Masonry wall assembly

Abstract

The present invention includes a method and a unit for a masonry wall system, each unit comprising a face shell wherein the interior surface has a transverse axis running from the top surface to the bottom surface of the face shell, and one or more webs having a front end and a rear end, wherein the rear end of each web is integral with or attached to the interior surface of the face shell along the transverse axis. The method for wall construction further comprising positioning one or more vertical reinforcement rods or tendons with one end embedded in a wall-foundation and laying a layer wall units on the wall-foundation such that the one or more webs of the layers of wall units are aligned, and the vertical reinforcement rods or tendons run through or are adjacent to the webs of the wall units.

Claims

1. A method for construction of a masonry wall comprising the steps of: positioning one or more vertical reinforcing rods or tendons having a first end and a second end, wherein the first end is embedded in a wall-foundation; and laying a first course of one or more wall units on the wall-foundation with each wall unit comprising: a single face shell comprising: an interior surface; an exterior surface, the exterior surface being spaced apart from the interior surface; a top surface; a bottom surface, the bottom surface being spaced apart from the top surface, wherein each of the top surface and the bottom surface extend between the interior surface and the exterior surface; a first end surface; and a second end surface, the second end surface being spaced apart from the first end surface, wherein each of the first end surface and the second end surface extend between the interior surface and the exterior surface and between the top surface and the bottom surface, wherein a first axis extends between the top surface and the bottom surface of the face shell along the interior surface, a second axis extends between the first end surface and the second end surface along the interior surface and perpendicular to the first axis, and a third axis extends between the interior surface and the exterior surface and perpendicular to the first and second axes; and a first web and a second web, each of the first web and the second web having a distal end and a proximal end and an inner surface and an outer surface extending between the distal and proximal ends, wherein the proximal end of each web is integrally attached to the interior surface of the face shell, the distal end is spaced apart from the proximal end along a direction of the third axis, at least a portion of the outer surface lies in a plane that intersects the second axis, and the inner surfaces are spaced apart from and face each other, wherein: the portion of the outer surface of the first web is spaced inwardly of the first end surface or the second end surface, at least a portion of the interior surface of the face shell disposed between the proximal end of the first web and the first or second end surface of the face shell adjacent the outer surface of the first web is visible from the direction of the third axis upon installation of two or more units atop each other, and a ledge extends outwardly from the outer surfaces of the distal ends of the webs in the direction of the third axis, the ledge having a horizontal surface that is spaced apart from and is spaced between upper and lower surfaces of the distal ends of the webs, wherein the horizontal surface lies within a plane that extends substantially parallel to the second and third axes.

2. The method of claim 1, further comprising laying a second course of one or more wall units above the first course such that first or second webs of each of the one or more wall units in the second course are at least one of aligned or flush with the first or second webs of an adjacent wall unit in the first course, and the one or more vertical reinforcing rods or tendons also run through or are adjacent to at least one of the first or second web of the one or more wall units in the second course.

3. The method of claim 1, further comprising laying a second course of one or more wall units above the first course, wherein first and second end surfaces of the face shell of the one or more wall units of the second course are staggered compared to the first and second end surfaces of the face shells of the one or more wall units of the first course, and the one or more vertical reinforcing rods or tendons also run through or are adjacent to at least one of the first or second web of the one or more wall units in the second course-layers.

4. The method of claim 1, further comprising the step of securing a fastener to the second end of the one or more vertical reinforcing tendons, or physically deforming the second end of the one or more vertical reinforcing tendon to post-tension each vertical reinforcing tendon to support the wall.

5. The method of claim 4, wherein the fastener further comprise a clip, nut, bolt, washer, or screw that secures over the second end of each vertical reinforcing rods or tendons which is threaded.

6. The method claim of 1, wherein the wall-foundation comprises a cast-in-place footing made from castable cement, concrete, grout, clay, fiberglass, fiber reinforced polymers, polymers, metals, pressure-wood, compacted aggregate, helical piers, pre-cast concrete or aggregate piers, a pier and beam foundation, or other moldable forming materials.

