Method for making aerated concrete blocks having at least one passageway therein

Abstract

A method for making aerated concrete blocks includes dispensing materials for making aerated concrete into a mold and allowing the materials to rise and stiffen into a body. The body may be divided into an array of blocks which are then cured. At least one passageway may be formed in each block, such as by drilling. The drilling may include drilling a plurality of spaced apart passageways through each block, and each passageway may have a circular cylindrical shape. The passageways permit easier grasping by the mason, reduce the weight without significantly compromising strength, and facilitate positioning of blocks during construction of a wall to facilitate the placement of vertical reinforcing members in aligned passageways. The positioning of the passageways in each of the blocks may assist alignment of adjacent passageways, especially at wall corners. The drilling may include providing a plurality of drills and causing relative movement between the drills and at least one group of blocks to simultaneously drill the one or more passageways in each block of the group. The step of causing relatively movement may include grasping and moving the group of blocks along a predetermined path while the plurality of drills remain stationary.

That which is claimed is:  
     
         1 . A method for making aerated concrete blocks comprising: 
 dispensing materials for making aerated concrete into a mold and allowing the materials to rise and stiffen into a body;    dividing the body into an array of blocks;    curing the array of blocks; and    forming at least one passageway extending through each block after curing.    
     
     
         2 . A method according to  claim 1  wherein forming at least one passageway comprises forming a plurality of spaced apart passageways through each block.  
     
     
         3 . A method according to  claim 1  wherein forming at least one passageway comprises drilling at least one passageway.  
     
     
         4 . A method according to  claim 3  wherein drilling at least one passageway comprises providing a plurality of drills and causing relative movement between the drills and a group of blocks to simultaneously drill passageways therein.  
     
     
         5 . A method according to  claim 4  wherein causing relative movement comprises grasping and moving the group of blocks along a predetermined path while the plurality of drills are stationary.  
     
     
         6 . A method according to  claim 5  wherein the drills are directed substantially vertically upward, and wherein the predetermined path is substantially vertical so that waste from drilling will fall by gravity for recycling.  
     
     
         7 . A method according to  claim 1  wherein each passageway has a circular cylindrical shape.  
     
     
         8 . A method according to  claim 1  further comprising packaging the blocks for storage and transportation after forming the at least one passageway.  
     
     
         9 . A method according to  claim 8  wherein packaging comprises packaging blocks on shipping pallets.  
     
     
         10 . A method according to  claim 1  further comprising recycling waste generated at least during forming of the at least one passageway.  
     
     
         11 . A method according to  claim 1  wherein each block has a generally rectangular shape defining a length between opposing ends, a width between opposing sides, and a height between a top and bottom; and wherein the at least one passageway extends in the height direction, is centered inwardly from opposing sides, and also has an axis positioned inwardly from an adjacent end a distance of about one-half the width to facilitate alignment with a corresponding passageway of an adjacent block at a wall corner.  
     
     
         12 . A method according to  claim 11  wherein the length is in a range of about two to three times the width.  
     
     
         13 . A method according to  claim 11  wherein the length is in a range of about 16 to 24 inches, the width is in a range of about 8 to 12 inches, and the height is in a range of about 8 to 12 inches.  
     
     
         14 . A method according to  claim 1  wherein each block has a generally rectangular shape defining a length between opposing ends, a width between opposing sides, and a height between a top and bottom; and wherein the at least one passageway comprises first and second passageways extending in the height direction, with each of the first and second passageways being centered inwardly from the opposing sides and also having an axis positioned inwardly from a respective adjacent end a distance of about one-half the width.  
     
     
         15 . A method according to  claim 14  wherein the at least one passageway further comprises a third passageway extending in the height direction, being centered inwardly from opposing sides, and being centered inwardly from opposing ends.  
     
     
         16 . A method according to  claim 1  further comprising mixing the materials prior to dispensing the materials into the mold.  
     
     
         17 . A method according to  claim 16  wherein mixing the materials comprises mixing sand or ash, cement, lime, water, and an aeration agent together.  
     
     
         18 . A method according to  claim 1  further comprising releasing the body from the mold prior to dividing the body.  
     
     
         19 . A method according to  claim 1  further comprising trimming at least one surface of the body during the dividing.  
     
     
         20 . A method according to  claim 1  wherein dividing comprises forming a series of laterally extending and vertically extending cuts through the body.  
     
     
         21 . A method according to  claim 1  wherein curing comprises subjecting the array of blocks to an elevated temperature and an elevated pressure for a predetermined time.  
     
