*This article by INSTALL executive director David Gross was originally featured in ProInstaller Magazine.
Magic Carpet: Continuing Growth of Synthetic Turf Market Promises Steady Work for Installers With Turf Training
While North American growth projections for the synthetic turf market vary from source to source, the consensus is the segment will continue to expand, by some estimates to as much as $4.8 billion by 2031 and $8.8 billion by 2033.1
For installers in the field (and on it), market analysis isn’t necessary to know they are busier than ever. With new material innovations, minimal maintenance, and year-round usability fueling synthetic turf’s fandom, the growing demand for the material is laying the groundwork for steady, lucrative opportunities for installers with the right skill set.
LIKE INDUSTRIAL CARPET, BUT DIFFERENT
When installing synthetic turf, some fundamental skills translate from industrial carpet installation practices. Site preparation is critical, and the sub-base (akin to the subfloor for carpet) must be sound, smooth, and free of debris. A properly prepared sub-base allows the installer to lay the turf cleanly and aids in creating seams and markings with precision. It also allows for proper drainage, which contributes to both the safety and the long-term performance of the material.
Turf field drainage is typically achieved using a surface drainage system, an internal drainage system, or a combination of the two. Like an industrial carpet project, the turf installer is responsible for accepting the sub-base preparation and ensuring it meets appropriate standards. Sometimes, the installer must also submit a certificate of site acceptance prior to beginning work.
To verify the sub-base is ready for turf, the installer must inspect and verify it for compliance with the project’s plan, the synthetic turf manufacturer’s specifications, and for other standards like the ASTM D1557 standard for compaction. The manufacturer’s specification, for instance, dictates the nailer or turf termination point, which must be approved by the installer along with field dimensions and any markings prepared by a surveyor. Similar to other floor installations, turf installation starts with the installer’s acceptance of the existing conditions, and all the work performed after site acceptance is then the installer’s responsibility.
Cushioning the blow
Cushioning can be an essential part of the synthetic turf installation for many reasons. Cushioning absorbs shock, which protects player and user safety, and it helps ensure consistent conditions, which are especially important for sports. Cushioning is also a major contributor to the long-term performance and durability of the turf surface. The types of cushioning used for turf and their respective application methods are what make specialized training necessary.
Cushioning options that are placed under synthetic turf include shock pads and elastic layer (E-layer). Shock pads are analogous to carpet padding. These prefabricated materials come in rolls or sheets and in a variety of materials like polyurethane, polyethylene, and rubber. E-layer is an in situ system that requires specialized equipment for installation. While more costly and technically challenging, E-layer delivers a unique consistency that accommodates dynamic sub-bases while also providing vertical drainage and good shock absorption ratings. Generally, the cushioning material is determined by the installation conditions, the intended use of the turf, and the project budget.
After the synthetic turf is laid, infill is applied. Infill is a material comprising tiny particles of rubber, sand, or both that is placed on top of the turf using a spreader or manual rake. Installers brush the infill into the turf fibers (similar to carpet pile) using a power broom or specialized turf brush. Installation can require multiple layers of infill to reach the specified level, and rollers or compactors may be necessary to ensure proper settling.
Infill plays a critical role in eliminating the directional grain. As the infill is worked into the fibers, it helps lift the fibers, filling the gaps between them and allowing the fibers to settle into a more uniform position.The result is reduction or elimination of the directional nature of the fibers, as the infill makes the fibers more stable and upright. When the turf is fully infilled and compacted, the grain or directional effect should disappear. A surface that is non-directional is similar to natural grass in terms of ball roll, bounce, and player footing.
Some synthetic turf systems, including those with minimal infill and without infill, may incorporate a resilient layer between the base and the turf. When part of a system, a resilient layer can help maintain consistent surface performance characteristics, control ball bounce, and lower the impact force when players run or fall. A resilient layer can also reduce compaction within the infill, prolonging surface system life and ensuring the field stays within the ASTM’s G-MAX surface hardness standard of less than 200.
Seams familiar: gluing and sewing
Making synthetic turf look realistic and aesthetically pleasing while also ensuring its long-term performance requires knowledge and experience with two different approaches to seams: gluing and sewing.
