Patent Publication Number: US-2010117260-A1

Title: Block press equipment having translating fluid injection apparatus and method of forming building blocks using same

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This patent application is a Continuation patent application of United States patent application having Ser. No. 12/283,682, filed on Sep. 15, 2008, entitled “Block Press Equipment Having Translating Fluid Injection Apparatus And Method of Forming Building Blocks Using Same”, having a common applicant herewith and being incorporated herein in its entirety by reference. 
    
    
     FIELD OF THE DISCLOSURE 
     The disclosures made herein relate generally to structural building blocks and, more particularly, to methods and equipment configured for fabricating structural building blocks comprising a curable binding material in compressed combination with organic chafe, soil, clay, aggregate materials and/or the like. 
     BACKGROUND 
     The formation of building blocks from compaction of materials such as, for example, soil, clay and/or aggregate is a well-known process utilized throughout the world. These types of structural building blocks are commonly and generically referred to as adobe blocks. Throughout the years, various applications designed to automate this process have been produced. Examples of known equipment configured specifically or similarly for fabricating building blocks by compaction of materials (i.e., conventional building block fabrication equipment) are disclosed in U.S. Pat. Nos. 266,532; 435,171; 3,225,409, 4,640,671, 5,358,760 and 6,224,359. 
     Such known building block fabrication equipment is known to suffer from one or more drawbacks. One such drawback is that they involve relatively complex mechanical procedures that adversely effect productivity in the number of blocks fabricated in a particular period of time and/or portability of the equipment itself. Another drawback is that they are limited in their ability to readily and efficiently produce building blocks of different sizes and/or shapes. Still another drawback is that they do not readily allows for two or more systems to be joined and operated simultaneously or independently, while maintaining easy access to replaceable components. 
     In addition to drawbacks associated with known building block fabrication equipment, structural building blocks whose physical integrity depends on compaction are known to exhibit shortcomings. Structural building blocks that rely solely on compaction for physical integrity often degrade over time as a result of aging and/or environmental conditions. Furthermore, such compaction is often positively or adversely impacted by variables such as, for example, moisture content of the compacted materials, natural degradation of the constituent organic materials and the like. Compressive forces applied to the building blocks during use of such structural building blocks can also exceed their load carrying capabilities. The result of the load carrying capability being exceeded resulting in cracking and/or crushing of such structural building blocks, which is aesthetically unappealing and impairs the structural integrity of the building structure made using such building blocks. 
     Therefore, fabricating structural building blocks in a manner that overcomes drawbacks and shortcomings associated with known methods and block fabricating equipment would be useful, advantageous and novel. 
     SUMMARY OF THE DISCLOSURE 
     Embodiments of the present invention relate to block fabricating methods and equipment that are configured in a manner that overcomes drawbacks and shortcomings associated with known block fabricating methods and equipment. More specifically, methods and equipment configured in accordance with the present invention utilize a curable binding material for enhancing physical integrity of compacted block-forming media and a translating activation material delivery device for enhancing dispersion and distribution of an activation material that reacts with the curable binding material. Curing of the curable binding material is initiated in conjunction with compaction of the block-forming media within a media receiving cavity of the block forming equipment. To this end, structural building blocks fabricated in accordance with the present invention offer improved performance relative to structural building blocks fabricated using prior art approaches. Furthermore, block fabricating equipment configured in accordance with the present invention allows a structural building block having a cured binding material dispersed within block forming media thereof to be made in a relatively fast, simple and uniform manner. 
     In one embodiment of the present invention, a method comprises a plurality of operations. An operation is performed for depositing a quantity of article-forming media within a media receiving cavity of article forming equipment. After depositing at least a portion of the article-forming media within the media receiving cavity, an operation is performed for depositing a volume of a prescribed fluid into the media receiving cavity. Depositing the prescribed fluid includes moving a first fluid delivery device through the quantity of the article-forming media while injecting the prescribed fluid through the first fluid delivery device into the quantity of the article-forming media. 
     In another embodiment of the present invention, a method of forming building blocks comprises a plurality of operations. An operation is performed for facilitating relative positioning of a compression case and two opposed compression bodies movably mounted within a compression body receiving passage of the compression case for forming a media receiving cavity within the compression body receiving passage between the compression bodies. After performing such relative positioning, an operation is performed for depositing a quantity of block-forming media within the media receiving cavity. The block-forming media includes a curable binding material dispersed therein and curing of the curable binding material is caused by contact with a prescribed activation material. An operation is performed for providing relative positioning of the compression case for closing an entry into the media receiving cavity through which the quantity of block-forming media was deposited after the quantity of block-forming media is deposited within the media receiving cavity. Thereafter an operation is performed for depositing a quantity of the prescribed activation material into the media receiving cavity. Depositing of the prescribed activation material includes moving a first activation material delivery device through the quantity of the block-forming media while injecting the prescribed activation material through the first activation material delivery device into the quantity of the block-forming media. After or during depositing of the quantity of the prescribed activation material, an operation is performed for moving at least one of the compression bodies toward the other one of the compression bodies under sufficient force to compress the block-forming media into a building block. Such moving is initiated one of during depositing of the prescribed activation material and upon completion of depositing the prescribed activation material. 
     In another embodiment of the present invention, block fabricating equipment such as a block press comprises a plurality of block press structures and a fluid delivery device. The plurality of block press structures are jointly configured for forming a media receiving cavity. The media receiving cavity is capable of having a quantity of block-forming media deposited therein. The fluid delivery device is configured for depositing a quantity of a prescribed fluid into the media receiving cavity after depositing at least a portion of the block-forming media within the media receiving cavity. The fluid delivery device extends through opposing block press structure walls defining the media receiving cavity and is configured for injecting the prescribed fluid into the media receiving cavity through a delivery orifice thereof while the fluid delivery device is being moved through the media receiving cavity. The delivery orifice is within the media receiving cavity during the injection. 
     In another embodiment of the present invention, block fabricating equipment comprising a plurality of block press structures and means for depositing a quantity of a prescribed fluid. The plurality of block press structures are jointly configured for forming a media receiving cavity. The media receiving cavity is capable of having a quantity of block-forming media deposited therein. The means for depositing the quantity of the prescribed fluid into the media receiving cavity is configured for doing so after depositing at least a portion of the block-forming media within the media receiving cavity. Depositing of the prescribed fluid includes moving a fluid delivery device through the media receiving cavity while injecting the prescribed fluid through the fluid delivery device into the media receiving cavity. 
     These and other objects, embodiments advantages and/or distinctions of the present invention will become readily apparent upon further review of the following specification, associated drawings and appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts a block forming apparatus in accordance with a first embodiment the present invention, which is configured for forming structural building blocks by compacting block forming media. 
         FIG. 2  is a cross-sectional view taken along the line  2 - 2  in  FIG. 1 . 
         FIG. 3  is a perspective view showing a compression case of the block forming apparatus depicted in  FIG. 1 . 
         FIG. 4  is a cross-sectional view taken along the line  4 - 4  in  FIG. 3 . 
         FIG. 5  is a perspective view showing a compression body of the block forming apparatus depicted in  FIG. 1 . 
         FIGS. 6-11  depict a method for fabricating a compacted structural building block in accordance with an embodiment of the present invention. 
         FIGS. 12 and 13  depicts an alternate construction and operation of the block forming apparatus depicted in  FIG. 1  and  FIGS. 6-11 . 
         FIG. 14  depicts a block press in accordance with the present invention. 
         FIGS. 15-17  depict various aspects of a block forming apparatus in accordance with a second embodiment the present invention, which is configured for forming structural building blocks by compacting block forming media and curing of a curable binding material dispersed within the block forming media. 
         FIGS. 18-22  depict a method for fabricating a compacted and cured structural building block in accordance with an embodiment of the present invention using the block forming apparatus of  FIGS. 15-17 . 
         FIGS. 23-25  depict various aspects of a block forming apparatus in accordance with a third embodiment the present invention, which is configured for forming structural building blocks by compacting block forming media and curing of a curable binding material dispersed within the block forming media in combination with translation of an activation material delivery apparatus. 
         FIGS. 26-31  depict a method for fabricating a compacted and cured structural building block in accordance with an embodiment of the present invention using the block forming apparatus of  FIGS. 23-25 . 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWING FIGURES 
       FIGS. 1 and 2  show a block forming apparatus  100  in accordance with an embodiment of the present invention. The block forming apparatus  100  is configured for forming structural building blocks by compacting block forming media. The block forming apparatus  100  includes a frame  102 , a compression case  104  and two opposed compression bodies  106 . As is discussed in greater detail below, the frame  102 , the compression case  104  and the two opposed compression bodies  106  are configured and interoperable in a manner that enabling the block forming apparatus  100  to carry out block fabrication functionality in accordance with present invention (e.g., in accordance with the method  200  disclosed herein). 
     As will become apparent in the ensuing discussion, the block forming apparatus  100  advantageously has a substantially integrated construction such that can be readily implemented into a block press having a substantially modular construction (i.e., the block forming apparatus  100  is a component of such modular construction). Alternatively, the block forming apparatus  100  can be implemented in a block press in a non-modular and/or non-interchangeable manner. Additionally, the block press apparatus  100  can be used in a block press configured for having a single block press apparatus mounted thereon at any point in time or a plurality of block press apparatuses mounted thereon at any point in time. 
     In the depicted embodiment, the frame  102  is preferably, but not necessarily, an elongated rectangular cross-section tube having an upper wall  110 , a lower wall  112  and spaced apart side walls ( 114 ,  116 ). The frame  102  includes compression case receiving passage  117  defined by interior surfaces of the walls ( 110 - 116 ) of the frame  102 . The compression case receiving passage  117  extends between opposed end faces ( 118 ,  119 ) of the frame  102 . 
     A media fill opening  121  extends through the upper wall  110  of the frame  102  and a block discharge opening  120  extends through the lower wall  112  of the frame  102  such that the media fill opening  121  and the block discharge opening  120  are communicative with the compression case receiving passage  117 . Preferably, but not necessarily, a central axis C 1  of the media fill opening  121  is aligned with a central axis C 2  of the block discharge opening  120  ( FIG. 2 ). It is disclosed herein that the central axes (C 1 , C 2 ) of the media fill opening  121  and the block discharge opening  120  need not be fully aligned with each other. 
     Referring now to  FIGS. 1-4 , the compression case  104  is slideably engaged within the compression case receiving passage  117  of the frame  102 . The slideably engagement between the frame  102  and the compression case  104  enables movement of the compression case  104  relative to the frame  102  along a longitudinal reference axis L 1  of the compression case  104 . In the depicted embodiment, the compression case  104  is preferably, but not necessarily, an elongated rectangular cross-section tube having an upper wall  122 , a lower wall  124  and spaced apart side walls ( 126 ,  128 ). Interior surfaces of the walls ( 122 - 128 ) of the compression case  104  define a compression body receiving passage  130  ( FIGS. 2 and 4 ) extending between opposed end faces ( 132 ,  134 ) of the compression case  104  along the longitudinal reference axis L 1 . A media fill opening  136  extends through the upper wall  122  of the compression case  104  and a block discharge opening  138  extends through the lower wall  124  of the compression case  104 . The media fill opening  136  of the compression case  104  and the block discharge opening  138  of the compression case  104  are communicative with the compression body receiving passage  130 . 
