BLOCKOUT DEVICE

Abstract

A blockout device for at least partially blocking a through cavity of a concrete block and supporting a settable material comprises a frangible region adapted to accommodate conduits of various transverse sizes, by providing an opening the size of which can be adjusted to accommodate a conduit of any of a number of different transverse sizes.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of foreign priority to Australian complete standard patent application No. 2011203311, filed on Jul. 6, 2011, entitled BLOCKOUT DEVICE, which claims priority to Australian provisional application no. 2010902992 filed on Jul. 6, 2010, entitled BLOCKOUT DEVICE, each of which are incorporated herein by reference.

FIELD

The present disclosure relates to a blockout device, and especially to a blackout devices for blocking a through cavity in a masonry block.

BACKGROUND

Hollow masonry blocks can be used to construct walls. The blocks may be provided with a through cavity which in use extends between an open bottom of the block and an open top of the block. In a wall, blocks may be arranged so that the cavities of vertically adjacent blocks are aligned to form a vertically extending cavity. One or more such vertically extending cavities may be filled with a settable reinforcing material, such as concrete, to provide a vertical reinforcement, or pillar, to enhance the strength of the wall. A wall may have a number of such vertical reinforcements, spaced apart along the length of the wall. The spacing between such vertical reinforcements may be approximately one to two metres. It is normally not desired to provide more closely spaced vertical reinforcements, due to the increased cost of doing so and, in particular, it is normally not desired to fill all of the vertically extending cavities with settable material. Thus only selected blocks are filled with settable material.

To further strengthen the wall, a substantially horizontal reinforcing beam (or “bond beam”) may be created. One way of creating such a substantially horizontal beam is to provide steel reinforcing bars which connect a number of blocks at substantially the same height, and then to pour a settable material such as concrete, to embed and secure the reinforcing bars and to fill the cavities in those blocks connected by the reinforcing bars.

In such an exercise it is desirable to prevent the settable material from flowing from the blocks to be filled into lower blocks (except, perhaps, for those selected blocks which are to form part of a vertical reinforcement, or pillar). A further consideration is that it may be desirable to provide service conduits extending into, through, and out of, one or more of the vertically extending cavities.

One previous approach has been to provide metal block out plates to restrain the settable material from flowing from the blocks to be filled into lower blocks. A known block out plate is described in Australian Patent No. 568948. The block out plate described in this document comprises a planar body adapted to be wedged in a through cavity of a masonry block, just above the base of the block (i.e. at the bottom of the cavity), to block off the base of the block and prevent or reduce flow of concrete out of the base of the block. The described block out plate provides one or more indented portions which can be removed to provide an aperture in the planar body to allow passage of a service conduit therethrough.

The inventor has perceived that there is a need for an improved, or at least alternative, block out device.

SUMMARY

According to a first aspect of the present disclosure, there is provided a blockout device, for use with a masonry block having at least one through cavity, the blockout device comprising:

at least one blocking region, adapted to extend at least partially across a through cavity of the masonry block in use, to at least partially block the through cavity, and to support a settable material above the block;

the at least one blocking region having a frangible region adapted to accommodate conduits of various transverse sizes, by providing an opening the size of which can be adjusted to accommodate a conduit of any of a number of different transverse sizes.

In an embodiment the opening may be formed by breaking or tearing one or more parts of the frangible region.

In an embodiment the frangible region may be adapted to provide a plurality of openings, each for accommodating a conduit.

In an embodiment the size of the opening can be adjusted by breaking or tearing one or more parts of the frangible region.

In an embodiment the size of the opening can be adjusted by forcing the conduit through the frangible region.

In an embodiment the size of the opening is substantially determined by the transverse size of the conduit forced therethrough.

In an embodiment the at least one blocking region is generally planar.

The frangible region may provide a number of predetermined areas of weakness.

One or more of the areas of weakness may comprise a line of weakness.

The frangible region may provide an array of areas of weakness adapted, in use, to provide an aperture the size of which can be adjusted by breaking, or tearing along, one or more of said areas of weakness.

One or more of said areas of weakness may comprise a line of weakness substantially defining a circle. A plurality of lines of weakness may be provided, forming substantially concentric circles.

The areas of weakness may be provided by perforations in the at least one blocking region.

The frangible region may provide an array of perforations adapted, in use, to provide an aperture the size of which can be adjusted by breaking or tearing along appropriate lines of perforations.

The array of perforations may comprise one or more curved lines of perforations.

One or more curved lines of perforations may define a circle.

The array of perforations may comprise one or more straight lines of perforations.

The array of perforations may comprise a plurality of lines of perforations which radiate outwardly relative to a common point, and which are angularly spaced apart about that common centre.

The frangible region may comprise an array of perforations adapted to allow an opening of any of a range of sizes to be formed.

The array of perforations may comprise a plurality of substantially concentric circles of perforations.

The array of perforations may comprise more than one set of substantially concentric circles of perforations.

One or more sets of substantially concentric circles of perforations may be offset from the centre of the device.

The array of perforations may comprise a plurality of lines of perforations which extend between two or more of the substantially concentric circles of perforations.

The device may be generally rectangular.

The array of perforations may comprise one or more substantially diagonal lines of perforations.

The frangible region may be adapted to allow said conduit to pass therethrough, whilst accommodating said conduit sufficiently snugly to substantially prevent the passage of a settable material between the planar region and the conduit.

In an embodiment the frangible region has a central portion which in use substantially corresponds to a transverse centre of a conduit which passes through the planar region, irrespective of the transverse size of the conduit.

In an embodiment the blockout device may be adapted to block out a plurality of masonry block through cavities. The blockout device may comprise a plurality of frangible regions. The blockout device may comprise two frangible regions. The blockout device may comprise four frangible regions. In use, each frangible region may be adapted to overlie a corresponding masonry block through cavity. The device may be adapted to allow a first part of the device, provided with one or more of said frangible regions, to be separated from a second part of the device. The second part of the device may be a part of the device provided with one or more of said frangible regions.

