Title:
Building Construction System and Structural Modules Thereof
Kind Code:
A1


Abstract:
Disclosed is a building construction system and structural modules for erecting structures such as walls quickly, easily, and effectively. The building structure comprising: a wall formed by a plurality of code blocks selected from the group consisting of full-length stretcher code blocks, one-third-length code blocks, full-length-plain-end stretcher code blocks, one-third-length-plain-end code blocks, belting code blocks, and combinations thereof, wherein the full-length stretcher code blocks, the one-third-length code blocks, the full-length-plain-end stretcher code blocks have a web-like structure capable of receiving a plurality of first reinforcement bars; and a beam structure disposed at a top or interim portion of the wall, the beam structure formed by a plurality of code blocks selected from the group consisting of full-length belting code blocks, one-third-length-plain-end code blocks, and combinations thereof, wherein, the full-length belting code blocks have a U-shaped knock-out capable of accommodating a cage of reinforcement bars and reinforcement ties.



Inventors:
Ebanks, Desmond A. (South Sound Grand Cayman, KY)
Application Number:
12/021371
Publication Date:
07/30/2009
Filing Date:
01/29/2008
Primary Class:
Other Classes:
52/261
International Classes:
E04B2/10; E04B1/00
View Patent Images:



Primary Examiner:
WENDELL, MARK R
Attorney, Agent or Firm:
JAY M. SCHLOFF (West Bloomfield, MI, US)
Claims:
What is claimed is:

1. A code block for constructing building structure, comprising: a front wall; a back wall positioned parallel to the front wall; a first side wall connecting the front wall to the back wall, the first side wall positioned perpendicular to the front wall and the back wall; a second side wall positioned parallel to the first side wall, the second side wall connecting the front wall and the back wall, such that, the front wall, the back wall, the first side wall, and the second side wall configure a hollow interior space therein, an extended portion of the front wall, an extended portion of the back wall and the second side wall configure an exterior space, the first side wall and the second side wall having first end portions, second end portions opposing the first end portions, and a cut out extending up to a substantially central position between the first end portions and the second end portions, the cut out having a web-like structure capable of receiving a plurality of first reinforcement bars along a longitudinal axis of the code block; and a pair of alignment lugs protruding perpendicular to an outer surface of the first side wall opposite to the hollow interior space on either side of the cut out.

2. The code block of claim 1, wherein the web-like structure has a plurality of notches capable of receiving the first reinforcement bars.

3. The code block of claim 2, wherein the web-like structure has three notches, such that, a central notch of the three notches receives a central reinforcement bar, and outer notches of the three notches receives two outer reinforcement bars of the plurality of reinforcement bars.

4. The code block of claim 1, wherein at least one second reinforcement bar is disposed vertically perpendicular to the first reinforcement bars in the hollow interior space at a position in proximity to either the first side wall or the second side wall.

5. A wall structure comprising a plurality of code blocks of claim 1, wherein the code blocks are interconnected, such that, a pair of alignment lugs of a first code block engages an extended portion of a front wall and an extended portion of a back wall of a second code block, and an extended portion of a front wall and an extended portion of a back wall of the first code block engage a pair of alignment lugs of a third code block.

6. The code block of claim 1, wherein the hollow interior space and the exterior space are capable of receiving liquid concrete poured there through.

7. A belting code block for building construction, comprising: a front wall; a back wall positioned parallel to the front wall; a first side wall connecting the front wall to the back wall, the first side wall positioned perpendicular to the front wall and the back wall; a second side wall positioned parallel to the first side wall, the second side wall connecting the front wall and the back wall, such that, the front wall, the back wall, the first side wall, and the second side wall configure a hollow interior space therein, an extended portion of the front wall, an extended portion of the back wall and the second side wall configure an exterior space, the first side wall and the second side wall having first end portions, second end portions opposing the first end portions, and a removable U-shaped knock-out extending between the first end portions and the second end portions, the U-shaped knock-out, when removed, capable of accommodating a cage of reinforcement bars and reinforcement ties; and a pair of alignment lugs protruding perpendicular to an outer surface of the first side wall opposite to the hollow interior space on either side of the U-shaped knock-out.

8. The belting code block of claim 7, wherein the U-shaped knock-out extends down to approximately three-fourths of a height of the belting code block between the first end portions and the second end portions.

