Abstract:
An erosion control mat provides a plurality of concrete blocks. Each block has an upper portion with a plurality of upper inclined side walls. Each block has a lower portion with a plurality of inclined lower side walls. The block has an upper surface and a lower surface and a block periphery in the form of an edge where the upper and lower side walls meet. Cables or ropes connect the blocks together to form a block matrix and the erosion control mat. Each block has a boot affixed to the block lower portion, the boot having a plurality of inclined side panels. Each boot side panel has an upper edge. The boot has a lower panel, a boot interior surface and an interior that is receptive of at least part of the block lower portion. The boot inclined side panels engage the block inclined lower side walls. The boot lower panel engages the block lower surface. A plurality of anchor posts are attached to the interior surface of the boot. Some of the anchor posts are attached to the side wall panels to enable a connection to be formed between the boot inclined side panels and the block inclined lower side walls. Some of the anchor posts are attached to the lower panel of the boot to enable a connection to be formed between the boot lower panel and the block lower surface. As part of the method, the boot is first placed in a mould. Slurried concrete is then added to the mould so that a connection is formed between the boot anchor posts and the concrete when the concrete sets after a time period.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This is a non provisional patent application of U.S. Provisional Patent Application Ser. No. 61/617,509, filed 29 Mar. 2012; and U.S. Provisional Patent Application Ser. No. 61/721,337, filed 1 Nov. 2012. 
         [0002]    Priority of U.S. Provisional Patent Application Ser. No. 61/617,509, filed 29 Mar. 2012; and U.S. Provisional Patent Application Ser. No. 61/721,337, filed 1 Nov. 2012, each of which is hereby incorporated herein by reference, is hereby claimed. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0003]    Not applicable 
       REFERENCE TO A “MICROFICHE APPENDIX” 
       [0004]    Not applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    1. Field of the Invention 
         [0006]    The present invention relates to mats used for erosion control, pipeline protection, crossings, and many other subsea uses, and methods of installing such mats. More particularly, the present invention relates to an improved mat and method of manufacture wherein a specially configured mould provides concave and convex sides, the concave side providing a plurality of inclined surfaces, each having one or more anchors and wherein the convex side provides hemispherically shaped projections which extend over a bottom surface of the mould, the mould being configured to accept a cementitious fill for forming an block and wherein the blocks can be connected with cables or ropes to form a mat. 
         [0007]    2. General Background of the Invention 
         [0008]    Erosion control mats have been used for many years to protect soil surfaces such as the banks of water bodies (lakes, rivers, etc.). 
         [0009]    Another example of an erosion control mat is the Pilaar patent (U.S. Pat. No. 3,597,928). The Pilaar patent relates to an erosion controlling protective surface for a soil mass. The device includes a flexible supporting sheet that can conform to the contour of the soil and blocks that are mounted on the supporting sheet. The mat provides drainage passageways therethrough so that water can pass through the surfacing. Preferably, the surfacing includes a filter and the blocks are secured with the supporting sheet. 
         [0010]    The Nelson patent (U.S. Pat. No. 3,386,252) shows a rip rap structure that employs concrete blocks connected together. 
         [0011]    Cables are employed to hold blocks together in the Landry patent (U.S. Pat. No. 4,227,829) to form a matrix. 
         [0012]    The Crow patent (U.S. Pat. No. 4,375,928) shows rows of blocks held together by a continuous wire cable which is embedded in each block. 
         [0013]    The Waters patent (U.S. Pat. No. 4,683,156) shows an erosion control blanket of segments. The segments are said to be of concrete placed into shells. The segments are held together with a rope network. Openings in the shells provide points of entry for the ropes. 
         [0014]    The Rudloff patent (U.S. Pat. No. 5,484,230) provides a concrete block revetment system for soil erosion prevention. The system of the Rudloff patent provides concrete blocks that are cable interconnected to form a matrix. The matrix of blocks overlies and holds in place a layer of permeable geotextile overlying a protected soil area. 
         [0015]    The Angel patent (U.S. Pat. No. 6,027,285) entitled “Mat Installation” shows cable connected erosion control blocks that can be used over pipe lines. Other patents issued to Angel include numbers U.S. Pat. Nos. 5,722,795; 5,846,023; and 5,944,449. 
         [0016]    The Landry patent (U.S. Pat. No. 4,486,120) provides a spreader bar for the installation of soil erosion prevention mats. 
         [0017]    The Daniel patent (U.S. Pat. No. 6,406,217) provides a lifting and placing device for seabed mats. 
         [0018]    Other patents possibly relevant to the construction and use of mats for erosion control, pipeline protection, crossings, and many other subsea uses can be seen in the following table, the listing being chronological and otherwise of no significance. Each of the patents listed in the table is hereby incorporated herein by reference. 
         [0019]    The following US patents are incorporated herein by reference: 
         [0000]    
       
         
               
               
               
             
           
               
                   
               
               
                   
                   