According to a second aspect of the present disclosure there is provided a blockout device, for use with a masonry block having a through cavity in order to at least partially block one or more through cavities of the masonry block, the blackout device comprising:

at least one device support region adapted to be placed upon an upper surface of a masonry block in order to support the blockout device relative to the upper surface;

at least one blocking region, the or each blocking region being for at least partially blocking a through cavity of said masonry block and for supporting settable building material; and

wherein at least one said blocking region is connected to at least one intermediate region, the intermediate region being for supporting said blocking region relative to at least one said device support region, wherein the intermediate region is adapted, in use, to extend downwardly from the device support region and at least partially defines at least one boundary of at least one device support region and/or at least one blocking region.

In an embodiment at least one blocking region is adapted to provide, in use, at least one aperture through which a conduit can pass from a first side of the device to a second side of the device.

In an embodiment at least one blocking region is substantially planar.

In an embodiment at least one blocking region is adapted to support settable building material above the upper surface of said block.

In an embodiment one or more of said device support regions substantially define a periphery of the blockout device.

The or each device support region may be substantially planar.

All of the device support regions may be substantially coplanar.

The or each blocking region may be substantially planar.

The plane of at least one blocking region may be substantially parallel to the plane of at least one device support region.

The blocking region may be offset from the device support region in a direction corresponding to the direction perpendicular to the upper surface of the block, in use.

One or more intermediate regions may define the perimeter of one of said blocking regions.

One or more intermediate regions may be (but do not have to be) substantially perpendicular to the blocking region.

One or more intermediate regions may be angled at between 75 and 15 degrees relative to the blocking region.

One or more intermediate regions may be angled at between 60 and 30 degrees relative to the blocking region.

One or more intermediate regions may be (but do not have to be) substantially perpendicular to the at least one device support region.

One or more intermediate regions may be angled at between 75 and 15 degrees relative to the at least one device support region.

One or more intermediate regions may be angled at between 60 and 30 degrees relative to the at least one device support region.

In an embodiment one or more intermediate regions are adapted to extend from at least one device support region into a cavity of the block.

In an embodiment one or more intermediate regions are dimensioned and positioned to assist in locating the device relative to a cavity of a block.

In an embodiment the intermediate regions are dimensioned so that in use they can assist in locating the device relative to a cavity, so that at least one device support region of the device is located on an upper surface of a block adjacent the cavity, so that the blocking region is located just below the top of the cavity, and so that the intermediate regions extend into the cavity from the at least one device support region to the generally central region.

In an embodiment at least one said blocking portion, and its immediately adjacent intermediate region(s) have at least one overall dimension which is substantially equal in size to a corresponding dimension of the cavity with which the device is to be used, thereby assisting in location of the device relative to the block.

In an embodiment at least one said blocking portion, and its immediately adjacent intermediate region(s) have at least one overall dimension which is substantially equal in size to a corresponding dimension of the cavity of a standard size masonry block of a first standard size. The standard size masonry block of a first standard size may be masonry block which is approximately 140 mm (plus or minus 20 mm) wide by 390 mm (plus or minus 20 mm) long. The standard size masonry block of a first standard size may be a series 150 masonry block.

In an embodiment the periphery of the device may be dimensioned so that the device is adapted to be wedged into the cavity of a standard size masonry block of a second standard size. The periphery of the device may be dimensioned so that the device is adapted to be wedged in a position such that the device is oriented substantially parallel to the plane of the upper surface of the block. The standard size masonry block of a second standard size may be masonry block which is approximately 190 mm (plus or minus 20 mm) wide by 390 mm (plus or minus 20 mm) long. The standard size masonry block of a first standard size may be a series 200 masonry block.

In an embodiment the device is provided with a tab extending from a part thereof, to facilitate manual manipulation of the device.

In an embodiment the device is provided with a tab extending from an edge region thereof.

The tab may extend from a peripheral part of a device support region of the device.

In an embodiment the device is made from plastic.

In an embodiment the device is made from a single piece of plastic.

In an embodiment the device is made from a single piece of sheet plastic.

In an embodiment the blockout device is adapted to block out a single through cavity of a masonry block.

In an embodiment the blockout device is adapted to block out a plurality of masonry block through cavities. The blockout device may comprise a plurality of blocking regions. The blockout device may comprise two discrete blocking regions. The blockout device may comprise four discrete blocking regions. In use, each blocking region is adapted to at least partially block a corresponding masonry block through cavity. The device may be adapted to allow a first part of the device, provided with one or more of said blocking regions to be separated from a second part of the device. The second part of the device may be a part of the device provided with one or more of said blocking regions.

The blockout device in accordance with the second aspect may also be in accordance with the first aspect. In this case, the (or each) frangible region may be provided as all or part of the (or a corresponding) blocking region.

According to a third aspect of the present disclosure there is provided a blockout device, for use with a masonry block having a through cavity, the blockout device comprising a blocking region, for at least partially blocking a through cavity of said masonry block, which is adapted to provide, in use, at least one aperture through which a conduit can pass from a first side of the device to a second side of the device, wherein at least part of the blockout device is made from a substantially transparent plastic, such that visibility, from the first side of device, of part of a conduit which is on the second side of the device, is facilitated.

The first side of the device may correspond, in use, to an upper side of the device, and the second side of the device may correspond, in use, to a lower side of the device.

The device may further comprise one or more device support regions adapted to be placed upon an upper surface of a masonry block in order to support the blockout device relative to the upper surface.

The blocking region may be fabricated from a substantially transparent plastic.

The blockout device may be fabricated from a substantially transparent plastic.

The blockout device in accordance with the third aspect may comprise a plurality of blocking regions.

The blockout device in accordance with the third aspect may also be in accordance with one or both of the first and second aspects.

According to a fourth aspect of the present disclosure there is provided a method of blocking a through cavity in a masonry block comprising use of a block out device in accordance with one or more of the first to third aspects.

According to a fifth aspect of the present disclosure there is provided a method of blocking a through cavity in a masonry block, comprising:

placing a blockout device on the masonry block so that:

• • a peripheral region of the blockout device is supported by an upper surface of the masonry block;
  • at least part of the device projects from the peripheral region into the cavity; and
  • at least part of the device extends across the cavity so as to be able to support a settable material above the block.

