U.S. patent application number 13/307704 was filed with the patent office on 2012-04-19 for prefabricated compound masonry units.
This patent application is currently assigned to CONSTRUCTIVE, L.L.C.. Invention is credited to Jim Gendron, Dave Muirhead.
Application Number | 20120090260 13/307704 |
Document ID | / |
Family ID | 45932863 |
Filed Date | 2012-04-19 |
United States Patent
Application |
20120090260 |
Kind Code |
A1 |
Muirhead; Dave ; et
al. |
April 19, 2012 |
PREFABRICATED COMPOUND MASONRY UNITS
Abstract
Disclosed herein are embodiments of prefabricated compound
masonry units and methods of producing the same. One embodiment of
a prefabricated compound masonry unit comprises at least one course
comprising a plurality of blocks mortared to form a layer, the at
least one course having a top surface and a bottom surface each
having a first side and a second side. Longitudinal tension
reinforcement is provided along at least a portion of a length of
the at least one course and held with bonding material.
Inventors: |
Muirhead; Dave; (Milford,
MI) ; Gendron; Jim; (Westland, MI) |
Assignee: |
CONSTRUCTIVE, L.L.C.
Ferndale
MI
|
Family ID: |
45932863 |
Appl. No.: |
13/307704 |
Filed: |
November 30, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13274502 |
Oct 17, 2011 |
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13307704 |
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61439863 |
Feb 5, 2011 |
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61393599 |
Oct 15, 2010 |
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Current U.S.
Class: |
52/585.1 ;
52/745.19 |
Current CPC
Class: |
E04B 2/20 20130101 |
Class at
Publication: |
52/585.1 ;
52/745.19 |
International
Class: |
E04B 2/48 20060101
E04B002/48; E04B 2/00 20060101 E04B002/00 |
Claims
1. A prefabricated compound masonry unit comprising: at least one
course comprising a plurality of blocks mortared to form a layer,
the at least one course having a top surface and a bottom surface
each having a first side and a second side; and longitudinal
tension reinforcement provided along at least a portion of a length
of the at least one course and held with bonding material.
2. The prefabricated compound masonry unit of claim 1, wherein the
longitudinal tension reinforcement extends along at least a portion
of both the first side and the second side of one or both of the
bottom surface and top surface of the at least one course and held
with bonding material.
3. The prefabricated compound masonry unit of claim 1, wherein the
at least one course is two courses having a lower course and an
upper course with the longitudinal tension reinforcement placed in
the bonding material along both the first side and the second side
of the top surface of the lower course with a bottom surface of the
upper course placed directly on the bonding material and aligned
with the lower course.
4. The prefabricated compound masonry unit of claim 1, wherein the
longitudinal tension reinforcement extends along substantially an
entire length of the at least one course.
5. The prefabricated compound masonry unit of claim 1, wherein each
of the first side and second side of at least one of the top
surface and bottom surface has a channel formed therein, with the
longitudinal tension reinforcement retained within each channel
with the bonding material.
6. The prefabricated compound masonry unit of claim 5, wherein the
longitudinal tension reinforcement is fiber reinforced polymer.
7. The prefabricated compound masonry unit of claim 6, wherein the
bonding material is one of epoxy and high strength mortar.
8. The prefabricated compound masonry unit of claim 5, wherein the
at least one course is a plurality of courses having a lowermost
course and an uppermost course with the first side and the second
side of at least one of the top surface and bottom surface of each
of the lowermost course and the uppermost course having the channel
formed therein, with the longitudinal tension reinforcement
retained within each channel with the bonding material.
9. The prefabricated compound masonry unit of claim 1, wherein the
at least one course has a corner and the longitudinal tension
reinforcement extends across the corner on one or both of the top
surface and the bottom surface of the at least one course.
10. The prefabricated compound masonry unit of claim 1, wherein the
at least one course is a plurality of courses having a lowermost
course and an uppermost course and further comprising: at least one
post-tensioning rod having a rod extending between a top surface of
the uppermost course and a bottom surface of the lowermost course
and attached to a plate at each end.
