Note: Descriptions are shown in the official language in which they were submitted.
81637286
MASONRY UNIT SYSTEMS AND METHODS
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Application Serial No. 13/312,831,
filed
on December 6, 2011.
TECHNICAL FIELD
This document relates to building materials, such as one or more masonry units
for use in designing and constructing a wall.
BACKGROUND
The construction of buildings and other structures may often employ concrete
masonry building materials, such as masonry units (commonly referred to as
masonry
blocks). For example, an individual masonry wall assembly may be constructed
using
either a single vertical section of masonry units (known as a "wythe") or
adjacent cavity
wall vertical sections (known as a "double wythe" or "multiwythe").
During the construction of some building structures, a set of masonry wall
assemblies can be used to provide a building envelope that defines a number of
exterior
walls of the building structure. In such circumstances, multiwythe masonry
walls are
commonly employed in an effort to resist the penetration of water or other
moisture to the
interior of a building. For example, double wythe masonry walls usually
provide an
interior vertical void or cavity between an exterior vertical section and an
interior vertical
section of the masonry wall, thereby in part creating a drainage path for
water or other
moisture that penetrates through the exterior vertical section and thus
reducing the
likelihood that the water will pass to the interior of the building.
These double wythe masonry walls, however, are usually more costly (in both
materials and labor) than single wythe masonry walls because the interior
vertical section
can serve as the structural wall while the exterior vertical section is
erected to serve as a
veneer. Conversely, a single wythe masonry wall may employ only a single
vertical
section of masonry units, but (depending on a number of factors) the single
wythe
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masonry wall might be less effective at resisting moisture penetration as
compared to the
more costly double wythe masonry wall.
Other supplemental techniques may be implemented during the design and
construction of a masonry wall in an effort to reduce the likelihood of
moisture
penetration through the wall. For example, the use integral water repellent
admixtures in
the masonry block compositions and in the mortar materials, as well as the use
of
concave joints when finishing the mortar and grout may contribute to moisture
control.
Also, the use of flashing at all horizontal interruptions of the wall surface
or the use of
drainage cores in the wall may contribute to moisture control. Another option
to
o supplement the masonry wall is for a builder to apply breathable
penetrating sealants or
coatings on the installed wall surface, and to install drainable "weeps" at
the base of the
wall to facilitate the redirection of accumulated moisture in the wall cavity
or masonry
unit cores to the exterior. Other conventional efforts to reduce the
likelihood of moisture
penetration include applying air/moisture barriers along the wall, using
condensation
control techniques at any areas where thermal bridges in the wall may be
present, and
using joint reinforcement and movement joints to reduce the likelihood of
cracking along
the masonry wall.
While these supplemental techniques can be useful, some masonry walls are not
always designed constructed using these techniques, or the workers
constructing the
masonry wall do not always implement these techniques in a consistent manner.
Accordingly, if these supplemental techniques are overlooked or not
satisfactorily
executed at the construction site, the ability of the masonry wall to resist
moisture
penetration can be compromised.
SUMMARY
Some embodiments of masonry units can be used to form a wall that provides an
improved resistance to moisture penetration that might otherwise advance to an
interior
surface of the wall. Moreover, in particular embodiments, the wall formed of
the
masonry units can provide a highly effective moisture penetration resistance
even when
other supplemental moisture control techniques are not implemented or not
properly
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executed at the construction site. In some embodiments, the masonry units
described
herein may provide a standard size and form factor such that the masonry units
may not
require special installation techniques other than those commonly used in the
industry,
but the masonry units described herein may be equipped with one or more
moisture
drainage elements formed in a surface of each masonry unit. In such
circumstances, the
moisture drainage elements can be arranged between an exterior face of the
masonry wall
and an interior face of the masonry wall so as to provide a drainage path for
water or
other moisture that migrates from the exterior face toward the interior face.
In one
example, some of all the masonry units may include one or more moisture
drainage
o elements integrally formed along on the respective unit's top surface so
that, when the
units are assembled into a wall structure, the moisture drainage elements are
configured
to divert water to drain vertically through a corresponding interior hollow
core of the
respective masonry unit, thereby permitting the water to drain vertically
through an
interior core of the masonry wall rather than migrating toward the interior
face of the
masonry wall.
Particular embodiments described herein may include a masonry wall system.
The masonry wall system may include a first row of masonry blocks (also
referred to
herein as masonry units), and a second row of masonry blocks positioned
vertically over
the first row of masonry blocks so as to provide vertical wall section having
an exterior
face and an interior face. Each masonry block of the first row of masonry
blocks may
include a top surface oriented toward the second row of masonry blocks and a
bottom
surface opposite from the top surface. Furthermore, each masonry block of the
first row
of masonry blocks may include includes at least one moisture drainage element
arranged
along the top surface of the respective masonry block. The moisture drainage
element
may include at least one downwardly slanted surface extending toward an
interior hollow
core of the respective masonry block. Optionally, the moisture drainage
element may be
spaced inwardly from an outer rim of the top surface of the respective masonry
block
such that the entire outer rim of the top surface of the respective masonry
block has a
generally continuous height relative to the bottom surface of the of the
respective
masonry block.
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Some embodiments described herein may include a masonry unit for use in a wall
system. The masonry unit may include a front face and a rear face, and a
vertical height
of the rear face may be substantially equal to a vertical height of the front
face. The
masonry unit may also include a plurality of web portions extending between
the front
and rear faces to define one or more interior hollow cores. Optionally, each
of the web
portions may extend generally perpendicularly to the front and rear faces, and
may have a
vertical height that is substantially equal to the vertical height of the
front face. The
masonry unit may further include a liquid diversion element arranged along a
top surface
of each web portion extending between the front and rear faces. Optionally,
the liquid
diversion element may include at least one downwardly slanted surface
extending toward
at least one of the interior hollow cores.
Other embodiments described herein may include a method of controlling
moisture penetration through a masonry wall. The method may include receiving
water
or other moisture along a top surface of a masonry block in a masonry wall.
