Patent Publication Number: US-10781588-B1

Title: Integrated, post-tensioned, building construction system

Description:
BACKGROUND OF INVENTION 
     The present invention relates to an integrated, post-tensioned, construction system for building structures that utilizes horizontally and vertically interlocking components, which are held in place and strengthened by tensioned internal tendons secured to beams in way of the top and the base of the structure. Connection of the interlocking components with adhesives or mortars is obviated. The system is more resistant to wind storm and seismic damage than conventional structures that use bonding agents for affixing building elements. 
     A building structure consists of a shell made from different interrelated parts with a fixed location on the ground. Some embodiments of building structures include agricultural barns, airport hangars, churches, clinics, commercial buildings, garages, government offices, greenhouses, hospitals, military barracks, museums, prisons, railway stations, residential houses, schools, silos, and warehouses. In contrast to building structures, civil engineering structures span between, facilitate access to, or protect geographical features. Some embodiments of civil engineering structures include abutments, aqueducts, bridges, dams, highway interchanges, tunnels, and viaducts. 
     Traditional building construction most often uses concrete-and-aggregate blocks that are held in place with cement mortar. When the mortar cures, it is approximately half the strength of the cured concrete-and-aggregate used in the blocks. Civil engineering structures most often utilize pre-stressed and/or post-tensioned tendons in pre-cast concrete-and-aggregate structures to augment the overall strength of the fabrication by introducing internal compressive stress to partially counteract tensile stresses caused by loads on the structure. This option has not been available for anisotropic, traditionally constructed, building structures, because of the disparity in strength between the concrete-and-aggregate blocks and the cement mortar. 
     When the walls of the building structure are assembled to the requisite height, the present invention uses a course of interlocking cap blocks above the interlocking blocks forming the walls. On top of the interlocking cap blocks, a structural beam is laid to connect to the top of tendons placed inside the walls. The bottom of the tendons is affixed to the foundation or to a structural beam below a course of interlocking base blocks in way of the foot of the wall. The tendons are tensioned by torquing fasteners in way of the beam above the interlocking cap blocks. The requisite tensioning of the tendons is dependent on the properties of the materials from which the interlocking components and the structural beam(s) are made. The interlocking components of the present invention may be made from virtually any curable or kiln-dried material that is currently being used in building structures; however, concrete-and-aggregate will be the most frequent embodiment. Concrete by itself is a weak binder that is similar to cement mortar. Cured concrete-and-aggregate forms a material that is strongest in compression, and the compression induced by the tensioned tendons augments the strength of the whole structure. 
     Construction using block, brick, or stone with cement mortar was invented in the late 18 th  century and has been used since that time with minor changes. Blocks or bricks are laid by skilled tradespeople called masons, who must take care to maintain a uniform thickness of the mortar seams and keep the rows of blocks or bricks level as construction progresses. The time required for construction is determined by the ability of the mason laying the blocks or bricks and the requisite time for the mortar to cure until it will support the weight of the structure. A significant portion of the cost of construction is remuneration of the skilled masons and the construction personnel, whose job time is influenced by the ability of the masons and the curing time of the mortar. 
     Utilization of the present invention eliminates the need for masons, because the interlocking blocks do not require mortar for assembly and are self-leveling. When the first course of interlocking blocks is placed on the foundation or on the base blocks in the proper orientation, the subsequent rows of interlocking blocks may be laid serially until the building is complete. This task may be done quickly by semi-skilled tradespeople. 
     In addition to the reduced labor for fabrication, the cost of construction is further reduced relative to traditional construction through reuse of components. If a building structure is to be taken down, the interlocking components may be disassembled for reuse. Similarly, if a building is partially damaged by a windstorm or seismic event, the undamaged components may be reused in a repair or a rebuild. Due to the aging properties of concrete, components taken from pre-existing buildings are significantly stronger than newly cured components, so disassembly is preferable to demolition. 
     The present invention is pan-global in application. The interlocking components may be made serially in the field or mass-produced through utilization of automation in a factory using engineered tooling in concrete-block-making machines. Do-it-yourself component fabrication and construction avails application of the system to most people in the world. In locations where infrastructure is limited, construction components may be transported utilizing draft animals, carts, boats, or other such conveyances. 
     SUMMARY OF THE INVENTION 
     The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new system for constructing building structures using post-tensioned, integrated components. 
     To attain this, the present invention uses interlocking blocks that are laid serially on a foundation to form the shell of a building structure. Some embodiments of the foundation may be reinforced-concrete, structural beams, or compacted-soil. When using a compacted-soil foundation, a bottom course of interlocking base blocks is laid that engages with the full-size and half-size interlocking blocks that form the walls. Full-size and half-size interlocking blocks are laid successively until the wall structure attains the requisite height. The top row of full-size and half-size interlocking blocks is overlaid with a course of interlocking cap blocks that engage with the interlocking features of the blocks forming the wall. Tendons are located inside hollow spaces inside the blocks. Below the base blocks and above the cap blocks are located pultruded, extruded, or composite structural beams that connect to the tendons. The ends of the tendons are mechanically fastened to the beams. 
     The wall built from of the interlocking blocks with internal tendons mechanically fastened to structural beams above-and-below the wall forms a composite structure that does not require mortar or adhesives to join together individual elements. Proper alignment is achieved through utilization of the interlocking features of the blocks. The tendons hold together the interlocking blocks that form the shell of the building. During construction, build stops are fitted below joints in the tendons to help stabilize the wall and to center the tendon in the openings in the interlocking blocks. When the end fasteners on the tendons are tightened to the structural beam(s) and/or foundation, the interlocking blocks cannot come apart, since the entire structure is mechanically connected. 
     Post-tensioning of the structure is performed by applying torque to the fasteners in way of the upper ends of the tendons where they connect to the structural beams. The tensioned tendons induce compression in the interlocking blocks between the top and bottom structural beams or between the top structural beam and the foundation. The amount of torque applied to the fasteners on the tendons is dependent on the strength of materials used in the blocks and the beams. The induced compression on the walls forms an internal stress that partially counteracts the tensile stresses caused by external loads on the structure. This improved ability of the structure to support loads beyond its own dead weight enables better performance when external loads are applied, such as by windstorms, seismic events, or settling of the foundation of the structure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein: 
         FIG. 1  is a top right perspective view of the full-size interlocking block. 
         FIG. 2  is a bottom right perspective view of the full-size interlocking block. 
         FIG. 3  is a top right perspective view of the half-size interlocking block. 
         FIG. 4  is a bottom right perspective view of the half-size interlocking block. 
         FIG. 5  is a top right perspective view of the cap interlocking block. 
         FIG. 6  is a bottom right perspective view of the cap interlocking block. 
         FIG. 7  is a top right perspective view of the base interlocking block. 
         FIG. 8  is a bottom right perspective view of the base interlocking block. 
         FIG. 9  is an exploded view of the principal components of the present invention. 
         FIG. 10  is a left perspective view of the exterior of a structure that utilizes the present invention. 
         FIG. 11  is a left perspective view of the internal elements of a structure that utilizes the present invention. 
         FIG. 12  is a cutaway view of a structure that utilizes the present invention. 
         FIG. 13  is a cutaway view of embodiments of the base of a structure that utilizes the present invention. 
     
