Plastics in Sport – The Contribution of UK manufacturers

Plastics played a crucial role in the staging of the London Olympic Games. It is time to celebrate the significant contributions made by UK manufacturers of plastic products to the success of the event. The plastics, particularly those made from PVC, were required to meet strict sustainability criteria. UK manufacturers gained invaluable experience during their involvement and are well-prepared to utilize this knowledge for future sporting events, whether Olympic or not.

Plastics were omnipresent in the London Olympic Park, not only in sports equipment and clothing but also in the infrastructure, including the stadiums, sanitation, and catering arrangements. Furthermore, plastics played an essential role in transportation and communication facilities.

Contents

1. Sports Equipment
2. Infrastructure
3. Clothing and Gear
4. Case Studies
     4.1 Loughborough University - Jabulani Football Developed for an Outstanding World Cup Performance
     4.2 Polypipe - Manufacturing Gold Standard Plastic Products
     4.3 ZoteFoams - The Lightest Footwear for Fast Running
     4.4 Polypipe - Manufacturing Gold Standard Plastic Products
     4.5 Altro Flooring - Safe and Sustainable Altro Flooring for the Olympic Games

1. Sports Equipment

Plastics have enabled a progressive lightweighting of sports equipment, assisting athletes in achieving enhanced performance. For instance, early twentieth-century tennis rackets transitioned from heavier wood to lighter plastic composites. Similarly, both the crafts and oars used in rowing have evolved from wood to plastic composites, facilitating the safe maneuverability of the equipment. The design flexibility offered by plastics has allowed for sleek designs, reducing wind resistance and enhancing performance.

2. Infrastructure

Plastics contribute to the safe enjoyment of major sporting events. Comfortable seating, protective roofing for spectators, and provisions for food and drink are all made possible through the use of plastics. They were extensively employed in the external and internal structures of stadiums and swimming arenas, totaling approximately 140,000 square meters of PVC used for flooring, roofing, and other building applications.
Plastics are durable, reusable, and recyclable, making them integral to any sustainability program associated with sporting events. PVC products are supported by the Vinyl Plus initiative, recognized by the European Commission, and partnered with the United Nations Environmental Programme. A key advantage of plastics is their low conductivity, contributing to energy savings.

3. Clothing and Gear

Plastics are widely utilized in sports clothing due to their durability and resistance to tearing. They are waterproof and can be designed to minimize wind resistance. Furthermore, plastics can easily be dyed and decorated for better recognition by spectators and sports officials. Their impact resistance makes them ideal materials for manufacturing safety helmets.

4. Case Studies

4.1 Loughborough University - Jabulani Football Developed for an Outstanding World Cup Performance
The football World Cup held in South Africa featured an advanced adidas ball, developed by engineers and scientists at Loughborough University for maximum performance. Constructed from eight 3-D spherically molded panels thermally bonded together, these panels are made from EVA and TPU, ensuring a perfectly round shape. The unique "Grip and Groove" profile of the ball enhances flight stability and grip in all weather conditions.

The ball's aero grooves and enhanced texture for grip make it the most stable and accurate adidas ball to date. Dr. Andy Harland from Loughborough University’s Sports Technology Institute expressed pride in the collaboration with adidas on this high-profile product. The University's testing facilities enabled comprehensive evaluations, including wind tunnel tests, to ensure optimal performance alongside the adidas football laboratory.

4.2 Polypipe - Manufacturing Gold Standard Plastic Products
Polypipe, the UK's largest plastic piping systems manufacturer, significantly contributed to the construction of the London stadia and facilities, including the Olympic Stadium, Velodrome, and Athletes' Village. Collaborating with various stakeholders from the outset, Polypipe provided almost one million meters of plastic pipe and over two million fittings to the Olympic Park.

Polypipe supplied several product systems for diverse applications across the Olympic construction, including six systems specifically for the Athletes' Village. Notably, their renowned Terrain above-ground soil and waste drainage systems were utilized in all major Park projects, with innovative products developed specifically for the venue.

