Cement blocks for masonry walls to buildings

Abstract

 These Cement Blocks are lightweight and multicellular; they are provided with a slab (2) as a base for the grooves (3) on one horizontal side; pyramoidal/conoidal tongues (6) on the opposite horizontal side for their mechanical interlocking. Grooves (3) are deeper than pyramoidal/conoidal tongues (6) to allow, the application of shear connectors, and bonding mortar, when desirable.
They are provided with tongues/grooves (5) (4) at their opposite vertical edges; with grooves (4) deeper than tongues (5) for mortar bonding to the perimetral contact with the bearing elements.
These blocks can be erected in running bond; at an angle by super-imposition; they eliminate thermal bridge, and facilitate the installation of plumbing/electrical conduits, without excessive mortar. From their fabrik they allow substantial reductions to wall plasterworks.

Description

[0001] The invention relates to a system of lightweight cellular cement blocks, for the construction of:

1- Unreinforced Masonry to Buildings

2- Reinforced Masonry to Buildings

[0002] Cement blocks for unreinforced masonry are consisted of vertical webs longitudinal/transversal, one base slab, tongues and grooves in a shape a layout and distances, to allow the straight engagement of the blocks at length, height and at an angle by superimpose of the blocks.

[0003] Cement blocks for reinforced masonry are consisted of longitudinal /transversal webs; tongues/grooves in a shape and layout, so as to allow their straight interlocking at length, height and at an angle. They are equiped with large cells for reinforcing, horizontally/vertically, and easy concreting.

[0004] The existing cement blocks for both applications, have production and site erection pecularities rendering their use nearly as expensive as the traditional known without special features, and thick plastering. Furthermore moisture-watertightness is not to an accepted aesthetic standard; and mechanical interlocking between blocks and masonry walls, is not adequately successful, with resulting problems of fragilities at edges and ridges, and/ or vertical/horizontal alignment.

[0005] The invention as described is intended to eliminate these disadvantages. Solves the problem of frequent wall levelling of the masonry and reduces meanwhile the dead weights of the bearing skeleton. It satisfies the existing requirements for the fire safety and provides even and closed textured surfaces, thus reducing the required plasterwork to a fine coating 2-6 MM milimetres or can be covered with wall paper, cement or akrylic paints e.t.c. It provides the possibility to construct the masonry without bonding mortar, except only perimetrically to the bearing skeleton and the application of a fine coating 2-6 MM milimetre, reinforced with polypropylene fibres or fibrilated polyethylene.

[0006] The first layer of the blocks is very important to be level for the truly vertical erection of the walls.

[0007] Cement blocks are built by design without mortar, thus avoiding the known quality problems mortar creates. Due to the shape and sizes of the grooves on the blocks for unreinforced masonry, it is possible to provide on site tie wires or shear connectors protruding from bearing element (column; or bearing wall)and laid in the grooves with mortar for lateral and shear rigidity of the wall. If longitudinal, to the wall, increased rigidity is desirable (e.g. for major earthquake zones) it is possible to apply mortar on horizontal joints only, for the unreinforced masonry blocks. Thanks to the special tongues/grooves of these blocks for their not hindered mechanical interlocking, and for some of them, with open large cells, through concreting later. They ascertain their joint moisture-water tightness/insulation during concreting or as unreinforced walls.

[0008] These cement blocks provide lightweight and due to their characteristics render wall erection, of any type, more productive, and straight forward building procedure. They provide; thermal, acoustic insulation, fire safety, reduction of dead weights and can be cut by a common saw.

[0009] Other benefits are: the elimination of thermal bridges through bonding mortar, possibility of bonding at an angle, either by superimposition or mechanical interlocking, change of their width in height and length of the masonry.

[0010] For the cement blocks of nonreinforced masonry, the easiness to cut chases, for the installation of plumbing pipes/electrical cables, and convenience to cover these chases quickly with mortar at site, is an appreciable advantage, thanks to their multicellular structure.

