SG184953A1

SG184953A1 - Concrete hollow modules and a wall or room construction method using the same

Info

Publication number: SG184953A1
Application number: SG2012077848A
Authority: SG
Inventors: Kim Hai Tan; Lee Kam Loo
Original assignee: Innovative Precast Builders Sdn Bhd
Priority date: 2010-05-12
Filing date: 2011-05-12
Publication date: 2012-11-29
Also published as: CN103025978A; WO2011141884A1; MY154355A; CN103025978B

Abstract

A concrete hollow module (10) assumes essentially the shape of a rectangular block, with some profiling variations. Its body is provided with a plurality of vertically disposed cavities (13). Two substantially parallel raised ridges (14) are integrally provided on each elongated side of the top opening of the vertically disposed cavity (13). These raised ridges (14') on one concrete hollow module (10') cooperate correspondingly with a groove depression (15") on adjacent concrete hollow module (10") to form a first surface-to-surface interlocking tongue and groove mechanism. Protruded surface (I V ) on one end of one concrete hollow module (10') cooperates correspondingly with a depressed surface (12") on one end of adjacent concrete hollow module (10") to form a second end-to-end interlocking tongue and groove mechanism. Each end of the concrete hollow module (10) is also provided with two parallel vertical groove lines (16) whereby the wall section in between the two groove lines (16) can be knocked off. A wall or room construction method using the same is also taught.

Description

Title of Invention: CONCRETE HOLLOW MODULES AND A

WALL OR ROOM CONSTRUCTION METHOD USING THE

SAME

Technical Field

[1] The present invention relates to concrete hollow modules and a wall or room con- struction method using the same. Particularly, the present invention relates to concrete hollow modules constituting L-shaped corners, T-junctions or cross junctions where necessary during wall or room construction. Adjacent concrete hollow modules are provided with surface-to-surface and preferably end-to-end tongue and groove mechanisms, so that they interlock one another.

Background Art

[2] In wall or room construction, bricks or blocks usually are laid on their flat sides to form courses (horizontal layers). Bricks or blocks are staggered so that they lap over each other. Thus, it is possible to distribute loads over a large area. Mortar, 3 to 13 mm thick, is disposed between bricks or blocks to form vertical and horizontal joints. The mortar secures an even bearing, holds the bricks or blocks in position, and makes a tight wall or room.

[3] The length, width and height of a brick are typically 215 mm, 102.5 mm and 65 mm, respectively. Because of these dimensions, bricks are conveniently used to constitute

L-shaped corners, T-junctions or cross junctions during wall or room construction.

[4] The main disadvantage of brickwork is that bricks are comparatively small-sized and requires the skills of a bricklayer. Construction of brickwork is slow, time-consuming and becomes expensive.

[5] The length, width and height of a clay block are typically 300 mm, 62.5 mm to 150 mm, and 215 mm, respectively.

[6] The length, width and height of a concrete block are typically 390 mm to 590 mm, 60 mm to 215 mm, and 90 mm to 215 mm, respectively.

[7] With an increase in the length of the blocks, the speed of on-site construction is improved.

[8] In an earlier Malaysian Patent Number MY-128946-A, the inventors disclosed a con- struction method employing precast concrete hollow modules, comprising elongated modules and connector modules. These modules can be easily handled manually or mechanically. Each elongated module takes the form of an elongated hollow block. A wall is thus constructed by stacking a plurality of said elongated modules on top of one another. Four walls of an enclosure such as a room are then constructed by stacking correspondingly precast concrete hollow T- or L-shaped or cross connector modules which adjoin said walls.

[9] The main disadvantage of this earlier Malaysian patent is that different moulds are required to manufacture the elongated modules, T-shaped connector modules, L- shaped connector modules and cross connector modules. This invariably increases the cost and time of wall or room construction.

Summary of the Invention

[10] The present invention has therefore as a primary object to provide interlocking tongue and groove mechanisms on adjacent concrete hollow modules in a wall or room construction method using the same.

[11] Another object of the present invention is to reduce the cost of construction. Yet, another object of the present invention is to minimize the use of mortar between adjacent concrete hollow modules while interlocking them. Still, another object of the present invention is to incorporate some profiling variations on either one elongated side face or both elongated side faces of concrete hollow modules which are used in constructing wall configurations.

[12] These objects are achieved in that each concrete hollow module without or with profiling variation, being the basic building module, assumes essentially the shape of a block, preferably rectangular in shape.

[13] Two substantially parallel raised ridges are integrally provided on each elongated side of the top opening of a vertically disposed cavity in the concrete hollow module.