                 Issue Date 
               
               
                 Patent No. 
                 Title 
                 MM/DD/YYYY 
               
               
                   
               
             
             
               
                 3,386,252 
                 Rip Rap Structure Device 
                 Sep. 8, 1966 
               
               
                 3,597,928 
                 Erosion Control 
                 Aug. 10, 1971 
               
               
                 4,227,829 
                 Soil Erosion Preventing Blocks 
                 Oct. 14, 1980 
               
               
                 4,375,928 
                 Flexible Concrete For Soil Erosion  
                 Mar. 8, 1983 
               
               
                   
                 Prevention 
                   
               
               
                 4,486,120 
                 Spreader Bar For Soil Erosion  
                 Dec. 4, 1984 
               
               
                   
                 Prevention Mats 
                   
               
               
                 4,683,156 
                 Flexible Blanket 
                 Jul. 28, 1987 
               
               
                 5,484,230 
                 Concrete Block Revetment System  
                 Jan. 16, 1996 
               
               
                   
                 For Soil Erosion Prevention 
                   
               
               
                 5,722,795 
                 Non-Abrasive Subsea Mat 
                 Mar. 3, 1998 
               
               
                 5,846,023 
                 Non-Abrasive Subsea Mat 
                 Dec. 8, 1998 
               
               
                 5,944,449 
                 Non-Abrasive Subsea Mat 
                 Aug. 31, 1999 
               
               
                 6,027,285 
                 Mat Installation 
                 Feb. 22, 2000 
               
               
                 6,406,217 
                 Lifting and Placing Device for  
                 Jun. 18, 2002 
               
               
                   
                 Seabed Mats 
               
               
                   
               
             
          
         
       
     
