Masonry Block With Partial Cells

Abstract

A masonry block configured to be larger than conventional two cell masonry block yet include cells that align with conventional cells in conventional two cell masonry blocks is disclosed. Thus, the masonry block disclosed herein may be used together with conventional two cell masonry blocks. In addition, the masonry block configured to be larger than conventional two cell masonry block may be formed from materials lighter than conventional materials yet possessing similar strength. As such, a mason is able to assembly more of a wall with the masonry block per unit of time using the masonry block disclosed herein than a conventional block. In at least one embodiment, a mason is able to lay about 50% more liner feet of block with the masonry block herein than using conventional two cell masonry block. Thus, the masonry block disclosed herein enables masons to realize substantial labor cost savings per job.

Claims

1. A masonry block, comprising: a first side wall; a second side wall spaced laterally from the first side wall; a first support web extending from the first side wall to the second side wall; a second support web extending from the first side wall to the second side wall and spaced apart from the first support web; a third support web extending from the first side wall to the second side wall and positioned between the first and second support webs; wherein the third support web forms a first cell defined at least in part by portions of the first and second side walls and the first and third support webs, whereby the first cell includes at least one top opening and at least one bottom opening; wherein the third support web forms a second cell defined at least in part by portions of the first and second side walls and the second and third support webs, whereby the second cell includes at least one top opening and at least one bottom opening; wherein the first and second side walls extend longitudinally beyond the first support web to form a first partial cell, whereby the first partial cell is formed from portions of the first and second side walls and the first support web; wherein the first and second side walls extend longitudinally beyond the second support web to form a second partial cell, whereby the second partial cell is formed from portions of the first and second side walls and the second support web; wherein the first partial cell is formed from a first half cell, and the second partial cell is formed from a second half cell; wherein the first half cell is formed from at least one top opening, at least one bottom opening and a side opening; wherein a length of the first half cell in a longitudinal direction of the masonry block is about one half a length of the first cell defined at least in part by portions of the first and second side walls and the first and third support webs; wherein a height of the first and second side walls are equal to a height of the first, second and third support webs; wherein upper and lower surfaces of the first and second side walls are coplanar with upper and lower surfaces of the first, second and third support webs; and wherein the first partial cell is configured to form a cell with an adjacent partial cell and to receive a reinforcing bar to increase structural integrity of a wall formed in part by the masonry block.

2. The masonry block of claim 1, wherein the second half cell is formed from at least one top opening, at least one bottom opening and a side opening.

3. The masonry block of claim 2, wherein a length of the second half cell in a longitudinal direction of the masonry block is about one half a length of the second cell defined at least in part by portions of the first and second side walls and the second and third support webs.

4. The masonry block of claim 1, wherein the masonry block is configured such that an overall length of the masonry block is greater than a width of the masonry block and is greater than a height of the masonry block.

5. The masonry block of claim 1, wherein the masonry block is configured such that an overall length of the masonry block is three times greater than a height of the masonry block.

6. The masonry block of claim 1, wherein the masonry block is configured such that an overall length of the masonry block is at least two times greater than a width of the masonry block.

7. The masonry block of claim 1, wherein the masonry block is configured such that an overall length of the masonry block is at least three times greater than a width of the masonry block.

8. The masonry block of claim 1, wherein the masonry block is formed from materials that are lighter per volume than Medium Weight materials used to form masonry blocks.

9. The masonry block of claim 1, wherein the masonry block is formed from materials including aggregate that are lighter per volume than Medium Weight materials used to form masonry blocks.

10. The masonry block of claim 1, wherein the masonry block is formed from materials including aggregate that are lighter per volume than Medium Weight materials used to form masonry blocks yet retain the same compression strength characteristics.

11. The masonry block of claim 1, further comprising a handhold formed in the third support web and accessible from above the masonry block.

12. The masonry block of claim 1, wherein the third support web is centered longitudinally within the masonry block.

13. The masonry block of claim 1, wherein the third support web is formed from a first subthird support web and a second subthird support web, wherein the first and second subthird support webs are separated by a gap thereby forming a splitable masonry block whereby a first section of the masonry block can be split from the second section of the masonry block.