11. The prefabricated compound masonry unit of claim 1, wherein the
at least one course has a joint between adjacent blocks with the
longitudinal tension reinforcement provided along at least a
portion of a length spanning each joint of both the first side and
the second side of one or both of the bottom surface and top
surface of the at least one course.
12. The prefabricated compound masonry unit of claim 11, wherein
the longitudinal tension reinforcement is fiber reinforced polymer
in dowel or biscuit form.
13. The prefabricated compound masonry unit of claim 1, wherein the
at least one course has a bed extending along a length of the
course, the bed positioned between external walls of the at least
one course, with the longitudinal tension reinforcement extending
along at least a portion of the length of the bed and retained in
the bed with the bonding material.
14. The prefabricated compound masonry unit of claim 11, wherein
the at least one course has a bed extending along a length of the
course, the bed positioned between external walls of the at least
one course, with the longitudinal tension reinforcement extending
along at least a portion of the length and retained in the bed with
the bonding material.
15. The prefabricated compound masonry unit of claim 1, wherein the
at least one course has a bed extending along a length of the
course, the bed positioned between external walls of the at least
one course, and a joint between adjacent blocks, with the
longitudinal tension reinforcement spanning each joint at at least
one location along a surface of the bed.
16. A method of making a prefabricated compound masonry unit prior
to transporting the unit to a building site comprising: forming a
first course from a plurality of blocks by joining adjacent blocks
with mortar; running longitudinal tension reinforcement along at
least a portion of a length of the first course; retaining the
longitudinal tension reinforcement to the first course with a
bonding material.
17. The method of claim 16, further comprising: forming a channel
along the first course, wherein the longitudinal tension
reinforcement is run within the channel.
18. The method of claim 17, wherein the channel is formed by one of
cutting or molding with the block.
19. The method of claim 16, further comprising: moving the
prefabricated compound masonry unit to the building site.
20. The method of claim 16, wherein the first course has a joint
between adjacent blocks and the longitudinal tension reinforcement
is run only to span each joint.
21. The method of claim 16, wherein the first course has a bed
extending along the length, the bed positioned between external
walls of the first course, wherein the longitudinal tension
reinforcement is run within the bed.
22. The method of claim 16 further comprising: forming a second
course from a plurality of blocks by joining adjacent blocks with
mortar, wherein the second course is formed with the bonding
material enclosing the longitudinal tension reinforcement between
the first course and second course.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
patent application Ser. No. 13/274,502 filed on Oct. 17, 2011,
which claims priority to U.S. Provisional Patent Application Ser.
No. 61/393,599 filed on Oct. 15, 2010 and U.S. Provisional Patent
Application Ser. No. 61/439,863 filed on Feb. 5, 2011, all of which
are incorporated herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates in general to reinforced
prefabricated compound masonry units and in particular to compound
units reinforced with fiber reinforced polymer.
BACKGROUND
[0003] Structures, including residential, commercial and industrial
buildings, are made from masonry using individual units laid in and
bound together by mortar. The common materials of masonry
construction are clay masonry such as brick and terra cotta; stone,
such as marble, granite, travertine, and limestone; concrete block,
including without limitation conventional concrete masonry units
and autoclaved aerated concrete; glass block; stucco; and tile.
Masonry is generally a highly durable form of construction.
However, the materials used, the quality of the mortar and
workmanship, and the pattern in which the units are assembled can
significantly affect the durability of the overall masonry
construction.
[0004] Concrete masonry is a commonly used building material
composed of individual units whose basic composition is concrete.
The units can be hollow or solid. Concrete is strong in compression
and weak in tension. For cast-in-place concrete, adding embedded
reinforcement provides tensile capacity. The reinforcement can
include steel reinforcing bars, steel fibers, glass fibers, or
plastic fiber. Reinforcement is not used in individual concrete
masonry units, but masonry elements constructed of hollow units can
be reinforced similar to cast-in-place concrete.
[0005] Masonry grout is similar to concrete and is poured into the
hollow concrete masonry units at the building site. Care needs to
be taken to properly cure the grout and achieve the required
strength. Concrete, concrete masonry units, mortar, and masonry
grout all contain Portland cement. Cement-based materials require a
moist, controlled environment to gain strength and harden fully.
