Abstract: A method is provided for forming a synthetic corrosion product layer on tube surfaces. The method utilizes two dissimilar materials with different coefficients of thermal expansion. An object tube and sacrificial tube are positioned one inside the other such that an annular region is created between the two tubes' surfaces. A slurry of synthetic corrosion products is injected into this annular region and the assembly is heat treated. This heat causes the tubes to expand, the inner tube with the higher coefficient of expansion expanding more than the outer tube, thereby creating internal pressures which consolidate the corrosion products and adhere the corrosion products to the tubing surfaces. The sacrificial tube may then be removed by conventional chemical etching or mechanical methods.

Abstract: A method for the production of substantially vertical walls, and specifically, walls made of concrete, includes a single sided concrete form used, for example, to form a concrete wall against a preexisting wall or embankment, by pumping concrete into a gap between the form and the preexisting wall or embankment, and raising the form vertically as the pumped concrete settles and drys. The method enables the construction of vertical walls of superior strength in less time as compared to currently available systems.

Abstract: A porous mold for manufacturing ceramics comprises a porous mold body including a mold central portion and a mold outer peripheral portion and having mold surface of a shape corresponding to an outer shape of a suspension insulator and other similar ceramics to be manufactured having a small diameter hollow cylindrical central core portion with a closed head portion and a large diameter shed portion extended from the core portion in a radial direction, wherein water absorption percentage of a mold surface side portion of the mold outer peripheral portion is larger than that of the mold central portion. The water absorption percentage of the mold surface side portion of the mold outer peripheral is 20-30%, and that of a mold head portion of the mold central portion is 10-20%. A difference of the water absorption percentage between the mold surface side portion of the mold outer peripheral portion and the mold head portion is 5-20%.

Abstract: The invention relates to an improved apparatus for the production of substantially vertical walls, and specifically, walls made of concrete which includes a single sided concrete form used, for example, to form a concrete wall against a preexisting wall or embankment, by pumping concrete into a gap between the form and the preexisting wall or embankment, and raising the form vertically as the pumped concrete settles and drys. The apparatus enables the construction of vertical walls of superior strength in less time as compared to currently available systems.

Abstract: A form set-up and a method for stripping upright form panels of the form set-up from a concrete unit. The form set-up defines a pouring space into which concrete is poured and cast so as to form a concrete unit. The form set-up includes at least two form panels. Each of the form panels has a contact surface in contact with a vertical surface of the concrete unit, a mounting surface opposed to the contact surface, and a reinforcing beam member secured to the mounting surface. The reinforcing beam members of the two form panels are aligned with each other. An interconnecting member is interposed removably between the two form panels and has a contact surface which is flush with the contact surfaces of the two form panels and which is in contact with the vertical surface of the concrete unit.

Abstract: Hydraulically settable mixtures and methods for extruding such mixtures into a variety of objects which are form-stable in the green state. High green strength is achieved by increasing the yield stress of the mixture while maintaining adequate extrudability. Optimizing the particle packing density while including a deficiency of water yields a hydraulically settable mixture which will flow under pressures typically associated with the extrusion of clay or plastic. In addition, a rheology-modifying agent can be added to increase the yield stress of the mixture while not significantly increasing the viscosity. The desired strength properties and other performance criteria of the final hardened extruded product are controlled by adding aggregates, fibers, a hydraulically settable binder, water, and other admixtures.

Abstract: Methods and apparatus for continuously extruding a hydraulically settable mixture and simultaneously placing continuous filaments within the extruding mixture to yield articles having a filament-reinforced, hydraulically settable matrix. The filaments can be placed within the mixtures in a parallel configuration, a helical configuration, or combinations thereof, in order to yield an article having the desired properties of, e.g., tensile strength, flexural strength, hoop strength, burst strength, toughness, and elongation ability. The desired properties of the hydraulically settable mixture, as well as of the cured hydraulically settable matrix of the hardened article, may also be adjusted by including varying amounts and types of aggregates, discontinuous fibers, binders, rheology-modifying agents, dispersants, or other admixtures within the hydraulically settable mixture.

Abstract: A mold box is flexibly mounted to a product forming machine having upper and lower vertically displaceable beams. A feed drawer dispenses concrete material into the mold box while a vibration system vertically vibrates the mold box while dampening horizontal vibration. The vibration system is driven by a single drive shaft that actuates first and second vibrator rods while at the same rotating a counter-weight in a counter-rotating direction. A set of alignment brackets lock the mold box into a predetermined aligned relationship while being mounted in the product forming machine. The bottom side of each mold box is mounted to the product forming machine in the same relative position to reduce machine readjustments. A set of telescoping legs hold the feed drawer assembly variable distances above the mold box. A unitized pallet feeder quickly moves pallets one at a time from an "on-deck" position to a "receiving" position underneath the mold box.

Abstract: A method for installing a mold apparatus in a manhole assembly and filling the mold apparatus with a sealing material to establish a solid bond that blocks inflow of fluids at the joint between abutting components of the manhole assembly includes providing an open ring, a retaining band for urging the open ring into contact with the manhole so that the open ring defines an annular channel at the joint, and a sealing material dispenser for conveying sealing material into the annular channel. The sealing material hardens in the annular channel to provide the solid bond at the joint between the two manhole components. The manhole components may be an abutting manhole frame and manhole, or two abutting sections of manhole.

