WO2010124345A1

WO2010124345A1 - A block for use in the construction of a wall

Info

Publication number: WO2010124345A1
Application number: PCT/AU2010/000506
Authority: WO
Inventors: Craige Jonathan Henrick
Original assignee: Craige Jonathan Henrick
Priority date: 2009-04-30
Filing date: 2010-04-30
Publication date: 2010-11-04

Abstract

A block (20) for the construction of a wall, the block comprising (i) a body (21) having multiple faces, and (ii) at least one facing panel (22) secured to at least one of the faces of the body (21), the facing panel (22) comprising at least part of an exposed surface of the wall when constructed, wherein the facing panel (22) is secured to the body (21) using a combination of a double sided tape (25) and one or more mechanical devices (26, 27).

Description

A BLOCK FOR USE IN THE CONSTRUCTION OF A WALL

Technical Field of the Invention

The present invention relates to a block for use in the construction of a wall such as a retaining wall or wall for a building or other edifice. The present invention further relates to a method of building a wall using the block of the present invention.

Background of the Invention

In this specification where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date publicly available, known to the public, part of the common general knowledge or known to be relevant to an attempt to solve any problem with which this specification is concerned.

While the present invention will be described with reference to construction of retaining walls the skilled person will appreciate that the invention is not so limited but applies to the construction of a wide range of walls for a variety of purposes.

Retaining walls are often constructed using blocks of stone or blocks of cast material siidh as cement or cement combined with sand. The retaining wall is typically formed by lining the blocks in a row. The wall is built to a desired height by simply stacking rows of blocks on the row immediately below. The wall can be located forward of any soil to be retained - the space between the soil and wall being filled with stone. In this manner the retaining wall does not contact the soil it retains and as such avoids water damage from moisture in the soil.

When the retaining wall is very prominent and located in a highly visible location it is often desired to improve the appearance of the stone or cast blocks and this can be achieved by attaching a facing to the wall. The facing often consists of large, relatively thin slabs of stone or other material that has greater aesthetic appeal than the blocks from which the wall is constructed. Typically, each slab is large enough to conceal a number of blocks in the face of a wall. The size and weight of each slab of stone facing means that relatively specialised engineering means must be employed to connect the stone facing to the wall, including the use of high strength bolts and braces. This type of work is typically carried out by a skilled tradesman. It also increases the time and materials required to construct the wall. The time, materials and labour involved in attaching the facing to a wall can equate to significant costs.

Attempts have been made to avoid the need to attach slabs of stone facing to a wall by the aforementioned method by attaching facing directly to the side(s) of a block that will form a visible face of a wall before installation. For example, US-5,930,964 (Boehning) describes construction of a composite wall block. The invention includes attaching a facing layer to bricks incorporating the use of complementary shaped interlocking means. Similarly, US-5,788,423 (Perkins) describes attachment of a decorative facing panel to a face of a masonry block using a keyway and key connection formed in the front face of the block and rear face of the decorative panel. Blocks having interlocking devices such as keyways and the like are relatively complex to manufacture and usually skilled tradesman are required to attach the facing to the block.

There have been attempts to use simpler systems to attach facing to the side of a block. For example, GB-2284834 and AU-2006100175 disclose a system wherein the facing panel is secured to the block using a bonding agent such as a resin, epoxy, adhesive or resin. However, these attempts have disadvantages including the time taken to manufacture the blocks and the risk of the facing panel shearing off the body of the block.

Accordingly, there is a need for an alternative way of imparting a desired appearance to a wall.

Summary of the Invention

The present invention provides a block for the construction of a wall, the block comprising:

(i) a body having multiple faces; and

(ii) at least one facing panel secured to at least one of the faces of the body, the facing panel comprising at least part of an exposed surface of the wall when constructed, wherein the facing panel is secured to the body using a combination of a double sided tape and one or more mechanical devices. The body can be any appropriate building material of any shape or size. Preferably, it is of parallelepiped shape.

