WO1996002712A1

WO1996002712A1 - Building blocks and method of building construction

Info

Publication number: WO1996002712A1
Application number: PCT/AU1995/000426
Authority: WO
Inventors: Caswold Hickson Lee
Original assignee: Caswold Hickson Lee
Priority date: 1994-07-18
Filing date: 1995-07-17
Publication date: 1996-02-01
Also published as: AU668058B2; AU2015295A

Abstract

The blocks (1) are interlocking and/or self-aligning and may be used without mortar between the block surfaces. The blocks may also be intersection blocks (15), corner (10), angle corner (9) interlocking jointer. The fencing method covers a block (53) having inserts to interlock, as well as blocks (54, 61) which can form corners or junctions of a wall where end portions of the block may be set at various angles.

Description

BUILDING BLOCKS AND METHOD OF BUILDING CONSTRUCTION

This invention relates to building blocks and a method of building construction utilising the blocks. More specifically, the invention relates to self-aligning building blocks. The invention also relates to a fence section which can be used for constructing fencing, the fence section comprising posts which provide for self alignment and retention of intervening panel sections.

The time-honoured method of constructing a building from bricks or concrete blocks comprises laying courses of the bricks or blocks with mortar between the bricks or blocks. The mortar acts as a cement which binds together walls consisting of the bricks or blocks.

Considerable skill is required in laying bricks or blocks in conventional building construction methodologies. Bricks or blocks must be carefully aligned to ensure that walls are constructed true. Furthermore, use of mortar requires extra finishing of the joints between the bricks or blocks and frequently requires cleaning of mortar splashes from wall surfaces. The problem of alignment of bricks during building construction has been addressed. For example, Australian Application No. 39826/93 describes inter¬ locking, self-aligning bricks. However, mortar is still required between bricks for building construction. There is therefore a need for interlocking and/or self-aligning bricks which can be used in building construction without requiring mortar between surfaces of the bricks.

Fencing is usually constructed by mounting a plurality of posts into the ground or to a substrate and providing cross-pieces to which palings or infill material can be fitted. Constructing fencing of conventional types is generally a labour intensive operation and requires a reasonable level of skill on the part of those constructing the fencing.

Modular fencing, consisting of posts and prefabricated infill panels, is known. Such fencing is typically fabricated from a metal material and is usually easier to construct than conventional wooden fencing.

Fencing constructed from timber has a finite life - typically 10 to 15 years - and can be prone to damage. Similarly, modular metal fencing can be easily damaged although such fencing may be more resistant to weather and environmental damage.

There is thus a need for fencing components and a method of constructing fencing which is simpler than conventional fencing construction methods and provides more durable fencing.

It is an object of the present invention to provide bricks or blocks for use in building construction which may overcome the disadvantages of the existing bricks or blocks for building construction. It is an object of the present invention to provide fencing components which may provide a simpler method of fencing construction and which may provide more durable fencing than known fencing.

According to a first embodiment of this invention, there is provided a building block having: ends adapted to interlock with an end of an adjacent like block so that faces of a plurality of said blocks in a course are aligned; upper and/or lower surfaces adapted to engage a surface of a said like block so that faces of a plurality of said blocks in adjacent courses are aligned; and at least one cavity extending between said upper and lower surfaces.

The term "block" is used in the proceeding paragraph and hereafter to denote a building element which can also be referred to as a brick.

Typically, the adaption of ends to interlock with an end of an adjacent like block comprises a projection extending centrally of one end of the block between the upper and lower surfaces and a complementary recess in the other end of the block. It will be appreciated from the foregoing that adjacent blocks in a course interlock by way of the projection from an end of one block being received by the complementary recess in the end of the adjacent block. This also aligns the faces of the blocks making up the course.

Similarly, the adaption of upper and/or lower surfaces of a block to engage a surface of a like block comprises a projection extending longitudinally of one of the upper or lower surfaces and, optionally, a complementary recess in the other of the upper or lower surfaces. Again, blocks in adjacent courses interlock by way of the projection from a surface of one block being received by complementary recess in a surface of a block in an adjacent course. Faces of blocks in adjacent courses are thus once again aligned.

Preferably, the longitudinally extending projection described in the preceding paragraph is located at the junction of a surface and a face of the block. The projection in this case is essentially an extension of the face. The complementary recess, if present, runs along the opposite edge of the face. Blocks according to the invention typically have two cavities extending between the upper and lower surfaces. The cavities preferably lie on a longitudinal plane running through the centre of a block. These cavities are utilised for tie members or mortar in a wall constructed from blocks as will be discussed below.

