Abstract: A method for dry casting concrete block using a resilient mold having a cavity for forming a block face and a form having a block body forming cavity. The form may be offset from the mold to provide steps where the block face joins the body for aligning stacked blocks. Alternately, the form cavity may have a dimension smaller that the height of the block face and can be offset to form a step between the block face and either the top or bottom of the block. Alternately, an insert may be placed in the form adjacent the mold for forming a downwardly projecting lip along the back of the block. Blocks are formed using a dry cast concrete block machine. After casting, the form is removed from the block. The block remains supported on the mold until after it has cured.

Abstract: A method for making a modular outdoor fireplace having textured exterior surfaces simulating natural stone or bricks and mortar. At least a fire-box unit and a chimney unit are cast from concrete with textured exterior surfaces. After placing the fire-box unit on a support surface, a fireplace insert is positioned in the fire-box unit and the chimney unit is supported either on the fire-box unit or on a cast concrete mantle which is first placed on the fire-box unit. The support surface may be a cast concrete hearth. A metal chimney is inserted through the chimney unit and the mantle and secured to the fireplace insert. A cast concrete cap is placed on the chimney unit.

Abstract: A method and apparatus for dry casting concrete wall blocks having a decorative face. The blocks are cast in a mold including a form, a flexible insert and a steel pallet. Magnets hold the insert on the pallet while permitting the insert to slide on the pallet into alignment with the form when the form and pallet are moved together. The insert creates a decorative face on one or more simultaneously cast blocks. After the blocks are cast, the uncured blocks and the insert are moved together from the form and transferred to a curing area. After the blocks cure, they are separated from the insert. Preferably, additional concrete mix is provided adjacent the insert prior to compacting to avoid voids in the block face. Optionally, the shoe which compacts the concrete mix may be shaped to impart a lip adjacent a back edge of the block.

Abstract: A form for casting concrete blocks and other products having a resilient insert defining a cavity in which the block is cast and a rigid support or frame for the resilient insert. After the block has cured, the block is removed from the insert either by inverting the form to allow the block to fall from the insert or by lifting the block from the insert. One or more areas of the insert are tethered to the support with at least one generally flat flexible strap so that at least a portion of the insert is allowed to move a limited distance relative to the support and to deform to release the block. One end of each tether strap is embedded in the insert. After the cast block is separated from the insert, the insert is returned to a position wherein it is supported for casting another block.

Abstract: A method and apparatus for forming a concrete block in form having a resilient insert forming a cavity in which the block is cast and a rigid support for the resilient insert. After the block has cured, the form is inverted. One or more areas of the insert are tethered to the support so that at least a portion of the insert can fall a short distance from the support. The weight of the cast block sufficiently deforms the insert to allow the block to fall free from the insert. When the form is again inverted to its upright position, the insert falls back into the support and returns to its original shape.