       BRIEF SUMMARY OF THE INVENTION 
       [0020]    The present invention provides an improved mat used for erosion control, pipeline protection, crossings, and many other subsea uses, that utilizes a plurality of concrete blocks, each block having an upper portion with a plurality of inclined side walls and a lower portion with a plurality of inclined lower side walls. The block provides an upper surface and a lower surface and a block periphery in the form of a block edge where the upper and lower side walls meet. 
         [0021]    Cables or ropes, more specifically copolymer rope, connect the blocks together to form a matrix. The cables or ropes can include multiple cables or ropes or one continuous cable/rope that is looped from one row of blocks or one column of blocks to the next column of blocks. 
         [0022]    Each block has a boot affixed to the block lower portion. The boot has a plurality of inclined side panels, each side panel having an upper edge. The boot has a lower panel and an interior surface. The boot has an interior that is receptive of at least part of the block lower portion. 
         [0023]    The boot inclined side panels engage the block inclined lower side walls. The boot lower panel engages the block lower surface. 
         [0024]    The boot has a plurality of anchor posts attached to the interior surface of the boot. These anchor posts include some anchor posts attached to the side wall panels of the boot. These first plurality of anchor posts enable a connection to be formed between one or more of the boot inclined side panels and the lower side walls of the block. 
         [0025]    Some of the anchor posts are attached to the boot lower panel. This second plurality of anchor posts enable a connection to be formed between the boot lower panel and the block lower surface. 
         [0026]    This improved boot arrangement solves the problem of peeling that can occur during deployment of the mats because they are often lowered to a pipeline resting on a seabed. Mechanical interaction between the mat and the pipeline can dislodge the boots which results in end complete protection for the pipeline. 
         [0027]    In one embodiment, a plurality of the anchor posts have central longitudinal axes that are parallel. 
         [0028]    In one embodiment, the boot lower panel has a plurality of projections. In one embodiment, the projections are hemispherically shaped. 
         [0029]    In one embodiment, there is a concavity on the interior surface of the boot bottom panel next to each projection. In this fashion, when the boot is placed in a mould and slurried concrete added to the mould, the slurry concrete not only fills the interior of the boot but also the concavities behind each projection, thus further reinforcing the projections during use. 
         [0030]    In one embodiment, at least some of the boot side panels have two or more anchor posts. In another embodiment, each side panel has two or more anchor posts. 
         [0031]    In one embodiment, the anchor posts do not extend beyond the upper edges of the boot. 
         [0032]    In one embodiment, the boot side wall upper edges do not extend above the block edge. 
         [0033]    In one embodiment, the boot upper edges are positioned below the cables/ropes. 
         [0034]    The present invention provides a method of constructing a mat. The method includes the providing of a mould apparatus that includes multiple moulds. 
         [0035]    A boot is placed in each mould. Each boot has a plurality of boot anchor posts, a plurality of inclined side panels, each side panel having an upper edge, the boot having a lower panel, a boot interior surface and a boot interior or cavity that is receptive of slurried concrete that can be added to the mould interior after the boot is placed in the mould interior. 
         [0036]    In a preferred embodiment, the exterior surface of the boot and the interior surface of the mould are correspondingly shaped at least in the lower half of the mould. 
         [0037]    As part of the method, the mould is filled with slurried concrete after the boot is placed in the mould. The slurried concrete sets after a time period to form a plurality of concrete blocks. Each block has an upper portion with a plurality of inclined side walls and a lower portion with a plurality of inclined lower side walls. The block has an upper surface, a lower surface and a block periphery in the form of a block edge where the upper and lower block side walls meet. 
         [0038]    Before the time period expires, one or more cables/ropes are placed into the moulds so that after the time period expires, the cable/rope or cables/ropes connect the blocks together to form a block matrix which farms a mat. 
         [0039]    A connection is formed of the boot to the slurried concrete before the time period expires using a plurality of anchor posts extending from the boot to the slurried concrete. 
         [0040]    The plurality of anchor posts are attached to the interior surface of the boot. Some of the anchor posts are attached to side wall panels to enable a connection to be formed between the boot inclined side panels and the block inclined lower side walls. 
         [0041]    Some of the anchor posts are attached to the lower panel to enable a connection to be formed between the boot lower panel and the block lower surface. In a preferred method, the boot lower panel has a plurality of projections. 
         [0042]    In one embodiment, there is a concavity on the interior surface of the boot bottom panel at each projection. This concavity is filled with slurried concrete as part of the method. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0043]    For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