7. The method of claim 1, further comprising laying a beam on an uppermost course of the wall units.

8. The method of claim 7, wherein the beam comprises wood, wood composites, plywood, reinforced grout bond beam, concrete, cement, iron, iron alloys, metal, nickel, steel, steel alloy, stainless steel alloys, aluminum, aluminum alloys, bronze alloys, brass, brass alloys, chromium, copper, copper alloys, fiberglass, polymers, plastic, reinforced polyester epoxy, fiber reinforced plastic, fiberglass, engineering plastics, PTFE, lead, natural or synthetic rubber, steel reinforced concrete, or some combination thereof.

9. The method of claim 7, wherein the beam further comprises one or more openings for each vertical reinforcing tendon to stabilize and support the vertical reinforcing tendons.

10. The method of claim 7, further comprising positioning a cap on top of the beam.

11. The method of claim 7, further comprising positioning a cap on top of the beam wherein the cap has one or more holes for each vertical reinforcing tendon to stabilize and support the vertical reinforcing tendons.

12. The method of claim 1, further comprising positioning a cap on an uppermost course of one or more wall units.

13. The method of claim 1, further comprising positioning a cap on an uppermost course of one or more wall units, wherein the cap has one or more holes for each vertical reinforcing tendon to stabilize and support the vertical reinforcing tendons.

14. The method of claim 10, wherein the cap further comprises either an elongated single piece with one or more holes for the one or more vertical reinforcing tendons, or two or more separate pieces each with one or more holes for receiving the one or more vertical reinforcing tendons.

15. The method of claim 10, wherein positioning the cap further comprises holding the cap in place with a separate fastener, or screwing the cap onto the second end of the respective vertical reinforcing tendon and post-tensioning the vertical reinforcing tendon.

16. The method of claim 1, wherein the face shell and the first and second webs comprise at least one of cement, concrete, cinder block, aggregate, clay, polymers, copolymers, metals, fiberglass, forming materials, wood, plywood, oriented strand board, particle board, cement board, engineering composite materials, bamboo, hemp, plastic, nylon, polyester, polypropylene, polystyrene, or metal.

17. The method of claim 1, further comprising one or more brick ties embedded in or fastened to the interior or exterior surface of the face shell, or embedded in or fastened to the first or second webs.

18. The method for constructing the masonry wall of claim 1, further comprising: laying one or more additional courses of one or more wall units above the first layer of one or more wall units wherein the vertical reinforcing rods or tendons are spaced such that each vertical reinforcing rod or tendon is running through or adjacent to at least one of first and second webs of the wall units in the one or more additional courses; and setting at least one of a beam or cap on an uppermost course of one or more wall units wherein the beam or cap each have openings for the vertical reinforcing rods or tendons to stabilize the vertical reinforcing rods or tendons.

19. The method of claim 18 further comprising the step of: post-tensioning the one or more vertical reinforcing rods or tendons to support the masonry wall.

20. The method of claim 1, wherein the distal ends of the first and second webs are directly coupled together to define a pocket with the inner surfaces of the first and second webs and a portion of the interior surface of the face shell disposed between the inner surfaces of the first and second webs.

21. The method of claim 1, wherein the inner surfaces of the first and second webs face each other and are spaced apart from each other a first distance, the distal ends of the first and second webs are spaced apart a second distance that is less than the first distance, and the distal ends have a thickness as measured in the direction of the second axis that is greater than a thickness of each web adjacent the respective proximal end as measured in the direction of the second axis.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures and in which:

(2) FIG. 1 is a perspective view of the wall unit incorporating the teachings of the present invention.

(3) FIG. 2 is a view of the side of the wall unit depicting the first end.

(4) FIG. 3 is a view of the top surface of the wall unit.

(5) FIG. 4 is a view of the bottom surface of the wall unit.

(6) FIG. 5 is a view of the interior surface of the wall unit.

(7) FIG. 6 is an inverted view of the wall unit that is shown in FIG. 5.

