US20090301028A1

US20090301028A1 - Method for constructing cultured stone block buildings

Info

Publication number: US20090301028A1
Application number: US12/381,075
Authority: US
Inventors: Steven Pfoff
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-03-07
Filing date: 2009-03-06
Publication date: 2009-12-10

Abstract

A method for constructing a building made from site specific cultured stone blocks is disclosed. The site specific cultured stone blocks are created by placing an open form on prepared ground covered by plastic sheeting and pouring in concrete into the open form. The pressure of the concrete on the plastic sheeting imparts the contours and details of the ground onto the facing of the block, creating a non-uniform facing that corresponds to the features of the ground. In one embodiment the blocks also contain a tongue and groove configuration to aid alignment of the blocks and to give added stability, strength and general air tightness. Many types of buildings and structures can be constructed with these blocks.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/068,648 filed on Mar. 7, 2008.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable.

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not Applicable.

FIELD OF THE INVENTION

The present invention relates to a method for building on site cultured stone block buildings.

BACKGROUND OF THE INVENTION

Buildings have been made of stone blocks since before recorded time. These blocks were made of stone cut into block shapes, typically cubes or six sided rectangular blocks, and the blocks stacked. In many cases the blocks were connected with an adhesive or cement mortar that allowed the blocks to be securely and essentially permanently attached. In some cases, if the blocks were sufficiently uniform, there was no need for any type of mortar. There have also been a variety of man-made blocks, such as bricks or cement blocks, which have been used to build buildings and other structures over the years. Standard bricks are typically made of clay, and are approximately two inches thick, four inches deep and eight inches long, although these dimensions vary greatly based on design and construction needs. Clay bricks are now frequently used for a wide variety of commercial and residential construction.
Concrete is also commonly used for a type of brick known as a concrete masonry unit or “cinder blocks.” These are typically eight inches high by eight inches deep by sixteen inches wide. Cinder blocks generally have rough external facing and they are most commonly used structurally, or to provide structural support for a building, and not frequently used for facing material. It is not uncommon, however, to see some types of commercial buildings, such as warehouses or factories that are constructed from standard cement cinder blocks. Some modern architects use the rough look as a design feature, but in many cases a facing material, such as stucco is applied over the cinder block to create a smoother and more pleasing appearance.
Concrete is widely used in the construction trades, and the onsite pouring of foundations, floors, and walls, in pre-framed moulds is well known. Concrete is generally made from a mixture of one part cement (typically Portland cement), two parts fine or medium aggregate (typically sand), and three parts course aggregate (typically crushed stone), and sufficient water to wet and mix the other materials and make the resulting slurry pourable.
It is not uncommon to use large poured concrete blocks in some types of construction. These blocks are sized based on the requirements of the builder or architect. Most commonly, these specialized blocks are poured off site. After the concrete has cured—as the process of hardened, solidifying and strengthening of the wet poured concrete is know—the blocks must be transported to the construction site. Because of the large size or the blocks, they are typically transported on the flat-bed trailer of a large truck. This adds the cost of transporting large, heavy and unwieldy blocks to the overall cost of construction. Additionally, there are times when it is not possible for a large tractor-trailer to directly access a construction site. This is particularly true in hilly or mountainous terrain where roads are steep, narrow, or excessively curved. In these situations the blocks must be shuttled from a staging area where the transport trucks are parked to the construction site by a separate smaller vehicle. This adds significantly to the cost of transportation and ultimately to the cost of construction. The present invention overcomes these drawbacks by pouring and curing the blocks on-site.
Most prefabricated construction blocks come with uniform facing. Cinder blocks, for example, generally have a rough concrete facing. Often, for use in commercial or agricultural buildings, the cinder block is left bare. In residential construction, or in most commercial construction, a separate decorative facing is added over the cinder blocks. There are also a variety of specialty blocks that have different facings. Landscape blocks are increasingly common, and these blocks have a rough stone-like surface that is knobby and uneven, which gives the facing the approximate appearance of a rough cut stone block. These blocks are poured in uniform molds, however, giving each block the same face. This makes it obvious to the naked eye that the blocks are artificial poured concrete blocks and are not natural stone. There is a need, therefore, for poured on site blocks with unique, non-uniform facing.

