U.S. patent application number 11/765319 was filed with the patent office on 2008-08-07 for insulated block with non-linearthermal paths for building energy efficient buildings.
Invention is credited to Scott Fischer.
Application Number | 20080184650 11/765319 |
Document ID | / |
Family ID | 39674973 |
Filed Date | 2008-08-07 |
United States Patent
Application |
20080184650 |
Kind Code |
A1 |
Fischer; Scott |
August 7, 2008 |
INSULATED BLOCK WITH NON-LINEARTHERMAL PATHS FOR BUILDING ENERGY
EFFICIENT BUILDINGS
Abstract
According to one aspect of the invention, a block for building
construction is provided. The block includes: a molded body formed
of an inorganic material, wherein the molded body defines (a) a
rectangular-box shape; (b) non-linear thermal paths of the body
material across the block by offsetting and restricting the cross
webbing of the block; and (c) at least two cavities in the block.
According to another aspect, a block for building construction is
provided, wherein the block includes: a molded body formed of an
inorganic material, wherein the molded body defines (a) a
rectangular-box shape; (b) at least two cavities in the block; and
wherein the block has nominal dimensions of
6''.times.6''.times.24''.
Inventors: |
Fischer; Scott; (Hot
Springs, AR) |
Correspondence
Address: |
CRUTSINGER & BOOTH
1601 ELM STREET, SUITE 1950
DALLAS
TX
752014744
US
|
Family ID: |
39674973 |
Appl. No.: |
11/765319 |
Filed: |
June 19, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60805152 |
Jun 19, 2006 |
|
|
|
Current U.S.
Class: |
52/606 ;
52/404.1 |
Current CPC
Class: |
E04B 2/8629 20130101;
E04B 2/54 20130101; B28B 7/24 20130101; B28B 7/0097 20130101; B28B
23/0025 20130101; Y02A 30/261 20180101; Y02B 30/90 20130101; E04B
2002/0291 20130101; E04C 1/397 20130101; Y02A 30/00 20180101; Y02B
30/94 20130101 |
Class at
Publication: |
52/606 ;
52/404.1 |
International
Class: |
E04C 1/40 20060101
E04C001/40; E04B 1/74 20060101 E04B001/74; E04B 2/02 20060101
E04B002/02 |
Claims
1. A block for building construction, the block comprising: a
molded body formed of an inorganic material, wherein the molded
body defines (a) a rectangular-box shape; (b) non-linear thermal
paths of the body material across the block by offsetting and
restricting the cross webbing of the block; and (c) at least two
cavities in the block.
2. The block according to claim 1, wherein the block has nominal
dimensions of 6''.times.6''.times.24''.
3. The block according to claim 1, wherein the inorganic material
is a cement-based mix.
4. The block according to claim 1, wherein the cavities of the
block are open to a face of the block, whereby the cavities can be
substantially filled with an insulating material to form an
insulated concrete block.
5. The block according to claim 4, further comprising an insulating
material positioned in the cavities of the block.
6. The block according to claim 5, wherein the insulating material
is an insulating foam material.
7. The block according to claim 6, wherein the insulating foam
material is in the form of one or more inserts of a size and shape
adapted to fit within the cavities of the block or the foam
material is spray filled into the cavities of the block.
8. The block according to claim 7, wherein at least one of the
insulating foam inserts spans across more than one block, whereby
any small gap between two adjacent blocks in a wall are insulated
to help insulate the wall of blocks.
9. The block according to claim 6, wherein the insulating foam
comprises an insulating material selected from the group consisting
of polystyrene and polyurethane.
10. The block according to claim 1, wherein at least one of the
cavities of the block allows for rebar to be positioned through the
block, whereby, when a plurality of the blocks are stacked to
define a wall, at least one rebar can be positioned through
adjacent blocks to reinforce the wall of block.
11. The block according to claim 10, wherein at least one rebar can
be positioned through adjacent blocks in the wall of the blocks in
a vertical orientation and at least one rebar can be positioned
through adjacent blocks in the wall of blocks in a horizontal
orientation.
12. The block according to claim 1, wherein at least one of the
cavities thereof allows electrical conduit to be positioned through
the block, whereby, when a plurality of blocks are stacked to
define a wall, at least one electrical conduit can be positioned
through adjacent blocks for servicing an electrical junction box or
outlet positioned in a cut-out made in a face of the block.
13. The block according to claim 1, further comprising a pre-finish
on at least one of the faces of the block.
14. The block according to claim 1, further comprising a
pre-insulated foam material in the cavities of the block.
15. The block according to claim 14, wherein the cross webbing of
the block is restricted to about one-half of the dimension of one
of the shorter nominal dimensions of the block.
16. The block according to claim 1, further comprising a vertical
sealant groove in a middle rib of the head of the block.
17. The block according to claim 16, wherein the vertical sealant
groove in a middle rib of the head of the block is V-shaped.
18. The block according to claim 1, further comprising a horizontal
sealant groove in the top of a middle rib of the block.
19. The block according to claim 18, wherein the horizontal sealant
groove in the top of a middle rib of the block is V-shaped.
20. The block according to claim 1, further comprising a vertical
ground-screw clearance groove in a middle portion of a middle rib
of the block to provide clearance for an electrical ground screw in
the back side of an electrical outlet box positioned in the
block.
21. A mold for manufacturing a block, wherein the block comprises:
a molded body formed of an inorganic material, wherein the molded
body defines (a) a rectangular-box shape; (b) non-linear thermal
paths of the body material across the block by offsetting and
restricting the cross webbing of the block; and (c) at least two
cavities in the block; and wherein the mold comprises: (a) a mold
box adapted for receiving and molding an inorganic material on a
manufacturing pallet into the form of at least one of the block;
and (b) a plunger head adapted for compacting and vibrating the
inorganic material in the mold box, and after the inorganic
material is sufficiently set, pushing the molded inorganic material
through the bottom of the mold box as the mold box is raised off
the manufacturing pallet.
22. The mold according to claim 21, wherein the block has overall
dimensions of about 6''.times.6''.times.24'' whereby three (3)
blocks can be simultaneously molded on a typical manufacturing
pallet that is 26''.times.18''.
23. The mold according to claim 21, wherein the mold box does not
have core bars across the top, whereby the block can be molded in
the mold box sideways to the direction of normal raking across the
top of the mold box without interference by any core bars.
24. A wall system for a building construction comprising a
plurality of blocks, wherein each of the blocks comprises: a molded
body formed of an inorganic material, wherein the molded body
defines (a) a rectangular-box shape; (b) non-linear thermal paths
of the body material across the block by offsetting and restricting
the cross webbing of the block; and (c) at least two cavities in
the block.
25. The wall system according to claim 24, wherein the blocks have
nominal dimensions of about 6''.times.6''.times.24''.
