Crane mats are essential for ensuring stability, safety, and efficiency on construction sites, particularly when operating heavy equipment like cranes, excavators, or piling rigs on challenging terrain. This buyer’s guide provides a detailed roadmap for choosing crane mats, covering types, sizing, material considerations, condition and cost factors, and key purchasing tips to optimize your investment.
Understanding Crane Mats and Their Role
Crane mats, also known as timber mats, construction mats, or heavy equipment mats, are robust platforms typically made of large timbers designed to distribute the weight of heavy machinery across unstable or sensitive surfaces. They serve multiple purposes on construction sites:
Ground stabilization: Crane mats provide a stable, level surface for equipment like crawler cranes, excavators, or piling rigs, preventing tipping or sinking on soft, uneven, or wetland terrain such as marshes or swamps.
Ground protection: They minimize environmental disruption by reducing ground erosion, vegetation damage, and changes in natural drainage, which is critical in environmentally sensitive areas.
Access creation: Crane mats can be used to build temporary roadways, bridges, or crane access trestles, enabling equipment and workers to reach remote or hard-to-access locations safely.
Safety enhancement: By offering adequate bearing capacity, mats reduce the risk of machinery toppling, ensuring safer operation for workers and protecting equipment from damage.
For example, in bridge construction, crane mats—often called bridge mats—create stable decking for workers and equipment, while in oil and gas projects, they facilitate temporary roads for pipeline construction in remote areas. Their versatility makes them indispensable across industries, but selecting the right mat requires careful consideration of project needs.
Types of Crane Mats and Their Applications
Crane mats come in various types, each suited to specific applications, equipment, and terrain. Understanding these options ensures you select mats that meet your project’s demands.
Timber Crane Mats
Description: Made of heavy, solid timbers (typically 8–12 inches thick), joined by steel through-bolts (lifting bolts) for durability. Common timbers include oak, mixed hardwood, Douglas fir, or southern yellow pine.
Applications: Ideal for supporting heavy equipment like cranes, excavators, and piling rigs on uneven or soft ground. They’re widely used in construction, oil and gas, and renewable energy projects, such as wind turbine construction, where mats stabilize equipment on marshy or remote sites.
Advantages: High load-bearing capacity (up to 200,000 pounds depending on subsurface and configuration), environmentally friendly, and reusable for multiple projects. Their uniform thickness ensures consistent support.
Considerations: Timber mats can weather and rot if exposed to moisture for extended periods, so proper storage and maintenance are crucial.
Laminated Mats
Description: Constructed from three-ply laminated hardwood, these mats are lighter and easier to handle than solid timber mats, typically 4–8 feet wide and 15–50 feet long.
Applications: Best for projects requiring flexibility across varied terrain, such as temporary roadways or platforms for lighter equipment in utility or power plant construction.
Advantages: Lightweight design simplifies transport and installation, and their strength makes them suitable for diverse job site challenges.
Considerations: Less durable than solid timber mats under extreme loads, so they’re better suited for lighter applications or as transition mats between matted and unmatted areas.
Composite Crane Mats
Description: Made from materials like plastic, rubber, or fiberglass instead of timber, offering a modern alternative with unique properties.
Applications: Used in environmentally sensitive areas or projects requiring long-term durability, such as pipeline construction or excavation in wetlands.
Advantages: Resistant to rot, moisture, and insects, with a longer lifespan than timber mats. They’re also lighter and easier to clean.
Considerations: Higher upfront cost compared to timber mats, and load-bearing capacity may vary depending on the composite material.
Crushed Concrete Mats (Piling Mats)
Description: Built from crushed concrete, often layered over existing ground and reinforced with steel mesh for added strength. They’re typically custom-built on-site.
Applications: Commonly used for piling rigs or crawler cranes that remain stationary for extended periods, such as on tarmac or thin concrete surfaces that need leveling without excavation.
