Note: Descriptions are shown in the official language in which they were submitted.
Il J 70~57
This invention relates to a wall element for use in
constructing walls, and a wall system constructed of two
parallel rows of a plurality of the wall elements laid in
courses in interconnecting relationship, the wall system
being used as constructlon forms for retaining fluid
concrete, or other materials such as sand, paper, insulation,
or other filler materials, poured into the space
therebetween, whereby the two walls remain as a permanent
part of the completed wall system, and a method of
constructing the described wall system from the wall elements
and accessory parts.
BACKGROUND OF THE INVENTION
_
In concrete forming, to construct walls and the
like, it is common practice, to construct a temporary form
from lumber, or other materials, to provide a retaining space
into which concrete alone, or in combination with other
materials, is poured in its fluid condition, after which the
concrete is allowed to set. After the concre-te has set to a
predetermined solid form capable of supporting itself, the
form is stripped away. Sometimes, the surfaces of the
concrete are cleaned and patched to give a smooth surface if
that is required by the job specifications. The forming
material is hauled away, perhaps to be discarded, or to be
used on another job site, if the forming material can be so
adapted.
Because of tne considerable hydrostatic pressure
that is created by the concrete when it is poured to any
reasonable depth, considerable lumber, or other materials,
and sturdy construction of the forms are required to provide
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the necessary strength to retain the heavy concrete.
Considerable time and hence expense is required by carpenters
or other assembly men to construct the forms which in the end
serve only a temporary purpose, namely, retention of the
poured-in-place concrete until it has set to a strength
strong enough to support itself.
The result of this conventional method of forming
concrete walls and the like usually gives an uneven surface
showing the imprint of the form itself. Further, the
'0 concrete often is not tamped into all areas of the form
sufficiently, thereby causing depressions, gaps or other
imperfections in the poured-in-place concrete. These
imperfections must subsequently be repaired by a cement
patching technique which involves extra time and expense.
Further, when the concrete forming technique described is
used, decorative finishes to the concrete surface cannot be
provided without further work and procedure.
The applicant is the owner of two Canadian patents,
Canadian Patents Nos. 922,495, granted March 13, 1973, and
941,588, granted February 12, 1974, both naming John Rudichuk
as inventor. These two patents disclose and claim a wall
forming system that comprises a series of wall elements that
are laid in superimposed courses in two parallel rows, to
provide a pour space therebetween. The two parallel rows of
elements are held in place by a system of H-hooks. When the
parallel walls have been erected with the H-hooks in place,
the fluid concrete is poured in the pour space between the
parallel walls and is permitted to set. The concrete sets
with the wall elements and H-hooks in place to provide a
unitary wall system.
1 1 70857
In the Rudichuk wall system, the wall elements must
be constructed to close tolerances with holes therein for
receiving the legs of the H-hooks. The H-hooks must also be
constructed to close tolerances so that they will fit in the
holes in the wall elements. The holes in the wall elements
and the close tolerances required increase the basic
production cost of the wall elements and the H-hooks. The
protruding legs of the H-hooks also slow erection time
because the holes in the wall elements must be carefully
fitted over the legs, a time consuming procedure.
Furthermore, the wall elements are flat on the top, bottom
and end surfaces and hence when they are placed in abutting
relationship with each other, there is no barrier to the
passing of moisture between the respective wall elements.
To provide further background for the invention,
the followiny is a list of United States and British patents
that disclose and claim various systems for forminy walls
using wall elements and various tying systems:
U.S. Patent No. Inventor
2,029,082 Odam
2,181,698 Langenberg et al.