The bottom surface of the concrete hollow module is correspondingly profiled in the shape of a groove depression. The raised ridges on one concrete hollow module would cooperate correspondingly with the groove depression on adjacent concrete hollow module to form a first surface-to-surface interlocking tongue and groove mechanism.

The first surface-to-surface interlocking tongue and groove mechanism also includes a space for insertion of reinforcing bars, cables and conduits. Furthermore, one end of the concrete hollow module includes a protruded surface, whereas the other end of the concrete hollow module includes a depressed surface. The protruded surface on one concrete hollow module would cooperate correspondingly with the depressed surface on adjacent concrete hollow module to form preferably a second end-to-end in- terlocking tongue and groove mechanism.

[14] Therefore according to the present invention, a wall or room construction method using concrete hollow modules comprises the steps of:-

[15] providing a first surface-to-surface and preferably a second end-to-end interlocking tongue and groove mechanisms on adjacent concrete hollow modules;

[16] forming a first course by using said concrete hollow modules;

[17] forming and stacking another course of said concrete hollow modules over the first course in a preferably staggered manner;

[18] filling any gap in one course with a cut-off section of said concrete hollow module, cut by sawing;

[19] stacking these courses in a preferably staggered manner to match the desired height of a wall; and

[20] stacking these courses to constitute L-shaped corners, T-junctions or cross junctions in a room where required.

[21] Concrete hollow modules without or with profiling variations are stacked to form walls, for low-rise houses, resort units, log cabins, retreat houses, staff quarters in remote area, temporary offices, guard houses, hawker stalls, fencing and the like.

Brief Description of the Drawings

[22] In order that the present invention may be more readily understood, the following de- scription is given, by way of example, of a concrete hollow module, without or with some profiling variations, and a wall or room construction method using the same.

[23] Reference will be made to the accompanying drawings, in which:-

[24] Figure la is a perspective view of one preferred embodiment of a concrete hollow module in accordance with the present invention, with two parallel vertical groove lines provided at each end of the concrete hollow module.

[25] Figure 1b is a top view of the concrete hollow module as shown in Figure 1a.

[26] Figure Ic is a side view of the concrete hollow module as shown in Figure 1a.

[27] Figure 1d is one end view of the concrete hollow module as shown in Figure 1a.

[28] Figure le illustrates an end view of three concrete hollow modules stacked one on top of another, without stagger.

[29] Figure 1f is a perspective view of the preferred embodiment as shown in Figure la where the wall section in between the two parallel vertical groove lines is being knocked off.

[30] Figure 2 is a perspective view of a L-shaped corner constituted by stacking courses of the concrete hollow modules in a preferably staggered manner.

[31] Figure 3 is a perspective view of a T-junction constituted by stacking courses of the concrete hollow modules in a preferably staggered manner.

[32] Figure 4 is a perspective view of a cross junction constituted by stacking courses of the concrete hollow modules in a preferably staggered manner.

[33] Figure Sa is a top view of one course of the concrete hollow modules.

[34] Figure 5b is a top view of another course of the concrete hollow modules adjacent to the course in Figure Sa.

[35] Figure 6 illustrates a perspective view of a L-shaped corner of a room fitted with a door frame and a window frame, formed by preferably staggered courses of the concrete hollow modules.

[36] Figure 7a is a wall constructed from courses of concrete hollow modules without and with first profiling variation.

[37] Figure 7b is an end view of the wall as shown in Figure 7a.

[38] Figure 8a is a wall constructed from courses of concrete hollow modules with second profiling variation.

[39] Figure 8b is an end view of the wall as shown in Figure 8a.

[40] Figure 9a is a wall constructed from courses of concrete hollow modules with third profiling variation.

[41] Figure 9b is a top view of the wall as shown in Figure 9a.

Disclosure of Invention Detailed Description of the Invention

[42] A preferred embodiment of concrete hollow modules (10) as a basic building module, with some profiling variations, is disclosed according to the present invention.

[43] To facilitate explanation, same numerals are used for common components or elements. To distinguish common components or elements, superscript symbol ' or " and suffix "x", "a", "b" or "c¢" are added to the same numerals.

[44] Further, a wall or room construction method uses concrete hollow modules (10) with some profiling variations (10a, 10b, 10c) to form courses to match the desired height of a wall or room.

[45] In this description, the term "tongue and groove mechanism" is used generally and should be understood as widely as technically known. For an instance, a "tongue" is es- sentially a protrusion which can be a protruded surface or a raised ridge. Similarly, a "groove" is essentially a reception to the "tongue", which can be a groove depression or a depressed surface. The tongue and the groove serve as an interlocking mechanism.