Preferably, at least one of the faces of the body comprises at least one projection extending toward the at least one facing panel. Typically, the body comprises three said projections, each extending normal to the body. In this embodiment, one side of the double sided tape engages the at least one projection on the face of the body and the other side of the double sided tape engages the at least one facing panel. Preferably, the three projections are equidistant from each other. More preferably, insulation is located in the void(s) created by the at least one projection. The body may be lightweight concrete or plastic or any other man made material. In a preferred embodiment, the body comprises cast material, extruded material or natural stone. In one preferred embodiment the cast material is chosen from the group comprising concrete, clay, mud, aerated "hebal" concrete, re-constituted stone or sand, polymer, recycled materials or combinations thereof. Masonry blocks for retaining walls typically are cast in metal moulds to form a unitary masonry block body. The material may be dried or fired as appropriate. In one preferred embodiment, the body is an aerated "hebal" concrete block. Another preferred embodiment uses concrete masonry blocks sold under the name Besser™ from Boral Besser Masonry Pty Ltd that are principally constructed of a compressed mixture of sand, cement, aggregate and water, with large recesses formed in the interior of the block to reduce the weight of the block without compromising structural integrity. A further preferred embodiment uses concrete masonry blocks sold under the name of BenexBlock™ from Benex Technologies Pty Ltd made using three different mixes to provide desired fire rating, water proofing, thermal and acoustic properties. In another embodiment, the body is pre-sealed with a sealant or primer. Preferably, the facing panel comprises natural or synthetic material. For example, the facing panel may be chosen from the group comprising stone (including but not limited to sandstone, bluestone, granite, marble), metal sheet, timber, composite materials and combinations thereof. Composite materials include materials which combines other materials listed as well as other materials such as plastic. For example, a composite material could be a mixture of stone and plastic wherein the stone has been crushed and dispersed in a plastic and then panels moulded from the stone plastic composite. The facing panel may be of any convenient conformation and thickness. In a preferred embodiment, the facing is 5 to 50 mm in thickness, more preferably 10 to 30 mm, or even more preferably 15 to 25 mm. In another embodiment, the facing panel is pre-sealed with a sealant or primer.

The double sided tape can be any suitable industrial tape for use in exterior bonding situations. A double sided tape is a tape having an upper and lower surface each carrying an adhesive. As such, the double sided tape may be used to affix two bodies together. It is in this sense that the words "double sided tape" are used in this specification. One example of a suitable double sided tape is 3M™ VHB™ Tapes, in particular tape number 4991 which affixes to surfaces in up to three minutes.

The mechanical device may be any appropriate mechanical devices for exterior work. Examples of appropriate mechanical devices include braces, pins, clips and staples. Typically, the mechanical device used will be made from stainless steel or spring stainless steel. Preferably, the pin, clip or staple has a first arm engaging the facing panel, a second arm engaging the body, and a third arm communicating between the first and second arm. Preferably, the first and second arms are substantially parallel to one another. In another embodiment, the pin, clip or staple comprises a fourth arm communicating between the second and third arm.

In a particularly preferred embodiment, the pin, clip or staple further includes a fifth arm extending away from the first arm to engage an adjacent facing panel. More preferably, the first and fifth arms are substantially parallel to one another.

In another embodiment, the first arm has a serrated portion for engaging the facing panel and/or the second arm has a serrated portion for engaging the body. In another preferred embodiment, the first arm has a barbed tail portion for engaging the facing panel and/or the second arm has a barbed tail portion for engaging the body.

Preferably, the facing panel may have a groove(s) extending partially or wholly along at least one edge thereof. In that case the first arm engages in the groove(s).

In a preferred embodiment, the body includes at least one internal cavity. Typically, the second arm is in contact with an inner face of the cavity. In another preferred embodiment, the body has at least one opening. The opening may be any shape. Typically, the opening is selected from the group consisting of grooves, holes, slots extending partially or wholly along at least one edge of the body and combinations thereof. Typically, the second arm is received in the at least one opening. The opening may be created using any suitable methods. In one embodiment, the opening is selected from the group comprised of preformed openings, pre-cut openings, pre-drilled openings, pre-moulded opening and combinations thereof. In another embodiment, an opening is created when the second arm is pressed into the body.