The
moisture may advance along the top surface from an exterior face of the
masonry wall in
a direction toward an interior face of the masonry wall. The method may also
include
diverting the moisture to drain generally vertically down one or more interior
hollow
cores of the masonry block. Optionally, the masonry block may include one or
more
moisture drainage elements formed in the top surface of the masonry block.
Each of the
moisture drainage elements may include at least one downwardly slanted surface
extending toward an adjacent one of the interior hollow cores of the masonry
block when
the blocks are assembled into a wall structure. The method may further include
directing
the moisture that drained down the hollow core of the masonry block to exit at
a location
that is exterior to the exterior face of the masonry wall.
Some of the embodiments described herein may optionally provide one or more
of the following advantages. First, some embodiments of the masonry units can
be used
to form a wall that provides an improved resistance to moisture penetration by
providing
a drainage path for water that might otherwise advance to the interior face of
the wall.
For example, the masonry units can provide a drainage path that directs the
migrating
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water through interior hollow cores of the respective masonry units before the
migrating water
can reach the interior face of the wall.
Second, in some embodiments, the masonry units can include one or more
moisture
drainage elements along a top surface of each masonry unit, yet the moisture
drainage
elements can be entirely concealed from view with the masonry units are
assembled into a
wall system. For example, the moisture drainage elements can be arranged along
the top
surface of each masonry unit while also being spaced inwardly from the outer
perimeter of the
top surface. Accordingly, in particular embodiments, the moisture drainage
elements can be
positioned to effectively divert water or other liquids through the hollow
interior cores even
though the moisture drainage elements are nonviewable from an exterior face of
the wall and
do not detract from the outer appearance of the wall.
Third, some embodiments of the masonry units can incorporate the moisture
drainage elements even though the overall size and shape of each masonry unit
is consistent
with a standard unit size and form factor. As such, the masonry units can be
readily installed
by a worker without necessarily requiring specialized installation techniques
other than those
commonly used in the industry.
According to an embodiment, there is provided a masonry wall system,
comprising:
a first row of masonry blocks; and a second row of masonry blocks positioned
vertically over
the first row of masonry blocks so as to provide vertical wall section having
an exterior face
and an interior face, wherein each masonry block of the first row of masonry
blocks includes a
top surface oriented toward the second row of masonry blocks and a bottom
surface opposite
from the top surface, and wherein each masonry block of the first row of
masonry blocks
includes at least one moisture drainage element arranged along the top surface
of the
respective masonry block, the moisture drainage element comprising at least
one downwardly
slanted surface extending toward an interior hollow core of the respective
masonry block,
wherein each masonry block of the first row of masonry blocks includes an
upper rim
perimeter defined by uppermost exterior edges of the top surface of the
respective masonry
block, and wherein the liquid diversion elements arranged along the top
surface of the
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respective masonry block are spaced inwardly from the upper rim perimeter such
that the
upper rim perimeter has a generally continuous elevation.
According to another embodiment, there is provided a masonry unit for use in a
wall system, comprising: a front face having a vertical height; a rear face
having a vertical
height that is substantially equal to the vertical height of the front face; a
plurality of web
portions extending between the front and rear faces to define one or more
interior hollow
cores, each of the web portions extending generally perpendicularly to the
front and rear
faces, and each of the web portions having a vertical height that is
substantially equal to the
vertical height of the front face; a liquid diversion element arranged along a
top surfacc of
each web portion extending between the front and rear faces, the liquid
diversion element
comprising at least one downwardly slanted surface extending toward at least
one of the
interior hollow cores; and an upper rim perimeter defined by uppermost
exterior edges of the
front face, the rear face, and at least two of the web portions, wherein the
liquid diversion
elements arranged along the top surfaces of said two web portions are spaced
inwardly from
the upper rim perimeter such that the upper rim perimeter has a generally
continuous
elevation.
According to another embodiment, there is provided a method of controlling
moisture penetration through a masonry wall, comprising: receiving moisture
along a top
surface of a masonry block in a masonry wall, the moisture advancing along the
top surface
from an exterior face of the masonry wall in a direction toward an interior
face of the masonry
wall; diverting the moisture to drain generally vertically down one or more
interior hollow
cores of the masonry block, the masonry block comprising one or more moisture
drainage
elements positioned in the top surface of the masonry block, each of the
moisture drainage
elements comprising at least one downwardly slanted surface extending toward
an adjacent
one of the interior hollow cores of the masonry block when the blocks are
assembled into a
wall structure, wherein the masonry block includes an upper rim perimeter
defined by
uppermost exterior edges of four exterior sides of the masonry block, and
wherein the one or
more moisture drainage elements are spaced inwardly from the upper rim
perimeter such that
the upper rim perimeter has a generally continuous elevation; and directing
the moisture that
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drained down the hollow core of the masonry block to exit at a location that
is exterior to the
exterior face of the masonry wall.
According to another embodiment, there is provided a method of controlling
moisture penetration through a masonry wall, comprising: receiving moisture
along a top
surface of a masonry block in a masonry wall, the moisture advancing along the
top surface
from an exterior face of the masonry wall in a direction toward an interior
face of the masonry
wall; diverting the moisture to drain generally vertically down one or more
interior hollow
cores of the masonry block, the masonry block comprising one or more moisture
drainage
elements formed in the top surface of the masonry block, each of the moisture
drainage
elements comprising at least one downwardly slanted surface extending toward
an adjacent
one of the interior hollow cores of the masonry block when the blocks are
assembled into a
wall structure, wherein the top surface of the masonry block is circumscribed
by an upper rim
perimeter defined by uppermost exterior edges of four exterior sides of the
masonry block,
wherein each respective moisture drainage element of the one or more moisture
drainage
elements is spaced inwardly away from the upper rim perimeter of the top
surface of the
masonry block such that the entire upper rim perimeter the masonry block is
defined by four
coplanar edges; and directing the moisture that drained down the hollow core
of the masonry
block to exit at a location that is exterior to the exterior face of the
masonry wall.