2,372,038 Westveer
3,238,684 Wood
3,562,991 Custusch
British atent No. Inventor
266,956 Bemis
SUMMARY OF THE INVENTION
The present invention overcomes many of the
disadvantages of the prior systems in the art by utilizing an
outer form made up of two parallel rows of a plurality of
wall elements held in fixed relation by horizontally disposed
1 ~ 7085 7
H-hooks, between which fluid concrete or other filling
material such as sand, paper, insulation, or the like, is
poured. The finished wall is comprised of the
poured-in-place concrete, or other filling material, the
H-hooks and the plurality of wall elements, the latter of
which remain as part of the overall wall structure and make
up the outwardly visible surface of the structure. The
poured concrete or other filling material is concealed. The
wall elements and the concrete or filling material poured
therebetween, by being secured together by the system of
H-shaped cross ties provides a wall structure that is held in
place in somewhat the same manner as are concrete walls held
together by steel reinforcing rods.
To add strength to the overall wall, a suitable
adhesive material may be applied between the wall elements to
cement them together. The adhesive material can also serve
as a vapour barrier to prevent or inhibit the passage of
water vapour between the wall elements.
The danger well known in the concrete construction
art of having the wall collapse by the removal of forms
before the concrete reaches its self-supporting strength is
eliminated since the combination of wall elements and H-cross
ties form part of the wall structure and thereby provide a
basically self-supporting wall. A savi.ng in time, labour and
material costs may be realized over conventional concrete
construction techniques because construction and subsequent
removal and disposal of conventional forms is not required.
The wall is complete once the concrete or other filling
material has been poured into the cavity between the parallel
1 1 7~s~357
rows of wall elements and adhesive material applied in the
joints, if adhesive is being used.
l~ith the precast members, subf]ooring construction
can commence immediately after pouring, thus saving time.
With the present invention, much of the conventional bracing
and supports is not required, and also conventional
excavation required to accommodate such supports is not
required because the form is essentially self-supporting. In
addition, because exterior supporting form work is not
usually required, it is possible to erect a wall according to
the subject invention very close to adjoining structures, or
objects. Erection of the subject invention can also take
place relatively quietly, and this is an advantage in areas
where the usual construction noise cannot be tolerated or is
prohibited.
The width of the concrete pour space between the
form walls can be varied by using H-cross ties of varying
cross bar size to suit the nature of the wall construction
required. The size and configuration of the retaining wal]
elements themselves can be varied by selecting appropriate
types and quantities of wall elements. The individual wall
elements may be cast with assorted surfaces such that the
completed wall provides a decorative block appearance, or a
flat, uniform surface.
There are several main advantages of the subject
invention over prior wall constructions known to the
applicant. These advantages are discussed as follows:
(1) The basic wall elements, unlike most other
wall building blocks taught in the art, have no holes,
1 1 ~0857
openings, or wells therein. The basic wall elements are of
relatively simple construction, and this uncomplicated design
lends itself to low cost and easy, reliable production of the
basic wall elements. A static mold can be used to form the
wall elements, and no moving parts are required in order to
form holes, or other openings, in the wall element.
(2) The tongue and groove design of the basic wall
element, particularly when the tongue and grooves extend on
all four end surfaces of the wall element, provide upon
interlocking with one another a natural moisture transmission
barrier, a feature which is not present when the ends of the
building blocks are formed with flat abutting edges.
Moisture penetration into walls of buildings, and the like,
can frequently be a troublesome problem, because moisture
tends to promote deterioration and degradation of the wall
system. To improve the water barrier properties or strength
of the wall, adhes:ive can optionally be used in the tongue
and groove joints.
(3) In the wall systems disclosecl in Canadian
Patent Nos. 922,49!;, and 941,58~, both naming John Rudichuk
as inventor, an average of four ll-ties per building block are
required. In the present invention, only an average of two
H-shaped cross-ties are required per wall element. A basic
~-shaped cross-tie is a relatively expensive item and cutting
in half the substantial number of ~I-shaped cross-ties that
must be used in erecting the wall, can result in a
considerable construction cost saving.
(4) The subject invention enables a wall to be
erected in a very simple manner. The horizontally disposed
H-cross tie design lends itself to simplicity in erecting the
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wall because there are no holes, openings or wells in which
ties must be fitted, and no vertically extending legs of
vertically disposed H-shaped cross-ties, over which holes or
openings in the wall element in the next course of wall
elements must be fitted. The elimination of any complex
fitting step for each wall element increases the rate at
which the wall can be erected. Moreover, while a wall can be
erected to precise dirnensions, tolerances within the
components of the subject invention are less strict than with
other wall construction techniques. This factor also
promotes accelerated wall erection time.