[0011] For the cement blocks of reinforced masonry, these services conduits, should be installed in the cells before the reinforcing steel and concreting works. Concreting for the reinforced masonry is effected, as low lift e.g. 1.40-1.60 metres in height for the blocks with closed short edges, and high lift e.g. 2.80-3.20 metres in height for the block with open short edges.

[0012] Considering the high labour costs and difficulty to find skilled technicians, one can easily conclude the practical and economic advantages with the choice of these blocks.

[0013] The blocks are manufactured from ordinary portland cement; grey or white; pumice, expanded or processed lightweight aggregates; man-made aggregates of low to medium modulus of deformation (8-17 N/MM²); natural aggregates at a low ratio, chemical and or active mineral additives; colour pigments (optional), and clean water, all at fixed ratios. With the proper analogies of raw materials and the appropriate production machinery, these blocks have even and closed textured surfaces.

CEMENT BLOCKS FOR NON REINFORCED MASONRY

[0014] Figure 1 shows in perspective the cement block for non reinforced masonry.

[0015] Figure 2 illustrates a plan from the underside of the block, that is not shown in fig. 1.

[0016] Figure 3 illustrates a transverse section of the block.

[0017] Figure 4 illustrates a longitudinal section of the block.

[0018] Figure 5 illustrates a plan from the upperside of the block.

[0019] Figure 6 illustrates a longitudinal section of the half block.

[0020] Figure 7 illustrates a transverse section of the half block.

[0021] Figure 8 and 9 illustrates a plan from the upperside and underside respectively, of the half block.

[0022] Figure 10 and 11 illustrates a plan from upperside and underside respectively, of the half block with straight shoulders for free wall ends and wall corners.

[0023] Figure 12 and 13 illustrates a plan from upperside and underside respectively, of the block with straight shoulders, for free wall ends and wall corners.

[0024] A half block with tongues/grooves (4),(5) of masonry wall both sides and a half block with straight shoulder create a block of the figure 12 and 13. The cellular cement blocks are composed of vertical webs (1) longitudinal adn transversal with a thin slab (2) as a base for the grooves (3). Grooves (3) are deeper than pyramoidal/conoidal tongues (6) to allow, when desirable, the application of tie wires/shear connectors, and bonding mortars with the trowel. Tongues (5) interlock during application within grooves (4), securing the mechanical and when required , through the mortar bonding at horizontal base grooves (3). Mortar is not required to the vertical short edges of the blocks, but only to the perimetral contact with the bearing elements (e.g. columns and wall bearing masonry), if concreted prior to wall erection. For this reason internal grooves (4) are deeper than tongues (5).

[0025] The pyramoidal or conoidal tongues (6) are locking within the grooves (3) ascertaining the transversal mechanical, in the grooves (3) bonding of blocks in height. During the blocks laying slab (1) lies on their upperside.

[0026] The pyramoidal/conoidal tongues (6) are equally spaced from both sides of the block, and are of the same dimensions. for all the thicknesses of walls used to buildings. With this provision it is possible to bond the blocks by superimposition; a valuable advantage for wall crossings and tying-up of partitions to main walls or partitions to themselves.

[0027] The cement blocks with straight shoulders are used for wall endings; free ends; windows; doors and for building walls at an angle.

[0028] These blocks; with the appropriate raw materials; provide thermal, acoustic insulation, fire safety and can be cut easily, to any size, by a common saw. The main cells are five to seven or nine to eleven for internal or external walls, respectively and wall thickness commonly in use.

CEMENT BLOCKS FOR REINFORCED MASONRY AND SHEAR WALLS

[0029] The basic types of this category cement blocks are divided into two groups; namely the blocks with closed short edges types for low lift erection, due to the vertical steel reinforcement; and the open short edges types for a complete storey height erection, which can reach up to 3.20 metres.

GROUP 1 THE CLOSED SHORT EDGES BLOCKS are mainly eight:

[0030] The bond (main) unit; the half bond; the bond with straight shoulder on one short edge, for wall with free endings (doors/windows) and corners, the pilaster for 200/250/300 milimetres thickness walss; the block with reveal for 250/300 milimetres thickness walss; the block for lintels/bond beam; the rolling shutters block; and the iso-insulating block. The block with reveal for openings can be cut in half with common saw.