The cement paste hardens over time, initially setting and becoming
rigid and gaining in strength in the days and weeks following.
Hydration and hardening during the first three days can be
critical. Fast drying and shrinkage due to factors such as
evaporation may lead to increased tensile stresses at a time when
the material has not yet gained significant strength, resulting in
greater shrinkage cracking. During the curing period, it is
preferable to maintain conditions with a controlled temperature and
humid atmosphere. Properly curing concrete leads to increased
strength and lower permeability, and avoids cracking from the
surface drying out prematurely. Care must also be taken to avoid
freezing or overheating. Improper curing can cause scaling, reduced
strength, poor abrasion resistance and cracking.
[0006] To ensure proper curing of cement-based products, it would
be desired to cure them in a controlled setting rather than at the
building site. This is one reason why the use of concrete masonry
units (blocks) is desirable. The concrete masonry units can be
partially or fully cured off site at a manufacturing facility.
[0007] The individual masonry units are transported to the building
site where they are installed. To build a structure over about five
feet in height, scaffolding is usually necessary to support the
masons while they work. Weather can affect the progress of the
masonry when laid on site as well. Individual concrete masonry
units have no reinforcement. The masonry reinforcement and grout
are added as and after the units are set.
SUMMARY
[0008] Disclosed herein are embodiments of prefabricated compound
masonry units and methods of producing the same. One embodiment of
a prefabricated compound masonry unit comprises at least one course
comprising a plurality of blocks mortared to form a layer, the at
least one course having a top surface and a bottom surface each
having a first side and a second side. Longitudinal tension
reinforcement is provided along at least a portion of a length of
the at least one course and held with bonding material.
[0009] The course of the prefabricated compound masonry unit has a
joint between adjacent blocks with the longitudinal tension
reinforcement spanning each joint of both the first side and the
second side of one or both of the bottom surface and top surface of
the at least one course. The longitudinal tension reinforcement can
be fiber reinforced polymer in dowel or biscuit form. The course
can have a bed extending along a length of the course with the
longitudinal tension reinforcement extending along at least a
portion of the length and retained in the bed with the bonding
material. The course can have a bed extending along a length of the
course a joint between adjacent blocks, with the longitudinal
tension reinforcement spanning each joint at at least one location
in the bed.
[0010] Also disclosed herein are methods of making a prefabricated
compound masonry unit prior to transporting the unit to a building
site. One such method comprises forming a first course from a
plurality of blocks by joining adjacent blocks with mortar, running
longitudinal tension reinforcement along at least a portion of a
length of the first course and retaining the longitudinal tension
reinforcement to the first course with a bonding material. The
method can further comprise forming a channel along the first
course, wherein the longitudinal tension reinforcement is run
within the channel. The channel can be formed by cutting into each
block or along the course or molding the channel into each block
when the block is molded. The first course has a joint between
adjacent blocks and the longitudinal tension reinforcement can be
run only to span each joint. The first course can have a bed
extending along the length and the longitudinal tension
reinforcement can be run within the bed. A second course can be
formed from a plurality of blocks by joining adjacent blocks with
mortar. The second course can be formed with the bonding material
enclosing the longitudinal tension reinforcement between the first
course and second course. Any number of courses can be formed to
make any size unit. The preformed compound masonry unit can then be
transported to the building site.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The description herein makes reference to the accompanying
drawings wherein like reference numerals refer to like parts
throughout the several views, and wherein:
[0012] FIG. 1 is a perspective view of an embodiment of a
prefabricated compound masonry;
[0013] FIG. 2 is a cross sectional view of FIG. 1 along line
2-2;
[0014] FIG. 3 is an enlarged perspective view of a portion of FIG.
