Dry-cast concrete block

Abstract

A concrete wall block manufactured using the dry cast process includes a top surface and a bottom surface. Opposing front and rear surfaces extend between the top surface and the bottom surface. Opposing first and second sidewall surfaces extend between the top surface and the bottom surface, and between the front and rear surfaces. The front surface and the first sidewall surface have a three dimensional texture imprinted thereon. The rear surface and the second sidewall surface may be smooth. The texturing on the front and first sidewall surfaces may generally resemble natural stone.

1 . A dry-cast concrete wall block comprising: 
 a top surface;    a bottom surface opposing front and rear surfaces extending between the top surface and the bottom surface; and    opposing first and second sidewall surfaces extending between the top surface and the bottom surface, and extending between the front and rear surfaces wherein the front surface and the first sidewall surface have a three dimensional texture imprinted thereon.    
   
   
       2 . The concrete wall block of  claim 1 , wherein the rear surface and the second sidewall surface are smooth.  
   
   
       3 . The concrete wall block of  claim 1 , wherein the texturing on the front and first sidewall surfaces generally resembles natural stone.  
   
   
       4 . The concrete wall block of  claim 1 , wherein the texturing of the front and first sidewall surfaces covers their entire extent.  
   
   
       5 . The concrete wall block of  claim 1 , further comprising an interlocking protrusion extending below the bottom surface of the block.  
   
   
       6 . A dry-cast concrete wall block comprising: 
 a top surface;    a bottom surface spaced apart from the top surface and defining a thickness of the block;    a first side surface extending between the top surface and the bottom surface, the first side surface having a three dimensional texture imprinted thereon;    a second side surface extending between the top surface and the bottom surface, the second side surface having a three dimensional texture imprinted thereon;    a third side surface extending between the top surface and the bottom surface, the third side surface opposing the second side surface;    a fourth side surface extending between the top surface and the bottom surface, the fourth side surface opposing the first side surface.    
   
   
       7 . The concrete wall block of  claim 6 , wherein the third side surface is tapered.  
   
   
       8 . The concrete wall block of  claim 6 , further comprising an interlocking extension extending below the bottom surface.  
   
   
       9 . A dry-cast concrete wall block comprising: 
 a top surface;    a bottom surface spaced apart from the top surface and defining a thickness of the block;    a front surface extending between the top surface and the bottom surface;    a rear surface opposite the front surface and extending between the top surface and the bottom surface; and    opposing side surfaces spanning between the front and back surfaces, wherein the front surface and one of the opposing side surfaces are configured to simulate natural stone.    
   
   
       10 . A method of manufacturing an uncured concrete block made using the dry-cast manufacturing process, the method comprising the steps of: 
 providing a mold, the mold comprising a pair of side walls, a pair of end walls, an open top side and an open bottom side defining a mold cavity;    providing a pallet;    providing an end liner within the mold cavity;    positioning the pallet with respect to the mold to temporarily close the open bottom side of the mold during a portion of the manufacturing process;    moving each a first end liner from a strip position to a fill position;    introducing a dry casting concrete mixture to the mold through the open top side;    vibrating the concrete mixture within the mold;    compacting the concrete mixture within the mold by pressing on the concrete mixture with at least one shoe attached to a compression head to impart a decorative face on the concrete mixture;    moving each the first end liner from the fill position to the strip position; and    releasing the concrete mixture from the mold by moving the pallet relative to the mold.    
   
   
       11 . The method of  claim 10 , further comprising the step of forming a decorative pattern on a side face of the uncured concrete block with the first end liner.  
   
   
       12 . The method of  claim 10 , further comprising the step of forming a tapered side face on the uncured concrete block with the first end liner.  
   
   
       13 . The method of  claim 10 , further comprising the step of providing a second end liner to each mold cavity disposed opposite the first end liner.  
   
   
       14 . The method of  claim 10 , further comprising the step of heating the first end liner.  
   
   
       15 . The method of  claim 10 , further comprising the step of providing a division plate within the mold to define multiple mold cavities.