(5) The rounded groove and the co-operating
rounded tongue of the basic wall element permit the wall
elements according to the subject invention to be slid easily
into place over the matching tongue or groove of the wall
blocks in a lower course in the wall. Furthermore, the
rounded shape of the tongue and the groove tends to reduce
chipping damage to the basic wall element and hence reduce
the number of wall elements that must be discarded in
erecting any particular wall. The matching tongue and
groove design of the subject wall elements also tends to
increase the lateral stability of the wall, thereby reducing
the necessity to rely upon the H-shaped cross-ties for
lateral stability. Further stability can be obtained by
applying adhesive between the tongue and groove on adjoining
wall elements.
(6) The protruding tongue construction of the
basic wall element provides a ridge behind which the leg of
the H-cross-tie fits, thus providing improved holding
characteristics for the wall element H-cross-tie combination
~ J 70~357
over a simple groove in the surface of the element in which
the leg of the H-cross-tie rests.
The present invention is directed to a wall element
adapted for use in association with other similar wall
elements and a plurality of H-shaped cross-ties to construct
a wall, the wall comprising a pair of spaced parallel
sub-walls defining a hollow space capable of being filled
with a filling or adhesive material, the sub-walls each being
comprised of a plurality of the wall elements, the sub-walls
being connected together by the plurality of H-shaped
cross-ties. The wall element has a top, a bottom, and an
interior and an exterior generally rectangular side surface
and two end surfaces, and at least one longitudinal groove in
the top or bottom thereof, and a matching longitudinal groove
in the opposite top or bottom thereof, and second and third
horizontal longitudinally extending grooves on at least the
top wall element, both being parallel to the first
longitudinal groove, the second and third grooves being
located in the region of the respective ends of -the top of
the wall element, each of the second and third grooves lying
in the same longitudinal line at the exterior side of the
longitudinal ridge or groove in the top of the wall element,
and being so configured as to accommodate one leg of one of
the H-shaped cross-ties.
One aspect of the invention is a wall constructed
by utilizing a plurality of the wall elements as described
above, and a plurality of H-shaped cross-ties, wherein the
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1 J 70857
wall elements may be laid in series end to end in at least
two superimposed courses in two parallel opposing rows, each
of the two parallel courses being of generally the same
height and each wall element in each course having an
opposite member directly across in the opposing row, the top
and bottom surfaces of each wall element overlying or
underlying and abutting members in the courses of wall
elements above and below, the wall elements being secured
together by horizontally disposed H-shaped cross-ties, one
lower extension of the H-shaped cross-tie fitting into one of
the second or third horizontal grooves on the top surface of
one of the wall elements in one row, the other lower
extension of the H-shaped cross-tie fitting into one of the
second or third horizontal grooves on the top surface of the
corresponding wall element in the opposite row, the cross~bar
of the H shaped cross-tie extending between the two opposing
elements, one upper extension of the H-shaped cross-tie
corresponding to the first lower extension fitting into one
of the second or third horizontal grooves on the top surface
of one of the wall elements in the same course abutting the
first wall element in end-to-end relation, the other upper
extension of the H-shaped cross-tie corresponding to the
other lower extensi.on fitting into one of the second or third
horizontal grooves on the top surface of one of the wall
elements in the same course abutting the wall element in
end-to~end relation, in the opposite row of wall elements,
the cross-bar of the H-shaped cross-tie extending between the
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I 1 70857
two opposing wall elemen-ts and linking the two opposing wall
elements together.
Another aspect of the invention is a structure
comprising a permanent form and concrete or other filler
material poured into the form, the form comprising a
plurality of wall elements as described above and a pluraLity
of H-shaped cross-ties. The form has inner and outer
conforming sides and a pour space in between, the inner and
outer sides being comprised of a plurality of wall elements
arranged in edge-to-edge and end-to-end abutting
relationship. The H-shaped cross-ties extend between and
connect together the inner and outside sides of the form.