According to a further aspect of the present disclosure there is provided a blockout device, comprising:

• • a peripheral region of the blockout device adapted to be supported by an upper surface of a masonry block;
  • a projecting part of the device adapted to project from the peripheral region into a cavity of the masonry block; and
  • a blocking part of the device adapted to extend at least partially across the cavity so as to be able to support a settable material above the block.

Features mentioned or set out above in relation to any one of the above aspects may applicable to one or more of the other aspects, and may be incorporated in embodiments in accordance with one or more of the other aspects.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described, by way of example only, with reference to the accompanying drawings in which:

FIG. 1(a) is a plan view of a embodiment of a blockout device in accordance with the present disclosure;

FIG. 1(b) is a reproduction of FIG. 1(a) annotated with various dimensions of a specifically sized embodiment.

FIG. 2 is an end view of the embodiment of FIG. 1(a);

FIG. 3 is a side view of the embodiment of FIG. 1(a);

FIG. 4 is a cross section on A-A of FIG. 1(a);

FIG. 5 is a perspective view of the embodiment of FIG. 1(a);

FIG. 6 is a perspective view corresponding to FIG. 5, but showing a conduit extending through the blockout device;

FIG. 7 is a schematic plan view showing the embodiment of FIGS. 1 to 5 in use, blocking an upper region of a cavity of a masonry block.

FIG. 8(a) is a schematic cross sectional view on D-D of FIG. 7, also illustrating, in schematic cross section adjacent parts of a masonry block wall in which the masonry block of FIG. 7 might be included in use;

FIG. 8(b) is a reduced-scale representation corresponding to FIG. 8(a) also illustrating still more adjacent parts of a masonry block wall in which the masonry block of FIG. 7 might be included in use;

FIG. 9(a) is a plan view of a variation of the embodiment of FIGS. 1 to 8(b) in which an alternative arrangement of perforations is used;

FIG. 9(b) is a reproduction of FIG. 1(a) annotated with an example of details of the angular spacing between various lines of perforations;

FIG. 10(a) is a plan view of an alternative embodiment of a blockout device in accordance with the present disclosure, which has different dimensions to the embodiment of FIGS. 1 to 8(b), and is adapted for use with a differently dimensioned masonry block;

FIG. 10(b) is a reproduction of FIG. 10(a) annotated with various illustrative dimensions;

FIG. 11 is an end view of the embodiment of FIG. 10(a);

FIG. 12 is a side view of the embodiment of FIG. 10(a);

FIG. 13 is a cross section on B-B of FIG. 10(a);

FIG. 14 is a perspective view of the embodiment of FIG. 10(a);

FIG. 15 is a perspective view corresponding to FIG. 14, but showing a conduit extending through the blockout device;

FIG. 16 is a schematic plan view showing the embodiment of FIGS. 10(a) to 14 in use, blocking an upper region of a cavity of a masonry block;

FIG. 17 is a schematic cross sectional view on C-C of FIG. 16, additionally also illustrating, in schematic cross section, adjacent parts of a masonry block wall in which the masonry block of FIG. 7 might be included in use;

FIG. 18(a) is a plan view of a variation of the embodiment of FIGS. 10(a) to 17 in which an alternative arrangement of perforations is used;

FIG. 18(b) is a reproduction of FIG. 18(a) annotated with an example of details of the angular spacing between various lines of perforations;

FIG. 18(c) is a plan view of a further variation in which an alternative arrangement of perforations is used;

FIG. 19 is a schematic plan view of an alternative embodiment, adapted to block two cavities; and

FIG. 20 is a schematic plan view of a further alternative embodiment, adapted to block four cavities.

DETAILED DESCRIPTION OF EMBODIMENTS

With reference to FIGS. 1(a) to 6 an embodiment of a blockout device, generally designated 1, for use with a masonry block having a through cavity, comprises a blocking region, which in this embodiment is in the form of a generally planar region 10, adapted to extend across most of the through cavity of the masonry block in use in order to at least partially block the cavity and to support a settable material above the block. The generally planar region 10 is generally rectangular, and provides a frangible region 20 through which a conduit can be forced. The frangible region 20 allows the device 1 to accommodate a conduit of any of a range of transverse sizes. This is accomplished by the frangible region being able to provide various sizes of opening for passage of a conduit therethrough. In this embodiment the frangible region 20 can be broken, to provide an aperture of appropriate size for a given conduit, by forcing the given conduit through the frangible region. More specifically, the frangible region 20 provides an array of perforations which together, in use, provide an aperture the size of which can be adjusted by breaking or tearing along appropriate lines of perforations. In the illustrated embodiment of a blockout device 1 the array of perforations includes curved lines of perforations (which define circles, as will be described below) and may include straight lines of perforations to facilitate breaking or tearing. Thus the size of the aperture created can be substantially determined by the transverse size of the conduit forced therethrough. In the illustrated embodiment the blockout device 1 is made of a suitable plastic, having a thickness of approximately 1 mm (although a lesser thickness may be suitable, depending on the plastic used and strength required).

In this embodiment the frangible region comprises an array of perforations in the form of a plurality of substantially concentric circles of perforations. More specifically, in this embodiment the array of perforations comprises first to fourth concentric circles of perforations 21, 22, 23, 24. The frangible region is provided with a central aperture 25. In this embodiment the first to fourth concentric circles of perforations 21, 22, 23, 24 have diameters of 45 mm, 35 mm, 25 mm and 10 mm respectively, and the central aperture 25 has a diameter of 5 mm. The array of perforations further comprises first to fourth lines of perforations 26, 27, 28, 29 each of which extends from the smallest, innermost, circle of perforations 24, substantially to corners 31, 32, 33, 34 of the rectangular generally planar region 10. Thus the lines of perforations 26, 27, 28, 29 extend or radiate outwardly from an approximate centre of the frangible region. Of course it will be appreciated that alternative arrangements of perforations are possible (for example more or fewer circles and/or radiating lies could be used, the circles of perforations could be joined by staggered lines segments of perforations, instead of the continuous lines of perforations 26, 27, 28, 29, etc.)

