Patent ID: 7521014
Filing Date: 2009-04-21
Classification: B28B,C04B,E04B,E04C,Y02W,Y10T

Abstract:
1. A method of constructing a lightweight building block having a rock face appearance on at least one face of the block comprises the steps of: a) selecting a specific type of fine sand with a predetermined level of alumina content for use in a mix to form said building block said fine sand including fines in a proportion per unit volume greater than 10% which would pass through a 150 micron mesh; b) taking a predetermined quantity of said fine sand and blending said fine sand with a predetermined mix of at least a cellulose fiber material and cement; c) mixing said fine sand, said cement and said cellulose fiber with a predetermined quantity of water, wherein the dry density of the blended mix ranges between 700 kg/m d) introducing said mix into a mold; e) allowing said mix to set for a predetermined period; and wherein each of said blocks produced from said mold has multiple faces, wherein at least one of said faces are cobblestone-like in appearance, and wherein said cobblestone appearance of said at least one face of said block is achieved by selecting a mix which is capable of a predetermined level of slump and allowing opposing faces of adjacent blocks to come in contact as a result of said slump.