Functional Training Area Setup: Equipment, Layout, and Budget Guide for Australian CrossFit & Functional Gyms (2026)
Building a functional training area for your Australian gym? This is where
your members will spend 40-60% of their training time.
Get it right and you'll create the most-used, highest-value zone in your facility. Get it wrong and you'll waste thousands on equipment that sits unused while your space feels cramped and chaotic.
This guide breaks down everything you need: must-have equipment vs. nice-to-haves, layout templates for 50m² to 200m² spaces, turf vs. rubber flooring, rig configurations, and real Australian costs.
By the end, you'll have a complete functional training area blueprint ready to execute.
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What is a Functional Training Area?
Definition: A dedicated zone for multi-joint, functional movements that mimic real-world activities: squatting, pushing, pulling, jumping, carrying, throwing.
Common equipment:
- Rigs (pull-up bars, dip stations)
- Olympic barbells and bumper plates
- Kettlebells and dumbbells
- Plyometric boxes
- Battle ropes
- Slam balls and medicine balls
- Sleds and prowlers
- Turf or rubber flooring
NOT functional training:
- Isolated machine work (leg extension, pec fly)
- Traditional bodybuilding splits
- Treadmill cardio
Why it matters: Functional training is THE fastest-growing segment in Australian fitness (25% CAGR 2020-2026). CrossFit, HYROX, F45, and boutique studios have made functional training mainstream.
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Essential Equipment: The Non-Negotiables
1. Rig or Rack
What: Steel frame with pull-up bars, J-hooks for squats, attachment points for accessories.
Options:
- Freestanding rig (no wall mounting required)
- Wall-mounted rig (space-efficient, requires structural support)
- Power rack (4-post standalone, compact option)
Minimum specs:
- Pull-up bar height: 2.75m (clearance for tall athletes)
- Width: 1.2m per athlete (2-6 athlete stations)
- Load capacity: 300kg+ per pull-up bar
Cost:
- 2-bay freestanding rig: $4,500-$8,000
- 4-bay freestanding rig: $9,000-$15,000
- Wall-mounted rig (3-cell): $3,500-$6,000
Why essential: Pull-ups, muscle-ups, ring work, squats, overhead press — 60% of functional movements use the rig.
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2. Olympic Barbells
What: 20kg (men's) or 15kg (women's) barbell rated for Olympic lifts (snatch, clean & jerk, deadlifts).
Minimum:
- 3-5 barbells for small gyms (6-12 members/class)
- 8-12 barbells for medium gyms (15-25 members/class)
Features:
- Rotating sleeves (smooth Olympic lifts)
- 28-29mm diameter (men's), 25mm (women's)
- PSI rating: 190,000+ (commercial quality)
Cost:
- Budget barbell: $250-$400
- Mid-range: $450-$700
- Premium (Rogue, Eleiko): $800-$1,500
Why essential: Squats, deadlifts, cleans, snatches, bench press — barbells are the foundation of strength training.
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3. Bumper Plates
What: Rubber-coated weight plates designed to be dropped from overhead without damage.
Minimum set (per barbell):
- 2 x 25kg
- 2 x 20kg
- 2 x 15kg
- 2 x 10kg
- 2 x 5kg
- 2 x 2.5kg
Total per set: 155kg
For 8 barbells: 8 sets x 155kg = 1,240kg of plates.
Cost:
- Budget bumpers: $4-$6/kg
- Mid-range: $7-$10/kg
- Competition (thin, color-coded): $12-$18/kg
Total cost (8 sets, mid-range): 1,240kg x $8/kg = $9,920
Why essential: Can't do Olympic lifts without bumper plates. Steel plates damage floors and can't be dropped.
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4. Kettlebells
What: Cast iron or steel weight with handle, used for swings, snatches, Turkish get-ups, goblet squats.
