U.S. patent number 3,875,278 [Application Number 05/302,352] was granted by the patent office on 1975-04-01 for masonry wall constructing process.
This patent grant is currently assigned to Brandt Automasonary Corporation. Invention is credited to Harry J. Brandt.
United States Patent |
3,875,278 |
Brandt |
April 1, 1975 |
MASONRY WALL CONSTRUCTING PROCESS
Abstract
A process for forming a masonry wall member from a plurality of
individual blocks bonded by mortar is disclosed. The blocks are
arranged in a mold in a predetermined pattern and the mold closed
to hermetically seal the mold and maintain the blocks therein in
spaced relationship. A source of mortar is connected to the
interior of the mold and a vacuum is created within the mold by
means of a vacuum pump. When the desired evacuation is reached,
further pressure reduction is discontinued while retaining the
vacuum within the mold. The mortar is then permitted to flow into
the mold to completely fill the interstices between the blocks as
well as pores therein. A positive pressure may also be applied to
the mortar to additionally facilitate filling of the mold with
mortar.
Inventors: |
Brandt; Harry J. (Granite City,
IL) |
Assignee: |
Brandt Automasonary Corporation
(Granite City, IL)
|
Family
ID: |
23167396 |
Appl.
No.: |
05/302,352 |
Filed: |
October 30, 1972 |
Current U.S.
Class: |
264/510;
264/DIG.78; 264/102; 264/261; 264/571 |
Current CPC
Class: |
B28B
19/0053 (20130101); B28B 1/24 (20130101); Y10S
264/78 (20130101) |
Current International
Class: |
B28B
19/00 (20060101); B28b 001/24 () |
Field of
Search: |
;264/101,102,261,328,90,DIG.78 ;425/405,DIG.60 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
"Prefab Masonry System Ready to be Marketed", pp. 42-45 of Brick
& Clay Record, July 1964..
|
Primary Examiner: White; Robert F.
Assistant Examiner: Pavelko; Thomas P.
Attorney, Agent or Firm: Denk; Paul M.
Claims
Having thus described the invention, what is claimed and desired to
be secured by Letters Patent is:
1. In the process of prefabricating a masonry wall member from a
plurality of construction blocks including bricks or the like
through the use of a form container and a vacuum pump, including
arranging a series of such blocks in the form container and into
the configuration of a wall member desired, rigidly enclosing the
arranged blocks within the container to allow for their hermetic
sealing therein, reducing the pressure in the closed container down
to an approximate vacuum, discontinuing any further pressure
reduction by ceasing the vacuuming of the sealed container by the
operation of the vacuum pump while maintaining the developed vacuum
within the sealed container, providing a source of flowable
cementitious for the interior of the container, then drawing the
flowable cementitious material into the container through the
influence of the developed vacuum to fill all the interstices
uniformly and completely between the arranged blocks, and
thereafter discontinuing the drawing of material into the container
and allowing the wall to set and commence cure.
2. The invention of claim 1 and including applying a pressure upon
the cementitious material as it is being drawn into the container
by the approximate vacuum force.
3. The process of claim 1 wherein the flowable cementitious
material has the following approximate composition:
and totaling about 100%.
4. The process of claim 1 and including disposing a pattern means
in the form container to facilitate the initial arrangement of the
series of blocks into the same.
Description
BACKGROUND OF THE INVENTION
This invention relates generally to the construction of masonry
walls, but more specifically, relates to the prefabrication of
masonry walls from construction blocks or bricks by means of vacuum
injecting of mortar material into a hermetically sealed container
to provide for complete filling of the interstices between the
arranged bricks, and then allowing for hardening of said
mortar.
