U.S. patent application number 11/804143 was filed with the patent office on 2008-06-12 for combination of a structural block and a facing element attached thereto.
Invention is credited to Tyler Matys, Angelo Risi.
Application Number | 20080134615 11/804143 |
Document ID | / |
Family ID | 38596645 |
Filed Date | 2008-06-12 |
United States Patent
Application |
20080134615 |
Kind Code |
A1 |
Risi; Angelo ; et
al. |
June 12, 2008 |
Combination of a structural block and a facing element attached
thereto
Abstract
Disclosed is the combination of a structural block with a facing
element. The facing element is hung to the structural block for at
least partially covering its longitudinal face by means of a hanger
affixed to the facing element. The hanger has a tab extending from
the facing element for engaging the structural block. The tab and
the block are engaged by means of at least one substantially
vertical post and at least one aperture for receiving the at least
one substantially vertical post. The at least one substantially
vertical post is part of either the tab or the structural block,
while the at least one aperture is part of the other.
Inventors: |
Risi; Angelo; (Richmond
Hill, CA) ; Matys; Tyler; (Aurora, CA) |
Correspondence
Address: |
COLLARD & ROE, P.C.
1077 NORTHERN BOULEVARD
ROSLYN
NY
11576
US
|
Family ID: |
38596645 |
Appl. No.: |
11/804143 |
Filed: |
May 17, 2007 |
Current U.S.
Class: |
52/598 |
Current CPC
Class: |
E02D 29/025 20130101;
E02D 29/0266 20130101 |
Class at
Publication: |
52/598 |
International
Class: |
E04C 1/39 20060101
E04C001/39 |
Foreign Application Data
Date |
Code |
Application Number |
May 18, 2006 |
CA |
2,547,415 |
Claims
1. The combination of a structural block with a facing element hung
thereto for at least partially covering a longitudinal face of said
structural block, wherein said facing element is hung to said
structural block by means of a hanger affixed to said facing
element, said hanger comprising a tab extending from said facing
element for engaging said structural block; and wherein said tab
and said block are engaged by engagement means comprising: at least
one substantially vertical post; and at least one aperture for
receiving said at least one substantially vertical post; said at
least one substantially vertical post being part of either said tab
or said structural block, while said at least one aperture is part
of the other.
2. The combination of claim 1 wherein the structural block
comprises said at least one substantially vertical post and the tab
comprises said at least one aperture.
3. The combination of claim 2 wherein the structural block
comprises at least one opening in its longitudinal face for
horizontally receiving said tab and enabling engagement of said at
least one aperture on the corresponding at least one substantially
vertical post.
4. The combination of claim 3 wherein said at least one
substantially vertical post is inset in said structural block and
creates a groove in an upper face of said structural block
surrounding said at least one substantially vertical post and said
opening in said longitudinal face.
5. The combination of claim 4 wherein said at least one
substantially vertical post has an upper surface lower than the
upper face of said structural block.
6. The combination of claim 5 wherein said at least one
substantially vertical post further comprises a longitudinal
surface which is flush with the longitudinal surface of said
structural block whereby said groove extends to said longitudinal
face.
7. The combination of claim 1 wherein said structural block has a
lower face and the said upper and lower faces of said structural
block comprise complementary shapes for allowing said structural
block to be stacked upon another structural block.
8. The combination of claim 1 wherein said hanger comprises a body
portion extending along, and substantially parallel to, said
longitudinal face of said structural block and wherein said tab
extends substantially perpendicularly from said body portion.
9. The combination of claim 8 wherein said hanger further comprises
a bumper portion extending from said body portion in the same
direction as said tab so as to abut said longitudinal face of said
structural block.
10. The combination of claim 9 wherein said tab and said bumper
portion are both in the form of rails that extend longitudinally
across said body portion and are interchangeable.
11. The combination of claim 8 wherein said facing element is made
of a pre-cast concrete.
12. The combination of claim 11 wherein said hanger is affixed to
said facing element by moulding said facing element around said
body portion.
13. The combination of claim 1 comprising two of said at least one
substantially vertical post and two of said at least one aperture,
said two substantially vertical posts being aligned with said at
least two apertures, respectively.
