Concrete wall supports that reduce or eliminate wall movement due to exterior horizontal forces. One support is a bracket mounted to a floor joist with a plate extending below the top of the wall and two legs extending from the plate and attaching to the joist. One leg is above the concrete wall on one horizontal side of the plate, and the other leg is on the opposite side of the plate. Another support has a plate that extends below the top of the wall with two legs on opposite sides of the joist above the wall. A leg attaches to the lower edge of the joist. A support against shear forces includes a highly water permeable aggregate composite disposed in the voids of the wall, with a supportive strip that is enclosed in the aggregate composite and extends out of the voids to the face of the wall.

Various implementations are directed to a single face building block and masonry wall assembly and methods. Each building block includes a single face shell, first and second webs extending from an interior surface of the face shell, and a pier that has a proximal surface disposed between distal ends of the webs and a distal surface that is opposite and spaced apart from the proximal surface of the pier. Interior surfaces of the webs, the proximal surface of the pier, and a portion of the interior surface of the face shell between the webs define a pocket. In addition, the building blocks may include a ledge that extends outwardly from the distal surface of the pier. This ledge forms a channel with an upper surface of the pier stacked above the block.

Various implementations are directed to a single face building block and masonry wall assembly and methods. Each building block includes a single face shell, first and second webs extending from an interior surface of the face shell, and a pier that has a proximal surface disposed between distal ends of the webs and a distal surface that is opposite and spaced apart from the proximal surface of the pier. Interior surfaces of the webs, the proximal surface of the pier, and a portion of the interior surface of the face shell between the webs define a pocket. In addition, the building blocks may include a ledge that extends outwardly from the distal surface of the pier. This ledge forms a channel with an upper surface of the pier stacked above the block.

An interlocking construction block system comprising a family of blocks that interlock along three axes, including a left/right axis, a front/back axis, and an up/down axis. The family of blocks are self-aligning and do not require skilled labor or mortar to create a structure of any length, width, height, or shape. Each block comprises a specific geometry that allows all blocks in the family to interlock in a woven pattern that not only locks the blocks in place but also allows even distribution of structural weights and stresses. The disclosed blocks can be manufactured in different sizes to conform to any building code requirement and to create wall lengths to a one-inch measurement. The blocks may comprise channel openings to allow for plumbing, electrical, and structural reinforcements in the structure and may each be reinforced with an internal mesh cage.

A hollow prefabricated masonry wall panel is made at a fabrication site and is configured for transportation to a build site. The hollow prefabricated wall panel has a base row and an upper row formed of hollow blocks. A slit is formed in the top of each of the two side walls of the hollow blocks of the base row and upper row, the slit having a width no larger than 20% a width of a side wall. Provisional reinforcement is provided within each slit with a bonding material, a size of the slit and the provisional reinforcement configured to provide tensile strength during transportation of the hollow prefabricated wall panel from the fabrication site to the build site. At least one mid-row is laid between the base row and upper row so the hollow cavities are aligned to preserve hollow wall cavities that can accept code required reinforcement once transported to the build site.

Embodiments of modular building units (blocks) are disclosed that can be stacked to provide insulating concrete forms (ICFs). The blocks are formed of a foamed polymer material, such as foamed polyurethane. The blocks, when assembled together in an ICF, are configured to form one or more vertical columns of concrete and one or more horizontal beams of concrete intersecting the one or more columns, in a manner of post and beam construction. The blocks can be tightly interlocked with other blocks in a construction process. The disclosed blocks can include significant interior space for rebar and concrete to be inserted to construct the structure. Molds and methods for producing modular units are also disclosed. The molds and methods enable rapid production and removal of modular building units from the molds. Methods of constructing structures using the modular building units are also disclosed.

Embodiments of modular building units (blocks) are disclosed that can be stacked to provide insulating concrete forms (ICFs). The blocks are formed of a foamed polymer material, such as foamed polyurethane. The blocks, when assembled together in an ICF, are configured to form one or more vertical columns of concrete and one or more horizontal beams of concrete intersecting the one or more columns, in a manner of post and beam construction. The blocks can be tightly interlocked with other blocks in a construction process. The disclosed blocks can include significant interior space for rebar and concrete to be inserted to construct the structure. Molds and methods for producing modular units are also disclosed. The molds and methods enable rapid production and removal of modular building units from the molds. Methods of constructing structures using the modular building units are also disclosed.

A mold set for manufacturing interlocking construction blocks comprising a modular family molds and connecting side walls. The molds may be configured to create assembled female molds that may be filled with fluid cement, which can be removed from the female molds with corresponding male molds. Each assembled female mold may comprise one or more interlocking sections that allow the resulting blocks to interlock in three directions along three axes, including a left/right axis, a front/back axis, and an up/down axis. Each block comprises a specific geometry that allows all blocks in the family to interlock in a woven pattern that not only locks the blocks in place but also allows even distribution of structural weights. The disclosed modular mold sets allow blocks to be manufactured in different sizes to conform to any building code requirement and to create wall lengths to a one-inch measurement.

An interlocking construction block system comprising a family of blocks that interlock along three axes, including a left/right axis, a front/back axis, and an up/down axis. The family of blocks are self-aligning and do not require skilled labor or mortar to create a structure of any length, width, height, or shape. Each block comprises a specific geometry that allows all blocks in the family to interlock in a woven pattern that not only locks the blocks in place but also allows even distribution of structural weights and stresses. The disclosed blocks can be manufactured in different sizes to conform to any building code requirement and to create wall lengths to a one-inch measurement. The blocks may comprise channel openings to allow for plumbing, electrical, and structural reinforcements in the structure and may each be reinforced with an internal mesh cage.

Concrete wall supports that reduce or eliminate wall movement due to exterior horizontal forces. One support is a bracket mounted to a floor joist with a plate extending below the top of the wall and two legs extending from the plate and attaching to the joist. One leg is above the concrete wall on one horizontal side of the plate, and the other leg is on the opposite side of the plate. Another support has a plate that extends below the top of the wall with two legs on opposite sides of the joist above the wall. A leg attaches to the lower edge of the joist. A support against shear forces includes a highly water permeable aggregate composite disposed in the voids of the wall, with a supportive strip that is enclosed in the aggregate composite and extends out of the voids to the face of the wall.