With the advent of modular type of construction becoming in vogue
in more recent years, for the purpose of expediting the
construction and resurrection of homes and buildings, various types
of processes have been devised mainly for the purpose of
accelerating home building, but in addition, to provide for cost
reduction. For example, a number of construction companies now
provide the service of constructing and furnishing custom made
masonry walls, wherein the wall is formed at a plant site, and then
shipped to the location where it is to be used according to
engineering and architectural specifications for constructing a
building or a home. Usually, these walls are constructed and
furnished to the contractors at specified dimensions, and generally
a plurality of such walls are ordered so that they can be mass
produced efficiently at the construction plant, and then
transported to the various job sites where they are required.
It is known that one particular contractor constructs a masonry
panel at its plant site by means of the arrangement of a plurality
of bricks into a mold, and then lowers an air bag onto the top of
the formed bricks to generally seal them in, and thereafter, pumps
mortar through a series of ports into the form for filling the
spaced between the arranged bricks. This procedure is helpful in
allowing for the reasonably rapid construction of preformed brick
walls, at least more rapid than can be achieved by a series of
bricklayers at a job site, but the concept of pumping under
pressure the mortar mix into a form or mold box approximating six
by twelve feet in dimension, and containing a large number of
bricks to provide a wall of that size, leaves an undesirable number
of voids or pits between a certain number of the arranged bricks
impairing the compressive strength of the brick wall when used.
This supplier after the mold box has been removed from its brick
wall, and the wall erected, then utilizes tuck pointers to fill the
always remaining pockets or void spaces that appear on the surface
of the wall.
Various prior art patents have considered methods for
prefabricating glass block panels and ceramic tile sheets, but not
masonry walls, mainly through the use of pressure injecting of
fluid grout material into a mold holding a plurality of adjacent
tiles, or simply arranging a series of glass blocks so as to
provide some space between the same, introducing a curable
cementitious bonding material into the frame and then vibrating the
assembly to provide compacting and eliminating of voids between the
glass blocks. These embodiments and methods are shown in the United
States patent to Abernathy, et al., U.S. Pat. No. 3,192,567, and in
the patent to Russell, et al., having U.S. Pat. No. 2,972,783.
The only use of reduced pressure or vacuum pressure, for mass
producting panels is shown in the two patents to Kastenbein, U.S.
Pat. No. 2,855,653, and Robinson, U.S. Pat. No. 2,781,554but the
use of vacuum or low pressure in the embodiments shown are simply
to hold the tile members in place while the grout is inserted
between the grooves formed intermediate adjacent tiles, and said
vacuum pressure is not used for the purpose of providing efficient
injecting of such grout between a series of tiles hermetically
sealed in a container.
In view of the foregoing, it is the principle object of this
invention to provide a method for deposition of mortar between a
plurality of bricks arranged in a hermetically sealed container and
in a manner which totally eliminates all voids or air pockets that
generally form intermediate such bricks under known methods.
It is a further object of this invention to provide an efficient
and rapid method for prefabricating a brick wall, and reducing the
amount of manual labor required to achieve the same.
It is a further object of this invention to provide an apparatus
that incorporates pattern means for expediting the arrangement of a
series of bricks in a container, with the same pattern means being
utilized for forming a uniform and pleasingly appearing joint
between adjacent bricks in a fabricated wall.
Another object of this invention is the provision of an apparatus
that can quickly form a brick wall in better alignment and
plumbness.
These and other objects will become more apparent to those skilled
in the art upon reviewing the following summary, and the
description of the preferred embodiment in view of the
drawings.
SUMMARY OF THE INVENTION
This invention includes a container formed of the usual side walls
and bottom wall and further incorporating a closure member that may
be employed for hermetically sealing the same when in use in
forming a prefabricated wall from construction blocks, bricks, or
the like. The container further includes the use of patterned
means, such as a layer of resilient or elastic material that may
rest upon the bottom wall of the container, so that as the
construction blocks are arranged therein and the closure member
fastened upon the container, the pressure of the closure member
upon the blocks forces their partial embedment into the resilient
material thereby forming a slight compressibility of the material
intermediate adjacent blocks to enhance the joint appearance after
formation of the wall. Other forms of spacers or the like either
for reducing the size of wall that may be formed from a mold box
having a maximum dimension that might be in the vicinity of 72
square feet, may be used for reducing the size of wall that may be
constructed in this apparatus, or such spacers may be used for
forming window openings, door openings, or other apertures that
might be required in a custom designed wall.
