Prefabricated running tracks are widely used in venues such as stadiums and school playgrounds due to their uniform elasticity, wear and aging resistance, and environmental friendliness. The quality of their installation directly impacts the track's lifespan and safety, requiring meticulous attention to detail throughout the entire process. Specific considerations are as follows:
Preliminary Preparation: Laying a Solid Foundation for Installation
1. Material Inspection and Control
Roll Material Inspection: Upon arrival, verify the prefabricated roll material specifications (thickness, width, length) and batch number. Inspect the surface for defects such as cracks, bubbles, and color variations. Request a product test report to ensure compliance with international standards and that the elastic layer's hardness and tensile strength meet specified standards.
Glue Compatibility: Use a two-component polyurethane glue specifically designed for prefabricated running tracks. Verify the glue's expiration date and mix ratio. Never use expired or non-specific glue. Conduct a small-area adhesion test in advance to verify the adhesive's bond strength and curing properties to avoid delamination later.
2. Base Preparation Requirements
Flatness Calibration: The base (usually concrete or asphalt) must be checked with a 3-meter ruler, with an error of no more than 3mm/3m. Any depressions should be leveled with a special repair mortar, and raised areas should be polished flat to prevent hollowing after the roll is laid.
Dryness Control: The base moisture content must be ≤8%. This can be checked by covering it with plastic film (make sure there is no condensation on the film after 24 hours). If the base is damp, extend the drying time or use a dehumidifier to prevent moisture from affecting the curing of the glue.
Cleaning and Sealing: Remove dust, oil, stones, and other debris from the base surface. Rinse with a high-pressure water jet and allow to dry. Apply a special sealant to any gaps or pores in the base to enhance the base's sealing properties and prevent moisture from seeping in and damaging the adhesive layer.
On-site Construction: Key Controls
1. Environmental Conditions
Temperature and Humidity Requirements: The construction environment must be maintained at a temperature of 10-30°C, with relative humidity ≤85%. Avoid construction on rainy days, windy days (wind speed ≥ level 5), or high temperatures (≥35°C). Low temperatures can delay glue curing, while high humidity can cause the roll to bulge. Check the weather forecast in advance and adjust the construction plan accordingly.
Ventilation: The construction site must be well ventilated, especially indoors. Exhaust systems should be activated to reduce the concentration of harmful gases emitted by the glue and protect the health of construction workers.
2. Roll Laying Specifications
Marking and Positioning: Based on the site design drawings, use an ink fountain to mark the runway centerline, sidelines, and joint locations. Ensure the roll laying direction aligns with the runway length and avoid excessive horizontal joints.
Pretreatment of the roll: After unrolling, the roll must be left on-site for at least 24 hours to acclimate to the ambient temperature and minimize deformation due to thermal expansion and contraction after installation. When cutting the roll, allow a 5-10cm overlap to prevent uneven seams due to dimensional deviation.
Laying Order: Work from one end of the site to the other, paving the standard runway area first, then finishing curves and corners. During installation, avoid excessive stretching of the roll (stretching ≤ 1%) to prevent internal stress concentration and cracking.
3. Glue Application Details
Mixing and Mixing: Strictly follow the glue's instructions (usually a base:curing agent ratio of 10:1-8:1). Use an electric stirrer for 3-5 minutes to ensure a uniform mixture with no particles or sediment. Use the glue within 1 hour to prevent curing failure.
Evenly Apply: Use a toothed scraper to apply glue to both the base and the back of the roll, maintaining a thickness of 0.8-1.2mm. Keep the tooth marks in the same direction. Apply more glue to corners and joints to ensure a secure bond.
Compacting: After applying the glue, wait until the surface is semi-dry (not sticky to the touch, usually 15-30 minutes). Lay the roll to the base and use a heavy-duty roller (over 50kg) to roll back and forth 2-3 times in the direction of installation, focusing on compacting the joints to expel air and prevent hollowing.
4. Key Points for Joint Treatment
Joint Cleaning: Before laminating, remove dust and glue residue from the joints to ensure a clean surface. If hot air welding is used, grind the edges of the rolls to a 45° bevel at the joint to maximize the weld surface.
Welding and Sealing: Control the heat gun temperature at 300-400°C and move it at a constant speed along the joint, melting the edges of the coils and ensuring a tight fit. The weld width should be ≥ 5cm. After welding, fill the joint gap with sealant to prevent rainwater seepage and debris accumulation.
5. Safety Measures
Personnel Protection: Construction workers must wear gas masks, nitrile gloves, and goggles to avoid direct skin contact with the glue and inhalation of hazardous gases. Warning signs should be posted at the construction site to prohibit unauthorized personnel from entering.
Fire Safety: Glue is flammable. Fire sources should be kept away from the construction site. Dry powder fire extinguishers should be available. Smoking and open flames are strictly prohibited.
Post-Curation: Extending Service Life
1. Curing and Curing Stage
Curing Time: At room temperature (20-25°C), the surface requires 24-48 hours of curing after installation to allow the glue to fully cure. If the temperature is below 15°C, the curing time must be extended to at least 72 hours. During this curing period, no one should be walking on, stacking heavy objects, or using vehicles.
Product Protection: During curing, use caution tape to enclose the construction area to prevent sharp objects from scratching the surface. In the event of rain, cover with tarpaulin to prevent water from soaking uncured joints.
2. Daily Maintenance Tips
Cleaning and Maintenance: For daily cleaning, rinse with clean water or a neutral detergent. Avoid using strong acids, strong bases, or organic solvents (such as alcohol or gasoline) to prevent corrosion of the surface.
Regular Inspections: Check the track surface monthly for cracks, bulging, and delamination. Quarterly, focus on inspecting the seals at joints. Small damage (≤10 cm) should be promptly filled and compacted with specialized repair adhesive. Larger damage requires cutting, replacing with new sheet metal, and re-welding.
Usage Specifications: Heavy vehicles (such as forklifts and rollers) are prohibited from rolling over the track. Sharp objects (such as shovels and nails) should also be avoided from scratching the surface. During large-scale events, protective matting should be laid on the track surface to prevent high heels and heavy objects from damaging the sheet metal.
Prefabricated track installation is a systematic process, requiring strict adherence to specifications at every stage, from initial material inspection and base preparation to environmental control during construction, sheet metal installation, adhesive application, and subsequent maintenance. Only by carefully monitoring details and implementing standardized procedures can the track maintain excellent elasticity, wear resistance, and safety, meeting the demands of athletic performance and extending its service life.
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