The invention also provides blocks which can be used to form corners in a wall. Corner blocks are provided by having end portions of a block at an angle to each other. To form a right-angled corner in a course of blocks, end portions of blocks are set at 90^β. However, end portions can be set at any angle and an angle of 135° (internally) is also preferred. This latter corner block allows an oblique corner to be included in a wall constructed from blocks according to the invention. Corner blocks typically comprise two cavities per end portion - a total of four cavities per block.

Yet another form of block according to the invention is a junction block. Such a block can be used

SUBSTJ.TU'l'bSHEET(Rule26) to form a junction between two walls in a building constructed from blocks according to the invention. A junction block typically an additional end portion projecting from a face of a block. The additional end portion preferably projects at an angle of 90° to the face to form, in effect, a Tee-piece.

Junction blocks typically have a total of six cavities therethrough.

Blocks according to the invention are typically fabricated from concrete. However, other materials used for building block construction can also be used. Concrete blocks are advantageously reinforced.

Blocks can be formed by any of the methods known to those of skill in the art. For example, concrete blocks can be formed by moulding.

Blocks can be of any dimensions appropriate to the building to be constructed. Typically, blocks are 2β0 mm high by 150 mm thick and 450 mm or 900 mm long.

According to a second embodiment of this invention, there is provided a method of constructing walls of a building, said method comprising the steps of:

1) providing a foundation having a plurality of spaced apart tie members upstanding therefrom;

2) forming successive courses comprising blocks according to the first embodiment, wherein courses are positioned on said foundation so that said tie members extend through at least some of the cavities in said blocks; and

3) filling aligned cavities in blocks of said successive courses with mortar.

Advantageously, blocks are specially adapted for use in the first and final courses of a construction according to the second embodiment. For use in a first course, blocks are provided having only an upper surface adapted to engage lower surfaces of blocks in the second course. Conversely, blocks for use in a final course are provided having only a lower surface adapted to engage upper surfaces of blocks in the penultimate course. In the method of the second embodiment, a sealant is advantageously added between abutted surfaces of adjacent blocks. A preferred sealant is a silicon sealant. According to a third embodiment of this invention, there is provided a fence section comprising a pair of spaced apart posts each having at least one longitudinally extending channel therein; and, a plurality of elongate panel sections stacked edge to edge between said posts; wherein the ends of said panel sections are located in said at least one longitudinally extending channel in each said post.

Posts used in conjunction with fence section according to the third embodiment typically include a longitudinally extending cavity therethrough. This cavity can be used to receive a tie for securing a post to a foundation.

Posts are typically of circular cross section with the at least one channel radiating from the axis of the post.

Posts preferably comprise two longitudinally extending channels disposed at an angle to each other. Typical angles are 90°, 135^β or 180". This allows a post to act as a junction between adjacent fence sections or to form a corner in fencing comprising fence sections according to the invention.

Posts can also be provided with three channels to allow for the junction of three fence sections about a common post. Advantageously, the first and third channels form angles of 90* to the second channel. It will be appreciated from the foregoing that the first and third channels are thus 180" apart. However, other angles between channels are within the scope of the invention. For example, channels can be equally spaced about the exterior surface of a post, the angles there¬ between being 120" with respect to the longitudinal axis of the post.

Panel sections are advantageously hollow.

SUBSTITUTE SHEET(Role26) Posts and panel sections are preferably fabricated from concrete, in particular reinforced concrete.

Posts can be of any dimension but are conveniently 800 mm in length and in the preferred form, 190 mm in diameter.

Panel sections are typically 200 mm wide by 45 mm deep and 900 mm or 1800 mm long.

It will be appreciated that the invention includes within its scope fencing comprising at least two fence sections according to the third embodiment. It will be further appreciated that adjacent fence sections in fencing according to the invention share a common post. According to a fourth embodiment of this invention, there is provided a method of constructing fencing, said method comprising the steps of:

1) providing at least two spaced apart foundations; 2) securing a post according to the panel sections of the third embodiment to or into foundations; and

3) installing panel sections between a pair of posts with edges of panel sections engaged in channels of said posts to form said fencing.

According to a fifth embodiment of this invention, there is provided a method of constructing fencing, said method comprising the steps of:

1) providing at least two spaced apart foundations each said foundation having a tie member upstanding therefrom;

2) passing a post according to the panel therethrough sections of the third embodiment having a longitudinally extending cavity therethrough over each said tie member and securing said post thereto; and

3) installing panel sections between a pair of posts with edges of panel sections engaged in channels of said posts to form said fencing. A preferred foundation for methods according to the fourth and fifth embodiments is a concrete block embedded in a substrate such as the ground.

