How natural rubber / vulcanised stall mats are made, and why it matters

Most mats marketed as natural rubber are vulcanised (heat + curatives). Compounds typically include fillers, processing oils/plasticisers, waxes, and mould release agents. With use and exposure, ozone and oxygen attack natural rubber’s double bonds, which drive surface cracking, embrittlement, and changes in hardness over time.

Common real-world challenges with natural rubber / vulcanised mats

1) Hard to glue down reliably

Because of surface films from bloomed waxes/oils/plasticisers and mould-release residues, many natural rubber/vulcanised mats are chemically unfriendly to adhesives, particularly on damp slabs. 

2) Curling, gapping and debris creep

With temperature swings and age, natural rubber/vulcanised mats tend to curl at corners and open gaps, letting waste, sand, and bedding work underneath. That leads to rocking mats, telegraphed seams, trip points, bad odours and longer cleaning times.

3) “Dimples for grip” wear flat, and gets slippery when wet

The bobbled/dimpled textures on many natural rubber/vulcanised mats can be slippery with urine and wash water. As the dimples wear down, the surface may become very slick, especially in wet areas. Relying on coarse texture alone is risky in wet conditions.

4) Hardening and cracking with age

Ozone/oxygen ageing of natural-rubber-rich vulcanised compounds commonly leads to hardening and surface cracking under strain, harsher under hoof, and more places for urine/bacteria to lodge. Natural rubber / vulcanised mats tend to be a lot harder than premium alternatives like REGUPOL and, over time, become even more unforgiving. 

5) “Just screw them down” creates new hazards

When natural rubber/vulcanised mats won’t bond, some people resort to mechanical fixings. But any protruding metal in horse traffic lines contradicts good, stable safety practice and opens up maintenance headaches. Surfaces should be flush to prevent trips and entrapment.

Why REGUPOL Is Built for Horses and What That Means in Your Stable

How REGUPOL is made: 

REGUPOL equine flooring is manufactured from high-density rubber granulate bound with engineered polyurethane resins under controlled pressure and temperature. Each format (tiles, interlocking pavers, rolls) is moulded to tight tolerances and cured for dimensional stability and a consistent surface texture. The result is a permanently elastic, dense material designed for hoof impact, moisture, detergents and daily cleaning.

Why REGUPOL is built for horse areas

• Formulated to absorb impact and reduce vibration/noise from hooves.

• Dense, fine-grain surface delivers reliable wet and dry traction without relying on dimples or grooves.

• Dimensional stability resists edge lift and mat creep in high-traffic zones.

• Available in formats matched to each zone: tiles/pavers/rolls for stalls and aisles, sheets/rolls for walkers and ramps.
  
  

Benefits you’ll notice 

• Permanently elastic: stays resilient under hoof load; doesn’t harden as it ages.

• No curling or cracking: engineered density and curing keep edges flat and surfaces intact.

• Flat, easy-clean surface: Tight seams and joints help prevent urine, sand, and chaff from getting underneath, resulting in faster hose-downs and fewer odours.

• High slip resistance, wet & dry: secure footing for horses and handlers in high moisture areas.

• Sound-dampening: Soft yet durable construction reduces hoof noise, supporting calmer barns.

• Long service life: with correct installation and care, REGUPOL systems routinely deliver 10–20+ years in commercial equine environments.

• Australian fit-for-purpose: proven in local climates with technical support and installer guidance.

• Glue-down or loose-lay:

  • Glue-down with a specified REGUPOL moisture barrier + polyurethane adhesive for a single, sealed, hygienic surface, ideal for stalls, aisles and wash bays.

  • Loose-lay options over compacted bases where you need speed or have no concrete/asphalt, no screws or plates in traffic lines.

Ready to upgrade your flooring? View the best REGUPOL solutions for stalls, aisles, wash bays and more 

Get a fast quote online → regupol-equine.com.au
or contact us directly for a quote using our contact form.