Abstract:
The invention relates to the Soloarmar construction system comprising an original wall construction method, in which the cavities in the blocks are precisely aligned in the vertical axis. According to the invention, the blocks are assembled using an inner engagement device such that resistant masonry can be produced quickly and specially adapted for clay or concrete blocks using specific industrial templates, machines, nozzles and dies designed by Soloarmar. The appearance and characteristics obtained are similar to those obtained with standard masonry techniques, but with the mixture only being used to lay the first course instead of between all of the blocks.

Description:
BACKGROUND 
     In a traditional method of building masonry walls, a mortar mix has been commonly used to hold blocks together horizontally as well as vertically. The mix of sand and cement resists compression but does not resist lateral impact. 
     BRIEF SUMMARY OF THE INVENTION 
     With the proposed method, which is based on the modular dimensioning of the blocks, a continuity of vertical holes in the blocks is achieved for both sand with cement, as well as clay. A specially designed device (called “connector”) is proposed for assembling one block with another and achieve such continuity of the holes in the blocks, in such a manner that the building of masonry walls is done in a dry mode, that is with no mortar mix needed for holding the blocks together, providing the following advantages:
         Savings in manpower, as skilled labor is not needed except for a bricklayer to install the first row.   Savings in materials, with less waste since a mortar mix is not used between blocks.   Time savings in the building of walls, which can be assembled much more rapidly, by positioning the blocks with no need for leveling and no use of mortar mix.   Time savings in the finishing of walls with mortar which is applied to the vertical surfaces of the blocks only to seal the blocks.   Savings in that plastic materials which are non-biodegradable are recycled to make the connectors used to hold the blocks together, thus lessening the impact on the environment.   Savings in the amount of mortar mix (sand and cement), reducing the indiscriminate extraction of sand from the littoral or beaches.       

    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an embodiment of a clay block according to the invention. 
         FIGS. 2A ,  2 B and  2 C are plane and elevation views of an embodiment of a clay block according to the invention with a slot for anchoring to a steel structure. 
         FIGS. 3A ,  3 B and  3 C show respectively a perspective view, plane view and side elevation view of an embodiment of the connector  1 A according to the invention. 
         FIGS. 4A ,  4 B and  4 C show respectively a perspective view, plane view and side elevation view of an embodiment of the connector  2 A according to the invention. 
         FIG. 5  shows a plane view of an embodiment of a concrete block according to the invention. 
         FIGS. 6A ,  6 B and  6 C show respectively a perspective view, plane view and side elevation view of an embodiment of the connector C 1  according to the invention. 
         FIG. 7  shows a plane view of an embodiment of a thicker block and connectors according to the invention. 
         FIGS. 8A ,  8 B and  8 C show respectively a plane view, elevation view and lateral view of an embodiment of a connector C 2  according to the invention. 
         FIGS. 9A ,  9 B and  9 C are schematic side view illustration of the fastening of the blocks in the top row by means of an extensor according to the invention. 
         FIGS. 10A ,  10 B and  10 C are schematic plane views of mortar-filled reinforcing columns at the corner and adjacent to the corner in T-shaped, +-shaped and L-shaped intersections of walls. 
         FIGS. 11A ,  11 B and  11 C are respectively perspective views of L-shaped, T-shaped and +-shaped intersecting walls reinforced at the corner with concrete filling around a steel bar. 
         FIGS. 11D and 11E  are respectively perspective views of holes reinforced with concrete filling around a steel bar adjacent to a window opening or at the edge of a free-standing wall. 
         FIGS. 12A ,  12 B and  12 C show respectively a front view, a plane view and another front view of an inclined wall reinforced with a mortar filled column and a reinforcing abutment. 
         FIG. 13  is a plane view showing the required dimensions for a whole block according to the invention. 
         FIG. 14  shows schematically an embodiment of a wall built with the blocks and connectors according to the invention. 
     
    
    
     DESCRIPTION OF THE INVENTION 
     The construction system of the invention consists of an original method in which the holes in the blocks are aligned exactly in a vertical direction. That is achieved by a special modular configuration for the blocks which can be of clay or concrete, both conventional primary materials. For joining the blocks we use a device that we call “connectors” to hold the blocks internally, providing great strength and sturdiness to the masonry, eliminating the use of mortar mix (cement and sand) between the blocks in the vertical as well as horizontal directions. 
     The construction system of the invention is characterized by the following:
     a. VERTICALITY. Due to the fact that the system consists of assembling the blocks by means of the internal connectors, the verticality of the wall is maintained (plumb and square.) Therefore the construction of the walls is completed without having to use fillers to ensure verticality, resulting in a direct saving in masonry.   b. PATTERN DEVELOPMENT. Blocks were developed with special patterns which are produced industrially by means of specific machinery, nozzles and dies designed by the inventor.   c. EFFICIENCY. Consists of rationalizing construction, reducing costs, shortening delivery dates and eliminating waste.   d. DRY CONSTRUCTION TECHNIQUE. Assembly done by an internal fitting system, very simple, low cost and efficient   e. CONNECTORS. The connector piece is made of recycled plastic material of high strength, which holds the blocks together internally.   f. APPEARANCE. Has an appearance similar to that of conventional masonry. The characteristic of this system of blocks and connectors is that they are the only unique and differentiated elements of the process, as the remaining components and their application are similar to conventional ones, except that their use is rationalized in terms of patterns and sizes.   

