Method of crating a fall-safe, synthetic turf-covered play area

Abstract

A method of constructing a play area with an all-weather resilient surface, the thickness and degree of resilience of which is objectively related to the height of the play equipment to be erected on the surface of the play area. Thicker, more resilient surfaces underlie higher equipment or decks. Single and multiple thickness surfaces can be constructed using a mixture of shredded rubber in a urethane binder. The cured surface is covered with a synthetic turf.

1 . A method of constructing a resilient play area surface on a pre-existing subsurface comprising the steps of:
 (a) preparing a flowable uncured mixture of particulate rubber and a urethane-based binder;   (b) determining the height or heights of climbable play equipment to be situated within the play area;   (c) determining the thickness of the flowable mixture when cured needed to meet an objective safety standard associated with the maximum of said heights;   (d) spreading the flowable mixture onto the subsurface until at least said thickness is reached;   (e) allowing the mixture to at least partially cure; and   (f) covering the at least partially cured mixture surface with a synthetic turf.   
   
   
       2 . The method described in  claim 1  wherein the particulate rubber consists of strands on the order of ¼ to ½ inch in length. 
   
   
       3 . The method of  claim 1  wherein the binder is at least partly polyurethane and is free of added solvents. 
   
   
       4 . The method of  claim 1  wherein the step of spreading the mixture is carried out at an ambient temperature of between 45 and 90 degrees Fahrenheit. 
   
   
       5 . The method of  claim 1  wherein the equipment is situated in the play area before the curable mixture is spread. 
   
   
       6 . A method of constructing a resilient play area surface on a subsurface comprising the steps of:
 (a) preparing a subsurface having at least two depths relative to a datum level;   (b) preparing a flowable uncured mixture of particulate rubber and urethane-based binder;   (c) spreading the flowable mixture onto the prepared subsurface up to the datum level so as to produce at least two different thicknesses of the spread material;   (d) allowing the mixture to at least partially cure; and   (e) covering the surface of the at least partially cured mixture with a synthetic turf.