Patent ID: 7810299

Claim:
A process for forming a floor tile for a raised floor system, comprising the steps of: forming a box-shaped support pan having a shallow upwardly-opening compartment defined by a bottom wall of the pan and upright side walls which join to edges of the bottom wall and protrude upwardly and terminate at top edges; forming a plurality of one-piece concrete sub-blocks having a thickness which equals or slightly exceeds the depth of the shallow compartment; positioning a predetermined plurality of preformed concrete sub-blocks in horizontally adjacent side-by-side relationship so that the sub-blocks, when opposed edge faces of said sub-blocks are sidewardly engaged with one another, define a plan-view profile which substantially corresponds to the plan view profile of the compartment; applying an adhesive to at least one edge face of each opposed pair of edge faces as defined on said sidewardly adjacent sub-blocks; pressing said sub-blocks sidewardly together to effect fixed securement of said sub-blocks at said opposed contacting edge faces due to curing of said adhesive so as to define a preformed one-piece main concrete block having a plan-view profile which substantially corresponds to said compartment; applying adhesive to one of (1) the bottom surface of said preformed main concrete block and (2) the inside surface of said pan bottom wall; applying adhesive to one of (1) inside surfaces of the pan side walls and (2) the edge faces of said preformed main concrete block; deflecting the side walls of the pan outwardly prior to positioning of the main concrete block into the compartment; then positioning the preformed main concrete block into said compartment of said pan so that the bottom surface of said main block contacts the pan bottom wall; deflecting the pan side walls inwardly into engagement with the edge faces of the main block after the main block has been positioned within the compartment of the pan; and allowing the adhesive at contact areas between the pan and the main concrete block to cure to effect fixed securement of the block to and within the pan.