Abstract: Disclosed is a method of manufacturing an artificial stone, and the method includes forming an artificial-stone paste which comprises 20-20 parts by weight of silica stone, metakaolim or silica fume, 200-300 parts by weight of quartz chips, 30-36 parts by weight if water, 1.5-3 part by weight of water-reducing agent and 0.2-3 parts by weight of pigment with response to 100 parts by weight of white cement; injecting the artificial-stone paste in a mold; primarily vacuum-molding the artificial-stone paste injected in the mold; secondarily vibration-molding the primarily molded artificial-stone paste; primarily curing the secondarily molded artificial-stone paste; secondarily curing the primarily cured artificial-stone paste, which induces a hydrothermal reaction and thus causes a pozzolanic reaction; releasing the secondarily cured artificial-stone paste from the mold; and surface-machining the released artificial-stone paste.

Abstract: The invention comprises a method of forming a slab on grade. The method comprises placing a first layer of insulating material horizontally on the ground and placing plastic concrete for a slab on grade on the first layer of insulating material. The plastic concrete is then formed into a desired shape having a top and sides. A second layer of insulating material is placed on the top of the plastic concrete and the first and second layers of insulating material are left in place until the concrete is at least partially cured. The second layer of insulating material is then removed. The product made by the method is also disclosed. A slab on grade is also disclosed.

Abstract: The present invention relates to an apparatus and method for forming molded tapered products, such as masonry blocks, whereby high quality finished products are removed from their mold without the need for complex machinery for demolding. The mold may include one or more mold cavities having one or more movable cavity walls. The movable cavity walls may include an end liner having a planar product forming surface capable of moving from a vertical position to an angled position. Tapered products may be formed by moving the mold towards a pallet so that the pallet engages with the end liner and causes the end liner to move from the vertical position to the angled position. Moldable material may then be introduced into the mold cavity and may be allowed to remain in the mold cavity until it is self-sustaining.

Abstract: A method and apparatus is provided for preventing a composite material used in forming slabs for residential and commercial construction from entering a predefined space that is maintained open for pipes, plumbing fixtures and other conduits. The preform apparatus comprises a body, apron and cover. The apparatus is assembled by placing the preform body in position to occupy a predefined space, press fitting the apron down over and around the body and the cover on top of the body. Thereafter, the composite material is poured around the preform and allowed to cure. After curing, the preform body and the cover are removed, leaving a material free void within and below the predefined space that the preform had occupied. The preform is straightforward, inexpensive to produce, easy to use and is assembled without fasteners and without disturbing the soil below the slab or the moisture/vapor barrier.

Abstract: An inorganic board contains, in a solid content ratio, 30 to 70 mass % of hydraulic material, 5 to 15 mass % of reinforcing fiber, and 1 to 30 mass % of wollastonite having a wet volume (after being allowed to stand for 30 minutes) of 15 to 45 ml. Also, a method includes: step of producing a slurry containing hydraulic material, reinforcing fiber, and wollastonite; step of producing a sheet by dehydrating the slurry; and step of pressing and curing the sheet; wherein, in the step of producing a slurry, a composition of the slurry is set so as to contain, in a solid content ratio, 30 to 70 mass % of hydraulic material, 5 to 15 mass % of reinforcing fiber, and 1 to 30 mass % of wollastonite having a wet volume (after being allowed to stand for 30 minutes) of 15 to 45 ml.

Abstract: A cementitious mixture for high-volume production of masonry products comprises a hydraulic binder accounting for 20 wt % or more of the cementitious mixture, the hydraulic binder comprising 75 to 100 wt % Class C fly ash with a CaO equivalent content of at least 15% by weight. The cementitious mixture also comprises one or more aggregates, and a set control system.

Abstract: A method of producing gypsum building board, in which there is added, to an aqueous gypsum slurry containing a water swellable clay, a basic water-soluble polymer having preferential affinity for clay. The slurry is allowed to set so as to form a board. The basic water-soluble polymer may be, for example, a polyvinyl alcohol or a polymer consisting essentially of carbon, nitrogen and hydrogen and having amine groups (which may be primary, secondary, tertiary or quaternary) in the polymer backbone and/or in side chains thereof.