The details of one or more embodiments of the invention are set forth in the
accompanying drawings and the description below. Other features, objects, and
advantages of
the invention will be apparent from the description and drawings.
DESCRIPTION OF DRAWINGS
FIG. 1 is perspective view of a wall system, in accordance with some
embodiments.
FIGS. 2A-2C show perspective, top, and cross-sectional views (respectively) of
an
example masonry unit for use in the wall system of FIG. 1.
FIG. 2D is a perspective view of an example drainage of moisture along the
masonry unit of FIGS. 2A-C.
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FIG 3 shows a perspective view of another example masonry unit for use in the
wall system of FIG 1.
FIGS. 4A-4B show perspective and top views (respectively) of a masonry unit,
in
accordance with some alternative embodiments.
FIGS. 5A-5C show perspective, top, and cross-sectional views (respectively) of
another masonry unit, in accordance with some alternative embodiments.
FIG. 6 shows a perspective view of a masonry unit, in accordance with some
alternative embodiments.
FIG 7 shows a perspective view of yet another masonry unit, in accordance with
o some alternative embodiments.
FIGS. 8A-8C show perspective, top, and cross-sectional views (respectively) of
an example masonry unit, in accordance with some alternative embodiments.
FIG. 9 shows a perspective view of a masonry unit, in accordance with some
alternative embodiments.
FIG. 10 shows a perspective view of another masonry unit, in accordance with
some alternative embodiments.
FIG 11 is a flow diagram of an example process for diverting the flow of
moisture across a masonry unit.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
Referring to FIG. 1, a wall system 100 can be formed from an assembly of
masonry units that provide a number of moisture drainage elements. In this
embodiment,
the masonry blocks 200 and 300 include a set of moisture drainage elements
220, 240,
320, and 340 extending along the top surfaces of the respective units 200 and
300. The
moisture drainage elements 220, 240, 320, and 340 can be formed on each block
200 and
300 in one or more rows 110 of the wall system 100. In this embodiment, the
wall
system 100 includes a first masonry wall 120 and a second masonry wall 130
that join at
a corner 140. In such circumstances, a first type of masonry blocks 200 can be
used
along the longitudinal length of the walls 120 and 130 while a second type of
masonry
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blocks 300 (referred to herein as "corner masonry blocks") are installed at
each corner
140 of the wall system 100. As described in more detail below, in some
embodiments,
the corner masonry blocks 300 may include an additional quantity of moisture
drainage
elements 320 compared to the first masonry blocks 200.
In some embodiments, each of the masonry blocks described herein can be
molded or otherwise formed as a unitary structure comprising a concrete mix
material
and, optionally, an integral water repellent admixture. Also, in the
embodiment depicted
in FIG 1, each of the masonry blocks 200 and 300 can be secured to the
adjacent blocks
in the wall using mortar material, such as a mortal material that includes an
integral water
o repellent admixture. As such, the wall system 100 can provide structural
support for a
building or other structure. In some embodiments, the wall system 100 can be
installed
along the rim of a building and over a foundation (not shown in FIG. 1) with
"weeps" and
drip edges (not shown in FIG 1) along the base of the wall system 100 to allow
moisture
that is directed vertically through hollow cores 250 and 350 of the masonry
blocks 200
and 300 to thereafter drain outwardly of an exterior face 150 of the wall
system 100.
Briefly, in use, some embodiments of the wall system 100 can be exposed to
water or other moisture 155 along the exterior face 150 of the wall system
100. In such
circumstances, the moisture 155 can migrate from the exterior face 150 of the
wall
system 100 in a direction toward an opposite interior face 160 of the wall
system 100.
For example, the moisture 155 may seep through cracks or porous joints in the
mortar
between adjacent masonry blocks 200, 300 and move along the top surfaces 210,
310 of
the masonry blocks 200, 300 in a direction toward the interior face 160 of the
wall system
100. In such embodiments, the moisture drainage elements 220, 240, 320, and
340
positioned along the top surfaces 210, 310 of the masonry blocks 200, 300 can
be
configured to redirect the moisture 155 such that the moisture 155 drain into
the hollow
cores 250, 350 of the masonry blocks 200, 300. Preferably, the moisture 155 is
drained
into the low cores 250, 350 before the moisture 155 is permitted to penetrate
the interior
face 160 of the wall system. In doing so, the moisture drainage elements 220,
240, 320,
and 340 can reduce the likelihood of the moisture 155 seeping into the
exterior face 150
and thereafter reaching the interior face 160. Moreover, is particular
embodiments, the
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moisture drainage elements 220, 240, 320, and 340 can achieve this benefit
even in some
circumstances when other supplemental moisture control techniques (e.g.,
double wythe
walls, sealants or coatings on the wall surface, and the like) are not
implemented or not
properly executed at the construction site.
Still referring to FIG. 1, some embodiments of the moisture drainage elements
220, 240, 320, and 340 of the masonry blocks 200, 300 can have a shape and
location the
improves the moisture drainage capabilities while continuing to provide the
masonry
blocks 200, 300 with an overall standard size and form factor. Accordingly, in
particular
embodiments, the masonry blocks 200, 300 can be assembled together to form the
wall
o system 110 in a manner that does not necessarily require specialized
installation
techniques other than those commonly used in the construction industry. For
example, as
shown in this embodiment in FIG. 1, each of the masonry blocks 200, 300 can
include a
rectangular shape with two hollow vertical cores 250, 350 that are separated
by a central
web portion. This rectangular shape of the masonry blocks 200, 300 permits
each row
110 of the wall system 100 to be arranged in a "brick pattern" relative the
adjacent row
100 while the hollow cores 250, 350 of the masonry blocks 200, 300 in each row
110 are
in fluid communication with the corresponding hollow cores 250, 350 of the
masonry
blocks 200, 300 in the adjacent row 110. Further, in this embodiment shown in
FIG 1,
the moisture drainage elements 220, 240, 320, and 340 can be arranged on the
masonry
blocks 200, 300 such that the moisture drainage elements 220, 240, 320, and
340 are
concealed from view when the wall system is constructed. As described in more
detail
below, each of the masonry blocks 200, 300 can be formed such that the outer
rectangular
rim edge of the top surface 250, 350 has a generally continuous height
relative to the
bottom surface of the block 200, 300. Accordingly, when an upper block 200,
300 is
assembled on top of a lower block 200, 300 in the wall system 100, the
moisture drainage
elements 220, 240, 320, and 340 of the lower block 200, 300 are concealed when
viewing
the exterior face 150 of the wall system 100.
