© Technical Textiles & Nonwoven Association 2013
Presenter: Dr Floriana Coman, FCST - Fabrics & Composites Science & Technologies
© Technical Textiles & Nonwoven Association 2013
1. ABOUT SYNTHETIC TURF
1.1 Definition
1.2 History
2. SYNTHETIC TURF COMPONENTS
AND THEIR ENVIRONMENTAL INPUT
2.1 Tapes (blades, piles)
Polymeric composition
Properties that warrant their use as synthetic turf components
2.2 Primary backing material
Polymeric composition
Properties that warrant their use as synthetic turf components
2.3 Infill material
CONTENT
© Technical Textiles & Nonwoven Association 2013
3. SYNTHETIC TURF: ENVIRONMENTAL CONSIDERATIONS
3.1 Symbiosis
3.2 Sustainability
4. FIELD OF USE
4.1 Application/technical specificity
• Sportgrounds
• Landscape
5. SYNTHETIC TURF:
DEVELOPMENTAL WORK AND THE WAY IN THE FUTURE
5.1 Polymeric innovations
5.2 Properties improvements
5.3. New infill materials
CONTENT
© Technical Textiles & Nonwoven Association 2013
ABOUT SYNTHETIC TURF
1.1 DEFINITION
What is Synthetic Turf?
• Terminology
• Synthetic = a material produced through the synthesis of natural monomers derived
from petroleum and coal
• Question arising: synthetic turf is a textile? Or a composite material?
• A composite material is composed of at least two elements of dissimilar
properties working together to produce material properties that are different to the
properties of those elements on their own.
• Consist of a reinforcement of some kind and a bulk material – the matrix. Because
synthetic turf is comprised of these two elements it is considered to be a
composite material. In fact, the proposed nomenclature is:
Polymer Loose Matrix Composites (PLMC)
• First Conclusion: synthetic turf is a high tech material.
© Technical Textiles & Nonwoven Association 2013
COMPOSITES EXPLAINED
Composites consist of a ‘matrix phase’ & ‘reinforcement phase’
The matrix phase is the continuous phase & the reinforcement phase contains
continuous or dispersed particles.
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TYPICAL PMC COMPOSITES PROPERTIES
Mechanical, physical and thermal properties are anisotropic dependent on:
• fibre direction
• type and amount of the fibres
• type and amount of resin
STRONG/STIFF
s
s
WEAK/COMPLIANT
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COMPOSITE MATERIAL PMC PROPERTIES
The properties of the composite are determined by:
1. The properties of the fibre
2. The properties of the resin
3. The ratio of fibre to resin in the composite
(Fibre Volume Fraction, or Vf)
4. The geometry and orientation of the fibres
in the composite
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PMC / PLMC – WHY SIMILAR?
1. The functions of turf blades are similar with composite reinforcements in that they will
provide stiffness, strength, fatigue resistance (in fact, all mechanical properties)
2. Can be assembled in situ
3. Greater design freedom
4. Have similar design factors that are science/art base:
• Structural thickness (science)
• Materials being used (science)
• Fibre orientation and stiffness (science/art)
• Environmental issues (science/art)
• Loading actions (science)
• Consolidation conditions (science/art)
• Adhesive type (science/art)
• Surface preparation (science/art)
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WHAT IS DIFFERENT?
• PMC get greater results if a perfect bonding between reinforcement and resin is assured.
• PLMC get results on disbonding.
• PMC, in most of the cases, targets mechanical properties while PLMC targets a function
and the aesthetic as well.
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ABOUT SYNTHETIC TURF
Generation 1
• (1962) US Government commissioned MonSanto Corporation USA
• “Chemturf “ and “Astroturf” made by knitted texturised nylon
1.2 HISTORY
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ABOUT SYNTHETIC TURF
Generation 2
• Introduced 1980
• Tufting method for manufacturing using PP
• Fibrillated tapes named plastic pitches
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ABOUT SYNTHETIC TURF
Generation 3
• (1996) Polyethylene turf blades are introduced
• (2005) Changes to softer feel yarns
Field turf long piles
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2. SYNTHETIC TURF COMPONENTS
2.1 BLADES
• During oil refining, ethylene, propylene (propene), and other compounds are produced.
• Polyethylene is a result of polymerisation of the monomer named ethylene.
