FLEXOTOP TM. Safety Surfacing Solutions

Transcription

1 FLEXOTOP TM Safety Surfacing Solutions

2 KOMPAN history Why Choose Flexotop KOMPAN is the world market leader in playground solutions with over 40 years of experience in developing solutions that are designed to improve children s health and learning. The concept of a new play area has broadened from playground equipment and now includes outdoor activity areas for all ages. To support inclusive outdoor activity areas, we have to take into consideration all components to deliver a complete solution. Which is why we take great pride in our safety surfacing; FLEXOTOP wetpour. Over the years KOMPAN has designed wetpour solutions throughout the world. The experience gained in playgrounds allows us to offer you a surfacing solution that is ideal not only as a safety surface but also for all other applications that benefit from a comfortable, coloured covering, with innovative design potential and brilliant characteristics for both indoor and outdoor sites. FLEXOTOP is the wetpour KOMPAN brand, based on a range of very high quality materials that allows you to create a high quality synthetic flooring. The best impact surface in terms of shock absorption with high durability and free from hazardous components. Porous, with good drainage, dust free properties, slip resistance, elasticity and hard wearing. A uniform surface with no joints or seams. Noise reducing. Highly Resistant to UV and usable in all weather conditions. Comfortable to walk on and wheelchair friendly. Very low maintenance cost, long-lasting and eco-friendly. Surfaces can be repaired and refurbished, if damaged. Good performance under flame test of construction materials. Potential for unique and creative designs using 2D and 3D graphics and a wide range of colours and blends. Designers can let their imagination run wild. Tested and certified under EN-1177:2008 and BS-7188:1988+A2:2009. FLEXOTOP

3 FLEXOTOP We know how to make better wetpour. Materials FLEXOTOP is made in situ from two layers of cast rubber that are laid on top of each other. The bottom layer is the base that provides the shock-absorbance. The thickness of this layer therefore has to be adapted to the critical fall height (CFH) in the case of playgrounds or fitness areas. The top layer is approximately mm thick and protects the shock absorbent base from wear and tear. This is where you can use different colours and create a wide variety of graphic features. Bottom layer The base consist of 100% recycled rubber, mainly from automotive source. All rubber is thoroughly cleaned to remove any brake residue or other textile contaminants before they are processed. The processed material is then sorted, using magnets to ensure that no metal fragments remain before being granulated. The material component of this layer is called SBR and the granule size is about 2-6 mm. This layer is bound with a non-flammable polyurethane resin. For a good finish we use a granule size of 1-3,5 mm. The granule size distribution gives the surface an excellent visual effect. An EPDM layer can be applied separately without a BASE layer. The thickness, in this case, must be 20 mm and the CFH is 70 cm. Top layer The top layer consists of specially made Premium EPDM granules. The content of virgin polymer is over 21 % and more than 30 different colours or blends are available. This layer is also bound with a polyurethane resin. 3

4 Colour chart SUR Blue SUR Light blue SUR Green SUR Light green SUR Red SUR Earth yellow SUR Bright yellow SUR Bright orange SUR Eggshell SUR Beige SUR Pink SUR Purple SUR Black SUR Brown SUR Teal SUR Light grey SUR Mid grey SUR Dark grey SUR Post Box red SUR Tierra Blend SUR Fuego Blend SUR Agua Blend FLEXOTOP

5 Glossary SBR (Styrene Butadiene Rubber) Granulated recycled rubber from automotive or different sources used in the bottom layer of surfacing for shock absorbency. A recycled rubber mix from tyres and other sources used for better absorption. EPDM (Ethylene Propylene Diene Modified) Granulated synthetic rubber which protects the surface, available in a wide range of colours and manufactured from virgin polymer or recycled parts from cars, electrical appliances or construction industries. PU BINDER A non-flammable polyurethane resin which is viscosity tested for good granule adhesion after mixing and several hours drying. CFH (Critical Fall Height) The impact attenuation of the surface material in terms of the maximum height from which a life threatening head injury would not be expected to occur. 5