     The construction system of the invention presents the following advantages: 
     The construction system of the invention presents the following advantages: 
     Speed (50% faster)
         Due to the fact that the construction is carried out in a toy building block-like manner, the walls are built quickly without having to wait for the mortar to set so that the external finish of the walls can be performed right after the assembly of the blocks.
           Lower cost (30% cheaper) per meter   
           Since no mortar mix is used between blocks, the need for skilled labor is reduced (one assistant and one masonry apprentice) for the assembly. Furthermore are savings in materials for the mortar mix and its respective waste.
           Elimination of the use of skilled labor in the erection of walls. Conventional masonry techniques are used only for the first row. Only one qualified bricklayer is needed for the leveling and laying of the first row. Computerized design of the work, flexibility in the modular design (three sizes of blocks). The design can dimension the walls with this system with elimination of waster, by using the three sizes of blocks, avoiding the need to split a block and discard the remainder.   Ease of expansion, addition and repair in civil construction sites. Can be performed very fast; construction of a wall can be extended in other directions by using the connectors, providing easy expansion without difficulty, reducing waste on the site while providing a solid and safe wall.
               Clean worksite without debris   Except for the blocks and connectors, the rest of the components of the construction are conventional and available commercially.   
               
               

     A. Ceramic Blocks: 
     A strict and exact modular sizing has been established for the ceramic (clay) blocks. 
     To streamline the construction three types of blocks are used, all of the same height, as shown in the following chart for clay blocks. An embodiment of such a block as shown in  FIG. 1  has three holes ( 2 ).  FIGS. 2A ,  2 B and  2 C show an embodiment of a block provided with a slot ( 4 ) for anchoring the block to a steel structure ( 6 ) with a steel bracket ( 5 ). 
                                                                                                                           TABLE FOR CLAY BLOCKS                    DIMENSIONS                            TYPE   E   H   L   AREA   VOLUME   WEIGHT       SERIES   BLOCK   THICKNESS   HEIGHT   LENGTH   (M 2 )   (M 3 )   (KG)                    A   A1   10   30.5   10   0.030   0.0013   1.560           A2           20   0.060   0.0026   3.120           A3           30   0.090   0.0044   5.280       B   B1   12.5   30.5   12.5   0.038   0.0018   2.160           B2           25   0.075   0.0035   4.200           B3           37.5   0.113   0.0051   6.120       C   C1   15   30.5   15   0.045   0.0023   2.760           C2           30   0.090   0.0044   5.280           C3           45   0.135   0.0064   7.680                    
Connectors
 
     As the construction is a dry construction system, a connector has been designed for the fitting of one block with another. Two connectors are used per block. For each type of block a respective type of connector was created.
         There are two types of connector for clay blocks: connector  1 A and connector  2 A.       

     CONNECTOR  1 A is shown in  FIGS. 3A ,  3 B and  3 C. 
     CONNECTOR  2 A is shown in  FIGS. 4A ,  4 B and  4 C.
         (For filling with concrete the holes in the block.)   The connectors are made of recycled plastic material having high strength.       

     The CONNECTOR  1 A is used to fit one block with another. The CONNECTOR  2 A is used when there is a need for more resistance and stability. 
     B. Concrete Blocks: 
     Just as with the ceramic blocks, the modular configuration is maintained in order to achieve continuity of the vertical holes. Rationalization is derived from the use of ⅓ blocks; ⅔ blocks and whole blocks. To streamline and reduce construction costs. See table below. 
     
       
         
               
             
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                 TABLE FOR CONCRETE BLOCKS 
               
             
          
           
               
                   
                   
                 DIMENSIONS 
                   
                   
                   
               
             
          
           
               
                   
                 TYPE 
                 E 
                 H 
                 L 
                 AREA 
                 VOLUME 
                 WEIGHT 
               
               
                 SERIES 
                 BLOCK 
                 THICKNESS 
                 HEIGHT 
                 LENGTH 
                 (M 2 ) 
                 (M 3 ) 
                 (KG) 
               
               
                   
               
             
          
           
               
                 A 
                 A1 
                 10 
                 21.5 
                 10 
                 0.0215 
                 0.00138 
                 3.036 
               
               
                   
                 A2 
                   
                   
                 20 
                 0.0430 
                 0.00281 
                 6.182 
               
               
                   
                 A3 
                   
                   
                 30 
                 0.0645 
                 0.00413 
                 9.086 
               
               
                 B 
                 B1 
                 12.5 
                 21.5 
                 12.5 
                 0.0215 
                 0.00269 
                 3.982 
               
               
                   
