Patent Publication Number: US-2011061331-A1

Title: Paving stone device and method

Description:
This application claims the benefit under 35 USC 119(e) of U.S. Provisional Application No. 61/169,821 filed Apr. 16, 2009, which is incorporated herein in its entirety by this reference to it. 
    
    
     FIELD 
     This specification relates to building products, particularly cast or molded products such as artificial paving stones. 
     BACKGROUND 
     The following paragraphs are not an admission that anything discussed therein is citable as prior art or part of the general knowledge of people skilled in the art. 
     A surface, such as a driveways or walkway, may be paved with a plurality of individual pavers, alternately called paving stones, cobble stones, bricks, or by other names. In one construction method, the pavers are natural stones of varying shapes and sizes selected and placed one by one to cover a surface. This method is extremely labour intensive and produces an arguably attractive but uneven paved surface. In another construction method, bricks are used in place of the natural stones. While still labour intensive, the generally uniform height of the bricks makes it easier to produce a more nearly uniform paved surface. Similarly, artificial stones may be used in place of natural stones. In these various examples, there are problems associated with handling, transporting and positioning large numbers of pavers. 
     SUMMARY 
     This summary is intended to introduce the reader to the more detailed description that follows and not to limit or define any claimed or as yet unclaimed invention. One or more inventions may reside in any combination or sub-combination of the elements or process steps disclosed in any part of this document including its claims and figures. 
     A paving assembly comprises a plurality of pavers arranged in a pattern. The pavers in the assembly are attached to each other and held in position relative to each other by a membrane, alternately called a mesh. The membrane comprises a plurality of connecting members connected end to end and generally co-planar with each other. Projections extend from the connecting members into the pavers. The membrane may be made, for example, of molded plastic, preferably a recycled plastic. 
     To make the assembly, the pavers are formed from a settable material that is poured into a mould having a plurality of cavities arranged in a desired configuration. Before the pavers have completely set, the membrane is positioned over the mould and at least one projection from the membrane is inserted into the settable material in each cavity. After the pavers set, the projections are retained within the pavers. 
     The membrane allows a plurality of pavers to be arranged in position relative to each other in a factory, and then transported and placed on the surface to be paved as a group while retaining the arrangement. A membrane with connecting members located below the bottom of the pavers also serves to separate one assembly from another when they are stacked for shipping. In particular, a membrane made of a relatively soft material such as plastic does not scratch the smooth upper surface of a lower assembly and prevents contact between the upper surface of a lower assembly and the rough lower surface of an upper assembly. Further, with the connecting members located below the bottoms of the pavers, the pavers may be thin since they do not need to encapsulate the connecting members and the connecting members can support the pavers when carried. 
     The pavers assemblies may be part of a system in which multiple assemblies, or parts of assemblies, are used to pave a larger area. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       Reference will now be made, by way of example, to the devices and methods shown in the accompanying drawings in which: 
         FIG. 1   a  is a top view of a paving system; 
         FIG. 1   b  is a top view of the paving system of  FIG. 1   a  in an interlocking arrangement; 
         FIG. 2   a  is a top view of a mesh; 
         FIG. 2   b  is a side view of the mesh of  FIG. 2   a;    
         FIG. 3   a  is a side view of portion of a mesh and a projection; 
         FIG. 3   b  is a top view the portion of a mesh and projection shown in  FIG. 3   a;    
         FIG. 4   a  is a partial side view of a projection on a mesh; 
         FIG. 4   b  is a perspective view of the projection of  FIG. 3   a;    
         FIG. 5   a  is a side view of a portion of a mesh and a deployable projection; 
         FIG. 5   b  is a top view of the portion of mesh and deployable projection of  FIG. 5   a;    
         FIG. 5   c  is a side view of the portion of mesh and deployable projection of  FIG. 5   a  with the deployable projection in a deployed position; 
         FIG. 6  is a top view of a mould containing pavers; 
         FIG. 7  is a top view of the mould containing pavers of  FIG. 6  overlaid with a mesh. 
     
    
    
     For simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity. Further, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. 
     DETAILED DESCRIPTION 
     The following description is not to be considered as limiting the scope of any claimed invention, but rather as providing an example within each claimed invention. However, each example may not be an embodiment of each claimed invention, for example a particular claim might relate to only one exemplary device. The claims should not be interpreted as necessarily including all of the features of any example, or all of the examples or requiring features common to all of the examples. 