So that the invention may be better understood, examples of the invention will now be described with reference to the accompanying drawings briefly described below.

Figures 1 to 4 are plan views of blocks according to the invention. Figure 5 is a cross-sectional view at A-A of the blocks depicted in Figures 1 to 4.

Figure 6 is a cross-sectional view of yet another block according to the invention.

Figure 7 depicts a method of constructing a wall using blocks according to the invention. The figure provides details of the wall and foundation thereto.

Figure 8 further depicts the method of wall construction as depicted in Figure 9 with detail of the connection of roofing members to the wall. Figures 9 to 12 are end views of posts for use in fence sections according to the invention.

Figures 13 and 14 are perspective views of panel sections.

Figure 15 is a perspective view of fencing comprising fence sections according to the invention.

Figure 16 depicts a method of constructing fencing with detail provided as to the securing of a post to a foundation.

Referring now to Figure 1, there is shown block 1 having an upper surface 2 and ends 3 and 4. End 3 includes a centrally positioned projection 5 running between the upper and lower surfaces while end 4 includes a recess 6 of complementary shape to projection 5. Block 1 also includes cavities 7 and 8 extending between the upper and lower surfaces.

Figures 2 and 3 depict in plan view corner blocks 9 and 10. It can be seen that blocks 9 and 10 are essentially the same as the blocks shown in Figure 1

SUBSTITUTESHEET(Role26) except that end portions, 11 and 12 of Figure 2, and 13 and 14 of Figure 3, are angled towards each other. The internal angles formed by the end portions of the blocks depicted in Figures 3 and 4 are 135" and 90° respectively.

A junction block 15 is depicted in Figure 4. This block is similar to block 1 of Figure 1 but has an additional end portion 16 projection from a face of the block to form a Tee-piece in plan. End portion 16 includes a recess 17 complementary to a projection such as 5 of Figure 1. Junction blocks can also be provided where end portion 16 has a projection rather than a recess.

Figure 5 is a cross-sectional view of block 1 of Figure 1 at A-A. The cross-sectional view depicts cavity 7 and faces 18 and 19. Longitudinal projection 20 and complementary recess 21 can also be seen. It can be appreciated from this figure that the inner surface 22 of projection 20 is sloped. This slope is shown as the double lines generally indicated at 23 of Figure 1.

It will be appreciated that blocks 9, 10 and 15 are the same in cross-section at A-A of Figures 2, 3 and 4 respectively as the cross-sectional view presented in Figure 5. It can be further appreciated from Figures 1 to

4 that a course of blocks can be aligned by interlocking of projections and complementary recesses. For example, projection 5 of block 1 of Figure 1 can be received by recess 24 of block 9 of Figure 2 when the blocks are abutted in a course. Similarly, projection 22 can be received by a complementary recess the same as 21 in a block of an adjacent course.

Blocks are typically laid in courses with ends of blocks in successive course aligned. In this way cavities are also aligned. However, blocks in successive courses can also overlap as is the standard practice in conventional brick-laying.

A block 25 suitable for use in a first or final course of a wall comprising blocks according to the invention is shown in cross-section in Figure 6. The cross-section is at a plane equivalent to A-A of Figure 1. Block 25 has a recess 26 but does not have a complementary projection like 20 of block 1 of Figure 5. This adaption thus provides a block with a flat surface.

General aspects of constructing a building using blocks according to the invention are shown in Figures 7 arid 8. Both figures are cross-sectional views of a wall through blocks at a plane equivalent to A-A of Figure 1.

Referring first to Figure 7, there is shown wall 30 comprised of a plurality of blocks. Blocks 31 and 32 are the same as block 1 of Figure 1 while block 22 is of similar configuration with the exception that there is not a complementary recess to projection 34 in the lower face 35 of the block.

Block 33 sits on foundation 36. The foundation is reinforced concrete. A tie rod 37 extends from foundation 36 through cavity 38 in block 33. Block 33 represents one block of a course of blocks to which course additional courses are added as represented by blocks 31 and 32. It will be appreciated that the interlocking nature of the blocks aligns the faces thereof to provide a wall with true surfaces. Tie rod 37 can be extended if required by additional rod 39 tied thereto. To complete a wall, mortar can be poured into cavities of blocks which are aligned in the assembled wall. The mortar when set and in conjunction with the tie rods produces a wall of greater strength than conventional brick or concrete block structures.

