Patent ID: 7707784

Claim:
A method of forming a building block structure comprising the steps of: a) providing a mass of randomly oriented straw stalks that includes rice straw stalks; b) shaping the mass of straw stalks into a block that includes a first wall and a second wall and sidewalls orthogonally connected to the first wall and the second wall, and defining a width that includes the first wall, the second wall and an intermediate block portion connecting the first wall and the second wall; c) forming at least one through hole in the intermediate block portion that extends between opposing connecting sidewalls; d) applying an added binding agent to the block or independently to the straw stalks to bond the straw stalks together; and e) applying pressure in the range of 1250 to 2000 psi to the mass of straw stalks at a temperature of about 250 to 350° F. for a period of approximately 20 to 30 minutes so that at least the first wall and the second wall locally densify to form a rigid skin portion that has a density greater than the intermediate block portion, the rigid skin portion being generally smooth, and of sufficient density that it receives and supports fasteners.