     As explained herein with reference to  FIGS. 1   a - 5 , there is disclosed a paving system comprising a plurality of pavers connected together, and held in position relative to each other, by a membrane or mesh. The plurality of pavers in the paving system may be described as “artificial”, or man made, articles as opposed to “natural” stones or rocks. That is, the pavers used in the current paving system are manufactured by filling a mould with settable material and allowing the material to set (or harden or cure or solidify) into a solid material. 
     Before the pavers have completely set, the mould may be overlaid by a mesh having at least one projection, extending from a node of the mesh, that is embedded into each paver. After the projections have been pressed into the pavers, the settable material is allowed to fully set, thereby fixing the projections within the pavers and affixing each paver to the mesh. 
     Once the pavers are affixed to the mesh, the pavers can be released from their moulds to form a paving assembly comprising a plurality of pavers attached to a single mesh. The completed paver assembly can then be installed where desired by a user. In addition, multiple paver assemblies can be used in combination (in either interlocking or non-interlocking configurations) to cover an area that is larger than the area of a single paving assembly. 
     By way of example, reference is made to the paving system  100  shown in  FIGS. 1   a  and  1   b . The paving system  100  shown in  FIG. 1   a  includes two paving assemblies  110 . Each paving assembly  110  includes a plurality of pavers  120  connected to each other, and held in a fixed position relative to each other by an underlying mesh  140 . The paving system  100  may be used in place of individual cobble stones, patio stones, paving stones, tiles or other articles that may be arranged to form a desired surface, such as a driveway, floor, patio or walkway. The paving system  100  may be used to provide a desired surface in a shorter time, at lower cost or having a more uniform paver placement compared to a comparable surface formed from individual, non-attached pavers. 
     Pavers 
     As shown, each paving assembly  110  includes a plurality of pavers  120  arranged in a desired, pre-configured pattern. In the example of  FIGS. 1   a  and  1   b  the pattern is staggered grid or brick-like pattern consisting of a multiple, offset rows of pavers  120 . This type of grid pattern may be desired if the paving system  100 , or a single paving assembly  110 , is to be used to make a generally square or rectangular surface or object, such as a driveway, pathway, parking lot, patio or sidewalk. Other patterns of pavers  120  may also be used. 
     In  FIGS. 1   a - 5 , the pavers  120  are schematically represented as being generally square or rectangular shaped. This is merely one example of paver shapes, but the pavers may be formed in other suitable, desired shapes. The pavers  120  may be of a specific geometric shape such as squares, circles or hexagons. In other instances, the pavers  120  may be of a generally square or rectangular shape to facilitate their arrangement in a pattern, but the edges and surfaces of each individual paver  120  may be curved, bumpy, jagged or otherwise non-linear so that each paver  120  may more closely resemble a natural stone. In some paving systems  100 , each paver  120  may be of the same, or generally similar shape. In other paving systems  100 , each paver  120 , or a sub-grouping of pavers  120 , in the system may be of different shapes. 
     In instances when the paving system  100  is used to provide a traveling surface, the pavers may be shaped such that both the upper and lower surfaces of the pavers are generally flat or planar to provide a level, even paved surface. However, the upper surface need not be completely flat. In some examples, the upper surface of the pavers may be a non-uniform surface modeled after the appearance of a natural paving stone or cobble stone. 
     If the desired finished surface to be formed using the paving system  100  has an area that is substantially equal to the size of a single paving assembly  110 , the entire surface may be covered using a single paving assembly  110 . If, however, the desired finished surface has an area that is larger than a single paving assembly  110 , multiple paving assemblies  110  or parts thereof may be used in combination. As shown in  FIG. 1   a , each paving assembly  110  may be configured to have an identical pattern (or configuration), and the two paving assemblies  110  shown in  FIG. 1   a  may be combined by abutting the edges of the paving assemblies  110  (for example, the two adjacent edges of the paving assemblies  110  as shown in  FIG. 1   a ). Such a configuration may be described as a non-interlocked configuration. In a non-interlocked configuration, the paving system  100  could provide a functional surface, for example a driveway, having the combined area of both paving assemblies  110 , but a user may be able to visually identify the boarders (or edges or outline or perimeter) of each paving assembly  110 . 
     In another example, the pavers  120  in each paving assembly  110  include removable pavers  122  and fixed pavers  124 . In  FIG. 1   b , the paving assemblies  110  of  FIG. 1   a  are shown with the removable pavers  122  removed and having been moved into an interlocking configuration. The boundary between the individual paving assemblies  110  is illustrated on  FIG. 1   b  using the dashed line extending between the paving assemblies  110 . 
