Architectural blocks with stone-like appearance and method of manufacture
AssigneeTuscan Stonework 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 fresh 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 fresh plaster composition includes a cementitious component, such as white Portland cement, water, 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 hardened or curted plaster surface via sanding and/or polishing.
Claims20
A method of manufacturing an architectural block having the appearance of cut stone, comprising:
- placing a fresh plaster composition comprising a cementitious binder, water, and an aggregate component into an applicator, the fresh plaster composition being in a flowable or plastic state;
- moving a block substrate on a conveyor under the applicator;
- the applicator applying the fresh plaster composition to a surface of the block substrate to form a fresh plaster layer;
- moving the block substrate with the fresh plaster layer on the conveyor under a leveler which levels the plaster layer and removes excess plaster composition;
- and
- causing or allowing the plaster layer to harden or cure to form a hardened or cured plaster layer.
A method of manufacturing an architectural block having the appearance of cut stone, comprising:
- placing a fresh plaster composition comprising a cementitious binder, water, and an aggregate component into an applicator, wherein the fresh plaster composition is free of epoxy resins and hardeners and in a flowable or plastic state;
- moving a block substrate adjacent to the applicator;
- the applicator applying the fresh plaster composition to a surface of the block substrate to form a fresh plaster layer;
- leveling the fresh plaster layer;
- and
- causing or allowing the leveled plaster layer to harden or cure to form a hardened or cured plaster layer.
A method of manufacturing an architectural block adapted to give the appearance of cut stone, comprising:
- providing a block substrate;
- applying a fresh plaster composition to a surface of the block substrate to form a fresh plaster layer, the fresh plaster composition comprising a cementitious binder, water, and an aggregate component including a fine sand and a coarse sand, wherein the fine sand has a D90 in a range of about 0.075 mm to 0.425 mm and the coarse sand has a D90 in a range of about 0.425 mm to 2.80 mm;
- leveling the fresh plaster layer within 5 minutes of applying the fresh plaster composition to the surface of the block substrate;
- and
- allowing the leveled plaster layer to harden or cure to form a hardened or cured plaster layer.
Dependencies are inferred from the claim text.