Building block

Abstract

A building block (10) is provided that comprises a top surface (11) and a bottom surface (12), a pair of longitudinal surfaces (13, 14) that are substantially parallel, and a pair of lateral surfaces (15, 16), the lateral surfaces (15, 16) extending between the longitudinal surfaces (13, 14), wherein the top surface (11) comprises a plurality of holes (21) extending towards the bottom surface (12) of the building block (10), and at least one groove (17) wherein the at least one groove (17) extend at least partially between the lateral surfaces (15, 16) of the building block (10).

Description

TECHNICAL FIELD

[0001] The embodiments described herein relate to a building block for a wall construction and a manufacturing method of such wall.BACKGROUND

[0002] Building blocks are traditionally developed for being used in the construction of buildings. They are usually ceramic and known for their significant durability as well as for offering high thermal insulation. Furthermore, due to their relatively low density (clay bricks typically include core holes while for example concrete bricks are usually frogged) they are light weight structures, thereby significantly decreasing the overall weight and cost of the structure.

[0003] In addition, conventional building methods typically comprise reinforced concrete masonry. A quite common reinforcement for a concrete masonry wall includes a steel wire that is laid in the mortar between the concrete blocks. Such methods have been found to provide increased resistance to forces that cause tensile and shear stresses. However, excessive use of concrete may result in significant increase of the construction cost. Moreover, the cost is further increased since in conventional building methods and in order to protect the building from exposure to extreme temperature conditions and adverse climatic factor, thermal facade is followed. Thermal facade is known to provide effective thermal insulation; however, it is a lengthy and costly process. Considering the above, further improvement is required to enhance the anti-seismic behaviour of the constructions, thereby increasing the level of safety of the building. Even more, improvement in thermal insulation techniques is required, while ensuring that the overall cost is also manageable. In view of these, there is a need for uncomplicated and complete construction solutions.

[0004] Load bearing reinforced masonry construction is a building technique wherein the wall elements are utilized as the framework of a structure, used for either interior or exterior walls. Even more, load bearing masonry including ceramic blocks is advantageous since ceramic blocks are resistant to corrosion and provide increased thermal efficiency. Therefore, a building method that could integrate the advantages of the load bearing reinforced masonry and of the building blocks would be beneficial for the construction industry.SUMMARY

[0005] According to a first aspect, a building block is provided. The building block is of substantially cuboid form and comprises a top surface and a bottom surface that is substantially parallel to the top surface, a first longitudinal surface and a second longitudinal surface, substantially parallel to the first longitudinal surface, a first lateral surface and a second lateral surface that is substantially parallel to the first lateral surface, said lateral sides extending between the first and second longitudinal surfaces, and at least one groove that extends between the first and the second lateral surfaces of the building block.

[0006] In embodiments, the building block is configured to receive within the at least one groove at least one horizontal reinforcing means.

[0007] In embodiments, the building block is configured to receive mortar within the at least one groove.

[0008] In embodiments, the building block comprises at least one cavity that extends from the top surface to the bottom surface of the building block.

[0009] In embodiments, the cavity is configured to receive vertical reinforcing means.

[0010] In embodiments, the cavity is configured to received mortar.

[0011] In embodiments, the building block comprises a plurality of vertical through holes extending from the top surface to the bottom surface of the block.

[0012] In embodiments, one or more or all of the plurality of holes are through holes, and they are filled with insulating material.

[0013] In embodiments, the insulating material is expandable polystyrene.

[0014] In embodiments, the horizontal and the vertical reinforcing means are steel rods.

[0015] In embodiments, a length (L) that is defined between the first and second lateral surfaces is of about 220mm and a width (W) that is defined between the first and second longitudinal sides is of about 300mm.

[0016] In embodiments, the at least one groove has a width that is less than 60mm and a depth that is less than 80mm.

[0017] In embodiments, the building block is a ceramic building block.

