AGGREGATE LOG AND METHOD OF BUILDING CONSTRUCTION

Abstract

An aggregrate log used with other such logs to form a wall of a house, or building, or a retaining wall, having a plurality of first openings oriented vertically when in situ in the wall, a plurality of second openings aligned along a horizontal axis and forming a conduit channel open from one end of the log to another and alignment means for aligning the log with an underlying log when in situ in said wall.

Description

FIELD

An aggregrate log used in making a mortarless aggregate block wall system of a type in which the blocks are layered one on top of the other.

BACKGROUND

Building construction, which employs layering of logs or blocks has been popular for many years. Log houses are difficult and time consuming to build because they require long straight logs that must be processed to smooth their surface and trim grooves in order that one log can be placed on another. A problem with such buildings is the difficulty in wiring them without exposing the wire or wire conduit on the interior surface. A similar problem exists for concrete blocks, although vertical pipes and lines can be passed through their hollow interior. A second problem with both log buildings and concrete block buildings has been the time required for construction. For concrete blocks the builder must have a constant supply of mixed mortar and repeatedly check for plumb and level across each row. Moreover, a number of bricklayers must be used to achieve an acceptable rate of construction.

For wooden log construction, a selection and purchase process must first be completed in order to obtain satisfactory raw material. The construction must first take place on a site near the plant of the builder. Each log must be grooved, trimmed and lifted into place by a crane. Insulation is placed in the grooves and the log placed atop a previous log in a layer by layer building process. Once the structure has been completed, the building is disassembled and all of the logs transported to the building site. The speed at which a log house can be constructed is generally slower than that of conventional construction and the construction costs are somewhat higher.

Accordingly, it is an object of the invention to provide an aggregate log, which can be assembled without mortar inexpensively and quickly. It is a further object to provide a log that can accommodate wiring, plumbing, central vacuum and heating lines in the interior of a wall made with several of the logs.

SUMMARY OF THE INVENTION

According to the invention there is provided an aggregrate log used with other such logs to form a wall of a house, or building, or a retaining wall, having a plurality of first openings oriented vertically when in situ in the wall, a plurality of second openings aligned along a horizontal axis and forming a conduit channel open from one end of the log to another and alignment means for aligning the log with an underlying log when in situ in the wall.

Preferably, the log has an elongated channel extending from one end of the log to the other end and positioned to be aligned with a corresponding elongated channel on another of the logs when in situ in the wall to form a heating channel, an interior surface of the heating channel mating with an outer surface of a pipe when positioned in the heating channel.

The exterior facing surface of the log may have a decorative facade.

The alignment means may be a raised elongated bead on one surface and a corresponding elongated recess on an opposite surface dimensioned to mate with the elongated bead.

The aggregate log may be made of concrete.

In another aspect of the invention there is provided a walled structure having walls made of a plurality of stacked aggregrate logs, each log having a plurality of first openings oriented vertically in said wall, a plurality of second openings aligned along a horizontal axis and forming a conduit channel open from one end of said log to another and alignment means for aligning the log with an underlying log in the wall.

Electrical conduit may be passed through said first openings and said second openings and electrical wire passed through said conduit.

Each of the logs has an elongated channel extending from one end of said log to the another end and positioned to be aligned with a corresponding elongated channel on another of the logs when in situ in the wall to form a heating channel, an interior surface of the heating channel mating with an outer surface of a pipe when positioned in the heating channel.

Water pipe may be fitted in the heating channels of the logs and a loose insulating material may be inserted into the first and second openings.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages will be apparent from the following detailed description, given by way of example, of a preferred embodiment taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a top view of the concrete log;

FIG. 2 is an end view of the concrete log;

FIG. 3 is a perspective view of a wall built with the concrete logs;

FIG. 4 is a top view of an alternative concrete log having insulation;

FIG. 5 is an end view of the concrete log of FIG. 4; and

FIG. 6-10 are various designs of fasads molded into the front face of each log.

DETAILED DESCRIPTION WITH REFERENCE TO THE DRAWINGS

FIGS. 1-2 illustrates a concrete log 10 having three first openings 12 aligned with openings of underlying logs to provide vertical passageways through the wall. Second openings 14 pass horizontally through connecting portions 13. Second openings 14 are shown to be round but can have any cross-sectional shape desired, such as rectangular as shown in FIG. 4. The top surface of the log has an elongated alignment rail 16 near one side and an elongated channel 18 near an opposite side. The bottom surface has three spaced apart channels 20, 22 and 23. Channel 20 is aligned vertically with rail 16 and is of a diameter such that it fits snugly over a rail 16 of an underlying concrete log 10. Channel 23 is aligned vertically with channel 18 and has the same diameter as the latter. Typical dimensions for the log are 3 feet in length by 8.5 inches in width by 12 inches in height, but can be made as long as desired or with other heights and widths.