(8) FIGS. 7A to 7O are perspective views of other embodiments of the wall unit incorporating various quantities and configurations of webs.

(9) FIG. 8 shows a vertical reinforcement tendon placement adjacent to the webs.

(10) FIG. 9 shows horizontal joint reinforcements placed in a horizontal mortar bed joint between wall units.

(11) FIGS. 10 to 11 are illustrations of partially completed wall constructed in accordance with the method of the present invention.

(12) FIG. 12 shows another partially completed wall using a different assembly configuration.

(13) FIGS. 13A and 13B show top views of wall units using the present invention.

(14) FIGS. 14A to 14D show side views of options for installation of the wall assembly on various types of foundations.

(15) FIGS. 15A to 15C show side views of a wall assembly with three variations for the top of the wall.

(16) FIGS. 16A, 16B, and 16C show embodiments of wall assemblies in which the face shell serves as the outside wall.

(17) FIGS. 16D, 16E and 16F show embodiments of wall assemblies in which the face shell serves as the inside wall.

(18) FIGS. 17A to 17D show embodiments of wall assemblies in which a clip pocket and ledge for attachment of interior finish framing is shown, and index marks are included to provide locations for cuts used for blocks in corners and/or window jambs.

(19) FIG. 18 shows an embodiment in which a ledge extends from distal ends of webs that are coupled together.

DETAILED DESCRIPTION OF THE INVENTION

(20) While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.

(21) To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as a, an and the are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as outlined in the claims.

(22) The present invention includes a wall unit for assembly into a masonry wall. The wall unit includes a single face shell with one or more webs attached or integral therewith. A face shell is the outer (or inner) sidewall of a concrete masonry unit, in other words, the face shell can be either on the outside or the inside of the structure. In the examples shown herewith the face shell is an exterior version of the wall unit. A web is a portion of the wall unit that extends from the face shell.

(23) The face shell and web can be made from the same material (or different materials), including but not limited to, castable cement, concrete, cinder block, clay, polymers, copolymers metals, forming materials, wood, aggregate, clay, plywood, oriented strand board, particle board, cement board, engineering composite materials, bamboo, hemp, plastic, nylon, polyester, polypropylene, polystyrene, metal, and combinations thereof. The portions of the wall unit that contact the foundation (or a wall unit above an existing wall unit) will often include a transition that provides mechanical attachment and/or insulation, e.g., they can include a tongue and groove design, dovetail joints, or crenellated joints to provide interlocking capabilities. Horizontal joint reinforcements (e.g., pencil rods) can be placed in a groove or in a mortar joint between ungrooved units, which is just one example of features or methods used to provide, e.g., mechanical strength, attachment, shear stabilization, and/or insulation between one or more layers of wall units. The horizontal joint reinforcements can be made of iron, iron alloys, metal, nickel, steel, steel alloy, stainless steel alloys, aluminum, aluminum alloys, bronze alloys, brass, brass alloys, chromium, copper, copper alloys, polymers, plastic, reinforced polyester epoxy, fiber reinforced plastic, fiberglass, engineering plastics, coated with Teflon, lead, natural or synthetic rubber.

(24) Constructing the present invention will generally require a wall-foundation that can support the weight of the wall and/or the strain of one or more vertical reinforcement tendons. The wall-foundation can include, but is not limited to, cast-in-place footing made from castable cement, concrete, grout, clay, fiberglass, fiber reinforced polymers, polymers, metals, pressure-wood, compacted aggregate, helical piers, pre-cast concrete or aggregate piers, a pier and beam foundation, or other moldable forming materials, or it can be a pre-existing surface of, e.g., concrete, ice, rock, dirt, gravel, earth, sand, etc.