[0031] Figure 14 shows a perspective view of the bond block.

[0032] Figure 15 illustrates a longitudinal section of the block with reveal for openings.

[0033] Figure 16 illustrates a plan of the block with reveal for openings.

[0034] Figure 17 illustrates a transversal section of the bond block.

[0035] Figure 18 illustrates a longitudinal section of the bond block.

[0036] Figure 19 illustrates a plan of the bond block.

[0037] Figure 20 illustrates a longitudinal section of the block with straight shoulders on one side, for wall free endings, to openings or at an angle.

[0038] Figure 21 illustrates a plan of the block with straight shoulders on one side, for wall free endings, to openings, or at an angle.

[0039] Figure 22 illustrates a longitudinal section for the half bond block.

[0040] Figure 23 illustrates a plan for the half bond block.

[0041] Figure 24 illustrates a longitudinal section for the pilaster block.

[0042] Figure 25 illustrates a plan for the pilaster block.

[0043] Figure 26 illustrates a transverse section for the pilaster block.

[0044] Figure 27 illustrates a transverse section for the lintel/bond beam block.

[0045] Figure 28 illustrates a longitudinal section for the lintel/bond beam block.

[0046] Figure 29 illustrates a plan for the lintel/bond beam block.

[0047] Figure 30 illustrates a transverse section for the lintel and perimetral slab endings blocks to buildings.

[0048] Figure 31 illustrates a longitudinal section for the lintel and perimetral slab endings blocks, to buildings.

[0049] Figure 32 shows a perspective view for the lintel and perimetral slab endings blocks to buildings.

[0050] Figure 33 illustrates a transverse section of the iso-insulating block, for external/common use walls.

[0051] Figure 34 illustrates a longitudinal section of the iso-insulating block, for external/common use walls.

[0052] Figure 35 illustrates a plan of the iso-insulating blocks, for external/common use walls.

GROUP 2 THE OPEN SHORT EDGES BLOCKS are mainly seven:

[0053] The bond (main) unit; of double I, in plan configuration; the half bond unit of I, in plan configuration; the M channel in plan configiration; the block for the reinforced concrete beam erection; the rolling shutters block; and the iso-insulating block.

[0054] Figure 36 illustrates a longitudinal section of a block, of shape M.

[0055] Figure 37 illustrates a longitudinal section of a block, of shape I.

[0056] Figure 38 illustrates a transverse section of a block, of shape O.

[0057] Figure 39 illustrates a plan of a block of shape M.

[0058] Figure 40 illustrates a plan of a block of shape I.

[0059] Figure 41 illustrates a transverse section of a block,of shape I.

[0060] Figure 42 shows a perspective view of a block of shape M.

[0061] Figure 43 shows a perspective view of a block, of shape double I.

[0062] Figure 44 illustrates a longitudinal section of a block, of shape double I.

[0063] Figure 45 illustrates a transverse section of a block,of shape double I.

[0064] Figure 46 illustrates a plan of a block, of shape double I.

[0065] Figure 47 shows a perspective view for the lintel and perimetral slab endings blocks to buildings.

[0066] Figure 48 illustrates a transverse section for the lintel and perimetral slab endings blocks to buildings.

[0067] Figure 49 illustrates a longitudinal section for the lintel and perimetral slab endings blocks to buildings.

[0068] Figure 50 illustrates a transverse section for the rolling shutters blocks.

[0069] Figure 51 illustrates a longitudinal section for the rolling shutters blocks.

[0070] Figure 52 illustrates a transverse section for the reinforced concrete beams erection blocks.

[0071] Figure 53 illustrates a longitudinal section for the reinforced concrete beams erection blocks.

[0072] Figure 54 illustrates a plan for the reinforced concrete beams erection blocks.

[0073] The figures illustrate the basic types of blocks for a load-bearing masonry system under Group 1 namely the closed short edges types, and for a high lift, high lift erection in one stage, load-bearing masonry or frame type construction system, consisted of columns/shear walls (and infill walls) under Group 2, namely the open short edges types.

