U.S. patent application number 11/410897 was filed with the patent office on 2007-01-25 for masonry wall system.
Invention is credited to Calvin Gray.
Application Number | 20070017176 11/410897 |
Document ID | / |
Family ID | 37545777 |
Filed Date | 2007-01-25 |
United States Patent
Application |
20070017176 |
Kind Code |
A1 |
Gray; Calvin |
January 25, 2007 |
Masonry wall system
Abstract
The masonry block wall system comprises masonry blocks fastened
together with interconnecting threaded steel fasteners. Four
fasteners on each block connect with a pair of identical blocks
immediately above and a pair of identical blocks immediately below
the block. The resulting masonry wall is structurally sound and
allows large vertical chases or conduits for electrical, plumbing
and the like. Unlike conventional masonry, the construction of the
present masonry wall does not require specialized knowledge and
skill of a mason and is relatively easy to build. As well, the
masonry wall system is not dependent upon weather during
construction and can be de-constructed without demolition.
Inventors: |
Gray; Calvin; (Winnipeg,
CA) |
Correspondence
Address: |
Ade & Company Inc.;1795 Henderson Highway
PO Box 28006
Winnipeg
MB
R2G 4E9
CA
|
Family ID: |
37545777 |
Appl. No.: |
11/410897 |
Filed: |
April 26, 2006 |
Current U.S.
Class: |
52/605 |
Current CPC
Class: |
E04B 2002/0254 20130101;
E04B 2/30 20130101; E04C 5/161 20130101; E04C 5/165 20130101 |
Class at
Publication: |
052/605 |
International
Class: |
E04C 2/04 20060101
E04C002/04 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 6, 2005 |
CA |
2,511,630 |
Claims
1. A masonry block for use with threaded masonry fasteners, the
block comprising: a rectangular body which is elongate in a
longitudinal direction extending between ends of the body, the body
having a pair of opposing, upright side walls spanning in the
longitudinal direction between the ends; and fastener apertures
formed through the rectangular body to extend from a top side to a
bottom side of the block for receiving the threaded masonry
fasteners therethrough; at least some of the fastener apertures
being spaced from one another in a lateral direction extending
between the opposing, upright side walls of the body.
2. The block according to claim 1 wherein at least some of the
fasteners are spaced in the longitudinal direction relative to one
another.
3. The block according to claim 1 wherein the fastener apertures
are located adjacent the side walls.
4. The block according to claim 1 wherein the fastener apertures
are spaced from each end of the body by approximately 1/4 of a
total length of the body in the longitudinal direction.
5. The block according to claim 1 wherein a pair of the fastener
apertures spaced from one another in the lateral direction are
spaced from each end of the body by approximately 1/4 of a total
length of the body in the longitudinal direction.
6. The block according to claim 1 in combination with a plurality
of threaded masonry fasteners, each fastener comprising: an
elongate body substantially corresponding in length to a height
between the top and bottom sides of the block; an externally
threaded portion near a bottom end of the elongate body; a nut
portion formed near a top end of the elongate body; and an
internally threaded bore formed in the nut portion at the top end
of the elongate body which is suitably sized to operatively receive
the externally threaded portion of an additional masonry fastener
of identical configuration; wherein the fastener apertures each
include a counter bore of increased diameter formed at the bottom
side of the body, the counter bores and the nut portions being near
one another in diameter for receiving the nut portion of one of the
fasteners in each counter bore.
7. The block according to claim 1 wherein each fastener aperture
includes a counter bore formed at the bottom side of the body, the
counter bore increasing in diameter towards the bottom side of the
body.
8. The block according to claim 1 in combination with a shear plate
spanning at least partway across one of the top or bottom sides of
the body, the shear plate including a pair of apertures formed
therein which are aligned with a pair of the fastener apertures in
the body which are spaced from one another in the lateral
direction.
9. A masonry block for use with threaded masonry fasteners, the
block comprising: a rectangular body which is elongate in a
longitudinal direction between ends of the body, the body having a
pair of opposing, upright side walls spanning in the longitudinal
direction between the ends and a pair of web portions spanning in a
lateral direction between the opposing, upright side walls; a
central conduit extending through the body from a top side to a
bottom side of the body between the web portions; a pair of partial
conduits extending through the body from the top side to the bottom
side of the body at the ends of the body, each partial conduit
being located between a respective one of the web portions and a
respective one of the ends of the body and substantially comprising
half of a cross-sectional area of the central conduit; and fastener
apertures formed through the rectangular body to extend from the
top side to the bottom side of the block for receiving the threaded
masonry fasteners therethrough.
10. The block according to claim 9 wherein the fastener apertures
are located in each web portion of the body.
11. The block according to claim 9 wherein at least some of the
fastener apertures being spaced from one another in a lateral
direction extending between the opposing, upright side walls of the
body.