Referring now to FIGS. 2A-2D, some embodiments of the first type of masonry
block 200' may include two of the drainage elements 220 and one drainage
element 240.
As previously described, the drainage elements 220 and 240 can be formed in
the top
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surface 210 of the masonry block 200. For example, the drainage element 240 is
formed
in the uppermost face of the central web 241 of the masonry block 200, and the
drainage
elements 220 are formed in the uppermost face of the end webs 221 of the
masonry block
200. Here, the block 200 includes a front wall portion 202 and a rear wall
portion 204,
and the central web 241 and the end webs 221 extend between the front and rear
walls
portions 202 and 204 so as to define the pair of interior cores 250. As shown
in FIG 2A,
the front wall portion 202, the rear wall portion 204, the central web 241,
and the end
webs 221 all have a generally uniform height h relative to a bottom surface
207 of the
block. In some embodiments, the front wall portion 202, the rear wall portion
204, and
the webs 221 and 241 are integrally formed as a unitary structure comprising a
concrete
material and, optionally, an integral water repellent admixture. As such, the
block 200 is
a generally rigid masonry unit that is suitable for construction of buildings
and other
structures.
In this embodiment, the top surface 210 of the block 200 includes outer
perimeter
211 that is generally rectangular in shape, and the outer perimeter 211 of the
top surface
210 has the generally continuous height h relative to the bottom surface 207.
For
example, even though the moisture drainage elements 220 and 240 are configured
as
depressions in particular areas of the webs 221 and 241 in this embodiment,
the moisture
drainage elements 220 and 240 are spaced inwardly from the outer perimeter 211
to
thereby enable the outer perimeter 211 in its entirety to have the generally
continuous
height h relative to the bottom surface 207. Such a configuration can in some
embodiments, permit the blocks 200 to be installed into a wall system 100 (FIG
1) in a
manner that permits the moisture drainage elements 220 and 240 to be conceal
from view
yet positioned to divert water into the interior cores 250.
As shown in FIGS. 2A-2B, the top surface 210 of the block 200 extends
generally
horizontally over the entire front and rear wall portions 202 and 204 and over
portions of
the webs 221 and 241. In this embodiment, the moisture drainage elements 220
and 240
are formed in the uppermost faces of the webs 221 and 241, so the uppermost
face of
each web 221 and 241 includes a horizontally extending surface region adjacent
to the
respective moisture drainage element 220, 240. Thus, even if water or other
moisture 155
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(FIG 1) can migrate along a generally horizontal region of the webs 221 and
241, the
moisture drainage elements 220 and 240 can divert the water or other moisture
155
before it reaches the opposite ends of the webs 221 and 241.
Referring to FIG 2C, at least some of the drainage elements 220 of the masonry
block 200 can include multiple sloped surfaces that extend downwardly toward
the
adjacent hollow core 250. In this embodiment, the moisture drainage elements
220
positioned along the end webs 241 have a different shape than the moisture
drainage
element 240 positioned along the central web 241. For example, the drainage
element
220 in this embodiment includes is spaced inwardly from the generally
horizontal top
1 o surface 210 and include a first downwardly sloped surface 222, an
intermediate surface
224, and a second downwardly sloped surface 226. The drainage elements 220 are
formed such that the first downwardly sloped surface 222 recedes below the
plane of the
top surface 210 so that the intermediate surface is positioned at a lower
height than the
top surface 210. In some implementations, the intermediate surface 224 may be
substantially parallel to the plane of the top surface 210 (e.g.,
approximately horizontal),
or may be sloped at an angle less than that of the first downwardly sloped
surface 222 or
the second downwardly sloped surface 226. The second downwardly sloped surface
226
recedes further below the intermediate surface 224, extending from the plateau
surface
224 to the hollow core 250. In this embodiment, the downward slope of the
first
downwardly sloped surface 222 is approximately equal to second downwardly
sloped
surface 226. As shown in FIG 2C, the moisture drainage element 220 of one end
web
221 is similar in shape to (and a mirror of) the oppositely positioned
drainage element
220 of the other end web 221.
Still referring to FIG. 2C, in this embodiment, the drainage element 240
positioned on the central web 241 of the masonry block 200 has a different
shape. For
example, the drainage element 240 includes two sloped surfaces 242 arranged in
a
pitched configuration with its peak extending along the lengthwise center of
the drainage
element 240. The two sloped surfaces extend downwardly away from one another
and
toward the respective hollow cores 250 on opposite sides of the drainage
element 240.
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In some implementations, the sloped surfaces 222, 226, and 242 may be oriented
at slope angle of about 2-degrees to about 89-degrees from the generally
horizontal top
surface 210, about 5-degrees to about 60-degrees from the generally horizontal
top
surface 210, and preferably about 10-degrees to about 30-degrees from the
generally
horizontal top surface 210. In this embodiment depicted in FIGS. 2A-2C, the
slope
surfaces 222, 226, and 242 are oriented at a downward slope angle of about 18-
degrees
from the horizontal. Here, the slope angle of the surfaces 222, 226, and 242
can be
selected to be sufficiently great so as to effective divert moisture toward
the cores 250
and without being too great so as to overly reduce the thickness and strength
of the webs
221 and 241. In this embodiment, the slope angle of the surfaces 222, 226, and
242 are
selected to that the total depression from the top surface 210 to the
lowermost edge of the
moisture drainage element 220, 240 is no greater than 0.5-inches, and
preferably about
0.4-inches.
