Abstract: A system includes one or more compacting wall retraction mechanisms for retracting one or more compacting walls of a compactable lightweight concrete block mold having at least two compacting walls. The compacting wall retraction mechanism(s) facilitate release of a compacted lightweight concrete block from the compactable lightweight concrete block mold. The system can include a mold feed conveyor, and a table for receiving the compactable lightweight concrete block mold from the mold feed conveyor. The system can include one or more tube extraction and re-insertion mechanisms for extracting or inserting tubes of a compactable mold. The system can include one or more end wall lock release mechanisms for releasing end walls to remove a molded block from the mold. Mold assembly and disassembly can be controlled by an electronic or computerized controller.

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: A system includes one or more compacting wall retraction mechanisms for retracting one or more compacting walls of a compactable lightweight concrete block mold having at least two compacting walls. The compacting wall retraction mechanism(s) facilitate release of a compacted lightweight concrete block from the compactable lightweight concrete block mold. The system can include a mold feed conveyor, and a table for receiving the compactable lightweight concrete block mold from the mold feed conveyor. The system can include one or more tube extraction and re-insertion mechanisms for extracting or inserting tubes of a compactable mold. The system can include one or more end wall lock release mechanisms for releasing end walls to remove a molded block from the mold. Mold assembly and disassembly can be controlled by an electronic or computerized controller.

Abstract: A system includes one or more compacting wall retraction mechanisms for retracting one or more compacting walls of a compactable lightweight concrete block mold having at least two compacting walls. The compacting wall retraction mechanism(s) facilitate release of a compacted lightweight concrete block from the compactable lightweight concrete block mold. The system can include a mold feed conveyor, and a table for receiving the compactable lightweight concrete block mold from the mold feed conveyor. The system can include one or more tube extraction and re-insertion mechanisms for extracting or inserting tubes of a compactable mold. The system can include one or more end wall lock release mechanisms for releasing end walls to remove a molded block from the mold. Mold assembly and disassembly can be controlled by an electronic or computerized controller.

Abstract: A compactable mold comprises a main mold frame structure and plural wall structures including two end wall structures and two side wall structures. The plural wall structures define a mold cavity for forming a block from a mixture introduced into the mold cavity. At least two of the plural wall structures are movable wall structures for compacting the mixture. A described compactable mold has end walls and side walls that are shaped for forming tongue and groove features on a compacted block, and the end walls and side walls are movable such that a formed block can be released easily from the mold. A described compactable mold comprises at least one tube attached to at least one of the compacting wall structures. The compacting wall structures are operable to compact the mixture by moving toward the center of the mold cavity while the at least one tube remains stationary.

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: A compactable mold comprises a main mold frame structure and plural wall structures including two end wall structures and two side wall structures. The plural wall structures define a mold cavity for forming a block from a mixture introduced into the mold cavity. At least two of the plural wall structures are movable wall structures for compacting the mixture. A described compactable mold has end walls and side walls that are shaped for forming tongue and groove features on a compacted block, and the end walls and side walls are movable such that a formed block can be released easily from the mold. A described compactable mold comprises at least one tube attached to at least one of the compacting wall structures. The compacting wall structures are operable to compact the mixture by moving toward the center of the mold cavity while the at least one tube remains stationary.

Abstract: A system includes one or more compacting wall retraction mechanisms for retracting one or more compacting walls of a compactable lightweight concrete block mold having at least two compacting walls. The compacting wall retraction mechanism(s) facilitate release of a compacted lightweight concrete block from the compactable lightweight concrete block mold. The system can include a mold feed conveyor, and a table for receiving the compactable lightweight concrete block mold from the mold feed conveyor. The system can include one or more tube extraction and re-insertion mechanisms for extracting or inserting tubes of a compactable mold. The system can include one or more end wall lock release mechanisms for releasing end walls to remove a molded block from the mold. Mold assembly and disassembly can be controlled by an electronic or computerized controller.