Building block and system for manufacture
A compressed building block formed of a pre-mix of fly ash, either of the Class C type, is combined with either ground or pulverized wood chips, or with fine sand, and a plasticizer, and accelerator, then moisturized, and lastly either extruded or compressed in a mold into the configuration of a block. The block lacks a binder, except Portland cement for select military applications. A mold retardant may be added to the mixture, to provide the formed block with further beneficial attributes. The blocks may be formed by a system for extruding such blocks from the formulation, or they may be formed by means of a hydraulic or other press and pressed into the configuration of the desired block, needed for the construction.
1 . The construction of a building block, one manufactured substantially from waste materials by molding or extruding into a high strength and multiple sided integrated block, said block having a formulation of ingredients including:
class C fly ash in a range of about fifty percent (50%) to about ninety percent (90%) by weight of the molded block;
ground celluostic material such as wood chunks, wood shavings, wood chips and textile byproducts, mixed in the formulation between about fifteen percent (10%) to fifty percent (50%) by weight of the mixed formulation;
water; and,
a plasticizer agent in the range of about 0.25 ounces to about 30 ounces by hundredweight of the fly ash in the mixed formulation.
2 . The building block of claim 1 and including:
an accelerator agent in the range of about 0.5 ounces to about 64 ounces by hundredweight of the fly ash of the mixed formulation.
3 . The building block of claim 2 and including:
boron, added in the range of ½% to 5% to furnish mold and insect retardency.
4 . The building block of claim 1 including water added as an ingredient to the formulation between about fifteen percent (15%) to twenty five percent (25%) by weight of the formulation.
5 . The building block of claim 4 wherein the water is sprayed into the molded block in an amount of approximately fifteen percent (15%) to twenty five percent (25%) by weight of the block formulation.
6 . The building block of claim 4 and further comprising:
said plasticizer agent is in the range of about 0.5 ounces to about 15 ounces by hundredweight of the fly ash in the mixed formulation.
7 . The building block of claim 6 and further comprising:
said plasticizer agent is in the range of about 0.5 ounces to about 2.0 ounces by hundredweight of the fly ash in the mixed formulation.
8 . The building block of claim 4 and further comprising:
said accelerator agent in the range of about 0.5 ounces to about 32 ounces by hundredweight of the fly ash in the mixed formulation.
9 . The building block of claim 8 and further comprising:
said accelerator agent to the range of about 0.5 ounces to about 12 ounces by hundredweight of the fly ash in the mixed formulation.
10 . The building block of claim 4 and further comprising:
said plasticizer agent is in the range of about 0.5 ounces to about 8.0 ounces by hundredweight of the fly ash in the mixed formulation; and
said accelerator agent in the range of about 0.5 ounces to about 12 ounces by hundredweight of the fly ash in the mixed formulation.
11 . The building block of claim 1 wherein said block has dimensions of approximately nine and ½ inches by eight inches by seventeen and ½ inches (9.5″×8″×17.5″) in configuration.
12 . The building block of claim 4 and including:
Portland cement added in the range of two percent (2%) by weight to twenty percent (20%) by weight to furnish additional strength to the ingredients when molded into block form for military usage.