Method and apparatus for precast wall and floor block system

Abstract

Precast planar construction wall blocks are provided with various configurations of fingers. Structures are rapidly assembled by aligning the fingers and inserting a pin through vertical sleeves provided in the fingers. Finger joints are typically shimmed and grouted for additional strength. Openings for doors and windows are provided in some wall blocks. Floor blocks are supported on ledges at the top of wall blocks or by portions of the top edges of wall blocks. A concrete or other topping may be added to floor blocks, and conduit may be run in the topping.

1 . A structure assembled from a plurality of precast blocks, the structure comprising
 a first floor comprising
 a first corner connection between
 a first block having a complementary finger arrangement of fingers with vertical sleeves, and 
 a second block having a different complementary finger arrangement of fingers with vertical sleeves, the corner connection comprising
 a pin inserted through the vertical sleeves of the first block fingers and the vertical sleeves of the second block fingers. 
 
 
   
   
   
       2 . The structure of  claim 1  wherein the corner connection further comprises
 a plurality of shims placed between adjacent fingers.   
   
   
       3 . The structure of  claim 2  wherein the corner connection further comprises
 grout placed around the shims and between adjacent fingers.   
   
   
       4 . The structure of  claim 1  further comprising
 a tee connection between
 a third block and a fourth block having a complementary finger arrangement of fingers with vertical sleeves, and 
 a fifth block having a different complementary finger arrangement of fingers with vertical sleeves, the tee connection comprising
 a pin inserted through the vertical sleeves of the finger elements of the third block, the fourth block, and the fifth block, 
 a plurality of shims placed between adjacent finger elements, and grout placed around the shims and between adjacent finger elements. 
 
   
   
   
       5 . The structure of  claim 1  further comprising
 at least one floor block supported by the first block and another block; and   a second floor comprising a plurality of wall blocks with fingers, such that the wall blocks are connected by finger joints.   
   
   
       6 . The structure of  claim 5  wherein
 the first block comprises a ledge; and   the floor block is partially supported by the ledge.   
   
   
       7 . The structure of  claim 5  wherein
 the first block comprises a plinth that extends above the floor block; and   another block, comprising a bottom edge with a grove, is positioned such that the plinth is aligned with the groove.   
   
   
       8 . The structure of  claim 5  wherein
 the floor block is partially supported by approximately one half the width of a top edge of the first block.   
   
   
       9 . A method of assembling a structure from a plurality of precast wall modules, the method comprising
 providing a plurality of groups of intersecting wall blocks, each group comprising
 a first set of at least one wall block, such that the first set has a complementary finger arrangement, and 
 a second set of at least one wall block, such that the first set has a complementary finger arrangement, such that the first set and the second set form a complementary mating arrangement; 
   assembling a first floor of the structure by, for each group of intersecting wall blocks of the first floor
 positioning a first block from the first set, 
 positioning a second block from the second set, 
 determining whether the first block and the second block represent all of the intersecting wall blocks for the group and if the first block and the second block represent all of the intersecting wall blocks for the group, then inserting a pin through the vertical sleeves of all of the intersecting blocks for the group, 
 otherwise inserting pipes between adjacent fingers of the positioned blocks for the group, thereby providing temporary support, and 
 continuing to sequentially position and temporarily support remaining blocks from the first set and second set until all blocks for the group are positioned, and then inserting a pin through the vertical sleeves of all of the intersecting blocks for the group. 
   
   
   
       10 . The method of  claim 9  further comprising
 shimming and grouting each finger connection of the groups of intersecting wall blocks of the first floor.   
   
   
       11 . The method of  claim 9  further comprising
 setting a plurality of floor blocks, such that the floor blocks are supported by at least a portion of the groups of intersecting wall blocks of the first floor.   
   
   
       12 . The method of  claim 10  further comprising
 assembling a second floor of the structure by, for each group of intersecting wall blocks of the second floor
 positioning a first block from the first set, 
 positioning a second block from the second set, 
 determining whether the first block and the second block represent all of the intersecting wall blocks for the group and
 if the first block and the second block represent all of the intersecting wall blocks for the group, then inserting a pin through the vertical sleeves of all of the intersecting blocks for the group, 
 otherwise inserting pipes between adjacent fingers of the positioned blocks for the group, thereby providing temporary support, and 
 continuing to sequentially position and temporarily support remaining blocks from the first set and second set until all blocks for the group are positioned, and then inserting a pin through the vertical sleeves of all of the intersecting blocks for the group. 
 
   
   
   
       13 . A precast wall block comprising
 a block portion having a top edge, a bottom edge, a first side edge, and a second side edge;   a plurality of spaced-apart fingers projecting from the first side edge in a first finger orientation, each finger comprising
 a top face, 
 a bottom face, and 
 a vertical sleeve having a top portion recessed from the top face of the finger and a bottom portion recessed from the bottom face of the finger; and 
   reinforcement elements affixed to each sleeve and extending into the block portion, such that the reinforcement elements reinforce the finger and the sleeve.   
   
   
       14 . The precast wall block of  claim 13  wherein the reinforcement elements further comprise
 a pair of hairpin reinforcement bars.   
   
   
       15 . The precast wall block of  claim 13  wherein the first finger orientation is complementary. 
   
   
       16 . The precast wall block of  claim 13  further comprising
 a plurality of spaced-apart fingers projecting from the second side edge in a second finger orientation, each finger comprising
 a top face, 
 a bottom face, and 
 a vertical sleeve having a top portion recessed from the top face of the finger and a bottom portion recessed from the bottom face of the finger; and 
   reinforcement elements affixed to each sleeve and extending into the block portion, such that the reinforcement elements reinforce the finger and the sleeve.   
   
   
       17 . The precast wall block of  claim 16  wherein
 the second finger orientation is complementary and is different from the first finger orientation.   
   
   
       18 . The precast wall block of  claim 16  wherein
 the second finger orientation is complementary and is same as the first finger orientation.   
   
   
       19 . The precast wall block of  claim 9  wherein
 the block portion has a front face; and   each finger has a front face inset from the front face of the block portion.   
   
   
       20 . The precast wall block of  claim 9  further comprising
 a groove in the bottom edge extending from the first side edge to the second side edge; and   a tongue in the top edge extending from the first side edge to the second side edge.