6 Sub-bases FLEXOTOP may be installed on both bound and unbound sub-bases. However, specific requirements apply in both cases to avoid drainage problems or permanent deformation. The requirements for the various sub-base types that may be used are detailed below. For top layer only applications the sub-base must be concrete or asphalt. 15 mm EPDM Top layer Bottom layer-base varies in thickness depending on fall height Packed stone material Used on surfaces where there are fall heights Crushed stones Generally speaking, the whole area of the base must be 100% self-draining and the base compressed to prevent any further settlement. The base consists of a compacted structural layer (min 35 MPa) with crushed stones 0 32 mm in 200 mm thickness and crushed stones of 0 4 mm fraction in 20 mm. This structural layer is laid on compacted soil (min 25 MPa). The following materials are unsuitable and would not be fit for purpose: slag, clay, recycled materials or materials with lower water permeability and more prone to icing. The recommended minimum thickness of FLEXOTOP for installation with a crushed stones system is 40 mm. Detail of sub-base for flexotop - Crushed stones EPDM Layer 15 mm SBR Layer (thickness according to CFH requested) CRUSHED STONES 0-4 mm / 20 mm CRUSHED STONES 0-32 mm / 200 mm COMPACTED SOIL (min 25 MPa) FLEXOTOP

7 Concrete and Asphalt Installing Flexotop on a hard, bound sub-base such as concrete, tarmac, asphalt, paving slabs or similar, requires the surface to be clean, unbroken, firm, have a descending gradient that leads surface water away (slope 1 %) or an alternative drainage solution. An incorrect descending gradient could result in large puddles in the finished area as well as damage during winter if water cannot run off when frost occurs. When FLEXOTOP is installed on top of an old bound sub-base, a primer is recommended. Detail of sub-base for flexotop - Concrete EPDM Layer 15 mm SBR Layer (thickness according to CFH requested) CONCRETE COMPACTED SOIL (Min 25 MPa) When only installing a 20 mm EPDM layer, a structural layer such as concrete or asphalt is the only sub-base permissible to avoid deformation. The concrete and asphalt sub-bases must be completed at least 21 days prior to the FLEXOTOP surface being laid, to avoid problems of humidity or the presence of flux oils. They must also be dust free to assure good adhesion of the binder and base layer. Detail of sub-base for flexotop - Asphalt EPDM Layer 15 mm SBR Layer ASPHALT COMPACTED SOIL (min 25 MPa) 7

8 FLEXOTOP What thickness? When installing playground equipment, the total thickness of the surfacing has to be adapted to the Critical Fall Height of the play equipment. When installing fitness equipment, there are different requirements for absorption at low fall heights. For up to 1 meter of fall height, we recommend a 20 mm FLEXOTOP layer which offers great appearance and high comfort. For up to 1.5 meter of fall height, fitness equipment can be installed on a 40 mm FLEXOTOP layer. Above 1.5 meter of fall height, the surfacing thickness follows the same pattern as playgrounds. Sport pitches have no fall height. All FLEXOTOP is in compliance with EN A fall onto a shock absorbing surface is less likely to cause a serious injury. 3,00 m CFH 3,00 m Flexotop has been independently tested and certified by TÜV in accordance to the standard EN-1177:2008 and the total thickness values needed for each Fall Height are: 0,80 m 1,00 m 1,20 m 1,60 m 1,80 m 2,20 m 2,40 m 2,70 m 2,80 m 20 mm 30 mm 40 mm 50 mm 60 mm 80 mm 100 mm 110 mm 130 mm 130 mm* 140 mm Thickness of FLEXOTOP (Including both layers SBR+EPDM) * 80% SBR+20% buffings The top layer thickness will always be the same but the base layer will vary in accordance with the thicknesses given in the above graph. FLEXOTOP