26. A building comprising a plurality of walls wherein at least one
of the walls comprises a plurality of blocks, and wherein each of
the blocks comprises: a molded body formed of an inorganic
material, wherein the molded body defines (a) a rectangular-box
shape; (b) non-linear thermal paths of the body material across the
block by offsetting and restricting the cross webbing of the block;
and (e) at least two cavities in the block.
27. The building according to claim 26, wherein the block has
nominal dimensions of about 6''.times.6''.times.24'', whereby three
(3) blocks can be simultaneously molded on a typical molding pallet
that is 26''.times.18''.
28. A block for building construction, the block comprising: a
molded body formed of an inorganic material, wherein the molded
body defines (a) a rectangular-box shape; (b) at least two cavities
in the block; and wherein the block has nominal dimensions of
6''.times.6''.times.24''.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S.
provisional application Ser. No. 60,805,152 filed on Jun. 19,
2006.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO MICROFICHE APPENDIX
[0003] Not applicable
SUMMARY OF THE INVENTION
[0004] Standard concrete block are referred to as "concrete masonry
units" or "CMU". Insulated concrete block are sometimes referred to
as "ICMU".
[0005] However, block is not limited to cement based mixes. Block
may be derived item glass, plastic, clay, etc, therefore "block"
herein refers to all block, insulated or not, with or with out
cement.
[0006] The block incorporates engineering designs that create
non-linear thermal paths across the block, thereby extending and
increasing the thermal mass properties by offsetting and
restricting the cross webbing of the block. Details include
electrical, rebar and grout reinforcement systems, post-tension
systems, dry stacked or mortared, foam filled or not. Typically,
foam fills a majority of the interior and all of the exterior
cavities, increasing insulation values, and filling voids creating
a relatively solid unit. The system has no wood or sheetrock
requirements. As an inorganic block wall system it is not food or
fuel for mold, termites, ants, or fire. As used herein, "inorganic"
means being or composed of matter other than plant or animal. Being
solid and free of voids there are no significant spaces for air to
fuel fire, water to support mold growth, or places for insect
habitation. The block is impervious to flood water damage and as a
heavy weight system, the block, or the building, would not float.
Combined with a quality roof, storm shutters, and a generator, the
system can be used to effectively create an energy efficient,
floodable, hurricane resistant home with an option not to evacuate.
The design negates the need for abandoning and or gutting walls
after a flood.
[0007] According to one aspect of the invention, a block for
building construction is provided. The block includes: a molded
body formed of an inorganic material, wherein the molded body
defines (a) a rectangular-box shape; (b) non-linear thermal paths
of the body material across the block by offsetting and restricting
the cross webbing of the block; and (c) at least two cavities in
the block.
[0008] According to another aspect of the invention, a mold for
manufacturing a block is provided. The block comprises: a molded
body formed of an inorganic material, wherein the molded body
defines (a) a rectangular-box shape; (b) non-linear thermal paths
of the body material across the block by offsetting and restricting
the cross webbing of the block; and (c) at least two cavities in
the block. The mold comprises: (a) a mold box adapted for receiving
and molding an inorganic material on a manufacturing pallet into
the form of at least one of the block; and (b) a plunger bead
adapted for compacting and vibrating the inorganic material in the
mold box, and after the inorganic material is sufficiently set,
pushing the molded inorganic material through the bottom of the
mold box as the mold box is raised off the manufacturing pallet.
Preferably, the mold box does not have core bars across the top,
whereby the block can be molded in the mold box sideways to the
direction of normal raking across the top of the mold box without
interference by any core bars.
[0009] According to yet another aspect of the invention, a wall
system for a building construction is provided. The wall system
includes a plurality of blocks, wherein each of the blocks
comprises: a molded body formed of an inorganic material, wherein
the molded body defines (a) a rectangular-box shape; (b) non-linear
thermal paths of the body material across the block by offsetting
and restricting the cross webbing of the block; and (c) at least
two cavities in the block.
[0010] According to yet another aspect of the invention, a building
is provided wherein the building includes a plurality of walls,
wherein at least one of the walls comprises a plurality of blocks,
and wherein each of the blocks comprises: a molded body formed of
an inorganic material, wherein the molded body defines (a) a
rectangular-box shape; (b) non-linear thermal paths of the body
material across the block by offsetting and restricting the cross
webbing of the block; and (c) at least two cavities in the
block.
[0011] According to still another aspect of the invention, a block
for building
[0012] construction is provided, wherein the block includes: a
molded body formed of an inorganic material, wherein the molded
body defines (a) a rectangular-box shape; (b) at least two cavities
in the block; and wherein the block has nominal dimensions of
6''.times.6''.times.24''.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings are incorporated into and form a
part of the specification to illustrate several examples of the
present inventions. These drawings together with the description
serve to explain the principles of the inventions. The drawings are
only for illustrating preferred and alternative examples of how the
inventions can be made and used and are not to be construed as
limiting the inventions to the illustrated and described examples.
The various advantages and features of the present inventions will
be apparent from a consideration of the drawings in which:
[0014] FIG. 1 is a perspective view of a concrete block having
overall dimensions of about 6''.times.6''.times.24'' according to
the invention without any insulating foam or rebar positioned
therein;
[0015] FIG. 2 is a perspective view of a concrete block according
the FIG. 1 having insulating foam shown positioned therein;
[0016] FIG. 3 is a perspective view of a concrete block according
to FIG. 1 having both insulating foam and steel rebar shown
positioned therein;
[0017] FIG. 4 is a perspective view of a concrete block according
to FIG. 1 having insulating foam and electrical conduit shown
positioned therein, including for servicing an electrical junction
box or outlet shown positioned in a cut-out of the concrete block
face.
[0018] FIG. 5 is an end perspective view of a concrete block
similar to FIG. 1, with the addition of interior wall side and
exterior wall side surface brushes.
[0019] FIG. 6 is a plan view of a concrete block according to FIG.
5.
[0020] FIGS. 7 and 8 are perspective views of a concrete block
according to FIGS. 5 and 6, having insulating polystyrene or
polyurethane foam inserts or spray filled shown positioned
therein.
[0021] FIG. 9 is a perspective view of a concrete block according
to FIG. 5, having both insulating foam and rebar shown positioned
therein.
[0022] FIG. 10 is a perspective view of a concrete block according
to FIG. 5, having insulating foam and electrical conduit shown
positioned therein, including for servicing an electrical junction
box or outlet shown positioned in a cut-out of the concrete block
face.
[0023] FIGS. 11-13 are side, plan, and end views, respectively,
without showing any exterior finish. Where appropriate, the block
can be cut to any desired length.
[0024] FIGS. 14-16 are side, plan, and end views, respectively,
with presently most preferred dimensions of a "large" polystyrene
foam insert for a concrete block as shown in FIGS. 1-4 or 5-10, or
11-13 having nominal 6''.times.6''.times.24'' dimensions, wherein
the "large" foam insert has a nominal length of 48'' and spans
across more than one such concrete block to help insulate the
blocks. Where appropriate, the "large" foam insert can be cut to
any desired length.
