Note: Descriptions are shown in the official language in which they were submitted.
CA 02245149 1998-08-13
RELOCATABLE MODULAR CONCRETE BLOCK PARTITION SYSTEM
SCOPE OF THE INVENTION
The present invention relates to a relocatable modular partition system which
may be
used as a full or partial-height wall or cubicle construction in factories,
healthcare, or long-term
care facilities, warehouses, retail or office space, and more particularly to
a concrete block
system which permits the simplified onsite erection of a relocatable partition
designed to
function as a space-dividing wall or as a fire-rated wall, without requiring
mortar.
BACKGROUND OF THE INVENTION
It is known to provide cubicles and partitions in warehouses, laboratories,
manufacturing
plants and office spaces. To achieve a firewall rating, as for example, where
a partition wall is to
contain flammable substances or protect sensitive equipment or documents from
fire damage,
conventional firewalls have been formed from cinder block construction. The
use of cinder
blocks necessitates that the office cubicle or wall be permanently erected by
masons using
concrete mortar.
Conventional partition systems suffer the disadvantage in that to install the
partitions, it is
often necessary to custom design the enclosure prior to installation. After
the design stage,
skilled tradesmen must then be employed to erect the cinder block partition.
In addition to
increased construction costs, conventional firewall partitions suffer the
significant disadvantage
in that they are formed as permanent constructions and may not be modified or
disassembled. If
change is required, as in expansion of a tenant's rented retail premises,
conventional firewall
partitions must be destroyed, removed to a waste dump, and rebuilt with new
material in the
desired new location.
A further disadvantage of conventional concrete wall systems exists in that
when erected,
the cinder block wall will typically have a density of about 150 lbs. per
cubic foot. The weight
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of such concrete walls therefore limits installation sites to newer
constructions which have
reinforced concrete floors adapted to support increased loads.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present to overcome the disadvantages of
the prior art
by providing a partition system which is easily adaptable for installation as
a modular
construction in almost any configuration.
Another object of the invention is to provide a partition system having walls
formed from
modular block units which may be erected without the use of mortar or the
hiring of specialized
tradesmen.
A further object of the invention is to provide a partition system which
permits simplified
disassembly after its erection, enabling the components to be reused or
relocated to another site.
Another object of the invention is to provide a modular partition system which
may
function effectively as a fire rated wall.
A further object of the invention is to provide a modular wall which is
characterized by a
concrete block construction formed having an overall density of less than 50
lbs. per cubic foot,
so as to permit the erection of a partition or enclosure in almost any
factory, healthcare or long-
term care facilities, office, warehouse or retail establishment.
The inventor has appreciated an improved light weight concrete partition
construction
which may be erected as either a partial enclosure, workstation divider or
even as a fire-rated
wall. The partition construction consists of a number of modular standard
sized concrete blocks
which are linked together by splines. The concrete blocks are made from
autoclaved aerated
concrete (AAC) having a density of less than 50 lbs. per cubic foot,
preferably 20 to 40 lbs. per
cubic foot, and most preferably 30 to 34 lbs. per cubic foot. The use of AAC
enables the blocks
to be easily transported and assembled into a partition construction in almost
any environment.
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In its simplest form, the partition system incorporates a sufficient number of
rectangular
blocks used to form the partition wall or walls having the desired height and
width. In a highly
preferred configuration, the blocks are formed with a length of about 24
inches, a width of 16
inches, and a thickness of approximately 4 inches. This size permits the
blocks to be easily
handled and lifted into place, and, in the appropriate configuration, provides
the partition with
fire rating properties. However, larger or smaller blocks may also be used,
depending upon the
intended application.
The principal blocks which are used to form the walls have a generally
rectangular shape
with parallel and coplanar top and bottom surfaces, joined at parallel edge
surfaces which extend
perpendicularly thereto. Grooves are formed across at least the top and bottom
surfaces of the
blocks, and preferably the grooves extend along the two of the edge surfaces
as well. The
grooves are preferably aligned with a mid-plane of the block and have the
identical profile,
extending as a parallel sided slot inwardly into the block a distance of
between 0.5 to 5 inches,
and optimally about 1 inch. The grooves have a lateral width which is selected
so as to not
interfere with the lateral integrity of the wall block. Depending on the
overall block thickness,
the groove width is optimally less than about 1 inch, and more preferably
about 0.1 inch. The
use of autoclaved aerated concrete is particularly advantageous in the
manufacture of the
modular blocks, as the finished blocks and the grooves may be readily cut by
the use of a circular
concrete blade or simple machine tools. The cutting of the wall blocks and
grooves
advantageously ensures that the modular blocks are formed to exacting uniform
tolerances.
