Carpet Bonded Foam - The Things You Need to Know

If you are considering the purchase of a Carpet Bonded Foam Floor, there is some basic information you need to know to make sense of the terminology you will find. We are defining Carpet Bonded Foam as a carpet and foam combination. This product can have quite a variety of uses. They are the product of choice for Cheer and Gymnastics. They are now becoming the product of choice in aerobic and martial arts due to their superior footing.
The standard competition cheer floor is usually 42' x 54' (9 rolls). The standard competition gymnastics floor is 42' x 42' (7 rolls). There are two main product groups which offer a carpet & foam combination -- Carpet Bonded Foam and Flexi-Rolls®. Each of these are available in a variety of thicknesses and foam types. (see below)

The bond between the carpet and foam is critical. Floors should not be glued, this is an unsatisfactory method of bonding. During manufacturing of the products described below, the foam liquefies and in the cooling process, the carpet and foam substrates actually become one piece, creating a permanent, virtually indestructible bond. Carpeted Foam Benefits Benefits of heat bonding over loose carpet and foam are considerable. Carpet wrinkling, twisting and shifting is eliminated while durability is greatly increased. Wear and tear on foam is greatly reduced. Bonding makes foam stronger, it dissipates landing impact and produces a much faster responding floor. Carpet Bonded Foam (CBF is sometimes referred to as Foam Backed Carpet - or Carpeted Crosslink.) This is a carpet laminated to trocellen foam making the top 2 layers one piece (see below). It is a remarkably durable product. Carpet Bonded Foam comes in 6' x 42' x a variety of thicknesses. Generally, for gym use, it is 1 3/8" or 2" thick. A 3/4" thickness is also available. It is used often in rhythmic gymnastics and for a safe coveringof exposed concrete throughout the gym. These comes in a variety of colors. Anything other than blue or light gray usually costs a bit more. To avoid surprises, make sure that velcro is included in your pricing. Velcro will come in either 2" or 4" widths depending on the manufacturer. Our pricing will include the 4" Velcro with each 42' roll.

Carpet Bonded Foam (2" shown here)

The Carpet
Strong Needle-Punch Carpet - This is the strongest carpet used anywhere in the industry, yet it is soft, with the touch of velour. The polyolefin fibers are not stringy and cannot be pulled out by velcro, a problem common to less expensive and lighter weight carpets. Similar products may look identical, but lighter weight 10–14 oz. carpets simply do not provide the quality, durability and performance of our tough 26 oz carpet. The carpet makes the floor.

The Foam
Rollable Floors are generally cross-linked polyethylene foam. There are several types of this foam. The most highly sought for sports performance a trocellen sport foam. This is a sport foam renowned for the fact that it will absolutely not harden over time, while maintaining maximum shock absorption and resiliency. This is what we offer at The American Gym. It was introduced in 1972, and is renowned for its shock absorption, resiliency and fast response. It's proven to substantially outlast non cross-linked foam as its cell structure will not break down under repeated bending or compression. Other polyethylene foams may look and feel like ours, but without its unique chemical composition, they are unable to provide the shock absorption and resiliency that ours offers. This foam will not support growth of fungi or mold and does not emit dust or fibre products.

Ease of Use
It is a simple product to put down and take up. It can be done in minutes. To put down, you simply unroll the unit. The velcro that keeps it together in a roll is used to join the segments. Velcro grips the carpet surface itself. To take up, just remove the velcro, flip the foam, and roll it with the carpet to the outside. Roll on the velcro strip to secure the foam until next time. Prices shown below include the velcro, but do not include freight.

Five-year Limited Warranty - on carpeted foam laminated products. Warranty covers carpet/foam bonding and carpet wear only when used as intended for cheerleading, gymnastics or aerobic activities.

