How do spray-applied systems differ from EPDM systems?

Polyurethane - what kind of material is it, and why does it dominate sports surfacing

Before comparing the systems, it's worth answering the question of what polyurethane is and why it comes up so often in the context of sports surfaces. Polyurethane is a polymer formed through a chemical reaction between a polyol and an isocyanate, which means it can be formed in a rigid, flexible, or foamed version depending on the application. The properties that make it such a versatile material are primarily its high elasticity, abrasion resistance, good adhesion to the substrate, and resistance to changing weather conditions. At EPUFLOOR, we use polyurethane as the base material in both spray-applied systems and Full PUR systems, but the method of application determines the final parameters of the surface.

Spray-applied systems - structure and application

Spray-applied systems consist of two main layers: an elastic base layer made of SBR or EPDM granulate bound with polyurethane binder, and a top layer sprayed by hand or machine, containing colored EPDM granulate embedded in polyurethane. This construction provides good shock absorption, decent elasticity, and an attractive surface appearance at a relatively lower implementation cost compared to Full PUR systems. EPUSPORT spray-applied systems work particularly well on athletic tracks, multi-purpose sports fields, and recreational areas, where the priority is an optimal quality-to-price ratio and usage intensity is not as extreme as at professional competitive facilities. It's worth noting, however, that the top layer in a sandwich system is thinner than in full-polyurethane systems, which translates into a somewhat shorter surface lifespan under very intensive use.

EPDM systems – uniform structure and higher durability

The Full PUR system, also called the full-polyurethane system, differs from the spray-applied system primarily in the homogeneous structure of its wear layer, in which EPDM granulate is evenly distributed throughout the entire thickness of the surface, not just on its surface. This construction means the surface retains its properties even after many years of intensive use, since abrasion of the top layer doesn't expose the elastic base, as happens with cheaper solutions. EPDM systems offered by EPUFLOOR feature higher resistance to point loads, better dimensional stability, and a longer lifespan reaching as much as a dozen or more years with proper use. We recommend this solution primarily for facilities with professional applications, such as athletics stadiums, venues for competitions certified by World Athletics, and locations with very heavy traffic.

Polyurethane properties and system selection

When deciding on a specific solution, it's worth analyzing how the properties translate into the real-world performance parameters of both systems. In the spray-applied system, the top layer is typically 8 to 15 millimeters thick, providing good shock absorption under moderate load, while in the EPDM system, the thickness of the entire structure tends to be greater and more uniform, resulting in an even distribution of pressure across the whole surface. Spray-applied systems have somewhat greater porosity, which makes it easier to drain rainwater, while EPDM systems offer a smoother, more compact surface that is easier to keep clean. Both solutions use the same chemical foundation, but the proportions of the components and the application method determine which one will work better in a given investment context.

Sports surfaces - how to choose the right system for a specific facility

When choosing sports surfaces for a specific project, it's worth considering several factors, such as the expected intensity of use, the project budget, the facility's location, and its sports or recreational purpose. For multi-purpose school sports fields, school athletic tracks, and municipal facilities, a spray-applied system often turns out to be the optimal solution, since it allows the project to be completed within a limited budget without a significant compromise on user safety. On the other hand, for club facilities, sports academies, and venues intended for hosting competitions, an EPDM system represents an investment that pays off through lower maintenance costs and a longer service life without the need for a major renovation.

Summary

Spray-applied systems and EPDM systems are two proven solutions based on the same material, polyurethane, but they differ in the structure of the wear layer, implementation cost, and expected surface durability. A spray-applied system works well where a favorable price-to-quality ratio is the priority, while an EPDM system is the solution for facilities with high performance and sporting demands.