The splines used to connect the blocks are made of metals such as steel,
aluminum or
other metal alloys. The splines are used to link successive courses of wall
blocks to each other
without mortar by partially locating with both the top grooves formed in the
wall blocks of the
underlying course, and the bottom grooves of overlying course of wall blocks
which rest directly
thereon. To achieve a fire-rated wall, the splines are preferably also
inserted into the vertical
grooves between abutting blocks at each end. In a simplified construction, the
splines are
formed as elongated rectangular bars which have a thickness which is
marginally less than the
lateral width of the grooves formed in the wall block. Splines of various
lengths may be used,
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however, optimum wall stability may be achieved where the horizontally
positioned splines have
a length which approaches that of the total wall length. Most preferably, the
splines have a
standard length of 8 to 12 feet.
To ensure that the splines do not interfere with the stacking of the wall
blocks on top of
each other or their placement end-to-end, each spline has a width which is
marginally less than
twice the depth of the grooves. Where aluminum alloys are used, the splines
preferably have a
width of marginally less than about 5 inches where 2.5 inch deep slots formed
in the blocks, and
marginally less than about 2 inches where 1 inch deep slots are used. The
spline has a lateral
thickness of between about .1 to .OS inches, and most preferably .08 inches to
provide the desired
wall stability and fire-rating properties.
One or more elongated T-shaped aluminum or other metal extrusions may also be
used in
the assembly of the modular partition construction. The T-shaped extrusions
are characterized
by a projecting tongue which extends outwardly from the back of the extrusion
a distance
marginally less than the depth of the slots formed in the rectangular wall
blocks. Like the
splines, the tongue has a thickness marginally less than the lateral width of
the slot.
In one possible partition wall assembly, the T-shaped extrusion is placed or
secured to the
floor by screws, nails, caulking, glue, grout or the like. The first course of
blocks is then placed
in position on the extrusion so that the tongue is received in the bottom slot
of each block. After
the first course of blocks is positioned, successive courses of blocks are
added. A spline is
positioned between each course extending longitudinally in the direction of
the top and bottom
grooves of the blocks forming the adjacent courses. The insertion of the
spline in the top
grooves ensures that the blocks in the course are aligned with their edge
surface of adjacent
blocks aligned in juxtaposition. The insertion of the spline in the upper
slots also provides
stability to the wall. After the spline is in place, the next overlying course
of blocks is positioned
directly on to the preceding course, with the spline thereafter being received
in the bottom slot of
each block of the overlying course.
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If desired, a T-shaped extrusion may be used as a cap rail to finish partition
walls which
do not extend fully to the overlying ceiling. Here, the tongue is inserted
within the top groove of
the uppermost course of blocks to provide both stability to the upper edge of
the top course of
blocks leaving the back of the extrusion exposed for a more refined
appearance. Similarly, if
openings for door or windows are desired, the T-shaped extrusion may be
vertically positioned
with the tongue inserted in the grooves formed in the vertically aligned edge
portions and the
grooves formed in the horizontally aligned edge portions of the wall blocks
which border the
opening.
Where the partition is to be used as a fire-rated wall, the splines are also
inserted in the
aligned vertical grooves of adjacent blocks. A cap block is preferably also
provided which forms
a connection with the overlying roof or ceiling. The cap block is formed from
AAC in a similar
manner to the modular wall blocks. The cap block is characterized by a lower
bottom groove
which when the cap block is moved into place, aligns with the top groove
formed in the
underlying course of modular wall blocks. The bottom groove in the cap block
is cut to double
height of those in the wall blocks and is marginally greater than the overall
spline width. This
permits a spline to be fully positioned therein when the cap blocks are
initially placed. As the
bottom groove of the cap blocks are moved into alignment with the top grooves
in the underlying
course of modular blocks, the spline drops under gravity into position so as
to be partially
disposed in both the top groove of the underlying course of modular blocks,
and the lower half of
the upper groove which is formed in the cap block.
Grout or other non-combustible filler may be buttered onto the top of the cap
block to
backfill any gap which may exist between the cap block and the overlying roof,
ceiling or floor
slab. More preferably, the T-shaped extrusion which is used as the wall/floor
support may also
be underfilled and leveled with fire retardant materials, such as grout, to
ensure a fire retardant
seal along the lower edge of the partition and along the vertical edges of the
partition.
