presenter: dr floriana coman, fcst - fabrics & composites

© Technical Textiles & Nonwoven Association 2013

Presenter: Dr Floriana Coman, FCST - Fabrics & Composites Science & Technologies


SYNTHETIC TURF ENVIRONMENTAL INPUT


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


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


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.


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.


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


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


TYPICAL PLMC COMPONENTS


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)


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.



Generation 1

• (1962) US Government commissioned MonSanto Corporation USA

• “Chemturf “ and “Astroturf” made by knitted texturised nylon

1.2 HISTORY



Generation 2

• Introduced 1980

• Tufting method for manufacturing using PP

• Fibrillated tapes named plastic pitches



Generation 3

• (1996) Polyethylene turf blades are introduced

• (2005) Changes to softer feel yarns

Field turf long piles


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


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.


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


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

http://upload.wikimedia.org/wikipedia/commons/e/e1/U+2673_DejaVu_Sans.svg


POLYETHYLENE

Differential Scanning Calorimetry (DSC) provides a thermogram of heat capacity of a

specimen plotted as a function of temperature


POLYETHYLENE BLADES:

HEAT CONDUCTIVITY

Material Heat

Conductivity

LDPE 8

HDPE 10-12

Polypropylene PP 2.8

Nylon 5.8

Water 15

Copper 9512


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


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.


UV RESISTANCE

The blades are UV stabilised to resist the most stringent UV exposure.

Accelerated UV testing


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?


YARNS: TURF BLADES DESIGN

• Single blade

• Twisted

• Folded

• Multifilament

• Crimped

• Back-boned

The synthetic blades are

designed to suit a given

application


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


2.2 PRIMARY BACKING MATERIAL:

POLYPROPYLENE

PROPYLENE

POLYMERIZATION

POLYPROPYLENE

(C3H6)n


2.2 BASE: SUPPORTING MATERIAL

POLYPROPYLENE


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”)


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


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.


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.



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!



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


2.3 INFILL MATERIAL

SBR (STYRENE BUTADIENE RUBBER) PU COATED SBR


2.3 INFILL MATERIAL

EPDM (ETHYLENE PROPYLENE DIENE MONOMER) ROUNDED SAND


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.”


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.


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.


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."


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.


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.


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.


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.


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.


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.


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


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


SUSTAINABILITY


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


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


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


RECYCLABILITY:

IN PRACTICE IN AUSTRALIA

Plastic wastes have more value than we believe!


4. FIELD OF USE

4.1 SPORTS GROUNDS: HOCKEY


4. FIELD OF USE

4.1 SPORTS GROUNDS: SOCCER


4.1 SPORTS GROUNDS: TENNIS

4. FIELD OF USE


4.1 SPORTS GROUNDS: GOLF

4. FIELD OF USE


4. FIELD OF USE

4.1 SPORTS GROUNDS: BOWLING


4. FIELD OF USE

4.6 LANDSCAPE


4. FIELD OF USE

4.6 LANDSCAPE

http://www.facebook.com/media/set/?set=a.382596391782434.85987.119902154718527&type=1&l=f8914b84fa


4. FIELD OF USE

4.7 LOGO AND FIELD GRAPHICS


WHERE ELSE IS IT USED?


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


5.2 IMPROVEMENTS

Infill replacement by yarns New cross-section profiles






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


5.3 NEW FILLING MATERIALS

Organic infills:

• Cork

• Coconut husk

• Bark

• Flax




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


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


ACKNOWLEDGEMENTS

Advanced Polymer Technology Australasia

KIWA ISA Sport

Martin Schlegel

The Netherlands

presenter: dr floriana coman, fcst - fabrics & composites

Documents