Environmentally responsible insulating construction blocks and structures

Abstract

Environmentally responsible insulating construction blocks and structures constructed primarily of recycled materials are disclosed. The environmentally friendly construction blocks and structures comprise shredded rubber tire pieces coated with silica fume, slag cement and cement, which are then mixed with water and formed in a mold. A layer of grout or a fireproof material may be disposed on one side of the environmentally responsible insulating construction block. The environmentally responsible insulating construction blocks provide high insulation as well as strength for applications such as green roofing, wall construction and green roofing decks. Environmentally friendly structures can be built by pouring the coated shredded rubber tire pieces into molds to form walls, and then to pour a layer of the coated shredded rubber tire pieces as a roof deck, thereby creating a self-supporting structure in a monolithic pour.

What is claimed is: 
     
         1 . An environmentally responsible insulated construction block for green decking application comprising:
 a first layer of a plurality of shredded rubber tire pieces coated with silica fume, slag cement and cement and a second layer of a plurality of pieces of a fireproof material coated with silica fume, slag cement and cement forming a block having a top surface, a bottom surface substantially parallel to the top surface and 4 side surfaces substantially perpendicular to the top surface and the bottom surface, wherein the block has a depth defined by the distance between the top surface and the bottom surface;   wherein the shredded rubber tire pieces range in size of between about ½ inch to 2 inches,   wherein the shredded rubber tire pieces comprise at least 50% by weight of the shredded rubber tire pieces, silica fume, slag cement and cement,   wherein the environmentally responsible insulated construction block forms an open matrix structure allowing liquid to pass substantially freely through the environmentally responsible insulated construction block.   
     
     
         2 . The environmentally responsible insulated construction block of  claim 1 , wherein the second layer is approximately 1 inch thick. 
     
     
         3 . The environmentally responsible insulated construction block of  claim 1 , wherein the block is about 12 inches square. 
     
     
         4 . The environmentally responsible insulated construction block of  claim 3 , wherein the thickness of the block is greater than about 2 inches. 
     
     
         5 . The environmentally responsible insulated construction block of  claim 4 , wherein the thickness of the block is about 4 inches. 
     
     
         6 . The environmentally responsible insulated construction block of  claim 4 , wherein the size of the shredded rubber tire pieces range in size between about 1 inch and 2 inches. 
     
     
         7 . The environmentally responsible insulated construction block of  claim 2 , wherein the block is used in a green decking system. 
     
     
         8 . The environmentally responsible insulated construction block of  claim 1 , wherein the fireproof material comprises expanded slate. 
     
     
         9 . A method of manufacturing an environmentally responsible insulated construction block for green roofing application comprising:
 mixing a first mix of substantially dry silica fume, slag cement and cement;   thereafter adding shredded rubber tire pieces to the first mix and mixing until the shredded rubber is substantially completely coated;   thereafter adding water until the mix of silica fume, slag cement, cement and shredded rubber tire pieces is fully wetted;   mixing a second mix of substantially dry silica fume, slag cement and cement;   thereafter adding shredded pieces of a fireproof material to the second mix and mixing until the pieces of fireproof material are substantially completely coated;   thereafter adding water until the mix of silica fume, slag cement, cement and pieces of fireproof material are fully wetted;   thereafter pouring a layer of the wetted fireproof material mix to the bottom of a mold;   thereafter pouring the wetted shredded rubber mixture into the mold on top of the layer wetted fireproof material mix until the mold is substantially full;   fitting each mold with a lid; and   allowing each mold to dry.   
     
     
         10 . The method of  claim 9 , wherein the fireproof material comprises expanded slate. 
     
     
         11 . The method of manufacturing an environmentally responsible insulated construction block of  claim 9 , wherein the mold dries in ambient air. 
     
     
         12 . The method of manufacturing an environmentally responsible insulated construction block of  claim 9 , wherein the shredded rubber tire pieces range in size between about ½ inch and 2 inches. 
     