In the formation of free-standing cubicles, separate L-shaped corner blocks
may be
provided. The L-shaped corner blocks are similarly formed from the same
autoclaved aerated
concrete as the modular rectangular wall blocks. The corner blocks preferably
have the same
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vertical dimension as the wall blocks with planar upper and lower surfaces.
The top and bottom
grooves corresponding in depth and width to those in the wall blocks extend
along the mid-plane
following the block L-shape, bending 90° with the block. To connect the
corner blocks to
abutting modular wall blocks, splines from abutting courses of wall blocks may
be extended into
the corner block in essentially the same manner as with the modular wall
blocks. Alternately,
corner splines bent at a 90° angle may be provided which extend from
the corner block in both
directions into the adjacent courses of wall blocks.
Other mechanical fasteners may also provided to secure a number of adjacent
blocks,
depending upon the overall load applications for the wall. In one simplified
embodiment, table
or draw bolts are used to mechanically couple laterally adjacent pairs of
blocks to each other.
Where table bolts are used, depressions are formed in either the upper or
lower surfaces of
adjacent blocks aligned with the grooves. The depressions extend inwardly into
the block a
sufficient distance as to permit the bolt or other mechanical fasteners to lie
below the top or
bottom surfaces of the blocks so as not to interfere with the placement of
succeeding courses of
block. Where larger bolts are used, the portion of the grooves extending from
the circular
depression to the abutting edges may be enlarged. While table bolts present a
preferred
mechanical fastener, it is to be appreciated that other mechanical fasteners,
including
conventional carriage bolts, clips, clamps and the like are also possible.
Accordingly in one aspect the present invention resides in a. modular
partition
construction comprising,
a plurality of generally rectangular blocks, comprising autoclaved aerated
concrete
having a density selected at between about 20 and 40 lbs. per cubic foot, each
said rectangular
block having generally parallel planar top and bottom surfaces, generally
parallel planar end
surfaces, and top and bottom parallel sided grooves formed in each of said top
and bottom
surfaces, respectively, the top and bottom grooves extending longitudinally
into both of said end
surfaces and having a lateral width of less than about 1 cm,
at least one substantially planar metal spline having a lateral thickness
marginally less
than the lateral width of each of said top and bottom grooves to permit
insertion of said spline
therein, and
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wherein in assembly a first rectangular block is coupled to a second
rectangular block
with the bottom surface of the first block abutting at least part of the upper
surface of the second.
block and a first one of the metal splines disposed in part in each of the
bottom groove of the first
block and the top groove of the second block.
In another aspect the present invention resides in a modular wall construction
comprising,
a plurality of identical generally rectangular blocks, each of said
rectangular blocks
consisting of autoclaved aerated concrete and having an overall density
selected at between
about 30 and 40 lbs. per cubic foot and having generally parallel planar top
and bottom surfaces,
generally parallel planar end surfaces oriented generally perpendicularly to
said top and bottom
surfaces, and a paxallel sided groove formed in each of said top, bottom end
surfaces, each of
said grooves being substantially co-planar with a mid-plane of said block and
having an identical
lateral width selected at about less than about .1 inches and an identical
depth selected at about
less than two inches,
a plurality of planar metal splines, each of said splines formed as a
generally rectangular
member having a lateral thickness marginally less than the lateral width of
said grooves to
permit insertion of said spline therein,
wherein in assembly a first rectangular block is coupled to a second
rectangular block
with the bottom surface of the first block directly abutting at least part of
the upper surface of the
second block and a first one of the metal splines disposed in part in each of
the grooves formed
in the bottom surface of the first block and the groove formed in the top
surface of the second
block.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects and advantages of the present invention will appear from the
following
description taken together with the accompanying drawings in which:
Figure 1 is a cross-section view of a modular concrete block partition erected
as a fire-
rated wall in accordance with a first embodiment of the invention;
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Figure 2 is a perspective schematic view of a modular concrete wall block used
in the
fire-rated wall shown in Figure 1;
Figure 3 is an exploded partial view of the spline and two vertically adjacent
courses of
wall blocks used in the partition shown in Figure 1;
Figure 4 is a partial perspective view of an assembled wall shown in Figure 1
coupled to
an existing partition wall;
Figure 5 is a partial cross-sectional view of the wall of Figure 4 taken along
line 5-5'
showing the anchoring of the modular partition construction to the existing
partition wall;
Figure 6 is a plan view of a corner block and corner spline for use with the
present
invention;
Figure 7 is a cross-sectional view of a doorway for use with a partition
enclosure in
accordance with the present invention;
Figure 8 shows a partial perspective view of a partition wall assembled in
accordance
with a further embodiment of the invention;
Figure 9 shows a perspective top view of a mechanical coupling of the corner
block of
Figure 6 with modular wall blocks shown in Figure 2 in accordance with a
further embodiment
of the invention; and
Figure 10 shows a partial perspective view of the upper extent of the modular
block
partition assembled as a fire-rated wall in accordance with a further
embodiment of the
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is now made to Figure 1 which shows a preferred modular wall
construction
which has been erected as a fire-rated wall extending from a concrete slab
floor 12 to a ceiling
14. As will be described, although the wall construction 10 is shown as a fire-
rated wall, the
modular nature of the system makes it also suitable for office and conference
room walls, low
partitions and counters, free standing factory offices as well as bank machine
and retail
enclosures.