[0025] FIGS. 17-19 are side, plan, and end views, respectively, of
a "small" polystyrene foam insert for a concrete block as shown in
FIGS. 1-4, or 5-10, or 11-13, wherein the "small" foam insert has a
nominal length of 48'' and spans across more than one such concrete
block to help insulate the blocks. Where appropriate, the "small"
foam insert can be cut to any desired length.
[0026] FIG. 20 is an end perspective view of a concrete block
similar to FIG. 1, except for having nominal
8''.times.8''.times.16'' dimensions.
[0027] FIG. 21 is a plan view of a concrete block according to FIG.
20 (not to the scale of the others).
[0028] FIGS. 22 and 23 are perspective views of the concrete block
according to FIGS. 20 and 21, having insulating polystyrene foam
shown positioned therein.
[0029] FIG. 24 is a perspective view of a concrete block according
to FIG. 20, having both insulating polystyrene foam and rebar shown
positioned therein.
[0030] FIG. 25 is a perspective view of a concrete block according
to FIG. 20, having insulating foam and electrical conduit shown
positioned therein, including for servicing an electrical junction
box or outlet shown positioned in a cut-out of the concrete block
face.
[0031] FIGS. 26-20 are perspective, side, top plan, end, and bottom
plan views, respectively of a concrete block according to the
invention as shown in FIG. 20 having nominal dimensions of
8''.times.8''.times.16''. Where appropriate, the block can be cut
to any desired length.
[0032] FIGS. 30-33 are perspective, side, plan, and end views,
respectively, of an "outside cell" polystyrene foam insert for a
concrete block as shown in FIG. 20 having nominal
8''.times.8''.times.16'' dimensions, wherein the "outside cell"
foam insert has a nominal length of 16,'' but it can he made to
span across more than one such concrete block to help insulate
between the adjacent heads of the blocks. Where appropriate, the
"outside cell" foam insert can be cut to any desired length.
[0033] FIGS. 33-37 are perspective, side, plan, and end views,
respectively, of an "inside cell" polystyrene foam insert for a
concrete block as shown in FIG. 20 having nominal
8''.times.8''.times.16'' dimensions, wherein the "outside cell"
foam insert has a nominal length of 16'' but it can be made to span
across more than one such concrete block to help insulate between
the adjacent heads of the blocks. Where appropriate, the "small"
foam insert can be cut to any desired length.
[0034] FIG. 38 is a perspective view, without dimensions, of the
two major parts (lower mold box and upper plunger head) of a mold
for manufacturing block according to the invention, which mold box
uses core bars to help support the mold cans for the cross-web
structures of the block, wherein the two major mold parts are shown
near one another in an aligned position as they would be used in
molding block.
[0035] FIG. 39 is a perspective view, without dimensions, of the
two major parts (lower is mold box and upper is plunger head) of a
mold for manufacturing a block according to the invention without
the need to use any core bars in the manufacturing, wherein the two
major mold parts are shown near one another in an aligned position
as they would be used in molding block. FIGS. 39a and 39b are end
and side views, respectively, of the plunger head of a mold for
manufacturing according to the invention.
[0036] FIG. 40 is a cross-sectional plan view of the mold box.
[0037] FIG. 41 is a side view of the lower part of a block wall set
on a footing,
[0038] wherein a vertical rebar is set in the foundation and can be
used to apply post-tension to the block wall system.
[0039] FIG. 42 is a side view of the upper part of a block wall,
showing how the upwardly extending rebar from the foundation on
which the wall is built (as shown in FIG. 41) can be used to apply
post-tension to the block wall system.
[0040] FIG. 43 is a perspective cut-away view of a formed-wall
system according to the invention, wherein a structural form of
two, spaced-apart structural sheets is used to pour a
concrete-based mixture around a webbing of rebar and at least one
insulating sheet therebetween to build the formed-wall system.
[0041] FIG. 44 is a perspective cut-away view of a wafer-wall
section according to the invention, wherein an outer wall layer, a
middle layer, and an inner wall layer, which can be of rebar
reinforced concrete or similar structural material, sandwich
insulating material, which can be foam, between the structural
layers. The layers of structural material and insulating material
can be simply glued together.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0042] As used herein, the words "comprise," "has," and "include"
and all grammatical variations thereof are each intended to have an
open, non-limiting meaning that does not exclude additional
elements or steps.
[0043] In general, as used herein, words describing relative
orientation or position, such as "inward," "outward," "head" or
"end," "top" and "bottom," and similar terms regarding various
elements in the views of the drawing are with respect to the
perspective of a block as it is to be normally used in the position
as shown in FIGS. 1-4, wherein an electrical outlet box would
normally be positioned as shown in FIG. 4 toward the interior side
of a wall made with the blocks. It is to be understood, of course,
that a block could be used in an upside down orientation, as in the
header for a window or door in a wall formed of the blocks.
[0044] The same reference numerals or used for similar parts in the
various embodiments of the invention and as shown in the Figures of
the drawing.
[0045] Referring first to FIGS. 1-4 of the drawing, a presently
preferred embodiment of a block is 100 is illustrated. In this
embodiment, the block has nominal dimensions of
6''.times.6''.times.24'', which may be referred to herein simply as
a "6.times.24" block.
[0046] The block 100 includes an inward rib 102, where "inward"
here means that when used to build an exterior wall for a building,
it is normally intended to face toward an interior of the building.
The inward rib 102 has an inward rib face 103 (visible in FIGS.
1-3, but not visible in the view of FIG. 1), which is similarly
normally intended to face toward an interior of a building.
[0047] The block 100 also includes an outward rib 104, where
"outward" here means that when used to build an exterior wall for a
building, it is normally intended to face toward an exterior of the
building. The outward rib 104 has an outward rib face 105, (visible
in FIGS. 1 and 4, but not in the views of FIGS. 2-3), which is
similarly normally intended to face toward an exterior of a
building.
[0048] The block 100 further includes a middle rib 106. The middle
rib 106 is located between and spaced apart from the inward rib 102
and the outward rib 104. The middle rib 106 provides additional
structure and strength to the block.
[0049] The block 100 further includes a plurality of inner
cross-webs 108 between the inward rib 102 and the middle rib 106.
Preferably, the block 100 includes two spaced-apart inner
cross-webs 108 (visible in FIG. 1, but not in FIGS. 2-4), and for
such a block, such as a 6.times.24 block, a pair of cross-webs 108
are structurally sufficient.
[0050] The block 100 further includes a plurality of outer
cross-webs 110 between the outward rib 104 and the middle rib 106.
The block 100 includes at three spaced-apart inner cross-webs 110
(at least one of which is partially visible in each of FIGS. 1-4),
and for such a block, such as a 6.times.24 block 100, three
cross-webs 110 are structurally sufficient.