The aforesaid container and its internal components are designed
for cooperating with a vacuum pump that may be coupled to a side
wall of the container, and communicating therein, as through some
form of a valve, so that as the container has been sealed with the
bricks properly arranged therein, the atmospheric pressure within
the container may be vacuumed, as for example, down to ten
millimeters of mercury, all in preparation for the subsequent
injection of a mortar mix into the container. A reservoir is
further adapted for communicating with various ports leading to the
container, and these ports may be located spacedly along the side
walls of the container so that when the mortar mix is released for
vacuum attraction into the mold, it will conveniently enter into
the container at a plurality of locations to provide for its
pervading throughout all of the interstices between the arranged
blocks, thereby filling these voids to capacity, and providing a
dense mixture of mortar between each brick for enhancement of the
walls eventual compressive strength as when used in construction.
It might be remarked that the vacuum injection of the mortar mix
into the container reduces the pressure and forces that are usually
urged upon the arranged bricks as occurs in the now used pressure
injection process. Pressure injection, as now used in the trade,
can cause undesirable shifting of bricks due to the force of the
incoming mortar, whereas in vacuum injection the mortar mix is just
drawn into the containers without exerting too much force.
To further facilitate the injection of the mortar mix into the
enclosed container, and to provide for its complete pervasion
throughout the spacing intermediate arranged bricks, it is
desirable to provide a chamber coupling with the container and
arranged intermediate it and the vacuuming means so that after the
bricks have been properly arranged within said container, and it
has been hermetically sealed, and then vacuumed, the vacuum pump
may be shut off, its valve closed, and then mortar mix may be
injected into the sealed container allowing it to fill all of the
spacings between said bricks, and also fill this additional chamber
to insure that the mortar mix has traveled through all portions of
the container filling all of the interstices between the arranged
bricks.
The type of mortar mix employed in this particular invention may be
of the usual type employed in cementing concrete blocks or bricks
together, and includes as ingredients, a fine aggregate, some
cement, water, and desirably, a mortar additive that adds
flowability to the mix. An example of this type of mortar additive
is the type that may be acquired from the Dow Chemical Company, of
Midland, Mich., and sold under the brand name Sarabond. It is
believed that this Sarabond brand mortar additive comprises a
synthetic polymer, including a combination of polymer and
co-polymer in a fifty percent solid suspension. The composition,
more specifically, is a vinylidene chloride polymer latex which add
the attributes to a mortar mix as aforesaid. The product is in an
emulsion form and adds fluidity to the mortar mix, in addition to
increasing its bonding stress, tensile strength, after the
prefabricated wall has hardened and cured. For example, test
specimen brick walls have been formed by the process of this
invention, in additon to manually being formed, and each of the
brick walls formed had the approximate dimensions of 31/2inches
wide, 163/4inches in length, by 153/4inches in height. The brick
wall formed manually when tested for compressive strength fatigued
under the Face Brick Prism test at the application of 2619 p.s.i.
On the other hand, the brick wall of the same size and formed
through the use of this invention, utilizing a Portland Cement
mortar mix incorporating the Sarabond mortar additive when tested
under the Face Brick Prism test for compressive strength fractured
at the application of 5935 p.s.i. Hence, the wall formed through
the use of this invention exhibited an increase of 126.6 percent
compressive strength over manually laid bricks. In addition, and it
might be remarked, that the injection of the mortar mix into the
bricks arranged in the container of this invention in forming the
machine made wall of this test took only a total of 7 seconds, over
the many minutes of time it took to manually apply a mortar mix
between the bricks when forming the manually laid brick wall of
this test.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, FIG. 1 discloses a perspective view of the
hermetically sealed container of this invention showing the
injection and outlet ports of the same;
FIG. 2 provides a schematic view of the various components employed
in the process of forming prefabricated brick walls under this
invention;
FIG. 3 discloses an exploded view of the container means of this
invention further showing the pattern means provided upon the
bottom wall of the same;
FIG. 4 provides a plan view of the bottom wall of this
invention;
FIG. 5 provides a sectional view taken along the line 5--5 of FIG.