(25) The size of each wall unit not limited to a certain width, height, and depth. It is possible that an entire wall is made up of only a single wall unit. The wall units can be of a length along the transverse axis of 4 in, 6 in., 8 in., 12 in., 16 in., 20 in., 22 in., 2 ft., 3 ft., 4 ft., 5 ft., 6 ft., 7 ft., 8 ft., 9 ft., 10 ft., 11 ft., 12 ft., 13 ft., 14 ft., 15 ft., 16 ft., 17 ft., 18 ft., 19 ft., 20 ft., 21 ft., 22 ft., 23 ft., 24 ft., 25 ft., 26 ft., 27 ft., 28 ft., 29 ft., and 30 ft., 40 ft., 50 ft., 60 ft. or more. Likewise with width of the face shell can be 4 in, 6 in., 8 in., 12 in., 16 in., 20 in., 22 in., 2 ft., 3 ft., 4 ft., 5 ft., 6 ft., 7 ft., 8 ft., 9 ft., 10 ft., 11 ft., 12 ft., 13 ft., 14 ft., 15 ft., 16 ft., 17 ft., 18 ft., 19 ft., 20 ft., 21 ft., 22 ft., 23 ft., 24 ft., 25 ft., 26 ft., 27 ft., 28 ft., 29 ft., and 30 ft., 40 ft., 50 ft., 60 ft. or more. The length of the webs can be 4 in., 6 in., 8 in., 10 in., 12 in., 16 in., or more. Generally, the size of the wall unit will confirm with standard building sizes in either metric or imperial units of measure.

(26) In one non-limiting example, a bond beam and/or cap can also placed on top of the wall. The bond beam and/or cap can include but is not limited to reinforced grout bond beam, concrete, cement, iron, iron alloys, metal, nickel, steel, steel alloy, stainless steel alloys, aluminum, aluminum alloys, bronze alloys, brass, brass alloys, chromium, copper, copper alloys, polymers, plastic, reinforced polyester epoxy, fiber reinforced plastic, fiberglass, engineering plastics, metal coated with Teflon, lead, natural or synthetic rubber, steel reinforced concrete, or any combination thereof.

(27) FIG. 1 depicts an individual wall unit 2, which includes a single face shell 14 with an interior surface 4, and two webs 8a and 8b integral with or attached to the face shell 14. A transverse axis 6-6 is shown on interior surface 4, and the webs 8a, 8b are attached to face shell 14 along the transverse axis from the top surface 10 to the bottom surface 12 of face shell 14. The wall unit 2 is not limited to the two webs 8a, 8b, but can also include e.g., one, two, three, four, five, or more webs. When there are two webs 8a, 8b or more, they are each separated with a gap 16. Webs 8a and 8b are also depicted as having fastener-receiving grooves 18 which extend from the top surface 24 of webs 8a, 8b to the bottom surface 26. Face shell 14 has portions that form a lifting edge 15 along the bottom of face shell 14. The presence of lifting edge 15 provides strength and a gripping feature to face shell 14, especially when face shell 14 is being lifted. Face shell 14 also has portions that form one or more face shell lugs 17 on the interior surface 4 of the face shell 14. Each face shell lug 17 also provides strength to the face shell 15. Each face shell lug 17 may be formed with portions that define a fastener receiving groove 28 for receiving a fastener (not shown in FIG. 1) for fastening the face shell 14 to another wall unit 2 or fastening building services (e.g., electrical, plumbing lines, etc.) to the wall.

(28) FIG. 2 is a side view of wall unit 2 depicting an opening 20 in web 8a, which may be an opening knock-out that may be used e.g., as a lifting pocket for wall unit 2 or for inspection of rods/tendons or to pass building services. Opening 20 can exist in web 8a, webs 8a and 8b (not shown), or all of the webs in a multi-web arrangement, which are integral with or attached to wall unit 2. Opening 20 can function as an opening for e.g., horizontal reinforcements or building services such as e.g., electrical, plumbing, tubing, conduit, vacuum, fiber optic, wiring (communication, telecom, internet, Ethernet, network, IT networks), vacuum, coaxial, conduits, air vents, HVAC, ventilation, refrigeration, gas sources, lighting. Opening 20 is not limited to just being at the top surface 24 of web 8a, but can also be positioned along the bottom surface 26 as well, or anywhere throughout web 8a. Face shell 14 has portions that form a lifting edge 15 along the bottom 12 surface of face shell 14. Lifting edge 15 provides strength and a gripping feature to face shell 14. Face shell 14 also has portions that form one or more face shell lugs 17 on the interior surface 4 of the face shell 14.