           [0044]      FIG. 1  is a perspective view of a preferred embodiment of the apparatus of the present invention; 
           [0045]      FIG. 2  is a side sectional view of a preferred embodiment of the apparatus of the present invention taken along lines  2 - 2  of  FIG. 1 ; 
           [0046]      FIG. 3  is a side sectional view of a preferred embodiment of the apparatus of the present invention taken along lines  3 - 3  of  FIG. 1 ; 
           [0047]      FIG. 4  is a top view of a preferred embodiment of the apparatus of the present invention; 
           [0048]      FIG. 5  is a side view of a preferred embodiment of the apparatus of the present invention; 
           [0049]      FIG. 6  is a fragmentary side elevation view of a preferred embodiment of the apparatus of the present invention; 
           [0050]      FIG. 7  is a fragmentary side elevation view of a preferred embodiment of the apparatus of the present invention; 
           [0051]      FIG. 8  is a perspective view of another embodiment of the apparatus of the present invention; 
           [0052]      FIG. 9  is a bottom view of the embodiment of  FIG. 8 ; 
           [0053]      FIG. 10  is a top view of an alternate embodiment of the apparatus of the present invention; 
           [0054]      FIG. 11  is a side view of an alternate embodiment of the apparatus of the present invention taken along lines  11 - 11  of  FIG. 10 ; 
           [0055]      FIG. 12  is a side sectional view of an alternate embodiment of the apparatus of the present invention taken along lines  12 - 12  of  FIG. 10 ; 
           [0056]      FIG. 13  is a perspective top view of an alternate embodiment of the apparatus of the present invention; 
           [0057]      FIG. 14  is a fragmentary perspective view of a preferred embodiment of the apparatus of the present invention showing the mould; 
           [0058]      FIG. 15  is a fragmentary perspective view of a preferred embodiment of the apparatus of the present invention showing the mould; 
           [0059]      FIG. 16  is a fragmentary perspective view of a preferred embodiment of the apparatus of the present invention showing the mould; 
           [0060]      FIG. 17  is a fragmentary perspective view of a preferred embodiment of the apparatus of the present invention showing the mould; 
           [0061]      FIG. 18  is a fragmentary perspective view of a preferred embodiment of the apparatus of the present invention showing the mould; 
           [0062]      FIG. 19  is a perspective view of a preferred embodiment of the apparatus of the present invention showing blocks and interconnecting ropes; 
           [0063]      FIG. 20  is a perspective view of a preferred embodiment of the apparatus of the present invention showing blocks and interconnecting ropes; and 
           [0064]      FIG. 21  is a perspective view of a preferred embodiment of the apparatus of the present invention showing blocks and interconnecting ropes; 
           [0065]      FIG. 22  is a top view of another alternate embodiment of the apparatus of the present invention; 
           [0066]      FIG. 23  is a side view of another alternate embodiment of the apparatus of the present invention taken along lines  23 - 23  of  FIG. 22 ; 
           [0067]      FIG. 24  is a side sectional view of another alternate embodiment of the apparatus of the present invention taken along lines  24 - 24  of  FIG. 22 ; and 
           [0068]      FIG. 25  is a perspective top view of another alternate embodiment of the apparatus of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0069]      FIGS. 1-7  show a preferred embodiment of the apparatus of the present invention which is designated generally by the numeral  10 . Mat apparatus  10  employs a boot  11  which can be placed in a mould  50  prior to the addition of a wet or slurried concrete mix. Once the concrete mix cures or sets, blocks are formed. The mould  50  provides halves  51 ,  52  and rope or cable  42  openings  53 . The openings  53  enable rope or cable, such as copolymer rope, wire rope or any other selected connecting rope or cable, to be used to connect the concrete or cast blocks  43 . The blocks  43  are preferably of concrete material which is initially a slurry added to the moulds  50  and allowed to set with the connecting rope  42  in place (see  FIG. 18 ). After the concrete sets, an erosion control mat  10  is formed of individual blocks  43  connected by rope  42  (see  FIGS. 19-21 ). The boot  11  is a liner that is placed in the mould  50  lower half  52 . Boot  11  then becomes a covering, coating or boot for a lower part of the block  43  after the concrete or cementitious filler material hardens or sets. As seen in  FIG. 17 , the rope or cable  42  runs through each block  43  in two directions, each such rope or cable perpendicular to the other within a given block  43 . Mould  50  can include multiple mould cavities  58 , one cavity forming one block  43 . An upper opening  54  enables intake of slurried or wet concrete. Rope or cable  42  can be of any material such as wire rope, polymeric rope, copolymer rope, or any other elongated tensile material. 