The frangible region 20 is thus adapted to allow a conduit of any of a range of sizes to pass therethrough, whilst accommodating the conduit sufficiently snugly to substantially prevent the passage of a settable material between the planar region 10 and the conduit. For example, if a conduit with an outside diameter of 25 mm were to be used, the frangible region could be broken along the third circle of perforations 23 (for example by pushing the conduit through the frangible region so as to tear the frangible region along the third circle of perforations 23) and the conduit could then be passed through the resulting 25 mm diameter aperture, with the boundary of that aperture fitting sufficiently closely to the exterior of the conduit to prevent substantial leakage of a settable material (which, in this application is typically quite viscous and is normally concrete) between the device 1 and the conduit. FIG. 6 illustrates a conduit 35 (which as illustrated has an external diameter of approximately 25 mm) extending though an aperture formed by breaking or tearing the frangible region along the third circle of perforations 23.

It should be appreciated that if a conduit with an outside diameter of 23 mm or 24 mm were used, any small gap between a 25 mm diameter aperture and the outside wall of the conduit would be sufficiently small to avoid problematic leakage of settable material between the device 1 and the conduit. Similarly, the generally planar region may, in use be adapted to fit other sizes of conduit by breaking or tearing appropriate parts of the frangible region, preferably utilising the perforations.

Because the circles of perforations are, in this embodiment, concentric, with their centres corresponding to the centre of the device, a circular conduit will, in use, be located substantially concentric with the perforated circles, and this at the centre of the device 1.

In use, the generally planar region 10 is adapted to be located just below the top surface of a masonry block, and just inside a through cavity of the masonry block, so as to support settable material above the block.

The blockout device 1 further comprises at least one support region, which in this embodiment is in the form of a peripheral rim 40, adapted to be placed upon an upper surface of the masonry block in order to support the blockout device relative to the upper surface. The generally planar region 10 is provided at a generally central region of the device 1 and is surrounded by the peripheral rim 40. The blockout device 1 further comprises an intermediate region, which in use extends in a direction perpendicular to the upper surface of the block, and which defines and connects the inner boundary of the peripheral rim 40 and the outer boundary of the generally planar region. In this embodiment the intermediate region is provided by an inclined region 50, angled at approximately 45 degrees to the peripheral rim 40, surrounding the rectangular planar region 10 and having first and second longer sides 51, 52, first and second shorter sides 53, 54 and first to fourth somewhat rounded corner regions 55, 56, 57, 58. The inclined region 50 thus spaces apart and offsets the generally planar region 10 from the peripheral rim 40, in this embodiment by approximately 5 mm to 6 mm, in a direction perpendicular to the upper surface of the block. Thus when the peripheral rim 40 rests on the upper surface of a masonry block, the generally planar region 10 is located just below the top surface, and just inside the through cavity, of the masonry block.

In the illustrated embodiment 1 the peripheral rim 40 forms a generally rectangular border of the device 1, is generally planar, and comprises first and second longer sides 41, 42, first and second shorter sides 43, 44 and first to fourth somewhat rounded corners 45, 46, 47, 48. An elongate tab 49 projects outwardly from the peripheral rim 40, and may assist in manual manipulation of the device. For example, the tab 49 may be used to manually retrieve the device if it inadvertently becomes inserted in the cavity of a block.

With reference to FIG. 7, the blockout device 1 is particularly adapted for use with a masonry block 60 (shown in plan view from above in FIG. 7) which has two substantially rectangular through cavities 61, 62 extending from the top surface 63 to the bottom surface (not shown) thereof. The masonry block 60 is generally rectangular and may be regarded as having first and second, longer, side walls 64, 65, first and second, shorter, laterally extending end walls 66, 67, and an laterally extending intermediate wall 68 which is generally perpendicular to the side walls 64, 65, generally parallel to the end walls 66, 67, and extends between central portions of the side walls 64, 65. Thus the first through cavity 61 may be regarded as being defined by: the first end wall 66; first-end parts of the first and second side walls 64, 65; and a first-end side of the intermediate wall 68. Similarly, the second through cavity 62 may be regarded as being defined by: the second end wall 67; second-end parts of the first and second side walls 64, 65; and a second-end side of the intermediate wall 68. Such masonry blocks are provided commercially in any of a small number of different standard sizes. The blockout device 1, in this particular embodiment, is dimensioned specifically for use with a standard size block, sometimes called a series 150 block, and the width of the parts which are adapted to extend into the cavity 62 (ie width of the generally planar region 10 plus the inclined region 50) is approximately 60 mm, which is only very slightly less than the width of the cavity 62 of a series 150 block. The blockout device 1 has an overall length (excluding the tab) of approximately 140 mm, an overall width of approximately 115 mm. These dimension allow the device 1 to be forced into, and be retained within the cavity of larger standard size block (a series 200 block), in order to support a settable material, thus providing a useful secondary functionality for this embodiment 1, which will be described further in due course. Of course a blockout device having features similar to this embodiment 1 could have different overall dimensions and need not have the secondary functionality.

Thus the width and length of the device 1 are sufficient to block out one of the cavities (the second cavity, 62, as illustrated in FIG. 7). The width and length of the peripheral rim 40 are greater than the respective width and length of each of the cavities 61, 62, so that in use at least a peripherally outermost part of the peripheral rim 40 can rest upon the top surface of the block which surrounds the cavity 62 which is to be blocked out. The overall lateral width of the peripheral rim 40 is less than the width of the block 60, and more specifically less than the width of the top surface 63 of the block 60, so that parts of the top surface of the block extend laterally beyond device 1. The width of the parts of the device 1 which are, in use, vertically offset from the peripheral rim 40 (i.e. the combined width of the planar region 10 and the inclined region 50) is only slightly less than the width of the cavity 62. Thus placing the device 1 on the block so that the planar region 10 is in the cavity, below the top surface 63 of the block 60, effectively locates the device laterally relative to the block 60. The device 1 can thus easily be placed in a position in which the peripheral rim 40 rests on the top surface 63 of the block, and in which the device is positioned to block out a cavity of the block (cavity 62, as illustrated in FIG. 7). The device 1 can then be secured in position by placing mortar on the peripheral rim 40 and on the adjacent top surface 63 of the block 60, so that the device 1 is held in position, relative to the block 60, by the mortar. More specifically, the device 1 can be secured in position by placing mortar on the longer sides 41, 42 of the peripheral rim 40, and on the adjacent top surface 63 of the block 60, so that mortar overlies and bridges the periphery of the device 1, and holds the device 1 is position, relative to the block 60. Of course, other methods of securing the device relative to the block could be used (for example, but not limited to, use of a thin layer of a suitable adhesive between the device and the block).