12. The block according to claim 9 in combination with a plurality
of threaded masonry fasteners, each fastener comprising: an
elongate body substantially corresponding in length to a height
between the top and bottom sides of the block; an externally
threaded portion near a bottom end of the elongate body; a nut
portion formed near a top end of the elongate body; and an
internally threaded bore formed in the nut portion at the top end
of the elongate body which is suitably sized to operatively receive
the externally threaded portion of an additional masonry fastener
of identical configuration; wherein the fastener apertures each
include a counter bore of increased diameter formed at the bottom
side of the body, the counter bores and the nut portions being near
one another in diameter for receiving the nut portion of one of the
fasteners in each counter bore.
13. The block according to claim 9 wherein each fastener aperture
includes a counter bore formed at the bottom side of the body, the
counter bore increasing in diameter towards the bottom side of the
body.
14. A masonry block in combination with threaded masonry fasteners:
the masonry block comprising a rectangular body and fastener
apertures formed in the rectangular body to extend from a top side
to a bottom side of the block; and each masonry fastener
comprising: an elongate body substantially corresponding in length
to a height between the top and bottom sides of the block; an
externally threaded portion near a bottom end of the elongate body;
a nut portion formed near a top end of the elongate body; and an
internally threaded bore formed in the nut portion at the top end
of the elongate body which is suitably sized to operatively receive
the externally threaded portion of an additional masonry fastener
of identical configuration.
15. The combination according to claim 1 wherein the fastener
apertures each include a counter bore of increased diameter formed
at the bottom side of the body for receiving the nut portion of one
of the fasteners in each counter bore.
16. The combination according to claim 15 wherein the counter bores
and the nut portions are near one another in diameter.
17. The combination according to claim 15 wherein each counter bore
increases in diameter towards the bottom side of the body.
18. A masonry wall system comprising rows of masonry blocks
supported one above the other to form a wall structure in which
each masonry block is connected to at least one masonry block
immediately therebelow by at least one respective masonry fastener;
each masonry block comprising a rectangular body and at least one
fastener aperture formed in the rectangular body to extend from a
top side to a bottom side of the block and receiving said at least
one respective masonry fastener therethrough; and each masonry
fastener comprising: an elongate body; a nut portion adjacent a top
end of the elongate body which engages a top side the respective
masonry block; an internally threaded bore formed in the nut
portion at the top end of the elongate body; and an externally
threaded portion near a bottom end of the elongate body in mating
engagement with the internally threaded bore of the respective
masonry fastener received through said at least one masonry block
immediately therebelow.
19. The system according to claim 18 wherein each fastener aperture
includes a counter bore formed at the bottom side of the block, the
counter bore snugly receiving the nut portion of a respective
fastener therein.
20. The system according to claim 18 wherein each block is elongate
in a longitudinal direction and includes opposing, upright side
walls spanning in the longitudinal direction of the block, at least
some of the fastener apertures being spaced from one another in a
lateral direction extending between the side walls of the
block.
21. The system according to claim 20 wherein there is provided a
shear plate spanning at least partway across one of the top and
bottom sides of the block, the shear plate including a pair of
apertures formed therein which are aligned with a pair of the
fastener apertures in the body which are spaced from one another in
the lateral direction.
22. The system according to claim 18 wherein each block is elongate
in a longitudinal direction and wherein there is provided a channel
extending in the longitudinal direction along one of the top and
bottom sides of the block for receiving an elongate reinforcement
bar therein.
23. The system according to claim 18 wherein there is provided a
corner block comprising: a body having a first rectangular portion
and a second rectangular portion which are formed integrally with
one another; the first rectangular portion having upright side
walls which are elongate in a longitudinal direction between ends
of the first rectangular portion and dimensions between top and
bottom sides and between the upright side walls which are
substantially identical to the masonry blocks; the second
rectangular portion having upright side walls extending outward
from the first rectangular portion in a lateral direction oriented
perpendicularly to the longitudinal direction of the first
rectangular portion and having dimensions between top and bottom
sides and between the upright side walls which are substantially
identical to the first rectangular portion; one of the side walls
of the second rectangular portion being flush with one end of the
first rectangular portion; and a difference between dimension of
the corner block in the longitudinal direction thereof and
dimension of the corner block in the lateral direction thereof
corresponding to approximately half a total length of the masonry
blocks in the longitudinal direction thereof.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a masonry wall system in
which masonry blocks are interconnected using threaded mechanical
fasteners.
BACKGROUND
[0002] Masonry block walls are presently constructed using concrete
blocks stacked on top of each other. The blocks are bonded together
using cement mortar (both in the horizontal and vertical joints). A
wire-reinforcing ladder is installed in the periodic horizontal
joints. Construction of a masonry block wall requires a skilled
mason. The construction of a masonry block wall requires a
controlled environment while the cement mortar cures.