14. The combination of claim 2 wherein said structural block
further comprises a substantially vertical slot opening along said
longitudinal face of said structural block and a complementary
insert comprising a shaft portion for engagement with said
substantially vertical slot, said complementary insert comprising
said at least one substantially vertical post.
15. The combination of claim 14 wherein said slot portion comprises
a generally tapered cross-section tapering outwardly from said
longitudinal face and said complementary insert has a corresponding
generally tapered cross-section.
16. The combination of claim 15 wherein said generally tapered
cross-section comprises a straight section and a flange, said
straight section being proximate to said at least one opening along
said longitudinal face.
17. The combination of claim 16 wherein said substantially vertical
post extends outwards from said straight section.
18. The combination of claim 17 wherein said substantially vertical
slot extends from an upper face of said structural block to a lower
face of said structural block.
19. The combination of claim 18 wherein said insert is shorter in
length that the distance between said upper and lower faces of the
structural block.
20. The combination of claim 1 wherein said structural block
comprises said at least one aperture and said tab comprises said at
least one substantially vertical post.
21. The combination of claim 20 wherein said at least one
substantially vertical post extends downward from said tab and said
at least one aperture comprises a downwardly extending void area in
said structural block.
22. The combination of claim 21 wherein said structural block
comprises an opening in said longitudinal face for horizontally
receiving said tab and said at least one substantially vertical
post, and for enabling engagement of said at least one aperture
into at least one substantially vertical post.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to the combination of a
structural block and a facing element attached thereto by means of
a hanger.
BACKGROUND OF THE INVENTION
[0002] Facing elements can be added to the exterior of a structure
for any number of reasons. For example, a facing element may be
chosen for its aesthetic attributes, or alternatively, it could be
chosen based on the resilience, sound dampening ability, or
reflective properties of its material.
[0003] The structures discussed herein can include buildings, steel
reinforced concrete block retaining walls and parapets, segmental
retaining walls, and fences or acoustical barriers. The facing
element can include any architectural or building material the
designer wishes to incorporate into the aesthetic or physical
properties of the structure. Examples include pre-cast concrete,
marble, glass, steel, granite and other natural stone, plastics, or
fabrics.
[0004] Structures can be broadly classified as either rigid or
flexible structures. Rigid structures are those which are not
designed to allow significant deflection or movement during or
following construction. Deflections larger than those within a very
narrow limit constitute a failure of the structure. Examples of
such structures include most buildings, bridges, reinforced
concrete block retaining walls, and pre-cast concrete culverts.
Flexible structures are those structures which, despite undergoing
movements, deflections, or settlements beyond the allowable limits
of a rigid structure, continue to perform their intended structural
function and are not considered to have failed. Examples of this
type of structure are conventional and geogrid-reinforced segmental
retaining walls. In this type of structure, blocks are dry-stacked
(no mortar or adhesive is used) and the integrity of the structure
is maintained by the structure's own weight in order to resist soil
pressure and other loads applied through the earth they are
retaining. The joints in a segmental retaining wall allow the units
to move relative to one another within a much greater range without
affecting the structural stability of the wall as a whole. An
advantage of this type of system is that it does not require the
foundation of the wall be buried below the frost line, or can be
constructed on foundation soils where settlement is
anticipated.
[0005] Currently, facings and building veneers are secured to the
underlying structure in a number of ways. However, facing elements
are not generally incorporated into flexible structures (i.e.
segmental retaining walls) due to the limitations in existing
techniques. Elements such as brick and stone are mortared and/or
tied mechanically to the underlying structure. Coating elements
such as stucco can be applied directly to the underlying structure
with the addition of a supporting layer such as metal lath. Panels,
such as those composed of reinforced pre-cast concrete, granite or
marble, are generally fastened to the underlying structure with
structural fasteners such as steel dowels and bolts, but can also
be chemically bonded. In order to ensure a strong bond, it is
however usually preferred to perform the bonding in a controlled
environment rather than in the field where chemical agents are more
prone to contamination.
[0006] In general, the facing material is meant to be more
aesthetically pleasing than the structural block it is covering,
and is therefore generally more expensive. The use of a facade or
veneer to create the desired outward look of the structure is
significantly more economical than attempting to use the facing
material as the entire structural element.
