Patent ID: 6972100

Claim:
An apparatus for forming a rigid foamed cementitious core within a plurality of article shells comprising: a shell bank for retaining a plurality of article shells and comprising a sled, each article shell having a generally planar construction and a generally uniform thickness with marginal edges and having first and second article skins helping to define an interior cavity, the sled having a sled surface sized to support at least one marginal edge of each article shell, each article shell being placed spaced apart on the shell bank and being provided with a reinforcement; a filling station comprising a filling nozzle for delivering a gas-entrained cementitious material to the interior cavity of each article shell; and a pump for pumping the gas-entrained cementitious material through the filling nozzle and into the interior cavity of each article shell, whereby the gas-entrained cementitious material cures to form a rigid foamed cementitious core within each article shell in the plurality of article shells.