Developing perfect artificial grass

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1 The Dow Chemical Company recently joined the fray in the quest to find the perfect artificial grass system, proving that its expertise can be utilised from the very outset. Soccer is increasingly being being played on artificial grass due to the fact it offers increased usage and can be used in all weather conditions and climates. Developing perfect artificial grass has been a challenge for the industry for many years. The complexity of the system, the high expectations of athletes and other users, and the increasing quality levels required, have forced turf companies to develop many different solutions. However, the industry continues to face the major challenge of finding the right components for yarn, infill and shock absorption, and the perfect combination of these. The Dow Chemical Company has now stepped into the area to fill the missing link of working both at the components and system levels. Artificial grass is increasingly proving to be a real and viable alternative to natural grass for many sports. As each sport requires the unique properties of its playing surface, artificial grass systems have proven their adaptability by offering playing characteristics specific to a particular sport. Artificial grass has made field hockey faster yet safer, enabled tennis to be played all year round, and increased the time of use, all while reducing the maintenance costs of stadiums and sports facilities in many countries, ensuring commercial success for their owners. With soccer increasingly being played on artificial grass, more people are playing the game more often due to the possibility of increased usage, and the fact that it can be used in all weather conditions. Being the biggest sport on the planet, the stakes in soccer are high, and the need to clearly specify pitch quality standards has been recognised by the European and International governing bodies, UEFA and FIFA respectively. After many years of testing, the two jointly introduced a quality standard in 2005, which has since become the benchmark for artificial grass fields. The standards described in the FIFA Quality Concept, i.e. FIFA-Recommended; FIFA WINTER 2007/08 P ANS TADIA 122

2 We interact with the whole value chain. As Dow is a supplier of a wide range of raw material technology for artificial turf, from yarn and infill polymers, to backing and shock absorbing sub-bases, we have multiple partnerships at each Sandeep Acharya, European and IMEA Marketing Manager, The Dow Chemical Company. stage... 2-Star; clearly specify the criteria a field must meet upon installation, and also how often they are to be tested. But how the criteria are met is something that is left to the installing company. Best of the Best Meeting the stringent criteria can be achieved in various ways, as an artificial grass system has many components. The yarn, infill, backing, and elastic layer each play a role and thus material selection at the individual component level can, to some extent, aide in meeting the FIFA Quality Concept standards. But only a perfect combination of the individual components (and the selection of an appropriate system construction technique) results in an artificial grass system that can meet the benchmark standard consistently and reliably. Hence, getting quality components to work together presents the next frontier for maximising artificial grass performance. This demands expertise in all aspects of materials science, processing know-how, and system evaluation and testing, in order to guarantee optimal playing characteristics similar to natural grass. We interact with the whole value chain. Because Dow is a supplier of a wide range of raw material technology for artificial turf, from yarn and infill polymers, to backing and shock absorbing subbases, we have multiple partnerships at each stage, said Sandeep Acharya, European and IMEA Marketing Manager for yarn polymers at The Dow Chemical Company, as he explained the advantageous position the company is in to advise on turf system design and construction. We have been in business for more than 100 years, helping diverse industries from food producers to car makers improve their profitability and grow their businesses by helping to solve process problems and improving end-use performance, he continued. In the artificial turf market, the need for advice is very much visible. Every so often stories appear about turf systems where the poor selection of components has had a devastating effect on the quality, performance and the lifespan of the field. Examples of fields with infill material that has negatively affected the yarn or where the e-layers and the infill have had an adverse effect on the playing surface are reported on a regular basis. Acharya added: As the industry evolves to next-generation artificial grass systems, raw material suppliers like Dow have to take an increasingly broad view of where to apply their research, processing and market development knowledge. Investment is Vital Heavy investment in R&D is essential for the successful introduction of next-generation systems. The Dow Chemical Company invests over US$1.3 billion annually in research and development, and has provided innovative technologies for diverse applications and markets. Its products and services are provided in more than 175 countries and range from fresh water, food and pharmaceuticals to paints, packaging and personal care products. The approach we take is to combine years of experience in the technology development of raw materials, then add partnerships with yarn and system producers, to construct a market-leading turf system solution, Acharya advised. The Dow Chemical Company not only approaches the artificial grass sector in this way, but also the many other industries in which it already works. The success of this collaborative and holistic market-facing approach has convinced Dow that it is the best way to achieve its goals in the artificial grass market. WINTER 2007/08 P ANS TADIA 123