4;
FIG. 6 discloses a sectional view taken along the line 6--6 of FIG.
5, and further showing the arrangement of a series of bricks upon
the bottom wall pattern member of this invention; and
FIG. 7 discloses a partial exploded view of a part of modified
container and pattern member of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In referring now to FIGS. 1 and 3 of the drawings, there is
disclosed the apparatus A of this invention shown as a container
having side walls 1 of a form like member, and incorporating a
bottom wall 2 and a top closure member 3, which when these
components are brought together and rigidly secured, comprises an
enclosure in which the prefabricated wall of this invention may be
formed. To insure the tight sealing of this container when closed,
the bottom wall 2 may include a layer of some elastic or resilient
material, as at 4, so that when the side walls 1 are rested in
contact upon the same, and pressed against the same, it will
provide for hermetic sealing at this juncture. In addition, the top
wall 3 also includes a layer of some form of a sealing or gasket
like material which is resilient and will additionally provide for
air tight sealing at this location. Furthermore, and as shown in
FIG. 3, one means for clamping the bottom wall and top closure
member against the form walls 1 may be achieved through the use of
a series of fasteners, as for example a series of bolts and nuts
(not shown) which may be inserted through the series of aligned
apertures 6 and 7 as provided through the members 2 and 3.
Obviously other forms of clamping means can be utilized.
By also referring to FIGS. 1 and 3, it can be seen that a series of
ports, one comprising a cementitious material or mortar mix inlet
port 8 is provided through one side wall, and it is through this
port that the mortar mix may be injected into the container, while
an outlet port 9 is provided at the opposite side wall and it is
through the use of this latter port that the vacuuming means may
withdraw atmospheric pressure from teh enclosed container, in
addition to providing access to a secondary chamber which will also
fill with the mortar mix during formation of a prefabricated wall.
Obviously, there may be one or more inlet ports or outlet ports
provided at various locations around the side walls, all depending
upon the size of prefabricated masonry wall to be constructed. But,
in the embodiment shown, which comprises the prototype apparatus
utilized in constructing the test walls, as previously described,
it was only necessary to utilize one inlet and one outlet port. If
the size of wall to be constructed through the use this invention
be of any greater size, as for example, in what has become the
standard form of prefabricated wall being generally 6 feet by 12
feet in dimension, then additional inlet ports should be
strategically located around various of the side walls for the
purpose of providing convenient access of the mortar mix into
various interior locations of the container during injection of the
same.
It should be noted from FIG. 3 that the bottom resilient layer 4
discloses one means of providing a pattern for arranging the
construction blocks or bricks into the container during set up for
formation of a prefabricated wall. In this particular instance, the
cushioning material of this layer 4, which might comprise a
polyurethane, or other polymer or soft rubber, and has imprinted
thereon a pattern which guides the workman in positioning of the
various bricks onto this bottom wall during their arrangement prior
to the hermetic sealing of the container into closure. This
pattern, as shown at 10, may comprise an imprinting of the same
thereon, and includes the usual dimensions or spacings, as at 11,
providing the joint or interstices between each arranged brick and
where the mortar mix eventually will settle between bricks after
injection into the container. To further aid in the arrangement of
bricks into the container, as during set up, this layer 4, and more
particularly its pattern 10, may be molded so that its joints 11
are formed in bas-relief so that they provide a guide for insertion
of the bricks therebetween, and in addition provide somewhat of a
concave joint for the mortar, to enhance the appearance of the
finally prepared masonry wall. Furthermore, and even where the
pattern 10 and joints 11 are not formed having a slight rise, after
the masonry blocks are arranged upon the liner 4, and as the entire
container, including its closure member 3, are brought together
into sealed closure, since the design of the side walls 1 exhibit a
height slightly less than the width of the standard bricks, the
bricks will then be squeezed or slightly pressed into the liners 4
and 5, providing a slight compressibility or protruding of the
pattern means and joints 10 and 11 a short distance interstitially
between the bricks thereby providing a pleasing appearance to the
mortar joint after the wall has been formed. As is well known, the
usual procedure in tuck pointing is to utilize a brick joiner for
providing some concavity to the mortar joints between laid bricks,
and this principle can be achieved through the use of this
invention by utilizing a resilient material to form the liners 4
and 5.