Minimum set:
- 4-8kg (women's starter)
- 8-12kg (women's intermediate)
- 12-16kg (women's advanced)
- 16-20kg (men's starter)
- 20-24kg (men's intermediate)
- 24-32kg (men's advanced)
Quantity:
- Small gym: 2-3 of each weight
- Medium gym: 4-6 of each weight
Cost:
- Cast iron: $3-$5/kg
- Powder-coated: $5-$7/kg
- Competition (steel): $8-$12/kg
Total cost (medium gym, 40 kettlebells): $3,000-$6,000
Why essential: Versatile, functional, popular with all demographics. Kettlebell swings alone burn 400-600 cal/hour.
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5. Plyometric Boxes
What: Wooden or foam boxes for box jumps, step-ups, elevated push-ups.
Standard sizes:
- 50cm (20")
- 60cm (24")
- 75cm (30")
Minimum:
- 6-10 boxes for small gym
- 12-20 boxes for medium gym
Types:
- Wooden boxes: Durable, stackable, $150-$250 each
- Foam boxes: Soft, safer, $200-$350 each
Cost: 10 wooden boxes: $1,500-$2,500
Why essential: Explosive power training. Box jumps, step-ups, plyometric depth jumps — critical for athletic performance.
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6. Battle Ropes
What: 10-15m heavy rope for wave exercises, slams, endurance training.
Specs:
- Length: 10-15m
- Diameter: 38-50mm
- Weight: 10-20kg
Minimum: 2-3 ropes (group class use).
Cost: $80-$200 per rope.
Installation:
- Wall anchor (included)
- Turf or rubber flooring (ropes damage unprotected concrete)
Why essential: High-intensity interval training (HIIT), full-body conditioning, burns 400-600 cal/30 min.
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7. Slam Balls & Medicine Balls
Slam balls: Heavy, non-bounce balls for overhead slams.
Sizes: 5kg, 10kg, 15kg, 20kg, 25kg, 30kg.
Minimum: 2-3 of each size.
Cost: $40-$100 each (depending on weight).
Medicine balls: Bounce-able balls for wall balls, partner throws.
Sizes: 4kg, 6kg, 9kg, 12kg, 14kg.
Minimum: 3-4 of each size.
Cost: $50-$120 each.
Why essential: Core training, explosive power, coordination. Wall balls are a CrossFit staple.
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8. Sleds & Prowlers
What: Weighted sleds for pushing/pulling, loaded with plates.
Types:
- Push sled: Low handles, forward push
- Pull sled: Harness or rope, backward/forward pull
- Prowler: High/low handles, multi-grip
Cost: $300-$800 per sled.
Minimum: 2-3 sleds (group class use).
Why essential: Lower-body power, conditioning, sprint training. Popular in HYROX training.
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Nice-to-Have Equipment (Budget Permitting)
- Concept2 rowers: $1,400-$1,800 each (2-4 units)
- Assault/Air bikes: $1,200-$1,800 each (2-4 units)
- Gymnastic rings: $50-$100 per pair (4-6 pairs)
- Resistance bands: $200-$500 set
- Foam rollers: $400-$800 (10-20 units)
- Landmine attachments: $150-$300 each
- TRX suspension trainers: $200-$400 each (4-6 units)
- Sandbags: $60-$150 each (various weights)
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Flooring: Turf vs. Rubber
Turf (Recommended for Functional Areas)
Why turf for functional training?
- Designed for sled pushes/pulls
- Comfortable for bodyweight work (lunges, push-ups, planks)
- High-end aesthetic (Instagram-worthy)
- Defines the functional zone visually
Specs:
- Pile height: 20-25mm (sled use)
- Backing weight: 2kg/m² (commercial durability)
- Width: 2m or 4m rolls
Cost: $100-$150/m²
For 50m² functional area: $5,000-$7,500
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Rubber (Budget Alternative)
Why rubber?
