WO2024248848A1

WO2024248848A1 - Environmentally responsible insulating construction blocks and structures

Info

Publication number: WO2024248848A1
Application number: PCT/US2023/067650
Authority: WO
Inventors: Richard P. Spreen
Original assignee: Shredded Tire Inc
Current assignee: Shredded Tire Inc
Priority date: 2023-05-31
Filing date: 2023-05-31
Publication date: 2024-12-05
Anticipated expiration: 2025-11-30

Abstract

Environmentally responsible insulating construction blocks and structures constructed from recycled materials from solid waste municipal landfills are disclosed. The environmentally friendly construction blocks and structures are made from pieces of solid waste materials coated with silica fume, slag cement and Portland cement, which are then mixed with water and dried in a mold. A layer of grout or a fireproof material may be disposed on one side of the environmentally responsible insulating construction block. The environmentally responsible insulating construction blocks provide high insulation as well as strength for applications such as green roofing, green decking and structure construction. Environmentally friendly structures can be built by pouring the wet mix of solid waste material pieces into molds to form walls, and then to pour a layer of the wet mix of solid waste material pieces as a roof deck, thereby creating a self-supporting structure in a monolithic pour.

Description

ENVIRONMENTALLY RESPONSIBLE INSULATING CONSTRUCTION BLOCKS AND STRUCTURES

[0001] FIELD OF THE INVENTION.

[0002] The invention relates to environmentally responsible insulating construction blocks and structures constructed from solid waste landfill materials (SWM) disposed in municipal solid waste landfills or industrial and construction and demolition landfills. The SWM are shredded, chopped, crushed or otherwise sized and subsequently coated with silica fume, slag cement and Portland cement, and thereafter are mixed with water and formed in a mold where they are air dried to form a construction block. The environmentally responsible insulating construction blocks provide high insulation as well as strength for applications such as green roofing, green decking and green structure construction. Environmentally friendly structures can be built by pouring the coated SWM pieces into molds to form walls, and then to pour a layer of the coated SWM pieces as a roof deck, therefore forming an entire structure in one single monolithic pour.

[0003] BACKGROUND.

[0004] In many developed countries the construction and use of buildings is a leading consumer of energy and producer of greenhouse gas emissions. Sustainable architecture seeks to minimize the negative environmental impact of buildings by efficiency and moderation in the use of materials, energy, and development space. Sustainable architecture uses a conscious approach to energy and ecological conservation in the design of the built environment.

[0005] Green building (also known as green construction or sustainable building) refers to both a structure and the using of processes that are environmentally responsible and resource-efficient throughout a building’s life-cycle, from siting to design, construction, operation, maintenance, renovation, and demolition. Green building rating systems such as BREEAM (United Kingdom), LEED® (United States and Canada), DGNB (Germany), CASBEE (Japan), and VERDEGBCe (Spain) help consumers determine a structure’s level of environmental performance. These systems award credits for building features that support green design in categories such as location and maintenance of building site, conservation of water, energy, and building materials, and occupant comfort and health. The number of credits generally determines the level of achievement. Additionally, green building codes and standards, such as the International Code Council’s draft International Green Construction Code, are rules created by standards development organizations that establish minimum requirements for elements of green building such as materials or heating and cooling.

[0006] Leadership in Energy and Environmental Design (LEED®) is a set of rating systems for the design, construction, operation, and maintenance of green buildings in the United States and Canada which was developed by the U.S. Green Building Council (USGBC). LEED® certification of a building is recognized across the globe as the premier mark of achievement in green building. LEED®-certified buildings cost less to operate, reducing energy and water bills by as much as 40%. Businesses and organizations across the globe use LEED® to increase the efficiency of their buildings, freeing up valuable resources that can be used to create new jobs, attract and retain top talent, expand operations and invest in emerging technologies.

[0007] The intent of LEED® is to provide a standard certification process that registers buildings constructed with environmental performance, efficiency, and occupant health and well-being as primary goals. Buildings receive points towards varying levels of certification based on the set of categories established by the USGBC. For example, points are awarded with respect to the following features:

• Site development that protects or restores habitat or that maximizes open space;

• Storm water design to minimize impervious surfaces;

• Heat island effect that uses alternative surfaces and nonstructural techniques to reduce imperviousness and promote infiltration, reducing pollutant loadings and use of vegetated roofs;

• Water efficiency by use of green roofing system without permanent irrigation or that minimizes potable consumption;

• Energy and optimization by establishing the minimum level of energy efficiency for the building and systems; and

• Materials and resources that reuse building materials and products to reduce demand for virgin materials and reduce waste, use of recycled components and use of regional material that has been manufactured and assembled within 500 miles of the building.

[0008] Green roofing systems installed on 50% of more of a roof surface virtually guarantees 2 point toward LEED® certification, and can contribute an additional 7+ points. This is almost 20% of the total number of points needed for a building to be LEED®-certified.

[0009] Low slope roofing systems have been developed for use with buildings. Low slope roofing systems commonly include a structural deck made of metal or concrete that is covered with a layer of insulation, and the insulation is then covered with a waterproof membrane. A commercial low slope roof system may use single-ply membranes of pre- fabricated sheets rolled onto the roof and attached with mechanical fasteners, adhered with chemical adhesives, or held in place with ballast such as gravel, stones, or pavers; built-up roofs consisting of a base sheet, fabric reinforcement layers, and a dark protective surface layer; modified bitumen sheet membranes having one or more layers of plastic or rubber material with reinforcing fabrics, and surfaced with mineral granules or a smooth finish; and spray polyurethane foam roofs constructed by mixing two liquid chemicals together that react and expand to form one solid piece that adheres to the roof then having a protective coating such as metal or tile placed over the polyurethane.