The invention is also directed to a system for
constructing a wall comprising a pair of spaced parallel
relatively thin walls defining a hollow space therebetween
adapted to be filled with poured-in-place concrete. The
system comprises in combination a plurality of H-shaped ties
formed from rod-like material, each tie comprising a pair of
parallel spaced side members joined by a cross-member
extending between points intermediate the end of -the
respective side members whereby each side member comprises
two rod-shaped legs one extending from each side of said
cross-member, and a plurality of wall elements as described
above.
The invention is further directed to a wall
structure constructed by utilizing the above described
system, the wall structure comprising a pair of relatively
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I 1 70857
thin spaced parallel walls defining a hollow space
therebetween, each wall being formed from a plurality of
superimposed courses of the wall elements, the longitudinal
ridges of the wall elements being received in the first
longitudinal grooves vertically adjacent wall elements, the
interior side surfaces of the wall elements in each parallel
wall facing the interior side surfaces of the wall elements
in the other parallel wall, each such wall element in one
parallel wall being in alignment with a corresponding wall
element in the other parallel wall, and a plurality of
H-shaped ties extending horizontally across the space between
the parallel walls, the two legs of each side member of each
H-shaped tie being accommodated in the second and third
grooves of horizontally adjacent wall elements in one of the
parallel walls.
The invention is also directed to a system for
constructing a wall comprised of a pair of half-lapped spaced
parallel thin walls. This system includes a plurality of
wall elements having a fourth horizontal longitudinally
extending groove co-linear with the second and third grooves,
which is located mid-way between such grooves, the fourth
groove being configured to accommodate the legs of one of the
H-shaped cross-ties, and wherein the longitudinal ridge has a
gap therein adjacent a mid-portion of the fourth groove, so
as to allow said fourth groove to accommodate the H-shaped
cross-tie in a horizontally disposed position.
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1 1 70857
The invention is also directed to a system for
constructing a wall which also comprises a plurality of
U-shaped integral end blocks having two sides connected by a
transverse portion.
Further understanding of the invention may be had
by reference to the accompanying drawings which illustrate
specific embodiments of the invention.
DRAWINGS
In the drawings:
FIGURE 1 represents an end view of a wall element
according to one form of the invention.
FIGURE 2 represents a top view of one form of the
wall element.
FIGURE 3 represents a top view of an alternative
for~ of the wall element wherein tongue and grooves are
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.
I ~ 70857
formed on the end faces of the wall element as well as on top
and bottom faces of the wall element.
FIGURE 4 represents a perspective view of the
manner in which two parallel rows of wall elements are linked
together by horizontal H-cross ties to form a basic wall
unit.
FIGURE 5 represents a perspective view of a corner
construction comprising two parallel rows of wall elements
linked together with horizontal H-cross ties.
FIGURE 6 represents a perspective view of a
partially formed wall comprising two parallel courses of wall
elements arranged in abutting end to end and superimposed
relationship linked together by horizontal H-cross ties.
FIGURE 7 represents a front view of an H-cross
tie.
FIGURE 8 represents a perspective view of
alternative methods of forming corner constructions with two
parallel rows of wall elements linked together with E~-cross
ties.
FIGURES ~, 10, 11, 12, 13 and 14 illustrate
cross-sections of various constructions of footings.
FIGURES 15 and 16 are perspective views of two
forms of end block useful in constructing walls in accordance
with the present invention.
DETAILED DESCRIPTION
Referring to Figure 1, which represents an end view
of a wall element 1, the wall element 1 is formed with a
concave bottom groove 2, in the bottom face of the wall
element 1, and a complementary convex top ridge or tongue 3,
which is rounded so that it has the sarne general radius as
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1 3 70857
concave bottom grove 2. Thus, top ridge 3 is formed to match
and fit with the bottom groove 2 of a similarly constructed
wall element 1. In the embodiment of wall element 1 shown in
~igure 1, the two end faces, one in full view and the other
in hidden view, and the broad front and back faces, shown in
profile, are flat.
