A few of the most common gym flooring solutions are revulcanized recycled rubber mats and 100% rubber stall mats. 

At first glance, both of these mats seem quite similar.  Both are 100% rubber, both are heavy duty and look “rugged”, and both protect your subfloor.  But, if you dig below the surface, you will find that not all rubber is created equal.

Which rubber flooring option stands up better to the relentless pounding of weights, high-impact workouts, and day-in-day-out foot traffic?

Let's break it down.

What Makes Rubber Mats Revulcanized and Why Does it Matter?

Revulcanization is a process where recycled rubber is heated and chemically treated to reform the molecular bonds. This restores much of the rubber’s original properties which includes elasticity, resilience, and density. Essentially, it takes recycled rubber and makes it stronger, tougher, and more uniform.

In contrast, stall mats, originally designed for horse stalls, are usually made from compressed, non-revulcanized recycled rubber. While still tough, they don’t go through the same molecular rebonding process which is a key difference when talking durability.  As a result, they tend to be more porous, inconsistent in density, and prone to crumbling or curling over time in high-stress environments like gyms.

Not All Rubber Is Created Equal.

Standard durability testing for rubber flooring looks at tensile strength, tear resistance and abrasion resistance.  The results are shocking.

Revulcanized recycled rubber has a tensile strength of approximately 800-1200 psi, while your average stall mat is only 200-500 psi.  That’s a HUGE difference!  Similarly, revulcanized mats have a high tear resistance and an excellent abrasion resistance while stall mats clock in with a moderate tear resistance and a low abrasion resistance. 

What does all of that translate to?

Revulcanized rubber mats can be expected to last 10+ years in a high-traffic gym while stall mats typically can only make it 3-5 years.  Stall mats can be appealing because of the initial price point, but what some do not realize is that they are spending considerably more in the long run, especially factoring in the extra installation costs associated with multiple installs instead of only one. 

Don’t Blame the Stall Mats.

Stall mats were designed for animals standing around in barns, not Olympic barbells slamming from six feet in the air. That’s why they often start breaking down when exposed to the kind of high-impact abuse that’s routine in a gym. Deadlifts, sled pushes, plyo box jumps all put intense stress on flooring, and stall mats just weren’t built for that.

Revulcanized mats, on the other hand, were engineered with this kind of abuse in mind. They absorb impact better, distribute force more evenly, and maintain their integrity even under heavy machinery and repeated high-impact use.

Another overlooked aspect is joint health. Revulcanized rubber has superior elasticity and consistency, offering more robust shock absorption. That means less wear and tear on your knees, ankles, and back during repetitive movement like jumping, lifting, or running drills.

Stall mats? They’re often dense in some spots, softer in others, and inconsistent across the surface. That inconsistency can actually contribute to joint strain, especially in environments with frequent jumping or directional movement.

For a deeper dive into how high quality rubber mats can protect your muscles  joints, check out this article here.

Perhaps one of the biggest reasons to invest in some sort of flooring for your gym space is to protect your subfloor.  A lot of gym owners and homeowners think any rubber mat will do the job of protecting their subfloor.  Revulcanized mats, with their higher density and resilience, are far more effective at absorbing and dispersing the energy of dropped weights or machines.

This means less risk of cracked concrete, warped wood, or other costly damage. Stall mats, especially as they age and start to compress or curl, allow more force to transfer straight through to the subfloor which means the protection you thought you were getting is slowly disappearing.

Revulcanized recycled rubber mats may come with a slightly higher upfront cost, but when you consider their longer lifespan, greater durability, better performance for joint safety, and superior subfloor protection, the ROI is undeniable. Buy it right, buy it once.

Stall mats are great for horses, but if you want rubber flooring that is going to last and set you up for success, you need to choose flooring that is engineered for the gym. 

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