What's the difference between a prefabricated track and one built on site? Which type offers the best performance? Which has set the most world records? Which is the most reliable over time?
Here's a concise guide to discover the specific characteristics of the different systems in terms of installation, technical quality, and safety for users and the environment.
The first clear distinction is obviously between prefabricated and poured-in-place tracks.
The main construction techniques are divided into:
INSTALLATION
Poured in place systems
In poured-in-place athletics tracks, the installation process is predominantly manual: the performance and physical properties of the track therefore depend on the expertise of the installation teams and the atmospheric conditions during installation, such as humidity, temperature, and curing time.
Prefabricated systems
Installation of a prefabricated athletics track is quick and unaffected by weather conditions. Uniformity, physical properties, and performance, as well as compliance with specifications, are tested and monitored at the manufacturing plant and are therefore consistent across all tracks.
JOINTS
Poured in place systems
Poured-in-place athletics tracks feature vertical joints between adjacent pours and horizontal joints between layers. In sandwich systems, horizontal adhesion can be reduced over time and is maintained by the weight of the top layers.
Prefabricated Systems
A Mondo athletics track is composed of two layers vulcanized together, so it has no horizontal joints. The vertical joints between the rolls are pre-stressed and sealed.
TRACK UNIFORMITY
Poured in place systems
In-situ athletics tracks are not subject to variations during the installation of straights or curves. Unevenness in the subfloor is compensated for during installation. Surface uniformity depends on the skills of the installation teams and the weather conditions at the time of installation.
Prefabricated Systems
A Mondo prefabricated athletics track is built under controlled conditions to ensure consistent characteristics and performance. At curves, thickness variations are limited to ±100 μm. This has no impact on athletic performance.
SURFACE RETOPPING
Poured in place systems
Tracks are renewed with 3 to 4 mm polyurethane layers depending on the surface conditions or the performance requirements.
Prefabricated systems
An athletics track can be resurfaced by covering it with a new 8/10/12 mm layer of Sportflex Super X or with a new polyurethane layer.
WORLD RECORDS
Poured in place systems
Each in-situ athletics track can have different performance characteristics. Even if it is World Athletics certified, this does not guarantee quality. Compliance with requirements is based on testing samples provided by the manufacturer and not on actual installations.
Prefabricated systems
70% of ratified world records have been set on athletics tracks (made by Mondo).
One factor that absolutely must not be underestimated when choosing a track is the health of users and the environment.
Compared to a prefabricated athletics track made of solid vulcanized rubber, cast-in-place systems use granules that can lead to the release of microplastics over time.
In recent years, with growing public interest in the topic, the European Commission has established increasingly clear regulations on the matter.
Commission Regulation (EU) 2023/2055 introduces and enforces restrictions on the intentional use of synthetic microplastics in products, including sports applications. Starting in October 2026, suppliers of products containing synthetic polymer microparticles are also required to provide instructions for use and disposal.
This change could lead athletics track manufacturers to shift toward other materials or new techniques.
In the meantime, the prefabricated vulcanized rubber track remains the safest solution for health and the environment.