[0007] However, the use of mortar, steel lathing, and other
adhesive compounds to apply a facing material to a structure
requires skilled labour, is dependent on the craftsmanship of the
installer, is dependent on climatic and moisture conditions, and
long term adherence is subject to degradation (mortar under freeze
thaw cycles). All of these elements add variability to the
installation and may increase costs, installation time, and
adversely effect long term performance (reliance on contractor for
good workmanship and proper application of bonding/adhesive
materials).
[0008] In addition, the use of coating elements such as stucco or
other compounds that are applied directly on to the structure are
known for poor long term performance under severe weather
conditions (spalling of stucco or mortar due to freeze thaw cycles
in Canada). The bond of mortar to concrete or brick, and the use of
other adhesives, is vulnerable to environmental conditions such as
temperature, moisture, pollutants, etc.
[0009] Another common problem associated with segmental retaining
walls is the staining cause by efflorescence. Efflorescence is a
phenomenon wherein water passing through the earth behind a
retaining wall, enters the concrete block, dissolves the natural
salts therein and evaporates from the outer surface of the
retaining wall leaving behind the dissolved salts. These salts
cause the white/grey/black staining commonly seen on masonry
products, which has been a major problem for precast concrete
manufacturers as the look of their walls is significantly
diminished by the staining. Various concrete admixtures, face
treatments and other techniques have been employed to help control
the negative effects of efflorescence. However, most have little
effect and are costly.
[0010] Furthermore, the practice of securing facings to flexible
structures, such as segmental retaining walls, is not commonplace.
Generally, structures such as segmental retaining walls are
constructed of pre-cast concrete blocks, which allow the
manufacturer to create various finishes on the face of the actual
structural block (split rock, smooth with chamfers, exposed
aggregate, etc). Architects are becoming more and more demanding
with respect to the appearance of such structures, ultimately
wanting these exterior landscape walls and structural retaining
walls to better compliment and blend into the surrounding natural
and built environment. As such, the addition of a more attractive
facing element would provide the manufacturer a competitive
advantage in the marketplace.
[0011] Canadian Patent 2,244,348, titled Block Retaining Wall with
Attached Facing Panels provides a segmental retaining wall block
with a vertical slot in the face to be used in conjunction with a
matching facing panel for securing the facing panel to the
segmental retaining wall block. The vertical slot in the face of
this segmental retaining wall block accepts a vertical tongue
protruding from the back of the facing panel. To secure the facing
panel to the structural block, the facing panel is slid vertically
into the groove on the face of the block, and rests on the unit
below, thereby supporting the panel vertically. As the facing
element itself is resting on the facing element below, no space is
provided between panels for movement or expansion. Contact between
panels that are subject to movement or settlement, as with a
flexible segmental retaining wall, creates stress on the panels as
they attempt to move relative to each other. Furthermore, panels
that rest on each other must be load bearing, as they take the load
of all the other panels above. This greatly restricts the type of
material that may be used as a facing.
[0012] This design requires that the panel be slid into the opening
at the top of the block and pushed down to rest on the block
underneath it. In order to install a facing panel on a block, the
top of the block must be unobstructed. This can only be
accomplished in one of two ways: either each course of blocks must
be setback considerably to expose the entrance to the slot on the
top of the block or, alternatively, the facing panels must be
installed as the wall is being built, with each row of panels being
secured prior to the stacking the successive course or blocks. Both
these scenarios present serious drawbacks to a designer.
[0013] Given that most rigid reinforced concrete block walls are
essentially vertical, and that flexible segmental retaining walls
are constructed either vertical or near vertical (batter on most
segmental retaining walls varies between 0.degree. and 12.degree.),
the first of the above-mentioned scenarios is clearly
impractical.
[0014] The second scenario, in which the facing panels are
installed as the structural portion of the wall is being
constructed, greatly increases the potential for damage to the
facing panels since they are being placed during a time of "heavy
construction". Large machines, bigger crews, and more activity in
general cause a greater exposure to potentially damaging
circumstances. In addition, the risk of theft or vandalism further
increase with the length of time left on site.
[0015] Additionally, the placement of the panels during
construction may slow progress on the actual structure, which may
be under a specific timeline in many cases the completion of one
structure is required to support other related structural elements.
Furthermore, the necessity of adding the facing panels during
construction limits the designer's flexibility to change or modify
the facing at later stages in construction or try different facings
on the finished structure prior to choosing the final one.