14. A masonry block, comprising: a first side wall; a second side wall spaced laterally from the first side wall; a first support web extending from the first side wall to the second side wall; a second support web extending from the first side wall to the second side wall and spaced apart from the first support web; a third support web extending from the first side wall to the second side wall and positioned between the first and second support webs; wherein the third support web forms a first cell defined at least in part by portions of the first and second side walls and the first and third support webs, whereby the first cell includes at least one top opening and at least one bottom opening; wherein the third support web forms a second cell defined at least in part by portions of the first and second side walls and the second and third support webs, whereby the second cell includes at least one top opening and at least one bottom opening; wherein the first and second side walls extend longitudinally beyond the first support web to form a first half cell, whereby the first half cell is formed from portions of the first and second side walls and the first support web; wherein the first and second side walls extend longitudinally beyond the second support web to form a second half cell, whereby the second half cell is formed from portions of the first and second side walls and the second support web; wherein the first half cell is formed from least one top opening, at least one bottom opening and a side opening; wherein a length of the first half cell in a longitudinal direction of the masonry block is about one half a length of the first cell defined at least in part by portions of the first and second side walls and the first and third support webs; wherein the second half cell is formed from least one top opening, at least one bottom opening and a side opening; wherein a length of the second half cell in a longitudinal direction of the masonry block is about one half a length of the second cell defined at least in part by portions of the first and second side walls and the second and third support webs; wherein a height of the first and second side walls are equal to a height of the first, second and third support webs; wherein upper and lower surfaces of the first and second side walls are coplanar with upper and lower surfaces of the first, second and third support webs; wherein the first half cell is configured to form a cell with an adjacent half cell and to receive a reinforcing bar to increase structural integrity of a wall formed in part by the masonry block; and wherein the masonry block is formed from materials that are lighter per volume than Medium Weight materials used to form masonry blocks.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the presently disclosed invention and, together with the description, disclose the principles of the invention.

[0021] FIG. 1 is a perspective view of a conventional concrete block with two open cells and a length of about 16 inches.

[0022] FIG. 2 is a perspective view of a masonry block with first and second cells and first and second half cells extending from longitudinal ends of the masonry block, thereby providing the masonry block with an overall length that is greater than an overall length of the conventional concrete block.

[0023] FIG. 3 is a bottom view of the masonry block shown in FIG. 2.

[0024] FIG. 4 is a bottom view of another embodiment of the masonry block shown in FIG. 2 together with a splitable third support web.

[0025] FIG. 5 is a cross-sectional view of a third support web including a handhold, taken as section line 5-5 in FIG. 2.

[0026] FIG. 6 is a cross-sectional view of first and second side walls forming a portion of the masonry block, taken as section line 6-6 in FIG. 2.

[0027] FIG. 7 is a cross-sectional view of another embodiment of the third support web including a handhold, taken as section line 7-7 in FIG. 2.

[0028] FIG. 8 is a perspective view of a masonry block with first and second cells and first and second half cells extending from longitudinal ends of the masonry block together with a reinforcing bar installed to pass vertically through a first half cell.

[0029] FIG. 9 is a perspective view of a plurality of masonry blocks, each with first and second cells and first and second half cells extending from longitudinal ends of the masonry blocks, assembled together into two courses to being forming a wall, together with reinforcing bars installed within chambers formed by vertically aligned cells.

[0030] FIG. 10 is a perspective view of a masonry block with first and second cells and first and second half cells extending from longitudinal ends of the masonry block, rotated 180 degrees from the view shown in FIG. 2 and flipped over to show the bottom of the masonry block.

