The latest technological advances have brought us seamless rubber coverings.
Eco-friendly, injury-prevention material has found its application in the field of physical education and sports, outdoor activities.
The manufacture of a rubber coating can be carried out both with the use of improvised means, and by partial mechanization of the process.
Let's consider the technology of laying a seamless rubber coating in more detail.
Regardless of the selected rubber coating technology, you will need:
Grinding degree rubber tire defines the further scope of their use.
When purchasing crumb rubber pay attention to the following conditions:
For 1 m 2 of coating, an average of 8 kg of rubber is required.
The crumb produced by mechanical processing of tires has smooth edges, therefore, much less binding elements are required than when using a grated analogue.
The cost of finished rubber crumb starts from 10-12 rubles. per 1 kg of the product and depends on the purchase volume and seasonal demand for the product.
For making seamless flooring made of rubber are used predominantly one-component formulations, less often - two-component.
As binder bitumen or polyurethane is used in the adhesive mixture. The choice of glue is due to operational properties future coverage and working conditions.
Polyurethane-based rubber adhesive has the following properties:
Another feature of the polyurethane binder is hardening at a sufficiently high humidity level - 60-70% and temperature environment 20-25 p.
Bitumen compounds are less suitable for making seamless rubber surfaces.
Bituminous components mix poorly with paint and have lower performance properties.
Cost of 1 kg. one-component glue - from 185 rubles.
The two-part adhesive is sold in separate containers containing an epoxy-polyurethane binder and a chemical hardener.
Both components are mixed directly at the time of work.
When choosing a two-component glue for crumb rubber, it should be taken into account that the ready-made composition should be used in the first 30-40 minutes after its preparation.
This feature of the glue requires a careful calculation of the need for it for the production of work during this period of time. The advantage of the two-component composition is its high chemical inertness.
The cost of 1 kg of glue - from 165 rubles.
The formation of a high-quality seamless rubber coating is possible only with strict adherence to the proportions recommended by the adhesive manufacturer.
For 1 kg of crumb rubber, about 250 g of polyurethane glue is required, the consumption of the binder depends on the size of the granules used.
Another condition for uniform polymerization of the working composition is maintaining the required level of humidity and temperature at the place of work.
The coloring of the future rubber coating is given by coloring pigments added to the working composition.
What should you look for when choosing a paint?
Such a component composition of the dye makes it resistant to precipitation and ultraviolet radiation, extending the aesthetic life of the coating.
The dye dosage depends on the desired color intensity of the surface being formed and averages 62 g per 1 kg of crumb rubber.
The uniform consistency of the working composition is achieved by exact adherence to the manufacturer's recipe.
The cost of 1 kg of dye is from 110 rubles.
A polyurethane-based primer is another component, without which a high-quality installation of a rubber seamless coating is impossible.
The material with good penetrating ability ensures high adhesion of the components of the mixture to be laid to the treated coating.
The price of a primer ranges from 10 rubles. for 1 kg. and depends on the purchased volumes.
The quality and durability of the future product largely depends on the equipment used in the production.
It is especially important to use special mechanisms when it is necessary to make a two-layer coating or large-scale work.
Equipment does not have to be purchased - can be rented the accessories you need.
High-quality mixing of crumb rubber, glue and dye is ensured by using an industrial mixer.
Unmixed lumps in the working mixture are a manufacturing defect and can nullify all your attempts to create a quality seamless rubber coating.
Distinctive features of the mixing device - simple construction and operational reliability.
Let's consider some types of crumb rubber mixers:
The Internet community has good reviews of the MSRK-90 crumb rubber mixer. The device has a top loading of the components of the working composition and comfortable window for removing the finished mixture.
The volume of the mixer capacity and the power of its motor allow qualitatively knead the mixture from 90 kg of rubber.
Mechanized rubber paving has the following dignity:
The stacker is a piece of equipment equipped with an adjustable scraper at the front of the working platform, a pressure plate and heating elements at the rear of the unit.
The stacker is controlled by adjusting the speed and direction of its movement; there are devices for manual movement of the mechanism.