A method of securing roofing elements to a wall is depicted in Figure 8. The wall shown in Figure 8 can be considered an extension of wall 30 of Figure 7. The penultimate course of blocks includes a block 40 like block 1 of Figure 1 while the final course includes a block 41 like block 25 of Figure 6. A roofing element 42 is supported by plate 43 which runs along the top of wall 44. Member 42 can be fixed to wall 44 by a strut 45. Strut 45 includes a hooked end 46 which can be simply hooked around a rod 47 running longitudinally through block 41. It will be appreciated that strut 45 projects into a cavity 48 of block 41.

It can be further appreciated from Figure 7 and 8 that the method of construction represented by these figures and the accompanying description is a considerably easier method than conventional methods. Mortar is not required between contact surfaces of blocks which eliminates the need for finishing mortar joints and substantially reduces the need for removing mortar spills. Mortar when added, is simply poured into cavities in aligned blocks. Referring new to Figures 9 to 12, there are shown end views of posts for use in fence sections according to the invention. Post 50 of Figure 1 is of circular cross-section and has two longitudinally extending channels 51 and 52. Posts 53 and 54 of Figures 10 and 11 respectively are similarly of circular cross- section and each having two longitudinally extending channels 55 and 56, and 57 and 58, respectively. The channels of the posts depicted in Figures 9 to 11 radiate from the centre axis of posts at angles of 135", 180° and 90", respectively, with respect to each other.

Figure 12 depicts a post 61 like those of Figures 9 to 11 but having three longitudinally extending channels 62, 63 and 64. Channels 62 and 64 are disposed at 180" to each other while channel 63 is at 90" to the other two channels.

All of the posts depicted in Figures 9 to 12 have a longitudinally hole, 65 to 68 respectively, extending therethrough.

Figures 14 and 15 depict panel sections 69 and 70. the panel sections can be seen to have a generally rectangular cross-section with rounded corners. Panel sections 69 and 70 are hollow.

Fencing 71 comprising a plurality of fence

SUBSTITUTESHEET(Role26) sections according to the invention is depicted in Figure 15. The exemplified fencing comprises posts 50, 53, 54 and 61 of Figures 9 to 12 plus a plurality of panel sections 69 according to Figure 13, one of which is indicated at 72. Post 73 has a single longitudinally extending channel.

It can be appreciated from Figure 5 that the differing angles between channels in posts allows construction of fencing with corners or deviations therein. Thus, the sections adjacent posts 54 are at 90° to each other while the sections adjacent posts 50 are at 135° to each other. Post 61 allows a junction in fencing, this post being common to three panel sections, 73, 74 and 75. A method of constructing fencing comprising fence sections according to the invention is represented in Figure 16. Figure 16 is an elevational view of a portion of fencing with post 76 in cross-section. Post 76 is of the same configuration as post 53 of Figure 10 and the cross-section is at a plane A-A as shown in Figure 10.

In Figure 16, a concrete block 77 is embedded in the ground. (The block is shown in cross-section). A tie rod 78 is included in the block and extends upwardly thereof. Post 76 is positioned over the tie rod where it passes through longitudinal hole 79 in post 76. Post 76 can then be secured to block 77 by tightening a nut 80 to a threaded end portion of tie rod 78.

Fence sections are then completed by slotting panel sections, one of which is indicated at 81, into the channels of post 76. A wall of a channel can be seen at 82 while the bottom of the opposite channel is indicated at 83.

It will be appreciated that fencing comprising panel sections as exemplified above is easily constructed once posts have been secured to foundations. Fencing comprising concrete components is also more durable than conventional metal or wooden fencing. It is an alternative method of fencing construction, the foundation can be a metal plate or material secured to a surface. A post can then be secured to the plate, preferably by a tie rod extending through the post.

It will also be appreciated that the posts of a panel section can be included in a foundation, such as a concrete block, or directly embedded in a substrate such as the ground. It will be further apprecaited that many modifications can be made to the invention as exemplified above without departing from the broad ambit and scope thereof, which ambit and scope is to be limited only by the appended claims.

Claims

The claims defining the invention are as follows:

1. A building block having: ends adapted to interlock with an end of an adjacent like block so that faces of a plurality of said blocks in a course are aligned; upper and/or lower surfaces adapted to engage a surface of a said like block so that faces of a plurality of said blocks in adjacent courses are aligned; and at least one cavity extending between said upper and lower surfaces.

