Flexible mat forming system

A method for making a flexible mat, the method comprising:

• providing a plurality of transverse rows of mold cavities;
• providing a panel having a plurality of slots;
• positioning the panel above the mold cavities and aligning the slots of the panel with the mold cavities;
• placing a sheet of mesh material between the panel and the mold cavities;
• depositing a hardenable paste through the slots and into the mold cavities of the transverse rows of mold cavities such that the sheet of mesh material becomes embedded in the hardenable paste over the mold cavities;
• displacing the panel from the mold cavities as the hardenable paste hardens in the mold cavities into blocks held together by the mesh, thereby forming a flexible mat;
• and
• removing the flexible mat from the mold cavities.

A system for making a flexible mat, the system comprising:

• a plurality of transverse rows of mold cavities;
• a panel having at least one row of slots;
• a support frame for adjustably supporting the panel above the transverse rows of mold cavities and aligning the slots of the panel with the mold cavities;
• and
• the panel spaced above the mold cavities a distance sufficient to receive a sheet of mesh material between the panel and the mold cavities.

A method for making a flexible mat, the method comprising:

• providing a plurality of transverse rows of mold cavities;
• providing a panel having a plurality of rows of slots;
• positioning the panel above the mold cavities and aligning the slots of the panel with the mold cavities, wherein positioning the panel above the mold cavities includes varying a height of the panel above the mold cavities to a selected spacing;
• placing a sheet of mesh material between the panel and the mold cavities;
• depositing a hardenable paste through the rows of slots and into the mold cavities such that the sheet of mesh material becomes embedded in the hardenable paste over the mold cavities;
• allowing the hardenable paste to harden into blocks held together by the mesh, thereby forming a flexible mat;
• and
• removing the flexible mat from between the panel and the mold cavities.