One of the most common questions we receive at Rubber Matting Direct is: "What thickness do I need?" It is a critical question. Choose matting that is too thin and it will not provide adequate protection, comfort, or durability. Choose matting that is too thick and you may create trip hazards, waste budget, or encounter installation difficulties.
This guide breaks down rubber matting thickness options from the thinnest sheets to the thickest heavy-duty products, explaining what each range is best suited for and how to make the right decision for your specific application.
Why Thickness Matters
The thickness of rubber matting directly affects its performance in several key areas:
- Impact absorption: Thicker matting absorbs more energy from falls, dropped objects, and foot impact. This is crucial in gyms, playgrounds, and industrial environments.
- Comfort: For applications where people stand for extended periods, thicker matting provides greater cushioning and reduces fatigue.
- Durability: Thicker matting generally lasts longer under heavy wear, as there is more material to wear through before the product fails.
- Insulation: Both thermal and acoustic insulation improve with thickness. Thicker mats dampen more sound and provide better cold-floor insulation.
- Load distribution: Heavy machinery and equipment benefit from thicker matting that spreads the load over a larger area, protecting the subfloor beneath.
Rubber Matting Thickness Ranges Explained
1mm – 3mm: Thin Sheet Rubber
The thinnest rubber matting options are typically used for bench tops, drawer liners, gaskets, and light-duty surface protection. At this thickness, the rubber is flexible and can be cut easily with scissors or a craft knife.
Common applications:
- Workbench surfaces and tool drawer liners
- Gasket material and sealing applications
- Anti-slip shelf and tray liners
- Electrical insulation (specialist grades)
- Packaging and cushioning
At 1–3mm, rubber matting does not provide meaningful impact protection or anti-fatigue benefits. It is primarily a functional surface material.
3mm – 6mm: Standard Duty
This is the most popular thickness range for general-purpose rubber flooring. It provides a noticeable improvement in comfort and slip resistance without creating significant level differences at doorways and transitions.
Common applications:
- Corridor and walkway flooring
- Workshop floors with light to moderate traffic
- Vehicle trailers and van floors
- Entrance matting (smooth types)
- General-purpose industrial flooring
A 3mm rubber floor covering is easy to install, relatively lightweight, and works well in areas where the primary requirement is slip resistance and surface protection rather than cushioning.
6mm – 10mm: Medium Duty
Stepping up to 6–10mm provides genuine comfort underfoot and meaningful impact protection. This range suits environments where workers stand for long periods or where dropped objects are a concern.
Common applications:
- Anti-fatigue matting for standing workstations
- Industrial rubber flooring in factories and warehouses
- Machine shop floors
- Assembly line workstations
- Veterinary and animal housing areas
At this thickness, you need to plan transitions to other floor surfaces carefully. Ramped edges or threshold strips prevent trip hazards where rubber matting meets thinner flooring.
10mm – 20mm: Heavy Duty
Heavy-duty rubber matting in the 10–20mm range is designed for the most demanding environments. It provides excellent impact absorption, superior comfort, and outstanding durability under extreme conditions.
Common applications:
- Gym flooring for free weights areas
- Stable mats and livestock housing
- Heavy industrial floors with forklift traffic
- Loading bays and goods-in areas
- Acoustic isolation applications
Products in this range are significantly heavier. A 15mm rubber mat weighs approximately 20kg per square metre, so handling and installation require planning.
20mm – 40mm+: Specialist and Safety
The thickest rubber matting products serve specialist purposes, primarily safety surfacing and extreme impact protection.
Common applications:
- Playground surfacing under climbing equipment
- Gym flooring for Olympic lifting and heavy free weights
- Industrial impact protection zones
- Anti-vibration mountings for heavy machinery
- Acoustic isolation for studios and plant rooms
At these thicknesses, rubber matting is often supplied as interlocking tiles rather than rolls, as the material becomes too rigid and heavy to handle in roll form.
