U.S. patent number 3,855,752 [Application Number 05/295,896] was granted by the patent office on 1974-12-24 for masonry block and building panels.
This patent grant is currently assigned to General Concrete Ltd.. Invention is credited to Norman N. Aylon.
United States Patent |
3,855,752 |
Aylon |
December 24, 1974 |
MASONRY BLOCK AND BUILDING PANELS
Abstract
A masonry building block capable of being used in prefabricated
structural panels is provided and includes cores therethrough to
receive reinforcing rods in the height of the prefabricated
panel.
Inventors: |
Aylon; Norman N. (Willowdale,
Ontario, CA) |
Assignee: |
General Concrete Ltd.
(Hamilton, Ontario, CA)
|
Family
ID: |
23139678 |
Appl.
No.: |
05/295,896 |
Filed: |
October 10, 1972 |
Current U.S.
Class: |
52/605; D25/116;
52/259; 52/437; 52/439; 52/606 |
Current CPC
Class: |
E04B
2/52 (20130101); E04C 2/041 (20130101); E04B
2002/0232 (20130101) |
Current International
Class: |
E04B
2/42 (20060101); E04C 2/04 (20060101); E04B
2/52 (20060101); E04B 2/02 (20060101); E04c
002/04 (); E04c 001/08 () |
Field of
Search: |
;52/436,437,438,606,607,259,227-229,503,504,505,605,439 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
465,097 |
|
Aug 1951 |
|
IT |
|
483,070 |
|
Jul 1953 |
|
IT |
|
872,063 |
|
Jan 1942 |
|
FR |
|
246,388 |
|
Apr 1966 |
|
OE |
|
987,253 |
|
Apr 1951 |
|
FR |
|
148,349 |
|
Sep 1952 |
|
AU |
|
1,039,079 |
|
May 1953 |
|
FR |
|
1,195,214 |
|
Jun 1965 |
|
DT |
|
Other References
Architectural Forum, 7-1952, pages 162, 163..
|
Primary Examiner: Perham; Alfred C.
Attorney, Agent or Firm: Sim & McBurney
Claims
I claim:
1. A masonry block capable of cooperating with other like blocks to
provide a structural panel, said block having a rectangular
parallelepiped shape and including substantially parallel and
smooth top and bottom faces and two end faces,
said block having an axial plane extending perpendicularly of said
top and bottom faces and extending longitudinally of said block
subdividing the width of said block into two areas of substantially
equal dimension,
a central core extending between and substantially perpendicularly
to the top and bottom faces and cross-sectionally shaped so that
the portion thereof on one side of said plane is the mirror image
of and has the same cross-sectional area as the portion thereof on
the other side of said plane,
a recess formed in each end face and extending between said top and
bottom faces, each of said recesses having the same cross-sectional
dimension and having a combined cross-sectional shape and area
substantially the same as those of the central core, and
four satellite cores positioned with a first two between the
central core and the recess in one end face of the block an a
second two between the central core and the recess in the other end
face of the block,
each satellite core having substantially the same cross-sectional
area and extending between and substantially perpendicularly to
said top and bottom faces, the satellite cores being separated from
each other, the central core and the recess within the block by
material of construction of the block,
one member of each of said first and second two satellite cores
being positioned on one side of said axial plane and each having
substantially the same cross-sectional shape and the other member
of each of said first and second two satellite cores being
positioned on the other side of said axial plane and each having
the same cross-sectional shape which is the mirror image of the
cross-sectional shape of said one member,
the central core having a cross-sectional shape consisting of two
part-circular portions the ends of which are joined by straight
line portions, the two part-circular portions of the central core
having the same centre and radius of curvature, the centre of
curvature of the two part-circular portions being located in said
axial plane, the straight line portions of said central core being
parallel to the longitudinal edges of the block,
each of the satellite cores having a cross-sectional shape which
includes a semicircular portion and a diametrical portion joining
the ends of the semicircular portion, the diametrical portions of
said satellite cores being parallel to the longitudinal edges of
the block,
the one members of said first and second two satellite cores having
their diametrical portions in the same straight line and in
straight line alignment with one of the straight line portions of
the central core, the other members of said first and second two
satellite cores having their diametrical portions in the same
straight line and in straight line alignment with the other
straight portion of the central core,
each recess having a crosss-sectional shape including a
part-circular portion of substantially the same radius of curvature
and circumferential length as the part-circular portions of said
central core and having its centre of curvature located at the
bisection of the plane of the respective end face and said axial
plane,
the semicircular portions of the satellite cores projecting
inwardly of the longitudinal areas of the block and the radius of
curvature thereof being such that the furthest distance between the
adjacent longitudinal edge of the block perpendicularly thereto and
the semicircular portion is substantially equal to the radius of
curvature of the part-circular portions of the central core and the
part-circular portion of the recesses,
the total cross-sectional area of said satellite cores being less
than the cross-sectional area of said central core,
the ends of said diametrical portions of said first two satellite
cores closer to their adjacent recess lying in a plane which
extends perpendicularly to the longitudinal edges of the block,
the ends of said diametrical portions of said second two satellite
cores closer to their adjacent recess lying in a plane which
extends perpendicularly to the longitudinal edges of the block,
the centres of curvature of the semicircular portion of said first
two satellite cores being located substantially one-quarter of the
length of the block from their adjacent end face,
the centres of curvature of the semicircular portions of said
second two satellite cores being located substantially one-quarter
of the length of the block from their adjacent end face.
