AcryLayer · 5 coats · spec September 2026

A practical 5-coat acrylic court for everyday outdoor play

The OSMS 5-layer AcryLayer build is the efficient outdoor court when you want a true acrylic system, a little underfoot give, and a short coating programme. Concrete courts take a primer, one resurfacer coat, one cushion coat and two colour coats. Bitumen courts skip primer, use two resurfacer coats, keep a single cushion coat and finish with the same dual colour system. Thickness still depends on how much fill the base actually needs.

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Overview

How the 5-layer system is built

Primer (on concrete), resurfacer, one cushion coat and dual colour - a lean outdoor stack with a light comfort layer.

Coats

1 primer · 1 resurfacer · 1 cushion · 2 colour

Finished thickness

1.8–2.7 mm after drying

Varies with base condition

Specified for

Concrete base

Outdoor acrylic courts

Specification

Coat-by-coat detail

Five coats over a prepared concrete slab: primer, one resurfacer, one cushion and two colour coats. Chosen when the slab is sound and you want adhesion, a uniform plane and a light comfort layer.

Coat 01 of 5PrimerLayer link
Concrete primer
Purpose
Locks the first body coat onto a prepared concrete slab. The primer soaks into open pores, cuts suction and gives later acrylics a keyed surface instead of sitting on dusty laitance.
Material
OSMS concrete primer - a pure acrylic primer specified for sports slabs.
Application
Rolled or squeegeed in one even pass after the concrete has been cleaned, repaired and left dry. Puddles are avoided so the film stays thin and penetrating.
Thickness
About 0.2–0.3 mm after drying
- Improves bond between slab and resurfacer
- Lowers the chance of later coats peeling
- Closes fine pores in the concrete face
- Helps resist moisture rising from the substrate
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Coat 02 of 5ResurfacerLayer link
Acrylic resurfacer
Purpose
Knocks down small hollows, trowel marks and open texture so the court plane is even before cushion or colour is applied.
Material
OSMS acrylic resurfacer - a pure acrylic body coat, usually mixed with fine silica where extra fill and tooth are needed.
Application
Squeegeed in a continuous wet edge. Silica is kept in suspension so low spots fill rather than telegraph through later coats.
Thickness
About 0.4–0.6 mm after drying
- Fills minor pits and hairline surface flaws
- Leaves a flatter, more consistent plane
- Gives cushion and colour a stable bed
- Adds toughness at the base of the system
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Coat 03 of 5CushionLayer link
AcryLayer cushion
Purpose
Adds a modest elastomeric film so the court feels less harsh under regular play, while the colour coats above still control pace and grip.
Material
AcryLayer cushion - an acrylic compound with elastomeric content, specified for outdoor sports courts.
Application
Laid in even coats with the approved tool. Each pass is left to cure before the next so thickness builds without trapping moisture between films.
Thickness
About 0.6–0.8 mm per coat after drying
- Adds spring and flex underfoot
- Takes the edge off impact during play
- Improves comfort on high-hour courts
- Keeps ball feel consistent when thickness is even
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Coat 04 of 5ColourLayer link
Acrylic colour · textured coat
Purpose
Sets the playing texture and first full colour. Silica in this coat gives the court its outdoor bite and hides the cushion or resurfacer below.
Material
OSMS pure acrylic colour with UV-stable pigments and anti-slip additives, mixed to the specified water and sand ratios.
Application
Colour is mixed with the specified silica and potable water, then squeegeed in one even film. The coat is left to dry (and may be lightly abraded) before the next colour pass.
Thickness
About 0.3–0.5 mm per coat (two coats together typically 0.6–1.0 mm)
- Gives the court an even, match-ready colour
- Provides outdoor traction under wet-dry cycles
- Shields the coats below from sun and wear
- Cleans easily as part of routine court care
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Coat 05 of 5ColourLayer link
Acrylic colour · finish coat
Purpose
A water-cut colour pass that locks in hue, UV protection and a cleaner finish over the sanded coat.
Material
OSMS pure acrylic colour with UV-stable pigments and anti-slip additives, mixed to the specified water and sand ratios.
Application
Colour is mixed with potable water only and squeegeed over the previous colour coat once that film is ready.
Thickness
About 0.3–0.5 mm per coat (two coats together typically 0.6–1.0 mm)
- Gives the court an even, match-ready colour
- Provides outdoor traction under wet-dry cycles
- Shields the coats below from sun and wear
- Cleans easily as part of routine court care
View product used in this coat

Key benefits

Why specify the 5-layer system?

Each coat has a job - keying the base, flattening the plane, adding comfort, or wearing as colour and grip.

Light comfort, not a rigid paint film

One cushion coat takes the sting out of hard slabs without moving into a deep academy stack.

Even playing plane

Resurfacer fills the small scars that would otherwise print through the colour.

Predictable outdoor grip

The sanded colour coat and clean finish coat are specified for stop-start court sports.

Sun and monsoon colour hold

UV-stable pigments protect the wearing face through Indian outdoor cycles.

Shorter coating window

Five coats keep weather risk and programme length tighter than the 8- and 9-layer builds.

Straightforward upkeep

The finished acrylic cleans simply and can take a later colour recode without rebuilding the court.

Our products

Acrylic products used in this system

From crack filler and primer through cushion and colour - each product has a defined role in the stack.

Crack filler

A flexible acrylic paste used to close cracks and small voids so later coats sit on a sound, even plane instead of bridging open gaps.

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Base refiner

A heavier acrylic levelling coat for hollows and coarse texture in the base, used where a standard resurfacer pass would not be enough.

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Concrete primer

A penetrating acrylic primer that keys porous concrete, reduces suction and helps the first body coat stay bonded through outdoor weather cycles.

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Acrylic resurfacer

A sand-extended acrylic body coat that fills minor pits and drag marks, leaving a uniform platform for cushion and colour.

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AcryLayer cushion

An elastomeric acrylic coat that adds spring underfoot. Extra passes deepen the comfort profile without changing the colour system on top.

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Acrylic colour

UV-stable pigmented topcoats that set court colour, surface texture and outdoor grip. The first pass is usually sanded; later passes are cleaner finish coats.

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Line marking

High-opacity acrylic line paint for crisp, durable court markings that stay readable under match lighting and monsoon dust.

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Silica sand

Graded silica blended into resurfacer and the first colour coat to control texture, ball bite and player traction.

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Suitable sports

One system. Multiple court applications.

Chosen from sport, court layout, base condition and how hard the pad will be used.

FAQs

Frequently asked questions.

Other layering systems

6 layers

6 Layer System

7 layers

7 Layer System

8 layers

8 Layer System

9 layers

9 Layer System

Specify the 5 Layer System for your court.

Share drawings, base type and sport. You will get a documented AcryLayer build-up and a material take-off - not a generic brochure.

See delivered work

A practical 5-coat acrylic court for everyday outdoor play

How the 5-layer system is built

Coat-by-coat detail

Concrete primer

Acrylic resurfacer

AcryLayer cushion

Acrylic colour · textured coat

Acrylic colour · finish coat