FIELD MANUAL

by

MEGADECK FIELD MANUAL

MEGADECK FIELD MANUAL: Instructions for use and maintenance of your

MegaDeck heavy duty matting system

THE MEGADECK SYSTEM

THE MEGADECK SYSTEM

Overview of MegaDeck
Specifications of MegaDeck
MegaDecks Locking Pin System

p2
p3
p3

TRANSPORT, STORAGE, AND HANDLING OF MEGADECK

Loading MegaDeck on Flatbed Trucks
Loading in ISO Containers or Closed Vans
Transport of MegaDeck Mats

p4
p5
p5

BASIC INSTALLATION OF MEGADECK

Discussion of CBR (California Bearing Ratio) and Loading
Capabilities of MegaDeck on Varying Ground Surfaces
Site Analysis and Ground Preparation
Connecting MegaDeck Mats
Installing MegaDeck Utilizing a Crane, Lull,
or Other Similar Equipment
Installing Mats ina Perpendicular Configuration
Removing MegaDeck Mats
Creating a MegaDeck Roadway
Passing Lanes and Turning Areas
Work Platforms, Bone Yards, and Contiguous Areas
Bridging Situations
Water Runoff Considerations
Geo-textiles and MegaDeck
Transitions and On/Off Ramps
Double Stacking MegaDeck

p5
p7
p7
p8
p9
p11
p11
p12
p12
p13
p13
p13
p13
p14

CLEANING AND MAINTENANCE OF MEGADECK

General Cleaning
Snow and Ice Removal

Overview of MegaDeck
MegaDeck is designed to provide access over soft ground for vehicles,
equipment, and personnel. The principal behind MegaDeck is distribution of
heavy weights over a larger surface area, thus allowing heavy equipment to
traverse varying ground conditions without problems.
MegaDeck can be used to create a temporary roadway, a work compound,
and a support surface for all types of applications. From shoring and general
construction applications to drilling and mining operations, MegaDeck is
designed to provide stable access and superior ground protection.
MegaDeck matting can be used in all weather conditions, from the coldest
regions to the warmest, and is manufactured using the highest quality
plastics. Each mat incorporates extensive engineering, testing, and a unique
material formulation that provides the ultimate in UV resistance, static
dissipative properties, and tremendous strength and loading capabilities
over a multitude of ground surfaces.
Each mats molded traction surface and environmentally friendly, nonporous design allows sections to be used in marshlands and other sensitive
environments where traction, access, and reusability is important.
MegaDeck mats outlive traditional wooden mats and will never rot,
delaminate, or become waterlogged.

p14
p14

Mats are fully modular and can be interconnected in any direction to form
larger work areas, passing lanes, turns, and a variety of other configurations.

Repairing Cracks and Surface Punctures

Repairing Locking Pin Receiver Damage

p14
p15

SERIAL NUMBERS &IC (INVENTORY CONTROL) CHIP USAGE

LIMITED WARRANTY

P15
P15

Mats incorporate a heavy-duty overlapping flange system that allows

adjacent mats flanges to nest for additional strength and rigidity. Each
flange incorporates a unique proprietary connection system that enables
mats to be locked to one another when overlapped, prevents mats from

REPAIRING DAMAGE TO MEGADECK

page

MEGADECK FIELD MANUAL

slipping or detaching from each other during use, and prevents seepage of
mud from the surface below.
Specifications of MegaDeck
MegaDeck is available in two sizes: Full and Half. These mats may be used
with one another as needed to create the desired dimensions.

UV Package:

5 year

Locking Pin and

Receiver Material:

Aluminum

Fire Rating:

UL94HB

Size
Full Size Mat (consists of two half mats permanently bolted together):
Actual: 4.2672m / 14ft (L) x 2.286m / 7.5ft (W) x 10.795cm / 4in (D)
Usable (due to flange): 3.9624m / 13ft (L) x 1.98m / 6.5ft (W) x
10.795cm / 4cm (D)

6.5
13

Half Size Mat:

Actual: 2.286m / 7.5ft (L) x 2.286m / 7.5ft (W) x 10.795cm / 4in (D)
Usable (due to flange): 1.98m / 6.5ft (L) x 1.98m / 6.5ft (W) x
10.795cm / 4cm (D)
Flange Thickness:

2 (5.08cm)

2 (5.08cm)

14

Note: Sizes are nominal and may vary slightly within standard production
tolerances. Such minor variation will not affect mat performance or
compatibility.
MegaDecks Locking Pin System