     To install the paving system  100  in the interlocked configuration, a number of removable pavers  122  are removed from each paving assembly  110 . The spaces in each paving assembly  110  left by the removal of the removable pavers  122  can serve as interlocking locations, indicated by arrows  123  on the right side of  FIG. 1   b . As illustrated in  FIG. 1   b , the paving system  100  is formed from two paving assemblies  110  and is configured to interlock with an additional paving assembly  110  (not shown) added to the right side of paving system  110 . 
     To remove a removable paver  122  from a paving assembly  110 , the portion of the mesh  140  connecting the removable paver  122  to the adjacent fixed pavers  140  may be broken, cut or otherwise severed to detach the removable paver  122  from the mesh. In other instances, the paving assembly  110  may be initially cast (or formed or moulded) using a modified mesh without removable pavers  122  in place. If desired, fixed pavers  140  may also be removed if desired to modify the shape or size of the paving assembly  110 . 
     In the examples shown, each paving assembly  110  is shown having an identical number of removable pavers  122 , and the removable pavers  122  are shown on two edges of each paving assembly  110 . However, each paving assembly  110  need not have an identical number of removable pavers  122 , and that removable pavers  122  may be formed along greater or fewer than two edges of the paving assembly  110 . A paving assembly  110  might also not include any removable pavers  122 . 
     In  FIGS. 1   a  and  1   b  the removable pavers  122  are illustrated as being approximately half the size of the fixed pavers  124 , but the removable pavers  122  may be of other suitable sizes and shapes that enables the interlocking arrangement or configuration of paving assemblies  110 . 
     In the described examples, the term pavers has been used to describe the individual articles or elements that are arranged to form the paving assembly. This term is appropriate for the example described herein, that is the use of the paving system in place of traditional coble stones, or other types of natural stone paving. However, the paving system may be used for other applications involving moulded (or cast or formed) articles that can be connected by the mesh in a pre-arranged pattern, including tiles, slabs, stones and bricks. 
     Similarly, the pavers have been described as being moulded from a settable material. In the context of an outdoor paving system for use on a driveway, pathway, patio or the like, the settable material used may be chosen from any suitable building material, including concrete, elastomer, thermoplastic, cement, asphalt, rubber or any combination thereof. In other applications, such as an arrangement of indoor tiles, the pavers (or tiles) may be made from any suitable settable material, including ceramic, plastic, cement, composite materials, glass and metal. In each example described above, the plurality of pavers  120  in each paving assembly  110  are held in a desired location by the mesh  140 , as shown in  FIGS. 2   a  and  2   b.    
     Mesh 
       FIGS. 2   a  and  2   b  show schematic representations of an example of a mesh  140  that can be used to underlie the pavers  120  of each paving assembly  110 . 
     As shown, the mesh  140  includes a plurality of connecting members  142 . The connecting members  142  are elongate members (i.e. having a length that is at least 10 times greater than their width/diameter) or segments or a larger structure. The connecting members  142  are connected to each other to form a network structure that is generally planar with large open spaces between the connecting members  142 . The connecting members  142 , or projections of them, intersect with each other to define a plurality of nodes  146 . In the example of  FIGS. 2   a  and  2   b , each node includes a plate  147  and a projection  148 . In the example of  FIGS. 4   a  and  4   b , the ends of the connecting members  142  do not touch each other, but instead terminate at the circumference of the bottom edge of another projection  148 . 
     Another example of a mesh  140  is shown in  FIG. 3   a , which a portion of a mesh  140  and illustrates the positioning of a joining plate  147  attached to the node  146  (or intersection or junction) between two connecting members  142 .  FIG. 3   b  is a top view of the portion of mesh  140  of  FIG. 3   a  showing the intersection of the connecting members  142  that defines a node  146  which is overlaid by joining plate  147 . The positions of the connecting members  142  beneath the joining plate  147  are shown by the dashed lines. Also, while the joining plates  147  are shown as being of a circular or disk-like configuration, it is understood that the joining plates  147  may be of any suitable shape, including square, triangular, rectangular or polygonal. 
