Why real ground conditions matter more than a big number on the spec sheet
Lesson 1 in ground protection: performance lives and dies by the ground underneath the mat. Big ton numbers on a spec sheet can look impressive, but they do not tell you how a mat will behave on real sites with real soils, weather, and loads. If you want consistent results, start with ground conditions, not a headline number.
How “tons” became a distraction
Tonnage ratings began as a simple way to compare products. In the early 2000s a respected manufacturer introduced the idea in good faith. Competitors quickly chased bigger numbers and the arms race was on. Great for ads. Not so great for decision making on site. As a way to choose ground protection mats, treating a single ton figure as gospel is misleading at best.
“The mat did not fail. The ground did.”
Scenario 1: A top-tier ground mat on soft, saturated ground
- Take the best product in the 4 by 8 ft class, AlturnaMat. It is widely regarded as a high-performing mat that does not break anywhere near as often as many competitors.
- The manufacturer cites a 120 ton rating.
- Put that same mat on muskeg, bog, peat, or swamp and place 200 lb on it. It goes down.
- Important note: the product did not fail and likely will not break. It is simply the wrong choice for that ground.
Result: the so-called weight rating depends entirely on what is supporting the mat.
Scenario 2: A light-duty mat that can carry heavy loads on the right ground
- Take FastCover. It is designed for pedestrians and light vehicular traffic in light-duty environments.
- Put it on grass and run a 5 to 10 ton machine across it. No problem at all when used sensibly.
- Put it on concrete and drive an 80 ton dump truck over it. Still no problem at all.
Result: if you buy on weight rating alone, you risk the wrong choice. The number without context can send you in the wrong direction.
What actually governs performance
- Ground support. Soil type, moisture, compaction, and whether the surface is reinforced. Soft, saturated soils deflect under load.
- Contact area. Tracks versus tires, duals versus singles, and the size of outrigger pads change ground pressure dramatically.
- Load path and duty cycle. Straight-through access versus constant turning, static point loads versus dynamic traffic, occasional use versus continuous shifts.
- Temperature and wear. Heat, cold, and abrasion all change how a mat performs over time.
How to read a spec sheet without getting misled
- Treat the “tons” figure as a lab number, not a site guarantee.
- Look first for guidance by ground condition: concrete, asphalt, gravel, firm soil, wet clay, peat, muskeg.
- Ask about ground pressure, not only vehicle weight.
- Match the product class to the job: walkways, access road mats, construction mats, and ground mats each have a role. Choose based on site conditions and duty, not on a single headline metric.
The Takeaway
Tonnage ratings are not useless, but they are only one input. The right decision balances ground support, contact area, duty cycle, and the product class. That is how you protect people, equipment, budgets, and the site.
Want a quick recommendation for your site? Contact us with your ground and load details and we will point you to the right mat. Important: Weight loading is not always straightforward, so read our weight loading guide before you choose.