Gluing seams involves the use of an adhesive and seam tape to bond the edges of turf sections. Using a loop pile cutter, carpet knife, or breakaway razor knife, the installer cuts both edges of the turf rolls to be seamed, cutting as close to the second tuft row as possible to avoid waste and create a clean edge. The installer orients the turf so that both pieces are going in the same pile direction and leaves a small space of approximately ¼ inch between the two pieces. This space prevents the turf edges from moving too close and bunching, and it must remain the same throughout the project to avoid unsightly inconsistencies and prevent tripping hazards.
Once laid out, the installer folds the seams back to the point where turf stays folded on its own, typically one to two feet. Next, seam tape 12 to 13 inches wide is rolled out and cut to the length of the seam. Hot tar or adhesive is applied to the tape, and turf edges are affixed, with all turf fibers or “blades” going in the same direction. To promote thorough adhesion, the installer may walk heel to toe along the seam or use sandbags, a heavy roller, or other weighted items to sustain pressure while the adhesive bonds. Some advantages of gluing are that it is quicker and easier than sewing and requires less labor and fewer specialized tools.
Sewing seams is the method used for the majority of installations. This requires manually or mechanically stitching together sections of turf with highly durable thread. The process requires an industrial sewing machine or specific hand tools, and it is generally considered more labor-intensive and costly than gluing but can serve a wider range of climate conditions. Holes are made in both turf sections and joined with thread or cord. Since sewing can place more stress at the seam, some end-users prefer a fully adhered field to eliminate the possibility of skewed lines or seam separation.
The decision to glue or sew seams is best determined through a collaboration between the synthetic turf manufacturer and the installer. Most manufacturers provide guidelines for seaming to ensure the longevity and performance of their products. These guidelines can indicate a specific type of adhesive or seam tape for gluing or whether sewing is preferred over gluing in high-traffic, heavy-use applications like sports fields. For custom installations, the installer may also consult the manufacturer to ensure turf compatibility with a specific adhesive or stitching material. In every case, the installer must review the turf installation manual provided by the manufacturer to achieve optimal results and protect the warranty.
Turf training
Cushioning, gluing, and seaming are just a few examples of the similarities and differences between traditional carpet and synthetic turf installation competencies. They demonstrate key reasons installers must have specialized training to be successful in the synthetic turf market segment.
To establish industry standards for turf installation, organizations like the International Standards & Training Alliance (INSTALL) collaborate with turf manufacturers and experienced professionals to develop and continually update their training curriculum. INSTALL turf training, for example, is an optional course within the organization’s carpet training curriculum. The 24-hour course provides journey-level INSTALL members with the knowledge and skills required for handling and installing synthetic turf. Students are introduced to the turf manufacturing process and the specialized tools and equipment used for installation. Students then practice essential hands-on skills that include layout, seam cutting, insert installation, and game lining. The course also covers hand-sewing seams, repairs, and glue-down installations. Successful completion requires perfect attendance, a minimum score on the final exam, and passing evaluations during demonstrations of the hands-on skills.
Traveling further afield
While sports fields and stadiums make up the largest segment of synthetic turf installations, the category has evolved far beyond its origins. With material innovations and more aesthetic options, turf is now appearing in residential, commercial, and public spaces, too.
In residential landscaping, synthetic turf is increasingly used to create low-maintenance lawns, pet-friendly play areas, and backyard putting greens. Homeowners appreciate the year-round greenery and its low maintenance as well as the water-saving benefits, particularly in regions prone to drought. Synthetic turf is also appealing to urban environments where natural grass struggles to grow, and it can be found on rooftops, balconies, and terraces.
In commercial spaces, synthetic turf serves decorative and functional purposes. Businesses incorporate it into event venues and outdoor patios to create inviting and visually appealing environments. Likewise, public spaces like parks and playgrounds benefit from its shock-absorbing cushion, durability, and resistance to heavy foot traffic.
Overall, synthetic turf presents an exciting opportunity for professional installers to diversify their skills and grow along with this expanding market. By leveraging existing knowledge of adhesives, substrates, and seam work, many installers are already well-positioned to transition into turf. All it takes is the right training to earn wins out on the field.