Advantages: Cost-effective for specific applications, as the concrete can be broken up and recycled after use. Provides a firm, level base for precision work like pile drilling.
Considerations: Requires site preparation, including surveys to determine levels and remove waste material, and may involve laying membranes in water-heavy areas to prevent soil seepage.
Ground Protection Mats
Description: Smaller than traditional crane mats, ground protection mats like the EZG Manufacturing Hogtrax Ground Protection Mats (GPM4x8) are made of high-density polyethylene (HDPE), measuring 4 feet by 8 feet. They feature a diamond cleat over a honeycomb dual-surface tread for enhanced grip and can support up to 120 tons per mat, depending on the application.
Applications: Ideal for creating stable pathways or protecting sensitive ground in wetland or uneven terrain, these mats are suited for lighter equipment like excavators or as supplementary mats alongside traditional crane mats in larger setups. They’re often used in utility projects or renewable energy sites where minimizing environmental impact is a priority.
Advantages: Lightweight and resistant to rot, water, and chemicals, HDPE mats are easy to handle and clean, with four handholds for manual positioning. They provide a durable, reusable solution for less demanding applications.
Considerations: Their smaller size and load capacity make them less suitable for heavy cranes (e.g., 200-ton crawler cranes), but they excel in protecting ground surfaces and supporting lighter equipment.
Sizing and Load-Bearing Considerations
Choosing the correct size and load-bearing capacity of crane mats is critical to ensure safety and performance. Mats that are too small or under-rated can lead to equipment instability, while oversized mats increase costs unnecessarily.
Standard Sizes
Dimensions: Common crane mat sizes range from 15 to 50 feet in length, 4 to 8 feet in width, and 8 inches to 1 foot in thickness. Transition mats, used for smooth transitions between matted and unmatted areas, are often 12 inches x 4 feet x 16 feet or custom lengths.
Customization: Many suppliers, such as Buckeye Mats, offer custom sizes through partnerships with sawmills, allowing you to tailor mats to specific project needs. For example, a narrow 4-foot-wide mat may suffice for a temporary roadway, while a 50-foot-long mat is better for a crane access trestle.
Load-Bearing Capacity
Weight support: Mats can support weights from 80,000 to over 200,000 pounds, depending on the type, configuration, and subsurface conditions. Timber mats generally offer the highest capacity, while laminated or composite mats may support lighter loads.
Factors to consider: The size and weight of your equipment (e.g., a 230-ton crawler crane), the type of ground (e.g., soft marsh vs. firm tarmac), and allowable ground-bearing pressure. Temporary works designs often specify mat requirements based on outrigger loads and subsurface conditions.
Example: A crawler crane on a wetland site may require 8-inch-thick timber mats to distribute its 200,000-pound load, while a lighter telescopic handler on firm ground might use a 6-inch laminated mat.
Site-Specific Needs
Conduct a site survey to assess terrain, ground conditions, and potential hazards like drainage, cables, or water pipes. This informs how much material (e.g., crushed concrete) or mat thickness is needed.
For uneven or water-heavy sites, consider additional measures like membranes under crushed concrete mats to prevent soil seepage, or wider mats to distribute loads more evenly.
Proper sizing and load-bearing capacity ensure your mats can handle the demands of your equipment and site, preventing accidents and delays.
Material and Condition: New vs. Used Mats
Crane mats vary in material and condition, impacting their durability, cost, and suitability. Weighing new versus used options helps balance performance with budget constraints.
Material Options
Hardwood types: Oak, mixed hardwood, Douglas fir, and southern yellow pine are common, with oak offering the highest durability and load capacity. Southern yellow pine, prevalent in the Western U.S., provides a cost-effective alternative with good strength.
Construction quality: Look for mats with uniform thickness and high-quality steel through-bolts (lifting bolts) to ensure structural integrity. Mats with wax-painted ends resist moisture penetration, extending lifespan.