[0003] In conventional masonry construction, the designer (the
design engineer) has few means of knowing that the block wall is
built in accordance with the designers specifications, for example:
the mortar being correctly installed and having adequate strength,
the concrete filled cores being completely filled and the
reinforcing steel being placed correctly or being installed at all.
The designer has to rely heavily on the integrity of the mason and
the mason's workers that the masonry wall was properly built.
[0004] Traditional masonry units have vertical chases or conduits
for installing plumbing lines, electrical conduits and other
building services, but the vertical holes are often small and are
commonly filled with cement grout or concrete and thus very often
not continuous from top to bottom.
[0005] U.S. Pat. No. 1,499,483 (Simms), U.S. Pat. No. 5,685,119
(Zschoppe), U.S. Pat. No. 5,899,040 (Cerrato) and U.S. Pat. No.
6,244,009 (Cerrato) disclose various examples of a wall
construction using masonry type blocks. In each instance, the block
has an irregular shape for interlocking connection with adjacent
blocks. The blocks thus require complex molds for manufacturing.
Rods are used in some instances for interconnecting adjacent
blocks, however the rods are intended to span plural rows resulting
is a wall which permits some relative movement between the blocks.
This relative movement is typically undesirable in a large static
structure.
[0006] U.S. Pat. No. 5,787,675 (Futagi) discloses a log wall
construction in which mechanical fasteners are used for
interconnecting the logs of the wall. The fasteners include a
washer formed integrally thereon which has cleats for bearing into
the logs being fastened. The configuration of the cleats would
interfere with the use of the fasteners on a masonry wall
construction.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the invention there is provided a
masonry block for use with threaded masonry fasteners, the block
comprising:
[0008] a rectangular body which is elongate in a longitudinal
direction extending between ends of the body, the body having a
pair of opposing, upright side walls spanning in the longitudinal
direction between the ends; and
[0009] fastener apertures formed through the rectangular body to
extend from a top side to a bottom side of the block for receiving
the threaded masonry fasteners therethrough;
[0010] at least some of the fastener apertures being spaced from
one another in a lateral direction extending between the opposing,
upright side walls of the body.
[0011] By providing fastener apertures which are spaced apart from
one another in a lateral direction extending between the opposing
upright side walls of the block, the support area joining each
block to the previous row is wider across the thickness of the wall
structure to more evenly anchor each block to the previous rows.
Furthermore the fasteners joining the rows are mounted closer to
the outer walls under tension so that the fasteners provide better
support to resist bending forces of the wall in either lateral
direction.
[0012] According to a second aspect of the present invention there
is provided a masonry block for use with threaded masonry
fasteners, the block comprising:
[0013] a rectangular body which is elongate in a longitudinal
direction between ends of the body, the body having a pair of
opposing, upright side walls spanning in the longitudinal direction
between the ends and a pair of web portions spanning in a lateral
direction between the opposing, upright side walls;
[0014] a central conduit extending through the body from a top side
to a bottom side of the body between the web portions;
[0015] a pair of partial conduits extending through the body from
the top side to the bottom side of the body at the ends of the
body, each partial conduit being located between a respective one
of the web portions and a respective one of the ends of the body
and substantially comprising half of a cross-sectional area of the
central conduit; and
[0016] fastener apertures formed through the rectangular body to
extend from the top side to the bottom side of the block for
receiving the threaded masonry fasteners therethrough.
[0017] Construction of the block to include a pair of webs spanning
between opposing side walls to define a central conduit
therebetween and a pair of partial conduits at the ends of the
block, results in an advantageous location of the fasteners in the
webs being located approximately a quarter of the length of the
block from each end of the block. In this configuration each block
is connected to a pair of adjacent and overlapped blocks in the
previous row by a fastener which is centrally located within the
area of overlap between the blocks for optimum distribution of
loads.
[0018] According to another aspect of the present invention there
is provided a masonry block in combination with threaded masonry
fasteners:
[0019] the masonry block comprising a rectangular body and fastener
apertures formed in the rectangular body to extend from a top side
to a bottom side of the block; and
[0020] each masonry fastener comprising:
[0021] an elongate body substantially corresponding in length to a
height between the top and bottom sides of the block;
[0022] an externally threaded portion near a bottom end of the
elongate body;
[0023] a nut portion formed near a top end of the elongate body;
and
[0024] an internally threaded bore formed in the nut portion at the
top end of the elongate body which is suitably sized to operatively
receive the externally threaded portion of an additional masonry
fastener of identical configuration.