2. The block of claim 1 wherein each of said recesses includes lips
which extend inwardly of the mouth of the recess towards each
other.
3. The block of claim 1, constructed of concrete and wherein said
satellite cores are adapted to receive structural panel reinforcing
rods in stable position therein and are spaced from said axial
plane the maximum distance which still allows
surface-to-reinforcement cover conforming to the building code to
be maintained.
Description
This invention relates to a novel masonry block and to novel
building panels.
In the construction of buildings, generally a plurality of
individual building blocks is juxtaposed and joined one to another
at the building site to provide the required structure, for
example, a wall. Many differing types of masonry block have been
suggested, and a number of prefabricated panels also have been
suggested.
However, such prefabricated panels generally either lack structural
strength in flexure or buckling resistance or are bulky and
unwieldy. In accordance with the present invention there is
provided a novel masonry block from which may be constructed
prefabricated panels having the desired structural strength in
flexure and buckling resistance while at the same time are not
bulky and unwieldy.
The invention is described by way of illustration with reference to
the accompanying drawings, in which:
FIG. 1 is a plan view of one form of masonry block of the
invention;
FIG. 2 is a plan view of a second form of masonry block of the
invention;
FIG. 3 is a plan view of a third form of masonry block of the
invention;
FIG. 4 is a sectional plan view of the first and alternate courses
of a building structure utilizing the blocks of FIGS. 1 to 3;
FIG. 5 is a sectional plan view of the second and alternate courses
of a building structure utilizingg the blocks of FIGS. 1 to 3;
FIG. 6 is an elevational view taken on line 6--6 of FIGS. 4 and
5;
FIG. 7 is an elevational view taken on line 7--7 of FIGS. 4 and
5;
FIG. 8 illustrates the supposition of the courses of FIGS. 4 and 5
at a corner joint;
FIG. 9 is a section of a unit accommodating horizontal steel
reinforcement; and
FIGS. 10A and 10B illustrate a plan view of courses of a
prefabricated panel in accordance with a further embodiment of the
invention.
In the drawings, referring first to FIG. 1, there is illustrated a
masonry block 10, manufactured of concrete or any convenient
material and having any desired dimensions. Standard building
industry practice utilizes blocks which have a nominal modular size
of 16 .times. 8 .times. 8 inches and the block 10 may be so
dimensioned. Adhesive-bonded blocks have dimensions slightly
smaller than the modular size to allow for the thickness of
adhesive, bonding the blocks together.
The end faces of the block 10 each have recesses 12 which may be of
any convenient shape and generally extend the dimension of the end
face between the top and bottom surfaces. Preferably, the recesses
12 in plan each are defined by a part circular surface 14 which
terminates at each end in lips 16 which project inwardly of the
recess 12 towards each other. The lips 16 are formed so that, by
use of, for example, a builders trowel, the portion of the block
between an extremity of a surface 14 and the adjacent side wall of
the block may be removed as indicated by a typical fracture line
17. Blocks 10 are utilized with one or more of the lips 16 removed
in this manner in certain embodiments of building structures formed
from these blocks as described in more detail below with reference
to FIGS. 4 to 7.
The lips 16 perform as keys providing mechanical bond with the
concrete grouting positioned in the recess 12, which serves in the
provision of a stable interlocking structural joint between
separate prefabricated panels, as well as a stable interlock beteen
blocks within the panel itself, wherever concrete grouting is
emloyed internally.
