Carpet Bonded Foam Guide: Thickness, Flexi vs Non-Flexi & ACTV Mats for Cheer & Gymnastics
In cheerleading and gymnastics, the right flooring makes a huge difference. It affects safety, performance, skill progression, and athlete comfort. Carpet bonded foam (also called carpet foam rolls or flexi-rolls, even called panels) is the go-to choice for many programs. It combines durable carpet with shock-absorbing foam with non-slip surface, impact protection, and easy setup.
But not all carpet bonded foam is the same. Thickness, density, flexi vs non-flexi design, and advanced options like VAspirit’s ACTV Mat change how the floor feels and performs. This guide breaks down the key differences so you can choose the best option for your scholastics program("school cheer” or “college cheer team”), cheer gym, or gymnastics facility.
Why Carpet Bonded Foam Is Essential for Schools(scholastic), Cheer, & Gymnastics
Carpet bonded foam rolls (usually 6' wide x 42' long) cover large areas quickly. They provide:
- Non slip surface for stunting, tumbling, and jumps
- Shock absorption to protect joints for take offs and landings
- Stable surface that lays flat and stays put
- Easy rolling/storage for multi-use spaces
Standard competition cheer floors use 9 rolls (42' x 54'), while gymnastics floors often need at least 7 rolls (42' x 42') . The foam is flame laminated to the carpet, so you get consistent performance without shifting.
Thickness Differences: 1-3/8" vs 2" (and Thicker Options)
Thickness controls cushioning, rebound, and stability.
- 1-3/8" (common standard): This thickness offers a balance of bounce and firmness. It works well on spring floors or rod floors where you want the built-in spring to shine through. It's lighter, rolls up easier, and lays flatter at the ends. Great for cheer gyms with spring floors or multi-purpose spaces. Less padding means more direct feel of the base floor. While most common in the competitive cheerleading industry, Victory feels this is the minimal thickness and not the safest or optimal product. Victory’s new “ACTV Duty” product will launch soon and will be an upgrade for the industry.
- 2" (or thicker like 2-1/8"): Extra cushioning reduces impact on joints such as knees, ankles, and wrist during tumbling or stunting. A thickness of 2” or more is Ideal for use on concrete/gymnasium floor or stages. It feels softer on take offs and landings and can further protect against injury during falls. Because 2” will absorb energy better than the 1-3/8” this also means that you would not want to add an excessive amount of foam as it may slightly mute rebound on spring floors; such as adding 3” of carpet bonded foam to spring floors(keep in mind not all spring floors are created equally).
Find the right balance of thickness for your activity.
More foam = more protection during falls and less stress on joints, but too thick can result in a less "lively" feel on spring systems. It can also result in less stable lateral movements which can make it less responsive.
Less foam = more responsive but less protection and more stress on joints
Flexi vs Non-Flexi: Which Is Right for Your Gym?
The biggest choice is flexi (rollable/flexible) vs non-flexi (flat/stiffer).
- Flexi Carpet Bonded Foam: Designed for easy rolling and storage. It has slits or flex cuts in the foam layer (every few inches) so it bends without damage. Perfect for quick set up/take down(events, multi-use rooms, schools). It rolls compactly and deploys fast. However, avoid flexi on spring floors in thicker options (like 2-1/8") — it can void warranties or cause instability. Also, avoid flexi on single layer spring floors.
- Non-Flexi Carpet Bonded Foam: Takes more time to roll up. Takes up more space when rolled up. It stays flat and stable during intense use. This makes it the best choice for permanent or semi-permanent setups on spring floors, rod floors, or high-traffic gyms. It provides better overall stability and longevity under heavy loads because there are no cuts in the foam. Non-flexi is the go-to when you need long-term use and more integrity in the product.
Quick tip: If your gym has a spring floor, choose non-flexi for stability, performance, and longevity. Flexi works best for portable or temporary setups.
ACTV Mats: Victory Athletics’ upgrade for Better Rebound & Joint Protection
VAspirit's ACTV Mat line takes carpet bonded foam to the next level. It eliminates the "dead mat" feel of the predecessor.
- Higher rebound → Livelier energy return so tumbling feels dynamic and powerful.
- Less joint stress → Better impact absorption during long practices.
- No DEAD MAT, lifeless sensation → Athletes notice the difference right away.
- Less stress - more reps
ACTV Mat FLEXI rolls up easily for storage but avoid it on spring floors (especially 2-1/8" thickness) — warranty voids if used there. Use NON-FLEXI on spring floors when choosing 2-1/8” ACTV Mat
ACTV Non-Flexi shines on spring/rod floors and gymnastics spring floors. It stays stable, durable, and responsive under heavy use.
Both come in multiple colors (Black, Blue, Charcoal Gray, Light Gray, and more). Custom logos available too (contact your rep with PNG/AI file). Velcro sold separately for secure connections.
Which Carpet Bonded Foam Should You Choose?
- For portable/multi-use gyms → Flexi standard or ACTV Flexi.
For competitive cheer event producers; ACTV mat line in flexi 1-3/8”
For competitive Gymnastics event producers; ACTV mat line 2-1/8” non-flexi
- For spring floor or permanent setups → Non-Flexi (especially ACTV Non-Flexi).
- For maximum rebound and joint protection → ACTV line.
- For high-volume tumbling on hard surfaces → ACTV 2-1/8” thickness or standard 2”
- For spring floor responsiveness → 1-3/8" to 2-1/8” ACTV non-flexi.
Shop VAspirit's in-stock options:
Ready to upgrade your gym floor? Contact VAspirit for expert advice or custom options. Train smarter, protect athletes, and rise faster!
Keep an eye out for carpet bonded foam products sold well below retail. Products imported from certain countries are using a lesser grade of carpet and a lower density foam. This saves the manufacturer money so the cost to you appears as a savings. But this can cost you big time! The carpet is thinner not stable enough to hold up when the flexi is cut in the foam. You will see tears in the carpet quickly. The foam is a less dense so it does not support the carpet or support the activity or have as much impact rating. Don’t learn the hard way. If the price is much lower than the industry trend then you are most likely buying a lesser product.