Weight
Full sized Mat:
Half Mat:

7.5

1,122 lbs. (555.5kg)

611 lbs. (277.7kg)

Material Composition
Base Material:

High Density Polyethylene Copolymer

Additives:

Anti Static Additive

Color Pigments
Proprietary Nano-Clay and other Fillers

MegaDeck incorporates the latest in connection technology to prevent mats

from shifting or drifting under heavy weight or torque. By connecting mats
in multiple locations, the unique connection system enables mats to handle
tremendous moving weights.
Each 14ft long x 7.5ft wide panel has 8 cam hole locations, ready to receive
Locking Pins. These holes are reinforced with aluminum receivers (vs.
plastic) and are designed to help guide and assist in the alignment of panels
on-site. The aluminum Locking Pin Receivers prevent damage to the main
mat and provide additional weight bearing capacity.

page

MEGADECK FIELD MANUAL

Each connection cam consists of a durable aluminum Locking Pin that is

inserted through two panels and rotated 45 degrees to lock using a standard
hex tool, available in any hardware store. When locked, arrows on the
Locking Pin will be aligned with the lock symbol on the Locking Pin Receiver,
and the arrows will be aligned with the unlock symbol when unlocked.
To remove Locking Pins, a simple flat head screwdriver is inserted into one
of two notches pre-molded into each pin.
MegaDecks integrated locking system is designed for the rigors of heavy
duty use. Components are manufactured using non-corroding aluminum that
is capable of withstanding tremendous weights. In the event of damage or
loss, Locking Pins and Pin Receivers are easily replaced with minimal effort
and without having to sacrifice an entire MegaDeck panel.
For more permanent or longer term applications, Signature offers more
permanent locking pins. These semi-permanent pins consist of two halves
that are actually bolted together to lock panels in a more rigid manner. They
can be unbolted as needed upon completion of the project and re-used if
desired.

TRANSPORT, STORAGE, AND HANDLING OF MEGADECK

Loading MegaDeck on Flatbed Trucks
Following are guidelines for loading and transporting MegaDeck on truck
and in standard ISO containers. Proper safety procedures, material handling
equipment, and Personal Protective Equipment should always be utilized
when handling MegaDeck or any other heavy load.
MegaDeck mats are designed to stack neatly both while in storage and
during transport. It is important to stack mats carefully and to align the
edges consistently when transporting mats over the road.
Depending on the capability of your forklift or crane, the size of MegaDeck
stacks will vary. Extended forklift forks are highly recommended for the safe
transport of mats, and it is recommended that sections be picked up from
the long side when loading onto flatbeds or transporting on-site
As each full MegaDeck mat weighs 1,030 lbs, it is possible to calculate the
total number of mats that can be transported in a single stack, based on the
weight loading capabilities of your forklift.

page

MEGADECK FIELD MANUAL

As over the road loads in the United States are often limited to
approximately 50,000 lbs, it is generally possible to transport 42 mats on a
typical flat bed truck. Generally, this consists of 2 stacks of 14 mats and 1
stack of 13 mats.
It is recommended not to exceed a stack height of 14 mats on a typical flat
bed truck. It is important to use heavy duty ratchet straps to secure mat
stacks on a typical flat bed trailer. Be sure that all straps are fastened tightly
so that loads do not shift in transit. 3-4 heavy duty ratchet straps/bands are
recommended per mat stack, or 9 to 12 straps per trailer.
It is important to place MegaDeck mats on 3 x 3 or 4 x 4 stringers (3
stringers per mat length) to enable easy access for forklifts. Stringers may
be used every 4-5 mats to help separate stacks of MegaDeck for easier
transport using a smaller forklift.

Loading in ISO Containers or Closed Vans

MegaDeck mats can be transported in closed vans and ISO containers.
Extended forks are recommended for placement of the mats into the
container. As fork lift extensions affect truck capacity, please refer to your
lift truck manufacturer for a derated capacity, when using extended forks.
As each mat is 14ft long, it is recommended that an extended fork length be
utilized when loading mats lengthwise into a closed truck or container.
Great care should be taken when loading mats into an enclosed van to avoid
potentially damaging contact with the sidewall or roof of the container.
Mats should be loaded one by one, using a loading dock. Never stand inside
the container and in front of MegaDeck when loading and use only
appropriately rated equipment when positioning and loading mats.