9. The belting code block of claim 7, wherein the belting code block is used in belting construction at interim positions and at a top of a wall.

10. The belting code block of claim 7, wherein the alignment lugs are capable of engaging an extended portion of a front wall and an extended portion of a back wall of an adjacent belting code block.

11. A building structure, comprising: a wall formed by a plurality of code blocks selected from the group consisting of full-length stretcher code blocks, one-third-length code blocks, full-length-plain-end stretcher code blocks, one-third-length-plain-end code blocks, belting code blocks and combinations thereof, wherein the full-length stretcher code blocks, the one-third-length code blocks, the full-length-plain-end stretcher code blocks have a web-like structure capable of receiving a plurality of first reinforcement bars; and a beam structure disposed at interim positions as well as at a top portion of the wall, the beam structure formed by a plurality of code blocks selected from the group consisting of belting code blocks, one-third-length-plain-end code blocks, and combinations thereof, wherein the full-length belting code blocks have a U-shaped knock-out capable of accommodating a cage of reinforcement bars and reinforcement ties.

12. The building structure of claim 11, wherein the full-length stretcher code blocks comprise a front wall, a back wall positioned parallel to the front wall, a first side wall connecting the front wall to the back wall, the first side wall positioned perpendicular to the front wall and the back wall, a second side wall positioned parallel to the first side wall, the second side wall connecting the front wall and the back wall, such that, the front wall, the back wall, the first side wall, and the second side wall configure a hollow interior space therein, an extended portion of the front wall, an extended portion of the back wall and the second side wall configure an exterior space, the first side wall and the second side wall having first end portions, second end portions opposing the first end portions, and a cut out extending up to a substantially central position between the first end portions and the second end portions, the cut out having the web-like structure capable of receiving the first reinforcement bars along a longitudinal axis of the full-length stretcher code block, and a pair of alignment lugs protruding perpendicular to an outer surface of the first side wall opposite to the hollow interior space on either side of the cut out.

13. The building structure of claim 12, wherein at least one second reinforcement bar is disposed vertically perpendicular to the first reinforcement bars in the hollow interior space at a position in proximity to either the first side wall or the second side wall of at least one of the full-length stretcher code blocks.

14. The building structure of claim 11, wherein the one-third-length code blocks comprise: a front wall; a back wall positioned parallel to the front wall; a sidewall connecting the front wall to the back wall, the side wall positioned perpendicular to the front wall and the back wall, such that, the front wall, the back wall, and the side wall configuring a hollow open space, the side wall having first end portions, second end portions opposing the first end portions, and a cut out extending up to a substantially central position between the first end portions and the second end portions, the cut out having a web-like structure capable of receiving the first reinforcement bars along a longitudinal axis of the one-third-length code block; and a pair of alignment lugs protruding perpendicular to an outer surface of the side wall opposite to the hollow open space on either side of the cut out.

15. The building structure of claim 14, wherein at least one second reinforcement bar is disposed vertically perpendicular to the first reinforcement bars in the hollow open space at a position in proximity to the side wall of the one-third-length code blocks.

16. The building structure of claim 11, wherein the full-length-plain-end stretcher code blocks comprise: a front wall; a back wall positioned parallel to the front wall; a first side wall connecting the front wall to the back wall, the first side wall positioned perpendicular to the front wall and the back wall; and a second side wall positioned parallel to the first side wall, the second side wall connecting the front wall and the back wall, such that, the front wall, the back wall, the first side wall, and the second side wall configure a hollow interior space therein, an extended portion of the front wall, an extended portion of the back wall and the second side wall configure an exterior space, the second side wall having first end portion, second end portion opposing the first end portion, and a cut out extending down to a substantially central position between the first end portion and the second end portion, the cut out having a web-like structure capable of receiving the first reinforcement bars along a longitudinal axis of the full-length-plain-end stretcher code blocks.

17. The building structure of claim 16, wherein at least one second reinforcement bar is disposed vertically perpendicular to the first reinforcement bars in the hollow interior space at a position in proximity to either the first side wall or the second side wall of the full-length-plain-end stretcher code block.

