Masonry block constructions with polymeric coating

Abstract

In the construction of a structural block wall the method includes the steps of erecting on a base a wall of mortarless structural blocks, applying to opposite faces of the wall a fibre reinforced polymeric coating and anchoring the wall to the base with the fibre reinforced coating. The resultant wall possesses a structural integrity wherein compressive loads are borne by the structure blocks and tensile loads are borne by the fibre reinforced skin extending over the surface of the wall and onto the base to anchor the wall to the base.

1 - 26 . (canceled)  
   
   
       27 . A method for construction of a structural block wall, said method comprising the steps of: 
 erecting on a structural base a wall of mortarless structural blocks wherein a base course of said structural blocks is anchored to said structural base; and, applying to opposite faces of said wall a fibre reinforced polymeric coating wherein said fibre reinforced polymeric coating on at least one of said opposite faces of said wall extends over a portion of said structural base to form a bond between said wall and said structural base.    
   
   
       28 . A method as claimed in  claim 27 , wherein said base course of structural blocks is anchored to said structural base by a polymeric adhesive compound.  
   
   
       29 . A method as claimed in  claim 27 , wherein said structural blocks include one or more projections engageable, in use, with complementary one or more recesses in an adjacent structural block.  
   
   
       30 . A method as claimed in  claim 29 , wherein said structural blocks include projections and complementary recesses on respective opposed faces.  
   
   
       31 . A method as claimed in  claim 27 , wherein said structural blocks are self-aligning when stacked.  
   
   
       32 . A method as claimed in  claim 30 , wherein said opposed faces comprise upper and lower faces.  
   
   
       33 . A method as claimed in  claim 32 , wherein said structural blocks include one or more apertures extending between said upper and lower faces.  
   
   
       34 . A method as claimed in  claim 27 , wherein said fibre reinforced polymeric coating extends over portions of said structural base on opposite sides of said walls.  
   
   
       35 . A method as claimed in  claim 27 , wherein said fibre reinforced polymeric coating extends over a top surface of said wall.  
   
   
       36 . A method as claimed in  claim 27 , wherein mounting brackets are secured to an upper course of structural blocks in said wall to permit, in use, connection of a roof structure to said wall structure.  
   
   
       37 . A method as claimed in  claim 36 , wherein said mounting brackets are secured to respective structural blocks by a polymeric adhesive compound.  
   
   
       38 . A method as claimed in  claim 27 , wherein reveal surfaces in wall openings have applied thereto a fibre reinforced polymeric coating formed contiguously with said fibre reinforced polymeric coatings on opposite faces of said wall.  
   
   
       39 . A method as claimed in  claim 27 , wherein said fibre reinforced polymeric coating includes a layer of fiberglass reinforcing material.  
   
   
       40 . A method as claimed in  claim 39 , wherein said layer of fiberglass reinforcing material comprises a sheet of woven or non-woven fiberglass.  
   
   
       41 . A method as claimed in  claim 40 , wherein said fiberglass reinforcing material is an alkaline resistant grade.  
   
   
       42 . A method as claimed in  claim 27 , wherein said fibre reinforced polymeric coating is formed by applying a base coating of a liquid curable polymeric composition to a surface of said wall, positioning on said base coating a layer of fibre reinforcing material, applying to an exposed surface of said layer of fibre reinforcing material a further coating of a liquid curable polymeric composition and allowing said liquid curable polymeric composition to cure.  
   
   
       43 . A method as claimed in  claim 42 , wherein said liquid curable polymeric composition is applied to a surface of the wall and/or said exposed surface of said layer of fibre reinforcing material by any suitable means including spraying, trowelling, screeding or squeegee application.  
   
   
       44 . A method as claimed in  claim 43 , wherein said base coating is applied to a substantially even thickness by means of guide projections extending from opposite normally exposed faces of said structural blocks.  
   
   
       45 . A method as claimed in  claim 44 , wherein said guide projections comprise spaced substantially parallel ribs serving, in use, to guide a screeding or trowelling device to apply said base coating to a substantially even thickness.  
   
   
       46 . A method as claimed in  claim 27 , wherein a decorative coating is applied over said fibre reinforced polymeric coating.  
   
   
       47 . A method as claimed in  claim 46 , wherein said decorative coating comprises a polymeric mineral finish sealant.  
   
   
       48 . A wall structure whenever constructed in accordance with the method of  claim 27 .  
   
   
       49 . A wall structure comprising: 
 a plurality of mortarless structural blocks stacked to form a wall wherein a base course of said structural blocks is anchored to a structural base; and    a fibre reinforced polymeric coating applied to opposite faces of said plurality of stacked mortarless structural blocks wherein said fibre reinforced polymeric coating on at least one of said opposite faces of said wall extends over a portion of said structural base to form a bond between said wall and said structural base.    
   
   
       50 . A wall structure as claimed in  claim 49 , wherein said base course of structural blocks is anchored to said structural base by a polymeric adhesive compound.  
   
   
       51 . A wall structure as claimed in  claim 49 , wherein said structural blocks include one or more projections engageable, in use, with complementary one or more recesses in an adjacent structural block.  
   
   
       52 . A wall structure as claimed in  claim 51 , wherein said structural blocks include projections and complementary recesses on respective opposed faces.  
   
   
       53 . A wall structure as claimed in  claim 49 , wherein said structural blocks are self-aligning when stacked.  
   
   
       54 . A wall structure as claimed in  claim 52 , wherein said opposed faces comprise upper and lower faces.  
   
   
       55 . A wall structure as claimed in  claim 54 , wherein said structural blocks include one or more apertures extending between said upper and lower faces.  
   
   
       56 . A wall structure as claimed in  claim 49 , wherein said fibre reinforced polymeric coating extends over a top surface of said wall.  
   
   
       57 . A wall structure as claimed in  claim 49 , wherein mounting brackets are secured to an upper course of structural blocks in said wall to permit, in use, connection of a roof structure to said wall structure.  
   
   
       58 . A wall structure as claimed in  claim 49 , wherein reveal surfaces of wall openings have applied thereto a fibre reinforced polymeric coating formed contiguously with said fibre reinforced polymeric coatings on opposite faces of said wall.  
   
   
       59 . A wall structure as claimed in  claim 49 , wherein said fibre reinforced polymeric coating comprises a sheet of woven or non-woven fiberglass.  
   
   
       60 . A wall structure as claimed in  claim 49 , wherein said structural blocks comprise guide projections extending from opposite normally exposed faces of said structural blocks.  
   
   
       61 . A wall structure as claimed in  claim 60 , wherein said guide projections comprise spaced substantially parallel ribs.  
   
   
       62 . A wall structure as claimed in  claim 49 , including a decorative polymeric mineral finish sealant applied over said fibre reinforced polymeric coating.