SUMMARY OF THE INVENTION

The present invention is drawn to a method for constructing buildings from poured on site “cultured” stone structural blocks. The blocks are poured in forms with the facing side place on plastic on the ground. This gives the facing of the blocks a non-uniform, natural, and site-specific look. Poured concrete that looks like natural stone is commonly referred to as “cultured stone.” In one embodiment of the present invention, the blocks have tongue and groove features, which allows them to be easily aligned and adjoined for constructing many types of residential, commercial, and agricultural structures. The cost of material and labor for pouring the blocks on site and assembling the structure are comparable to, if not somewhat cheaper than, wood, steel or cinder block construction for similar sized structures.
In one embodiment the concrete for the blocks are batched—mixed—on site. The blocks are generally made from a conventional concrete mix, which typically comprises one part Portland Cement, two parts fine aggregate, three parts course aggregate, and water as needed to make the mix pourable. Typically the fine aggregate is sand or screened sand, and the course aggregate is crushed stone. A considerable cost savings can be realized by bringing bags of Cement and loads of sand and crushed stone on site as opposed to brining mixed cement in a cement truck. In most uses and for most sites it is approximately thirty percent (30%) cheaper to bring the concrete mix materials on site and mix on site than to bring the concrete in conventional concrete mixer trucks. There is an additional savings when the construction site is in a hard to reach location since standard concrete mixer trucks might have difficulty accessing the site.
Fly ash is increasingly used as a replacement for Portland Cement in standard construction concrete, and it is within the conception of the invention to use fly ash in place of Portland Cement. Fly ash is a waste product of industrial combustion which is frequently disposed of. Many combustion facilities such as coal fired power plants pay to have the fly ash removed from their site, so it is significantly cheaper to use the fly ash in concrete than cements such as Portland cement.
Course aggregate is commonly made from crushed stone. In one embodiment of the invention the forms and material used for making the blocks are brought onto the site of a building that will be demolished. In addition to the standard demolition material for disassembling the building, a stone crusher is also used, and the stone, brick, and other stone-like materials of the demolished building are crushed and used as the coarse aggregate in the concrete mixture. This essentially allows a building to be recycled on site, by recycling most of the construction materials.
Cultured stone blocks can be used in a variety of types of construction. Its aesthetic features make it desirable for residential construction, and its strength makes it ideal for commercial construction. Cultured stone blocks are ideal for agricultural use because they will not deteriorate through contact with animal waste or organic materials. Animal barns made of wood or steel can be damaged by animal urine and feces. Wood rots and metal rusts or oxidizes. Wood barns are traditional and aesthetically pleasing, but they inevitably deteriorate. This may take many years, but the deterioration of wood will inevitably require that the building be replaced. Steel lasts significantly longer, although it too can be damaged by animal waste and contact with other organic materials, but while steel lasts longer than wood, it is not aesthetically pleasing. The present invention discloses an aesthetically pleasing building material that is also highly durable.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a four sided open form used for making the blocks.

FIG. 2 is an exploded detail plan view of the components of the forms.

FIG. 3 is a perspective view of a form in position on the ground.

FIG. 4 is a perspective view of a block.

FIG. 5 is a sectional view of a block showing the tongue and groove feature and the location of the rebar clip.

FIG. 6 is a perspective view of a group of blocks in position to make a structure.

