Composite masonry block and method of making the same

A composite structural block comprising:

• a pair of generally planar facing panels each formed from a masonry material including concrete, wherein each of the facing panels defines an outer surface of the structural block
• a pair of truss-web members extending between and interlocked and embedded within an inner surface of each of the pair of facing panels, wherein the truss-web members are each formed from a non-masonry material;
• and
• a pair of connector panels that join the pair of truss-web members to define a unitary truss module, wherein the pair of connector panels create a mold forming boundary.

A method of forming a composite structural block comprising the steps of:

• positioning a pair of truss-web members formed from a non-masonry material in a mold assembly, the truss-web members each including a pair of opposite ends each having an open channel and at least one connector tongue extending into the open channel, wherein the positioning of the truss-web members creates two residual cavity spaces in the mold cavity
• pouring a masonry material including concrete into the two residual cavity spaces defined by the truss-web members and the mold assembly to form a pair of generally planar facing panels, wherein the two residual cavity spaces are open to the open channels of the truss-web members such that the masonry material fills the open channels to interlock the truss-web member to the facing panel;
• and
• removing the interlock facing panels and the truss-web members from the mold assembly as a composite structural block.