Still referring to FIG 2C, it should be understood that the bottom surface 207
of
the masonry block 207 can also be configured to reduce the likelihood of water
or other
moisture migrating toward a rear face of the block 200. For example, when the
blocks
200 are assembled in a wall system (e.g., wall system 100 in FIG 1), the
blocks 200 in an
upper row 110 (FIG. 1) may be positioned above the same type of blocks 200 in
a lower
row 110. In such circumstances, water or other moisture 115 might migrate in a
path
along a portion of the bottom surface 207 (FIGS. 2A and 2C) of an upper block
200 in the
upper row 115 (FIG 1) rather than migrating along the top surface 210 of a
lower block
200 in the lower row 155. In the embodiments described herein, the bottom
surface 207
of each block 200 can include one or more structural or composition features
to reduce
the likelihood that the water will track along the bottom surface 207 of the
upper block
200 along the full path from the front face 202 to the rear face 204 (thereby
bypassing the
drainage elements 220, 240). For example, the bottom surface 207 of each block
200 can
include a 90-degree comer 209 (to the extent reasonable under the
manufacturing
tolerances) along a rectangular periphery of the bottom surface 207 (including
along the
lower front comer 209 as shown in FIG 2A) such that any water that reaches the
periphery of the periphery of the bottom surface 207 will be induced to drip
down to the
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lower block 200 below. In addition or in the alternative, the bottom surface
207 of each
block 200 can include textured surface elements, such as a non-uniform texture
formed
during a block molding process or a predetermined pattern of small ribs,
grooves, or
ridges, that induce any water tracking along the bottom surface to drip down
to the lower
block 200 below (and thereby migrating to the drainage elements of the lower
block 200).
In addition or in the alternative, the bottom surface 207 of each block 200
can include a
material comprising an integral water repellant admixture (in combination with
the
concrete mix) to reduce the surface tension along the bottom surface and
inhibit water
tracking along the bottom surface. Similar features can be implemented on the
bottom
surfaces of the alternative masonry blocks 300, 360, 400, 500, 560, 600, 700,
and 750
described herein.
Referring to now FIG 2D, the moisture drainage elements 220 and 240 are
positioned along the top surface 210 of the masonry block 200 so as to divert
water or
other moisture 155 toward the interior hollow cores 250 before the moisture
155
penetrates to the rear wall portion 204. When the masonry block 200 is
installed in a wall
system (refer, for example, to the system in FIG. 1), the front wall portion
202 can be
arranged on along the exterior face of the building or other structure such
that it may be
exposed to water or other moisture 155. In the event that the moisture 155
seeps past the
mortar joints or otherwise migrates along the top surface 210 of the block
200, the
moisture 155 can be intercepted and diverted by the drainage elements 220 and
240. For
example, water or another liquid migrating along the top surface 210 of the
block 200 can
migrate along only a portion of the webs 221 and 241 before the drainage
elements 220
and 240 direct the liquid into the hollow cores 250 by the force of gravity
and the slope
surfaces 222, 226, and 242 of the drainage elements 220 and 240. As such, in
the
illustrated example, the moisture drainage elements 220 and 240 can reduce the
likelihood of the moisture 155 migrating from the front wall portion 202 of
the block and
thereafter penetrating the rear wall portion. Moreover, in some circumstances,
this
beneficial function can be achieved even in wall systems that employ a single
wythe wall
configuration of the masonry blocks. As described in more detail below,
similar
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Attorney Docket No. 35974-0002CA1
redirection and drainage of the moisture 155 can be accomplished by using the
alternative
masonry blocks 300, 360, 400, 500, 560, 600, 700, and 750.
Referring now to FIG. 3, some embodiments of corner masonry blocks 300 can be
useful for installation at corner junctions of a masonry wall system (e.g.,
refer to corner
140 of the wall system 100 in FIG 1). In this embodiment, the corner masonry
blocks
300 include moisture drainage elements 320 that are similar in shape and
function to the
previously described moisture drainage elements 220, and also include a
moisture
drainage element 340 that is similar in shape and function to the previously
described
moisture drainage element 240. However, the corner masonry blocks 300 in this
embodiment include two additional of moisture drainage elements 320 compared
to the
first masonry blocks 200 (FIGS. 2A-2D). The location of the drainage elements
320 on
the front and rear sides of the block 300 permit the corner masonry blocks 300
to be used
to form either left or right corners.
In particular, the masonry block 300 includes two additional drainage elements
320 formed in the top surface 310 of the block over the front wall portion 302
and the
rear wall portion 304. As shown in FIG. 1, these additional drainage elements
320 along
the front and rear wall portions 302 and 304 are positioned so as to provide
the moisture
drainage capabilities even when the block 300 is positioned at a corner
junction of a wall
system (e.g., even when one of the end webs 321 serves as an exterior face of
the wall
system).
Similar to the masonry block 200 previously described in connection with FIGS.
2A-2D, the corner masonry block 300 includes a front wall portion 302 and a
rear wall
portion 304, and the central web 341 and the end webs 321 extend between the
front and
rear walls portions 302 and 304 so as to define the pair of interior cores
350. Also similar
to the previously described embodiments, the outer rim perimeter 311 of the
top surface
310 is generally rectangular in shape and has a generally continuous height
relative to a
bottom surface 307 of the block 300. In this embodiment, the front wall
portion 302, the
rear wall portion 304, and the webs 321 and 341 are integrally formed as a
unitary
structure comprising a concrete material. As such, the block 300 is a
generally rigid
masonry unit that is suitable for construction of buildings and other
structures.
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Attorney Docket No. 35974-0002CA1
In some implementations, the additional moisture drainage elements 320 formed
on the masonry block 300 permit the masonry block to be used as multipurpose
block.
