Insulated Concrete Masonry System

Abstract

An insulated masonry wall system comprised of special blocks of 24″×16″×8″ dimension filled with reclaimed rubber crumbs resulting in high R values to resist transmission of heat and cold. Insulation is blown and vibrated into the special concrete blocks as walls are developed. Construction of wall will be similar to standard masonry blocks. Facings attached to the blocks can be vinyl and wood siding, brick, stucco, textured acrylic finish, fiber-cement siding hardboard, photovoltaic siding, and wood shakes.

Claims

1. A special 24″×16″×8″ concrete block with actual dimensions of 151/2″×71/2″×231/2″ having four smooth sides that can be rotated to produce a smooth sided corner arrangement with alternating joints for wall construction.

2. A special 24″×16×8″ concrete block with admixtures, pigments, or glazers added to give blocks increased compressive strength, decorative effect, or provide protection against deterioration.

3. A special 24″×16″×8″ concrete block with internal slots for reinforcement rod insertion when utilized in residential, institutional, religious, commercial, and industrial building construction to further increase structural strength in earthquake and other severe calamity areas.

4. Rubber crumbs obtained from chopped and granulated new and recycled and recycled tires inserted by air pressure and agitation into hollow block cavities, during construction.

5. Blocks to be offset by 8″ as each row is formed during construction.

6. Blocks to be permanently secured together with mortar premix (comprised of a blend of portland cement, lime and masonry sand) per present cement type construction.

7. Blocks to be positioned so that the 16″ face is exposed to outside wall surface per present block construction. Exception is at corners where alternate 16″ and 8″ surfaces are exposed.

8. Blocks to be positioned to obtain a 24″ thickness of wall, resulting in maximum structural strength and thermal resistance.

9. Outside surface of wall construction modified to include coatings, brick veneer and sidings, including photovoltaic sidings.

10. To simplify and increase building construction strength, steel joist hangers are attached to special blocks during construction to support floor joists.

11. To resist hurricane, tornado, and other weather related conditions, hurricane straps and roof connectors are attached to special blocks to further increase building strength.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1—General Description of the Special Block

[0017] FIG. 2—Wall Construction Without Insulation

[0018] FIG. 3—Addition of Rubber Insulation

[0019] FIG. 4—Corner Wall Construction

[0020] FIG. 5—Surface Application-Layers of Stucco on Concrete Blocks

[0021] FIG. 6—Surface Application-Layers of Textured Acrylic Finish (TAF) on Concrete Blocks

[0022] FIG. 7—Surface Application-Brick Veneer on Concrete Blocks

[0023] FIG. 8—Surface Application-Various Siding on Concrete Blocks

[0024] FIG. 9—Hurricane and Tornado Proof Building Construction

[0025] FIG. 10—Detail Drawing of Special Block

[0026] FIG. 11—Detail Drawing of Special Block with Crumb Rubber

[0027] FIG. 12—Technique for Locating Reinforcing Rods in Foundation for Insulated Masonry System

[0028] FIG. 13—Installation of Reinforcement Rods in an Insulated Masonry System

[0029] FIG. 14—Installation of Modified USP 2″×8″ Joist Hanger on Special Cement Blocks

REFERENCED DIMENSIONS

[0030] a-Nominal Dim=16″ (Actual 15.63″)

[0031] b-Nominal Dim=8″ (Actual 7.63″)

[0032] c-Nominal Dim=24″ (Actual 23.63″)

[0033] d-8″ Overlap

[0034] Typically, the interior wall finish is gypsum wallboard. To attach the wallboard to the special blocks the wallboard installer places a vapor barrier (plastic film) against the inside surface of the blocks. Furring strips are attached with screws to the film and blocks and the wallboard is then glued or screwed to the furring strips.

[0035] Different finishes go on to the foundation walls (1) and the course of the building above. The concrete blocks of the foundation and the blocks exposed above ground need to be covered by a material with high impact resistance to avoid damage from landscaping and other equipment. Installers typically use wire mesh covered by a layer of stucco or stucco-like coatings that do not require the mesh.

[0036] The most widely used exterior finishes include: [0037] a) FIG. 5 describes stucco on concrete blocks utilizing brown coat (12), scratch coat (13), lath (14), and finish coat (15). [0038] b) FIG. 6 describes layers of textured acrylic finish (TAF) on concrete blocks utilizing top coat (16), base coat (17), fiberglass mesh (18), and color coat (19). [0039] c) FIG. 7 describes brick veneer on concrete blocks utilizing brick (20), on ledge (21), and finishing (22). [0040] d) FIG. 8 describes vinyl, beveled wood, fiber-cement, photovoltaic siding, and hardboard wood shakes and shingles which utilizes shingles (23) and tar paper (24). Wood sheathing (6) next to the concrete block is glued to the block and acts as a vehicle to staple, nail, or screw siding (23) to during installation. Also, to install necessary photovoltaic siding wiring, a space is provided between sheathing to utilize tubing (31) for wiring.

[0041] Further increases in R-value can be accomplished by the addition of outsulation (EIFS) cadding systems by Dryvit.

[0042] An additional feature of our special wall installation (FIG. 9) is the use of USPHW with heavy-duty welded joist brackets (8), which can be slipped in while he walls are erected (FIG. 14). This simplifies the installation of the floor joists (27) in buildings (FIG. 9). Also shown is the ease of installing hurricane straps (26), and roof connectors (25) on roof frame (29) to protect structures from hurricane and tornado damage on insulated concrete masonry systems (28).

[0043] Also, to achieve maximum insulated concrete masonry system strength for extreme weather-related conditions, steel reinforcement rods (30) can be added (FIGS. 12 and 13). Layout of reinforcement rods can be simplified by the use of wooden templates (5) (FIG. 12).