Preferably, when the mechanical device is a staple, the staple is pressed into the groove on the facing panel and the groove, hole or slot on the body.

In a preferred embodiment, the addition of facing to the body to form a block improves the thermal efficiency of the body and so the walls constructed of the block. In a preferred embodiment, the blocks of the present invention meet the Building Code of Australia's Energy Code which requires walls to achieve a minimum total insulation value of R 1.0. In another preferred embodiment, the block contains insulation to further improve the R value of the wall.

Australia's Commonwealth Scientific & Industrial Research Organisation (CSIRO) has developed a number of test methods specifically for evaluating the properties of natural stone facing. They comprise 14 test procedures for testing natural stone tiles, collectively known as the CSIRO Built Environment Stone Tile (BEST) test methods. These test methods, with the appropriate slip resistance standard (e.g. Australian Standard 4586) for specifying minimum requirements for natural stone as a tiling system component in Australia, now make a comprehensive set of preferred product 'standards'. In a particularly preferred embodiment, the facing panel is made of stone and has a density of at least 1 Ton/m³, or more preferably at least 2 Ton/m³ as measured using the CSIRO BEST 2 test method. Preferably the body has a flexural strength of at least 8 Mps, more preferably, at least 10 Mps using CSIRO BEST 3 test method.

In a particularly preferred embodiment, the body has a density of at least 1 Ton/m³, or more preferably at least 2 Ton/m³. Typically, the body is a full size Besser™ masonry block measuring approximately 390 x 190 x 210 mm, or alternatively a half block or a quarter block. In another preferred embodiment, the body is a full size BenexBlock™ masonry block measuring approximately 600 x 200 x 200 mm, or alternatively a half block or a quarter block.

The present invention also provides a method for construction of a wall from blocks of the present invention, the method including the step of positioning a plurality of said blocks to form a wall, with the facing panels positioned in the most visible or prominent part of the wall. For example, the facing panels may be located in the same plane, or parallel planes. Blocks located at a corner or end of a wall that can be viewed from more than one angle or direction may for example, have facing on two or more faces of the body.

In a preferred embodiment, the blocks of the present invention are used in walls constructed according to all relevant building code requirements. For example, local building codes may require that the blocks be pinned or retained at appropriate vertical or horizontal intervals, such as at each floor level when the wall forms part of a building. If the blocks are hollow or include recesses, it may be necessary to include reinforcing bars and/or concrete in the blocks.

Local building code requirements may have special requirements for walls exceeding a particular height. For example, when the wall is particularly tall, it may be mandatory to additionally use a mechanical device such as a brace or pin to ensure that the facing does not disengage from the body of blocks located high up in the wall thus creating a safety hazard for passers-by. It may also be required that the mechanical devices are used to retain facing on blocks at the end of walls or around openings such as doors and windows.

Typically, control joints will be required by building codes. Control joints are for example, often required at major changes in wall height, thickness (other than for piers and buttresses) at one or both sides of wall openings or near wall intersections. Joints in the wall are typically filled with mortar, grout or flexible silicon based material.

In another embodiment of the invention, there is provided a block for the construction of a wall, the block comprising:

(i) a body having multiple faces; (ii) an insulating member having a first face secured to at least one of the faces of the body; and

(iii) at least one facing panel secured to a second face of the insulating member, the facing panel comprising at least part of an exposed surface of the wall when constructed,

wherein the facing panel, insulating member and the body are secured together using a combination of a double sided tape and one or more mechanical devices.

