HARTRU_IndoorMaintenanceManual

8/12/2019 HARTRU_IndoorMaintenanceManual

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Indoor Har-TruMaintenance

Manual


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Table of Contents

1.0 Introduction 3

2.0 The Issues 3

A. Surface Compaction 3B. Irrigation 4C. Humidity 5

3.0 Daily Maintenance 5

A. Tools Required 5B. Rolling 5C. Grooming 5D.Scarification 6E. Watering 6

4.0 Periodic Maintenance 7A. Tools and Materials Required 7B. Scarification 7C. Application of Coarse Blend 8D.Patching 8

5.0 Annual Reconditioning 9

A. Tools and Materials Required 9B. Cleaning the Court Surface 9C. Deep Scarification 10D.Application of New Material 10

6.0 Long-Term Renovation Practices 11A. Aerification 11B. Deep Scarification 12C. Milling Machines 12

7.0 Conclusion 13

8.0 Indoor Parameters 13

A. Surface Stiffness/Compaction 13

9.0 Indoor Structures 15


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1.0 INTRODUCTIONWhat is the perfect winter bubbled or indoor Har-Tru court? What does it look like,feel like and play like? Should it just be the same as an outdoor Har-Tru court?Because there are considerably more outdoor courts than there are winter bubbled orindoor courts, outdoor playability and performance is generally used as the standard.However, even outdoor courts perform across a widely variable range. And playerpreferences vary widely only adding to the confusion one persons perfect court isanothers disaster.

The objective of this manual is not to answer the question of what is the perfectwinter bubbled or indoor Har-Tru court. It is to provide bubbled and indoor courtowners with information about indoor courts and with routines for maintaining themat optimum playability. It is an attempt to synthesize industry practices with theprincipals of Har-Tru and the latest tools, equipment and technology. Also providedwith this manual are some parameters for indoor courts and a resource page forinformation on indoor structures.

2.0 THE ISSUESIndoor and bubbled Har-Tru courts exist in a controlled environment, free from rainand wind and freezing and thawing. Evaporation rates are typically very low andhours of use are typically very high. Consequently, indoor Har-Tru courts present adifferent set of maintenance challenges than their outdoor counterparts, and adiscussion of these challenges up front helps frame the maintenancerecommendations that follow in this manual. The issues are surface compaction,irrigationand humidity.

A. SURFACE COMPACTION

Severe compaction in the Har-Tru surface occurs indoors because of extremely highuse and because of the lack of weatherization; rain/evaporation and freeze/thawcycles that keep outdoor courts soft. This compaction creates a surface that is bald,slippery and difficult to irrigate. Compaction occurs when the loose surface materialgets ground down into extremely fine particles that come to rest on the courtsurface. These fines cement together, creating a thin surface layer that isextremely hard and nearly impervious. Water contributes to the cementing, and ifthe water has a high salts content it likely exacerbates the problem. Consistent useof aggressive grooming tools daily, and scarification tools and Coarse Blendperiodically will help keep courts safe, but unless the fines generated during theseason are removed the problem will not be resolved. The 4 photographs belowillustrate a compacted surface.


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Photo 1: Top 1/16 Compacted Photo 2: Bald Top Surface

Photo 3: Good Surface Below Compaction Photo 4: Magnified View of Compaction

B. IRRIGATIONIt may be difficult to maintain an appropriate amount of water in the surface profileof an indoor court. A dry court surface is extremely hard and slippery but with slowevaporation rates indoors, flooding the courts with too much water is also a realconcern. Adding to the challenge is that fact that the external temperature andrelative humidity have an impact. A truly cold dry winter day in the northeast candry courts out faster than even the hottest days in the southeast.

Strategies for maintaining water in the profile without over-wetting the court aredifficult to come by for several reasons. The first is that surface compaction in most

cases keeps the water from penetrating into the court surface. Instead the waterpools on top and the court rapidly becomes too flooded to continue watering. Thesecond challenge is scheduling time to water. Playing schedules are so busy that inmost cases, the only time is between 11pm and 6am. Most are watering by handwith a hose and this is slow and time-consuming.