For example, the masonry block 300 may be used as a corner block at a corner
junction
140 (refer, for example, to FIG 1) in a wall system. Also, the masonry block
300 may be
used to for a "T" or "X" shaped intersection of different wall sections in a
wall system.
In yet another example, the masonry block 300 may be installed along the
longitudinal
length of the rows 110 in a wall system (e.g., as an alternative to using the
masonry block
200).
Referring now to FIGS. 4A-4B, some alternative embodiments of a masonry
block 360 may be suitable for use as an end block in a wall system. The
masonry block
360 in this embodiment can include a single hollow core 365 that is surrounded
by a front
wall portion 362, a rear wall portion 364, and a pair of end webs 366. Also
similar to the
previously described embodiments, the end block 360 includes a generally
horizontal top
surface 363 and an outer rim perimeter of the top surface 363 has a generally
continuous
height relative to a bottom surface of the block 360.
In this embodiment, the block 360 includes moisture drainage elements 370
along
the top surface 363 over two adjacent sides of the masonry block 360. For
example, the
moisture drainage elements 370 can be formed in an uppermost face of the front
wall
portion 362 and in an uppermost face of an adjacent end web 366. In this
embodiment,
the moisture drainage elements 370 are similar in shape and function to the
previously
described moisture drainage elements 220 (FIGS. 2A-2D). Here, these drainage
elements
370 can be arranged to provide the moisture drainage capabilities when the end
block 360
is positioned, for example, at a corner junction of a wall system.
Referring now to FIGS. 5A-5C, some alternative embodiments a masonry block
400 may have a shape and a function similar to the previously described
masonry block
200 (FIGS. 2A-2D), except that the moisture drainage elements 420, 440 of the
depicted
masonry block 400 have a different shape. Similar to the masonry block 200
previously
described in connection with FIGS. 2A-2D, the corner masonry block 400 a front
wall
portion 402 and a rear wall portion 404, and the central web 441 and the end
webs 421
extend between the front and rear walls portions 402 and 404 so as to define
the pair of
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Attorney Docket No. 35974-0002CA1
interior cores 450. Also similar to the previously described embodiments, the
outer rim
perimeter 411 of the top surface 410 is generally rectangular in shape and has
a generally
continuous height relative to a bottom surface 307 of the block 300. In this
embodiment,
the front wall portion 402, the rear wall portion 404, and web 421 and 441 are
integrally
formed as a unitary structure comprising a concrete material. As such, the
block 400 is a
generally rigid masonry unit that is suitable for construction of buildings
and other
structures.
In this embodiment, the masonry block 400 includes two drainage elements 420
having a single slanted surface 422, and one drainage element 440 having a
pair of
to downwardly slanted surfaces 442. Similar to previously described
embodiments, the
drainage elements 420 and 440 are formed in the top surface 410 of the masonry
block
400. The drainage element 440 is formed along a portion of the central web 441
of the
masonry block 400, and the drainage elements 420 are formed along portions of
the end
webs 421 of the masonry block 400.
As shown in FIG 5C, at least some of the drainage elements 420 of the masonry
block 400 can a single sloped surface that extend downwardly toward the
adjacent hollow
core 450. In this embodiment, the moisture drainage elements 420 positioned
along the
end webs 441 have a different shape than the moisture drainage element 440
positioned
along the central web 441. For example, the drainage element 420 in this
embodiment
includes is spaced inwardly from the generally horizontal top surface 410 and
includes a
single downwardly sloped surface 422 that extends to the edge defining the
hollow core
450. As shown in FIG 5C, the moisture drainage element 420 of one end web 421
is
similar in shape to (and a mirror of) the oppositely positioned drainage
element 420 of
the other end web 421.
Still referring to FIG. 5C, in this embodiment, the drainage element 440
positioned on the central web 441 of the masonry block 400 has a different
shape. For
example, the drainage element 440 includes two sloped surfaces 442 arranged in
a
pitched configuration with its peak extending along the lengthwise center of
the drainage
element 440. The two sloped surfaces extend downwardly away from one another
and
toward the respective hollow cores 450 on opposite sides of the drainage
element 440.
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Attorney Docket No. 35974-0002CA1
In some implementations, the sloped surfaces 422 and 442 may be oriented at
slope angle of about 2-degrees to about 89-degrees from the generally
horizontal top
surface 410, about 5-degrees to about 60-degrees from the generally horizontal
top
surface 410, and preferably about 10-degrees to about 30-degrees from the
generally
horizontal top surface 410. In this embodiment depicted in FIGS. 5A-5C, the
slope
surfaces 422 and 442 are oriented at a downward slope angle of about 18-
degrees from
the horizontal. In this embodiment, the slope angle of the surfaces 422 and
442 are
selected to that the total depression from the top surface 410 to the
lowermost edge of the
moisture drainage element 420, 440 is no greater than 0.5 inches, and
preferably no
greater than about 0.4 inches. As previously described, the masonry blocks 400
can be
used in a wall system (refer, for example, to system 100 in FIG 1) so as to
provide
moisture drainage capabilities similar to those described in connection with
the
previously described masonry block 200 in FIG 2D.
Referring now to FIG 6, some embodiments of a corner masonry block 500 can
be useful for installation at comer junctions of a masonry wall system (e.g.,
refer to
comer 140 of the wall system 100 in FIG 1). In this embodiment, the comer
masonry
block 500 includes moisture drainage elements 520 that are similar in shape
and function
to the previously described moisture drainage elements 420 (FIGS. 5A-5C), and
also
includes a moisture drainage element 540 that is similar in shape and function
to the
previously described moisture drainage element 440 (FIGS. 5A-5C). However, the
comer masonry block 500 in this embodiment include two additional of moisture
drainage elements 520 compared to the previously described masonry block 400
(FIGS.
5A-5C).
In particular, the masonry block 500 includes two additional drainage elements
520 formed in the top surface 510 of the block over the front wall portion 502
and the
rear wall portion 504. As previously described, these additional drainage
elements 520
along the front and rear wall portions 502 and 504 are positioned so as to
provide the
moisture drainage capabilities even when the block 500 is positioned at a
corner junction
of a wall system (e.g., even when one of the end webs 521 serves as an
exterior face of
the wall system).
