Heavy-duty slabs are temporary or permanent elements for load distribution and ground protection. They create load-bearing access routes, assembly areas and standing positions for machines, power units and transport vehicles—especially where subgrades are soft, sensitive or uneven. In the context of deconstruction, demolition, rock works and natural stone extraction, heavy-duty slabs enable safe working routes, reduce settlements and protect surfaces. In conjunction with the work equipment of Darda GmbH—such as when working with concrete demolition shears or with stone and concrete splitters—they help reduce point loads, increase stability and keep workflows predictable.
Definition: What is meant by heavy-duty slab
A heavy-duty slab is a load-distributing component made of steel, high-molecular plastics, composite materials or wood that transfers wheel loads, track loads and support forces to the subgrade over a large area. Heavy-duty slabs are used as ground protection mats, roadway plates, crane mats or load distribution plates—depending on the application. They serve to build temporary site access routes, assembly areas and work platforms and are used in demolition, specialist deconstruction, tunnels and quarry sites as well as in inner-city areas. In interaction with equipment from Darda GmbH—for example hydraulic power packs, concrete demolition shears or stone and concrete splitters—heavy-duty slabs secure access, protect existing floors and improve working conditions for operators and machines.
Application logic: function, benefits and limits
Heavy-duty slabs distribute concentrated loads over a larger area so that the permissible bearing pressure is not exceeded. They reduce rutting, prevent vehicles from sinking and minimize damage to surfaces such as asphalt, paving or concrete. On sensitive areas—e.g., in existing buildings during strip-out and cutting operations—they protect load-bearing structures and installations. Limits arise with inadequate subgrade preparation, missing shear transfer between slabs or incorrect sizing. For the final structural assessment and the evaluation of soil parameters, competent persons should be consulted; the information in this text is general in nature.
Materials and designs for heavy-duty slabs
Different materials and geometries are used depending on the application. The selection influences load capacity, handling, service life and behavior under weather conditions.
Steel
Steel slabs are robust, resistant to point loads and insensitive to high temperatures and sparks—advantageous for demolition with spark formation or thermal cutting. They are heavy, often require lifting gear and can corrode if not protected. Profiled surfaces improve slip resistance but increase cleaning effort.
High-molecular plastics
Plastic slabs made of HDPE or UHMWPE are comparatively light, corrosion-free and easy to handle. They are suitable for quick route installation and changing locations. Temperature-dependent deformation and limited compressive stiffness set limits for use under extreme point loads. Bolted or interlocking systems facilitate shear transfer and prevent slab migration.
Fiber-reinforced composites (GFRP/CFRP)
Composite slabs combine low weight with high stiffness. They are suitable when frequent repositioning and high sustained loads coincide. Compared with steel, they are more sensitive to sharp-edged tracks and localized impact loads, which is why pads or load-distributing layers can be sensible.
Wood and wood composites
Planks and glulam mats are proven, damp vibrations and are efficient on soft subgrades. They are moisture-sensitive, can swell and require regular inspection. For long-term outdoor applications, protective measures and consistent maintenance are essential.
Surfaces and edges
Ribbing, studs and grain/texture increase slip resistance. Chamfers reduce trip hazards and make crossing easier. Hand holes, lifting eyes or integrated couplings simplify handling and improve interlock between slabs.
Sizing: loads, subgrade and safety
The design is based on the governing loads, soil parameters and the planned operation. The goal is to keep contact pressures below permissible values and to ensure serviceability (settlements, evenness, slip resistance).
Relevant influencing factors
- Machine and vehicle loads: dead weight, payload, axle loads, track or tire contact areas
- Point loads from supports: e.g., from lifting devices, cutting or splitting equipment, hydraulic power packs
- Subgrade: soil type, moisture, compaction, existing surfaces, drainage
- Installation method: single-layer, multi-layer, with overlap, coupled or butted
- Operating conditions: slope, weather, temperature, chemicals, vibrations
Subgrade assessment
Load-bearing, evenly prepared formation surfaces improve load transfer. Cohesive, moist soils require larger areas and, if necessary, intermediate layers (e.g., gravel base course). On concrete and asphalt, slab action and edge loading must be considered; full-surface bearing reduces damage.
