Saving rubber & reducing microplastics
With 50 years of experience we understand what is needed to install tracks in a responsible way.
In tracks, such as the Rekortan Gel Series or Rekortan M, where the EPDM rubber top layer is thrown, or ‘broadcast’ on to the liquid polyurethane layer, we focus on reclaiming the rubber and reducing the spread.
The art of ‘broadcasting’
“Broadcasting” the rubber is a skill and to the untrained eye there seems to be a huge amount of rubber being thrown on to the track. However, it is necessary to over-chip the rubber to get the full coverage needed to create a beautiful track.
The “broadcasting” can be done by machine, but typically we prefer using experienced installers who have years of practice in landing the rubber perfectly on the PU layer. It is important that the rubber doesn’t roll and become coated in polyurethane as this creates a shiny finish, or land too heavy as this causes it to sink and create ripples in the polyurethane.
The skill is throwing rubber in a very fine fan, so it settles with a full coverage avoiding heavy and light spots.
Consistency and timing is the key
During the installation the polyurethane team is in the lead, followed closely by the broadcast team, who are in turn followed by a crew member looking for ‘fatty spots’ where the rubber has sunk causing the polyurethane to come through. These spots create an unattractive glossy look so additional rubber must be thrown to cover them.
As there is only a 20-minute window before the polyurethane has set, this is a continual and fast-moving process. It may not be Usain Bolt speed, but with intense work, an experienced team can complete 100m a day.
Over-chipping with a mix of quality EPDM granules and powder gives the track the full coverage. The next day the track is swept to brush off any loose granules leaving a consistent and even finish. These loose granules are reclaimed and recycled.
“As there is only a 20-minute window before the polyurethane has set, this is a continual and fast-moving process. It may not be Usain Bolt speed, but with intense work, an experienced team can complete 100m a day.”
Capturing loose rubber
Saving rubber and limiting microplastics is a top priority.
For the top layer, we allow 4.2 kgs of EPDM per square meter and with best practice we aim to reclaim up to 2 kgs per square meter. This means up to 45% of the rubber is reclaimed or unused.
24 tonnes saved at the Manchester Arena (UK)
At the recent installation of a Polytan/Rekortan M track at the Manchester Arena in the UK, we were able to recycle or repurpose 24 tonnes of EPDM. This was achieved by laying plastic catch sheets during the topcoat installation. The sheets captured EPDM rubber granules, which were reused as we progressed.
This slows the work but by using this method we saved 7 tonnes of unused EPDM and reclaimed 17 tonnes that will be repurposed in shock pads in future tracks.
Only clean rubber can be used back on the top layer, so it is important to use clean sheets and manage the process carefully.
Reclaimed rubber is also repurposed in shock pads for future tracks. Due to its excellent durability it has significant benefits as paving for high stress areas, such as the 100m start and the jumping and throwing areas. We also recycle it into e-layers for synthetic grass facilities, into playground and landscaping surfaces, and golf course pathways.
Filters protect the waterways
All drains and gullies are taped off during the installation to prevent rubber from escaping. Many new tracks are now designed with drains and gullies fitted with filters capable of capturing microplastics. We encourage this and promote it as best practice in design.
We also encourage track owners to have an ongoing maintenance program; filters are no good if they are not cleaned!
Best practice onsite
As well as managing the EPDM we focus on responsible construction and best practices in all areas, this includes:
Recycling the PU containers (steel drums or IBCs)
Site storage area on a hard surface, so any spillage is captured
Covering and protecting mixing stations so any leak is controlled
Also, COVID Health and Safety is a now essential and will be for the foreseeable future.