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One solution is to keep the court surface soft so water penetrates easily. Strategiesfor accomplishing this were discussed above. Another solution, though not availableto many facilities because of hours of use, is to water frequently for very shortdurations. Watering every 3-4 hours for 2-3 minutes just to keep the dust down isan example of this. This solution is short term because, unless water trulypenetrates down into the surface, it will get harder and harder.

Sub-surface irrigation, when properly regulated, has been used effectively indoors tokeep the courts soft and uniformly wet. Water itself tends to soften courts and whenit is being fed from below, this process occurs during every watering cycle.

C. HUMIDITYWhether the indoor courts are in a permanent structure or and air structure,controlling humidity levels is vital to make the playing environment safe andpleasant. Simultaneously trying to keep the court surface wet and the air dry is a bitif a conundrum. In relative humidity greater than 65% condensation occurs morefrequently causing mold and mildew to start growing. Too much humidity also

results in the fines clinging to tennis balls making them dirty and heavy.

3.0 DAILY MAINTENANCEYour daily maintenance routines keep the courts in optimal playing condition. At thesame time, effective daily practices will reduce the amount of periodic and annualmaintenance that is required.

A. TOOLS REQUIREDSteel Bristle Drag Brush (Photo 5)Court Rake (Photo 6)

Line Sweeper (Photo 7)Lute Scarifier (Photo 8)

Photo 5 Photo 6 Photo 7 Photo 8

B. ROLLINGIndoor Har-Tru courts do not require rolling. The surface gets compacted byrepeated, high volume use and does not undergo any of the environmental orweathering changes that loosen it up.

C. GROOMINGHar-Tru courts are groomed to redistribute the loose granular surface. This ensuressafe traction, proper ball bounce and a good appearance.


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Indoor courts can and should be groomed as often as the playing schedule will allow,using aggressive grooming tools such as the Steel Drag Brush and the Court Rake.Aggressive tools help scarify while sweeping. This increases the amount of loosegranular material improving traction, and keeps the top surface layer porous allowingwater to penetrate. Adding weight to the Steel Drag Brush and Court Rake increaseseffectiveness, but may decrease the life of the tool.

D. SCARIFICATIONAfter grooming, the court should be inspected for areas that are devoid of surface orparticularly slippery under foot, and for any spots that need to be repaired. Theseareas should be scarified using the serrated edge of a Lute/Scarifier. Scratching upbald areas will increase sliding material and improve traction. Scratching up sectionsthat need repair will take out the high spots and fill in the low. If hand scarifyingfails to produce the desired results, application of some Coarse Blend or somepatching may be necessary (see Periodic Maintenance).

E. WATERINGOn an indoor Har-Tru court, water keeps the dust down, reduces or minimizescompaction and improves traction. The more water that can be applied to the Har-Tru surface, the better the court will play. That being said, evaporation rates indoorsare very low and care must be taken not to over water for two reasons. One is thatthe court simply will not dry and will be unplayable. Two is that too much water willcause humidity levels within the structure to rise to unsafe levels. Playing on asurface that has too much moisture will also increase the level of compaction.

Structures that have the capability to move air across the court, whether via airconditioning, dehumidification or ventilation, typically have greater room for error

and can apply water more liberally. Develop an understanding for your facilitys airhandling systems and apply water with care. Apply as much water as possible dailywhile keeping humidity levels within the structure below 65%.

Facilities with sub-surface irrigation are typically able to get more water into theprofile of the court as they are not restricted by the surface puddling that occursduring above ground watering. Good record keeping and a complete understandingof how the system works is necessary to avoid getting the courts too wet.


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no mans land and the doubles alleys, are locations where ground up fines tend tosettle and lock in place.

Often these areas will be notably higher than other sections of the court. Weight canbe added as necessary to increase effectiveness. The goal is to break up the topsixteenth to quarter inch of the court surface, scrape it into piles and remove it.Once accomplished, the court should be swept in two directions using the Steel DragBrush or Court Rake and then watered. The work will require closing the court forapproximately two hours and should be performed as scheduling permits.

C. APPLICATION OF COARSE BLENDCoarse Blend is Har-Tru with lower dust content. It consists of the larger, coarsersize particles that when applied to the court surface, increase traction and scarify thesurface during play. An application of one bag per court per week throughout theindoor playing season is recommended. It can be applied with a broadcast spreaderor cast out by hand with a shovel.