    
    
     
       
         
           
               
             
               
                   
               
               
                 REFERENCE NUMERALS IN FIGS. 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
            
               
                 1 
                 Fill -size Interlocking Block (FIB) 
               
               
                 2 
                 Top Face of FIB 
               
               
                 3 
                 Bottom Face of FIB 
               
               
                 4 
                 Front Face of FIB 
               
               
                 5 
                 Back Face of FIB 
               
               
                 6 
                 Side Wall of FIB 
               
               
                 7 
                 Bosses of FIB 
               
               
                 8 
                 Top Faces of Bosses of FIB 
               
               
                 9 
                 Passages of FIB 
               
               
                 10 
                 Half-size Interlocking Block (HIB) 
               
               
                 12 
                 Top Face of HIB 
               
               
                 13 
                 Bottom Face of HIB 
               
               
                 14 
                 Front Face of HIB 
               
               
                 15 
                 Back Face of HIB 
               
               
                 16 
                 Side Wall of HIB 
               
               
                 17 
                 Boss of HIB 
               
               
                 18 
                 Top Face of Boss of HIB 
               
               
                 19 
                 Passage of HIB 
               
               
                 20 
                 Cap Interlocking Block (CIB) 
               
               
                 21 
                 Top of Recesses of CIB 
               
               
                 22 
                 Top Face of CIB 
               
               
                 23 
                 Bottom Face of CIB 
               
               
                 24 
                 Front Face of CIB 
               
               
                 25 
                 Back Face of CIB 
               
               
                 26 
                 Side Wail of CIB 
               
               
                 28 
                 Passages for Tendon of CIB 
               
               
                 29 
                 Recesses of CIB 
               
               
                 30 
                 Base Interlocking Block (BIB) 
               
               
                 32 
                 Top Face of BIB 
               
               
                 33 
                 Bottom Pace of BIB 
               
               
                 34 
                 Front Face of BIB 
               
               
                 35 
                 Back Face of BIB 
               
               
                 36 
                 Side Wall of BIB 
               
               
                 37 
                 Bosses of BIB 
               
               
                 38 
                 Passages for Tendon of BIB 
               
               
                 39 
                 Top Faces of Bosses of BIB 
               
               
                 50 
                 Seal Ply 
               
               
                 52 
                 J-Bolt Anchor 
               
               
                 54 
                 Expansion BoltAnchor 
               
               
                 56 
                 Earthnchor 
               
               
                 58 
                 Top Beam 
               
               
                 60 
                 Bottom Beam 
               
               
                 62 
                 Concrete Foundation 
               
               
                 64 
                 Soil Foundation 
               
               
                 66 
                 Tendon 
               
               
                 68 
                 Nut 
               
               
                 70 
                 Tendon Coupling 
               
               
                 72 
                 Build Stop 
               
               
                 74 
                 Build Stop Nut 
               
               
                 76 
                 Flat Washer 
               
               
                 78 
                 Lock Washer 
               
               
                   
               
            
           
         
       
     