1;
[0015] FIG. 4 is an enlarged perspective view of an uncompleted
prefabricated compound masonry unit having a corner;
[0016] FIG. 5 is a perspective view of an embodiment of a
prefabricated compound masonry unit having post-tensioned rods;
[0017] FIG. 6 is a side view of another embodiment of a
prefabricated compound masonry unit;
[0018] FIG. 7 is a side view of a prefabricated compound masonry
unit being hoisted into the air for placement on a means of
transportation;
[0019] FIG. 8 is a side view of another embodiment of a compound
masonry unit as disclosed herein;
[0020] FIG. 9 is a cross sectional view of FIG. 8 along line
9-9;
[0021] FIG. 10 is a plan view of FIG. 8;
[0022] FIG. 11 is a side view of another embodiment of a compound
masonry unit as disclosed herein;
[0023] FIG. 12 is a cross sectional view of FIG. 11 along line
12-12;
[0024] FIG. 13 is a cross sectional view of an alternative
embodiment of FIG. 12; and
[0025] FIG. 14 is a cross sectional view of another embodiment of a
compound masonry unit as disclosed herein with a reusable
carrier.
DETAILED DESCRIPTION
[0026] The concept of prefabricated compound masonry units
reinforced with fiber reinforced polymer (hereinafter "frp)
includes individual concrete masonry units constructed as elements
(walls, beams, lintels or other masonry elements) and reinforced
with frp that can be transported to the building site for
incorporation into a building structure. The frp provides tensile
strength to the units during transportation and handling and during
installation of subsequent masonry.
[0027] Prefabricated compound masonry units are disclosed herein
along with carriers for transporting the prefabricated compound
masonry units. As used herein, a "block" is a single concrete
masonry unit. As used herein, "compound" refers to the use of two
or more individual blocks. A block can be clay masonry such as
brick and terra cotta; stone, such as marble, granite, travertine,
and limestone; concrete block, including without limitation
conventional concrete masonry units and autoclaved aerated
concrete; glass block; stucco; and tile. Compound masonry units can
comprise a plurality of these blocks with one or more layers each
of frp, epoxy or high strength mortar. Post tensioning tendons or
rods incorporated into the compound masonry unit can provide added
strength during handling or in the finished assembly.
[0028] The prefabricated compound masonry units are manufactured in
a controlled factory setting using accepted code and practices in
such a manner as to be easily transported and easily integrated
into field building applications. This procedure would use
craftsmen currently trained in the discipline of masonry and
schooled in the new art of incorporating frp reinforcement for
strategic advantages of strength. Process monitoring of the build
would produce design compliance, assuring strict code conformance
to achieve product quality regardless of the weather and the
natural environment. The integration of one or more frp layers
allows for sufficient rigidity and soundness for transportation and
handling.
[0029] The prefabricated compound masonry units have many
advantages over using individual units at the build site or pouring
concrete at the build site. The prefabricated compound masonry
units are adaptable for add-ons for last minute owner requirements.
The prefabricated compound masonry units are built using the
existing contingent of building trades. Use of the prefabricated
compound masonry units can eliminate work stoppage due to weather
conditions and lessen transportation damage and site damage of the
individual units and other components. The use of prefabricated
compound masonry units can also lessen occurrences of theft of
product from unguarded building sites as the compound masonry units
are too large to be easily transported without the proper assist
and truck. The prefabricated compound masonry units limit
moisture-related shrinkage issues and can be produced with
consistent quality. The use of the prefabricated compound masonry
units can provide "ease of building" on tight or busy sites and
also provide safe, dust free construction solutions. These
advantages are provided as examples and are not meant to be
limiting. Those skilled in the art will recognize these advantages
and more associated with the prefabricated compound masonry units
and their use.
[0030] The prefabricated compound masonry units can be made to any
overall shape and size desired or required by those skilled in the
art so long as the units can be transported. Examples of
applications for which the use of the prefabricated compound
masonry units is contemplated include but are not limited to the
following: columns, decorative walls, corners, floors, roofs,
footings "neat" or insulated, headers for doors and windows,
lintels, beams, posts, key walls, knee walls, ledges, retaining
walls, wall sections, wall sections with returns and walkways.