Where it is desired to construct a wall to smaller dimensions,
various types of spacers, as for example, the spacer 12 shown in
FIG. 3, may be inserted within the form walls 1 of the container so
as to reduce the dimensions of the prefabricated wall being
constructed. Furthermore, and where the apparatus may be of large
dimensions, as when it is desired to construct large segments of a
wall, spacers of various configuration such as shown at 12 may be
used at various locations inwardly of the formed walls 1 so as to
provide openings for doors, windows, or the like. Obviously, the
height of the spacers 12 should be equivalent to the width of the
bricks being used, so that the edges of this spacer will depress
slightly into the resilient liners 4 and 5 and prevent the mortar
mix from oozing therebetween. Where the spacers are to be used as a
liner along the inner surfaces of the walls 1, as shown in FIG. 3,
then it may include an aperture 13 for alignment with each inlet
and outlet port 8 and 9, so that the mortar mix may enter into its
interior and form a filling between the arranged bricks. On the
other hand, where the spacer 12 is being used to form an aperture
interiorly of the side walls 1, then there should be no apertures
13 provided therein so that no mortar mix can get within the
confines of the spacer.
FIGS. 4 through 6 disclose another form of liner 14 that may be
utilized in place of the liner 4 previously described. In this
particular instance, it can be seen that the resilient material is
molded having a series of raised edges, as around its periphery 15,
in addition to providing a uniformly and pleasingly appearing
mortar joint between each brick after this cementitious composition
has been injected into the same.
The various types and modifications for providing pattern members
for use in arranging bricks into this container are numerous, and
another example as shown in FIG. 7. In this particular instance,
the bottom wall 2 and its liner 4 are the same as previously
described, and the type of side wall formed as shown in FIG. 3 will
also be provided. But, instead of utilizing a spacer, such as
spacer 12 previously described, in this particular modification the
spacer will comprise an upper component 17 and a lower component
18, which when brought together one on top of the other, have a
height equivalent to the previously described spacer 12. In
addition, intermediate the upper and lower components of this
spacer there may be arranged a pattern member 19 which may be
constructed of any type of metal, plastic, or other reinforcing
material, and will have previously had the pattern for the bricks
to be arranged punched therein, as shown at 20. Hence, it can be
seen that this pattern member 19 is arranged approximately one half
the width of the concrete block or brick above the bottom wall 2,
and preferably will be located somewhere at the location of the
mid-height of the inserted blocks. Hence, when cementitious
material is injected into the ports 21 of the spacer, it will
pervade around the various interstices of the bricks arranged
within the container, in addition to flowing upwardly and
downwardly of this pattern member 19, providing for its permanent
embedment within the prefabricated wall. Hence, in this manner, the
prefabricated wall will have the enhanced compressive strength
desired from a brick-mortar wall, but in addition, this reinforcing
member will add significant tensile strength to the prefabricated
wall. The usual outlet portion 22 is shown and is formed by
bringing the upper and ower components 17 and 18 of this spacer
together.
It is also likely that usual clip angles and L-bolts (not shown)
may be cemented into the formed wall and provide the means for
joining a plurality of these masonry panels together.