[0010] Low slope roofing insulation became more prevalent during the 1960’s and forward as increasingly more buildings became air conditioned and as the cost of energy, both for heating and cooling rose dramatically. Currently insulation levels may exceed R30 as specified by code or because of the building’s use and geographic location.

[0011] Insulated panels are known to be used on wall and roof building applications to form part or all of the building envelope. An insulation panel typically has opposing inside and outside surfaces with an insulating foam core adhered between the surfaces. The panel can then be mounted onto support structures to form the wall or roof application in a building.

[0012] In the luxury real estate market, buyers in high rise structures seek living spaces on the roof of the structure for providing such amenities as gardens and pools. A green roof, or living roof, is a roof of a building that is partially or completely covered with vegetation and a growing medium, planted over a waterproofing membrane. It may also include additional layers such as a root barrier and drainage and irrigation systems. [0013] One disadvantage of green roofs is the additional mass of soil and retained water that can place a large strain on the structural support of a building. Some types of green roofs also have more demanding structural standards such as in seismic and hurricane- prone regions of the world. Some existing buildings cannot be retrofitted with certain kinds of green roofing because of the weight load of the substrate and vegetation exceeds permitted static loading. For example, the weight of a green roof caused the collapse of a large sports hall roof in Hong Kong in 2016.

[0014] One known way to provide rooftop green spaces for high rises is through the use of Inverted Roof Membrane Assemblies (IRMA), also called a Protected Membrane Roof system (PMR) or a Built-up-Roof (BUR) system. In IMRAs, typically a waterproofing membrane is adhered to the roof structure of the building, then a protective moisture resistant insulation layer is laid to protect the membrane from atmospheric degradation such as sun, wind and rain, and also foot traffic. A layer of mesh may be laid to filter for debris, and the insulation layer is held down with a form of ballast such as gravel wooden decking or paving stones. A camber, or slope, of the roof is created during construction to carry water to a roof drain. An example of a IRMA is shown in Figure 1 .

[0015] A wide variety of materials are currently disposed in municipal solid waste landfills and industrial and construction and demolition (C&D) landfills. Such materials include but are not limited to concrete; wood; asphalt; gypsum; metal; brick; glass; plastics; and rubber tires.

[0016] According to the University of Michigan Center for Sustainable Systems, SWM generation in the US has increased on an annual basis by 93% between 1980 and 2018 to 292 million tons per year, <https://css.umich.edu/publications/factsheets/material- resources/municipal-solid-waste-factsheet>. Per capita SWM generation increased from 3.7 to 4.9 pounds per person per day in the US. Comparatively, in Sweden, SWM generation rates are 2.7; in Germany, 3.8; in the UK, 2.8. Statistically an American weighing 180 SWM generates his/her own weight in SWM every 37 days. In 2018, 50% of generated MSW was disposed of in landfills, which are the third largest source of US anthropogenic CH4 emissions as of 2020 and accounted for 109.3 million metric tons CO2-equivalent emissions, about 1 .8% of total GHG emissions.

[0017] According to the US Environmental Protection Agency, (EPA), an estimated 600 million tons of C&D debris were generated in the US in 2018, more than twice the amount of MSW. <https://www.epa.gov/facts-and-figures-about-materials-waste-and- recycling/construction-and-demolition-debris-material>. Of this, approximately was sent to landfills. Some C&D material is intended for a “next-use” market, which depending on the material may include fuel, manufactured products, aggregate, compost and mulch or soil amendment. For example, some C&D material may be processed by grinding, crushing or extracting and melting for incorporation in the manufacture of new products. Other C&D such as asphalt may be processed for use in the production of asphalt mixtures.

[0018] Tire recycling or rubber recycling is the process of recycling vehicles’ tires that are no longer suitable for use on vehicles due to wear or irreparable damage. These tires are a large and difficult source of waste due to the large volume produced, and the fact they contain a number of components that are ecologically problematic. In the United States alone the Environmental Protection Agency (EPA) estimates that roughly 300 million scrap tires are generated annually. Over 60 million of these tires end up in landfills, ocean, lakes, greatly harming our environment. Local recycling facilities are having a very difficult time dealing with this problem because of the enormous quantities of tires being generated each year and with only so many limited re-use options available to them.

[0019] The same characteristics that make waste tires problematic - cheap availability, bulk, and resilience - also make them attractive targets for recycling. Tires are known to be recycled for use on basketball courts, in hot melt asphalt, for increasing burning value of TDF in incineration plants and new shoe products.

[0020] SUMMARY OF THE INVENTION.

[0021] The invention relates to an environmentally responsible insulating construction block for green roofing and decking applications as well as environmentally responsible green structure construction. The environmentally responsible construction blocks provide high insulation as well as strength. Additionally, environmentally responsible green structures can be built in one single monolithic pour.

[0022] In one embodiment, environmentally responsible insulating construction blocks are used for green roofing applications. An insulating layer is adhered to a roof substrate of a building and a plurality of environmentally responsible insulating construction blocks are adhered to the top layer of the insulating layer. A waterproof membrane is adhered to the top surface of the plurality of environmentally responsible insulating construction blocks to provide a green roofing application.

[0023] In one embodiment, the tops of the environmentally responsible insulating construction blocks that form the green roofing application are tapered to create a “slope to drain” roofing system. In this embodiment, the slope of the tops of the environmentally responsible insulating construction blocks can direct liquids to a roof drain. [0024] In one embodiment of the invention, environmentally responsible insulating construction blocks are provided for use for green decking applications. In this embodiment, environmentally responsible insulating construction blocks are adhered to a surface to provide a green deck to which growing media or tiles may be adhered. The environmentally responsible insulating construction blocks for green decking application comprise a porous matrix through which water can flow freely.

