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HOW IT’S MADE

XFloors™ are all made in Europe by following strictly quality and enviroment-friendly processes.

Xenios USA® selected some long-term experienced factories, all able to handle the full production process: from raw material sourcing and processing up to mass production of the nished products.
XFloors™ are made by using raw rubber granulate and powder, both produced thru a mechanical and chemical process whithin which used car tyres are involved. Just younger than 5 years used tyres are sourced to perform such process and they are not mixed with any other kind of recylced rubber, such as poor quality shoes’ soles. Recylced tyres are collected and processed by the more strictly recycled material disposal and collecting regulations to protect the enviroment.

Factories involved with this special process are all working in compliance with DIN EN ISO 9001:2008 and 14001:2005 certication rules. One of the factories who was chosen by Xenios USA® as XFloor™ maker, is every year producing 1.5 million of square meters of rubber mats for many kind of uses: public areas, sport areas, kid playgrounds, constructions etc.

Thanks to the recycling processes, a new life is given to used car tyres.

Used rubber tyres are chopped, granulated, savied and separated using the most advanced technologies. The result of this process is clean rubber granulate and powder. The granulate can come out with different crumb sizes, according to the several uses they are going to be employed for.

Once the right granulate and powder is chosen, the second production step of the XFloors™ change according to the nal product that is going to be manufactured.

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To make the rubber mats (either rolls and die-cut tiles) urethane binding compounds are mixed with the rubber granulate, in order to produce rubber bales. During the above production phase, the black color granulate is also mixed together with pure EPDM chips in order to give the nished mats their black/colored outlook (the higher is the percentage of the EPDM chips, the wider will be the color of the oor mat).

Xenios USA® XFloor™ EPDM rolls and tiles are made with 20% of EPDM chips but they can be also made with a higher ratio according to the special needs of the customers). EPDM additive is also used to make the floor mats stronger and longer lasting. EPDM stands for Ethylene-Propylene Diene Monomer.

It is a synthetic kind of rubber and they are mostly used to provide rubber mats (either for flooring and for insulation) more resistance to the heat, the elements, the UV-rays and the steam. Once ready, rubber bales are then pressed in to huge streching press machines so to have the rolls manufactured. EPDM mixed rubber puzzle tiles are made starting from the rubber mat rolls. They are made by using die-cutting molds all, having the Xenios USA® X Floor™ special designed edges.

Pure EPDM and binding compounds are mixed with rubber granulates to become rst bales, then rubber mats.

Besides the EPDM-mixed rubber mat rolls and tiles, XFloor™ range lists also some kind of special heavy-duty thick tiles, developed and made to bear severe workouts. There are the at bottom “weight drop” tiles and the dimpled-bottom “heavy duty shock absorbing” tiles. To make such kind of tiles, either with a at bottom or with a dimpled one, the production process concern the use of special molds and high-torque hydraulic press-machines.

The rubber granulate crumbs involved within this process have a bigger diameter and shape, than the ones involved with the making of the EPDM-mixed rubber mats. The so-made rubber granulate is mixed  with binding  compunds and a percentage of virgin SBR (stirene-butadiene rubber),that  is also the original raw material used to make the new tyres. The so-mixed granulate is then hot pressed in to the molds and  it comes out with the shape of  the tile. When color is required, the granulate is mixed together with a colored  pigment. The thick  tiles, once out from the mold, are further handled to be ready to become an heavy duty

workout oor. First the left- over mold edges lines are cut, then the side faces of the tiles are drilled and pin-equipped in order to be locked each other once put in place.

For some special uses, the thick tiles can also be made by adding in to the mold a top layer of pure EPDM granulate so to have a tile topped with a stronger (than SBR) top layer, really hard to be scratched and worn. Up to customer needs, the above said top layer can be also added in a second phase, after having molded the tile, by glueing cut pieces of the EPDM-mixed rubber  mats (usually 4 to 5 mm. thick). Thickness, shape, sizes of the thick tiles can be made according to customers’ needs. X Floor™ heavy duty tiles come  with 20 and 30 mm. thickness at-bottom tiles and with 50 mm. thickness dimpled-bottom tiles. The dimpled bottom of the X Floor™ heavy duty tiles was drawn just thinking to the weightlifting uses, so it protects bar and plates while dropped and it prevents under-floor damages.

