COURT CONSTRUCTION AND REBUILD

THE NEW BUILD OR REBUILD PROCESS

If your goal is a flawless, long lasting court that is level, smooth, and free from cracks, pooling, or depressions then this is the only route to true long term performance.

At Plasticourt, we do not patch symptoms, we engineer lasting solutions. Cracks and undulations stem from structural failure beneath the surface; these can only be properly resolved by removing and rebuilding the existing base layers to correct the foundation.

For new courts, this process ensures structural integrity from day one, preventing costly failures later.
By contrast, short-term fixes such as Chip and Spray methods offer a limited lifespan of six weeks to three years before structural defects inevitably reappear. It is not a matter of if, but when.
When you build with Plasticourt, you invest once and build it right.

QUOTATION PHASE & SCOPE OF WORK

Every Plasticourt project starts with a comprehensive site inspection and technical assessment to ensure the
foundation meets professional sporting standards. We do not guess, we measure, test and design to specification!
Site & Engineering Evaluation

Site and engineering evaluation:

• Site survey : Verifies space, layout, and compliance with sport specific dimensions.
• Earthworks assessment : Determines required excavation, retaining, and levelling.
• Soil density testing : Multi-point compaction testing to confirm structural capacity.
• Soil sampling & lab analysis : Determines soil composition (e.g. loam, clay, silt).
• Engineering design : Based on laboratory data, ensuring correct material specifications and compaction profiles.
  (Lab turnaround is typically one week.)
  
  

STANDARD LAYER WORKS (IDEAL CONDITIONS)

*See the court layer works diagram for details and visuals
*Mod AASHTO is an acronym for the Modified Proctor test, a standard laboratory procedure used to determine the
maximum dry density and optimum moisture content of soil

1. Excavation

• Excavate to a controlled depth of +/- 500 mm.
• Rip and re-compact sub grade to restore density and eliminate voids.

2. Base Preparation

• Import and compact G6 aggregate (+/-150 mm) to 93% Mod AASHTO.
• Install pre-cast interlocking garden kerbs to lock perimeter edges.
• Import and compact G5 aggregate (+/-150 mm) to 95% Mod AASHTO, stabilised with 3% cement.
• Conduct independent laboratory compaction verification and provide certified results, for each layer.

3. Asphalt Surfacing

• Apply bitumen tack coat (SS60) to prime the base.
• Import and apply SANS approved Hot Premix Asphalt (TPA Fine) ,30 mm laid, compacted to 25 mm.
• Ensure finished surface stands 50 to 100 mm above natural ground level with a 1% to 3% gradient for efficient
  water run-off

4. Fencing & Structural Components

• Install all fencing posts, sports posts, sleeves, and caps.
• Erect fencing to project specification and sport-specific height regulations.

5. Surface Coating & Line Marking

• Apply four layers of CourtGuard All-Weather Surface, alternating directions for uniformity.
• Apply three layers of CourtGuard All-Weather Paint, alternating directions for consistency.
• Paint regulation sport lines precisely to required standards.

OUR GUARANTEE: CONFIDENCE IN EVERY LAYER

All Plasticourt court builds are backed by a 5 -Year Structural and Surface Guarantee, underwritten by our Terms &
Conditions.

When you choose Plasticourt, you’re not just resurfacing, you are future-proofing your investment with certified
engineering, premium materials, and a brand that is trusted across South Africa’s sports infrastructure sector.

Plasticourt Surface Solutions (Pty) Ltd
Engineered. Tested. Proven.