A building block and mortarless method

The invention relates to building blocks, for example, that can be connected to other building blocks without the use of mortar. The invention further relates to methods of using said building blocks.

The mortarless approach to building is becoming increasingly popular due to the substantial environmental benefits associated with not using mortar. In addition, it can be less time consuming as it is not necessary to mix up large quantities of mortar and apply it to building blocks. A further advantage is that the mortarless approach is often cheaper than other building methods.

However, there are significant problems with the types of mortarless building blocks and systems that are currently available. One problem is that known mortarless building blocks and systems require one shape of building block for the centre of walls and a different shape for the edges and for window and door frames. Thus, it is necessary to produce more than one die in order to form the blocks and this can be very expensive.

Furthermore, this means that the planning for building is more complicated as it is necessary to estimate the amount of different types of building blocks that are required.

Another significant problem is that known systems, irrelevant of the type of bonding that is being used, require modifications to the building blocks post firing. This of course can be time consuming and therefore more expensive.

In addition, known mortarless building systems use wall ties that can be difficult to fit because they require clips to match up with holes in the building blocks. A further limitation is that the ties can only be adjusted in increments.

Another disadvantage is that the known mortarless building systems do not allow for stack bonding.

Accordingly the present invention provides building blocks that can be used in mortarless building systems. These building blocks are configured such that they can be connected to each other stably and with ease. This is achieved by forming building blocks comprising stability enhancement passages between the weight bearing surfaces of the blocks. This is done when the building blocks are made initially and thus, there is no need for post firing adjustments. In use, the building blocks are laid in courses as normal and deformable pegs are inserted into the passages such that each peg is positioned between two building blocks, ensuring a strong and stable connection.

The building blocks are also configured such that one of the faces that is perpendicular to the weight bearing faces, has an indent that will house approximately half of a support such as a wall tie. Thus, when the blocks are laid, they are arranged such that, where a tie is required, the blocks are orientated so that the indents meet and a wall tie is housed at one end within the indents and attached to a wall at the other end. This arrangement means that only one type of building block is required when building an entire wall, window and/or door frames. This is because when an edge is required, the building block can simply be arranged such that the blind face (that is, a face configured for external presentation) is at the edge. This is in contrast to known mortarless building systems in which the building blocks have grooves or indents on two opposing faces of the building blocks.

Embodiments of the invention will now be described by way of example with reference to the drawings of which:

Fig. Ia shows a plan view of building blocks of dimensions 300 x 100 x 100mm according to the present invention. Fig. Ib shows a plan view of building blocks of dimensions 200 x 100 x 100mm according to the present invention.

Fig.2a shows an overview of a peg and fig.2b shows an overview of a tool for inserting the peg into the correct position according to the present invention.

Fig.3 shows a plan view of half bonding according to the present invention with two pegs in place and a wall ties in place.

Fig.4a shows a plan view of half bonding construction according to the present invention and fig. 4b shows an overview of half bonding construction according to the present invention.

Fig.5a shows a front view of a half bonded wall according to the present invention.

Fig.5b shows a front view of a one third bonded wall according to the present invention.

Fig. 6a shows a plan view of a stack bonded wall according to the present invention.

Fig. 6b shows an overview of a stack bonded wall according to the present invention.

Fig. 7 shows a front view of a stack bonded wall according to the present invention.

Although any appropriate dimension may be adopted, building blocks of dimensions 200 x 100 x 100 mm and 300 x 100 x 100 mm are illustrated by figure 1. Tolerance is built into the bricks.

The 200 x 100 x 100 mm building block (1) comprises two stability enhancement passages (2). The stability enhancement passages (2) are hollow, generally cylindrical columns that extend in a substantially vertical manner between the surface of the building block (1) that faces upwards when the building block (1) is in use, through the building block (1) to the surface of the building block (1) that faces towards the ground when in use. The stability enhancement passages (2) contribute to the stability, structural integrity and structural strength of a building structure.

Alternatively, the 300 x 100 x 100 mm building block (3) may comprise three stability enhancement passages (2).