9 FLEXOTOP More colour options? 60% black 20% light blue 20% dark blue SUR % brown 50% beige SUR % dark green 50% light green SUR % black 20% earth yellow 20% red SUR % black 20% eggshell 20% beige SUR % black 20% red 20% brown SUR FLEXOGRIND SUR % black 40% red SUR % black 50% light green SUR Different colours can be mixed together to achieve any wetpour finish. On top of the colours in the colour chart, we can offer additional blends such as the ones above. You can also mix your own blends on site but the examples above are blended at our factory and packed in bags using precise proportions, removing the risk of mistakes from mixing on site. There is a possibility the wet pour surface could become affected by UV light from the sun. One possible effect can be the yellowing of the binding agent, which can change the appearance of bright colours. However, this can be avoided by selecting our aliphatic binder. The rubber granulates are as such colour stable but will, depending on the colour, fade slightly over time. 9

10 FLEXOTOP Wetpour cast graphics FLEXOTOP offers more than two hundred prefabricated 2D and 3D graphics in EPDM rubber. These graphics may be used in any wetpour area in schools, children s playgrounds and amusement parks. The graphics make playground areas more fun, giving added value to the play area surface. Wetpour graphics can be installed the same day as the top layer of a FLEXOTOP surface, guaranteeing significant savings in time, labour and materials. Wetpour graphics are always 10 mm thick but can come in different shapes, sizes and designs. The products are made from high quality EPDM and polyurethane binder. For the full graphics range available, please consult your Kompan representative. FLEXOTOP

11 Installation guide for cast graphics 1 Apply the silicon glue SUR to underside of graphic. 2 Apply silicon glue to SBR layer. Place graphic on top of SBR 3 layer. Screed 6 and compress EPDM top layer for a good finish and coat around graphic. 5 Check top of graphic is clean and apply PU blinder to prime the edges. 4 Press down hard to ensure glue is evenly distributed. 11

12 Examples FLEXOTOP

13 Certificates and Tests Flexotop has been subject to strict scrutiny in accordance with the following standards to ensure the highest quality, safety and durability of the product thereby allowing us to install top quality surfacing. Description Standard Norm Comments Test for the presence of Heavy Metals / PAH and PBDE on EPDM and SBR EN-71 Part 3: /48/EC Pass Test report Fall protection of Safety Surfaces from 20 mm to 140 mm thickness EN-1177:2008 EN Certificate and Test Reports for each thickness Slip resistance in wet and dry conditions, durability, resistance to heavy wear, ease of ignition, tensile properties BS 7188:1998+A2:2009 Passed Flame source test EN ISO Passed Flammability classification of construction materials EN A1 EN ISO :2010 Class D Water infiltration rate EN-12616:2013 Passed Synthetic surfaces for outdoor sports areas Specification EN-14877:2013 Relevant requirements passed Surfaces for Sport Areas. Determination of tensile properties of synthetic sports surfaces EN-12230:2003 Section of EN-14877:2013 corresponding to tensile properties requirements passed UV colour stability and resistance EN A02 Test report available for up to h accelerated test 13

14 Main application environments FLEXOTOP can be used in many different environments where safety or comfort come first. The mechanical properties of FLEXOTOP make it very suitable for: Playgrounds Outdoor Fitness Areas Waterparks Multisport Courts Golf course pathways Garden paths Swimming pool surrounds Indoor Sport Halls / Facilities, Fitness Rooms Schools and nursery schools FLEXOTOP

15 Painted lines and graphics for sport and fitness areas The surfacing design is an integrated and crucial part of sport and fitness areas. By adding lines, designs, symbols or markings on the surface the use of space is maximized. For FLEXOTOP, we use a special UV and weather resistant two-component polyurethane paint which provides good long term elasticity and abrasion resistance. The material contains a solution that is especially suited for all synthetic sports and fitness surfaces. 15

16 KOMPAN Czech Republic, s.r.o. Vlastimila Pecha 1267/ Brno-Černovice Czech Republic