     In some instances, particularly when the pavers  120  of the paving system  100  are relatively thin (such as tiles), the joining plates  147  may serve as the projections  148  that are inserted into the pavers  120 . When the pavers  120  of a paving assembly  110  are relatively thin, the projections  148  illustrated in  FIGS. 2   a  and  2   b  may extend from the mesh  140  by a distance that is greater than the thickness of the pavers  120 . In such a situation, the projections  148  may protrude through the upper surface of the pavers  120 , reduce the structural integrity of the pavers  120  or cause other undesirable mechanical and aesthetic concerns. Therefore, in these situations, the use relatively thin projections  148  (in the form of joining disks  147  or any other type of member extending from the node  146 ) received within thin pavers  120  enables the pavers  120  to be connected to the mesh  140  while reducing the structural and aesthetic disturbances to the pavers  120  described above. 
     The connecting members  142  that define mesh  140  may be formed from any suitable material that has suitable mechanical properties. In one example, the mesh  140  may be made from a molded, recycled plastic material. 
     In the examples and Figures described herein, the mesh  140  is illustrated as having a plurality of connecting members  142  arranged in a generally diamond and triangular shapes to provide one node  146  per paver  120 . Optionally, the mesh  140  may be reinforced by the addition of reinforcing members  143 , shown as dashed lines in  FIG. 2   a  to produce all triangular shapes. While the mesh  140  has been shown having a number of nodes that is equal to the number of pavers  120  to be secured, the mesh  140  might alternately include a number of nodes  146  that is greater than the number of pavers  120  attached to the mesh  140  although this is not preferred. 
     The entire mesh  140  may be molded as a unitary structure. Alternately, the connecting members may be connected to each other, and optionally to the joining plates  147 , using an attachment method that is suitable for the material selected, such as sonic welding or chemical adhesives in the case of plastic. Another option is to mold the connecting members only into an integral structure and then attach the joining plates  147 , or an assemblies of a joining plate  147  and a projection  148 , as described above. In another example, the connecting members  142  and the joining plates  147  may be integrally formed and the projections  148  attached later. 
     The mesh  140  is made strong enough to support the pavers  120 , but may be flexible or bendable to reduce the amount of material required and allow the mesh  140  to at least partially follow the contour of the underlying surface to which it is applied. 
     Also, because the connecting members  142  of the mesh  140  are proud of the surface of the attached pavers  120 , the mesh  140  may act as a spacer or insulator when multiple paving assemblies  100  are stacked upon each other for storage or transport, for example on a palette or skid. This may be advantageous because the presence of the mesh  140  between stacked paving assemblies  110  may reduce the amount of rubbing, hitting or scrapping between pavers  120 . The material used to form the pavers  120  may be hard and brittle when set (for example concrete or cement or ceramic). In these examples, direct contact between pavers  120  may result in damage, for example in the form of chipping or scratching, to one or both of the pavers  120 . Also, in some examples the underside of the pavers  120  (the side facing down when installed) may be rougher and more abrasive than the exposed surface of the pavers  120 . As a result, the exposed surfaces of the stacked pavers  120  might suffer damage if not separated by the mesh  140 . The mesh  140  is preferably formed from a material that is softer than the material of the pavers  120 . The softer mesh  140  may provide a buffer or cushion between pavers  120  that may reduce accidental chipping and scratching. 
     Positioning the connecting members  142  of the mesh  140  outside of the pavers  120  may also enable the mesh  140  to better flex and bend as compared to an encapsulated mesh which could only bend in the spaces between pavers  120 . External connecting members also support the pavers  120  from their bottom surface rather than turning their edges. Because the pavers  120  are rigid, virtually all bending or flexing is accomplished by exposed portions of the mesh. If the mesh were to pass through each paver  120 , the exposed portion of the connecting web would be limited to the area between the pavers  120 . As the spacing between pavers is relatively small, the available length of web to bend and flex is also relatively small. Having a relatively small piece of web to flex and bend can exert relatively high stress on the web, and can restrict the flexibility of the paving assembly as a whole. In contrast, having the connecting members  142  outside the pavers  120  may allow the flexing and bending forces to be absorbed over more of the entire length of the connecting members  142 . In response to external bending or flexing loads, the connecting members  142  may flex and bow toward or away from the surface of the pavers  120 . 