[0018] According to a second aspect, a method of constructing a wall is provided. The method comprises the steps of positioning two or more building blocks according to the first aspect the one next to the other, wherein second the lateral surface of a first block is adjacent to the first lateral surface of a second block, thereby forming a first row of blocks, placing at least one horizontal reinforcement means in at least one groove of each building block, placing mortar in the at least one horizontal grove of each building block, forming a second row of blocks superposed over the first row of blocks, wherein the cavity of the second upper row being above the cavity of the first lower row, thereby creating a vertical cavity throughout the entire wall, placing a vertical reinforcement means within the vertical cavity of the entire wall, placing mortar in the vertical cavity of the entire wall. The method may further comprise the step of filling with insulating material the vertical through holes that each building block may further comprise.

[0019] An effect of the technique of the present disclosure is to provide a building block that is advantageous for its mechanical and thermal properties while it ensures the overall safety of the construction of a building since it has highly effective anti-seismic properties.

[0020] It is also beneficial for the personnel that will carry out the building process since its application does not require any special skill and knowledge.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 illustrates an example of a building block according to an embodiment of the present disclosure. Figure 2 illustrates another example of side view of the building block according to an embodiment of the present disclosure. Figure 3 schematically illustrates a single building block of the present disclosure. Figure 4 schematically illustrates an example of a top view of the building block according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0022] According to the first aspect, the building block 10, which may be made of ceramic, clay, concrete or other suitable building material, has a substantially rectangular parallelepiped or cuboid form and comprises a top surface 11, a bottom surface 12, which is configured for being placed horizontally on a base surface, or on a lower row of blocks, a first longitudinal surface 13 and a second longitudinal surface 14 that is substantially parallel to the first longitudinal surface 13, both longitudinal surfaces being perpendicular to the top 11 and bottom 12 surfaces. The block further comprises a first lateral surface 15 and a second lateral surface 16, which are configured to be placed against the similar or corresponding surfaces of a previous and a next block, in order to form a row of building blocks. The block 10 comprises at least one groove that extends between the first and second lateral surfaces (15, 16) and can be considered as parallel to the longitudinal surfaces 13, 14. In examples, the block 10 may be configured to receive within the at least one groove at least one horizontal reinforcing means. The arrangement and the formation (engravement) of the groove 17 on the top surface 11 of the block 10 is highly advantageous since it allows the placement of the horizontal reinforcing means 18, without influencing the overall thermal efficiency of the building block 10. In detail, the thermal characteristics of the block remain unaffected, thereby mitigating any risk of thermal bridging that could result in durability implications and to undesired condensation within the components or walls of a building. In examples, mortar may be placed within the at least one groove of the building block 10.

[0023] An exemplary configuration of the building block comprises a single groove 17, which may receive a steel rod 18 or any other suitable material as horizontal reinforcement of the wall. During experimentation and further research, it was found that the structural strength and stability of the construction would be further improved, if the block was provided with two substantially horizontal grooves 17, as it can be seen in figures 1-4, which would receive two respective reinforcement means, such as steel rods 18. A second exemplary configuration of the building block may comprise two grooves, without undermining the advantages of the simplest configuration comprising only one groove. This last embodiment could be used for example in simpler, lower cost constructions.

[0024] The groove or grooves 17 may have a width that is less than 60mm and a depth that is less than 80mm, depending on the type of reinforcement means 18 which will be used and the amount of mortar which will be elected to be used, in order to get the desired strength of the wall.

[0025] In examples, the building block 10 may further comprise at least one groove or cavity 19 that extends from the top surface to the bottom surface of the block 10. The cavity 19 is configured to receive vertical reinforcing means 20, such as one or more steel bars 20. The vertical means 20 are therefore mounted within cavity 19. In the frame of the current disclosure, the term "vertical reinforcing means" 20 should be understood as vertical relative to the horizontal reinforcing means 18.