[0051] The cross-webs 108 and 110 provide sufficient structure
across the block 100, but the cross-sections of the cross-webs 108
and 110 are minimized to minimize thermal pathway across the block,
as the inorganic material, e.g., concrete, has a relatively low
insulation factor to the transmission of heat energy through such
material. Furthermore, the cross-webs 108 are staggered or off-set
from the cross-webs 110 (and vice-versa, of course), whereby the
thermal pathway provided by the cross-webs 108 and 110 and the
middle rib 106 is a non-linear pathway between the inward rib 102
and the outward rib 104 of the block.
[0052] The overall structure of the ribs 102, 104, and 106 defines
the nominal dimensions of the block 100, including bounded by the
inward rib face 103, the outward rib face 105, the heads 111
(defined by ends of ribs 102, 104, and 106), the top 113 defined by
the tons of the ribs 102, 104, and 106), and the bottom 115
(defined by the bottoms of ribs 102, 104, and 106).
[0053] Continuing to refer to FIGS. 1-4, the inward rib 102 and
middle rib 106 and the cross-webs 108 define an inward cavity 117.
The outward rib 104 and middle rib 106 and the cross-webs 110
define an outward cavity 119. Preferably, both the inward cavity
117 and the outward cavity 119 are completely open along the entire
length of the top 113 of the block 100, and both the inward cavity
117 and the outward cavity 119 have open portions along the bottom
115 of the block. In addition, preferably both the inward cavity
117 and the outward cavity 119 are at least partially open at
either end or header 111 of the block 100.
[0054] Preferably, the inward cavity 117 is substantially larger
than the outward cavity 119. As partially shown in FIGS. 2-4, the
cavities 117 and 119 are adapted to accept insulating material 200,
such as in the form of foam inserts 202 and 204 adapted for the
cavities 117 and 119, respectively. The insulating material 200 in
the form of foam inserts 202 and 204 may be inserted into the
cavities 117 and 119 as courses of a wall formed of a plurality of
the blocks 100 are laid. The large openings to the cavities 117 and
119, respectively, especially at the ends or headers 111 of the
block 100, allows for placement of insulating foam inserts filling
spanning the headers of adjacent blocks placed in courses forming a
wall, which provides for better thermal insulation.
[0055] Alternatively, for example, and as will be appreciated by
those of skill in the art, flowable beads or small pellets (not
shown) of insulating material 200 can be blown downward from an
upper course of a wall downward into the cavities 117 and 119 of
stacked block 100 after a wall is constructed with a plurality of
blocks 100, where the adjacent cavities 117 and 119 allow for
downward flowing of such a flowable insulation material 200 to fill
the cavities of lower blocks first, filling up the wall with
insulation.
[0056] According to one embodiment of the invention, a foam insert
202 would be used for the inward cavities 117 of block after being
placed into courses for a wall, whereas a flowable insulating
material would he used for filling the outward cavities 119 of
adjacent blocks from the top of a wall of the blocks 100.
[0057] Further, the inward cavity 117 is preferably made to be
wider across than the outward cavity 119, whereby the inward cavity
can accept not only insulating material, but also rebar 300 (as
shown in FIG. 3) and electrical conduit 402 and junction box or
outlet 404 (as shown in FIG. 4).
[0058] The inward cavity 117 is adapted to be sufficiently wide
between the inward rib 102 and the middle rib 106 across to
substantially accept electrical items, such as electrical conduit
402 and a standard-sized electrical junction box 404. Typically, an
electrical junction or outlet box 404 has a ground screw 406 (not
shown in FIGS. 1-4) projecting through the back of the junction or
outlet box 404. A cut-out in the inward rib 102 can be made in a
block 100 as desired during building of a wall with the blocks 100.
If desired, a cut-out can be pre-formed during manufacture of the
block, as in many applications for the blocks 100 an interior
surface material is expect to be applied over the inward wall face
103, which would cover such unused wall access cut-outs.
[0059] Continuing to refer to FIGS. 1-4, the block 100 preferably
includes vertical mortar grooves 150 in the ends of the inward rib
102 and the outward rib 104, whereby mortar can be placed between
adjacent blocks 100 in a course of blocks. As shown in the figures,
these mortar grooves 150 preferably have a rectangular shape, for
added strength.
[0060] FIGS. 5-10 are various views of a concrete block 100a
similar to the block 100 shown in to FIGS. 1-4, with the addition
of a vertical sealant groove 160 (preferably V-shaped) in middle
rib 104 of the ends or head for helping in the placement of
insulating foam or weather stripping. The vertical sealant groove
160 can be only one of either end of the block or in both the ends
or heads of the block. In addition, the concrete block 100a
includes an interior wall side surface finish 170, which can be of
any desired texture or color, preferably appropriate for indoor
purposes, and similarly an exterior wall side surface finish 172,
which can be of any desired texture or color, preferably
appropriate for outdoor purposes. FIGS. 7-10 show the inclusion of
foam inserts 202 and 204. FIG. 9 shows the positioning of rebar 300
in the block 100a, and FIG. 10 shows the positioning of conduit 402
and an electrical junction box or outlet 404 in a cut-out 180 made
in the inward rib 102.
[0061] FIGS. 11-13 are side, plan, and end views, respectively, of
the block 100b similar to the block shown in FIGS. 5-6 having
nominal 6''.times.6''.times.24'' dimensions, but with a V-shaped
sealant groove 160 in only one end of the block 100b, a horizontal
sealant groove 102 (preferably V-shaped) in top of the block 100b
for foam/weather stripping/sealant, and without showing any
interior or exterior surface finishes. Where appropriate, the block
can be cut to any desired length. As best shown in FIGS. 11-13, the
block 100b preferably also includes an electrical box guide groove
for a ground screw that may protrude from the back side of a
typical electrical junction or outlet box 404 (not shown in FIGS.
11-13).
[0062] FIGS. 14-16 are side, plan, and end views, respectively, of
a "large" polystyrene foam insert 202 for a concrete block 100,
100a, or 100b as shown in FIGS. 1-4, or 5-10, or 11-13,
respectively, having nominal, 6''.times.6''.times.24'' dimensions,
wherein the "large" foam insert has a nominal length of 48'' and
spans across more than one such concrete block to help insulate the
blocks. Where appropriate, the "large" foam insert can be cut to
any desired length. The insert 202 has leg portions that fill the
cavity 117 adjacent or between the cross-webs 108 of block 100,
100a, or 100b.
[0063] FIGS. 17-19 are side, plan, and end views, respectively, of
a "small" polystyrene foam insert 204 for a concrete block 100,
100a, or 100b as shown in FIGS. 1-4, or 5-10, or 11-13,
respectively, having nominal 6''.times.6''.times.24'' dimensions,
wherein the "small" foam insert has a nominal length of 48'' and
spans across more than one such concrete block to help insulate the
blocks. Where appropriate, the "small" foam insert can be cut to
any desired length. The insert 204 has leg portions that fill the
cavity 119 adjacent or between the cross-webs 110 of block 100,
100a, or 100b.