     DETAILED DESCRIPTION OF THE INVENTION 
     In reference to  FIGS. 1-8 , the interlocking block components of an integrated, post-tensioned, building construction system are shown. In some embodiments, the interlocking block components may be made from concrete-and-aggregate, structural clay, or adobe (mud-bricks). The mechanical fit between adjacent blocks provides the horizontal and vertical integration of the wall structure. Interlocking is accomplished when the raised boss on the top of a block engages with a matching opening in the bottom of a passage through an adjacent block. The interior of the blocks is hollowed to reduce weight while maintaining strength. 
       FIG. 1  illustrates the full-size interlocking block (FIB)  1  from the top and  FIG. 2  shows the same block from the bottom. Full-size interlocking block (FIB)  1  has a top face of FIB  2 , a bottom face of FIB  3 , a front face of FIB  4 , a back face of FIB  5 , and side walls of FIB  6 . Opposing faces of full-size interlocking block (FIB)  1  and opposing side walls of FIB  6  are generally parallel to each other. Raised, tapered bosses of FIB  7  extend above top face of FIB  2  and end at the top faces of bosses of FIB  8 . Full-size interlocking block (FIB)  1  has two passages of FIB  9  defined therethrough. In some embodiments, full size interlocking block (FIB)  1  may have one or more than two passages therethrough. The openings of passages of FIB  9  in top faces of bosses of FIB  8  are smaller than the openings of passages of FIB  9  in the bottom face of FIB  3 , because passages of FIB  9  taper inward from bottom to top. Bosses of FIB  7  engage with the openings of passages in way of the bottom face of adjacent full-size interlocking block (FIB)  1  or half-size interlocking block (HIB)  10 . Bosses of FIB  7  may also engage with the recesses of CIB  29  in cap interlocking block (CIB)  20 . 
       FIG. 3  illustrates the half-size interlocking block (HIB)  10  from the top and  FIG. 4  shows the same block from the bottom. Half-size interlocking block (HIB)  10  has a top face of HIB  12 , a bottom face of HIB  13 , a front face of HIB  14 , a back face of HIB  15 , and side walls of HIB  16 . Opposing faces of half-size interlocking block (HB)  10  and opposing side walls of HIB  16  are generally parallel to each other. A raised, tapered boss of HIB  17  extends above top face of HIB  12  and ends at the top face of boss of HIB  18 . Half-size interlocking block (HIB)  10  has a passage of HIB  19  defined therethrough. In some embodiments, half-size interlocking block (HIB)  10  may have more than one passages therethrough. The opening of passage of HIB  19  in top face of boss of HIB  18  is smaller than the opening of passage of HIB  19  in the bottom face of HIB  13 , because passage of HIB  19  tapers inward from bottom to top. Boss of HIB  17  engages in the opening of passage in way of the bottom face of adjacent full-size interlocking block (FIB)  1  or half-size interlocking block (HIB)  10 . Boss of HIB  17  may also engage with a recess of CIB  29  in cap interlocking block (CIB)  20 . 
     The cap interlocking block (CIB)  20  is illustrated from the top in  FIG. 5  and from the bottom in  FIG. 6 . Cap interlocking block (CIB)  20  has a top face of CIB  22 , a bottom face of CIB  23 , a front face of CIB  24 , a back face of CIB  25 , and side walls of CIB  26 . Opposing faces of cap interlocking block (CIB)  20  and opposing side walls of CIB  26  are generally parallel to each other. Cap interlocking block (CIB)  20  has two recesses of CIB  29  that begin at the bottom face of CIB  23  and end at the top of recesses of CIB  21 . Recesses of CIB  29  receive the bosses of full-size interlocking block (FIB)  1  or half-size interlocking block (HIB)  10  or base interlocking block (BIB)  30 . In some embodiments, cap interlocking block (CIB)  20  may have one or more than two recesses therein. The cap interlocking block (CIB)  20  has two passages for tendon of CIB  28  located in way of the centerline of recess of CIB  29 , extending from top of recesses of CIB  21  to top face of CIB  23 . The passages for tendon of CIB  28  facilitate insertion of tendon  66 . In some embodiments, cap interlocking block (CIB)  20  may have one or more than two passages for tendon therethrough. 
