My son and I have come up with the idea of using a 20 ton vertical press to make our blocks. We have just been playing around with it and have produced a cylinder style PC that can be ejected immediately after pressing, using only water, paper and cement the cylinder could be handled immediately and was dry and ready to use in three days. I believe if we had used the method listed below it would work even better. Our real blocks will be 12wx16l and 8 high and I am hoping they will be ready to use in 12 hours like stated below. This is the process the Masongreenstar uses and it makes a lot of sense.
"The present invention can provide a method for fabricating insulating building material comprising the steps of :
- Combining water, sodium silicate. and shredded paper in a mixer for a period of time sufficient to allow thorough wetting of the shredded paper with the water and sodium silicate mixture. Which is typically no less than twenty minutes:
- Introducing cement and a water-reducing superplasticizer into the mixer and accelerating the mixing;
- Introducing additional water together with an air entraining resin or surfactant and a viscosity modifier: and,
- Pouring the mixture into one or more drying molds.
This method can further provide for the steps of allowing initial water runoff from the filled curing molds;
- Striking off excess material in the filled curing molds;
- Permitting initial hardening to occur; and, removing the curing insulating building material from the molds.
These steps should take no longer than seventy-five minutes and produce a curing molded building block capable of being palletized in twelve hours from the start of the process.
This method also can provide for the recovery of water runoff for the incremental reuse in mixing of the insulating building material to provide an ecologically sound fabrication method.
The curing of the molded blocks formed from this insulating building material can be accomplished in a wet-heated curing chamber to accelerate the drying process. Thereby speeding up the curing and palletizing step previously described.
The shredded paper recycled is a short fiber paper derived from a group consisting of newsprint, phone books, waste office paper and lottery tickets. This ecologically sensitive method of creating new building materials permits further use of trees without further deforestation. While still providing well insulated buildings; thereby saving on the use of fossil fuels for heating and cooling."
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