All components used during the production processes, such as binding compounds, EPDM granulate, SBR etc. are sourced just among the best European raw material makers, and they are all tested and certied by the EU regulations.

THE RANGE

XFloor™ range includes several kind of items to cover and to protect the workout areas.

The 5% EPDM-mixed floor mats can come either as a rolls or as die-cut tiles, drawn with the Xenios USA® proprietary interlocking puzzle-edges design. Either rolls and tiles can be made with several thicknesses, from 6 up to 12 mm. Both are made just with a rubber density of 1050 Kg./m3. The right one to let the floor mats have a really long lifespan. A lower density may result in to wide pores rubber surfaces, easy to be affected by the elements and the usage. The standard color of the EPDM chips mixed with the black rubber granulate crumbs is the Xenios USA® navy blue, but they can have any color (even two or three mixed together), according to customers’ demands.

Puzzle tiles are cut out from the rolls. The desing of the puzzle prole was thought to let all tiles be bond each other once put in place and to avoid any sliding/liting of the tiles’ edges while stressed by the usage. Both rolls and tiles can be either set on any kind floor,  for instance wood, concrete, tiles etc.. The higher is the thickness the more stable the rubber mat floor will be. Xenios USA® always recommends to glue  the rubber mats on to the under-oor surface. Among XFloor™ rubber mats, there is also a special kind of mat, made with the same production process of  the EPDM-mixed ones.

It is called Acoustic Mat and it comes just as a roll. This special mat is made by using a special density of the granulate, and,  sometimes, it is also mixed with cork crumbs. This mat is 15 mm. thick (and it can be also made thinner or thicker according to customers’ needs). The main purpose of this mat is the insulation from vibration and noise that can rise up from workout uses. This Acoustic layer can be put under the Accessories for rubber mats: Xenios USA® tested several kind of glues and then selected a special 2-components urethane glue for rubber oor mats, produced by the French Stockmeier. Stockmeir glue is the most suitable for EPDM-mixed rubber mats and, moreover is one of the few products suitable for indoor uses.

The main purpose of this mat is the insulation from vibration and noise that can rise up from workout uses.

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Due to the long term experience with rubber floor producing of the XFloor™ makers, Xenios USA® was even able to introduce some special “tool” to nish rubber mats and to let them really last longer and longer. Thanks to the several tests made on the EPDM-mixed XFloor™, Xenios USA® could add to its range of products, a special compound, made by the German BASF, developed to seal the top surface of rubber mats, so to close all the micro-pores of the mat and to protect the rubber for years. This innovating treatment can even make the rubber mat a fully-washable surface, without reducing the grip provided by the rubber mats. BASF is one of the leading chemical company to produce painitngs, primers and liquid toppers for any kind of surfaces. The one chosen by Xenios USA® is a 2-components urethane compound with a neutral color. Once having mixed the two components it can be applied on to the rubber mat with a painting roll. After 24 hours drying, the surface of the rubber mat will result slightly laqued and it will last 40% to 50% longer than without it. Same as the glue, Xenios USA® technicians looked for a water-based resin in order to be really suitable for indoor uses: odorless and chemical-vapors less.

Besides the above kinds of flooring solutions, X Floor™ range carries also some special high-thickness tiles for heavy duty uses. Thick tiles are all made by using the same rubber granulate involved with the making of the EPDM-mixed rolls and puzzletiles it has just a different diameter and shape and it is not mixed with EPDM chips. Thick tiles are made by mixing the so said granulate with virgin SBR and with binding compounds. According to cusotmer’s special needs, tiles can also be manufactured with a top layer of pure EPDM granulate or EPDM-mixed cut rubber mat, especially when a stronger top-layer of the tiles is needed for high-impact uses. Thick tiles can be also made by mixing the granulate with special kind of color pigment so to have a full colored tile. Navy blue color is the one provided as standard within XFloor™ range but any color can be made according to costumers’ demand. Thick tiles for heavy duty uses can be made either with a solid-at-bottom (“Weight Drop tile”) or with a dimpled-bottom (“Heavy Duty Shock Absorber tile”). These heavy-duty tiles are made by hot-molding the granulate in to big hydraulic press-machines.

