FLEXOTOPTMSafety Surfacing Solutions

FLEXOTOP™

KOMPAN is the world market leaderin playground solutions with over 40 yearsof experience in developing solutions thatare designed to improve children’s healthand 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 youa surfacing solution that is ideal not onlyas 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 materialsthat allows you to create a high qualitysynthetic 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.

KOMPAN history Why ChooseFlexotop™

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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 15-10 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.

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.

For a good finish we use a granule size of 1-3,5 mm. The granule size distribution gives the surfacean 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.

FLEXOTOP™We know how to make better wetpour.

FLEXOTOP™

Colour chart

SUR11115-902 Bright orange

SUR11114-902 Bright yellow

SUR11118-902 Eggshell

SUR11117-902Beige

SUR11125-902Pink

SUR11122-902Purple

SUR11124-902Teal

SUR11101-902 Black

SUR11103-902Mid grey

SUR11119-902Brown

SUR11104-902 Dark grey

SUR11105-902Light grey

SUR11111-902 Green

SUR11109-902Blue

SUR11107-902 Red

SUR11108-902Light blue

SUR11113-902 Earth yellow

SUR11110-902Light green

SUR11152-902Tierra Blend

SUR11106-902Post Box red

SUR11153-902Fuego Blend

SUR11154-902Agua Blend

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SBR (Styrene Butadiene Rubber) Granulated recycled rubber from automotive or different sources used in the bottom layerof 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 rangeof colours and manufacturedfrom virgin polymer or recycled parts from cars, electrical appliances or construction industries.

PU BINDER A non-flammable polyurethane resin whichis 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.

Glossary

FLEXOTOP™

FLEXOTOP™ may be installed on both bound and unbound sub-bases. However, specific requirements apply in both cases to avoiddrainage 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 concreteor asphalt.

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 mmin 200 mm thickness and crushed stones of 0 – 4 mm fraction in 20 mm. This structural layer is laidon 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 permeabilityand more prone to icing.The recommended minimum thicknessof FLEXOTOP for installation witha crushed stones system is 40 mm.

Sub-bases

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

EPDM Layer 15 mmSBR Layer (thickness according to CFH requested)

CRUSHED STONES 0-4 mm / 20 mmCRUSHED STONES 0-32 mm / 200 mmCOMPACTED SOIL (min 25 MPa)

Detail of sub-base for flexotop - Crushed stones

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Concrete and Asphalt Installing Flexotopon a hard, bound sub-base such as concrete, tarmac, asphalt, paving slabs or similar, requires the surface to be clean, unbroken, firm, havea 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 installedon top of an old bound sub-base, a primeris recommended. When only installing a 20 mm EPDM layer,a structural layer such as concrete or asphaltis the only sub-base permissible to avoid deformation. The concrete and asphaltsub-bases must be completed at least 21 daysprior to the FLEXOTOP surface being laid,to avoid problems of humidity or the presenceof flux oils.They must also be dust free to assure good adhesion of the binder and base layer.

EPDM Layer 15 mmSBR Layer (thickness according to CFH requested)

CONCRETECOMPACTED SOIL (Min 25 MPa)

Detail of sub-base for flexotop - Concrete

EPDM Layer 15 mmSBR LayerASPHALTCOMPACTED SOIL (min 25 MPa)

Detail of sub-base for flexotop - Asphalt

FLEXOTOP™

When installing playground equipment, the total thicknessof the surfacing has to be adapted to the Critical Fall Heightof 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 followsthe same pattern as playgrounds. Sport pitches have no fall height.All FLEXOTOP is in compliance with EN 14 877 - 2013.

A fall onto a shock absorbing surface is less likely to causea serious injury.

Flexotop™ has been independently tested and certified by TÜVin accordance to the standard EN-1177:2008 and the totalthickness values needed for each Fall Height are:

FLEXOTOP™What thickness?

The top layer thickness will always be the same but the base layer will vary in accordance withthe thicknesses given in the above graph.

Thickness of FLEXOTOP (Including both layers SBR+EPDM)

0,80 m

20 mm 30 mm 40 mm 50 mm 60 mm 80 mm 100 mm 110 mm 130 mm 140 mm130 mm*

1,00 m

1,20 m

1,60 m

1,80 m

2,20 m

2,40 m

2,70 m

2,80 m

3,00 m3,00 m

* 80% SBR+20% buffings

CFH

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Different colours can be mixed togetherto achieve any wetpour finish. On topof the colours in the colour chart, we can offer additional blends such as the ones above.You can also mix your own blends on sitebut the examples above are blended at our factory and packed in bags using precise proportions, removing the risk of mistakesfrom mixing on site.

FLEXOTOP™More colour options?

FLEXOGRINDSUR11255-903

50% black 50% light green SUR11257-902

60% black 40% redSUR11258-902

50% brown 50% beigeSUR11262-902

60% black 20% light blue 20% dark blueSUR11263-902

50% dark green50% light green SUR11260-902

60% black 20% eggshell 20% beige SUR11261-902

60% black 20% red 20% brown SUR11264-902

60% black 20% earth yellow20% redSUR11259-902

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.

FLEXOTOP™

FLEXOTOP™ offers more than two hundred prefabricated2D and 3D graphics in EPDM rubber. These graphics may be used in any wetpour area in schools, children’s playgroundsand 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 significantsavings 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™Wetpour cast graphics

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Installation guide for cast graphics

Apply

the silicon glue

SUR18490-000

to underside

of graphic.

Apply silicon glue

to SBR layer.

Check top of graphic is clean

and apply PU blinder to prime

the edges.

Screed

and compress

EPDM top layer

for a good finish

and coat around

graphic.

1

2Place graphic

on top of SBR

layer.3

Press down

hard to ensure

glue is evenly

distributed.

46

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FLEXOTOP™

Examples

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Flexotop has been subject to strict scrutinyin accordance with the following standardsto ensure the highest quality, safety

Certificates and Tests

and durability of the product thereby allowingus 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 3:20132009/48/EC

Pass – Test report

Fall protection of Safety Surfaces from 20 mm to 140 mm thicknessEN-1177:2008EN-1176-1

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 11925-2 Passed

Flammability classification of construction materialsEN 13501-1+A1EN ISO 11925-2:2010

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-12230:2003Section of EN-14877:2013 corresponding to tensile properties requirements passed

UV colour stability and resistance EN-20105-A02Test report available for up to 1 000 h accelerated test

FLEXOTOP™

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

Main application environments

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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 polyurethanepaint which provides good long term elasticity and abrasion resistance. The material containsa solution that is especially suited for all synthetic sports and fitness surfaces.

Painted lines and graphics for sport and fitness areas

KOMPAN Czech Republic, s.r.o.Vlastimila Pecha 1267/6627 00 Brno-ČernoviceCzech Republic