         [0070]    In  FIGS. 1-5 , the boot  11  has a panel  12  which can be characterized as a bottom panel. The boot  11  can be about 9 15/16″-10⅛″ (25.2 cm-25.7 cm) long, about 9 15/16″-10⅛″ (25.2 cm-25.7 cm) wide, and about 3″ (7.6 cm) high. Panel  12  can be about 6¼″ (15.9 cm) wide and about 6¼″ (15.9 cm) long. The under surface of the panel  12  is provided with a plurality of projections  13  that are arranged in an array. The projections  13  can be hemispherically shaped projections as seen in  FIGS. 2-3, 5 . The array of projections or hemispherical projections  13  can thus include a plurality of rows  14  of projections  13  and a plurality of columns  15  of projections. In  FIGS. 1-5 , there can be seen six rows  14  of projections and six columns  15  of projections to form the array of projections  13 . Projections  13  can be located about 1″ (2.5 cm) apart from each other on panel  12 . The projections  13  located closest to the edges of panel  12  can be located about ⅝″ (1.6 cm) from the edge of panel  12 . Projections  13  can extend about ¼″ (0.6 cm) from the under surface of panel  12  and can be about ½″ (1.3 cm) wide. The boot  11  includes a plurality of inclined side walls  24 ,  25 ,  26 ,  27 . As shown in  FIGS. 1-5 , each inclined side wall  24 ,  25 ,  26 ,  27  is joined to panel  12  and to other side walls. The combination of bottom panel  12  and inclined side panels,  24 ,  25 ,  26 ,  27  can be a one piece plastic boot  11  such as an injection moulded integral part. 
         [0071]    A plurality of generally cylindrically shaped posts or anchors  16  are attached to the inside surface of panel  12  as seen in  FIGS. 1-4 . Each of the posts or anchors  16  (see  FIG. 7 ) can provide a generally cylindrically shaped side wall  17  (about 1¼″ (3.2 cm) long), an upper end portion  22  (about ⅜″ (1.0 cm) wide) and a lower end portion  23  (about 1 1/16″ (2.7 cm) wide). The lower end portion  23  can be flat and circular where the anchor or post  16  is joined to panel  12 . The upper end portion  22  of each post  16  can provide recess or concavity  18 , a projecting portion  19 , and curved surfaces at  20  (having a radius of curvature of ⅛″ (0.3 cm)),  21  (having a radius of curvature of ¼″ (0.6 cm)). 
         [0072]      FIG. 6  shows a post or anchor  28 . A post or anchor  28  is attached to an inclined side wall or panel  24 ,  25 ,  26 ,  27 . In a preferred embodiment, multiple of the panels  24 ,  25 ,  26 ,  27  have posts  28 . Each post  28  has a generally cylindrically shaped side wall portion  29 , a diagonally extending or inclined surface  36 , and end portions  34 ,  35 . The end portion  35  provides the diagonally extending or inclined surface  36 . Post or anchor  28  can be about ½″ (1.3 cm) wide. End portion  34  can be about ¼″ (0.6 cm) wide. 
         [0073]    As with the post  16 , the post  28  provides end portion  34  having a recess or concavity  30 , projecting portion  31 , and curved surfaces at  32  (having a radius of curvature of 1/16″ (0.2 cm)),  33  (having a radius of curvature of 3/16″ (0.5 cm)). In the embodiment shown, each of the posts  16  has a central longitudinal axis that forms a right angle or 90 degrees with the panel  12  as shown in  FIGS. 4, 7 . The central longitudinal axes of the posts  16 ,  28  can be parallel. 
         [0074]    In the embodiment shown in  FIGS. 1 and 4 , the panel  12  provides five posts  16 . Each of the inclined side walls or panels  24 ,  25 ,  26 ,  27  provides a pair of posts  28 . Each post or anchor  28  has a central longitudinal axis that forms an acute or obtuse angle with the panel  24 ,  25 ,  26 ,  27  to which it is attached. Post  28  can be about ½″ (1.3 cm) diameter and about 1 11/16″ (4.3 cm) long. Post  16  can be about ¾″ (1.9 cm) in diameter and about 1¼″ (3.2 cm) long. 
         [0075]    Each inclined side wall or panel  24 ,  25 ,  26 ,  27  provides an upper edge which defines the top of the boot  11 . These edges can be seen in  FIG. 4  as edges  37 ,  38 ,  39 ,  40 . Edges  37 ,  38 ,  39 ,  40  can be about 9 15/16″-10⅛″ (25.2 cm-25.7 cm) long. In a preferred embodiment, the top of each post or anchor  16 ,  28  is at or below edges  37 ,  38 ,  39 ,  40 . The boot  11  provides a cavity  41  that is receptive of wet or slurried concrete or other suitable filler material which fills the mould  50  cavity  58  in order to form a final block  43  of the erosion control mat  10 . 
         [0076]    In  FIGS. 14-19 , the mould or moulds  50  can be shown in more detail. Padeyes  55  can be used to lift and transport the moulds  50 . Each mould  50  can provide an upper mould half  51  and a lower mould half  52 . Mould halves  51 ,  52  each provide semi-circular openings so that when the two mould halves  51 ,  52  are assembled, a rope opening  53  is provided. Preferably, there are four rope openings  53  spaced equal distance around the periphery of the mould  50  cavity  58  as shown. In  FIGS. 16-18 , the rope or other cable  42  can be shown inserted through the rope openings  53  and interconnecting the blocks  43 . Once the moulds  51 ,  52  are filled with concrete in its slurried or wet form the ropes  42  are encapsulated with concrete. Connecting members  57  can be used to help keep the moulds  50  at the correct spacing. Each mould  50  thus provides a mould cavity  58  which defines the overall shape of each block  42 , that final block  42  shape seen in  FIGS. 19-21 .  FIGS. 17-19  show the mould cavities  58  and the multiple cavity mould assembly  56 . Each block  43  has a periphery  44  and an upper block section  45  and lower block section  46 . The boot  11  would thus be placed in the mould  50  lower half  52  before slurried concrete in its wet form is added to the mould  50  via upper opening concrete inlet  54 . The concrete not only fills the mould cavity  58  but also fills the cavity  41  of the boot  11 . Hemispherically shaped concavities  59  can be provided, one for each projection or hemispherical projection  13 . These hemispherically shaped concavities  59  would also be filled with concrete when the liquid or slurried concrete mix is added to the mould  50  interior or cavity  58 . The entire boot  11  including panel  12 , panels  24 ,  25 ,  26 ,  27 , post  16 , posts or anchors  28 , and projecting hemispherical projections  13  can be a one piece injection moulded member. 