     The respective interior surface of each one of the side walls ( 126 ,  128 ) has a respective block release recess ( 140 ,  142 ) therein. The block release recesses ( 140 ,  142 ) extending between the upper wall  122  and the lower wall  124 . The block release recesses ( 140 ,  142 ) are positioned between a forward lateral edge  144  of the block discharge opening  138  and a rear lateral edge  146  of the block discharge opening  138 . Preferably, a width of each one of the block release recess ( 140 ,  142 ) is the same as a length of the block discharge opening  138 . A central axis C 3  of the media fill opening  136  of the compression case  104  is offset from a central axis C 4  of the block discharge opening  138  of the compression case  104 . 
     At a minimum, the central axis C 3  of the media fill opening  136  of the compression case  104  is offset from the central axis C 4  of the block discharge opening  138  by a distance equal to a length of the media fill opening  136  of the compression case  104 . It is disclosed herein that, in an alternate embodiment of the compression case  103  (not shown), the block discharge opening  138  intersects adjacent end  134  of the compression case  104 . In such an alternate embodiment, the adjacent end  134  of the compression case  104  defines the rear lateral edge  146  of the block discharge opening  138 . 
     Preferably, dimensions of the block discharge opening  120  of the frame  102  are the same as or larger than the corresponding dimensions of the block discharge opening  138  of the compression case  104 . Similarly, it is preferable that dimensions of the media fill opening  121  of the frame  102  are the same as or larger than the corresponding dimensions of the media fill opening  138  of the compression case  104 . 
     It is disclosed herein that the frame  102  and the compression case  104  can optionally both have a different cross sectional shape than rectangular. Examples of such different cross-sectional shapes include, but are not limited to, round, hexagonal, etc. In view of the disclosures made herein, a skilled person will appreciate that the present invention is not necessarily limited to a particular cross-sectional shape of the frame  102  or the compression case  104 . Additionally, a skilled person will appreciate that the frame  102  can be a non-tubular structure (e.g., an open chassis) while still providing for the required functionality of movable engagement with the compression case  104  and necessary engagement of the block forming apparatus  100  by a block press. 
     Referring now to  FIGS. 1 ,  2  and  5 , each compression body  106  is slideably mounted within the compression body receiving passage  130  of the compression case  104 . Thus, each compression body  106  is mounted in a manner enabling movement (i.e., simultaneous, independent and/or linked) of each compression body  106  along the longitudinal reference axis L 1  of the compression case  104 . In the depicted embodiment, each compression body  106  has a media compaction portion  148  and an actuator engagement portion  150  connected to the media compaction portion  148 . An inboard face  149  of the media compaction portion  148  can be substantially flat, can be partially flat with a non-flat feature or can be substantially contoured. The media compaction portion  148  of each compression body  106  has a relatively low clearance fit (i.e., an intimate fit) within the compression body receiving passage  130  and, preferably, a length of the media compaction portion  148  is relatively long with respect to cross-sectional dimensions of the compression body receiving passage  130  to limit a tendency for rocking within compression body receiving passage  130 . The actuator engagement portion  150  includes a generally flat engagement flange  152 . The engagement flange enables distributed delivery of a force onto the compression body  106  through a force application means such as, for example, a force application platen connected to a hydraulic cylinder. 
     Preferably, but not necessarily, the actuator engagement portion  150  of each compression body  106  is sized to provide a relatively large clearance between perimeter edges thereof and the interior surfaces of the walls ( 122 - 128 ) of the compression body  104 . Optionally, all of the actuator engagement portion  150  of each compression body  106  or a portion of the actuator engagement portion  150  of each compression body  106  can have a relatively low clearance fit with the compression body receiving passage  130 . Additionally, it is disclosed herein that the media compaction portion  148  of each compression body  106  can consist of a flat plate attached to the actuator engagement portion  150 , such that the compression body essentially includes two flat plates having a rigid member (e.g., a steel tube) connected therebetween. Additionally, one or more other flat plates serving as intermediate support ribs can be attached to the rigid member at locations between the ends of the rigid member. 
     A skilled person will recognize that the various components of a block press in accordance with the present invention will preferably be made from suitably strong, rigid and durable materials. For example, in view of the disclosures made herein, it will be appreciated that a frame, a compression case and compression bodies in accordance with the present invention will preferably be made from one or a collection of pieces (e.g., welded, fastened with threaded fasteners, etc) of a hardened steel alloy material. Furthermore, interfaces subject to excessive wear from moving contact will preferably incorporate wear plates to limit such wear, enable adjustment to compensate for such wear and/or to enable replacement of worn contact surfaces. Such wear plates are preferably made from hardened steel alloy capable of withstanding high abrasion. 
     Now, we turn to a discussion of fabrication functionality of the block forming apparatus  100  for forming a structural building block. A method in accordance with the present invention, which is referred to herein as the method  200 , is depicted in  FIGS. 6-11 . While the method  200  is depicted and discussed as being carried out in accordance with the block forming apparatus  100  depicted in  FIGS. 1-5 , a skilled person will appreciate that other apparatuses in accordance with the present invention are fully capable of carrying out the method  200 . 
     Referring now to  FIG. 6 , a block fabrication cycle begins with facilitating relative positioning of the compression case  104  and each two compression body  106  for forming a media receiving cavity  205  within the compression body receiving passage  130  between the compression bodies  106 . Relative to completion of a previously performed block fabrication cycle, facilitating such relative positioning for forming the media receiving cavity  205  includes moving the compression case  104  to a respective media loading position P 1  relative to the frame  102  and moving each compression body  106  to a respective media loading position P 2  relative to the compression case  104 . With the compression case  104  in its respective media loading position P 1  and each compression body  106  in its respective media loading position P 2 , the media receiving cavity  205  is provided within the compression body receiving passage  130  between the two compression bodies  106 . 
     As depicted in  FIG. 7 , a quantity of media  210  from which a building is made is deposited into the media receiving cavity  205  through an opening  215  defined by the media fill openings ( 119 ,  136 ) of the frame  102  and the compression case  104  after relative positioning of the compression case  104  and each two compression body  106  is performed for forming the media receiving cavity  205 . Examples of such media  210  include, but are not limited to, freshly dug soil, conditioned soil (e.g., aerated soil), soil enhanced with known binding material and/or known inert filler material such as plant cellulose, industrial waste and the like. It is disclosed herein that the media can be deposited through use of any number of media delivery and/or conditioning apparatuses. In view of the disclosures made herein, a skilled person will identify and/or devise one or more media delivery and/or conditioning apparatuses suitable for delivering media in a relatively low-density form to the media receiving cavity  205 . Thus, such media delivery and/or conditioning apparatuses will not be discussed herein in further detail. 
     It is disclosed herein that the quantity of media  210  will preferably be of a relatively low density with respect to the density of media in corresponding formed structural building block. In one embodiment of the present invention, the quantity of the media  210  delivered to the media receiving cavity  205  is quantitatively determined prior to or in conjunction with the quantity of media  210  being deposited in the media receiving cavity  205 . In another embodiment, a length of deposit time is correlated to the quantity of media  210 . In yet another embodiment, a weight is correlated to the quantity of media  210 . In still another embodiment, a fill level of media within the media receiving cavity  205  is determined in conjunction with delivery of the quantity of media  210 . 
     After the quantity of media  210  is deposited within the media receiving cavity  205 , relative positioning of the compression case  104  is facilitated for closing an entry  215  into the media receiving cavity  205  through which the quantity of media  210  was deposited ( FIG. 8 ). Facilitating relative positioning of the compression case  104  for closing the entry  215  includes moving the compression case  104  to a chamber sealing position P 3  relative to the media fill opening  121  of the frame  102 . In the chamber sealing position P 3 , the media fill opening  136  of the compression case  104  is entirely offset from the media fill opening  121  of the frame  102 . Upon closing of the entry  215 , the space within the compression body receiving passage  130  between the two compression bodies  106  becomes a media compression chamber  220  (i.e., a generally sealed chamber). 
     Next, as depicted in  FIG. 9 , each compression body  106  is moved toward the other compression body  106  under sufficient applied force to compress the quantity of media  210  into a structural building block  225 . A compressed quantity and shape of the structural building block  225  corresponds to the cross sectional shape and cross-sectional area of the compression body receiving passage  130  and a distance between the inboard face  149  of each compression body  106  when each compression body  106  is in a fully displaced position P 4 . In one embodiment of the present invention, longitudinal displacement of each compression body  106  is determined for enabling assessment of a degree of compaction of the quantity of media  210  and/or for enabling assessment of physical dimensions of the structural building block  225 . 
     With the quantity of media  210  ( FIG. 8 ) compressed into the structural building block ( FIG. 9 ), relative positioning of the compression case  104  and the compression bodies  106  is facilitated for enabling discharge of the structural building block  225  from within the compression chamber  220  through the block discharge openings  120  of the frame  102  and through the block discharge opening  138  of the compression case  104 . Facilitating relative positioning for enabling discharge includes moving the compression case  104  to a block discharging position P 5  with respect to the compression bodies  106  and removing all or a portion of the applied force on the compression bodies  106  whereby the compression bodies  106  are in substantially non-compressing engagement with the structural building block  225 . The operation of removing all or a portion of the applied force on the compression bodies  106  by the compression bodies  106  reduces the potential for pressure exerted by the compression bodies  106  resulting in damage to the structural building block  225  as the compression case  104  is moved from the chamber sealing position P 3  to the block discharging position P 5 . Moving the compression case  104  to the block discharging position P 5  includes limiting longitudinal movement of the compression bodies  106  while moving the compression case  104  to the block discharging position P 5 . In the block discharging position P 5  ( FIG. 10 ), a central axis C 3  of the block discharge opening  138  of the compression case  104  is aligned with a central axis C 4  of the block discharge opening  120  of the frame  102  and the block discharge opening  138  of the compression case  104  is laterally between the inboard faces  149  of the compression bodies  106 . 
     With the compression case  104  in the block discharging position P 5 , the compression bodies  106  are moved toward the respective media loading position P 2  ( FIG. 11 ). Moving the compression bodies toward their respective media loading position P 2  disengages the compression bodies  106  from the structural building block  225 . This disengagement in conjunction with structural building block  225  being exposed to the block release recesses ( 140 ,  142 ) of the compression case  104  promotes discharging of the structural building block  225  from within the compression body receiving passage  130  of the compression case  104 . Discharge of the structural building block  225  completes the block fabrication cycle. 
     It is disclosed herein that a vibratory apparatus can be attached to each compression body  106  and/or to the compression case  104 . In compressing media to form the structural building block  225 , portions of the media engaged with each compression body  106  can sometimes have a tendency to stick to one of the engaged compression bodies  106 . Attachment of a vibratory apparatus to each compression body  106  and activation of the vibratory apparatus just prior to when the engaged compression bodies  106  is moved toward its respective media loading position P 2  will contribute to releasing media of the structural building block  225  from engaged compression bodies  106 . In doing so, the tendency for a surface of the structural building block  225  being damaged through the act of retracting the engaged compression bodies  106  is reduced. 
     Additionally, it is disclosed herein that the vibratory apparatus can be activated during the media fill operation. In doing so, density of the media  210  is increased by virtue of vibrations from the vibratory apparatus causing entrapped air in the media to be released. 