[0025] The fasteners described herein are suitably arranged to span
only a single row of blocks in the preferred embodiment. In this
arrangement a much simpler block construction can be used as the
blocks do not require any additional interlocking or alignment
mechanism to connect to the previous row other than simply aligning
the fasteners from one row to the next. The simplicity of the block
design reduces manufacturing costs of the block when only fastener
apertures are required and the top and bottom faces of the block
can remain substantially flat and free of complex interlocking
shapes. The fasteners are much easier to align with a previous row
of fasteners when assembling only a single row at a time.
[0026] According to another aspect of the present invention there
is provided a masonry wall system comprising rows of masonry blocks
supported one above the other to form a wall structure in which
each masonry block is connected to at least one masonry block
immediately therebelow by at least one respective masonry
fastener;
[0027] each masonry block comprising a rectangular body and at
least one fastener aperture formed in the rectangular body to
extend from a top side to a bottom side of the block and receiving
said at least one respective masonry fastener therethrough; and
[0028] each masonry fastener comprising:
[0029] an elongate body;
[0030] a nut portion adjacent a top end of the elongate body which
engages a top side the respective masonry block;
[0031] an internally threaded bore formed in the nut portion at the
top end of the elongate body; and
[0032] an externally threaded portion near a bottom end of the
elongate body in mating engagement with the internally threaded
bore of the respective masonry fastener received through said at
least one masonry block immediately therebelow.
[0033] According to yet another aspect of the present invention
there is provided a corner block comprising:
[0034] a body having a first rectangular portion and a second
rectangular portion which are formed integrally with one
another;
[0035] the first rectangular portion having upright side walls
which are elongate in a longitudinal direction between ends of the
first rectangular portion and dimensions between top and bottom
sides and between the upright side walls which are substantially
identical to the masonry blocks;
[0036] the second rectangular portion having upright side walls
extending outward from the first rectangular portion in a lateral
direction oriented perpendicularly to the longitudinal direction of
the first rectangular portion and having dimensions between top and
bottom sides and between the upright side walls which are
substantially identical to the first rectangular portion;
[0037] one of the side walls of the second rectangular portion
being flush with one end of the first rectangular portion; and
[0038] a difference between dimension of the corner block in the
longitudinal direction thereof and dimension of the corner block in
the lateral direction thereof corresponding to approximately half a
total length of the masonry blocks in the longitudinal direction
thereof.
[0039] According to a further aspect of the present invention there
is provided a method of assembling a masonry wall on a supporting
surface, the method comprising:
[0040] providing a plurality of masonry blocks, each comprising a
rectangular body and fastener apertures formed in the rectangular
body to extend from a top side to a bottom side of the block;
[0041] providing a plurality of masonry fasteners, each comprising
an elongate body; a nut portion integrally formed near a top end of
the elongate body; an internally threaded bore formed in the nut
portion; and an externally threaded portion near a bottom end of
the elongate body;
[0042] forming a first row of blocks by placing the masonry blocks
sequentially in an end to end configuration along the supporting
surface;
[0043] connecting each of the masonry blocks of the first row to
the supporting surface using the masonry fasteners by inserting
each externally threaded portion through a respective fastener
aperture until the nut portion engages the top side of the
respective block and the externally threaded portion is anchored to
the supporting surface; and
[0044] forming subsequent rows of blocks in which each subsequent
row is formed by: [0045] placing the masonry blocks sequentially in
an end to end configuration along a previous row of blocks with the
fastener apertures of the masonry blocks being aligned with
respective fastener apertures of the previous row of blocks; and
[0046] connecting each of the masonry blocks to the masonry blocks
of the previous row of blocks using the masonry fasteners by
inserting each externally threaded portion through a respective
fastener aperture until the nut portion engages the top side of the
respective block and the externally threaded portion is threadably
received in the internally threaded bore of the respective masonry
fastener in the previous row of blocks.
[0047] Preferably at least some of the fasteners are spaced in the
longitudinal direction relative to one another in addition to being
spaced in the lateral direction. Also preferably, some or all of
the fastener apertures are located adjacent respective side walls
of the block in the web portions.
[0048] Each fastener aperture preferably includes a counter bore
formed at the bottom side of the block wherein a length and a
diameter of the counter bore are respectively equal to or greater
than a length and a diameter of the nut portion of the fastener.
The counter bores and the nut portions of the fasteners may be near
one another in diameter for snugly receiving the nut portion of one
of the fasteners in each counter bore. In some embodiments, the
counter bore may increase in diameter towards the bottom side of
the body.
[0049] There may be provided a flat washer between the nut portion
and the externally threaded portion which is greater in diameter
than the counter bore and which is formed integrally with the nut
portion.
[0050] A pair of laterally spaced fastener apertures may be spaced
from each end of the block by approximately 1/4 of a total length
of the block in a longitudinal direction of the block for alignment
of the fastener apertures when the blocks are stacked to overlap
half a block length of the blocks immediately therebelow.
