Updated October 19, 2026
The best way to prevent anti-fatigue mats from curling is to choose materials that are chemical resistant, make sure they're designed not only to lay flat but remain flat, and test them for weeks in your workplace before making a purchase.
Curling anti-fatigue mats are more than an inconvenience. They are an undeniable slip, trip, and fall hazard. In fact, according to our 2027 State of Industrial Anti-Fatigue Mats report, 68% of safety, manufacturing engineering, and continuous improvement leaders have experienced curling borders. Twenty-nine percent of these leaders say curling is their biggest frustration with anti-fatigue mats today.
At AcroMat, we've spent more than 20 years studying how anti-fatigue mats perform in industrial environments. We've evaluated thousands of mats in real-world applications and worked with independent, OSHA-accredited testing laboratories to better understand why some mats curl while others maintain their shape.
In this article, we explain why anti-fatigue mats curl, what you can do about existing mats that are curling, and five ways to prevent the problem from happening again.
Why Do Anti-Fatigue Mats Curl?
Anti-fatigue mats typically curl when their materials or construction can no longer maintain their original shape. The most common causes include:
Liquid and chemical exposure: Anti-fatigue mats that are open cell (i.e., porous, permeable) often absorb oils, grease, cleaning agents, water, and other substances. This absorption shrinks the material and buckles the borders, like bacon on a frying pan, causing borders to curl upwards.
Poor mat construction: Mats made with multiple layers or overhanging surfaces, often referred to as the "waterfall" design, tend to curl when those separate components deteriorate or change shape at different rates.
Heavy use: Repeated foot traffic, carts, equipment, and other physical stresses that constantly bang the edges, especially if the edges are laying flay, can accelerate curling and edge damage.
Environmental conditions: Similar to liquids and chemicals, heat, humidity, temperature fluctuations, and other related conditions can change the shape of an anti-fatigue mat and cause the borders to curl.
Not every mat curls for the same reason. In many cases, it's a combination of material quality, design and construction, and the conditions in which the mat is used. This is why preventing curling starts long before an anti-fatigue mat ever reaches your facility.
Anti-fatigue mat borders often curl because the material is porous and permeable, leading to shrinking and buckling followed by lifting edges.
Can You Fix an Anti-Fatigue Mat That's Already Curling?
If an anti-fatigue mat is curling because its material has permanently deteriorated or deformed, replacement is generally the safest long-term solution. While solutions like industrial tape can work for a time, flattening the edge temporarily will rarely fix underlying problem.
First, determine whether the edge is lifting because of a placement issue or because the mat itself has changed shape. If the mat is folded, improperly positioned, or pushed up against equipment, solving the problem may simple require repositioning and giving it time to settle.
However, if the edge remains raised, the material has shrunk, or the mat is cracking, separating, or deteriorating, the problem may be permanent. Avoid relying on temporary fixes such as taping down a deteriorating edge, placing heavy objects over the mat, or stacking another mat on top. These approaches may conceal the underlying issue or create additional hazards.
Before replacing a curling mat with the same product, take time to understand why it failed. Otherwise, you'll likely find yourself dealing with the same problem again.
Curling is often a symptom of a larger issue, such as material construction and design. Understanding why your mats are curling is the most important step in preventing the trip hazard long term.
5 Ways to Prevent Anti-Fatigue Mats from Curling
1. Choose Materials That Resist Curling
The material used to manufacture an anti-fatigue mat is one of the biggest factors in its long-term durability. Three common industrial anti-fatigue mat materials include:
- PVC foam
- PVC/nitrile blends
- 100% nitrile rubber foam
PVC foam is widely used because it's versatile and relatively inexpensive. PVC/nitrile blends are another common option, combining characteristics of both materials. While versatile and inexpensive, PVC foam is vulnerable to deterioration because its open cell, porous, and prone to absorbing liquids.
Over time, this deterioration can cause PVC foam mats to shrink, buckle, and lose their shape. When this happens, it can lift the borders of the mat off the ground. Take a closer look at this issues in the 2-minute video below.
In this episode of What's Wrong With Your Anti-Fatigue Mat?, I talk about why the PVC foam mats behind Target retail counters are curling, how it affects aesthetic, and the hazard it creates for employees. Full playlist.
100% nitrile rubber foam is generally a stronger choice for demanding industrial environments, particularly because the material is molded, closed cell, and impervious to liquids. At AcroMat, our 100-1, 100-Cleanroom, and 100-ESD Series mats are manufactured from 100% nitrile.
Still, material composition alone doesn't tell the whole story. The quality of the formulation, manufacturing process, and mat construction also play key roles.
What to look for: Ask manufacturers exactly what their mats are made from, how the materials respond to your workplace conditions, and what testing supports their durability claims.
This windows and doors manufacturer replaced curling and eroding PVC tiles with a 100% nitrile custom 100-1 Series mat. Unlike PVC and PVC/nitrile blends, 100% nitrile will not absorb liquids, flatten, or curl.