Located on the top surface of the wall element 1 is
a tie groove 4 which is located adjacent and parallel with
top ridge 3. An optional lateral tie groove 5 may also be
formed in the top face of wall element 1. The bottom face
of wall element 1 adjoining bottom groove 2 is identified as
bottom element face 6.
To avoid an unsightly monolithic broad face
appearance to a wall erected with a plurality of abutting
wall elements 1 in courses, a front face recess 7 is formed
at the top front edge of the wall element 1. Thus, when a
plurality of wall elements 1 is assembled in abutting
end-to-end relationship superimposed upon each other to form
courses, front face recess 7 provides a sight-relieving
groove at each element intersection that extends the length
of the front face of the wall erected from the plurality of
wall elements 1.
Turning to Figure 2, which shows a top view of
wall element 1, it can be seen that the top rounded ridge 3
extends the length of the wall element 1. Two tie grooves 4
are positioned at the two respective ends of the top face of
the wall element 1. The front face recess 7 also extends the
length of the wall element 1. Figure 2 also illustrates the
optional lateral top face mid-groove 9, which can be located
midway the length of wall element 1 to accommodate an
additional H-cross-tie for extra stability.
I 1 70857
With reference to Figure 3, which illustrates a top
view of an al ernative embodiment of wall element 1, it can
be seen that the wall element 1, in addition to rounded top
ridge 3, and front face recess 7, can be constructed to have
an end face groove 10 at one end face of the wall element 1,
and a rounded end face ridge 11 at the other end of the wall
element 1. The radius of curvature of end face groove 10 is
substantially the same as rounded end face ridge 11 so that
end ridge 11 of one wall element 1 will fit snuggly into the
end face groove 10 of an adjoining wall element 1, when a
plurality of wal] e~ements 1 are laid in end to end abutting
orientation.
Figure 4 illustrates the manner in which a
plurality of wall elements 1 are assembled together in
superimposed relationship to form two adjacent parallel
walls. In assembling a wall composed of two parallel rows of
wall elements, two wall elements 1 are first set in parallel
relationship, opposing one another, on a suitable founda-tion
such as a footing, and then two corresponding wall elements 1
are laid on top of the first two parallel wall elements, the
bottom grooves 2 of the upper two wall elements 1 fitting
upon the respective top ridges 3 of the two underlying base
wall elements 1. The opposing pairs of parallel wall
elements 1 are held in place opposite one another by means of
horizontally disposed H-shaped cross-ties 8, the legs of
which fit in the tie grooves 4 forrned at the ends of each of
the top faces of the pairs of wall elements 1. By repeating
the foregoing described assembly procedure, and utilizing
additional wall elements 1 and H-cross ties 8, an entire wall
system can be constructed, with two opposing parallel outside
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I 1 70857
faces, and a pour space therebetween, which can be filled
with poured concrete or some other suitable wall forming
material.
Figure 5 demonstrates the manner in which a corner
can be formed from the basic wall element 1, laid in pairs.
The 90 corner-type wall element 1 can be specially formed
from specially designed molds, or the corner construction can
be formed simply by vertically breaking basic wall elements 1
into required lengths in order to construct on site wall
corners as required by the job specification. The ends of
the respective parallel wall elements 1 are linked together
by horizontally disposed E-l-cross-ties 8.
Figure 5 also demonstrates how an H-shaped
cross-tie 8 can be positioned in horizontal orientation at
midpoint grooves 9 on the upper faces of opposing wall
elements 1. The provision of H-cross ties 8 at midpoints
along the top faces o~ the opposing wall elements 1 provide
the outer wall elements 1 with additional strength to
withstand translated hydrostatic pressures that may occur
when concrete is poured in the space that exists between the
opposing faces of the wall elements 1.
