Crash Mat Foam Replacement: Re-Foaming Gymnastics & Landing Mats
Crash mat foam is the shock absorbing core inside a gymnastics, tumbling or landing mat, usually a combination of firm and softer polyurethane or closed cell polyethylene layers inside a wipe clean cover. When a mat goes flat, splits or bottoms out, the cover can often be refilled with new foam cut to its exact size. GB Foam Direct cuts chip foam, Plastazote closed cell foam and high density polyurethane to size for re-foaming crash mats and gym mats.
Key takeaways
- Crash mats are made from polyurethane foam, polyethylene foam or layers of both, inside a durable, water resistant cover.
- GB CHIP reconstituted foam has a nominal block density of 86 to 105 kg/m3 and comes in sheets from 12mm to 100mm thick for firm gym mats.
- Plastazote LD33 closed cell foam has a nominal density of 33 kg/m3 and water absorption under 1%, in 200cm x 100cm sheets from 5mm to 50mm.
- Thicker crash pads often use two or three layers, with closed cell foam on the top and bottom to stop the faller bottoming out.
- Gymnastic mats for schools, training and competition are covered by BS EN 12503-1:2013, so clubs should check with the mat maker or their insurer before re-foaming a certified mat.
- GB Foam Direct has cut foam in High Wycombe since 1976, with a 5 year guarantee against faults in manufacture.
What Is Crash Mat Foam?
Crash mat foam is the cushioning core of a mat built to absorb the impact of a fall or landing.
Our foam for sports and leisure guide explains that crash mats can use polyurethane and polyethylene foams, often combined in layers and enclosed in a durable, water resistant cover. Thin, firm mats protect against hard floors during floor work, while thick, softer landing mats slow a faller over a greater depth. Wikipedia’s summary of gymnastics mats gives landing mats a range of 1.5 to 28 inches (about 4 to 71cm) thick, from relatively firm to very soft.
Why Do Crash Mats Need Re-Foaming?
Crash mats need re-foaming when the foam loses its height or springs back slowly, because a flattened core lets the user feel the floor.
Repeated landings in the same spot crush the cells of softer foams, and older polyurethane can crumble or split inside the cover. Covers usually outlast the foam, so replacing the core is often cheaper than buying a new mat. It also lets you choose a firmer or softer feel than the original.
Which Foams Are Used for Crash Mats?
The three foams used most for crash mats and gym mats are reconstituted chip foam, closed cell polyethylene and high density polyurethane.
| Foam | Key Figure | Feel | Best For |
|---|---|---|---|
| GB CHIP reconstituted foam | 86 to 105 kg/m3 nominal block density | Very firm, heavy duty | Thin gym and exercise mats, mat bases |
| Plastazote LD33 closed cell | 33 kg/m3, under 1% water absorption | Firm, light, does not soak up water | Top and bottom layers, portable mats |
| High density polyurethane | 31.4 to 43 kg/m3 (GB upholstery grades) | Soft to hard, open cell | Cushioning core of thicker landing mats |
| Pit foam cubes and logs | Loose fill | Very soft, deep | Foam pits, not mats |
Chip foam is made by bonding shredded polyurethane offcuts into a dense block, and we list gym mats among its uses. Our guide to reconstituted foam explains how it is made. Plastazote is a cross linked closed cell foam, so it resists compression and does not absorb water, as our Plastazote page shows.
Which Crash Mat Foam Should You Choose?
Choose by the mat type, its thickness and who uses it.
| Mat Type | Recommended Foam | Why |
|---|---|---|
| Thin exercise or gym mat, 25 to 50mm | GB CHIP | Dense and hard wearing for floor work |
| Portable or outdoor mat | Plastazote LD33 | Light and does not soak up water |
| Home tumbling or landing mat | Plastazote top and base with a polyurethane core | Firm skin over a cushioning core |
| Mat base layer | GB CHIP | Stops a softer core bottoming out on hard floors |
| Certified club or school mat | Ask the mat maker first | Re-foaming may affect its BS EN 12503-1 rating |
| Bouldering pad | Closed cell and high density layers | See our bouldering mat guide |
These are starting points, not tested specifications. Our bouldering mat foam guide covers crash pads for climbing, where most pads use two layers and higher fall pads use three.
Pit Foam for Gym Pits and Trampoline Parks
Pit foam is loose foam filling for a sunken or framed pit, and it takes deep landings from height that a mat cannot. We supply pit foam cubes and logs for gymnastics clubs, trampoline parks, BMX and skate pits and parkour centres.
Our gym pit foam comes in grades from best value to premium, and we can match most RAL and Pantone colours. Our gym pit calculator works out how much filling a pit needs from its dimensions, and we have worked with gymnastics clubs on bespoke pit designs. For large or bulk orders, contact us directly, as we may be able to offer a discount.
A foam pit and crash mats do different jobs: the pit takes deep landings, while solid mats cover floor work and fixed landing areas. If you need both, we can quote for pit filling and replacement mat foam together.
Do Re-Foamed Gym Mats Have to Meet a Safety Standard?
