MAPEI scores win in construction of sports complex

The construction of the Fort Bend Epicenter sports complex in Fort Bend, Texas, was a monumental project that demanded high-quality setting materials for its flooring and wall installations. MAPEI, a leading manufacturer of construction and setting materials, played a crucial role in the construction of this state-of-the-art sports complex by supplying products known for durability, quality and ease of application.

The Epicenter spans an impressive 230,000 square feet (21 368 m²) and stands as a versatile venue that is capable of accommodating tournaments and events of various sizes. With over 8,600 fixed seats and a scalable capacity exceeding 10,000, the arena is designed to offer an incredible view to every guest.

This project called for the installation of 35,000 square feet (3 252 m²) of tile, including 27,300 square feet (2 536 m²) of various-sized tiles that were installed using MAPEI setting materials. These products were essential to ensure the durability and longevity of the installations.

The play clock starts

The Epicenter was a new build, emphasizing the need for precision and excellence in the construction process. “MAPEI was on the specifications along with two other setting-material options,” explained Lance Farrar, MAPEI’s South Central Area Sales Director. “The contractor works well with our products and knows that MAPEI is high-quality and long-lasting, and so we were awarded the project.”

“The overall size of the project was 230,000 square feet [21 368 m²], and MAPEI’s contribution included the installation of over 10,000 square feet [929 m²] of floor tile, 14,500 square feet [1 347 m²] of wall tile and 2,800 linear feet [853 linear m] of tile base. The scope of MAPEI’s work showcased the versatility and adaptability of their setting materials in various applications throughout the complex,” Farrar said.

“The extensive construction of the new structure also allowed for intense coordination among the various trades,” he continued, “although that also meant that the challenge of different trades working concurrently existed.”

The seven-man team of skilled tile setters from Westway Construction was ready for the challenge. The team’s expertise and efficiency contributed to the successful installation of MAPEI’s setting materials within the specified timeframe.

Farrar explained, “While the project did not face unusual factors such as environmental sensitivities or extreme weather conditions, the construction of the Epicenter from the ground up meant that different trades were working simultaneously, necessitating careful coordination to avoid conflicts. Attention to the construction schedule, constant communication and safety were always stressed in the daily and weekly jobsite meetings.”

Strict adherence to safety measures was a priority on the jobsite. The use of personal protective equipment (PPE) such as hard hats, safety vests and other necessary gear ensured a secure working environment for the Westway team.

The play clock starts

MAPEI’s setting materials were applied to various substrates, including concrete floors, cinderblock columns and wallboard. These new substrates required proper surface preparation to ensure a long-lasting installation.

First, the crew used rollers to apply Mapelastic CI membrane for surface preparation in select areas that included restroom floors and elevator floors, as well as some floor spaces in the VIP Lounge bar area. The use of Mapelastic CI ensured stable crack-isolation membranes for the subsequent tile installations.

Next, Keraflex Plus Gray mortar and Ultracolor Plus FA grout were used to set and grout tiles on floors and walls. Mapesil T sealant was then applied in specific areas, such as all restrooms, 11 showers, the Event and Lounge concession areas, the VIP lounges, drinking-fountain walls and the sauna room.

Keraflex Plus Gray provided excellent bonding properties and flexibility. Ultracolor Plus FA filled the grout joints, which not only provided protection, but also provided color to enhance the visual appeal of the installation. Mapesil T was used to protect joints in areas of heavy traffic and movement.

“The entire installation took six months,” Farrar said, “which shows how a well-executed game plan can come together beautifully when there are top-notch players on the team.”

In fact, the tile installation was so successful and so visually appealing that the installer, Tommy Vu from Westway, was awarded NTCA’s Tile Setter Craftsperson of the Year for 2023. Vu was nominated by three separate people, a first in the history of the award, according to an article in Floor Covering Weekly.

Durable and aesthetically appealing, MAPEI’s tile-setting materials played a pivotal role in the successful construction of the Fort Bend Epicenter sports complex. The adherence to project specifications, the expertise of the construction team and the quality of MAPEI’s products collectively contributed to the creation of a lasting and visually stunning venue. The collaboration between MAPEI’s experts and the construction team showcased the effectiveness of MAPEI system solutions in various applications, reinforcing the company’s reputation as a reliable choice for construction projects of this scale.