Abstract: There is provided a process for producing precast concrete parts, in particular pylon segments. Concrete is poured into a casting mold with a planar bottom for producing a planar underside. After the concrete has reached at least a minimum strength an equalization layer is applied to a join surface of the precast concrete part that is opposite to the underside. As soon as the equalization layer has reached the minimum strength, the precast concrete part is placed on a horizontally oriented surface and the equalization layer on the top side is removed in a plane-parallel relationship with the underside.

Abstract: A method apparatus and product is provided which includes the use of an S-Tile mold, combined with a scoring/knifing process, which allows for subsequent controlled separation of what would normally be an S-Tile into two separate tile sections each having a general C-shaped cross section. This allows for two types of tiles (S-tiles and Two-Piece Mission tiles) to be made from one type of mold (S-tile). A method, apparatus and product is also provided which includes the use of an S-Tile mold, including or combined with a scoring, knifing, or forming process for providing a channel or other suitable shape, which allows for an S-Tile to be produced which appears to be two separate but cooperating tile sections having a general C-shaped cross section. The longitudinal channel 9 or other shape and or proximate area may also be painted, colored, or otherwise darkened in order to accent a “shadow” effect which causes the eye to better perceive separation of the two portions 6 and 7 of the tile 5.

Abstract: In manufacturing composite material by curing fluid, strength deterioration of the composite material due to repair before the fluid is cured is reduced. A suction hole is formed in a bag film (3) for sealing a space for fibers being impregnated with resin, after start of impregnation. The suction hole is covered by a plate (56) with holes (57). The resin is sucked from the space through the plate (56). According to such composite material manufacturing method, a defect, which occurs during fibers are impregnated with resin, can be repaired before the resin is cured without causing disorder and damage in the fibers. In a composite material formed from one repaired in the above way, the repaired portion is strong, namely, there is no strength deterioration due to repair after curing, and thus, the material is preferred as compared with a composite material which is repaired after resin is cured.

Abstract: The invention comprises a method of making a cement-based object or structure having a compressive strength greater than about 1,000 psi. The method comprises placing a cement-based material in an insulated concrete form, wherein the insulated concrete form has an R-value of at least 1.5, wherein the cement-based material comprises approximately 10% to approximately 80% by weight portland cement, and at least one of approximately 10% to approximately 90% by weight slag cement and approximately 5% to approximately 80% by weight fly ash. The invention also comprises a method of making a cement-based object or structure. The invention further comprises objects or structures made by the foregoing methods.

Abstract: Molds and processes that permit high-speed, mass production of retaining wall blocks having patterned or other processed front faces, as well as retaining wall blocks formed by such processes. The invention permits the front face of the block to be impressed with a pattern or otherwise directly processed, to allow the formation of pre-determined block front faces, while at the same time facilitating high-speed, high-volume production of blocks. A mirror image of the desired pattern can be created on a stripper shoe by selecting a desired three-dimensional surface from a naturally occurring or man made object and digitally scanning the selected three-dimensional pattern to create scanned data. The scanned data can then be used to machine a face of the stripper shoe that is the mirror image of the selected pattern.

Abstract: A concrete footing is laid by a set of forms each with side walls forming an elongate area and transverse connecting elements with at least one lift element mounted for lifting by a fork lift system extending across the side walls. The forms include legs engaged into the ground and adjusted to a required height relative to the ground. After setting of the concrete the elongate frame members are lifted from the concrete using the fork lift system. Connecting members shaped to match the side walls are clamped on an inside surface so as to bridge between the frame members. The set is carried on a transport cradle which includes a pair of side walls on which a lowermost one of the set sits with a pair of transverse sleeves connected across the side walls by which the cradle is lifted by the forks of the fork lift system.

Abstract: A low-pressure method for producing construction materials, such as blocks, bricks or slabs, utilizing high percentages of waste cement dust in admixture with additive material capable of effectively neutralizing the high lime content and agglomerating the extremely fine particles of the cement dust upon blending of the admixture with water. The resulting blend may simply be cast in molds of various shapes and sizes and cured under normal atmospheric pressure conditions into a hardened construction material exhibiting high strength, light weight and high thermal insulation.

Abstract: The invention relates to a hydraulic binder product [12, 10] which includes a mixture of a hydraulic binder [38, 202], a polyvinyl alcohol [14, 204] and a gelling agent [54] which reacts with the polyvinyl alcohol and a method [8] of producing same.