DETAILED DESCRIPTION

[0031] As shown in FIGS. 2-10, a masonry block 10 configured to be larger than conventional two cell masonry block 12 yet include cells 14 that align with conventional cells 16 in conventional two cell masonry blocks 12 is disclosed. Thus, the masonry block 10 disclosed herein may be used together with conventional two cell masonry blocks 12 so that the cells are aligned enabling reinforcement bars and concrete to be placed therein. In addition, the masonry block 10 configured to be larger than conventional two cell masonry block 12 may be formed from materials lighter than conventional materials yet possessing similar strength. As such, a mason may be able to assembly a greater amount of a wall with the masonry block 10 per unit of time using the masonry block 10 disclosed herein than a conventional block 12. In at least one embodiment, a mason is able to lay about 50% more liner feet of masonry block 10 with the masonry block 10 herein than using conventional two cell masonry block 12. Thus, the masonry block 10 disclosed herein enables masons to realize substantial labor cost savings per job.

[0032] In at least one embodiment, the masonry block 10 may be include a first partial cell 36 extending longitudinally from a first end and as second partial cell 40 extending longitudinally from a second end that is generally on an opposite end from the first end. The first partial cell 36 may be configured that when matched up to another masonry block 10, the first partial cell 36 forms a full cell. The first partial cell 36 may be configured to be anything less than a full volume of a full cell. In at least one embodiment, the first partial cell 36 may be a first half cell 36 whereby the volume of the void created by the first half cell 36 is approximately one half of a volume of a full cell. The volume of the first half cell 36 is not limited to precisely one half of a volume of a full cell but may include variations greater and less than one half. Similarly, the second partial cell 40 may be configured that when matched up to another masonry block 10, the second partial cell 40 forms a full cell. The second partial cell 40 may be configured to be anything less than a full volume of a full cell. In at least one embodiment, the second partial cell 40 may be a second half cell 40 whereby the volume of the void created by the second half cell 40 is approximately one half of a volume of a full cell. The volume of the second half cell 40 is not limited to precisely one half of a volume of a full cell but may include variations greater and less than one half. The first and second half cells 36, 40 may be configured such that when mated with another block, the first and second half cells 36, 40 form full cells at the first and second ends of the masonry block 10.

[0033] In at least one embodiment, as shown in FIGS. 2 and 10, the masonry block 10 may be formed from a first side wall 18, a second side wall 20 spaced laterally from the first side wall 18, a first support web 22 extending from the first side wall 18 to the second side wall 20, and a second support web 24 extending from the first side wall 18 to the second side wall 20 and spaced apart from the first support web 22. The masonry block 10 may include a third support web 26 extending from the first side wall 18 to the second side wall 20 and positioned between the first and second support webs 22, 24. The third support web 26 may form a first cell 28 defined at least in part by portions of the first and second side walls 18, 20 and the first and third support webs 22, 26, whereby the first cell 28 may include one or more top openings 30 and one or more bottom openings 32, as shown in FIGS. 3, 4 and 10. The third support web 26, as shown in FIGS. 2-4 and 10, may form a second cell 34 defined at least in part by portions of the first and second side walls 18, 20 and the second and third support webs 24, 26, whereby the second cell 34 includes one or more top openings 30 and one or more bottom openings 32.

[0034] The first and second side walls 18, 20 may extend longitudinally beyond the first support web 22 to form a first half cell 36, whereby the first half cell 36 may be formed from portions of the first and second side walls 18, 20 and the first support web 22. In at least one embodiment, a volume of the first half cell 36 may be approximately one half of a volume of the first cell 28. In yet another embodiment, volume of the first half cell 36 may be approximately one half of an average volume taken of the volumes of the first and second cells 28, 34. The volume of the first half cell 36 may be determined based upon the three dimensional volume defined by the portions of the first and second side walls 18, 20 and the first support web 22 forming the first half cell and outer surfaces 38 of the first support web 22 and portions of the first and second side walls 18, 20.

[0035] The first and second side walls 18, 20 may extend longitudinally beyond the second support web 24 to form a second half cell 40, whereby the second half cell 40 is formed from portions of the first and second side walls 18, 20 and the second support web 24. In at least one embodiment, a volume of the second half cell 40 may be approximately one half of a volume of the second cell 34. In yet another embodiment, volume of the second half cell 40 may be approximately one half of an average volume taken of the volumes of the first and second cells 28, 34. The volume of the second half cell 40 may be determined based upon the three dimensional volume defined by the portions of the first and second side walls 18, 20 and the second support web 24 forming the first half cell and outer surfaces 38 of the second support web 24 and portions of the first and second side walls 18, 20.

