System and Method For Precision Grinding and Self-Leveling Installation of Concrete Masonry Systems

Abstract

A stackable building block 1102 for constructing a masonry wall includes a front section 502 having an outer surface, an inner surface, a bottom surface, and a top surface. The top surface may be divided into a higher surface 1111 positioned between two lower surfaces 1109 . The building block also has a rear section 504 substantially parallel to the front section having an outer surface, an inner surface, a bottom surface, and a top surface. Two or more webs 1106 coupling the inner surface of the front section to the inner surface of the rear section have a top surface and a bottom surface. Two or more pairs of lugs 508 may extend above the top surface of the front section and the top surface of the rear section. During manufacturing the higher surface of the top surface is ground to a precision height. During assembly of the stack building block, a thin set mortar, grout or adhesive is used between successive courses.

1 . A method of producing a stackable building block for constructing a masonry wall, the method comprising the acts of:
 molding a concrete block having a front section coupled to and substantially parallel with a rear section, each of the front and rear sections having a bottom surface and a top surface, wherein the top surface on both the front and rear sections includes a central region having a height which is greater than first and second end regions located on either side of the central region; and   grinding the central region of the top surface of the front and rear block sections to a predetermined height.   
   
   
       2 . The method of producing a stackable building block for constructing a masonry wall of  claim 1 , wherein the building block is a dry stackable concrete block. 
   
   
       3 . The method of producing a stackable building block for constructing a masonry wall of  claim 1 , wherein the building block is a wet stackable concrete block. 
   
   
       4 . The method of producing a stackable building block for constructing a masonry wall of  claim 1 , wherein the central region has an undulating surface. 
   
   
       5 . The method of producing a stacked building block wall utilizing the stackable building block of  claim 1 , and further comprising the acts of:
 applying a flowable, thin set mortar onto the top surface of the stackable building block using a high speed applicator.   
   
   
       6 . The method of producing a stacked building block wall utilizing the stackable building block of  claim 5 , wherein the high speed applicator is a grout bag. 
   
   
       7 . The method of producing a stacked building block for constructing a masonry wall of  claim 5  wherein the mortar is applied to a thickness of ⅛ of an inch or less. 
   
   
       8 . The method of producing a stackable building block for constructing a masonry wall of  claim 1  wherein the grinding of the higher surface of the top surface is precision ground to provide a stack building block of a specific precision height. 
   
   
       9 . The method of producing a stackable building block for constructing a masonry wall of  claim 1  wherein the central region of the top surface further includes a plurality of indents or serrations or channels. 
   
   
       10 . The method of producing a stacked building block wall utilizing the stackable building block of  claim 9 , and further comprising the acts of:
 applying a flowable, thin set mortar onto the top surface of the stackable building block using a high speed applicator; and   allowing the mortar to enter the plurality of indents or serrations or channels on the central region of the top surface, wherein the addition of the mortar does not significantly increase the specific precision height of the stackable building block.   
   
   
       11 . The method of producing a stacked building block wall utilizing the stackable building block of  claim 1 , and further comprising the acts of:
 stacking a second duplicate stack block staged halfway off-center; and   stacking a third duplicate stack block staged halfway off-center in a direction opposite and adjacent to the second stack block.   
   
   
       12 . The method of producing a stack building block for constructing a masonry wall of  claim 1  wherein the stack building block has a chamfered or beveled edge on one more exterior edges of the building block.