In the process of work, the rubber mixture spread out on the rough surface is distributed and leveled by the stacker over the entire width of the working area of the device. Heating elements heat the rubber mixture, thereby accelerating the process of glue polymerization.
Hand rollers for compacting the rubber-adhesive mixture must be heavy enough. Light fixtures unable to effectively compact the working composition, which will lead to the rapid destruction of the rubber coating.
There are three types of rollers used to form rubber surfaces:
The spray device provides the technology uniform application working composition on the treated surface.
The advantage of the sprayer is the ability to hide minor "flaws" in the production of the coating by applying a thin finishing layer of raw materials.
The operation of the equipment is carried out in the following way - the composition, ready to be applied to the working plane, is placed in the receiving hopper.
Using a pump, mix under high pressure fed to the spray gun and applied to the surface with a layer of the required thickness, the spray radius of the raw material is adjustable.
The equipment works well with chips up to 1 mm in size. The larger fraction will clog the spray nozzle and render it unusable.
Exact adherence to the proportions of the ingredients of the working composition is a condition for obtaining a high-quality seamless rubber surface.
It is unacceptable to use measuring containers to determine the volume of one or another component of the mixture - a deviation from the norm of 5-10% significantly reduces performance characteristics finished coating.
Laying a seamless rubber coating is available even for amateur craftsmen. The main requirement for the production of work - strict adherence to instructions when preparing the working composition, as well as gentle stirring and application of the mixture.
Installation of the rubber cover is carried out in the following sequence.
The service life of the future coating largely depends on the quality and type of base.
The most popular are the following types of bases:
Crushed stone... It is used for the installation of rubber coating on playgrounds, sports facilities for running and walking.
Efficiency and moisture permeability are the main features of the crushed stone base.
The coating laid on crushed stone must have a thickness of more than 15 mm. and used exclusively for light loads.
Excavation of soil is carried out at the work site.
The size of the depression depends on the level of occurrence groundwater as well as the type of soil and its drainage capacity.
The distance from the stormwater wells is also important.
The next step is soil compaction and drainage... Then layers of sand and crushed stone of various fractions are laid with compulsory compaction. The top layer is formed from fine screenings.
A high-quality crushed stone base has a slight slope to drain moisture, does not contain hollows and bulges, does not squeeze when walking.
Asphalt. The base made of asphalt concrete allows to lay rubber crumb in a layer of 1 cm. This type of base is used in the construction of professional sports facilities. Its advantage is its high strength, withstanding the weight of special equipment.
Another condition is the absence of oil stains.
An asphalt base can be formed in one or two layers, with the obligatory arrangement of underlays of sand and crushed stone.
Compliance with the technology of manufacturing asphalt pavement allows you to obtain a base that can withstand significant mechanical stress.
Concrete. The concrete base is the strongest and most durable, it has a universal scope of use.
Like asphalt pavement, it can withstand heavy loads and can even be used to form a floor in car parks.
High quality concrete pavement requires an effective waterproofing and sanding device.
What else to look for when constructing a concrete base?
Rubber layer on concrete base- from 1 cm
To increase the "adhesion" properties of the adhesive to the subfloor or subfloor, it is necessary to prime the surface.
For these purposes, you can use store-bought primer mixes or prepare them yourself.
For the simplest primer, you need turpentine and polyurethane-based glue. The components are mixed in equal proportions and applied with a roller to the surface to be treated.
The period of "hardening" of the primer depends on the level of humidity, temperature of the place of work and is from half an hour to several hours... The consumption of the mixture per 1 m 2 of the surface is 300 g.
Depending on the volume of the mixer tank and the power of its engine, you can immediately prepare the composition for laying on 5-10 m 2 of the base.
So, in the step-by-step formation of a rubber coating 1 cm thick in "steps" of 5 m 2, you will need:
The finished components are fed into the mixer tank in the following order: crumb, after 2 minutes, pigment dye. After the rubber particles are uniformly colored, glue is added to the mixer. The composition is mixed until a homogeneous mixture is obtained and, as a rule, takes 10-15 minutes.