ETHYLENE
POLYMERIZATION
(CH2-CH2)n
POLYETHYLENE
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ABOUT POLYETHYLENE
This is a very simple structure with only 6 atoms with a low degree of freedom and no
free electrons to readily conduct thermal energy, therefore conducts energy only by
vibrational or rotational movement from one chain to another.
HDPE having the chains closer to each other conduct better the heat then LDPE.
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POLYETHYLENE HISTORY
Polyethylene produced by accident!
• (29 March 1933) Two scientists from British company Imperial Chemical Industry (ICI)
intended to study the high pressure reaction of ethylene and benzaldehyde.
• Benzaldehyde was recovered unchanged and a polymer of ethylene was identified.
• It took 2 more years until it become reproducible with set conditions and, in 1935,
patented.
• 1937 - a pilot plant was established; a great achievement considering that involved a
pressure vessel resisting to high pressure (22,500 psi).
• Full production in 1942 - first use: insulator for submarine communication cable
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POLYETHYLENE: THE MOST POPULAR
THERMOPLASTIC COMMODITY
LDPE, MDPE and HDPE grades have excellent chemical resistance, meaning that it is
not attacked by strong acids or strong bases. It is also resistant to gentle oxidants and
reducing agents.
• Degree of polymerization: >100 to 250,000
• Molecular weight: > 1,400 to 3,500,000
• Branching: The higher the branching, the lower the density
• Density: 0.9 - 0.94 g/cm3
• Melting point: 105 - 110 degrees Celsius- 120 to 130°C
SAFE to use in food industry and medicine
Recyclable
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POLYETHYLENE
Differential Scanning Calorimetry (DSC) provides a thermogram of heat capacity of a
specimen plotted as a function of temperature
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POLYETHYLENE BLADES:
HEAT CONDUCTIVITY
Material Heat
Conductivity
LDPE 8
HDPE 10-12
Polypropylene PP 2.8
Nylon 5.8
Water 15
Copper 9512
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2.1 BLADES: EXTRUSION CONSIDERATION
Material considerations for best product outcome:
• Molecular weight determination
- Solution viscometry
• Melt rheological characterisation
- Flow properties
- Flow rate with an extrusion plastometer
- Capillary rheometry
- Rheology by dynamic mechanical analysis
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2.1 BLADES: EXTRUSION CONSIDERATION
• Thermal analysis - expansion, shrinkage, weight and shape change
• Density determination
• Cross-linking analysis
• Mechanical properties
Why is important to know all these base material properties?
• The base material determines turf blades properties, therefore, manufacturers need to
ensure consistent properties every time.
• Encapsulated pigments and the polymer are melted and extruded together.
• Therefore, nothing can come up in contact or absorbed by human body or released into
the environment. In over 40 years, there has never been an instance of human illness or
environmental damage caused by synthetic turf.
© Technical Textiles & Nonwoven Association 2013
UV RESISTANCE
The blades are UV stabilised to resist the most stringent UV exposure.
Accelerated UV testing
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POLYETHYLENE YARNS (BLADES)
Denier (Tex) = textile unit to determine yarn linear density
Den = How many grams; Tex = How many grams;
9000m of yarn 1000m of yarn
8,000-denier, 100-micron yarn, and you could have a 15,000-denier, 80-micron yarn.
Guess which one is better?
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YARNS: TURF BLADES DESIGN
• Single blade
• Twisted
• Folded
• Multifilament
• Crimped
• Back-boned
The synthetic blades are
designed to suit a given
application
© Technical Textiles & Nonwoven Association 2013
2.2 TURF BLADES: BACKING MATERIAL
POLYPROPYLENE
• During oil refining, ethylene, propylene (propene) and other compounds are
produced.
• Propylene is produced from petroleum, natural gas and, to a much lesser extent,
coal.