3 IN THE MIX Strategic Alliances Dow s approach has already resulted in several alliances with companies in the artificial grass chain. Back in October 2007, prior to the FSB exhibition in Cologne in Germany, The Dow Chemical Company announced a partnership with carpet manufacturers Lano from Belgium and Domenech Hermanos from Spain, for the development of a new backing. We are thrilled to be working with Lano Sports and Domenech Hermanos to produce a high-quality Polyurethane backing system for artificial turf, said Peter Mackey, Dow s European Business Development Manager for Polyurethane Artificial Turf Systems. This partnership allows us to effectively reach the European artificial turf market. Dow also has a similar level of cooperation with carpet producers in the Middle East. Another option in choosing a backing system in artificial grass systems is Latex, as oppose to Polyurethane, as it provides a strong tuft bind in both dry and wet conditions, and imparts dimensional stability to the artificial turf, which extends its surface life and appearance. High-quality system producers have long known that the backing, whether it is Polyurethane or Latex, plays an important role in the artificial grass system. Its dimensional stability contributes to the lifespan of the field and avoids the carpet being affected by problems like line-dancing. Technically-Advanced The Dow ENFORCER Sport Polyureth ane backing system also delivers excellent tuft bind and dimensional stability, Dow claims even when the playing field is continually wet. It effectively locks the fibres in place to the backing, allowing for improved durability and longer life. This contributes to player safety. The backing also minimizes the possibility of distortion and shrinkage. The outcome is a uniform and predictable playing surface that will help retain its appearance for years to come. The development of the perfect artificial grass system requires interaction between multiple suppliers, including partners with base construction knowhow, shock pad suppliers, grass systems and infill. This grass system is directly related to yarn types and production expertise, explained Bernard Coorevits, Marketing Manager with Lano. Various Components The cooperation with Lano and Domenech Hermanos is only the first step, and reflects just a small part of Dow s overall capabilities. The company has also developed yarn grade polyethylene resins, which are particularly suited to creating fibres that provide the right combination of softness, resilience and mechanical toughness. This contributes to play at a professional level and the player s safety. Because of its superior mechanical properties, weatherability and WINTER 2007/08 P ANS TADIA 124

4 The development of the perfect artificial grass system requires interaction between multiple suppliers, including partners with base construction know-how, shock pad suppliers, grass systems and infill. This grass system is directly related to yarn types and production expertise... Bernard Coorevits, Marketing Manager, Lano. yarn resilience, turf yarn made using these resins is suitable for use at the highest level of professional sports. Dow s Polyolefin offers yarn producers another resin option in order to obtain a desired combination of mechanical properties, processing ability, and product performance for grass yarn. Environmental Infill The Polyolefin Elastomer materials Dow supplies are recyclable and strike a balance between price and performance. They form a perfect base for the production of infill material. Infill is vital to any artificial grass surface. It is the substance that provides shock absorption, keeping the yarn standing, traction for the players, and has a big impact on the players impressions of the surface. Previously, non-recyclable infill was a significant deterrent for the use of artificial fields Ikast Stadion in Denmark is a modern, multi-use, indoor stadium home to FC Midtjylland, it recently had a new artificial grass system installed. WINTER 2007/08

