The Asana Custom Pad Process
A Step-by-Step Process of Planning to Use
Top Rope and Lead Areas should be covered with a firm, but cushioned style flooring. Top rope areas are considered to be highly safe given that the rope is anchored to the top of the wall. Climbers rarely take long falls in these areas given good staff and climber training. Lead climbing areas have a higher risk of fall; therefore a solid level of protection is necessary. There is a good possibility that a climber may take a ground fall from lower clips. These clips are typically placed at 8 feet and higher above the ground. Given the high safety rating, flooring materials will be selected for foot and heel strikes from 3-4 feet off of the ground. A 6 inch flooring system is recommended for both top rope and lead areas. We recommend a floor with 2 inch of closed-cell foam and 4 inches of high density open-cell foam.
Bouldering Area padding should be designed for the highest level of comfort with regards to heel strikes and back falls. The depth of padding for bouldering depends on the height of the bouldering area and the steepness of the wall angle. As the height factor increases, so does the need for a thicker pad. This requires that a good solid slab of foam is on the floor ready to support a fall and to provide a relatively comfortable landing as well. As the angle of the wall moves from vertical into a steeper angle, back falls become more of an issue. It can be quite painful to land on ones tailbone or back. For this reason, a nice soft landing zone should be provided in these types of areas. We normally recommend a minimum of 6 inches of padding for any bouldering area. For at or taller walls than 12 to 16 feet, 8, 10, 12, or 16-inch padding may be necessary. Please call us to discuss wall height factor and climbing style in your bouldering area. We can provide consultation as to how soft and how thick we feel your padding needs to be.
Quote Process The quote process must begin with an estimation of the square footage of the area to be covered with a landing surface.
Customer Survey If the customer chooses to provide square footage, then it is necessary for the customer to measure the length and width of the entire area to be padded.
NOTE: If the area is too large or complex to estimate square footage, please call Asana. If a discrepancy in the measurements is found after the design process begins, a re-quote may be necessary. Please avoid this inconvenience by providing highly accurate square footage measurements.
Asana Survey When using this option, Asana will travel to your site to get an exact measurement of the area to be padded. Asana provides a quote based on the square footage of the padded area in the gym.
Asana emails or faxes a contractual quote and Custom Pad Process to the customer.
Customer faxes or mails signed contractual quote, Purchase Order, and Custom Pad Process to Asana.
Customer mails a minimum of a 50% deposit to Asana.
Project is placed on the production schedule at the receipt of the deposit.
University Customers: When working with universities, Asana understands that a deposit may not always be possible. In these cases, a receipt of the Purchase Order places the project on the timeline.
Getting a Precise Survey of the Landing Area
A determination needs to be made by the customer whether or not Asana will be contracted for completing a survey of the landing area. We almost always recommend that we complete the survey for a couple of reasons. First, we believe we are better skilled at determining landing areas and mapping out the area and determining the best fit for the pads when we are on-site and the walls are complete. By means of a phone call, we can work together to determine if a simple template or travel is required to get an accurate layout of the padded area. This usually depends on the size and complexity of the gym. The customer pays for the template materials, customer developed survey, or the travel and fees for the Asana-developed survey. None of these are included in the square footage rate.
WARNING: If you and/or your organization, as the customer, choose to waive Asana completing the survey, you take on several risks you should be aware of. When you complete the survey yourself, your organization takes on ALL of the risk for fit.
Customer Provided Template (Only for areas 300 square feet or less) Customer may provide a physical template using a lightweight plastic. To complete this process, lay out lightweight plastic sheeting (4 mil thickness) next to or close to the wall based on the steepness of the wall off the ground. The sheeting for making this template can be obtained at a local hardware store. Keep in mind that your pads may need to fit against the wall, but that this may not be at the place where the wall meets the floor. For example, if your pad is 6 inches thick and the wall is at 45 degrees, the 6 inch pad will not fit. It will be like trying to push a cinder block against the wall. The pad will only go as far as the angle of the wall will allow. In many cases like this, the template for the padding will need to start away from the wall allowing for the thickness of the padding to slide into place. (Figure 1A). The thicker the pad and the steeper the wall, the further from the wall the template will need to be. To best way to determine where to lay the template, drop a plumb line that is the same length as the padding thickness from the wall.
Customer Provided Survey
Asana only accepts Google Sketch Up models for this purpose. Asana only needs the overview of the landing area. There is no bneed for the customer to layout the pad divisions for the system. Keep in mind that when measuring, your pads may need to fit against the wall, but that this may not be at the place where the wall meets the floor. For example, if your pad is 6 inches thick and the wall is at 45 degrees, the 6 inch pad will not fit. It will be like trying to push a cinder block against the wall. The pad will only go as far as the angle of the wall will allow. In many cases like this, the survey for the padding will need to start away from the wall allowing for the thickness of the padding to slide into place. The thicker the pad and the steeper the wall, the further from the wall the template will need to be. To best way to determine where to lay the template, drop a plumb line that is the same length as the padding thickness from the wall.
If the customer provides a survey and the pads do not fit in the gym, then an analysis will be completed to find out if there was an error in the template or the construction of the pads. Once the causes of these errors are determined, then the customer is fully responsible for paying for all costs associated with these changes. If there is an error in the construction of a correct survey, Asana will pay to make the necessary adjustments.
Asana Provided Survey
The best option is for Asana to travel to your site and do a detailed survey and layout of the entire area. This involves creating a digital drawing of the area by using laser squares and reference points. This process usually takes about 1-4 days for mapping up to 5000 square foot floors. Any floor larger than 5000 square feet may take up to a week. An additional charge will be added to our quote if you choose this to have a survey completed.