(29) FIG. 3 is a top view of wall unit 2 depicting top surface 10 of face shell 14 and top surface 24 of webs 8a and 8b. Top surface 10 may be formed with portions that define one, two three, four, and five or more receiving fastener grooves 28 shown in relation to the top surface 10.

(30) FIG. 4 depicts the bottom view of wall unit 2 and shows the bottom surface 12 of face shell 14. FIG. 4 also shows the location of the fastener receiving grooves 28 that extend through the bottom surface 12 of face shell 14.

(31) FIG. 5 is a frontal view of wall unit 2 depicting the interior surface 4 of face shell 14. FIG. 5 shows that webs 8a and 8b are placed closer to the second end 32 of face shell 14 (see FIG. 1) and both are to the right of the middle transverse axis 34-34 of face shell 14. Face shell 14 has portions that form a lifting edge 15 and one or more face shell lugs 17 on the interior surface 4 of the face shell 14. Top surface 10 is shown along with bottom surface 12, fastener receiving grooves 28, shown with line 34-34 to show alignment and side surface 30.

(32) FIG. 6 is a frontal view of wall unit 2 showing an inverted view (i.e., rotated 180 degrees) of the wall unit 2 that is shown in FIG. 5. The wall units 2 however are not limited to this type of placements of the one or more webs. Webs 8a and 8b are placed closer to the second end 32 of face shell 14 (see FIG. 1) and both are to the left of the middle transverse axis 34-34 of face shell 14. Top surface 10 is shown along with bottom surface 12, side surfaces 30 and 32.

(33) FIGS. 7A to 7O are perspective views of other non-limiting embodiments of the wall unit that incorporate various quantities and configurations of webs and while shown with specific configurations, the skilled artisan will recognized that whether the webs are right-of-center, in the mid-point or left-of-center, these can be configured in the opposite manner and can include any variants of the same. The various figures show the wall unit 2 with: a single web to the right-of-center (7A), a single web in the center with a center-aligned enlarged web (7B), a left-of-center web that is enlarged but not centered (7C), a double web configuration with both webs right-of-center (7D), a double web with each web adjacent the centerline of the wall unit and having an enlarged portion (7E), a double web configuration with both webs left-of-center and having an enlarged portion that extends into the opening between the webs (7F), a double web configuration where the webs are attached to each other and are right-of-center (7G), a centered double web configuration in which the webs are also attached and further comprise additional material outside the opening between the webs (7H), a double web configuration that is left-of-center and is attached without additional material (7I), a triple web configuration with two webs right-of-center and one web left-of-center (7J), a triple web configuration with a web in the center, the right-of- and left-of-center with additional material at the end (7K), a triple web configuration shown with two webs left-of-center and one web right of center with additional material (7L), a triple web configuration with a single web left-of-center and two connected webs right-of-center (7M), a triple web configuration with a single web left-of-center and two connected webs right-of-center both with additional material (7N), and a triple web configuration with a double web left-of-center connected webs and a single right-of-center web (7O). The skilled artisan will recognize that the masonry unit can contain more than three webs, that the exemplary masonry units shown are not limiting but rather show various optional configurations which can be mixed and matched to produce variants on either side, middle, or both.

(34) FIG. 8 shows the placement of a vertical reinforcement tendon 38 in gap 16 between webs 8a and 8b of wall unit 2. Face shell 14 (see FIG. 1) has portions that form a lifting edge 15 along the bottom 12 surface of face shell 14. Lifting edge 15 provides strength and a gripping feature to face shell 14. Face shell 14 also has portions that form one or more face shell lugs 17 on the interior surface 4 of the face shell 14. Also shown are bottom surface 12 and fastener receiving grooves 28.