[0036] In at least one embodiment, the first half cell 36 may be formed from one or more top openings 42, one or more bottom openings 44 and one or more side openings 46. The top opening 42 may be on the same plane as a top outer surface 48 of the first and second side walls 18, 20 and the first support web 22. The bottom opening 44 may be on the same plane as a bottom outer surface 50 of the first and second side walls 18, 20 and the first support web 22. The side opening 46 may be on the same plane as a side outer surface 52 of the first and second side walls 18, 20. In at least one embodiment, the first half cell 36 may have a length in a longitudinal direction 54, such that is aligned with a longitudinal axis 56 of the masonry block 10, that is less than a length in a longitudinal direction 54 of the first cell 28. In at least one embodiment, a length of the first half cell 36 in a longitudinal direction 54 of the masonry block 10 may be about one half a length of the first cell 28 defined at least in part by portions of the first and second side walls 18, 20 and the first and third support webs 22, 26.

[0037] In at least one embodiment, the second half cell 40 may be formed from one or more top openings 60, one or more bottom openings 62 and one or more side openings 64, as shown in FIG. 10. The top opening 60 may be on the same plane as a top outer surface 48 of the first and second side walls 18, 20 and the second support web 24. The bottom opening 62 may be on the same plane as a bottom outer surface 50 of the first and second side walls 18, 20 and the second support web 24. The side opening 64 may be on the same plane as a side outer surface 66 of the first and second side walls 18, 20. In at least one embodiment, the second half cell 40 may have a length in the longitudinal direction 54, such that is aligned with a longitudinal axis 56 of the masonry block 10, that is less than a length in the longitudinal direction 54 of the second cell 34. In at least one embodiment, a length of the second half cell 40 in the longitudinal direction 54 of the masonry block 10 may be about one half a length of the second cell 34 defined at least in part by portions of the first and second side walls 18, 20 and the second and third support webs 24, 26.

[0038] The overall length of the masonry block 10 may be larger than an overall length of a conventional two cell masonry block 12, as shown by comparison of FIGS. 1 and 2. In at least one embodiment, the overall length of the masonry block 10 may be about 1.5 times (1.5) larger than an overall length, 1, of a conventional two cell masonry block 12. The masonry block 10 may be configured such that an overall length of the masonry block 10 is greater than a width of the masonry block 10 and is greater than a height of the masonry block 10. The masonry block 10 may be configured such that an overall length of the masonry block 10 is three times greater than a height of the masonry block 10, such as, but not limited to, when an overall length of the masonry block 10 is about 24 inches and a height of the masonry block 10 is about eight inches. The masonry block 10 may also be configured such that an overall length of the masonry block 10 is at least two times greater than a width of the masonry block 10, such as, but not limited to, when an overall length of the masonry block 10 is about 24 inches and a width of the masonry block 10 is about 12 inches. The masonry block 10 may also be configured such that an overall length of the masonry block 10 is at least three times greater than a width of the masonry block 10, such as, but not limited to, when an overall length of the masonry block 10 is about 24 inches and a width of the masonry block 10 is about eight inches.

[0039] The masonry block 10 may be formed from any appropriate size while enabling the first and second cells 28, 34 to be aligned with other cells in other courses in a concrete block wall. For example, and not limitation, the masonry block 10 may be formed with widths such as, but not limited to, six inches, eight inches, ten inches, and twelve inches. The masonry block 10 may also be formed with a length enabling first and second cells 28, 34 and first and second half cells 36, 40 to be aligned with cells in concrete block courses below the course being laid and may be, but is not limited to being about 24 inches. Such length of the masonry block 10 enables the masonry block 10 with first and second cells 28, 34 and first and second half cells 36, 40 to be laid together with conventional concrete block with only two open cells and typically 16 in length.

