Static structures (e.g. – buildings) – Processes – Barrier construction
Reexamination Certificate
1999-01-07
2001-01-09
Kent, Christopher T. (Department: 3635)
Static structures (e.g., buildings)
Processes
Barrier construction
C052S745130, C052S747120, C052S749130, C052SDIG001, C401S193000
Reexamination Certificate
active
06170221
ABSTRACT:
BACKGROUND OF THE INVENTION
(a) Field of the Invention
This invention relates to a new system and method for building wall construction and more particularly, but not by way of limitation, to a system and method for placing mortar on structural block or brick in order to build a wall or the like from the block or brick.
(b) Discussion of Known Art
Heretofore, brick and block masonry walls have been built by hand, one brick or block at a time. The wall was erected using hand tools for applying mortar on the sides and on the tops of the bricks or blocks. The mortar was mixed on site. This type of wall construction is labor intensive, it is expensive, it is time consuming, it requires mixing mortar on site and it requires skilled masons for well constructed walls.
Also, brick and block walls have been preconstructed by forming walls in forms on a horizontal surface on a job site. When the wall is completed, the wall is hoisted upwardly using heavy equipment into a vertical position and attached to a side of a building. This method of wall construction is also time consuming and expensive when having to use additional equipment for lifting each completed wall into place.
The subject invention as described herein eliminates the above mentioned problems related to brick and block wall construction. The new method of wall construction allows unskilled brick layers to build a brick or block wall. The method takes half the time when compared to building brick and block walls using mortar and hand tools thereby greatly reducing the overall cost of building construction.
SUMMARY OF THE INVENTION
In view of the foregoing, it is a primary objective of the subject system and method of forming a structural wall to greatly reduce the time required to build either a brick or a block wall. The reduced time being in an order of up to half of what is normally required in standard brick and block wall construction using mortar and mason hand tools.
Another object of the invention is to eliminate the need for manual application of mortar, the mixing of mortar and eliminating mortar clean up after the wall is built. Additionally, because only a stream or bead of mortar is used, the holes in the brick or block are free for receiving steel reinforcing bars and the like for strengthening the wall construction. Thus, a wall built using the disclosed construction system and method is well suited for use in earth quake areas.
Still another object of the disclosed invention is to provide a system and method which allows the use of novice or unskilled workman to quickly build a brick or block wall that is straight, level and plumb thereby eliminating the need for skilled craftsman. The wall can be build at a greatly reduced cost due to savings in time and labor.
Yet another object of the invention is the wall can be started at any part of the building i.e. a corner, a center, etc. Further, a minimum of scaffolding is required using the disclosed type of wall construction system and method.
An important feature of the disclosed invention is the use of a mortar delivery system which uses compressed air to force mixed mortar through a hose to a delivery nozzle. The nozzle eliminates the need to use a trowel and mortar holding bin during the erection of block buildings.
Another important new and useful result achievable with the instant invention is the precise and expedient delivery of the optimal amounts of mortar needed for the proper construction of a block or brick wall.
A further object of the invention is the new wall construction system and method uses light weight alignment panels or alignment grids which are used as a guide during the brick or block laying. The panels provide a means for keeping the new wall plumb, straight and level. The panels eliminate the need for having to continuously use a hand level or plumb line to double check if the wall is level or plumb as the bricks or blocks are laid course after course. The panels also serve as a guide for the nozzle used with the invention to assure proper placement of the precise amounts of mortar to be used. Also, window and door frames can be attached to the side of an alignment panel for ease in installation.
The new method of forming a structural wall using either lightweight or heavyweight block or brick and using lightweight removable alignment panels includes first installing one or more removable panels vertically next to a chalk line on a building foundation. The chalk line is used to mark a horizontal line along one side of the wall to be constructed. Each panel is plumbed vertically and leveled horizontally. The panel includes horizontal level lines 8 inches, 2 feet and 6 feet from a bottom of the panel. The level lines are used as a level guide to make sure each row or course of blocks are level as a block wall is built upwardly. This method as described herein will apply equally well to building a brick wall. Also, the bottom of the alignment panel is used as leveling device for the floor or foundation.
Mortar is now placed on the bottom and on one end of a plurality of concrete blocks for forming a first course of blocks. The blocks are then laid end to end next to each other and next to one side of the alignment panel for forming a first course of blocks. The mortar is now applied to the top of the first course of blocks. The mortar is now applied to the ends of a plurality of concrete blocks for forming a second course of blocks. The blocks are then laid end to end next to each other on top of the first course of blocks for forming a second course of blocks. The applying of the mortar to the blocks and laying a third course of blocks and additional courses of blocks one on top of each other is continued upwardly until the top of the last course of blocks coincides with the top of the alignment panel.
These and other objects of the present invention will become apparent to those familiar with brick and block wall construction and the problems associated therewith from the following detailed description, showing novel construction, combination, and elements as herein described, and more particularly defined by the appended claims, it being understood that changes in the precise embodiments to the herein disclosed invention are meant to be included as coming within the scope of the claims, except insofar as they may be precluded by the prior art.
REFERENCES:
patent: 1779007 (1930-10-01), Makowski
patent: 3162886 (1964-12-01), Wise
patent: 3786966 (1974-01-01), Behunin et al.
patent: 3830678 (1974-08-01), Behunin
patent: 5681125 (1997-10-01), Amaya
patent: 5878921 (1999-03-01), Chase et al.
patent: 5937610 (1999-08-01), Behunin
Crabtree Edwin H.
Kent Christopher T.
Margolis Donald W.
Pizarro Ramon L.
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