[0051] The masonry block may be used in combination with a shear
plate spanning at least partway across one of the top or bottom
sides of the body. The shear plate preferably includes a pair of
apertures formed therein which are aligned with a pair of the
fastener apertures in the body which are spaced from one another in
the lateral direction.
[0052] There may also be provided a channel extending in the
longitudinal direction along one of the top and bottom sides of the
block for receiving an elongate reinforcement bar therein in a
horizontal direction across a plurality of blocks.
[0053] The method of assembling a masonry wall described herein may
include forming a supporting surface of concrete with some of the
masonry fasteners embedded therein for alignment with the fastener
apertures of the first row of blocks and anchoring the masonry
fasteners received in the first row of blocks to the masonry
fasteners embedded in the concrete.
[0054] As described herein, the masonry wall system results in a
mortarless block wall comprising concrete block units that are
connected together with steel connectors. The steel connectors main
purposes are to provide tensile strength to the wall to resist
bending stresses (created from lateral loads such as wind and
eccentric vertical wall loading). The block walls are placed on top
of the lower course of masonry units (the vertical joints are
stagger from the block course below--running bond). The steel
connectors also serve a secondary purpose of providing a guide for
the masonry block units being placed.
[0055] The masonry wall system of the present invention (or
mortarless block wall) possesses numerous benefits and advantages
over the traditional masonry wall construction. Most significantly,
the mortarless block wall can be built without the specialized
skills and knowledge of a mason. As well, the mortarless block wall
can be constructed in any weather conditions without affecting its
structural integrity (unlike traditional masonry wall construction
that is effected by weather condition that in turn affects its
structural integrity such as frozen mortar in cold weather, baked
mortar in hot weather or dried mortar in windy weather). As well,
as the mortarless block wall is constructed it has immediate
structural strength (unlike conventional masonry construction,
which only has strength after the cement mortar has cured). Having
instantaneous strength is beneficial when the walls are exposed to
construction in windy conditions. Another benefit to the mortarless
block wall is that the construction can be de-constructed by simply
reversing the construction process. The masonry block units and the
metal connectors can be re-used over and over again.
[0056] The mortarless block wall is lighter than traditional block
walls and the walls have greater resistance to wind loads (both
positive pressure loads and negative suction loads). As well, the
mortarless block wall has greater horizontal shear resistance than
traditional block walls (which relies on the strength of the cement
mortar).
[0057] The mortarless block wall requires the use of the masonry
fasteners of the present invention to work property and so there is
no incentive or means for the wall builder to skimp on material or
do shoddy workmanship.
[0058] Another advantage of the mortarless masonry block is that it
has large continuous vertical holes in the center. These holes can
be used for installing plumbing lines, electrical conduits and
other building services and won't get plugged with mortar or
concrete when installed due to the use of the masonry fasteners
according to the present invention.
[0059] The masonry block wall's vertical holes must line up
vertically and in fact are guide for the proper placement of the
block units.
[0060] One embodiment of the invention will now be described in
conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] FIG. 1 is a perspective view of the masonry wall system.
[0062] FIG. 2 is a front elevational view of the masonry wall
system.
[0063] FIG. 3A and FIG. 3B are respective exploded and assembled
elevational view of the masonry fastener for use in the masonry
wall system.
[0064] FIG. 4 is a perspective view of the masonry block for use in
the masonry wall system.
[0065] FIG. 5 is a bottom plan view of the masonry block.
[0066] FIG. 6 is a side elevational view of the masonry block.
[0067] FIG. 7 is a sectional view of the masonry wall system along
the line 7-7 of FIG. 2.
[0068] FIG. 8 is a perspective view of the shear plate for use in
the masonry wall system.
[0069] FIG. 9 is a perspective view of the masonry wall system with
the fasteners and the shear plates shown removed.
[0070] In the drawings like characters of reference indicate
corresponding parts in the different figures.
DETAILED DESCRIPTION
[0071] Referring to the accompanying figures there is illustrated a
masonry wall system generally indicated by reference numeral 10.
The system 10 includes a plurality of masonry blocks 12 which are
mechanically coupled to one another using masonry fasteners 14 as
described herein.
[0072] Each masonry block 12 comprises a rectangular body of
pre-cast concrete which is elongate in a longitudinal direction
between opposing ends 16 of the body. The height and width in a
lateral direction perpendicular to the longitudinal direction are
approximately equal to one another, having dimensions each of
approximately 200 millimetres while the length is approximately
double. The blocks each include opposing, upright and flat side
walls 18 extending longitudinally between the ends and which form
the surfaces of the wall structure being formed when the blocks are
stacked on top of one another. Each block also includes a flat top
side 19 and a flat bottom side 20 which permits stacking of the
blocks on top of the other.