A schematic drawing as to how the principle of this invention may
be put into operation is disclosed in FIG. 2. As shown, a mixer 23
may be provided for the continuous and proximate mixing of the
mortar composition used in this invention, and the mixer after
completing this operation transfers its mix to a reservoir 24,
which is designed having a capacity for holding enough mortar to
fill the requirements of the apparatus container A as it injects
its mix through the inlet port 8 of the same, in addition to
filling the residue chamber 25 connecting with the container A
through the outler port 9. Some means 26 may be provided upon the
reservoir 24 for exerting a slight pressure thereon so as to
prevent any air bubbles or the like from being drawn into the
vacuumed container A during the mortar injecting process.
Connecting with the container A through the chamber 25 is a vacuum
pump 27, and which is used for vacuuming the container after it has
become ladened with the arranged bricks. The valve may be provided
at the location of 29, in addition to a filter as at 28, so that
when the container has ben vacuumed, or approaches vacuuming, the
valve may be shut off for removing the pump from the system, and in
addition, the filter acts to prevent any residue mortar or dirt, as
from a previous cycle, from entering into the vacuum pump and
damaging the same. Also, a valve 30 may be provided at the inlet
port for use in closing off the container as while it is being
vacuumed.
An example of the operation of the principle of this invention is
as follows. A cementitious mixture of materials comprising a fine
aggregate within the range of from 30percent to 45percent by weight
of the total composition, cement at 30percent to 45percent of the
total composition, by weight, water within the vicinity of
10percent to 20percent by weight, and, if desired, a mortar
additive such as the Sarabond brand additive as previously
described may be included within the range of from 5percent to
15percent of the final mortar mix and all added to the mixer 23,
and thoroughly agitated to provide a mortar mix having a
consistency of flowable viscosity to provide for its easy passage
through the various tubes and ports employed in this apparatus. A
high vacuum pump was coupled to the vacuum box through the outlet
port 9 and the container. With its closure member 3 removed, the
bottom 2 was then lined with a thick rubber sheet type of material,
forming the lower liner 4 of this invention. Then, the form or side
walls 1 were lowered into place upon the bottom wall 2 and its
liner 4. It might also be remarked that the container of this
particular test was manufactured from magnesium to provide
sufficient strength from this lightweight of material. After the
bricks were arranged upon the liner 4 within the container, the lid
or closure member 3, with its rubber liner 5 was lowered in place
upon the walls and fastened through the use of a series of clamps.
The mortar reservoir was coupled with two inlet ports provided in
the side walls, with the vacuum pump, as previously described,
being connected to a single outlet. The valve 30 provided at the
inlet port 8 was shut off, so as to prevent the ingress of any
mixed mortar, while the valve at the outlet port was opened, and
the vacuum pump rendered operative to reduce the pressure within
the sealed container down to approximately ten millimeters of
mercury. The vacuum pump was run for approximately five minutes to
achieve this pressure reduction. The valve on the vacuum pump side
of the container was closed, and then the valve on the injection
side of the container was opened and the mortar was drawn rapidly
into the device, and in this particular instance, within seven
seconds. After it appeared that the mortar had completed its
injection into the container, apparently increasing the pressure
within the container to approximately atmospheric pressure, the lid
was removed and mortar mix allowed to set to hardening. It was
quite obvious that the mortar mix had filled all of the voids or
air spaces in the container, being attracted to the same by the
force of the vacuum pressure, leaving the face side and back side
of the formed masonry wall free from any residue material and
having uniformly appearing mortar joints due to the slight
protrusion of the gum rubber liners intermediate the arranged
bricks. Finally, and in this particular instance, the side walls 1
of the container were separated to allow the brick wall to be
totally exposed and removed from the container.
In view of the foregoing, numerous variations in the construction
of this mortar injecting apparatus, in addition to its method of
use, within the scope of the appended claims, will occur to those
skilled in the art in light of the foregoing disclosure. The
described embodiments are merely illustrative of the principle and
operation of this invention.
* * * * *