         [0077]    Another or alternate boot is shown in  FIGS. 8-9 , designated by the numeral  60 . The boot  60  can be about 9 15/16″-10⅛″ (25.2 cm-25.7 cm) long, about 9 15/16″-10⅛″ (25.2 cm-25.7 cm) wide, and about 3″ (7.6 cm) high. In  FIGS. 8-9 , the boot  60  has a panel  61  which can be characterized as a bottom wall or panel. Panel  61  can be about 6¼″ (15.9 cm) wide and about 6¼″ (15.9 cm) long. The under surface of the panel  61  is provided with a plurality of projections  62  that are arranged in an array (see  FIGS. 8-9 ). The projections  62  can be hemi spherically shaped projections as seen in  FIG. 9 . The array of projections or hemispherical projections  62  can thus include a plurality of rows  63  of projections  62  and a plurality of columns  64  of projections  62 . In  FIGS. 8-9 , there can be seen six rows  63  of projections and six columns  64  of projections to form the array of projections  62 . Projections  62  can be located about 1″ (2.5 cm) apart from each other on panel  61 . Projections  62  can extend about ¼″ (0.6 cm) from the under surface of panel  61  and can be about ½″ (1.3 cm) wide. 
         [0078]    The boot  60  includes a plurality of inclined side walls  73 - 76 . As shown in  FIGS. 8-9 , each inclined side wall  73 - 76  is joined to panel  61  and to other side walls. The combination of bottom panel  61  and inclined side panels  73 - 76  can be a one piece plastic boot  60  such as an injection moulded integral part. 
         [0079]    A plurality of generally cylindrically shaped posts or anchors  16  are attached to the inside surface of panel  61  as seen in  FIG. 8 . Posts or anchors  16  attached to boot  60  can be configured as seen in  FIG. 7 . One or more posts or anchors  28  are attached to an inclined side wall or panel  73 - 76 . Posts or anchors  28  attached to boot  60  can be configured as seen in  FIG. 6 . In a preferred embodiment, multiple of the panels  73 - 76  have posts  28 . 
         [0080]    In the embodiment shown in  FIGS. 8-9 , each of the posts  16  has a central longitudinal axis that forms a right angle or 90 degrees with the panel  61 . The central longitudinal axes of the posts  16 ,  28  can be parallel. 
         [0081]    In the embodiment shown in  FIGS. 8-9 , the panel  61  provides five posts  16 . Each of the inclined side walls or panels  73 - 76  provides a pair of posts  28  as seen in  FIG. 8 . Each post or anchor  28  has a central longitudinal axis that forms an acute or obtuse angle with the panel  73 - 76  to which it is attached. Posts  16  in  FIGS. 8-9  can be about ¾″ (1.9 cm) in diameter and about 1¼″ (3.2 cm) long. Posts  28  in  FIGS. 8-9  can be about ½″ (1.3 cm) in diameter and about 1 5/16″ (3.3 cm) long. 
         [0082]    Each inclined side wall or panel  73 - 76  provides an upper edge which defines the top of the boot  60 . These edges  86 - 89  can be seen in  FIG. 8  as edges  86 - 89 . In a preferred embodiment, the top of each post or anchor  16 ,  28  is at or below edges  86 - 89 . The boot  60  provides a cavity  90  that is receptive of wet or slurried concrete or other suitable filler material which fills the mould  50  cavity  58  and cavity  90  in order to form a final block  43  of the mat  10 . Each mould cavity  58  is thus fitted with a boot  60  before slurried concrete is added. 
         [0083]    In  FIGS. 8 and 9 , there are provided a plurality of projecting lips that project inwardly of the upper edges  86 - 89  of the inclined side walls  73 - 76 . The inwardly extending lips  91 - 94  are spaced from the recesses, concavities or corrugations  100 ,  101  that are on opposing sides of each corner  95 ,  96 ,  97 ,  98 . Each corner  95 - 98  includes a curved side wall  99  that is in between two recesses, concavities or corrugations  100 ,  101 . As seen in  FIGS. 8 and 9 , each of the recesses, concavities or corrugations  100 ,  101  has a larger upper end portion  102  and a smaller lower end portion  103 . The cross section of each recess or concavity  100 ,  101  gradually decreases between the upper end portion  102  and the lower end portion  103  as shown in  FIGS. 8 and 9 . 
         [0084]    The inwardly projecting lips  91 - 94  help to sturdy or rigidify the side walls  73 - 76 , preventing them from flexing. If the side walls  73 - 76  flex inward, concrete can easily flow over the side of the boot  60  and compromise the protection that the boot provides. 
         [0085]    The corners  95 - 98  are provided with the recesses at  100 ,  101  to allow the side walls  73 - 76  to flex in and out. The design of each of the corners  95 - 98  with recesses  100 ,  101  provide some flexibility to the side walls if the height of the individual block  43  changes such as for example, from 9″ to 12″ (22.9 cm to 30.5 cm). Thus, the angle assumed by each of the outer walls to change as the height of the block  43  changes. The “fluted” corners provide this flexibility. 