[0073] Each block includes a centrally located conduit 24 of
generally octagonal cross section and having a lateral dimension
which is more than half of the width of the block. The conduit 24
extends through the block from the top side to the bottom side
thereof. The conduit is centered both laterally and
longitudinally.
[0074] Each end 16 of the block also includes a partial conduit 26
which comprises a channel open to the exterior end of the block and
which is shaped to correspond to half of the cross sectional shape
of the central conduit 24. Accordingly when two blocks are abutted
in an end to end configuration two partial conduits 26 are opened
to one another and form an assembled conduit which is identical in
cross section to the central round conduit 24.
[0075] Two webs 28 are integrally formed in each block to span in
the lateral direction between the opposing side walls 18 of the
block to divide the central conduit 24 from each of the partial
conduits 26 at opposing ends of the block. Each web 28 is located
spaced from a respective end of the block by approximately one
quarter of a length of the block in the longitudinal direction so
that the resulting space between the webs 28 locating the central
conduit therebetween is approximately equal to double the space
between each web 28 and the respective end of the block locating
the partial conduits. The partial conduits are thus each defined
between a respective one of the webs and a respective one of the
ends of the block.
[0076] Fastener apertures 30 are also formed in the block for
slidably receiving the masonry fasteners 14 therethrough. Each of
the fastener apertures 30 comprises a through bore extending from
the top side 19 to the bottom side 20 of the block. A counter bore
32 is formed at the bottom side of each fastener aperture 30 which
is slightly larger in diameter than the through bore of the
fastener apertures and to define an annular shoulder at the inner
end of the counter bore. The counter bore 32 extends axially less
then half a depth of the masonry block 12. In the illustrated
embodiment, the counter bore 32 has an increasing diameter from the
inner end which snugly receives an end of the fastener therein
towards an outer end at the bottom side of the block.
[0077] Two fastener apertures 30 are provided at spaced positions
in the lateral direction within each web 28 so that the apertures
30 are located adjacent the side walls 18 and so that a set of four
fastener apertures 30 are provided in each block in a rectangular
configuration spaced both laterally and longitudinally relative to
one another. By locating the apertures 30 spaced apart within each
of the webs, the fastener apertures are similarly located so as to
be spaced from a respective end of the block by approximately one
quarter of a total length of the block in the longitudinal
direction. Accordingly, the fastener apertures of the two webs are
spaced apart from one another approximately twice the distance of
the spacing of each fastener aperture from the respective end of
the block.
[0078] Each masonry fastener 14 has a height which substantially
corresponds in length to a height of the block between the top and
bottom sides thereof so that the fastener spans the height of the
block, but with some additional length for overlapping in a
lengthwise direction the fastener of an adjacent row of blocks
stacked thereabove when the fasteners are engaged with one another
in a mating connection.
[0079] The fastener 14 includes an elongate shaft 33 having an
external threaded portion 34 at both the bottom end and the top
end. Diameter of the shaft 33 and threaded portions 34 is
approximately equal to the diameter of the through bore of the
fastener apertures 30 for slidably receiving the fasteners within
the apertures in use. The external threaded potion 34 comprises a
machine screw for threaded securement to a suitable mating nut.
[0080] A nut portion 36 is provided for mounting at the top end of
the shaft 33. The nut portion has a hexagonal cross section similar
to conventional nuts for example for gripping with a wrench or
socket tool and the like. Length and diameter of the nut portion 36
is approximately equal to or less than the respective length and
diameter of the counter bore 32 so that the nut portion is receive
within the counter bore when stacking blocks. The through bore and
counter bore of the fastener apertures 30 are close enough in
dimensions to the shaft defining the threaded portion 34 and the
nut portion 36 of the masonry fasteners to provide a snug fit of
the fasteners within the apertures to maintain proper alignment of
the masonry blocks 12 relative to adjacent blocks. The increasing
dimension of the counter bore provides ease of insertion at the
outer end while snugly receiving the nut portion at the inner end
where the nut portion and counter bore are near one another in
diameter for aligning the blocks relative to one another.
[0081] The nut portion 36 includes an internally threaded bore 38
therethrough from the bottom end to the top end which is suitably
sized for mating engagement with the threaded portion 34 at the top
end of the respective shaft 33 and for mating engagement with
threaded portion 34 at the bottom end of another masonry fastener
14 of identical configuration. A dimple is centrally located within
the internally threaded bore in the nut portion for engaging the
top end of the respective shaft 33 inserted therein and prevent
over-threading of the shaft beyond a longitudinal centre of the nut
portion.