• Discovered in March 1954
• Second most important commodity plastic
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2.2 PRIMARY BACKING MATERIAL:
POLYPROPYLENE
PROPYLENE
POLYMERIZATION
POLYPROPYLENE
(C3H6)n
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2.2 POLYPROPYLENE CHARACTERISTICS
Density: 0.855 g/cm3, amorphous 0.946 g/cm3, crystalline
Melting Point: 130–171 °C
Resistance to: - corrosion
- chemical leaching
- fatigue, to most forms of physical damage, including impact and freezing,
but
- liable to chain degradation from exposure to heat and UV radiation from sun
• Excellent for underground use
• Recyclable (has the number "5”)
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2.2 BACKING MATERIAL:
TYPICAL CONFIGURATION
Woven
Nonwoven (random mat)
• Chopped strand mat
• Continuous fibre mat
• Tissues
Majority of cases the base material is a plain woven fabric in 1 or 2 layers + nonwoven
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2.2 BACKING MATERIAL
The PP base material for the turf blades is, in most of the cases, a plain woven fabric for
the following reasons:
• Excellent dimensional stability
• Good strength
• Best anchoring material for blades
• Water absorption is almost nil
Fabric made of polypropylene yarn transports humidity from outside to another absorbent
layer from where it gradually dissipates.
© Technical Textiles & Nonwoven Association 2013
BLADES + BACKING ENVIRONMENTAL INPUT
NO EMISSION OF FORMALDEHYDE
When formaldehyde-containing materials have been added to the product as a part of the
production process, the product shall be tested and classified into one of two classes:
E1 or E2. Note: products of class E1 can be used without causing an indoor air
concentration greater than 0,1 x 10-6 mg/kg (0,1ppm) of formaldehyde. The test
requirement does not apply to sports floor systems to which no formaldehyde containing
materials were added during production or post-production processing. These need not be
classified, but may, without any testing, be declared as Class E1.
NO EMISSION OF PENTACHLOROPHENOL
Sports floor systems does not contain pentachlorophenol or a derivative thereof as a
component in the production process of the product or of its raw materials. In cases where
verification is required, if the content is less than 0,1 % by mass this requirement shall be
considered to be met.
© Technical Textiles & Nonwoven Association 2013
BLADES + BACKING ENVIRONMENTAL INPUT
TOXICITY EVALUATION
• State-of-the-art Australian synthetic turf does not contain heavy metals !
• It was a practice of 1st Generation to colour the nylon with inorganic pigments containing led.
• Problem of the past
• Be careful on imports!
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BLADES + BACKING ENVIRONMENTAL INPUT
VOC EMISSION EVALUATION
Melting point: 105 - 110 °C for LDPE
120 - 130 °C for HDPE
Up to 105 °C for LDPE the product is inert and does not release
There is nothing harmful in Synthetic Grass
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2.3 INFILL MATERIAL
SBR (STYRENE BUTADIENE RUBBER) PU COATED SBR
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2.3 INFILL MATERIAL
EPDM (ETHYLENE PROPYLENE DIENE MONOMER) ROUNDED SAND
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WORLD RESEARCH ON SBR
ENVIRONMENTAL INPUT
US Environmental Protection Agency, November 2009
• “The levels of particulate matter, metals, and volatile organic compound concentrations
in the air above the synthetic turf were similar to background levels;
• All air concentrations of particulate matter and lead were well below levels of concern;
• Zinc, which is a known additive in tires, was found to be below levels of concern.”
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WORLD RESEARCH FINDINGS ON SBR VOC
California Office of Environmental Health Hazard Assessment (OEHHA)
Pesticide and Environmental Toxicology Branch
Funded by the Department of Resources Recycling and Recovery (CalRecycle)
October 2010
Safety Study of Artificial Turf Containing Crumb Rubber Infill Made from Recycled Tires:
Measurements of Chemicals and Particulates in the Air, Bacteria in the Turf, and Skin
Abrasions Caused by Contact with the Surface
Conclusions:
• No public health concerns were identified regarding the inhalation of volatile organic
compounds (VOCs) or particulates (PM2.5) above artificial turf;
• Artificial turf harboured fewer bacteria (including MRSA and other Staphylococci) than
natural turf.
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SBR METAL CONTENT
U.S. Environmental Protection Agency EPA , November 2009
"A Scoping-Level Field Monitoring Study of Synthetic Turf Fields and Playgrounds”
This study and statements of safety by the U.S. EPA of synthetic turf fields and playgrounds
containing crumb rubber from recycled tires complements the study and statement of safety
by the CPSC in 2008 (see below).
Conclusion:
• The levels of particulate matter, metals and volatile organic compound concentrations in
the air samples above the synthetic turf were similar to background levels;
• All air concentrations of particulate matter and lead were well below levels of concern;
• Zinc, which is a known additive in tires, was found to be below levels of concern.