- Cheaper ($50-$80/m²)
- More durable long-term (turf mats down over time)
- Better for heavy weight drops
Specs:
- Thickness: 15-20mm (functional area)
- Format: Tiles or rolls
Cost: $50-$80/m²
For 50m² functional area: $2,500-$4,000
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Recommendation: Hybrid approach:
- Turf for sled track (10-20m lane)
- Rubber for Olympic lifting zone (weight drops)
- Turf for central functional area
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Layout Templates
Small Functional Area (50m²)
Space: 10m x 5m
Equipment:
- 2-bay freestanding rig
- 6 Olympic barbells
- 6 sets bumper plates (155kg each)
- 20 kettlebells
- 8 plyo boxes
- 2 battle ropes
- 2 sleds
- 10 slam balls, 10 medicine balls
Layout:
- Rig: Back wall (10m wide)
- Turf sled track: Center (10m x 2m)
- Olympic lifting area: Front (rubber mats, 3m x 5m)
- Storage: Side wall (plate trees, kettlebell racks)
Cost:
- Equipment: $25,000-$35,000
- Flooring: $4,000-$7,000
- Total: $29,000-$42,000
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Medium Functional Area (100m²)
Space: 10m x 10m
Equipment:
- 4-bay freestanding rig
- 10 Olympic barbells
- 10 sets bumper plates
- 30 kettlebells
- 12 plyo boxes
- 3 battle ropes
- 3 sleds
- 2 Concept2 rowers
- 2 Assault bikes
- 15 slam balls, 15 medicine balls
Layout:
- Rig: Back wall (10m wide, 4 bays)
- Turf area: 10m x 6m (sled track + bodyweight zone)
- Olympic lifting: Front corner (rubber mats, 4m x 4m)
- Cardio corner: 2 rowers + 2 bikes (3m x 3m)
- Storage: Side walls
Cost:
- Equipment: $50,000-$70,000
- Flooring: $8,000-$12,000
- Total: $58,000-$82,000
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Large Functional Area (200m²)
Space: 20m x 10m
Equipment:
- 6-bay freestanding rig (or 2 x 3-bay rigs)
- 16 Olympic barbells
- 16 sets bumper plates
- 50 kettlebells
- 20 plyo boxes
- 4 battle ropes
- 4 sleds
- 4 Concept2 rowers
- 4 Assault bikes
- 6 Olympic lifting platforms
- 20 slam balls, 20 medicine balls
- TRX systems, gymnastic rings, resistance bands
Layout:
- Rig: Back wall (full 20m span, 6 bays)
- Turf area: 15m x 8m (sled track + central functional zone)
- Olympic lifting platforms: Side area (6 platforms, 2.4m x 2.4m each)
- Cardio row: Front corner (4 rowers + 4 bikes)
- Storage: Custom racks along side walls
Cost:
- Equipment: $100,000-$140,000
- Flooring: $16,000-$24,000
- Total: $116,000-$164,000
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Rig Configuration Options
Option 1: Freestanding Rig
Pros:
- No wall mounting (works in any space)
- Relocatable (not permanent)
- High load capacity
Cons:
- Takes up more floor space (stabilizer feet extend outward)
- More expensive than wall-mounted
Best for:
- Rental spaces (can't drill into walls)
- Gyms planning to move/expand
- Multi-purpose spaces
Cost:
- 2-bay: $4,500-$8,000
- 4-bay: $9,000-$15,000
- 6-bay: $14,000-$22,000
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Option 2: Wall-Mounted Rig
Pros:
- Space-efficient (no footprint except wall)
- Cheaper than freestanding
- Clean aesthetic
Cons:
- Permanent (drilled into wall studs or concrete)
- Requires structural support (engineer sign-off in some cases)
- Not relocatable
Best for:
- Owned facilities
- Purpose-built functional training areas
- Dedicated CrossFit boxes
Cost:
- 2-cell: $2,500-$5,000
- 4-cell: $5,000-$9,000
- 6-cell: $7,500-$13,000
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Option 3: Power Rack (Compact Alternative)
Pros:
- Compact footprint (1.2m x 1.2m)
- Standalone (no rig required)
- Budget-friendly ($1,200-$3,000)
Cons:
- Single-user (vs. rig with 4-6 athlete stations)
- Limited attachment points
Best for:
- Small PT studios
- Home gyms
- Budget-conscious startups
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Storage Solutions (Often Overlooked)
Plate Storage Trees
Capacity:
- 6-post tree: 300-400kg
- 9-post tree: 500-600kg
Cost: $300-$600 each.