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The basic wall construction 10 includes as its principal components a number
of modular
generally rectangular wall blocks 16 which form the principal building
components of the wall
partition 10, at least one T-shaped aluminum alloy extrusion 18, a number of
elongated
aluminum alloy splines 20, and an uppermost course of cap blocks 22.
Figures 2 and 3 show best the modular wall blocks 16 used in the erection of
the wall
construction 10. The wall blocks 16 are formed from non-reinforced autoclaved
aerated concrete
(AAC) which has a density of between about 20and 40 lbs. per cubic foot, and
more preferably
about 30 to 34 lbs. per cubic foot. The use of autoclaved aerated concrete
advantageously
provides the wall construction 10 with a lower overall mass, enabling the wall
to be easily
transported and erected. As well, the use of AAC allows the blocks 16 to be
cut with
conventional saws to exact tolerances, ensuring that the block surfaces are
flat and uniform. In
the conventional wall partition construction 10 shown, the blocks 16 are
rectangular having a
longitudinal length 1 of about 24 inches, a height h of about 16 inches and
are optimally 4 inches
thick. It has been found that this configuration advantageously achieves a
fire resistance of
CAN-S-101 with a three hour fire resistance rating. The ACC provides thermal
insulation
properties of ASTM C-236 at 0.9 BTU per hour per square foot per °F.
per inch. The sound
transmission of the blocks in testing has achieved STC 41. As well, the AAC is
an inert material
which does not contribute to indoor or environmental pollution.
Figure 2 shows best the block as including parallel planar top and bottom
surfaces 32,34,
and planar parallel edge surfaces 36,38 which extend perpendicularly thereto.
A 1 inch deep
groove 40a,40b,40c,40d is formed along each of the block surfaces 32,34,36,38,
respectively.
The grooves 40a,40b,40c,40d are positioned at the longitudinal mid-plane of
the block 16,
dividing it symmetrically in the longitudinal direction into right and left
halves. The grooves
40a,40b,40c,40d are identically formed as a narrow slot having parallel side
walls and a lateral
width formed at between about .15 and .OS inches, and most preferably about
.09 inches. By
forming the grooves 40a,40b,40c,40d with the same dimension, each aligned with
the block mid-
plane, the blocks 16 may be erected without regard to whether the right or
left halves of the
block face inwardly or outwardly or which planar surface 40a,40b faces
upwardly. Although not
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essential, the blocks 16 and 20 may be provided with a sealant or colored
coating to reduce
chalking, and achieve a more enhanced esthetic appearance.
The horizontal aluminum splines 20 are formed having a generally rectangular
construction with a width of marginally less than two inches and a thickness
selected marginally
less than the lateral width of the grooves 40a,40b,40c,40d, and preferably
about .08 inches.
The T-shaped extruded track 18 is shown best in Figure 1 as having a planar
back 43 and
a flattened tongue 44 which projects at right angles from a longitudinal
middle portion of the
back 43. The tongue 44 projects from the back 43 a preferred distance of
between about .75
inches to marginally less than 1 inch so as to permit it to be fully received
in the bottom groove
40b formed in the bottom surface 34 of a block 16. In this manner, the
lowermost course of
blocks 16a (Figure 1) can be positioned on the T-shaped track 18 so that the
tongue 44 is
received entirely within the bottom groove 40b.