During the playing season, bald areas often develop where the surface has becomecompacted and the sliding material has been pushed away. Apply Coarse Blend tothese areas in small amounts and distribute it with the flat edge of the Lute/Scarifier.This will provide better traction and sliding capability and also help loosen theseareas up. A one court application will take 10-20 minutes depending on the conditionof the court and the method of application.

D. PATCHINGDue to the high volume of doubles play, the area of the court just behind thebaseline and the tracks where players serve and volley for doubles, tend to get worndown. These areas of the playing surface should be inspected weekly and patched as

needed. Experience has shown that frequent thin patches set up more effectivelyand require fewer repairs. Patching indoors can be tricky because it is hard to getthe patch to adhere to the compacted court surface and there is rarely much time tolet the patch set up before players are back on it.

If possible, the court should be shut down about 3pm and should be dry. Theaffected area should be thoroughly cleaned of old material and ball fuzz using a brushand scarified to a minimum depth of 1/16 using any or all of the tools listed above.New Har-Tru should be opened and dumped onto the court surface and spreadevenly with a long straight edge, such as a ladder, to fill in all low spots. Oncecomplete, the patch should be hand watered just enough to activate the binder (notso much as to puddle) and rolled by hand. The patch should be watered and rolled

again 2 or 3 more times that day. The court can be opened for play the nextmorning at the normal time. (NOTE:Only regular Har-Tru should be used forpatching. Coarse Blend will not work.) Patching areas will tend to be softer than therest of the court and will get damaged during play. Touch the patch up by lightlyhand scarifying.


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5.0 ANNUAL RECONDITIONINGAnnual reconditioning is performed to preserve the life of the court and to improveplayability. It includes removing all of the old, worn Har-Tru and the ball fuzz anddebris that accumulate during a season of play, patching low spots and adding newmaterial as needed. These procedures are discussed below.

A. TOOLS AND MATERIAL REQUIREDLute Scarifier (Photo 17)Har-Tru (Photo 18)Coarse Blend (Photo 19)Court Devil (Photo 20)Tow Scarifier (Photo 21 which cannot be pulled over line tapes)Push Broom (No photo)Aussie Clean Sweep (Photo 22)Spreader (Photo 23)


Photo 21 Photo 22 Photo 23

(NOTE: Prior to reconditioning, all tools and equipment should be inspected thoroughly.

Nails, blades, teeth and tines wear down very quickly on the hardened indoor surface andare rendered ineffective. Purchase and install replacement parts as needed.)

B. CLEANING THE COURT SURFACEIf replacing the marking tapes begin by removing all tapes and nails from the courtsurface (NOTE:Tapes may not need to be replaced every season. Monitor the wearof the pattern on the tape surface. When worn the tape will become slippery and willneed to be replaced). Using a power brush or push broom, sweep all loose surface


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material and debris into piles and remove it with a flat bottom shovel andwheelbarrow or cart.

Caution:The use of dust masks while top dressing indoors is highly recommended.Every attempt should be made to ventilate the area as well. Use of gasoline or dieselequipment produces carbon monoxide that must be ventilated completely duringemission. Use of a carbon monoxide detector is required for safety.

C. DEEP SCARIFICATIONThe objective of deep scarification is to penetrate a minimum of into the courtsurface to loosen it up. Deep scarification should be performed after fines have beenremoved as described above. Add weight to a court devil or tow scarifier and makemultiple passes in all different directions until surface penetration of is achieved.Then drag the court with an Aussie Clean Sweep to redistribute and level theloosened surface. The leveled surface may need to be rolled if the surface hasbroken up in clumps.

D. APPLICATION OF NEW MATERIALIndoor courts experience very little surface erosion. Most of that erosion comes fromtracking Har-Tru off the court in the soles of shoes. It is estimated that less that aton of material is lost during the playing season. Therefore it is not necessary to addlarge quantities of Har-Tru each season.

The first step is to assess the surface depth on the court. Perform core tests in fourlocations across the court and average the numbers together to get the averagesurface depth. Be sure to check the high wear areas just behind the baseline asthose spots typically wear faster than the rest of the court.

