Engineered for Extremes: Crush-Proof + Leak-Proof + and Chemical-Resistant Industrial Safety Mats

What Are Industrial Safety Mats for Machines?

A Pressure‑Sensitive Safety Device

An Industrial Safety Mat (also known as a safety pressure mat) is a pressure-sensitive safety device: when a preset minimum weight is applied, the mat acts as a switch and sends a stop signal to the controller, which immediately halts the protected machinery. This ensures effective protection for operators against potential hazards.

Applications of Safety Mats for Machines

These mats provide area protection around equipment like:

• Welding robots

• Rubber & plastic machines

• Assembly lines

• Material handling systems

• Packaging and press machinery

• Automotive production

• Steel and metallurgical operations

Compared to physical guards, sliding doors, or pull-back stops, industrial safety mats offer freedom, flexibility, and effort savings. They preserve full visibility and accessibility of the workspace while enhancing safety and reducing injury risk.

Core Features of Industrial Safety Mats

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DADISICK safety mats are constructed from heavy-duty PVC or NBR, featuring die-cast impact-resistant structures. They resist delamination and corrosion caused by acids, alkalis, and salts. DADISICK's DT series support loads between 200‑400 N/cm² (strong enough to withstand light vehicle crushing). With expected lifetimes of over 1–3 million cycles and omnidirectional installation capability, they are durable and adaptable.

Standard sizes are limited to ≤1.5 m². For larger areas, multiple mats can be seamlessly assembled.

How Safety Pressure Mats Work

Piezoresistive Force Sensors

Inside the safety pressure mat, a piezoresistive force sensor detects pressure: under load, the conductive layer’s resistance changes, generating an electrical signal. The controller monitors this resistance, and upon threshold triggering, issues a machine-stop command in real time.

While similar in principle to strain-gauge sensors (which detect deformation via resistance change), piezoresistive mats are designed for:

• Large-area, heavy-duty environments

• Fast, reliable response for on/off control

• High durability under frequent crush and wear conditions

In contrast, strain-gauges offer higher precision with complex circuitry but aren’t suitable for rugged factory floors.

Integration of Industrial Safety Mats in Machinery

Layout Planning for Safety Mats for Machines

Industrial safety mats are installed around equipment to form a protective perimeter. When someone steps onto the mat, the piezoresistive sensor captures the pressure and converts it into an electrical switch signal. This signal is relayed to a safety relay or controller, prompting instantaneous machine shutdown before body contact with moving parts—ensuring operator safety.

Typical placement includes

1. Entry points to presses, bending machines, or robotic zones

2. Operator load/unload areas

3. Zones inadequately covered by light curtains

Key layout considerations

• Proper sizing and positioning to cover all risk zones

• Avoid creating trip hazards while maintaining responsiveness

• Seamless coordination with other safety systems

Mats integrate with safety relays (e.g., TER-A), creating compliant systems per EN 1760‑1, ISO 13856‑1, EN 62061, ISO 13849‑1, IEC 61508, EN 60204‑1.

Collaborative Safety: Safety Switch Mats and a Comprehensive Safety Network

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Safety switch mats don’t operate in isolation—they’re part of layered safety systems. When combined with light curtains, interlock switches, safety relays, and emergency stop buttons, they offer redundancy and wider protection coverage.

• Mats guard the lower levels while light curtains protect the upper body

• Safety relays consolidate inputs from mats, doors, and E-stops for safe logic decision-making

• With PLC integration, safety mat wiring diagrams facilitate diagnostics, real-time monitoring, and zoned safety management

This integrated system ensures operators are protected regardless of entry point, fulfilling global safety requirements under ISO 13849 and OSHA.

Installation & Wiring Diagram Guidelines

Typical Setup Instructions

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