DETAILED DESCRIPTION OF THE INVENTION

Detailed embodiments of the present invention are disclosed herein. It is to be understood that the disclosed embodiments are merely exemplary of the invention and that the invention may be embodied in various and alternative forms. Therefore, specified structural and functional details disclosed herein are not to be interpreted as limitations, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.
FIG. 1 shows a form 10 used for creating the cultured stone blocks 60. The form 10 has four sides, a top 20, a bottom 30, a right side 40, and a left side 50. There is no “front side” or “back side” of the form 10. In use, the form 10 will lie on the ground 70 and the face 65 of the block 60 will be created when concrete 100, or other pourable structural material, is poured into the form 10 as described below. The concrete 100 will be poured into the back opening in the form 10 and when filled and cured the concrete 100, in this position, will form the back 66 of the block 60.
FIG. 2 is an exploded view of the disassembled form 10. Concrete forms are well known in the art, and their use and assembly are well known. To use the form 10 the four sides, 20, 30, 40, & 50, are attached. There are numerous different types of attachments for concrete forms, and such attachments are well known in the construction trades. In some configurations the attachments are made through a series of grooves in one form and a corresponding lip in the other form. In other configurations the attachment is achieved through a series of clips which hold the adjoining sides in place. In yet another configuration the attachment is achieved through corresponding holes and corresponding hardware such as nuts and bolts. The specific nature of the attachments between the corresponding sides of the form 10 are immaterial and do not constitute part of the invention. There is a top-right attachment 24, that attaches the top 20 to the right side 40, a top-left attachment 25 that attaches the top 20 and the left side 50, a bottom-right attachment 34 that attaches the bottom 30 with the right side 40, and a bottom-left attachment 35 that attaches the bottom 30 with the left side 50.
Each of the four sides, 20, 30, 40 & 50, of the form 10 has an indention. The placement of the indention creates either a protrusion—known as a tongue—in the block 60, or an indent—known as a groove—in the block 60. The bottom 30 has a bottom indent 31 which is placed so that it protrudes into the inside of the form 10. The right side 40 has a right indent 41 that is placed to protrude out from the form 10, and which will create a protrusion from the right side 63 of the block 60. The left side 50 has a left indent 51 that is place to protrude into the form 10 to create an indent into the block 10. The top has two protrusions, a top-right protrusion 22 and a top-left protrusion 23. Both top protrusions, 22 and 23 are configured so that they extend from the inside of the form 10 and create two external protrusions from the block 60. The top 20 also has a gap 21 placed in approximately the center of the top 20. In end blocks, or in blocks used around structural features such as doors and windows, the form may not include an indent. This will produce an essentially flat portion of the block, and be appropriate for end pieces or for doors and windows.
In producing the block 60, a flat and level piece of ground 70 is found, or prepared by scrapping, sweeping, rolling or any other means to produce a relatively flat and level surface. A tarp 75 or other type of plastic sheeting or material is placed on the ground 70, as shown in FIG. 3. The tarp 75 can be made from many types of common construction sheeting materials, but is commonly made from plastics, or from cloth sheeting coated with plastic material. These types of plasticized sheeting are well known in the trade and any suitable sheeting will suffice. In preparing the ground 70 it is not necessary to create a perfectly smooth surface. In fact, one of the desired features of the disclosed invention is the creation of a non-uniform look on the face 65 of the block 60. Therefore, slight variations in the smoothness or in the surface of the ground 70 are actually desired to create a natural, non-uniform look on the face 65 of the block 60. In addition, if the ground is rocky or uneven, it is possible, and in some cases desirable, to leave some of these variations on the ground 70 in order to create a site specific look to the face 65 of the block. For example, if the ground is rough and rocky, these feature can be transposed to the face 65 of the block 60. The tarp 75 is placed on the ground 70. The tarp 75 needs to be somewhat smooth, but need not be taught or perfectly smooth. Slight creases or other wrinkling in the tarp 75 will also help create the desired non-uniform look on the face 65 of the block 60.
As shown in FIG. 3, the assembled form 10 is placed on the tarp 75. The opening that is on the tarp 75 will be the face 65 of the block 60. The ground 70 needs to be essentially level so that the form 10 remains square—that is the sides remain attached at essentially right angles—so that an adequate seal develops between the ground 70 and the edges of the sides of the form 10. This seal prevents concrete 100 from seeping out from under the form 10.
After the form 10 is placed, concrete 100 is poured carefully into the form 10. The pouring of concrete 100 is well known in the construction trades and the proper techniques are well understood. In the preferred embodiment the concrete 100 is made of the conventional mix of one part Portland cement, two parts fine aggregate, three parts crushed stone and water as needed. In the preferred embodiment the fine aggregate is sand, and the course aggregate is crushed stone. In one embodiment of this mix the concrete is produced in the conventional manner and then brought on site by standard concrete mixer trucks. In the most preferred embodiment the concrete is mixed on site from dry cement (typically brought on site in bags), sand, crushed rock, and water. In one alternate embodiment the Portland cement is replaced by fly ash. In another alternate embodiment the coarse aggregate is prepared on site with a conventional stone crusher. In one variation of this embodiment materials from an existing building are used and crushed to create the coarse aggregate.