[0016] Furthermore, installing the facing panels as the structure
is being constructed means installing the facing panels before the
structure has settled, a situation particularly important for
flexible structures. With specific reference to the wall structure
disclosed in CA 2,244,348, the facing units bear directly on each
other, or on the structural unit below. If these panels are subject
to movements or settlements, as they are in direct contact with
each other and/or the structural block, they will be vulnerable to
additional stresses and loads caused by differential movement. This
may result in fractures or breakage of the facing panels due to
expansion forces or differential settling of the structure.
[0017] As such, there exists a need for a system for attaching a
facing element to a structural block which overcomes some of the
afore-mentioned problems found in the prior art.
SUMMARY OF THE INVENTION
[0018] The object of the present invention is to provide a system
for attaching a facing element to a structural block which
apparatus overcomes the above-identified deficiencies found in
existing techniques.
[0019] More specifically, the invention is directed to the
combination of a structural block with a facing element hung
thereto for at least partially covering a longitudinal face of the
structural block, [0020] wherein the facing element is hung to the
structural block by means of a hanger affixed to the facing
element, the hanger comprising a tab extending from the facing
element for engaging the structural block; and [0021] wherein the
tab and the block are engaged by engagement means comprising:
[0022] at least one substantially vertical post; and [0023] at
least one aperture for receiving the at least one substantially
vertical post; [0024] the at least one substantially vertical post
being part of either the tab or the structural block, while the at
least one aperture is part of the other.
[0025] Preferably, the structural block comprises the at least one
substantially vertical post and the tab comprises the at least one
aperture.
[0026] Preferably also, the combination comprises two of
substantially vertical posts and two apertures, the two
substantially vertical posts being aligned with the two
apertures.
[0027] With architects, designers, and consumers constantly looking
for new and more appealing textures, colours, and aesthetic
elements to incorporate into and enhance the built environment, the
integration of a wide variety of materials is becoming increasingly
popular. The present invention provides a means through which
attractive facing materials can be incorporated into both rigid and
flexible structures with better economics, better performance, and
greater ease than existing methods and systems. The present
invention further provides a means of controlling the negative
effects of efflorescence.
[0028] The invention will be better understood upon reading the
following non-restrictive description of preferred embodiments
thereof, made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIGS. 1 and 2 are exploded perspective views of a system for
attaching a facing element to a structural block according to a
first preferred embodiment of the invention.
[0030] FIG. 3 is an unexploded perspective view of the system for
attaching a facing element to a structural block shown in FIGS. 1
and 2.
[0031] FIG. 4 is a side view of the embodiment shown in FIGS. 1 to
3 with portions of the hanger being shown in phantom lines.
[0032] FIG. 5 is a perspective view of the structural block
according to the first preferred embodiment of the present
invention.
[0033] FIG. 6 is a side view of the structural block according to
the first preferred embodiment of the present invention with
portions of the hanger being shown in phantom lines.
[0034] FIGS. 7 and 8 are perspective views of the hanger according
to the first preferred embodiment of the present invention.
[0035] FIGS. 9 and 10 are top and side views, respectively, of the
hanger according to the first preferred embodiment of the present
invention.
[0036] FIGS. 11 to 16 are side views illustrating the steps to be
carried out for applying facing elements to two vertically disposed
structural blocks, with portions of the hanger being shown in
phantom lines.
[0037] FIGS. 17 to 22 are perspective views illustrating the steps
to be carried out for applying facing elements to a retaining wall
in accordance with the present invention.
[0038] FIG. 23 is a partially exploded plan view of a system for
attaching a facing element to a structural block according to a
second preferred embodiment of the present invention.
[0039] FIG. 24 is a side view of the partially exploded system
shown in FIG. 23.
[0040] FIG. 25 is a perspective view of the partially exploded
system shown in FIGS. 23 and 24.
[0041] FIGS. 26, 27 and 28 are top, perspective and side views of a
hanger insert according to the second preferred embodiment of the
present invention.
[0042] FIGS. 29 and 30 are perspective views of a hanger according
to the second preferred embodiment of the present invention.
[0043] FIG. 31 is a side view of stacked structural blocks and
facing elements of varying sizes according to the second preferred
embodiment of the present invention.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0044] FIGS. 1 to 4 illustrate a combination 10 comprising a
structural block 12, a facing hanger 14 and a facing element 16
according to a first preferred embodiment of the invention.