The AcroMat 100-1 Series, 100-Cleanroom Series, 100-ESD Series, and NitriTuf Diamond Series anti-fatigue mats are guaranteed not to curl under out Lifetime Performance Warranty.
2. Look Closely at Mat Construction and Edge Design
Material and design work hand in hand. Even a durable material can perform poorly if the mat's construction creates unnecessary stress along its edges. One common example is the traditional diamond-plate anti-fatigue mat with a waterfall-style edge.
In this design (left photo below), the top surface extends beyond the underlying foam cushion and slopes toward the floor. Because the underlying foam is made from open cell PVC foam, it has shrunk as a result of heavy use and exposure to liquids. As the pad shrinks, the waterfall edge lifts off the ground and curls.
At AcroMat, our NitriTuf Diamond Series uses a different approach. Rather than relying on an overhanging surface, we use a cut-and-bond design in which the anti-fatigue cushion and diamond-plate surface extend to the edge of the mat. A separate nitrile border is then bonded to create a gradual transition to the floor. This design creates a more intentional and permanent slope towards the floor surface.
Our 100-Series mats also use molded nitrile construction and bonded borders designed to remain flat throughout their service life. The objective is straightforward: Build the mat so its edges remain stable rather than becoming the first point of failure.
What to look for: When comparing products, look beyond the appearance of the beveled edge. Ask how the mat is constructed underneath and what happens to that construction after years of use. Ask how the mat is designed to prevent curling.
Left: Waterfall design and buckled PVC pad led to curling. Right: AcroMat NitriTuf Diamond Series cut-and-bonded at the edges to eliminate curling risks.
3. Look for Independent Durability Testing
Every anti-fatigue mat manufacturer makes claims about durability. The question is whether these claims are supported by evidence. The best way to evaluate curling resistance is through independent testing that examines how a mat responds to prolonged environmental and physical stress.
AcroMat worked with CSA Group, an independent and OSHA-accredited testing organization, to evaluate the curling resistance of our 100-Series nitrile anti-fatigue mats.
The evaluation included five years of accelerated aging, with AcroMat samples tested alongside a traditional extruded PVC foam mat featuring a vinyl diamond-plate surface and waterfall-style edge. The results showed a significant difference in curling performance:
AcroMat 100-Series: No curling observed after 5 years of accelerated aging.
Traditional PVC foam diamond-plate mat: Curling appeared within the equivalent of 1 year and became more pronounced as testing continued.
These results support the importance of material composition and mat construction when evaluating long-term performance. They also provide independent evidence behind AcroMat's Lifetime Performance Warranty against curling.
Accelerated aging is not a guarantee that every product will perform identically in every workplace. However, it provides a useful, controlled way to compare durability and evaluate manufacturer claims.
What to look for: Ask your mat provider for third-party test for curling resistance. If test data isn't available, ask them why not and how you are protected.
After the equivalent of 5 years of harsh environmental stress, the AcroMat 100-1 Series mat edges remained completely flat. The diamond-plate mat showed signs of curling after 1 year and worsened as the test wore on.
Related: AcroMat Shows Zero Curl After 5 Years of Accelerated Aging
4. Make Sure the Warranty Actually Covers Curling
A long warranty doesn't necessarily mean a mat is guaranteed to perform for a long time. Many anti-fatigue mat warranties limit their protections to manufacturing defects. They rarely cover the problems facilities encounter most frequently, including curling, flattening, and mats or times coming apart.
Before your next anti-fatigue mat purchase, review the warranty in detail. Read the fine print. Make sure you are unequivocally clear on how you are protected if your mats fail to perform.
Ask these questions:
- Does the warranty specifically cover curling or raised edges?
- Does it protect against permanent loss of ergonomic cushion?
- Are there exclusions related to normal use or environmental exposure?
- How long does the coverage last?
- What happens if the mat fails to perform as promised?
A manufacturer's warranty and a performance warranty aren't the same thing. A manufacturing-defect warranty generally addresses problems with how a product was made. A performance warranty goes further by protecting specific outcomes throughout the product's use.
At AcroMat, our 100-1, 100-Cleanroom, and 100-ESD Series mats are backed by our Lifetime Performance Warranty covering two specific commitments:
- The mat will never curl along its borders.
- The mat will never permanently flatten or lose its ergonomic cushion.
What to look for: Don't judge a warranty by the number of years printed on the product page. Evaluate exactly what the manufacturer promises to protect.
The AcroMat Lifetime Performance Warranty is backed by third-party, OSHA-accredited laboratory testing. Testing & Certifications.
5. Test Anti-Fatigue Mats in Your Actual Work Environment
Independent testing is important, but there's no substitute for understanding how a mat performs in your facility. Before making a large investment, request a sample or arrange a trial.
Not a mat you have to rent, not a down payment, but a free, full-sized trial mat you can keep and put to the test for weeks or even months. At AcroMat, we recommend at least 200 working hours before making buying decisions.
