When picking an HVAC pad for installation, many contractors opt for the heaviest one, assuming it'll last the longest. While older concrete pads rewarded that logic, today "heavier means better" is just a myth. Thanks to innovative designs using modern materials and injection molding, the best pads are often lighter.
Take, for example, DuraPlas' PolarPad, a plastic pad designed and engineered as a base for HVAC equipment. Injection-molded from polyethylene, it's lightweight yet durable enough to support 40 pounds. It's also engineered to resist cracking, breaking, and warping, and is UV- and weather-resistant.
The Problem With Weight-Based Judgments
When pads were mostly made of poured concrete or early-generation plastics, weight was a major indicator of strength. Heavier meant less flex and a lower chance of equipment vibration or movement in the wind. But that extra weight also made the pad harder to move and position, prone to cracking, and more likely to settle unevenly over time.
Additionally, no matter how heavy the pad, weight can't prevent weathering or long-term degradation either. No matter how heavy, concrete spalls and old plastic fractures. These materials also absorb moisture, which expands when frozen and accelerates surface spalling. Once the pad starts breaking down, it's no longer reliable or level, and vibrations from the unit accelerate deterioration.
Injection-molded pads help avoid these problems. Made from lightweight yet durable materials like polyethylene, they can withstand weathering and long-term degradation. The PolarPad is specifically engineered to stay flat, withstand extreme temperatures and weather conditions, prevent cracking and warping, and resist oils, refrigerants, and canine urine.
What Actually Matters in HVAC Pads
If weight doesn't matter in modern HVAC pads, then what should you look for? Here's what to focus on when buying your next HVAC pad.
Ribbing
A great plastic HVAC pad should have uniform ribbing on the underside. This does several things:
- Distributes weight evenly across the ground
- Prevents corner sag
- Adds rigidity in all directions
- Reduces vibration transfer
- Allows pads to stay flat over time
A smooth, heavy slab may feel solid, but without ribbing, it'll flex more under a condenser sitting on soft soil.
Load Rating
Some traditional pads don't publish an actual load rating. Contractors will buy them because they look and feel solid. Modern HVAC pads are different. They specifically state how much weight they can support, so contractors know what to expect. PolarPad lists load ratings for each model. For example, POLAR2424-2, the smallest and lightest model, only weighs 6 pounds but supports up to 1,210 pounds. On the other end, POLAR5252-3, the biggest and heaviest model, weighs 37.5 pounds and supports up to 2,100 pounds.
UV and Weather Resistance
Outdoor equipment pads endure years of exposure to the sun, rain, freeze-thaw cycles, lawn chemicals, pet waste, cleaning agents, and blowing debris. A lighter pad engineered to be UV- and weather-resistant will likely last longer. Thanks to its design, it'll resist cracking, breaking, and warping. The same can't be said for the older, heavier concrete and plastic models.
Texture and Surface Design
HVAC pads must do two things at once: stay anchored to the ground and keep equipment from shifting. Be sure to look for one with a textured surface, which helps maintain alignment and prevents the base from slipping.
East of Installation
Lighter, modern pads aren't just designed to last longer, they're also easier to carry. PolarPad was intentionally designed for one-person handling.
See How PolarPad Holds Up, Even With a Smaller Raw Mass
"Heavier" no longer means better in the HVAC world. The evidence is in lighter, modern condenser pads, such as the PolarPad.
Interested in learning more about PolarPad? Contact us today to learn more.