[0045] Generally, structural blocks or units such as structural
block 12 are designed to bear the load of the structure
(compression, shear, etc) either on their own or by being combined
with other structural materials. Such structural materials include,
but are not limited to, reinforcing steel, geosynthetic
reinforcements, mortar/grout, and concrete. Examples of such
structural blocks, which have been in use for many years, include
typical masonry building blocks, concrete, clay bricks, and
segmental retaining wall units.
[0046] Blocks may range is size considerably. Typically masonry
building blocks are manufactured in dimensions that allow a
bricklayer or mason to place them by hand (i.e. weighing less than
20 kg) with typical dimensions of 190 mm (h).times.390 mm
(l).times.100 mm (w). Such manually placed blocks often have hollow
cores to decrease their weight and allow for the placement of grout
and/or steel reinforcement.
[0047] For the construction of segmental retaining walls, the
blocks may either be hand-placed pre-cast blocks (weighing less
than 35 kg) with typical dimensions of 150 mm (h).times.200 mm
(l).times.300 mm (w), or machine-placed pre-cast blocks (weighing
up to and including 750 kg) with typical dimensions of 300 mm
(h).times.1830 mm (l).times.610 mm (w). Such blocks can also have
hollow cores to decrease their weight and allow for the placement
of grout and/or steel reinforcement.
[0048] Hanger 14 serves to hang facing element 16 from block 12,
which provides a facade for an exposed, longitudinal face 20 of
block 12. Hanger 14 can be machined from metal stock or fabricated
from bent sheet metal, but is preferably a moulded plastic.
[0049] Facing element 16 is composed of a material or materials
that have a preferred physical property or attribute, but are, for
example, more expensive or less structurally sound than the
material of structural block 12. The physical property can be an
electrical, chemical or mechanical. Facing element 16 may be chosen
for aesthetic reasons, or alternatively, facing element 16 could be
chosen, for example, based on its resilience, sound dampening
ability, or reflective properties. Facing element 16 could be made
of pre-cast concrete, steel, marble, granite or other cut stone,
glass, or wood panels.
[0050] Hanger 14 can be secured to facing element 16 mechanically,
chemically, or, preferably, by placing it into a mould and allowing
it to set into the facing material while the facing material is in
a non-solid form, such as pouring wet concrete or plastic into a
mould with the hanger 14 already inserted, thereby enveloping a
portion of the hanger 14 within the facing material, as seen in
FIGS. 4 and 11 to 16.
[0051] Preferably, facing element 16 is attached or integrated with
hanger 14 at the place of manufacture. In the case of using a cast
concrete facing panel, which is usually manufactured using a
wet-cast mould with shapes/textures resembling natural stone or
brick, the body 22 of hanger 14 is set into the facing element
mould prior to pouring the concrete. Tabs 24 and a lower bumper
portion 26 and are left out of the mould, allowing the wet concrete
to surround and/or bond to the majority of the hanger body,
covering it in the process. It is to be noted that presence of a
bumper portion, like bumper 26, is not essential to the functioning
of the present invention. A hanger 14 which is stabilised and
aligned only by the engagement of tab, or tabs, 24 and structural
block 12 is within the scope of the invention.
[0052] In the case where a marble facing element 16 is preferred,
hanger 14 is preferably glued to the marble element 16. For yet
other types of facings 16, it may be preferable to otherwise
mechanically or chemically bond hanger 14 to facing element 16.
[0053] Block 12 and tabs 24 are engagable by engagement means 13
including a post and an aperture located on one or the other of
block 12 and tabs 24.
[0054] In the illustrated embodiment, block 12 is provided with at
least one inset mounting post 28, incorporated into the top of
block 12 and from which facing element 16 is hung along
longitudinal side 20 of block 12. Posts 28 can be manufactured as
part of the block mould, in the case of a block 12 made of
concrete, or can be added later through machining. Posts 28 can
further be manufactured separately and attached to block 12
thereafter.
[0055] In the present example, which is to be considered in no way
limiting, block 12 comprises two mounting posts 28. It is to be
noted, however, that the numbers of posts 28 can vary according to
the wide variety of applications of the present invention.