5 Dow Team Helps Danish Pro Football Club Experience Best Ever Artificial Turf Artificial turf pitches have long been plagued by concerns over the quality of play and safety. This has slowed their acceptance as playing surfaces, despite the fact that in a number of instances they are better than natural grass fields due to the advantages they offer such as: consistency of play, durability, and low maintenance. This was precisely the challenge facing facility managers at Ikast Stadion in Denmark. With the rising success of their football club, they wanted to improve their pitch and at the same time enhance the performance of their players. Ikast Stadion is the training ground for FC Midtjylland Wolves, who after their first appearance in the Danish Superliga top division in 2000, soon secured their status as a leading national club. FC Midtjylland recently qualified for the UEFA Cup and the national Royal League. Ikast Stadion is a modern, multi-use indoor stadium and its average usage rate of five hours a day in both the summer and winter seasons soon exceeded the limits of its artificial turf pitch, which no longer met players requirements. In 2007 heavy use of the pitch meant it had to be replaced. The stadium turned to one of Denmark s leading floor covering manufacturers, Fletco, for a state-of-the-art artificial turf that would meet its demands. Our challenge was to improve some characteristics of our artificial turf system to provide a pitch that would better respond to players needs in terms of comfort, safety and performance, recalled Fletco s owners brothers Brian, Bent and Benny Jensen. This design objective resulted in a combined effort between value chain partners: Fletco (the tufter), Foamtex (the backing coater), PV Sand (the infill supplier), Jene Sport (the installer) in cooperation with Virklund Sport, and Dow s Artificial Turf Solutions team. Dow was the natural partner to advise us on solutions that would enhance the processing and performance of our artificial turf system, explained the Jensen brothers. Achieving acceptable performance with an artificial turf pitch means thinking beyond merely improving yarn and shock absorption or reducing friction burns, explained Filip Tauson, Global Market Manager, Specialty Plastics & Elastomers at Dow. The entire system needs to be approached from the user s perspective, and Dow is able to advise designers on how individual applications within a system perform together. In the Ikast project, cooperation between all application producers was the key to finding a solution that address players requirements. Claus Steinlein, Academy Manager at FC Midtjylland, noted how impressed his team was by the new pitch: The players have all had experiences with previous generations of artificial turf pitches and were generally critical about performance and safety. They said the new pitch was the best one they have ever IN THE MIX due to environmental concerns, in particular in regions such as Scandinavia. Fifteen soccer pitches free of used tyre rubber infill, have already been installed in the Nordic region, and orders for nine more outdoor soccer pitches have been placed. Recyclable Thermoplastic Elastomers (TPE) infill solutions are increasingly gaining market acceptance and the trend towards eco-friendly pitches is set to continue. It is expected that 50% of the artificial turf installations in this region will be without used tyre rubber infill within two years. Applying Science The ability to predict how an artificial turf system will respond to changes in specific components, and the way in which they are combined, has become increasingly important for the creation of long-lasting, environmentally-friendly, high performance systems. The challenge to the industry comes from recognising that the ability to optimise the performance criteria of each system component will come not from random trial and error attempts to improve one dimension, but from a truly integrated, system-wide approach, commented Filip Tauson, Global Market Manager, Specialty Plastics & Elastomers at Dow. He continued: This is becoming particularly critical, as the recommended performance criteria from bodies such as FIFA, are now becoming enshrined in the standards and certification systems that are being developed by the various sport governing bodies. Most companies, including carpet manufacturers like Lano, have well equipped laboratories at their disposal. Nevertheless, Tauson still feels that a scientific approach is required: We first look at science to improve the polymer engineering, and then offer materials and processing know-how to our customers. Both of these approaches enhance the final artificial grass system. Customers of The Dow Chemical Company can be assured of the support of a dedicated turf team, combining expertise in the polymer market and the production of specialist resins, as well as the experience of its four specialist units: Base Plastics, Specialty Plastics & Elastomers, Polyurethane (PU) Systems and Latex. Tauson confirmed: Dow s specialist turf team can advise and support decision-makers in creating tailored-made solutions for long-lasting and high performance artificial grass systems, offering compatible combinations of raw materials for yarn, infill, backing, and shock absorption. Ultimate Winners Selecting the best, cheapest or most durable artificial grass system is a process that has not become any easier over the years. The market is flooded with systems designed for particular markets or purposes. However, Hendrik Vercouter, Sales Manager at Lano, believes the price of the system will still remain a key issue: This will not change. Overkill in the grass system is too expensive, he said, thus emphasising the importance of carefully designing a system. With its roots in chemicals and plastics, the close involvement of The Dow Chemical Company in sports is remarkable. It is mainly a raw material supplier for chemicals and plastics. But sport is emotionally driven, something that cannot always be said of plastics and chemicals. We have always been passionate about what we do, Acharya advised. Our brand campaign The Human Element reflects a new Dow Chemical Company emerging one that is bringing chemistry and humanity together for the betterment of the world and the company s business. In that respect, artificial grass is perhaps the perfect vehicle to achieve this, as Acharya concluded: The artificial turf market gives us an opportunity to really make a difference in the performance, safety, aesthetics, and environmental effectiveness of a rapidly growing market. WINTER 2007/08 P ANS TADIA 126

6 played on, because it so closely resembles natural turf. Plus, the pitch is odourless and the colour looks natural. Significant differences have also been reported in ball performance, as FC Midtjylland s winger and Danish national football team player, Dennis Soerensen explained: The ball roll is very good and ball bounce is perfect. The team has also found that the infill appears to move when the ball makes contact with the surface. This is particularly important when playing, as the ball reacts more naturally. A rubber coated sand infill was used to provide a natural playing experience and ball reaction, as Anders West, Managing Director at PV Sand, explained: Flexsand Action is a new infill that integrates sand and rubber in one component. Compared to other infill materials, the shock absorption is more natural, as the infill moves under impact. Most current infill systems work like a spring, and bounce back up at players when running; the density of this infill makes it stay in the carpet. The end result is a natural playing experience in terms of ball-player interaction characteristics. clearview In comfort and viewing quality it is indistinguishable from permanent stadium seating. We were all surprised to see how well the turf performs on foot torque, perhaps even too well. The grip on the studs is excellent, allowing for natural reactions and movements, commented Anders Rasmussen, the team s goalkeeper. I was particularly pleased with the regular ball rebound; this is critical for a goalkeeper and has been a traditional shortfall of pitches I have experienced in the past. The challenge to the industry comes from recognising that the ability to optimise the A Revolutionary Seating System clearview is the world s first demountable parabolic seating system. The design allows the system to be configured to provide the optimum sightlines for any given event and then reconfigured for another type of event or venue whilst minimizing the height of the rear row. This revolutionary seating system helps to deliver the ultimate spectator experience. The benefits are clear, the benefits are clearview performance criteria of each system component will come not from random trial and error attempts to improve one dimension, but from a truly integrated, system-wide Filip Tauson, Global Market Manager, Specialty approach... Plastics & Elastomers at Dow. CONTACT US NOW TO RECEIVE OUR NEW DVD PRESENTATION AND SEE HOW IT COULD TRANSFORM YOUR EVENT WINTER 2007/08 Telephone Website