Abstract: In embodiments, a flexible mat forming system includes a rotating drum having a plurality of mold cavities; a hopper that receives a hardenable paste and deposits the hardenable paste into the mold cavities as the drum rotates relative to the hopper; and a sheet of mesh material that is fed between the hopper and the mold cavities facing the hopper. The hopper includes a plurality of side walls and a bottom panel having an opening, wherein the plurality of walls and the bottom panel define an interior chamber; and an auger rotatably mounted in the interior chamber and having a plurality of radially extending protrusions along a length thereof, the radially extending protrusions including angled surfaces to displace the material received in the interior chamber along a length of the interior chamber to fall through the opening into the mold cavities.

Abstract: In an exemplary embodiment, a system for forming a flexible mat having an open mesh embedded in and interconnecting a plurality of blocks of a hardened paste includes a rotating drum having a plurality of mold cavities about an outer periphery thereof that receive a hardenable paste; a sheet of the open mesh that is fed over the mold cavities so that the mesh is embedded in the hardenable paste deposited in the mold cavities; and a flexible sheet that is placed against the outer periphery of the drum over the mold cavities containing the hardenable paste and the sheet of open mesh of the rotating drum to retain the hardenable paste within the mold cavities and retain the open mesh embedded in the hardenable paste as the hardenable paste solidifies to form the flexible mat.

Abstract: In an exemplary embodiment, a system for making tied block mat with a border includes a mold having an array of mold cavities; and a hopper that receives a hardenable paste and is spaced from the mold to receive a sheet of mesh material therebetween, the hopper having an opening for depositing the hardenable paste into selected mold cavities, the hopper forming a filling zone with the mold wherein the hardenable paste flows through the opening into the selected mold cavities, and a blocked zone where the hardenable paste is prevented from entering other selected mold cavities of the mold; whereby the tied block mat is formed wherein the hardenable paste in the selected mold cavities becomes embedded in the sheet of mesh material in the filling zone, and a border is formed in the blocked zone where the hardenable paste is blocked from entering the other selected mold cavities.

Abstract: In embodiments, a flexible mat forming system includes a rotating drum having a plurality of mold cavities; a hopper that receives a hardenable paste and deposits the hardenable paste into the mold cavities as the drum rotates relative to the hopper; and a sheet of mesh material that is fed between the hopper and the mold cavities facing the hopper. The hopper includes a plurality of side walls and a bottom panel having an opening, wherein the plurality of walls and the bottom panel define an interior chamber; and an auger rotatably mounted in the interior chamber and having a plurality of radially extending protrusions along a length thereof, the radially extending protrusions including angled surfaces to displace the material received in the interior chamber along a length of the interior chamber to fall through the opening into the mold cavities.

Abstract: In an exemplary embodiment, a system for making tied block mat with a border includes a mold having an array of mold cavities; and a hopper that receives a hardenable paste and is spaced from the mold to receive a sheet of mesh material therebetween, the hopper having an opening for depositing the hardenable paste into selected mold cavities, the hopper forming a filling zone with the mold wherein the hardenable paste flows through the opening into the selected mold cavities, and a blocked zone where the hardenable paste is prevented from entering other selected mold cavities of the mold; whereby the tied block mat is formed wherein the hardenable paste in the selected mold cavities becomes embedded in the sheet of mesh material in the filling zone, and a border is formed in the blocked zone where the hardenable paste is blocked from entering the other selected mold cavities.

Abstract: In an exemplary embodiment, a system for forming a flexible mat having an open mesh embedded in and interconnecting a plurality of blocks of a hardened paste includes a rotating drum having a plurality of mold cavities about an outer periphery thereof that receive a hardenable paste; a sheet of the open mesh that is fed over the mold cavities so that the mesh is embedded in the hardenable paste deposited in the mold cavities; and a flexible sheet that is placed against the outer periphery of the drum over the mold cavities containing the hardenable paste and the sheet of open mesh of the rotating drum to retain the hardenable paste within the mold cavities and retain the open mesh embedded in the hardenable paste as the hardenable paste solidifies to form the flexible mat.