(35) FIG. 9 shows the placement of horizontal joint reinforcements 36 on the face shell and webs of wall unit 2. The horizontal joint reinforcements 36 sit between the top surface 10 and bottom surface 12 of different layers of wall units 2, which can be inserted into grooves 29. This is only one example of the construction design between the top surface 10 and bottom surface 12 of different wall units 2. The design serves to provide both mechanical features such as friction and reducing shear movement between the surfaces, and non-mechanical features such as insulation for the wall.

(36) As shown in FIGS. 10 and 11, wall 100 is constructed by first positioning one or more vertical reinforcement rods or tendons 38 in a wall-foundation 110, followed by the laying of a first layer of one or more wall units 2 on the wall-foundation 110 such that the one or more vertical reinforcement rods or tendons 38 are adjacent to webs 8a and 8b and are in gap 16. The skilled artisan will recognize that the rods or tendons 38 can be a single piece or multiple pieces that are fastened together and tightened and may be pre-inserted into the foundation prior to installation of the masonry units, or may even be added during or even after installation of some of or the entire wall. The wall construction further includes laying one or more subsequent additional layers of wall units 40 such that the webs of the subsequent layer is aligned and flush with the webs 8a, 8b of the previous layers of wall unit 2. Additionally, the one or more vertical reinforcement rods or tendons 38 also run through or are adjacent to the webs 8a, 8b of the subsequent layer of wall unit 2. Wall 100 is shown alternating wall unit 2 in an upright and inverted orientation between layers. With the aligning of the webs 8a, 8b, the different wall units causes the first end 30 and second end 32 of the subsequent layers to be staggered compared to the first end 30 and second end 32 of the previous layers. FIG. 11 is an isometric view of wall 100 showing the alignment of the webs 8a, 8b that allows the continued placement of the vertical reinforcement rods or tendons 38 to be adjacent to the webs 8a, 8b, or to potentially go through them and are depicted with a filler, concrete or equivalent in gap 16.

(37) FIG. 12 shows wall 200 constructed with wall unit 2 with all units in an inverted orientation as shown in wall 100 of FIGS. 10 and 11. The first and second ends 30 and 32 in wall 200 are not staggered, but instead are aligned for wall units 42. The webs in wall 200 are also aligned and flush for the proper placement of vertical reinforcement rods or tendons 38. Placement of all units in an upright orientation is another embodiment and will create a similar condition.

(38) After the final layer of the wall unit is laid and the optional bond beam and cap placed, a downward tension is created in the vertical reinforcement tendon to enhance the ability of the wall to receive lateral loading without failing in tension. The creating of the downward tension in the vertical reinforcement tendon can be but is not limited to being accomplished with a fastener such as a clip, nut, bolt, washer, or screw that secures over a threaded second end of each vertical reinforcement tendon. Additional methods include but not limited to physically deforming the vertical reinforcement tendon to also create the downward tension and stabilize the vertical reinforcement tendon.

(39) The single face shell provides access to vertical reinforcement tendon members for inspection, maintenance, and replacement, as well as access to wall interior during or after construction for installation of concealed building services, damp proofing, and insulation. Allowing access to wall interior results in decreases in construction time and increases in construction efficiency.

(40) The masonry unit of the present invention provides several distinct advantages: including but not limited to: singlet sided single face shell: access to interior of wall after erection, which: reduces trade scheduling dependencies; allows installation of: vertical reinforcing/post-tensioning tendon, damp proofing, insulation, building services (elec., plumbing, low-voltage, etc.), and allows inspection of building services (elec., plumbing, low-voltage, etc.) after the wall is erected.

(41) The masonry unit of the present invention also provides an open system, which allows for: modular coursing with standard block; works with installation of conventional non-proprietary (e.g., inexpensive) insulation systems; allows typical or conventional installation for electric, or plumbing), or low-voltage systems; and supports typical interior/exterior finishes other than masonry if desired.