The tongue 44 preferably is also formed with a thickness selected marginally
less than the
lateral width of the grooves 40a,40b,40c,40d, and preferably which is selected
at approximately
0.08 inches. With this dimension, when the tongue 44 is received in one of the
grooves 40a,
40b,40c,40d, the engagement of the tongue 44 with the parallel sidewalls of
the grooves 40
prevent twisting of the blocks 16 relative thereto.
The wall partition is preferably sold in the form of a stock sized pre-
engineered kit which
is ready for assembly. Preferably, both the T-shaped extruded tracks 18 and
splines 20 extend
the horizontal length of the modular wall construction 10. In this regard,
when the construction
10 sold as unassembled pre-engineered kits, the extruded track 18 and splines
20 are provided in
standard 8, 10 or 12 foot lengths. It is to be appreciated, however, that
where necessary,
customized partition constructions may be designed with minor modifications.
The partition construction 10 shown in Figure 1 is of a floor anchored
configuration in
which the T-shaped extruded track 18 is initially secured to the floor by
screws 26 (Figure 1 ) in
alignment with the desired positioning of the wall construction 10. In
addition, the back 43 of
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11
the T-shaped track 18 may be first buttered with grout 28 to compensate for
any irregularities in
the floor surface and provide a fire break beneath the assembled construction
10.
Figures l and 3 show best the placement of a first lowermost course of blocks
16a on the
T-shaped extruded track 18, and the positioning of subsequent courses of
blocks 16b thereon.
The bottom course of blocks 16b is merely placed over the track 18 so that the
tongue 44 locates
within the groove 40b formed in the bottom surface 34 of each block 16a. The
blocks 16a are
positioned on the T-shaped track 18 with the edge surfaces 36,38 of adjacent
blocks 16a in
abutting contact. It is to be appreciated that as successive blocks 16a are
moved into place, the
engagement of the tongue 44 within the bottom grooves ensures the proper
alignment of the
bottom course of blocks 16a at the desired location.
To secure the succeeding overlying course of blocks 16b to the bottom course
16a, a
spline 20 is inserted into the upper slot 40a which is formed in the upper
surface 32 of each block
16a. The insertion of the spline 20 into the slots 40a ensures alignment of
the top surfaces 32 of
the lower course blocks 16a and prevents the blocks 16a from moving relative
to each other. The
next course of blocks 16b is then positioned with their bottom surfaces 34
straddling the top
surface 32 of two underlying blocks 16a, so that the spline 20 is also
partially disposed in the
bottom slots 40b of the blocks 16b. The spline 20 has a lateral width which is
marginally less
than the total depth of the upper slots 40a formed in the top of the lower
course blocks 16a and
the bottom slots 40b formed in the overlying course of blocks 16b. With this
construction, the
spline 20 is fully received in the aligned slots 40a,40b, and does not
interfere with the stacking of
the blocks 16a,16b directly on top of each other. It is to be appreciated that
further succeeding
courses of blocks 16 are assembled in the identical manner until either a
partition wall of the
desired height is achieved or the uppermost course of blocks 16 locates
approximately a distance
equal to the height of the cap blocks 22 from the ceiling 14.
Because the blocks 16 and splines 20 are assembled without mortar, if desired,
the
partition 10 may be easily disassembled later for re-use elsewhere.
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Figure 1 shows the cap blocks 22 used to form the fire-rated partition 10. The
cap blocks
22 are also formed from non-reinforced AAC, and differ from the wall blocks 16
in that they
include only a bottom groove 48. The cap block groove 48 is formed with
approximately double
the depth of the grooves 40 which are formed in the modular wall blocks 16.
The increased
depth permits a spline 20 to be fully inserted within the slot 48 while the
cap blocks 22 are
moved into position above the uppermost course of wall blocks 16. Once the
blocks 22 are
moved into alignment with the underlying courses of wall blocks 16, their
slots 48 align with the
upper groove 40a formed in the underlying course of modular wall blocks 16.
When the grooves
48 and 40a align, the spline 20 will drop under gravity to the position shown
in Figure 1
straddling part of the bottom groove 48 in each cap blocks 22 and the upper
grooves 40a of the
underlying modular wall blocks 16.
For firewall rating, additional grout 50 may be buttered on the upper surface
49 of the cap
block 22 to complete the fire break and ensure that no gaps in the erected
wall exist between the
floor 12 and ceiling 14.