[0026] It has to be mentioned that the formation of a cavity 19 where the vertical reinforcing means 20 is placed, facilitates the construction of the block since it eliminates the need of the formation of, for example, a hole that would request to break, and therefore damage at least a part of the bricks. In examples, the cavity 19 is formed on the first lateral surface 15 and extends towards the second lateral surface 16. Further, the vertical reinforcing means, or bar 20 is used to strengthen and aid the block 10 under tension, thereby increasing the tensile strength of the structure. More than one vertical reinforcing bars 20 may be contemplated, depending on the size of the block, without deviating from the scope of the current specification. It can be derived therefore, that the combination of the at least one groove 17 where respective horizontal reinforcing bars 18 are mounted and of the vertical reinforcing bar 20 within the cavity 19, result in a construction solution with significantly improved anti-seismic properties that is not susceptible to adverse climatic or environmental conditions.

[0027] In other examples (not shown), the at least one groove 17 extend fully from the first longitudinal surface 13 to the second longitudinal surface 14.

[0028] In examples, the at least two horizontal reinforcing means 18 extend over the longitudinal length of the building block 10, thereby further ensuring the anti- seismic properties and the structural integrity of the block 10. In examples, the horizontal 18 and the vertical 20 reinforcing means may be made of steel which has excellent compressive and tensile strength as well as high durability.

[0029] In examples, the building block 10 comprises a plurality of vertical holes extending from the top surface 11 to the bottom surface 12 of the block 10.

[0030] In examples, one or more or all the plurality of the holes of the block 10 are through holes. Such holes are desired to ensure the structural integrity of the structure while at the same being able to receive the necessary insulation. In one example, one or more or all of the through holes are filled with insulating material which may be expandable polystyrene (EPS) which provides excellent thermal and acoustic insulation while it has long lifetime durability. In examples, the at least one groove 17 comprise a layer of mortar that is used as a joint element for connecting two or more building blocks. In examples, the mortar layer is a mixture of cement and materials of small grain size. Such layer of mortar provides enhanced compressive strength. In examples, mortar may be also used to fill the cavity 19, thereby further ensuring the structural strength of the block and consequently of the wall.

[0031] The building block 10 according to the current disclosure, provides the benefits of a complete and reliable building solution since it combines a plurality of advantages. The presence of both horizontal reinforcement means 18 and of at least one vertical reinforcement means 20, being mounted within the groove 17 and within the cavity 19 respectively, significantly enhance the anti-seismic properties of the block, thereby ensuring the safety of the structure. Further, the fact that the through holes of building block 10 may be filled with insulating material results in the mitigation of the necessity of any thermal facade on the outer surface of a building. Consequently, the overall cost of the construction is reduced while the timing that is required to complete a building is reduced, while having the highest quality standards. Moreover, such combination of elements as described herein, meaning the at least one groove 17 and the insulating material in the holes of the block 10, result in the need of a relatively thinner layer of mortar to be used as joint, when compared to conventional layers of mortar. In an example, the layer of the mortar according to the current concept may be of about 3mm. This is significantly thinner when compared to conventional blocks where the thickness of the layer of the mortal is normally about 12mm.

[0032] In examples, the building block 10 comprises a length L that is defined between the first and second lateral surfaces (15, 16). In a typical building block 10 according to the present specification such length L may be between 150-300 mm, more specifically between 200-250mm, most specifically of about 220mm. Moreover, building block 10 has a width W that is defined between the first and second longitudinal surfaces (13,14). Such width W may be between 200-400mm, more specifically between 250-350mm and most specifically of about 300mm. In examples, the building block is of substantially cubical shape.