(42) Another advantage of the masonry unit of the present invention is that is uses less material per square foot of wall area (efficient with material and labor) and more wall area per unit (in particular when used as a one-handed unit for installation). Another advantage is that the units can be nested for shipping, pressing and curing, which allows for more efficient manufacturing and palletizing, shipping, and/or staging.

(43) Additional advantages of the masonry unit of the present invention includes that the masonry units are reversible (integral masonry surface (e.g., the face shell) can be inside or out) allowing an earlier building dry-in for accelerated construction schedules. Other advantages include: reinforcing options/flexibility, such as: conventional grouted rebar; and no-grout post-tensioned reinforcing. The masonry units allow for true back dam flashing in single wythe construction, and it also allows industrial buildings to later be upgraded to more finished uses without supplemental framing.

(44) FIGS. 13A and 13B include two top views of masonry unit of the present invention showing two variations for providing mechanical strength to the wall, before, during or after installation. In FIG. 13A, a masonry unit 2, is shown with face shell 14 and webs 8a and 8b. A vertical reinforcement tendon 38 is shown within a grout 90, which is held in place while hardening using an integral knock-out 92. In FIG. 13B, a masonry unit 2, is shown with face shell 14 and webs 8a and 8b. A vertical reinforcement tendon 38, but in this version the post-tensioning of the rod provides all the support without the addition of a grout 90 or other packing materials in the space between webs 8a and 8b.

(45) FIGS. 14A, 14B, 14C, and 14D show various side views of wall assemblies positioned on various types of foundations. FIG. 14A shows a vertical reinforcement in which the wall assembly 50 is shown over a footing integrated with a slab on-grade edge. In FIG. 14B, the wall assembly 50 is shown over a continuous linear cast-in-place strip foundation. In FIG. 14C, the wall assembly 50 is shown over a compacted aggregate with steel tube and spreader plates. FIG. 14D shows the wall assembly 50 is shown over helical piers with steel tube and plates.

(46) FIGS. 15A, 15B, and 15C show three variants for mechanical support at the top of wall. FIG. 15A shows the use of a tube 92 and spreader plates 94 on wall assembly 50, in relation to the vertical reinforcement tendon 38. In the embodiment shown in FIG. 15B, grout 90 and longitudinal reinforcing is used within a beam 96, shown on wall assembly 50 also, in relation to the vertical reinforcement tendon 38. In FIG. 15C, grout 90 and longitudinal reinforcing is used within a continuous cavity formed by units supported by lugs and ridges of masonry units.

(47) FIGS. 16A, 16B, and 16C show examples of an embodiment of the present invention in which, once the wall has been assembled it can include various finishes using a configuration in which the face shell 14 serves as the exterior wall surface of wall unit 2. The face shell 14 serves as the exterior wall surface, which can be, e.g., sealed, painted directly, and/or can be pre-painted. The wall assembly 50 is shown with an internal damp-proofing 108, batt insulation 110 (also shown for illustration purposes as rigid insulation 114), which can be inserted with friction based on the size of the wall unit and the insulation, or attached with ties, and the interior wall 112. Also for purposes of illustration the interior wall can be a wall-board, e.g., sheetrock, concrete board, fiberglass, or wood (with or without a pre-existing moisture barrier), and/or brick 116.

(48) FIGS. 16D, 16E and 16F show examples of an embodiment of the present invention in which the wall, once assembled, has a face shell 14 serves as the interior wall surface. The face shell 14 serves as the interior wall surface, which can be, e.g., sealed, painted directly, and/or can be pre-painted. The wall assembly 50 is shown with an internal damp-proofing 108, batt insulation 110 (also shown for illustration purposes as rigid insulation 114), which can be inserted with friction based on the size of the wall unit and the insulation, or attached with ties, and the interior wall 112. Also for purposes of illustration the exterior wall can be a wall-board, e.g., concrete board, fiberglass, metal, or wood (without or without a pre-existing moisture barrier), and/or brick 116.