An end-to-end interlocking tongue and groove mechanism means that a tongue is disposed on one end of a concrete hollow module (10') to cooperate correspondingly with a groove disposed on one end of adjacent concrete hollow module (10").

[46] Figures la, 1b, Ic and 1d show a preferred embodiment of a concrete hollow module (10) in accordance with the present invention. This is the basic building module for the wall or room construction method as disclosed. The concrete hollow module (10) assumes essentially the shape of a rectangular block.

[47] The body of the concrete hollow module (10) includes a plurality of vertically disposed cavities (13). Each vertically disposed cavity (13) has its vertical axis in its opening parallel to the plane of its side surface. Both the length and the width of the concrete hollow module (10) play a part in determining the number of vertically disposed cavities (13) and also the size of the vertically disposed cavities (13). In other profiling variations, at least one elongated side face of each concrete hollow module

(10) can be inclined or ridged.

[48] To facilitate explanation, five vertically disposed cavities (13) are shown in the drawings. Three vertically disposed cavities (13) are suitably rounded, preferably oval- shaped, whereas two terminal vertically disposed cavities (13) are substantially truncated towards the end of the concrete hollow module (10). It is important to note that other rounded shapes of the cavities are possible. The rounded shape of the cavity is to prevent crack lines from appearing at the corner of the vertically disposed cavity (13).

[49] As in prior art, these vertically disposed cavities (13) in the concrete hollow module (10) are useful for some other functions which will not be elaborated in this speci- fication. For an example, these vertically disposed cavities (13) can be filled with filler material and reinforcement to form columns and beams by placing bars where needed.

These vertically disposed cavities (13) are also used for concealed piping and wiring.

[50] On one hand, on the top surface of the concrete hollow module (10), two sub- stantially parallel raised ridges (14) are integrally provided on each elongated side of the top opening of the vertically disposed cavity (13). It is also important to note that the raised ridges (14) can be replaced by raised surfaces. The raised ridges (14) can be considered as "tongues" in the first surface-to-surface tongue and groove mechanism.

The bottom surface of the concrete hollow module (10) is correspondingly profiled in the shape of a groove depression (15) to traverse the span between the raised ridges (14), and to receive and engage the raised ridges (14). The raised ridges (14') on one concrete hollow module (10') and the groove depression (15") on adjacent concrete hollow modules (10") cooperate correspondingly to form a first interlocking tongue and groove mechanism as shown in Figure le. The first interlocking tongue and groove mechanism takes place at the surface-to-surface sections of the concrete hollow modules (10, 10"). It is also important to note that the first surface-to-surface in- terlocking tongue and groove mechanism includes a space for reinforcing bars, cables and conduits.

[51] On the other hand, one end of the concrete hollow module (10) includes a protruded surface (11), whereas the other end of the concrete hollow module (10) includes a depressed surface (12). As seen in Figure 2, the protruded surface (11') on one concrete hollow module (10') would cooperate correspondingly with the depressed surface (12") on one end of adjacent concrete hollow module (10") to form a second interlocking tongue and groove mechanism. The second interlocking tongue and groove mechanism takes place at the end-to-end sections of the concrete hollow modules (10, 10").

[52] The two interlocking tongue and groove mechanisms allow adjacent concrete hollow modules (10, 10") to self-align during a wall or room construction, thus reducing the need for skilled workers. As seen in Figure le, these interlocking tongue and groove mechanisms provide a good guidance to courses of concrete hollow modules (10', 10") when forming a wall.

[53] The length of the concrete hollow module (10) can be varied during production by changing the length of the mould. For one instance, the weight of the concrete hollow module (10), at 750 mm length, is approximately 26 kg. A suitable weight for a worker to carry should not exceed 30 kg. The strength of the concrete hollow module (10) will be reduced if it is made longer. This increased length will result in more breakages during handling and transportation. The length of the concrete hollow module (10) is also constrained by the block machine. Concrete hollow modules (10) with longer length will face difficulty in achieving even pressure across the mould. This will result in uneven distribution of cement and appearance of weak spots. Thus, 750 mm is the optimum length, all things considered.

[54] The concrete hollow module (10) is also provided with two parallel vertical groove lines (16) on each end as shown in Figure 1a. These parallel vertical groove lines (16) are provided to facilitate on-site knocking using a hammer during construction. Figure 1f shows the concrete hollow module where the wall section in between the two parallel vertical groove lines (16) has been knocked off. The knocking off of the wall section is done when the concrete hollow modules (10', 10") are joined together to form beams by adding steel bars and filling concrete into the vertically disposed cavities (13).