     It is disclosed herein that only one compression body  106  need be movable (i.e., the moving compression body) for forming structural building blocks through use of the block forming apparatus  100 . One compression body (i.e., the stationary compression body) can be maintained in a fixed position via a substantially rigid member such as, for example, a beam connected between a chassis bulkhead and the stationary compression body. In the case of a block forming apparatus implemented with one movable compression body and one stationary compression body, an inboard face of the media compaction portion of the face the stationary compression body is aligned with an edge of the media fill opening  121  of the frame  102  (i.e., the media fill opening  121  positioned between inboard faces  149  of the compression bodies  106 ) and with an edge of the block discharge opening  120  of the frame  102  (i.e., the block discharge opening  120  positioned between inboard faces  149  of the compression bodies  106 ). Such alignment allows for block in accordance with the method  200  with the exception that only one compression body  106  is moved relative to the frame  102 . 
       FIGS. 12 and 13  depict an alternate embodiment of the block forming apparatus  100  depicted in FIGS.  1  and  6 - 11 . In this alternate embodiment, the compression case  104  includes a movable portion  104 ′ and a fixed portion  104 ″. The movable portion  104 ′ moves substantially the same as discussed in reference to  FIGS. 6-9 . The fixed portion is immovably attached to the frame  102  or to an immovable structure of a block press in which the block forming apparatus  100  is incorporated. The fixed portion  104 ″ includes a cavity plate  155  connected to a cavity plate actuator  157 . As depicted in  FIG. 12 , the cavity plate  155  resides within the block discharge opening  138  during the operations of loading media (discussed in reference to  FIGS. 6 and 7 ), during the operations of compressing the media (discussed in reference to  FIGS. 8 and 9 ) and during the operation of releasing load on the compression bodies  106  (discussed in reference to  FIG. 9 ). For facilitating discharge of the structural building block  225  (see  FIG. 13 ), the cavity plate actuator  157  (e.g., a hydraulic actuator) moves the cavity plate  155  such that the structural building block  225  is lowered via movement of the cavity plate  155 . Thereafter, a manual or automated operation for indexing or removing the structural building block  225  is performed. 
     It is disclosed herein that all or a portion of the surface of the cavity plate  155  exposed within the compression receiving passage  130  of the compression body  104  can have a texture formed thereon. In this manner, a corresponding textured pattern is formed on a face of the structural building block  225  that is engaged with the cavity plate  155 . 
       FIG. 14  depicts a block press in accordance with the present invention, which is referred to herein generally as the block press  300 . The block press  300  includes a chassis  302 , a plurality of block forming apparatuses ( 304 - 310 ), a plurality of compression case actuators ( 312 ,  314 ) and a plurality of compression body actuators ( 316 - 322 ). The chassis  302  includes spaced apart bulkheads ( 324 ,  325 ), a plurality of longitudinal main beams  326 , a plurality of lateral support beams  328 , a plurality of longitudinal support beams  330 , a block forming apparatus carriage  332  and a plurality of upper support beams  334 . The bulkheads ( 324 ,  325 ) are each attached at their lower end to the longitudinal main beams  326  in a spaced apart upright manner. The lateral support beams  328  are each attached to the longitudinal main beams  326  extending generally perpendicular in direction to that of the longitudinal main beams  326 . The upper support beams  334  are attached between upper ends of the bulkheads ( 324 ,  325 ). The block forming apparatus carriage  332  is engaged with a plurality of the lateral support beams  328  between the bulkheads ( 324 ,  325 ). 
     As depicted in  FIG. 14 , the block forming apparatus carriage  332  and engaged ones of the lateral support beams  328  are jointly configured for enabling lateral movement of the block forming apparatus carriage  332  with respect of a longitudinal reference axis L 2  of the chassis  302 . However, it is disclosed herein that the block forming apparatus carriage  332  can be non-movable with respect to the chassis  302 . Optionally, a block press apparatus in accordance with the present invention and configured substantially the same as the block press  300  can have only a single block press apparatus mountable thereon. 
     The plurality of block forming apparatuses ( 304 - 310 ) are mounted on the block forming apparatus carriage  332 . Advantageously, each one of the block forming apparatuses ( 304 - 310 ) is self-contained and is preferably mounted in the block forming apparatus carriage  332  without the use of fasteners. For example, mating locating structures can be incorporated into the block forming apparatus carriage  332  and each one of the block forming apparatuses ( 304 - 310 ) for facilitating locating and retention functionality of the block forming apparatuses ( 304 - 310 ) with respect to the block forming apparatus carriage  332 . Optionally, physical fastening means (e.g., threaded fasteners) can be used for locating and fastening each one of the block forming apparatuses ( 304 - 310 ) to the block forming apparatus carriage  332 . 
     Each one of the block forming apparatuses ( 304 - 310 ) has a construction substantially the same the block forming apparatus  100  depicted and discussed in reference to  FIGS. 1-13 . Accordingly, for the remainder of this discussion, terminology used in the discussion of  FIGS. 1-13  will be used in the discussion of the plurality of block forming apparatuses ( 304 - 310 ). The reader is encouraged to refer to the discussion of  FIGS. 1-13  for additional details into the structure and function of the block forming apparatuses ( 304 - 310 ). 
     Each one of the block forming apparatus ( 304 - 310 ) includes a frame  352 , a compression case  354  and two compression bodies  356 . The frame  352  is releasably engaged with the block forming apparatus carriage  332 . Each compression case  354  is movably engaged with a frame  352  of the respective block forming apparatus ( 304 - 310 ) in a manner enabling movement of the compression case  354  along a respective longitudinal reference axis. The respective longitudinal reference axis of compression case  354  of each block forming apparatus ( 304 - 310 ) extends substantially parallel with the longitudinal reference axis L 2  of the chassis  302 . The compression case  354  of each block forming apparatus ( 304 - 310 ) has a compression body receiving passage extending between opposed end faces thereof along the respective longitudinal reference axis of the compression case  354 . Each block forming apparatus ( 304 - 310 ) has two compression bodies  356  movably mounted within the compression body receiving passage of the compression case in a manner enabling movement of the compression bodies  356  along the longitudinal reference axis of the compression case  354 . 
     A first compression case actuator  312  is connected between the first bulkhead  324  and the compression case  354  of a first block forming apparatus  304 . A second compression case actuator  316  is connected between the first bulkhead  324  and the compression case  354  of a second block forming apparatus  306 . Each one of the compression case actuators ( 324 ,  325 ) is connected between one of the bulkheads and a respective one of the block forming apparatuses ( 304 - 310 ) for facilitating movement of the attached compression case to accomplish positioning functionality as discussed in reference the method of  FIGS. 6-11 . A hydraulic cylinder is an example of each one of the compression case actuators ( 324 ,  325 ). 
     Each compression case actuator ( 312 ,  314 ) is releasably connected to the respective compression case and is pivotably connected to the first bulkhead  324 . This releasable and pivotable mounting configuration advantageously allows each compression case actuator ( 312 ,  314 ) to be independently disconnected from the respective compression case and, pivoted out of the way, which is useful when servicing, replacing or switching position of one or more of the block fabrication apparatuses ( 304 - 310 ). 
     A first compression body actuator  316  and a second compression body actuator  318  are attached to the first bulkhead  324 . A third compression body actuator  320  and a fourth compression body actuator  322  are attached to the second bulkhead  324 . The first compression body actuator  316  is longitudinally aligned with the third compression body actuator  320 . The second compression body actuator  318  is longitudinally aligned with the fourth compression body actuator  322 . Spacing between the first compression body actuator  316  and the second compression body actuator  318  is substantially the same as the spacing between longitudinal reference axes of the adjacent block fabrication apparatuses ( 304 - 310 ). Spacing between the third compression body actuator  320  and the fourth compression body actuator  322  is substantially the same as the spacing between longitudinal reference axes of the adjacent block fabrication apparatuses ( 304 - 310 ). 
     The compression body actuators ( 316 - 322 ) each include a force generating device  360  (e.g., a hydraulic cylinder) and a platen  362  attached to the force generating device  360 . A first end of the force generating device  360  is attached to a respective one of the bulkheads ( 324 ,  325 ). A second end of the force generating device  360  is attached to the platen  362 . Through lateral positioning of the block forming apparatus carriage  332 , two adjacent ones of the block fabrication apparatuses ( 304 - 310 ) are aligned with in line-pairs of the compression body actuators ( 316 - 322 ). For example, as depicted in  FIG. 14 , the block forming apparatus carriage  332  is positioned such that the first compression body actuator  316  and the and third compression body actuator  320  are aligned with the first block forming apparatus  304  and the second compression body actuator  318  and the and fourth compression body actuator  322  are aligned with the second block forming apparatus  306 . 
     Each force generating device  360  delivers a force to the respective compression body  356  by application of such force through the platen  362  (e.g., via engagement with a flange of an actuator engagement portion of the compression body  356 ). Accordingly, each force generating device  360  is capable of facilitating movement of a respective compression body  356  toward an opposing compression body  356 . Retraction of two opposed compression bodies can be facilitated by one of any number of different approaches. For example, each platen  362  can be physically attached to a respective compression body  356  such that retraction of the platen  362  causes a corresponding retraction of the attached compression body  356 . 
     However, for reasons of time and convenience, it is preferable that the compression body actuators ( 316 - 322 ) are not physically attached to the compression bodies  356  such that the block forming apparatuses ( 304 - 310 ) can be removed, replaced and/or serviced without requiring disconnection from the compression body actuators ( 316 - 322 ). To this end, it is disclosed herein that each block forming apparatuses ( 304 - 310 ) can be configured for facilitating self-retraction of each compression body  356 . For example, a return spring can be attached between each compression body  356  and a respective compression case  354  or a respective frame  352  for returning the compression body  356  to a static position (e.g., no appreciable force applied by the return spring) from a displaced position (i.e., a position corresponding to full compression of a structural building block). 
     It is disclosed herein that platen spacers can be attached to a compression block engagement face of one or more platen  362  for adjusting a displaced distance of a respective one of the compression bodies  306 . In such an arrangement, a space is provided between the plate  362  and the respective compression body  306 . Accordingly, a portion of the total travel of the respective compression body actuator  322  is used for accomplishing contact between the platen  362  and the compression body  306 . Through use of such spacers, the amount of travel of the respective compression body actuator  322  can be adjusted. 
     It is disclosed herein that the static position of each compression body can be adjustable such that a media receiving cavity length is adjustable. For example, a compression body limiter can be adjustable attached to a frame of a block press apparatus such that an adjusted position of the compression body limiter dictates the static position of the compression body. Examples of the usefulness in being able to readily vary the quantity of the media receiving cavity include, but are not limited to, compensating for media density for a given block size, providing for different block sizes and limiting compression body stroke. 
     Through the disclosed construction of the block press  300 , the block press  300  is specifically configured for simultaneously making up to two blocks. However, as depicted, one pair of opposed compression body actuators can be deactivated/removed, allowing for only one block to be made per block making cycle. Also, it is disclosed herein that the chassis  302  can be configured for allowing the addition of compression body actuators and compression case actuators such that all of the block forming apparatuses ( 304 - 310 ) can simultaneously make building blocks. 
     Through implementation of a plurality of block forming apparatuses ( 304 ,  310 ), building blocks of different configuration (e.g., sizes, shapes, textures, colors, etc) can be readily made without the need to remove and install new block forming apparatuses. Lateral adjustment of the block forming apparatus carriage  332  enables selection of the block forming apparatuses ( 304 - 310 ), which will be presently active. Also, relative positioning of the installed block forming apparatuses ( 304 - 310 ) within the block forming apparatus carriage  332  can be facilitated as needed to achieve a desired mix of blocks configurations. As depicted, the block press  300  is configured for enabling up to 4 different configurations of blocks to be made without the need to remove and install new block forming apparatuses. If desired, multiple block forming apparatuses ( 304 ,  310 ) of the block press can be used for making the same configuration building block (e.g., simultaneously making two blocks of the same configuration). 