[0031] The prefabricated compound masonry units can be built on a
build base 10 as seen in FIG. 1. The build base 10 is shown raised
off the ground for the comfort of the builder. However, the build
base 10 does not need to be raised off the ground. The build base
10 is leveled so that the resulting prefabricated compound masonry
unit 100 built on the base 10 is level. The building materials can
be laid directly on the build base 10 or a base cover can be used
to cover the build base 10 to prevent build up of building
materials such as epoxy and mortar on the build base 10.
[0032] One embodiment of a prefabricated compound masonry unit is
illustrated in FIGS. 1 and 2 and comprises at least one course 12
comprising a plurality of blocks 40 mortared to form a layer, the
at least one course 12 having a top surface 14 and a bottom surface
16 each having a first side 18 and a second side 19. Longitudinal
tension reinforcement 20 is provided along at least a portion of a
length L of the at least one course 12 and held with bonding
material 30.
[0033] Longitudinal tension reinforcement 20 can be laid out on the
build base 10 or base cover in an amount and configuration that is
determined by the desired prefabricated compound masonry unit. Frp
is used as the longitudinal tension reinforcement 20. As used
herein as non-limiting examples, frp includes carbon fibers, aramid
fibers, or glass fibers which are set in bonding material, which is
epoxy or high strength mortar or an equivalent material. These frps
can be used as the longitudinal tension reinforcement 20 because
they have limited stretch, thereby providing the longitudinal
reinforcement required when the prefabricated compound masonry unit
100 is lifted. Bonding material is used interchangeably with epoxy
and high strength mortar and refers to the material that adheres
the frp to the masonry blocks. The amount and configuration will
change depending on one or more of the dimensions, weight and
application of the resulting prefabricated compound masonry unit
100.
[0034] As seen in FIGS. 1 and 2, the longitudinal tension
reinforcement 20 can be located in channels 25 that can be cut into
or molded into the individual blocks 40 or courses 12 of such
blocks 40. The channels 25 are configured to receive the frp 20.
Bonding material 30 is applied to the frp 20 and blocks 40 are
placed on top of the epoxy 30 and frp 20 so that the epoxy 30 and
frp 20 are received in the channels 25. Each of the first side 18
and second side 19 of at least one of the top surface 14 and bottom
surface 16 can have a channel 25 formed therein, with the
longitudinal tension reinforcement 20 retained within each channel
25 with the bonding material 30.
[0035] If the longitudinal tension reinforcement 20 is in the
bottom surface 16, the blocks 40 ca be laid over the epoxy 30 and
frp 20 to form a base layer or first course 12 of the prefabricated
compound masonry unit 100 in the desired dimensions. It is also
contemplated that a first course 12 of blocks 40 will be laid and
mortared on the build base 10 or base cover with the channels 25
made in the top surface of the first course 12. The epoxy 30 and
frp 20 can be slid into these channels to form the first course 12
of the prefabricated compound masonry unit 100. When the base layer
is complete, one or more additional layers of blocks 40 can be laid
and mortared as required to achieve the final dimensions of the
prefabricated compound masonry unit 100. When the number of layers
is complete, additional frp 20 is incorporated into the top layer
as shown in the figures. Alternatively, when all courses but one
are laid and mortared, channels 25 can be provided in the surface
of the next to last course within which the epoxy 30 and frp 20 is
placed. When the final course is placed on top, the epoxy 30 and
frp 20 will be hidden from view to provide an aesthetically
finished product.
[0036] It is also contemplated that frp 20 and epoxy 30 can be used
between one or more layers as required to assure the prefabricated
compound masonry unit 100 has the required strength. FIG. 3 is an
enlarged view of the channel 25, epoxy 30 and frp 20. FIG. 4 is an
enlarged photo of a corner of a prefabricated compound masonry unit
100 made from autoclaved aerated concrete (AAC). An example is
provided of channels 25 formed for frp in a corner. The
prefabricated compound masonry unit 100 can have a course 12 with
at least one corner 50 and the longitudinal tension reinforcement
20 can extend across the corner 50 on one or both of the top
surface 14 and the bottom surface 16 of the at least one
course.