The peripheral rim 40 may be provided with one or more characteristics or features which facilitate securing of the device 1 to the block 60. In an embodiment, such characteristics or features comprise features which facilitate securing of the device 1 by mortar by enhancing secure engagement of the peripheral rim 40 by mortar, once the mortar is set. For example, rather than providing a smooth upper surface, the peripheral rim may be provided with texturing, apertures, slots and/or protuberances so that the peripheral rim 40, and thus the device, can be held securely by set mortar laid across the top of the rim 40 and block 60. In one embodiment, the peripheral rim is provided with one or more upwardly projecting protuberances formed by one or more corresponding regions of increased thickness, for example, as illustrated in FIG. 18(c) which will be described in detail below, an upwardly projecting ridge 348 is provided. (In the particular embodiment illustrated in FIG. 18(c) the upwardly projecting ridge extends upwardly approximately 1 mm (0.04 inches) and extends around the device, just within the outer periphery of the peripheral rim, although it will be appreciated that this is just one example of a feature which facilitates entrapment of part of the peripheral rim by set mortar, and any suitably configured feature could be used.) Having the peripheral rim 40 securely located relative to the block 60 may be useful, depending on the stiffness of the device and the load/pressure of settable material to be borne, in avoiding downwards bowing and collapse of the device under the load of the settable material which could occur under some circumstances if the peripheral rim 40 were not adequately secured and were thus able to be pulled into the cavity by the load of settable material.

FIG. 8(a) shows, in schematic cross section, part of a masonry block wall, and illustrates the blockout device 1 in use, in a position relative to the block 60 corresponding to that illustrated in FIG. 7. The blockout device 1 extends slightly into the cavity 62 of block 60 and supports a settable filling material above the block, for example so that the material can form part of a horizontally extending beam 69A. By way of illustration a first additional block 60A, having cavities 61A, 62A, and a second additional block 60B, having cavities 61B, 62B are illustrated. The first additional block 60A is located (in the course above the block 60) so that the first cavity 61A thereof is directly above the device 1 and directly above the second cavity 62 of the block 60. The second additional block 60B is located horizontally adjacent the block 60, so that the first cavity 61B thereof is directly below the second cavity 62A of the first additional block 60A.

The settable filling material is used to fill the cavities 61A, 62A of the first additional block 60A, for example to provide part 69A of a horizontally extending beam. The device 1 supports the settable filling material in the first cavity 61A of the first additional block 60A above the block 60, and prevents it falling into the blocked out second cavity 62 of the block 60. Conduit 35 (placed prior to provision of the settable filling material) extends though the device 1 to provide service distribution in the finished construction. The first cavity 61B of the second additional block 60B is not provided with a blockout device, and settable filling material has therefore fallen from the second cavity 62A of the first additional block 60A into the first cavity 61B of the second additional block 60B. It may be desirable to allow such downwards passage of settable filing material at selected locations in order to provide one or more pillars 69B.

FIG. 8(b) illustrates schematically a larger section of masonry block wall, which additionally includes third, fourth, fifth and sixth additional blocks 60C, 60D, 60E, 60F. As illustrated, blockout devices 1 are used with all the blocks which are in the same course as block 60, in order to support settable filling material thereabove, for example to for a horizontally extending beam 69C. More specifically, blockout devices 1 are used with: first and second cavities 61, 62 of block 60, second cavity 62B of second additional block 60B, and first and second cavities 61D, 62D of fourth additional block 60D. The first cavity 61B of the second additional block 60B is not provided with a blockout device, as set out above, in order to allow formation of pillar 69B. As illustrated schematically in FIG. 8(b) the horizontal beam 69C and pillar 69B may be provided with reinforcing bars 70, 71. The blocks in the course above the block out devices 1 may of the type known as ‘knock out bond beam’ blocks, which are provided with slots or apertures in their laterally extending walls to facilitate accommodation of one or more generally horizontally extending reinforcing bars 70.

It will be appreciated that in constructing a masonry block wall or wall section, as illustrated schematically in FIGS. 8(a) and 8(b), embodiments of the blockout device disclosed herein can easily be positioned as desired, on the upper surfaces of selected masonry blocks. If repositioning or removal of one or more blockout devices is desired, this can easily be achieved prior to the devices being fixed in place (eg by use of mortar). If a device 1 is fixed in place, positioned to block out a cavity which it is subsequently desired not to block out, unblocking of the cavity is still relatively easy and convenient, since the blockout device 1, being made of a sheet plastic material, can be cut, broken or melted, without undue difficulty, using equipment which builders will typically have conveniently to hand. The disclosed embodiment is also light and large numbers are easy to transport and carry. The plastic blockout devices 1 are also economical to manufacture, and may have low environmental impact (eg carbon footprint) especially if made from a recycled plastic. Further, the perforated region facilitates provision of an aperture therethrough to accommodate a conduit of any of a range of sizes. The device can be made from a transparent plastic, which can assist in positioning a bottom part of a conduit, since it allows a user to see the part of the conduit which is below the device. The blockout devices can be manufactured by a suitable plastic thermoforming or plastic injection process.