[0064] FIGS. 1-4 or 5-10 or 11-13 or show variations of block 100,
100a, and 100b, respectively, having nominal
6''.times.6''.times.24'' dimensions, wherein the "small" foam
insert has a nominal length of 48'' and spans across more than one
such concrete block to help insulate the blocks. Where appropriate,
the "small" foam insert can be cut to any desired length.
[0065] FIGS. 20-25 are various views of a concrete block 500
similar to the block 100 previously described and shown in FIGS.
5-10, and with similar elements with the same reference numerals,
except for having nominal 8''.times.8''.times.16'' dimensions, with
appropriate dimensions of the foam inserts 202a and 204a to
accommodate the dimensional differences in the block 500. As the
block 500 is substantially shorter than the
6''.times.6''.times.24'' blocks 100, 100a, and 100b, only two
cross-webs 110 can be employed in this embodiment.
[0066] FIGS. 26-29 are perspective, side, top plan, end, and bottom
plan views, respectively of a concrete block 500 according to the
invention as previously described and shown in FIGS. 20-25 having
nominal dimensions of 8''.times.8''.times.16''. Where appropriate,
the block 500 can be cut to any desired length.
[0067] FIGS. 30-33 are perspective, side, plan, and end views,
respectively, of an "outside cell" or "smaller" polystyrene foam
insert 204a for a concrete block 500 as shown in FIG. 20 having
nominal 8''.times.8''.times.16'' dimensions, wherein the "outside
cell" foam insert 204a has a nominal length of 16'', but the insert
204a can be made to span across more than one such concrete block
to help insulate between the adjacent heads of the blocks when
placed in courses to build a wall. Where appropriate, the "outside
cell" foam insert 204a can be cut to any desired length.
[0068] FIGS. 33-37 are perspective, side, plan, and end views,
respectively, of an "inside cell" or "larger" polystyrene foam
insert 202a for a concrete block 500 as shown in FIG. 20 having
nominal 8''.times.8''.times.16'' dimensions, wherein the "outside
cell" foam insert 202a has a nominal length of 16'', but the insert
202a can be made to span across more than one such concrete block
to help insulate between the adjacent heads of the blocks when
placed in courses to build a wall. Where appropriate, the "inside
cell" foam insert 202a can be cut to any desired length.
[0069] The Insulated Concrete Masonry Units ("ICMU") and the
resulting Insulated Reinforced Masonry Wall System ("IRMWS")
consists of expanded polystyrene inserts or spray foam designed for
use with the hollow mortared concrete masonry units that comply as
Grade N units under Uniform Building Code ("UBC") Standard 21-4.
The mortared masonry units are manufactured by concrete block
manufacturers.
[0070] One or two curtains of foam inserts are installed in each
masonry unit in the field. The ICB foam inserts are expanded, from
polystyrene beads, to a density of 1.0 to 2.0 pcf (16 to 32 kg/m3).
The inserts have a maximum flame-spread rating of 25 and a
smoke-developed rating of less than 450. The inserts comply with
ASTM C 578 as Type I. See the description of the figures and the
figures for additional details of the ICMU foam inserts.
[0071] Simply stated, the new block is very strong. The strength
and durability combination of concrete and steel is unmatched in
the construction industry today. All concrete systems are
engineered to meet local code requirements and can be made stronger
by adding more Portland cement to the concrete mix and/or adding
more steel into the system. The difference is always economics.
[0072] In general, the block shares the same process, materials,
volumes, and testing used to produce a standard C-90 spec block.
But more specifically, the block according to the invention has 12%
more mass and 4% greater compression surface area than the standard
C-90 spec block, thereby achieving greater strength. At nearly 60
sq. inches using 3,000 psi concrete the block will test at loads in
excess of 180,000 pounds, or 90 tons of compression per block.
[0073] Today's coastal environments are also concerned with wind or
horizontal loads. Shear loads in earthquake zones. And of course
impact resistance due to flying debris.
[0074] As a wall system, the block is reinforced with steel rebar.
It is the steel rebar that does a majority of the work. I have been
told more than once, by engineers and architects both, that you
could jack hammer away the block and the remaining steel and
surrounding grout grid would still easily support standard roof and
shear loads. Typical engineered placement of 1/2 inch rebar every 4
foot with-in the wall, both horizontally and vertically, produces a
140 mph wall. Increasing size and/or frequency can easily produce a
250 plus mph wall, again, economics. For example: 5/8 inch rebar
every 24 inches. A Dallas prison spec requires 3/4 inch rebar every
8 inches. This would be easily done within the block wall according
to the invention without cutting. Of course, with every interior
cell filled with rebar and grout "R" performance would drop,
however, maximum strength and security can be achieved.
[0075] A non-linear thermal path is created by the onset and
restricted pathways, combined with the "thermal mass" of the block
itself effect the thermal flywheel and the Adobe principles that
heat will not travel from one side of the wall to the other in a
twelve hour day, the sun goes down, the air cools down, and the
collected heat is released back out into the night and the passive
energy efficient solar cycle begins again.
[0076] The aggressive pursuit to design and build not only a
survivable but sustaining exterior building envelope for hurricanes
began with concrete and steel, incorporates current technology and
theory and is combined with new leading edge design features to
create a floodable, hurricane resistant, safer home, and more cost
effective home.
[0077] The thermal blocks are designed for insulation inserts or
spray foam tilled on-site, and can be pre-insulated at the factory.
The design preferably includes factory pre-finishes. So the block
could be delivered pre-insulated and pre-insulated to the job site,
this intern would reduce sub-contractors and labor costs.
Pre-insulated foam will also be pre-cored to create a handle for
the block, electrical wires, electrical boxes, plumbing, rebar
reinforcement, and post-tension systems.
[0078] The block may also incorporate an insulation bed of
expanding foam, or weather stripping foam vertical sealant groove
160 just prior to setting the block. Vertical sealant grooves 160
in the middle rib of the head provide support for foam or weather
stripping. This provides an additional thermal break for the
system, and an air and water infiltration barrier. Preferably, the
block 100b includes such a vertical sealant groove 160 in the
middle rib 106 of one end or head of the block. Preferably, such a
vertical groove is V-shaped.
[0079] Referring briefly ahead to the plunger head 650 of the mold
600 shown in FIGS. 39a and 39b, a horizontal sealant groove 162 is
formed in the top of the block 100b to provide a groove for a
sealant, such as a bead of caulk or weather stripping, to be placed
between the heads of block in courses of the block 100b. This
provides additional thermal break for the wall system, and an air
and water infiltration barrier. Preferably, the sealant groove is
formed in the top of a middle rib of the block as shown in FIGS.
39a and 39b. Preferably, the sealant groove 162 is V-shaped.
[0080] A groove is formed in the middle rib to provide clearance
for the electrical ground screw in the back side of an electrical
outlet box, which can be installed as shown m FIG. 4. This
ground-screw clearance groove also advantageously marks the middle,
or center, of the block for accurate quick cutting of the block in
half.