Load distribution and joints
For traffic routes, staggered joints and sufficient overlap are important to avoid edge breakage. Mechanical connections improve shear transfer, especially on slopes or in braking zones. For point loads, it is advisable to estimate the required bearing area and—if necessary—use a multi-layer solution composed of stiff and elastic layers.
Application areas in the context of products and applications of Darda GmbH
Heavy-duty slabs are useful as a logistical foundation in many applications of Darda GmbH. They increase workplace availability and improve safety.
- Concrete demolition and specialist deconstruction: When working with concrete demolition shears, combination shears or Multi Cutters, heavy-duty slabs provide load-bearing access routes in courtyards, on slab edges or over basements. They protect screeds and waterproofing and help limit edge loads from crawler undercarriages.
- Strip-out and cutting: For sawing technology and the use of hydraulic power packs, slabs create level, clean standing areas. Cable and hose routing can be guided with slip resistance; moisture and slurry can be kept under control.
- Rock demolition and tunneling: When using stone and concrete splitters as well as stone splitting cylinders, heavy-duty slabs stabilize transport routes in the heading, reduce sinking in soft zones and protect waterproofing in segment lining areas. In such rock demolition and tunnel construction contexts, they serve as a work platform with increased slip resistance.
- Natural stone extraction: In block extraction and when handling delicate natural stone surfaces, slabs prevent damage and enable the safe transport of heavy raw blocks. Steel shears or concrete demolition shears can be used more efficiently and with less vibration at defined standing positions.
- Special use: When working on sensitive soils, in protected areas or on contaminated sites, heavy-duty slabs reduce ground scarring and make cleaning easier. Tank-cutting or cutting tasks benefit from spark-resistant surfaces.
Installation: procedure and practical recommendations
Careful installation is crucial for load-bearing capacity and occupational safety. The following steps have proven effective:
- Prepare the subgrade: remove unevenness, excavate soft areas and, if necessary, install a load-bearing intermediate layer.
- Plan the installation pattern: define driving direction, joint pattern, curve radii and transitions; provide interlock on slopes.
- Place the slabs: install with suitable lifting gear or hand grips; fit edges neatly, avoid trip hazards.
- Create connections: close couplings, pins or interlocks; secure edge areas against shifting.
- Inspection and test pass: check evenness, slip resistance and joint pattern; readjust if necessary.
Transport, storage and handling
Weights and dimensions should be matched to the available lifting and transport equipment. Stackable geometries speed up repositioning. Markings for permissible surface load and for installation orientation increase process reliability.
Occupational and environmental protection
Slip-resistant surfaces, marked transitions and adjusted driving speeds reduce risks. Dripping operating fluids must be avoided; cleaning after use maintains grip. Notes on protective measures are to be understood generally and do not replace a project-specific risk assessment.
Quality assurance and maintenance
Regular visual inspections reveal damage, deformations or worn connection points. Smooth surfaces must be cleaned of slurry, dust and oils. For steel, corrosion spots must be treated; for wood, the residual load-bearing capacity must be assessed. Documented inspection intervals and load-related operating limits support proactive scheduling.
Typical mistakes and how to avoid them
- Insufficiently prepared subgrade: leads to settlements and edge breakage—prepare the formation level, check load-bearing capacity.
- Incorrect installation pattern: straight joints in braking zones—provide interlock or stagger.
- Overloading due to point loads: missing intermediate layers—enlarge bearing areas, use multi-layer systems.
- Unsuitable material: soft plastic under hot demolition—choose more temperature-resistant materials.
- Neglected cleaning: loss of slip resistance—plan regular maintenance.
Selection criteria: purchase, rental and project fit
Decisive factors are load level, frequency of repositioning, transport logistics and environmental conditions. For changing sites, light, connectable slabs are advantageous. For high point loads and thermally demanding work, stiff, heat-resistant variants offer advantages. Coordination with the planned work equipment from Darda GmbH—such as concrete demolition shears, stone and concrete splitters, hydraulic power packs or steel shears—helps to size bearing areas, routing and standing positions appropriately.
Life cycle and sustainability
Durable materials, repairable systems and designs suitable for recycling reduce environmental impacts. Reuse across multiple projects, short transport routes and careful cleaning extend service life and preserve function.