     A skilled person will recognize that any number of different systems can be utilized for facilitating control of a block press in accordance with the present invention (e.g., the block press  300 ) for carrying out a block fabrication method in accordance with the present invention (e.g., the method  200 ). More specifically, it will be appreciated that a programmable control unit (e.g., a programmable logic control unit) can be used to control one or more hydraulic pumps, one or more control valves and other known control components in a manner suitable for carrying out block fabrication functionality in accordance with the present invention. For example, through the use of position sensors for sensing movement and/or position of components of a block press in accordance with the present invention and by controlling delivery of pressurized hydraulic fluid to actuators of such a block press, required movement and positioning of such block press components can be accomplished. However, the present invention is not limited by such chosen, known control solutions. Different known control solutions of various configurations can be used with equal or suitable success in controlling a block press and/or method in accordance with the present invention. 
     Referring now to  FIGS. 15-22 , shown are various aspects on a block forming apparatus  400  specifically configured in accordance with an embodiment of the present invention for forming structural building blocks by compacting block forming media and curing of a curable binding material dispersed within the block forming media. The block forming apparatus  400  includes a frame  402 , a compression case  404  and two opposed compression bodies  406 . As is discussed in greater detail below, the frame  402 , the compression case  404  and the two opposed compression bodies  406  are configured and interoperable in a manner that enabling the block forming apparatus  400  to carry out block fabrication functionality in accordance with present invention (e.g., in accordance with the method  500  disclosed herein). 
     As will become apparent in the ensuing discussion, the block forming apparatus  400  advantageously has a substantially integrated construction such that can be readily implemented into a block press having a substantially modular construction (i.e., the block forming apparatus  400  is a component of such modular construction). Alternatively, the block forming apparatus  400  can be implemented in a block press in a non-modular and/or non-interchangeable manner. Additionally, the block press apparatus  400  can be used in a block press configured for having a single block press apparatus mounted thereon at any point in time or a plurality of block press apparatuses mounted thereon at any point in time. 
     The frame  402  is preferably, but not necessarily, an elongated rectangular cross-section tube having an upper wall  410 , a lower wall  412  and spaced-apart side walls  414 . Both spaced apart side walls  414  are not shown, but can have the same configuration as spaced-apart side walls  114 ,  116  shown in  FIG. 1 . The frame  402  includes compression case receiving passage  417  defined by interior surfaces of the walls ( 410 - 414 ) of the frame  402 . The compression case receiving passage  417  extends between opposed end faces ( 418 ,  419 ) of the frame  402 . 
     A media fill opening  421  extends through the upper wall  410  of the frame  402  and a block discharge opening  420  extends through the lower wall  412  of the frame  402  such that the media fill opening  421  and the block discharge opening  420  are communicative with the compression case receiving passage  417 . Preferably, but not necessarily, a central axis C 1  of the media fill opening  421  is aligned with a central axis C 2  of the block discharge opening  420 . It is disclosed herein that the central axes (C 1 , C 2 ) of the media fill opening  421  and the block discharge opening  420  need not be fully aligned with each other. 
     The compression case  404  is slideably engaged within the compression case receiving passage  417  of the frame  402 . The slideable engagement between the frame  402  and the compression case  404  enables movement of the compression case  404  relative to the frame  402  along a longitudinal reference axis L 1  of the compression case  404 . In the depicted embodiment, the compression case  404  is preferably, but not necessarily, an elongated rectangular cross-section tube having an upper wall  422 , a lower wall  424  and spaced apart side walls  426 . Both spaced-apart side walls  426  are not shown, but can have the same configuration as spaced-apart side walls  126 ,  128  shown in  FIG. 1 . 
     Interior surfaces of the walls ( 422 - 426 ) of the compression case  404  define a compression body receiving passage  430  extending between opposed end faces ( 432 ,  434 ) of the compression case  404  along the longitudinal reference axis L 1 . A media fill opening  436  extends through the upper wall  422  of the compression case  404  and a block discharge opening  438  extends through the lower wall  424  of the compression case  404 . The media fill opening  436  of the compression case  404  and the block discharge opening  438  of the compression case  404  are communicative with the compression body receiving passage  430 . 
     The respective interior surface of each one of the side walls  426  has a respective block release recess  442  therein. These block release recesses are not shown in  FIG. 15 , but can be substantially the same as the block release recesses ( 140 ,  142 ) shown in  FIG. 4 . The block release recesses extending between the upper wall  422  and the lower wall  424 . The block release recesses are positioned between a forward lateral edge  444  of the block discharge opening  438  and a rear lateral edge  446  of the block discharge opening  438 . Preferably, a width of each one of the block release recess is the same as a length of the block discharge opening  438 . A central axis C 3  of the media fill opening  436  of the compression case  404  is offset from a central axis C 4  of the block discharge opening  438  of the compression case  404 . 
     At a minimum, the central axis C 3  of the media fill opening  436  of the compression case  404  is offset from the central axis C 4  of the block discharge opening  438  by a distance equal to a length of the media fill opening  436  of the compression case  404 . It is disclosed herein that, in an alternate embodiment of the compression case  403  (not shown), the block discharge opening  438  intersects adjacent end  434  of the compression case  404 . In such an alternate embodiment, the adjacent end  434  of the compression case  404  defines the rear lateral edge  446  of the block discharge opening  438 . 
     Preferably, dimensions of the block discharge opening  420  of the frame  402  are the same as or larger than the corresponding dimensions of the block discharge opening  438  of the compression case  404 . Similarly, it is preferable that dimensions of the media fill opening  421  of the frame  402  are the same as or larger than the corresponding dimensions of the media fill opening  438  of the compression case  404 . 
     It is disclosed herein that the frame  402  and the compression case  404  can optionally both have a different cross sectional shape than rectangular. Examples of such different cross-sectional shapes include, but are not limited to, round, hexagonal, etc. In view of the disclosures made herein, a skilled person will appreciate that the present invention is not necessarily limited to a particular cross-sectional shape of the frame  402  or the compression case  404 . Additionally, a skilled person will appreciate that the frame  402  can be a non-tubular structure (e.g., an open chassis) while still providing for the required functionality of movable engagement with the compression case  404  and necessary engagement of the block forming apparatus  400  by a block press. 
     Referring now to  FIGS. 1 ,  2  and  5 , each compression body  406  is slideably mounted within the compression body receiving passage  430  of the compression case  404 . Thus, each compression body  406  is mounted in a manner enabling movement (i.e., simultaneous, independent and/or linked) of each compression body  406  along the longitudinal reference axis L 1  of the compression case  404 . Similar to the compression body  106  shown in  FIGS. 1 ,  2  and  5 , each compression body  406  has a media compaction portion and an actuator engagement portion connected to the media compaction portion. An inboard face of the media compaction portion can be substantially flat, can be partially flat with a non-flat feature or can be substantially contoured. The media compaction portion of each compression body has a relatively low clearance fit (i.e., an intimate fit) within the compression body receiving passage and, preferably, a length of the media compaction portion is relatively long with respect to cross-sectional dimensions of the compression body receiving passage  430  to limit a tendency for rocking within compression body receiving passage  430 . The actuator engagement portion includes a generally flat engagement flange. The engagement flange enables distributed delivery of a force onto the compression body  406  through a force application means such as, for example, a force application platen connected to a hydraulic cylinder. 
     Preferably, but not necessarily, the actuator engagement portion of each compression body  406  is sized to provide a relatively large clearance between perimeter edges thereof and the interior surfaces of the walls ( 422 - 426 ) of the compression body  404 . Optionally, all of the actuator engagement portion of each compression body  406  or a portion of the actuator engagement portion of each compression body  406  can have a relatively low clearance fit with the compression body receiving passage  430 . Additionally, it is disclosed herein that the media compaction portion of each compression body  406  can consist of a flat plate attached to the actuator engagement portion  450 , such that the compression body essentially includes two flat plates having a rigid member (e.g., a steel tube) connected therebetween. Additionally, one or more other flat plates serving as intermediate support ribs can be attached to the rigid member at locations between the ends of the rigid member. 
     A skilled person will recognize that the various components of a block press in accordance with the present invention will preferably be made from suitably strong, rigid and durable materials. For example, in view of the disclosures made herein, it will be appreciated that a frame, a compression case and compression bodies in accordance with the present invention will preferably be made from one or a collection of pieces (e.g., welded, fastened with threaded fasteners, etc) of a hardened steel alloy material. Furthermore, interfaces subject to excessive wear from moving contact will preferably incorporate wear plates to limit such wear, enable adjustment to compensate for such wear and/or to enable replacement of worn contact surfaces. Such wear plates are preferably made from hardened steel alloy capable of withstanding high abrasion. 
     Still referring to  FIG. 15 , for facilitating delivery of activation material to enable curing of a curable binding material, an activation material delivery mechanism  470  is provided within a first one of the compression bodies  406 . The activation material delivery mechanism  470  includes an activation material delivery device  472  and a delivery device actuator  474 . In one embodiment, the activation material delivery device  472  is a ram and the delivery device actuator  474  is a forced fluid cylinder (e.g., hydraulic or pneumatic). The activation material delivery device  472  is translatably connected to the delivery device actuator  474  in a manner allowing the delivery device actuator  474  to cause translation of the activation material delivery device  472  along a delivery device translation axis extending effectively parallel with the longitudinal axis L 1 . For example, through application of fluid pressure at a first fluid supply line  478  and at a second fluid supply line  480 , the activation material delivery device  472  translates in a first direction and a second (i.e., opposite) direction along the delivery device translation axis. The activation material delivery device  472  extends through an opening  482  in a media compressing face  484  of the first one of the compression body  406 . A second one of the compression bodies  406  (i.e., the opposing compression body) has a delivery device receiving opening  486  therein such that through translation of the activation material delivery device  472 , the activation material delivery device  472  can be extended into the delivery device receiving opening  486 . 
     Referring now to  FIGS. 15-17 , the activation material delivery device  472  comprises an outer sleeve  488 , an inner sleeve  490  slideably mounted within the outer sleeve  488  and a material delivery conduit  491  connected to the inner sleeve  491 . Inner sleeve orifices  492  are alignable with outer sleeve orifices  494  through translation of the inner sleeve  490  with respect to the outer sleeve  488  from a retracted position P 6  and a displaced position. In the retracted position P 6 , the orifices ( 492 ,  494 ) are fully misaligned to prevent flow therethrough. In the displaced position P 7 , the orifices ( 492 ,  494 ) are at least partially aligned to allow flow therethrough. A spring  495  biases the inner sleeve to the retracted position P 6 . An alignment member  496  is fixedly engaged with the outer sleeve  488  and engages a slot  498  of the inner sleeve  490  for preventing rotation of the inner sleeve  490  with respect to the outer sleeve  488  and for limiting the spring  495  to biasing the inner sleeve  490  to the at-rest position. Material such as, for example, an activation material or a curable binding material can be delivered into the inner sleeve  490  via the material delivery conduit  491  for allowing such material to be dispensed via the injected through the orifices ( 492 ,  494 ). 
     Now, a discussion of fabrication functionality of the block forming apparatus  400  for forming a structural building block is presented. A method in accordance with the present invention, which is referred to herein as the method  400 , is depicted in  FIGS. 18-22 . While the method  400  is depicted and discussed as being carried out in accordance with the block forming apparatus  400  depicted in  FIGS. 18-22 , in view of the disclosures made herein, a skilled person will appreciate that other suitably configured block forming equipment can be used for carrying out the method  400 . 