                 B2 
                   
                   
                 25 
                 0.0430 
                 0.00538 
                 8.118 
               
               
                   
                 B3 
                   
                   
                 37.5 
                 0.0645 
                 0.00806 
                 11.058 
               
               
                 C 
                 C1 
                 15 
                 21.5 
                 15 
                 0.0215 
                 0.00323 
                 4.928 
               
               
                   
                 C2 
                   
                   
                 30 
                 0.0430 
                 0.00645 
                 9.878 
               
               
                   
                 C3 
                   
                   
                 45 
                 0.0645 
                 0.00968 
                 14.044 
               
               
                   
               
             
          
         
       
     
     The connectors are of the same size and shape as the holes in the blocks. The connector is at one end of the same size as the upper portion of the hole, and at the other end has the dimension of the lower portion of the hole, the holes in the block being slightly conical. In the middle of the connector is a horizontal plate which separates the two connected blocks in a uniform manner. 
     Depending on the building needs the following are provided: 
     B.1. 10 cm×45 cm Blocks 
     10 cm blocks. Having conventionally a length of 45 cm. With three oval shaped holes. Said holes are of trapezoidal shape to facilitate unmolding during the manufacture of the blocks. 
     Connectors C 1 . 
     The connectors for the 10 cm concrete blocks have two dimensions because of the configuration of the holes in the block, since those holes are slightly trapezoidal. 
     B.2. 15 cm×45 cm Blocks 
     To meet the needs in different stages of the construction, a block of large thickness, as shown in  FIG. 7 , has been designed as required for thicker walls, e.g. bathrooms. 
     Connectors C 2 : 
     The connectors for 15 cm concrete blocks were designed in a manner that they can be used in both directions in the holes of the blocks, to provide better stability to the wall and maintain the fitting in two dimensions due to the configuration of the hole of the block, the holes being slightly trapezoidal. These connectors are illustrated in  FIGS. 8A ,  8 B and  8 C. 
     With the construction system of the invention, the process starts after having the floor or slab for the construction. To proceed, follow the sequence of steps described below:
         1. The first row is placed on mortar or a traditional mix and checked to be plumb and square, the subsequent blocks are positioned by means of the connectors, using two connectors per block, preferably in the outermost holes.   2. Doors and windows are dimensioned in a modular format. For example, the opening for a door should end in row number 7 or a multiple of 30 cm. Proceed with the same format for windows.   3. When reaching the final row, a piece called “EXTENSOR” is used to fix the wall to the tie beam or existing slab. See  FIGS. 9A ,  9 B and  9 C showing an extensor ( 7 ) between a block at the top of the wall and the lower face ( 13 ) of a slab or beam. A NEOPRENE rubber plate ( 8 ) is pressed against the lower face ( 13 ) by a screw ( 9 ) provided with a nut ( 10 ) and a washer ( 11 ). A flat bar of galvanized steel ( 12 ) is placed between the block at the top of the wall and the screw/nut/washer assembly.   4. Tie columns: To increase resistance and stability small columns are created by filling the holes in the block with 1:3:3 concrete and ⅜″ steel Embodiments of such columns formed by inserting a steel bar ( 14 ) in a hole and filling the hole with concrete ( 15 ) are shown in  FIGS. 10A ,  10 B, and  10 C, and  FIGS. 11A ,  11 B and  11 C.
           a. Applied in cases such as: wall intersections in shape of L, T and +. The corners and the first hole in each direction are filled.   b. The holes adjacent to windows and doors openings are filled in the same manner.   c. In free standing walls, i.e., which do not intersect, the last hole is filled in the same manner.   d. When the walls have long stretches, more than 2 meters, the holes are reinforced at every meter.   e. An inclined wall as seen in  FIGS. 12A ,  12 B and  12 C may have a column filled with concrete ( 15 ) as well as an abutment ( 16 ) filled with concrete.   
               

     In preferred embodiments of the system of the invention, the blocks are characterized by the dimensions represented by the distance ( 2 A) at the center being twice the distance (A) at the end of a block, i.e., equal parts from center to center of each section of the block. This exact and repetitive modular configuration ensures continuity of the holes in a vertical succession of holes from one layer to another. An example of these dimensions is shown in  FIG. 13 , which illustrates that the distance X should be the same in all the sections of the blocks. This principle also applies to blocks with different sizes and numbers of cells or holes, and for holes with different shapes but of equal dimensions. By following this modular configuration the holes or cells are held in vertical continuity, as illustrated in  FIG. 14 . 
     As we have described the invention consists of two basic and indispensable elements for fulfilling the purpose of the invention, one being the blocks to be correctly set in modular fashion, and the other being the connectors which are fitted in the holes of the blocks. One advantageous aspect of the system of the invention is that no mortar is needed for fixing one block to another, either in the vertical or horizontal direction. Another novel aspect is that, since the assembly is a dry technique, it is not necessary to wait for the setting or hardening of the mortar so that the wall can be completed by proceeding immediately to the step of applying an outer finishing layer to the wall.