     
         22 . A method according to  claim 1  further comprising separating the blocks after curing.  
     
     
         23 . A method for making aerated concrete blocks comprising: 
 dispensing materials for making aerated concrete into a mold and allowing the materials to rise and stiffen into a body;    dividing the body into an array of blocks;    curing the array of blocks; and    drilling a plurality of spaced apart passageways extending through each block of a group of blocks after curing by causing relative movement between the group of blocks and a plurality of drills.    
     
     
         24 . A method according to  claim 23  wherein causing relative movement comprises grasping and moving the group of blocks along a predetermined path while the plurality of drills are stationary.  
     
     
         25 . A method according to  claim 24  wherein the drills are directed substantially vertically upward, and wherein the predetermined path is substantially vertical so that waste from drilling will fall by gravity for recycling.  
     
     
         26 . A method according to  claim 23  wherein each passageway has a circular cylindrical shape.  
     
     
         27 . A method according to  claim 23  further comprising packaging the blocks for storage and transportation after drilling.  
     
     
         28 . A method according to  claim 23  further comprising recycling waste generated at least during drilling.  
     
     
         29 . A method according to  claim 23  further comprising mixing the materials prior to dispensing the materials into the mold.  
     
     
         30 . A method according to  claim 29  wherein mixing the materials comprises mixing sand or ash, cement, lime, water, and an aeration agent together.  
     
     
         31 . A method according to  claim 23  wherein curing comprises subjecting the array of blocks to an elevated temperature and an elevated pressure for a predetermined time.  
     
     
         32 . A method according to  claim 23  further comprising separating the blocks after curing.  
     
     
         33 . A method for making aerated concrete blocks comprising: 
 mixing together materials for making aerated concrete;    allowing the materials to rise and stiffen into a body after mixing;    processing the body to form blocks; and    forming at least one passageway extending through each block.    
     
     
         34 . A method according to  claim 33  wherein forming at least one passageway is performed after processing.  
     
     
         35 . A method according to  claim 33  wherein forming at least one passageway comprises forming a plurality of spaced apart passageways through each block.  
     
     
         36 . A method according to  claim 33  wherein forming at least one passageway comprises drilling at least one passageway.  
     
     
         37 . A method according to  claim 36  wherein drilling at least one passageway comprises providing a plurality of drills and causing relative movement between the drills and a group of blocks to simultaneously drill passageways therein.  
     
     
         38 . A method according to  claim 37  wherein causing relative movement comprises grasping and moving the group of blocks along a predetermined path while the plurality of drills are stationary.  
     
     
         39 . A method according to  claim 38  wherein the drills are directed substantially vertically upward, and wherein the predetermined path is substantially vertical so that waste from drilling will fall by gravity for recycling.  
     
     
         40 . A method according to  claim 33  wherein each passageway has a circular cylindrical shape.  
     
     
         41 . A method according to  claim 33  further comprising packaging the blocks for storage and transportation.  
     
     
         42 . A method according to  claim 33  further comprising recycling waste generated at least during forming at least one passageway.  
     
     
         43 . A method according to  claim 33  further comprising mixing the materials prior to dispensing the materials into the mold.  
     
     
         44 . A method according to  claim 43  wherein mixing the materials comprises mixing sand or ash, cement, lime, water, and an aeration agent together.  
     
     
         45 . A method according to  claim 33  wherein processing comprises dividing the body into an array of blocks and curing the array of blocks.  
     
     
         46 . A method for making aerated concrete blocks of a type having at least one passageway extending therethrough, the method comprising: 
 providing a plurality of aerated concrete blocks;    providing a drilling station comprising a plurality of drills; and    drilling a plurality of spaced apart passageways extending through each block of a group of blocks by causing relative movement between the group of blocks and a plurality of drills.    
     
     
         47 . A method according to  claim 46  wherein causing relative movement comprises grasping and moving the group of blocks along a predetermined path while the plurality of drills are stationary.  
     
     
         48 . A method according to  claim 47  wherein the drills are directed substantially vertically upward, and wherein the predetermined path is substantially vertical so that waste from drilling will fall by gravity for recycling.  
     
     
         49 . A method according to  claim 46  wherein each passageway has a circular cylindrical shape.  
     
     
         50 . A method according to  claim 46  further comprising packaging the blocks for storage and transportation after drilling.  
     
     
         51 . A method according to  claim 46  further comprising recycling waste generated at least during drilling.