[0025] In one embodiment, environmentally responsible insulating construction blocks can be adhered to the top layer of a waterproof membrane of a roofing system for use as a green decking application. In one embodiment, a layer of environmentally responsible insulating construction blocks can be adhered to the top layer of a waterproof membrane, which has been adhered to a layer of environmentally responsible insulating construction blocks in a green roofing application, for use as a green decking application.

[0026] In one embodiment, where the tops of the environmentally responsible insulating construction blocks that form the green roofing application are tapered to create a “slope to drain” roofing system, the bottom surfaces of the environmentally responsible insulated construction blocks that form the green decking application are tapered to correspond to the tapering of the tops of the environmentally responsible insulated construction blocks for green roofing application. In this embodiment, the slope of the tops and bottoms of the environmentally responsible insulating construction blocks can direct liquids to a roof drain. The permeability of the environmentally responsible insulating construction blocks for green decking application allows for water to pass through and be directed to the roof drain. [0027] In one embodiment, environmentally responsible insulating construction blocks can be provided in a side by side and stacked relation to substantially similar environmentally responsible insulating construction blocks for construction of a green structure.

[0028] The environmentally responsible insulating construction blocks comprise SWM that has been shredded, chopped, crushed, minced or otherwise sized (SWM pieces), which SWM pieces are then mixed with silica fume, slag cement and Portland cement until the SWM pieces are coated. Water is then added to the coated mix of SWM pieces and the wetted mix of SWM pieces is placed in a mold whereupon it dries into an environmentally responsible insulating construction block. The dried environmentally responsible insulating construction block comprises an open matrix.

[0029] In one embodiment, a mix of wetted SWM pieces prepared as previously described can be poured into molds to form walls and a roof for a structure.

[0030] BRIEF DESCRIPTION OF THE DRAWINGS.

[0031] The invention will now be described, by way of example, with reference to the accompanying drawings, in which like numerals refer to like elements.

[0032] FIG. 1 depicts the construction of a typical IRMA.

[0033] FIG. 2 depicts an environmentally responsible insulating construction block according to one embodiment of the invention.

[0034] FIGS. 3A-3E depict various embodiments of an environmentally responsible insulating construction block for green roofing application topped with an environmentally responsible insulating construction block for green decking application. [0035] FIGS. 4A-4K depict the steps of manufacturing an environmentally responsible insulating construction block according to one embodiment of the invention.

[0036] FIGS. 5A-5H depict the steps undertaken in the construction of a structure made entirely of an environmentally responsible insulating mix of SWM pieces coated with silica fume, slag cement and Portland cement, and mixed with water prior to pouring the structure.

[0037] FIG. 6 depicts a roofing system comprising an environmentally responsible insulating construction block according to one embodiment of the invention.

[0038] FIGS. 7A-7G depict the steps of manufacturing an environmentally responsible insulating construction block according to one embodiment of the invention.

[0039] DETAILED DESCRIPTION OF THE INVENTION.

[0040] The invention relates to environmentally responsible insulating construction blocks for green roofing and green decking applications. The environmentally responsible insulating construction blocks provide high insulation as well as strength. Additionally, environmentally responsible structures can be built in one single monolithic pour or manufactured using environmentally responsible insulating construction blocks, or combinations of both.

[0041 ] In one embodiment, environmentally responsible insulating construction blocks are used for green roofing applications. An insulating layer is adhered to a roof substrate of a building and a plurality of environmentally responsible insulating construction blocks are adhered to the top layer of the insulating layer. A waterproof membrane is adhered to the top surface of the plurality of environmentally responsible insulating construction blocks to provide a green roofing application. [0042] In one embodiment, the environmentally responsible insulating construction blocks for green roofing application comprise a layer of grout. In one embodiment, the top surface of the environmentally responsible insulating construction block comprises the grout layer.

[0043] In one embodiment for green roofing applications, the environmentally responsible insulating construction blocks can further comprise insulation foam disposed in the interior open matrix of the blocks.

[0044] In one embodiment, the tops of the environmentally responsible insulating construction blocks for green roofing application are tapered to create a “slope to drain” roofing system.

[0045] In one embodiment of the invention, environmentally responsible insulating construction blocks are provided for use for green decking applications. In this embodiment, environmentally responsible insulating construction blocks are adhered to a surface to provide a green deck to which growing media or tiles may be adhered. The environmentally responsible insulating construction blocks for green decking application comprise a porous matrix through which water can flow freely.

[0046] In one embodiment, the environmentally responsible insulated construction blocks for green decking application comprise a layer of permeable fireproof material. In one embodiment, the top surface of the environmentally responsible insulating construction block comprises a permeable fireproof material. In one embodiment, the permeable fireproof material comprises expanded slate.

[0047] In one embodiment, environmentally responsible insulating construction blocks can be adhered to the top layer of a waterproof membrane of a roofing system for use as a green decking application. In one embodiment, a layer of environmentally responsible insulating construction blocks can be adhered to the top layer of a waterproof membrane, which has been adhered to a layer of environmentally responsible insulating construction blocks in a green roofing application, for use as a green decking application.

[0048] In one embodiment, where the tops of the environmentally responsible insulating construction blocks that form the green roofing application are tapered to create a “slope to drain” roofing system, the bottom surfaces of environmentally responsible insulated construction blocks for green decking application are tapered to correspond to the tapering of the tops of the environmentally responsible insulated construction blocks for green roofing application. In this embodiment, the slope of the tops and bottoms of the environmentally responsible insulating construction blocks can direct liquids to a roof drain. The permeability of the environmentally responsible insulating construction blocks for green decking application allows for water to pass through and be directed to the roof drain.

[0049] In one embodiment, environmentally responsible insulating construction blocks for green roofing and green decking application are provided in a side by side relation to substantially similar environmentally responsible insulating construction blocks.

