Prepared Track Base
Correct civil works, levels, drainage and asphalt/concrete quality form the foundation of the synthetic surface.
Sandwich athletics system · SBR resilient base · dense PU surface · German raw materials
Sandwich Running Track System for Professional Athletics & Durable Track Construction
Sport Floor manufactures and supplies Sandwich Running Track System materials for athletics tracks that combine a resilient PU-bound SBR base with a pore-sealed, dense polyurethane upper surface finished with EPDM where specified.
The Sandwich concept sits between Full PU and Spray Coat in construction logic. It uses a rubber-rich resilient base for cushioning and material efficiency, but unlike a simple spray system it receives a pore sealer and dense polyurethane wearing layer above the base.
Sport Floor manufactures its own polyurethane sports-flooring materials, uses system materials in project activity and supplies them directly for international orders. German raw materials are used within applicable Sport Floor PU formulations, creating a strong material-quality platform for contractors, distributors and project buyers.
Sport Floor ManufacturedCore polyurethane components are part of the Sport Floor PU sports-flooring range.
German Raw MaterialsGerman raw materials are used within applicable Sport Floor PU formulations.
Balanced System DesignResilient rubber base below a dense PU wearing surface.
International B2B SupplyFor track contractors, distributors, importers and project procurement.
What is a Sandwich running track?
A resilient rubber base protected by a sealed, dense polyurethane wearing system
Sandwich running tracks are in-situ synthetic athletics surfaces built around two distinct functional zones: a resilient lower layer made from rubber granules bound with polyurethane, and a dense polyurethane upper zone that creates the final running surface.
The lower SBR/rubber layer provides resilience and reduces the volume of dense polyurethane required compared with a Full PU system. A pore sealer then closes the open rubber structure so the dense upper polyurethane layer can be installed continuously above it.
The exposed surface is completed with a compatible PU layer and EPDM granules or equivalent approved finish according to the selected system. This combination gives the Sandwich family its characteristic balance between resilience, dense surface construction and material efficiency.
PU-bound SBR/rubber base creates the resilient lower layer.
PU Pore Sealer closes the porous rubber base before dense PU surfacing.
Dense upper polyurethane layer differentiates Sandwich from a basic Spray Coat system.
EPDM granules can form the exposed wearing texture where specified.
German raw materials used within applicable Sport Floor PU formulations.
Available as a coordinated material package for international contractors.
Core construction logic
Primer → SBR resilient base → pore sealer → dense PU / EPDM wearing surface
PU-Bound SBR Layer
A resilient rubber-granule layer is installed using compatible polyurethane binder according to the selected system.
PU Pore Sealer
The open rubber surface is sealed so the dense polyurethane upper layer can be applied continuously.
Dense PU + EPDM Finish
The track receives a dense polyurethane wearing layer with EPDM granules or approved finish according to project specification.
Installation control
The Sandwich system works only when the rubber base and dense upper layer are properly connected
The rubber base should be uniform, correctly compacted and compatible with the binder. Excessive open texture, weak granule bonding or inconsistent base thickness can affect the pore-sealing stage and the dense polyurethane layer above.
The pore sealer is a critical transition product. Its job is to close the rubber base sufficiently for the self-leveling or dense PU layer that follows. It should not be treated as an optional cosmetic coat.
Exact binder consumption, SBR size, pore-sealer consumption, PU thickness, EPDM requirement and cure intervals should follow the selected Sport Floor system and current technical documents.
The pore-sealing stage is central to Sandwich construction
It creates the transition from resilient rubber base to dense polyurethane upper surface.
Conceptual layer sequence
Resilience below — dense PU protection above
International Sandwich systems commonly use a PU-bound SBR resilient layer, followed by a pore sealer and a dense self-leveling polyurethane upper layer incorporating or receiving EPDM granules.
This structure is what separates Sandwich from Spray Coat: the top is not simply a sprayed finish over a porous base. Instead, the base is sealed and covered by a denser PU wearing layer.
The diagram explains the system logic only. Final layer thicknesses, products, rubber sizes and quantities remain project-specific.
Why buyers choose Sandwich
A practical balance between surface quality, resilience and material efficiency
Resilient Lower Layer
The PU-bound SBR base provides the resilient foundation beneath the denser athletics surface.
Dense Wearing Surface
The pore-sealed base receives a dense PU upper layer rather than only a thin sprayed coating.
Material Efficiency
The rubber base reduces the need for a fully dense PU build-up through the entire system depth.
Professional Track Category
Sandwich is a recognized international athletics-surface system family used by major track manufacturers.
Repairable Layer Logic
The system has clearly defined base, sealing and upper-surface zones that can be assessed separately during maintenance.