Installation
[0081] The mortared masonry units are installed hi a running-bond
or stack-bond pattern. Grout must have a 28-day minimum compressive
strength of 2,000 psi (13.8 MPa). Wall construction should also
comply with Section 2104 of the 1997 Uniform Building Code (UBC).
Construction quality should comply with Section 2105 of the UBC.
Anchor bolts and wall anchors should be embedded in fully grouted
bond beams without the foam plastic inserts.
Design
[0082] Structures are preferably designed as reinforced masonry in
accordance with Sections 2105, 2106, 2107 and 2108, inclusive, of
the UBC, with the following provisions:
[0083] Specified compressive strength, f m, used in design must be
between 1,500 psi and 2,000 psi (10.3 MPa and 13.8 MPa).
[0084] Specified compressive strength, f m, must be verified by
prism tests
[0085] described in Section 2105.3.2 of the UBC.
[0086] Lintel beam design width must be the block width minus the
loam plastic insert thickness, if used.
[0087] Notations used in this evaluation are set forth in Section
2101.4 of the UBC.
[0088] Allowable Stress Design Method:
[0089] The maximum tensile stress in deformed bars is 20,000 psi
(138 MPa).
[0090] The nominal block width may be used as the value "t" in the
allowable axial stress (Fu) equations.
[0091] Determine allowable axial stress in reinforced walls.
[0092] Strength Design Method:
[0093] Determine design axial load.
[0094] Determine design moment.
[0095] Steel reinforcement must be centered in the grouted
section.
[0096] Allowable in-plane shear stress of reinforced walls must be
based on the reinforcing steel resisting all shear.
[0097] Anchor bolts are designed and installed in accordance with
Section 1701.5.7 of the UBC.
Four-Hour Fire-Resistive Wall Assembly
[0098] The four-hour fire-resistive wall assembly (of a
light-weight material) consists of walls constructed in running
bond. Horizontal bond grouted beams are required at the top and
bottom of the walls and intervals, as required by the code, or 32
inches (813 mm) on center, whichever is less. Vertical cells must
be grouted at intervals as required by the code or 48 inches (1219
mm) on center, whichever is less. Both inner and outer cells are
grouted and reinforced as required by the code, but with no less
than No. 4 deformed steel reinforcement complying with the code.
Grouted inner and outer walls must occur in the same course, or
staggered one course. Foam inserts occur in all ungrouted cells.
The surface-bonding cement must be applied to a minimum 1/4-inch
(6.4 mm) thickness. The axial load on the wall is determined in
accordance with the code, not to exceed an allowable stress design
service load of 5,370 plf (78.4 kN/m).
Special Inspection
[0099] Special inspection is required in accordance with Section
1701.5.7 of the UBC for installations located in Seismic Zones 3
and 4. Unless design stresses are reduced in accordance with
Section 2107.1.2 of the UBC, special inspection is also required
for installations located in Seismic Zones 1 and 2.
[0100] The special inspector is responsible for verifying
compliance of materials, plans and specifications, mortar
preparation and use, masonry unit placement, anchor placement,
reinforcement placement, grout preparation and use, preparation and
handling of prisms, and mortar and grout test sample
preparation.
[0101] Verification must be submitted to the building official that
the masonry units comply as Grade N units in accordance with UBC
Standard 21-4.
[0102] For each project, plans and calculations demonstrating
compliance with the code are submitted to the building official for
approval.
[0103] Design and construction complies with the manufacturer's
instructions. A copy of the manufacturer's instructions and ASTM C
946 must be submitted to the building official for each
protect.
[0104] Special inspection is provided.
[0105] Foam inserts are manufactured under a quality control
program with inspections by Underwriters Laboratories Inc.
(AA-668).
[0106] The block foam inserts are installed at the jobsite in
accordance with the manufacturer's instructions and approved
plans.
[0107] Walls are four-hour fire-resistive assemblies when
constructed in accordance with the building specifications for the
block. Walls are noncombustible when the foam inserts are covered
by at least 1 inch (25.4 mm) of masonry at all points.
Non-Concrete Block
[0108] The thermal block with a non-linear thermal path design is
not limited to being made of a concrete mixture alone. Other
structural suitable structural material can be used. Today, as
always, there are new technologies creating new materials. The
constant demand for efficient, renewable, and recyclable materials
is ever growing. Currently the block can be manufactured from
glass, or an enzyme and clay mixture can be used. The block can be
used as an end fill application with no structural properties.
There are also injectables, such as expanding foam based composite
materials.
Mold For Manufacturing Block
[0109] The vast majority of block today are produced on only two
brands of equipment, Columbia and Besser. The standard "3 out"
machines use a steel pallet size of 26''.times.18''. The front of
the pallet as it comes out of the machine in a forward motion is
the 26'' inch side while the depth of the machine and the pallet is
18''. Three 8''.times.8''.times.16'' conventional concrete blocks
are produced side by side at one time with the head of the blocks,
the three 8''.times.8'' dimensions, coming out first with the 16''
inch dimensions trailing front to back. Core bars suspend core cans
front to back in the mold box, where the core cans define the mold
for the cavities of the block. After the concrete material is added
to the mold box, a rake bar that is slotted to not interfere with
the core bars then moves front to back to evenly distribute and
proportion the concrete material within the mold box. Next, the
plunger head is lowered and vibrated to compact the concrete
material in the mold box. Next, the mold box is lifted and the
plunger head pushed or extracts the block onto the pallet around
these core bars, however, the presence of the core bars creates
slight visual and structural imperfections on the tops of all the
blocks being formed in the mold because the pressing of the plunger
head cannot be applied where the core bars lie in the field of the
mold box.
[0110] A mold 600 adapted for manufacturing the
8''.times.8''.times.16'' block 500 is shown in FIG. 38. The mold
600 has the two major parts, a mold box 610 and a plunger head 650.
The two major mold parts, the mold box 610 and the plunger head 650
are shown near one another in an aligned position as they would be
used in molding block. Usually three of the block 500 in one mold
box can fit on a typical pallet in a block molding machine (not
shown).
[0111] The mold box 610 has a pair of side walls 612a and a pair of
end walls 612b forming a rectangular body that is open at the
bottom for molding one or more block 500. A pair of handles 614 is
attached to the side walls 612a, whereby the sides of the mold box
610 can be attached to the rest of the molding machine (not shown).
The core bars 616 help support the mold cores 618 within the mold
box 610 for defining the cavities 117 and 119 of the block 500. The
core bars are aligned with the side walls 612a.
[0112] The mold box 610 is lowered by the handles 614 onto a pallet
in a block manufacturing machine (not shown) and a cement-based
mixture is poured into the mold. A rake (not shown) of the molding
machine moving parallel to the side walls 612a scrapes off any
excess of the cement based-mixture of which the block 500 is to be
made from above the tops of the side walls 612a and end walls 612b
of the box 610.