Additional mounting posts 28 could be located on the opposite side
of block 12 for use in a structure that has two exposed faces and
requires a facing on both the front and back of the structure. For
larger blocks, there may be a larger number of mounting posts 28,
so as ensure an even hanging and ensure that the allowable spanning
distance of the panel is not exceeded.
[0056] Preferably, a post 28 is formed entirely within the walls of
block 12, i.e. no part of post 28 extends beyond the six sides of
block 12. In this way, each post 28 comprises five exposed
surfaces: a front longitudinal surface 30 which is co-planar with
front surface 20, lateral surfaces 32 which are parallel to the
lateral surfaces of block 12, a back surface which tapers downward
away from longitudinal faces 20 and 30, and a top surface 34 which
is parallel to upper face 36 of block 12.
[0057] As seen in the Figures, the block 12 is cut-out around in
order to form post 28, leaving a horseshoe-shaped groove 33 with
the longitudinal surface 30 being flush with the exposed face 20 of
block 12. In a first embodiment, top surface 34 of post 28 is lower
than upper face 36, creating a space 38 therebetween. This space 38
allows the hanger 14 to be inserted horizontally into the top of
block 12, without being obstructed by the next course of blocks 12
stacked above it. As such, facing elements 16 can be placed after
the wall/structure is built, regardless of whether the structure is
vertically aligned or is battered back.
[0058] In an alternate embodiment, top surface 34 and upper face 36
are co-planar. In order to allow the placement of a facing element
16 on a post 28, an additional cut out is provided along the lower
face of block 12 (and therefore any corresponding blocks 12
positioned above) in line with post 28, in order to allow create an
equivalent space 38, this time above the lower block 12 in the
bottom side of the block 12 above it and provide access to post
28.
[0059] As discussed above, hanger 14 comprises tabs 24 and a bumper
26 that protrude from facing element 16. In addition, each tab 24
comprises an aperture 40 which is slightly larger in size than a
post 28. Hanger 14 slips over the 1.0 mounting posts 28, ultimately
resting in the horseshoe-shaped groove 33 set in the top of the
block 12. Body 22 or hanger 14 is slightly smaller than facing
panel 16 and longitudinal face 20. Tabs 24 extend from the top of
the hanger 14 at a 90 degree angle to a distance roughly equivalent
with the depth of groove(s) 33 inset into the top of block 12.
Hanger 14 also comprises gussets 42 extending between tab 24 and
body 22. The vertical thickness of tab 24 is slightly less than the
vertical space 30 between top surface 42 of post 28 and top face 44
of block 12. This ensures that tab 24 can be inserted horizontally
into the face of block 12, and, once inside, be slipped down over
mounting post 28. As such, facing element 16 can be placed after
the wall or structure is built, even if the block 12 is positioned
below another block 12.
[0060] In yet another alternate embodiment, the locations of post
28 and aperture 40 are reversed within engagement means 13. In this
embodiment, tab (or tabs) 24 of hanger comprises a downwardly
extending vertical post at its outer edge. A corresponding aperture
is then provided in block 12 to receive the downward facing post.
The functionality of this alternative is maintained by similarly
providing space 38 below the upper 36 face of block 12 in which tab
24 is inserted horizontally without being obstructed by the next
course of blocks stacked above it. The aperture in block 12 should
be about the same size as the downwardly extending vertical post,
or could be part of a much larger void, as in a hollow block. In
either case, hanger 14 allows facing element 16 to be hung from
block 12.
[0061] With reference now to FIGS. 11 to 22, the method of
installing facing panels 16 to a wall 50 of blocks 12 will be
described. The following method can also be applied to any of the
above-mentioned alternate embodiments.
[0062] Retaining wall 50 which is illustrated comprises four
courses of structural blocks 12a, 12b, 12c and 12d stacked
alternatingly one atop the other. A first facing element 16a is
aligned with a first block 12a from the bottommost course, so that
tab 24 is aligned with space 38. Hanger 14 is then inserted, in
direction 52, into the space between post 28 and the bottom face of
the block above of course 12b. When bumper 26 engages the
longitudinal face 20 of block 12a, facing element 16 is lowered in
direction 54. Once lowered, tab 24 fully surrounds post 28, and the
bottom side of tab 24 rests on the bottom of the horseshoe-shaped
groove 33, including gusset 42.