Abstract: A mold assembly for manufacturing concrete blocks in an automated dry-cast block machine. The mold assembly includes a plurality of liner plates which together form a mold cavity, wherein at least one of the liner plates includes an internal network of shafts which is configured to receive and provide a flow path for heated fluid to pass through to heat the at least one liner plate.

Abstract: Methods and equipment for forming beveled edge(s) around the core opening in a concrete block are disclosed. The formation of the beveled edge(s) minimizes feathering along the block edges that are beveled as the block is stripped from a mold. Any feathering that does occur is shifted away from the bottom surface of the block to allow the block to lay flat on other blocks when dry stacked in a wall.

Abstract: Polymerization of siloxane is improved using a gypsum-based slurry that includes stucco, Class C fly ash, magnesium oxide and an emulsion of siloxane and water. This slurry is used in a method of making water-resistant gypsum articles that includes making an emulsion of siloxane and water, then combining the slurry with a dry mixture of stucco, magnesium oxide and Class C fly ash. The slurry is then shaped as desired and the stucco is allowed to set and the siloxane polymerizes. The resulting product is useful for making a water-resistant gypsum panel having a core that includes interwoven matrices of calcium sulfate dihydrate crystals and a silicone resin, where the interwoven matrices have dispersed throughout them a catalyst comprising magnesium oxide and components from a Class C fly ash.

Abstract: A method for forming a concrete wall structure is provided. The method includes providing a frame having a plurality of spaced-apart wall studs interconnecting opposing frame members within a casting bed. A plurality of blocks are positioned proximal the frame within the interior area of the casting bed. Concrete is poured and finished within the casting bed.

Abstract: A mat for creating patterns in concrete includes a center portion, a feathered border surrounding the center portion, a top surface, and a bottom surface. A design stamp is positioned in the center portion of the bottom surface.

Abstract: The present invention relates to a production method for a lightweight construction material using asbestos waste, and more specifically to a production method for a lightweight construction material using asbestos waste in which the production takes place with the addition of loess, silicon carbide, a zeolite and half silty clay to asbestos waste, and relates to a lightweight construction material produced thereby. By adding silicon carbide, loess, a zeolite and half silty clay to asbestos waste, the present invention has the advantageous effect that construction materials can be made lighter in weight without the asbestos component being detected, and an environmentally friendly lightweight construction material can be produced which has outstanding strength, thermal insulation properties, forming properties, water-absorbing power and water-retaining ability.

Abstract: Devices and methods for making hollow concrete elements are disclosed. A device includes a drum mold having a tubular mold wall. The mold wall has a first and a second end flange each with an inner periphery smaller than the inner periphery of the mold wall at each respective end. The device further includes a compaction roller positionable inside the mold wall. The compaction roller has a profile that defines the interior shape of the concrete element. The compaction roller is supported by a hydraulically height adjustable supporting mechanism that is operable to independently adjust the distance of each end of the compaction roller with respect to the inner periphery of the mold wall.

Abstract: A concrete composition comprising a mouldable mixture of aggregate, binder and liquid vehicle, wherein the aggregate comprises sulphur concrete-derived aggregate and wherein the binder comprises hydraulic binder. The use of crushed sulphur concrete as aggregate in cement-based concrete reduces the hardening time of the concrete.

Abstract: Cement compositions comprising carboxylated inulin and methods of using the same to cement a workspace. In one embodiment, a method of cementing includes providing a cement composition comprising a carboxylated inulin, for example, in a subterranean formation. The method further includes allowing the cement composition to set. In some embodiments, the cement composition has a thickening time of from about 2 hours to about 11 hours. In other embodiments, the cement composition has a viscosity that is about constant for a period of time after the cement composition is placed.

Abstract: A method for use in manufacturing a ceramic matrix composite article includes assembling a ceramic fiber sheet between a tool and a die, where the tool is conformable to the shape of the die and the melting point of the die is greater than the melting point of the tool. The assembly is then heated to soften the tool. At least one of the tool, the die or a separate inflatable member is then pressurized to conform the tool and the ceramic fiber sheet to the die. Next, the assembly is cooled and the pressure is vented before removal of the tool and ceramic fiber sheet from the die. A preceramic resin with a catalyst is then applied to the ceramic fiber sheet and cured at a curing temperature that is below the melting point of the tool, to form a preform. The tool is then removed from the preform.

