EP2397619A1

EP2397619A1 - System of self supporting masonry walls and building procedure

Info

Publication number: EP2397619A1
Application number: EP11170144A
Authority: EP
Inventors: Luis Adell López; Manuel Serra Armangué
Original assignee: Geo-Hidrol SA; Torho SA
Current assignee: GEO-HIDROL, S.A.; Torho SA
Priority date: 2010-06-16
Filing date: 2011-06-16
Publication date: 2011-12-21
Also published as: ES2385010B1; ES2385010A1

Abstract

System (1) of self-supporting masonry walls and procedure for their construction. The system (1) comprises an assembly of interlocking masonry pieces (2) with inward cuts (3), outward protuberances (4) and grooves (5) on the top edges and on the upper and lower faces, and reinforcing bars (7) placed on the plane of the masonry pieces (2) of some of the courses. The reinforcing bars (7) are placed on grooves (5) bored longitudinally in the plane of the masonry pieces (2), and the masonry pieces (2) comprise some recesses (6) placed on the upper face following a predetermined sequence, coinciding with the sequence of the positions of some respective parts of reinforcing bars (7) that are lodged in said recesses (6). There are joining means placed on reinforcing bars (7) in recesses (6) of the upper face of masonry pieces (2) to immobilize the reinforcing bars (7) in a longitudinal direction.

Description

Field of the Invention

The present invention refers to a system for constructing masonry walls using prefabricated masonry pieces made from any material and other auxiliary elements, joined in a mechanical manner, having its main application in the construction of monolithic self-supporting walls, with strong structural features. It also refers to a construction procedure of said self-supporting masonry walls.

Background of the Invention

Currently there are systems for building dry joint walls (without mortar), in which it is not possible to incorporate reinforcing bars that carry out a unifying structural role with the pieces, unless said reinforcing bars are inlaid in concrete or mortar to enable the transmission of forces by adherence.
Thus, for example, Spanish Patent 2061377 , entitled "System of construction of enclosures and habitats", which refers to a system with walls supported on a foundation in which the foundation comprises an inferior granular base, a course of prefabricated solid blocks embedded in line, and an upper distribution plate; this upper distribution comprises a tied reinforcing rod inserted into the cited blocks, at least partially, and covered by a cap of cement or concrete running the length of the course of blocks, with a width equal to or slightly wider than the wall, and with the embedded reinforcing rods.
Walls made without interior reinforcing have some mechanical conditions that could be subpar for transmitting the actions that bear directly on the wall to the structure of the building, basically the lateral actions caused by wind or earthquakes.
A consequence of the fact that reinforcing bars cannot be incorporated in dry joint systems is that the elements cannot be self-supporting, given that they do not provide a monolithic structural response. This translates into the need to recur to an auxiliary support structure for the wall itself. This type of wall cannot perform any structural performance functions because when enduring certain forces the wall collapses. The structural performance functions dependent on these elements are entrusted to the auxiliary support elements.
There are also construction systems for self-supporting walls that resolve all of the structural performance functions in the thickness of the wall itself, with embedded auxiliary reinforcement elements. But in this case, the force transfer is always done by adherence, for which it is absolutely necessary that the interlocking pieces and their connection to the reinforcement elements be executed with mortar or any other conglomerate.

Summary of the Invention

The object of the instant invention is to provide a system of self-supporting masonry walls with high structural functions that do not require mortar or any other type of conglomerate to be built.
The invention teaches a system of self-supporting masonry walls, that comprises an assembly of interlocking masonry pieces with inward cuts, outward protuberances and grooves on the top edges and on the upper and lower faces, and reinforcing bars placed on the plane of the masonry pieces of some of the courses, in which:

reinforcing bars are placed on grooves bored longitudinally in the plane of the masonry pieces,
the masonry pieces comprise some recesses placed on the upper face following a predetermined sequence, coinciding with the sequence of the positions of some respective parts of reinforcing bars that are lodged in said recesses,

The invention also teaches a procedure of constructing self-supporting masonry walls, that employs the above system and that comprises the following steps:

layout and level the first course of masonry pieces so as to correctly position the starting point of the wall,
insert reinforcing bars on the plane of masonry pieces,
place the connecting means on reinforcing bars in recesses of the upper face of masonry pieces,
engage pieces of the second course on top of the first course without the need of controlling the level or plumb,
lay several courses without reinforcing bars,
lay a course inserting reinforcing bars and joining means every few courses of the wall.