One groundbreaking innovation, Terrain Firetrap firesleeves, achieved an unprecedented four-hour fire protection for above-ground plastic drainage systems, tailored to the needs of the Athletes' Village. Adam Turk, Polypipe Terrain's Commercial Director, expressed pride in their contributions to the London projects, which showcased the UK’s manufacturing heritage globally while propelling sustainable construction.

Polypipe's achievements at the London Games have been recognized in the ODA’s "Learning Legacy: Lessons Learned from the London Games Construction" report and featured in the Plastics for Gold Exhibition at the Museum of Design in Plastics, highlighting the critical role of plastic.

4.3 ZoteFoams - The Lightest Footwear for Fast Running
When Nike and Pelé Sports needed lightweight footwear with temperature resistance, Zotefoams plc emerged as the ideal solution. Zotefoams is the UK's leading supplier of closed-cell cross-linked block foams for various applications, including sports. They developed a specialized foam for midsoles and insoles called PebaxFoam®, which is five times lighter than EVA foam and offers superior temperature resistance. This innovation enables athletes to run faster due to the excellent energy return provided by PebaxFoam®.

Zotefoams’ products are utilized across numerous sports applications, including protective pads, helmet liners, mats, swimming aids, back protectors, and footwear, making them a natural choice for various sporting uses.

4.4 Polypipe - Manufacturing Gold Standard Plastic Products
Polypipe made substantial contributions to the construction of London’s stadia and facilities, including the Olympic Stadium, Velodrome, and Athletes’ Village. Collaborating with stakeholders from early stages, Polypipe supplied nearly one million meters of plastic pipe and over two million fittings to the Olympic Park.

They provided a range of product systems for multiple applications within the Olympic build, particularly six systems devoted to the Athletes’ Village. Their acclaimed Terrain above-ground soil and waste drainage systems were employed in every key project on the Park, and several groundbreaking products were designed specifically for this initiative.

An innovation worth noting includes Terrain Firetrap firesleeves, which achieved an unprecedented four-hour fire protection for above-ground plastic drainage systems, meeting the specific needs of the Athletes' Village.

Adam Turk of Polypipe Terrain expressed pride in their participatory role in the London projects. The opening ceremony showcased the UK’s manufacturing prowess, while the British construction sector demonstrated its capability to deliver landmark projects efficiently and sustainably.

Polypipe's contributions to London have been recognized in the ODA’s "Learning Legacy: Lessons Learned from the London Games Construction" report, and as part of the Plastics for Gold Exhibition celebrating plastics' impact.

4.5 Altro Flooring - Safe and Sustainable Altro Flooring for the Olympic Games
UK manufacturer Altro was the sole PVC manufacturer of safety flooring and hygienic wall cladding approved for use during the Games, providing over 50,000 square meters of flooring to 33 venues. The supplier demonstrated compliance with the Olympic Delivery Authority's (ODA) sustainability policy for PVC used within the London Olympic and Paralympic Games.

Kevin Webb from Altro stated, "The ODA aimed to facilitate the most sustainable Olympic Games in history, thus the approval criteria for suppliers were exceptionally rigorous." After four years of discussions with the London Organizing Committee of the Olympic Games and Paralympic Games (LOCOG), Altro earned the lifetime opportunity to contribute to London 2012’s sustainability efforts.

A total of 15 different products were supplied, with specific criteria met for temporary structures, including Altro XpressLay™, the first-ever adhesive-free safety flooring, designed for easy removal, reuse, or recycling post-event. In high-traffic areas, such as the massive McDonald's restaurant at the Olympic site, a non-slip, durable, and sound-absorbing Altro Stronghold™ floor was installed.

Altro XpressLay is laid loosely, making it reusable in different locations unlike conventional bonded flooring. A recipient of some of this prestigious flooring was St. John’s Primary School in Kent, where Head Teacher Sally Quirk remarked, "The installation has transformed the school beyond recognition, offering students the chance to tread the same floor as Olympians, serving as an inspiration for them."