Referring to FIG. 3 an assembled wall 24 having concrete logs 10 stacked one upon another has electrical outlet holes 28 and 34 chiseled through to first openings 12. An electrical receptacle box is fitted into each hole (not shown) as well as plastic conduit (not shown) and then the electrical wire inserted into hole 28 and passed through the conduit to its destination. It may be necessary to open one or more additional holes to achieve the required routing of the conduit. Once wire is passed through the conduit, they are attached to switch 26 and to plug 32 in the usual way.

If wall heating is used, PVC pipes 36 are passed through the opening left by channels 18 and 23. The pipes are joined to inlet and an outlet pipe of larger diameter leading to a pump and an underground heat exchanger (not shown). The depth underground of the heat exchanger will depend on the desired temperature of the water. All of the outside walls carry the pipes 36 with the result that the concrete logs are kept at a constant temperature. Once the outside walls are wired any holes opened in order to pass the wire are patched with concrete grout. Additional services such as central vacuum pipes can be passed through the first 12 and second openings 14.

The corners of the outside walls are left open so that the pipe 36 in one wall can be joined to that in the adjacent wall. Similarly, conduit to house electrical wire is passed from a second opening 14 in one wall to that in the adjacent wall. Once all of the wiring is complete and the pipes 36 are connected at the corners, a corner piece is inserted and cemented in place.

Referring to FIGS. 4-5 an alternative concrete log 10a is shown made in two separate halves, namely inner half 11 and outer half 13. Nuts 44 are cast into upper and lower regions of half 11 as seen in FIG. 5 above and below second openings 14 in the sections which connect the two halves 11 and 13. Similarly, boltholes are molded into the outer half 13 so that bolts 46 can pass through and engage nuts 44. Bolt heads 48 are recessed into the log. Insulation boards 40 are positioned between the two halves 11 and 13 and the bolts 46 inserted and tightened into nuts 44. Once the log is in place the boltholes can be pargeted. This system provides a thermal break, which enhances considerably the insulating capacity of the concrete logs 10a. For example, the area of the connecting portions 27 and 29 of connecting region 25 is less than 10% of the area of inner half 11 that faces the outer half 13. When these small contact areas are insulated the heat transfer through each log is very small.

It will be appreciated that there are other designs, which could be employed such as hexagonal logs. Various facades can be molded into a front face of each log to give a number of different appearances such as half rounds, tiled, paneled, broken slate, shingles or shakes. Some of these are shown in FIGS. 6-10.

Accordingly, while this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments as fall within the true scope of the invention.

Claims

1. An aggregrate log used with other such logs to form a wall of a house, or building, or a retaining wall, comprising:

a body having a plurality of first openings oriented vertically when in situ in said wall, a plurality of second openings aligned along a horizontal axis and forming a conduit channel open from one end of said log to another end, and alignment means for aligning said log with an underlying log when in situ in said wall.

2. The log of claim 1, including an elongated channel extending from one end of said body to said another end and positioned to be aligned with a corresponding elongated channel on another of said logs when in situ in said wall to form a heating channel, an interior surface of the heating channel mating with an outer surface of a pipe when positioned in said heating channel.

3. The log of claim 1, wherein a cross-section of said body is rectangular.

4. The log of claim 1, wherein an exterior facing surface of said body has a decorative facade.

5. The log of claim 1, wherein said alignment means is a raised elongated bead on one surface of said body and a corresponding elongated recess on an opposite surface of said body, said elongated recess dimensioned to mate with an elongated bead of another said log.

6. The log of claim 1, wherein said aggregate log is made of concrete.

7. The log of claim 1, wherein said body is made of an inner section and an outer section with connecting portions of said inner and outer sections forming connecting regions and forming said first and second openings and said body having fastener receptacles formed in each of said inner and outer sections.

8. The log of claim 7, including insulating pads between each of said connecting portions.

9. The log of claim 8, including nuts molded into connecting portions of one of said outer sections and boltholes molded into corresponding connecting portions of said inner sections with bolts insertable into said boltholes and threadedly engaging said nuts.

10. A walled structure having walls made of a plurality of stacked aggregrate logs, each said log, comprising:

(a) a plurality of first openings oriented vertically in said wall;

(b) a plurality of second openings aligned along a horizontal axis and forming a conduit channel open from one end of said log to another; and

(c) alignment means for aligning said log with an underlying log in said wall.

11. The walled structure of claim 10, wherein electrical conduit is passed through said first openings and said second openings and electrical wire passed through said conduit.

12. The walled structure of claim 10, wherein each of said logs has an elongated channel extending from one end of said log to the another end and positioned to be aligned with a corresponding elongated channel on another of said logs when in situ in said wall to form a heating channel, an interior surface of the heating channel mating with an outer surface of a pipe when positioned in said heating channel.

13. The walled structure of claim 11, including water pipe fitted in the heating channels of said logs.

14. The walled structure of claim 10, including a loose insulating material in said first and second openings.