     As mentioned above, in some examples each joining plate  147  serves as a base, or support for a projection  148 . Each projection  148  extends away from its supporting joining plate  147  and out of the plane defined by the mesh  140 . The height of each projection  148  is determined based on the thickness of the pavers  120  used in the paving assembly  110 . During the forming of the paving assembly  110 , each projection  148  of the mesh  140  is pressed into the bottom surface of corresponding paver  120  before the paver  120  material has fully set. The projections  148  are then left in the pavers  120  as the pavers  120  fully set, thereby retaining the projection  148  within the paver  120 . In order to prevent the projection  148  from extending through the entire height of the paver  120  and becoming visible on the upper surface of the paver  120 , the height of the projection  148  is limited to a height that is less than the thickness of the paver  120 . In some examples, the projections  148  may be approximately 50% of the thickness of the pavers  120 . In other examples, the projection  148  height may be a smaller, or larger proportion of the paver  120  thickness. In  FIGS. 2   a  and  2   b  the projections  148  have been represented schematically as cylinders, but the projections  148  may be of other shapes that are suitable for insertion into, and retention in the pavers  120 . The projection  148  may be solid or open and may have a roughened or contoured outer surface to be better retained in the pavers  120 . 
     Also, as discussed above, the projections  148  may be relatively thin disk-like structures, for example the joining plates  147  as shown in  FIGS. 3   a  and  3   b.    
       FIGS. 4   a  and  4   b  show an example of a projection  148  extending from a joining plate  147 . The joining plate  147  overlies the node  146  (which may be notional or real) located at the intersection of connecting members  142  and supports the projection  148 . In this example, the projection  148  includes a ring  149  spaced apart from the joining plate  147  and supported by a plurality of struts  150 . The ring  149  may have a diameter that is smaller than the diameter of the joining plate  147  causing the projection to have a generally conical shape. The resulting structure is open in the sense that the non-set material of the paver  120  can flow through gaps between the struts  150  or through a hole in the ring  149  into the projection  148 . The projection  148  may be formed and attached to the mesh  140  without a distinct joining plate  147 , or may be integrally formed with the mesh  140 . 
       FIGS. 5   a - 5   c  show another example of a projection  148  in the form of a deployable projection  150 . One example of a deployable projection  150  is shown in  FIGS. 5   a - 5   c  as a generally conical projection that extends from the node  146 . In  FIGS. 5   a  and  5   b  the deployable projection  150  is shown in its collapsed position. In  FIG. 5   c , the deployable projection  150  is shown in its deployed configuration. 
     In the example shown, the deployable projection  150  comprises a central frame  151  and two deployable leaves  152  movably connected to the deployable projection  150 . When the deployable projection  150  is inserted into a corresponding paver  120  and the mould vibrated, the leaves  152  may move away from the central frame  151 , as shown in  FIG. 5   c . As the leaves  152  move away from the frame, settable material may flow into the spaces formed between the leaves  152  and the central frame  151 . In the deployed configuration, the deployable projection  148  may have more surface area exposed to, and engaged with, the settable material of the paver  120  which may increase the strength of the attachment between the two. Also, in the deployed configuration, the portion of the deployable projection  150  submerged in the paver  120  may be wider than the base of the projection  150  (the portion attached to the mesh  140 ) which may enable increase the strength of the connection between deployable projection  150  and paver  120  by allowing the settable material to fill in a region between the deployed portion of the projection and the mesh  140 . 
     In the example shown, the deployable projection  150  is shown having two leaves  152  that are movably connected to the projection and meet at a central frame  151 . Other examples of deployable projections  150  may include other components and may deploy in other manners. For example, the deployable projection may not have a central frame  151  between the leaves  152 , and it may include a greater or fewer number of movable leaves. Also the leaves  152 , or any movable component, may be attached at the base (i.e. proximate the mesh  140 ) of the deployable projection  150 , or at some other location on the projection. The leaves may move outward from the projection (as shown) or they may be configured to collapse, or mover inward from the surface of the projection. The leaves (and the rest of the projections) may be solid, or they may have a roughened surface, a grooved or ribbed surface, a surface comprising a plurality of apertures or other surface treatments that may tend to increase the strength of the connection between the projection and the paver  120 . 
     In other examples, a deployable projection  150  may include a biasing means that is used to control the deployment of the projection. The biasing means may include, for example, a spring, an elastic or a mechanical means. Also, the movable portion of a deployable projection  150  may be mechanically linked to the projection (as shown) or it may be of any another type of moveable structure such as bendable or deformable structure. 
     Mould 
       FIG. 6  shows a schematic top view of a mould  160  that is used to cast (or mould or form) the plurality of pavers  120  used in the paving system  100 . As shown, a single mould  160  may be configured to form all of the pavers  120  of a complete paving assembly  110 . In another example, the pavers  120  for a single paving assembly may be formed by a plurality of separate moulds arranged in the appropriate configuration. In another example, a single mould may form the pavers  120  for more than one complete paving assembly. 