At least some of these features are in marked contrast to features of at least some known attempts at providing devices for blocking masonry block cavities. One known device comprises a metal planar body or plate adapted to be wedged in a through cavity of a masonry block, just above the base of the block (i.e. at the bottom of the cavity), to block off the base of the block and prevent or reduce flow of concrete out of the base of the block. The planar body provides several separate, spaced apart, circular indented portions of different diameters, a selected one of which can be pushed out from its location on the plate leave a suitably sized aperture in the planar body to allow passage of a service conduit therethrough. Once wedged into a cavity, such devices can be very difficult to remove. Further, because the parts which can provide apertures are indented metal portions, connected by metal parts to the remainder of the planar body, they can be difficult to remove, and provision of an aperture for a conduit can be difficult. This is especially true if the device has been wedged into a cavity with the wrong side of the device facing upwards, since the indented portions are difficult or impossible to push out from the ‘wrong’ side of the plate. The above described difficulty in removing the wedged planar body from the bottom part of a masonry block exacerbates this problem, since the incorrectly oriented planar body cannot easily be removed and replaced in the correct orientation. Manufacture from metal plate makes some known devices relatively heavy (and therefore less convenient to carry in large numbers), and also relatively expensive to manufacture and relatively environmentally unfriendly. Metal plates are also opaque, so that visibility of part of a conduit which is below the plate is poor or non-existent.

Of course, it should be appreciated that many variations of the described embodiment 1 of a blockout device are possible. For example FIGS. 9(a) and 9(b) illustrate an embodiment 100 which is, in many ways similar to the embodiment 1 illustrated in FIGS. 1 to 7, differing only in that it has an alternative arrangement of perforations. In this embodiment 100 the frangible region 120 comprises an array of perforations in the form of a number of lines radiating away from, and angularly space about, a single circle of perforations. More specifically, in this embodiment the array of perforations comprises a single circle of perforations 121 and first to twelfth lines 122 to 133, angularly spaced apart by approximately between about 27 degrees and about 35 degrees, and radiating outwardly (towards intermediate portion 150) from the single circle of perforations 121. In use this provides a generally triangular segment of generally planar region 110 between each two neighbouring lines of perforations. Forcing a conduit through the frangible region 121 has the effect of tearing along the lines of perforations sufficiently to form an aperture (by separation and deformation of the generally triangular segments) just large enough to accommodate the conduit.

FIGS. 10(a), 10(b), 11, 12, 13, 14, 15, 16 and 17 show an alternative embodiment 200 which, it will be appreciated, has many similarities in principle and design to the blockout device 1, but which is a larger device suitable for use with a larger masonry block. The embodiment 200 is suitable for use with a 190 mm wide by 390 mm long masonry block (sometimes called a “series 200” masonry block, although series 200 blocks may have slightly differing sizes) in contrast to the device 1 which is suitable for use with a 140 mm wide by 390 mm long masonry block (sometimes called a “series 150” masonry block, although series 150 blocks may have slightly differing sizes). It will be appreciated that there are many similarities between the blockout device 200 and the blockout device 1, and the similarities will not be described in detail herein. It will further be appreciated that FIGS. 10(a), 10(b), 11, 12, 13, 14, 15, 16 and 17, respectively correspond in general terms to the views of FIGS. 1(a), 1(b), 2, 3, 4, 5, 6, 7 and 8(a) respectively, but illustrate the larger embodiment 200. The blockout device 200 is dimensioned specifically for use with series 200 blocks, and has an overall length (excluding the tab) of approximately 160 mm, and an overall width of approximately 140 mm. The width of the parts which are adapted to extend into a cavity of a masonry block (ie width of generally planar region 210 plus inclined region 250) is approximately 100 mm, which is only slightly less than the width of the cavity in the series 200 block. In a 190 mm wide by 390 mm long “series 200” masonry block the width of the cavity is approximately 110 mm, and the length of the cavity is approximately 135 mm: thus it will be appreciated that the smaller embodiment 1 (of FIGS. 1(a), 1(b), 2, 3, 4, 5, 6, 7 and 8(a)) is dimensioned so that can be forced into the cavity of a series 200 block, in order to support a settable material, as foreshadowed above.

As the width of generally planar region 210 of device 200 is considerably greater than the width of the generally planar region 10 of device 1, a greater number of concentric circles of perforations can be provided (allowing effective accommodation of a greater range of conduit sizes). As illustrated, device 200 includes eight concentric circles 224 of perforations (although, of course, other numbers could be provided if desired).

FIG. 15 illustrates the blockout device 200 with a 25 mm outside diameter conduit 35 extending therethrough.

FIG. 16 illustrates the blockout device 200 positioned, for use, on a series 200 block 260.

FIG. 17 illustrates the blockout device 200 positioned in part of a wall structure.

As with the smaller embodiment, alternative embodiments are of course possible, and FIGS. 18(a) and 18(b) illustrate an embodiment of a blockout device 300, which has many similarities to the blockout device 200, but adopts an alternative array of perforations, configured with similarities to the array of perforations in the embodiment 100 of FIGS. 9(a) and 9(b). In this embodiment 300 frangible region 320 comprises an array of perforations in the form of a number of lines radiating away from, and angularly spaced about, a single circle of perforations. More specifically, in this embodiment the array of perforations comprises a single circle of perforations 321 and first to sixteenth lines (eg line 322) angularly spaced apart by approximately between about 20 degrees and about 25 degrees, and radiating outwardly (towards intermediate portion 350) from the single circle of perforations 321. In use this provides a generally triangular segment of generally planar region 310 between each two neighbouring lines of perforations. It will be appreciated that, as illustrated, the greater angular spacings are between adjacent lines which are orientated in or close to the width or lateral direction of the blockout device (ie shorter lines) and the lesser angular spacings are between adjacent lines which are orientated in or close to the length direction of the blockout device (ie longer lines), which avoids undue disparity in the size and area of the triangular segments. Forcing a conduit through the frangible region 321 has the effect of tearing along the lines of perforations sufficiently to form an aperture (by separation and deformation of the generally triangular segments) just large enough to accommodate the conduit.

