Building block and system for manufacture
A compressed building block formed of a pre-mix of fly ash, Class C type, are combined with various aggregates either ground wood and/or chips, having maybe a small amount of Portland cement added thereto, moisturized, and then either molded, extruded or compressed in a press into the configuration of a block. Boron as a mold retardant and an insecticide, may be added to the composition, 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 mold or hydraulic or other press and pressed into the configuration of the desired block, needed for the construction.
1 . The construction of a building block, said block being fabricated from molding, extruding, or compressing the blocks into a high strength, medium weight building block, said block fabricated into a multi-sided integrated block, and molded from a formulation of ingredients which when the ingredients are mixed and, treated with water there occurs a pozzolanic reaction, the mixture of ingredients including:
class C fly ash in containing calcium hydroxide and added in the range of about fifty percent (50%) to ninety percent (90%) by weight of the mixed formulation,
ground cellulosic material or other aggregate material in the fibrous or solid state and mixed in the formulation between about ten percent (10%) to fifty percent (50%) by weight of the mixed formulation,
water added in the range of about ten percent (10%) to about twenty percent (20%) by weight of the mixed formulation, and
whereby pressure in the range of about 200 psi to 600 psi is applied to said mixed ingredient formulation after the pozzolanic reaction commences to form the mixture into the block form.
2 . The building block of claim 1 and including Portland cement, added in the range of ten percent (10%) to twenty percent (20%) by weight of the mixed formulation to furnish an increase pozzolanic reaction to the ingredients when forming the building block.
3 . The building block of claim 2 wherein said cellulostic material is selected from ground wood, textile fiber, ground bamboo, rice hulls, that are combined with either ground wood and/or chips, or with fine sand, and having an amount of Portland cement added thereto, water is added to moisturize the composition, and then the composition is processed by one of extrusion or compression in a press to form the configured block.
4 . The building block of claim 4 and including the addition of one or more fire retardant, and an insecticide, to make the block mold resistant and resistant to deterioration by insects.
5 . The building block of claim 3 and including said building block having end walls, side walls, and a top and bottom wall, at least one of said end walls and at least one of said top and bottom wall having a tongue portion, and the other of said end wall, and the other of said top and bottom wall having a groove, to accommodate the insertion of another building block tongue therein during the erection of a wall.
6 . Construction of a building block, said block being fabricated from molding or extruding into a high strength, light weight building block, said block ingredients which when the ingredients are mixed creates a pozzolanic reaction including:
class C fly ash in a range of about fifty percent (50%) to ninety percent (90%) by weight of the mixed formulation,
ground cellulosic material mixed in the formulation between about ten percent (10%) to fifty percent (50%) by weight of the mixed formulation,
water added in the range of about ten percent (10%) to about to about twenty percent (20%) by weight of the mixed formulation, and
whereby pressure in the range of approximately 200 to 600 PSI is applied to said mixed ingredient formulation and forms it into the block form.
7 . The building block of claim 6 and including Portland cement, added in the range of ten percent (10% to twenty percent (20%) by weight of the mixed formulation to furnish binding to the ingredients when forming the building block.
8 . The building block of claim 7 wherein said cellulostic material is selected from the group consisting of wood shavings, saw dust, wood chips, beet sugar waste and sugar cane and pulverized cardboard.
9 . The building block of claim 8 and including boron, added in the range of one-half percent (½%) to five percent (5%) by weight of the mixed formulation to furnish fire retardancy and as a preventer of insect infestation to the molded block.
10 . The building block of claim 8 wherein additional pressure may be applied to the mixed ingredient formulation up to approximately 3,000 psi.
11 . The building block of claim 8 wherein silica fume is added to the ingredient mixture.
12 . The building block of claim 6 wherein a plasticizer is added to the ingredient mixture in an amount about one-eight percent (⅛%) to two percent (2%) by weight of the mixture.