Architectural blocks with stone-like appearance and method of manufacture
AssigneeTuscan Stoneworx USA, LLC
InventorMat T. Nielsen
Life of this patent
Estimating the term…
Abstract
The present disclosure describes architectural blocks configured to give the appearance of real cut stone. A plaster composition may be applied to one or more surfaces of a block, such as a concrete masonry unit (CMU) to form an architectural block having the appearance of cut stone. The plaster composition includes a cementitious component, such as white Portland cement, a limestone aggregate component, and optionally an adhesive component. The limestone aggregate component includes a fine sand portion and a coarse sand portion that effectively enable the appearance of cut stone after finishing of the plaster surface via sanding and/or polishing.
Claims20
A method of manufacturing an architectural block adapted to give the appearance of cut stone, the method comprising:
- providing a block substrate;
- placing a plaster composition comprising a cementitious binder, water, and an aggregate component into an applicator chute;
- moving the block substrate on a conveyor under the applicator chute;
- the applicator chute applying the plaster composition to a surface of the block substrate to form a plaster layer;
- moving the block substrate with the plaster layer on the conveyor under a leveler which levels the plaster layer and removes excess plaster from an outer surface of the plaster layer;
- and
- allowing the plaster layer to harden or cure to form a hardened plaster layer,
- the hardened plaster layer being formulated to resemble cut stone when applied to the surface of the block substrate and allowed to harden or cure.
A method of manufacturing an architectural block adapted to give the appearance of cut stone, the method comprising:
- providing a block substrate;
- applying a plaster composition to at least one surface of the block substrate to form a plaster layer, the plaster composition comprising;
- a cementitious binder component selected from Portland cement, white cement, and optionally one or more supplementary cementitious materials (SCMs);
- water;
- and
- an aggregate component including at least two gradations of aggregate, including a fine sand portion and a coarse sand portion, wherein the fine sand portion has a D90 within a range of about 0.075 mm to 0.425 mm and the coarse sand portion has a D90 within a range of about 0.425 mm to 2.80 mm;
- leveling the plaster layer;
- allowing the plaster layer to harden or cure to form a hardened plaster layer;
- and
- finishing the plaster layer using one or more finishers selected from one or more sanders and/or one or more polishers,
- the plaster layer being formulated to resemble cut stone when applied to the surface of the block substrate and allowed to harden or cure.
A method of manufacturing an architectural product adapted to give the appearance of cut stone, the method comprising:
- providing a substrate selected from a concrete block, cement board, drywall, polymer, or concrete structure;
- applying a plaster composition to at least one surface of the block substrate to form a plaster layer, the plaster composition comprising;
- a cementitious binder component selected from Portland cement, white cement, and optionally one or more supplementary cementitious materials (SCMs);
- water;
- a water reducer;
- a latex or latex-based adhesive;
- and
- an aggregate component including at least two gradations of aggregate, including a fine sand portion and a coarse sand portion, wherein the fine sand portion has a D90 within a range of about 0.075 mm to 0.425 mm and the coarse sand portion has a D90 within a range of about 0.425 mm to 2.80 mm;
- leveling the plaster layer;
- allowing the plaster layer to harden or cure to form a hardened plaster layer;
- and
- finishing the plaster layer using one or more finishers selected from one or more sanders and/or one or more polishers,
- the plaster layer being formulated to resemble cut stone when applied to the surface of the substrate and allowed to harden or cure.
Dependencies are inferred from the claim text.