The concrete is carefully spread and leveled to ensure that no air bubbles form in the wet concrete. The presence of air bubbles can lead to thin spots and can weaken the concrete. When the form 10 is approximately one half full reinforcing bars 92 (commonly called “rebar”) are added as shown in FIG. 5. These are added as needed to increase the structural strength of the blocks, and their position in the cut away block as shown in FIG. 5 is representational only. Rebar is well known in the building trades and is commonly used to reinforce concrete. Rebar is made from metal, most commonly steel, and is typically one half inch in diameter, though other thicknesses are used for different purposes. Additionally a short piece of bent, substantially V-shaped rebar of approximately eighteen inches in length is inserted into the wet concrete 100 in the form 10. As shown in FIG. 5, the V-shaped rebar is inserted into the form 10 such that, when poured, the tip of the V will extend through the gap 21, and the remaining portion will be a couple of inches below the top surface of the top 61 of the block 60, and so the point of the V-shaped portion will extend up from the top 61 of the block 60. The V-shaped extending portion will form a rebar clip 90, which will be used for moving the block 60 once it has cured and been removed from the form 10.
The pressure of the concrete 100 on the tarp 75 forces the tarp down on to the ground 70, which forces both ground 70 imperfections and tarp 75 imperfections into the concrete 100, and imprint those imperfections into the block 60. This forces the concrete 100 to solidify in the non-uniform configuration of the ground 70. If the ground is relatively smooth, the front facing portion of the block, known as the face 65, will be relatively smooth. If the ground is rocky, the front facing will have a more porous and rocky look. The use of the tarp to create the non-uniform front facing portion creates a site specific look.
In the preferred embodiment, as described above, the form 10 has indents and protrusions. These protrusions in the form 10 created the tongue and groove feature of the finished blocks 60. In the typical configuration the top 61 of the block 60 has a small linear protrusion, which is commonly referred to as a tongue, and the bottom 62 of the block 60 has a linear indent, which is commonly referred to as a groove. The tongue and the groove are sized to correspond, so that when the blocks 60 are stacked the tongue fits into the groove. This allows easy alignment of the blocks, secures the blocks, and prevents them from slipping. There are similar corresponding tongue and groove structure on the left and right side of the blocks. Typically, there will be a tongue on the right side of a block and a groove on the left side of the corresponding block, which allows easy alignment of the blocks during construction. While the tongues must be on the top 61 of the block 60, and the corresponding bottom groove 82 must be on the bottom 62 of the block 60, it is not important that the tongue or groove be on either the left of right side of the block 60. What is important is correspondence between the tongue and groove. In other words if there is a tongue on the left side 64 of the block 60, there must be a groove on the right side 63 of the block 60 so that they two blocks 60 will fit together. The drawings, in particular FIG. 4, show the right tongue 83 on the right side 63, and the left groove 84 on the left side 64.
FIG. 4 shows the competed cultured stone block 60. In the preferred embodiment the blocks 60 measure approximately one foot thick measured from the back side 66 to the front 65, two feet tall measured from the bottom 62 to the top 61, and four feet wide measured from the right side 63 to the left side 64. The blocks can vary in size based on the builder's needs, and can be in just about any size appropriate for construction, though most typically they will be six sided right angle block shaped. The size of the blocks in the preferred embodiment are roughly the same size as natural stone blocks historically used by stone masons. This correlation between cut stone blocks used by stone masons for construction of many ancient and historical buildings and the cultured stone blocks described herein, further enhances the desired look of natural stone.
A multiplicity of cultured stone blocks 60 will be produced to construct a building or structure. The actual number will be determined by the size and configuration of the desired structure. It is envisioned and within the conception of the invention, to use the cultured stone blocks 60 for construction of houses as well as commercial and agricultural structures. The blocks can also be used for a variety of decorative landscape features, such as retaining walls or sound barrier walls used along busy roadways. The blocks 60 are ideally suited for agricultural use since they will not deteriorate from contact with animal waste or the changing water content levels of agricultural products. The cultured stone blocks 60 are load bearing, and can easily support walls up to three stories high. This is of sufficient size for many residential, commercial and agricultural needs. In many situations more blocks 60 will be needed for constructing a structure than there will be forms 10 available on site. In those situations the forms 10 will simply be reused after the blocks 60 have been cured and hardened. In that situation a first series of forms 10 will create a first group of blocks 60, and then the forms 10 will be used for a second group of blocks 60, and so on until sufficient blocks 60 have been produced to complete the desired structure.
To construct a building using a multiplicity of the cultured stone blocks 60, a foundation must first be prepared. Foundations are well known in the construction trade. To create a foundation for the cultured stone block building, a footer is laid around the perimeter of the proposed building, at the desired placement of the walls. In the preferred embodiment the face 65 of the blocks 60 are the exterior of the building. It is possible, and within the conception of the invention, to use the cultured stone blocks 60 for internal walls inside the structure, but because the desired purpose of the invention is to construct a structure or building with blocks 60 having the appearance of cut natural stone, the construction of the exterior walls will be described herein. The footer will typically be made by compacting the soil and then pouring concrete in the standard manner of approximately two feet wide. Once the concrete of the footer has dried, and the blocks 60 have been cured, the blocks 60 can be set in place with the site specific face 65 on the exterior of the structure, as partially shown in FIG. 6.