Abstract: The present invention relates to a method of manufacturing watercourse blocks continuously arranged in the construction spot, which continuously arranges the watercourse blocks according to the construction spot by preparing iron bar grates to be orthogonal to each other inside molding frames that are continuously arranged, casting concrete, preventing moisture evaporation and frost damage and employing iron bar grates so that the watercourse blocks continuously arranged according to the construction spot can be manufactured and constructed on the spot. Therefore, works for manufacturing the watercourse blocks in a plant and then assembling or fixing them in the construction spot according to the related art can be reduced as much as possible, the watercourse blocks can be simply manufactured and constructed on the spot to reduce a manufacturing cost and a construction time, which can thus significantly reduce the prime cost of the construction cost and diminish accident risk.

Abstract: A method of making a building block from clay-containing compounds, which includes employing a major amount of such clay-containing material in combination with a calciferous additive and water to cure the shape the same under the influence of controlled pressure and temperature for a pre-determined time to create building block which is characterized by a mineralogical crystalline phase. The clay-containing compound includes a mixture of fine particulate material and coarser particulate material. The product produced by the method is also disclosed.

Abstract: A constructional building material, such as a brick, with at least one base section and a vane extending from the base section. The vane defines, at least in part, a volume of space within an envelope boundary that facilitates fluid flow, such as airflow, through a wall system formed at least in part from one or more constructional building materials. Adjacent vanes, either of the same constructional building material or of different constructional building materials, may operate to provide or define one or more common volumes of space and corresponding fluid flow channels and associated fluid flow paths. A wall system, formed in accordance with the present invention, allows fluid to pass from one side to the other through the wall system while also providing up to complete visual obstruction through the wall depending upon how the wall system is constructed.

Abstract: In accordance with an embodiment, a method for producing an aggregate is disclosed comprising mixing IBA and a second, silicoaluminous material having a calcium content less than the IBA. The method further comprises agglomerating the mixture, such as by pelletizing, and pyroprocessing the agglomerates, such as by sintering or vitrification, to form the aggregate. The second material may be a clay, such as bentonite or kaolin, a mining waste, such as granite sawing residues, waste glass, or furnace bottom ash, for example. The addition of the second material has been found to facilitate production of lightweight and normal weight aggregates. Preferably, the IBA or the mixture of IBA and the second material are wet milled prior to agglomeration. Methods for producing expanded aggregates are also disclosed.

Abstract: A method for forming a clay slab includes providing a frame, a first panel supported on the frame in a vertical orientation and a second panel supported on the frame in a vertical orientation, with the first panel and the second panel defining a gap therebetween. The method further includes positioning a block of clay adjacent the gap defined by the first panel and the second panel, moving at least one of the first panel and the second panel from an initial position to an intermediate position to draw the block of clay between the first panel and the second panel and thereby form the clay slab, and moving at least one of the first panel and the second panel from the intermediate position back to the initial position to withdraw the clay slab from between the first panel and the second panel.

Abstract: Bridge decking panels are cast in a form that has at least one and preferably two or more channel-forming sheets attached to the bottom wall of the form and extending from wall to wall. Each sheet is dimensioned to receive an anchor plate assembly and form a channel in the cast concrete between runner bars.

Abstract: The present invention may be attached to a vehicle for movement adjacent to a generally vertical wall structure for imprinting a pattern in a surface of the wall structure. An imprint form frame may be attached to an imprint form. The imprint form frame may be attached to a support frame that may be of generally rectangular form with horizontal and vertical members. The support frame may be attached to one or more position support members so as to be movable in a horizontal and perpendicular direction relative to the plane of the support frame. The perpendicular movement may be controlled by a power actuator. The position support member may be attached to a frame support beam for attachment to a vehicle and may be movable vertically.

Abstract: A ductile ultra-high performance concrete which includes in relative parts by weight: 100 of Portland cement; 50 to 200 of a sand having a single grading with a D1O to D90 between 0.063 and 5 mm, or a mixture of sands, the finest sand having a D1O to D90 between 0.063 and 1 mm and the coarsest sand having a D1O to D90 between 1 and 5 mm; 0 to 70 of a particulate pozzolanic or non-pozzolanic material or a mixture thereof having a mean particle size less than 15 ?m; 0.1 to 10 of a water-reducing superplasticizer; 10 to 30 of water; and 0.5 to 5% by volume relative to the volume of the hardened composition of glass fibers having an aspect ratio of 6 to 120.