A central core 18 is formed through the block 10 and extends
continuously between the top face and the bottom face. The core 18
has any convenient shape and iss substantially perpendicular to the
top and bottom faces. Preferably, the core 18 has a cross-sectional
shape including two opposed part circular surfaces 20 and 22, the
adjacent extremities of which are joined by parallel straight line
surfaces 24 and 26. The straight line surfaces 24 and 26 are
substantially parallel to the side walls of the block 10.
The central core 18 and the recesses preferably are dimensioned so
that the surfaces 20 and 22 of part-circular cross-sectional shape
have substantially the radius of curvature of the surfaces 14 of
the recesses 12. Additionally, the length of the straight line
surfaces 24 and 26 preferably is substantially twice the straight
line distance between the extremities of the surfaces 14 and the
external face of the end surfaces of the block 10. The reason for
this preferred dimensioning will become apparent hereinafter when
prefabricated structures are discussed.
One preferred form of the central core 18 and the recesses 12 is
illustrated. As will become more apparent hereinafter, these
features may have any desired cross-sectional shape and preferably
each recess 12 has a cross-sectional shape which is substantially
half the cross-sectional shape of the central core 18, so that if
two blocks 10 are placed in abutting end-to-end relationship, the
combined cross-sectional shape of the adjacent recesses 12 is
substantially that of the central core 18. Dimensioning in this
manner is preferred for the reasons set forth in detail below.
Four satellite core 28 are provided extending continuously through
the block 10 from the top face to the bottom face, substantially
perpendicular thereto. The satellite cores 28 are arranged in two
pairs 30 and 32. Each pair is located between the central core 18
and a recess 12.
In the embodiment illustrated, there are four individual satellite
cores. This number is preferred to accommodate structural
reinforcing steel and other practical considerations. It is
possible to employ other numbers of such satellite cores, although
the number generally is even and at least two satellite cores are
required.
The satellite cores 28 are positioned regularly spaced from the
recesses 12 and the central core 18. Where numbers of such cores 28
other than four is employed, it is necessary to ensure that they
are adequately positioned with reference to the central core 18 and
the recesses 12 so that upon positioning of the blocks 10 upon one
another in a building structure with the vertically adjacent blocks
10 being offset from a central block, the satellite cores 28 are
aligned throughout the vertical height of the building structure.
This relationship is discussed in more detail below with reference
to FIGS. 4 to 8.
Each of the satellite cores 28 may be of any convenient shape and
preferably each of the satellite cores 28 is of substantially the
same cross-sectional shape. In FIG. 1 a preferred form of the
satellite cores 28 is illustrated and the cores 28 each have a
cross-sectional shape including a semi-circular portion 34 and a
straight line portion 36. Each pair 30 and 32 of satellite cores 28
includes complementarily cross-sectional-shaped cores.
The straight line portion 36 of each satellite core 28 preferably
extends substantially parallel to the side faces of the block 10
and the semi-circular portion 34 extends inwardly of the side faces
of the block.
While the satellite cores 28 are illustrated in FIG. 1 as having a
particular cross-sectional shape, this shape may be varied as
desired. Generally, however, the cores 28 each have substantially
the same cross-sectional shape. The choice of cross-sectional shape
to some degree is dictated by the chosen cross-sectional shape of
the central core 18, as will become more apparent hereinafter
during discussion of wall constructions utilizing the blocks
10.
The satellite openings 28 are positioned inwardly of the side walls
of the block a predetermined distance and the minimum distance is
determined by the building regulations for the jurisdiction in
which the building to be erected using the blocks 10 is located. In
the preferred embodiment illustrated in FIG. 1, the straight line
portions 36 of the longitudinally aligned satellite cores 28 of
each pair 30 and 32 are in a straight line with each other and
additionally with the appropriate straight line surface 24 and 26
of the central core 18.
The purpose of the satellite cores 28 will become apparent
hereinafter during discussion of building structures formed from
the blocks 10.
The block 10 represents a basic building block from which a variety
of structures may be formed. These structures may be prefabricated
or constructed on-site, as described in more detail below. The
versatility of the blocks 10 in being able to provide both an
on-site built structure and also satisfactory prefabricated
building panels for later erection on-site represents a
considerable advance in the art of building materials.
While the building block illustrated in FIG. 1 may be utilized in a
variety of building structures as the basic unit, in order to
provide smooth flat ends and corners in typical prefabricated and
on-site built structures, other specialized end-blocks are provided
by this invention employing basically the same concepts as are
embodied in the block 10 of FIG. 1.