[0037] As non-limiting examples, the longitudinal tension
reinforcement 20 can extend along at least a portion of both the
first side 18 and the second side 19 of one or both of the bottom
surface 16 and top surface 14 of the at least one course 12 and
held with bonding material 30. The longitudinal tension
reinforcement 20 can extend along substantially an entire length L
of the at least one course 12. The prefabricated compound masonry
unit 100 can have a plurality of courses 12 having a lowermost
course and an uppermost course with the first side 18 and the
second side 19 of at least one of the top surface 14 and bottom
surface 16 of each of the lowermost course and the uppermost course
having the channel 25 formed therein, with the longitudinal tension
reinforcement 20 retained within each channel 25 with the bonding
material 30.
[0038] Post-tensioning rods or bars can optionally be incorporated
into the prefabricated compound masonry unit 100 as required. The
need for post-tensioning rods, as well as the number of
post-tensioning, will be determined by one or a combination of the
dimensions, weight and application of the resulting prefabricated
compound masonry unit 100, as non-limiting examples. As shown in
FIG. 5, the post-tensioning can be inserted vertically into
existing openings in the blocks 40 to span one or more of the
courses in the prefabricated compound masonry unit 100. The
post-tensioning rods are threaded at their ends. They are held in
place (put in tension), by running them through a hole in steel
plates 60 at the bottom and the top of the wall, then putting nuts
65 on the rods 70 and tightening them to apply a compressive load
to the wall. Basically, the rods 70 act like a large clamp, which
resists loads that might otherwise tend to flex the wall and
thereby crack the mortar joints. Once the wall is set in place, the
nuts can be removed, and the post-tensioning may be incorporated as
a portion of the vertical reinforcement required in the masonry
walls. If required, the post-tensioning can be grouted in place.
Post-tensioning rods or bars can also be used horizontally in the
prefabricated compound unit as tension reinforcement by itself or
in combination with frp.
[0039] The epoxy 30 can be installed in the channels 25 before
laying the frp 20 in the channel 25 and/or after laying the frp 20
in the channel. It is also contemplated that mortar or cement be
used instead of epoxy 30 to adhere the frp 20 to the channel 25.
The epoxy 30 is cured as required.
[0040] Other embodiments of the longitudinal tension reinforcement
20 are also contemplated. For example, the frp 20 can be moved into
the cavity in the middle of the blocks. There the block could be
cut to create a trench, or the tooling for the block molds could be
amended to create a trough in which to lay the frp 20 and contain
the epoxy 30 until it sets up and binds the frp in place.
[0041] Another alternative is to place the frp 20 directly in the
wet mortar bed used to bind the blocks 40 together, as illustrated
in FIG. 6, eliminating the need for the channel 25 and also
eliminating the need for the epoxy. To avoid slippage or sliding
when the mortar is dry, the frp 20 can be coated in silica sand or
other abrasive before laying it in the wet mortar bed. For example,
the prefabricated compound masonry unit 100' can have two courses
having a lower course 112 and an upper course 114 with the
longitudinal tension reinforcement 20 placed in the bonding
material 30 along both the first side 18 and the second side 19 of
the top surface 116 of the lower course 112 with a bottom surface
118 of the upper course 114 placed directly on the bonding material
30 and aligned with the lower course 112.
[0042] Another embodiment uses tensioned steel as the longitudinal
tension reinforcement is the bottom course and frp in the top most
course of the prefabricated compound masonry unit. Middle courses
can incorporate with the tensioned steel or the frp as longitudinal
tension reinforcement as desired or required by the
application.
[0043] As shown in the figures, the longitudinal tension
reinforcement 20 is in the form of a wire or rod. The longitudinal
tension reinforcement can be post-tensioned or not. However, other
embodiments of the longitudinal tension reinforcement 20 are
contemplated. For example, the longitudinal tension reinforcement
20 can be mesh, plate or shaped frp. The shapes can include, as
non-limiting examples, dowels, biscuits and other joinery known to
those skilled in the art. The dowels or biscuits can be placed
along joints of adjacent blocks 40 in the channels 25 if provided,
in existing openings in the individual units or in apertures cut
into the individual units specifically to receive the shaped
frp.