Minimum:
- 1 tree per 2 barbells
- For 10 barbells: 5 trees
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Kettlebell Racks
Types:
- 3-tier rack (holds 12-15 kettlebells)
- Wall-mounted rack (holds 6-10 kettlebells)
Cost: $200-$500 each.
Minimum:
- 2-3 racks for 30-40 kettlebells
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Barbell Storage
Options:
- Vertical barbell holder (9-hole): $250-$400
- Horizontal wall rack: $150-$300
Minimum:
- 1 holder per 8-10 barbells
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Accessory Storage
Needed for:
- Slam balls, medicine balls
- Battle ropes (wall hooks)
- Resistance bands
- Jump ropes
- Foam rollers
Cost: $500-$1,500 (custom racks/shelves).
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Common Mistakes to Avoid
❌ Mistake 1: Buying Too Much Equipment Upfront
Trap: "I'll buy everything on the wish list right now."
Reality:
- You don't know what members will use most
- Equipment sits unused
- Cash flow problems (over-invested)
Better approach: Start with essentials. Add equipment based on member demand after 3-6 months.
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❌ Mistake 2: Skimping on Flooring
Trap: "I'll use cheap rubber mats. Save $5,000."
Reality:
- Cheap flooring fails in 12-18 months
- Looks bad (members notice)
- Equipment damage (plates punch through thin mats)
Better approach: Budget $100-$150/m² for quality turf, $60-$80/m² for quality rubber.
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❌ Mistake 3: Not Planning for Growth
Trap: "I'll start with a 50m² functional area. Expand later if needed."
Reality:
- Expansion is expensive (flooring doesn't match, equipment gaps)
- Members outgrow the space (classes full, wait times)
Better approach: Build 20-30% larger than you think you need. Easier to grow into space than retrofit later.
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❌ Mistake 4: Ignoring Traffic Flow
Trap: "I'll cram as much equipment as possible into the space."
Reality:
- Cramped space = unsafe (barbells swinging, sleds moving)
- Poor member experience (feels chaotic)
Better approach: Leave 1.5-2m clearance between equipment zones. Plan traffic paths.
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❌ Mistake 5: Buying Home-Grade Equipment for Commercial Use
Trap: "This barbell is $200 vs. $500. Same thing, right?"
Reality:
- Home-grade barbells bend, sleeves seize, knurling wears off
- Fail within 6-12 months under commercial use
Better approach: Buy commercial-rated equipment (PSI 190,000+, rated for 50+ uses/week).
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Functional Training Area Costs (Summary)
| Size | Equipment Cost | Flooring Cost | Total Cost | Members Capacity | |------|---------------|---------------|------------|------------------| | Small (50m²) | $25k-$35k | $4k-$7k | $29k-$42k | 6-10 per class | | Medium (100m²) | $50k-$70k | $8k-$12k | $58k-$82k | 12-18 per class | | Large (200m²) | $100k-$140k | $16k-$24k | $116k-$164k | 20-30 per class |
Not included:
- Storage racks (add $2k-$5k)
- Mirrors (add $1k-$3k)
- Sound system (add $1k-$3k)
- Lighting (LED, $500-$2k)
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ROI: Is a Functional Training Area Worth It?
Yes. Here's why:
Higher Member Retention
Functional training areas are the most popular zone in modern gyms:
- 65% of members aged 25-45 prefer functional training over traditional machines
- Members who use functional areas have 30% higher retention rates
Result: Better retention = higher lifetime value per member = more revenue.
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Premium Pricing
Gyms with functional training areas can charge premium memberships:
- Standard gym: $40-$60/month
- Functional training gym: $70-$100/month
Example: 200 members x $20 extra/month = $4,000/month = $48,000/year extra revenue.
Payback period (medium functional area): $58,000-$82,000 investment ÷ $48,000/year extra revenue = 1.2-1.7 years.