(49) FIG. 17A is an isometric view, FIG. 17B a side view, FIG. 17C is a top-view and FIG. 17D is another side view of an individual wall unit 2, which includes a single face shell 14 with an interior surface 4, and two webs 8a and 8b integral with or attached to the face shell 14. As depicted in FIG. 17A, this embodiment of the individual wall unit 2 further includes notches 150a, 150b at the end of the two webs 8a and 8b opposite the face shell 14 that can be used, e.g., as a ledge for a HAT or furring channel. Also shown in FIG. 17A is a channel 152, designed to receive fasteners, e.g., to receive a tension clip for the attachment of interior finish framing (not shown). In addition, another optional feature shown in this embodiment of the individual wall unit 2 are cut index marks 154a, 154b, and 154c. The cut index marks 154a, 154b, and 154c are spaced to provide convenient marks for cutting the individual wall unit 2 to form corners, door or window jambs. The face shell 14 is depicted in this embodiment having a reduced concrete volume by tapering the interior surface 4 of the face shell 14, until either end of the face shell is reached, wherein the face shell 14 is thickened to a uniform thickness, e.g., 1 inches. The edges of the two webs 8a and 8b are shown having rounded internal edges to facilitate manufacturing of the units. The two webs 8a and 8b are shown forming an opening or gap 16 between the webs 8a and 8b.

(50) FIG. 18 illustrates an embodiment of a unit 2 similar to the embodiment shown in FIG. 1 in that the distal ends of webs 8a, 8b are coupled together. However, in this embodiment, a ledge 250 extends from the outer surfaces of the distal ends 8a, 8b in the direction of an axis C-C that extends orthogonal to an axis A-A that extends through the top 10 and bottom surfaces 12 of the face shell 14 and an axis B-B that extends through the ends 30, 32 of the face shell 14. The ledge 250 includes a horizontal surface 251 that is spaced apart from and between the top surface 24 and the bottom surface 26 of the webs 8a, 8b. The horizontal surface 251 lies within a plane that extends substantially parallel to the axes B-B and C-C.

(51) It is contemplated that any embodiment discussed in this specification can be implemented with respect to any method of construction. It will be understood that particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention can be employed in various embodiments without departing from the scope of the invention. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.

(52) All publications and patent applications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

(53) The use of the word a or an when used in conjunction with the term comprising in the claims and/or the specification may mean one, but it is also consistent with the meaning of one or more, at least one, and one or more than one. The use of the term or in the claims is used to mean and/or unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and and/or. Throughout this application, the term about is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.

(54) As used in this specification and claim(s), the words comprising (and any form of comprising, such as comprise and comprises), having (and any form of having, such as have and has), including (and any form of including, such as includes and include) or containing (and any form of containing, such as contains and contain) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps. In embodiments of any of the compositions and methods provided herein, comprising may be replaced with consisting essentially of or consisting of. As used herein, the phrase consisting essentially of requires the specified integer(s) or steps as well as those that do not materially affect the character or function of the claimed invention. As used herein, the term consisting is used to indicate the presence of the recited integer (e.g., a feature, an element, a characteristic, a property, a method/process step or a limitation) or group of integers (e.g., feature(s), element(s), characteristic(s), propertie(s), method/process steps or limitation(s)) only.

(55) The term or combinations thereof as used herein refers to all permutations and combinations of the listed items preceding the term. For example, A, B, C, or combinations thereof is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.

(56) As used herein, words of approximation such as, without limitation, about, substantial or substantially refers to a condition that when so modified is understood to not necessarily be absolute or perfect but would be considered close enough to those of ordinary skill in the art to warrant designating the condition as being present. The extent to which the description may vary will depend on how great a change can be instituted and still have one of ordinary skilled in the art recognize the modified feature as still having the required characteristics and capabilities of the unmodified feature. In general, but subject to the preceding discussion, a numerical value herein that is modified by a word of approximation such as about may vary from the stated value by at least 1, 2, 3, 4, 5, 6, 7, 10, 12 or 15%.

(57) All of the compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.

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