Compression Moulded vs Extruded Ground Protection Mats

Compression Moulded Mats vs Extruded Mats: Choosing the Right Option for Your Site

Choosing the right ground protection mat is not just about what is in stock or what looks cheapest on paper. The manufacturing process has a direct impact on strength, lifespan, and how reliably the mat performs in real site conditions. At GroundGuards, we supply both compression moulded and extruded mats - and knowing the difference helps you make a better decision for your next job.

How Are These Mats Made?

Compression moulded mats

Compression moulded mats, such as EnviroMat, are made by pressing a blend of plastics under high heat and pressure inside a mould. This produces a mat that is solid and consistent throughout, with tightly bonded fibres and plastic. There are no hollow sections, and no “thin spots” where the mat is more likely to fail.

Extruded mats

Extruded mats, such as ProMat, are produced by forcing molten plastic through a shaped die to create a continuous sheet, which is then cut down into mat sizes. This is a faster process and typically uses less material, resulting in a mat that is lighter and often more flexible - but with a more layered, less dense structure.

Why Does Manufacturing Matter?

You tend to see the difference quickly once mats are under load and being moved around day-to-day.

As a compression moulded mat, EnviroMat is built for demanding conditions and repeated use. It is designed to cope with trucks, machinery, and tracked vehicles without splitting or deforming. If you cut through an EnviroMat, you would see the same solid construction from top to bottom. That consistency helps the mat distribute weight properly, protect the surface below, and keep access routes stable and predictable.

ProMat, as an extruded option, is much lighter and easier to handle. It is well suited to pedestrian access, trolleys, and light equipment on firm ground - especially for short-term or occasional use. However, it is not designed for heavy vehicles or soft, muddy ground. Under excessive loading or in poor ground conditions, an extruded mat can flex more than intended and may crack.

EnviroMat vs ProMat: A Practical Comparison

  • Load capacity: EnviroMat is intended for higher weight loadings and use with machinery and HGVs. ProMat is best kept to lighter applications.

  • Durability: Compression moulded mats like EnviroMat typically deliver a longer working life under hard, repeated use. ProMat suits light, temporary access, but is not aimed at tougher site conditions.

  • Ground protection: EnviroMat spreads weight more evenly, helping reduce rutting and ground damage. ProMat works well for pedestrian routes over firm surfaces but is not designed to protect soft or sensitive ground.

  • Value for money: EnviroMat can cost more upfront, but is designed to last longer and perform in a wider range of conditions. ProMat is cost-effective for occasional, light-duty use, but it is not a substitute for a more robust mat.

Which Mat Should You Choose?

If you are running heavy equipment, working on soft or uneven ground, or need mats that will stand up to repeated use over time, a compression moulded mat like EnviroMat is the right fit.

If your priority is fast handling for short-term pedestrian access, events, or light equipment movement over firm ground, ProMat can be a practical option.

What this means for similar projects

  • Match the mat type to the ground conditions first - firm ground gives you more flexibility; soft ground reduces your options quickly.
  • If machinery or vehicles are involved, prioritise a mat built for higher loading and repeated use.
  • Consider the true cost over time - a cheaper mat is rarely cheaper if it fails early or limits what the site can do.
  • Think about handling and install time alongside performance - lighter mats can be useful when loads are low and speed matters.
  • When in doubt, choose the mat that gives you the most margin for error on site, especially where conditions can change.

Need help choosing?

If you are unsure which mat is best for your application, speak to our team. We will ask the right questions about loading, access routes and ground conditions, then recommend a solution that performs properly on site - with fewer headaches once the job is underway.

 

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They can also be used for: Walkways between welfare and work areas Storage and laydown zones where materials are loaded and unloaded High-traffic pinch points such as gates, corners, and turning areas The less exposed soil you have in these busy areas, the less chance you will be battling dust when the weather turns dry or the wind picks up. The site stays tidier and the air is cleaner for everyone - including the team working there day in, day out. Why mats help with dust control (in simple terms) Ground protection mats reduce dust because they help you do three things well: Stabilise the surface - less breakup of dry ground. Control movements - vehicles and people stick to defined routes. Reduce housekeeping pressure - fewer fine particles being created means less cleaning and fewer issues at the boundary. 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