     The base interlocking block (BIB)  30  is shown from the top in  FIG. 7  and from the bottom in  FIG. 8 . Base interlocking block (BIB)  30  has a top face of BIB  32 , a bottom face of BIB  33 , a front face of BIB  34 , a back face of BIB  35 , and side walls of BIB  36 . Opposing faces of base interlocking block (BIB)  20  and opposing side walls of BIB  36  are generally parallel to each other. The top of BIB  32  has two, raised, tapered bosses of BIB  37  formed thereon that couple with the bottom openings of passages of full-size interlocking block (FIB)  1  and/or half-size interlocking (HIB) block  10 . Bosses of BIB  37  may also engage with a recesses of cap interlocking block (CIB)  20 . In some embodiments, base interlocking block (BIB)  30  may have one or more than two bosses thereon. The base interlocking block (BIB)  30  has two passages for tendon of BIB  38  located in way of the centerlines of the two bosses of BIB  37 , extending from the bottom face of BIB  33  to the top faces of bosses of BIB  39  to facilitate insertion of ends of tendon  66 , j-bolt anchor  52 , expansion bolt anchor  54 , or earth anchor  56 . In some embodiments, base interlocking block (BIB)  30  may have one or more than two passages for tendon therethrough. 
     The interrelation of the principal components of the present invention is shown in the exploded view in  FIG. 9 . In this embodiment, rows of full-size interlocking block (FIB)  1  and half-size interlocking block (HIB)  10  are laid on base interlocking block (BIB)  30 . Each row of full-size interlocking block (FIB)  1  is staggered relative to adjacent rows, so that each boss and each passage or recess engages with a different block. This maximizes the integration of the wall, since every full-size interlocking block (FIB)  1  is interconnected with four other blocks. Above the top row of full-size interlocking block (FIB)  1  and half-size interlocking block (HIB)  10  is a course of cap interlocking block (CIB)  20  to close the top of the structure. Tendon  66  that starts below bottom beam  60  under base interlocking block (BIB)  30  passes through rows of full-size interlocking block (HIB)  1  and terminates above top beam  58  above cap interlocking block (CIB)  20 . Lengths of tendon  66  shorter than the span between the base interlocking block (BIB)  30  and cap interlocking block (CIB)  20  are joined by tendon couplings  70  to expedite the laying of rows of full-size interlocking block (FIB)  1  and/or half-size interlocking block (HIB)  10  over tendon  66 . Nut  68  located above and below each tendon coupling  70  are tightened to the tendon coupling  70  to torsionally lock each joint. Below each tendon coupling  70  is build stop  72 , which is held in place on tendon  66  by tensioning build stop nut  74 . Some embodiments of build stop  72  may be plastic sheet, plywood, or metal sheet. Build stop  72  stabilizes the wall during construction by helping to prevent movement or dislodging of the interlocking blocks. Build stop  72  also holds tendon  66  in the center of the opening in the interlocking block to facilitate coupling to the adjacent section of tendon  66 . Build stop  72  may be left inside the wall after construction, since it will not interfere with post-tensioning of the structure. The top of each threaded end of tendon  66  is secured with a flat washer  76  and nut  68  in way of top beam  58  above cap interlocking block (CIB)  20 . The bottom of each threaded end of tendon  66  is secured with a lock washer  78  and nut  68  in way of bottom beam  60  below base interlocking block (BIB)  30 . Seal ply  50  is inserted or applied between the vertical ends of adjacent blocks to reduce the possibility of air or water to flow through this lacuna. In some embodiments, seal ply  50  may be expanded polyethylene foam, expanded polystyrene foam, cork sheet, or polymer sealing paste. 