Figure 6 illustrates in perspective view a partial
assembly of a plurality of abutting wall elements 1 arranged
in courses to form two parallel walls which run through a 90
corner, the two parallel walls being linked together by a
plurality of H-cross ties 8 being set in the respective tie
grooves 4 located on the top surfaces of each wall
element 1. The wall assembly rests upon a footing 12, which
is common construction practice.
1~70857
A detail of the H~cross tie is shown in Figure 7.
This H-cross tie 8 is always laid horizontally so that the
legs of the El-cross-tie are received in the horizontal tie
grooves 4 formed in the top surfaces of the wall elements 1.
rhe advantage of having the H-cross tie 8 lie in horizontal
position is that no vertical projections exist over which
overlying wall elements 1 must be fitted in place, as in the
Rudichuk construction disclosed and claimed in Canadian
Patents Nos. 922,495 and 941,588. The absence of vertical
projections increases wall erection time and minimizes the
chance that such vertical projections will be bent or
damayed.
Figure 8 illustrates alternative corner
constructions that can be used in place of the corner
constructions illustrated in Figures 5 and 6 above. In
Figures 5 and 6, no horizontally disposed El-cross ties were
present at the precise corners. However, as demonstrated in
Figure 8, El-cross ties 8 can be located directly at the
corner of the inside wall element so that in effect one
H-cross tie 8a con~inues in a line with one of -the interior
wall elements la while the other El-cross tie 8b continues in
a line with wall element lb.
In a further alternative, H-cross ties 8a and 8b
need not be present and a single diagonally oriented ll-cross
tie 8c can be used. In this system, the legs of E-l-cross
tie 8c must be bent (which can be done on the job si-te) so
that the overall cross-tie 8c takes on an "arrow" shape.
This is necessary so that the legs of -the El-cross tie 8c will
fit in the angled tie grooves 4 of the respective corner wall
elernents 1.
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1 1 70857
In the construction of a basic wall made up of a
plurality of wall elements 1, it is customary to first pour a
concrete footing (See footing 12 in Figure 6) to serve as a
base for the wall. The top surface of the footing may be
constructed to accommodate the overlying rows of parallel
walls according to well-known construction techniques, for
example, forming a pair of parallel grooves in the top
surface of the footing so that the bases of the parallel rows
of wall elements are received in the grooves. These grooves
thereby provide a holding action against lateral pressure
exerted on the bases of the plurality of wall elements caused
by poured concrete or other filling material.
The two parallel walls are erected by laying a
first course of wall elements 1 in end-to-end abutting
relationship, and a second course of opposed parallel wall
elements 1 directly opposed to the wall elements in the first
wall, the two courses of parallel wall elements 1 thereby
defining a pour space in between. The two parallel rows of
wall elements are secured in place by laying ll-cross ties 8
horizontally in each of the tie grooves 4 that are formed on
the top surface at the ends of each of the wall elements 1.
The cross-bar of the ll-cross tie extends from the top of one
wall element 1 in perpendicular manner directly across the
pour space to the opposite wall element 1. It will be
recoynized that the inner and outer walls comprised of a
plurality of wall elements 1 must be spaced apart a distance
that corresponds basically with the length of the cross bar
of the H-cross tie 8 so that the legs of each H-cross tie 8
are received in the respective horizontal tie grooves 4 of
the wall elements 1. Furthermore, the opposing wall
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~ 170~57
elements 1 in the parallel rows must be placed so that they
are directly opposed to one another so that the tie grooves 4
are directly across from each other. This orientation
enables the horizontal legs of the H-cross ties 8 to be laid
in position in the grooves 4 located at the ends of the top
surface of the opposing wall elements 1.
