Rubber Flex Poured Rubber Installation Guide

Seamless Strength. Poured to Perfection.

RubberFlex is a high-performance, poured-in-place surfacing solution designed for ultimate durability and safety. Combining premium EPDM granules with a high-strength aliphatic binder, this system creates a seamless, slip-resistant, and weather-ready finish perfect for playgrounds, patios, and athletic walkways. Follow this guide to ensure a smooth application and a surface that lasts for years.

STEP 1 : Site Preparation

A successful install begins with a perfect base.

  • Clean: The surface must be dry, level, and free of grease, oil, or debris.
  • Drainage: If outdoors, ensure the area has proper slope for water runoff.
  • Layout: Use tape or chalk to mark your work zones and boundaries.
  • Weather: Only install when temperatures are between 10°C and 27°C (50°F–80°F).

*Optional Base Layer (SBR Recycled Rubber)

Required ONLY if installing over a compacted crushed stone base. Skip this step if installing over concrete or asphalt.

  • Mix: Combine 1 gallon of aromatic binder with 69 lbs of SBR granules until uniform.
  • Apply: Spread to a thickness of 1" to 2" over well-compacted stone. This provides the shock absorption and comfort.

STEP 2 : EPDM Surface Layer Preparation

The Perfect Mix for Peak Performance.

  • Ratio: Mix one bag (44 lbs / 20 kg) of EPDM granules with 1 gallon of aliphatic binder.
  • Mix Time: Mix for approximately 3 minutes until every granule is fully coated and the mix is homogeneous.
  • Batching: Work in small batches (½ to 1 bag at a time) to prevent the mixture from curing before it is applied.

Step 3 : Application Process

Spread, Compact, and Smooth.

  • Prime as You Go: Roll a thin coat of aliphatic binder on the ground just before spreading each batch.
  • Spread: Lay the EPDM mixture at a thickness of 1/4" to 1/2".
  • Compact: Use a trowel to apply light pressure. Pass over each area 2–3 times for a tight bond.
  • Tool Care: Use Magic Whip on your trowel to prevent sticking. NEVER use water.

STEP 4 : Curing & Final Drying

Time to Set, Ready to Last.

  • Cure Time: Allow the surface to dry for 48–72 hours. Do not walk on it while tacky.
  • Traffic: Keep heavy traffic and equipment off the surface for at least 4 days.
  • Pro Tip: This is a steady process. Not a fast one. Plan → Mix → Install → Protect.

Step 5 : Initial Maintenance

Quality You Can Stand On.

  • Cleaning: Use mild soap and water for periodic cleaning.
  • Long-Term Care: Apply Rubberflex Surface Sealant 3 years after installation to maintain color and strength.
  • Leftovers: Keep a small amount of extra granules for future minor touch-ups.

COMMON MISTAKES TO AVOID

Refine Your Process. Elevate Your Finish.

Use this quick checklist to prevent common issues during application and installation.

INCORRECT RATIOS

Consequence:

Bubbling, swelling, or a weak, crumbling surface.

Follow the 1 gallon to 44 lbs rule exactly.

Mixing Too Much

Consequence:

Premature curing and lumps

Mix in small batches (½ bag at a time).

Poor Compaction

Consequence:

Loose granules or peeling

Cross-compact with firm, consistent pressure.

Using Water on Tools

Consequence:

Binder reaction and discoloration

Only use Magic Whip to lubricate tools.

Ignoring Moisture

Consequence:

Poor adhesion or binder failure

Concrete must cure 28 days; surface must be dry.

Visible Seams

Consequence:

"Cold joints" between sections

Always work "wet-on-wet" to blend sections.