Abstract: A process of manufacturing a formliner is disclosed. The process includes applying a formliner material to a mold, the mold having pocket molds for producing formliner pockets and a lattice of ridge molds for producing formliner ridges, then forming the formliner, and then demolding the formliner from the mold to produce the formliner having the formliner pockets and the formliner ridges. The lattice of the ridge molds have texture for producing texture in the formliner ridges and/or the mold includes a rigid high-density urethane closed cell foam or a rigid polyisocyanurate foam.

Abstract: A process of manufacturing an overlapping formliner is disclosed. The process includes applying a formliner material to a mold, the mold having pocket molds for producing formliner pockets and a lattice of ridge molds for producing formliner ridges, then forming the overlapping formliner, the overlapping formliner having a varied ridge width being configured to be positioned to overlap an adjacent formliner, and then demolding the formliner from the mold to produce the formliner having the formliner pockets and the formliner ridges.

Abstract: A formliner and master mold are disclosed. The master mold corresponds with the formliner, which includes a plurality of courses, each course having a plurality of pockets, each pocket sized and configured to receive a decorative brick, and a plurality of ridges arranged and disposed to separate the pockets. In the embodiment, the ridge lattice has a first ridge having a dimension that differs from a same dimension of a second ridge or a portion of the first ridge.

Abstract: A formliner is disclosed. The formliner includes a plurality of courses, each course having a plurality of pockets, each pocket sized and configured to receive a decorative brick. The formliner is modular in nature and includes a joining portion for overlapping or being overlapped by a second formliner. At least one ridge of the formliner is at least partially within the joining portion.

Abstract: A formliner and master mold are disclosed. The master mold corresponds with the formliner, which includes a plurality of courses, each course having a plurality of pockets, each pocket sized and configured to receive a decorative brick, and a plurality of ridges arranged and disposed to separate the pockets. In the embodiment, the ridge lattice has a first ridge having a dimension that differs from a same dimension of a second ridge or a portion of the first ridge.

Abstract: A formliner and master mold are disclosed. The master mold corresponds with the formliner, which includes a plurality of courses, each course having a plurality of pockets, each pocket sized and configured to receive a decorative brick, and a plurality of ridges arranged and disposed to separate the pockets. In the embodiment, each pocket has an angle of rotation in the range of about ?5.0° to about 5.0° and the angle of rotation of at least one pocket is other than 0°.

Abstract: A formliner is disclosed. The formliner includes a plurality of courses, each course having a plurality of pockets, each pocket sized and configured to receive a decorative brick. The formliner is modular in nature and includes a joining portion for overlapping or being overlapped by a second formliner. At least one ridge of the formliner is at least partially within the joining portion.

Abstract: A formliner and master mold are disclosed. The master mold corresponds with the formliner, which includes a plurality of courses, each course having a plurality of pockets, each pocket sized and configured to receive a decorative brick, and a plurality of ridges arranged and disposed to separate the pockets. In the embodiment, each pocket has an angle of rotation in the range of about ?5.0° to about 5.0° and the angle of rotation of at least one pocket is other than 0°.