Both building blocks (1) and (3) comprise a single or sole face that comprises an indented formation (4) that is configured to receive a wall tie (12). Thus, from a plan view, the formation in one building block is a half cross shape that will accommodate approximately half a threaded plate (15) and approximately half a threaded member (14). The face that comprises the formation is one of the vertical faces of the building blocks that are narrower and perpendicular to the weight bearing face. This formation does not occur vertical, facing on the other surfaces of the block. The weight bearing face is a face that is substantially horizontal when the building block is in use.

The stability enhancement passages (2) in the building blocks (1) and (3) are configured to receive a peg (6) as illustrated in figure 2. The peg (6) is an octagonal cross-sectional prism with concave sides (7) forming a star shape and acts as a dowel. Equally the peg could be any polygonal shape i.e. have any number of sides. The peg (6) is deformable such that when it is knocked into the stability enhancement passages (2), the peg (6) forms an interference fit and hence fits the passage (2) tightly.

A dowelling tool (8), also illustrated in figure 2, can be used to assist in knocking the pegs (6) into the stability enhancement passages (2). The tool (8) is shaped such that it has a circular base section (9), which has a slightly smaller diameter than the stability enhancement passages (2), so that the circular base section (9) can fit into the stability enhancement passages (2). The base section (9) corresponds to approximately half the length of a peg (6), which is approximately a third of the total tool (8). The remainder of the tool (8) is also a circular structure (10) but has a larger diameter than the base (9), such that it does not fit into a stability enhancement passage (2), with the upper most section (11) tapered to a flat and circular shape.

Figure 3 illustrates a wall tie (12). The wall tie (12) is a support that can be used to attach a mortarless structure to a substrate. The wall tie (12) comprises an elongate member (13). Approximately half of the elongate member is threaded (14). The threaded section (14) comprises a square threaded plate (15) that has a hollow centre through which the threaded section (14) is fitted. The threaded plate can also be circular or any other appropriate shape. The other half of the elongate member (12) comprises a flattened portion (16) near the centre of the member (12) and, between the flattened portion (12) and the end of the member that is not receivable by the mortarless structure, a support

structure (17) to assist in holding insulation against the substrate. The flattened portion (16) can be easily gripped by a gripping tool and twisted in either direction such that the tie (12) is tightened or loosened. A support bracket (18) is located at the end of the member (13) that is not receivable by the mortarless structure. The wall tie (12) is adjustable continuously (i.e. not in increments).

Building blocks (1) and (3) with the configurations described above and illustrated in figures 1 and 2 are suitable for half and one third bonding. Both these types of bonding using the building blocks of the invention are illustrated in figure 4 and figure 5.

Figure 4 and figure 5a illustrate a wall constructed with half bonding. A wall laid only to half bonding has a peg (6) in every stability enhancement passage (2). The lower portion of the pegs (6) that are placed in the first course of building blocks will, when in place, extend into the stability enhancement passages (2) about half way through the depth of the building block in the first course and the upper portion will extend about half way into the stability enhancement passages (2) of the second course of building blocks. Thus, the pegs (6) do not extend to the lower half of the first course of building blocks. When a third course of building blocks are in place pegs (6) will be positioned such that the lower portion of pegs (6) extend into the stability enhancement passages (2) of the second course of building blocks to about halfway through the depth of the building block in the second course and the upper portion will extend about half way into the stability enhancement passages of the third course of building blocks. This pattern will be repeated for as many courses of building blocks as required. Wall ties are included where required, which will be typically every two building blocks at the most and may be less frequently depending on the type and purpose of the construction. The advantage of the

building blocks having indents on only one face is achieved because it has been recognised that the ties are not required between every building block.

In order to construct a half bonded wall, a first course of blocks of 200 x 100 x 100 mm are laid. This layer can be attached to the base by glue, for example. A second course of the same size building blocks are laid on top of the first course of building blocks. A peg (6) is taken and placed into a stability enhancement passage (2). As the peg (6) is deformable it can be pushed into the passage, initially either by hand, using a dowelling tool (8), such as that described above, or using some sort of mallet. The peg (6) is pushed into the stability enhancement passage (2) and deforms so that it fits in and expands to fit the space. The peg (6) is star shaped with concave sides (7), as discussed above (although any appropriate shape may be adopted), and this allows the peg (6) to be easily fitted into a relatively tight space. The peg (6) is pushed so that approximately half of it extends into the first course of building blocks and the upper half remains in the lower half of the second course of building blocks. Suitably, this can be achieved using a dowelling tool (8) as described above. The base of the dowelling tool (8) is used to push the peg (6) into the stability enhancement passage (2). When the dowelling tool (8) cannot be pushed down any further because the section of the tool that has a larger diameter (10) than the stability enhancement passage (2) meets the building block, the peg (6) is in the correct position.

