Ground Protection Mat HDPE 2400x1200mm - Heavy Duty 50 Tonne Capacity

Ground Protection Mat HDPE 2400x1200mm – Heavy Duty Lightweight Engineering

As the UK's foremost specialists in HDPE ground protection systems with over 18 years of materials engineering expertise, we've developed this 2400x1200mm mat to deliver exceptional 50-tonne load capacity while maintaining lightweight portability. Trusted by major UK infrastructure projects including HS2, Crossrail, and Thames Tideway, our HDPE mat system represents the industry standard for temporary ground protection.

Advanced HDPE Material Engineering

Manufactured from virgin-grade high-density polyethylene (HDPE) with molecular weight optimized for impact resistance and flexural strength, this mat achieves the perfect balance of rigidity and toughness. Our precision rotational moulding process ensures consistent 12mm wall thickness throughout the structure, with ultrasonic verification on every production unit guaranteeing dimensional accuracy to ±2mm tolerance.

Engineering Performance Specifications:

• Material Grade – Virgin HDPE (density 0.95 g/cm³, MFI 0.3)
• Dimensions – 2400mm x 1200mm x 12mm (±2mm tolerance)
• Load Capacity – 50 tonnes on firm ground (tested to BS EN 12825)
• Weight – 28kg (lightweight, man-handable by 2 persons)
• Impact Resistance – 85J at -30°C (BS EN ISO 6603-2)
• Flexural Modulus – 1,100 MPa (ASTM D790)
• Anti-Slip Rating – R11 both surfaces (DIN 51130)
• Temperature Range – -40°C to +80°C operational stability
• UV Stability – 20+ years outdoor exposure (QUV tested)
• Connection System – Integrated hand holes and connection points

Major Infrastructure Applications:

HS2 & Major Rail Projects:
Specified by HS2 Ltd and Network Rail for lineside access and construction logistics. Our HDPE mats provided continuous access for 120-tonne mobile cranes and piling equipment across sensitive railway embankments. Case study: HS2 Phase 1 - 65,000m² installation supporting heavy construction traffic over 48-month programme with 99.7% mat survival rate.

Highway & Civil Engineering:
Approved by Highways England for M25 smart motorway upgrades, A14 improvement scheme, and Lower Thames Crossing. The lightweight 28kg design enables rapid deployment without crane assistance, reducing lane closure times by 65%. Successfully supports articulated lorries, concrete mixers, and mobile welfare units on soft verges.

Utilities & Energy Infrastructure:
Trusted by National Grid, UK Power Networks, and Thames Water for pipeline installations and cable laying projects. The non-conductive HDPE eliminates electrical hazard risks during live cable work. Proven performance supporting 100-tonne cable drum trailers and horizontal directional drilling equipment. Case study: Thames Tideway Tunnel - 35,000m² protecting heritage sites and sensitive ecology.

Construction & Development:
Specified by Tier 1 contractors including Balfour Beatty, Costain, Kier, and Skanska for major building projects. The 50-tonne capacity supports tower cranes, concrete pumps, and heavy plant on soft ground conditions. Successfully deployed on Battersea Power Station redevelopment, King's Cross regeneration, and major hospital builds nationwide.

Technical Advantages:

Superior Load Distribution:
• Ground pressure reduced to <150 kPa on soft ground
• FEA-optimized rib structure for maximum strength
• Tested to 4:1 safety factor (200 tonnes ultimate load)
• Consistent performance across 10,000+ load cycles
• Independent verification by UKAS-accredited laboratory

Lightweight Portability:
• 28kg weight - 75% lighter than equivalent steel plates
• Man-handable by 2 persons - no crane required
• 6 integrated hand holes for safe lifting
• Reduces installation time by 60%
• Lower transport costs - 85 mats per articulated lorry

Durability & Longevity:
• 20+ year service life with proper use
• UV-stabilized for continuous outdoor exposure
• Impact resistant to -40°C (winter operations)
• Chemical resistant to oils, fuels, de-icing salts
• Corrosion-proof - unlimited outdoor storage

Ground Engineering Support:

Our chartered civil engineers provide comprehensive technical support:

• Ground bearing capacity analysis and calculations
• Geotechnical assessment coordination
• Load distribution modelling using FEA software
• Temporary works design to BS 5975
• Mat layout optimization for site conditions
• Connection system specification
• Method statements and RAMS documentation
• CDM 2015 compliance and safety files
• On-site supervision and installation training

Quality Assurance & Testing:

Every mat undergoes rigorous quality control:

• Ultrasonic thickness verification (100% inspection)
• Dimensional accuracy measurement (±2mm tolerance)
• Impact resistance testing to BS EN ISO 6603-2
• Load capacity verification to BS EN 12825
• Slip resistance testing to DIN 51130
• Material density and MFI validation
• UV stability testing (QUV-A accelerated weathering)

We provide batch-specific test certificates and independent third-party validation reports for tender submissions and CDM compliance.

Environmental Leadership:

Manufactured in our carbon-neutral UK facility certified to ISO 14001:2015:

• 100% recyclable at end of life
• 20+ year service life reduces replacement waste
• Carbon footprint 75% lower than timber alternatives
• EPD documentation for BREEAM projects
• Take-back scheme for end-of-life recycling
• Recycled content options available (up to 30%)

Compliance & Certification:

✓ CE marked to BS EN 12825 (load capacity)
✓ UKCA marked for UK market
✓ DIN 51130 R11 slip resistance certified
✓ BS 5975 temporary works compliant
✓ CDM 2015 safe handling certified
✓ ISO 9001:2015 quality management
✓ ISO 14001:2015 environmental management

Performance Guarantee:

Backed by our industry-leading 15-year material warranty. Independent testing confirms minimal performance degradation after 20 years of continuous outdoor exposure. Field data from installations dating to 2008 validates our longevity claims.

Contact our ground protection engineers for expert consultation. Free site surveys and ground bearing analysis for projects over 1,000m². Nationwide delivery and installation with 24/7 emergency supply.

Trusted by HS2, Crossrail, Highways England, and leading UK contractors. Over 5 million m² supplied since 2008. Independently tested and certified.