Abstract: A process for producing and curing hydraulic material to reduce its hydrophilic characteristics and increase its strength. By preventing water loss and by adding water, efflorescence is controlled and the number of and size of voids created by water evaporation and hydration are reduced. Controlling the cure environment, humidity, temperature and pressure and using fluid barriers and water, control the physical and chemical composition formed during curing. The controls can be used before and/or after the initial set or shape formation of the hydraulic material.

Abstract: Production of plasterboard includes spreading of a mixture formed of gyps fibers and water onto a continuously moving belt to form a spread layer subsequently precompressed to 110% to 180% of a final board thickness and successively wetted from both sides and thereafter compressing the wetted layer to the final board thickness.

Abstract: A method of transversely cutting a prefabricated slab having one or more hollow longitudinal cores includes inserting a pair of expandable plugs into at least one of the one or more cores, the plugs of the or each pair being positioned in a respective core spaced apart on opposite sides of an intended cut line and post-insertion expansion of the plugs blocking the respective core; introducing settable material into a portion of the or each blocked core between its spaced apart pair of expanded plugs; and after at least partial setting of the introduced settable material, cutting the slab transversely across the intended cut line.

Abstract: A process for producing an inner refractory lining of a ladle or metallurgical vessel for casting steel. The inner refractory lining incorporates wall passages with conical nozzle bricks and/or bubble bricks. The inner lining is produced by using a thixotropic vibrational lining mass. Templates are employed to maintain openings for the wall passages during production of the inner lining. After the inner lining is produced, the templates are removed from the inner lining. Once the templates are removed from the inner lining, the conical nozzle bricks and/or the bubble bricks are inserted into the openings. Each of the bricks is mortared into an opening without using seating blocks. The bricks are mortared into the openings so that the bricks remain free from contact with the inner lining.

Abstract: Spherical particles having a diameter between 0.007" and 0.040" are formed from melt extruded thermoplastic material suitable for casting on a heated mold surface and melting thereon to form a thin layer of material having a nominal thickness of 0.040" that is cooled and removed from the mold surface as a part having a porosity less than a visually observable threshold. The process includes the steps of providing microspheres formed of blended and melt extruded thermoplastic, plasticizers (if necessary) and pigment additives that constitute less than 5% by weight of the blend and shaped as a smooth round spherical particle. The microspheres may then be distributed as predetermined charge of such microspheres against the heated casting surface to melt the microspheres as a layer of thermoplastic material having a porosity less than 0.003 inches and thereafter cooling and removing the non-porous layer from the casting surface.

Abstract: Spherical particles having a diameter between 0.007" and 0.040" are formed from melt extruded thermoplastic material suitable for casting on a heated mold surface and melting thereon to form a thin layer of material that is cooled and removed from the mold surface as a part having a porosity less than a visually observable threshold. The process includes the steps of providing microspheres formed of blended and melt extruded thermoplastic, plasticizers (if necessary) and pigment additives that constitute less than 5% by weight of the blend and shaped as a smooth round spherical particle. The microspheres may then be distributed as a predetermined charge of such microspheres against the heated casting surface to melt the microspheres as a layer of thermoplastic material having a porosity less than 0.003 inches and thereafter cooling and removing the non-porous layer from the casting surface.

Abstract: A method of decorating concrete including the steps of mixing water, aggregate and cement to provide mortar, pouring the mortar into a form and allowing it to cure and harden into a concrete block having an exterior surface, and applying sulfate to a selected portion of the block to color the surface of the block to a predetermined depth while the mortar is being cured.

Abstract: A portable concrete molding apparatus for forming concrete structures of a predetermined configuration, either on-site or at a central manufacturing facility. The apparatus includes a trailer having furnace plenum bounded by a pair of fixed walls. Each fixed wall cooperates with a movable wall for forming a mold therebetween. Each movable wall includes a concrete inlet for introducing concrete into the bottom portion of the mold. The fixed and movable walls include push-off valves for ensuring separation of a concrete structure from the mold walls, as the mold walls are separated.

Abstract: A ceramic article such as a sanitary pottery ware is produced by slip casting using a porous composite mold. A green ceramic body of a part such as a trap of sanitary ware is separately formed in advance by, for example, slip casting. The green ceramic body is placed in the mold cavity of the porous composite mold. Then, a slip as the material of the main part of the sanitary ware is supplied into the mold cavity to form deposit integral with the green ceramic body, whereby an integral sanitary ware is obtained by slip casting.

Abstract: A method of manufacturing an open top, walled member for containing a molten metal, including the steps of forming an inner wall of a mold with a metal sheet and an inner lining covering the sheet, wherein the inner wall defines an inside surface of the walled member and transferring a casting compound between an outer wall of the mold and the inner lining of the inner wall to form the walled member. The metal sheet and inner lining are then removed to allow one to apply heat to dry the casting compound. In the case where the metal sheet includes a plurality of openings, one may also retain the inner wall during the heating step. The heat to dry the casting compound is applied to the inner lining to a sufficient temperature to melt the inner lining and uncover said openings of the metal sheet. The metal sheet is removed when the casting compound is dried.

Abstract: A modular panel formed by solidifying a composite mixture of material within a frame. The panel is suited for use as a structural component and multiple panels are joined together to form structural components such as foundations, floors, walls and roofs. The panels are fixedly joined as by welding the frames of adjacent panels together. The structural components are similarly joined together as by welding to form a building. The material is primarily wood products and has cement, starch and other materials as a binding agent. The material provides a surface that is suited for conventional finishing material. In addition to providing structural integrity, the panels are relatively light in weight, are not subject to deterioration and provide insulating quality.