FIG. 18(c) illustrates a further alternative embodiment of a blockout device 360, which has many similarities to the previously described embodiments, but which provides an alternative array of perforations. In this embodiment 360 frangible region 362 comprises an array of perforations having similarities to the array of perforations in the blockout device 1, but further including a number of apertures 364, and concentric circles of perforations 366 which are offset from the center of the device. This provides additional utility in enabling the blockout device 360 to accommodate more than one conduit and/or other elongate members. Further, there may be circumstances in which it is desired to have a conduit or other elongate member offset from the centre of the cavity, and the blockout device 360 accommodates this. More specifically, in this embodiment, in addition to the aperture and perforations provided by the blockout device 1, the blockout device 360 provides apertures 364 and concentric circles of perforations 366 which are offset from the centre of the device towards corners of generally rectangular generally planar region 368. In this embodiment four offset groups of perforations are provided, but it will be appreciated that, in variations, different numbers of offset groups could be provided. It will be appreciated that each group is similar in operation to the array provided in the blockout device 1: for example, an opening can be created (or enlarged) by forcing a conduit through a part of the frangible region corresponding to a group, and the size of the opening can be adjusted by selective breaking/tearing of the frangible region, and may be effectively determined by the transverse size of a conduit pushed through the frangible region. In a further variation, the offset groups do not include an aperture: in such a variation groups of perforations, optionally laid out as concentric circles, but without respective apertures associated therewith may be provided. In further variations different parts of the frangible region, each adapted to provide an opening might not overlap (or intersect) as is the case in the blockout device 360.

In the illustrated embodiments the frangible regions are provided by means of perforations. In some embodiments the perforations comprise small holes or apertures which are elongate in the direction of the lines formed by the perforations, adjacent perforations are separated by bridges of plastic, and each perforation (aperture) has a length between two and four times the length of the bridge (although it is not essential that all the apertures, or all the bridges are of equal dimensions). Such an arrangement has been found to provide sufficient weakness to allow a conduit to be forced through the frangible area, but sufficient strength to adequately support settable material above the device, in use. However, the configuration may be varied if desired, according the strength and thickness of the material used, desired strength, and/or other factors.

Many further variations are possible. For example, other types of frangible areas or lines could be used. For example the frangible region could be provided by one or more areas or lines of weakness comprising one or more areas of reduced thickness (rather than through apertures). Such lines of weakness could have ‘bridges’ of greater thickness therebetween (similar to bridges in the lines of apertures described above), but provision of such bridges might not be necessary, depending on the material and requirements for the device.

Furthermore a blockout device could comprise two or more areas, each adapted to block a through cavity, so that the device is essentially equivalent to two or more block out devices, as described above, formed as a single device. FIG. 19, for example, illustrates schematically an embodiment 400, of a blockout device, which comprises first and second blocking regions (which may additionally or alternatively comprise frangible regions) 410, 420 respectively, each adapted to be located just inside a cavity 61, 62 of a masonry block (eg, block 60, which is shown in FIG. 19 to illustrate the relative dimensions of the embodiment 400 and a masonry block 60 with which the embodiment 400 is intended for use). It will be appreciated that the embodiment 400 effectively comprises two of the blockout devices 1, of FIGS. 1(a), 1(b), 2, 3, 4, 5, 6, 7 and 8(a), formed as a single unit, and that similarities between the embodiments will not be described explicitly. However, it will be appreciated that a device support region 440 located between the first and second blocking regions 410, 420, is dimensioned so that the first and second blocking regions 410, 420 can each be located just inside a cavity of a masonry block (eg, block 60), in use. The embodiment 400 may be advantageous over the embodiment blockout devices 1, since only one device per block, rather than two, need be used, which may enhance convenience and facilitate use.

FIG. 20 illustrates schematically a further embodiment 500, of a blockout device, which comprises first to fourth blocking regions (which may additionally or alternatively comprise frangible regions) 510, 515, 520, 525 respectively. Since this embodiment has four blocking regions, it will be appreciated that it is adapted to be used to block four cavities: eg, the cavities of two adjacent blocks. Thus, as illustrated in FIG. 20, the first to fourth blocking (and/or frangible) regions 510, 515, 520, 525 are each adapted to be located just inside a cavity 61, 62, 61A, 62A of masonry blocks 60, 60A. It will be appreciated that the embodiment 500 effectively comprises four of the blockout devices 1, of FIGS. 1(a), 1(b), 2, 3, 4, 5, 6, 7 and 8(a) formed as a single unit. However it will be appreciated that one or more device support regions 530, 532, 536 located between neighbouring blocking regions 510, 515, 520, 525 are dimensioned so that the blocking regions 510, 515, 520, 525 can each be located just inside a cavity 61, 62, 61A, 62A of one of the masonry blocks 60, 60A, in use. The embodiment 500 may be advantageous over the embodiment blockout devices 1, since only one device per two blocks need be used, which may enhance convenience and facilitate use. However, it will be appreciated that, in use, the number of cavities in a course of blockwork which requires blocking out will frequently not be a multiple of four. Thus, in order to facilitate use in such circumstances, the embodiment 500 is provided with division lines 540, 542, 544, 546 (which may be lines of perforations) which allow the embodiment 500 to be divided into a number of parts. Each part may be equivalent to one, two or three of the blockout devices 1, of FIGS. 1(a), 1(b), 2, 3, 4, 5, 6, 7 and 8(a), and additionally, in this embodiment, the embodiment 500 includes a spacing part 450 between the two pairs of blocking regions 510, 515, 520, 525. If desired, some or each of the parts into which the embodiment 500 can be divided may be dimensioned so as to be able to fit within the cavity of a larger block than the block 60, 60A for which the embodiment is primarily intended, as discussed above with reference to the ‘secondary functionality’ for the embodiment 1.

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

It will be understood to persons skilled in the art of the invention that many modifications may be made without departing from the spirit and scope of the invention.

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

Claims

1. A blockout device, for use with masonry blocks having at least one through cavity, the blockout device comprising:

at least one blocking region, adapted to extend at least partially across a through cavity of the masonry block in use, to at least partially block the through cavity, and to support a settable material above the block;

the at least one blocking region having a frangible region adapted to accommodate conduits of various transverse sizes, by providing an opening the size of which can be adjusted to accommodate a conduit of any of a number of different transverse sizes.

2. A blockout device as claimed in claim 1, wherein the size of the opening can be adjusted by breaking or tearing one or more parts of the frangible region.

3. A blockout device as claimed in claim 2, wherein the size of the opening can be adjusted by forcing said conduit through the frangible region, so that the size of the opening is substantially determined by the transverse size of the conduit forced therethrough.

