Our Products
EPDM Rubber Flooring
We are specialized in designing and installing premium-quality EPDM Rubber Flooring, a versatile and reliable solution for sports and recreational surfaces. Engineered with Ethylene Propylene Diene Monomer (EPDM), this flooring system offers exceptional durability, weather resistance, and performance, making it ideal for both indoor and outdoor applications. Whether for sports courts, playgrounds, walkway and athletic track facilities, ensure flooring that delivers safety, comfort, and long-lasting value.
Our EPDM Rubber Flooring is designed with superior shock absorption and slip resistance, significantly reducing the risk of injuries while enhancing the overall playing and training experience. The flooring retains its vibrant colors and structural integrity even under extreme weather conditions, heavy foot traffic, and continuous use. Available in a wide variety of thicknesses, textures, and color combinations, we provide fully customizable solutions tailored to meet the functional and aesthetic needs of each client.
With years of expertise in sports infrastructure, we deliver EPDM Rubber Flooring installations that align with international quality standards. Our dedicated team ensures precision in design, seamless installation, and reliable after-sales support, making us a trusted choice for schools, sports clubs, fitness centers, and recreational complexes. By combining innovation, quality, and customer-focused service, we continues to set benchmarks in providing safe, durable, and high-performance flooring solutions.
Base Layer
Made of SBR granules (Styrene Butadiene Rubber)
Top Layer
Made of color EPDM granules
Manufactured from EPDM rubber granules mixed with PU binder, providing excellent cushioning ideal for playgrounds.
The granules have inbuilt color, ensuring long-lasting vibrancy without fading.
Standard granule size ranges from 1–4 mm.
The top EPDM layer is applied with a fixed thickness of 6 mm in all systems.
EPDM granules feature high resistance to weather and heat, and are a non-toxic, child-safe product.
Methodology
1. Surface Preparation: Clean and level the base surface, such as concrete, asphalt, or compacted stone, repairing cracks or holes. Apply polyurethane primer for better adhesion, especially on concrete.
2. Base Layer Installation: Mix SBR rubber granules with PU binder at a 20:1 ratio and spread to 5-30 mm thickness using a trowel for impact absorption. Allow 24 hours curing before proceeding.
3. Top Layer Application: Mix EPDM granules with PU binder (5-10% by weight) until evenly coated, then pour and trowel evenly to 8-15 mm thickness for a seamless, colorful finish.
4. Finishing and Curing: Compact with a roller if needed, smooth edges with molds or rulers, and cure for 24-48 hours without traffic or water. Test for uniformity and safety compliance post-cure.
EPDM Flooring Properties
1. Weather Resistant
2. Highly Flexible
3. Water Resistant
4. Long-Lasting Durability
5. Low Maintenance
| Thickness | Black SBR Base | EPDM Coloured Granules |
|---|---|---|
| 15 mm | 9 mm | 6 mm |
| 20 mm | 14 mm | 6 mm |
| 25 mm | 19 mm | 6 mm |
| 30 mm | 24 mm | 6 mm |
| 36 mm | 30 mm | 6 mm |
Athletic Tracks
Costa Sports designs its athletic tracks with the specific needs of athletes in mind. Engineered for superior shock absorption and enhanced with anti-slip properties, these tracks provide a safe and high-performance surface. Easy to clean and resistant to algae growth, Costa Sports athletic tracks deliver the perfect combination of safety, durability, and long-term reliability.
The following outlines our process for executing the athletic track:
Base Preparation
Concrete Base
1. Surface Preparation: Clean the proposed court area by removing weeds, grass, and unwanted soil.
2. Slope Formation: Create a slope of 1 inch for every 10 feet along the shorter axis to allow drainage into an open saucer drain.
3. Compaction & Base Layer: Compact the sloped surface using a lawn roller, then lay a 3-inch-thick layer of 40–50 mm brickbats mixed with Jamuna sand, followed by compaction.
4. First Concrete Layer: Apply a 2-inch-thick layer of 1:4:8 concrete mix over the compacted base.
5. Initial Curing: Allow this layer to harden for 1–2 days. Once set, place a second layer of 1½-inch thickness using a 1:2:4 concrete mix.
6. Final Curing: Cure the surface for 14–15 days to ensure proper setting and strength.
Asphalt Base
A standard asphalt base typically comprises an 8-inch pavement structure consisting of:
1. Excavate the surface to a depth of 3–6 inches, or as required, ensuring complete removal of weeds and grass including roots. Provide a slope of 25 mm every 5 meters along the shorter axis, maintaining precise control for a correct slope of 1” in every 10’.
2. Compact the prepared sub-base using an 8–10 ton roller.
3. Apply anti-termite and weedicide treatment by creating 9” deep holes at 12” intervals, injecting chemicals, and spraying the entire area.
4. Lay the first layer of 3” compacted Water Bound Macadam (WBM), ensuring dense compaction with proper keying and interlocking of stones to prevent settlement.
5. Lay the second layer of 3” compacted WBM with smaller-sized stones, following the same procedure as above.
6. Apply a 30 mm thick compacted Hot Mix Asphalt Binder (BM) course.
7. Apply a 20 mm thick compacted Hot Mix Asphalt Concrete (A.C.) course.
8. Finish with a seal coat of stone dust.
EPRF- HPU-500 Running Track
(Thickness 12mm) (Sport Shoes)
Supply and apply of EPRF cushion Roll The base thickness is 10 mm, fixed with a water-based adhesive with Hybrid Polyester filament reinforcement.
One layer of flexible cushion is applied for flexblity and sealing the pores.
The top layer of colored PU + ethylene propylene diene monomer (EPDM) granules size 2- 4mm is sprayed permanently embedded on top of the EPRF CUSHION BASE.
The Total Top Layer will be 2 mm with Game line marking as per IAAF standards.
TOTAL THICKNESS (10+2MM = 12MM)
EPRF- HPU-500 Running Track
(Thickness 14mm) (Sport Shoes & Spikes)
Supply and installation of EPRF Cushion Roll with a base thickness of 10 mm, reinforced with hybrid polyester filament and fixed using a water-based adhesive.
Application of two layers of flexible cushion to enhance flexibility and effectively seal surface pores.
The top layer consists of colored PU mixed with EPDM granules (size 2–4 mm), permanently sprayed and embedded over the EPRF cushion base.
The final top layer thickness will be 4 mm, including game line markings in accordance with IAAF standards.
Total system thickness: 14 mm (10 mm base + 4 mm top layer).