[0050] In one embodiment, environmentally responsible insulating construction blocks are provided in a side by side and stacked relation to substantially similar environmentally responsible insulating construction blocks for construction of a green structure. In one embodiment, the environmentally responsible insulating construction blocks are fastened together using hydrofluorolefin (HFO) foam. In other embodiments, the environmentally responsible insulating construction blocks are fastened together using any type of adhesive desired by the user now known or later developed.

[0051] Environmentally responsible insulated construction blocks according to the invention comprise SWM that has been shredded, chopped, crushed, minced or otherwise sized (SWM pieces), which SWM pieces are then mixed with silica fume, slag cement and Portland cement until the SWM pieces are coated. Water is then added to the coated mix of SWM pieces. The wetted mix of SWM pieces is placed in a mold whereupon it dries into an environmentally responsible insulating construction block. The block comprises a bottom surface, a top surface, and four side surfaces substantially perpendicular to the top surface and the bottom surface, wherein the environmentally responsible insulating construction blocks have a thickness defined by the distance between the top surface and the bottom surface.

[0052] In one embodiment, water soluble SWM is soaked in water prior to mixing with the silica fume, slag cement and Portland cement. In one embodiment, the water soluble SWM pieces are soaked in water for 1 -24 hours. In one embodiment, the water soluble SWM pieces are soaked in water for up to 24 hours. In one embodiment, the water soluble SWM pieces are soaked in substantially room temperature water. Excess water is substantially drained from the water soluble SWM pieces prior to mixing them with silica fume, slag cement and Portland cement.

[0053] In one embodiment, the SWM pieces are sized on average to approximately 2 inches. In one embodiment, the SWM pieces on average have a size greater than approximately ¹/2 inch but smaller than approximately 2 inches. In one embodiment, the SWM pieces on average have a size greater than approximately 1 inch but smaller than approximately 2 inches. In one embodiment, the SWM is shredded to an average size of approximately ¹Z> inch.

[0054] In one embodiment, SWM is shredded to form SWM pieces. In one embodiment, SWM is chopped to form SWM pieces. In one embodiment, SWM is crushed to form SWM pieces. In one embodiment SWM is minced to form SWM pieces. In one embodiment, SWM can be shredded, crushed, minced, chopped or combinations thereof to form SWM pieces. Any method now known or later developed may be used to size SWM into SWM pieces.

[0055] In one embodiment, SWM comprises concrete; wood (including but not limited to painted, treated and coated wood and wood products such as laminated wood, plywood, particle board and fiber board); asphalt; gypsum; metal; brick; glass; plastics; rubber tires; roofing shingles; fiberglass; cloth; and combinations thereof. In one embodiment, SWM is obtained from municipal solid waste landfills. In one embodiment, SWM is obtained from C&D landfills. In one embodiment, SWM is obtained in part from municipal solid waste landfills. In one embodiment, SWM is obtained in part from C&D landfills. In one embodiment, SWM is obtained in part from municipal solid waste landfills and in part from C&D landfills. In one embodiment, SWM pieces comprise shredded tires. In one embodiment, the steel from the tires is removed but nylon (fluff) remains in the shredded rubber tire pieces.

[0056] In one embodiment of the invention, the environmentally responsible insulating construction blocks have a thickness (measured from the bottom surface to the top surface) ranging from around 2 inches to around 20 inches, with length and width (measured along the side surfaces) of around 12 inches square. Other dimensions of the environmentally responsible insulating construction blocks may be constructed in accordance with the principles of the invention and these preceding dimensions are listed as examples only and are not intended in any way to limit the invention.

[0057] In one embodiment, the mix of wetted SWM pieces is poured into molds in a monolithic pour to form walls and a roof for a structure. In one embodiment, the mix of wetted SWM pieces is poured directly onto a scarified concrete slab. In one embodiment, the mix of wetted SWM pieces is poured on top of a layer of grout that has been placed on top of a scarified concrete slab. Rods are inserted through the length of the molds so that a top can be placed on the poured mix of wetted SWM pieces for compression while it dries. The top may be a plywood sheet.

[0058] In one embodiment, a layer of mix of wetted SWM pieces is poured on a plywood layer to form a roof covering. A plurality of rods extends upward from the plywood layer to allow for a top to be placed over the poured mixed wetted SWM pieces to compress it while it dries.

[0059] Turning to the figures, FIG. 1 depicts a typical IRMA 100. A sloped insulating roofing layer 1 10 is adhered to a roofing substrate 120. A waterproof membrane 130 is adhered to the top of the roofing layer 1 10. Insulation 150 is placed on top of drainage space 140. A drainage and vent layer 160 is formed on top of the insulation 150, which may include a root barrier 165. Filter fabric 170 can be placed on insulation 160. A deck can then be formed using gravel 180 and concrete pavers 190. The deck may also include a planting medium 195.

[0060] FIG. 2 depicts an environmentally responsible insulating construction block for green decking application 200 comprising a bottom surface 201 ; a top surface 202 having a permeable layer of a fireproof material 215; and four side walls 203. SWM pieces 205 have been coated with silica fume, slag cement and Portland cement and then mixed with water and dried to form an open matrix in the interior of environmentally responsible insulating construction block for green decking application 200. In one embodiment, the permeable layer of fireproof material 215 comprises expanded slate which has been coated with silica fume, slag cement and Portland cement and then mixed with water, then placed in a mold whereupon the wetted mix of SWM pieces is placed in the mold and dried to form the environmentally responsible insulating construction block for green decking application 200.

[0061] FIGS. 3A-3E depict various embodiments of an environmentally responsible insulating construction block for green roofing application coupled with an environmentally responsible insulating construction block for green decking application.