FIGS. 2 and 3 illustrate typical modifications of the structure of
block 10 to provide end-blocks for various uses. Thus, in FIG. 2, a
block 40 includes a central core 42, satellite cores 44 and a
recess 46 in one end face only of the block. The form and shape of
the central core 42 are substantially the same as those of the
central core 18 of FIG. 1, the form and shape of satellite cores 44
are substantially the same as those of the satellite cores 28 in
FIG. 1, and the form and shape of the recess 46 are substantially
the same as those of the recessess 12 of FIG. 1. In common with
recesses 12 of FIG. 1, the recess 46 has lips 48 at the end face.
Reference is made to the above discussion of the equivalent items
in FIG. 1 and the comments made therein with reference thereto
apply equally here. A further form of end-block is shown in FIG. 3.
An end-block 50 is approximately half the longitudinal size of
blocks 10 and 40 and has a single recesss 52 formed in one end. A
single pair of satellite cores 54 also is provided. The halfblock
50, as compared with block 10, lacks a central core of the type 18
and has only a single pair of satellite cores 54. The form and
shape of recess 52 and of satellite cores 54 are substantially
those of recesses 12 and satellite cores 28 of block 10. The
discussions above with reference to these itsms apply to the
equivalent items in block 50.
The blocks shown in FIGS. 1 to 3 represent the blocks necessary to
provide prefabricated wall panels or structural walls constructed
on-site having a plurality of differing manners of interconnection
one with another, as described in detail below with reference to
FIGS. 4 to 8. Using blocks 10 and 40 of the nominal dimension 16
.times. 8 .times. 8 inches, and blocks 50 of the nominal dimension
8 .times. 8 .times. 8 inches, it is possible to provide
prefabricated or on-site building structures which are based upon
an 8 inch module.
Prefabricated wall structures of any desired dimension may be
provided utilizing the blocks of FIGS. 1 to 3. The prefabricated
wall structures or panels may be structured so that the finished
structural item may include rectangular openings at any desired
location for windows or the like, consistent with the basic 8 inch
module.
In addition to use in the prefabrication and onsite building of
wall panels, the building blocks illustrated in FIGS. 1 to 3 may be
used to provide piers, columns, spandrels, girders, beams and
lintels by applying the constructional principles discussed below
with reference to FIGS. 4 to 8.
A typical building structure formed from prefabricated wall units
is illustrated in FIGS. 4 to 8. A number of differing manner of
joining the prefabricated panels is illustrated.
A typical prefabricated panel 110 includes a plurality of
individual courses 112 in which blocks 114 are provided. The
courses 112 are arranged so that alternate ones are identical but
adjacent ones vary from each other. The blocks 114 in each course
abut each other in end-to-end relation and the line of abutment of
the blocks 114 in one course is located at approximately the
mid-point of the length of the vertically adjacent blocks 114. The
blocks 114 in adjacent courses therefore are offset from each
other. In this way, there are provided continuous passages
throughout the height of the panel defined by the central cores in
the blocks of one set of alternate courses and the adjacent end
recesses of blocks in the other set of alternate courses.
Additionally, the satellite cores in vertically adjacent blocks of
the courses are aligned throughout the height of the wall 110 and
hence continuous passages defined thereby also are provided.
In the panel 110, the first course 116 and each alternate course in
the height of the panel typically consists of a plurality of
end-to-end aligned blocks 114, each of such blocks 114 being of the
type illustrated in FIG. 1. The second course 118, and each
alternate course in the height of the panel includes two differing
forms of blocks 114. The bulk of these courses 118 is provided by a
plurality of blocks 114 of the type illustrated in FIG. 1, arranged
so that the point of end-to-end contact with an adjacent block is
located at the approximate mid-point in the length of the blocks
114 in the courses 116.
At each end of the courses 118 is provided a block of the type
illustrated in FIG. 3, in each instance with its recess 52
projecting outwardly for joining of the wall 110 to an adjacent
wall panel. Thus, throughout the height of the panel 110 at each
side edge is a continuous vertical channel defined by the recesses
12 and 52 of the blocks adjacent the edges. Such a channel is an
essential feature in the joining of the wall panel to adjacent
panels. Other edge channel configurations are possible as will
become apparent in the further discussion below of FIGS. 4 to 8.
The satellite cores 54 in the end blocks align with the end pair 30
or 32 of satellite cores in the vertically adjacent blocks of
courses 116.