In another embodiment of the invention, there is provided a building element for constructing a wall comprising (i) a body of parallelepiped shape, and (ii) at least two substantially parallel projections extending normal to a face of the body from a pair of sides of the body. Preferably, an additional projection is provided extending from the face of the body and intermediate the other two said projections. More preferably, the additional projection is equidistant from the other two projections.

The present invention also provides a process for manufacturing the blocks of the present invention the process including the step of securing the facing panel to a face of the body to form the block. If the body is to be used at the end or corner of a wall, the facing panel may be secured to two or more faces of the body. Typically, the facing is secured to the block in a factory, such as on a mass production line so that the quality of the blocks is adequately controlled. In one preferred embodiment, the method of manufacturing the block comprises the steps of:

(a) applying double sided tape to a face of the body;

(b) placing the facing panel onto the double sided tape so that the facing panel is affixed to the body; and (c) engaging a mechanical device with both the facing panel and the body.

More preferably, the method of manufacturing the block comprises the steps of:

(a) applying a sealant or primer to at least a first portion of a face of the body; (b) applying a sealant or primer to at least a first portion of the face of the facing panel which is to be secured to the body;

(c) applying double sided tape to the first portion of the body;

(d) placing the first portion of the facing panel onto the double sided tape so that the facing panel is affixed to the body; and

(e) engaging a mechanical device with both the facing panel and the body. Brief Description of the Drawings

Representative embodiments of the present invention are described herein, by way of example only, with reference to the accompanying drawings, wherein: Figure 1 is an expanded view of one embodiment according to the present invention without the mechanical device installed.

Figure 2 is an expanded view of body 21 of Figure 1.

Figure 3 is an expanded view of the assembled block of Figure 1 showing the mechanical device installed. Figure 4 is a profile view of the mechanical device used in Figure 3.

Figures 5a, 5b, 5c, 5d are side views of examples of other mechanical devices which can be used in the invention.

Figure 5e is a profile view of a staple type mechanical device that can be used in the invention. Figure 5f is a profile view of the pin type mechanical device in Figure 5b.

Figure 6 is an example of a different shaped body and facing panel which could be used in a second embodiment of the invention.

Figure 7 is an example of another shape of body which could be used in a third embodiment of the invention. Figure 8 is a top view of another embodiment according to the present invention. Figure 9 is an expanded view of an alternate assembled block. Figure 10 is an expanded view of another embodiment according to the present invention. Detailed description of a preferred embodiment

In Figure 1, block 20 includes a body 21 which is secured to a facing panel 22. The facing panel 22 is secured to body 21 using a combination of double sided tape 25a, 25b, 25c and mechanical device 26, 27 (see Figure 3). Body 21 can be any appropriate building material of any shape or size. It could be light weight or concrete or plastic or any other man made material. Typically, the body is an appropriately shaped Besser™ masonry block or BenexBlock™ of any size. As well as the simple rectangular block, there are many variations available from suppliers such as Cowra Concrete Products. For example, there are blocks with projections that will enable the inclusion of double insulation (see Figure 7). The bottom width of a simple rectangular block body is typically narrower (eg 30 mm) than the top width (eg 40 mm) as it is easier to hold the mortar on the wider width. In Figure 1, body 21 has projections 21a, 21b, 21c. Alternatively, as shown in Figure 9 and Figure 10 the body 21 may have no projections.

The body 21 may have one or more internal cavities with internal faces designed to receive the mechanical device. In Figure 1 , body 21 has internal cavities 31 a, 31 b with internal faces 32a, 32b.

In another representative embodiment, body 21 may have one or more openings designed to receive the mechanical device. Typically, the openings are a groove(s), hole(s) or slot(s). In Figure 8, body 21 has holes 33a, 33b, 33c, 33d. Facing panel 22 has pre-cut grooves 23, 24 cut into each of its long sides designed to receive the mechanical device. In the figures, the grooves 23, 24 are shown as extending across the length of the long sides, however the grooves may be cut only along a portion of the side to receive the mechanical device without being visible from the side of the block (see Figure 8). Facing panel 22 may also be formed with lugs to provide room for insulation between facing panel 22 and body 21 (see Figure 6). The facing panel 22 can be made of any material including but not limited to stone, wood, clay, metal sheet, concrete, tile, plastic or glass. The display face of the facing panel 22 may be pretreated with various materials such as anti-graffiti products or weather proofing.