2. Block according to claim 1, wherein said adaption of ends to interlock with an end of an adjacent like block comprises a projection extending centrally of one end of said block between said upper and lower surfaces and a complementary recess in the other end of said block.

3. Block according to claim 1 or claim 2, wherein said adaption of upper and/or lower surfaces to engage a surface of a said like block comprising a projection extending longitudinally of one of said upper or lower surfaces and a complementary recess in the other of said upper or lower surfaces.

4. Block according to claim 3, wherein said longitudinally extending projection is located at the junction of an upper or lower surface and a face of said block and said complementary recess is located at the junction of the other of said upper or lower surface and said face of said block.

5. Block according to any one of the proceeding claims having two spaced apart cavities therein disposed along a central plane extending longitudinally of said block.

6. Block according to any one of claims 1 to 5, wherein end portions of said block are at an angle to each other so as to form a corner in a course of blocks including said block.

7. Block according to claim 6, wherein said end portions are at an angle of 135°.

8. Block according to claim 6, wherein said end portions are at an angle of 90".

9. Block according to any one of claims 1 to 5, said block further including an additional end portion projecting from a face of said block so as to form a junction in a course of blocks including said block.

10. Block according to claim 9, wherein said additional end portion projects from said face at an angle of 90" .

11. A building block, substantially as hereinbefore described with reference to any one of Figures 1 to 6.

12. A method of constructing walls of a building, said method comprising the steps of:

1) providing a foundation having a plurality of spaced apart tie member upstanding therefrom;

2) forming successive courses comprising blocks according to any of claims 1 to 11, wherein courses are positioned on said foundation so that said tie members extend through at least some of the cavities in said blocks; and

3) filling aligned cavities in blocks of said successive courses with mortar.

13. Method according to claim 12, wherein upper surfaces only of blocks in the first course are adapted to engage surfaces of blocks in the second course.

14. Method according to claim 12 or claim 13, wherein lower surfaces only of blocks in the final course are adapted to engage surfaces of blocks in the penultimate course.

15. Method according to any one of claims 12 to 14, wherein a sealant is provided between surfaces and between ends of said blocks in said courses.

16. Method according to claim 15, wherein said sealant is a silicon sealant.

17. Method of constructing walls of a building, which method is substantially as hereinbefore described with reference to Figure 7 and the exemplification.

18. A fence section comprising a pair of spaced apart posts each having at least one longitudinally extending channel therein; and, a plurality of elongate panel sections stacked edge to edge between said posts; wherein the ends of said panel sections are located in said at least on longitudinally extending channel in each said post.

19. Fence section according to claim 18, wherein each said post includes a longitudinally extending cavity therethrough for receiving a tie for securing a said post to a foundation.

20. Fence section according to claim 18 or claim 19, wherein each said post is of circular cross-section.

21. Fence section according to any one of claims 18 to 20, wherein at least one of said posts has two longitudinally extending channels therein.

22. Fence section according to claim 21, wherein said channels form an angle of 90" therebetween with respect to the longitudinal axis of said at least one post.

23. Fence section according to claim 21, wherein said channels form an angle of 135" therebetween with respect to the longitudinal axis of said at least one post.

24. Fence section according to claim 21, wherein said channels form an angle of 180" therebetween with respect to the longitudinal axis of said at least one post.

25. Fence section according to any one of claims 18 to 20, wherein at least one of said posts has three longitudinally extending channels therein.

26. Fence section according to claim 25, wherein the first and third channels each form angles of 90° to the second channel with respect to the longitudinal axis of said at least one post.

27. Fence section according to claim 26, wherein said panel sections are hollow.

28. A fence section, substantially as hereinbefore described with reference to Figure 15.

29. A fence section, substantially as hereinbefore described and comprising posts essentially in accordance with any one of Figures 9 to 12.

30. Fencing comprising at least two fence sections according to any one of claims 18 to 29.

31. A method of constructing fencing, said method comprising the steps of:

1) providing at least two spaced apart foundations; 2) securing a post according to the panel sections of any one of claims 18 to 29 to or into foundations; and

32. A method of constructing fencing, said method comprising the steps of:

2) passing a post according to the panel sections of claim 19 and claims dependent thereon over each said tie member and securing said post thereto; and

33. Method according to claim 31 or claim 32 wherein said foundations are concrete blocks embedded in a substrate.

34. A method of constructing fencing, which method is substantially as hereinbefore described with reference to Figure 16 and the exemplification.