Abstract: Cementitious compositions and methods for making same, in which the cementitious compositions include 35-60 wt. % cementitious reactive powder (also termed Portland cement-based binder), 2-10 wt. % expanded and chemically coated perlite filler, 20-40 wt. % water, entrained air, and optional additives such as water reducing agents, chemical set-accelerators, and chemical set-retarders. In addition, the lightweight cementitious compositions may contain 0-25 wt. % on a wet basis secondary fillers such as expanded clay, shale aggregate, and pumice.

Abstract: A device and method for producing a green compact from a powdered or granular material by successive application and compression of the material, is disclosed. The device includes a fill shoe, which is filled with the material and is adjustable by an adjusting device, where a first park position is provided for the fill shoe. A matrix having at least one construction chamber is filled with the material layer-by-layer by the fill shoe between a first and second end position. A press having a lower punch and an upper punch, which are adjustable by a height adjustment device, compresses the material applied layer-by-layer in the at least one construction chamber. After filling the construction chamber with the material, the fill shoe is moved out of the second end position into a second park position, where the second park position is different from the first park position.

Abstract: A precast concrete meter pit consisting of a plurality of precast concrete hollow elongated cylindrical wall sections in end to end relation to one another is fabricated by utilizing a slip form packerhead apparatus in which the wall sections are formed with an annular slip ring when concrete is injected into the slip form apparatus.

Abstract: A concrete product is produced by providing red dune sand having a particle size of 45 microns or less and mixing the red dune sand with hydraulic cement in a ratio of about 30% of the cement being replaced by the red dune sand. The cement and red dune sand are then mixed with fine and course aggregate, water and a superplasticizer and cast after pouring into a mold cavity. Then within 24 hours of casting, the cast article is steam cured for 12 hours under atmospheric pressure, demolded and placed in an auto clave at 100% humidity. The temperature in the auto clave is raised to 180° C. within one to two hours and maintained at that temperature for 4 to 5 hours. The temperature also increases the pressure to about 10 bars. The pressure is released to reach atmospheric pressure within 20-30 minutes and the temperature reduced gradually, so that the article can be removed.

Abstract: A form and process for casting concrete blocks, each having at least one side textured. The blocks are cast in cavities which have a resilient insert on at least one side for imparting texture to the blocks. After the cast blocks are cured, the form is inverted and placed on a support surface. At least the side having the resilient insert is moved laterally away from the block and the form is lifted to leave the block on the support surface. The textured side can release from the form despite deep grooves and crevices simulating natural stones.

Abstract: The invention relates to a method for producing a concrete shaft bottom which comprises a drain having a defined shape. According to said method, concrete is introduced into a bottom mold (1) that comprises a mold jacket (2) and a mold bottom (3). On said mold bottom (3), a molded body (8) forming the negative shape of the drain is disposed to configure the drain. The aim of the invention is to allow for the inexpensive and mechanized production of a shaft bottom having an individual drain. For this purpose, the molded body (8) is configured from at least one molded piece (9) that is fixed on the bottom mold (1), especially on the mold bottom (3). The molded piece (9) is adapted to the dimensions of the defined shape of the drain and is removed from the shaft bottom once or while the formwork is dismantled from the shaft bottom.

Abstract: The invention relates to a hydraulic binding agent comprising a binding agent component having free-flowing or solidifying properties when water is added and an acceleration component which is used to accelerate solidification. The acceleration component contains ultrafine calcium hydroxide having a high specific surface and low grain size.

Abstract: A lightweight concrete mixture (e.g., comprising cement and polystyrene foam) is introduced into a compactable mold having a mold cavity defined by plural wall structures including at least two compacting wall structures. After introducing the lightweight concrete mixture into the compactable mold, the compacting wall structures are moved such that the lightweight concrete mixture is compacted in the mold cavity. The respective positions of the plural compacting wall structures can be maintained during curing of the lightweight concrete mixture such that the lightweight concrete mixture is held under compression during curing. A compactable mold may also include one or more tubes for forming tube-shaped cavities within a building block formed in the mold. Tubes can form intersecting cavities within the building block. Tubes can remain stationary while the compacting walls are moved, even when the tubes are attached to a compacting wall.

