Synthetic turf fields have become a durable counterpart to natural grass, and today, they are extensively used in professional and practice fields, as well as in home lawns, sporting facilities, gyms, and decorative lawns in most spaces. Synthetic turf is compatible with various landscapes and different weather conditions; it also lasts for a very long period with minimal efforts in maintenance. But have you ever stopped to think what makes them so strong, what’s behind their resilience, or how they’re made in the first place? The following article will try to look inside the manufacturing process and some of the secrets hidden behind synthetic turf field durability.

Durability of synthetic turf 

Synthetic turf is designed and engineered to face extreme conditions and heavy footfalls. The materials used in production, the manufacturing process, and the quality control measures all ensure that the synthetic grass turf stays durable. Though artificial turf fields generally need minimal maintenance compared to natural grass fields, with timely maintenance checks and regular upkeep of the field, synthetic turf could last 15 to 20 years!

Synthetic turf manufacturing

Synthetic turf fields are known for their durability and weather resistance, and these qualities are the result of a spectacular manufacturing process.

Synthetic grass production

 The grass fibres or yarn of synthetic turf are made of materials like polyethylene, nylon, and polypropylene. These materials are combined with UV additives and colourants to make the grass fibres, and the process is called extrusion. Of the three raw materials, polyethylene is increasingly popular for grass fibre production due to its softness, versatility, durability, and aesthetic quality.

Tufting

Tufting is a process in which synthetic grass fibres or yarn are stitched onto the backing material using a tufting machine, creating the grass mat we see on the surface of turf fields, which looks and feels just like real grass! Backing of high quality coupled with high-end grass fibres creates a good turf mat, and usually the backing is made of materials such as polypropylene, polyurethane, and latex.

Infill, seaming, and nails

Infill is one of the major components of synthetic turf that protects the turf’s integrity and durability. The infill is usually material like crumb rubber, silica sand, zeofill, acrylic sand, etc., and it provides support to the grass fibres, shock absorption, and keeps the turf durable for a long time. The seaming is another part of artificial grass fields that keeps the turf in place; the materials used for seaming include industrial double-sided tape, seaming tape and glue, and staples and nails. The nails are also responsible for securing the edges of the artificial grass mat on your synthetic turf. Aside from these regular materials and processes, additional finishing treatments will be done on the synthetic turf to enhance its weather resistance and ensure its durability.

Quality control

At each manufacturing stage, quality control ensures that the turf meets the quality standards in performance and appearance. Quality control ensures that only superior-quality materials are used in the production process of yarns. Quality control is also for monitoring the manufacturing process, equipment, strength testing, and colour consistency. The performance testing also measures durability, shock adsorption capacity, and drainage. Other than checking the quality of the turf at every stage of production, the final inspection ensures material of high-end quality before it is shipped to the customer with no irregularities or defects.

Conclusion

First and foremost, the production process and quality control measures are mainly responsible for the incredible durability of synthetic turfs. However, the right installation process and appropriate maintenance measures can influence and even increase the lifetime of an artificial turf field. Would you like to know more about synthetic turf installation? Or are you searching for the right team to help you install an artificial football turf in your area?

Surekha Exports is one of India’s best artificial sports infrastructure builders, with more than 18 years of experience and 700+ projects spread across India under our belt. We use advanced technology and internationally certified products, ensuring custom-made solutions, top results, and the best after-sale experience. Connect with us to get detailed information on the turf installation process and our special maintenance team!