The most preferred method of building a structure with cultured stone blocks 60 involves the following procedures 60. First a building site is prepared. A foundation for the building is prepared in the common way, by creating a footer for the walls, and preparing the area under the foundation. The footer for the walls is prepared in the conventional manner, around the perimeter of the building and in the location where the external walls will be placed. In the preferred embodiment, the footer will be constructed of concrete.
The blocks 60 can be prepared while the foundation and footers are being constructed. The blocks 60 are prepared by creating a flat and roughly sooth area, and laying a multiplicity of tarps 75 on the ground 70. A multiplicity of forms 10 are then placed on the tarps 75. In the preferred embodiment, concrete 100 is prepared on site by bringing the materials in dry form to the site and then mixing sand, aggregate, Portland Cement and water. Mixing on site significantly reduces the cost of preparing the concrete. In alternate embodiments, concrete 100 can be trucked onto site in conventional concrete mixer trucks. Concrete 100 is poured into the multiplicity of forms 10. For simplicity the procedure used in a single form 10 will be described herein. Once about the form 10 is about half full of concrete 100, a rebar clip 90 is placed in the concrete 100 and through the gap 21 in the top 20 of the form 10. If desired, additional strengthening rebar will also be added. When the form 10 is full of concrete 100, the exposed surface, which will be the back 66 of the block 60, is smoothed in the conventional manner. The concrete 100 filled form 10 is then left to cure. The curing process for this thickness of concrete generally takes two to three days, but that can vary depending on temperature and humidity.
Standard concrete is a grey tone when fully dried. The color is largely determined by the color of the sand and aggregate used, and these materials are typically tan or grey in tone. It is possible to alter the coloration of the dried concrete by adding coloring agents to the concrete mixture to give the blocks 60 color, or to stain the blocks 60 after they have dried or after they have been placed in the structure. Modern stains and concrete coloring agents come in every color and hue. One of the purposes of the disclosed invention is to create concrete blocks that have the appearance of natural stone, commonly known in the trade as “cultured stone.” This is done through use of the facing procedure described herein, to give the face 65 of the block 60 a natural, non-uniform look. The use of color can also enhance the natural look of the blocks. Natural stone blocks come in a variety of colors, but the most common have “earth tone” hues, or browns, tans, and grays. As a result, these will be the colors most commonly used. It is within the conception of the invention, however, to use any color in the concrete to create any color stone that the builder, architect, or owner desires.
When the concrete 100 is fully cured, the form 10 can be removed from the blocks 60. The form 10 is removed by dis-attaching the attachments, 24, 25, 34, 35, and removing the top 20, the bottom 30, the right side 40 and the left side 50. In some cases excess concrete may need to be trimmed off as is common in concrete construction work. The block 60 can now be moved by means of the rebar clip 90. A block 60 of this size weighs hundreds of pounds, and will typically be moved by means of a construction machinery such as a crane or fork lift. The crane or lift can move the block 60 by attaching to the rebar clip 90. As the block 60 is lifted into its upright position, the tarp 75 is peeled away from the face 65 of the block 60.
As can be seen in FIG. 6, a first block 60 will be placed at the corner of the footer and then a second block will be aligned with the left groove 84 aligned such that the right tongue 83 fits within the left groove 84. Additional blocks are added as needed and desired. If the building is an agricultural or commercial storage structure, there is no need to add grout or mortar between the blocks 60. With proper alignment, the tongue and groove of the blocks will provide sufficient air and water tightness for these types of usage. For residential buildings, and in the preferred embodiment of the invention, standard mortar or grout is added between the blocks to create a substantially watertight and airtight seal, and to more permanently adhere the blocks 60 together. Once the first row of blocks 60 are placed on the footer, as partially shown in FIG. 6, a second layer of blocks 60 can be added. When adding the second layer of blocks 60, the bottom groove 82 will be aligned over the top right tongue 80 of a first block 60 and the top left tongue 81 of a second block 60, so that the blocks 60 are off set in each row. Grout or mortar can be used to adhere the blocks 60 of the second row onto the blocks 60 of the first row. Spaces can be left to provide for doors and windows, as is common and well known with construction with any type of block structure.
Once the external walls have been completed, a roof can be added if called for in the construction plans. The blocks 60 are fully load bearing and can be used to construct a wide variety of structures and buildings. The remainder of the construction of the structure or building will proceed in accordance to well known principles. For example, doors and windows can also be added as needed or as desired. If desired, internal walls can also be added. For residential and commercial uses, internal facing walls can be added to the back 66 of the blocks 60. As is common and well known in the art, plumbing and electrical wiring can be placed against the back 66 of the block 60 and a separate facing wall can be constructed to cover the exposed utility fixtures. These features are beyond the scope of the present invention but are necessary to complete a structure.
The present invention is well adapted to carry out the objectives and attain both the ends and the advantages mentioned, as well as other benefits inherent therein. While the present invention has been depicted, described, and is defined by reference to particular embodiments of the invention, such reference does not imply a limitation to the invention, and no such limitation is to be inferred. The depicted and described embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the present invention is intended to be limited only by the spirit and scope of the claims, giving full cognizance to equivalents in all respects.

