Case Study: Wyndham City Council & Western United FC Choose Fuji Mats Australia to Rebuild Their Gym Floor the Right Way

Client:

Wyndham City Council & Western United Football Club (A-League Men’s, Women's  & Youth Academy)

Project Summary:

When a brand-new, high-performance gym space started failing just months after installation, Wyndham City Council and Western United FC turned to Fuji Mats Australia for help. After a full inspection and assessment, our team removed the unsafe flooring and replaced it with a purpose-built solution designed for elite athletes—raising the facility to a world-class standard.

The Challenge:

Just six months after the opening of a state-of-the-art training facility for Western United Football Club, players, coaching staff, and youth development teams began to experience issues with the gym flooring. Complaints ranged from lack of stability to soft, uneven areas that made lifting and movement hazardous.

Wyndham City Council’s Senior Projects Officer, Steve Spencer, contacted Fuji Mats Australia for advice. He asked if we could drop by for an assessment. When we arrived and the frosted glass doors slid open, we were impressed to see a modern, well-equipped gym. But beneath the surface, the problem was clear.

What Went Wrong?

The flooring system consisted of:

• 50mm Regupo FX50l Shock Pad - Base Layer

• 8mm Regupol Rolled Rubber Top Layer

• 1m x 15m sled turf track

While the top layer looked great and was holding up nicely, the base layer was fundamentally flawed for this high-performance environment. The shock pad, intended for playgrounds, was manufactured using a dual-layer system consisting of a crumb rubber base—fine rubber on top and long-strand fibre rubber underneath. This long-strand material fails to evenly fill gaps, creating air pockets and inconsistencies across in the final product resulting in soft spots and instability across the floor.

For elite men and women footballers and strength & conditioning coaches, this meant:

• Unstable footing during lifts

• Increased risk of injury

• Lack of confidence and full effort actions during explosive movement

• No reliable support for high-intensity training

The Solution:

The solution was clear—the entire gym flooring needed to be replaced. But it wouldn’t be easy. The existing dual-layer system had been fully glued down, requiring heavy manual labour, machinery, and precision.

Step 1: Full Floor Removal

• 3 days of hard labour to remove glued-down shock pads and rolled rubber.

• Industrial scraping to remove risidual glue and prepare the concrete base.

• Surface was brought back to a clean, level state.

Step 2: Installation of Elite-Grade Flooring

• Installed Fuji Legend 60mm Extreme Impact Gym Tiles

  • Designed specifically for high-performance strength training

  • Superior shock absorption, density, and stability

  • Fully branded with 2 custom Western United FC logos

  • Sealed with an aliphatic Polyurethane topcoat for hygiene and easy cleaning

• Installed Fuji Custom Performance Turf

  • Built-in club logo, line markers, agility circles, and a speed ladder

  • Fully bonded for sled use and sprint training

  • Designed for both functionality and visual impact

The Result:

Today, the gym at Western United FC stands not just restored—but upgraded to elite pro standards.

Key Benefits Delivered:

• Safe, stable flooring for lifts, sprints, and explosive movements

• Professional branding integrated into the floor system

• Improved hygiene and maintenance with PU topcoat protection

• Increased confidence and usability for coaches, youth teams, and pro players alike

This project is now being used as a benchmark for future gym builds across council facilities and elite sports centres across the country and internationally.

Testimonial:

“Fuji Mats Australia understood exactly what we needed and executed the project with precision. The new flooring not only meets but exceeds our expectations.”

– Steve Spencer, Senior Projects Officer, Wyndham City Council

Conclusion:

Fuji Mats Australia was proud to partner with Wyndham City Council and Western United FC to turn a flawed installation into a high-performance training environment. Whether you're outfitting a local council facility or a professional sports club, getting the flooring right is non-negotiable—and Fuji Mats is the trusted name to get it done.