Thickness Comparison Table
| Thickness | Weight (approx.) | Impact Protection | Anti-Fatigue | Best For |
|---|---|---|---|---|
| 1–3mm | 1.5–4.5 kg/m² | Minimal | None | Bench tops, gaskets, liners |
| 3–6mm | 4.5–9 kg/m² | Low | Slight | Corridors, workshops, van floors |
| 6–10mm | 9–15 kg/m² | Moderate | Good | Industrial floors, standing stations |
| 10–20mm | 15–30 kg/m² | High | Excellent | Gyms, stables, loading bays |
| 20–40mm+ | 30–60+ kg/m² | Very high | Excellent | Playgrounds, Olympic lifting, safety zones |
Factors That Influence Your Thickness Choice
Traffic Type and Volume
Consider not just the number of people walking on the matting, but the type of traffic. Pedestrian-only corridors can use thinner matting than areas with trolleys, pallet trucks, or forklifts. Wheeled traffic concentrates load onto small contact patches, requiring thicker, harder-wearing matting.
Standing Duration
If workers stand in one position for more than two hours per shift, invest in thicker anti-fatigue matting (8mm minimum). The health benefits — reduced back pain, improved circulation, and better concentration — far outweigh the additional cost.
Fall Height and Impact Risk
In areas where falls are possible (playgrounds, climbing walls, gymnastics) or where heavy objects may be dropped (warehouses, workshops), thickness must be calculated based on the potential impact energy. For playground surfacing, BS EN 1177 provides specific requirements linked to equipment height.
Subfloor Condition
Uneven or damaged subfloors benefit from thicker matting, which can bridge minor imperfections. However, thicker matting is not a substitute for proper subfloor preparation — significant defects must be repaired before installation.
Transition Heights
Every millimetre of thickness creates a height difference at the edge of the matted area. Building regulations typically require that level changes of more than 5mm must be ramped. If your matting is 10mm thick, you need ramped edge strips or recessed installation to maintain accessibility.
Budget
Thicker matting costs more per square metre due to the additional raw material. However, false economy is a real risk — a 3mm mat that wears out in two years costs far more over a decade than a 6mm mat that lasts eight years. Consider lifecycle cost, not just purchase price.
Common Mistakes to Avoid
- Going too thin to save money: This is the most common error. Under-specified matting wears out quickly, provides inadequate protection, and ends up costing more in the long run.
- Ignoring transition strips: Thick matting without proper edge treatment creates trip hazards that can lead to accidents and liability claims.
- Not accounting for compression: Rubber matting compresses under load. A 10mm mat under a heavy machine may compress to 7–8mm. Factor this into your calculations.
- Specifying the same thickness everywhere: Different areas have different requirements. A one-size-fits-all approach either over-specifies (wasting money) or under-specifies (compromising safety).
- Forgetting about doors: Thick matting can prevent doors from opening. Check clearances before installation.
How to Measure and Specify
When ordering rubber matting, specify thickness in millimetres rather than vague descriptions like "thick" or "heavy duty". Here is a simple process:
- Identify the application: What will the matting be used for? Refer to the table above for guidance.
- Check standards: Are there specific requirements (e.g., BS EN 1177 for playgrounds, or HSE guidance for industrial floors)?
- Measure the area: Calculate the square metreage needed, accounting for any obstacles, columns, or irregular shapes.
- Check transitions: Measure the height of adjacent flooring to determine whether ramped edges are needed.
- Request samples: Always request samples to check thickness, density, and surface finish before committing to a large order.
Find the Right Thickness for Your Project
Choosing the correct thickness of rubber matting ensures optimal performance, safety, and value for money. Whether you need a thin liner for a workbench or heavy-duty gym tiles for a CrossFit box, getting the thickness right is the foundation of a successful installation.
Browse our full range of rubber matting in various thicknesses at rubbermatting-direct.co.uk. If you are unsure which thickness suits your application, contact our team for free, no-obligation advice. We provide samples, technical data sheets, and expert guidance to help you specify with confidence.