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SBR LEACHING
New York State Department of Environmental Conservation and New York State
Department of Health, May 2009
"An Assessment of Chemical Leaching, Releases to Air and
Temperature at Crumb-Rubber Infilled Synthetic Fields”
Conclusion:
In its press release, the NYSDEC announced that this new comprehensive study concludes
that crumb rubber infilled synthetic fields "poses no significant environmental threat to air
or water quality and poses no significant health concerns."
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SBR AIR QUALITY
New York City Department of Health and Mental Hygiene
"Air Quality Survey of Synthetic Turf Fields Containing Crumb Rubber Infill”
Prepared for NYCDHMH in March 2009
Conclusion:
An analysis of the air in the breathing zones of children above synthetic turf fields do not
show appreciable impacts from COPCs [contaminants of potential concern] contained in the
crumb rubber. Therefore, a risk assessment was not warranted from the inhalation route of
exposure. Of 69 VOCs, 17 PAHs, including benzothiazole, 10 metals and a range of
particulate matter tested, the COPCs that were detected in the ambient air samples above
the crumb rubber synthetic turf fields were found in similar concentrations in the air samples
above the grass field and the background locations.
© Technical Textiles & Nonwoven Association 2013
SBR AIR QUALITY
Milone & MacBroom
Engineering, landscape architecture, and environmental science firm based in Connecticut
December 2008
“Evaluation of the Environmental Effects of Synthetic Turf Athletic Fields”
Conclusion:
20 air samples were collected above and around two synthetic turf playing surfaces in Connecticut. 10 of the samples were
analyzed for volatile nitrosamine content and 10 were analyzed for benzothiazole and 4-(tert-octyl) phenol content. The
samples were collected on warm, late summer days during periods of light to calm winds. In one case, the synthetic turf
surface had been groomed three days prior to the sampling. The sampling was conducted during periods when the
temperature of the crumb rubber in-fill material was elevated due to exposure to the sun. The combination of air
temperatures, surface temperatures, wind speed and, the recent maintenance of one of the fields, are believed to be
conditions favourable for generating maximum concentrations of the analytes in the air column above and around the
playing surfaces. This study determined that under favourable conditions for vapour generation, no detectable
concentrations of volatile nitrosamines or 4-(tert-octyl) phenol existed in the air column at a height of four feet above the
tested synthetic playing surfaces or in the air either upwind or downwind of the fields.
© Technical Textiles & Nonwoven Association 2013
SBR INGESTION / INHALATION
Enviro-Test Laboratories, Alberta Centre for Injury Control and Research,
Department of Public Health Sciences
July 2003
“Toxicological Evaluation for the Hazard Assessment
of Tire Crumb for Use in Public Playgrounds”
Conclusion:
• Genotoxicity testing of tire crumb samples following solvent extraction concluded that
no DNA or chromosome-damaging chemicals were present.
• This suggests that ingestion of small amounts of tire crumb by small children will not
result in an unacceptable hazard of contracting cancer.
© Technical Textiles & Nonwoven Association 2013
SBR DERMAL CONTACT
INTRON, commissioned by two tyre associations, and supervised by the National
Institute for Public Health and the Environment and by the Ministry of Housing,
Spatial Planning and the Environment in the Netherlands
April 2008
“Follow-up study of the environmental aspects of rubber infill”
Conclusion:
Based on the available literature on exposure to rubber crumb by swallowing, inhalation and
skin contact and our experimental investigations on skin contact we conclude that there is not
a significant health risk due to the presence of rubber infill from used car tyres.
© Technical Textiles & Nonwoven Association 2013
SBR WATER QUALITY
Milone & MacBroom
Engineering, landscape architecture, and environmental science firm based in Connecticut
December 2008
“Evaluation of the Environmental Effects of Synthetic Turf Athletic Fields”
Conclusion:
The evaluation of the stormwater drainage quality from synthetic turf athletic fields included the collection and analysis of 8
water samples over a period of approximately 1 year from three different fields, the collection and analysis of samples of
crumb rubber in-fill from the same three fields plus a sample of raw crumb rubber obtained from the manufacturer, and the
evaluation of the effect of the stone base material on the pH of the drainage water. The results of the study indicate that the
actual stormwater drainage from the fields allows for the complete survival of the test species called Daphnia pulex. An
analysis of the concentration of metals in the actual drainage water indicates that metals do not leach in amounts that
would be considered a risk to aquatic life as compared to existing water quality standards. Analysis of the laboratory based
leaching potential of metals in accordance with acceptable EPA methods indicates that metals will leach from the crumb
rubber but in concentrations that are within ranges that could be expected to leach from native soil.