     Referring now to  FIG. 18 , a block fabrication cycle begins with facilitating relative positioning of the compression case  404  and each two compression body  406  for forming a media receiving cavity  505  within the compression body receiving passage  430  between the compression bodies  406 . Relative to completion of a previously performed block fabrication cycle, facilitating such relative positioning for forming the media receiving cavity  505  includes moving the compression case  404  to a respective media loading position P 1  relative to the frame  402 , moving each compression body  406  to a respective media loading position P 2  relative to the compression case  404 , and moving the activation material delivery device  472  to an extended position P 8 . In this configuration, the compression bodies  406  are in spaced apart relationship with respect to each other, and a tip portion of the activation material delivery device  472  is positioned within the delivery device receiving opening  486  of the opposing compression body  406  (i.e., through translation with respect to the delivery device actuator  474 ). Accordingly, with the compression case  404  in its respective media loading position P 1  and each compression body  406  in its respective media loading position P 2 , the media receiving cavity  505  is provided within the compression body receiving passage  430  between the two compression bodies  406 . 
     In the case of gravity feed of the block forming media where the compression case  404  serves as the block forming media shut-off structure for an associated media hopper/media supply, the activation material delivery device  472  must be in extended position prior to block forming media entering the media receiving cavity  505 . For example, the activation material delivery device  472  can be moved to the extended position immediately following ejection of a formed block from a prior block fabrication cycle. In the case of unrestricted gravity feeding of block forming media from a hopper into the media receiving cavity  505 , vibratory means or the like can be employed for causing complete fill of the media receiving cavity as defined between the compression when the media receiving cavity  505  are a prescribed distance apart from each other (i.e., defining a media receiving cavity  505  of a prescribed quantity. 
     As depicted in  FIG. 19 , a quantity of media  510  from which a building is made is deposited into the media receiving cavity  505  through an opening  515  defined by the media fill openings ( 419 ,  436 ) of the frame  402  and the compression case  404  after relative positioning of the compression case  404  and each two compression body  406  is performed for forming the media receiving cavity  505 . The block forming media includes a curable binding material dispersed therein. Curing of the curable binding material is caused by contact with a prescribed activation material. 
     It is disclosed herein that the quantity of media  510  will preferably be of a relatively low density with respect to the density of media in corresponding formed structural building block. In the case of the quantity of block forming media being controlled by a delivery hopper, there are a number of approaches for such hopper controlling such delivered quantity of block forming media. In one such approach, the quantity of the media  510  delivered to the media receiving cavity  505  is quantitatively determined prior to or in conjunction with the quantity of media  510  being deposited in the media receiving cavity  505 . In another such approach, a length of deposit time is correlated to the quantity of media  510 . In still another such approach, a weight is correlated to the quantity of media  510 . In still another such approach, a fill level of media within the media receiving cavity  505  is determined in conjunction with delivery of the quantity of media  510 . In the case of the quantity of block forming media being controlled by size of the media receiving cavity  505  and media delivery to the media receiving cavity  505  being unrestricted, one preferred approach to delivering the block forming media is to position the compression bodies  406  a prescribed distance apart such that a media receiving cavity  505  of a prescribed quantity is defined and using means such as a vibratory device to assure that this prescribed quantity is sufficiently filled with block forming media. 
     As depicted in  FIG. 20 , after the quantity of media  510  is deposited within the media receiving cavity  505 , relative positioning of the compression case  404  is facilitated for closing the entry  515  into the media receiving cavity  505  through which the quantity of media  510  was deposited. Facilitating relative positioning of the compression case  404  for closing the entry  515  includes moving the compression case  404  to a chamber sealing position P 3  relative to the media fill opening  421  of the frame  402 . In the chamber sealing position P 3 , the media fill opening  436  of the compression case  404  is entirely offset from the media fill opening  421  of the frame  402 . Upon closing of the entry  415 , the space within the compression body receiving passage  430  between the two compression bodies  406  becomes a media compression chamber  520  (i.e., a generally sealed chamber). 
     After the positioning the compression case  404  for forming the media compression chamber  520 , a quantity of the prescribed activation material  517  is injected (i.e., deposited) under pressure into the media compression chamber  520 . More specifically, the quantity of media  510  at least partially covers the activation material delivery device  472  such that at least a portion of the prescribed activation material is injected into the quantity of media  510 . Furthermore, the prescribed activation material is injected under high pressure whereby such high pressure results in a force being applied on the inner sleeve  490  thereby causing translation of the inner sleeve  490  with respect to the outer sleeve  488  from the at rest position P 6  to the displaced position P 7  and, thus, allowing flow of the prescribed activation material  517  through the orifices ( 492 ,  494 ) of the inner and outer sleeves ( 488 ,  490 ). Spring biasing force from exerted by the spring  495  causes the inner sleeve  490  to translate back to the at rest position P 6  upon completion of the prescribed activation material being supplied to the activation material delivery device  472  under sufficiently high pressure. 
     Preferably, depositing (e.g., injecting) the prescribed activation material  517  includes delivering the prescribed activation material  517  to the activation material delivery device  472  at a pressure that causes the prescribed activation material  517  to be sprayed from the orifices ( 492 ,  494 ) of the inner and outer sleeves ( 488 ,  490 ) at high speed and/or with a high degree of exhibited turbulence. More specifically, it is preferred for the prescribed activation material  517  to be injected in a manner that causes it to be widely dispersed throughout the quantity of media  510 . It is disclosed herein that the configuration of the orifices ( 492 ,  494 ) of the inner and outer sleeves ( 488 ,  490 ) can be specifically designed to enhance such velocity, turbulence and/or dispersion. For example, the orifices  492  of the inner sleeve  490  can be specifically configured for enhancing quantity and pressure of the prescribed activation material  517  as delivered to the orifices  494  of the outer sleeve  488 , and the orifices  494  of the outer sleeve  488  can be specifically configured for enhancing velocity and droplet size (e.g., atomisation) of the prescribed activation material  517  as delivered to the quantity of media  510 . Turbulence can also be imparted by selection of a curable binding material and corresponding activation material that together react in a turbulent manner (e.g., bubbling, foaming, etc). Such binding material induced turbulence can be at least partially controlled/mitigated through compressions exerted on the block forming media by the compression bodies  406 . The amount of the prescribed activation material  517  can be dictated by an amount of time such injection is performed or by a quantity of the prescribed activation material  517  that is delivered. 
     As depicted in  FIG. 21 , during or after injection of the prescribed activation material, each compression body  406  is moved toward the other compression body  406  under sufficient applied force to compress the quantity of media  510  into a structural building block  525 . A compressed quantity and shape of the structural building block  525  corresponds to the cross sectional shape and cross-sectional area of the compression body receiving passage  430  and a distance between the inboard faces (i.e., media engaging face) of each compression body  406  when each compression body  406  is in a fully displaced position P 4  (i.e., as dictated by a maximum applied pressure, a defined travel limit, or the like). In one embodiment of the present invention, longitudinal displacement of each compression body  406  is determined for enabling assessment of a degree of compaction of the quantity of media  510  and/or for enabling assessment of physical dimensions of the structural building block  525 . 
     With the quantity of media  510  ( FIG. 20 ) compressed into the structural building block ( FIG. 21 ) and, optionally, after a prescribed curing time for the curable binding material has elapsed (e.g., after the curable binding material has cured to a specified or approximated degree such as a gel or crystallized state), relative positioning of the compression case  404  and the compression bodies  406  and retraction of the activation material delivery device  472  is facilitated for enabling discharge of the structural building block  525  from within the compression chamber  520  through the block discharge openings  420  of the frame  402  and through the block discharge opening  438  of the compression case  404 . Facilitating relative positioning for enabling discharge includes moving the compression case  404  to a block discharging position P 5  with respect to the compression bodies  406  and removing all or a portion of the applied force on the compression bodies  406  whereby the compression bodies  406  are in substantially non-compressing engagement with the structural building block  525 . The operation of removing all or a portion of the applied force on the compression bodies  406  by the compression bodies  406  reduces the potential for pressure exerted by the compression bodies  406  resulting in damage to the structural building block  525  as the compression case  404  is moved from the chamber sealing position P 3  to the block discharging position P 5 . Moving the compression case  404  to the block discharging position P 5  includes limiting longitudinal movement of the compression bodies  406  while moving the compression case  404  to the block discharging position P 5 . In the block discharging position P 5  ( FIG. 10 ), a central axis C 3  of the block discharge opening  438  of the compression case  404  is aligned with a central axis C 4  of the block discharge opening  420  of the frame  402  and the block discharge opening  438  of the compression case  404  is laterally between the inboard faces of the compression bodies  406 . 
     With the compression case  404  in the block discharging position P 5  and the activation material delivery device  472  moved to its retracted position P 6 , the compression bodies  406  are moved toward the respective media loading position P 2  ( FIG. 22 ). Moving the compression bodies  406  toward their respective media loading position P 2  disengages the compression bodies  406  from the structural building block  525 . This disengagement in conjunction with structural building block  525  being exposed to the block release recesses of the compression case  404  promotes discharging of the structural building block  525  from within the compression body receiving passage  430  of the compression case  404 . Alternatively, means such as block holding pad device of the compression case  404  can be selectively engaged with the structural building block  525 , the activation material delivery device  472  and compression bodies  406  can be retracted, and then the block holding means retracted to allow the structural building block  525  to be discharged (e.g., under the force of gravity). In one embodiment, the block holding pad device include an inflatable diaphragm that is pneumatically activated and deactivated for causing block holding pads to selectively engage and disengage the structural building block  525 . In another embodiment, the block holding pads can be selectively engage and disengage through activation means that is electric, hydraulic or other suitable means. Preferably, but not necessarily, the block holding pads are fully or partially located within the block release recess  442  ( FIG. 22 ). Discharge of the structural building block  525  completes the block fabrication cycle. 
     It is disclosed herein that a vibratory apparatus can be attached to each compression body  406  and/or to the compression case  404 . In compressing media to form the structural building block  525 , portions of the media engaged with each compression body  406  can sometimes have a tendency to stick to one of the engaged compression bodies  406 . Attachment of a vibratory apparatus to each compression body  406  and activation of the vibratory apparatus just prior to when the engaged compression bodies  406  is moved toward its respective media loading position P 2  will contribute to releasing media of the structural building block  525  from engaged compression bodies  406 . In doing so, the tendency for a surface of the structural building block  525  being damaged through the act of retracting the engaged compression bodies  406  is reduced. 
     Additionally, it is disclosed herein that the vibratory apparatus can be activated during the media fill operation. In doing so, density of the media  510  is increased by virtue of vibrations from the vibratory apparatus causing entrapped air in the media to be released. 
     It is disclosed herein that only one compression body  406  need be movable (i.e., the moving compression body) for forming structural building blocks through use of the block forming apparatus  400 . One compression body (i.e., the stationary compression body) can be maintained in a fixed position via a substantially rigid member such as, for example, a beam connected between a chassis bulkhead and the stationary compression body. In the case of a block forming apparatus implemented with one movable compression body and one stationary compression body, an inboard face of the media compaction portion of the face the stationary compression body is aligned with an edge of the media fill opening  421  of the frame  402  (i.e., the media fill opening  421  positioned between inboard faces of the compression bodies  406 ) and with an edge of the block discharge opening  420  of the frame  402  (i.e., the block discharge opening  420  positioned between inboard faces of the compression bodies  406 ). Such alignment allows for block in accordance with the method  500  with the exception that only one compression body  406  is moved relative to the frame  402 . 