The complete elimination of any type of mortar in the construction of the wall implies numerous advantages in relation to the ease of assembly, the results in the execution and the excellent conditions of the exterior finish that is obtained without the need of using traditional leveling techniques, plumbs and levels.
The elimination of mortar in the composition of the wall also implies a substantial improvement in the energy efficiency of the element, as well as the elimination of any pathological risk in the process derived from this component, and notably reduces the conditions needed for an adequate maintenance.
The elimination of the mortar also leads to an elimination of a variable in the calculations with very disperse and highly unreliable mechanical performances. It also implies eliminating the secondary effects of the behavior of the wall, incorrect installation of the joints, or deficient elaboration conditions, fabrication and curing of the mortar.
Another advantage of the invention lies in the extraordinary ease of construction of the wall. This is because it is only necessary to set the first course; the rest of the wall is raised engaging pieces, and so the verticality and flatness of the element is guaranteed the whole time, without requiring the service of a person skilled in masonry.
With the system that is the object of the invention being proposed, everything is obtained without diminishing the required mechanical performance of this type of construction elements.
Other advantageous embodiments of the invention are disclosed in the dependent claims.

Brief Description of the Drawings

The following will show, in a non-exclusive manner, the object of the present invention with reference to the accompanying figures, in which:

Figure 1 shows a perspective view of the construction system of the invention with the masonry pieces assembled.
Figure 2 shows a detailed perspective view of the lodging of the reinforcing rods in the masonry pieces.
Figure 3 shows a detailed perspective view of the staple for immobilizing the reinforcing rods in a longitudinal direction.
Figure 4 shows a perspective view of the construction system of the invention with the reinforcing rods in the overlapping zone, in which the length of the overlap implies a soldered junction of each reinforcing bar in the lattice.
Figure 5 shows a perspective view of the construction system of the invention with the reinforcing rods in the overlapping zone, in which the length of the overlap implies two soldered junctions of each reinforcing bar in the lattice.
Figure 6 shows a detail in perspective view of the system of the invention with an overlapping zone at the ends of the reinforcing rods.
Figure 7 shows a sectioned detail of a wall with reinforcing rods inserted and with a mechanical overlapping device in the shape of a staple cutting through the overlapping zone.
Figure 8 shows a sectioned detail of a wall with reinforcing rods inserted cutting through the overlapping zone.

Detailed Description of the Invention

Figures 1 to 3 show system 1 of self-supporting walls of the invention and the main constituting elements of the same, namely, masonry pieces 2, reinforcing rods 7 and the joining means (in the shape of joining staples 9 in Figure 3), the purpose of which is to obtain dry joint constructed masonry units with structure performances of solidity and monolithic character, so that that walls constructed in this way are self-supporting without the need of any auxiliary exterior support structure.
Specifically, Figure 1 shows a perspective view of several engaged masonry pieces 2. This Figure and Figure 2 shows the interlocking masonry on the plan and on the top edge, as well as the grooves bored in said pieces 2 for lodging reinforcing bars 7.
System 1 enables a perfect engagement between masonry pieces 2, both if available in the classic pairing and if carried out with continuous joints, due to the specific geometry of the same, with grooves and protuberances in the plane and on the edges, that enable the coupling of pieces 2 by the interlocking procedure both horizontally and vertically.
System 1 likewise presents an efficient joining of pieces 2 and the metallic elements that constitute the interior reinforcing bars of the wall, by means of mechanical devices that act in the manner of staples 9 (one of which is represented in Figure 3), enabling the assembly to have the corresponding structural behavior of an monolithic element capable of resisting bending forces having a considerable value.
The following is a more detailed description of the main elements constituting system 1.