Transport of MegaDeck Mats

20ft ISO Containers 20 full sized mats

40ft ISO Containers 40 full sized mats and 20 half sized mats
40ft Truck - Flat Bed - 42 full sized mats
48ft Truck Flat Bed 42 full sized mats
48ft Truck Enclosed Van 56ft Truck Enclosed Van

BASIC INSTALLATION OF MEGADECK

Discussion of CBR (California Bearing Ratio) and loading capabilities of
MegaDeck on varying ground surfaces
Soil properties are generally determined using California Bearing Ratio (CBR)
guidelines. By understanding the CBR of the subgrade that MegaDeck will
sit on, it is possible to better understand the loads that can be traversed and
placed over MegaDeck.
CBR strength tests yield a value for comparing load bearing capacity of a
subgrade material to that of well-graded crushed stone. CBR is a
penetration test for evaluating the mechanical strength of road subgrades
and has been in use since before World War II.
CBR tests are performed by measuring the pressure required to penetrate a
soil sample with a plunger of a particular size. Several companies
manufacture soil plungers to perform this test (ASTM D4429 for soils tested
in the field; also AASHTO T193:BS1366: Soils for civil engineering purposes:
Part 4, compaction related tests).
The harder the surface, the higher the CBR rating. The higher the CBR rating,
the greater the support under MegaDeck, and the heavier the loads that can
traverse the system.

page

MEGADECK FIELD MANUAL

0.70

40,000

0.60

35,000
30,000

0.50

25,000

0.40

20,000

0.30

15,000

0.20

10,000

0.10

5,000

CBR = P/Ps * 100

The following chart shows approximate CBR values for various ground types
as well as the corresponding Modulus of Elasticity (PSI) for each surface
type, according to the calculation above.

Following is a graph showing estimated loading capacity and expected

deflection at each loading level.

60

80

0.00
100

Tire patch over panel joint

50,000

0.80

45,000

0.70

40,000

0.60

35,000
30,000

0.50

25,000

0.40

20,000

0.30

15,000

0.20

10,000

0.10

5,000
0

Load capacity
Deflection

0.00
0

Finite Analysis Testing (FEA) was done on the MegaDeck panel, simulating a
10x20 inch tire patch over the center of the panels ribbed structure and at
the joint between panels. The tire load was increased until peak stress
reached 1,500 PSI (Material tensile strength) for CBR values of 0.5, 2, 10, 25,
50, and 100.

40

(lb)

M R 2555 CBR0.64

20

CBR

Load capacity (lb)

CBR = CBR (%)

P= measured pressure for site soils (N/mm2)
Ps = pressure to achieve equal penetration on standard soil [N/mm2]
The American Association of State Highway and Transportation Officials
(AASHTO) published the Mechanistic Empirical Pavement Design Guide
(MEPDG) in 2008. AASHTO MEPDG uses the formula below to convert CBR
to resilient modulus (MR) (in psi), which is itself an approximation of
modulus of elasticity.

Load capacity
Deflection

(in)

Modulus of elasticity (psi)

48,700
31,200
20,000
11,200
4,000
1,640

0.80

45,000

Peak deflection at capacity (in)

CBR value
100
50
25
10
2
0.5

50,000

Peak deflection at capacity (in)

Subgrade type
Crushed stone high range
Crushed stone low range
Sandy soil
Clay soil
Organic soil
Very soft sub grade

Tire patch over center of ribbed structure

Load capacity (lb)

A CBR of 3 equates to tilled farmland, a CBR of 4.75 equates to turf or moist

clay, while moist sand may have a CBR of 10. High quality crushed rock has a
CBR over 80. The standard material for this test is crushed California
limestone which has a value of 100.

20

40

60

80

100

CBR

Note that the above FEA calculations are for a single tire patch that is 10 x
20 and a typical vehicle will have multiple tires, thus the weight of the
overall vehicle (assuming uniform weight distribution) would approximate
Load Capacity x Number of Tires. Tire patch size may vary as well, and this
should be considered when assessing loading.
It is important to note that ground surfaces can vary dramatically from the
controlled model above and such variances in ground surfaces can affect
page

MEGADECK FIELD MANUAL

loading capability. As such it is always better to factor in safety when
considering loading of MegaDeck panels, as well as common sense and
experience to dictate appropriate loading.