[0082] A washer 40 is located between the nut portion 26 and the
shaft 33 when assembling the nut portion on the shaft for abutment
against the top side of the masonry block 12 which receives the
threaded portion 34 through one of the fastener apertures 30
therein. An engaging surface of the washer 40, which faces the
threaded portion and which lies perpendicular to a longitudinal
direction of the fastener, is flat for abutment with the top side
of the masonry block 12.
[0083] In further embodiments, the shaft 33, the nut portion 26 and
the washer may be formed as an integral body, in which the shaft is
externally threaded at one end of the body and the nut portion 26
is internally threaded at the opposing end of the body.
[0084] When assembling a wall structure,shear plates 50 are mounted
to span between opposed pairs of the fasteners where additional
shear strength is desired. Each shear plate 50 comprises a flat
plate of rigid metal which has a length which is near the width of
the blocks 12 in the lateral direction. The plates 50 have a width
which is only slightly greater than the webs 28 so that the
conduits remain substantially unobstructed when the shear plates
are mounted to span the top side of respective blocks 12 in
alignment with respective webs 28. The shear plates 50 span across
a laterally spaced pair of the apertures 30 in the blocks and each
include a respective pair of mounting apertures 52 therein. The
mounting apertures 52 are spaced apart from one another by the same
lateral spacing as the apertures in the blocks 12 for alignment
therewith. The apertures 52 in the plate 50 have a diameter which
closely fits the shaft 33 of the fasteners 14 therein so that the
shear plates are commonly mounted with the blocks 12 to a previous
row of blocks during assembly.
[0085] As best shown in FIG. 9, a channel 54 is formed in the top
side of each block, also when additional strength is desired. The
channel 54 extends a full length of the block in the longitudinal
direction, centrally located in the lateral direction between the
side walls 18. The channel 54 comprises a groove open to the top
side of the block and which is suitably sized for receiving an
elongate reinforcement member, commonly referred to as rebar, to
extend through the channel and span a plurality of blocks along a
given row of the wall structure. The reinforcement member is
received in the channel 54 prior to attachment of the shear plates
50 so that the shear plates enclose the open top end of the channel
54 at each web 28 once installed.
[0086] As shown in FIGS. 1 and 9, a corner block 60 is provided for
joining to linearly assembled wall structures at right angles to
one another. The corner block 60 has a body having a first
rectangular portion 62 and a second rectangular portion 64 which
are formed integrally with one another.
[0087] The first rectangular portion 62 has upright side walls 66
which are elongate in a longitudinal direction between ends 68 of
the first rectangular portion. Dimensions of height between top and
bottom sides and width in the lateral direction between the upright
side walls which are substantially identical to the masonry blocks
12 described above.
[0088] The second rectangular portion 64 also has upright side
walls 66, but the side walls of the second rectangular portion
extend outward from the first rectangular portion in a lateral
direction oriented perpendicularly to the longitudinal direction of
the first rectangular portion. The second rectangular portion has
dimensions of height between top and bottom sides and of width
between the upright side walls which are substantially identical to
the first rectangular portion.
[0089] The first rectangular portion 62 corresponds in length to 1
and 1/4 times a length of the blocks 12 in the longitudinal
direction. Two complete conduits are provided in the first
rectangular portion with a partial conduit being provided at only
one end. The opposing end is enclosed by a flat end wall and is
joined with the second rectangular portion so that one of the side
walls of the second rectangular portion is flush with the enclosed
end of the first rectangular portion.
[0090] The second rectangular portion 64 corresponds in length to
3/4 a length of the blocks 12 in the longitudinal direction
thereof. Accordingly, a difference between dimension of the corner
block in the longitudinal direction thereof and dimension of the
corner block in the lateral direction thereof corresponds to
approximately 1/2 a total length of the masonry blocks 12 in the
longitudinal direction thereof. Accordingly, by alternating
position of the first and second rectangular portions of the corner
block with each successive row, the blocks 12 abutted with the
corner block at each row will be offset by 1/2 a length of a block
in relation to the blocks of the adjacent rows thereabove and
therebelow.
[0091] Using the masonry wall system 10, a wall structure can be
erected in which masonry blocks 12 are mechanically joined by
masonry fasteners 14 as described herein. A base of concrete 42 is
first formed where the wall is to be erected. Fasteners 14 are
embedded in the concrete when the concrete is still wet. The
fasteners 14 are embedded such that the threaded portion 34 is
embedded into the concrete but the nut portion extends above the
top surface of the concrete. A retention nut 44 can be secured to
the bottom end of the bottom threaded portion 34 prior to insertion
of the fasteners into the wet concrete. The fasteners are suitably
spaced from one another for alignment with the fastener apertures
30 of the first row of blocks to be formed.