Coordinated Material Supply
Sport Floor can supply the SBR, PU materials, pore sealer, EPDM and markings as a single commercial package.
German raw-material advantage
The Sandwich system depends on compatibility between multiple PU products
Binder, pore sealer and dense upper polyurethane layer must work together as one system rather than unrelated materials.
German Raw Materials
Sport Floor uses German raw materials within applicable PU formulations used across the Sandwich system.
Own PU Product Family
Sport Floor manufactures binders, pore sealers, self-leveling PU, primers, line marking and related materials.
Manufacturer + Installer + Exporter
Sport Floor combines manufacturing, project application knowledge and direct international material supply.
Sandwich vs Full PU vs Spray Coat
Choose the system by build-up, surface type and project economics
| Selection point | Sandwich | Full PU | Spray Coat |
|---|---|---|---|
| Lower resilient layer | PU-bound SBR/rubber base. | Dense polyurethane-rich layers. | PU-bound SBR/rubber base. |
| Pore sealer | Core transition layer. | Usually not the defining system feature. | Usually not required in basic open spray-coat logic. |
| Upper surface | Dense PU wearing layer with EPDM. | Dense PU / EPDM system through the upper build-up. | Sprayed PU/EPDM finish over porous base. |
| PU intensity | Medium to high. | Highest of the three typical families. | Lower due to thinner sprayed finish. |
| Commercial positioning | Balanced performance and material efficiency. | Premium dense polyurethane route. | Economical / training-oriented route where suitable. |
| Dedicated page | Current system | Full PU Running Track System | Spray Coat Running Track System |
World Athletics context
Sandwich is a recognized international track-surface category
World Athletics maintains current certification documentation for track-surfacing products, and its certified-product records include systems described as Sandwich alongside Full PUR, Spray Coat and prefabricated systems.
This confirms Sandwich as a genuine athletics-surface category. However, the category itself does not mean that every Sandwich product is World Athletics certified.
For any project requiring World Athletics certification, the exact surfacing product, facility construction, geometry, installed system and testing route should be confirmed against current World Athletics procedures and product certificates.
Important: This page does not claim that the Sport Floor Sandwich system currently holds a World Athletics Product Certificate. Any certification statement should be supported by current product-specific evidence.
System material package
Source the Sandwich track from one coordinated material supplier
PU Primer & Binder
Primer for the base and polyurethane binder for the resilient SBR layer.
SBR Rubber Granules
Rubber granules for the resilient lower track layer according to system specification.
Pore Sealer & Dense PU
Intermediate pore-closing material plus the dense polyurethane upper layer.
EPDM & Line Marking
Final colored granules and compatible athletics marking materials where specified.
Best-fit buyers
Designed for professional athletics and B2B system supply
Running-Track Contractors
Contractors installing complete track systems and requiring coordinated rubber and PU materials.
Sports Construction Companies
Companies delivering stadium, school, club and institutional athletics projects.
Distributors & Importers
Buyers developing local stock and supply capability for sports-flooring contractors.
Consultants & Procurement
Teams comparing system build-ups, technical documentation, BOQs and export options.
Base & drainage
The Sandwich surface still depends on correct civil construction beneath it
Stable Base
The asphalt or concrete base should be structurally sound, prepared and suitable for polyurethane surfacing.
Correct Levels
Track geometry and falls should be established before the synthetic layers are installed.
Drainage Strategy
Water management should be resolved in the track design rather than relying on the Sandwich surface to correct drainage defects.
Installation workflow
Build the Sandwich system from the base upward
Inspect & Prime
Confirm base condition, levels, drainage and apply the compatible primer.
Install SBR Base
Mix and install the polyurethane-bound resilient rubber layer according to the system.
Seal the Pores
Apply the specified pore sealer to prepare the resilient base for dense polyurethane surfacing.
Finish & Mark
Install the dense PU/EPDM wearing surface, cure correctly and apply athletics markings.
Technical data
Use the selected system's current technical documentation
Sandwich systems are highly layer-dependent. Exact values should come from the actual Sport Floor products and project specification.
| Item | Sport Floor Sandwich System | Why it matters |
|---|---|---|
| System Type | In-situ Sandwich running-track system. | Defines the technical and commercial family. |
| Base | Prepared compatible asphalt or concrete. | Controls long-term surface stability. |
| Primer | Selected according to base and environment. | Creates the interface to the resilient layer. |
| Resilient Layer | PU-bound SBR/rubber granules. | Provides the lower cushioning zone. |
| Pore Sealer | Sport Floor PU Pore Sealer or approved system product. | Closes the rubber base before dense PU surfacing. |
| Upper PU Layer | Dense compatible polyurethane layer. | Creates the continuous wearing zone. |
| EPDM | Selected according to final surface specification. | Defines color and exposed surface texture where used. |
| Thickness | Project-specific; use current system documentation. | Critical to BOQ and specification. |
| Consumption / Mix Ratio | Use current TDS for each supplied material. | Controls installation and quantities. |
| Cure / Application Limits | Follow current Sport Floor technical data. | Important for site quality and scheduling. |
| Certification | Only claim product/facility certification when current evidence supports it. | Prevents unsupported compliance claims. |
Common specification mistakes
Sandwich is not simply rubber base plus red paint
Skipping the Pore Sealer
The pore sealer is central to creating the dense upper layer over the rubber base.