For Asana to be able to complete this survey, several things are required. First and foremost, the climbing walls or at least the base foorprint must be completed. If the walls are not complete, then your organization is required to pay for any and all pad corrections associated with padding fit. Secondly, and equally as important, the entire area must be cleaned and cleared of any standing water, objects, tools, cords, debris, construction materials, or anything else in the area where the padding will be placed. If the area is not clear, then Asana cannot and will not provide the survey. The customer will be charged for any delays in this process including the time paid to the professional surveyor, hotel costs, meals costs, rental car expenses, and travel expenses.
The survey will take into account several different factors including, but not limited to wall angle, style of climbing in the area, level of risk associated with a climber’s feet hitting the floor next to the wall, and the ability of the survey to accurately match to contours throughout the gym once the system is put into place.
An authorized wall representative must be on site to confirm that the survey has been completed and that Asana can move forward with the plans from the survey.
Pad System Design
Asana will use the customer’s template or the digital files created by Asana to develop a padding system based on the specifications for each area. Once a final digital file has been created, no changes to the design of the pad can be made based on the risk of such changes causing effects throughout the padding system fit.
Asana manufactures the padding covers and tarp systems according to the specifications of the template and the use of the pads. This process can take anywhere from 1 week to 6 weeks depending on size and complexity.
Depending on project size, Asana may ship the pads complete with foam or travel on-site to install the raw foam in the shells. Pad shells shipped separately from the foam are boxed in heavy duty packaging. Foam is usually shipped wrapped in a heavy-duty plastic via LTL freight trucks. Pads are shipped using the most affordable rate of freight.
If the pads and/or foam are shipped to your location, please notify the driver immediately regarding any and all damages made in transit. If there are damages to any packaging or to the product, make note of these issues on the Receiving Note and/or Bill of Lading. Note that if comments regarding damages are not made on the Receiving Note, the receiver is accepting packages as is and removes the shipping company from liability based on damages. If a comment regarding damages is made to the driver and on the Receiving Note and/or Bill of Lading, then a claim can be made for damages and claim settlements could take as long as 90 days from the date the claim is made to resolve with the freight company.
If the Customer receives a complete Padding System
Unwrap each pad.
Use Installation Layout provided by Asana to place each pad into place. If you cannot find the installation layout/blueprint, give us a call and we’ll send you one.
Cover joints between pads with Velcro seam covers according the layout.
If the system is shipped for Asana to install
Asana will arrive at the site, open all packaging and boxes and install the entire padding system.
The customer is responsible for receiving the product from the truck and placing the freight in a secure place. Refer to the Shipping section of this document for topics related to receiving the raw goods.
Installation charges range from $1.25 to $2.00 depending on project complexity.
Asana Installation and Assembly
Asana fabricates foam into custom shapes, inserts foam into the padding covers, and fits completed pads into place with attaching Velcro "Seam Covers"
For Tarp Systems, an agreement for how the installation is completed is made between Asana and ther Customer.
On a regular basis, take a look at the pad system on a regular basis and inspect the covers, zippers, foam, and seam covers.
If a pad cover is ripped or torn, contact Asana immediately for a diagnosis and plan for pad cover repair or replacement.
If a sewn seam is torn, contact Asana immediately to develop a plan for repair or replacement.
When foam is beginning to breakdown, contact Asana to discuss options for replacement or for additional foam.
Inspect the seam covers regularly to make sure they are holding in place. Do not move pads unless it is absolutely necessary. Removing seam covers frequently will and does reduce the life of the system. All gyms should regularly inspect seam covers for thread wear and tear. If thread seams are broken on the seam cover, call Asana for replacements. One the replacements are in the gym, we can also repair the seam covers with the wear and tear issues. Seam covers will need to be replaced at least once every three years depending on use. Some of the higher traffic gyms are replacing seam covers once every year. There is a charge for replacement seam covers and for repairing seam covers.
When pads get dirty, use a soft bristled broom to sweep the areas clean. Use of a vacuum cleaner is acceptable as long as the vacuum does not use a spinning bristled brush.
A non-bleaching spray may be used for problem areas, but make sure that a conservative amount of spray is used so that it does not penetrate the shell cover.
For stained spots, use a damp rag or sponge with a mild stain remover.
Given good maintenance and regular care, the pad system will provide years of protection, however, we cannot protect against all factors.
Asana will provide regular inspections of the padding systems upon request. There is an additional charge for this service.
Warranties and Exclusions
Asana’s warranty covers defective manufacturing for one calendar year. This means that we will do our best to repair or replace products that are defective based on our sewing techniques in individual cases. Although we have the best industrial sewers, they do not always produce perfect gear. We will make that determination as to whether we have made mistakes or if it is wear and tear.
Wear and Tear- Asana does not warranty the pads for wear and tear. This means that the foam will take abuse and that Asana is not responsible for that abuse. We buy the highest quality foams on the market as a means to extend the life of the padding systems. This does not mean that we can guarantee how long they will last. Many factors such as gym traffic, placement, handling, and environmental exposure play a part in the life expectancy of a pad.
Foam- Asana is committed to putting the best quality foam in its pads, but Asana does not warranty foam. Foam takes constant impact and therefore, by nature, slowly breaks down over time. Foam elements will have to be replaced from time to time. All gyms should be making regular foam checks, maintenance, and replacements.
Seam Covers- Seam covers are not covered under our warranty.
Vinyl Welds- Asana does not warranty vinyl welds on tarps. Asana is available to instruct and consult on the methods for gluing tarp welds back together, but in most cases the welds will have issues purely related to the impacts in the gym.
If you are ever concerned about the safety or condition of your flooring system, please contact Asana either by phone or email immediately.