At the end of the walls a half block is used, where necessary, to obtain a flat finished wall. This approach is used for window and door openings as illustrated in figure 4.

Wall ties (12) are inserted where appropriate depending on the type of construction. The wall ties (12) may be inserted every 2, 3, 4, 5, 6, 7 or more

blocks. Where a wall tie (12) is to be inserted, the building blocks are arranged such that the formations that are configured to receive a wall tie (12) are facing each other (see the arrangement of the building blocks in figure 4). A wall tie (12) is then inserted by fitting the threaded member (14) and the threaded plate (15) into the formation that from a plan view is a cross shape between two building blocks. The brackets (18) are attached to a substrate such as a wall. Where insulation is present, a means to hold the insulation back (17) can also be adjusted so that it supports the insulation layer and holds the insulation to the wall when the tie (12) is tightened.

A spirit level can then be placed on the building blocks and the tie (12) tightened or loosened by a gripping tool gripping the flattened portion (16) so that the wall is brought to or away from the substrate depending on what is required.

In order to construct a one third bonded wall, a first course of blocks of 300 x 100 x 100 mm is laid. The method used is then the same as that used for half bonding except the building blocks are arranged as per one third bonding and the pegs (6) are only placed in two of the three stability enhancement passages (2). Figure 5a illustrates the pegs (6) inserted in the two stability enhancing passages (2) at either end of each building block. This results in a very strong and stable arrangement. It is also possible that the pegs (6) are inserted into stability enhancement passages (2) that are next to each other in a building block. At the end of the wall, building blocks that are 200 x 100 x 100 mm and blocks half that size can be used to ensure a flat edge is achieved. Wherever the 200 x 100 x 100 mm blocks are used pegs (6) are positioned into both stability enhancement passages (2), as described above.

It is also possible to use the techniques of the present invention for stack bonding. Stack bonding is where building blocks are laid in vertical non- overlapping columns. Figure 6 illustrates building blocks that are 100 x 200 x 300 mm for use in stack bonding. The building blocks used for one third bond building (as illustrated in figure 5b) can also be used for stack bonding. The blocks for stack bonding include the same stability enhancement passages (2) as described above in relation to the building blocks used for half and one third bonding. Each building block comprises three such stability enhancement passages (2). The building blocks used for stack building also contain the formations configured to receive wall ties (12), as discussed above. In the stack bonded wall illustrated in figure 7, a wall tie (12) is present between every other vertical joint in every third course of building blocks. However, the number of wall ties (12) included may vary depending on the type and purpose of the structure being constructed. In addition, the building blocks used for stack bonding comprise formations configured to receive cross joint ties (19).

The indented formations configured to receive cross joint ties (19) can comprise slots and are quadrant shaped (20) and occur such that the apex of the quadrant (21) is in substantially the centre of the edge between the upper weight bearing face and each of the narrower faces that are perpendicular to the weight bearing faces. The indented quadrant (20) configurations are incorporated into the building blocks post firing. A building block can contain quadrant indentations (20) on both of the narrower faces that are perpendicular to the weight bearing faces, one of such faces or no quadrant indentations (20).

The cross tie (19) is formed from a circular structure of resilient material which is folded in half such that when it is inserted into the slot it springs out slightly to fit the formation in the building blocks tightly.

In order to construct a stack bonded wall, the first course of building blocks is laid as normal. The bottom layer may be secured to the base by any conventional means including industrial glue. In the first course, all building blocks have quadrant configurations on both of the narrower faces that are perpendicular to the weight bearing face and the quadrant indentation (20) in one each side of each building block lines up with a quadrant indentation (20) on another building block to form a semi-circular indentation (as illustrated in figure 7). It is also possible for not every building blocks to have quadrant indentations (20) and even for none of the building blocks to have quadrant indentations (20).