Figures 4 and 5 shows a perspective partial view of a preferred wall
construction wherein
the wall blocks 16 are staggered relative to those of each preceding and
successive course, and
with an edge of the partition 10 coupled to an existing partition wall 52. To
secure the
construction 10 to the partition 52, a further T-shaped extruded track 58 is
used. The track 58 is
identical to the track 18 and is mounted with the back 45 of the track 58
coupled to the partition
52 by screws 54, so that the tongue member 44 of the track 58 extends
vertically. With this
configuration, the tongue 44 of track 58 locates within an edge slot 40c
formed in the edge
surface 36 of the blocks 16 which are immediately adjacent to the partition
52. To permit the
corner cap block 22a (Figure 4) to be slid in place, the guide track 58
extends from the floor 12
only to the uppermost edge of the top course of modular wall blocks 16.
Figure 6 shows a specialized corner block 62 used in the erection of free
standing office
enclosures and which is used to join two adjacent courses of blocks 16 at a
90° angle. The
corner block 62 is L-shaped having two mutually perpendicular end surfaces
68,70. The block
62 and has an overall height of 16 inches and a width of 4 inches,
corresponding to those of the
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modular wall blocks 16. An L-shaped groove 64 is formed down the medial center
of the corner
block 62. The groove 64 has a corresponding depth and lateral width as the
slots
40a,40b,40c,40d formed in the modular blocks 16. An L-shaped aluminum spline
66 having a
width corresponding to the splines 20 and a thickness of approximately .08
inches is inserted in
the groove 64 to couple the corner blocks 62 to the adjacent courses of blocks
16. Most
preferably, the spline 66 extends beyond the end surfaces 68,70 of the corner
block 62 in both
directions approximately mid-way across the next adjacent wall block 16.
Figure 7 shows the assembly of the wall blocks 16 in the formation of a door
jamb 74
permitting access to an enclosure formed with the modular wall construction
10. To form the
door jamb 74, courses of the bordering wall blocks 16c are assembled with the
desired spacing.
A pair of T-shaped aluminum extruded tracks 78 identical to the T-shaped
extruded track 18 are
then positioned with the tongue 44 of each track 78 inserted into the
vertically extending edge
grooves 40c,40d slots formed in the opposing edge surfaces 36,38 of the wall
blocks 16c. After
placement, the tracks 78 are secured in place by screws 79. . Once the door
opening is roughed
in, a door may be secured in place in a conventional manner.
Although Figure 4 illustrates the construction of a wall in a conventional
staggered
manner, the invention is not so limited. Figure 8 shows an alternate possible
wall construction
wherein like reference numerals are used to identify like components and in
which the edge
surfaces 36,38 of each wall block 16 are aligned. With the construction 10
shown, the splines 20
are again positioned so as to extend the horizontal length of the wall
construction 10 straddling
both the top and bottom grooves 40a,40b formed in adjacent lower and upper
courses of blocks
16.
While Figure 7 illustrates a bent spline 66 as being used to connect a corner
block 62 to
adjacent wall blocks 16, the invention is not so limited. Figure 9 shows an
alternate mechanical
connector used to couple the corner block 62 to adjacent wall blocks 16. In
Figure 9, table or
draw bolts 80a,80b are used to maintain the blocks 62,16 with their end
surfaces in abutting
juxtaposition. To position the table top bolts 80a,80b, 1 inch deep circular
recesses 82 are drilled
in the top surfaces of the corner block 62 and wall blocks 16 approximately 1
inch inwardly from
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14
the block edge surfaces which are to be positioned in juxtaposition. The
recesses 82 are formed
having a size and depth so as to permit the table top bolts 80a,80b to be
positioned and tightened
therein so as not to interfere with the placement of successive courses of
blocks 16,62 thereon. If
necessary, the portion of the grooves 40 between the recesses 82 and block
edges may be
enlarged to permit insertion of larger fastened bolts. It is to be appreciated
that a modular wall
construction 10 may be erected without having to mechanically secure all of
the adjacent blocks
to each other with bolts 82. Rather, depending upon the height and length of
the wall
construction 10, only key blocks may be mechanically coupled to each other to
provide overall
enhanced structural integrity to the wall construction 10. Similarly, it is
envisioned that where
smaller or only partial partitions are desired, the use of the corner bolts
80a,80b may be omitted
in their entirety.