     The corner of a building structure fabricated through utilization of the present invention is illustrated in  FIG. 10-12 .  FIG. 10  shows the exterior of the building structure.  FIG. 11  displays the internal elements of the structure without the blocks. These elements include J-bolt anchor  52 , top beam  58 , tendon  66 , nut  68 , tendon coupling  70 , build stop  72 , build stop nut  74 , and flat washer  76 . The internal elements of the structure would most often be made from structural steel. Alternate embodiments of these internal elements include aluminum, fiberglass reinforced plastic, carbon fiber reinforced plastic, semi-crystalline polyamides, and fiber-filled nylon.  FIG. 12  illustrates representative elements in the wall structure with the blocks cut away. In this embodiment, walls are laid on concrete foundation  62  instead of on base interlocking block (BIB)  30 . J-bolt anchor  52  are positioned inside concrete foundation  62  when the material of which concrete foundation  62  is made has partially cured. Tendon  66  are connected to j-bolt anchor  52  with tendon coupling  70 . Tendon  66  are torsionally locked by nut  68  above and below each tendon coupling  70 . 
     The opening shown in  FIG. 10  and  FIG. 12  is typical of any opening in a building structure that utilizes the present invention. Some embodiments of these openings would be windows, doors, and façades. The bottom or sill of the opening is formed from cap interlocking block (CIB)  20  that cover and interconnect with the full-size interlocking block (FIB)  1  and/or half-size interlocking block (HIB)  10  below the opening. Top beam  58  on cap interlocking block (CIB)  20  is the end plate for tendon  66  that extend up from concrete foundation  62 . Each tendon  66  that terminates at the sill of the opening is secured and tensioned with nut  68 , which sits on flat washer  76 . The top or header of the opening is formed from base interlocking block (BIB)  30  that covers and interconnects with full-size interlocking block (FIB)  1  and/or half-size interlocking block (HIB)  10  above the opening. Bottom beam  60  below base interlocking block (BIB)  30  is the end plate for tendon  66  that extends upward through the top of the wall. Each tendon  66  that terminates at the header is secured and tensioned with nut  68 , which engages lock washer  78 . 
     The sides of openings in the building structure are closed with half-size interlocking block (HIB)  10  when necessary. Since the full-size interlocking block (FIB)  1  are laid in staggered courses, gaps in way of the opening will need to be filled with half-size interlocking block (HIB)  10 . 
       FIG. 13  illustrates several possible embodiments of the bottom of walls of building structures made with the present invention. All embodiments provide a means of securing the bottom of tendon  66 . If concrete foundation  62  is used, anchor bolts may be inserted before or after the material has cured of which concrete foundation  62  is made. J-bolt anchor  52  or equal would be inserted in a partially cured concrete foundation  62 . Expansion bolt anchor  54  or equal would be inserted in a fully cured concrete foundation  62 . Concrete foundation  62  may be either a footing in way of the walls of the building structure, a slab under the entire building structure, or a reinforced-concrete beam. In lieu of concrete foundation  62 , elevated buildings or buildings spanning a gap could utilize bottom beam  60  sized for the requisite structural loads and the dead weight of the building structure. If concrete foundation  62  is not utilized, the walls of the shell may rest upon soil foundation  64 . In this embodiment, the full-size interlocking block (FIB)  1  are stacked on a leveled course of base interlocking block (BIB)  30 . Below base interlocking block (BIB)  30  is bottom beam  60  into which the ends of tendon  66  are affixed. In order to connect the building structure to the substrate on which the structure sits, earth anchor  56  may be used. Earth anchor  56  may connect to the threaded end of tendon  66  with a thread tapped joint in the top of earth anchor  56  or by using tendon coupling  70  that is torsionally locked with nut  68  above and below tendon coupling  70 . When inserted into a substrate that has been mechanically compacted, the pull-out strength of earth anchor  56  can exceed that of j-bolt anchor  52  or expansion bolt anchor  54 . 
     With respect to the above description, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function, and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. 
     Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.