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Group Class Revenue
Functional training areas enable group classes:
- CrossFit classes: $25-$35/class
- HYROX training: $30-$40/class
- Bootcamp: $20-$30/class
Example: 10 classes/week x 12 members/class x $30/class = $3,600/week = $187,200/year.
Even at 50% capacity: $93,600/year.
Payback period (medium functional area): $58,000-$82,000 ÷ $93,600/year = 7-10 months.
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Compound Fitness Functional Training Equipment
At Compound Fitness, we specialize in functional training fitouts for Australian gyms. Here's what we recommend:
Our Top Functional Training Products:
Rigs & Racks:
- 2-Bay Freestanding Rig — $6,995
- 4-Bay Freestanding Rig — $12,495
- Commercial Power Rack — $2,795
Barbells & Plates:
- Olympic Lifting Barbell (Chrome) — $495
- Commercial Bumper Plate Set (155kg) — $1,295
Kettlebells & Dumbbells:
Functional Equipment:
- Wooden Plyometric Box Set — $1,695 (set of 6)
- Battle Rope (15m) — $145
- Commercial Prowler Sled — $595
Flooring:
- Premium Functional Training Turf (20mm) — $120/m²
All backed by our 5-year commercial warranty.
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Your Next Steps
1. Measure Your Space
Functional training area size: ___ m²
Calculate equipment and flooring needs based on templates above.
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2. Set Your Budget
Budget tier: $500-$800/m² (rubber flooring, essential equipment only) Mid-range: $800-$1,200/m² (turf flooring, full equipment list) Premium: $1,200-$1,600/m² (premium turf, top-tier equipment, custom rig)
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3. Request a Custom Functional Training Quote
Visit our Burleigh Heads showroom: See and test all functional training equipment.
Get a custom functional area design: Send us your floor plan. We'll design your rig, flooring, and equipment layout.
📞 Call: 0414 275 045 ✉️ Email: sales@compoundfitness.com.au
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4. Browse Our Functional Training Equipment
Rigs & Racks → Bars & Weights → Functional Equipment → Gym Turf & Flooring →
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Functional training areas are the highest-ROI investment in modern gyms:
- Higher member retention (30% improvement)
- Premium pricing ($20-$40 extra/month)
- Group class revenue ($90k-$180k/year potential)
Start with essentials: Rig, barbells, bumper plates, kettlebells, plyo boxes, turf flooring.
Expand based on demand: Add sleds, rowers, bikes, rings, TRX as members request them.
Don't skimp on flooring. Turf makes functional areas look and feel premium.
Test equipment before buying. Visit showrooms. Ask for references.
Your functional training area will define your gym. Make it count.
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About Compound Fitness
Compound Fitness is Australia's leading supplier of premium commercial gym equipment. Based in Burleigh Heads, QLD, we specialize in functional training fitouts for CrossFit boxes, boutique studios, and commercial gyms. With 5-year warranties, nationwide delivery, and expert support, we're the trusted choice for gym owners across Australia.
Browse Our Functional Training Equipment →
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Categories: Functional Training, Gym Setup, CrossFit Equipment, Buyer's Guides
Tags: functional training area, CrossFit equipment, gym rigs, functional training setup, gym flooring, turf flooring, Olympic barbells, Australian gym owners, gym fitout
Image Suggestions: 1. Hero: Completed functional training area with rig, turf, sleds 2. Layout diagram: 50m² / 100m² / 200m² templates 3. Close-up: Rig with pull-up bars and attachments 4. Action shot: Athletes using functional training equipment 5. Before/after: Empty space → finished functional area 6. Equipment collage: Barbells, kettlebells, sleds, boxes 7. CTA: Compound showroom with functional training setup
Internal Links:
- Functional Equipment Collection: https://www.compoundfitness.com.au/collections/functional-equipment
- Rigs & Racks: https://www.compoundfitness.com.au/collections/rigs-and-racks
- Gym Turf: https://www.compoundfitness.com.au/collections/gym-turf
- Complete Gym Fitout Guide:
- Contact Us: https://www.compoundfitness.com.au/pages/contact