     Referring now to  FIGS. 23-31 , shown are various aspects on a block forming apparatus  600  specifically configured in accordance with an embodiment of the present invention for forming structural building blocks by depositing a prescribed activation material into a volume of block forming media having a curable binding material dispersed therein and, thereafter, compacting such block forming media. The block forming apparatus  600  includes a frame  602 , a compression case  604  and two opposed compression bodies  606 . As is discussed in greater detail below, the frame  602 , the compression case  604  and the two opposed compression bodies  606  are configured and interoperable in a manner that enabling the block forming apparatus  600  to carry out block fabrication functionality in accordance with present invention (e.g., in accordance with the method  700  disclosed herein). 
     As will become apparent in the ensuing discussion, the block forming apparatus  600  advantageously has a substantially integrated construction such that can be readily implemented into a block press having a substantially modular construction (i.e., the block forming press  300  is a press of such modular construction). Alternatively, the block forming apparatus  600  can be implemented in a block press in a non-modular and/or non-interchangeable manner. Additionally, the block press apparatus  600  can be used in a block press configured for having a single block press apparatus mounted thereon at any point in time or a plurality of block press apparatuses mounted thereon at any point in time. 
     The frame  602  preferably, but not necessarily, includes an elongated rectangular cross-section tube having an upper wall  610 ; a lower wall  612  and spaced-apart side walls  614 . Both spaced apart side walls  614  are not shown, but can have the same configuration as spaced-apart side walls  114 ,  116  shown in  FIG. 1 . The frame  602  includes compression case receiving passage  617  defined by interior surfaces of the walls ( 610 - 614 ) of the frame  602 . The compression case receiving passage  617  extends between opposed end faces ( 618 ,  619 ) of the frame  602 . A media fill opening  621  extends through the upper wall  610  of the frame  602  and a block discharge opening  620  extends through the lower wall  612  of the frame  602  such that the media fill opening  621  and the block discharge opening  620  are communicative (i.e., intersect) with the compression case receiving passage  617 . 
     The compression case  604  is slideably engaged within the compression case receiving passage  617  of the frame  602 . The slideable engagement between the frame  602  and the compression case  604  enables movement of the compression case  604  relative to the frame  602  along a longitudinal reference axis L 1  of the compression case  604 . In the depicted embodiment, the compression case  604  preferably, but not necessarily, includes an elongated rectangular cross-section tube having an upper wall  622 , a lower wall  624  and spaced apart side walls  626 . Both spaced-apart side walls  626  are not shown, but can have the same configuration as spaced-apart side walls  126 ,  128  shown in  FIG. 1 . As discussed below in greater detail, the upper wall  622  and the lower wall  624  include hollow portions for facilitating delivery of prescribed activation material and/or other types of useful functionality. 
     Interior surfaces of the walls ( 622 - 626 ) of the compression case  604  define a compression body receiving passage  630  extending between opposed end faces ( 632 ,  634 ) of the compression case  604  along the longitudinal reference axis L 1 . A media fill opening  636  extends through the upper wall  622  of the compression case  604  and a block discharge opening  638  extends through the lower wall  624  of the compression case  604 . The media fill opening  636  of the compression case  604  and the block discharge opening  638  of the compression case  604  are communicative (i.e., intersect) with the compression body receiving passage  630 . The respective interior surface of each one of the side walls  626  can have a respective block release recess therein, configured in a similar manner as discussed above in reference to  FIGS. 15-22 . These block release recesses are not shown in  FIG. 15 , but can be substantially the same as the block release recesses ( 140 ,  142 ) shown in  FIG. 4 . 
     At a minimum, the central axis of the media fill opening  636  of the compression case  604  is offset from a leading edge of the block discharge opening  638  by a distance equal to a length of the media fill opening  636  of the compression case  604 . It is disclosed herein that, in an alternate embodiment of the compression case  403  (not shown), the block discharge opening  638  intersects adjacent end  634  of the compression case  604 . In such an alternate embodiment, the adjacent end  634  of the compression case  604  defines a rear lateral edge  646  of the block discharge opening  638 . 
     Preferably, dimensions of the block discharge opening  520  of the frame  452  are the same as or larger than the corresponding dimensions of the block discharge opening  538  of the compression case  504 . Similarly, it is preferable that dimensions of the media fill opening  521  of the frame  502  are the same as or larger than the corresponding dimensions of the media fill opening  538  of the compression case  504 . 
     It is disclosed herein that the frame  602  and the compression case  604  can optionally both have a different cross sectional shape than rectangular. Examples of such different cross-sectional shapes include, but are not limited to, round, hexagonal, etc. In view of the disclosures made herein, a skilled person will appreciate that the present invention is not necessarily limited to a particular cross-sectional shape of the frame  602  or the compression case  604 . Additionally, a skilled person will appreciate that the frame  602  can be a non-tubular structure (e.g., an open chassis) while still providing for the required functionality of movable engagement with the compression case  604  and necessary engagement of the block forming apparatus  600  by a block press. 
     Still referring to  FIG. 23 , each compression body  606  is slideably mounted within the compression body receiving passage  630  of the compression case  604 . Thus, each compression body  606  is mounted in a manner enabling movement (i.e., simultaneous, independent and/or linked) of each compression body  606  along the longitudinal reference axis L 1  of the compression case  604 . Similar to the compression body  106  shown in  FIGS. 1 ,  2  and  5 , each compression body  606  can include a media compaction portion and an actuator engagement portion connected to the media compaction portion. An inboard face of the media compaction portion can be substantially flat, can be partially flat with a non-flat feature or can be substantially contoured. In one embodiment the media compaction portion of each compression body can have a relatively low clearance fit (i.e., an intimate fit) within the compression body receiving passage  630  and, preferably, a length of the media compaction portion is relatively long with respect to cross-sectional dimensions of the compression body receiving passage  630  to limit a tendency for rocking within compression body receiving passage  630 . The actuator engagement portion can include a generally flat engagement flange. The engagement flange enables distributed delivery of a force onto the compression body  606  through a force application means such as, for example, a force application platen connected to a hydraulic cylinder. In another embodiment, the compression bodies are integrally connected to a press beam supporting arm structure having a separate frame or rail for independent support and movement in relation to the support frame and movement of the compression case. This embodiment allows for unrestrained independent movement of the compression bodies within the compression case and the compression case independently moves in relation to the compression bodies. Actuating cylinder apply pressure to the press beam support arm structure which then translate this force to a single or multiple compression bodies being integrally part of the press beam support arm structure. 
     Still referring to  FIG. 23 , a prescribed activation material delivery mechanism  670  is provided within a first one of the compression bodies  606  for facilitating delivery of prescribed activation material to enable curing of a curable binding material. The activation material delivery mechanism  670  includes a first activation material delivery device  672  and a delivery device actuator  674 . In one embodiment, the delivery device actuator  674  includes a ram and a forced fluid cylinder (e.g., hydraulic or pneumatic). The delivery device actuator  674  allows for translation of the first activation material delivery mechanism  670  with respect to the compression body  606  on which it is mounted. 
     The first activation material delivery device  672  is translatably connected to the delivery device actuator  674  in a manner allowing the delivery device actuator  674  to cause translation of the first activation material delivery device  672  along a delivery device translation axis extending effectively parallel with the longitudinal axis L 1 . For example, through application of fluid pressure at a first fluid supply line  678  and at a second fluid supply line  680  (i.e., differential applied pressure), the first activation material delivery device  672  translates in a first direction and a second (i.e., opposite) direction along the delivery device translation axis. The first activation material delivery device  672  extends through an opening  682  in a media compressing face  684  of the first one of the compression body  606 . A second one of the compression bodies  606  (i.e., the opposing compression body) has a delivery device receiving opening  686  therein such that through translation of the first activation material delivery device  672  and/or the second one of the compression bodies  606 , the first activation material delivery device  672  can be extended into the delivery device receiving opening  686  of the second one of the compression bodies  606 . 
     Referring now to  FIGS. 15-17 , the first activation material delivery device  672  comprises a delivery tube  688 , a nozzle body  689  and a material delivery conduit  690 . An end wall  691  of the delivery tube  688  has delivery orifices  692  extending therethrough and a delivery tube extension  693  extending therefrom. The material delivery conduit  690  intersects a fluid passage  694  of the delivery tube  688  for allowing prescribed activation material to be supplied into the delivery passage  694  through controlled translation speed of the first activation material delivery device  672 . The delivery tube extension  693  extends through the nozzle body  689 . The delivery tube extension  693  and the nozzle body  689  are jointly configured for allowing the nozzle body  689  to slide on (i.e., translate relative to) the delivery tube extension  693 . A nozzle preload spring  695  engaged between the nozzle body  689  and a tip portion of the delivery tube extension  693  biases the nozzle body  689  to an at-rest position with respect to the delivery tube  688  (as shown in  FIG. 24 ). In the at-rest position, a first end portion of the nozzle body  689  abuts the end wall  691  of the delivery tube  688  such that flow of prescribed activation material from within the delivery tube  688  is inhibited. Spring force exerted on the nozzle body  689  is maintained at a level such that the nozzle body  689  is maintained in the at-rest position until pressure at which the prescribed activation material is supplied into the delivery tube  688  overcomes such spring force, thereby moving the nozzle body  689  to a displaced position (as shown in  FIGS. 24 and 25 ). In the displaced position, the first end portion of the nozzle body  689  is spaced away from the end wall of the  691  of the delivery tube  688  such that prescribed activation material from within the delivery tube  688  flows through the delivery orifices  692  and through the space between the end portion of the nozzle body  689  and the end wall of the  691  of the delivery tube  688 . 
     A pressure adjustment nut  696  and travel adjustment nut  697  are separately threaded onto the tip portion of the delivery tube extension  693 . A stop plate  698  is positioned between the pressure adjustment nut  696  and the travel adjustment nut  697 . The tip portion of the delivery tube extension  693  passes through a passage in the stop plate  698  in a manner allowing the tip portion of the delivery tube extension  693  to translate with respect to the stop plate  698 . The stop plate  698  includes external threads that are threadedly engaged with mating internal threads within recess within a tip portion of the nozzle body  689 . The stop plate  697  includes a cavity therein configured for receiving the pressure adjustment nut  696 . The stop plate  697  and the nozzle body  689  are jointly configured such that, with sufficient displacement of the nozzle body toward the displaced position, a second end face of the nozzle body engage the stop plate  698 . 
     Through rotation of the pressure adjustment nut  696  with respect to the delivery tube extension  693 , preload of the nozzle preload spring  695  can be adjusted. Such adjustment allows the fluid pressure required for moving the nozzle body  689  from the at-rest (i.e., closed) position to the displaced position (i.e., open position) to be selectively adjusted. Through rotation of the travel adjustment nut  697  with respect to the delivery tube extension  693  and/or through rotation of the stop plate  698  with respect to the nozzle body  689 , overall displacement of the nozzle body  689  can be adjusted. In this mariner, an opening pressure of the nozzle body  689  and a maximum displacement of the nozzle body  689  can be independently adjusted. More specifically, the space between the between the end portion of the nozzle body  689  and the end wall of the  691  of the delivery tube  688  when the nozzle body  689  is in the displaced position and fluid pressure required for achieving such displacement can be adjusted for altering deliver properties (i.e., flow rate, dispersion, etc) of the prescribed activation material delivered from the first activation material delivery device  672 . Such adjustability is important because the smaller (e.g., narrower) the opening between the end portion of the nozzle body  689  and the end wall of the  691  of the delivery tube  688  for any given pressurised fluid (i.e., the prescribed activation material), the greater the velocity of the fluid. This velocity has a shearing or mixing affect on the activation material  717  and block forming media  710  that is advantageous. With controlled pressure and controlled opening size and by controlling the velocity at which the first activation material delivery device  672  moves relative to the compression body, a calculated quantity of prescribed activation material can be evenly dispersed and completely mixed throughout the block forming media. As can be seen, controlling the speed of translation of the first activation material delivery device  672  and controlling the pressure at which prescribed activation material is supplied to the first activation material delivery device  672  influences the volume and uniformity (i.e., distribution and dispersion) of the prescribed activation material. 
