Artificial Turf History: #1 Guide to the Evolution of Modern Synthetic Grass

In this article, we will delve into the remarkable journey of artificial turf, exploring its early beginnings, the advancements in materials and manufacturing technology, and its impact on various industries.
Artificial Turf History

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From its early days as Astroturf® to the sophisticated synthetic grass we see today, artificial turf history and evolution have been nothing short of remarkable. Advancements in materials, manufacturing technology, and environmental considerations have turned synthetic grass into a sustainable, versatile, and safe option for a wide range of applications. 

As we look to the future, the possibilities for artificial turf technology are limitless, promising even more exciting developments in the years to come. Whether it’s for sports, landscaping, or residential use, artificial turf has truly transformed our green spaces.

Today, artificial turf systems are highly advanced and versatile, offering a range of benefits. This is especially apparent when comparing artificial grass vs. natural grass. Synthetic turf systems are durable, require minimal maintenance, and can withstand heavy use. Artificial turf is also more resistant to weather conditions, making it an ideal choice for sports fields, playgrounds, and other outdoor areas.

Despite its widespread use, artificial turf has also faced criticism, particularly regarding its environmental impact and potential health risks. However, ongoing research and development are addressing these concerns, with the introduction of more eco-friendly materials and improved manufacturing processes.

Artificial turf has come a long way since its inception, revolutionizing the way we think about green spaces. In this article, we will delve into the remarkable journey of artificial turf, exploring its early beginnings, the advancements in materials and manufacturing technology, and its impact on various industries.

Artificial Turf History: Early Beginnings of Synthetic Grass

The common belief that synthetic grass was developed specifically for the Houston Astrodome in 1965 is a misconception. To understand the full story, we need to look back further. Originally created to replace concrete and brick, synthetic grass was intended to bring green spaces to city schoolyards.

During the Korean War, the U.S. Army observed that urban recruits were less physically fit than their rural counterparts, and identified the lack of green areas as a potential cause. The Ford Foundation funded research by Monsanto to develop a synthetic grass replica in 1962, aiming for a wear-resistant, cost-efficient, cushioned, and traction-tested surface. Two years later, employees from the Chemstrand Company, a subsidiary of Monsanto, fulfilled this ambition by introducing “ChemGrass.” 

This innovative synthetic surface was first installed at the Moses Brown School in Providence, Rhode Island. While the new product met all the original criteria outlined by the Ford Foundation, it was expensive to produce, making it unsuitable for inner-city playgrounds. However, this setback led to a new beginning for the product and a fresh name. Keep reading to learn how AstroTurf® revolutionized the world of sports, offering a durable and comfortable alternative to traditional surfaces.

1960’s - 1970’s_ First-Generation Turf a.k.a AstroTurf®

1960s – 1970s: First-Generation Turf a.k.a. Astroturf 

In 1965, the Houston Astrodome made history as the first domed stadium with a glass-covered roof, allowing real grass to grow inside. However, the glass caused a glare that made it difficult for athletes to track the ball. Attempts to paint the glass resulted in the grass dying. 

In 1966, Houston introduced ChemGrass, later known as AstroTurf®, as a solution. The initial iteration, was far from the lush, realistic surfaces we see today. Astroturf was made from coarse nylon fibers, offering durability but lacking the natural look and feel of real grass.

The drive behind the development of early artificial turf was the need for a low-maintenance, all-weather playing surface for sports. It was a response to the limitations of natural grass, which required extensive care, suffered from wear and tear, and became unusable in inclement weather. Astroturf, although not perfect, provided a significant improvement in these areas. However, its abrasive texture led to concerns about athlete injuries.

This artificial turf revolutionized sports and became popular in stadiums worldwide. Despite its initial drawbacks, AstroTurf® has provided a durable and consistent playing surface for athletes, hosting numerous iconic sporting events, such as:

  • 12 World Series
  • 11 Super Bowls
  • 10 Olympics
  • 8 Major League All-Star Games
  • 32 NFL Pro Bowls 

It has become the preferred surface for stadiums worldwide. However, the first generation of artificial turf posed challenges such as joint problems, player injuries, and material deterioration. Over the years, advancements have been made to improve artificial turf for better performance and player safety.

Astroturf marked the birth of synthetic grass and served as the foundation for future developments. Its introduction brought about a significant shift in sports facility management, allowing for year-round play. However, it had its drawbacks, including a hard and abrasive texture that led to increased injuries among athletes.

Over time, the desire for a more natural look and feel, as well as enhanced safety, drove further innovations in the world of artificial turf. The influence of athlete feedback, coupled with advances in materials and manufacturing technology, played a crucial role in shaping artificial turf history and the ongoing evolution of synthetic grass.

1980s - 1990s_ Second Generation Turf

1980s – 1990s: Second-Generation Turf

The second-generation synthetic turf was first invented in 1976 by Frederick T. Haas. The 1980s and 1990s were a time of significant technological progress in the artificial turf industry. With increasing demands for better performance and player safety, manufacturers began creating more advanced turf systems. These surfaces included a shock-absorbing pad beneath a carpet with much longer fibers compared to the first-generation systems. 

One important development during this period was the introduction of infill systems. Instead of relying solely on the turf itself for cushioning and support, an infill material was added. The carpet pile was filled with silica sand, which filled the spaces between the turf fibers, allowing them to stand upright. This innovation greatly improved shock absorption, reducing the risk of player injuries, particularly in high-impact sports like football. 

Additionally, the materials used in artificial turf underwent significant enhancements. Second-generation turf systems featured longer and softer fibers, making the playing surface even more similar to natural grass. 