[55] According to the present invention, a first course of the concrete hollow modules (10) is laid. A second course of the concrete hollow modules (10") is laid in a preferably staggered manner on the first course. Preferably staggered courses are thus stacked to build up the desired height and allow them to be load-bearing.

[56] Therefore according to the present invention, a wall or room construction method using concrete hollow modules (10) comprises the steps of:-

[57] providing a first surface-to-surface and preferably a second end-to-end interlocking tongue and groove mechanisms on adjacent concrete hollow modules (10°, 10");

[58] forming a first course by using said concrete hollow modules (10);

[59] forming and stacking another course of said concrete hollow modules (10") over the first course in a preferably staggered manner;

[60] filling any gap in one course with a cut-off section (10x) of said concrete hollow module (10), cut by sawing;

[61] stacking these courses in a preferably staggered manner to match the desired height of a wall; and

[62] stacking these courses to constitute L-shaped corners, T-junctions or cross junctions in a room where required.

[63] Further, in accordance with the present invention, concrete hollow modules (10) can be transported and handled easily. They would require less hassle on site with dry con- struction method. Concrete hollow modules without or with profiling variations (10, 10a, 10b, 10c) are ideally stacked to form walls, for low-rise houses, resort units, log cabins, retreat houses, staff quarters in remote area, temporary offices, guard houses, hawker stalls, fencing and the like.

[64] In Figure 2, a L-shaped corner is constituted by stacking two walls of preferably staggered courses of concrete hollow modules (10). Any gap in one course due to this preferably staggered stacking can be filled up by a cut-off section (10x) of the concrete hollow module (10), where it is cut by sawing.

[65] In Figure 3, a T-junction is constituted by stacking two walls of preferably staggered courses of concrete hollow modules (10). Any gap in one course due to this staggered stacking can also be filled up by a cut-off section (10x) of the concrete hollow module (10), where it is cut by sawing.

[66] In Figure 4, a cross junction is constituted by stacking two walls of preferably staggered courses of concrete hollow modules (10). Any gap in one course due to this staggered stacking can also be filled up by a cut-off section (10x) of the concrete hollow module (10), where it is cut by sawing.

[67] Figures 5a and 5b illustrate respectively particular orientation of two adjacent courses of concrete hollow modules (10', 10") of wall construction. Any gap in one course due to this preferably staggered stacking can also be filled up by a cut-off section (10x) of the concrete hollow module (10), where it is cut by sawing. Workers will require training on how to lay and preferably stagger these concrete hollow modules (10', 10").

[68] In Figure 6, a L-shaped corner of a room is fitted with a door frame and a window frame, courses of concrete hollow modules (10) are stacked in a preferably staggered manner.

[69] In the above description, the concrete hollow module (10) has been explained as a basic building module. It is important to note that concrete hollow modules of other profiling variations are possible.

[70] In Figures 7a and 7b, the concrete hollow modules (10, 10a) without and with profiling variation on one elongated side face are shown to be stacked without stagger in one preferred wall configuration.

[71] In Figures 8a, 8b, 9a and 9b, the concrete hollow modules (10b, 10c) with profiling variations on one elongated side face are shown to be stacked without stagger in preferred wall configurations.

[72] In Figures 7a and 7b, concrete hollow module (10a) of a first profiling variation is il- lustrated by varying the width of the concrete hollow module (10) on one elongated side face. The wall surfaces on these elongated side faces become staggered due to different widths. A preferred wall configuration is thus constructed using the concrete hollow modules (10, 10a) of different widths at alternate course. The other elongated side faces of each course of the concrete hollow modules (10, 10a) remain aligned, so that a flush wall surface is achieved.

[73] In Figures 8a and 8b, concrete hollow module (10b) of a second profiling variation lies in inclining one elongated side face of the concrete hollow module. The wall surfaces on these elongated side faces become undulating due to the inclined faces of each course. A preferred wall configuration is thus constructed, where the other elongated side faces of each course of the concrete hollow modules (10b) remain aligned, so that a flush wall surface is achieved.

[74] In Figures 9a and 9b, concrete hollow module (10c) of a third profiling variation lies in ridging one elongated side face of the concrete hollow module. The wall surfaces on these elongated side faces become ridged due to the ridges on the face of each course.

A preferred wall configuration is thus constructed, where the other elongated side faces of each course of the concrete hollow modules (10c) remain aligned, so that a flush wall surface is achieved.