The panel 110 is illustrated as commencing from the bottom and
terminating at the top with courses of the type 116. This
construction is preferred from an ease of construction and an
aesthetic point of view, but other configurations may be adopted.
For example, the panel 110 may commence and terminate with courses
of the type 118. Alternatively, the panel 110 may commence with a
course of type 116 and terminate with a course of the type 118.
Further, the panel may commence with a course of the type 118 and
terminate with a course of the type 116.
Each block 114 in each course 112 is joined to the adjacent one by
any convenient adhesive. There is a number of commercially
available construction material adhesives and any of such adhesives
may be utilized. Also, the vertically adjacent blocks are
adhesively bonded together by any convenient adhesive. The
continuous passages defined by the central cores and end recesses
are filled in whole or in part with grouting in accordance with any
specific structural design or may be used for the ducting of
utilities.
In order to provide the desired structural strength to the
prefabricated panel 110, steel reinforcing rods of any desired size
are positioned in a selected number of the continuous passages
defined by the vertically aligned satellite cores and these
passages are filled with grout or concrete. Prior art systemss do
not provide continuous passages of small cross-sectional area to
accommodate steel reinforcing, as provided by the present
invention. Prior art systems also do not locate reinforcing
passages near each face of the block structure, as provided in the
present invention, but rather tend to locate any reinforcement
centrally of the panel. Hence the present invention is a
considerable improvement over the existing art in these
respects.
By providing steel reinforcement passages throughout the height of
the panel and close to its faces it is possible to provide a
prefabricated wall panel having structural strength and flexural
resistance and hence it may readily be transported and handled. The
panel may readily be joined to other wall panels to provide the
desired building structure. The steel reinforcement of the panel
has the added advantage that the final building structure is
structurally stronger than conventionally formed on-site built
structures, and may support heavier loads. The provision of
reinforcement close to the faces of the panel results in a
structure which is stronger than conventional block walls with
equivalent reinforcement in a central position.
The size of the reinforcing rods depends on a number of factors,
for example, the size of the panel element to be prefabricated and
the ultimate end use of the panel element. As mentioned above, the
location of the satellite cores in the blocks 10, 40 and 50 is
controlled to some degree by regulations. Most jurisdictions
provide a certain minimum cover to reinforcement in reinforced
structures and hence when steel reinforcing rods are utilized in
the structure in accordance with this invention, then the location
of the satellite cores must comply with the appropriate
regulationss while at the same time retaining consistency with the
principles of the present invention as discussed above.
In the case of large prefabricated elements it may be desired to
provide additional structural strength and this may be achieved by
utilizing the item shown in FIG. 9. This is an elongated unit 60
having lateral and vertical dimensions substantially those of the
blocks 10. The unit 60 includes an elongated U-shaped channel 62
which extends the length of the unit. The unit is provided in a
length which is the width of the prefabricated panel and is
positioned usually at the bottom of the wall panel, although it may
be positioned both at the top and bottom of the panel, if desired.
A reinforcing rod may be positioned in the channel 62 and hence
extending horizontally in the wall. Extensions of the vertical
reinforcing rods in the continuous channels defined by the aligned
satellite cores are hooked around the horizontal rod or rods and
the channel 62 is normally filled with grout or concrete.
As indicated above, all wall panels in accordance with the present
invention basically employ a plurality of blocks of the type
illustrated in FIG. 1. The form of the ends of the courses in the
wall panels may be varied to provide a variety of different joints
with other panels.
A typical building structure including a plurality of prefabricated
wall panels is illustrated in FIGS. 4 to 8. The construction
illustrated in FIGS. 4 to 8 is intended to depict the many
variations of the form of joint which are posible. In the desired
construction, the choice of the type of joint between adjacent
panels, and hence the choice of the construction of the panels,
depends on the individual requirements. Thus, the building
structured from prefabricated panels, constructed in accordance
with this invention, may include one or more of the joint forms
illustrated in FIGS. 4 to 8.
As illustrated in FIGS. 4 to 8, a building structure 120 includes a
plurality of prefabricated wall panels or units 110, 122, 124, 126,
128, 130, 132 and 134 which are joined together to form the
building structure. As noted earlier in each prefabricated wall
panel or element, the bulk of the building blocks are of the form
shown in FIG. 1, and hence in the plan views of FIGS. 4 and 5,
generally the sections of the panels between the edge termination
for each panel, have not been shown in detail.
In FIGS. 4 and 5, there are illustrated respectively the first and
each alternate course and the second and each alternate course.