The projections 21a, 21b and 21c on body 21 are sealed using an appropriate sealant or primer (see dark panels in Figure 2). Appropriate sealants include silicon based sealants, such as Dense-Crete Sealer and Clear Rock Sealer, both supplied by Mixa Pty Ltd. Appropriate primers include 3M 94 Primer. The sealant or primer may be only applied to the areas to which the double sided tape will be affixed or to the whole face or to the whole block 21. The sealant' s or primer's primary functions are to improve the affixing of the double sided tape to the body 21 and inhibit moisture getting to the double sided tape. A drying time of typically 5 to 20 minutes is required depending on the sealant or primer used.

The respective areas on the facing panel 22 are similarly sealed using an appropriate sealant or primer (not shown). The sealant or primer may be only applied to the areas to which the double sided tape will be affixed or to the whole face or to the whole facing panel 22. The sealant' s or primer's primary functions are to improve the affixing of the double sided tape to the facing panel 22 and inhibit moisture getting to the double sided tape. A drying time of typically 5 to 20 minutes is required depending on the sealant or primer used.

Once the sealant or primer is dried, the double sided tape 25a, 25b, 25c is attached to the relevant portions of proj ections 21 a, 21 b and 21 c on body 21. The double sided tape can be any suitable industrial tape for use in exterior bonding situations. One example of a suitable double sided tape is 3M™ VHB™ Tapes, in particular tape number 4991. The double sided tape is typically guaranteed for a minimum of 20 years. The length of double sided tape used will depend on the weight of the facing panel 22. Whilst the figures show the double sided tape extending the full depth of the block, the length of double sided tape will typically be shorter for cost efficiency and to minimise the visual impact of the tape. Typically, 100 mm of double sided tape is used.

The top cover film on the double sided tape 25a, 25b, 25c is then removed and the facing panel 22 is placed onto the double sided tape. Normally, a pressure must then be applied for at least 3 minutes to allow for proper affixing. However, the placement of the mechanical device 26, 27 alleviates the need for this pressure. Mechanical device 26, 27 (plus two mechanical device below not shown) are placed to attach the body 21 to facing panel 22. It is the pull down force of these mechanical device 26, 27 which alleviates the need for the 3 minute downward force to be applied to each block 20. The mechanical device 26, 27 can be any appropriate mechanical device for exterior work, including braces, pins, clips and staples. Since the body 21 typically has a different width at its top and bottom, different sizes of mechanical device may be needed for use on the bottom and the top of the block. Typically, the mechanical device used will be spring stainless steel or stainless steel pins, clips or staples (see examples in Figures 4 and 5). The double clip shown in Figure 5 a comprises arms and an intermediate tensioner. Adjustment of the tensioner allows for use with facing panels of different width.

Typically, a hose clamp winding system is suitable as a tensioner. Alternatively, a double sided pin as shown in Figure 5b and Figure 5f can be used to assist with insertion of the top (capping) of a stone wall or for the next row of blocks to lock into which increases the strength of the pinning system. The mechanical device may have a number of arms. In Figure 4, the mechanical device has a first arm 34, a second arm 35 and a third arm 36 communicating between the first and second arm. In Figure 5d, the mechanical device additionally has a fourth arm 37 communicating between the second arm 35 and third arm 36.

Typically, the first arm 34 engages the facing panel 22. In one embodiment, the first arm 34 engages groove 23 extending across the length of the long sides in facing panel 22 (see Figure 3). In another representative embodiment, the first arm 34 engages grooves 42a, 42b, 42c, 42d extending partially along at least one edge of facing panel 22 (see Figure 8).

