Sustainable court surfaces using emulsion-waste rubber cushions and acrylic-rice husk top coatings

This study explores a sustainable court surface system using styrene acrylic emulsion (SAE) and styrene butadiene rubber (SBR) binders combined with waste rubber powder (WRP) to develop cushioning layers that reduce surface impact. A pure acrylic top coat, reinforced with rice husk (RH), was formulated to improve slip resistance, abrasion durability, and UV stability on the cushions. A comparative analysis evaluated how filler amount, WRP proportion, and binder type and content influence the physical, mechanical, thermal, and morphological properties of the cushions. Increasing SAE or SBR content in cushions by 8.21% enhanced their tensile strength by 30.28% and 32.77%, respectively, due to improved matrix cohesion. However, the microporous structure of WRP introduced voids that reduced tensile strength and elongation, particularly at high loadings or when binder content was low, reflecting a trade-off between mechanical performance and shock attenuation. CaCO₃ filler occupies voids within WRP, enhancing dimensional stability but disrupting polymer chain continuity and flexibility. This reduces free volume and limits chain mobility, both essential for elastic deformation. 15% RH-loaded topcoat reduced adhesion pull-off and elongation by 5.15% and 89.1%, respectively, while increasing tensile strength and abrasion resistance by 46% and 30.5%. These enhancements are attributed to the fibrous nature and filler interaction of RH within the acrylic matrix. The developed multilayer system is suited for indoor and outdoor multipurpose sports courts; such as those used for basketball and tennis where durability, shock absorption, and environmental sustainability are essential.