| 1.0 |
Scope
This guideline covers the components and methods of installation of full pour polyurethane system track surfaces. A full pour polyurethane system is the application of multiple layers of polyurethane coating and rubber, which may either be black SBR or colored EPDM. The top layer is a massive application of polyurethane coating with colored EPDM granules broadcast or encapsulated into the coating. The system is a resilient all weather surface. It is textured and impermeable and is used in both indoor and outdoor applications.
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| 2.0 |
Materials
A variety of products may be used in the construction of the track surface. The terms defined below are to clarify the language used in this guideline and in proprietary specifications.
| A. |
Primer
The primer is a mixture of polyurethane binder and a viscosity reduction vehicle that allows for a light film application.
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| B. |
Polyurethane Coating
Two component 100% solids polyurethane coating consisting of a Part A colored polyol and a Part B isocyanate activator. Specific gravity of 1.15 to 1.30.
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| C. |
Polyurethane Aliphatic Top Coating
A single or two component aliphatic top coating applied to structural surfaces that need to be protected from UV degradation.
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| D. |
SBR/EPDM Black Rubber
Fully cured rubber granules that may either be ambient or cryogenically ground from post-industrial by-products to a size of not less than 1 nor more than 4mm. The general cut of the granules should be cubicle. They should contain less than 4% dust and be free of foreign debris. They should not contain any other color within the granule.
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| E. |
Colored EPDM Rubber
Colored EPDM granules should be ground from fully cured virgin slabs of peroxide- or sulfur-cured rubber (the curing process must be compatible with the polyurethane chemicals being used). The EPDM content should be not less than 20%. The general cut of the granules should be cubicle and they should contain less than 4% dust.
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| 3.0 |
Surface Specifications
Surface specifications should include:
Color
Depth
Type of facility:
Governing Body, International Properties or Competition Properties
Events to be Marked
Surface properties for consideration:
Flatness and Imperfections Thickness
Modified Vertical Deformation; Force Reduction
Friction; Wet Spike Resistance
Tensile Properties; Elongation
Weathering Color
Flammability
Testing Methods
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| 4.0 |
System Thickness, Weight and Specific Gravity
Each surface system should be at least 1/2” (12.5mm) in total thickness to allow for variation in the underlayment and to prevent spiked shoes from penetrating to the base layer, potentially disrupting the bond. The total weight of the system is contingent upon the depth of the surface and the specific gravity of the materials. Both SBR and EPDM rubber particles will vary in specific gravity and bulk density value of rubber. This coupled with the application methods, shape and size will affect the rubber required to achieve 1/2” thickness. The chart below is intended for guidance.
Per 1/8"
| Color/Type |
Size/Shape |
Specific Gravity |
Shore A Hardness |
| Black SBR |
1-4mm Granules |
1.15-1.40 |
55-70 |
| Black EPDM |
1-4mm Granules |
1.20-1.50 |
55-70 |
| Colored EPDM |
1-4mm Granules |
1.40-1.60 |
55-70 |
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| 5.0 |
Installed Materials
The installation contractor should provide the owner with a manifest listing the quantities of materials to be used for surfacing in the following format:
(_____) lbs. coating Part A (_____) no. of drums (_____) weight/drum
(_____) lbs. coating Part B (_____) no. of drums (_____) weight/drum
(_____) lbs. of base granules (_____) no. of bags (_____) weight/bag
Type of base granules _____ Size of base granules _____
(_____) lbs. of colored EPDM (_____) number of bags (_____) weight/bag
Size of top granules _____
Aliphatic Layer (when applicable)
(_____) lbs. coating Part A (_____) no. of drums (_____) weight/drum
(_____) lbs. coating Part B (_____) no. of drums (_____) weight/drum
(_____) lbs. 1 component (_____) no. of drums (_____) weight/drum
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| 6.0 |
Material Delivery
All materials should be delivered to the job site in labeled and marked containers. Quantities needed to complete the project in accordance with the manufacturer’s specifications should be verified. All materials should be located to allow for work to proceed without interruption.
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| 7.0 |
Installation Equipment
All installation equipment including mixers, pavers, sprayers and hand tools should be kept free of moisture while in use. They should be cleaned daily. No equipment or vehicles used in the installation process should leak any gas, petroleum products, solvents, etc.
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| 8.0 |
Surface Preparation
The asphalt or concrete base should be sufficiently cured and cleaned in order for work to progress. Recommended cure times - 14 days for asphalt, 28 days for concrete.
Prior to installation of the track surface system, the entire base should be checked for planarity and surface tolerance. Any areas that vary +/- 1/4” when measured with a 10’ straightedge in any direction should be patched with a compound compatible with the base material and approved by the manufacturer of the track surfacing system. After patching, the surface should not allow water to stand greater than 1/16” deep one hour after rain has ended.
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| 9.0 |
Installation
| A. |
Primer
The surface should be primed with the appropriate polyurethane primer using spray equipment or rollers. Application rates range between 0.18 - 0.27 lbs. per square yard. For an asphalt base, primer application may be reduced by the contractor when extreme heat conditions soften the asphalt. Some manufacturer’s systems will not require a primer.
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| B. |
Mixing
All two component polyurethane coatings are to be mixed in a manner to accurately measure and thoroughly mix all materials to the ratios specified by the manufacturer.
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| C. |
Applying Base Materials
The two component self leveling polyurethane coating is flow applied to the base in multiple layers with either black SBR or colored EPDM granules being applied into the coating to attain the specified base depth. The ratio of base rubber will be between 15% and 35% of the total weight of the finished surface.
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| D. |
Top Coat
| 1. |
The top coat is a massive flow application of the two component coating that is mixed according to the ratios of part A and B listed by the manufacturer. The material is to be self leveling and should be free of ridges. Prior to initial set, colored EPDM rubber granules are broadcast into the coating with sufficient excess granules being applied to assist in the embedding process. Normally 5 to 5.5 lbs. of granules per square yard will be embedded. All loose excess granules are removed after initial cure.
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| 2. |
The alternative top coating is a spray application of two component coating and encapsulated EPDM rubber granules applied at an approximate ratio of 60% coating to 40% rubber to sufficiently protect the base.
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| E. |
Aliphatic Top Coating
If the encapsulated top coating is unprotected for UV resistance, then a thin mil layer of the one or two component aliphatic top coating should be spray-applied, normally in two applications, over the surface in accordance to the manufacturer’s recommendation.
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| F. |
Line Markings
The surface system manufacturer must approve the type and brand of marking paint used. All lane and event markings should be in accordance with the applicable governing body.
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| 10.0 |
Cautions
| A. |
All packaging and excess materials must be disposed of in accordance with state, local and federal standards and regulations.
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| B. |
Do not allow liquid binders to freeze.
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| C. |
Resilient surfacing systems will not resolve inadequacies in the base or asphalt mix.
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| D. |
This guideline does not cover proper subbase and base construction or drainage considerations. The success of any surface is dependent upon a properly constructed base and good drainage.
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See also ASBA Guidelines for: |
I.A.
I.B.
I.C.
I.D.
I.E.
III.A.
III.B.
III.I.
III.J. |
General Conditions for Construction
Site Investigation
Site Preparation, Earthwork, Drainage and Subbase Construction
Vegetation Control or Vegetation Regrowth Prevention
Subsurface and Surface Drainage for Recreational Areas
Basic Layout, Dimensions & Site Considerations for Track Construction
Hot Mix Asphaltic Concrete Construction or III.C. Concrete Construction
Drawings
Quantitative Analysis of Installed Track Surfaces |
