Equipment melts the plastic together and extrudes it through a perforated steel plate. The strands exit the steel plate into a water trough, solidifying the synthetic grass mixture. A machine pulls the strands through a large pulley and keeps them separated while they move on to the next station. Rollers stretch the strands until they become as thin as natural grass. Spools hold the synthetic grass strands. Once a spool has been filled, different color strands are woven together to form multiple synthetic yarns. Traveling through guides while wound around a giant spool prevents the yarn from slackening.<\/p>\n
Mesh fabric merges with synthetic sheeting while the synthetic yarn travels through tubing to a tufting machine. A tufting machine is like a giant sewing machine, containing over 200 needles to hook the yarn through the sheeting.<\/p>\n
While the turf is being tufted, small knives underneath cut the ends to make the yarn appear like grass blades. The backing is moved to a coating roller which picks up adhesive to apply to the turf\u2019s backing.<\/p>\n
The adhesive is dried in both open air and an enclosed setting. As the turf exits the drying, hot pins burn holes into the turf for drainage.<\/p>\n
After multiple inspection points, including measuring the turf fiber length and minor trimming, the turf is moved to a device simulating football cleats to affirm the turf\u2019s durability.<\/p>\n
This comprehensive video featured on the Discovery Channel\u2019s hit show \u201cHow it\u2019s Made\u201d takes you through each step of the synthetic grass process.<\/div><\/div><\/div>
Through years of research and development, synthetic grass has been modified and transformed into what we now know as \u201cthird-generation\u201d synthetic grass, according to the Synthetic Turf Council.<\/p>\n
Through this constant evolution, synthetic grass has become the high-quality material we know today for most landscape installations.<\/p>\n
The actual green blade of synthetic grass comprises a polyethylene material, a common form of plastic found in items such as bottles and plastic bags. The polyethylene comes in a solid pellet and is heated down along with any color tones and UV-resistant additives.<\/p>\n
The thatch layer of synthetic grass is made from polypropylene, polyethylene or nylon. The thatch layer provides the turf with an added support layer and blade recovery.<\/p>\n
Synthetic grass blades are inserted into the backing in rows through a tufting machine, which is basically a giant sewing machine with hundreds of needles. This machine gives the grass blades and thatch a more secure hold, increasing the turf\u2019s life and durability.<\/p>\n<\/div><\/div><\/div>
What began as a part of a solution to help improve inner city youth\u2019s physical fitness in the 1950s sprouted into an entire industry dedicated to synthetic grass production.<\/p>\n
The Ford Foundation\u2019s Education Facilities Laboratory, in conjunction with Monsanto Industries and Chemstrand, encouraged the use of synthetic fiber carpeting in schools. From 1962 through 1966, The Creative Group, Chemstrand\u2019s research organization, tested the synthetic turf carpet surfaces for water drainage and resistance, and durability regarding foot traction.<\/p>\n
The first large synthetic grass installation occurred in 1964 at Moses Brown School in Providence, Rhode Island. The grass was referred to as \u201cChemgrass.\u201d<\/p>\n
In 1965 Houston\u2019s Astrodome was in dire need of a consistent playing field as environmental conditions did not permit a decent atmosphere for natural grass growth. Instead of the field often coated with green paint among the dirt and patches of grass, Astrodome developer Judge Hofheinz consulted Monsanto about installing Chemgrass.<\/p>\n
The Major League Baseball Team, the Houston Astros, began their season in 1966 throwing pitches and knocking out home runs on top of Chemgrass, formally re-named \u201cAstroturf,\u201d the household name known to much of America today. Invented by James M. Faria and Robert T. Wright of the Chemstrand Company, Astroturf\u2019s first-generation synthetic grass showcased tightly curled nylon fibers woven into a foam backing.<\/p>\n
A Trademark patent was officially issued for artificial turf on July 25, 1967.<\/p>\n
Following Astrodome\u2019s success, Indiana State University installed artificial turf for the first outdoor stadium in 1967.<\/p>\n
