How PU Binder Works with EPDM Granules in Track Construction
Every athlete deserves a track that performs as hard as they do. Whether it’s sprinting, hurdling, or marathon training, a high-quality track must be durable, shock-absorbent, and weather-resistant.
In this detailed guide, we’ll uncover how PU Binder and EPDM granules combine to create the world’s most reliable athletic tracks — ensuring safety, resilience, and top-tier performance.
You’ll learn what each material does, how they work together, and why PFS Sports (Polska Fabryka Sportów) is the trusted name in premium sports surface construction across Europe and beyond.
Understanding the Basics – What Are PU Binder and EPDM Granules?
What is PU Binder?
PU Binder, short for Polyurethane Binder, is the invisible yet essential glue that holds the entire track system together. It’s a high-performance adhesive designed to bind rubber granules into a uniform, flexible, and weather-resistant surface.
There are two main types:
- Single-component (1K) – moisture-cured binders that are easy to apply.
- Two-component (2K) – chemically reactive systems for advanced, heavy-duty applications.
The binder gives the track its resilience, durability, and elastic properties, allowing it to withstand extreme temperatures and repeated impact without cracking.
What Are EPDM Granules?
EPDM (Ethylene Propylene Diene Monomer) granules are synthetic rubber particles used as the top layer in sports surfaces. They’re available in multiple colors, sizes (usually 1–4 mm), and are known for their:
- UV resistance
- Flexibility
- Vibrant color retention
- Weather and ozone resistance
EPDM granules form the visible surface of a track, providing traction, comfort, and aesthetic appeal. When combined with a high-quality PU Binder, they create a surface that’s both functional and visually striking.
The Science of Bonding – How PU Binder and EPDM Granules Work Together
The Bonding Process
Building a synthetic running track is a layered engineering process. PU Binder and EPDM granules play a central role in forming the top surface, where athletes interact.
The key bonding process includes:
- Mixing:
EPDM granules are mixed with a precise percentage of PU Binder (usually 15–25% by weight). - Spreading:
The mixture is evenly spread over the base layer using specialized equipment to achieve uniform density and texture. - Curing:
Once laid, the binder cures — forming a flexible, cohesive layer that locks the EPDM granules together while maintaining surface elasticity. - Finishing:
After curing, the surface is inspected for smoothness, color consistency, and resilience. Line markings are added afterward.
The Role of Each Component
- PU Binder: Acts as the adhesive and protective sealant.
- EPDM Granules: Provide traction, safety, and aesthetics.
- Result: A seamless, shock-absorbent, UV-resistant, and water-draining athletic surface.
This synergy ensures the track withstands years of intensive use — from school-level athletics to international events.
Step-by-Step Process of Track Construction Using PU Binder and EPDM Granules
Step 1 – Surface Preparation
A solid foundation is critical. The base layer, usually asphalt or concrete, must be smooth, clean, and dry. Any imperfections can affect adhesion and long-term durability.
Step 2 – Applying the Cushion Layer
Below the EPDM surface lies a shock-absorbing cushion layer made from recycled SBR (Styrene Butadiene Rubber) granules mixed with PU Binder. This layer enhances impact absorption and athlete comfort.
Step 3 – Laying the EPDM + PU Binder Layer
The EPDM granules are mixed with the PU Binder in a mechanical mixer until every granule is evenly coated.
The mixture is then poured and spread evenly on the cushion layer.
Proper proportioning is vital — too little binder leads to weak bonding; too much binder creates stiffness.
Step 4 – Curing Process
Curing allows the PU Binder to harden and achieve its elastic properties. Ideal curing time depends on temperature and humidity, typically between 24–48 hours.
Once cured, the track achieves the perfect balance of elasticity, durability, and resilience.
H2: Step 5 – Line Marking and Finishing
Finally, the surface is marked with lanes, logos, and game lines using PU-based paints. The surface is tested for shock absorption, friction, and hardness before official certification.