X Floor™ weight drop tiles come in 20 mm. or 30 mm. thickness while the special Heavy Duty Shock Absorbing dimpled-bottom tiles come in 50 mm. thickness. Either the 30 mm. thick tiles with at bottom and the 50 mm. thick tiles with dimpled bottom, can come with with pre-drilled holes on each side. They are made to host special pins for interlocking purposes. Pins are made of an high resistance plasitic polimer. Pins are M8 x 70 or M15 x 85, they carry special extruded rings to avoid tiles to move apart. There are 8 pins per each square meter.Interlocking pins are sold as an option.

HEAVY DUTY SHOCK ABSORBING TILES: PROPRIETARY DESIGNED DIMPLED BOTTOM The Weight Drop tiles are also provided with a budget-wise formula. Their features are lower-end than the standard Xenios USA® proprietary one, but they can better match lower budget needs. The heavy duty shock-absorbing tiles feature a rst 40 mm. thick solid layer. This high-thickness top layer is made with a really high density rubber so to provide enuogh stability while exercising on it. Most of shock-absorbing tiles on the market, even with dimpled bottom, are thought to protect kids from falls while playing on outdoor playgrounds.

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Xenios USA® developed a tile for workout purposes: it must provide a stable and rmly top-surface along with a shock absorbing bottom side. The tiles must absorbe over-head loaded bar drops so to either preserve bars and bumper plates from earlier worn and to protect the underlayer original oor of the gym.

These kinds of tiles can be also put on top of a rubber mat (roll or puzzle tiles) to have an even more high resistance to the drops of the loaded bars.

The special design of the dimpled bottom is thought to spread the fall-power all along the edges of the dig areas. The principle involved within this process is the same used by architeths when projecting bridges. Dig areas absorbe the hits of the bumper plates, preserving them from earlier worn (bending and/or breackages). Either Weight Drop tiles and Heavy Duty Shock Absorbing tiles come in two several sizes: 50×50 and 100×100 cm.

One of the special feature of all Xenios USA® thick tiles is the seamless edge. All tiles are molded with 90° slightly rounded edges to provide an almost totally seamless ooring when put in place. Among the range of thick tiles ooring there are also several options and special features that can be chosen by customers. Tiles can be manufactured with a color-epdm-granules mixed surface (20%); or, even coupled in to the mold, with a top layer made with the 20% epdm-mixed rubber roll (6 mm.).

In order to match all workout ooring needs, we have developed and tested also a full range of Acoustic and Insulating Underneath Mats that are helpful to reduce the spreading of noise and vibrations on closer areas and floors, such as below oors when gyms are set in to multi-oor buildings, or wall-to-wall areas. We have developed and tested two solutions. The rst one is an SBR-rubber granulate Roll.

It comes in a standard thickness of 15 mm. and but it can be made also according to special customer’s requirements. Such roll can be put directly on to the concrete oor, just before to have the workout surface rubber ooring on top. Thanks to its special density and kind of granulate, it can reduce the noise produced by the weight dropping activities.

Its surface is quite “grippy” and it lets the above rubber ooring layer to be stable and not easy to get moved, even in those cases where glue and/or tape is not used.

Keep going on with the Xenios USA® several underneath flooring solutions, the next item is made of a special and high density (250 Kg./cbm) PU-Foam and it comes either as a roll or as a tile (for higher thicknesses). This kind of special ooring can help to reduce and absorb either noise and vibrations that can be spread by working out and/or weight dropping. Even in this case, any kind of workout rubber ooring can be put on top, and, in case of high thickness (so weight) rubber ooring, neither tape nor glue will be necessary to avoid each-other ooring moves.

Notwithstanding the Xenios USA® underneath oorings are thought and developed to reduce, and help to reduce, noise and vibrations, it is not totally guaranteed that neighbors’ claims will be avoided. Noise and vibrations produced by the weight dropping are really intense and, due to their low-frequency, they can run for dozens of meters along concrete ooring and/or brick walls.

