How is Artificial Turf Made? Our Formula Revealed. Really.

By Courts & Greens - January 15th, in Service, Main Service, Turf

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Artificial turf has become an increasingly popular choice for transforming various spaces, whether it’s a spacious front yard or a modest backyard. The installation of artificial grass effectively revamps these areas into vibrant green retreats in no time at all. Its rise in preference over natural grass in residential and commercial sectors is evident.

Initially, artificial grass was primarily used in sports arenas, stadiums, and fields, but it has since found applications in homes, office exteriors, playgrounds, and more. The maintenance-free nature of artificial turf—which requires minimal to no watering—has made it a favored option. If you find that your yard is perpetually shaded or difficult to cultivate with real grass, artificial grass could be the perfect alternative for you.

If you're keen to learn more about artificial grass, we’ve got you covered. Read on as we delve into the intricate details of its composition and manufacturing process.

Understanding Artificial Grass: Its Origins and Development

The journey of artificial grass began in the 1960s, with its manufacturing initially mirroring carpet production. However, advancements in technology and materials have drastically improved the quality and production methods over the years.

Today, manufacturers utilize high-grade materials and cutting-edge technology to produce artificial turf that closely resembles the look and feel of natural grass. This modern turf is UV resistant, devoid of harmful chemicals, and contributes to significant savings on water and maintenance costs, ensuring your lawn remains lush throughout the year.

So, what exactly is artificial grass made of? Let’s break it down.

The Components of Artificial Turf

Given the frequent foot and paw traffic on artificial turf, it’s subject to wear and tear. Despite being robust enough to endure extreme temperatures and UV exposure, the quality of the materials used is crucial for optimal performance.

We prioritize durability in our designs and back our products with a 16-year warranty.

Our artificial turf comprises several key components: grass blades, a thatch layer, primary turf backing, and secondary backing. The three primary synthetic materials we use include:

1. Yarn/Blade: Polyethylene C8 grade
2. Thatch: Polypropylene C8 grade
3. Primary Backing: Double Polypropylene cloth
4. Secondary Backing: Urethane

Grass Blades

The grass blades are constructed from polyethylene or nylon. Polyethylene is favored for its skin-friendly properties and durability, serving as the primary material due to its resemblance to actual grass. This plastic transforms into lush green blades through melting, coloring, and mixing with UV resistant agents.

Alternatively, nylon sheets can be extruded into fine fibers for high-quality blades that closely replicate the natural product.

Thatch Layer

Constructed from resilient polypropylene, the thatch layer adds support and cushioning to the artificial turf. This layer enhances the overall feel and appearance, ensuring a more realistic experience.

Turf Backing

The turf backing is crafted from both polypropylene and urethane. The tufting machine stitches grass blades into this backing, securely attaching both the grass and thatch layers.

Cushioning

For cushioning, polyester foam or a rubber base is typically used, often derived from recycled materials. We ensure that only high-quality materials are utilized for the top fabric panels and threads, enhancing the artificial turf's durability and longevity.

Once you know what materials go into the making of your artificial turf, let’s explore the manufacturing process. Although the complexity may seem daunting, we will simplify it for you.

The Manufacturing Journey of Artificial Grass

The process of tufting artificial grass employs techniques akin to carpet production. However, unlike carpets that utilize threads, artificial grass relies on polyethylene or nylon fibers.

We can create grass in various shapes and sizes based on your preferences, allowing for customized products to meet specific needs. Our manufacturing starts with feeding raw materials into a hopper.

Next, dyes are introduced to impart the signature green hue to the grass blades, along with agents that render the grass UV resistant.

This mixture is then transitioned to a steel mixer, where it is blended until it achieves a viscous liquid consistency, subsequently passed through an extruder that shapes it into long strands.

Carding machines twist these strands into loose ropes, which are then straightened and transformed into yarn. This yarn is heated to create a twisted shape before being fed into the tufting machine.

The tufting needle punctures the artificial turf backing, looping the yarn in a stitching pattern until the backing is fully covered, resulting in a finished artificial grass carpet.

A urethane coating is applied to the underside of the carpet, which is then sealed with another layer of polypropylene. The artificial turf is cured under heat lamps to complete the process. Finally, any excess fibers are trimmed, and the grass is rolled, making it ready for installation.

Installing Your Artificial Grass

With a firm understanding of how artificial grass is made, consider transforming your outdoor space with Courts and Greens. We specialize in artificial turf installation for both commercial and residential properties. For further inquiries on synthetic grass, explore our comprehensive guide.

Contact Courts and Greens for Your Free Consultation Today

At Courts and Greens, we assist you in planning, financing, and building the lawn of your dreams! We offer tailored solutions to satisfy your requirements and realize your vision. Contact us today at (661) 585- to schedule your free consultation!

For additional information, please visit Artificial Turf Factory.

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