[75] In the above preferred wall configurations, profiling variations are disposed on one elongated side faces of the concrete hollow modules (10), whereas the other elongated side faces of the concrete hollow modules (10) are essentially flush with adjacent concrete hollow modules (10, 10a, 10b, 10c). It is important to note that profiling variations can be disposed on both elongated side faces of the concrete hollow modules (10) which are used to construct other wall configurations.

Claims

Claims

[Claim 1] Concrete hollow modules used for wall or room construction is char- acterized in which the concrete hollow module (10) assumes essentially the shape of a block, preferably rectangular, with a plurality of vertically disposed cavities (13) in its body, each with a vertical axis in its opening parallel to the plane of its side surface; two substantially parallel raised ridges (14) are integrally provided on each elongated side of the top opening of a vertically disposed cavity (13), and the bottom surface of the concrete hollow module (10) is cor- respondingly profiled in the shape of a groove depression (15) that traverse the span between the raised ridges (14) to receive and engage the raised ridges (14), whereby the raised ridges (14) on one concrete hollow module (10’) cooperate correspondingly with the groove depression (157) on adjacent concrete hollow module (107) to form a first surface- to-surface interlocking tongue and groove mechanism; one end of the concrete hollow module (10) includes a protruded surface (11), and the other end of the concrete hollow module (10) includes a depressed surface (12); whereby the protruded surface (11) on one end of one concrete hollow module (10) cooperates correspondingly with the depressed surface (127) on one end of adjacent concrete hollow module (10) to form a second end-to-end interlocking tongue and groove mechanism.
[Claim 2] Concrete hollow modules (10) of Claim 1 in which the first surface- to-surface interlocking tongue and groove mechanism includes a space for reinforcing bars, cables and conduits.
[Claim 3] Concrete hollow modules (10) of Claim 1 in which the openings of the vertically disposed cavities (13) are suitably rounded, preferably oval- shaped.
[Claim 4] Concrete hollow modules (10) of Claim 1 in which profiling variation can be disposed on one elongated side faces of the concrete hollow modules (10) while the other elongated side faces of each course of the concrete hollow modules (10, 10a, 10b, 10c) remain aligned, so that a flush wall surface is achieved when a preferred wall configuration is constructed.
[Claim 5] Concrete hollow modules (10) of Claim 1 in which profiling variation can be disposed on both elongated side faces of the concrete hollow modules (10) which are used to construct a wall configuration.
[Claim 6] Concrete hollow modules (10) of Claim 1 in which two parallel vertical groove lines (16) are provided on each end of the concrete hollow module (10), whereby the wall section in between the two parallel vertical groove lines (16) can be knocked off.
[Claim 7] A wall or room construction method using concrete hollow modules (10) comprises the steps of:- providing a first surface-to-surface and preferably a second end-to-end interlocking tongue and groove mechanisms on adjacent concrete hollow modules (10°, 10”); forming a first course by using said concrete hollow modules (107); forming and stacking another course of said concrete hollow modules (107) over the first course in a preferably staggered manner; filling any gap in one course with a cut-off section (10x) of said concrete hollow module (10), cut by sawing; stacking these courses in a preferably staggered manner to match the desired height of a wall; and stacking these courses to constitute L-shaped corners, T-junctions or cross junctions in a room where required; whereas each concrete hollow module (10) assumes essentially the shape of a rectangular block with a plurality of vertically disposed cavities (13) in its body.
[Claim 8] A wall or room construction method as in Claim 7 in which the top surface of each concrete hollow module (10) is integrally provided with two substantially parallel raised ridges (14) on each elongated side of the opening of the vertically disposed cavity (13), while its bottom surface is correspondingly profiled in the shape of a groove depression (15), whereby the raised ridges (14) on one concrete hollow module (10”) and the groove depression (157) on adjacent concrete hollow module (107) cooperate correspondingly to form a first surface- to-surface interlocking tongue and groove mechanism.
[Claim 9] A wall or room construction method as in Claim 7 in which one end of each concrete hollow module (10) includes a protruded surface (11) while the other end includes a depressed surface (12), whereby the protruded surface (11’) on one end of one concrete hollow module (10”) and the depressed surface (12°) on one end of adjacent concrete hollow module (10) cooperate correspondingly to form a second end-

to-end interlocking tongue and groove mechanism.
[Claim 10] A wall or room construction method as in Claim 7 in which each end of the concrete hollow module (10) is provided with two parallel vertical groove lines (16), whereby the wall section in between the two groove lines (16) can be knocked off.