     In the example shown, the mould  160  contains a plurality of paver-forming cavities  162  arranged in a desired pattern. In this case, the pattern shown in  FIG. 4  is suitable to produce the paving assemblies  110  shown in  FIGS. 1   a  and  1   b , but it may be another pattern as described above. Generally, each paver-forming cavity  162  is sized and shaped to form a single paver  120 . The mould  160  contains paver-forming cavities  162  for forming both fixed pavers  124  and removable pavers  122  if necessary. The mould  160  may be formed from any suitable material known in the art, including metal, rubber, plastic, fiberglas, wood, sand or sand. 
     The inner surface features of the paver-forming cavities  162  serve to form the outer surface features of the pavers  120  cast from the mould  160 . If a user desires pavers  120  having a smooth outer surface, a mould  160  may be created having smooth paver-forming cavities  162 . If a user desires pavers  120  having an irregular, natural stone-like appearance then a mould  160  may be created having irregularly shaped paver-forming cavities  162 . In either example, the pavers  120  are formed by pouring a generally liquid, or at least flowable, settable material into the paver-forming cavities  162 . Prior to pouring the settable material into the paver-forming cavities  162 , the paver-forming cavities may be treated with a lubricant, curing agent or any other suitable substance 
     After the paver-forming cavities  162  have been filled, the settable material will begin to set (or cure or harden). Before the settable material fully sets (or solidifies), the mesh  140  is positioned relative to the mould  160  so that each projection  148  of the mesh  140  is aligned with a corresponding paver  120 . In the example shown, the ratio of nodes  146 , joining plates  147  and projections  148  to pavers  120  is 1:1; in other examples this ratio may be different. When aligned with the mould  160 , the mesh  140  is in an inverted orientation so that the projections  148  extend from the mesh  140  toward the mould  160 . In this orientation, the plane defined by the mesh  140  is generally parallel to, and is offset from a plane defined by the top surface of the mould  160 . The filled paver-forming cavities  162  may be scrapped (or otherwise leveled) so that the exposed surface of the pavers  120  in the mould  160  is generally flush with the surface of the mould  160  and the surfaces of the surrounding pavers  120 . 
     After being positioned, the mesh  140  is moved toward the mould  160  until the projections  148  impinge on the exposed surface of the pavers  120  contained within the paver-forming cavities  162 . Additional pressure can then be applied to each projection  148  to drive the projection  148  into the still-fluid pavers  120  until the projections  148  are substantially submerged within the pavers  120  and the joining plates  147  are adjacent to, with or abut the exposed surface of the pavers  120 . However, the connecting members are preferably not immersed and no additional settable material is applied over the connecting members. The upward facing surface of the mesh  140  (which is the bottom surface of the mesh  140  when the paving assembly is installed) remains exposed and is not covered with settable material. 
     Once the projections  148  have been inserted in the pavers  120 , the mould  160  may be vibrated to help release trapped air pockets and to alter the distribution of aggregate material in each paver-forming cavity  162 . For example, vibrating the mould  160  may cause larger particles in the settable material to rise to the surface of the paver  120  being cast. As a result, the bottom surface of the paver  120  as cast, which is the top surface of the paver  120  when in use, may have a smoother and more uniform finished surface. Further, vibration assists the flow of the settable material into or around the surfaces of the projections  148 . 
     With the projections  148  submerged within the pavers  120  the pavers are allowed to completely set, thereby trapping the projections  148  within the now-hardened pavers  120 . When all the pavers  120  have fully set, the completed paving assembly  110  may be removed from the mould by pulling or ejecting each paver  120  from its corresponding paver-forming cavity  162 . The result of this process is a paving assembly  110  comprising a plurality of pavers  120  each of which is fixedly cast around a projection  148  extending from the mesh  140 . Accordingly, the position of each paver  120  relative to its adjacent pavers  120  is restrained by its attachment to the mesh  140 . This relationship enables the paving assembly  110  to be moved and handled as a single article and eliminates the need for each paver  120  to be individually placed during installation. 
     To install the paving system  100  in its desired location, the installation location is prepared in a manner that is suitable for the placement of individual pavers, including grading, leveling and compacting. Having prepared the underlying surface (or alternatively forgoing the preparation step) each paving assembly  110  is placed in its desired location (in an interlocked or non-interlocked configuration with its neighbours) and the spaces between adjacent pavers  120  are filled a suitable filler such as sand, silicate, soil, gravel, or grout. 
     What has been described above has been intended to be illustrative of the invention and non-limiting. Other variants and modifications may be made without departing from the scope of the invention as defined in the claims.