[0040] The masonry block 10 may be formed from materials that are lighter per volume than materials used to form conventional masonry blocks 12. One or more components of the materials used to form conventional masonry blocks 12 may be substituted for a lighter material without compromising strength of the masonry block 10. In at least one embodiment, the masonry block 10 may be formed from materials including aggregate that are lighter per volume than materials used to form conventional masonry blocks 12. The masonry block 10 may be formed from materials including aggregate, such as, but not limited to rock, stone and the like, that are lighter per volume than materials used to form conventional masonry blocks yet retain the same strength characteristics, such as, but not limited to, compression strength characteristics. Conventional CMU (concrete) blocks are typically made with aggregates of 125 pound (lb) per cubic foot (PCF). In at least one embodiment, masonry block 10 can be formed with lightweight (LT WT) aggregates not to exceed 105 lb PCF. Masonry block 10 with first partial cell 36 extending longitudinally from a first end and second partial cell 40 extending longitudinally from a second end produced with LT WT aggregates, less than or equal to about 105 lb PCF, are comparable in overall weight to conventional CMU block produced with 125 lb PCF aggregates and classified normal weight. Masonry block 10 with first partial cell 36 extending longitudinally from a first end and second partial cell 40 extending longitudinally from a second end, when produced with LT WT aggregates will allow the mason to place the same amount of masonry block 10 units as conventional CMU's with no additional weight to the mason, which is very important to the mason. Overloading a mason with additional weight severely hinders the mason's productivity by reducing his daily output.

[0041] With regard to the density classification of the aggregate used in the masonry block 10, the American Society for Testing and Materials (ASTM) C 90-11b, Standard Specification for Loadbearing Concrete Masonry Units, Table #2 classifies block into three Categories based upon densities PCF: Lightweight (LT WT)less than 105 lbs; Medium Weight105 lbs to less than 125 lbs and Normal Weight125 lbs or more. ASTM C 90-11b provides that each classification have a minimum net area compressive strength equal to 1900 lbs. Thus, the masonry block 10 can be formed with lightweight (LT WT) aggregates not to exceed 105 lb PCF, as defined by ASTM C 90-11b or other applicable building code or regulation. Any aggregate meeting the ASTM C 90-11b or other applicable building code or regulation for weight and strength may be used. Lightweight aggregate may include, but is not limited to, StaLite by Carolina Stalite Company, Salisbury, N.C. and Livelite by Tombigbee Lightweight Aggregate Co. in Livingston, Ala.

[0042] The masonry block 10 may include a handhold 68 formed in the third support web 26 and accessible from above the masonry block 10, as shown in FIGS. 2-4, 5 and 7. The handhold 68 may have any appropriate configuration. In at least one embodiment, the handhold 68 may have a greater width than other aspects of the third support web 26. As such, the handhold 68 provides a place for the mason to realize better gripping ability on the masonry block 10. The handhold 68 may taper in ever widening width moving upward towards top outer surface 48. As such, the handhold 68 provides a place for the mason to obtain better gripping ability on the masonry block 10. The third support web 26 may be centered longitudinally within the masonry block 10. A handhold 68 formed in the third support web 26 and accessible from above the masonry block 10 forms a centered handhold 68. The centered handhold 68 is very desirable as the force exerted by a mason to pick up the masonry block 10 and place it in position on a wall is much less for a centered handhold 68 than if the mason must use an off-centered grip on the masonry block 10 because he needn't waste any energy fighting a moment force.

[0043] In at least one embodiment, the masonry block 10 may include a third support web 26 formed from a first subthird support web 70 and a second subthird support web 72. The first and second subthird support webs 70, 72 may be separated by a gap 74 thereby forming a splitable masonry block 10 whereby a first section 76 of the masonry block 10 can be split from the second section 78 of the masonry block 10, as shown in FIG. 4.

[0044] During use, a mason may install masonry block 10 with mortar and may level and align each block 10, as shown in FIG. 9. The mason may align the cells in a masonry block 10 with courses of blocks below such that once the wall is formed, reinforcing bars 80, such as steel rods, which may be referred to as rebar, as shown in FIGS. 8 and 9, may be positioned within the hollow channels formed by the multiple cells 14 aligned vertically with each other. Concrete may be poured into the cells 14 with the reinforcing bars 80 to increase the structural integrity of the wall.

[0045] The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of this invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of this invention.