         [0086]      FIGS. 10-13  show an additional embodiment of the apparatus of the present invention in the form of an alternate boot or pad, designated by the numeral  104 . Boot or pad  104  can be used in place of the boot  11 , in conjunction with boot  11  to have both top and bottom surfaces of a non-abrasive nature, or the boot or pad  104  can be used on both top and bottom to provide non-abrasive surfaces on both sides. Boot or pad  104  is similar to boot  11  but does not have the inclined side walls of boot  11 . Boot or pad  104  can be about 8¾″ (22.2 cm) long and about 8¾″ (22.2 cm) wide. Boot or pad  104  has a panel  105  with upper surface  106  and lower surface  107 . Lower surface  107  can be about 8½″ (21.6 cm) long and about 8½″ (21.6 cm) wide. Panel  105  can has a border portion  119  and base portion  120  (see  FIG. 12 ). Border portion  119  can be about ⅛″ (0.3 cm) thick. Base portion  120  can be about ⅛″ (0.3 cm) thick. Boot or pad  104  has a periphery  108  that includes edges  109 - 112 . Each edge  109 - 112  has a beveled or inclined surface. Edge  109  has beveled or inclined surface  113 . Edge  110  has beveled or inclined surface  114 . Edge  111  has beveled or inclined surface  115 . Edge  112  has beveled or inclined surface  116 . Surface  106  has a plurality (e.g. five (5) as shown in  FIG. 10 ) of posts or anchors  16 . The posts or anchors  16  can thus be configured as shown in  FIG. 7 . In  FIG. 10-13 , the four posts or anchors  16  that are located near the edges of the panel  105  can each be located about 2⅜″ (6.0 cm) from the edges of panel  105 . Posts or anchors  16  can extend about 1⅜″ (3.5 cm) from the lower surface  107  of panel  105 . Lower surface  107  has rows  117  and columns  118  of projections  13  (e.g. six (6) projections  13  in each row  117  and six (6) projections  13  in each column  118 ). Projections  13  can be located about 1″ (2.5 cm) apart from each other on panel  105 . The projections  13  located closest to the edges of panel  105  can be located about 1¾″ (4.4 cm) from the edge of lower surface  107 . Projections  13  can extend about ¼″ (0.6 cm) from the under surface of panel  105 . As with the preferred embodiment and boot  11 , the boot or pad  104  is a liner that is placed in the mould  50  lower half  52 . Boot or pad  104  then becomes a covering, coating or boot for a lower part of the block  43  after the concrete or cementitious filler material hardens or sets. Optionally, boot  104  can be placed in the mould  50  upper half  51  and the lower half  52 . Optionally, boot  104  can be placed in the mould  50  upper half  51  when boot  11  is placed in the lower half  52 . 
         [0087]      FIG. 22-25  show an additional embodiment of the apparatus of the present invention in the form of another alternate boot or pad, designated by the numeral  130 . Boot or pad  130  can be used in place of the boot  11  or pad  104 , in conjunction with boot  11  to have both top and bottom surfaces of a non-abrasive nature, or the boot or pad  130  can be used on both top and bottom to provide non-abrasive surfaces on both sides. Boot or pad  130  is similar to boot  11  but does not have the inclined side walls of boot  11 . Boot or pad  130  can be about 6¼″ (15.9 cm) long and about 6¼″ (15.9 cm) wide. Boot or pad  130  has a panel  131  with upper surface  132  and lower surface  133 . Lower surface  133  can be about 5¼″ (13.3 cm) long and about 5¼″ (13.3 cm) wide. Panel  131  can has a border portion  134  and base portion  135  (see  FIG. 24 ). Border portion  134  can be about ¼″ (0.6 cm) thick. Base portion  135  can be about ⅛″ (0.3 cm) thick. Boot or pad  130  has a periphery  136  that includes edges  137 - 140 . Each edge  137 - 140  has a beveled or inclined surface. Edge  137  has beveled or inclined surface  141 . Edge  138  has beveled or inclined surface  142 . Edge  139  has beveled or inclined surface  143 . Edge  140  has beveled or inclined surface  144 . 
         [0088]    Surface  132  has a plurality (e.g. five (5) as shown in  FIGS. 22, 25 ) of posts or anchors  147 . Posts  147  have upper end portion  148  and lower end portion  150 . The upper end portion  148  of each post  147  can provide recess or concavity  151 , a projecting portion  152 , and curved surfaces at  153  (having a radius of curvature of ⅜″ (0.9 cm)),  154  (having a radius of curvature of ¼″ (0.6 cm)). In  FIG. 22-25 , the four posts or anchors  147  that are located near the edges of the panel  131  can each be located about 1⅛″ (2.9 cm) from the edges of panel  131 . Posts or anchors  147  in  FIGS. 22-25  can be about 1¾″ (4.4 cm) long and about ½″ (1.3 cm) wide. The upper end portion  148  of post  147  can be about 7/16″ (1.1 cm) wide and the lower length  149  below recess  151  of post  147  can be about 1″ (2.5 cm) long. Lower surface  133  has rows  145  and columns  146  of projections  13  (e.g. five (5) projections  13  in each row  145  and five (5) projections  13  in each column  146 ). Projections  13  can be located about 1″ (2.5 cm) apart from each other on panel  131 . The projections  13  located closest to the edges of lower surface  133  can be located about ⅝″ (1.6 cm) from the edge of lower surface  133 . Projections  13  can extend about ¼″ (0.6 cm) from the under surface of panel  131 . Panel  131  has a plurality (e.g., four (4) as shown in  FIGS. 22 and 25 ) of holes  155 . Holes  155  extend through panel  131  from upper surface  132  to lower surface  133  of pad  130 . As with the preferred embodiment and boot  11 , the boot or pad  130  is a liner that is placed in the mould  50  lower half  52 . Boot or pad  130  then becomes a covering, coating or boot for a lower part of the block  43  after the concrete or cementitious filler material hardens or sets. Optionally, pad  130  can be placed in the mould  50  upper half  51  and the lower half  52 . Optionally, pad  130  can be placed in the mould  50  upper half  51  when boot  11  is placed in the lower half  52 . 
         [0089]    The following is a list of parts and materials suitable for use in the present invention: 
         [0000]    
       
