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The full PU (full polyurethane or "full pour") system is the highest class of in-situ athletics track surfaces. While a sandwich system has an SBR rubber base at the bottom, a full PU system is polyurethane-based throughout. This gives the same elasticity, grip and durability at every point of the track.
A full PU surface consists of two-component polyurethane poured on the asphalt in layers. Lower layers may contain rubber granules within the polyurethane for elasticity; on top, EPDM granules are broadcast into the final pour. The result is a solid, void-free, impermeable surface.
Total thickness is usually designed at 13 mm and increased in zones such as the high jump take-off area and the end of the javelin runway.
Because full PU self-levels, the evenness and slopes of the asphalt are critical. The surface is checked with a straightedge, level errors are corrected and the surface is cleaned.
After priming, the polyurethane is mixed with a metering machine and poured with a gauge-controlled squeegee. The target thickness is reached in more than one layer.
The final polyurethane layer is poured and EPDM granules are broadcast while it is wet. After curing, loose granules are swept off.
The track is surveyed and lines are painted. If certification is planned, thickness, force reduction, vertical deformation, friction and evenness are tested on site by an accredited laboratory.
Full PU is ideal for heavily used tracks such as stadiums hosting international championships, national team training centres, universities and club facilities. If the budget is limited, the sandwich system is a strong competition-level alternative. See the differences in our comparison article.
Full PU tracks should be swept regularly, kept free of leaves and sand, and washed with low-pressure water at least once a year. Vehicles, scaffolding and sharp equipment must not be placed on the surface, and protective panels should be used during events. Lines and channel covers should be checked periodically.
SFS Engineering installs full PU systems together with groundworks, drainage, line marking and athletics equipment in its athletics track construction projects.
A sandwich system has an SBR rubber base with 3–4 mm of poured polyurethane on top. In a full PU system the whole surface is poured polyurethane, giving more uniform performance and higher durability.
No, full PU is solid and impermeable. Rainwater is directed to drainage channels by the surface slope.
Depending on use and maintenance it lasts many years. A worn top surface can be renewed without removing the system.
Asphalt is the standard base for outdoor tracks. Indoors it can also be applied on an even, dry concrete slab.
Get technical support for your project: SFS Engineering handles site survey, design, material selection and installation as a single contractor. Send us your dimensions and site details through our contact page and we will work out the right solution together.