Functional Training and Group Fitness Equipment

Functional Training Rigs and Modular Systems: My 30-Year Journey from Skeptic to Believer

When functional training rigs first started appearing in gyms back in the day, I was initially not a super fan. I’ve always liked diversified training techniques but like most are sometimes opposed to change. As someone who has been in the fitness equipment business since the early 90s, I have seen plenty of trends come and go, and I honestly thought these jungle gym-looking contraptions were just another fad that would disappear within a year or two.

Again, like so many other new strategies I was wrong about that one.

I remember installing our first functional training rig at one of our client gyms about 25 years ago. The owner was absolutely insistent despite my gentle attempts to steer him toward more traditional equipment. “Trust me,” he said, “this is where training is headed.”https://www.rushwalter.com/how-to-start-a-corporate-gym-in-2025-equipment-costs-planning-guide/ I set it up reluctantly, convinced he’d be calling me to replace it with regular squat racks within months.

Six months later, I was back at his gym, but not to remove the rig. I was there taking measurements to install a BIGGER one because the first had become so popular they needed to expand. And the cool thing I have learned and now like about rigs is they are expandable.

What I’ve learned over three decades in this industry is that functional training isn’t just some passing trend – it fundamentally changed how we approach fitness equipment design and workout spaces. The versatility is what makes these systems so brilliant. One well-designed rig can replace 7-9 individual pieces of equipment, which is a game-changer for smaller facilities working with limited square footage.https://www.rushwalter.com/essential-cardio-equipment-for-commercial-gyms-in-2025/

The modularity aspect is what really got me hooked, though. You can literally customize these systems to fit any space or training philosophy. Starting small with a basic frame? No problem. Want to expand later when budget allows? Just add modules. It’s like fitness Lego for adults, and I’m here for it.https://www.rushwalter.com/understanding-commercial-vs-residential-gym-equipment/

I made a huge mistake early on with these systems that I now avoid. I once designed a gorgeous custom rig for a high-end boutique gym without properly considering their programming needs. It looked amazing but wasn’t functional for the types of classes they actually taught. The owner was… let’s just say less than thrilled with me. Now I always start by asking clients about their specific training methodologies before even thinking about design.

From a technical standpoint, there’s a few things I always tell people to look for in a quality rig:

• Weight capacity ratings (at least 1,000 lbs for commercial use)
• Powder coating quality (chip-resistant is worth paying extra for)
• Connection point versatility (the more attachment options, the better)
• Expandability potential (will the manufacturer still carry compatible parts in 5 years?)

I’ve watched countless gyms transform their entire business model around a well-designed functional training area. One client in particular went from struggling to fill classes to having waitlists after reconfiguring their space around a central rig system.https://www.rushwalter.com/corporate-gym-budget-development/ Their members loved the community aspect of working out together in a shared space instead of being isolated on individual machines.

If you’re considering adding functional training equipment to your facility, let’s start with a needs assessment rather than just picking something that looks cool online. And I’ll help you not make the mistake of underestimating how much floor space you’ll need around the rig for actual movement. Nothing more frustrating than having a beautiful rig that people can’t actually use properly!

The truth is, after 30 years in this business, functional training rigs and modular systems have proven to be one of the most significant innovations I’ve witnessed. They’ve changed not just how we design equipment, but how we think about training spaces altogether.

Group Training Stations and Circuit Training Setups: Learning From My Biggest Failures

After three decades in the fitness equipment business, I’ve seen circuit training evolve from those old-school air-hydraulic resistance machines to the dynamic, multifunctional setups we have today. And let me tell you, early on, I made a few mistakes when designing these spaces for clients.

My first attempt at installing a group circuit training setup was less than perfect. This was back in the early 2000s, and I was so focused on cramming as many stations as possible into the space that I completely ignored flow. The trainer couldn’t even see half the participants from certain positions! The gym owner called me two weeks later saying, “People are literally running into each other during transitions.” Talk about embarrassing.

What I learned from that epic fail is that spatial planning is everything with circuit training. You need to consider not just the footprint of the equipment itself, but the actual movement patterns people will use at each station. I now recommend at least 50-60 square feet per station for most circuit setups, which sounds like a lot until you see how much space people actually need when doing medicine ball throws or battle rope waves.