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Take note: When comparing prices, our pricing does include the 4" Velcro. This pricing above reflects the price for Blue or Light Gray rolls. For Red, Purple, or Black, add $15 per roll. Charcoal rolls are available for $140 per roll more and these colors are only available in the Carpet Bonded Foam. Rolls (in 42' lengths) are normally shipped within 1 week. About roll length -- Carpet Bonded Foam (and Flexi-Rolls) regardless of the manufacturer, will not arrive in an exact 42' length. This is impossible for the manufacturer to accomplish because of the nature of the product. They will be something more than 42' -- usually 2" to 5" over. The rolls should be laid out flat and allowed to acclimate for 24 to 48 hours before assessing whether they need to be cut or not. They may be hot or cold after shipping and therefore longer or shorter than they will ultimately be in your facility -- even altitude has an effect. Cutting is not difficult, but as the saying goes 'measure twice, cut once'. Flexi-Rolls® Flexi-Rolls® by Dollamur were (until 12/09) a little more expensive, now they are the same price! These take even less effort than the Carpet Bonded Foam. These are quite popular for use by schools - where rolling and unrolling them is routine. They come in the same widths and thicknesses as the Carpet Bonded Foam, but there is no flipping when you are done. These are manufactured with trocellen foam. Standard Orders ship within a week of approved order Five-Year Limited Warranty Easy to Move and Set up One-Person Setup, No Flipping of Rolls Carpet is Protected on Inside of Roll When Stored Rolled Mats Won't Unroll When Set on Edge Quick & Easy Storage Introducing the quickest and easiest mat ever made! One person can set-up or break down a 42’ X 42’ Dollamur Flexi-Roll® floor in just minutes. Even a preschooler can unroll a section! You'll get the same great performance of our regular rollable mats chosen for years by top gymnastics and cheerleading programs. The same high performance sports foam, the same durable carpet and the same state-of-the-art bonding method. The best just got better! Rolling out and rolling up can be easily accomplished by kids due to the foam backing being slit (every 4"). The 1 3/8" thick rolls form into a nice round roll, the 2" makes more of an oval roll. These rolls also tends to lay flatter more consistently at the ends than the Carpet Bonded Foam. Prices shown below include the velcro, but do not include freight. These prices are for blue or light gray. For red, purple, or black, add $15 per roll. Rolls are normally shipped within 1 week. Five year Limited Warranty - on carpeted foam laminated products. Warranty covers carpet/foam bonding and carpet wear only when used as intended for cheerleading, gymnastics, martial arts and aerobic activities. Request a Quote Take note: When comparing prices, our pricing does include Take note: When comparing prices, our pricing does include the 4" Velcro. This pricing above reflects the price for Blue or Light Gray rolls. For Red, Purple, or Black, add $15 per roll. Available Colors in the Flexi Black, Red, Purple, Light Gray, and Royal Blue Close-ups - true lighting Flexi-Roll® is a registered trademark of Dollamur, LP About roll length -- Flexi-Rolls® (and Carpet Bonded Foam) regardless of the manufacturer, will not arrive in an exact 42' length. This is impossible for the manufacturer to accomplish because of the nature of the product. They will be something more than 42' -- usually 2" to 5" over. The rolls should be laid out flat and allowed to acclimate for 24 to 48 hours before assessing whether they need to be cut or not. They may be hot or cold after shipping and therefore longer or shorter than they will ultimately be in your facility -- even altitude has an effect. Cutting is not difficult, but as the saying goes 'measure twice, cut once'. High-Performance Tri-Flex® -- EVA Enhanced CBF and Flexi-Rolls® The Ultimate in Speed, Rebound and Shock Absorption The Tri-Flex® floor is unlike any foam floor surface you have ever used before. Three different foam layers and densities are fused to provide extraordinary speed, rebound and shock absorption. Dollamur’s exclusive cross-linked polyethylene formula combined with EVA foam provides height and airtime that can’t be touched by any other mat on the market. Available in 1 3/4” and 2 1/4” thickness, as well as foam-only rolls. This is the fastest, liveliest and most dynamic rollable floor in the world. Available in the same 5 colors choices above. The EVA Enhanced Rolls do take a bit longer to ship than the regular trocellen. These normally ship within 2 weeks, though. Request a Quote Take Note: When comparing prices, our pricing does include the 4" Velcro. The above pricing is for Blue or Light Gray. For EVA Enhanced Carpet Bonded Foam or Flexi-Rolls® in colors other than Blue or light Gray, add $15 per roll. With your city, zip code,city, the quantity, and which product(s) you think would work the best for you, we can give you definite delivered pricing. Request a Quote Related: to Tumble Strips to Foam and Carpet (that are sold separately) to Flexi-Roll® Care to Spring Floors to How to keep your Cheer Floor Clean to Fire Rating Specifications