[0063] This process is then repeated for each block 12a in the
bottom most course, and then similarly for the blocks 12b in the
course above that, and so on until each block 12 is has a facing
element affixed thereto, as seen in FIG. 21.
[0064] Note that it is important to start from the bottommost
course and work upwards because, as seen most clearly in FIG. 16,
first facing element 12a cannot be raised enough to withdraw it
from block 12 if a second facing element 12b is positioned
above.
[0065] Lastly, finishing blocks 56 are fixed on top of each block
12 whose upper face 36 is exposed, thereby preventing the top
course of finishing elements 16d from being removed.
[0066] As such, the structural elements of wall 50 can be erected,
allowing the remainder of the construction to continue, while
allowing the facing panels to be installed at a later date.
[0067] FIGS. 23 to 31, illustrate another preferred embodiment of
the invention.
[0068] This other combination 100 comprises a structural block 112,
a hanger 114, a facing element 116 and at least one hanger insert
118. In this embodiment, hanger inserts 118 are inserted into block
112 via vertical a vertical slots 120. The slots 120 have a larger
cavity set back from the face of block 112.
[0069] As pictured, a pair of hanger inserts 118 fit into vertical
slots 120 in block 112, which extend from upper face 122 to lower
face 124 of block 112 and have a complementary shape to that of
insert 118. The larger backside of insert 118 and slot 120 prevents
insert 118 from any frontward or backward movement. Once insert 118
is placed inside block 112 and the following course of blocks 112
are laid thereabove, insert 118 is locked in place.
[0070] With specific reference to FIGS. 26 to 28, each insert 118
comprises a shaft 126 and a substantially vertical post 128
extending outwards and upwards from shaft 126. Shaft 126 comprises
straight section 130 and flanges 132 extending laterally outwards
from therefrom, the combination of which creates a tapered
cross-section which is of substantially constant over the length of
shaft 126. Opposite to flanges 132, post 128 projects from straight
section 130 and forms a groove 134 therebetween comprising vertical
surface 138, bottom surface 140 and outer surface 142 of straight
section 130. Angled surface 136 is further provided to ease placing
of hanger 114 within groove 134, which is equivalent to
above-mentioned groove 33.
[0071] The complementary shape of each slot 120 takes the form of
shaft 126 (i.e. straight section 130 and flanges 132), but of
slightly greater dimensions so as to allow movement of insert 118
within slot 120 and forms an opening down the longitudinal face of
block 12 the width of straight section 130. In this way, shaft 126
can slide freely in a vertical direction within slot 120 with post
128 outside slot 120. Furthermore, because the widths of flanges
132 and post 128 are greater than that of straight section 130,
insert 118 is constrained to move in the vertical direction
only.
[0072] The height of insert 118 is less than the height of block
112, i.e. the distance between upper face 122 and lower face
124.
[0073] The embodiment illustrated in the preceding Figures
describes a block 112 with two slots 120 and a corresponding two
inserts 118, however it is to be noted that embodiments involving a
single slot 120 and corresponding insert 118, as well as more than
two of each, are within the scope of the present invention.
[0074] A shown in FIGS. 29 to 31, tabs 144 of hanger 114 comprise
rails 144 projecting from body 146. Each rail 144 comprises one or
more apertures 148 dimensioned to receive a post 128 of insert 118
and rest in groove 134. As pictured, the two rails 144 are
identical and either one is capable of engage posts 128, while the
remaining rail functions as a bumper stabilising hanger 114 and
ensuring that facing element 116 is properly aligned with the
longitudinal face of block 112. This versatility advantageously
enables the installation of each facing element 116 in one of two
distinct orientations, effectively doubling the options available
to an architect or designer. Furthermore, apertures 148 are
considerably wider than posts 128, enabling a user to slide the
facing back and forth a certain distance.
[0075] As with the above-described hanger 16, hanger 116 is
preferably attached or integrated with hanger 114 at the place of
manufacture. In the case of a cast facing panel, body 146 is set in
the facing panel mould material prior to setting. Rails 144 are
left outside the mould, while the wet concrete material is allowed
to flow around body 146, through casting apertures 150 and around
the C-shape created by outer rails 152, thereby securing the facing
material to hanger 114 when hardened.
