Methods of quality control in concrete block production

A process for producing a plurality of concrete blocks;

• the process comprising the steps of:
• providing a mold having at least a first row of block-forming cavities;
• each block-forming cavity in the first row having an open top and an open bottom;
• the first row comprising at least five block-forming cavities comprising at least:
• a first end cavity;
• and, a second, opposite, end cavity, separated from the first end cavity by a plurality of cavities;
• positioning a single pallet under the entire first row of block forming cavities to temporarily close the open bottoms of the block-forming cavities in the first row;
• introducing dry cast concrete into each block-forming cavity in the first row, through the open top of each cavity;
• actuating a single compression head to lower a stripper shoe into each of the block-forming cavities in the first row;
• the step of actuating including compacting the dry cast concrete in each block-forming cavity to mold a pre-cured concrete block therein;
• each pre-cured block having a front face, a rear face and opposite side faces;
• the rear face of each pre-cured concrete block resting on the pallet during molding of the pre-cured block and conforming to the surface of the pallet during molding;
• the front face of each pre-cured block being formed facing upwardly and being molded by an associated stripper shoe to have a three-dimensional pattern that is not parallel to the rear face of the block;
• the front face of a pre-cured concrete block molded in the first end cavity having a first plurality of measurement locations thereon comprising a first plurality of flat spots molded by an associated stripper shoe;
• each one of the first plurality of flat spots having a minimum dimension of at least ⅛ inch and being substantially smaller in area than the front face;
• each flat spot in the first plurality of measurement locations corresponding to a measurement location being bordered, at least partially, by a non-flat portion of the three-dimensional pattern on the front face of the corresponding block;
• the front face of a pre-cured concrete block molded in the second end cavity having a second plurality of measurement locations thereon comprising a second plurality of flat spots molded by an associated stripper shoe;
• each one of the second plurality of flat spots having a minimum dimension of at least ⅛ inch and being substantially smaller in area than the front face;
• each flat spot corresponding to a measurement location being bordered, at least partially, by a non-flat portion of the three-dimensional pattern on the front face of the corresponding block;
• discharging pre-cured concrete blocks from the bottoms of the first row of block-forming cavities and onto the pallet;
• measuring at least:
• the respective distances between at least two selected ones of the measurement locations on the front face of the first end block and the rear face of the first end block;
• and,
• the respective distances between at least two selected ones of the measurement locations on the front face of the second end block and the rear face of the second end block;
• evaluating the measurements to assess molding quality, without conducting measurements on molded blocks from every one of the cavities in the first row;
• the step of evaluating including comparing the measurements to target distances;
• and, adjusting the alignment of at least one of the compression head and the stripper shoe with the mold based on results obtained from the evaluating step, if necessary.