a recess 319 which is provided in its side face 304 in a region close to end face 310. The recess 319 is generally dovetail-shaped in cross section and extends vertically from the upper face 312 to the lower face 314 of the block 302. The recess 319 is shaped to receive a projection such as projection 16 provided in block 2, projection 116 provided in block 102 or a projection corresponding to projection 316 provided in block 302.

This block is additionally provided with a further layer of insulating material 321, which is bonded to end face 310.

Figure 1h shows a block 302 having the features of the block 302 shown in Figure lg, but with only half the height.

Blocks 302 are intended for use in forming corners. By providing either a recess or a projection on a side face, rather than an end face, it is possible to connect another block or blocks to the block 302 at right-angles.

Figure li shows a block 402 generally similar to the block shown in Figure lc. However, this block 402 is truncated in the horizontal direction which extends parallel to side faces 404, 406, so as to form a block which has only half the length of the block shown in Figure lc.

Figure lj shows a block 402 having the features of the block 402 shown in Figure li, but with only half the height.

Figure 1k shows a block 502 similar to the block 402 shown in Figure li, but with the dovetail-shaped projection 416 replaced with a dovetail-shaped recess 518.

The block 502 generally corresponds with the block 202 shown in Figure 1e. However, block 502 is truncated in the horizontal direction which extends parallel to the side faces 504, 506, so as to have only half the length of the block 202.

The block shown in Figure 11 is generally the same as the block shown in Figure lk, except that it is half the height of the block shown in Figure lk.

Figure 2 shows a wall formed from a plurality of the blocks shown in Figures la, 1b and lc.

It can be seen that the blocks are arranged in vertical columns which, for convenience, have been labelled ''C1'' to IIC 611.

To build the wall, an initial horizontal layer of blocks are layed. If, for example, the initial layer is commenced with column C1, initially a block C1(a) is positioned, then the next block C2(a) is fitted adjacent to the first block C1(a) by sliding the recess 18 of the second block C2(a) over the projection 116 of the first block C(a), thereby locking the two together.

It is to be noted that block C2(a) is of the type 102 shown in Figure 1b. Next, block C3(a) is positioned next to block C2(a) whilst locking the two together by sliding the recess 18 provided in block C3 (a) over the projection 16 provided on block C2(a). It is to be noted that block C3(a) is of the type 2 shown in Figure la.

To form the lower row, blocks 2 are connected to each other in the same manner until the wall reaches the desired length. The final block should be a solid block 102. It should be noted that the blocks should be selected such that the bottom row of blocks should alternate between a full height block (e.g. as shown in Figs. la, lc, le, 1g, li, lk) and a half height block (eg. as shown in Figs. lb, ld, lf, lh, lj, 11) from column to column, in order to stagger the height of the bottom row of blocks.

Additionally, each end column of blocks must be formed form solid blocks such as the blocks 102, 202, 402, 502. The reason for this will be explained below.

Full height blocks 2, 102 are then built up on to the first row so as to form a series of columns C1 to C6, which are interlocked with each other. It should be noted that, due to the selection of alternating full height blocks and half height blocks for the bottom row, each junction between vertically adjacent blocks within a particular column (e.g. C1) does not align with a junction between vertically adjacent blocks in an adjacent column (e.g. C2). The result of this is that, with the exception of the blocks at the very top and the very bottom of each column, each block in column C2 through to C5 is interlocked with four other blocks. This provides good structural support for the wall.

Once the wall has been finished to the desired height, it can be levelled off by inserting half height blocks into the recesses at the tops of the columns. In the case of Figure 2, the wall would be levelled off by fitting half height blocks of the type shown in Figure Ib into columns C2, C4 and C6.

Once the wall has been constructed in this manner, it can be further stabilised by filling the open columns defined by the openings 22, 24 in each open block with a stabilising material. The stabilising material can be concrete, foamed concrete mortar, grout or any other suitable material which will give the wall further structural strength. Additionally, the filling material can improve the thermal resistance of the wall.

Because, the blocks in column C1 are chosen to be solid, to enable them to be cut to size, the blocks cannot be filled with a stabilising material as described above. Because these blocks are only linked to one other column (column C2), and because they are solid and lack the stabilising filling, they would not be as stably supported as the blocks of the remaining columns if merely interconnected by means of the dovetail formations. Therefore, the blocks are affixed to one another by a thin layer of adhesive, which is applied between vertically adjacent blocks in this column. The solidity provides a greater surface area for adhesion than the hollow blocks and, therefore, solid blocks are preferably used in this position, even if there is no need to cut blocks down.

The wall constructed in this manner can be built without the need for mortar. This is because the mechanical keying provided by the dovetail projections and the dovetail recesses affords stability during dry laying and the subsequent core filling stage.

The insulating layers 20, 120, 220, 320, 420, 520, 321 provided on the blocks will, together, form an insulating layer over one entire face of the wall. This will further reduce thermal transmission.

The thermally insulating layers could be omitted if desired. However, this would lead to a reduction in thermal resistance.