Usually the panel or wall element will commence and terminate in
its vertical height with the course shown in FIG. 4. As noted
earlier in discussion of panel 110, this may be varied as desired.
It is possible to vary the construction of the courses, so that
there is a random selection of courses throughout the height of the
panel. However, for ease of construction, it is preferred that each
alternate course in the height of the panel is identical.
Since each alternate course throughout the height of each panel or
wall element is identical, description of one of each type of
course in the height of the panel only is required. The following
description, therefore, in describing one course is intended to
refer additionally to each alternate course and should be
interpreted as such.
The panel 122 is of substantially the same form as wall panel 110
described above and no further description is required. Wall panels
110 and 122 each have an open channel running the height of the
ends thereof. Upon abutting the terminal blocks 136 and 138 of
panel 110 with terminal blocks 140 and 142 of panel 122 and upon
adhesive securement therebetween, grouting may be positioned in the
closed keyway 144 defined therebetween.
The wall panel 124 is similar to panel 110 but has important
differences relating to its connections with other panels. As seen
in FIG. 4, in one course, at the approximate mid-point of its
length the abutting ends of blocks 146 and 148 have been modified.
Thus, on each of the abutting ends of blocks 146 and 148, the lips
16 (FIG. 1) adjacent to each other and nearest to the wall panel
132 have been removed, so that there is a vertical opening 150 in
the course shown in FIG. 4, providing access to the interior of the
core 152 defined by the juxtaposed recesses 12 (FIG. 1) of blocks
146 and 148. The provision of the opening 150 serves in the joining
of the panel 124 to panel 132 by means of grouting. While this
arrangement is illustrated at the mid-point of the width of the
panel 124, clearly the arrangement may be provided at any
convenient location across the width of the panel 124, depending on
the desired location of the panel 132.
In contrast, as seen in FIG. 5, in the courses adjacent to those
illustrated in FIG. 4, at the location equivalent to the position
of the channel 150, the block 154 is unmodified, and retains the
form shown in FIG. 1.
The keyway joints at the ends of panel 124 are of different
configurations. As seen in FIG. 4, the alternate courses terminate
at each end in block 156 and 158 which is of the basic type shown
in FIG. 1. However, in the courses of FIG. 5, end blocks 160 and
162, each of the type illustrated in FIG. 3, are utilized. The end
block 160 is arranged so that its recess 52 opens toward the panel
134 to serve in the joining of the panel 134 to the panel 124. At
the right hand end, as seen in FIG. 5, the block 162 is arranged in
the same manner as in panel 110 with its recess 52 opening towards
the panel 130.
Therefore, at the right hand vertical end of the wall panel 124
there is a continuous open channel, provided by the vertically
aligned recesses 12 of the blocks 158 and recesses 52 of the blocks
162. At the left hand vertical end, there is alternately a recess
12 of blocks 156 and the flat face of blocks 160, resulting in a
castellated keyway.
With the exception of the end blocks 160, the courses in the wall
panel 124 are superimposed to provide continuous grouting cores and
continuous reinforcing and grouting channels, as discussed above in
connection with panel 110. At the end blocks 160, the satellite
cores 54 of the end blocks 160 coincide, one with the recess 12 and
one with the central core 18 of the block 156. The recess 52 of the
block 160 coincides with one of the satellite cores 28 of the
blocks 156. Thus, grouting and reinforcing rods may readily be
utilized at this end of the wall panel 124.
The wall panel 130 includes in one course (FIG. 4) a plurality of
blocks of the type illustrated in FIG. 1. The end block 164
adjacent the join with wall panel 124 is of the type illustrated in
FIG. 2. In the other course (FIG. 5), the wall panel 130 also
includes a plurality of blocks of the type illustrated in FIG. 1
and an end block 166 of the type illustrated in FIG. 3. The end
block 166 is positioned with its recess facing the recess of end
block 162 of panel 124. The facing recesses in end blocks 162 and
166 define a keyway 168 therebetween.
At the side of the wall panel 130 adjacent the wall panel 126,
there are provided in adjacent courses blocks 170 (FIG. 4) of the
type shown in FIG. 1 and end blocks 172 (FIG. 5) of the type shown
in FIG. 3. The end block 172 is positioned with its recess 52
facing the wall panel 126. Since the recesses 12 of blocks 170
align with the recesses 52 of the end blocks 172, there is provided
a continuous channel in this side of the wall panel 130.
One of the satellite cores 54 of blocks 166 coincide with the
central core 42 of the vertically adjacent blocks 164.