Claims

1. A method for constructing a structure made from site specific cultured stone blocks which comprises:

(a) preparing a construction site having a foundation with a perimeter, and a footer located at said perimeter;

(b) preparing a level portion of bare ground adjacent said construction site;

(c) making a multiplicity of cultured stone blocks by;

(1) providing a multiplicity of four sided open forms, wherein each of said four sided open forms consist of a form top, a form bottom, a form right side, and a form left side

(2) connecting said form top to said form right side and said form left side, and then connecting said form bottom to form right side and form left side opposite said form top to create a four sided open form having two open ends, wherein said first open end creates an open front side and the second open end creates an open back side;

(3) laying a multiplicity of plastic sheeting on the bare ground;

(4) placing the open front side of said multiplicity of four sided open forms on said plastic sheeting;

(5) pouring concrete into said open back side of said multiplicity of four sided open frames, wherein the weight of said concrete on said plastic sheeting imprints any site specific features of the ground or the plastic sheeting onto the concrete and creates a non-uniform site specific face;

(6) allowing said concrete to cure to create a multiplicity of cultured stone blocks having a top, a bottom, a right side, a left side, a back and a non-uniform site specific face; and

(7) removing said multiplicity of four sided open forms from said multiplicity of said cultured stone blocks; and

(d) placing said multiplicity of cultured stone blocks on said footing to create a structure.

