Abstract: A multi-level unitary safety surface tile. The tile may be of monolithic construction. The tile may include rubber. The tile may include an upper level and a lower level. Hollow protrusions may extend between the levels. At least one protrusion may include resilient walls extending from the upper layer and converging to a protrusion bottom-cap in the lower level. Inter-protrusion ribs may span between and support adjacent protrusions. With the lower layer disposed upon an underlayer, the protrusions may support the upper level. The tile may attenuate impact forces incident upon the upper layer. The tile may constitute a unitary safety surface. The tile may include structures facilitating interlocking of adjoining tiles into a multi-tile unitary safety surface. Protrusion extensions and/or support ribs may support the structures. The tile may be manufactured in a one-piece molding process utilizing mold forms maintained parallel to opposable faces of a mold press.

Abstract: Method for manufacturing a unitary mat on site includes placing loose fill material into a defined area in which the mat is to be formed, mixing rubber particles with at least one binder to form a mixture, placing the mixture over the loose fill material, and allowing the mixture to dry whereby the dried mixture in combination with the loose fill material forms the unitary mat. In one embodiment, the loose fill material includes only rubber particles, without a binder. The mixture placed over these loose rubber particles seals and contains the loose rubber particles. The mixture may incorporate color, e.g., by adding a colorant to the mixture and/or using colored rubber particles. Alternatively or additionally, an additional, colored mixture may be prepared and placed over the dried mixture.

Abstract: Method for manufacturing a unitary mat on site includes placing loose fill material into a defined area in which the mat is to be formed, mixing rubber particles with at least one binder to form a mixture, placing the mixture over the loose fill material, and allowing the mixture to dry whereby the dried mixture in combination with the loose fill material forms the unitary mat. In one embodiment, the loose fill material includes only rubber particles, without a binder. The mixture placed over these loose rubber particles seals and contains the loose rubber particles. The mixture may incorporate color, e.g., by adding a colorant to the mixture and/or using colored rubber particles. Alternatively or additionally, an additional, colored mixture may be prepared and placed over the dried mixture.