Masonry pieces:

Masonry pieces 2 constituting elements of system 1 may be made of any of the materials customarily used. When speaking of masonry pieces reference is made to those units that can be a hydraulic based material (concrete blocks), ceramic materials (baked clay), artificial stone, etc.
The sizes of pieces 2 can vary, although they must meet two basic requirements. The first requirement is that they must have a weight that permits manual placement by a single worker. The second requirement is that they must have a width of no less than 110mm so that the resulting walls will have the possibility of being self-supporting, that is, that they can hold themselves up without the need of profile elements or auxiliary support substructures.
The geometry of pieces 2 is specific so as to enable their assembly through interlocking, without the need of any type of mortar in the construction of the wall. For this end they have inward cuts 3 and outward protuberances 4, and grooves 5 in the joining faces. There is only one position in which pieces 2 interlock with the next, which ensures a perfect plumbing and leveling of the constructed wall.
Furthermore, pieces 2 have cavities that cross the wall horizontally, to make possible the drainage of runoff water that could penetrate from the exterior or porous humidity from condensation or construction that exists in the layers of the external walls.
The basic geometrical feature of pieces 2 that constitute system 1 are recesses 6 bored in the plane to enable the lodging of horizontal reinforcing rods 7, and which are best observed in Figure 2. Said recesses 6 must follow a predetermined sequence that coincides with the sequences of soldered junctions 13 of reinforcing bars 7.

Reinforcing bars:

Reinforcing bars 7 are prefabricated elements, in general metallic, with different geometric configurations, with an essential requirement that they cannot be deformable in their plane. They can be constituted by steel bars, in a lattice configuration, with two longitudinal cords 11, joined at their vertices by soldering with another diagonal cord in zigzag 12, forming a triangular shape (as shown in Figures 1 and 2). They can also be constituted by sheet metal with the corresponding tabs folded to enable the engagement in the grooves of pieces 2 (not shown in the figures).
The sequence of the lattice steps (when reinforcing rods 7 are made of bars) or the sequence of the position of the engaging tabs (when reinforcing rods 7 are made of folded sheet metal) must have the same sequence as recesses 6 of pieces 2, so as to enable their correct lodging.
Reinforcing rods 7 are placed in the grooves bored in the plane of pieces 2, which must run horizontally along the entire length of the wall. The length of reinforcing rods 7 is variable, according to manufacturing and transportation conditions, although in the calculations they must be considered continuous. Therefore, it is necessary to adequately resolve the overlaps with mechanical overlapping devices that enable the correct transmission of forces.
The exterior protection of the metallic material that constitutes reinforcing rods 7 must be adequate for resisting, without rusting, the possibility of humidity entering the interior of the wall.
Figure 2 shows a detailed perspective view of Figure 1, in which can be seen reinforcing rods 7 consisting in steel rods of a triangular truss type and their lodging in masonry piece 2. Figure 2 shows recesses 6 in the plane of pieces 2, conveniently spaced to leave the space necessary for soldered junctions 13 of reinforcing rods 7. Longitudinal cords 11 of reinforcing rods 7 are left encased in the horizontal grooves that run continuously in the plane of pieces 2. With this the wall is endowed with a monolithic character to enable it to withstand lateral actions perpendicular to its plane.

Connecting Means:

For reinforcing rods 7 to be able to fulfill their purpose of withstanding lateral bending or vertical bending forces (as the case may be) that the wall must transmit, it is absolutely necessary that the horizontal movement of pieces 6 and reinforcing rods 7 be compatible. This requires an efficient connection between both elements so that the reinforced wall may be considered an assembly with monolithic behavior, and differential movements may be avoided in a longitudinal direction between reinforcing rods 7 and masonry pieces 2.
System 1 foresees the connection of reinforcing rods 7 and masonry pieces 2 by means of a connection like joining or immobilization staples 9 (see Figure 3), that function by pressure. Staple 9 is placed in its corresponding location in recesses 6 of the plane of masonry piece 2 and when piece 2 is coupled staple 9 exerts the necessary pressure for the connection of reinforcing rod 7 with masonry piece 2. The number of staples 9 or the sequence required for them must be determined by calculating.
In conventional systems of reinforced walls this connection is accomplished by adherence with mortar.
Given that the length of reinforcing rods 7 is limited, generally it becomes necessary to use and couple several of them to construct walls that will overlap at a determined length according to the invention, so as to give continuity to reinforcing rods 7.
Figures 4 and 5 are perspective views of the schematics of system 1 with connecting rods 7 in the overlap points. The length of the overlap must be sufficient so that at least one junction 13 of each reinforcing rod 7 is left connected with the same. The rods overlap vertically, in such a way that reinforcing rod 7 are left superimposed on different planes.
Figure 4 shows a perspective view of system 1 constituting the invention, with reinforcing rods 7 in the overlap zone 10, in which the length of the overlap implies a junction 13 of each latticed reinforcing rod 7.
Figure 5 shows a perspective view of system 1 constituting the invention, with reinforcing rods 7 in overlap zone 10, in which the length of the overlap implies two junctions 13 of each latticed reinforcing rod 7.
Figure 6 is a detailed perspective view of system 1 of the invention, in which two lengths of reinforcing rods 7 are represented with their overlap zone 10, and in which it can be seen that the length of the overlap implies two junctions 13 of latticed reinforcing rods 7.
To ensure the joining of reinforcing rods in the zone of overlap 10, mechanical overlap devices may be employed (not represented in Figures 4, 5 and 6, but represented in Figure 7). One example of the mechanical overlap device could be connecting staple 9 (see Figure 7), which, besides carrying out its function of connecting a section of reinforcing rods 7 to masonry piece 2, can also connect the two overlap zones 10 of two consecutive sections of reinforcing rods 7.
Said Figure 7 is a sectioned detail view, formed by cutting around overlap zone 10, of a wall with reinforcing rods incorporated and a mechanical overlap device in the form of connecting staple 9.
Figure 8 is a sectioned detail cut around the zone of the overlap, with reinforcing rod 7 incorporated. The section of piece 2 is shown corresponding to a vertical half plane, as well as the lodging grooves of reinforcing rods 7. The detail shows the placement of reinforcing rods overlapping vertically.
In this detail the geometry of sectioned piece 2 is shown, in which can be seen inward cut 3 and outward protuberance 4 on the plane for the perfect engagement of the same.
Also seen is the lower cutout or hollow 14 of the transversal partitions 8, for forming a continuous drainage cavity in the base.
System 1 of the invention can also comprise optionally other support elements capable of being incorporated into it, such as the connectors or anchoring devices (not shown). These elements have the function of keeping the wall from overturning and transmitting the reactions generated in the edges of the wall to the structure, stemming from its structural task. These devices are efficiently connected to reinforcing rods 7 with mechanical type processes, by means of pressure or engagement.
The position of the anchoring devices must be in the grooves that are provided for reinforcing rods 7, horizontally separated with the same sequence (or multiple thereof) that the 6 recesses located on the plane of pieces 2 have.
Preferably devices that administer a selective reaction against the building structure should be used, in such a way that they permit some determined movements (in particular, the contents in the plane of the wall) and prevent others, so as to avoid pathological processes provoked by local accumulations of tension.
Thus the auxiliary elements enable connecting the wall to the structure and to the rest of the construction elements of the buildings if the particular situation of the wall so requires.
Thus with system 1 of the invention a construction procedure is obtained of self-supporting masonry walls that are extremely simple and comprise the following steps:

layout and level the first course of masonry pieces 2 so as to correctly position the starting point of the wall,
insert reinforcing bars 7 on the plane of masonry pieces 2,
place the connecting means on reinforcing bars 7 in recesses 6 of the upper face of masonry pieces 2,
engage pieces 2 of the second course on top of the first course without the need of controlling the level or plumb,
lay several courses without reinforcing bars 7,
lay a course inserting reinforcing bars 7 and joining means every few courses of the wall.

