System structure of synthetic surfaces

Professional testing of the system structure

System structure of synthetic surfaces in outdoor areas

The system structure is very important to ensure that a synthetic surface for outdoor sports area is suitable for the intended sport and meets the relevant standards. The system consists of several layers, which are installed in the following order: firstly, a subgrade; secondly, if necessary, a filter layer; thirdly, an unbound base layer; and finally, a single-layer or multi-layer bound base layer. The synthetic surface layer is then installed on top. Moreover, the annex to DIN EN 14877 as well as DIN 18035-6 differentiate between several types of surfaces, which is of great relevance to subsequent use. Ultimately, the surface types fall into two distinct categories: permeable to water (porous) and impermeable to water (non-porous). Porous surfaces are primarily used for recreational and school sports, while non-porous surfaces are more commonly used at competition venues as they are generally more stable and durable. All types of surfaces are essentially composed of rubber granules and elastomer, but differ in terms of surface.

ISP GmbH – Institut für Sportstättenprüfung tests not only the synthetic surface layers but also the underlying layers for their condition and compliance with the requirements of the relevant standard. The tests are carried out both in a laboratory (surface products) and on the finished sports field. This is particularly important in the run-up to a planned refurbishment of your sports field if individual components of the synthetic surface system, such as the underlying layers, are to remain in place when the surface is replaced. What is the condition of the individual layers? Is proper drainage still ensured or is the surface still impermeable to water? Is the structure and condition of the system in line with the planned modernisation? An inspection of the existing sports facility can provide answers to all these questions. However, even if no refurbishment is planned, the condition of your sports facility can be professionally assessed by ISP GmbH – Institut für Sportstättenprüfung.

From the subgrade to the surface layer

The lowest layer of a synthetic surface for outdoor sports areas is the subgrade. It is installed on top of the subsoil, ensuring that planarity and slopes can be specified and established in advance. Depending on the nature of the subsoil, it may be necessary to install a filter layer on top of the subgrade if there is a risk of fine subsoil particles penetrating the base layers and affecting the drainage system. The unbound base layer, which is at least 150 mm thick, is designed to ensure the load-bearing capacity of the layers above it and to absorb rainwater in the case of porous structures. The bound base layer consists of mineral aggregates and bituminous binders, providing the necessary stability for the surface layer on top. It can be made of asphalt and is generally constructed in two layers for facilities staging competitions.

The different types of surfaces

The synthetic surface layer has a minimum thickness of 10 mm. DIN EN 14877 differentiates between seven types of surfaces (A-G), six of which comprise a top layer and an underlying base layer. Type A, also referred to as a textured spray-coated surface, is predominantly used on general athletics tracks that are not designated for high-level competition, but it is definitely capable of withstanding running shoe spikes. It is permeable to water and its sprayed-on top layer has a granular structure. The base layer is poured in situ from a mixture of elastomer and rubber granules, prefabricated and then installed.

The latter also applies to type B, the two-layer EPDM surface. It is suitable for a wide range of sports activities, particularly in the school and leisure sectors. It is also permeable to water, but has a top layer made of flat granules, which is levelled in situ.

Type C synthetic surfaces are installed in the same way. This surface type is the only one that consists of a single layer, and it is the ‘simplest’ of the surface types in terms of structure. It is also permeable to water and can be found on general sports fields.

Type D surface, the sandwich system, can be found on most athletics facilities used for training and competition. It is impermeable to water. While this may appear to be a disadvantage at first, it is actually a benefit. The material's impermeability to water results in enhanced strength, minimal change over time, and increased durability. The special design of the athletics tracks nevertheless ensures that rainwater dries quickly and drains away. The base layer for the type D surface is poured in situ in the same way as for types A and B. However, the top layer is cast from elastomer into which rubber granules are broadcast. This produces the water-impermeable layer, a feature shared by types E and F. The surface of all three surface types D-F is made up of granules that have been scattered with a visible tip.

The difference between surface types D and E is that the cast top layer of type E is multi-layered and often thicker. While this results in type E surfaces being of a higher quality, they also incur a higher cost.

Type F surfaces do not have a base layer at all, but only feature a very thick single-layer cast top layer under the playing surface. In practice, this surface type is rarely encountered.

While types A-F surfaces are all sprayed, levelled or cast in situ, type G surfaces consist of calendered, vulcanised and industrially prefabricated sheets. With a relief structure on the surface, a rubber compound underneath and a top layer as a base layer, this type of surface differs the most from the other six types. It is also impermeable to water and is used for tennis courts and running tracks.

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While the lower layers of a synthetic surface for outdoor sports areas are essentially identical, the surface layer can be divided into seven different surface types. These are delineated in the annex to DIN EN 14877 and, to a large extent, also in DIN 18035-6. ISP GmbH – Institut für Sportstättenprüfung will be pleased to inspect and test the components of the synthetic surface system on your sports field and provide you with a professional assessment of their condition and compliance with the relevant standards.

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We will be happy to advise you on the procedure and background to testing synthetic surfaces.

Synthetic surfaces

Sports Test criteria
Athletics Sports function
Basketball Protective function
Hockey Technical properties
Tennis Environmental compatibility