[0044] The use of the longitudinal tension reinforcement as a
lightweight tension member prevents cracking of the mortar joints
during shipment of the prefabricated compound masonry units 100. As
shown in FIG. 7, when the prefabricated compound masonry unit 100
is hoisted to and from a truck or other means of transportation,
the longitudinal reinforcement provided by the disclosed
embodiments prevents the unit 100 from cracking.
[0045] FIG. 8 is a side view of another embodiment of a compound
masonry unit 200. As shown in FIG. 8, a single course of blocks 202
can be used to make the compound unit 200. The individual units are
joined together with mortar 204 to make the course. FIG. 10 is a
plan view of a portion of the course.
[0046] FIG. 9 is a cross-sectional view of FIG. 8 along line 9-9.
As shown in FIG. 9, a thin layer 206 of mortar mix is spread in the
bed 208 of the unit 200. The thin layer 206 can be approximately
0.25 inch to 1 inch. This thickness is not meant to be limiting and
is provided as example only. Other thicknesses can be used as
desired or required. However, increased thickness will increase the
weight of the compound unit. It is also contemplated that epoxy can
be used in place of the mortar mix to form the thin layer 206. Frp
210 is laid on the thin layer 206 of mortar. The frp 210 can be in
strands, and one or more strands can be used. The frp can also be
in plates or rods, and one or more plates or rods can be used. Over
the frp is placed another layer 212 of mortar mix to enclose the
frp. The layer 212 can be of the same thickness or a different
thickness than the thin layer 206.
[0047] The layers 206, 212 of mortar mix and frp 210 can run the
length of the compound masonry unit 200. It is also contemplated
that at least the frp 210 only be placed in the bed 208 across the
joints of individual units 202. Alternatively, the frp 210 can be
laid in multiple sections in any suitable lengths that provide the
requisite strength to the compound masonry unit 200.
[0048] Frp 210 can also be added to the compound unit 200 to bridge
the joints between individual units 202 at the top of the course,
as shown in FIG. 9. FIG. 10 is a plan view of a portion of the
course that includes the joint between two units 202. The joint is
defined by the mortar 204. As shown in FIG. 9, the frp 210 bridges
the joint 204 between the individual units 202. A length of frp 210
is set in slots in the units 202 and set in place with epoxy. The
course can be put together with the frp 210 in the bridge joints,
with the frp 210 in the bed 208 being laid after the course is
made. The frp can be installed in strips at each joint or
continuous through all joints. Bridging the joints with frp 210 can
be used alone or in conjunction with using the frp 210 in the bed
208.
[0049] Another embodiment of the compound unit 200' is shown in
FIGS. 11 and 12. In this embodiment, the compound unit 200' is
shown with two courses 201 of blocks. Although the compound unit
200' is shown having two courses, it is contemplated that the
compound unit 200' can be made of more than two courses. The bottom
course is made of a plurality of units 202' while the second course
is made of a plurality of units 204'. In this embodiment, frp 210'
is added to the compound unit 200' to bridge the joints between
individual units 202' at the top of the bottom course, as well as
to bridge the joints between individual units 204' at the top of
the second course. The frp 210' bridges the joints between the
individual units 202' and 204'. A length of frp 210' is set in
slots in the units 202', 204' and set in place with epoxy.
[0050] The embodiment of FIG. 12 is shown without any additional
reinforcement added to the bed 208'. Alternatively, the layers
described with regard to FIG. 9 can be incorporated into the
compound unit 200'. A thin layer 206 of concrete mix can be spread
in the bed 208' of the compound unit 200'. The thin layer 206 can
be approximately 0.25 inch to 1 inch. This thickness is not meant
to be limiting but rather enabling. Other thicknesses can be used
as desired or required. However, increased thickness will increase
the weight of the compound unit. It is also contemplated that
mortar or epoxy can be used to form the thin layer 206. Frp 210' is
laid on the thin layer 206 of mortar mix. The frp 210' can be in
strands, and one or more strands can be used. The frp can also be
in plates or rods, and one or more plates or rods can be used. Over
the frp is poured another layer 212 of mortar mix to enclose the
frp. The layer 212 can be of the same thickness or a different
thickness than the thin layer 206.