While this second-generation artificial turf worked well for sports like field hockey, it did not replicate the behavior of natural grass for football, baseball, and lacrosse. Not only did the ball not behave “right,” but it also caused painful abrasion injuries from the sand. In the early 1990s, many sports stadiums switched back to natural grass playing fields. However, issues persisted with natural fields, such as challenging maintenance and the need for abundant sunlight.

2000s - Present_ Third-Generation Turf

2000s – Present: Third-Generation Turf

Third-generation turf surfaces involve filling the space between vertical pile fibers with a granular material, creating an infilled system. These systems use infill materials such as crumb rubber or a combination of crumb rubber and silica sand, unlike the pure sand used in second-generation systems. The initial third-generation system was created by FieldTurf and was first installed in 1997 at a Pennsylvania high school. Subsequently, multiple companies have produced similar products.

The most recent iteration of sports turfs provides an exceptional playing surface that exceeds all previous versions. Thanks to revolutionary advancements in materials, artificial grass blades have become softer and less abrasive. Combined with high-performance backing materials, these modern sports turfs are specifically engineered to meet the unique requirements of every major sport. 

Third-generation artificial turf fields now provide improved safety, playability, appearance, and durability, with lower operating costs and reduced annual maintenance needs. These fields are used more frequently than natural grass fields due to their lower maintenance requirements, making them suitable for use even in unfavorable weather conditions.

Maintaining synthetic grass is easy, which is why many universities and professional teams are opting to install it once again. The new, 3rd generation sports turf brings significant enhancements. The grass blades are taller and spaced farther apart, allowing players to dig their cleats deeper into the turf. This reduces strain on joints and gives athletes better traction and performance. 

Furthermore, the use of polyethylene instead of polypropylene has resulted in softer and less abrasive blades. Tackles can now be executed comfortably, without the concern of skin abrasion. With the introduction of these advanced sports turfs, athletes can now play at higher speeds with reduced risk of injury. 

Now that we’re caught up on artificial turf history and how it has evolved over the years, let’s drill down further. Below, we’ll explore the advancements in materials, technologies, and manufacturing processes. We’ll also provide an overview of the components and features that make modern synthetic grass possible.

Advancements in Materials

Advancements in Materials

One of the key drivers behind the evolution of artificial turf has been the continuous improvement of materials used in its construction. Over the years, synthetic grass has seen remarkable advancements in materials, leading to improved performance and aesthetics. Beginning with short, dense nylon fibers that were less than 0.05” (<1.25mm), the original iterations of artificial turf left a lot to be desired.

Advancements in technology, design, and manufacturing have resulted in artificial turf with less dense and much longer fibers. Composed of Polyethylene, Polypropylene, or Nylon, modern turf fibers can range from 0.5” (13mm) to 2.75” (70mm) or more. The increased space between fibers allows for the inclusion of granular infill materials like crumb rubber and sand. It’s a combination of longer fibers, granular infill materials, and impact-absorbing shock pads that helped to create modern turf products.

Nylon

Nylon fibers added versatility to artificial turf. Known for their strength and resilience, nylon fibers are commonly used in sports fields, ensuring the turf can withstand the demands of various sports and activities. The influence here was to create a turf that could accommodate a wide range of sports without compromising performance.

Polypropylene

Polypropylene fibers brought enhanced durability to artificial turf. They are resistant to wear and tear, making synthetic grass a long-lasting choice for high-traffic areas. This development was driven by the need for longevity, especially in sports fields that faced heavy use. The influence of maintaining performance over time was a driving force behind the use of polypropylene. With the introduction of Polyethylene, Polypropylene became the go-to material for Thatch Fibers.

Polyethylene

The introduction of polyethylene fibers revolutionized artificial turf, as they provided a softer, more natural appearance and feel. Polyethylene mimics the texture of real grass blades, enhancing the overall look and comfort of synthetic turf surfaces. This shift was largely influenced by the desire to create a more lifelike alternative to natural grass. The true-to-life look and feel of Polyethylene turf fibers made it much more appealing for residential applications.

Advancements in Manufacturing Technology

Technological innovations have played a pivotal role in shaping the manufacturing process, or how synthetic turf is made. These advancements have made the production of artificial grass more efficient and consistent.

Tufting & Stitching Techniques

Tufting & Stitching Techniques

The improvement of tufting and stitching techniques has significantly enhanced the production of artificial turf. Tufting involves the insertion of synthetic grass fibers into a backing material to create a turf’s surface. Advances in this technique have allowed for more precise placement of fibers, resulting in a seamless and natural appearance. 

Computer-controlled machinery plays a crucial role in this aspect by ensuring consistent spacing and alignment of the fibers. It has revolutionized the manufacturing process of artificial turf, offering several advantages, including increased speed and precision. Stitching techniques, which are responsible for securing the turf fibers to the backing, have also evolved.

These techniques have become more sophisticated, ensuring that the fibers remain firmly attached, even under heavy use. Overall, the refinement of tufting and stitching methods has improved the overall quality and aesthetics of artificial turf, making it virtually indistinguishable from natural grass.

Automated systems can tuft and stitch fibers at a much faster rate than manual labor, leading to higher production efficiency. Moreover, computer control ensures consistency in fiber placement, density, and alignment, resulting in a more uniform and visually appealing surface. This level of precision is especially critical for sports fields, where consistent playing conditions are essential. 

Additionally, computer-controlled machinery allows for customization, enabling manufacturers to tailor turf designs to meet specific performance requirements for different sports and applications. The integration of computer technology has streamlined the manufacturing of artificial turf, resulting in higher quality and more versatile products.