Gymnastic mats sold for schools, training and competition are covered by BS EN 12503-1:2013, which sets safety requirements for 8 types of gymnastic mat.
According to BSI, the standard covers shock absorption, the slip resistance of the mat base and the friction of the top surface, plus marking instructions. A mat refilled with new foam has not been tested to that standard as a finished mat, so we cannot certify it. Clubs, schools and leisure centres should check with the original manufacturer, their governing body or their insurer before re-foaming mats used for coached gymnastics. For home use, choose foams that match the original layers and thickness.
How to Re-Foam a Crash Mat
Re-foaming a crash mat takes about an hour once the foam arrives: measure the cover, note the old layers, choose the foams and fit them in order.
Empty the cover. Open the zip or hook and loop panel and take out the old foam in one piece if you can.
Note the layers. Record the thickness and feel of each layer from top to bottom, such as a firm skin, a softer core and a dense base.
Measure the cover. Measure the internal length, width and depth of the cover with the fabric pulled flat, and note any folding hinges.
Choose the foams. Match each layer to a GB foam, for example GB CHIP for a dense base and Plastazote LD33 for a closed cell top.
Order the pieces cut to size. Order each layer cut to the cover size, with separate panels for folding mats so they hinge at the seams.
Fit and check. Slide the layers into the cover in order, close it and test the mat on a hard floor before use.
For mats that fold, cut one block per panel so the cover can still bend at each seam. Our guide to cutting foam helps if you are trimming pieces yourself.
Mistakes to Avoid When Re-Foaming Crash Mats
- Using one soft block. A single soft foam bottoms out under a hard landing, so pair it with a firm base or closed cell layer.
- Using upholstery seat foam alone for thin mats. Seat foam under 50mm is too soft for floor work, where chip foam or closed cell foam lasts longer.
- Ignoring the hinges. A solid block in a folding mat cover stops it folding and strains the seams.
- Assuming the mat is still certified. A re-foamed club mat has not been tested to BS EN 12503-1 as a finished product.
- Leaving a wet mat closed. Open cell foam holds water, so dry a damp mat with the cover open or choose closed cell foam for outdoor use.
Why Choose GB Foam Direct?
GB Foam Direct has converted foam in High Wycombe since 1976 and cuts chip foam, Plastazote and polyurethane to size with CNC machines and experienced freehand cutters. We supply everything from one mat for a home gym to repeat orders for clubs, work to ISO 9001 and give a 5 year guarantee against faults in manufacture. Orders before 11am Monday to Thursday are eligible for next working day delivery.
Speak to Our Team
If you need help choosing crash mat foam or the right layers for your mat, call us on 01494 441177, email sales@gbfoam.com or fill out our contact form. We are in the office from 9am to 5pm Monday to Thursday and 9am to 3pm on Friday.
Crash Mat Foam FAQs
What foam is inside a crash mat?
Crash mats use polyurethane foam, polyethylene foam or layers of both inside a durable, water resistant cover. Thin gym mats are often dense chip foam or closed cell foam, while thick landing mats add a softer polyurethane core.
Can you replace the foam in a crash mat?
Yes, you can replace the foam in most crash mats by opening the cover and fitting new layers cut to its internal size. Club and school mats certified to BS EN 12503-1 should be checked with the maker or insurer first, because a re-foamed mat has not been tested as a finished product.
What is the best foam for a gym mat?
Reconstituted chip foam is a strong choice for firm gym and exercise mats because it is dense and hard wearing. GB CHIP has a nominal block density of 86 to 105 kg/m3 and comes in sheets from 12mm to 100mm thick.
Is closed cell foam good for crash mats?
Closed cell foam is good for the top and bottom layers of a crash mat because it resists compression and does not soak up water. Plastazote LD33 has a nominal density of 33 kg/m3 and water absorption under 1%.
How thick should a crash mat be?
Crash mat thickness depends on the activity, from thin mats for floor work to thick landing mats for new skills. Wikipedia gives gymnastics landing mats a range of 1.5 to 28 inches (about 4 to 71cm), so match the depth of your existing cover when re-foaming.
What standard covers gymnastics mats in the UK?
BS EN 12503-1:2013 sets safety requirements for gymnastic mats used in schools, training and competition. It covers shock absorption, slip resistance of the base and friction of the top surface.
Can I use pit foam cubes instead of a crash mat?
Pit foam cubes are made for foam pits, not for filling mat covers, because loose cubes shift and leave gaps. A crash mat needs solid layers cut to the size of the cover. GB Foam Direct supplies pit foam cubes and logs for gym pits, trampoline parks and BMX pits.
Cameron has emerged as a key marketing expert since joining GB Foam Ltd in 2017. A graduate of the University of Winchester, with a professional background in Public Relations; he has combined his content writing and brand awareness expertise with an in-depth knowledge of foam products and foam conversion technology to enhance the company’s marketing strategies and industry presence. Cameron has led numerous marketing campaigns, in both B2B and B2C segments, to further brand recognition and open up new business avenues worldwide.