Formliner and method of use

A formliner for use in creating a decorative pattern on cementitious material, the formliner comprising:

• a cell;
• and
• a rib system extending along the cell and forming a boundary of the cell, the rib system comprising:
• a first section comprising a first exterior surface and a first interior surface, the first exterior surface configured to face the cementitious material in use and having a first cross-sectional exterior profile, the first interior surface having a first cross-sectional interior profile;
• a second section comprising a second exterior surface and a second interior surface, the second exterior surface having a second cross-sectional exterior profile that is smaller than the first cross-sectional interior profile, the second interior surface having a second cross-sectional interior profile;
• a third section comprising a third exterior surface, the third exterior surface having a third cross-sectional exterior profile that is smaller than the second cross-sectional interior profile;
• and
• a first transition zone between the first section and the second section, the first transition zone connecting the first section with the second section, the first transition zone having a first varying cross-sectional exterior profile increasing from the second cross-sectional exterior profile of the second section to the first cross-sectional exterior profile of the first section,
• wherein at least one formliner is configured to be connected with at least two other formliners by overlaying at least a portion of a second section of a rib system of a first formliner of the at least two other formliners onto at least a portion of a third section of a rib system of the at least one formliner and by overlaying at least a portion of a first section of a rib system of an other formliner of the at least two other formliners onto the portion of the second section of the rib system of the first formliner of the at least two other formliners,
• wherein, when the at least one formliner and the at least two other formliners are connected, a first exterior surface of the first section of the rib system of the other formliner of the at least two other formliners and a first exterior surface of a first section of the rib system the first formliner of the at least two other formliners are substantially flush with each other, and
• wherein, when the at least one formliner and the at least two other formliners are connected, the first section of the rib system of the other formliner of the at least two other formliners is positioned adjacent to a first transition zone of the rib system of the first formliner of the at least two other formliners.

A panel for forming a pattern on a surface, the panel comprising:

• a plurality of cells for receiving material to form the pattern on the surface, the plurality of cells arranged in rows with cells of each row being offset with respect to cells of an adjacent row;
• and
• a panel periphery bounding the plurality of cells, the panel periphery comprising:
• a first section having a first recess and a first opening;
• a second section having a second recess and a second opening, the second section configured to fit within the first recess of the first section and extend through the first opening of the first section;
• and
• a third section configured to fit within the second recess and extend through the second opening of the second section,
• wherein at least one panel is configured to be connected with at least two other panels by overlaying at least a portion of a second section of a panel periphery of a first panel of the at least two other panels onto at least a portion of a third section of a panel periphery of the at least one panel and by overlaying at least a portion of a first section of a panel periphery of an other panel of the at least two other panels onto the portion of the second section of the panel periphery of the first panel of the at least two other panels, and
• wherein, when the at least one panel and the at least two other panels are connected, an exterior surface of the first section of the panel periphery of the other panel of the at least two other panels is substantially flush an exterior surface of a first section of the panel periphery of the first panel of the at least two other panels.

A formliner for use in creating a pattern on curable material, the formliner comprising:

• a cell;
• and
• a rib extending along the cell and forming at least a part of a boundary of the cell, the boundary comprising:
• an overlapping section comprising a first cross-sectional profile, the overlapping section configured to face the curable material in use;
• an overlapped section comprising a second cross-sectional profile, wherein the first cross-sectional profile is configured overlay onto the second cross-sectional profile by the first cross-sectional profile having an inner surface larger than an outer surface of the second cross-sectional profile;
• and
• a sub-overlapped section comprising a third cross-sectional profile, wherein the second cross-sectional profile is configured to overlay onto the third cross-sectional profile by the second cross-sectional having an inner surface larger than an outer surface of the third cross-sectional profile,
• wherein at least one formliner is configured to be connected with at least two other formliners by overlaying at least a portion of an overlapped section of a boundary of a first formliner of the at least two other formliners onto at least a portion of a sub-overlapped section of a boundary of the at least one formliner and by overlaying at least a portion of an overlapping section of a boundary of an other formliner of the at least two other formliners onto the portion of the overlapped section of the boundary of the first formliner of the at least two other formliners, and
• wherein, when the at least one formliner and the at least two other formliners are connected, the overlapping section of the boundary of the other formliner of the at least two other formliners and an overlapping section of the boundary the first formliner of the at least two other formliners are substantially flush with each other.