Abstract: The present invention provides a mold for shaping a sulphur cement product, which mold has an inner surface describing an inner volume for receiving a cast material, an outer surface and a barrier comprised between the inner surface and the outer surface, which barrier has a thermal conductance per unit area of at most 100 W/m2K in a direction perpendicular to the inner surface. The invention further provides a process for shaping a sulphur cement product.

Abstract: A dental article includes yttria stabilized tetragonal zirconia polycrystalline ceramic, and no more than about 0.15 wt. % of one or more coloring agents of one or more of: Fe, Er, Co, Pr, Tb, Cr, Nd, Ce, V, Eu, Ho, Ni, and Cu, oxides thereof, and combinations thereof, whereby the dental article is provided with a color corresponding to a natural tooth shade; and wherein the dental article has a flexural strength of at least about 800 MPa. Corresponding methods are also described.

Abstract: Method and apparatus for casting a concrete product with a substantially horizontal slipform casting process, wherein the concrete mix is fed at least in one step through a limited cross-section moving progressively along with the cast, whereby the height of the product forming part (1) is changed during the cast. The invention also comprises a product forming part (1) having an adjustable height.

Abstract: The invention relates to a method of controlling the quality of blocks that are produced front face-up in a mold, and verifying the accuracy of the production of such blocks, to ensure that the blocks are manufactured with consistent quality and minimal block-to-block variability. Measurement locations are formed on the front faces of predetermined blocks. By measuring the distances between the measurement locations and the rear faces and comparing with a target distance, any variation provides an indication that the blocks are not being properly formed. The process variables, such as the alignment of the compression head and/or the pressure plates to the mold, can then be adjusted accordingly.

Abstract: A method of producing a sheet-form material having an exposed solid surface comprises pre-mixing cement with at least one pozzolan to provide a cement/pozzolan mixture with a high pozzolan to cement ratio, adding to the cement/pozzolan mixture an aqueous solution comprised of water and a high range water reducer to produce a cement/pozzolan dough-like substance, adding and mixing a sufficient quantity of glass aggregate to said cement/pozzolan dough-like substance to produce a moldable composition, wherein, after adding and mixing in the glass aggregate, the pozzolan is present in the composition at about 5% to about 20% by weight, the cement is present in the composition at about 3% to about 20% by weight, and the aggregate glass is by weight a relatively high percentage of the composition. The moldable composition is placed into a mold and vibrated, and is allowed to cure.

Abstract: A mold for making dry cast concrete blocks includes a pair of vertical shoulder forming sections, one along each of the opposite sides of the mold to form vertical front shoulders of a block. Each shoulder forming section has a shoulder roughening arrangement to result in molded, roughened shoulders of the block. Methods of making such blocks and the resulting block are included.

Abstract: A method of operating a mold assembly having a plurality of liner plates forming a mold cavity. The method includes driving a master drive element back and forth in a continuous loop about at least a portion of exterior perimeter sides of the mold cavity to provide a first and second linear forces in first and second directions substantially in parallel with each perimeter side of the mold cavity about which the primary drive element is routed, and driving a secondary drive element, which engages the at least one moveable liner plate, with the first and second linear forces to drive at least one moveable liner plate toward and away from the interior of the mold cavity.

Abstract: The present invention relates to a composition for producing lime sand brick comprising lime, sand, water and at least one plasticizer, in particular a comb polymer KP having side chains bound to the main chain via ester or ether groups. The invention further relates to a method for producing lime sand brick.

Abstract: In a first embodiment of the invention, aged brushite is combined with calcium sulfate hemihydrate and water to make a gypsum slurry. Aged brushite slurry behaves similarly to calcium sulfate dihydrate to act as a seed crystal and rapidly initiate crystallization. The brushite slurry does not require the addition of a coating to maintain its activity over time compared to calcium sulfate dihydrate set accelerators. A gypsum-based product made using brushite slurry as the set accelerator is a second embodiment. The product has the brushite molecules integrated as part of the calcium sulfate dihydrate matrix and is distributed throughout the matrix.