Confusing Sandwich with Spray Coat
A Sandwich system has a denser upper PU layer, not only a sprayed PU/EPDM finish.
Weak SBR Base
Poor granule bonding or compaction can affect every layer installed above it.
Copying Competitor Thickness
Layer thickness and quantities should follow the selected Sport Floor system.
Ignoring Drainage
The synthetic surface cannot correct defective track levels or civil drainage design.
Assuming Certification
Certification is product- and facility-specific and must be documented.
Manufacturer + installer + exporter
Buy the Sandwich system materials from one coordinated supplier
Sport Floor can combine the polyurethane products and rubber materials required by international running-track contractors.
PU Manufacturing
Sport Floor manufactures the primers, binders, pore sealers, dense PU products and related materials used around the system.
Rubber Material Supply
SBR/rubber granules and EPDM can be coordinated around the track build-up.
Project Experience
System selection is informed by real sports-flooring project activity and installation requirements.
International Export
Material packages can be prepared for contractors, importers and distributors in overseas markets.
Request an accurate Sandwich quotation
Send the track build-up — not only the square metres
Track Area
Total area and project dimensions.
Required System
Confirm Sandwich or send consultant specification if system selection is open.
Base Type
Asphalt, concrete or planned civil track construction.
Target Use
Stadium, club, school, training, competition or community athletics.
Layer Specification
Send required SBR, pore sealer, PU and EPDM information where available.
Surface Color
Provide EPDM or finished track color requirements.
Destination
Country, city and preferred port or delivery point.
Documents
TDS, SDS, packing, test or consultant-submittal requirements.
Continue through the track system family
Compare Sandwich with the other Sport Floor athletics systems
Sandwich Running Track FAQ
Questions contractors and buyers ask before selecting Sandwich
What is a Sandwich running track system?
It is an in-situ athletics surface built with a PU-bound SBR/rubber resilient base, a pore sealer and a dense polyurethane upper surface finished with EPDM or another approved wearing finish.
Why is it called a Sandwich system?
Because the finished track is built from distinct functional layers: resilient rubber base below, sealing/intermediate layer in the middle and dense polyurethane wearing surface above.
Is Sandwich the same as Full PU?
No. Full PU relies more heavily on dense polyurethane layers throughout the build-up. Sandwich uses a rubber-rich resilient base below a dense PU upper zone.
Is Sandwich the same as Spray Coat?
No. Spray Coat typically finishes a porous rubber base with a sprayed PU/EPDM coat. Sandwich includes pore sealing and a denser polyurethane upper surface.
Does Sport Floor manufacture the PU materials?
Yes. Sport Floor manufactures polyurethane primers, binders, pore sealers, self-leveling PU, line marking and other sports-flooring materials.
Does Sport Floor use German raw materials?
Yes. German raw materials are used within applicable Sport Floor polyurethane formulations.
What does the pore sealer do?
It closes the open structure of the resilient rubber base so a dense PU layer can be installed continuously above it.
Can Sport Floor supply SBR and EPDM too?
Yes. A coordinated quotation can include compatible rubber granules together with the required PU system materials.
How thick is a Sandwich running track?
Thickness depends on the selected system and project specification. Use current Sport Floor system documentation rather than a generic value.
Is Sandwich recognized by World Athletics?
World Athletics certified-product records use Sandwich as a recognized system description. Certification still belongs to specific surfacing products and facilities, not automatically to every Sandwich system.
Does this page claim World Athletics certification for Sport Floor?
No. Sport Floor should only make such a claim when current product-specific certification evidence is available.
Can Sport Floor export Sandwich track materials?
Yes. International contractors, distributors, importers and project buyers can request direct material supply at info@sportfloor-m.com.
Can I request TDS and SDS?
Yes. Request current technical documents for the specific products included in your proposed track build-up.
Sandwich track system · German raw materials · manufacturer direct · global supply
Build the athletics track with a resilient SBR base and a dense polyurethane wearing system from one coordinated supply route.
Send the track area, base, required system, layer specification, target use, surface color and destination. Sport Floor can prepare a Sandwich system material package including compatible primer, binder, SBR, pore sealer, dense PU products, EPDM and line marking materials.