A construction apparatus for forming modular construction components is disclosed. The construction apparatus comprises a first shell piece and a second shell piece that define an interior chamber defining a space for receiving a moldable material. The construction apparatus further comprises a separation device to move the first shell piece and the second shell piece from a closed configuration to an open configuration. The construction apparatus further comprises one or more cores within the interior chamber, one or more pins extending within the interior chamber, and one or more retaining plates for retaining the pins on the first shell piece. The interior chamber may be filled with the moldable material in the closed configuration and the moldable material may be cured. The construction apparatus may be shifted to the open configuration by the separation device and the pins and retaining plates may be used to extract the molded block from the first shell piece and/or second shell piece.

The invention provides novel aerated composite materials made from a carbonatable calcium silicate composition, and formulations and methods of manufacture and use thereof, in particular, the use of novel additive mineral compositions in the form of magnesium, magnesium salts or magnesium oxides, to improve physical chemical properties of low density concrete materials. The low density, aerated material is comprised of calcium carbonate (CaCO.sub.3) and silica (SiO.sub.2), as cured products of carbonatable calcium silicate compositions.

The present invention relates to a system for the production of thermal insulating, architectural and structural foam materials cast in molded volumes configured for a subsequent milling process, wherein molded foam volumes are cut into dimensional products or product components.

The invention provides novel aerated composite materials made from a carbonatable calcium silicate composition, and formulations and methods of manufacture and use thereof, in particular, the use of novel additive mineral compositions in the form of magnesium, magnesium salts or magnesium oxides, to improve physical chemical properties of low density concrete materials. The low density, aerated material is comprised of calcium carbonate (CaCO.sub.3) and silica (SiO.sub.2), as cured products of carbonatable calcium silicate compositions.

A method of forming a plurality of cured concrete bodies, each body possessing a cured compressive strength, the disclosed method includes: introducing a flowable mixture of constituent components of the concrete into a plurality of molds; molding the flowable mixture within the plurality of molds with the aid of one or more support, thereby forming a plurality of green bodies; partially curing the green bodies to a degree sufficient to provide a compressive strength that is lower than the cured compressive strength, thereby producing a plurality of pre-cured green bodies; assembling at least a portion of the plurality of pre-cured green bodies to form a collection thereof having a predetermined geometrical configuration; and curing the collection of pre-cured green bodies to a degree sufficient to achieve the cured compressive strength, thereby producing a collection of cured bodies having the predetermined geometrical configuration.

The present invention relates to a system for the production of thermal insulating, architectural and structural foam materials cast in molded volumes configured for a subsequent milling process, wherein molded foam volumes are cut into dimensional products or product components.

The present invention relates to a system for the production of thermal insulating, architectural and structural foam materials cast in molded volumes configured for a subsequent milling process, wherein molded foam volumes are cut into dimensional products or product components.

A construction apparatus for forming modular construction components is disclosed. The construction apparatus comprises a first shell piece and a second shell piece that define an interior chamber defining a space for receiving a moldable material. The construction apparatus further comprises a separation device to move the first shell piece and the second shell piece from a closed configuration to an open configuration. The construction apparatus further comprises one or more cores within the interior chamber, one or more pins extending within the interior chamber, and one or more retaining plates for retaining the pins on the first shell piece. The interior chamber may be filled with the moldable material in the closed configuration and the moldable material may be cured. The construction apparatus may be shifted to the open configuration by the separation device and the pins and retaining plates may be used to extract the molded block from the first shell piece and/or second shell piece.

The present invention relates to a system for the production of thermal insulating, architectural and structural foam materials cast in molded volumes configured for a subsequent milling process, wherein molded foam volumes are cut into dimensional products or product components.