How does the puzzle connection (zipper system) work in rubber tiles?

The edges of a rubber tile with a puzzle connection – also known as a zipper system by WARCO – are not cut straight, but instead resemble the edge of a postage stamp. However, these are not the perforated edges of a stamp; they are dovetail joints (a familiar term in carpentry) or small interlocking puzzle teeth. The precisely formed teeth of adjacent tiles interlock, tooth by tooth like a zipper, joining the individual tiles into a cohesive, form-fitting surface.

This connection is the sturdiest and most durable achievable with rubber tiles. It is uniformly executed along all sides and extends over the entire height of the tile. The size and shape of the individual puzzle teeth vary depending on the model series, but in WARCO’s rubber tiles the teeth interlock so precisely—with no noticeable gap—that no open joints occur. This practically prevents weed growth outdoors and, when installed correctly, stops dirt from entering between or underneath the tiles.

Tiles with a puzzle connection are manufactured in two versions: one in which the edges of the teeth are chamfered or beveled, and another where the teeth are sharply and square-cut. The sharp cut ensures that the interlocking mechanism is barely visible on the surface. Additionally, the tile’s colour design affects the visibility of the joint – monochrome tiles display the structure more clearly than those with an organically mixed colour scheme.

Typically, tiles with a puzzle connection are not glued to each other or to the substrate. In certain cases, such as with small cutouts or when vandalism is a risk, applying adhesive can be advantageous.