     Referring back to  FIG. 23 , the compression case  604  includes a plurality of second activation material delivery devices  660  (e.g., spray nozzles) exposed within openings of walls defining the compression body receiving passage  630 . The second activation material delivery devices  660  are located within a first hollow portion  661  of such walls of the compression case  604 . Through adequate positioning of the compression case  604  with respect to the compression bodies  606 , prescribed activation material supplied to the second activation material delivery devices  660  under pressure via an activation material delivery line  662  can be delivered (e.g., injected, sprayed, etc) into the compression body receiving passage  630  between the compression bodies  606 . The compression case  604  also includes a plurality of auxiliary delivery devices  663  (e.g., spray nozzles) exposed within openings of walls defining the compression body receiving passage  630 . The auxiliary delivery devices  663  are located within a second hollow portion  664  of such walls of the compression case  604 . Through adequate positioning of the compression case  604  with respect to the compression bodies  606 , a fluid such as stream or hot water supplied to the auxiliary delivery devices  663  under pressure via an auxiliary material delivery line  665  can be delivered (e.g., injected, sprayed, etc) into the compression body receiving passage  630  between the compression bodies  606 . For example, soil or flyash can require very small amounts of water to allow these materials to be joined together under pressure. Other materials can require steam curing under pressure to complete crystallisation. For example calcium silicate, and geopolymers can require steam curing after or during compression. Also, the injection of small amounts of water in the form of steam may be used in place of the reactant materials through the first or second injectors before pressing fly ash or soils, which can only require a small amount of moisture as the reactant material. The second activation material delivery devices  660  and the auxiliary delivery devices  663  can be distributed within all of the walls defining the compression body receiving passage  630  (i.e., not limited to placement in any particular ones of such walls). 
     It is disclosed herein that the second activation material delivery devices  660  and/or the auxiliary delivery devices  663  can each be plumbed in combination with one or more respective adjustable pressure relief valve. The adjustable pressure relief valves are fixed and set to open at a pre-determined pressure. In this manner, simultaneous opening of one or more fluid delivery devices attached to a respective pressure relief valve is provided for at the predetermined pressure. 
     Now, a discussion of fabrication functionality of the block forming apparatus  600  for forming a structural building block is presented. A method in accordance with the present invention, which is referred to herein as the method  700 , is depicted in  FIGS. 26-31 . While the method  700  is depicted and discussed as being carried out in accordance with the block forming apparatus  600  depicted in  FIGS. 23-31 , in view of the disclosures made herein, a skilled person will appreciate that other suitably configured block forming equipment can be used for carrying out the method  700 . 
     Referring now to  FIG. 26 , a block fabrication cycle begins with facilitating relative positioning of the compression case  604  and each compression body  606  for forming a media receiving cavity  705  within the compression body receiving passage  630  between the compression bodies  606  and moving the first activation material delivery device  672  such that the nozzle body  689  is positioned within the delivery device receiving opening  686  of the second one of the compression bodies  606 . A quantity of release agent can be spayed onto surfaces of the compression case  604  and compression bodies  606  that contact the block forming media for allowing clean release of an as-formed structural building block from such surfaces of the compression case  604  and compression bodies  606 . Relative to completion of a previously performed block fabrication cycle, facilitating such relative positioning for forming the media receiving cavity  705  includes moving the compression case  604  to a respective media loading position P 1  relative to the frame  602 , moving each compression body  606  to a respective media loading position P 2  relative to the compression case  604 , and moving the first activation material delivery device  672  to an extended position P 8 . In this configuration, the compression bodies  606  are in spaced apart relationship with respect to each other, and a tip portion of the first activation material delivery device  672  is positioned within the delivery device receiving opening  686  of the opposing compression body  606  (i.e., through translation with respect to the delivery device actuator  674 ). Accordingly, with the compression case  604  in its respective media loading position P 1  and each compression body  606  in its respective media loading position P 2 , the media receiving cavity  705  is provided within the compression body receiving passage  630  between the two compression bodies  606 . 
     In the case of gravity feed of the block forming media where the compression case  604  serves as the block forming media shut-off structure for an associated media hopper/media supply, the first activation material delivery device  672  must be in an extended position (i.e., extending through the delivery device receiving opening  686  of the opposing compression body  606 ) prior to block forming media entering the media receiving cavity  705 . For example, the first activation material delivery device  672  can be moved to the extended position immediately following ejection of a formed block from a prior block fabrication cycle. In the case of unrestricted gravity feeding of block forming media from a hopper into the media receiving cavity  705 , vibratory means or the like can be employed for causing complete fill of the media receiving cavity as defined between the compression when the media receiving cavity  705  are a prescribed distance apart from each other (i.e., defining a media receiving cavity  705  of a prescribed quantity. 
     As depicted in  FIG. 27 , a quantity of block forming media  710  from which a building block can be made is deposited into the media receiving cavity  705  through an opening  715  defined by the media fill openings ( 619 ,  636 ) of the frame  602  and the compression case  604  after relative positioning of the compression case  604  and each two compression body  606  is performed for forming the media receiving cavity  705 . The block forming media  710  includes a curable binding material dispersed therein. Curing of the curable binding material is caused by contact with a prescribed activation material. 
     It is disclosed herein that the quantity of media  710  will preferably be of a relatively low density with respect to the density of media in corresponding formed structural building block. In the case of the quantity of block forming media being controlled by a delivery hopper, there are a number of approaches for such hopper controlling such delivered quantity of block forming media. In one such approach, the quantity of the media  710  delivered to the media receiving cavity  705  is quantitatively determined prior to or in conjunction with the quantity of media  710  being deposited in the media receiving cavity  705 . In another such approach, a length of deposit time is correlated to the quantity of media  710 . In still another such approach, a weight is correlated to the quantity of media  710 . In still another such approach, a fill level of media within the media receiving cavity  705  is determined in conjunction with delivery of the quantity of media  710 . In the case of the quantity of block forming media being controlled by size of the media receiving cavity  705  and media delivery to the media receiving cavity  705  being unrestricted, one preferred approach to delivering the block forming media is to position the compression bodies  606  a prescribed distance apart such that a media receiving cavity  705  of a prescribed quantity is defined and using means such as a vibratory device to assure that this prescribed quantity is sufficiently filled with block forming media. 
     As depicted in  FIGS. 28 and 29 , after the quantity of block forming media  710  is deposited within the media receiving cavity  705 , relative positioning of the compression case  604  is facilitated for closing the entry  715  into the media receiving cavity  705  through which the quantity of media  710  was deposited. Facilitating relative positioning of the compression case  604  for closing the entry  715  includes moving the compression case  604  to a chamber sealing position P 3  relative to the media fill opening  621  of the frame  602 . In the chamber sealing position P 3 , the media fill opening  636  of the compression case  604  is entirely offset from the media fill opening  621  of the frame  602 . Upon closing of the entry  715 , the space within the compression body receiving passage  630  between the two compression bodies  606  becomes a media compression chamber  720  (i.e., a generally sealed chamber). 
     After positioning the compression case  604  for forming the media compression chamber  720 , a quantity of the prescribed activation material  717  is injected (i.e., deposited) under pressure into the media compression chamber  720 . More specifically, the quantity of media  710  at least partially covers the first activation material delivery device  672  such that at least a portion of the prescribed activation material  717  is injected into the quantity of media  510  via the first activation material delivery device  672 . Furthermore, the prescribed activation material  717  is injected under high pressure whereby such high pressure results in a force being applied on the nozzle body  689  thereby causing translation of the nozzle body  689  with respect to the delivery tube  688  from the at-rest position (See  FIG. 24 ) to the displaced position (see  FIG. 25 ) and, thus, allowing flow of the prescribed activation material  717  into the media compression chamber  720 . Spring biasing force from exerted on the nozzle body  689  causes the nozzle body  689  to translate back to the at-rest position from the displaced position upon completion of the prescribed activation material being supplied to the activation material delivery device  672  under sufficiently high pressure. 
     Still referring to  FIGS. 28 and 29 , it can be seen that during delivery of the prescribed activation material  717  from the first activation material delivery device  672 , the first activation material delivery device  672  is translated through the media receiving cavity  705  such that prescribed activation material  717  is dispersed and distributed throughout the quantity of block forming media  710 . As such, the first activation material delivery device  672  sprays prescribed activation material  717  in a 360 degree radius with respect to a translation axis of the first activation material delivery device  672 , spraying from a central region of the media receiving cavity  705  toward an outer region of the media receiving cavity  705 . Furthermore, it can be seen that prescribed activation material  717  is also delivered into the media receiving cavity  705  via the second activation material delivery devices  660 . Such delivery from the second activation material delivery devices  660  can be performed simultaneously with delivery of prescribed activation material  717  from the first activation material delivery device  672 , partially with the delivery of prescribed activation material  717  from the first activation material delivery device  672  and completely separate from delivery of prescribed activation material  717  from the first activation material delivery device  672 . The second activation material delivery devices  660  can be configured to provide different spray patterns. This allows for greater control of placement of the prescribed activation material  717  reaching areas where the prescribed activation material  717  from the first second activation material delivery devices  672  does not reach. In view of the disclosures made herein, a skilled person will appreciate a plurality of first activation material delivery devices  672  (e.g., fed by a common manifold or separate manifolds) can be implemented rather than a single one. 
     Accordingly, it can be seen that the first activation material delivery device  672  sprays prescribed activation material  717  towards the second activation material delivery devices  660  and, similarly, the second activation material delivery devices  660  spray prescribed activation material towards the first activation material delivery devices  672 . Such spraying is performed at predetermined pressure such that a mixing process (i.e., agitation) takes place between the curable binding material in the block forming media  710  and the prescribed activation material  717 . This mixing coupled with the displacement of the first activation material delivery device  672  provides for relatively uniform depositing of the curable binding material in the block forming media  710  and the prescribed activation material  717 . 
     It is disclosed herein that a single second activation material delivery device  660  can be provided in the compression case  604  as opposed to a plurality of second activation material delivery devices  660 . In such an alternate embodiment, the compression case translates in a similar manner as does the first activation material delivery devices  672 . Such translation of the second activation material delivery device  660  through translation of the compression case  604  provides for distribution and dispersion of prescribed activation material  717  from the second activation material delivery device  660 , much in the same way as distribution and dispersion of prescribed activation material  717  from the first activation material delivery device  660  is provided. 