[0092] The first row is formed by placing the blocks in an end to
end configuration in a longitudinal direction of the blocks so that
the partial conduits 26 of each block join with those of adjacent
blocks to form complete conduits. The counter bores 32 are inserted
overtop of the nut portions which project up and outwardly from the
concrete base 42 once the base has cured. The blocks in the first
row are secured in place by inserting the threaded portion 34 of a
masonry fastener 14 into each of the fastener apertures 30 so that
the bottom end is matingly engaged with the internally threaded
bore 38 of the fasteners embedded in the concrete therebelow.
[0093] As the fasteners 14 received through the blocks are threaded
into the fasteners therebelow and tightened in place, the washer 40
and nut portion 36 thereabove clamp down on to the top side of the
blocks. The close fit of the fasteners with respect to the through
bore and counter bore of the fastener apertures 30 assists in
proper alignment of the masonry blocks.
[0094] Each subsequent row is place above the previous row by
sequentially placing the masonry blocks in an end to end
configuration in a longitudinal direction of the blocks along the
previous row. The fist block is positioned so as to be offset in a
longitudinal direction by half a block length relative to the
previous row to form a staggered pattern. Due to the spacing of the
conduits and fastener apertures, each pair of joined partial
conduits 26 aligns with a central round conduit 24 of the rows
thereabove and therebelow.
[0095] Similarly the fastener apertures of each masonry block align
with fastener apertures of two separate blocks in the rows
immediately above and below. As each subsequent row is formed, the
masonry fasteners inserted therein are threadably engaged with the
fasteners of the pervious row and tightened until the nut portion
thereof clamps down onto the top surface of the respective blocks.
The location of the masonry fasteners permits the first row of
blocks to be anchored to the concrete base forming a supporting
surface of the wall while each block in the subsequent rows is
anchored to two adjacent blocks in the row above and two adjacent
blocks in the row below. Accordingly, the finished wall structure
includes blocks which are sufficiently interconnected by mechanical
fasteners to be self supporting without any grout material being
required to join the blocks.
[0096] As described herein, the masonry wall system 10 (or
mortarless block wall) consists of a masonry block 12 and a masonry
fastener 14 comprising a steel connector. Construction of the block
wall starts with first installing a connector to a concrete base
(concrete wall, slab, footing, etc) with a base steel connector.
This base steel connector is either installed in wet concrete (not
hardened yet) or installed in cured concrete (hardened concrete).
If the base steel connector is installed in wet concrete, a nut is
placed at the end of the steel connector to increase the tensile
anchorage strength of the steel connector. If the steel connector
is installed in cured concrete, then an oversized hole is drilled
in the concrete and the connector is installed with an epoxy grout
in the hole with the connector. In either installation of the base
connector, care is required to place the connector in the correct
location.
[0097] Once the base connector is installed, the standard masonry
blocks 12 are installed over the base connector. The standard steel
connectors are then inserted in the top of the masonry block (or
unit) and after the wall has been straightened and plumbed, the
steel connectors are tightened snug. After the first masonry course
is placed the second course is installed and again the steel
connectors are inserted in the top of the masonry unit. Again after
the second course of masonry units have been straightened and
plumbed, the steel connectors are tightened snug. The process is
continued until the full height of the wall is completed.
[0098] A form can be placed at the ends of the wall, or at an
opening, etc and the rough openings or ends of the wall can be
finished with concrete. To achieve a greater fire resistance in the
mortarless block wall, the vertical and horizontal joints in the
wall can be caulked with a fire retardant caulking. The caulking
serves another purpose, to straighten out vertical block
unevenness.
[0099] The wall system as described herein is advantageous to
owners as compared to conventional masonry walls as it is typically
less expensive, faster to construct, and can be de-constructed and
reused. Advantages to contractors include: (1) Does not need
hoarding & heating (or cooler weather) to construct, (2) Less
skilled labour to construct the wall, (3) The project schedule is
not dictated by a masonry contractor, (4) Installation of plumbing
line & electrical conduit can be done after wall is constructed
(the vertical cores within the wall are continuous), (5) The wall
has instant structure strength when the connectors are tightened
(and so temporary lateral bracing is less likely), and (6)
Construction of the wall can be done with only access with one side
of the wall (and still achieve a similar exterior finish quality).
Advantages to Architects and Engineers include: (1) More consistent
quality in structural strength than a concrete or masonry wall, (2)
Stronger lateral & vertical load capacity than a masonry wall,
(3) More consistent wall strength than a concrete or masonry wall,
(4) Better surface finish, and (4) More durable block than a
standard masonry block.
[0100] Since various modifications can be made in my invention as
herein above described, and many apparently widely different
embodiments of same made within the spirit and scope of the claims
without department from such spirit and scope, it is intended that
all matter contained in the accompanying specification shall be
interpreted as illustrative only and not in a limiting sense.
* * * * *