A method and apparatus for forming a part having a cavity with a complex contour is presented. The molding apparatus comprises a mold cavity and a molding insert. The mold cavity is formed by a first mold portion and a second mold portion. The molding insert is within the mold cavity, wherein the molding insert has a forming surface, and wherein the molding insert is configured to move in more than one direction relative to the first mold portion.

A mold for manufacturing interlocking, dry-cast concrete retaining wall blocks in an upright orientation comprises a mold box comprising two side walls joined to end walls to define a mold cavity, a top face, and a substantially open bottom face. Partitions configured to define a space between adjacent blocks or a space between a block and a side of the mold box extend parallel to the side walls of the mold box substantially from the top face into the mold cavity, to form first transverse portions of the profile of the top and bottom surfaces the blocks which do not include any undercut portion that would impede removal of the mold box in a substantially vertical direction. At least one removable insert comprises insert members which, when positioned in the mold box beneath the partitions, form remaining transverse portions of the profile of the top and bottom surfaces, the remaining transverse portions including at least one undercut portion. The insert members, when in position in the mold box for casting, are substantially in lateral alignment with respective bottom surfaces of at least some of the partitions and can be inserted and retracted through openings in an end wall of the mold box.

A block reinforcement cage made from reinforcing material and adapted for loading within a machine during a block manufacturing process for molding a concrete U-wall construction block structure. The block cage includes an open aperture formed in each of its stem reinforcing portions. During the block manufacturing process, the first and second support members of a support mechanism are inserted within the open apertures formed in the stem reinforcing sections of the block cage, and cooperate with the open apertures of the block cage so as to (i) support the block cage when being loaded into a block manufacturing machine, (ii) define central apertures molded in each stem portion of the concrete U-wall construction block structure, and (iii) lift the molded concrete U-wall construction block when being unloaded from the machine.

A block reinforcement cage made from reinforcing material and adapted for loading within a machine during a block manufacturing process for molding a concrete U-wall construction block structure. The block cage includes an open aperture formed in each of its stem reinforcing portions. During the block manufacturing process, the first and second support members of a support mechanism are inserted within the open apertures formed in the stem reinforcing sections of the block cage, and cooperate with the open apertures of the block cage so as to (i) support the block cage when being loaded into a block manufacturing machine, (ii) define central apertures molded in each stem portion of the concrete U-wall construction block structure, and (iii) lift the molded concrete U-wall construction block when being unloaded from the machine.

A permeable surface covering unit comprises a top surface and at least two pairs of irregularly shaped mating sides, one or more passageways extending downwardly from the top surface, and at least one under channel connected to the passageways for retaining liquid, such as storm water. The sides of the unit preferably define an irregular rotational tessellation element. The passageways may comprise gaps or side cavities between units and/or core cavities or other passageways within the unit. Optional undercuts may be provided in the core cavities. Pervious material plugs are cast into the cavities extending into the channel or undercut. Thereby the plug is locked into the cavity like a rivet and resists being dislodged by mechanical or hydraulic forces. A permeable surface embodiment comprises a combination of pervious and impervious units, wherein the ratio of permeable to impermeable units and resulting surface absorption rate may be adjusted.

A mold assembly and method for molding two concrete blocks in face-to-face non-contacting relationship forms blocks having smooth front faces. The mold assembly includes a mold box having two mold cavities configured to form two blocks in face-to-face non-contacting relationship. A common partition plate separates the two mold cavities and opposite sides of the partition plate form the smooth front faces of the blocks. The two mold cavities are each configured to form a block having a raised front face with a beveled edge around its entire perimeter and a border around the entire perimeter of the beveled edge. The portions of the border at the top and the sides of the raised front face are curved and the portion of the border at the bottom of the raised front face is straight. A core bar is slidably inserted into the mold box beneath the bottom of the partition plate, and opposite sides of the core bar extend into and form the front bottom portions of the mold cavities.

A molded concrete U-wall construction block including a molded concrete U-wall construction block structure formed from cured concrete poured about a block cage made from reinforcing material during a block manufacturing process. The block cage includes an open aperture formed in each of its stem reinforcing portions. During the block manufacturing process, the first and second support members of a support mechanism are inserted within the open apertures formed in the stem reinforcing sections of the block cage, and cooperate with the open apertures of the block cage so as to (i) support the block cage when being loaded into a block manufacturing machine, (ii) define central apertures molded in each stem portion of the concrete U-wall construction block structure, and (iii) lift the molded concrete U-wall construction block when being unloaded from the machine.

A mold for manufacturing interlocking, dry-cast concrete retaining wall blocks in an upright orientation comprises a mold box comprising two side walls joined to end walls to define a mold cavity, a top face, and a substantially open bottom face. Partitions configured to define a space between adjacent blocks or a space between a block and a side of the mold box extend parallel to the side walls of the mold box substantially from the top face into the mold cavity, to form first transverse portions of the profile of the top and bottom surfaces the blocks which do not include any undercut portion that would impede removal of the mold box in a substantially vertical direction. At least one removable insert comprises insert members which, when positioned in the mold box beneath the partitions, form remaining transverse portions of the profile of the top and bottom surfaces, the remaining transverse portions including at least one undercut portion. The insert members, when in position in the mold box for casting, are substantially in lateral alignment with respective bottom surfaces of at least some of the partitions and can be inserted and retracted through openings in an end wall of the mold box.

A method and apparatus for forming a part having a cavity with a complex contour is presented. The molding apparatus comprises a mold cavity and a molding insert. The mold cavity is formed by a first mold portion and a second mold portion. The molding insert is within the mold cavity, wherein the molding insert has a forming surface, and wherein the molding insert is configured to move in more than one direction relative to the first mold portion

A mold for manufacturing interlocking, dry-cast concrete retaining wall blocks in an upright orientation comprises a mold box comprising two side walls joined to end walls to define a mold cavity, a top face, and a substantially open bottom face. Partitions configured to define a space between adjacent blocks or a space between a block and a side of the mold box extend parallel to the side walls of the mold box substantially from the top face into the mold cavity, to form first transverse portions of the profile of the top and bottom surfaces the blocks which do not include any undercut portion that would impede removal of the mold box in a substantially vertical direction. At least one removable insert comprises insert members which, when positioned in the mold box beneath the partitions, form remaining transverse portions of the profile of the top and bottom surfaces, the remaining transverse portions including at least one undercut portion. The insert members, when in position in the mold box for casting, are substantially in lateral alignment with respective bottom surfaces of at least some of the partitions and can be inserted and retracted through openings in an end wall of the mold box.