[0074] THE CLOSED SHORT EDGES TYPES GROUP 1 have basic characteristics the shape, size and layout of the horizontal grooves (2) (4) (5), tongues (1) (3) (6), the vertical: grooves (7) (8) (11) (13) and tongues (9) (10), with the tongues (10) projecting further to tongues (9), for enabling these tongues to positively interlock into the respective grooves (8) and (13), for a run/stack bond or at an angle, providing stability and insulation against mortar escape, during concreting.

[0075] The grooves (7) provide easy path for the grouting concrete, for most consistencies of concretes in addition horizontal reinforcement do not hinder concreting and distribute more uniformly the stresses from infill concrete to the blocks, either as shrinkage or lateral reinforecements.

[0076] The cross-webs (12) positioned at the lower half of the blocks provide the advantage of producing these blocks without production pallet, by means of an appreciably low investment mobile block-maker. The arrangement of horizontal tongues (1) (3) (6) provide for more uniform distribution of stresses on the blocks and for thinner external face shells; thus lighter blocks.

[0077] The half bond block with straight shoulder on one edge (without tongues/grooves) is required for the free wall endings; to openings; for up to 200 milimetres wall thicknesses. The pilaster block is provided for local reinforcement of slender walls, since it can be steel reinforced and concreted, as a normal column.

[0078] The cement blocks lintel/bond beam, is provided with a base slab (15), grooves (4) and notches (16) for the cut-out part of the base, to provide path to vertical steel reinforcement and concrete, at opening's sides. The cement block for lintels for the perimetral slab endings to buildings, is provided with a raised external face shell (12A) that acts as an external mould (shuttering) for the slabs casting, while the tongue (1) is utilized for the continuation of masonry work on the upper floor, and for insertion into groove (2) during manufacturing for stacking and palletizing convenience/economy.

[0079] The combination of these cement blocks provide for lintel and beam construction with the same fabric and finish, as a compatible system.

[0080] It is possible the construction of external face areas of slabs in various architectural features; thanks to the layout of the tongues (1) (3) and grooves (2) of the bond block.

[0081] The iso-insulating blocks for external/common use walls, are provided additionally with a slab (17) of expanded polystyrene (EPS) of high density 25-35 Kg/m³, with the shape as shown hatched in figures 33 and 35, and to one side only, for insulating purposes, and not hindering or participating to the carrying capacity of the combination load-bearing face shell and reinforced concrete poured in the cells.

[0082] This arrangement provide less higher insulating material per block, reducing thus costs; provide larger structural concrete area with the thinner wall masonry, from any other available block. Other obvious advantage is the EPS monoblock design, as one piece, without empty spaces/volumes; rendering this design more economic during manufacturing/transport/handling/erection.

[0083] Another advantage is the simplicity of erection at masonry corners and crossings, often overlooked, and not provided by other systems. The EPS slab is inserted during the production of the blocks, without difficulty, as part of their production cycle. This block design provides the highest value of uniform thermo-acoustic insulation, and higher structural concrete area. Iso-insulating (uniform insulation) blocks can be manufactured also as half of the normal, a unit for lintels/tie beams and that with a straight shoulder on one edge.

[0084] THE OPEN SHORT EDGES TYPES GROUP 2 as shown on the detailed drawings have the additional advantage, from those stipulated under Group 1; the higher erection/concreting height; their use for the construction of columns/shear walls, of whatever orthogonal cross-section, at an angle, or with cross flanges, with thicknesses of 200 to 300 milimetres.

[0085] The flanges of block of shape n has 1/8 - 2/8 (one eighth-two eighths) of the nominal length of a normal block. The nominal length of the face shells of the blocks I and double I are 6/8 - 7/8 (six eighths-seven eighths) of the length of a normal block.

[0086] The grooves (13) are provided for the interlocking of blocks with shapes I or double I, for the construction of shear walls/columns at an angle and with cross flanges e.t.c.

[0087] The grooves (14) at half the block's height are provided for the additional mechanical interlocking of concrete with blocks of shape M, I and double I and as notches for cutting-off pieces (by knocking or pulling) for the construction of column/shear wall sections at an angle, cross flanges, wherever required.