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Attorney Docket No. 35974-0002CA1
Similar to the masonry block 400 previously described in connection with FIGS.
5A-5C, the corner masonry block 500 includes a front wall portion 502 and a
rear wall
portion 504, and the central web 541 and the end webs 521 extend between the
front and
rear walls portions 502 and 504 so as to define the pair of interior cores
550. Also similar
to the previously described embodiments, the outer rim perimeter 511 of the
top surface
510 is generally rectangular in shape and has a generally continuous height
relative to a
bottom surface of the block 500. In this embodiment, the front wall portion
502, the rear
wall portion 504, and the webs 521 and 541 are integrally formed as a unitary
structure
comprising a concrete material. As such, the block 500 is a generally rigid
masonry unit
o that is suitable for construction of buildings and other structures.
In some implementations, the additional moisture drainage elements 520 formed
on the masonry block 500 permit the masonry block to be used as multipurpose
block.
For example, the masonry block 500 may be used as a corner block at a corner
junction in
a wall system (e.g., at corner junction 140 shown in FIG 1). Also, the masonry
block 500
may be used to for a "T" or "X" shaped intersection of different wall sections
in a wall
system. In yet another example, the masonry block 500 may be installed along
the
longitudinal length of the rows in a wall system (e.g., as an alternative to
using the
masonry block 200 or 400).
Referring now to FIG 7, some alternative embodiments of a masonry block 560
may be suitable for use as an end block in a wall system. The masonry block
560 in this
embodiment can include a single hollow core 565 that is surrounded by a front
wall
portion 562, a rear wall portion 564, and a pair of end webs 566. Also similar
to the
previously described embodiments, the end block 560 includes a generally
horizontal top
surface 563 and an outer rim perimeter of the top surface 563 has a generally
continuous
height relative to a bottom surface of the block 560.
In this embodiment, the block 560 includes moisture drainage elements 570
along
the top surface 563 over two adjacent sides of the masonry block 560. For
example, the
moisture drainage elements 570 can be formed in an uppermost face of the front
wall
portion 562 and in an uppermost face of an adjacent end web 566. In this
embodiment,
the moisture drainage elements 570 are similar in shape and function to the
previously
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Attorney Docket No. 35974-0002CA1
described moisture drainage elements 420 (FIGS.5A-5C). Here, these drainage
elements
570 can be arranged to provide the moisture drainage capabilities when the end
block 560
is positioned, for example, at a comer junction of a wall system.
Referring now to FIGS. 8A-8C, some alternative embodiments a masonry block
600 may have a shape and a function similar to the previously described
masonry block
200 (FIGS. 2A-2D), except that the moisture drainage elements 640 of the
depicted
masonry block 600 have a different shape. Similar to the masonry block 200
previously
described in connection with FIGS. 2A-2D, the comer masonry block 600 a front
wall
portion 602 and a rear wall portion 604, and the central web 641 and the end
webs 621
o extend between the front and rear walls portions 602 and 604 so as to
define the pair of
interior cores 650. In this embodiment, the front wall portion 602, the rear
wall portion
604, and web 621 and 641 are integrally formed as a unitary structure
comprising a
concrete material. As such, the block 600 is a generally rigid masonry unit
that is suitable
for construction of buildings and other structures.
In this embodiment, the masonry block 400 includes three drainage elements 640
having a substantially similar shape that are formed along portions of the end
webs 621
and the central web 641. For example, the drainage elements 640 may have a
substantially similar shape and function as the centrally positioned drainage
element 240
depicted FIGS. 2A-2D.
As shown in FIG. 8C, the drainage elements 640 each include two sloped
surfaces
642 (FIG 8C) arranged in a pitched configuration with their peaks extending
along the
lengthwise centers of the drainage elements 640 and sloping downward toward
each side
of the respective web 621, 641. In some implementations, the sloped surfaces
642 may
be oriented at downward slope angle of about 2-degrees to about 89-degrees
from the
generally horizontal top surface 610, about 5-degrees to about 60-degrees from
the
generally horizontal top surface 610, and preferably about 10-degrees to about
30-degrees
from the generally horizontal top surface 610. In this embodiment depicted in
FIGS. 8A-
8C, the slope surfaces 642 are oriented at a downward slope angle of about 18-
degrees
from the horizontal. As previously described, the masonry blocks 600 can be
used in a
wall system (refer, for example, to system 100 in FIG 1) so as to provide
moisture
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Attorney Docket No. 35974-0002CA1
drainage capabilities similar to those described in connection with the
previously
described masonry block 200 in FIG 2D.
Referring now to FIGS. 9-10, some embodiments of a masonry block may be
formed with core bar marks 725 that extend across one or more the moisture
drainage
elements. The core bar marks 725 can be a byproduct of the block forming
process, and
thus can be readily implemented any embodiments of the masonry blocks 200 300,
360,
400, 500, 560, 600, 700, and 750 described herein (already depicted on the
masonry
blocks 700 and 750 herein). Additionally, some embodiments of the masonry
block can
include end extensions 730 that protrude outwardly and generally
perpendicularly to the
end webs 721 of the block 700. These end extensions 730 can be useful in
particular
construction applications, and thus can be readily implemented any embodiments
of the
masonry blocks 200 300, 360, 400, 500, 560, 600, 700, and 750 described herein
(already
depicted on the masonry blocks 700 and 750 herein).