The beauty of modern group training stations is their versatility. I’ve worked with facilities that completely transform their circuit setup seasonally based on member goals. One of my clients runs a “Summer Shape-Up” circuit focused on metabolic conditioning in spring, then switches to a strength-focused circuit for fall and winter. Their retention rates are through the roof because members never get bored.

From a practical standpoint, I’ve found that the most successful circuit setups follow a few key principles:

First, visibility matters enormously. Both trainers and participants need clear sightlines across the entire circuit area. I once designed what I thought was a clever L-shaped circuit configuration, but instructors hated it because they couldn’t monitor proper form for everyone at once.

Second, equipment selection should balance variety with simplicity. You want enough diversity to target different movement patterns and energy systems, but not so many complicated pieces that people waste transition time figuring out what to do. My sweet spot is usually 8-12 distinct station types.

Third, don’t skimp on flooring! I made this mistake years ago with a beautiful circuit setup installed on standard commercial carpet per the client’s direction. Within three months, that carpet was absolutely destroyed from kettlebell impacts and sled pushes. Now I always encourage my clients to invest in at least 8mm rubber flooring throughout circuit areas, even if it means increasing an existing budget.

One thing that constantly surprises me is how effective simple, inexpensive equipment can be in these setups. Some of the most popular stations in circuits I’ve designed use nothing more than sandbags, plyo boxes, and suspension trainers. It’s not always about having the flashiest gear – it’s about creating intuitive stations that deliver results.

The timing system is another critical component people often overlook. I’ve installed gorgeous circuit setups that clients ended up hating because their timing system was confusing or unreliable. Now I always build the cost of a quality timer with large displays into my initial proposals – it’s not an add-on, it’s essential infrastructure.

After all these years, I still get excited when designing new circuit training spaces. When done right, they create this amazing energy that just doesn’t exist in traditional training environments. There’s something special about seeing twenty people moving simultaneously through a well-designed circuit, all working at their own level but motivated by the group dynamic.

Suspension Training Systems for Commercial Use: What I’ve Learned the Hard Way

When suspension trainers first hit the market, I was skeptical that they were just another gimmicky fitness tool that would disappear as quickly as those weird vibrating belt machines from the ’80s. Fast forward a few years, I began using one, and I found myself installing suspension training stations in practically every commercial gym we worked with. Talk about enjoying a new fitness tool!

My first commercial suspension training setup was for a boutique gym in 2010. I mounted the anchor points directly into their drywall because the owner was in a rush and insisted it would be fine. Guess what happened three weeks later? Yep, complete wall failure during a group class. Nobody was hurt, thankfully, but I learned a critical lesson that day – proper anchoring isn’t just important, it’s absolutely non-negotiable with suspension systems.

These days, I refuse to install commercial suspension stations without either dedicated ceiling-mounted anchor points rated for at least 1,000 pounds or a freestanding frame system. Most folks opt for the free-standing system. Your insurance provider will thank you, believe me.

The versatility of suspension trainers is what makes them so valuable in commercial settings. I’ve worked with facilities that serve everyone from elite athletes, rehab client’s, to senior fitness classes, and they all utilize the same basic suspension setup – just with different progressions and modifications. One system, endless possibilities for programming.

Durability is where I see most commercial gyms make mistakes with their suspension systems. They buy consumer-grade equipment and then act surprised when it falls apart after three months of heavy use. Commercial suspension trainers should have reinforced stitching, metal (not plastic) components, and easily replaceable straps. Yes, you’ll pay more upfront, but you won’t be replacing them every quarter.

Storage is another headache that gym owners often overlook. I once designed a beautiful suspension training zone with 12 stations, but completely forgot about where they’d store the trainers when not in use. The staff ended up just piling them in a corner, which led to tangling issues and premature wear. Now I always include dedicated storage hooks or a mobile storage rack in my designs.

Height adjustability is crucial for commercial installations. Your members range from 5-foot-nothing to nearly 7 feet tall, and they all need to be able to adjust their trainers quickly between exercises. I prefer systems with clear markings on the straps and simple adjustment mechanisms that don’t require reading a manual to figure out.

