Building blocks include a tongue and groove on each block that allow the blocks to be placed in a way that interlocks the tongue and groove of one block with the corresponding groove and tongue, respectively, of another block facing the opposite direction. In a first embodiment, the same building block that has a decorative front face is used for both sides of the wall, resulting in a wall with opposed finished surfaces. In a second embodiment, a first plurality of blocks that have a decorative front face are used for one side of the wall, while a second plurality of blocks that have a thicker and non-decorative face are used for the other side of the wall, with the first and second plurality of blocks interlocking back-to-back via their respective tongues and grooves. Both types of blocks can be made using the same concrete form.

Building blocks include a tongue and groove on each block that allow the blocks to be placed in a way that interlocks the tongue and groove of one block with the corresponding groove and tongue, respectively, of another block facing the opposite direction. In a first embodiment, the same building block that has a decorative front face is used for both sides of the wall, resulting in a wall with opposed finished surfaces. In a second embodiment, a first plurality of blocks that have a decorative front face are used for one side of the wall, while a second plurality of blocks that have a thicker and non-decorative face are used for the other side of the wall, with the first and second plurality of blocks interlocking back-to-back via their respective tongues and grooves. Both types of blocks can be made using the same concrete form.

A concrete building block for masonry block walls is formed with first, second and third spaced parallel rectangular face shells, where the second face shell is intermediate the first and third face shells. First and second vertical end cross webs connect the first and second face shells and first and second spaced intermediate vertical cross webs connect the second and third face shells. Insulating inserts include end protrusions extending outwardly at the top edge thereof to fit into notches of the cross webs and include cutouts to accommodate mortar crumbs. The inserts further include longitudinal notches along the entire bottom edges and longitudinal notches along the entire top edges wherein said longitudinal notches along a bottom edge are dimensioned to mate with longitudinal notches along a top edge of neighboring ones of the insulating inserts creating an overlap that serves to (i) insulate against temperature transfer and (ii) provide a sound barrier.

A concrete building block for masonry block walls is formed with first, second and third spaced parallel rectangular face shells, where the second face shell is intermediate the first and third face shells. First and second vertical end cross webs connect the first and second face shells and first and second spaced intermediate vertical cross webs connect the second and third face shells. Insulating inserts include end protrusions extending outwardly at the top edge thereof to fit into notches of the cross webs and include cutouts to accommodate mortar crumbs. The inserts further include longitudinal notches along the entire bottom edges and longitudinal notches along the entire top edges wherein said longitudinal notches along a bottom edge are dimensioned to mate with longitudinal notches along a top edge of neighboring ones of the insulating inserts creating an overlap that serves to (i) insulate against temperature transfer and (ii) provide a sound barrier.

A hybrid wall reinforcement wall anchoring system is described for use in masonry cavity walls. The reinforcement and anchor is hybrid device installed within the backup wall and interlocked with novel veneer ties. The novel veneer ties are wire formatives and are manually connected and interlocked with the anchor. Once interlocked and installed within the cavity wall, lateral, vertical and front-to-back veneer tie movement is limited, strengthening the cavity wall structure. The inclusion of a reinforcement wire within the veneer tie and the exterior wall provides a seismic structure.

A hybrid wall reinforcement wall anchoring system is described for use in masonry cavity walls. The reinforcement and anchor is hybrid device installed within the backup wall and interlocked with novel veneer ties. The novel veneer ties are wire formatives and are manually connected and interlocked with the anchor. Once interlocked and installed within the cavity wall, lateral, vertical and front-to-back veneer tie movement is limited, strengthening the cavity wall structure. The inclusion of a reinforcement wire within the veneer tie and the exterior wall provides a seismic structure.

A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

What is provided is a precast hollow block, a precast wall system incorporating the precast hollow block, and forms for manufacturing a hollow block and a coping cap. Accordingly, the precast hollow block and its incorporation into a precast wall system provide solutions to current “level up” block coping techniques, wall flood protection, wall force protection, and the like. Instead of having mismatched or missing face textures on sloped portions of the wall, the precast wall system allows for easier installation of face-textured blocks directly at the top of the wall. As a result, the precast wall system may readily account for slope transitions of a wall, conform to specific Department of Transportation project requirements, accommodate existing wall construction specifications, and be easily customizable for a variety of applications.

What is provided is a precast hollow block, a precast wall system incorporating the precast hollow block, and forms for manufacturing a hollow block and a coping cap. Accordingly, the precast hollow block and its incorporation into a precast wall system provide solutions to current “level up” block coping techniques, wall flood protection, wall force protection, and the like. Instead of having mismatched or missing face textures on sloped portions of the wall, the precast wall system allows for easier installation of face-textured blocks directly at the top of the wall. As a result, the precast wall system may readily account for slope transitions of a wall, conform to specific Department of Transportation project requirements, accommodate existing wall construction specifications, and be easily customizable for a variety of applications.

A system and method of masonry construction using masonry blocks and anchors, wherein the blocks are laid end to end, and an anchor is inserted between them. The anchor both spaces and secures the blocks, even before mortar is applied. The anchors contain legs recess between the walls of the masonry construction, and create a space for the walls to recess in to on the anchor, thereby providing multi-directional securement of the system. Embodiments of the system also contain grooves for additional securement and complemental engagement of the anchors.