Site Analysis and Ground Preparation

MegaDeck is designed to be used over a variety of ground surfaces and
types and is able to handle reasonable ground variations and undulations.
Before installing MegaDeck it is always a good idea to review the site in
advance of delivery to ensure suitability of the ground surface. Our team is
ready to assist your engineering team in reviewing the suitability of a
particular jobsite and in assessing the overall weight loading capacity of
MegaDeck specific to the sub-grade and expected traffic.
The ideal method of analysis is testing CBR, but this is often unrealistic in
remote locations and as such an estimate of CBR may be used to calculate
estimated loading capabilities (for more information on estimating CBR see
the section Discussion of CBR above). Of course, it is always advisable to
use a safety margin when considering loading requirements.
As testing shows, MegaDeck is capable of handling tremendous loads over a
variety of ground surfaces, but MegaDeck is not designed as a bridging
device. While small ground variations will not seriously impact the
performance of MegaDeck, it is always preferable to grade and/or smooth
the ground surface prior to installation. This will create a more uniform work
surface, facilitate easier installation, and enable mats to handle heavier
loads. This process also eliminates pockets under MegaDeck, into which
water can seep.
MegaDeck mats have a natural built-in flexibility which allows some
contouring to the ground surface and enables the system to handle ground
undulations and variances.
It is important to remove large boulders or rocks from the site as these can
interfere with connection and alignment of mats, and could cause damage.

Connecting MegaDeck mats

MegaDeck mats incorporate a nesting flange system, which allows mats to
overlap one another for a secure connection and additional strength. This
system is designed to provide the greatest strength at the intersection,
while easing installation and positioning.
Connection of the mats occurs when the flanges are overlapped (i.e. mats
are positioned adjacent to each other) and the cam locks are aligned. The
Locking Pin is then inserted and rotated 45 degrees, locking the mats to each
other.

Arrows
indicate
installation
direction

As a general rule, it is best to position mats so that the projecting flange

(under-lapping) on the first mat is open to receiving an overlapping mat
flange. The surface of the flanges should be free of debris that could
interfere with proper connection. Consideration should be given upfront to
laying the first mat in such a way that the under-lapping flanges (2 sides) are
always open in the direction(s) of installation.
Installation teams should assign one team member to the task of aligning
and positioning mats, using a positioning bar if needed. As the second mat is
positioned and aligned, a Locking Pin can be dropped through the receiver
hole in the overlapping mat and into the receiver hole in the under-lapping
mat. Each connection point can be locked with a 45 degree turn of an Allen
key. Depending on the subsurface conditions, not every hole necessarily
requires a locking pin for lightweight applications, though for optimal

page

MEGADECK FIELD MANUAL

performance on softer subsurfaces, we recommend that all connector
holes/locks be utilized.
When connecting mats, it can sometimes become difficult to lock the pin
into place. This is likely due to ground variation or debris such as in muddy
environments. It is often helpful to put pressure on the overlapping mat
flange to press the two mats together. This should assist in such situations.
Once the first series of mats are laid, mats may be continuously laid in the
direction of the projecting under-lapping flanges. Should positioning of a
mat underneath a projecting flange be required, a mat can generally be
nudged with a forklift underneath the overhanging flange, due to the unique
round design of the flange end, which guides the under-lapping flange
underneath the overlapping flange.
Radius edge
allows forklifts
to nudge mats
underneath
projecting
flanges

Note: Each MegaDeck mat incorporates a proprietary radius edge at the end
of each flange that tapers towards the inside of the flange. This radius
corresponds to the adjacent mats radius located between the main body
and the flange of each mat, and is designed to allow easier positioning of
mats. As a result of this radius, mats may be nudged into position more
easily (vs. straight edges that would stop the movement and positioning of
the mat without one mat being lifted over the opposing flat edge). It is
important to use these radiuses to assist with positioning as needed.

Radius edge
eases
positioning
of flanges.

Installing MegaDeck Utilizing a Crane, Lull, or Other Similar Equipment:

MegaDeck may be installed utilizing a crane or similar equipment with a
cable, hoisting hook, and 4 properly sized lifting straps.
By utilizing 4 lifting straps it is possible to lift mats in a perfectly horizontal
position, while maintaining balance. This eases the positioning of the mats to
be installed and allows the overlapping flange of mats to be positioned by
the crane directly over the under-lapping flange. Alignment of
Cam/connector holes can be done before placement of the mat, easing final
connection.
Installing the lifting straps: It is important to run the lifting straps through 4
holes at the center of the panel (See diagram), NOT the 4 holes on the
corners of the mat. This provides additional stability and keeps mats flatter
during positioning. Ideally, loop straps through the cam holes and connect
the other side to the main crane hook or to the strap itself using a
Carabineer or hook with
safety latch.
Positioning the mat for
connection: Once lifting
straps are in place, use the
controls of the crane or other
equipment to position the
mat such that the mats
overlapping flange is
positioned over underlapping flange of the already
positioned mat. Confirm that
cam holes of the overlapping
and under-lapping mats are
aligned before lowering.
Lowering mats and removing the lifting straps: When lowering mats into
place, be sure to place a 1-2 pipe, bar, or piece of wood underneath 2
positions of the not-yet-connected overlapping flange.

