Method and apparatus for casting prefabricated concrete products with a substantially horizontal slipform casting process, where the concrete mass is fed in at least one feeding stage to a slipform casting mold compacting and defining the product to be cast, wherein at least one part is embedded in the concrete mass after the at least one concrete mass feeding stage and before the final compaction of the upper surface of the product to be cast.

An erosion control mat provides a plurality of concrete blocks. Each block has an upper portion with a plurality of upper inclined side walls. Each block has a lower portion with a plurality of inclined lower side walls. The block has an upper surface and a lower surface and a block periphery in the form of an edge where the upper and lower side walls meet. Cables or ropes connect the blocks together to form a block matrix and the erosion control mat. Each block has a boot affixed to the block lower portion, the boot having a plurality of inclined side panels. Each boot side panel has an upper edge. The boot has a lower panel, a boot interior surface and an interior that is receptive of at least part of the block lower portion. The boot inclined side panels engage the block inclined lower side walls. The boot lower panel engages the block lower surface. A plurality of anchor posts are attached to the interior surface of the boot. Some of the anchor posts are attached to the side wall panels to enable a connection to be formed between the boot inclined side panels and the block inclined lower side walls. Some of the anchor posts are attached to the lower panel of the boot to enable a connection to be formed between the boot lower panel and the block lower surface. As part of the method, the boot is first placed in a mold. Slurried concrete is then added to the mold so that a connection is formed between the boot anchor posts and the concrete when the concrete sets after a time period.

A process for the formation of highly durable cementitious board using lightweight aggregate is disclosed. The process comprises pouring a core mix onto a conveyor, wherein the core mix is comprised of one or more lightweight aggregate filler in the amount of 0.5 to 5 weight percent of the core mix, one or more binders in the amount of 35 to 75 weight percent of the core mix, rheological admixture in the amount of about 0.5 to 5 weight percent of the core mix, surfactant in the amount of 0 to 0.1 weight percent of the core mix, one or more normal weight aggregate filler in the amount of 5 to 50 weight percent of the core mix, and water in the amount of 5 to 20 weight percent of the core mix. The process further comprises passing the core mix under a screed roller to flatten the core mix to produce an extruding board with a desired thickness.

An erosion control mat provides a plurality of concrete blocks. Each block has an upper portion with a plurality of upper inclined side walls. Each block has a lower portion with a plurality of inclined lower side walls. The block has an upper surface and a lower surface and a block periphery in the form of an edge where the upper and lower side walls meet. Cables or ropes connect the blocks together to form a block matrix and the erosion control mat. Each block has a boot affixed to the block lower portion, the boot having a plurality of inclined side panels. Each boot side panel has an upper edge. The boot has a lower panel, a boot interior surface and an interior that is receptive of at least part of the block lower portion. The boot inclined side panels engage the block inclined lower side walls. The boot lower panel engages the block lower surface. A plurality of anchor posts are attached to the interior surface of the boot. Some of the anchor posts are attached to the side wall panels to enable a connection to be formed between the boot inclined side panels and the block inclined lower side walls. Some of the anchor posts are attached to the lower panel of the boot to enable a connection to be formed between the boot lower panel and the block lower surface. As part of the method, the boot is first placed in a mould. Slurried concrete is then added to the mould so that a connection is formed between the boot anchor posts and the concrete when the concrete sets after a time period.

A composite structural building panel has a first concrete layer and a second concrete layer in spaced apart relationship with one another so as to receive an insulation layer spanning between the first concrete layer and the second concrete layer. A plurality of shear connectors are individually supported to extend through respective bores in the insulation layer between opposing first and second ends of the shear connector which are entirely embedded in the first and second concrete layers respectively. At least some of the shear connectors are oriented at an inclination to a normal axis of the insulating layer.

A method and system for manufacturing a tile product includes applying a concrete mixture to a mold, applying an adhesive to a first side of a tile, after the adhesive is applied, facing the first side of the tile toward the concrete mixture in the mold and positioning the first side of the tile on the concrete mixture in the mold and then followed by removing the product from the mold.

The present disclosure is directed to a construction element produced by additive manufacturing, an additive manufacturing system for producing the construction element and a method for manufacturing the construction element. The construction element includes an outer layer. The outer layer is configured to define or form an enclosure. The construction element further includes an inner matrix. The inner matrix is formed within the enclosure. The outer layer and the inner matrix are formed integrally, by depositing successive layers using an additive manufacturing system. The inner matrix is defined by a first layup and a second layup. The first layup is laid along a first direction and across the enclosure. The second layup is laid juxtaposing the first layup. The first layup and the second layup define a plurality of air pockets in the inner matrix. Further, a filler material is infused into at least some air pockets of the plurality of air pockets.

The present disclosure is directed to a construction element produced by additive manufacturing, an additive manufacturing system for producing the construction element and a method for manufacturing the construction element. The construction element includes an outer layer. The outer layer is configured to define or form an enclosure. The construction element further includes an inner matrix. The inner matrix is formed within the enclosure. The outer layer and the inner matrix are formed integrally, by depositing successive layers using an additive manufacturing system. The inner matrix is defined by a first layup and a second layup. The first layup is laid along a first direction and across the enclosure. The second layup is laid juxtaposing the first layup. The first layup and the second layup define a plurality of air pockets in the inner matrix. Further, a filler material is infused into at least some air pockets of the plurality of air pockets.

The present disclosure is directed to a construction element produced by additive manufacturing, an additive manufacturing system for producing the construction element and a method for manufacturing the construction element. The construction element includes an outer layer. The outer layer is configured to define or form an enclosure. The construction element further includes an inner matrix. The inner matrix is formed within the enclosure. The outer layer and the inner matrix are formed integrally, by depositing successive layers using an additive manufacturing system. The inner matrix is defined by a first layup and a second layup. The first layup is laid along a first direction and across the enclosure. The second layup is laid juxtaposing the first layup. The first layup and the second layup define a plurality of air pockets in the inner matrix. Further, a filler material is infused into at least some air pockets of the plurality of air pockets.