Once the first course of building blocks is laid, cross joint ties (19) are inserted into the semi-circular indentation and the cross joint ties (19) spring apart with the indentation to fit the space tightly and provide lateral support. Equally a stack bonded wall can have cross joint ties (19) only every 2, 3, 4, 5, 6, 7, 8, 9, or 10 building blocks or even less frequently. It is also possible for a stack bonded wall to contain no cross joint ties (19) but the present of cross ties (19) contributes to the stability of the wall.

Subsequently a second course of building blocks is laid and every building block has a quadrant indentation (20) on one face and a formation indented to receive a wall tie (12) on the other face and the building blocks are arranged such that the formation indented to received a wall tie (12) faces the same indentation in the adjacent building block, as illustrated in figure 7. Pegs (6) are inserted into two of the three stability enhancement passages (2) in the building blocks, typically excluding the centre passage although a peg can be inserted into the central stability enhancement passage (2) if increased stability or strength is required, and knocked or pushed down in the same manner as

described above for half and one third bonding. Cross joint ties (19) are inserted into the semicircular indentations that are formed by quadrant indentations in two building blocks facing each other, as described above (see figure 7). As discussed above, it is also possible to quadrant indentations to be included less frequently.

In addition, wall ties (12) are placed in the configurations designed to receive them. As discussed above, a spirit level can then be used to determine if the wall is plumb and, if it is not, the wall tie (12) can be adjusted such that the wall is plumb (see figure 7).

Subsequently a third course is laid and all blocks have quadrant configurations (20) on both of the narrower faces that are perpendicular to the weight bearing face and the quadrant indentation (20) in one side of each building block lines up with a quadrant indentation (20) on another block to form a semi-circular indentation. The pegs (6) and cross joint ties (19) are inserted as discussed above. The fourth course is laid in the same manner. The fifth course is laid the same as the second course i.e. with each block comprising an indentation for receiving half a cross joint tie (19) on one of the faces that is perpendicular to the weight bearing faces and an indented formation configured to receive a wall tie (12) on the other face and the building block arranged such that the matching indentations face each other. This process is continued until the structure is completed (see figure 7).

The building blocks of the invention are manufactured by extrusion methods. The building blocks can also be manufactured by moulding. One type of die is required for half bond building and one type of die is required for one third bond building and stack bond building. Thus, only two dies are required for these three styles of building. The building blocks used for stack bond building

can be modified post firing to add quadrant indentations (20) on either or both of the narrower faces that are perpendicular to the weight bearing faces.

The building blocks of the invention are generally made from fired clay but can be made from any other material used to produce bricks.

The pegs (6) are deformable and as such can be made of plastic or any other deformable material and have any appropriate cross-section. In a preferred embodiment, the pegs (6) have a core of pultruded glass and a coating of polypropylene. The pegs are very strong.

The pegs in accordance with the present invention are easy to use and cheap to produce.

The ties are made of any strong and durable material. In the case of the cross joint ties (19), the material is at least slightly resilient and the tie and receiving slots can take any appropriate geometric shape. In a preferred embodiment, the ties are made of stainless steel.

Different types of ties can be used depending on the distance required between the wall being constructed and the substrate to which it is attached and whether any space is required between the wall being constructed and the substrate.

The wall ties according to the invention are adjustable and are also easy to use.

The dowelling tool (8) is made of any appropriate material such as wood or plastic.

There are a number of substantial advantages associated with the present invention. The building blocks are configured such that they can be connected to each other stably and with ease.

In addition, all blocks required for half bond building can be manufactured from one die and all blocks required for one third bonding and stack bonding can be manufactured from one die, as an indented configuration for receiving a wall tie is only present on one face. Thus, the blocks that occur at the end of a wall or at a window or door frame can simply be orientated such that the indented configuration does not face the wall that is on show.

As discussed above, the building blocks used for one third bond building can easily be adapted for use in stack bond building simply by inserting quadrant indentations. In addition, the cross joint ties used in relation to the stack bonding approach are easy to use and cheap to produce and could be supplied easily with the stack bonding building blocks.

The building blocks of the invention can be used to form door and window openings. Where broad window openings are required, a slip faced lintel could be employed to use with the building blocks of the invention. Standard steel lintels could also be used with slight modifications to the building blocks.