# US 12,759,935 B2 · Caustic based material building methods and apparatus

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- Number: US 12,759,935 B2
- Document ID: US12759935B2
- Status: Granted
- Kind: B2
- Application number: 18/190,802
- Filed: 2023-03-27
- Published: 2024-10-03
- Granted: 2026-10-13
- Earliest claimed: 2023-03-27
- Assignees: Elkhorn Capital Holdings LLC
- Applicants: Elkhorn Capital Holdings LLC
- Inventors: Randall Stremmel
- Web page: https://patentgrep.com/patent/US12759935B2

## CPC

- C04B 18/08: Flue dust {, i.e. fly ash}
- B28B 3/02: wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
- 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
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)

## Abstract

Embodiments presented provide for a method of making a material building block using a caustic material within the matrix of the material. In embodiments, dry ingredients are mixed together, followed by steps of adding the caustic material the mixed dry ingredients. The resulting mixture may be cured into shapes or forms conducive to be used as building materials.

## Claims

### Claim 1

A method for making a caustic-based building material, comprising:
retaining material constituents of the building material;
mixing dry constituents of the material constituents of the building material to result in a mixed dry constituent mixture;
adding a caustic solution to the mixed dry constituent mixture to form a resultant mixture, wherein the caustic solution is sodium hydroxide;
placing the resultant mixture in a form;
compressing the resultant mixture in the form; and
curing the resultant mixture wherein the curing occurs in an autoclave in saturated steam at a temperature of 190 degrees C. for 8 hours.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the compressing of the resultant mixture in the form occurs at 5000 pounds per square inch.

### Claim 3 (depends on 1)

The method according to claim 1, wherein the sodium hydroxide is less than 16M concentration.

### Claim 4 (depends on 1)

The method according to claim 1, wherein the sodium hydroxide is 10M concentration.

### Claim 5 (depends on 1)

The method according to claim 1, wherein the sodium hydroxide is 2M concentration.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the dry constituents are at least one of a rock, a lime, a fly ash and a bottom ash.

### Claim 7 (depends on 1)

The method according to claim 1, wherein the form is a brick form.

### Claim 8 (depends on 1)

The method according to claim 1, wherein the form is a block form.

### Claim 9 (depends on 1)

The method according to claim 1, wherein the resultant mixture is poured into the form.

### Claim 10

A method for making a caustic-based building material, comprising:
mixing at least one of a lime, a fly ash and a bottom ash together to form a mixed dry constituent mixture;
adding a solution of sodium hydroxide to the mixed dry constituent mixture to form a resultant mixture;
placing the resultant mixture in a form;
compressing the resultant mixture in the form; and
curing the resultant mixture wherein the curing occurs in an autoclave in saturated steam at a temperature of 190 degrees C. for 8 hours.

### Claim 11 (depends on 10)

The method according to claim 10, wherein the compressing the resultant mixture in the form occurs at 5000 pounds per square inch.

### Claim 12 (depends on 10)

The method according to claim 10, wherein the sodium hydroxide is less than 16M concentration.

### Claim 13

A method for making a caustic-based building material, comprising:
mixing at least one of a fly ash and a bottom ash and a solution of sodium hydroxide to form a resultant mixture;
placing the resultant mixture in a form;
compressing the resultant mixture in the form; and
curing the resultant mixture wherein the curing occurs in an autoclave in saturated steam at a temperature of 190 degrees C. for 8 hours.