18. The building structure of claim 11, wherein the one-third-length-plain-end code blocks comprise: a front wall; a back wall positioned parallel to the front wall; and a sidewall connecting the front wall to the back wall, the side wall positioned perpendicular to the front wall and the back wall, such that, the front wall, the back wall, and the side wall configure a hollow open space.

19. The building structure of claim 11, wherein the full-length belting code blocks comprise: a front wall, a back wall positioned parallel to the front wall, a first side wall connecting the front wall to the back wall, the first side wall positioned perpendicular to the front wall and the back wall, a second side wall positioned parallel to the first side wall, the second side wall connecting the front wall and the back wall, such that, the front wall, the back wall, the first side wall, and the second side wall configure a hollow interior space therein, an extended portion of the front wall, an extended portion of the back wall and the second side wall configure an exterior space, the first side wall and the second side wall having first end portions, second end portions opposing first end portions, and a U-shaped knock-out extending down to approximately three-fourth of a height of the full-length belting code block between the first end portions and the second end portions, the U-shaped knock-out capable of accommodating a cage of reinforcement bars and reinforcement ties, and a pair of alignment lugs protruding perpendicular to an outer surface of the first side wall opposite to the hollow interior space on either side of the U-shaped knock-out.

20. The building structure of claim 19, wherein the alignment lugs of one of the full-length belting code block engages an extended portion of a front wall and an extended portion of a back wall of an adjacent full-length belting code block.

Description:

FIELD OF THE INVENTION

The present invention relates generally to building construction systems, and, more particularly, to structural modules having specialized contours for rendering strength and rigidity to construction structures, such as, buildings, walls, and the like, in a fast, easy, reliable, inexpensive, and effective manner and at the same time making major labor, and time saving due to the minimal usage of a mortar bed.

BACKGROUND OF THE INVENTION

Constructing building structures in areas prone to natural calamities such as high winds, earthquakes, hurricanes, floods, is a very challenging and difficult task. The climate and weather conditions in many areas may or may not favor concrete construction. To facilitate the quick and easy construction in these areas, various types of structural modules are available, as suggested in the prior art. These structural modules are manufactured away from the site of construction and brought to the site and integrated therein. The structural modules such as building blocks, generally have rectangular shape with hollow cavities and no physical locking means, and are used to quickly construct building structures. Of the conventional building blocks, many at times do not provide means for making the building structures strong enough to bear the external forces or face natural calamities easily without causing any damage to the building structure, thereby, unable to protect life and property. Further, due to the need for wet work, construction of masonry building structures by using conventional approaches is not simple, effective, reliable and economic. Most of the conventional building blocks require some uncommon degree of skill for building construction. Due to high skill level requirement and wet work, for such construction, the construction costs have been somewhat more expensive to the end customer. Additionally, the conventional building blocks do not provide means to enhance strength of the construction, for example, means for carrying a plurality of reinforcing materials, such as rebar or easy flow of concrete throughout the structure during construction, except for those placed vertically.

Attempts have been made in the past to address the above mentioned drawbacks. For example, U.S. Pat. No. 6,588,168 discloses blocks for constructing walls and other structures. The blocks include a plurality of horizontal and vertical channels that are adapted to receive reinforcing rods (“rebar”).

US Patent Publication Number 20060000179 discloses a building block with an open top and bottom. One end of the block is provided with a pair of vertical slots and the other end of the block is provided with a pair of vertical fins for insertion into the vertical slots of an adjacent block. The bottom of the block is provided with a pair of horizontal slots and the top of the block is provided with a pair of horizontal fins for insertion into the horizontal slots of an overlying block. The horizontal fins and slots are respectively provided with pegs and holes positioned in adjacent blocks, can be brought into registry with one another. One end of the block is also provided with a notch and the other end of the block is provided with a key for insertion into a notch in an adjacent block.

US Patent Publication Number 20050257466 discloses a method and block for constructing a block wall providing the appearance of a brick facade. Each block includes a front wall, rear wall, left sidewall, and a right side wall. The method includes forming at least one groove on a front face of the front wall of each block or providing blocks with at least one groove on the front face. The method further includes attaching the blocks to each other thereby forming a block structure.