Why the PU Binder + EPDM Combination Is Perfect for All-Weather Tracks
Superior Elasticity and Impact Absorption
The elasticity from PU Binder ensures the track can flex under stress without cracking, while EPDM granules cushion the athlete’s joints.
This balance reduces fatigue and injury risk — a must for professional training and competition venues.
Unmatched UV and Weather Resistance
EPDM granules retain their color and integrity under extreme UV exposure. When paired with UV-stable PU Binder, the surface resists fading, cracking, or hardening, even in scorching climates.
Long-Lasting Performance
A well-constructed EPDM + PU Binder track can last 10–15 years with minimal maintenance. This durability makes it a cost-effective solution for schools, stadiums, and training facilities.
Enhanced Safety and Slip Resistance
The textured surface created by EPDM granules offers superior grip, even in wet conditions. PU Binder’s elasticity prevents water penetration, ensuring safe play in all seasons.
Factors Affecting the Quality of PU Binder and EPDM Application
Mixing Ratios
The ratio of EPDM granules to PU Binder determines the surface’s flexibility and strength. For most applications, the mix is 80–85% EPDM granules and 15–20% PU Binder by weight.
Environmental Conditions
Temperature and humidity directly impact curing. The best installation occurs in moderate, dry weather to prevent moisture interference.
Quality of Materials
Not all EPDM granules or binders are equal. Premium materials from PFS Sports are tested for tensile strength, UV resistance, and long-term elasticity — ensuring uncompromised performance.
Common Problems and How PFS Sports Solves Them
Issue 1 – Weak Bonding
Cheap binders or poor mixing can lead to delamination.
Solution: PFS Sports uses certified PU Binders with precise formulation for strong adhesion and flexibility.
Issue 2 – Fading Colors
Low-quality EPDM granules lose their color under sunlight.
Solution: PFS Sports sources UV-stable EPDM granules that retain color for years, even under heavy exposure.
Issue 3 – Cracking and Hardening
Improper curing can make the track brittle.
Solution: PFS Sports ensures optimal curing conditions and uses weather-resistant aliphatic PU Binders that maintain elasticity.
The PFS Sports Advantage
PFS Sports (Polska Fabryka Sportów) isn’t just another supplier — it’s a complete sports infrastructure partner. Here’s what sets them apart:
1. Premium Quality Materials
Every EPDM granule and PU Binder from PFS Sports is tested for quality, color uniformity, and performance durability.
2. Expert Installation Team
PFS Sports’ engineers and applicators bring years of field experience, ensuring flawless track construction from base to finish.
3. Customized Solutions
Whether it’s a school track, Olympic training center, or community ground, PFS Sports designs solutions based on usage, climate, and budget.
4. Sustainability Commitment
All PFS Sports products are eco-friendly, using recyclable rubber materials and low-VOC binders that meet international standards.
5. Global Expertise, Local Execution
With operations across Europe and a growing global footprint, PFS Sports combines international quality with local expertise, ensuring superior service delivery.
Maintenance Tips for Long-Lasting Tracks
Regular Cleaning
Dust, debris, and organic matter should be regularly removed to prevent wear and microbial growth.
Avoid Sharp Objects
Spikes, tools, or heavy machinery can damage the surface. Always use protective mats where needed.
Routine Inspection
Schedule periodic inspections to detect early signs of wear or damage. PFS Sports provides expert after-sales support for maintenance and repairs.
Conclusion
PU Binder and EPDM granules are the dynamic duo behind every world-class athletic track. Together, they provide elasticity, resilience, color vibrancy, and long-lasting performance.
With PFS Sports (Polska Fabryka Sportów), you get more than just materials — you get expertise, innovation, and reliability. Their advanced PU Binder formulations and premium EPDM granules ensure every project meets global performance standards.
👉 Build a track that performs as hard as your athletes. Visit https://pfs.sport to explore premium PU Binder and EPDM granule solutions designed for lasting success.