The mechanical device engages body 21. In one embodiment, the second arm 35 is in contact with internal faces 32a and 32b of internal cavities 31a and 31b of body 21 (see Figure 3).

In another representative embodiment, the second arm 35 is received in openings in body 21. The opening may include but is not limited to a groove(s), hole(s) or slot(s) extending partially or wholly along at least one edge thereof. In Figure 8, second arm 35 is received in holes 33a, 33b, 33c, 33d. The first arm 34 and or/second arm 35 may have serrated portions 38a, 38b to assist with engaging the body 21 and facing panel 22 and also to resist detachment from body 21 and facing panel 22 (see Figure 5d). In another representative embodiment, the first arm 34 and or/second arm 35 may have barbed tail portions 39 to assist with engaging body 21 and facing panel 22 and to resist detachment of body 21 and facing panel 22 (see Figure 5e). Typically, when the mechanical device is a staple, the staple is pressed into the groove on the facing panel and the groove, hole or slot on the body. In combination, the double sided tape and mechanical device system used in this preferred embodiment provides an improved block 20 with a fail safe sheer off system. The mechanical device 26, 27 provide a back up to the double sided tape 25a, 25b, 25c. Once the blocks 20 are laid on mortar or dry packed, the mechanical device 26, 27 are locked by the downward force of the weight of the wall and gravity. Once the blocks 20 are filled with concrete, the mechanical device 26, 27 are further locked by the core filling, providing another back up against the sheer off factor.

In an embodiment which involves the inclusion of insulation, the double sided tape can also be used to affix the insulation 30a, 30b to the body 21. Alternatively, the insulation 30a, 30b may be kept in place using a liquid adhesive (eg Liquid Nails™) or the mechanical device 26, 27 will also keep the insulation in place as it is between the body 21 and facing panel 22. The insulation may be for different purposes, eg sound proofing or heat/cold insulation). Depending on the purpose, the insulation space may be of various sizes. In another embodiment, a facing panel 22 may be attached to more than one side of the body 21 (eg, 2, 3 or 4 sides).

The block 20 according to the invention provides a number of potential advantages including:

• Reducing the manufacturing time as there is no need to wait for glues or resins to dry. For example, to glue and pin one square metre together as per the prior art typically takes 50 minutes plus 24 hours drying time. In contrast, to tape and pin together one square metre of blocks according to the invention takes 20 minutes including a drying time of up to three minutes.

• The block according to the invention has a multi faceted fail safe sheer off protection. In contrast, a glue and pin system according to the prior art can fail the sheer off test simply because the facing panel is not seated properly.

• The ability to significantly raise the R value of the insulation depending on the width of the gap and the type of insulation used.

• The weight of the final product can be up to 60% less than a solid block. • The saved costs as there is no need to incur the additional costs of a stone mason or an insulation installer.

• The option to save further costs using double sided facia so that the internal walls are precladded with a finished product (eg granite tiles) (eg using the body as shown in Figure 7).

• Sound proofing can be inserted into the insulation gap for use in high noise areas such as along busy roadways.

• The facing panel can be pretreated (eg weather proofing or anti-graffiti) which can also reduce installation costs. The word 'comprising' and forms of the word 'comprising' as used in this description and in the claims does not limit the invention claimed to exclude any variants or additions.

Modifications and improvements to the invention will be readily apparent to those skilled in the art. Such modifications and improvements are intended to be within the scope of this invention.

Claims

The claims defining the invention are as follows:

1 A block for the construction of a wall, the block comprising:

(i) a body having multiple faces; and

(ii) at least one facing panel secured to at least one of the faces of the body, the facing panel comprising at least part of an exposed surface of the wall when constructed, wherein the facing panel is secured to the body using a combination of a double sided tape and one or more mechanical devices.

2 The block of claim 1 wherein the body is a parallelepiped shape.

3 The block according to either claim 1 or 2 wherein the at least one of the faces of the body comprises at least one projection extending toward the at least one facing panel, and wherein one side of the double sided tape engages the at least one projection and the other side of the double sided tape engages the at least one facing panel.