Most of such blocks in the prior art have been very expensive to produce. Moreover, it is difficult to maintain the required tight tolerances for accurate construction of large walls or other structures through the molding and cutting steps and does not address the requirement of strength and providing rigidity to such constructions. Thus, installing blocks over the vertical reinforcing bar can be a significant problem with tall structures.

Accordingly, there persists a continuing need for improvements in conventional construction building block systems to permit low cost, easy to install block manufacturing, and more particularly, to those block systems having enhanced resistance to the forces of nature like, high winds, earthquakes, hurricanes, and floods.

SUMMARY OF THE INVENTION

In view of the foregoing disadvantages inherent in the prior art, the general purpose of the present invention is to provide an improved building construction system and structural modules thereof for constructing structures such as buildings, walls, foundations, and the like, in the areas prone to natural calamities such as high winds, earthquakes, hurricanes, and floods, in quick, easy, effective, and economical manner, and meeting the requirement for providing strength and rigidity to such structures, to include all the advantages of the prior art, and to overcome the drawbacks inherent therein.

In one aspect, the present invention provides a “code” block for constructing a building structure. The code block comprising: a front wall; a back wall positioned parallel to the front wall; a first side wall connecting the front wall to the back wall, the first side wall positioned perpendicular to the front wall and the back wall; a second side wall positioned parallel to the first side wall, the second side wall connecting the front wall and the back wall, such that, the front wall, the back wall, the first side wall, and the second side wall configure a hollow interior space therein, an extended portion of the front wall, an extended portion of the back wall (and the second side wall) configure an exterior space, the first side wall and the second side wall having first end portions, second end portions opposing the first end portions, and a cut out extending down to a substantially central position between the first end portions and the second end portions, the cut out having a web-like structure capable of receiving a plurality of first reinforcement bars along a longitudinal axis of the code block; and a pair of alignment lugs protruding perpendicular to an outer surface of the first side wall opposite to the hollow interior space on either side of the cut out.

In another aspect, the present invention provides a belting code block for building construction. The belting code block comprising: a front wall; a back wall positioned parallel to the front wall; a first side wall connecting the front wall to the back wall, the first side wall positioned perpendicular to the front wall and the back wall; a second side wall positioned parallel to the first side wall, the second side wall connecting the front wall and the back wall, such that, the front wall, the back wall, the first side wall, and the second side wall configure a hollow interior space therein, an extended portion of the front wall, an extended portion of the back wall and the second side wall configure an exterior space, the first side wall and the second side wall having first end portions, second end portions opposing the first end portions, and at least one U-shaped knock-out extending between the first end portions and the second end portions, the at least one U-shaped knock-out capable of being removed upon the application of force thereon, and upon the knock-out's removal of accommodating a cage of reinforcement bars and reinforcement ties as required; and a pair of alignment lugs protruding perpendicular to an outer surface of the first side wall opposite to the hollow interior space on either side of the U-shaped knock-out.

In yet another aspect, the present invention provides a building structure, comprising: a wall formed by a plurality of code blocks selected from the group consisting of full-length stretcher code blocks, one-third-length code blocks, full-length-plain-end stretcher code blocks, one-third-length-plain-end code blocks, and combinations thereof, wherein the full-length stretcher code blocks, the one-third-length code blocks, the full-length-plain-end stretcher code blocks have a web-like structure capable of receiving a plurality of first reinforcement bars; and a beam structure disposed at interim positions and at a top portion of the wall, the beam structure formed by a plurality of code blocks selected from the group consisting of full-length belting code blocks, one-third-length-plain-end code blocks, and combinations thereof, wherein the full-length belting code blocks have a U-shaped knock-out capable of accommodating a cage of reinforcement bars and at least one reinforcement tie.