[0062] FIG. 3A depicts a side view of an environmentally responsible insulating construction block for green roofing application topped with an environmentally responsible insulating construction block for green decking application. A plurality of environmentally responsible insulating construction blocks is adhered by a layer of adhesive 312 to a layer of insulation 325 on top of a roofing substrate 320 to form a green roof 310. A waterproof membrane 330 is adhered to the top of the green roof 310. In this embodiment, a plurality of environmentally responsible insulating construction blocks that have been topped with a permeable fireproof material 345, such as coated expanded slate, are placed on top of a layer of grout 355 to adhere to the waterproof membrane 330 to form a green deck 350. Green deck 350 may comprise growing media 380 and/or pavers or tiles 390. Green roof 310 may comprise growing media 380 and/or pavers or tiles 390. Green deck 350 may include planting media 395 and/or artificial turf (not shown). The top surface of green roof 310 may be sloped to drain water that passes through green deck 350 toward a drain 335.

[0063] FIG. 3B depicts a cross-sectional view of one embodiment of an environmentally responsible insulating construction block for green roofing application topped with an environmentally responsible insulating construction block for green decking application comprising turf. In this embodiment, environmentally responsible insulating construction blocks are adhered by a layer of grout 312 to a waterproof membrane 325 on top of a roofing substrate 320 to form a green roof 310. A waterproof membrane 330 is adhered to the top of the green roof 310. In this embodiment, a plurality of environmentally responsible insulating construction blocks that have been topped with a permeable fireproof material 345, such as coated expanded slate, are placed on top of a layer of grout 355 to adhere to the waterproof membrane 330 for use as a green deck 350. Green deck 350 may comprise growing media 380 and/or pavers or tiles 390. Green roof 310 may also comprise growing media 380 and/or pavers or tiles 390. Green deck may include artificial turf (not shown) that can be bonded to the top of the layer of fireproof permeable material 345.

[0064] FIG. 3C depicts a cross-sectional view of one embodiment of an environmentally responsible insulating construction block for green roofing application topped with an environmentally responsible insulating construction block for green decking application comprising turf. Environmentally responsible insulating construction blocks are adhered to a layer of a waterproof membrane 325 on top of a roofing substrate 320 for use as a green roof 310. In this embodiment, an insulation board 327 is adhered to a waterproof membrane 325 by use of adhesive 328. A waterproof membrane 330 is adhered to the top of green roof 310. A plurality of environmentally responsible insulating construction blocks that have been topped with a permeable fireproof material 345, such as coated expanded slate, are placed on top of a layer of grout 355 to adhere to the waterproof membrane 330 to form a green deck 350. Green deck 350 may comprise planting media 395 and/or artificial turf (not shown) that can be bonded to the top of the layer of fireproof permeable material 345.

[0065] FIG. 3D depicts a cross-sectional view of one embodiment of an environmentally responsible insulating construction block for green roofing application topped with an environmentally responsible insulating construction block for green decking application comprising pavers or tile. Environmentally responsible insulating construction blocks are adhered on top of a roofing substrate 320 with a layer of grout 312 to form a green roof 310. A waterproof membrane 330 is adhered to the top of the green roof 310. A plurality of environmentally responsible insulating construction blocks that have been topped with a permeable fireproof material 345, such as expanded slate, are placed on top of a layer of grout 355 to adhere to the waterproof membrane 330 to form a green deck 350. Green deck 350 may comprise pavers or tiles 390 bonded to the top of the layer of fireproof permeable material 345 with adhesive 392.

[0066] FIG. 3E depicts a cross-sectional view of one embodiment of an environmentally responsible insulating construction block for green roofing application topped with an environmentally responsible insulating construction block for green decking application comprising pavers or tile. In this embodiment, environmentally responsible insulating construction blocks are adhered to an insulation board 327 and then adhered on top of a roofing substrate 320 using adhesive 328 to form a green roof 310. A waterproof membrane 330 is adhered to the top of green roof 310. A plurality of environmentally responsible insulating construction blocks that have been topped with a permeable fireproof material 345, such as coated expanded slate, are placed on top of a layer of grout 355 to adhere to the waterproof membrane 330 to form a green deck 350. Green deck 350 may comprise pavers or tiles 390 bonded to the top of the layer of fireproof permeable material 345 with adhesive 392.

[0067] FIGS. 4A-4J depict the steps of manufacturing environmentally responsible insulating construction blocks according to one embodiment of the invention.

[0068] In FIG. 4A, a first mix is made from silica fume, slag cement and Portland cement. [0069] In FIG. 4B, SWM pieces are added to the first mix prepared in FIG. 4A and mixed until coated.

[0070] In FIG. 4G, water is added to the mix of coated SWM pieces until the mix is substantially fully wetted to form a second mix.

[0071 ] In FIG. 4D, a third mix is made from silica fume, slag cement and Portland cement. [0072] In FIG. 4E, pieces of a fireproof material such as expanded slate are added to the third mix and mixed until coated.

[0073] In FIG. 4F, water is added to the third mix of coated fireproof material until the third mix is fully wetted to form a fourth mix.

[0074] In FIG. 4G, molds are prepared and a layer of the fourth mix is added to the bottom of each mold.

[0075] In FIG. 4H, the second mix is added into each mold on top of the fourth mix.

[0076] In FIG. 4I, each mold is fitted with a lid and left to sit in ambient air until dry. [0077] In FIG. 4J, the dried environmentally responsible insulating construction blocks are removed from the molds and are ready for use.

[0078] FIG. 4K depicts an alternative mold form, showing a sloped surface to allow for moisture to drain.

[0079] The order of mixing of ingredients may be altered as desired by the operator. For example, the SWM pieces or fireproof material, such as expanded slate, may be placed in the mixer, then the mixture of silica fume, slag cement and Portland cement may be added prior to coating the SWM pieces or the fireproof material.

[0080] In one embodiment, Steps 4D-4H are omitted and the second mix prepared by Steps 4A-4C is placed in the mold without a layer of fireproof material and dried.