Assuming that the average surface depth is 7/8 or greater, no new Har-Tru needs tobe added. Instead, an application of 6 bags of Coarse Blend per court isrecommended. It can be applied with a drop spreader and brushed out using a SteelDrag Brush or Aussie Clean Sweep.

Any patching that needs to be done should be done after scarification and beforesurface application. See the Periodic Maintenance section for instructions onpatching. After patching and applying new material, the entire surface should bewatered thoroughly by hand. Once the surface dries, new line tapes can be installed.


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6.0 LONG TERM RENOVATION OF COURTSOver a period of years, an indoor Har-Tru court will end up with successive layers ofcemented fines covered with layers of new Har-Tru. This layering significantlyreduces permeability and makes managing both surface hydration and hydration andhumidity levels very difficult. Additionally, effective scarification becomes tougher.Aggressive grooming tools, Coarse Blend, and heavy duty scarifiers are no longereffective in improving playing conditions and the only answer is to keep adding moreand more Har-Tru. At this point, it is time for more major intervention.

Photo 24: Har-Tru Surface Layering

Several techniques are currently used to counteract the negative effects of thecompaction. They are procedures that may require the assistance of an outsideprofessional and it is recommended that clubs consult Lee Tennis and their localcontractor. The procedures are discussed below.

A. AERIFICATIONThe Toro HydroJect (photo 25) and the DriJect (photo 26) are two pieces ofequipment that were invented for use on golf courses and have been appliedsuccessfully on indoor courts. These machines shoot highly pressurized jets of water,about the size of a pencil lead, down into the court surface (photo 27). In theprocess they create lateral fractures in the surface. These holes and lateral fractures

open space for water to travel through the profile, loosening or softening it up.

The procedure is typically conducted several weeks before the indoor playing seasonbegins. Multiple passes are made with the machine across the court surface. Afterthe holes are drilled, they are back filled with Coarse Blend and then the courts areflooded.


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Photo 25 Photo 26 Photo 27

A big advantage of this procedure is that the marking tapes do not need to beremoved and it takes only a couple of days to conduct, with minimal surfacedisruption. As a result, many facilities are choosing to have this done annually as apreventive measure rather than waiting until the court becomes very hard animpermeable. The disadvantage of the procedure is that depending on the level ofcompaction, the machine may not achieve very deep penetration and the processmay need to be repeated more than once. Fortunately, the effects of aerification arecumulative and compaction is lessened with each time it is performed.

B. DEEP SCARIFYING

Tennis court contractors with a laser grader have a box blade with teeth on it thatthey can use to tear up hardened surfaces. The laser can be set to a controlleddepth to avoid getting into the stone base below. Once broken, the surface can bere-graded flat and the facility is left with a court that is almost like new.

The advantages of this technique are that it is quick and accurate. The disadvantageis that some courts are so hard that the teeth cannot penetrate. Even if they canpenetrate, the surface typically comes up in chunks and these have to be eliminatedbefore the surface can be re-graded effectively. Also, this procedure does notremove all the fines generated during the playing season or over many playingseasons. This means that the material being reused is out of specification and will

tend to compact too much and be less permeable than new Har-Tru. If the courtsare very old, removal of the existing surface material and applying 1of new Har-Truis recommended.

C. MILLING MACHINESThe Milling Machine (photos 28-30) and the Asphalt Grinder (photo 31) arespecialized pieces of equipment that can be used to mill the surface into powder.They can be operated with a tractor and the depth can be controlled automaticallywith a laser. There are several types of machines from asphalt grinders topulverizers that have been used to varying degrees of success.

The advantage of using these machines is they are most effective at breaking up the

old Har-Tru and making the court almost like new. The disadvantage is the processrequires specialized equipment, more time and typically costs more. Also, as above,this procedure does not remove all the fines generated during the playing season orover many playing seasons. This means that the material being reused is out ofspecification and will tend to compact too much and be less permeable than new Har-Tru. If the courts are very old, removal of the existing surface material and applying1 ofnew Har-Tru is recommended.