Artificial turf became a surface success that continued to climb slowly but surely through the 1970s with sports arenas throughout the United States and Canada. Cincinnati\u2019s Riverfront Stadium, Philadelphia\u2019s Veterans Stadium, and Pittsburgh\u2019s Three Rivers Stadium followed the artificial turf trend.<\/p>\n
As the 1970s came into full swing, the artificial turf industry followed the shag carpet trend and introduced \u201cshag turf.\u201d The longer yarns were created from a softer polypropylene material, much more user-friendly than its first-generation predecessor. Sports like field hockey benefited from this surface. However, soccer was left in the dust due to the soccer ball\u2019s reaction to the grass’s surface.<\/p>\n
Fast forward to the middle of the 1990s to third-generation artificial turf, which featured a much softer polyethylene blade fiber. You will find this turf on any residential, commercial or sports landscape today. The third-generation synthetic grass also features longer fibers spaced farther apart and a \u201cthatch,\u201d or dead grass yarn, positioned between the grass blades and the backing. For ideal turf form, function and stability, infill is spread throughout for extra comfort while providing adequate foot traction.<\/p>\n<\/div><\/div><\/div>
Artificial turf captured America\u2019s attention after Astroturf installed the first generation of synthetic grass for the Houston Astrodome\u2019s baseball field in 1966. This installation set a precedent for many sports fields across America that could not otherwise maintain natural grass.<\/p>\n
Through peaks and valleys of media scrutiny along many product modifications, second and third-generation artificial grass became a staple for FIFA at the 2010 World Cup Games in South Africa. In addition to taking root on the lawns of American homeowners, synthetic grass has since replaced Hollywood\u2019s infamous red carpet several times, including the Teen Choice Awards, the Latin Grammy\u2019s, and other large Hollywood parties to encourage the \u201cgo green\u201d lifestyle.<\/p>\n<\/div><\/div><\/div>
By definition, a turf\u2019s denier measures the density of the turf fibers. According to Merriam Webster\u2019s Merriam-Webster\u2019s<\/a> definition, a denier is a unit of fineness for yarn equal to the fineness of a yarn weighing one gram for every 9000 meters.<\/p>\n<\/div><\/div><\/div> Drainage systems are primarily designed to allow water to percolate through the backing of the turf and drain through the base layer into the water table. Most synthetic grass backing is perforated with holes that measure approximately \u00bd centimeter in diameter and can drain at a rate of more than 400 inches per hour per square yard.<\/p>\n With the exception of most synthetic putting greens, nearly all landscape turf is perforated and allows for easy drainage. A good drainage system can not only help with clean up, but it will also help prevent spores and bacteria from building up within the synthetic grass.<\/p>\n<\/div><\/div><\/div> Oval Fiber<\/strong> Diamond De-Lustered Fiber<\/strong> 3D Curvy “W” Fiber<\/strong> Omega Fiber<\/strong> “C” Shaped Fiber<\/strong> “M” Shaped Fiber<\/strong> S Blade<\/strong> Corrugated<\/strong> U Shape<\/strong> Diamond De-Lustered & Mini Ultra<\/strong> 3D Curvy W & Curvy Ribbed C<\/strong> When the nail rusts, it will swell, which helps secure the turf to the base layer. Non-galvanized nails are ideal for synthetic grass installations.<\/div><\/div><\/div> It is within the synthetic grass construction process that an adhesive glue is coated to the back of the synthetic turf. The coating must be done with the right elements for the synthetic grass to have a secure and strong backing.<\/p>\n A coated backing is most commonly comprised of either a urethane material or a latex material.<\/div><\/div><\/div> Throughout recent years, synthetic grass has been utilized as an alternative to natural grass. Not only does synthetic grass stay green all year long, but it also aids in multiple aspects of environmental conservation.<\/p>\n 1. Water Conservation:<\/strong> 2. Pesticides:<\/strong> 3. Carbon Emissions:<\/strong> A synthetic lawn not only benefits the end user but also has multiple environmental advantages. By eliminating water and chemical waste and reducing carbon emissions, artificial turf can solve many ongoing environmental problems.