Figure 3 shows a plan view of a cavity wall construction. In this construction, the inner leaf of the cavity wall has been formed from blocks according to the first aspect of the invention. It can be seen from Figure 3 that, to form a corner in the wall, use is made of blocks of the type shown in Figures 1g and lh. By providing a recess on one side face of the block 302, rather than one end face of the block, another block may be connected to it at right-angles. It is to be noted that an insulating layer 321 is provided on one end face of the block 302, in order to match with the insulating layer provided on the outwardly directed surface of any block which keys with the recess 319 in the block 302.

Although the block 302 is shown provided with openings 322 and 324, it is equally possible to form the block as a solid block, similar to those blocks shown in Figures ic to if. Additionally, the position of the projection 316 and the recess 319 could be reversed, if desired.

All of the blocks shown in Figure 3 comprise the open channels 22 and 24 or 322 and 324, except for the blocks at the ends of the walls. These should be solid blocks, in order to facilitate gluing between adjacent vertical blocks in the columns to which these blocks belong.

One advantage of providing an insulating layer on each of the blocks is that, once constructed, the leaf will not require insulating slabs or batts to be fitted to the wall.

The blocks can be formed from concrete and may be moulded or extruded.

Many further modifications and adaptations will suggest themselves to those versed in the art upon making reference to the foregoing description, which is given by way of example only and is not intended to limit the scope of the present invention in any way.

Claims

1. A masonry block comprising tuo end faces, t'vo side faces, a top face, a bottom face and a keying formation, the said keying formation being adapted to engage a complementary keying formation provided on a block situated adjacent the said block and in such a manner as to obviate or mitigate the need for a mortar joint between the blocks.

2. A block according to claim 1, wherein the keying formation is in the form of a dovetail projection or a dovetail recess which is shaped to engage with a dovetail recess or dovetail projection of a similar block

3. A block according to claim 2 comprising a dovetail projection on one end face and a dovetail recess in the opposite end face.

4. A block according to claim 2 comprising a dovetail projection on one end face and a dovetail recess in one side face.

5. A block according to claim 2 comprising a dovetail projection on one side face and a dovetail recess in one end face.

6. A block according to claim 1 wherein the keying formation comprises a portion which has a partcircular profile.

7. A block according to any preceding claim wherein the block is provided with a layer of insulating material on one or more of its side andlor end faces.

8. A block according to any preceding claim wherein the block is solid.

9. A block according to any one of claims 1 to 7, wherein the block comprises perforations extending partially from one to the other of its top and bottom faces.

10. A block according to any one of claims 1 to 7, wherein the block comprises perforations extending completely from one to the other of its top and bottom faces.

11. A wall comprising a plurality of masonry blocks, a first one of the said masonry blocks comprising a keying projection and a second one of the said masonry blocks being situated with one of its side or end faces directly adjacent a side or end face of the said first masonry block and comprising a keying recess, the said keying projection being keyed with the said keying recess; the two blocks being connected together without an intermediate layer of connecting mortar.

12. A wall according to claim 11, wherein the blocks forming the wall are arranged in vertical columns, with blocks from adjacent columns being vertically staggered with respect to one another.

13. A wall according to claim 12, wherein alternate columns comprise blocks of reduced or increased height in order to achieve the staggering arrangement.

14. A wall according to any one of claims 11 to 13, wherein each block is provided with a layer of thermally insulative material on one surface thereof, the blocks being arranged so that the insulative material is situated on a predetermined face of the wall.

15. A wall according to any preceding claim, wherein each block of at least one column of blocks of the wall comprises at least one opening which extends from the upper face thereof to the lower face thereof, the or each said column of blocks thereby defining an open column extending from a lower region of the wall to an upper region of the wall.

16. A wall according to claim 15, wherein at least one said open column contains means for stabilising the wall.

17. A wall according to claim 16, wherein at least one said column is filled with concrete, foamed concrete, mortar or grout.

18. A wall according to any one of claims 11 to 17, wherein a column situated at an end of the wall is formed from solid blocks, which blocks are secured on top of one another by means of an adhesive.

19. A wall according to claim 18 wherein the adhesive is an epoxy glue.

20. A wall according to any one of claims 11 to 19 and defining the inner leaf of a cavity wall.

21. A method of constructing a wall comprising arranging a plurality of blocks in vertical columns whilst causing blocks from adjacent columns to interengage by means of complementary keying formations.

22. A method according to claim 21 comprising arranging blocks from adjacent vertical columns to be vertically staggered with respect to one another

23. A method according to claim 22, wherein blocks having reduced or increased height are installed in alternate columns in order to cause the blocks from alternate columns to be vertically staggered with respect to one another.

24. A method according to any one of claims 21 to 23 comprising forming an open column extending from an upper region of the wall to a lower region of the wall by fitting blocks which each have an opening extending from an upper surface of the block to a lower surface of the block above one another.

25. A method according to claim 24, comprising installing stabilising means in the open column.

26. A method according to claim 25, comprising filling the open column with concrete, foamed concrete, mortar or grout.

27. A method according to any one of claims 21 to 26 comprising erecting a column of solid blocks at at least one end of the wall and securing the blocks one on top of another by means of an adhesive.

28. A block substantially as herein described with reference to any one of figures la to le of the accompanying drawings.

29. A wall substantially as herein described with reference to Figure 2 or Figure 3 of the accompanying drawings.

30. A method of assembling a wall substantially as herein described with reference to Figures la to le, 2 or 3 of the accompanying drawings.