These together with other aspects of the present invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed hereto and forming a part of this invention. For a better understanding of the present invention, its operating advantages, and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which, there are illustrated exemplary embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, wherein:

FIG. 1A is a plan perspective view of a full-length stretcher code block 10, according to an exemplary embodiment of the present invention;

FIG. 1B is a front plan view of the full-length stretcher code block 10 with a plurality of first reinforcement bars 30 placed therein, according to an exemplary embodiment of the present invention;

FIG. 1C is a side plan view sectioned along the axis X-X illustrating the longitudinal placement of the first reinforcement bar 30 within the full-length stretcher code block 10, according to an exemplary embodiment of the present invention;

FIG. 1D is a top view of the full-length stretcher code block 10, according to an exemplary embodiment of the present invention;

FIG. 2 is a plan perspective view of a one-third-length code block 40, according to an exemplary embodiment of the present invention;

FIG. 3 is a plan perspective view of a full-length-plain-end stretcher code block 60, according to an exemplary embodiment of the present invention;

FIG. 4 is a plan perspective view of a one-third-length-plain-end code block 80, according to an exemplary embodiment of the present invention;

FIG. 5A is a plan perspective view of a full-length belting code block 90, according to an exemplary embodiment of the present invention;

FIG. 5B is a front plan view of the full-length belting code block 90 with a cage of reinforcement bars 110 and reinforcement tie 112 disposed there within, according to an exemplary embodiment of the present invention;

FIG. 5C is a side plan view sectioned along the axis Y-Y illustrating the longitudinal placement of the cage of reinforcement bars 110 within the full-length belting code block 90, according to an exemplary embodiment of the present invention;

FIG. 5D is a top view of the full-length belting code block 90, according to an exemplary embodiment of the present invention;

FIG. 5E is a perspective view of a full-length belting code block 90 with two U-shaped knock-outs 120 intact, according to an exemplary embodiment of the present invention

FIGS. 6A and 6B illustrate construction of a wall using a combination of the full-length stretcher code block 10, the one-third-length code block 40, the full-length-plain-end stretcher code block 60, the one-third-length-plain-end code block 80, and the placement of reinforcement bars 30 horizontally and vertically there within, according to an exemplary embodiment of the present invention; and

FIG. 6C illustrates a belting construction at a top of the wall using the full-length belting code block 90, according to an exemplary embodiment of the present invention.

Like reference numerals refer to like parts throughout several views of the drawings of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The exemplary embodiments described herein detailed for illustrative purposes are subject to many variations in structure and design. It should be emphasized, however, that the present invention is not limited to a particular building construction system and structural modules thereof, as shown and described. Rather, the principles of the present invention may be used with a variety of configurations and structural arrangements, e.g., for aesthetics, structural purposes, and/or for simplicity in assembling and disassembling. It is understood that various omissions, substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.

Furthermore, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof, herein, is meant to encompass the items listed thereafter, and equivalents thereof, as well as additional items. As used herein, the terms “a” and “an” do not denote a limitation of quantity, but rather, denote the presence of at least one of the referenced item.

The present invention provides an improved, simplified, and efficient building construction system and structural modules for constructing building structures, such as, walls, and the like. The building construction system of the present invention employs a plurality of structural modules for enhancing the construction environment, without imposing any limitation on location and constructional orientation, in a fast, easy, reliable, inexpensive, and effective manner. More particularly, the building structures constructed using the structural modules of the present invention aides in withstanding high winds, earthquakes, hurricanes, floods, and the like natural calamities, in areas prone to the same. The structural modules of the present invention can be mass produced inexpensively and by virtue of their design, the structural modules lend themselves well for mass production without the need for stringent quality control measures during production. Further, the system of the present invention is does not require mortar in construction which enhances the quality of construction while making major savings in terms of labor, and time.

The present invention refers to structural modules, such as, code blocks used in building construction. More specifically, mortarless stretcher code blocks of the present invention are used in wall construction; and mortarless belting code blocks of the present invention are used in belting (beam) construction at interim positions and at the top of a wall.

Referring now, to FIGS. 1A, 1B, 1C and 1D, a full-length stretcher code block 10, is shown. The full-length stretcher code block 10 may take form of a parallelepiped comprising a front wall 12, a back wall 14, a first sidewall 16, and a second sidewall 18. The front wall 12, the back wall 14, the first sidewall 16, and the second sidewall 18 are configured in a manner, such that, a hollow interior space 20 is created therein. The front wall 12 and the back wall 14 have a flat surface and are positioned parallel to each other. At a first side end of the full-length stretcher code block 10, the first side wall 16 connects the front wall 12 to the back wall 14, such that, the first side wall 16 is perpendicular to both the front wall 12 and the back wall 14 (see FIG. 1A). The second side wall 18 connects the front wall 12 to the back wall 14 at a second side end, positioned parallel to the first side wall 16, such that, an extended portion 13 of the front wall 12, an extended portion 15 of the back wall 14 and the second side wall 18 configures an exterior (unenclosed) space 22.