         
               
             
               
               
             
               
               
             
           
               
                   
               
               
                 PARTS LIST 
               
             
          
           
               
                 PART NUMBER 
                 DESCRIPTION 
               
               
                   
               
             
          
           
               
                 10 
                 mat apparatus 
               
               
                 11 
                 boot 
               
               
                 12 
                 panel/bottom wall 
               
               
                 13 
                 projection/hemispherical projection 
               
               
                 14 
                 row of projections 
               
               
                 15 
                 column of projections 
               
               
                 16 
                 post/anchor 
               
               
                 17 
                 cylindrical side wall 
               
               
                 18 
                 recess/concavity 
               
               
                 19 
                 projecting surface 
               
               
                 20 
                 curved surface 
               
               
                 21 
                 curved surface 
               
               
                 22 
                 end portion 
               
               
                 23 
                 end portion 
               
               
                 24 
                 inclined side wall/panel 
               
               
                 25 
                 inclined side wall/panel 
               
               
                 26 
                 inclined side wall/panel 
               
               
                 27 
                 inclined side wall/panel 
               
               
                 28 
                 post/anchor 
               
               
                 29 
                 cylindrical side wall 
               
               
                 30 
                 recess/concavity 
               
               
                 31 
                 projecting position 
               
               
                 32 
                 curved surface 
               
               
                 33 
                 curved surface 
               
               
                 34 
                 end portion 
               
               
                 35 
                 end portion 
               
               
                 36 
                 diagonal/inclined surface 
               
               
                 37 
                 edge 
               
               
                 38 
                 edge 
               
               
                 39 
                 edge 
               
               
                 40 
                 edge 
               
               
                 41 
                 boot cavity 
               
               
                 42 
                 cable/rope/copolymer rope 
               
               
                 43 
                 block 
               
               
                 44 
                 periphery 
               
               
                 45 
                 upper block section 
               
               
                 46 
                 lower block section 
               
               
                 50 
                 mould 
               
               
                 51 
                 mould half 
               
               
                 52 
                 mould half 
               
               
                 53 
                 rope opening 
               
               
                 54 
                 upper opening/concrete inlet 
               
               
                 55 
                 padeye 
               
               
                 56 
                 multiple cavity mould assembly 
               
               
                 57 
                 connecting members 
               
               
                 58 
                 mould cavity 
               
               
                 59 
                 concavity 
               
               
                 60 
                 boot 
               
               
                 61 
                 panel/bottom wall 
               
               
                 62 
                 projection/hemispherical projection 
               
               
                 63 
                 row of projections 
               
               
                 64 
                 column of projections 
               
               
                 73 
                 inclined side wall/panel 
               
               
                 74 
                 inclined side wall/panel 
               
               
                 75 
                 inclined side wall/panel 
               
               
                 76 
                 inclined side wall/panel 
               
               
                 86 
                 edge 
               
               
                 87 
                 edge 
               
               
                 88 
                 edge 
               
               
                 89 
                 edge 
               
               
                 90 
                 boot cavity 
               
               
                 91 
                 inwardly projecting lip 
               
               
                 92 
                 inwardly projecting lip 
               
               
                 93 
                 inwardly projecting lip 
               
               
                 94 
                 inwardly projecting lip 
               
               
                 95 
                 corner 
               
               
                 96 
                 corner 
               
               
                 97 
                 corner 
               
               
                 98 
                 corner 
               
               
                 99 
                 curved side wall 
               
               
                 100 
                 recess/concavity/corrugation 
               
               
                 101 
                 recess/concavity/corrugation 
               
               
                 102 
                 larger upper end of recess 
               
               
                 103 
                 smaller upper end of recess 
               
               
                 104 
                 boot/pad 
               
               
                 105 
                 panel 
               
               
                 106 
                 upper surface 
               
               
                 107 
                 lower surface 
               
               
                 108 
                 periphery 
               
               
                 109 
                 edge 
               
               
                 110 
                 edge 
               
               
                 111 
                 edge 
               
               
                 112 
                 edge 
               
               
                 113 
                 beveled/inclined surface 
               
               
                 114 
                 beveled/inclined surface 
               
               
                 115 
                 beveled/inclined surface 
               
               
                 116 
                 beveled/inclined surface 
               
               
                 117 
                 row of projections 
               
               
                 118 
                 column of projections 
               
               
                 119 
                 border portion 
               
               
                 120 
                 base portion 
               
               
                 130 
                 boot/pad 
               
               
                 131 
                 panel 
               
               
                 132 
                 upper surface 
               
               
                 133 
                 lower surface 
               
               
                 134 
                 border portion 
               
               
                 135 
                 base portion 
               
               
                 136 
                 periphery 
               
               
                 137 
                 edge 
               
               
                 138 
                 edge 
               
               
                 139 
                 edge 
               
               
                 140 
                 edge 
               
               
                 141 
                 beveled/inclined surface 
               
               
                 142 
                 beveled/inclined surface 
               
               
                 143 
                 beveled/inclined surface 
               
               
                 144 
                 beveled/inclined surface 
               
               
                 145 
                 row of projections 
               
               
                 146 
                 column of projections 
               
               
                 147 
                 post/anchor 
               
               
                 148 
                 upper end portion 
               
               
                 149 
                 post lower length 
               
               
                 150 
                 lower end portion 
               
               
                 151 
                 recess/concavity 
               
               
                 152 
                 projecting portion 
               
               
                 153 
                 curved surface 
               
               
                 154 
                 curved surface 
               
               
                 155 
                 hole 
               
               
                   
               
             
          
         
       
     
         [0090]    All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise. 
         [0091]    The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.