© Technical Textiles & Nonwoven Association 2013
3. SYNTHETIC TURF
ENVIRONMENTAL CONSIDERATION
3.1 SYMBIOSIS
• How turf, earth grounds and surrounding plants coexist?
• While synthetic turf is a filtering medium the water passes through and is absorbed by
the ground and the surrounding plants.
• There are no concerns at all, in fact, tree roots love synthetic turf.
© Technical Textiles & Nonwoven Association 2013
3.2 ADVANTAGES OVER NATURAL GRASS
Low maintenance
• Savings: water, fuel, energy
• Eliminate noise
• Eliminate stress
• Always green and lush
• No downtime required for recovery
• Harbour fewer bacteria than natural turf
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3.3 SUSTAINABILITY EU
KIWA Institute of Sport
International standards for Life Cycle Assessment
(ISO14040 and ISO14044)
Assesses the environmental impact of a product throughout all its life cycle phases:
• Raw materials extraction + production
• Transport of finished products
• Installation
• Usage and maintenance
• Disposal
• Waste treatment and/or recycling
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EU ENVIRONMENTAL CONCLUSION
• Disposal scenario’s order of eco-impact:
1. re-use
2. incineration
3. landfill
• Top layer has the largest contribution to total eco-impact
• Should be a clear distinction between products
• European countries environmental impact expressed in monetary value ( € / m2/yr )
can be a solution
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3.3 SUSTAINABILITY AU
FOR AUSTRALIA - PRODUCT STEWARDSHIP ACT 2012
Product stewardship is an approach to managing the impacts of different products and
materials.
It acknowledges that those involved in producing, selling, using and disposing of products
have a shared responsibility to ensure that those products or materials are managed in a way
that reduces their impact, throughout their lifecycle, on the environment and on human health
and safety.
Reference:
www.environment.gov.au/settlements/waste/product-stewardship/index.html
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EMBODIED ENERGY
• Embodied energy is the energy associated with manufacture.
• Composites have a significantly lower embodied energy coefficient than metals.
205102
Primary energy consumption (MJeq)
20
6
Greenhouse gas emission (kg CO2eq)
2.07
0.48Total environmental impact (points)
Stainless steel (316) I-Beam
Exel I-Beam
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RECYCLABILITY:
IN PRACTICE IN AUSTRALIA
Plastic wastes have more value than we believe!
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4. FIELD OF USE
4.6 LANDSCAPE
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5.1 POLYMERIC INNOVATIONS
In 2008, Dow Chemical Company determined that the blades extruded from octene-based
polyethylene resins:
• last twice as long as those made from butene-based resins. and
• have 30% better abrasion resistance.
5. SYNTHETIC TURF DEVELOPMENT
WORK AND WAY IN THE FUTURE
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5.2 IMPROVEMENTS
Infill replacement by yarns New cross-section profiles
5. SYNTHETIC TURF DEVELOPMENT
WORK AND WAY IN THE FUTURE
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5. SYNTHETIC TURF DEVELOPMENT
WORK AND WAY IN THE FUTURE
5.2 IMPROVEMENTS
• Reported by China Institute of Sports
• Turf Blade surface modification by using nano-SiO2 to
- Improve the wear resistance
- Improve mechanical resistance overall
© Technical Textiles & Nonwoven Association 2013
5.3 NEW FILLING MATERIALS
Organic infills:
• Cork
• Coconut husk
• Bark
• Flax
5. SYNTHETIC TURF DEVELOPMENT
WORK AND WAY IN THE FUTURE
© Technical Textiles & Nonwoven Association 2013
SUMMARY
• There is science behind any good synthetic turf
• Synthetic Turf is a high-tech material
• For best product outcome, we have to take in consideration: raw materials,
processes used and the environment
• There is nothing harmful in synthetic turf
• There is a scope for new developments
© Technical Textiles & Nonwoven Association 2013
REALITY! WHAT ABOUT THE FUTURE?
• Limitations are determined by the materials we use and our imagination
• Creating smart, recyclable materials is a high priority for the world
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