The first sidewall 16 and the second side wall 18 have first end portions 24, second end portions 26 opposing the first end portions, and a cut out extending up to a substantially central position between the first end portions 24 and the second end portions 26. The cut out extends from the first end portions 24 towards the second end portions 26 and forms a web-like structure 28 at a lower portion of the cutout. The web-like structure 28 is capable of receiving a plurality of first reinforcement bars 30 (also termed as rebars) along the longitudinal axis of the full-length stretcher code block 10 (See FIGS. 1B, 1C and 1D). The web-like structure 28 on the first side wall 16 and the second side wall 18 lie on the same plane, such that, the reinforcement bars 30 passing along the longitudinal axis of the full-length stretcher code block 10 are seated therein, as shown in FIG. 1C, illustrating a side plan view sectioned along axis X-X. In one embodiment, the web-like structure 28 has three notches for receiving the first reinforcement bars 30 (See FIG. 1B and FIG. 1D). Further, at least one second reinforcement bar (not shown) may be disposed vertically perpendicular to the first reinforcement bars 30 in said hollow interior space 20 at a position in proximity to either the first side wall 16 or the second side wall 18.

A pair of alignment lugs 32 protrudes perpendicular to an outer surface 27 of the first side wall 16 opposite to the hollow interior space 20 on either side of the cut out. The pair of alignment lugs 32 forms a first interlocking unit. Additionally, the extended portion 13 of the front wall 12 and the extended portion 15 of the back wall 14 configure a second interlocking unit (mating interlocking unit).

Now, referring to FIG. 2, a plan perspective view of a one-third-length code block 40, is shown. The one-third-length code block 40 comprises a front wall 42, a back wall 44, and a sidewall 46. The front wall 42, the back wall 44 and the sidewall 46 are configured in a manner, such that, a hollow open space 48 is created therein. The front wall 42 and the back wall 44 have a flat surface and are positioned parallel to each other. The side wall 46 connects the front wall 42 to the back wall 44, such that, the side wall 46 is perpendicular to both the front wall 42 and the back wall 44. The sidewall 46 has a first end portion 50, a second end portion 52 and a cut out extending down to a substantially central position between the first end portion 50 and the second end portion 52. The cut out extends from the first end portion 50 towards the second end portion 52 and forms a web-like structure 54 at a lower portion of the cutout. The web-like structure 54 is capable of receiving a plurality of first reinforcement bars (not shown) along the longitudinal axis of the one-third-length code block 40. In one embodiment, the web-like structure 54 has three notches capable of receiving reinforcement bars, such that a central notch of the three notches receives a central reinforcement bar, or outer notches of the three notches receives two outer reinforcement bars. In another embodiment, a user may select to install only a central reinforcement bar in the central notch or to install two outer reinforcement bars in the outer notches. Further, at least one second reinforcement bar (not shown) may be disposed vertically perpendicular to the first reinforcement bars in the hollow open space 48 at a position in proximity to the side wall 46. A pair of alignment lugs 56 protrudes perpendicular to an outer surface 57 of the side wall 46 opposite to the hollow open space 48 on either side of the cut out. The pair of alignment lugs 56 forms an interlocking unit.

Referring to FIG. 3, a plan perspective view of a full-length-plain-end stretcher code block 60 is shown. The full-length-plain-end stretcher code block 60 comprises a front wall 62, a back wall 64, a first sidewall 66 and a second sidewall 68. The front wall 62, the back wall 64, the first sidewall 66, and the second sidewall 68 are configured in a manner, such that, a hollow interior space 70 is created therein. The front wall 62 and the back wall 64 have a flat surface and are positioned parallel to each other. At a first side end of the full-length-plain-end stretcher code block 60, the first side wall 66 having a flat surface connects the front wall 62 to the back wall 64, such that, the first side wall 66 is perpendicular to both the front wall 62 and the back wall 64. The second side wall 68 connects the front wall 62 to the back wall 64 at a second side end, positioned parallel to the first side wall 66, such that, an extended portion 63 of the front wall 62, an extended portion 65 of the back wall 64 and the second side wall 68 configure an exterior (unenclosed) space 72. The second side wall 68 has a first end portion 74, a second end portion (not shown) and a cut out extending down to a substantially central position between the first end portion 74 and the second end portion. The cut out extends from the first end portion 74 towards the second end portion and forms a web-like structure 76 at a lower portion of the cutout. The web-like structure 76 capable of receiving a plurality of first reinforcement bars (not shown) along a longitudinal axis of the full-length-plain-end stretcher code block 60. In one embodiment, the web-like structure 76 has three notches for receiving the first reinforcement bars. Further, at least one second reinforcement bar (not shown) is disposed vertically perpendicular to the first reinforcement bars in said hollow interior space 70 at a position in proximity to either the first side wall 66 or the second side wall 68.

