FallSAFE Pour-in-Place Rubber Surfacing: Lifecycle Planning Guide
A guide on FallSAFE™ Pour-in-Place Rubber Surfacing costs when installed by BDI Play Designs.
Lifecycle Cost & Planning Overview for School Divisions & Municipalities in North America's Climate
What is Pour-in-Place Rubber Surfacing?
Pour-in-Place (PIP) rubber is a seamless, unitary playground surface installed on site using rubber granules, either recycled SBR or virgin EPDM, together with a binder. For playground surfaces, it is comprised of an impact absorbing bottom layer (depth determined by Critical Fall Height) made using recycled rubber with a lower concentration of binder, and a top layer that contains either recycled SBR, virgin EPDM, or a hybrid, together with a higher concentration of binder. Typically, when using more than 25% EPDM in a top wear-course mixture, it is recommended that a UV resistant aliphatic resin is used to ensure the colour remains vibrant, since aromatic resins amber in UV light.
BDI's FallSAFE™ always includes an additional layer between the top wear course and the buffings layer, which includes the higher resin concentration of the top layer and bound to the top layer - effectively doubling the thickness of your wear-course to ensure the product lasts the full lifecycle of the playground.
Why Do School Divisions & Municipalities Choose PIP?
- Accessibility First: Supports inclusive play and barrier-free access
- Low Daily Maintenance: No raking or material top ups required
- Visual Safety: Discarded items, broken glass or used needles are easy to identify and remove, not concealed by surfacing
- Clean Environment: Keeps play areas tidy and contained
- High Visual Impact: Enhances school identity and play value
Lifecycle Replacement Costs & Maintenance
As a general rule of thumb, we recommend budgeting approximately $1.00 per square foot, per year, which is primarily for lifecycle replacement, but can also be useful for covering damage or vandalism over the years.
Important Planning Insight
PIP is low maintenance, but not maintenance-free. Damage and vandalism can occur, and it is important that your maintenance department is ready to address it on short notice so the damage doesn't spread. For this reason, we recommend our Convenience Patch Kits, featured below.
Surfacing Comparison at a Glance
| Feature | PIP Rubber | Engineered Wood Fibre | Playground Pea Gravel |
|---|---|---|---|
| Accessibility | High | Moderate | Low |
| Maintenance | Low | Moderate (Lower with Resilient Wear Mats) | High |
| Cleanliness | Excellent | Moderate | Lower (Migration/Dust) |
| Upfront Cost | Higher | Lower | Lower |
| Lifecycle Planning | Scheduled | Ongoing | Ongoing |
| Drainage | Excellent (Porous) | Good | Excellent |
| Stability | Fixed Surface | Requires Leveling | Shifts Easily |
| Winter Performance | Good (Plowable with Care) | Poor | Poor |
Prepared for School District & Municipality Planning & Capital Decision-Making.