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AcryLayer · 9 coats · spec September 2026

The fullest AcryLayer cushion stack - nine coats

The 9-layer system is the maximum outdoor acrylic comfort profile we document. Concrete is primer, two resurfacer coats, four cushion coats and two colour coats. Bitumen is two resurfacer coats, four cushion coats and three colour coats - the extra colour pass is how that base reaches nine coats while keeping a four-coat cushion core. It is the specification for elite training centres and hospitality courts that want the softest outdoor acrylic feel without giving up traction or colour stability.

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9 Layer System outdoor court

Overview

How the 9-layer system is built

Four cushion coats on both bases; bitumen also takes a third colour coat. Specified where comfort is non-negotiable.

Coats

9

1 primer · 2 resurfacer · 4 cushion · 2 colour

Finished thickness

3.6–5.1 mm after drying

Varies with base condition

Specified for

Concrete base

Outdoor acrylic courts

  1. 01 / 09

    Concrete primer

    Primer

    About 0.2–0.3 mm after drying

  2. 02 / 09

    Acrylic resurfacer · coat 1

    Resurfacer

    About 0.2–0.3 mm per coat (both coats together typically 0.4–0.6 mm)

  3. 03 / 09

    Acrylic resurfacer · coat 2

    Resurfacer

    About 0.2–0.3 mm per coat (both coats together typically 0.4–0.6 mm)

  4. 04 / 09

    AcryLayer cushion · coat 1 of 4

    Cushion

    About 0.6–0.8 mm per coat after drying

  5. 05 / 09

    AcryLayer cushion · coat 2 of 4

    Cushion

    About 0.6–0.8 mm per coat after drying

  6. 06 / 09

    AcryLayer cushion · coat 3 of 4

    Cushion

    About 0.6–0.8 mm per coat after drying

  7. 07 / 09

    AcryLayer cushion · coat 4 of 4

    Cushion

    About 0.6–0.8 mm per coat after drying

  8. 08 / 09

    Acrylic colour · textured coat

    Colour

    About 0.3–0.5 mm per coat (two coats together typically 0.6–1.0 mm)

  9. 09 / 09

    Acrylic colour · finish coat

    Colour

    About 0.3–0.5 mm per coat (two coats together typically 0.6–1.0 mm)

Specification

Coat-by-coat detail

Nine coats on a sound, prepared concrete slab: primer, two resurfacer coats, four cushion coats and two colour coats.

  1. Coat 01 of 9PrimerLayer 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
    View product used in this coat
  2. Coat 02 of 9ResurfacerLayer link

    Acrylic resurfacer · coat 1

    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 0.2–0.3 mm per coat (both coats together typically 0.4–0.6 mm)
    • 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
    View product used in this coat
  3. Coat 03 of 9ResurfacerLayer link

    Acrylic resurfacer · coat 2

    Purpose
    A second resurfacer pass tightens remaining drag lines and leaves a more uniform bed for the coats above.
    Material
    OSMS acrylic resurfacer - a pure acrylic body coat, usually mixed with fine silica where extra fill and tooth are needed.
    Application
    Applied only after the previous resurfacer coat has dried. The second pass is pulled at right angles where the base still shows texture.
    Thickness
    About 0.2–0.3 mm per coat (both coats together typically 0.4–0.6 mm)
    • 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
    View product used in this coat
  4. Coat 04 of 9CushionLayer link

    AcryLayer cushion · coat 1 of 4

    Purpose
    Builds the comfort core of the system. Each extra cushion pass increases resilience so longer sessions put less peak load into joints.
    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
    View product used in this coat
  5. Coat 05 of 9CushionLayer link

    AcryLayer cushion · coat 2 of 4

    Purpose
    Builds the comfort core of the system. Each extra cushion pass increases resilience so longer sessions put less peak load into joints.
    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
    View product used in this coat
  6. Coat 06 of 9CushionLayer link

    AcryLayer cushion · coat 3 of 4

    Purpose
    Builds the comfort core of the system. Each extra cushion pass increases resilience so longer sessions put less peak load into joints.
    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
    View product used in this coat
  7. Coat 07 of 9CushionLayer link

    AcryLayer cushion · coat 4 of 4

    Purpose
    Builds the comfort core of the system. Each extra cushion pass increases resilience so longer sessions put less peak load into joints.
    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
    View product used in this coat
  8. Coat 08 of 9ColourLayer 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
    View product used in this coat
  9. Coat 09 of 9ColourLayer 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 9-layer system?

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

Maximum cushion in the AcryLayer range

Four cushion coats are the deepest elastomeric core we specify for outdoor acrylic.

Aimed at elite and hospitality use

Built for high-volume academies and guest courts where comfort is part of the brief.

Joint-friendlier stop-start play

Higher impact absorption across tennis, pickleball and shared court programmes.

A refined wearing face

Concrete keeps dual colour; bitumen adds a third colour coat for a more even, closed finish.

Longer outdoor service

The full stack is designed so colour takes the weather load and the cushion stays protected.

Clear for tenders

Each coat is numbered with a thickness band so BOQs and handover packs stay unambiguous.

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.

Product link

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.

Product link

Concrete primer

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

Product link

Acrylic resurfacer

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

Product link

AcryLayer cushion

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

Product link

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.

Product link

Line marking

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

Product link

Silica sand

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

Product link

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

5 layers

5 Layer System

6 layers

6 Layer System

7 layers

7 Layer System

8 layers

8 Layer System

Specify the 9 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
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