Next, referring to FIG. 4, a plan perspective view of a one-third-length-plain-end code block 80, is shown. The one-third-length-plain-end code block 80 comprises a front wall 82, a back wall 84 and a side wall 86. The front wall 82 and the back wall 84 are substantially flat and parallel to each other. The front wall 82, the back wall 84 and the sidewall 86 are configured in a manner, such that, a hollow open space 88 is created therein. The side wall 86 having a flat surface connects the front wall 82 to the back wall 84, such that, the side wall 86 is perpendicular to both the front wall 82 and the back wall 84.

Now, referring to FIGS. 5A, 5B, 5C and 5D, a full-length belting code block 90, is shown. The full-length belting code block 90 may take the form of a parallelepiped comprising a front wall 92, a back wall 94, a first sidewall 96, and a second sidewall 98. The front wall 92, the back wall 94, the first sidewall 96, and the second sidewall 98 are configured in a manner, such that, a hollow interior space 100 is created therein. The front wall 92 and the back wall 94 have a flat surface and are positioned parallel to each other. At a first side end of the full-length belting code block 90, the first side wall 96 connects the front wall 92 to the back wall 94, such that, the first side wall 96 is perpendicular to both the front wall 92 and the back wall 94 (see FIG. 5A). The second side wall 98 connects the front wall 92 to the back wall 94 at a second side end, and is positioned parallel to the first side wall 96, such that, an extended portion 93 of the front wall 92, an extended portion 95 of the back wall 94 and the second side wall 98 configures an exterior (unenclosed) space 102. The first sidewall 96 and the second side wall 98 have first end portions 104, second end portions 106 opposing the first end portions, and at least one U-shaped knock-out 120 extending down to approximately three-fourths of a height of the full-length belting code block 90 between the first end portions 104 and the second end portions 106. The at least one U-shaped knock-out 120 extends from the first end portions 104 towards the second end portion 106 and, after a portion of the at least one U-shaped knock-out 120 is removed from a belting code block 90, the remaining portion of the at least one U-shaped knock-out 120 forms a cavity 108, the cavity 108 capable of accommodating a cage of reinforcement bars 110 and reinforcement ties 112 (also known as links, or stirrups) along the longitudinal axis of the full-length belting code block 90 (See FIG. 5B). Additionally, the cage may be doubled in height, thus creating a deeper beam, by inverting a second row of belting code blocks 90 over a first row of belting code blocks 90. Such an arrangement, whether single or double height, eliminates the need for formwork. The cavities 108 on the first side wall 96 and the second side wall 98 lie in the same plane, such that, the cage of reinforcement bars 110 passing along the longitudinal axis of the full-length belting code block 90 is seated therein, as shown in the side view (See FIG. 5C), and more specifically in the top view (See FIG. 5D).

Additionally, a pair of alignment lugs 114 protrudes perpendicular to an outer surface 97 of the first side wall 96 opposite to the hollow interior space 100 on either side of the cavity 108. The pair of alignment lugs 114 forms a first interlocking unit and the extended portion 93 of the front wall 92, and the extended portion 95 of the back wall 94 configures a second interlocking unit.

