Our Products
Synthetic Flooring
Synthetic Flooring is engineered to deliver superior performance, combining the ideal balance of cushioning and firmness to create a safe and comfortable playing surface. The flooring is designed with advanced formulations that make it antifungal, antimicrobial, and UV resistant. This ensures long-lasting durability and consistent performance, even after years of continuous use under extreme weather conditions such as scorching heat, heavy rains, or prolonged sun exposure.
The unique application system of Synthetic Flooring is specifically developed to reduce jerk and absorb impact, thereby minimizing stress and preventing injuries to players’ joints and muscles. This makes it an excellent choice for a wide range of sports and recreational activities, ensuring both safety and comfort for athletes at every level.
Along with superior performance, Synthetic Flooring is low-maintenance, easy to clean, resistant to microbial growth, and retains its durability and appearance with minimal effort—making it a cost-effective, reliable choice for sports facilities, schools, clubs, and recreational complexes.
Synthetic Surfaces
The superior performance of Costa Sport Infrastructure, combined with specialized expertise in its design and installation, has resulted in a wide range of world-class hard-court and cushioned sports systems.
Asphalt Base for Recreational Surfaces
Hot Mix Asphalt (HMA) surfaces play a vital role in today’s recreational surfacing industry. Known for their durability and cost-effectiveness, HMA provides an all-weather pavement foundation for athletic surfaces worldwide. Acrylic coatings for sports like tennis, basketball, and volleyball were initially developed specifically for asphalt applications. For maximum strength and longevity, the American Sports Builders Association (ASBA) recommends the following asphalt surface specifications:
Base Treatment
ASPHALT SUB BASE: 200MM Thickness
Earthwork: Excavation up to 4–5 inches, followed by leveling and compaction using an 8–10 ton road roller.
Soil Filling: Any required ground soil filling will be provided by the client.
WMM Layer: Laying 150 mm loose thickness of Wet Mix Macadam (WMM), leveled and compacted with an 8–10 ton road roller.
Tack Coat: Application of bitumen emulsion using a sprayer on the prepared surface.
Base Course: Laying 30 mm loose thickness of 20 mm stone-size bituminous macadam (hot mix) with 60/70 grade bitumen.
Wearing Course: Laying 20 mm loose thickness of bituminous concrete using 6 mm chips, coarse and fine aggregates, and compaction with an 8–10 ton road roller.
Seal Coat: Application of hot mix bitumen seal coat (without thickness), compacted with an 8–10 ton road roller.
Toe Wall: Excavation, leveling, and providing a 50 mm PCC bed, followed by constructing a 12-inch-high brick wall with plastering. (Below the ground 6" and above the ground 6")
Drain Construction: Excavation, leveling, and providing a 50 mm PCC bed, followed by a 6-inch-wide and 6-inch-high brick wall drain with smooth plastered finish. The client will be responsible for connecting the main line.
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Methodology
Synthetic acrylic flooring for sports courts applies multiple layers of water-based acrylic coatings over a prepared concrete or asphalt base, creating a cushioned, durable surface suitable for tennis, badminton, or basketball.
1. Surface Preparation: Clean the concrete or asphalt base thoroughly, removing debris, dust, oil, and old coatings, then repair cracks or low spots for a smooth, level surface with proper drainage slope. Fill imperfections with patching compound and ensure moisture content is below 4% before priming.
2. Primer Application: Apply acrylic primer evenly with roller or squeegee at 0.05 kg/m² to seal the base and promote adhesion, allowing full drying (typically 4-6 hours). This step prevents moisture issues and ensures layer bonding..
3. Resurfacer and Cushion Layers: Mix acrylic resurfacer with silica sand (1.5 kg/m² total) and apply 2 coats at 0.5 kg/m² per coat using squeegee for texture and filling voids. Add cushion layer (0.85 kg/m²) for shock absorption in multi-layer systems, drying between coats.
4. Topcoat and Markings: Apply 2 coats of colored acrylic topcoat at 0.5 kg/m² per coat with squeegee or roller for UV protection and traction, maintaining 15-25°C temperature. Mark lines with specialized paint (0.02 kg/m²) using stencils for precise court dimensions per ITF/FIBA standards.
5. Curing and Testing: Allow 48-72 hours curing without traffic, protecting from rain or direct sun, then test for evenness, ball bounce, and slip resistance. .
6. Syntehtic product is ITF certified and avaliable in 5 and 8 layers systems.
| Court Type |
Court Area |
Dimension in Feet | Net Height |
||
|---|---|---|---|---|---|
| Length | Width | Total Sq. Ft. |
|||
| Badminton | Standard Area | 50.00 | 25.00 | 1250.00 | 5' 1" |
| Playing Area | 44.00 | 20.00 | 880.00 | ||
| Pickleball | Standard Area | 60.00 | 30.00 | 1800.00 | 3' - 2'10" |
| Playing Area | 44.00 | 20.00 | 880.00 | ||
| Padel | Standard Area | 66.00 | 33.00 | 2178.00 | 3'2" |
| Playing Area | 66.00 | 33.00 | 2178.00 | ||
| Lawn Tennis | Standard Area | 120.00 | 60.00 | 7200.00 | 3'6" - 3' |
| Playing Area | 78.00 | 36.00 | 2808.00 | ||
| Basketball | Standard Area | 107.00 | 63.00 | 6741.00 | 10' |
| Playing Area | 94.00 | 50.00 | 4700.00 | ||
| Volleyball | Standard Area | 80.00 | 50.00 | 4000.00 | 7' 4" - 7' 11" |
| Playing Area | 60.00 | 30.00 | 1800.00 | ||
| Squash | Doubles | 32.00 | 25.00 | 800.00 | |
| Singles | 32.00 | 21.00 | 672.00 | ||
| Handball | Standard Area | 143.00 | 78.00 | 11154.00 | |
| Playing Area | 131.00 | 66.00 | 8646.00 | ||
| Football | Standard Area | 143.00 | 78.00 | 11154.00 | |
| Playing Area | 131.00 | 66.00 | 8646.00 | ||
| Cricket Pitch | Standard Area | 70.00 | 12.00 | 840.00 | |
| Playing Area | 66.00 | 10.00 | 660.00 | ||
| Box Cricket | Standard Area | 100.00 | 55.00 | 5500.00 | |