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7.0 CONCLUSIONPrevailing wisdom has it that Har-Tru courts perform too poorly in an indoorenvironment to bother installing them. Perhaps by understanding what is happeningand clearly outlining a proactive approach to handling the challenges associated withindoor clay courts, this manual will help to dispel that sentiment. We have a tennispopulation that is rapidly aging and needs the soft sliding characteristics of Har-Tru,both indoor and out, to be able to play the game of tennis for life.

One observation in closing facilities with continuity in their maintenance personneland facilities that keep detailed records always have the best performing courts. Thisis true regardless of the age of the courts, the type of structure they are under, theirrigation system, or the air handling system in place. Keep detailed records oftemperature and humidity, amounts of water applied, time spent on the differentmaintenance procedures, dates and amounts for when material was added, andrecords of when parts were replaced on tools and equipment. These records, alongwith a person who understands what they mean, are likely the most importantingredients for having a successful indoor clay court facility.

8.0 INDOOR PARAMETERSLee Tennis is in the process of developing parameters around what makes an optimalHar-Tru court. The goal is to provide a range for the variables below that create thebest playing conditions. A facility will be able to use these parameters for guidanceand comparative purposes. It is a work in process and the information will be addedto this manual as it comes in. You can stay up to date by becoming an activemember of the Indoor Clay Court Community Forum on our web-site,www.hartru.com.

A. SURFACE STIFFNESS/COMPACTIONHar-Tru has been using a piece of equipment called a Clegg Hammer to establish a

measure of how hard a court is. We have now used this tool for 2 years on dozens ofcourts, some multiple times. We have correlated readings with a subjectiveobservation of the softness and traction. Additionally, we have compared readingsfrom facility to facility, indoors to outdoors, from court to court and even from onelocation on the court surface to another. These readings have given us a sense forwhat is too hard and what is too soft. It has also allowed us to understand whichareas of a court are most susceptible to hardening.
http://www.hartru.com/http://www.hartru.com/http://www.hartru.com/


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We feel fairly confident that this is an acceptable tool for measuring hardness and wewill continue to test courts and build a data bank. We will also be trying to conductplay testing and correlate readings with player observations.

Photo 32: The Clegg Hammer is used to measure surface stiffness

Traction TBD: This parameter will help clubs understand if their courts are too slipperyor do not allow enough slide.

Surface Hydration TBD:This parameter will allow facilities to discern whether there is adesirable amount of water in the surface profile.

Air Temperature Recommended Range = 50-65 F


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9.0 Indoor StructuresBelow is an alphabetical list of companies that manufacture structures for use overHar-Tru courts. This list will be updated when more information comes in. Contactthem directly for technical assistance or sales information.

Indoor Courts of AmericaICA East*1280 N. WinchesterOlathe, KS 66061T:913-780-0775 F:913-780-0770Or:39 Fields LaneNorth Salem, NY 10560T:914-669-4394 F:914-669-4395www.icasbs.com

Membrane Structure Solutions

27 OConner CircleWest Orange, NJ 07052T:908-520-0112 F:908-520-0116Email:[email protected]

Summit Structures946 North Van Buren StreetAllentown, PA 18109T: 800-615-4777 (toll free)www.summitstructures.com

Universal Fabric Structures, Inc.Corporate Headquarters/USA and International Sales2200 Kumry RoadQuakertown, PA 18951T:215-529-9921 F:215-529-9936 Toll Free:800-634-8368www.usfinc.com

Yeadon Fabric Domes, Inc.1567 East Country Road E.St. Paul, Minnesota 55510T:651-633-7400 F:651-633-2019 Toll Free:800-493-2366

Email:[email protected]
http://www.icasbs.com/http://www.icasbs.com/mailto:[email protected]:[email protected]:[email protected]://www.membranestructuresolutions.com/http://www.membranestructuresolutions.com/http://www.summitstructures.com/http://www.summitstructures.com/mailto:[email protected]:[email protected]:[email protected]://www.yeadondomes.com/http://www.yeadondomes.com/http://www.yeadondomes.com/mailto:[email protected]://www.summitstructures.com/http://www.membranestructuresolutions.com/mailto:[email protected]://www.icasbs.com/


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Har-Tru2200 Old Ivy Road, Suite 100

Charlottesville, VA 22903877-4-HAR-TRU fax 434-971-6995

www.hartru.com

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