page

MEGADECK FIELD MANUAL

Parallel Installation:

Perpendicular Installation:

UPPER FLANGE

UPPER FLANGE

LOWER FLANGE

LOWER FLANGE

OVERLAPPING FLANGES

OVERLAPPING FLANGES

Ensure a safe installation: Be sure to check lifting strap stability and

connection prior to lifting mats. Always use hooks with safety latches. For
added safety, never lift mats higher than 1ft, unless necessary to overcome
obstacles. Two persons should be on hand to maneuver mats
Installing Mats in a Perpendicular Configuration
The perpendicular installation of MegaDeck mats adds stability and extra
strength due to the staggering of seams.
It can cause some initial
confusion however,
because when one mat is
rotated 90, the pin
receivers line up in such a
way that they appear unlockable. The following
steps outline the simple
installation of MegaDeck
mats in a perpendicular
configuration.

OVERLAPPING FLANGES

Pin receivers are parallel and

ready to receive pin

Pin receivers are perpendicular and pin

doesnt seem to fit
page

MEGADECK FIELD MANUAL

Installing MegaDeck mats in a perpendicular

configuration is easy if you just follow these steps.
You will need either a 2 x 4 plank of wood or a pipe
with a 2 diameter.

1)

Install your first row of mats and lock together, just as you would for
a parallel layout.

2) Lay pipe or 2x4 along the inside edge of the flange waiting to
receive the perpendicular mats. Be sure to leave enough of the pipe
or plank hanging over the edge to be able to pull it out later.

5) Using your hex key, turn the locking pins 90 to the locked
position.

3) Lay top mat over the pipe or wood, aligning the pin receivers along
both flanges.
4) Drop locking pins through the top receivers. The locking graphics
will point to the "unlocked position.
UNLOCKED POSITION

LOCKED POSITION

6) Pull out the pipe or strip of wood. The pins will now drop all the way
through both receivers.
7) Use your hex key to turn the locking pins 90 back to the unlocked
position. The mats are now locked firmly together in an extra
strong perpendicular configuration.

page

10

MEGADECK FIELD MANUAL

Connect mats
along 14
edge for 13
wide
roadways

Removing MegaDeck Mats

MegaDeck mats are removed in the opposite direction in which they were
laid. In other words, mats with flanges overlapping adjacent mats should be
removed first, thus freeing the next mat for removal.
To remove mats, simply unlock the Locking Pins, thus disengaging mats from
adjacent mats. Remove locking pins and store in a safe place for future use.
A forklift should be used to remove mats from their location. To facilitate
future transport, it is advised that mats be stacked on 4 x 4 or 8 x 8
wooden beams, 20 mats to a stack, thus allowing the forks of a forklift to be
positioned easily under the stack. Additional wooden beams may be placed
between mat stacks as needed for fork access.
Consideration should always be given to the weight of mats and the
capabilities of your forklift, when considering movement of mats and mats
should be secured with proper safety banding, as is appropriate.
Forklift forks should always be spaced evenly to ensure a balanced load and
extended forks are advised for smaller forklifts.

Alternatively, mats may be connected two mats wide, short-side to shortside. Mats may be laid side by side or staggered, depending on the need for
additional strength. It is generally recommended that when connecting
roadways using the short-side to short-side method that mats be staggered
for greater strength.
(Using the staggered methodology there are no 4 way intersecting seams,
only 3 way intersecting seams and this assists in distributing weight.
Remember to only stagger mats such that a 3 way seam intersection is
created vs. another 4 way seam).
Remember to always connect MegaDeck in the direction of the underlapping flange, so that they are always ready to receive the next overlapping
mat.
Roadway 2: Stagger joints for greater strength
Staggered
Roadway

Creating a MegaDeck Roadway

MegaDeck is designed to connect in two directions, thus allowing flexibility
in roadway design. Typical full sized mats are 7.5ft Wide x 14ft Long and
mats can be connected lengthwise and widthwise.