FIG. 5E shows a belting code block 90 with the at least one U-shaped knock-out 120 intact. The at least one U-shaped knock-out 120 comprises a flange that removably attaches to the front wall 92 and a flange that removably attaches to the back wall 94 of the code block, with the flanges being separated by a breach 124. The at least one U-shaped knock-out 120 further comprises a channel 122 that extends at least partially along the junction of the knock-out 120 and the front wall 92 and back wall 94 of the code block. The channel 122 enables the user to remove the at least one U-shaped knock-out 120 from the front wall 92 and back wall 94 to which it is attached. The at least one U-shaped knock-out 120 remains attached after production and during transportation of a belting code block 90 to contribute to the structural integrity of the code block 90 and to reduce damage to the code block 90 after production and during transportation. When the belting code block 90 is ready for use in construction, the user applies force to the at least one U-shaped knock-out 120 such that the at least one U-shaped knock-out 120 is separated from the code block 90, whereby a cavity 108 is formed, the cavity 108 capable of accommodating a cage of reinforcement bars 110 and reinforcement ties 112 along the longitudinal axis of the full-length belting code block 90 (See FIG. 5B).

Using the stretcher code blocks and the belting code blocks of the present invention, a wall construction is explained in detail with reference to FIGS. 6A and 6B. For a wall construction, a combination of the stretcher code blocks (full-length stretcher code block 10, a one-third-length code block 40, a full-length-plain-end stretcher code block 60 and a one-third-length-plain-end code block 80) may be used. With the exception of the first course (which may be wet set directly into the slab), all the stretcher code blocks, are laid dry in a one-third running bond pattern, and then bonded with liquid concrete. The stretcher code blocks are also adapted to receive the second reinforcement bar in a vertical position. When casting the foundation, the second reinforcement bars may be positioned at an 8 inch, 16 inch, 24 inch, 32 inch, or 48 inch intervals. The base of the foundation is checked to ensure that the base is level. When laying the first course, the wall may generally start at a corner with the full-length stretcher code block 10 positioned in a manner, such that, the exterior (unenclosed) space 22 forming the second interlocking unit, runs towards the centre of the wall. The interlocking of two full-length stretcher code blocks 10 is achieved by engaging the second interlocking unit of a full-length stretcher code block 10 with the first interlocking unit formed by the alignment lugs 32 of an adjacent full-length stretcher code block 10. More specifically, in the corners or wall ends, the full-length-plain-end stretcher code block 60 or the one-third-length-plain-end code block 80 may be used. Additionally, at T-junctions and cross junctions, a combination of the full-length stretcher code block 10, the one-third-length code block 40, the full-length-plain-end stretcher code block 60 and the one-third-length-plain-end code block 80, may be used (See FIG. 6B). After the code blocks are raised, for example, in lifts of a maximum eleven courses, the casting of the concrete may be done using a concrete pump or other methods which provide a similar cascading effect through the interconnecting cavities (the hollow interior space 20, 70, 100, the exterior (unenclosed) space 22, 72, 102 and hollow open space 48, 88) in the wall. The variations in the sizes of stretcher code blocks (full-length stretcher code block 10, one-third length code block 40, full-length-plain-end stretcher code block 60 and one-third-length-plain-end code block 90 helps in positioning the code blocks along the corners of the wall and other places where a full-length stretcher code block 10 cannot be accommodated. Channel formwork (shuttering) (not shown) may also be used at openings or wall ends which are easily fixed in position and readily re-usable.

The full-length belting code block 90 may be used for belting construction at interim vertical positions and at the top of the wall, and requires no formwork to be installed (See FIG. 6C). The full-length belting code block 90 is mortar-less and may be designed in both 6 inch and 8 inch widths. The full-length belting code block 90 may be installed in multiple rows like a standard belt block. The full-length belting code block 90 has the flexibility of being able to be inverted over another stretcher code block for increased cage height, or another code block to maximize the cage height, up to 12 inch or 16 inch respectively. For example, an 8 inch belting code block, and an 8 inch mortarless stretcher code block, with knock-outs removed, is able to accept layers of 2 or even 3 reinforcement bars, in a cage to accommodate longer spans. Even for the construction of lintels and bond beams, support is only required below the lintel or beam and no other formwork is necessar. This adds considerable savings in materials and time while enhancing the quality of construction. The full-length belting code blocks 90 are designed to comply with the construction methods used with the mortarless stretcher code blocks.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions, substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.





 
Previous Patent: BALCONY STRUCTURE

Next Patent: COMPOSITE WALL AND FLOOR SYSTEM