EPDM flooring is a type of artificial flooring that adds colour, patterns and softness to any play or sports area. EPDM flooring, often called as synthetic rubber flooring, makes a play area safer for children to fall on and adds a certain amount of springiness to sports tracks such as jogging or running tracks.
EPDM Granules
EPDM stands for Ethylene Propylene Diene Monomer and comes in the form of colourful granules that are 1 to 3 mm in size. When mixed with a PU (Polyurethane) Binder, they stick together to form a hard surface with a texture and a certain springiness. There are many colours of granules that are readily available and specific colours can be formulated too.
As of date, we have 16 colours in ready stock, the 15 shown in the image and white. While these colours look dull in the form of granules, when the liquid PU binder is mixed with the granules, the colours shine out and become darker too. Our stock of EPDM has >22% virgin polymers, this is important as it gives a longer life to the EPDM surface. While some vendors offer recycled EPDM, we ensure that only virgin EPDM, manufactured with polymer imported from USA/Europe is used in our projects.
These are the specifications of the EPDM used in our projects:
The Base Layer for EPDM Flooring
The surface on which EPDM flooring needs to be should be a hard level floor, like a Plain Cement Concrete (PCC) floor. The top of the floor should be neatly finished with cement mortar, so that a smooth surface is formed on which adhesive will stick. Having a gradient in the floor or drainage pipes under the floor, such that water can drain off instead of being stagnant is crucial. Both the EPDM and the base layers are porous and will allow water to permeate through.
EPDM granules are expensive, so a base layer of recycled rubber buffing or SBR (Styrene-Butadiene-Rubber) is usually created on the flooring. The thickness of this layer varies from 10mm to 130mm, depending on the fall height of the equipment being installed. The choice between rubber buffing and SBR also depends on the softness required – rubber buffing is much softer and will add a lot more bounce to the floor than SBR. It is also possible to mix rubber buffing with SBR to create the right base layer – we recommend a mix of 80% SBR with 20% buffing to create just the right base layer for children’s play areas. The base layer is mixed with 15% PU binder and pasted onto the cleaned surface, and usually dries between 8 to 12 hours.
The Top Layer of EPDM
Once the base layer is dry, the EPDM granules, mixed with up to 25% PU binder are pasted onto the base layer. Dust is blown off the base layer before the top layer work begins. The colours of the EPDM granules are positioned in such a way that they form patterns as per the sites design. It is also possible to form borders with different colours or have a perfect joint between two colours. Some designs require a mix of two or more colours of EPDM granules to create unique colours.
While most specifications are of a top layer of 6mm EPDM, we highly recommend at least 10mm EPDM top layer whereas 15mm is the preferred choice internationally. Increasing the thickness of the top layer increases the cost of the installation but also improves the quality and longevity of the flooring significantly.
Polyurethane (PU) Binders
A key component of both the base layer and the top EPDM layer is the PU binder. The binder is essentially an adhesive and is available from various companies. Some of the reputed ones are BASF, Dow and Huntsman. PU Binders are available in 50KG and 200KG drums. While it is easier to handle 50KG drums, there is less wastage in 200KG drums.
Finished EPDM Flooring
If the EPDM flooring is designed well and correctly installed by a skilled team, it can easily last for 10 years. Newton® offers a 1 year warranty on all its installations. While it is natural for the colours of the top layer to change a bit due to UV light, other problems such as the joints opening up or the layers detaching from the surface are all covered in the warranty. The finished surface looks beautiful and inviting for play, have a look at these pictures below.
For all your EPDM flooring needs, contact us.
