Modular rig mat

Abstract

A modular rig mat is formed from a core panel have a plurality of edges, and a perimeter frame surrounding the core panel comprising a plurality of frame rails having a transverse profile for engaging corresponding edges of the core panel and a plurality of corner components adapted to connect between adjacent frame rails.

1 . A modular rig mat comprising:
 a. a core panel have a plurality of edges;   b. a perimeter frame surrounding the core panel, and comprising a plurality of frame rails having a transverse profile for engaging corresponding edges of the core panel and a plurality of corner components adapted to connect between adjacent frame rails and defining a pocket for receiving the core panel.   
     
     
         2 . The rig mat of  claim 1  wherein the core panel is square or rectangular having two short edges and two long edges. 
     
     
         3 . The rig mat of  claim 2  further comprising a connector box adapted to connect between two frame rails disposed end-to-end. 
     
     
         4 . The rig mat of  claim 2  wherein the connector box is a shackle box comprising a shackle. 
     
     
         5 . The rig mat of any  claim 3  wherein either or both of the corner components and the shackle box are cast components. 
     
     
         6 . The rig mat of  claim 5  wherein the cast components comprise steel, aluminum, metal alloys, a plastic or polymer, or a composite material. 
     
     
         7 . The rig mat of  claim 2  wherein each long edge comprises at least two side rails interconnected by a shackle box. 
     
     
         8 . The rig mat of  claim 6  wherein the cast components comprise steel and are welded to the frame rails 
     
     
         9 . The rig mat of  claim 1  wherein each frame rail transverse profile is angled or rounded between a top flange and a bottom flange. 
     
     
         10 . The rig mat of  claim 1  wherein each frame rail transverse profile is substantially square. 
     
     
         11 . The rig mat of  claim 8  wherein the core panel edge has a profile matching the frame rail transverse profile. 
     
     
         12 . The rig mat of  claim 11  wherein each corner connector comprises a nesting connector profile having a shape matching the frame rail transverse profile. 
     
     
         13 . The rig mat of  claim 12  wherein each connector box comprises a connector profile having a shape matching the frame rail transverse profile. 
     
     
         14 . The rig mat of  claim 4  wherein the shackle box defines a drain hole. 
     
     
         15 . The rig mat of  claim 4  wherein the shackle box is configured such that the shackle does not rest on a bottom of the shackle box. 
     
     
         16 . The rig mat of  claim 1  further comprising a tie rod extending between and affixed to opposing frame rails. 
     
     
         17 . The rig mat of  claim 3  further comprising a tie rod extending between and affixed to opposing connector boxes. 
     
     
         18 . A method of assembling a rig mat having a core panel, comprising the steps of:
 a. assembling a perimeter frame around the core panel, the perimeter frame comprising a plurality of corner connectors and a plurality of frame rails, each defining a channel or pocket for receiving and engaging the core panel; and   b. fastening the corner connectors and frame rails together.   
     
     
         19 . The method of  claim 18  wherein the perimeter frame further comprises connector boxes for connecting two end-to-end frame rails. 
     
     
         20 . The method of  claim 19  wherein the perimeter frame components are welded together. 
     
     
         21 . The method of  claim 20  wherein the perimeter frame components are welded together with an overlapping joint.