Once the first course of wall elements 1 is in
place in the two parallel rows, the second course of inner
and outer wall elements 1 is then placed in end-to-end
abutting relationship on top of the first course of the
two opposing parallel rows of wall elements 1. Tt is
customary, as in conventional brick-mortar wall construction,
to stagger the position of the wall elements 1 of the second
course of wall elements 1 so that the end joints of the
second course of wall elements 1 meet at about the midpoint
of the wall elements 1 forming the underlying first course of
wall elements 1. The bottom grooves 2 of the overlying
second course of wall elements 1 fit precisely over the top
ridges 3 of the first course of wall elements 1, to provide a
snug fit which is capable of withstanding lateral pressure
being placed upon the courses of wall elements 1. The tongue
ahd groove arrangement complements the strength provided by
the cross-linking ll-cross ties 8.
In the manner described, successive courses of wall
elements 1, linked together by the tongue and groove
construction and the required number of H-cross ties ~, are
laid until a wall of desired height is reached. Once the
desired height of wall is reached, the pour space formed
between the opposing parallel walls can be filled with poured
concrete or some other suitable filling material.
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1 ~ 708~7
In an alternative embodiment of the invention, wall
elements 1 which have grooves 10 and ridges 11 on the end
faces of the wall elements 1, in addition to the ridges and
grooves on the top and bottom surfaces, can be utilizedO
Such wall elements 1 can be used where it is desired to have
the plurality of wall elements 1 mesh by tongue and groove
technique not only on the respective top and bottom surfaces
of the wall elements 1, but also at the respective ends of
the wall elements 1. Wall elements 1 having the end
grooves 10 and end ridges 11 are more expensive to construct,
but the use of such wall elements 1 may be advisable where a
particularly strong wall is required, or it is desired to
provide a barrier between the abutting wall elements 1 to
minimize the passage of moisture and other matter into the
interior space of the opposing parallel rows of wall
elements 1.
The wall elements 1 may be formed from pre-cast
concrete, and may optionally incorporate embedded wire, or
other reinforcing rods, to provide additional strength to the
wall elements 1. This may be necessary to provide resistance
to fracturing, particularly in applications where a
relatively high lateral strength is required, such as in
situations where walls of ext.reme height are being formed, or
where the wall elements 1 are relatively thin in width.
Figures 9, 10, 11, 12, 13 and 14 illustrate
cross-sectional views of various alternative methods whereby
the wall element 1, may be positioned in pairs, on footings.
These methods are merely exemplary and are not to be
considered as exhaustive.
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t ~ 70~57
Figure 9 illustrates the positioniny of pairs of
wall elements 1 in pairs of grooves 19 in the footing 12.
Figure 10 illustrates a method whereby the wall
elements are held in place by boards 13 which are temporarily
nailed to the footing 12 by nails 14, which are removed after
the wall has been built.
Figure 11 illustrates a method whereby a single
broad groove 15 is formed in the footing 12.
Figure 12 illustrates a system of holding the wall
elements in place by means of a U-shaped bracket 16 ernbedded
in the footing 12.
Figure 13 illustrates a construction where the
pairs of wall elements 1 are held in place by pins 17
embedded in pairs in the footing 12.
Figure 14 illustrates a method of holding the wall
elements 1 in place by means of a U-shaped bracket 18
positioned on the footing 12.
Referring ayain to E'igure 6 of the drawing, it will
be understood that, when a wall is being cons-tructed in
accordance with the present invention, it is sometimes
necessary to provide a vertical end to the wall structure, to
allow for a window or door aperture, or for sorne other
reason. A vertical end may be formed in conventional
fashion, by utilizing blocks of half the standard length, to
terminate alternate horizontal rows. That is, if the
standard blocks are of length X, alternate rows are
terminated by blocks of length X/2, which may be either
pre-formed half blocks, or may be formed by cutting or
otherwise severing standard blocks, at the job site.
However, if this method of forming a vertical end is
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~ 1 7085~
utilized, it will be necessary to install framing, or an
auxiliary form element, to close off the hollow space in the
interior of the wall structure, before the concrete or other
filler material is poured.
Accordingly, it is preferable to form a vertical
end to the wall, by utilizing U-shaped integral end blocks.