     
         13 . A green roof deck, comprising:
 a membrane roofing system comprising an insulating layer adhered to a substrate of a roof of a structure and a waterproof membrane layer adhered to the insulating layer distal from the roof substrate; and   an environmentally responsible insulated construction block adhered to the waterproof membrane layer of the membrane roofing system,   wherein the environmentally responsible insulated construction block comprises:   a first layer of a plurality of shredded rubber tire pieces coated with silica fume, slag cement and cement and a second layer of a plurality of pieces of a fireproof material coated with silica fume, slag cement and cement forming a block having a top surface, a bottom surface substantially parallel to the top surface and 4 side surfaces substantially perpendicular to the top surface and the bottom surface, wherein the block has a depth defined by the distance between the top surface and the bottom surface;   wherein the shredded rubber tire pieces range in size between about ½ inch and 2 inches,   wherein the shredded rubber tire pieces comprise at least 50% by weight of the shredded rubber tire pieces, silica fume, slag cement and cement,   wherein the environmentally responsible insulated construction block forms an open matrix structure allowing liquid to freely pass through the environmentally responsible insulated construction block.   
     
     
         14 . The green roofing deck of  claim 13 , wherein the fireproof material comprises expanded slate. 
     
     
         15 . An environmentally responsible insulated structure comprising:
 a foundation, a plurality of exterior walls and a roof,   wherein one or more of the exterior walls is prepared by:
 preparing a mold; 
 placing the mold on the foundation; 
 placing a layer of grout on the foundation at the bottom of the mold; 
 pouring a mix comprising shredded rubber tire pieces coated with silica fume, slag cement and cement into the mold; 
 placing a cover over the top surface of the poured mix and attaching it to the metal rods; 
 placing pressure on the cover to compress the mix in the mold; 
 allowing the mix in the mold to dry; and 
 thereafter removing the cover and the mold, 
   wherein the roof is prepared by:
 preparing a roof structure atop the plurality of exterior walls; 
 placing forms around the exterior edges of the roof structure; 
 attaching a plurality of metal rods to the roof structure to extend perpendicular from the roof structure upward; 
 pouring a mix comprising shredded rubber tire pieces coated with silica fume, slag cement and cement on the roof structure; 
 placing a cover over the top surface of the mix poured on the roof structure and attaching it to the metal rods; 
 placing pressure on the cover to compress the mix poured on the roof structure; 
 allowing the mix poured on the roof structure to dry; 
 removing the cover and the forms; and 
 thereafter covering the dried mix on the roof structure with a protective layer, 
   wherein the shredded rubber tire pieces in the mix range in size of between about ½ inch to 2 inches,   wherein the shredded rubber tire pieces comprise at least 50% by weight of the mix of shredded rubber tire pieces, silica fume, slag cement and cement.   
     
     
         16 . The environmentally responsible insulated structure of  claim 15 , wherein each exterior wall is approximately twelve inches thick. 
     
     
         17 . The environmentally responsible insulated structure of  claim 16 , wherein the cover comprises a plywood sheet. 
     
     
         18 . The environmentally responsible insulated structure of  claim 16 , wherein the protective covering comprises one of stucco, roof paint or a combination thereof. 
     
     
         19 . The environmentally responsible insulated structure of  claim 16 , wherein the foundation comprises the ground. 
     
     
         20 . An environmentally responsible insulated construction block for green roofing application comprising:
 a layer of a plurality of shredded rubber tire pieces coated with silica fume, slag cement and cement forming a block having a top surface, a bottom surface substantially parallel to the top surface and 4 side surfaces substantially perpendicular to the top surface and the bottom surface, wherein the block has a depth defined by the distance between the top surface and the bottom surface;   wherein the shredded rubber tire pieces range in size of between about ½ inch to 2 inches,   wherein the shredded rubber tire pieces comprise at least 50% by weight of the shredded rubber tire pieces, silica fume, slag cement and cement,   wherein the environmentally responsible insulated construction block forms an open matrix structure.