[0081] FIGS. 5A-5H depict the steps undertaken in the construction of a structure made entirely of an environmentally responsible insulating mixture of SWM pieces coated with silica fume, slag cement and Portland cement, and mixed with water prior to monolithic pouring of the structure.

[0082] FIG. 5A depicts bags 505 filled with SWM pieces 205 having on average a nominal size of approximately ¹/2 inch but smaller than approximately 2 inches and containers 510 filled with a mix of silica fume, slag cement and Portland cement.

[0083] FIG. 5B depicts bags 505 filled with sized SWM pieces 205 being added to a mixer 515, wherein they are mixed and thereafter the remaining dry ingredients (silica fume, slag cement and Portland cement) are added and mixed to coat the SWM pieces 205.

[0084] In FIG. 5C, water 520 is added to the coated SWM pieces in mixer 515 and mixed. [0085] In FIG. 5D, wall molds 525 are built for the walls 527 of the structure upon a foundation, with a layer of grout 530 placed on the foundation 535 at the bottom of each mold. A roof structure 529 is built atop the wall molds 525. Metal rods are placed inside each mold and on the roof structure.

[0086] In FIG. 5E, the wetted mix of SWM pieces 540 is poured into the wall molds 525.

[0087] In FIG. 5F, the wetted mix of SWM pieces 540 is poured atop the roof structure 529.

[0088] In FIG. 5G, a plywood cover 545 is placed on top of the wetted mix of SWM pieces 540 that has been poured atop the roof structure 529 and is attached to metal rods 550, wherein the cover 545 is tightened to compress the wetted mix of SWM pieces 540 during drying.

[0089] In FIG. 5H, once the wetted mix of SWM pieces 540 is dried, the cover 545 and molds 525 are removed and a structure comprising an environmentally responsible insulating mixture of SWM pieces coated with silica fume, slag cement and Portland cement is formed.

[0090] FIG. 6 depicts one embodiment of a green roof 600 comprising environmentally responsible insulated construction blocks 610. Green roof 600 comprises a low slope roof structure 620 that includes a metal or concrete deck 630 and a plurality of environmentally responsible insulated construction blocks 610.

[0091] Environmentally responsible insulated construction blocks 610 are attached to the metal or concrete deck 630 using high strength self-setting grout 640, and a waterproof membrane 650 is disposed on an adhesive or glue layer 625 that is disposed on the top surfaces 615 of the environmentally responsible insulated construction blocks 610. [0092] In one embodiment, waterproof membrane 650 comprises any membrane known today or later developed for roofing or other construction purposes. Waterproof membrane 650 may vary according to the use and the climate of the construction.

[0093] FIGS. 7A-7G depict the steps of manufacturing environmentally responsible insulating construction blocks according to one embodiment of the invention.

[0094] In FIG. 7A, a first mix is made from silica fume, slag cement and Portland cement. [0095] In FIG. 7B, SWM pieces 205 having on average a nominal size of approximately ¹/2 inch but smaller than approximately 2 inches are added to the first mix and mixed until coated.

[0096] In FIG. 7C, water is added until the SWM pieces coated with the first mix are substantially fully wetted to form a second mix.

[0097] In FIG. 7D, molds are prepared and a layer of grout is added to the bottom of each mold.

[0098] In FIG. 7E, the second mix is added into each mold until full.

[0101] In FIG. 7F, each mold is fitted with a lid and left to sit in ambient air until dry.

[0102] In FIG. 7G, the dried environmentally responsible insulating construction blocks are removed from the molds and are ready for use.

[0103] In one embodiment, the wet mix of SWM pieces is placed in the mold without a layer of grout and dried.

[0104] EXAMPLES.

[0105] The following examples illustrate the manufacture and characteristics of environmentally responsible insulated construction blocks in further detail. These examples are exemplary only and in no way limit or are intended to limit the scope of this invention.

[0106] EXAMPLE 1.

[0107] Manufacture of an Environmentally Responsible Insulated Construction Block Comprising Wood SWM Pieces.

[0108] Approximately 1 gallon of silica fume weighing 6.4 lbs., approximately 1 gallon of slag cement weighing 9.2 lbs. and approximately 1 .5 gallons of Portland cement weighing 15.3 lbs. were mixed together for at least 2 minutes. Wood recovered from solid waste municipal landfills was randomly sized to a size range of approximately 1 inch to 2 inches. The sized wood pieces were mixed and then randomly poured into three separate 5- gallon containers, which were then added to the mix of silica fume, slag cement and Portland cement. The resulting mixture was mixed for another five (5) minutes. Thereafter, 2 gallons of water were added to wet the coated wood pieces.

[0109] A layer of the wetted wood pieces mix was poured into molds sized 12 inches by 12 inches by 4 inches deep. The molds were filled and a lid closed over the mold and left to dry for 5 days at room temperature in the ambient environment. Once the mixture was dry in each mold, the resulting environmentally responsible insulated construction blocks were removed and were ready for use in green decking, green roofing or green structure construction applications.

[01 10] EXAMPLE 2.

[01 11] Environmentally responsible insulated construction blocks for green decking application can be prepared as in Example 1 except that the bottom of the mold is sloped such that the dried environmentally responsible insulated construction blocks have a sloped top surface upon drying.

[01 12] EXAMPLE 3.

[01 13] Manufacture of an Environmentally Responsible Insulated Construction Block Comprising Wood SWM Pieces.

[01 14] Approximately 1 gallon of silica fume weighing 6.4 lbs., approximately 1 gallon of slag cement weighing 9.2 lbs. and approximately 1 .5 gallons of Portland cement weighing 15.3 lbs. were mixed together for at least 2 minutes. Wood recovered from solid waste municipal landfills was randomly sized to a size range of approximately ¹/2” to 2 inches. The sized wood pieces were soaked in water and the water was substantially drained. The wetted wood pieces thereafter were mixed and randomly poured into three separate 5-gallon containers. The wetted wood pieces were then added to the mix of silica fume, slag cement and Portland cement. The resulting mixture was mixed for another five (5) minutes. Thereafter, 2 gallons of water were added to the coated wetted wood pieces.