Additionally, one of the satellite cores 42 of the block 164
coincides with the recess 52 of the block 166. Therefore, there are
provided grouting and reinforcement channels. The overlap of the
blocks 164 and 166 and the relative locations of the satellite
cores 42 and 54, the central core 42 and the recess 52 are
illustrated in FIG. 8. As seen in FIG. 8, satellite core 54a of
block 166 is located wholly within central core 42 of block 164.
Similarly, satellite core 44a of block 164 is located wholly within
recess 52 of the end block 166. Thus, the combination of satellite
cores and central core and recess provide a plurality of channels
to receive reinforcing rods 174.
With the provision of blocks 164 and 166 in the wall panel 130, the
corner joint between panels 124 and 130 has smooth flat internal
and external surfaces.
The wall panel 132 is constructed of alternate courses which
contain a plurality of blocks of the type illustrated in FIG. 1. In
one course (FIG. 4), the end adjacent the wall panel 124 has an end
block 176 of the type illustrated in FIG. 3 and having its recess
52 opening towards the vertical opening 150. At the end remote from
the end block 176 is a block 178 of the type illustrated in FIG. 1.
In the other course (FIG. 5), the arrangement of blocks is
reversed. In this case, end block 180 of the type illustrated in
FIG. 3 is arranged with its recess 52 opening towards the wall
panels 126 and 128. At the end adjacent the wall panel 124, a
terminal block 182 of the type illustrated in FIG. 1 is
provided.
Wall panel 126 is connected to panels 130 and 132. As seen in FIG.
4, in one course there is provided a plurality of blocks of the
type illustrated in FIG. 1, together with two end blocks. End block
184 adjacent the wall panel 132 is of the type illustrated in FIG.
3 with one of the lips of the recess 52 removed. End block 186 is
of the type illustrated in FIG. 2. In the other course (FIG. 5)
there again is a plurality of blocks of the type illustrated in
FIG. 1 and in this case the end block 188 located adjacent the wall
panel 132 is of the same type as block 146. The lip 16 adjacent the
end block 180 is removed. The other end block 190 of this course is
of the type illustrated in FIG. 3 with its recess 52 opening
towards the recess 52 in end block 172 of the panel 130. The
recesses 52 of the end blocks 172 and 190 define a grouting keyway
192 therebetween. One of the satellite cores 54 of the end block
190 coincides with the central core 18 of the end block 186, in
similar manner to the relative location of blocks 164 and 166.
By providing end blocks 186 and 190 on wall panel 126, the corner
join of wall panels 130 and 126 is smooth internally and
externally.
The wall panel 128 is provided with ends adjacent the panel 132
similar to those on panel 126 adjacent the panel 132. Thuss, in one
course (FIG. 4) a block 194 of the same type as block 188 is used
and in the other course (FIG. 5), a block 196 of the same type as
block 184 is used. The abutting ends of the wall panels 126 and 128
by reason of the removed lips, define a continuous vertical opening
198 extending through the height thereof. The continuous vertical
opening 198 communicates with the channel defined by the recesses
52 and 12 in the panel 132 to provide a grouting keyway.
The other end of the panel 128 interleaves with the adjacent end of
panels 134. This is achieved by providing for one course (FIG. 4) a
block 200 of the type illustrated in FIG. 1 located a distance
equal to approximately the width of a block from the ultimate side
extremity of the wall. For the other course (FIG. 5), an end block
202 of the type illustrated in FIG. 2 is provided extending a
distance equal to approximately the width of a block beyond the
extremity of the block 200. In this way, an end block 204 of the
panel 134 (FIG. 4) overlaps the end block 202 of the panel 128 and
simultaneously abuts against the block 200 of panel 128. Similarly,
the block 206 (FIG. 5) of the type illustrated in FIG. 1 of unit
134 abuts against the end block 202 of panel 128. Hence, the ends
of the panels 128 and 134 are interleaved to provide a corner
structure having smooth internal and external surfaces. Usually,
where interconnection is provided, biplanar panels are
prefabricated with interleaved interconnections at the corners.
This structure is described further below.
In the overlapping of the end blocks 202 and 204, one of the
satellite cores 44 of the end block 202 coincides with the central
core 42 of end block 204, while one of the satellite cores 44 of
the end block 204 coincides with the central core 42 of end block
202, in analogous manner to the overlap illustrated in FIG. 8. In
this way, grouting and reinforcing passages through the eheight of
the corner joint are provided.