2. The method for constructing a structure made from site specific cultured stone blocks of claim one comprising the additional step of providing concrete made from a mixture of one part cement, two parts fine aggregate, three parts course aggregate and water.

3. The method for constructing a structure made from site specific cultured stone blocks of claim two wherein said concrete is mixed on site from dried materials.

4. The method for constructing a structure made from site specific cultured stone blocks of claim two wherein fly ash is used in place of the one part cement.

5. The method for constructing a structure made from site specific cultured stone blocks of claim two comprising the further step of crushing preexisting building material on site to provide the course aggregate.

6. The method for constructing a structure made from site specific cultured stone blocks of claim one wherein said form top, said form bottom, said form right side, and said form left side are made from plates having at least one indent, wherein said indent in said form bottom is placed such that it creates a bottom groove in the bottom of said cultured stone block, said indent in said form right side is placed such that it creates a right tongue in the right side of said cultured stone block, said indent in said left side is placed such that it creates a left groove in the left said of said cultured stone block, and wherein said form top has at least two indents placed such that it creates a top right tongue and a top left tongue in the top of said cultured stone block.

7. The method for constructing a structure made from site specific cultured stone blocks of claim six comprising the further step of placing a first cultured stone block and a second cultured stone block such that the right tongue of a first cultured stone block aligns within said left groove of a second cultured stone block, and placing a third cultured stone block wherein said bottom groove of a third cultured stone block aligns over the top right tongue of the first cultured stone block and the top left tongue of the second cultured stone block, and wherein these steps are repeated to construct a structure.

8. The method for constructing a structure made from site specific cultured stone blocks of claim one comprising the further step of placing a multiplicity of reinforcing steel bars in said concrete after pouring and before curing wherein the presence of said multiplicity of reinforcing bars increases the strength of said cultured stone blocks.

9. The method for constructing a structure made from site specific cultured stone blocks of claim one comprising the further step of inserting a bent reinforced steel bar in said concrete after pouring and before curing such that it protrudes from said top of said block to form a rebar clip.

10. A method of producing a site specific cultured stone block comprising the steps of:

leveling and smoothing a section of bare ground having site specific features;

placing plastic sheeting on said section of bare ground;

providing a four sided form having a top, a bottom, a left side and a right side;

attaching the four sides of the four sided form to create a four sided open form having an open front and an open back;

placing the open front of said four sided form onto said plastic sheeting;

pouring concrete into the open back of said four sided form and onto the plastic sheeting wherein the site specific features of the section of bare ground is imprinted into the concrete on the plastic sheeting;

inserting reinforcing bars into the concrete;

curing said concrete to produce a site specific cultured stone block having a face that is at the front opening and against the plastic sheeting; and

removing said four sided form from said site specific cultured stone block.

11. The method of producing a site specific cultured stone block of claim 10 comprising the further steps of producing a multiplicity of site specific cultured stone blocks and building a structure from said blocks.

12. The method of producing a site specific cultured stone block of claim 10 wherein said concrete is mixed on site with one part cement, two parts fine aggregate, three parts course aggregate and water.

13. The method of producing a site specific cultured stone block of claim 12 wherein said cement consists of fly ash.

14. The method of producing a site specific cultured stone block of claim 12 wherein said course aggregate is crushed on site from an existing building.

15. The method of producing a site specific cultured stone block of claim 11 wherein the four sided forms further comprise features to impart a tongue or a groove into the sides and top of the cultured stone block, wherein the tongue of one cultured stone block corresponds to the groove of another cultured stone block.