Abstract: A polymer masonry unit (PMU) and methods and systems for forming PMUs are presented. In embodiments, a PMU may be made from a PMU mixture of a polymer, a quarry byproduct, such as a limestone aggregate, and water. The PMU may be ambient-dried to become a brick unit. The proportions of the PMU mixture may include 1-10% polymer, 80-90% quarry byproduct, and 1-10% water. The process for making a brick using the PMU of embodiments may avoid a kiln-firing process, which is costly, creates waste, and consumes significant energy. Furthermore, the PMU mixture may be formulated to enable the PMU mixture to be extruded from an extruder, enabling a system for making bricks to take advantage of the extrusion method, which can be very efficient and cost-effective for making bricks, and which is currently not possible with existing techniques and systems.

Abstract: A polymer-based compound, useful as a polymer masonry unit is disclosed that can include a polymer added to a quarry byproduct to manufacture a quality brick unit. The present disclosure solves the technological problem of providing a structurally sound brick or concrete alternative without the need for kiln firing, using traditionally unusable waste material. By combining quarry byproduct and a polymer, a polymer masonry unit can be fabricated having compressive strength and architectural utility. In one exemplary embodiment, fiber elements can be added to the byproduct and polymer mixture to increase structural stability. The present disclosure improves the performance of the system itself by providing a basic block or brick unit using an environmentally responsible manufacturing process that reduces cost and waste. The manufacturing process includes a polymer/base material that can be poured into molds that cures over a predetermined period, without the need for kiln firing.

Abstract: A polymer-based compound, useful as a polymer masonry unit is disclosed that can include a polymer added to a quarry byproduct to manufacture a quality brick unit. The present disclosure solves the technological problem of providing a structurally sound brick or concrete alternative without the need for kiln firing, using traditionally unusable waste material. By combining quarry byproduct and a polymer, a polymer masonry unit can be fabricated having compressive strength and architectural utility. In one exemplary embodiment, fiber elements can be added to the byproduct and polymer mixture to increase structural stability. The present disclosure improves the performance of the system itself by providing a basic block or brick unit using an environmentally responsible manufacturing process that reduces cost and waste. The manufacturing process includes a polymer/base material that can be poured into molds that cures over a predetermined period, without the need for kiln firing.

Abstract: A polymer masonry unit is disclosed that can include a polymer added to a quarry byproduct to manufacture a quality brick unit. The present disclosure solves the technological problem of providing a structurally sound brick or concrete alternative without the need for kiln firing, using traditionally unusable waste material. By combining quarry byproduct and a polymer, a polymer masonry unit can be fabricated having compressive strength and architectural utility. In one exemplary embodiment, fiber elements can be added to the byproduct and polymer mixture to increase structural stability. The present disclosure improves the performance of the system itself by providing a basic block or brick unit using an environmentally responsible manufacturing process that reduces cost and waste. The manufacturing process includes a polymer/base material that can be poured into molds that cures over a predetermined period, without the need for kiln firing.