Composite alternatives: Plastic, rubber, or fiberglass mats are rot-resistant but may have lower load capacities. They’re best for long-term use in harsh environments.
Condition and Grading
New mats: Offer peak performance and longevity (up to 5 years with proper care), with no wear or damage. They’re ideal for high-stakes projects where reliability is paramount, such as bridge construction or wind turbine installation.
Used mats: Graded from A to C based on condition. Grade A mats are like-new, Grade B mats have minor surface damage but remain functional, and Grade C mats show noticeable wear but are usable for lighter applications or as filler. Used mats can save 30–50% on costs, making them attractive for budget-conscious contractors.
Prior applications: Ask sellers about the mat’s history (e.g., used in heavy crane work vs. temporary roadways) to gauge stress and remaining lifespan. Mats previously used under extreme loads may have reduced durability.
Cost vs. Longevity
New timber mats cost $500–$2,000 depending on size and material, while used mats range from $200–$1,000 based on condition. Composite mats are pricier upfront ($1,000–$3,000) but last longer in wet conditions.
Used mats in Grade A or B condition offer the best value, balancing cost savings with reliability. Grade C mats are heavily discounted but may require pairing with stronger mats for safety.
Choosing between new and used mats depends on your project timeline, budget, and risk tolerance. For long-term or high-risk projects, new mats provide peace of mind, while used mats suit shorter, cost-sensitive jobs.
Key Purchasing Tips and Best Practices
To maximize value and ensure your crane mats meet project needs, follow these best practices when buying and using them:
Define Project Requirements
Document your equipment specs (e.g., weight, outrigger loads), terrain conditions, and intended use (e.g., crane stabilization, temporary roadway). This ensures you select mats with the right size, type, and load capacity.
For example, a 60-ton all-terrain crane on a wetland site requires 8-inch-thick timber mats, while a lighter excavator on firm ground may use 6-inch laminated mats.
Source from Reputable Suppliers
Partner with trusted vendors like Eiffel Trading, Buckeye Mats, or Ritter Forest Products, which offer a range of new and used mats with detailed grading and load-bearing specs. Buckeye Mats, for instance, maintains inventory across 80+ locations for quick delivery, shipping over 6,000 truckloads in 2023.
Check supplier expertise—Buckeye Mats boasts 14 years in the business with 59 years of combined team experience, ensuring they can recommend mats tailored to your site.
Inspect Mats Before Purchase
For used mats, inspect for cracks, warping, or bolt damage. Ensure lifting bolts are intact, as they simplify loading and installation. Mats with excessive wear (Grade C) may be discounted but should be used cautiously for heavy loads.
Request prior application history to assess stress levels. A Grade A mat used for light roadway access will outlast a Grade B mat used under a 200-ton crane.
Consider Logistics and Storage
Mats are stackable and easy to transport, but delivery timelines vary. Suppliers like Buckeye Mats provide accurate delivery updates through dedicated logistics teams, ensuring timely arrival.
After use, sell unused mats to recoup costs and free up storage space. Timber mats can rot if left outdoors, so store them in dry, covered areas to preserve their 5-year lifespan.
Leverage Customization and Support
Opt for custom sizes if standard dimensions don’t fit your needs. Suppliers like Buckeye Mats partner with sawmills to offer tailored solutions, such as 12-inch x 4-foot x 16-foot transition mats for enhanced safety.
Seek suppliers offering site assessments. Buckeye Mats provides free evaluations to recommend mats based on terrain and equipment, reducing the risk of under- or over-specifying.
Plan for Reuse or Resale
Crane mats are built for multiple project cycles. If you don’t plan to reuse them, sell them on platforms like Eiffel Trading’s marketplace, where there’s high demand for Grade A, AB, and B mats.
Selling used mats not only recovers part of your investment but also saves on storage costs, which can be significant if you store equipment offsite.
By following these tips, you can select crane mats that align with your project goals, budget, and timeline, ensuring efficient and safe operations.