[0088] The use of the combination of blocks, with shape M, I and double I, provide the possibility to construct columns/shear walls after the installation of vertical reinforcing steel. The concreting is effected easily to a height of up to 3.20 metres. For higher pours multiple lift concreting is followed.

[0089] Tying-up of lintel blocks and rolling shutters blocks, for this group is effected through bolts inserted into the holes (18) provided. The cement blocks can be manufactured by Vibrating/Compressing Presses stationary or mobile with built-in tray/pallet, suitable self-levelling suspension system, cleaning equipment, level-even laying platforms and high efficiency vibrators. The dosage and mixing of the raw materials can be effected with suitable dosing/mixing machinery and electronic control of aggregate's moisture content.

Claims

1- The Cement Blocks for non reinforced/grouted masonry are consisted of vertical webs (1) longitudinal/transversal and are characterized by the narrow cells, a base slab (2) with narrow longitudinal grooves (3), the pyramoidal/conoidal tongues (6) shallower than grooves (3) ; the grooves (4) deeper than tongues (5), in shape, and layout that allow their interlocking by length/height and at an angle by superimposition.

2- The Cement Blocks according to claim 1 are characterized by that they have pyramoidal/conoidal tongues (6) in one horizontal side and arranged at right angles to the face shells, and a base slab (2) with strips/grooves (3) at the opposite horizontal side. The shape/dimensions/layout of these tongues /grooves allow erection of masonry at an angle by superimpo-sition, and wire-tying to vertical bearing element.

3- The Cement Blocks according to claim 1 are characterized from internal longitudinal/vertical webs, and vertical grooves (4) deeper than tongues (5).

4- The Cement Blocks for reinforced/grouted masonry with closed short edges, Group 1, are consisted of vertical webs (12) longitudinal/transversal, with cross-webs at mid-height from the base level of the blocks; and resting on this level; except for the units with straight shoulder at one edge; and are characterized from their horizontal narrow tongues (1) (3) (6), with (3) on cross-webs with face webs joints; narrow grooves (2) (4) (5); their vertical: tongues (9) (10), grooves (7) (8) (11) (13) in a shape/size/layout to allow their mechanical interlocking by length, height and at an angle, without mortar, and allow the unobstructed concreting of cells in vertical/horizontal direction without losses. Groove (7) has half the height of the block and provide adequate space for steel reinforcing and concreting.

5- The Cement Blocks according to claim 4 are characterized by their horizontal grooves (2) (4) (5) and their tongues (1) (3) (6) for their horizontal straight interlocking/alignment and leak proof concreting.

6- The Units according to Claim 4 are characterized by cross-webs with half of the units height, and full height at face shell (web) connection, and with base level coinciding to that of the units.

7- The Units according to Claim 4 are characterized by their vertical tongues (10) that are extending beyond tongue (9), for securing their mechanical interlocking within the grooves (13) for the accurate wall erection at an angle or crossings, and concreting of the cells without losses.

8- The Units for lintels or perimetral slab endings, and rolling shutters blocks, are provided with a raised face shell (12A) that act as an external shuttering for the slabs casting, and the shuttering roller, respectively; while the tongue (1) is utilized for the continuation of masonry work on the upper floor, and for insertion into groove (2).

9- The Iso-insulating cement blocks are provided additionally with an Expanded Polystyrene (EPS) slab (17) on one side only, of such a shape, with wedged projections (19) (20) and position, that secure mechanical interlocking of the two material/com-ponents.

10- The Cement Blocks with shapes M, I and double I with open short edges, Group 2, are characterized by their grooves (2) (4) (8) (11) (13), and their tongues (1) (6) (9) (10), with tongues (10) extending further to nominal face shell length, and staggered diagonally on block's plan view, on the face shells only for mortarless erection; that secure their mechanical interlocking and stability during concreting, without losses. Are provided with notches (14) for an additional mechanical interlocking with the poured concrete and cutting-off pieces, wherever required. The cross-webs (12) are placed internally, with half the height and same base level of the block.

Drawing