[0051] The layers 206, 212 of mortar mix and frp 210' can run the
length of the unit 200'. It is also contemplated that at least the
frp 210' only be placed in the bed 208 across the joints of
individual units 202'. Alternatively, the frp 210' can be laid in
multiple sections in any suitable lengths that provide the
requisite strength to the compound unit.
[0052] FIG. 13 is an alternative embodiment to FIG. 12. The
alternative embodiment is the same in many respects as the
embodiment in FIG. 10 and thus the description will not be
repeated. As shown in FIG. 13, the frp 210'' in the bottom course
202'' is inserted in a different position than that in FIG. 11.
Rather than bridging the joints of the units 202'' at the top of
the course, the frp" bridges the joints between the units 202'' in
two places along the bed 208'' of the compound unit 200''. A length
of frp 210'' is set in slots in the units 202'' and set in place
with epoxy. Only two pieces of frp 210'' are illustrated. However,
this is not meant to be limiting. One or more pieces of frp 210''
can be used to bridge the joints as desired or required. The
position of the frp 210'' along the bed is also provided by means
of example and is not meant to be limiting. The positions can be
adjusted as desired or required. The depth of the frp 210'' in the
units 202'' is also illustrative and not meant to be limiting.
[0053] FIG. 14 is a cross-sectional view of an alternative
embodiment of a compound masonry unit 200'' that incorporates the
frp 210'' in the joints between individual units 202'' to bridge
the joint as shown in FIG. 12, and incorporates into the same
course the frp 210'' bridging the joints between the units 202'' in
two places along the bed 208'' of the compound unit 200'', as shown
in FIG. 13.
[0054] Also illustrated in FIG. 14 is an embodiment of a reusable
carrier 220 for the prefabricated compound masonry units 200. The
reusable carrier 220 allows for transportation of prefabricated
compound masonry units manufactured as disclosed herein, enabling
transportation of the units to the build sites. The reusable
carrier 220 comprises a support member 222 having two support legs
224 extending from the support member 222 to form an inverted "U"
shape. The support member 222 and support legs 224 can be made of
lumber.
[0055] As shown in FIG. 14, a prefabricated compound masonry unit
200'' is set on the support member 222 of the reusable carrier 220.
The prefabricated compound masonry unit 200'' would be banded to
the carrier 220 in a plurality of positions along their lengths.
The slings of a crane would then be placed around the combined unit
and the unit moved to the transporter for transportation to the
building site. At the building site, the combined unit would be
removed in the same way from the transporter. The reusable carrier
220 can be used for a portion of the shoring support as well as
shipping. Once the prefabricated compound masonry unit is
incorporated into the final structure, reinforced, grouted and then
cured, the carrier shoring is removed. The reusable carrier 220
would be brought back to the manufacturing site for reuse. Use of
the reusable carrier 220 is not limited to the compound masonry
units disclosed herein. The reusable carrier 220 can be used to
shore and transport other masonry units known in the art.
[0056] In the embodiments disclosed herein, the compound masonry
units can be compressed or post tensioned horizontally prior to
applying the frp. When concrete masonry units are used other than
brick, the compression reduces possible issues from mortar and unit
shrinkage. The frp can be applied after compression to ensure that
the proper reinforcement is provided.
[0057] In the embodiments described herein, a coating comprising
poly urea can be applied to the compound masonry units prior to
transporting to the build site. The poly urea provides corrosion
protection and abrasion resistance and fills joints. As used
herein, "poly urea" means a polymer coating that uses many
different formulations of poly urea with different physical
property ranges. A poly urea coating can also be used to water
proof the compound masonry units as desired or required.
[0058] While the invention has been described in connection with
certain embodiments, it is to be understood that the invention is
not to be limited to the disclosed embodiments but, on the
contrary, is intended to cover various modifications and equivalent
arrangements included within the spirit and scope of the appended
claims, which scope is to be accorded the broadest interpretation
so as to encompass all such modifications and equivalent structures
as is permitted under the law.
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