Cleanliness became a major concern with shared suspension equipment, especially after 2020. I now recommend antimicrobial straps and handles for all commercial installations, plus installing sanitizing stations nearby. Some of my clients have also implemented color-coded systems where used trainers go in a specific bin for thorough cleaning before being returned to service.

The biggest change I’ve seen over my years in the industry is the integration of suspension training with other modalities. Modern commercial setups rarely feature suspension training in isolation – they’re usually part of functional training zones that include battle ropes, kettlebells, and plyometric elements. This creates more programming possibilities and maximizes the use of space.

From a business perspective, suspension systems offer an incredible ROI for commercial facilities. They’re relatively inexpensive compared to traditional strength equipment, take up minimal space, and enable both personal training and group fitness programming. One client completely transformed their struggling gym by replacing an underused line of isolation machines with a 10-station suspension training zone. Their group training revenue doubled within three months.

If I could give one piece of advice after thirty years in this business: don’t cut corners on installation or equipment quality with suspension systems. Your members’ safety depends on it.

Plyometric Boxes, Battle Ropes, and Medicine Balls: The Equipment Trifecta That Changed Everything

I fondly remember the day I realized these three simple pieces of equipment were going to change fitness forever.https://www.youtube.com/watch?v=lHYvqJlrAUE It was around 2012, and I was visiting a client’s gym that had been struggling with membership retention. The owner had basically ignored my advice and purchased a small set of plyo boxes, battle ropes, and medicine balls instead of the expensive machine package I’d recommended.

I walked in expecting to see those items gathering dust in a corner. Instead, I found a packed class absolutely loving their workout. People were sweating, laughing, and pushing themselves harder than I’d seen on any fancy machine. That was my wake-up call.

The beauty of this equipment trifecta is its simplicity and effectiveness. I’ve installed high-end gyms with six-figure budgets, but honestly, these three basic items often get more use than equipment costing 20 times more. There’s something primal about slamming a medicine ball, jumping onto a box, or creating waves with heavy ropes that connects with people on a different level.

From a practical standpoint, plyo boxes are probably the trickiest of the three to get right in a commercial setting. I made a huge mistake early on recommending wooden boxes to a high-volume fitness center. Within months, the edges were splintering and causing injuries. Now I only recommend soft-sided plyo boxes for commercial facilities. Yes, they’re more expensive initially, but they last longer and drastically reduce injury risk.

Height variety is critical with plyo boxes. I typically recommend a set that includes at least 12″, 18″, 24″, and 30″ options for commercial use. One client tried to save money by just getting 24″ boxes for everyone, and it was a disaster – too high for beginners and too low for advanced athletes. Nobody was happy.

Battle ropes taught me an important lesson about flooring considerations. The first set I installed for a client actually damaged their beautiful hardwood floors within weeks from the constant friction. Now I encourage direction on either installing dedicated anchor points in concrete floors or using protective mats underneath if they’re going on premium flooring.

Thickness matters enormously with battle ropes. I’ve found that 1.5″ diameter ropes are the sweet spot for most commercial applications – thick enough to provide substantial resistance but not so thick that smaller members can’t grip them properly. The 2″ monsters look impressive in photos but are actually impractical for about 70% of typical gym members.

Medicine balls are deceptively technical. The cheap vinyl-covered ones I initially installed for clients would split at the seams after just a few months of slamming exercises. I learned to look for seamless construction and textured surfaces that improve grip when hands get sweaty. For commercial use, I now only recommend rubber or polyurethane shells with sand filling rather than air-filled options.

Weight progression is crucial with medicine balls. I recommend commercial facilities stock at least 4-30 pound options in 2-pound increments. Color coding by weight is also extremely helpful for quick transitions during group classes.

Storage is the detail most people overlook with all three of these items. I once visited a gym six months after installing a beautiful functional training area to find medicine balls rolling around everywhere, plyo boxes stacked haphazardly in corners, and battle ropes tangled in piles. Now I include dedicated storage solutions with every installation – wall-mounted racks for medicine balls, vertical storage for plyo boxes, and hanging systems for battle ropes.