For the convenience of work, you can mark the work surface into segments with an area of 1 m 2. A mixture weighing 10.2 kg is poured into each square. The rubber-adhesive mass is leveled over the surface with special devices in the form of spatulas and pressed down with rollers.
With a mechanized method of work, the inventory at hand is replaced by an auto-stacker.
Only minor imperfections of the finished surface, which periodically arise when using the equipment on large areas, are manually corrected.
Complete sintering of the composition depends on weather conditions and an average of 8-12 hours.
The rubber coating can be laid in one or two layers. With a two-layer technology of work, you can save on painting the lower layers of rubber.
To make the coating more elastic, it is advisable to use fine crumbs (up to 2.5 m) to form the first rubber layer.
After the first layer of rubber has completely solidified, it is necessary to reinforce the surface fiberglass mesh... This technique increases the strength of the coating, increases its service life.
The top layer of rubber can be formed with the addition of ready-made colored rubber granules or be composed entirely of them. In this case, pigment dyes are not used.
The thickness of the top layer, depending on the purpose of using the future coating, is from 1 cm.
The technologies we have considered belong to the category of assembling rubber floors with your own hands using bonding components. There is another method, the so-called "dry" rubber floor production.
The laying technology is a simple spreading of crumb rubber with a layer of more than 8 cm on the base.
This way of doing work good for quick formation temporary floor covering, and this all its advantages are limited.
Self-production and do-it-yourself installation of a rubber coating is the most a budget option production of works. The cost of third-party services is very different and depends on the following factors:
Let us present the results of a study of the market for services for the production of seamless rubber surfaces (consumption and prices per 1 m 2) in the following table:
It is very cost effective to set up a styling business if you are out of tires yourself. Of course, to open such a case, you need equipment that you can familiarize yourself with.
This video clearly demonstrates how the mixture for a seamless coating of rubber crumb is applied, distributed and rolled using a roller:
Manufacturing of seamless rubber surfaces - a great way to use recycled products.
Economical products with high consumer properties can be used for personal needs or become the subject of commercial use.
In contact with
Crumb rubber is a seamless, resilient coating that is resistant to temperature extremes and atmospheric precipitation. It is used for the construction of playgrounds, jogging and cycling paths, spaces along pools and skating rinks.
(In the picture: construction mixer)
Depending on the area to be covered with crumb rubber, different equipment is used.
If we are talking about a large site, for example, a sports arena subject to exposure, then an automatic crumb rubber stacker is indispensable. It allows you to control the thickness and width of the coating, work with high speed(at least 800 square meters per day), as well as evenly distribute the material over the surface, press it down so that it does not flake off.
(Shown: auto stacker)
Usage: pour the prepared polymer mixture onto the surface in even parts, then level it with an auto-layer.
The budgetary and the easiest-to-use equipment for laying rubber crumb is a roller and a grater. A large roller and trowel are used to compact the coating, a forming roller is used for corners and joints. Before starting, the tools are impregnated with turpentine so that the rubber crumb does not stick to the surface.
(In the picture: roller)
(In the picture: grater)
Usage: pour the prepared polymer mixture onto the surface in even parts, then smooth it with a roller and press down with a float.
The sprayer consists of air compressor and pumps. It is used to spray the second layer of rubber crumb, to cover vertical surfaces with a layer of crumb up to 1 millimeter. It allows you to evenly apply the components and hide the unevenness of the first layer.
(Pictured: spray)
Usage: the polyurethane mixture is poured into the receiving hopper, from there, by means of a pump, it is fed to the spray gun and applied to the surface under pressure.
After placing the crumb rubber, you need to wait until it dries within 24 hours. Complete curing of the coating occurs after five days.
Clean the equipment with organic solvents: acetone or xylene.
The Alfa-SPK company offers high-quality stackers for laying seamless crumb rubber coatings.