<\/p>\n<\/div><\/div><\/div> Both of these will require seaming tape and glue instead of nails due to the potentially high activity on these surfaces. However, staples and nails are still needed to fasten the outside edges of these surfaces.<\/p>\n For more information about installing turf using nails and staples, please watch this video:<\/div><\/div><\/div> Synthetic grass installation can be basic; however, no two synthetic grass installs are done exactly the same way. There will always be unique situations for each install; however, there are basic differences for specific synthetic grass needs. A typical synthetic grass installation can last anywhere between one to three days.<\/p>\n For a basic synthetic grass installation, consider these steps:<\/p>\n 1. Pre-Installation:<\/strong> 2. Base Preparation:<\/strong> 3. Compacting Base:<\/strong> 4. Weed Retardant Layer (optional):<\/strong> 5. Laying Turf:<\/strong> 6. Custom Fitting Turf:<\/strong> 7. Tucking Turf (optional):<\/strong> 8. Apply Infill:<\/strong> 9. Final Groom:<\/strong> Set the cups at the grade level if you use a Poly Putt, Nylon putting green or a True Putt product. Cut and shape the green and attach your fringe. An optional final step is to use a soil vibratory plate compactor to distribute the sand infill into the putting green materials.<\/div><\/div><\/div><\/i><\/i><\/span>6. Face Weight: What It is and What It Means<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>7. Drainage Rate: Why It Matters and How It Helps<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>8. The Many Shapes of Synthetic Grass Blades<\/span><\/a><\/h4><\/div>
\nTurfs that have oval-shaped fibers are commonly found in many different landscape installations. These fibers feel soft to the touch while still maintaining durability.<\/p>\n
\nSynthetic turf that features a diamond de-lustered shape maintains a soft but sturdier feel. It works ideally as a landscape grass for commercial and residential areas.<\/p>\n
\nThe 3D Curvy \u2018W\u2019 fiber is a strong fiber that can withstand large amounts of pressure and helps the turf, as a whole, bounce back to its original state. The blade offers multiple support points, which allows for greater durability and a \u201cmemory\u201d effect. The turf will bounce back to its original state, despite the surface weight.<\/p>\n
\nThe omega blade shape can be found most often in pet turfs as well as shorter pile heights.<\/p>\n
\nThe C-shaped blade gives the turf a natural look and helps the synthetic grass feel soft to the touch. This blade shape can be applied on any installation; however, it is most commonly found on residential and commercial property landscapes.<\/p>\n
\nThe \u201cM\u201d shaped blade creates more durability making the turf ideal for heavy foot traffic. Used primarily for areas that experience high amounts of foot traffic, the \u201cM\u201d blade is excellent for landscapes with high foot traffic.<\/p>\n
\nThe \u201cS\u201d Blade is built utilizing an S’s curves to reflect less sunlight – giving it a more natural and realistic appearance. The extra volume in shape and increased durability in the surface area give the blade moderate traffic resilience.<\/p>\n
\nThe Corrugated blade fiber has a unique shape that allows for enhanced recovery and stability. The intricate shape also reduces shine and creates a more visual texture and depth in each blade, making this shape ideal for residential and commercial projects with moderate traffic.<\/p>\n
\nThe curvature on the \u201cU\u201d shaped blades is designed to create a visual feeling of added depth to your turf, especially when viewed from above. The broader blades result in the natural look of a strong and healthy landscape, bringing to life any project with moderate foot traffic.<\/p>\n
\nThe Diamond De-Lustered & Mini Ultra shape combination ensures a turf that is ideal for commercial and residential landscape installations as it maintains a soft yet sturdy feel.<\/p>\n