The durability factor varies dramatically between brands, which I learned the hard way. We once outfitted an entire university athletic facility with budget battle ropes that started fraying within weeks. The replacement cost wiped out any initial savings. Now I inform clients that with these items, buying commercial-grade the first time is always cheaper than replacing economy options repeatedly.

The beauty of this equipment trio is how they work together in circuit formats. I’ve helped design some incredibly effective training spaces using just these three elements plus body weight exercises. The combination targets power, strength, stability, and conditioning in ways that traditional equipment simply can’t match.

Flooring Solutions for Functional Training Zones: My Expensive Education

If there’s one thing I’ve learned over 30 years in the fitness equipment business, it’s that flooring might be the least sexy part of gym design, but it’s absolutely the most critical. And boy, have I learned this lesson through trial and error.

Back in the early 2000s, I installed a beautiful functional training zone for a high-end health club with standard rubber flooring that was only about 1/4 inch thick. Looked great on opening day! Six months later? Not so much. The constant dropping of kettlebells and medicine balls had cracked the concrete underneath, and the thin rubber was torn to shreds. The repair cost more than doing it right the first time would have.

The truth is, functional training demands specialized flooring solutions. This isn’t like the old days when equipment stayed bolted in place and members moved predictably from machine to machine. Today’s workouts involve jumping, dropping weights, dragging sleds, and all kinds of high-impact movements that standard commercial gym flooring just can’t handle.

Thickness is absolutely non-negotiable when it comes to functional zones. I now encourage clients to install nothing less than 8mm rubber for basic functional areas, and for dedicated lifting platforms or heavy drop zones, we’re talking a minimum of 15-20mm, sometimes with additional shock absorption systems underneath. Your wallet and concrete slab will thank you.

One mistake I see gym owners make constantly is choosing flooring based on what looks prettiest in Instagram photos. Those bright-colored interlocking foam tiles might pop in pictures, but they’ll be destroyed within months in a commercial setting. I always tell clients: “You can have pretty floors that you replace annually, or slightly less pretty floors that last five plus years. Your choice.”

Seam integrity is another critical factor most people overlook. I once installed beautiful 4×6 rubber mats for a functional zone, but didn’t properly secure the seams. Within weeks, those mats were shifting during workouts, creating tripping hazards and gaps that caught equipment. Now I always recommend either puzzle-edge interlocking systems or products that can be heat-welded at the seams for high-traffic functional areas.

Sound dampening properties are worth their weight in gold, especially if your functional zone shares a building with other businesses. One of my clients nearly lost their lease because their neighbors below couldn’t handle the constant thudding from medicine ball slams. We ended up installing a floating floor system with dedicated acoustic underlayment that solved the problem, but it cost them triple what doing it right initially would have.

Cleanability is another factor that’s become super important. Functional training makes people sweat – like, really sweat – and that moisture gets trapped in flooring. I’ve seen mold develop under improperly sealed rubber flooring in as little as six months. Now I always recommend antimicrobial treatments and proper sealing protocols for all functional zone installations.

The return on investment for quality flooring is undeniable. One of my clients initially balked at the $30,000 quote for specialized functional zone flooring. They went with a $12,000 alternative from a big box supplier. Guess what? They ended up spending another $35,000 replacing it all eighteen months later, plus lost revenue during the renovation. Sometimes the cheapest option is actually the most expensive in the long run.

I’ve found that the best approach is often a zoned flooring system. Not every square foot of your functional area needs the same level of impact protection. We now design with specific zones in mind – extra thick padding under plyometric stations, specialized turf for sled work, high-density rubber for heavy lifting areas. This targeted approach maximizes performance while managing costs.

The most successful functional training floors I’ve installed over the years all share one thing in common: they were designed specifically for the programming they needed to support. There’s no one-size-fits-all solution here. Your floor needs to match your training methodology, not the other way around.

If I could go back and redo every functional training zone I’ve installed over the past three decades, the one thing I’d change would be investing more in the foundation. Because at the end of the day, your functional training is only as good as the floor it happens on.