Skip the breakroom or businss office. Place the mat in an environment representative of where it will ultimately be used. For example, if your facility operates around oils, chemicals, moisture, heavy foot traffic, or rolling equipment, evaluate the mat under these same conditions.
A useful trial should answer several questions:
- Does the mat remain flat along every edge?
- Does it maintain its original shape and thickness?
- Is the surface holding up to the surrounding environment?
- Does the mat remain stable without sliding?
- Are employees satisfied with its ergonomic support?
- Does the mat continue to fit the workstation properly?
- Don't limit the evaluation to the first few days.
At AcroMat, we provide free samples for qualified business applications so facilities can evaluate our materials before making a larger investment. We've also conducted easily-repeatable demonstrations you can use to evaluate liquid absorption and chemical exposure.
In one demonstration, shown below, we submerged our nitrile material in water for 72 hours and compared its weight before and after. In another, also shown below, we exposed the material to chemicals over several weeks to evaluate its resistance.
What to look for: Choose a mat provider that's willing to let you test their products in your specific environment, rather than asking you to rely solely on marketing claims.
Waterproof test: Soak a sample in water for multiple days, weighing the mat before and after. Above is a 72-hour test we conducted to illustrate the waterproof capabilities of 100% nitrile. The mat weighed the same before and after being submerged, indicating zero absorption.
Chemical-resistance test: We filled a box made from our mat materials with harsh chemicals and let it sit for 6 weeks. In short, the 100% nitrile material will endure indefinitely without wear or break down.
How Often Should You Check Anti-Fatigue Mats for Curling?
Even when mats are designed to resist curling, facilities should inspect them regularly for developing safety and ergonomic problems.
For most industrial environments, a formal inspection every 30, 60, or 90 days is a reasonable starting point. More demanding applications may require more frequent checks.
- During each inspection, look for:
- Raised or curling borders
- Cracks, tears, or surface deterioration
- Separation between materials or along seams
- Sliding or movement
- Loss of cushion or permanent flattening
- Gaps, overlaps, or poor workstation coverage
A formal, proactive, and consistence inspection process can help identify issues like curling before they become true safety concerns.
Ask employees whether they've noticed any changes, too. The people standing on the mats every day are often the first to recognize developing problems. Document your findings and compare them over time. The goal isn't simply to identify curling after it becomes dangerous. It's to recognize changes early enough to take corrective action.
Related reading: How Often Should Anti-Fatigue Mats Be Inspected?
Frequently Asked Questions About Curling Anti-Fatigue Mats
Why do anti-fatigue mats curl at the edges?
Anti-fatigue mats curl when their materials or construction lose the ability to maintain their original shape. Common causes include material deterioration, shrinking, environmental exposure, repeated compression, and poor edge design. Curling is particularly concerning because raised edges can create workplace trip hazards.
Can you flatten a curling anti-fatigue mat?
Sometimes a mat that has been temporarily folded or improperly positioned can settle. Industrial tapes can help with slight curling as well. However, if curling is caused by permanent material deterioration, shrinking, or structural damage, flattening the edge may not resolve the problem. Mats with curling edges are a trip hazard and should be removed from service.
How do you keep rubber floor mats from curling?
Choose mats made from materials appropriate for the workplace, evaluate their construction and edge design, and look for independent durability testing. Proper placement, regular inspections, and a warranty that specifically covers curling can also help facilities reduce recurring problems.
Is nitrile rubber better than PVC foam for preventing curling?
High-quality, 100% nitrile rubber foam generally offers strong durability and resistance to many industrial liquids and chemicals. PVC-based mats vary considerably by formulation and construction, and some are more vulnerable to deterioration in demanding environments. Material quality, edge design, and verified testing should all be considered when comparing curling resistance.
Jake Berger, Vermeer EHS Manager, and two operators share how replacing their curling anti-fatigue mats with AcroMat helped re-shape safety throughout their 7-building, 2,400-employee campus in Pella, IA. Full case study.
Should you replace an anti-fatigue mat if the edges are curling?
If curling creates a trip hazard and cannot be safely corrected, the mat should be removed from service and replaced or otherwise resolved according to the manufacturer's guidance. Before purchasing a replacement, determine why the original mat curled so the same problem doesn't continue.
Curling Shouldn't Be an Accepted Part of Mat Ownership
Curling is one of the most visible signs that a mat is no longer performing. Yet, many facilities continue replacing curling mats with the same products, accepting short lifespans and recurring hazards as part of the cost of doing business. It doesn't have to be this way.
Preventing curling starts with understanding the materials, evaluating the design, reviewing independent testing, and choosing a provider willing to stand behind the product's performance. At AcroMat, we've made curl resistance a central part of how we design, manufacture, test, and warranty our anti-fatigue mats.
Before your next investment, ask one simple question: What evidence do I have that this mat will remain flat? The answer should go beyond a promise on a product page.
Want to evaluate the material for yourself?
Request a free AcroMat sample for your facility to keep put to the test.