Any time a Weight Lifting facility is going to be opened, it is duly recommended to perform some noise and vibration test and to check which kind of interventions could be necessary to reduce and/or to stop the same. Sometimes an anti-vibes or acoustic underneath flooring can x issues, while in some other cases more structure intervention may be necessary. In order to provide to our customers a really comprehensive range of professional workout floorings, we have thought and developed also a range of speciality flooring. The Articial Turf rolls, for example, were developed to be employed with the heavy duties uses of Functional training areas.

The XeniosUSA® TURF is of course suitable for running and sprint tracks. Thanks to its low-height yards and to the high density (number of yards per cm.) and strength of the same, it is also perfect to be used for sled dragging and pushing.
Since it was made with water resistance materials, it can be installed either indoor and outdoor. When the R&D dept. of Xenios USA® developed such kind of articial Turf, the focus was put especially on loaded-sled- uses. Turf should be able to bear heavy pressures and to stay at while sleds are pushed or pulled.

The TURF Rolls are quite thin (10 mm.) so easy to be managed either when installed on side of a Rubber Roll Mat or on top of any Workout Rubber Thick Tile. The bottom layer of the TURF is made of a special anti-slip pvc-rubber material.
It provides a high grip, even in those cases where the roll is not stuck by using glue and/or tape. The several available colors, make the Xenios USA® TURF even ready to match any outlook requirement. Turf Rolls come either in 2 m. width and in 4 m. width.

Besides the TURF, at Xenios USA® we have also thought to those who need to have a Martial Art Workout area or a “pure” Bodyweight Workout area. We have developed a full range of TATAMI. Our TATAMI range can count on several kind of items. The rest on the list is a Puzzle-Edged Tile made of EVA, suitable especially for those who need to match a low budget or for those who need a softer feeling surface. They are made just by using a virgin EVA so to be a no-smell option. They come either in 2 or 3 or 4 cm. thickness and they are all made with the typical dual-face color feature of the Tatami.
The surface of the EVA Tatami is molded with a special kind of texture in order to either be gently with the skin of the users and to provide enough grip. A special wood-like surface option can be chosen in order to increase the friction with hands or feet. The professional Tatami Puzzle-edged tiles made of XPE (a special kind of closed cells Poly-Ethylene) represent the choice for those who need to get closer to traditional Martial Arts Tatami features.

Thanks to the XPE raw material tiles can be made either with a one-only density or with a dual density (harder on top and bottom sides, and softer in the middle). The dual density option let the Tatami tiles be stronger on their surface (so even more durable), and meanwhile to have a softer core, that can better absorb the falls of athletes.

The XPE Tatami tiles are all texturized with the traditional rice-straw surface that provide the perfect grip for all martial arts such as Judo, Karate, MMA and so on.

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XPE Tiles come also in several color options, all “dual faced”. Available thicknesses arte 2, 3,4 and 5 cm. Either the EVA and the XPE tiles feature a special proprietary design of the puzzle edges. It is cut by CNC and thanks to its shape it is really strong in keep tiles bonded each other. Thanks to such special design of the puzzle, tiles keep also being easy to be put on and off place and that is an important feature for those who need to set up a Tatami area in to a multi purposes room.

All puzzled-edged tiles come with their closing edges. The last and best kind of TATAMI choice is the one we use to call “Legacy”. That is the really genuine one for martial arts and contest rooms. It is made of 200×100 cm. (100×100 cm. size is available on request) tiles with at edges. Tiles are made either of PU-Foam (Polyurethane Foam) or of PU- Foam + PE-Foam (closed cells Polyethylene foam). The former ensure the higher density, while the latter combines such hard density with the lighter one provided by the PE-Foam. The PU+PE Tatami was thought to reduce the tiles’ weight and so to help those who frequently need to move in and out of the workout rooms the Tatami.

All Legacy Tatami tiles are then coated with a high-quality PVC, rice-straw texturized on top, and equipped with a pvc-rubber bottom layer that let the tiles have a high friction on the underneath flooring, even in case it is a wood ooring. Legacy Tatami tiles come just in 4 cm. thickness that is the more common for Martial Arts contests, including Judo, where falls are very frequently. Several color options are of course available. The Legacy Tatami is approved and certied by the C.R.I.T.T. (Regional Center of Innovation and Technology Transfer – France) as Martial arts contests surface. The C.R.I.T.T. certication is mandatory for contest uses.

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