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Why pad sizing gets skipped
A crane that tips because of a pad failure rarely fails because of the crane. It fails because the ground underneath could not hold the load, and the pad that was supposed to spread that load was undersized, cracked, or sitting on soil nobody actually checked. OSHA’s standard on cranes and derricks is direct about this, outriggers must not be used unless ground conditions are firm, drained and graded well enough to support the load.
Most crews reach for whatever pad matches the crane’s storage rack, or whatever was used on the last job. That works until the soil is different, the load is heavier, or the crane is fully extended at a longer radius than usual. None of those change the pad in the rack. All of them change the pressure that pad needs to spread.
How to size the pad
Start with the total weight on each outrigger, which is the crane’s own weight plus the load plus any counterweight, divided across the number of outriggers in contact with the ground. Then check the ground bearing capacity for the soil type you are actually working on, since compacted gravel and soft clay are not interchangeable numbers.
Divide the outrigger load by the ground bearing pressure the soil can support, and the result is the minimum pad area you need. If you are working from a crane manufacturer’s load chart, use the worst case radius and boom length in the calculation, not the average one. For soft ground, sand or unstable surfaces common on GCC sites, the pad’s full surface area does the work, and on the softest sites it is common practice to stack two pads or add timber cribbing underneath rather than move up a single pad size.
What BPS pads are actually rated for
| Specification | 800mm Model | 1000mm Model |
|---|---|---|
| Dimensions | 800 x 800 x 80mm | 1000 x 1000 x 80mm |
| Load capacity | 45 tons | 60 tons |
| Weight | 18 kg | 28 kg |
| Material | UV stabilized HDPE | |
| Temperature range | Minus 40C to plus 80C | |
| Compliance | OSHA 1926.1402 | |
| Warranty | 1 year against material and workmanship defects | |
As a rough starting point directly from BPS’s own product data, the 800mm pad suits cranes up to around 30 tons capacity and the 1000mm pad suits the 30 to 60 ton range, but this is a starting reference, not a substitute for checking your specific crane’s outrigger load chart against your actual site conditions.
Material matters as much as size
High density polyethylene pads spread load well, resist water and chemicals, and do not splinter the way timber cribbing can under repeated use. The UV stabilized HDPE used in BPS’s CraneBase pads is rated across a minus 40C to plus 80C range, which matters across both GCC summer heat and cold storage or export applications. Steel pads handle higher point loads but weigh more and can dent under uneven ground. Match the material to how often the pad gets used and what it sits on, not just to price.
Common ordering mistakes
- Ordering by outrigger foot size instead of calculated ground bearing pressure
- Assuming a pad rated for one crane model works the same way under a heavier one
- Reusing a cracked or delaminated pad because it still looks flat from the top
- Not accounting for a fully extended, minimum counterweight lift, which is usually the worst case, not the average one
Relevant BPS product. BPS’s CraneBase outrigger pads are available in 800mm and 1000mm sizes with a 1 year warranty and typical 72 hour delivery across the GCC. Bulk pricing steps down at 5 to 10 pads, 10 to 20 pads, and 20 plus pads, worth asking about if you are equipping a fleet rather than a single crane.
What to send with your RFQ. Crane make and model, maximum load and radius for the job type you run most often, typical ground conditions, and whether you need the 800mm or 1000mm pad. Photos of your current pads help if you are matching an existing set.
Frequently Asked Questions
What size outrigger pad do I need for my crane?
As a general starting point, the 800mm pad suits cranes up to roughly 30 tons capacity and the 1000mm pad covers the 30 to 60 ton range, but always confirm against your crane’s own outrigger load specification and your typical ground conditions before ordering.
Are these pads suitable for soft ground or sand?
Yes. The large surface area, about 0.64 square meters for the 800mm pad and 1.0 square meter for the 1000mm pad, is specifically built to distribute load on soft ground, sand and unstable surfaces common on GCC sites. For extremely soft conditions, stacking two pads or adding timber cribbing underneath is common practice.
What warranty comes with a BPS outrigger pad?
BPS’s CraneBase pads carry a 1 year manufacturer warranty covering cracking or splitting under rated load, handle detachment, and manufacturing defects. Normal wear, improper use or overloading is not covered.
Source referenced in this guide: OSHA 1926.1402, Ground Conditions
Need help identifying the correct part?
Send the equipment make and model, existing part number, required quantity and available photos or technical documents.
Related Guides
- When Should Crane Outrigger Pads Be Replaced (coming soon, links to blog)
- Crane Wire Rope Lubrication and Inspection Guide
- What Information Should Be Included in a Spare Parts RFQ
Editorial note. Load capacity, weight, dimensions, temperature range and warranty figures were pulled directly from the live CraneBase Outrigger Pads product page on bestpartssales.com and are real, not estimated. The hero image is hotlinked from that same live page for this draft, re-host it on the blog’s own media library before publishing. This page merges the two existing outrigger pad posts, redirect both old URLs here once approved.