Roadway 3: Connect short edge to short edge

For typical roadways, it is recommended that mats be connected long-side

to long-side, which creates a 13ft wide roadway, suitable for typical vehicles
and equipment.

Straight
Roadway

page

11

MEGADECK FIELD MANUAL

Passing Lanes and Turning Areas
Mats can be built
out in both
directions for
large turning
areas and turnouts

While straight roadways are ideal, there will always be situations where the
length of the roadway would dictate the need for a passing area. For these
situations, it is possible to add additional mats to the roadway for both the
short-side and long-side connection methodologies.
Passing lane mats should be added to the side where the under-lapping
flange is exposed, thus facilitating the connection and positioning of the
passing lane mats. Depending on the length of the passing area required,
additional MegaDeck sections can be added to the passing area, once again
on the side where the under-lapping flanges are exposed.
Depending on whether your roadway is short end to short end or long end
to long end, between one and two mats are required to create a suitable
passing area x the length of the passing lane required.

Passing Lane for

straight roadway
using optional
half mats

Passing
Lane for
Staggered
Roadway

To create a large turning area or turn-out, the same methodology would

apply, in that mats are most easily installed with the overlapping flange
placed over the exposed under-lapping flange. Matting can be built out in
both directions of the exposed flanges

Work Platforms, Bone Yards, and Contiguous Areas

MegaDeck is designed to connect in all directions, allowing for the
construction of a work compound, equipment pad, bone yard, or other
contiguous surface.
It is generally recommended that MegaDeck slated for use in long term or
semi-permanent work compounds be positioned using the staggered
methodology described above. While this method provides the greatest
strength, it is important to keep in mind that it leaves a staggered edge
along the perimeter of the compound.
To begin installation, always begin in one corner of the site (preferably
closest to access road) and be sure to lay the first row of mats in as straight a
manner as possible, ensuring that the first row of mats is parallel to the site
so that further mats dont drift off course. This first row is the most
important, as subsequent rows of mats simply follow the same line. To
verify alignment it is suggested that a string line be run for the first row
installed.
Remember to always position the first mat such that the under-lapping
flanges are open and ready to receive the next MegaDeck.

page

12

MEGADECK FIELD MANUAL

Access Road
1

15

16

22
29

23
30

10
17
24
31

4
11
18
25
32

6
12

19
26
33

Some thought should be given to the amount of water runoff expected from
a large area and the ability of the surrounding area to handle the water that
runs off of the work pad.

7
13

20
27
34

14
21
28

Compound
Build-out
Method

Crowning
exaggerated
to show
runoff

35

Bridging Situations

Geo-textiles and MegaDeck

It is important to remember that MegaDeck is not designed as a bridging

solution and should not be considered for crossing large holes or gaps
greater than 2ft. In such situations, it is recommended that you consult with
an experienced bridge engineer to determine what bridging options can be
placed under MegaDeck.

While not necessary, Geo-textiles are an inexpensive way to speed

installation and removal time, as the presence of a geo-textile provides a
clean and uniform installation surface and prevents debris or mud from
interfering with the MegaDeck connection system. Geo-textiles can be used
to provide a barrier between dirt, mud and the mats above, while minimizing
the cleaning required upon removal of MegaDeck

MegaDeck is designed with some inherent flex, both within each mat and
between mats. This allows MegaDeck to handle varying ground contours
and to conform somewhat to the ground surface. This prevents see-sawing
and a fulcrum point that could build stress and potentially damage mats.

Water Runoff Considerations

Consideration of water run-off is particularly important when dealing with
large compound areas. In this regard, it is important to consider building up
the subsurface of an area to prevent low spots within the MegaDeck matrix,
where water may gather. Fill dirt or gravel may be brought in or other site
preparation work can be done in advance of MegaDeck installation.
Like a sports field, a slightly crowned MegaDeck installation will be
unnoticeable to the naked eye; however, it will allow water to flow and
runoff along the perimeter of the MegaDeck pad and away from the work
area.

