Building block and system for manufacture

Abstract

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.