\nThe 3D Curvy W & Curvy Ribbed C shape combination allows for strong fibers that can stand up to foot traffic while still maintaining a natural appearance and softness to the touch. These blade shapes will help the turf return to its original form with multiple support points and make it ideal for residential and commercial landscape installations.<\/div><\/div><\/div><\/i><\/i><\/span>9. Non-Galvanized Nail vs. Galvanized Nail<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>10. The Thatch Revolution: What It Did for Synthetic Grass<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>11. Tuft Binds: Why It\u2019s Important<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>12. Fading<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>13. How Synthetic Grass Helps the Environment<\/span><\/a><\/h4><\/div>
\nWithin the past few years, many areas across the nation and world have suffered from extreme drought, and water rationing is becoming commonplace. According to the Southern Nevada Water Authority, one square foot of synthetic grass can save up to 55 gallons of water in one year.<\/p>\n
\nIt may rid your plants and grass of annoying bugs, weeds and other overgrowths; however, pesticide chemicals have proven harmful side effects that not only hide in your lawn but eventually seep into your local water table. According to the Cancer Research Center-UK<\/a>, studies suggest pesticides could be linked to cancers such as leukemia, brain tumors, and breast and prostate cancer.<\/p>\n
\nAccording to the Environmental Protection Agency, gas-powered gardening equipment like lawnmowers represents five percent of air pollution<\/a> in the U.S. A synthetic lawn requires minimal upkeep with gas-powered gardening equipment and would eliminate the need for these items.<\/p>\n<\/i><\/i><\/span>14. Seaming Tape vs. Nails: When to Use What<\/span><\/a><\/h4><\/div>
\n
<\/i><\/i><\/span>15. A Typical Synthetic Turf Installation<\/span><\/a><\/h4><\/div>
\nRemove existing materials and rough grade the area to create a solid sub-base. Rough grade the area to uncover everything underneath, including electric wiring, irrigation and pipes. Cap sprinklers at the pipe level to avoid any kind of leakage. Install bender board to provide a clean separation for plants and turf.<\/p>\n
\nInstall \u00bd\u201d or less crushed base to allow for proper drainage. Install this layer three inches deep. Distribute the base and ensure it is level to account for any sloping areas. Install drainage area. A smooth base will account for the surface-level appearance of the project.<\/p>\n
\nCompact base by vibrating, tamping and rolling the gravel. This ensures the base is solid so nails can be driven into the turf.<\/p>\n
\nThe weed cloth layer prevents growth from the base through the turf. This layer is not recommended if the installation involves pet usage. Overlap weed cloth edges by six inches and secure with as many flathead nails as possible to prevent the cloth\u2019s movement. Trim the cloth to fit the area and leave a quarter-inch gap along the hardscape or border areas to allow for easier tucking.<\/p>\n
\nFind a straight edge of the turf or a perpendicular edge for alignment. Square to fit the area and minimize cutting and fitting on all four sides. Secure the turf edges with nails to hold them in place. *Remember to soldier the turf towards your privileged viewpoint; in other words, consider the natural blade direction of the grass<\/p>\n
\nOvercut the turf by one inch along the edges to provide excess turf necessary for tucking. If there are doubts, cut the turf fatter than estimated, as it can be trimmed later. Use a seaming tool to seam edges together. Cut the seams in an S-shape to avoid the turf pushing up. Install nails every six inches along the edges and drive them \u00be of the way down. Remember to move the surrounding fibers with another nail or staple, then tap the nail head all the way to the backing. Use U-shaped nails for the seams to join the turf edges together.<\/p>\n
\nHide the edges of your turf against the hardscape by using a metal bar known as a \u201cwonder bar.\u201d<\/p>\n
\nUse a power brush to force grass blades up for infill to be applied. Apply your specified infill layer. The infill layer acts as a balance to hold the blades upright and gives the turf more weight.<\/p>\n
\nPower brush the turf once again to lightly force infill granules into the base of the turf. Remove any excess debris.<\/p>\n<\/div><\/div><\/div><\/i><\/i><\/span>16. A Typical Pet Installation<\/span><\/a><\/h4><\/div>
<\/i><\/i><\/span>17. A Typical Putting Green Installation<\/span><\/a><\/h4><\/div>