[01 15] A layer of the wetted mix of coated wetted wood pieces was poured into molds sized 12 inches by 12 inches by 4 inches deep. The molds were filled and a lid closed over the mold and left to dry for 5 days at room temperature in the ambient environment. Once the mixture was dry in each mold, the resulting environmentally responsible insulated construction blocks were removed and were ready for use in green decking or green roofing or green decking applications.

[01 16] EXAMPLE 4.

[01 17] Compression Testing. [01 18] A first mix of SWM, Sample 1 , was prepared in the manner described in Example 1 except using shredded rubber tire pieces as SWM instead of wood pieces. Second and third mixes of SWM as described in Example 1 and Example 3 (designated Samples 3 and 2, respectively) were prepared. The wet mixes of Samples 1 , 2 and 3 were dried inside of cylinders each having an inner diameter of 6.01 inches and a cross section area of 28.37 sq. inches. Four cylinders were prepared for each of Sample 1 (1 -A; 1 -B; 1 -C; and 1 -D); Sample 2 (2-A; 2-B; 2-C; and 2-D); and Sample 3 (3-A; 3-B; 3-C; and 3-D) and measured under conditions similar to ASTM C-39 standards for compressive strength at 7 days; 28 days (twice); and 56 days of drying. The results are shown in Table 1 .

TABLE 1

[01 19] All 3 samples showed improvement in compressive strength over 56 days, with Sample 3 exhibiting the highest compressive strength and Sample 1 showing the lowest compressive strength.

[0120] EXAMPLE 5.

[0121] Flexural Testing.

[0122] A first mix of SWM, Sample 1 , was prepared in the manner described in Example 1 except using shredded rubber tire pieces as SWM instead of wood pieces. Second and third mixes of SWM as described in Example 1 and Example 3 (designated Samples 3 and 2, respectively) were prepared. The 3 samples were tested according to the standards of ASTM C78 for flexural strength of concrete by use of a simple beam with third-point loading. Results are reported as the modulus of rupture (MOR) in psi or Mpa, which is the flexural strength of the concrete sample just before it yields. The samples were measured for flexural strength at 7 days; 28 days (twice); and 56 days of drying. The results are shown in Table 2.

TABLE 2

[0123] All 3 samples showed improvement in flexural strength over 56 days, with Sample 3 exhibiting the highest flexural strength and Sample 1 showing the lowest flexural strength.

[0124] A structure having four walls and a roof can be built using the coated wood pieces mix of Examples 1 or 3. A scarified concrete slab can be poured as the base of the structure. Molds for walls of about twelve (12) inches thickness can be constructed and a layer of grout can optionally be placed over the scarified concrete slab at the base of the molds. Metal rods can be inserted from the base to extend beyond the tops of the molds. [0125] A plywood sheet can be placed on top of the poured coated wood pieces mixture to provide compression to the mixture while it dries. A roof structure can be built on the top of the walls using plywood. A layer of the coated dried wood pieces mix twelve (12) inches thick can be poured on the plywood layer to form the roof. The roof can thereafter be coated with stucco and roof paint. A plurality of rods can be placed to extend upward from the plywood layer to allow for a top to be placed over the poured coated wood pieces mix to compress it while it dries.

[0126] The above examples disclose environmentally responsible insulated construction blocks comprising wood (wetted and not wetted) as SWM. When using other types of SWM, the same weight amounts of silica fume, slag cement, Portland cement, water and where applicable expanded slate can be used with the same volume of sized SWM pieces. For example, to prepare an environmentally responsible insulating construction block using SWM other than wood (wetted or not wetted), 1 gallon of silica fume weighing 6.4 lbs., approximately 1 gallon of slag cement weighing 9.2 lbs. and approximately 1.5 gallons of Portland cement weighing 15.3 lbs. can be mixed with approximately 15 gallons of the sized SWM pieces (wetted or not wetted), wherein the SWM pieces are randomly mixed and poured freely into three 5-gallon containers. This is to maintain approximately the same volume of SWM in the environmentally responsible construction blocks without regard to the different densities and thus different weights of the various types of SWM that may be used.

[0127] In one embodiment, the SWM pieces are subjected to mild compression when being measured for volume prior to mixing with the silica fume, slag cement and Portland cement.

[0128] In other embodiments, the volume of SWM pieces used to prepare the environmentally responsible insulated construction blocks or the mix for monolithic pour of a green structure may be adjusted from the volume described in the Examples above as compared to the amount of the silica fume, slag cement and Portland cement. The user may elect various recycled content of the final environmentally responsible insulated construction blocks or the green structure according to the invention. The user may vary the volume of SWM pieces in the mix of SWM pieces, silica fume, slag cement and Portland cement by increasing or decreasing the volume of the silica fume, slag cement and Portland cement in the mix used to fully coat the SWM pieces. For example, if a lower recycled content is desired than the volume of Examples 1 and 3, a higher volume ratio of the mix of silica fume, slag cement and Portland cement to the volume of SWM pieces than that described in Examples 1 and 3 may be used. A person having ordinary skill in the art can determine the desired recycled content and adjust the volume of the SWM pieces and the mix of silica fume, slag cement and Portland cement to be used for an application. The environmentally responsible insulating construction blocks and mix may be used in applications other than green roofing, green decking, and green structure construction, and the invention is not intended to be limited to such applications.

[0129] In the foregoing description, the invention has been described with reference to specific exemplary embodiments thereof. It will be apparent to those skilled in the art that a person understanding this invention may conceive of changes or other embodiments or variations, which utilize the principles of this invention without departing from the broader spirit and scope of the invention. The specification and drawings are, therefore, to be regarded in an illustrative rather than a restrictive sense.

