Woodgreen Leisure Centre: Gym Flooring System Overhaul

The Challenge: A Floor Failure Under Pressure

The ground-floor gym at Woodgreen Leisure Centre in Banbury faced a critical and urgent issue: the flooring in its free weight section was failing structurally, creating significant safety risks.

Installed just eight years prior, the 10mm rubber matting and its associated timber subfloor were well short of their expected 10-15 year service life. Key problems included:

• Premature System Breakdown: The 10mm matting in the free weight area, along with the subfloor beneath, had completely failed.
• Safety Hazard: This failure presented as cut, chipped, and compressed rubber, alongside “soft spots” in the subfloor beneath the weight rack, resulting in an uneven surface and a serious trip hazard for members.
• Aesthetic Wear: The carpeted section of the main gym also showed considerable wear, discoloration, and water staining.

This collapse required a full engineering solution—not just a simple replacement—to manage the intense load and high impact characteristic of a busy free weight environment, ensuring long-term durability and member safety.

The Solution: Designing for Durability

PPM initiated a detailed design and specification process. The core mission was to resolve the failure with a robust, high-performance solution.

The project objectives were set as follows:

1. Structural Reconstruction: Design and construct a new, durable raised timber subflooring system capable of withstanding heavy impact.
2. Maximised Impact Mitigation: Upgrade the free weight floor covering to a specialized 40mm thick rubber matting. This significant increase in thickness (four times the original) ensures adequate impact absorption and protection for the new subfloor.
3. Aesthetic and Functional Upgrade: Replace the worn carpet in the main gym area with a specified, non-slip alternative, such as a high-grade Polyfloor option.
4. Critical Performance Standards: Ensure the final floor system meets all requirements for a professional gym, including superior subflooring protection, effective soundproofing, and high slip resistance.

Key Deliverables for Practical Completion

The complete service package, with a target Practical Completion Date of May 2025, included:

• Full floor preparation, including the application of self-levelling latex.
• Demolition and certified disposal of the existing floor tiles and subfloor.
• Supply and installation of the new 40mm rubber matting and the main gym area flooring.
• Provision of all necessary handover documentation: 

This complete system overhaul provides Woodgreen Leisure Centre with a safe, compliant, and durable gym environment built to last.

Cherwell

Cherwell District Council

• Project Management
• Employers Agent
• Contract Administration

The finished project: