Method and apparatus for creating concrete blocks with the appearance of natural fossil stone

Abstract

A generally conventional concrete block is cast using known procedures. After pouring concrete in a mould, or otherwise forming a block, and before the surface of the concrete has set, shaped bodies of ice are randomly placed on the surface or surfaces to be treated and pressed into the surface(s) to desired depths. The ice bodies will melt during curing of the concrete, but not before the concrete has set enough to keep the shape of the indentations made by the ice bodies. Thus, when the concrete block has set completely, there remains a textured surface having a structure similar to that of natural fossil stone. Alternatively, shaped bodies of combustible material are randomly placed on the surface or surfaces to be treated and pressed into the surface(s) to desired depths. The combustible bodies will make the concrete keep the shape of the indentations made by the bodies after the concrete has cured. After curing, the combustible bodies are heated to their combustion temperature and burned away from the concrete surface. Thus, when the bodies have been removed, there remains a textured surface having a structure similar to that of natural fossil stone.

1 . A method of producing surface textured concrete blocks, comprising the steps of: 
 a) Providing an un-cured concrete block of a pre-determined outer shape;    b) Introducing formed bodies onto a desired surface of said concrete block;    c) Pressing said formed bodies down to a desired depth in said surface;    d) Removing the pressed concrete block, which has sufficient green strength to keep its shape, said formed bodies still pressed into said surface; and    e) At least partly curing said pressed concrete block;    f) Removing said formed bodies.    
     
     
         2 . The method as recited in  claim 1 , further comprising the step of leveling off the layer of deposited ice bodies, by raking the ice bodies, after introducing the formed bodies in step b) and prior to step c).  
     
     
         3 . The method as recited in  claim 1 , where said formed bodies are manufactured from a meltable material and step f) comprises heating said at least partly cured concrete block to a temperature at which said formed bodies melt and are removed from said concrete block.  
     
     
         4 . The method as recited in  claim 3 , where the material of said formed bodies is chosen from any of the group comprising ice and wax.  
     
     
         5 . The method as recited in  claim 1 , where said formed bodies are manufactured from a combustible material and step f) comprises heating said at least partly cured concrete block to a temperature at which said formed bodies combust and are removed from said concrete block.  
     
     
         6 . The method as recited in  claim 5 , where the material of said formed bodies is chosen from any of the group comprising wood, saw dust, leaves, cardboard, paper, rubber, plastic and hemp.  
     
     
         7 . The method as recited in  claim 1 , where step a) comprises providing a mould of the desired concrete block outer shape and filling said mould with a pre-determined amount of soft aggregate material mix.  
     
     
         8 . The method as recited in  claim 7 , further comprising the step of compressing said material in said mould to a desired height within said mould after step a) and before step b).  
     
     
         9 . The method as recited in  claim 7 , where step c) further comprises compressing said material in said mould to a desired height within said mould.  
     
     
         10 . The method as recited in  claim 1 , where step a) comprises providing an extruded concrete block of the desired shape and placing said concrete block in a holder.