4 The block according to claim 3 wherein the at least one face of the body comprises three projections, each extending normal to the body.

5 The block according to claim 4 wherein the projections are equidistant from each other.

6 The block according to any one of claims 3 to 5 wherein at least one void is created by the at least one said projection, and insulation is located at least partially in the void(s) created by the at least one projection.

7 The block according to any one of claims 1 to 6 wherein the body is pre-sealed with a sealant or primer.

8 The block according to any one of claims 1 to 7 wherein the facing panel is pre- sealed with a sealant or primer. The block according to any one of claims 1 to 8 wherein the mechanical device is selected from the group consisting of pins, clips, staples and combinations thereof having:

(i) a first arm engaging the facing panel;

(ii) a second arm engaging the body; and

(iii) a third arm communicating between the first and second arm.

The block according to claim 9 wherein the mechanical device comprises a fourth arm communicating between the second and third arm.

The block according to either claim 9 or 10 wherein the first and second arms are substantially parallel to one another.

The block according to any one of claims 9 to 11 wherein the mechanical device further includes a fifth arm extending away from the first arm to engage an adjacent facing panel.

The block according to claim 12 wherein the first and fifth arms are substantially parallel to one another.

The block according to any one of claims 9 to 13 wherein the mechanical device comprises an arm having a serrated portion for engaging the block wherein the arm is selected from the group consisting of the first arm, the second arm and combinations thereof.

The block according to any one of claims 9 to 14 wherein the mechanical device comprises an arm having a barbed tail portion for engaging the block wherein the arm is selected from the group consisting of the first arm, the second arm and combinations thereof.

The block according to any one of claims 9 to 15 wherein the facing panel has a groove extending at least partially along at least one edge and the first arm engages into the groove. The block according to claim 16 wherein the facing panel has a groove extending fully along at least one edge and the first arm engages into the groove.

The block according to any one of claims 9 to 17 wherein the body includes at least one internal cavity defined by at least some of the faces of the body and the second arm contacts an internal face of the cavity.

The block according to any one of claims 9 to 18 wherein the body includes at least one opening defined by at least some of the faces of the body and the second arm is received in the at least one opening.

The block according to any one of the preceding claims wherein the facing panel is chosen from the group comprising stone, metal sheet, timber, composite materials or combinations thereof.

The block according to claim 20 wherein the facing panel is stone and is chosen from the group comprising marble, granite, sandstone or bluestone.

A block according to any one of the preceding claims wherein a decorative surface of the facing panel has been pretreated.

A block for the construction of a wall, the block comprising: (i) a body having multiple faces;

(ii) an insulating member having a first face secured to at least one of the faces of the body; and

(iii) at least one facing panel secured to a second face of the insulating member, the facing panel comprising at least part of an exposed surface of the wall when constructed, wherein the facing panel, insulating member and the body are secured together using a combination of a double sided tape and one or more mechanical devices.

A building element for constructing a wall comprising:

(i) a body of parallelepiped shape; and (ii) at least two substantially parallel projections extending normal to a face of the body from a pair of sides of the body.

The building element of claim 24 further comprising an additional projection extending from the face of the body and intermediate the other two said projections.

The building element of claim 25 wherein the additional projection is equidistant from the other two projections.

A method of manufacturing the block of any one of the preceding claims comprising the steps of:

(a) applying double sided tape to a face of the body;

(b) placing the facing panel onto the double sided tape so that the facing panel is affixed to the body; and

(c) engaging a mechanical device with both the facing panel and the body.

A method of manufacturing the block of any one of claims 1 to 23 comprising the steps of:

(a) applying a sealant or primer to at least a first portion of a face of the body;

(b) applying a sealant or primer to at least a first portion of the face of the facing panel which is to be secured to the body;

(c) applying double sided tape to the first portion of the body;

(e) engaging a mechanical device with both the facing panel and the body.