     Preferably, depositing (e.g., injecting) the prescribed activation material  717  includes delivering the prescribed activation material  717  to the activation material delivery device  472  at a pressure that causes the prescribed activation material  717  to be sprayed from the activation material delivery devices  672 ,  660  at high speed and/or with a high degree of exhibited turbulence. More specifically, it is preferred for the prescribed activation material  717  to be injected in a manner that causes it to be widely dispersed throughout the quantity of media  710 . Orifices/delivery passages of the activation material delivery devices  672 ,  660  can be specifically configured to enhance such velocity, turbulence and/or dispersion. For example, such orifices/delivery passages can be specifically configured for enhancing velocity and droplet size (e.g., atomisation) of the prescribed activation material  717  as delivered to the quantity of media  710 . Turbulence can also be imparted by selection of a curable binding material and corresponding activation material that together react in a turbulent manner (e.g., bubbling, foaming, etc). Such binding material induced turbulence can be at least partially controlled/mitigated through compressions exerted on the block forming media by the compression bodies  606 . The amount of the prescribed activation material  717  can be dictated by an amount of time such injection is performed or by a quantity of the prescribed activation material  717  that is delivered. 
     As shown in  FIG. 30 , following delivery of the intended quantity of the prescribed activation material, the first activation material delivery device  672  is positioned such that the interface between the nozzle body  689  and the delivery tube  688  is outside of the media compression chamber  720 . More specifically, the interface between the nozzle body  689  and the delivery tube  688  is beyond a compression face of the compression body  606  opposite the compression body  606  that carries the first activation material delivery device  672 . Furthermore, the compression case  604  is translated such that the second activation material delivery devices  660  are fully offset from the media compression chamber  720 , thereby preventing activation material-laden block forming media  710  from entering the openings in which the second activation media delivery devices  660  are exposed and clogging the second activation media delivery devices  660  during compaction of the activation material-laden block forming media  710 . 
     Still referring to  FIG. 30 , during or after injection of the prescribed activation material  717 , each compression body  606  is moved toward the other compression body  606  under sufficient applied force to compress the quantity of block forming media  710  into a structural building block  725 . In the depicted embodiment, the auxiliary delivery devices  663  deliver steam and/or hot water to aid in catalytic process between the activation material  717  and the curable binding material in the block forming media  710 . Alternatively, the auxiliary delivery devices  663  can be omitted and, optionally, the hollow wall space in which the auxiliary delivery devices  663  were located can be used for receiving a refrigerant/cooling material for controlling temperature of the block forming media after the activation material is added thereto. 
     A compressed quantity and shape of the structural building block  725  corresponds to the cross sectional shape and cross-sectional area of the compression body receiving passage  630  and a distance between the inboard faces (i.e., media engaging face) of each compression body  606  when each compression body  606  is in a fully displaced position P 4  (i.e., as dictated by a maximum applied pressure, a defined travel limit, or the like). In one embodiment of the present invention, longitudinal displacement of each compression body  606  is determined for enabling assessment of a degree of compaction of the quantity of media  610  and/or for enabling assessment of physical dimensions of the structural building block  725 . Mechanical means (i.e., limit stops) for maintaining a minimum distance between the compression bodies  606  can be provided. 
     Referring now to  FIG. 31 , after the quantity of media  710  is compressed into the structural building block  725  and, optionally, after a prescribed curing time for the curable binding material has elapsed (e.g., after the curable binding material has cured to a specified or approximated degree such as a gel or crystallized state), relative positioning of the compression case  604  and the compression bodies  606  and retraction of the first activation material delivery device  672  is facilitated for enabling discharge of the structural building block  725  from within the compression chamber  720  through the block discharge openings  620  of the frame  602  and through the block discharge opening  638  of the compression case  604 . Facilitating relative positioning for enabling such discharge includes moving the compression case  604  to a block discharging position P 5  with respect to the compression bodies  606  and removing all or a portion of the applied force on the compression bodies  606  whereby the compression bodies  606  are in substantially non-compressing engagement with the structural building block  725 . The operation of removing all or a portion of the applied force on the compression bodies  606  by the compression bodies  606  reduces the potential for pressure exerted by the compression bodies  606  resulting in damage to the structural building block  725  as the compression case  604  is moved from the chamber sealing position P 3  to the block discharging position P 5 . Moving the compression case  604  to the block discharging position P 5  includes limiting longitudinal movement of the compression bodies  606  while moving the compression case  604  to the block discharging position P 5 . 
     As shown in  FIG. 31 , with the compression case  604  in the block discharging position P 5  and the activation material delivery device  672  moved to its retracted position P 6 , the compression bodies  606  are moved toward the respective media loading position P 2  ( FIG. 26 ). Moving the compression bodies  606  toward their respective media loading position P 2  disengages the compression bodies  606  from the structural building block  725 . This disengagement in conjunction with structural building block  725  being exposed to the block release recesses of the compression case  604  promotes discharging of the structural building block  725  from within the compression body receiving passage  630  of the compression case  604 . It is disclosed herein that any number of means can be implemented for holding the structural building block  725  in place while the compression bodies  606  are being disengaged. A suitable configured inflatable diaphragm coupled to the compression case  604  or other suitable structure is one example of such means. 
     It is disclosed herein that only one compression body  606  need be movable (i.e., the moving compression body) for forming structural building blocks through use of the block forming apparatus  600 . One compression body (i.e., the stationary compression body) can be maintained in a fixed position via a substantially rigid member such as, for example, a beam connected between a chassis, bulkhead and the stationary compression body. In the case of a block forming apparatus implemented with one movable compression body and one stationary compression body, an inboard face of the media compaction portion of the face the stationary compression body is aligned with an edge of the media fill opening  621  of the frame  602  (i.e., the media fill opening  621  positioned between inboard faces of the compression bodies  606 ) and with an edge of the block discharge opening  620  of the frame  602  (i.e., the block discharge opening  620  positioned between inboard faces of the compression bodies  606 ). Such alignment allows for block in accordance with the method  700  with the exception that only one compression body  606  is moved relative to the frame  602 . 
     A skilled person will appreciate that the present invention is not unnecessarily limited to a particular curable binding material or activation material. Functionally, a curable binding material in accordance with the present invention preferably will bind to all or a portion of other constituent materials of the block forming media, will exhibit preferred mechanical/physical properties over a relatively long-term, will be partially or fully curable within a desired duration of time after being exposed to a suitable activation material, and/or will exhibit a turbulent (i.e., physically active) reaction when chemically subjected to a corresponding catalyst. 
     One preferred example of a rapid setting curable binding material and corresponding activation material is a metal oxide (e.g., magnesium oxide) and an acid solution (e.g., phosphoric acid), respectively. Together, such a rapid setting curable binding material and corresponding activation material are referred to herein as a rapid set matrix composition. Another example of such a rapid set matrix composition includes a rapid set geo-polymeric matrix composition, which are formed through a chemical reaction between silicoaluminates and alkali silicates in contact with highly alkaline solutions or compounds. Examples of silicoaluminates include, but are not limited to, mineral powders, fly-ash and metakaolin. Examples of alkaline solutions include, but are not limited to, hydroxide, silicate, or a combination thereof, as well as potassium chloride and calcium chloride. 
     As can be seen, the present invention advantageously capitalizes on the reactive properties of rapid setting curable binding material and corresponding activation material. Furthermore, the present invention advantageously overcomes difficulties of working with very rapid setting or hardening of rapid set matrix compositions. For example, by catalysing such materials within the block-forming cavity of a block press, time considerations of forming a block with such rapid set matrix compositions is fully or sufficiently mitigated. Furthermore, such time considerations (e.g., cure time of a rapid set matrix composition) can be at least partially influenced through use of additives that retard the setting and/or hardening time of rapid set matrix composition. Such additives are well known in the art. Preferably, rapid set matrix composition useful with embodiments of the present invention undergo a chemical reaction such that the rapid set matrix composition begin to set or harden almost instantly or within seconds after contact between the rapid setting curable binding material and corresponding activation material. Accordingly, embodiments of the present invention take advantage of these rapid chemical reacting materials when molding such rapid set matrix compositions into an article (e.g., a structural building block). 
     In view of the block fabrication cycle shown in  FIGS. 18-22  and/or the block fabrication cycle shown in  FIGS. 26-31 , it can be seen that bringing a rapid setting curable binding material and corresponding activation material into contact with each other within an article-forming cavity (e.g., block forming cavity) filled with a block forming media and timing compression of such block forming media and rapid setting curable binding material/activation material is important for any number of reasons. One reason is that, for materials configured for very rapid setting or hardening, after contact is made and just before setting or hardening, these materials can take on a viscoelastic-like consistency or a paste-like consistency. In reactant materials designed for rapid setting, the time that the viscoelastic or paste like consistency is present is very short. It is in this viscoelastic and/or paste-like state that the reactant materials have the characteristics to bind to block forming media with which they are in contact. Accordingly, timing of the compression stage is important in that, after or during contact between the rapid setting curable binding material and corresponding activation material, compression takes place to disperse the paste-like rapid set matrix composition throughout the block forming media, thereby intermingling with constituent components of the block forming media. In this manner, a more complete reaction between the rapid setting curable binding material and corresponding activation material takes place as these materials are dispersed by compressive forces of the compressing operation. 
     A skilled person will appreciate that the present invention is not unnecessarily limited to a particular form in which the curable binding material, catalyst and/or corresponding activation material are provided. In one embodiment, the curable binding material is a dry constituent component of the block forming media (i.e., dispersed therein) and the activation material is a liquid catalyst injected into contact with the curable binding material via an activation material delivery device in accordance with the present invention. In another embodiment, the curable binding material is a dry constituent component of the block forming media (i.e., dispersed therein), a catalyst for the curable binding material is also a dry constituent component of the block forming media (i.e., dispersed therein), and the activation material is also a liquid (e.g., water) injected into contact with the curable binding material and catalyst via an activation material delivery device in accordance with the present invention. In still another embodiment, the catalyst is a dry or wet constituent component of the block forming media (i.e., dispersed therein) and the curable binding agent is a liquid injected into contact with the catalyst via an activation material delivery device in accordance with the present invention. It is also disclosed herein that the activation material (e.g., the catalyst or water) can be heated to a temperature that accelerates curing of the curable binding agent or can be chilled to a temperature that slows curing of the curable binding material. For example, in the situation where the activation material is water, the water can be in the form of chilled water, heated water or steam. Similarly, other types of activation materials (i.e., including chemical catalysts such as acid solutions) can be heated or chilled as desired or required to control the rate of curing of the curable binding material. 
     It is disclosed herein that an expandable composition (e.g., a foaming agent) can be used to ensure intended volume and formation of structural building blocks formed in accordance with embodiments of the present invention. In one particular embodiment, a quantity of block forming media deposited into a media compression chamber of a block press configured in accordance with the present invention is less than that required to fill the media compression chamber such that it can not be compressed when bringing the compression bodies together to a predefined separation during compression of the block forming media. The expandable composition is within the block forming media or the activation material. When combined with a suitable catalyst (i.e., within the or the activation material or block forming media, respectively) during or after the compression bodies are brought together to the predefined separation, the expandable composition expands so as to fill any space within the media compression chamber that is not filled by block forming media. 
     In the preceding detailed description, reference has been made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the present invention can be practiced. These embodiments, and certain variants thereof, have been described in sufficient detail to enable those skilled in the art to practice embodiments of the present invention. It is to be understood that other suitable embodiments can be utilized and that logical, mechanical, chemical and electrical changes can be made without departing from the spirit or scope of such inventive disclosures. To avoid unnecessary detail, the description omits certain information known to those skilled in the art. The preceding detailed description is, therefore, not intended to be limited to the specific forms set forth herein, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents, as can be reasonably included within the spirit and scope of the appended claims.