The semi-automatic stacker is designed for the production of seamless coatings based on crumb rubber and polyurethane glue of various thicknesses and purposes. Installation of seamless rubber flooring is carried out on solid base: concrete or asphalt.
The main field of application of the rubber stacker is sports, playgrounds, playgrounds, sports arenas, Treadmills etc.
In the field of using crumb rubber - the direction of seamless coatings is considered one of the most profitable and most in demand. Laying a quality rubber base on pedestrian roads, garden plots, playgrounds, at the entrances to shops, in swimming pools, water parks, on staircases, in the subway, etc. more and more it enters our life as a natural thing, which cannot be dispensed with in the modern world.
Automatic laying of rubber flooring with a paver has several advantages over manual application of seamless flooring:
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Stacker performance |
TPJ-1.5 |
TPJ-2.5 |
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Adjustable temperature |
90 0 С-120 0 С |
90 0 С-120 0 С |
For the purchase of stackers, please contact the office of the company. To receive commercial proposal and another additional information fill out the request form.
RUB 450,000
Machine for applying a top spray layer on sports surfaces made of rubber crumb. Differs in high performance and fine tuning. Suitable for equipping treadmills.
RUB 90,000
Electric mixer for the production of rubber coatings. Mixes crumb rubber, polyurethane binder and pigments into a homogeneous mass in 5 minutes. The maximum permissible one-time loading is 90 kg.
RUB 24
Fine rubber crumb is intended for creating the upper sprayed layer of sports surfaces and for backfilling artificial turf. The granulate is packaged in big run. The mass of crumb rubber in one bag is 1000 kg.
Protect the glue from heat
How to protect glue from high temperatures summer?
IMPORTANT! How to store glue in winter
All isocyanate-containing products, when temperatures drop below +5 degrees, begin to crystallize and can be in the form of cereals and cloudy lumps. The product must be warm during use! It is necessary to warm up in volume, but not higher than +50.
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Materials for 1 sq.m. coverings
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A set of materials and consumables for covering 1 sq.m.
In the spring, you found that in the winter you slightly damaged the cover with a shovel when clearing snow and now you want to repair it? Did you get a call from a client to whom you made a sports or playground with a request to make some minor repairs? Do you need to cover steps or entrance lobby?
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In our country, crumb rubber coatings have recently become very popular. produced in sports facilities, playgrounds, both outdoors and indoors. This is primarily due to the shock-absorbing properties. Plus to everything, trauma safety of rubber coatings, high anti-slip properties, elasticity, resistance to abrasive wear. And the most important advantage of such a coating is its seamlessness.
The final result, that is, the durability and quality of the coating, will depend on such a simple operation in the future. If, for some reason, the granules are poorly covered with glue, and there will be no connection between the rubber crumb and the glue, then this often leads to the appearance of holes, brittleness, cracks and bald spots in the coating. By the way, the lifespan of a poorly mixed coating is not long at all - a maximum of 2 years. And if all the recommendations are followed, then the coating will last more than 10 years. The quality of the coating is greatly influenced by the quality of the components that make up the composition.
If the crumb rubber contains a large amount of steel cord and textiles, this may affect appearance and the coating would then become very hazardous to operate. The presence of dust will also deteriorate the adhesion of the granules to the glue and often cause destruction of the coating. If the quality of the glue is very low and does not provide the required viscosity of the mixture, then the laid coating will acquire fragility, fragility and lack of shock-absorbing properties.
It is best to entrust the installation of the coating to professionals, so as not to change it several times a year in the future. Though necessary components for such work are of low cost. As you know, today there are four methods of laying rubber crumb coatings:
It is better to entrust the laying of crumb rubber to professionals, then the coating will be of high quality and durable
It is recommended to use special equipment for laying the rubber coating. This allows you to reduce maintenance personnel and increase labor productivity. One of the specialized tools is the automated rubber tile stacker. It is a steel crawler construction and consists of a pressure plate and a manually adjustable front scraper that allows you to set the required coating thickness. The width can be adjusted using the upper limiter, and the plate has 4 functions.
The top layer of crumb rubber is sprayed under high pressure