4. A blockout device as claimed in claim 3 wherein the frangible region provides an array of areas of weakness adapted, in use, to provide an aperture the size of which can be adjusted by breaking, or tearing along, one or more of said areas of weakness.

5. A blockout device as claimed in claim 3, wherein said frangible region comprises a plurality of lines of weakness provided in the blocking region, forming at least one set of substantially concentric circles.

6. A blockout device as claimed in claim 3, wherein the frangible region provides an array of perforations, the array comprising a plurality of lines of perforations, and the array being adapted, in use, to provide an aperture the size of which can be adjusted by breaking or tearing along appropriate lines of perforations.

7. A blockout device as claimed in claim 6, wherein the array of perforations comprises one or both of: at least one curved line of perforations defining a circle; and a plurality of lines of perforations which radiate outwardly relative to a common point and which are angularly spaced apart about that common point.

8. A blockout device as claimed in claim 7, wherein the array of perforations comprises at least two sets of substantially concentric circles of perforations.

9. A blockout device as claimed in claim 8, wherein the array of perforations further comprises a plurality of lines of perforations which extend between two or more substantially concentric circles of perforations.

10. A blockout device as claimed in claim 3, wherein the frangible region is adapted to allow a conduit to pass therethrough, whilst accommodating said conduit sufficiently snugly that in use passage of a settable construction material between the blocking region and the conduit is substantially prevented.

11. A blockout device as claimed in claim 1, wherein the blockout device is be adapted to block out a plurality of masonry block through cavities, and comprises a plurality blocking regions adapted to block respective masonry block through cavities, each blocking region being provided with a frangible region.

12. A blockout device as claimed in claim 11, wherein the blockout device is provided with a further frangible region adapted to allow a first part of the device, provided with a blocking region, to be separated from a second part of the device provided with a blocking region.

13. A blockout device as claimed in claim 1, further comprising at least one device support region adapted to be placed upon an upper surface of a masonry block in order to support the blockout device relative to the upper surface;

wherein at least one said blocking region is connected to at least one intermediate region, the intermediate region being for supporting said blocking region relative to at least one said device support region, wherein the intermediate region is adapted, in use, to extend downwardly from the device support region and at least partially defines at least one boundary of at least one device support region and at least one blocking region.

14. A blockout device as claimed in claim 3, wherein the frangible region is adapted to provide a plurality of openings, each opening adapted to allow a conduit to pass therethrough, and wherein the frangible region is configured so that the size of each opening is adjustable to accommodate a conduit of any of a number of different transverse sizes.

15. A blockout device as claimed in claim 1, wherein at least part of the blockout device is made from a substantially transparent plastic, such that visibility, from a first side of device, of part of a conduit which is on a second side of the device, is facilitated.

16. A blockout device, for use with a masonry block having a through cavity in order to at least partially block one or more through cavities of the masonry block, the blockout device comprising:

at least one device support region adapted to be placed upon an upper surface of the masonry block in order to support the blockout device relative to the upper surface;

at least one blocking region, the or each blocking region being for at least partially blocking a through cavity of said masonry block and for supporting settable building material; and

wherein at least one said blocking region is connected to at least one intermediate region, the intermediate region being for supporting said blocking region relative to at least one said device support region, wherein the intermediate region is adapted, in use, to extend downwardly from the device support region.

17. A blockout device as claimed in claim 16, wherein at least one blocking region is substantially planar, wherein the or each device support region is substantially planar and wherein the plane of at least one blocking region is substantially parallel to a plane of at least one device support region.

18. A blockout device as claimed in claim 16, wherein one or more intermediate regions is angled at between 90 and 15 degrees relative to the blocking region.

19. A blockout device as claimed in claim 16, wherein at least one blocking region is configured to provide, in use, at least one aperture through which a conduit can pass from a first side of the device to a second side of the device.

20. A blockout device as claimed in claim 16, wherein one or more intermediate regions are adapted to extend, in use, from at least one device support region supported on an upper surface of the block, into a cavity of the block and to assist in locating the device relative to a cavity of a block so that the blocking region is located in the cavity of the block below the top of the cavity, by engaging a part of the block which defines the cavity thereof.

21. A blockout device as claimed in claim 20, wherein at least one said blocking region, and its immediately adjacent intermediate region(s) have at least one overall dimension which is substantially equal in size to a corresponding dimension of the cavity of a masonry block of a standard size, thereby assisting in location of the device relative to the block.

22. A blockout device as claimed in claim 21, wherein the periphery of the device is dimensioned so that the device is adapted to be wedged into the cavity of a standard size masonry block of a second standard size such that the device is oriented substantially parallel to a plane defined by the upper surface of the block.

23. A blockout device as claimed in claim 16, wherein the device is made from a single piece of plastic.

24. A blockout device as claimed in claim 16, wherein the blackout device comprises a plurality of blocking regions and is adapted to block out a plurality of masonry block through cavities.

25. A blockout device as claimed in claim 16, wherein the blockout device comprises two or more discrete blocking regions, each adapted to at least partially block a corresponding masonry block through cavity.

26. A blockout device as claimed in claim 25, wherein the blockout device is provided with a frangible region adapted to allow a first part of the device, provided with a blocking region, to be separated from a second part of the device provided with a blocking region.

27. A blockout device, for use with a masonry block having a through cavity, the blockout device comprising a blocking region, for at least partially blocking a through cavity of said masonry block, which is adapted to provide, in use, at least one aperture through which a conduit can pass from a first side of the device to a second side of the device, wherein at least part of the blockout device is made from a substantially transparent plastic, such that visibility, from the first side of device, of part of a conduit which is on the second side of the device, is facilitated.

28. A blockout device as claimed in claim 27, wherein the device further comprises one or more device support regions adapted to be placed upon an upper surface of a masonry block in order to support the blockout device relative to the upper surface, and one or more.

29. The blockout device as claimed in claim 27, wherein the device comprises a plurality of blocking regions and is adapted to block out a plurality of masonry block through cavities.

30. A blockout device as claimed in claim 17, wherein at least one said device support region comprises the one or more features adapted in use to facilitate securing of at least part of said device support region by a material applied to said support region to secure the device to a masonry block.