Custom HYROX turf is planned around the actual training or event floor rather than supplied as a generic roll of gym grass. A suitable specification uses 12–15 mm KDK crimped yarn, an unfilled surface and custom roll widths from 1 m to 4 m. LFL Grass supports the layout, seam plan, embedded white lines, 12.5 m shuttle markings, colour and LOGO design before production, with EXW, FOB, CIF or DDP delivery for gyms and international event projects.
Why a HYROX floor needs more than standard gym turf
HYROX training combines sled push and sled pull, shuttle running, burpee broad jumps and loaded carries in the same facility. Each zone places a different demand on the surface. The sled needs controlled friction and enough stability to slide without digging into the pile; the running and functional areas need predictable grip and a surface that recovers after repeated loading.
A short decorative turf may look correct in photographs but flatten quickly when used for sled work. A deep landscape turf can make the sled feel sluggish and may trap debris. The practical solution is a dedicated short-pile sports build, planned lane by lane, with markings integrated into the surface and transitions aligned to the surrounding rubber flooring.
KDK crimped yarn and unfilled construction
Our HYROX build uses KDK crimped yarn technology. The dense curled fibre structure is designed to provide stable friction, high resilience and resistance to flattening under the concentrated load of a sled lane. The short 12–15 mm pile keeps the sled moving evenly while maintaining enough texture for pushing and pulling.
The recommended construction is unfilled. This keeps the surface fast and clean, avoids loose rubber or sand moving around the gym, and makes routine cleaning simpler. A matte black base provides a neutral event appearance and gives embedded white markings a strong visual contrast.
Custom widths from 1 m to 4 m
Roll width affects both the appearance and the long-term durability of a sled area. LFL Grass manufactures full-width rolls from 1 m to 4 m, allowing the turf to follow the measured training zone rather than forcing every lane into one standard width.
For finished areas wider than 4 m, we plan a multi-piece layout before production. Typical arrangements include:
- 2 m + 4 m
- 2 m + 2 m + 2 m
- 3 m + 3 m
The best combination depends on the room dimensions, sled direction, roll direction, installation method and the positions where the installer can safely form and secure a seam. Every extra seam creates another place that needs accurate joining, so the objective is not simply to choose a wide roll — it is to choose the layout that reduces risk and waste.
Markings, shuttle distances and logo design
A HYROX-style floor becomes easier to use when the markings are part of the turf rather than tape added after installation. We support embedded white lines, lane divisions, start and finish positions, a 12.5 m shuttle scale and project-specific text or LOGO artwork.
The design team can review the finished-size drawing and prepare a layout showing roll direction, seam positions, lane numbering and the placement of shuttle marks. Artwork should be supplied in vector format where possible, and all measurements should be confirmed before production. This pre-production review reduces the risk of inaccurate cuts, misplaced lines or graphics that do not line up with the room.
Technical support from drawing to installation
Supplying a gym floor is not only a yarn and shipment question. LFL Grass supports the technical process from initial specification through delivery:
- Floor-plan review — check the room dimensions, lane count, columns and transitions to rubber areas.
- Roll-width planning — select the most efficient combination of 1–4 m rolls.
- Seam plan — set seam positions and roll direction before cutting.
- Marking and artwork review — confirm white lines, shuttle marks, numbering and LOGO placement.
- Factory cutting — cut pieces to the approved plan and label them for installation.
- Packing and shipping — prepare the loading plan under EXW, FOB, CIF or DDP terms.
- Installation guidance — provide remote support and discuss on-site assistance for suitable projects.
Permanent gym floors and event installations
A permanent training facility and a temporary event floor should not share the same installation brief automatically. A permanent gym can use a securely fixed modular turf floor with adhesive and edge details designed for daily training. An event project may need faster installation, removable zones, easier access for rigging and a layout that can be packed and reused.
The turf specification can remain consistent, but the fixing method, edge termination, storage plan and number of separately labelled pieces must be agreed around the venue. Sharing those requirements at quotation stage prevents the installer from improvising onsite.
Colour, branding and repeat orders
Gyms and event operators can specify turf colour, length, width, edge details, marking layout and LOGO design. The matte black base can be paired with green or accent-colour lanes to match a facility or event identity.
For multi-site operators, we retain the approved yarn, colour and production specification so future orders can be made against the same reference. This helps a second or third facility look like part of the same brand rather than a slightly different shade or pile.
Production control and export packing
Each order is checked against the approved cutting list and lane layout before packing. Roll pieces can be labelled by zone and sequence, making it easier for the installation team to identify the sled lanes, connecting areas and marked sections. Export packing is planned according to the delivery method and destination.
We quote EXW, FOB, CIF or DDP. Fast production and shipment can be arranged subject to the final quantity, custom colour, marking complexity and artwork approval. The requested installation date should be shared at the beginning of the project so production and freight are planned against the real onsite date.
Information needed for a technical quotation
To prepare a useful HYROX turf quotation, send:
- Measured floor plan and finished width of each training zone.
- Number of sled lanes and whether push and pull share a lane.
- Required lane length and location of columns or fixed equipment.
- Marking plan, shuttle scale, lane numbers and LOGO artwork.
- Permanent adhesive installation or event/removable requirement.
- Delivery country, preferred Incoterm and required onsite date.
With these details, the HYROX flooring landing page can be matched to a specific material and cutting plan rather than a generic price per square metre.
Frequently asked questions
What turf is used for a HYROX training floor?
A HYROX training floor usually uses 12–15 mm KDK crimped artificial turf for the sled and shuttle zones, combined with rubber or other stable flooring around the remaining stations.
Why is KDK crimped yarn preferred over standard gym turf?
KDK crimped yarn provides a resilient curled structure that helps resist flattening under repeated sled loads while maintaining stable friction for pushing and pulling.
Can LFL manufacture turf wider than 4 metres?
LFL manufactures full-width rolls from 1 m to 4 m. Wider finished areas are supplied as a planned multi-piece layout such as 2 m + 4 m, 2 m + 2 m + 2 m or 3 m + 3 m.
Can you include 12.5 m shuttle markings and a custom logo?
Yes. LFL supports embedded white lines, a 12.5 m shuttle scale, lane numbering and custom LOGO design. Approved drawings and vector artwork are required before production.
Do you provide installation support?
LFL provides layout drawings, seam plans, labelled roll pieces and remote installation guidance. On-site support can be discussed for suitable project sizes and locations.
Which trade terms are available?
LFL can quote EXW, FOB, CIF and DDP, with export packing prepared for the agreed delivery method.
Build your HYROX floor from an approved drawing
Start with the HYROX artificial turf technical guide, compare our 15 mm gym turf and KDK crimped gym turf, or read how the fibre is engineered on our artificial grass yarn technology page. Send your floor plan through the contact form for a design review and quotation.