[0033] According to a second aspect of the disclosure, a method of manufacturing a wall is provided. The method comprises the steps of positioning two or more building blocks 10 the one next to the other, wherein the second lateral surface 16 of a first block 1 is adjacent to the first lateral surface 15 of a second block 2, thereby forming a first row of blocks that will consequently form a wall. The method further comprises placing at least one reinforcement means in at least one horizontal groove of each building block and placing mortar in the at least one horizontal grove of each building block and forming a second or upper row of blocks superposed over the first row of blocks. The cavity of the upper row is above the cavity of the first lower row, thereby creating a vertical cavity throughout the entire wall. The method further comprises placing a vertical reinforcement means within the vertical cavity of the entire wall and then placing mortar in the vertical cavity of the entire wall.

[0034] The method may further comprise the step of filling with insulating material the vertical through holes that each building block may further comprise.

[0035] Any number of building blocks can be contemplated, depending on the desired construction, without deviating from the scope of the present specification. With that arrangement, which is different from the widely used crosswise method of building bricks, precise joining of the block is succeeded while there is ensured the structural integrity of the constructed wall. Although the present disclosure herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure.

[0036] It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims.

Claims

1. A building block (10) of substantially cuboid form comprising: a. a top surface (11) and a bottom surface (12) substantially parallel to the top surface (11), b. a first longitudinal surface (13) and a second longitudinal surface (14), substantially parallel to the first longitudinal surface, c. a first lateral surface (15) and a second lateral surface (16), substantially parallel to the first lateral surface (15), said lateral surfaces extending between the first and second longitudinal surfaces and d. at least one groove (17) wherein the at least one groove extends between the first (15) and the second (16) lateral surfaces of the building block (10).

2. The building block (10) according to claim 1 being configured to receive within the at least one groove (17) at least one horizontal reinforcing means (18).

3. The building block (10) of claim 2 being configured to receive mortar within the at least one groove (17).

4. The building block (10) according to claims 1-3 comprising at least one cavity (19) that extends from the top surface (11) to the bottom surface (12) of the building block (10).

5. The building block (10) according to claim 4, wherein the cavity (19) is configured to receive vertical reinforcing means (20).

6. The building block (10) according to claim 5, being configured to receive mortar within the cavity (19)7. The building block (10) according to any of the preceding claims, comprising a plurality vertical through holes (21) extending from the top surface (11) to the bottom surface (12 of the block (10).

8. The building block (10) according to claim 7 wherein one or more or all the plurality of holes are configured to be filled with insulating material.

9. The building block (10) according to claim 8 wherein the insulating material is expandable polystyrene.

10. The building block (10) according to claims 5-9 wherein the horizontal (18) and the vertical (20) reinforcing means are steel rods.

11. The building block (10) according to any of the preceding claims wherein the groove (17) has a width that is less than 60mm and a depth that is less than 80mm.

12. The building block (10) according to any of the preceding claims wherein a length (L) that is defined between the first and second lateral surfaces (15, 16) is of about 220mm and a width (W) that is defined between the first and second longitudinal sides (13, 14) is of about 300mm.

13. The building block (10) according to any of the preceding claims, wherein the block (10) is a ceramic block.

14. A method of manufacturing a wall comprising the steps of: a. positioning two or more building blocks (10) according to claims 1-13 one next to the other, wherein the second lateral surface (16) of a first block (10) is adjacent to the first lateral surface (15) of a second block (10), thereby forming a first row of blocks (10), b. placing at least one reinforcement means (18) in at least one horizontal groove (17) of at least one building block (10) c. placing mortar in at least one horizontal groove (17) of each block (10) d. forming a second row of blocks superposed over the first row of blocks, wherein the cavity (19) of the second upper row being above the cavity (19) of the first lower row, thereby creating a vertical cavity 19 throughout the entire wall, e. placing a vertical reinforcement means (20) in the vertical cavity (19) of the entire wall. f. Placing mortar in the vertical cavity (19) of the entire wall.

15. The method according to claim 14 wherein each building block (10) comprises a plurality of vertical through holes and wherein the method comprises the step of filling at least one of said vertical through holes with insulating material.

Images