Bespoke Mat Sizes, Custom Mat Lengths and Mats to fit Areas of Various Shapes and Sizes

There are times when standard, out of the box, mat sizes are just not what you require. Typically you have an irregularly shaped entrance area, an oddly shaped mat well or a long corridor that just does not conform to ‘standard’ sizes. You can’t simply make do with something that isn't quite right, you want the perfect fit. In these instances, you are in need of a custom sized mat. So what are your options? We explore the most common bespoke matting solutions below. Option 1: Mats sold off a roll Usually supplied in standard widths of 3, 4 and 5 foot (90, 120 and 150cm), but can be cut to practically any length. A good choice for long corridors, entrance runs and production lines that just keep on going. Some of the better mat suppliers will also be able to offer you mats in both custom widths and lengths, but normally within set size parameters. These parameters tend to depend on the width of the machine used to stitch the face fabric to the membrane, so a maximum width of 150cm or 200cm may be typically expected, but this still provides plenty of scope to solve the majority of customer requirements for bespoke sizes. Option 2: Joining mats together There is also the possibility of joining mats together to give the appearance of one large mat. The mats are joined at the rear, usually by gluing an extra strip of rubber to join the rubber backs of the mats together.Mats joined together to form a large mat On the plus side, joining mats enables you to make a larger mat of virtually any size or shape, but the negatives associated with this approach generally outweigh the positives. There will be a natural weakness along the join which may cause issues of durability over time, such as the mat rucking up or splitting which may create a trip hazard. Choosing a heavy, rubber based mat will make this less of an issue. Joining mats is a fairly laborious process and will most likely have to be done manually which has cost implications. Furthermore, the face of the mat may show the join particularly if it is a low profile, plain coloured mat. Mats with patterns, or mats with raised profiles work best to hide the joins. Option 3: Tiled mats and modular mat systems Mats in tiled form can be pieced together like a jigsaw, which means they can cover areas of virtually all shapes and sizes. This is a great way to fill mat wells, which are often an irregular shape despite doing their very best to look rectangular to the naked eye. It’s also a good choice for anti fatigue mat requirements, where covering areas where people frequently stand or walk is a requirement. Tiles are also a good choice if you wish to put mats down from wall to wall. The tiles can be cut to fit flush to the walls where no edging is required. If you require tiles with edging then there are many modular mat systems that offer this capability too. The edges are either supplied separately for fitting or gluing to the tiles or sometimes you will be able to buy tiles that come with edges as part of the tile. With these latter systems you have to determine how many ‘middle’ tiles, ‘edge’ tiles and maybe even ‘corner’ tiles you require, so a bit of forethought and measuring up will be required before purchase. Option 4: Cutting standard sized mats down to your required size or shape The final option is also perhaps the most overlooked. Bespoke sized mats are often more expensive than their standard sized counterparts, so selecting an oversized mat and then cutting it down to the size you require may work out to be a more cost effective solution. Beware that not all mats are designed to be cut and that lower quality mats may end up fraying or splitting as a result. If you require a border to the mat either for aesthetic or safety reasons, then this will also be compromised by cutting the mat. You will also most likely void any warranty that came with the mat, so you’d be advised to do your homework on whether they can be cut before getting your scissors out. Even better, ask for a sample and cut this first to see if you’re going to get the results you require. If you need any more information on choosing the right mat for your situation, then we have a team of experts on hand to answer your questions. Call 0121 351 4444 during normal UK office hours and we’ll be happy to help. Alternatively you can book a free mat audit, whereby we’ll arrange for someone to come and visit your premises to understand your matting requirements first hand and come up with the best solution for your individual needs. Simply click the banner below to get started and take the guess work out of choosing the right mat for you.