For a wall constructed in the manner shown in Figure 6, a
vertica] end may be constructed by utilizing two
configurations of end block. The first type of end block may
be as shown in Figure 15, having the dimensions shown, where
X and Y are the length and height of a standard block,
respectively, and W is the exterior width of the wall being
constructed, i.e. the distance between the exterior vertical
wall surfaces. The second configuration of end block (not
shown) will be of length X/2, rather ~han X, but will be
otherwise the same as the end block shown in Figure 15, and
the full-length and half-length end blocks, will of course be
used to terminate alternate horizontal rows, to form a
vertical end to the wall structure.
In the wall construction shown in Figure 6, the
elements in the respective parallel form walls, are aligned
in one-to-one relationship; i.e. the elements in a yiven
horizontal course in one of the form walls, are directly
opposite coxresponding elements in the corresponding
horizontal course in the other form wall. Elowever, if the
wall elernents are provided with optional lateral top face
mid-grooves 9, as shown in Figure 2, it will be possible, and
may be preferable, to use a different form of alignment
between the elements in the respective parallel form walls,
in which the elements in a given horizontal course in one
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form wall, are in staggered, i.e. half-lapped, alignment with
the elements in the corresponding horizontal course in the
other form wall, so that the junctions between wall elements
in a horizontal course in one form wall, are directly
opposite the mid-points of the wall elements in the
corresponding horizontal course in the other form wall. In a
wall so constructed, each H-shaped tie will extend between
the junction of two horizontally adjacent elements in one
form wall, and the mid point of an element in the other form
wall, one end of the H-shaped tie being fitted in tie grooves
4 of the two adjacent elements in the first forrn wall, and
the other end of the tie being fitted in the lateral top face
mid-groove 9 of an element in the corresponding horizontal
course, in the other form wall. A vertical end on a wall
constructed in this manner, may of course be formed by using
half-length blocks in appropriate locations, closing off the
hollow interior space of the wall, with suitable framing or
the like, as discussed above. However, it is again
preferable to utilize integral U-shaped end blocks, to form a
vertical end. Such a vertical end may be formed utilizing
two configurations of U-shaped end block, one being as shown
in Figure 16, having the dimensions indicated, where X, Y and
W represent the same quantities as in Figure 15; the other
being the mirror image of the end block shown in Figure 16.
These two configurations of end block are, of
course, used to terminate alternate horizontal courses of
elements, to form a closed vertical end.
In embodiments of the invention, wherein the end
surfaces, as well as the top and bot-tom surfaces, of the wall
elements, are provided with interlocking tongues and grooves,
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the end blocks described above will, of course, be provided
with appropriate tongues or grooves in their end surfaces,
for interlocking with the standard wall elements.
Persons skilled in the art will, of course,
understand that, in addition to the 9~ corner elements, and
U-shaped end blocks, previously described, other specialized
elements may be included in the system of the present
invention, for specific purposes.
It will also be understood that, if the interior
space of a wall constructed in accordance with the present
invention, is filled with poured-in-place concrete, the
result will be a very strong structure, having many of the
attributes of a solid reinforced concrete wall. If such
great structural strength is not required, however, a
different filling material may be selected. If the wall
elements are bonded to each other by means of a suitable
adhesive, as previously mentioned, a wall having satisfactory
structural strength for many purposes may be constructed,
even if the filling material makes no significant
contribution to the structural strength of the wall, i.e. if
the filling material is of low structural strength, or does
not set into a solid mass, or is not capable of bonding to
the interior surfaces of the wall elements. For example, the
filling material may be a thermo insulating material, such as
cellulose insullation, foam insullation, etc. The use of a
thermo insulating material to fill the interior of the wall
will, of course, increase the thermal insulating value of the
wall, which may be an important factor in many applications,
particularly in view of currently escalating energy costs,
and actual or threatened shortages of fuels customarily used
for heating the interior of buildings.
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While particular embodiments of this invention have
been described and shown, it will be understood that many
modifications may be made to the invention to adapt it to
other models and designs without depar-ting from the spirit of
the invention, and it is contemplated by the appended claims
to cover any such modifications as fall within the true
spirit and scope of this invention.
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