Depending on the type of geo-textile utilized and how porous it is, it will help
keep mud and subsurface water from seeping up to the top surface and can
keep contaminants from seeping down from the jobsite into the ground
below.
To use a geo-textile in combination with MegaDeck, simply unroll the geotextile on the ground surface and install MegaDeck using the standard
installation procedures detailed above.
Transitions and On/Off Ramps
As MegaDeck mats are over 4 thick, it is advisable to build a transition
between the access road and the matting material. Use of our molded
rubber transition strip is advised, but it is always possible to simply build up
the ground surface (using dirt, gravel, or lumber) to provide a transition onto
the MegaDeck surface.

page

13

MEGADECK FIELD MANUAL

We recommend placing 2 thick wooden beams underneath the projecting
overlapping flange that exists on two edges of a MegaDeck installation. This
will help protect the flange from damage and provide support for heavy
loads transitioning onto the mats. Alternatively, mounding dirt underneath
the flange will provide some additional support and extend the life of your
system.
Double Stacking MegaDeck
Though generally not necessary, it is possible to double stack layers of
MegaDeck to create an ultra-strong access pad over very soft ground.
Standard installation procedures should be applied for both layers, except
that seam lines should be staggered between the top layer and the bottom
layer, providing additional strength and loading capabilities.

Snow and Ice Removal

MegaDeck may be shoveled or plowed with standard snow removal
equipment; however, care should be given to avoiding damaging mats with a
vehicle-based plow blade. The area most susceptible to damage is the seam
line between mats, especially if mats are not fully connected or are unevenly
positioned. Care should be made to avoid catching the seam lip or damaging
the surface traction pattern of the MegaDeck.
Salt, sand, and other traction aids are appropriate for use on MegaDeck and
should be kept on hand to ensure that surfaces do no become slippery with
snow, ice, grease, or other lubricants.

REPAIRING DAMAGE TO MEGADECK

Double stacking is suitable for deep mud applications or for areas where
greater clearance from a soft ground surface is required.

CLEANING AND MAINTENANCE OF MEGADECK

MegaDeck is designed to facilitate repair to mats, thus extending a mats

useable life. The components of MegaDeck that may be repaired or replaced
are the metal locking pin receivers, the main seal of lid, the flange seal off
lids, and even the main body.
Repairing Cracks and Surface Punctures

General Cleaning
Mats are non-porous and the material used in manufacturing MegaDeck will
not absorb water, contaminants, bacteria, and other substances.
MegaDeck is designed to be cleaned using a high powered pressure washer.
Most commercial cleaning agents will not damage the surface, but
consideration should be given to environmental concerns when cleaning
mats on a jobsite.
In this regard, contaminants such as grease, oil, and lubricants should be
removed directly from the mat surface, in advance of mat removal and only
ecologically sound cleaning solutions should be used.

Surface punctures as a result of a heavy impact can generally be patched

using a hand held plastic extruder (plastic extrusion welder) that is available
for purchase directly from Signature or from a third party supplier. These
extruders will extrude hot HDPE through a nozzle and the HDPE will bind to
the surrounding material to create a seal. This method of repair is ideal for
surface punctures, but is not recommended for repairing long cracks or
other structural breaks.
Should an entire lid (either the main body lid or the flange lid) need to be
removed due to cracking or a puncture beyond repair, simply unbolt the
main lid or flange lid from the main body using standard tools. A
replacement lid may be ordered as well as replacement mounting hardware
(barrel nuts/Chicago bolts) and gaskets if needed. Be sure to replace the
seal off gasket around the perimeter of the lid to ensure that liquids are

page

14

MEGADECK FIELD MANUAL

unable to penetrate the mat, and that all bolts are appropriately tightened.
Lock Tight should be used when re-screwing bolts together to prevent
loosening of bolts over time.
If a puncture exists on the main body of the mat, this may be repaired using
the extruder patching method above. Should this method prove inadequate,
an entire main body part is available for purchase and existing lids and
hardware can be used, thus minimizing the cost to get the such a mat back
into service.
Repairing Locking Pin Receiver Damage
MegaDeck mats are designed such that the metal receivers placed into each
mat can be easily replaced if damaged, thus prolonging the life of a
MegaDeck mat. In order to replace the receivers, it is necessary to remove
the appropriate lid by unscrewing the through bolts holding the lid to the
main body. Once removed, the receiver bolts will become visible and the
damaged receiver can be unscrewed using a 9/64 hex key. Once removed,
simply replace the receiver with a new receiver, bolt back into place, and
replace the corresponding lid, bolting it back in place to the main body. Be
sure to replace the gasket material around the perimeter of the lid, to ensure
that liquids and other substances do not penetrate the main body.

SERIAL NUMBERS & IC (INVENTORY CONTROL) CHIP USAGE

Each MegaDeck Mat is stamped with a unique serial number for easy
inventory control and tracking.