Claims

CLAIMS What is claimed is:

1 . An environmentally responsible insulated construction block comprising: a plurality of pieces of a solid waste landfill material coated with silica fume, slag cement and Portland cement, mixed and dried to form an environmentally responsible insulated construction block having a top surface, a bottom surface substantially parallel to the top surface and 4 side surfaces substantially perpendicular to the top surface and the bottom surface, wherein the environmentally responsible insulated construction block has a depth defined by the distance between the top surface and the bottom surface; wherein the environmentally responsible insulated construction block forms an open matrix structure allowing liquid to pass substantially freely through the environmentally responsible insulated construction block.

2. The environmentally responsible insulated construction block of claim 1 , wherein the silica fume has a density of approximately 6.4 lbs. per gallon, wherein the slag cement has a density of approximately 9.2 lbs. per gallon and wherein the Portland cement has a density of approximately 10.2 lbs. per gallon, wherein further the weight ratio of the silica fume, slag cement and Portland cement in the dry mix of the silica fume, slag cement and Portland cement is approximately 1 :1 .5:2.5.

3. The environmentally responsible insulated construction block of claim 2, wherein the volume ratio of the silica fume, the slag cement, the Portland cement and the solid waste landfill pieces in the dry mix of the silica fume, slag cement, Portland cement and solid waste landfill pieces is approximately 1 :1 :1.5:15 when the volume of each of the silica fume, slag cement, Portland cement and solid waste landfill pieces are measured separately by mixing and randomly pouring each of the silica fume, slag cement, Portland cement and solid waste landfill pieces into a separate container.

4. The environmentally responsible insulated construction block of claim 3, wherein the plurality of pieces of the solid waste landfill material randomly range in size between about 1/2 inch to 2 inches.

5. The environmentally responsible insulated construction of claim 4, wherein the solid waste landfill material comprises concrete, wood, asphalt, gypsum, metal, brick, glass, plastics, roofing shingles, fiberglass, cloth or combinations thereof.

6. The environmentally responsible insulated construction of claim 5, wherein the solid waste landfill material comprises painted, treated and coated wood and wood products and combinations thereof.

7. The environmentally responsible insulated construction of claim 6, wherein the solid waste landfill material comprises laminated wood, plywood, particle board, fiber board and combinations thereof.

8. The environmentally responsible insulated construction of claim 5, wherein the plurality of solid waste landfill material pieces is soaked in water prior to mixing the solid waste landfill material pieces with the silica fume, the slag cement and the Portland cement.

9. The environmentally responsible insulated construction block of claim 1 , wherein the environmentally responsible insulated construction block is used in a green decking system.

10. The environmentally responsible insulated construction block of claim 9, further comprising a second layer of a plurality of pieces of a fireproof material coated with silica fume, slag cement and Portland cement.

1 1 .The environmentally responsible insulated construction block of claim 1 , wherein the environmentally responsible insulated construction block is used in a green roofing system.

12. A method of manufacturing the environmentally responsible insulated construction block according to claim 1 comprising: preparing a first mix by combining the silica fume, slag cement and Portland cement; thereafter preparing a second mix by adding the plurality of pieces of solid waste landfill material to the first mix and mixing until the plurality of pieces of solid waste landfill material pieces are substantially completely coated; thereafter preparing a third mix by adding water to the second mix until substantially fully wetted; thereafter pouring the third mix into a mold until the mold is substantially full; fitting the mold with a lid; and allowing the third mix to dry.

13. The method of manufacturing an environmentally responsible insulated construction block of claim 12, wherein the plurality of pieces of solid waste landfill material randomly range in size between about ¹/2 inch and 2 inches.

14. A green roof deck, comprising: a membrane roofing system comprising an insulating layer adhered to a substrate of a roof of a structure and a waterproof membrane layer adhered to the insulating layer distal from the roof substrate; and a plurality of the environmentally responsible insulated construction blocks according to claim 1 adhered to the waterproof membrane layer of the membrane roofing system.

15. An environmentally responsible insulated structure comprising: a foundation, a plurality of exterior walls and a roof, wherein one or more of the exterior walls is prepared by: preparing a mold; placing the mold on the foundation; placing a layer of grout on the foundation at the bottom of the mold; pouring a first mix comprising shredded solid waste material pieces coated with silica fume, slag cement and Portland cement into the mold; placing a cover over the top surface of the poured first mix and attaching the top to a plurality of first metal rods; placing pressure on the cover to compress the first mix within the mold; allowing the first mix in the mold to dry; and thereafter removing the cover and the mold, wherein the roof is prepared by: preparing a roof structure atop the plurality of exterior walls; placing forms around the exterior edges of the roof structure; attaching a plurality of second metal rods to the roof structure to extend perpendicular from the roof structure upward; pouring a second mix comprising solid waste material pieces coated with silica fume, slag cement and Portland cement on the roof structure; placing a cover over the top surface of the second mix poured on the roof structure and attaching the cover to the plurality of second metal rods; placing pressure on the cover to compress the second mix poured on the roof structure; allowing the second mix to dry; removing the cover and the forms; and thereafter covering the dried second mix on the roof structure with a protective layer, wherein the solid waste material pieces in the first mix and the second mix randomly range in size of between about ¹/2 inch to 2 inches, wherein the solid waste material pieces comprise concrete, wood, asphalt, gypsum, metal, brick, glass, plastics, rubber tires, roofing shingles, fiberglass, cloth or combinations thereof.

16. The environmentally responsible insulated structure of claim 15, wherein each exterior wall is approximately twelve inches thick.

17. The environmentally responsible insulated structure of claim 15, wherein the protective covering comprises stucco, roof paint or a combination thereof.

18. The environmentally responsible insulated structure of claim 15, wherein the foundation comprises the ground.