[0113] The plunger head 650 has a plunger head adapter plate 651,
which can be used to connect the plunger head 650 to various types
of typical block manufacturing machines (not shown). The plunger
head 650 supports at least one press plate, and usually a plurality
of press plates 652. As will be appreciated by those of skill in
the art, the press plates 652 of the plunger head 650 compacts the
cement-based mixture and forms the shape of the block in the mold
that is oriented upward during molding.
[0114] Referring now to FIG. 38, a mold 600a adapted for
manufacturing the 6''.times.6''.times.24'' block 100b. The mold
600a has the two major parts, a mold box 610a and a plunger head
650a. The two major mold parts, the mold box 610a and the plunger
head 650a are shown near one another in an aligned position as they
would be used in molding block. One of the innovations is that by
orienting the forms inside the box 610a sideways to the
conventional orientation, and avoiding the use of core bars, three
such larger block 100a can be manufactured simultaneously, i.e.,
"3-out." Usually three of the block 100b in one mold box can fit on
a typical pallet in a block molding machine (not shown). As best
shown in FIG. 40, dividers 620 separate the forms for molding three
of the block 100b.
[0115] FIGS. 39a and 39b are end and side views, respectively, of
the plunger head 650a of the mold 600a for manufacturing block 100a
according to the invention. As shown in FIGS. 39a and 39b, the
sealant groove 162 to be formed in the top of the middle rib 106 of
the block 100b can be formed with the downwardly oriented V-shaped
sealant groove forming ridge 654.
[0116] As shown in FIGS. 39-40, the sideways producing a mold box
without corebars is unique. This mold box is specifically designed
to produce insulated concrete masonry units (ICMU'S) sideways with
no core bars. This allows for greater compaction, added block
length, and a seamless, zero-flaw, block that is stronger and more
stable.
[0117] The new 6''.times.24'' mold according to the present
invention is unique in two ways. In order for the 24 inch long
block to be produced on an 18 inch deep pallet, the block is set
sideways, parallel to the front 26 inch side of the pallet. This
complicates the standard core bar configuration because the core
bars cannot be placed sideways. The primary reason is due to fact
that the rake bar only travels front to back and requires the core
bar to be parallel with the action of the rake bar, seen that
having perpendicular core bars would interfere and prevent the rake
from raking. Secondly, if the core bars were placed in parallel to
the rake bar multiple visual and structural imperfections would be
placed on both, interior and exterior, surfaces of the block. The
second unique factor is allowed for by the design of the block
according to the invention itself. Due to the restricted cross
webbing, the voids or cavities are continuous form one head of the
block to the other bead. This allows the core cans to be welded
together and then welded to parallel inside walls of the mold box
itself, thereby eliminating the need for suspending the cans by the
use of core bars on top of the mold box. So now, a mold box can
produce block according to the invention in a direction
perpendicular to the direction of standard block production on a
pallet with no core bars to interfere with the rake or producing
defects in the blocks themselves. The result is a stronger more
perfect block.
Post-Tension CMU Wall System
[0118] As shown in FIGS. 41-42, the post-tension CMU wall system
700 includes a series of concrete anchors, tension rods and top
wall plates that will increase transverse wind loads. The system
700 includes post-tension roof tie downs tensioning the roof
trusses to the tension rods themselves that are anchored to the
footers directly.
[0119] FIG. 41 is a side view of the lower part of a block wall
702, preferably made of block according to the invention,
especially block 100b, and set on a footing 710. The footing 710 is
preferably reinforced with rebar 712. A vertical top-threaded
tension rod 714 is attached with a bottom-end "crab claw" 715 to
the foundation 710 with a bell-end J-bolt anchor 716.
[0120] FIG. 42 is a side view of the upper part of a block wall 702
made of courses of block 100b. The upwardly extending top-threaded
tension rod 714 from the foundation on which the wall is built (as
shown in FIG. 41) can be used to apply post-tension to the block
wall 702. Preferably, a top plate 720 is positioned on top of the
block wall 702. The post-tension is applied with a leaf spring 722,
nut 724, and turnbuckle 720. The turnbuckles 726 used in the system
are connected to a tie-down cable 730 placed over the tops of the
rafters 732.
[0121] The Exterior Building Envelope
[0122] Combined with architectural design the Floodable,
Post-tension, CMU and insulated, ICMU construction would have a
front line, ocean side rating in excess of 250 mph wind loads
effectively saving your single largest cash asset, your home and
quite possibly your life and the lives of your family.
Benefits of New Insulated Block and a Wall Built With the Block
[0123] Energy Efficiency
[0124] According to the invention, an 8 inch insulated concrete
block having polystyrene foam inserts is provided to achieve high
performance "R" value rating in the range of 24. The six inch block
"R" rating is 20, and the 12 inch block "R" 38. Such high "R"
values, together with the nature of thermal mass reduces heating
and cooling energy costs by 40 to 70%. The block is energy
efficient due to non-linear thermal pathways and expanded
polystyrene foam inserts that are highly resistant to heat flow.
The higher mass of this wall system stores a large amount of heat
that is slowly released facilitating moderate indoor temperature
changes. The thermal mass maintains a constant and consistent
temperature throughout the entire home. These homes are naturally
warm in winter and cool in summer. These solid walls also
effectively seal out uncomfortable drafts. The economic result is
lower monthly operating expense of 40 to 70%.
[0125] Hurricane Resistant Wall
[0126] When reinforced with fiber, steel rebar, and grout, the
insulated concrete block becomes a wall system engineered to resist
or withstand hurricanes, tornadoes, earthquakes and wind loads in
excess of 140 miles per hour. Flying debris during hurricanes and
tornadoes cause most of the structural damage to buildings. A wall
built with the insulated concrete block according to the invention
is capable of resisting damage from flying debris and with no
structural damage where a conventional wall system would be easily
perforated by such flying debris.
[0127] Capable of Below Grade Installation
[0128] The insulated concrete block can be installed in a wall
built below grade.
[0129] Sound Resistant Wall
[0130] A wall made of the 8 inch insulated concrete block according
to the invention is nearly sound proof (STC-61).
[0131] Mold, Mildew, and Moisture Resistant
[0132] A wall made with the insulated concrete blocks according to
the invention is highly resistant to mold, mildew, and moisture
penetration. This is due to the fact that the wall is essentially
inorganic and is a waterproof one piece monolithic wall from the
footings to the roof with no ground seams or corner seams.
[0133] Insect Resistance
[0134] The Block is not a food for mold, termites or carpenter ants
that commonly damage or destroy homes. A wall formed with the block
is also insect resistant due to the fact that it is essentially
solid waterproof one piece monolithic wall from the footings to the
roof with no ground seams or corner seams.
[0135] Hypo Allergenic
[0136] The block is also hypo allergenic and exceeds all government
"GREEN" standards. The block is hypoallergenic and "Green" by
having no VOC's (volatile organic compounds) and no dust.
