# US 11,028,598 B2 · Dry-cast lightweight veneer block, system, and method

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 11,028,598 B2
- Document ID: US11028598B2
- Status: Granted
- Kind: B2
- Application number: 15/579,382
- Filed: 2016-01-29
- Published: 2018-06-28
- Granted: 2021-06-08
- Earliest claimed: 2015-06-26
- Assignees: Anchor Wall Systems, Inc.
- Applicants: Oldcastle Architectural, Inc.
- Inventors: Leonard Browning; David Rice
- Web page: https://patentgrep.com/patent/US11028598B2

## CPC

- E04F 13/0885: {specially adapted for being adhesively fixed to the wall; Fastening means therefor; Fixing by means of plastics materials hardening after application}
- C04B 14/06: Quartz; Sand
- C04B 18/027: {Lightweight materials}
- C04B 28/02: containing hydraulic cements other than calcium sulfates
- C04B 30/00: Compositions for artificial stone, not containing binders
- E04F 13/14: stone or stone-like materials, e.g. ceramics {concrete,}; of glass {or with an outer layer of stone or stone-like materials or glass (E04F13/0864 takes precedence; producing shaped elements from concrete, ceramic compositions or other stone-like materials B28B; prefabricated panels in general E04C2/00)}
- E04F 13/141: {with an outer layer of concrete (E04F13/147 takes precedence)}
- C04B 2111/00051: {Mortar or concrete mixtures with an unusual low cement content, e.g. for foundations}
- C04B 2111/40: Porous or lightweight materials
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE

## Abstract

Described are dry cast lightweight veneer blocks and a system and method of installing lightweight veneer blocks. The courses can be assembled without mortar between the courses. As an example, sides of the veneer blocks have areas that recede from an imaginary plane between adjacent veneer blocks to give a deep texturing and a shadow effect between veneer blocks. The installation system and method include a substrate, an air barrier applied to the substrate, a plurality of veneer blocks, and an adhesive applied between the plurality of veneer blocks and the air barrier.

## Claims

### Claim 1

A block comprising:
a dry cast mixture comprising 35-45% by weight lightweight aggregate and 25-35% by weight fine sand and resulting in a dry cast veneer block having a weight less than or equal to 15 lb/ft2.

### Claim 2 (depends on 1)

The block of claim 1, wherein pigmentation is dispersed throughout the block.

### Claim 3 (depends on 1)

An assembly of blocks of claim 1, wherein courses of the blocks are assembled without mortar between the courses.

### Claim 4 (depends on 1)

A method of installing a plurality of blocks of claim 1 on a substrate, the method comprising:
applying an adhesive to the substrate; and
installing the plurality of blocks in courses by pressing the plurality of blocks against the adhesive.

### Claim 5 (depends on 4)

The method of claim 4, wherein the substrate comprises wood, plywood, exterior sheathing, oriented strand board, drywall, chipboard, hardboard, cement board, concrete, blockwork, or fiber cement siding.

### Claim 6

An installation system comprising:
a substrate;
a plurality of dry cast lightweight veneer blocks, each have a weight of less than or equal to 15 lb/ft2, each of the blocks comprising 35-45% by weight lightweight aggregate and 25-35% by weight fine sand; and
an adhesive to adhere the plurality of lightweight veneer blocks to the substrate.

### Claim 7 (depends on 6)

The installation system of claim 6, wherein the substrate comprises wood, plywood, exterior sheathing, oriented strand board, drywall, chipboard, hardboard, cement board, concrete, blockwork, or fiber cement siding.