Figure 10 shows a modular partition construction 10 in accordance with a
further
embodiment of the invention, and wherein like reference numerals are used to
identify like
components. The partition construction 10 of Figure 10 incorporates a
plurality of wall blocks
16 as shown in Figure 2. The wall blocks 16 are linked to each other by
horizontally placed
splines 20 in the identical manner as described with reference to Figure 1. In
addition, a number
of shorter vertical splines 95 are positioned in the aligned grooves 40c,40d
formed in the abutting
edge surfaces of adjacent blocks 16. The vertical splines 95 are formed from
extruded aluminum
having the identical width and thickness as splines 20.
In assembly, the vertical splines 95 of each course of blocks 16 are slid into
place prior to
placing the spline 20 horizontally in the top grooves 40a of each course of
blocks 16.
The partition of Figure 10 incorporates only a single cap block 22 as a "key".
To
complete the upper course, a T-shaped extrusion 96 identical to extrusion 18
and a spline 20a,
each having a shortened length selected at the partition width less than the
width of the cap block
22, are secured to the ceiling 14 and underlying row of wall blocks 16',
respectively. Fire rated
grout 28 is again buttered on the side of the extrusion 96 which is placed in
contact with the
ceiling 14.
CA 02245149 1998-08-13
Prior to installing the cap block 22, the upper course of blocks 16" are then
individually
slid horizontally into place with the tongue of the extrusion 96 received in
their upper slot 40a
and the spline 20a received in their lower slot 40b. After each block 16" is
moved into place, a
vertical spline 95 is positioned in its exposed edge slot 40c. The next
horizontally adjacent block
16" is then moved into place so that the exposed edge of the spline 95 locates
in the adjacent
edge slot 40d.
Once the upper course of wall blocks 16" is in place leaving only space for
the key, the
cap block 22 is positioned using a short spline 20b in the manner previously
described. Most
preferably, the top and side edges of the cap block 22 are buttered with grout
to achieve a
maximum fire-rating.
Although the detailed description of the invention discloses the splines 20
and T-shaped
extruded tracks 18 as extending the lateral width of the wall 10, the
invention is not so limited.
If desired, a number of shorter splines 20 and tracks 18 could also be used
and will now become
apparent. Similarly, while the use of aluminum alloys presents various
advantages in
workability, weight and fire resistance, the invention is not so limited. If
desired, the splines
20,95 and T-shaped extrusions 18,58,96 could equally be made from other
metals, such as steel,
copper or other alloys.
While blocks of approximately 2 feet by 1.3 feet advantageously permit ease of
portability and assembly of the modular partition construction 10, the
invention is not so limited.
It is envisioned that the present invention may also be used with smaller or
larger block
members. By way of one non-limiting example, it is envisioned that modular
blocks extending
up to 20 feet in length, may be used where the partition 10 is to be erected
for use in commercial
applications such as in the formation of retail space enclosures.
While the alignment of the grooves 40a,40b,40c,40d with the mid-plane of the
block 16
advantageously increases the modular nature of the blocks, the invention is
not so limited. In a
less preferred embodiment, the grooves 40 cold be provided off center along
the blocks 16,62
without departing from the spirit of the invention.
CA 02245149 1998-08-13
16
Although Figure 1 illustrates the modular wall construction 10 as being
anchored to the
floor 12 by use of the T-shaped track 18, the invention is no so limited. If
desired, the track 18
may be omitted and the lowermost course of blocks 16 and the wall could be
erected as a floating
wall without attachment to the underlying floor 12.
While Figure 1 shows use of a cap blocks 22 to provide a finished upper edge
to the wall
construction 10, the invention is not so limited. If only a partial partition
is desired, or if the
partition wall construction need not provide a fire-rated protection, the cap
blocks 22 could be
omitted. With such a construction, the top of the uppermost course of modular
wall blocks 16
could be finished by inserting a further T-shaped extruded track identical to
T-shaped track 18 in
the upper groove 40a of the top course of blocks 16, in a mirror manner to the
insertion of the T-
shaped guide track 18 into the bottom grooves 40b.
While the preferred embodiment discloses the use of the T-shaped extrusion 18
as
forming the base of the construction 10, the invention is not so limited. If
desired, adjustable
base assembly, as for example adjustable by jack-screws or the like, could
also be used as a
support for the partition.
Although the disclosure describes and illustrates preferred embodiments, the
invention is
not so limited. Many modifications and variations will now become apparent to
a person skilled
in this art. For a definition of the invention, reference may be had to the
appended claims.
