The present disclosure describes modular blocks configured to give the appearance of natural or cut stone. An aesthetic coating composition may be applied to one or more surfaces of a block having a low-density, such as an insulating concrete form (ICF), to form an modular block having the appearance of cut stone. The aesthetic coating composition includes a binder component, such as a cementitious binder made from white Portland cement, or a polymer binder such as an acrylic binder, an aggregate component, such as a limestone aggregate component, and optionally an adhesive component. The aggregate component includes a fine sand portion and a coarse sand portion that effectively enable the appearance of cut stone after finishing of the aesthetic coating surface via sanding, polishing, sandblasting, acid etching, acid finishing, or exposed aggregate finishing.

A precast composite wall structure and method for forming the wall structure are disclosed. The method includes providing a casting bed defining a plurality of shapes corresponding to a three-dimensional outer surface of a wall structure, placing a first layer of uncured concrete to conform to the shapes defined by the lower surface, positioning a forming member in overlying relation above the frame, the forming member defining a plurality of rectangular-shaped channels therebetween, positioning a stud frame within the casting bed along the forming member, placing a second layer of uncured concrete within the casting bed to conform to the rectangular-shaped channels between the rectangular protrusions, and allowing the concrete to cure.

A method for manufacturing a pre-fabricated element for construction and electricity production includes providing a formwork mould; introducing a photovoltaic module into the formwork mould, and for this purpose vertically positioning the photovoltaic module against or in replacement of one of the walls of the formwork mould, the front face of the at least one photovoltaic module being arranged so as to face an area of the space located outside the mould; depositing an adhesive structural material or a mixture of adhesive structural materials on all or part of the rear face of the at least one photovoltaic module arranged so as to face an area of the space located inside the mould, the adhesive structural material including at least one polymer from the epoxide, polyurethane, acrylic, or styrene-acrylic family, and pouring fresh concrete into the formwork mould so as to cover the adhesive structural material.

Provided is a system and method for building retaining and freestanding stone walls, wherein wall panels are made, then transported to an installation location, and installed on site quickly and efficiently. The wall panels are made in wall frames that use joint forms to provided wall panels having sides that reliably and securely mater together. The joint forms include zig-zag like connections and a structural interlocking key, engineered to prevent vertical and lateral deformation of the assembled wall. Drainage and strengthening materials are built into the wall panels while in the wall frames. A lifting apparatus is also provided that engages a wall panel through openings formed in a rear side, and stably lifts and flips the wall panel from a facedown orientation to an upright orientation.

The disclosure is directed to thermal and moisture insulated interlocking brick comprising natural, in-situ carved stone faade coupled to a backing layer comprised of a massive and lightweight portions, as well as methods of forming the brick and methods for cladding and using the bricks in load bearing walls and in non-load-bearing walls (light construction).

The invention relates to a pointing device (10) for pointing brickwork a method for pointing brickwork and use of the pointing device (10) for pointing brickwork. The pointing device comprises: a support (12) that is configured for supporting a product (14) comprising brickwork; a filling nozzle (20); a pointing substance container (22) that is operatively coupled with the filling nozzle (20), wherein the pointing substance container (22) is configured for holding a pointing substance; movement means (24) that are configured to position the filling nozzle (20) relative to the support (12); a control unit (26) configured for controlling the movement means (24); and determining the amount of pointing substance in relation to a point; a sensor (28) that is operatively connected to the controller (26), and is configured for sensing the location and size of the point; and orientation means (30) that are configured to establish a relative position between the filling nozzle (20) and the support (12).

Apparatus, systems, and methods for applying plaster compositions to block substrates to yield a product having the appearance of cut stone. An example apparatus includes: a manifold; a mold connected to the manifold with a channel to receive the block substrate; a delivery hose connected to a top of the manifold to deliver plaster composition to the manifold for application to the block substrate; a pressure release hose connected to the manifold; and a vibrating mechanism connected to the mold. A system further includes a conveyor that moves block substrates through the mold. An example method includes: wetting a surface of a block substrate; moving the block substrate through an application apparatus as described, applying a layer of plaster composition to a surface of the block substrate, vibrating the mold and block substrate during application of the plaster composition, and allowing the plaster composition to harden.

Apparatus, systems, and methods for applying plaster compositions to block substrates to yield a product having the appearance of cut stone. An example apparatus includes: a manifold; a mold connected to the manifold with a channel to receive the block substrate; a delivery hose connected to a top of the manifold to deliver plaster composition to the manifold for application to the block substrate; a pressure release hose connected to the manifold; and a vibrating mechanism connected to the mold. A system further includes a conveyor that moves block substrates through the mold. An example method includes: wetting a surface of a block substrate; moving the block substrate through an application apparatus as described, applying a layer of plaster composition to a surface of the block substrate, vibrating the mold and block substrate during application of the plaster composition, and allowing the plaster composition to harden.

A method for manufacturing a layered tile comprising a mutually connected ceramic tile and a concrete body, the method comprising the steps of applying an organic primer to a first surface of the ceramic tile, optionally positioning the ceramic tile in a mold, exposing the first surface, applying a concrete mixture on top of the tile's first surface, pre-hardening the concrete mixture for obtaining a green product, removing the product from the mold, and fully hardening the concrete for obtaining the layered tile.

The present disclosure describes modular blocks configured to give the appearance of natural or cut stone. An aesthetic coating composition may be applied to one or more surfaces of a block having a low-density, such as an insulating concrete form (ICF), to form an modular block having the appearance of cut stone. The aesthetic coating composition includes a binder component, such as a cementitious binder made from white Portland cement, or a polymer binder such as an acrylic binder, an aggregate component, such as a limestone aggregate component, and optionally an adhesive component. The aggregate component includes a fine sand portion and a coarse sand portion that effectively enable the appearance of cut stone after finishing of the aesthetic coating surface via sanding, polishing, sandblasting, acid etching, acid finishing, or exposed aggregate finishing.