In the beginning: a pellet
The artificial grass story begins with synthetic pellets. Each year Desso Sports Systems melts down as many as 2.5 million kilos of these granulates in the process of creating artificial-grass fibres. The pellets are made from polypropylene or polyethylene.
Twice around the earth in a day
The granulates are melted at high temperature and extruded through a mould under pressure. The mould imitates the grain structure of a natural blade of grass and creates long artificial grass fibres that, after cooling with water, are then drawn over rolls. This ‘stretching’ makes the fibres extra strong. Each day we produce roughly 90 000 km of fibres…enough to go twice around the world.
Ready for processing
The artificial grass fibres are now ready for processing. The bobbins of yarn will either be dispatched to site where they will be injected to reinforce a natural pitch (Desso GrassMaster) or will be sent to the tufting department.
Large sewing machine
The artificial grass fibres are tufted into a polypropylene mat. The basic principle of tufting has been derived from the sewing machine. Across the whole width of the mat hundreds of needles are positioned, each of which pulls a long artificial grass fibre through the mat. When the needle returns a loop is formed. The loop is cut at the top so the fibres will stand straight up. Line markings can be tufted into the mat in a colour of choice.
Any small corrections necessary are made immediately with a "first check", e.g. cutting long fibres down.
Coat of latex
To anchor the fibres in the mat a 1 mm thick layer of liquid latex is applied and hardened in an oven at 85° C. The fibres are secured and the artificial turf is then resistant to the heaviest sliding tackles. The artificial turf is now ready for installation.
A final inspection
Each roll of turf is inspected, metre by metre, under bright light prior to being packed and transported to its final destination.
- Stage 1. Excavation
The proposed pitch area is excavated to a depth of between 35 and 50 cm.
- Stage 2. Laying the foundation layer
For good drainage, the excavated area is filled with quartz sand or another water-permeable material such as rubble, gravel or a mix of mineral matter. Extra drainage is provided by means of drainage hoses.
Then a layer approximately 10cm deep, comprising a mixture of lava and/or rubber, is applied. Alternatively, an e-layer or elastic layer made from bonded rubber can be used. This top layer provides shock absorption and energy rebound and influences the technical sporting characteristics of the artificial pitch.
- Stage 3. Rolling the foundation layer
The foundation layer applied is rolled until it is smooth and even.
- Stage 4. Laying the geo-textile (optional)
Geo-textile (foil or root mat) can help ensure an even distribution of pressure over the synthetic pitch.
- Stage 5. Laying rolls of artificial grass
Each roll of artificial grass is rolled out carefully and put in position according to a laying plan. This plan is specially prepared by Desso Sports and is custom-made for each area of artificial grass.
- Stage 6. Gluing
After rolling out the artificial grass, the seams are glued to seaming tape using a special artificial grass adhesive.
- Stage 7. Cutting the line markings (if necessary)
Any game lines that run straight across or along the pitch can be tufted in during production. Other lines and features, such as the centre circle, have to be cut in on site by expert installers.
- Stage 8. Pressing the glued seams
All seams receive extra pressing to ensure that they do not form weak spots in the artificial turf.
- Stage 9. Infill
Depending on the type of artificial grass and the sport for which the field is intended, the synthetic turf is in-filled with sand and/or rubber-like material (SBR, EPDM, TPE). First, a machine precisely distributes the sand over the entire area. This is then brushed in thoroughly using a brushing machine. If required, the rubber infill is then applied evenly.
- Stage 10. Your pitch is finished
The average installation can take between 6 to 8 weeks. Your synthetic grass pitch is then ready for use. Naturally, not every installation follows the exact same stages above; every pitch is different because each synthetic pitch is custom-made. Desso Sports is happy to help you make the right choice of surface for your synthetic pitch.
Curious about the installation of reinforced natural grass (Desso GrassMaster)? Find out here.