Equipment for HIIT and Boot Camp-Style Classes: What I Wish Someone Had Told Me

When I first started setting up HIIT and boot camp spaces back in the early 2000s, I was a bit clueless. I basically threw together a bunch of cardio equipment, some dumbbells, and called it a day. Spoiler alert: that approach failed miserably.

My first real boot camp setup was for a gym that wanted to start offering high-intensity classes to compete with the boutique studios popping up everywhere in Atlanta. I persuaded them to invest in fancy equipment that looked impressive but proved completely impractical. The programmable LED timer system I insisted on? Broke within a month. The interactive touch-screen workout stations? Too complicated for quick transitions. I learned pretty quickly that the KISS principle (Keep It Simple, Stupid) reigns supreme in HIIT environments.

The beauty of effective HIIT equipment is its simplicity and versatility. After years of trial and error, I’ve found that the most successful boot camp setups focus on equipment that facilitates quick transitions, accommodates multiple fitness levels, and can withstand serious abuse. Because trust me, these items take a beating like nothing else in your gym.

Durability is non-negotiable. I once outfitted a studio with standard retail-grade equipment, and within three months, they were replacing half their inventory. Commercial-grade HIIT equipment costs more upfront but saves a fortune in replacement costs. Look for equipment with reinforced seams, welded (not bolted) connections, and materials tested specifically for high-volume use.

Storage efficiency might seem boring, but it’s absolutely critical for HIIT spaces. Most boot camp studios transition between multiple class formats throughout the day, so equipment needs to move quickly. I learned this lesson when a client called me frantically before their grand opening because they had nowhere to put 30 sets of equipment between classes. Now I always design with mobile storage solutions and quick-access racks as part of the initial plan.

I’ve found the most versatile HIIT equipment lineup includes:

Battle ropes (varying lengths and thicknesses), kettlebells (ranging from 8-70 lbs), slam balls (10-30 lbs), suspension trainers, plyo boxes (soft-sided for safety), agility ladders, resistance bands, and some form of push/pull apparatus like sleds or tanks. This combination allows for literally hundreds of exercise variations while minimizing space requirements.

Flooring considerations are absolutely crucial for HIIT spaces. After seeing multiple facilities damage their concrete foundations from repeated medicine ball slams, I now insist on shock-absorbing flooring systems specifically designed for high-impact zones. The initial investment might give you sticker shock, but it’s far cheaper than repairing structural damage to your building (a few of my clients have learned that one the expensive way).

Space allocation is where most boot camp setups go wrong. I once designed a beautiful HIIT studio that looked perfect on paper but became a chaotic mess during actual classes. Why? I hadn’t factored in the movement patterns and transition spaces needed between stations. Now I always calculate at least 50 square feet per participant for HIIT formats – anything less creates bottlenecks and safety hazards.

The most successful HIIT spaces I’ve designed incorporate clearly defined stations with visual cues for exercise selection. Color-coded zones, numbered stations, and simple exercise placards eliminate confusion during high-intensity intervals when people’s brains are oxygen-deprived. One client saw their class participation double after we implemented a color-zone system that made their workouts essentially idiot-proof (in a good way).

Equipment maintenance is the unglamorous reality of HIIT programming. These items take more abuse in a month than most traditional gym equipment sees in years. I now include quarterly maintenance protocols with every boot camp installation, focusing on checking connections, replacing worn parts, and testing structural integrity before small issues become dangerous failures.

After three decades in this business, the biggest lesson I’ve learned about HIIT equipment is that simplicity always wins. The most successful boot camp programs I’ve helped develop focus on fundamentals with equipment that can be used by anyone, regardless of fitness level. Because at the end of the day, it’s not about having the flashiest equipment – it’s about creating an environment where people can safely push themselves to their limits and see results.

Functional training and group fitness training are healthy ways to build your fitness facility membership and revenue. Contact me and I’ll show you how you can build up your athletic facility and encourage increased membership options.
Thank you for reading this fitness blog. May you enjoy a healthy day.
Walter
Proverbs 24:34; By wisdom a house is built, and by understanding it is established; and by knowledge the rooms are filled with all precious and pleasant riches.