The course interspersed with reinforcing bars 7 and connecting means like connecting staples 9 can be placed every 5 or 6 courses, for example.
The application of system 1 is very broad, given that a wall constructed in this manner not only holds itself up, but also can have an important structural function in the transmission of forces determined by calculation.
It serves for building weight bearing walls, partitions, basement walls and exterior cladding walls.
Although some embodiments of the invention have been described and represented, it is clear that modifications may be made that fall within its scope and the invention should not be considered limited to said embodiments, but only to the content of the following claims.

Claims

System (1) of self-supporting masonry walls, that comprises an assembly of interlocking masonry pieces (2) with inward cuts (3), outward protuberances (4) and grooves (5) on the top edges and on the upper and lower faces, and reinforcing bars (7) placed on the plane of the masonry pieces (2) of some of the courses, characterized in that:
- reinforcing bars (7) are placed on grooves (5) bored longitudinally in the plane of the masonry pieces (2),

- the masonry pieces (2) comprise some recesses (6) placed on the upper face following a predetermined sequence, coinciding with the sequence of the positions of some respective parts of reinforcing bars (7) that are lodged in said recesses (6),
and additionally in that it comprises joining means placed on reinforcing bars (7) in recesses (6) of the upper face of masonry pieces (2) to immobilize the reinforcing bars (7) on said masonry pieces (2) in a longitudinal direction.
System (1) of self-supporting masonry walls, in accordance with claim 1, characterized in that the joining means between reinforcing bars (7) and masonry pieces (2) are staples (9) in a wedge shape.
System (1) of self-supporting masonry walls, in accordance with claim 2, characterized in that reinforcing bars (7) are constituted by steel bars and are configured in a lattice.
System (1) of self-supporting masonry walls, in accordance with claim 3, characterized in that the lattice of reinforcing bars (7) is configured by two longitudinal cords (11) linked by another soldered cord in zigzag (12) at its vertices, forming soldered junctions (13) of reinforcing bars (7).
System (1) of self-supporting masonry walls, in accordance with claim 4, characterized in that the parts of reinforcing rods (7) that are lodged in recesses (6) on the upper face of masonry pieces (2) are soldered junctions (13)
System (1) of self-supporting masonry walls, in accordance with claim 1, characterized in that reinforcing bars (7) are made of sheet metal.
System (1) of self-supporting masonry walls, in accordance with claim 6, characterized in that the parts of reinforcing bars (7) lodged in recesses (6) of the upper face of masonry pieces (2) are folded tabs.
System (1) of self-supporting masonry walls, in accordance with any of claim 3 to 5, characterized in that it comprises overlapping zones (10) between consecutive reinforcing bars (7), with overlapping vertical bars, with mechanical overlapping devices to join reinforcing bars (7) in said overlapping zones (10), comprising each overlapping zone (10) of at least one junction (13) of each reinforcing bar (7).
System (1) of self-supporting masonry walls, in accordance with either of claim 6 and 7, characterized in that it comprises overlapping zones (10) between consecutive reinforcing bars (7) with mechanical overlapping devices to join reinforcing bars (7) in said overlapping zones (10).
System (1) of self-supporting masonry walls, in accordance with any of the previous claims, characterized by masonry pieces (2) that comprise transversal panels (8) with lower cutouts (14).
System (1) of self-supporting masonry walls, in accordance with any of the previous claims, characterized by the incorporation of connectors or auxiliary anchoring devices that enable the joining of reinforcing bars (7) and the structure and the rest of the construction elements of the building.
A procedure of constructing self-supporting masonry walls employing system (1) of any of claims 1 to 11, characterized by comprising the following steps
- layout and level the first course of masonry pieces (2) so as to correctly position the starting point of the wall,

- insert reinforcing bars (7) on the plane of masonry pieces (2),

- place the connecting means on reinforcing bars (7) in recesses (6) of the upper face of masonry pieces (2),

- engage pieces (2) of the second course on top of the first course without the need of controlling the level or plumb,

- lay several courses without reinforcing bars (7)

- lay a course inserting reinforcing bars (7) and joining means every few courses of the wall.