As shown in FIG 9, some embodiments of a corner masonry block 700 can be
include core bar marks 725, end extensions 730 or both. In this embodiment,
the corner
masonry blocks 700 include moisture drainage elements 720 that are similar in
shape and
function to the previously described moisture drainage elements 320 (FIG. 3),
and also
include a moisture drainage element 740 that is similar in shape and function
to the
previously described moisture drainage element 340 (FIG 3). Similar to the
masonry
block 200 previously described in connection with FIG 3, the masonry block 700
includes a front wall portion 702 and a rear wall portion 704, and the central
web 741 and
the end webs 721 extend between the front and rear walls portions 702 and 704
so as to
define the pair of interior cores 750. Also similar to the previously
described
embodiments, the outer rim perimeter 711 of the top surface 710 is generally
rectangular
in shape and has a generally continuous height relative to a bottom surface of
the block
700. However, the masonry block 700 in this embodiment includes core bar marks
725
that extend across a plurality of the drainage elements 720 and 740. In
particular, the
core bar marks 725 can be formed as a byproduct from the block forming
process, and
the location of the core bar marks 725 can be selected so as to serve as
portions of the
drainage elements 720, 740 on the webs 721, 741. The core bar marks 725 can
protrude
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Attorney Docket No. 35974-0002CA1
above the slanted surfaces of the drainage elements 720, 740 and can be
generally level
with the top surface 710 of the masonry block 700. In use, this configuration
for the core
bar marks 725 can enhance the water diversion capabilities of the drainage
elements 720
and 740.
As shown in FIG. 10, other embodiments of a masonry block 750 can be include
core bar marks 725, end extensions 730 or both. In this embodiment, the
masonry block
750 include moisture drainage elements 754 that are similar in shape and
function to the
previously described moisture drainage elements 420 (FIG 5A), and also include
a
moisture drainage element 756 that is similar in shape and function to the
previously
described moisture drainage element 440 (FIG 5A). However, the masonry block
750 in
this embodiment includes core bar marks 725 that extend across a plurality of
the
drainage elements 754 and 756. In particular, the core bar marks 725 can be
formed as a
byproduct from the block forming process, and the location of the core bar
marks 725 can
be selected so as to serve as portions of the drainage elements 754, 756 on
the webs. The
core bar marks 725 can protrude above the slanted surfaces of the drainage
elements 754,
756 and can be generally level with the top surface 710 of the masonry block
700. As
previously described, this configuration for the core bar marks 725 can
enhance the water
diversion capabilities of the drainage elements 754, 756. Additionally, the
masonry block
750 can include end extensions 730 that protrude outwardly and generally
perpendicularly to the end webs of the block 750.
A number of different embodiments of masonry blocks have been described
herein. Some or all of these embodiments can be used to implement methods of
controlling moisture penetration through a masonry wall.
For example, referring to FIG. 11, a process 800 for controlling moisture
penetration through a masonry wall can include a number of operations perform
by a
masonry block, such as any embodiment of the masonry blocks 200 300, 360, 400,
500,
560, 600, 700, and 750 described herein. The process 800 may include the
operation 810
of receiving moisture along a top surface of a masonry block in a masonry
wall. For
example, the moisture may advance along the top surface of the masonry block
from an
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Attorney Docket No. 35974-0002CA1
exterior face of the masonry wall in a direction toward an interior face of
the masonry
wall.
In some embodiments, the process 800 may also include the operation 820 of
diverting the moisture to drain generally vertically down one or more interior
hollow
cores of the masonry block. This operation 810 can be accomplished, for
example, using
one or more of the moisture drainage elements previously described in any of
the
aforementioned embodiments of the masonry blocks 200 300, 360, 400, 500, 560,
600,
700, and 750. For example, the moisture drainage element can be formed in the
top
surface of the masonry block, and the moisture drainage element can include at
least one
downwardly slanted surface extending toward an adjacent interior hollow core
of defined
by the masonry block.
The process 800 may also include the operation 830 of directing the moisture,
which has drained down the hollow core of the masonry block, to exit at a
location that is
exterior to the exterior face of the masonry wall. For example, the wall
system can be
installed along the rim of a building and over a foundation with a weep
system, flashing,
drip edges, or a combination thereof installed along the base of the wall
system. These
structures can guide the moisture to drain outwardly of the exterior face of
the wall
system.
Still referring to FIG 11, the process 800 may optionally include the
operation of
the maintaining an interior face of the wall system in a generally dry
condition. As
previously described, the masonry blocks used in the wall system can provides
an
improved resistance to moisture penetration by providing a drainage path for
water that
might otherwise advance to the interior face of the wall. Because the moisture
is drained
away from the wall before the moisture penetrates the interior face of the
wall system, the
masonry blocks can be useful in maintaining the interior face of the wall
system in a
generally dry condition even when the exterior face of the wall system is
saturated with
water or other moisture over a period of time.
A number of embodiments of the invention have been described. Nevertheless, it
will be understood that various modifications may be made without departing
from the
spirit and scope of the invention. For example, the aforementioned embodiments
of the
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Attorney Docket No. 35974-0002CA1
masonry blocks can be used in a single wythe masonry wall system, or
alternatively in a
multiwythe masonry wall system. In another example, some embodiments of the
masonry
blocks described herein can incorporate the moisture drainage elements so as
to provide
adequate moisture control either without the inclusion of integral water
repellent in the
masonry unit composition or with the inclusion of integral water repellent
masonry unit
composition. Also, the aforementioned embodiments can be used in a wall system
in
combination with flashing, termination bars, weeps, drip edges, vents and
other masonry
accessories including but not limited to joint reinforcement and movement
joints.
Furthermore, the aforementioned embodiments can be used in a wall system in
o combination with full grouting and reinforcement or with partial grouting
and
reinforcement. In another example, the aforementioned embodiments can be used
in a
wall system in combination with or without post-applied wall sealants,
coatings, air
barriers, vapor permeable materials, membranes, or other similar moisture
control
materials. Moreover, the aforementioned embodiments of the masonry blocks can
be
used in combination with mortar material that does not contain integral water
repellent
admixture or with mortar material does contain integral water repellent
admixture.
Likewise, the aforementioned embodiments of the masonry blocks can be used in
combination with masonry grout does not contain a water reducer (whether high
range or
not) or with masonry grout that does contain a water reducing admixture.
Accordingly,
other embodiments are within the scope of the following claims.
22
