Process for making an insulated building block

A process for preparing a building block, comprising the steps of:

• (a) providing a substantially serpentine, integral, insert adapted to form a multiplicity of interlocking projections with curvilinear structure, wherein:
• 1. said insert is comprised of at least one projection which is curvilinear;
• 2. said insert consists essentially of material with a density of from about 1.0 to about 2.0 pounds per cubic foot, a flexural strength of from 25 to 125 pounds per square inch, and a shear strength from 25 to 175 pounds per square inch;
• (b) providing a substantially rectangular mold;
• (c) disposing said insert within said mold;
• (d) providing a cementitious material, wherein said material is comprised of at least about 30 weight percent of aggregate, and at least about 5 weight percent of cement;
• (e) placing said cementitious material around said insert within said mold;
• (f) pressing said cementitious material to form a block until said block has a density of from about 80 to about 150 pounds per cubic foot and until said insert extends beyond the top of said block by from about 0.2 to about 0.6 inches;
• (g) removing said block from said mold;
• and
• (h) heating said block for from about 4 to about 10 hours at a temperature of from about 75 to about 250 degrees Fahrenheit.