As there are many types of IC/RFID chips available in the marketplace today,
it is important to specify the type and brand of inventory control chip to be
used at the time of an order. For additional assistance on inventory control
chips, dont hesitate to contact our technical team.

Limited Warranty
MegaDeck LIMITED WARRANTY
1. What is covered by this warranty. Signature Systems Group, LLC
warrants to the original purchaser only or to those customers or an
Authorized MegaDeck Dealer, that the product that is the subject of this
sale
(a) conforms to Signature Systems Group, LLC published
specifications, and (b) is free from defects in material and workmanship.
The duration of this warranty is six (6) months from date of sale. If the
buyer discovers within this time a failure of the product to conform to
specifications or a defect in material or workmanship, it must promptly
notify Signature Systems Group, LLC in writing, [but not later than 30
days after expiration of the warranty] of the exact manner in which the
product was so defective, the conditions of usage which gave rise to
such claims, and deliver to Signature Systems Group, LLC therewith a
representative sample exemplifying the claimed defects, for examination
by Signature Systems Group, LLC engineers. Should the product prove
to be defective as set forth above, then Signature Systems Group, LLC at
its own cost and expense shall repair the defective item or replace with
new and ship to purchaser, replacement product for all those items
demonstrating such defects that are shipped back prepaid to its
manufacturing plant in Sanford, FL.
2.

Inventory control chips do not come standard with MegaDeck mats and may
be ordered at the time of an initial order or retrofitted into an existing
MegaDeck mat at a later time. Retrofitting is achieved by removing a single
flange lid and inserting the IC chip in the outmost corner of the mat. The
space created by the ribbed support structure is ideal for holding a variety of
inventory control chip types.

What is not covered by this warranty. Signature Systems Group, LLC

does not warrant, (a) any product not manufactured by Signature
Systems Group, LLC or, (b) defects caused by failure to provide a
suitable installation environment, (c) damage caused by use of the
product for purposes other than those for which it was designed, (d)
damage caused by disasters such as fire, flood, loading beyond its
design specifications, (e) damage caused by unauthorized attachments
or modifications, (f) damage during shipment, storage, mishandling or
any abuse by the purchaser. Goods have been manufactured &
inspected at our plant with the greatest care. However, damages

page

15

MEGADECK FIELD MANUAL

caused by mishandling during a customer installation can be avoided by
due care and attention to installation and shipping instructions.
3. Warranty of title. In addition to the warranties set forth in the previous
paragraphs Signature Systems Group, LLC warrants that it has good title
to the product free of any encumbrance, and that the product shall be
delivered directly from Signature Systems factory.
4. Disclaimer of warranty. The foregoing warranties are in lieu of all other
warranties, express or implied, including but not limited to the implied
warranties of merchantability and fitness for a particular purpose.
5. Limitations of remedies. In no case shall Signature Systems Group, LLC
be liable for any special, incidental or consequential damages
(Damages) based upon breach of contract, negligence, strict tort, or
any other legal theory. Such Damages include, but are not limited to
loss of profits, loss of savings or revenue, loss of use of the product or
any associated equipment, cost of capital, cost of any substitute
equipment, facilities or services, down-time, the claims of third parties,
including customers, and injury to property. This limitation does not
apply to damages caused by breach of the warranty of title, nor to claims
for personal injury. Some states do not allow limits on warranties, or on
remedies for breach in certain transactions. In such states, the limits in
this paragraph and in paragraph 4 may not apply.
6. Time limit for bringing suit. Any action for breach of warranty must be
commenced within 12 months following delivery of the goods.
7. No other warranties. Unless modified in writing signed by both parties,
this agreement is understood to be the complete and exclusive
agreement between the parties, superseding all prior agreements, oral
or written, and all other communications between the parties relating to
the subject matter of this agreement. No representative or employee of
Signature Systems Group, LLC, or any other party, is authorized to make
any warranty in addition to those made in this agreement.

Signature Systems Group, LLC

50 East 42nd Street 14th Floor
New York, NY 10017
Toll Free In US 800-709-8181 +1 212-953-1116 Fax +1 212-953-1117
www.megadeckmats.com

8. Allocation of risk. This agreement allocates the risks of product failure

between Signature Systems Group, LLC and the purchaser. This
allocation is recognized by both parties and is reflected in the price of
the goods. The purchaser acknowledges that it has read this agreement,
understands it, and is bound by its terms.

page

16