[0076] FIG. 31 shows four structural blocks 112a, 112b, 112c and
112d stacked on top of each other. Facing element 116a is hung from
insert 118a which is vertically supported by the upper face of
block 112b. It is important to note that, in this case, blocks
112a, 112b, 112c and 112d are stacked such that respective slots
120a, 120b, 120c and 120d (not shown) are not in alignment. Were
this the case, each insert 118 could fall into the lower block's
slot 120 as each insert 118 is shorter than each corresponding slot
120.
[0077] Alternatively, a slot 120 could be provided which does not
extend completely through block 112, but rather from upper face 122
to somewhere above lower face 124, thereby creating a surface to
vertically support insert 118. Alternatively again, a small plate
of greater dimension than the cross-section of slot 120 could be
inserted between two vertically stacked blocks 112, and positioned
so as to prevent an insert 118 from falling into the slot 120 of a
lower block.
[0078] Facing element 116a is dimensionally smaller than
corresponding block 112a, which leaves an opening 154 between
facing element 112a and any adjacent facing elements. This opening
154 is particularly important in situations where some movement or
settling is expected from the structure. An opening 154 between
facing element 116a and a laterally adjacent facing element 116
(not shown) allows for small adjustments of the position of element
116a relative to block 112a.
[0079] Providing a facing system which "floats", rather than being
rigidly fixed or resting on a lower block, allows the use of facing
panels that can extend over one and a half, or two courses of
structural blocks. As further seen in FIG. 31, facing element 116b,
hung from insert 118b, and facing element 116d, hung from insert
118d, can combine to provide facing to block 116c. This feature is
advantageous in that it visually interrupts up the unnatural
horizontal lines in the face of the wall. This interruption of
horizontal lines reduces the look of a manufactured "dimensional"
facing, and creates a more natural, aesthetically pleasing look as
the eye does not pick up the horizontal joints as easily.
Furthermore, this system has the ability to hide slight variances
in the horizontal alignment of the wall, which are often caused by
differential settlement or an uneven base. The less continuous the
lines are, the more difficulty the eye has in picking up these
variances.
[0080] Combinations 10 and 100 are simple and do not require
skilled labour as would the use of mortar, steel lathing, and other
adhesive compounds. Thus, combinations 10 and 100 are not subject
to expensive labour costs or the craftsmanship and/or knowledge of
the installer. As well, combinations 10 and 100 require no mortar
or other chemical adhesives to secure them, removing any
vulnerability to non-ideal weather conditions or long term
degradation.
[0081] Similarly, combinations 10 and 100 do not require chemical
bonds to secure them, and therefore are not subject to the spalling
or degradation often found with stucco and other coatings in
extreme weather environments. When a marble facing element 16 or
116 is favoured, and it remains necessary to glue the marble facing
element to hanger 14 or 114, such gluing can be performed off-site
and at any time prior to final installation. This represents a
major improvement over prior art systems which would otherwise
necessitate non-ideal fabrication conditions and be at the mercy of
varying weather conditions and work schedules.
[0082] Combinations 10 and 100 are "floating systems", allowing the
facing to hang from the structural block with no part off the
facing contacting or bearing on any other facing element. This
structural independency allows for the settlement or movement
between adjacent units and expansion or contraction of the various
elements relative to one another. Being structurally independent
ensures each individual facing panel 16 will not rely on or be
effected by other surrounding panels. This also allows for
replacement of damaged panels without having to remove all of the
surrounding panels 16.
[0083] In addition, the use of the "floating panel" system
described herein provides a space between body 22 or 146 of hangar
14 or 144, respectively, and structural block 12 or 112, ensuring
that water does not continue through to the facing and essentially
severing the efflorescence process. This is a clear advantage over
existing facing panel systems which place facing elements flush
with the face of the structural block to which they're
attached.
[0084] Lastly, by allowing the user to place the facing elements at
any time after construction, the more expensive, delicate facing
can be store off-site and installed at a time when the "heavy
construction" is not taking place, thereby significantly lowering
exposure potentially damaging conditions, and reducing the risk of
theft or vandalism.
[0085] The above description of a preferred embodiment of the
present invention should not be read in a limitative manner as
refinements and variations are possible without departing from the
spirit of the invention. The scope of the invention is defined in
the appended claims and their equivalents.
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