[0137] Durability
[0138] Concrete, rebar, and polystyrene foam are non-deteriorating
materials. The block is used as part of a very strong inorganic
reinforced concrete block system that resists rot and decay. The
surface bond or "skin" of the system is a combination of
concentrated cement, silica sand, reinforced fiberglass, lime and
calcium stearate that greatly assist in making the entire wall
system highly resistant to extreme weather, hot or cold, wet or
dry, storm damage, wind blown debris, driving rain, flooding, UV
rays, cracking, fading, peeling or blistering and insect
penetration.
[0139] Fire Resistance
[0140] The block and a wall build with the blocks are capable of
being fare tested under ASTM guidelines to achieve the building
industries' highest fire rating.
[0141] Security
[0142] The insulated concrete block builds a wall that is resistant
to burglary and offers greater overall security. Many homes today
are burglarized by simply cutting a large hole in an exterior wall,
by passing the alarm system for access. Thermal block makes this
far more difficult.
[0143] Traditional Design Finishes
[0144] The block can be in the traditional design look (exterior
finish incorporating the molded look of stucco) or manufactured in
a number of polished or textured finishes. Any design may be used
incorporating the institutive core material.
[0145] Various Sizes
[0146] The block can be manufactured in various sizes. The blocks
are preferably of standard dimensions and easy to install.
Currently the blocks are 8''.times.8''.times.16'',
8''.times.12''.times.16'', and 6''.times.6''.times.24''.
[0147] Economical Building Cost
[0148] The cost of a fully installed end-to-end wall system is
lower than quality conventional construction systems. The wall
system requires fewer subcontractors and therefore reduces
complexity. The infrastructure for this "new system" is already in
place because the improved block is compatible with conventional
concrete block manufacturing facilities and the trained experienced
installation labor force exists in the form of masons. All of the
many benefits of the improved insulated concrete block and building
system come at a lower cost compared to a conventionally built
home.
[0149] The block cuts cost across the board, from planning ail the
way through to ownership for generations.
[0150] Planning costs are less. The block is a complete wall
system. It is the interior, middle, and exterior wall detail in
one. Pre construction costs are less. Fewer materials on the job
for an exterior one wall system. Self stores outside in bad weather
for years. At 26 to 30 lbs apiece, the block is heavy to steal and
not easily damaged.
[0151] Construction costs are less. For example, a 6''.times.24''
face block is a full square foot of wall coverage. Unlike its
cousin, the 8''.times.16 '' face block, equals only 89% of a square
foot. For example, a 10,000 8.times.16 block wall would spec only
8,900 blocks, 1,100 less blocks to purchase, and 1,100 less blocks
to set. The block takes up less square floor footage. The
6.times.6.times.24 is two inches thinner, finished, and insulated
at the 6 inch depth. The 8.times.8.times.16 is 8 inches thick plus
a finish and an insulation application can expand the depth to 12
or more inches. The pre-finished block will save 30% over a stucco
finish. A true "R"-20, high mass wall will reduce ac tonnage by
20%. A one sub system reduces labor and scheduling miscues, and
time is money. Clear span engineered roof trusses can be installed
immediately after the exterior walls set, greatly reducing exposure
and quickly bringing the building into the "dry" for security and
all interior work.
[0152] Post construction costs are less. Block building can be
designed with little or no cuts making for very little on-site
clean-up. Block is inorganic and is a stable on-site fill material.
The pre-finished block needs no on-site finishes or there
messes.
[0153] Economical to Maintain
[0154] Additionally, lower costs for maintenance and for pest and
termite control will produce maintenance savings compared to a
conventionally built home.
[0155] Economical to Insure
[0156] The block is capable of achieving the building industry's
highest fire insurance safety rating. Current savings are 2% on
insurance for extreme fire ratings with the potential of a 60%
savings for 900+ insurance rating.
[0157] Ownership Annual Costs and Risk Are Reduced
[0158] The total economic construct model of an efficient,
affordable, energy efficient, storm resistant, floodable, fire
proof, mold proof, sound proof, enclosure implicates profound
savings. And not just in cash, and not just for the homeowner, but
also the financier, the insurance companies, and perhaps even the
town itself.
Alternative Embodiments
[0159] Basically there are four forms of concrete: Block ("CMU"),
precast, liquid, and sheet goods, half inch thick by 4.times.8
foot. The block system is as described above form system uses a
liquid cement-based mixture, and the "wafer" system uses sheet
goods.
[0160] A representative formed-wall system 800 is shown in the
cut-away view of FIG. 43. The formed-wall system 800 is made by
positioning a structural form made of structural sheets, such a
first structural sheet 810 and a second structural sheet 820, which
are spaced apart several inches, for example, about 8''. The first
and second structural sheets 810 and 820 can be of any convenient
structural sheet material, such as plywood or pressed wood.
[0161] A webbing of rebar 830 is positioned between the first and
second sheets 810 and 820 and spaced apart from both.
[0162] At least one insulating sheet 840, such as of a polystyrene
foam, is positioned between the first and second sheet materials
810 and 820. Preferably, an insulating sheet 840 is placed on
either side of the webbing of rebar 830 and between the first and
second structural sheets 810 and 820. The insulating sheet
preferably has a plurality of openings or boles 842, which may be
of any desired shape, to allow limited fluid communication across
the insulating sheet 840.
[0163] A flowable, cement-based mixture is poured between the first
and second structural sheet materials 810 and 820, which fills up
the void spaces between the structural sheets 810 and 820, flows
through the plurality of holes 842 in the insulating sheet 840, and
around the webbing of rebar 830. (The cement-based mixture is shown
only partially filling the voids between the structural sheets 810
and 820.) The cement-based mixture 850 is allowed to set as it is
contained between the structural sheets 810 and 820. The holes 842
should he relatively sufficient to provide the desired structural
rigidity and strength, to the formed wall system 800. However, the
number and size of the holes 842 is preferably minimized to
maintain most of the thermal insulating value of the insulating
sheet 840 relative to the lower insulating value of the
cement-based material, to restrict and limit the thermal paths
across the wall system 800.
[0164] After the cement-based material 850 has set in the form, the
structural sheets 810 and 820 can be optionally removed.
Wafer System
[0165] The wafer-wall system 900 is a multi-layered structural
insulated panel ("SIP" panel). With a minimum of three layers, two
exterior and one middle interior, reinforced concrete sheets 910
sandwich rigid foam insulation sheet 920 in a 4.times.8 foot sheet
as shown in FIG. 44.
Liquid Concrete Formed Wafer
[0166] The liquid concrete form is a break-away form wall system.
The entire wall, including footers is pre-formed with electrical
conduit, steel rebar and a minimum double curtain foam layers with
off set foam cross connecting webbing, creating a non-linear
thermal path thereby dramatically extending and restricting the
thermal path of the poured concrete wall.
[0167] After careful consideration of the specific and exemplary
embodiments of
[0168] the inventions described herein, a person of ordinary skill
in the art will appreciate that certain modifications,
substitutions and other changes can be made without substantially
deviating from the principles of the inventions. The detailed
description is illustrative, the spirit and scope of the inventions
being limited only by the appended claims.
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