The wall panel 134 has an end structure adjacent the wall panel 124
which is similar to that of panel 130 adjacent wall panel 126. As
may be seeen in FIG. 4, the terminal block 208 is of the type
illustrated in FIG. 1 and abuts the external surface of the block
156 of panel 124, while in FIG. 5, the end block 210 is of the type
illustrated in FIG. 3 and has its recess 52 opening towards the
recess 52 in end block 160 of panel 124.
The satellite cores have been indicated as providing passageways
for reinforcing rods and grouting. However, certain of the
passageways may be utilized to receive handling loops for the
prefabricated panels.
It wiil be seen, therefore, that the present invention is able to
provide a plurality of differing forms of prefabricated panels,
which may be erected and located in any desired location with
reference to one another by uing basically a building block of the
type shown in FIG. 1 and appropriate use of the blocks of FIGS. 2
and 3 as end blocks for particular purposes.
As will be observed from the above description of the embodiments
of FIGS. 4 to 7 that at each corner and joint, there are smooth
internal and external surfaces.
There are many forms of joints between prefabricated panels which
are possible, as described above, and the particular one utilized
will be a matter of choice and convenience for the particular
building operation. The types of joint possible may be summarized
as follows: (a) a butt joint, such as between panels 110 and 122
for the joining of panels in the same plane. The abutting ends are
sealed by means of gaskets and the continuous closed keyway 144 is
filled with grouting to complete the structural connection between
the panels; (b) a corner joint, such as beteen panels 124 and 130,
or panels 126 and 130; (c) an interleaved corner joint, such as
between panels 128 and 134; (d) an offset T-joint, such as between
panels 124, 110 and 134; (e) an intersecting T-joint, such as
between panels 132 and 124; and (f) a centric T-joint, such as
between panels 126, 128 and 132.
The interleaved corner joint between panels 128 and 134 usually is
used to provide a biplanar prefabricated panel which may be erected
in an upright position before joining with other panels without the
use of shores or other auxiliary hardware.
The two courses of a typical panel formed in this manner are
illustrated in FIGS. 10A and 10B. The course illustrated in FIG.
10A represents the bottom and top courses and each alternate course
therebetween, while the course illustrated in FIG. 10B repressents
the other alternate courses in the panel.
As shown in FIGS. 10A and 10B, the panel 250 includes a first wall
portion 252 which extends in a first plane and is of substantial
width. Any desired width may be used. Second wall portions 254 each
is located in a plane perpendicular to the plane of the first wall
portion 252 and extends only a short distance from the first wall
portion 252. At the corner joints of the first and second wall
portions 252 and 254, the blocks are interleaved as illustrated
above in connection with the joint between panels 128 and 134, to
provide a prefabricated panel with corner joints having smooth
inner and outer faces.
In the course illustrated in FIG. 10A, the end blocks 256 each is
of the type illustrated in FIG. 2 with the flat end face providing
the outer extremity of each end of the first wall portion 252. In
this course, the remainder of the blocks are shown in FIG. 1. The
second wall portions 254 in this course each is provided by a
single block 258, which may be of the type shown in FIG. 1 or of
the type shown in FIG. 2 with the flat end wall thereof being
remote from the first wall portion 252.
In the course illustrated in FIG. 10B, the end blocks 260 of the
first wall portion 252 each are of the type illustrated in FIG. 1
and hence the same as the remainder of the blocks in the course.
Each of the end blocks, 260 terminates one half-block distance from
lateral extremities of the first wall portion 252 of the course
shown in FIG. 10A.
The second wall portions 254 of this course each includes a block
262 of the type shown in FIG. 2 with its flat end face being
located adjacent the end block 260. At the end of the blocks 262
remote from the flat end is located a half block 264 of the type
illustrated in FIG. 3, the recesses of the blocks 262 and 264
cooperating to form a channel 266 to receive grouting. The
satellite cores are provided with reinforcement as discussed
above.
It will be seen, therefore, that in accordance with this embodiment
of the invention, there may be provided a prefabricated panel which
possesses improved structural strength in flexure and buckling
resistance and also is self-standing.
As mentioned above, the principles involved in constructing the
wall elements described above may be utilized to form other
structural elements, such as piers, columns, spandrels, girders,
beams and lintels.
The constructional elements described above are the structural load
bearing wall panels for the particular building structure. Any
desired architectural functions may be superimposed on the faces of
the panels where apropriate by patterning, texturing or the
like.
Modificationss are possible within the scope of the invention.
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