Exhibit_3_Polytan_Service_Handbook_English.PDF

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Sport Fields and Playground Maintenance Services
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Exhibit 3 - Polytan Service Handbook English

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PM/fas/120308-Polytan Pflegeanleitung Fußballrasen 2012_EN .doc - 1 -

Service and Maintenance

Polytan|STI football turf systems with monofilament turf and sand and rubber filling

Maintenance instructions

Aim and scope

This service handbook is designed to assist groundsmen and maintenance personnel in the care and maintenance of Polytan|STI synthetic turf pitches.

1 Polytan|STI football turf

Modern football turf and football turf systems are already very close to the ideal type of natural turf. Polytan|STI football turf systems with an elastic layer are always of the same design. It consists of an elastic layer made of rubber granules bound with polyurethane installed in-situ. The synthetic turf with a sand and rubber infill is laid on top of this.

Polytan|STI synthetic turf with smooth fibres Polytan|STI synthetic turf with textured fibres

A distinction is made between turf types with smooth fibres and those with crimped (textured) fibres.

Polytan|STI turf systems have blades of synthetic grass with a length (tuft height) of between 30 and 50 mm and are filled with quantities of rubber granules of between 4 and 7 kg per m² depending on the system.

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2 Different types of maintenance

Maintenance measures are divided up as follows:

Section 3 General inspection and maintenance work Section 4 Maintenance work for turf and rubber granules (system) Section 5 Special care and maintenance work

You will find information on the settings for maintenance equipment and suitable service and maintenance plans at the end of the servicing instructions. Please send any further questions to the relevant Polytan|STI contact addresses.

3 General inspection and maintenance work

We recommend that the condition of the football pitch is regularly inspected and that routine maintenance is carried out on an ongoing basis. Seasonal factors must be duly considered at the same time.

Remove surface dirt regularly

Remove leaves, pine needles, paper, cigarettes etc. straight away. The easiest way to remove these is to use a blower to work them from the centre to the edge or a brushing machine adapted to the turf system.

Regular maintenance of the edge zones and the external area

Remove leaves, pine needles, soil etc. to ensure that natural grass, moss and lichen cannot become established.

Existing pitch growth must be removed by mechanical means

Tear out, cut or spray with high-pressure water. Do not use aggressive cleaning nozzles. The fill level of sand and granules must then be checked.

Sharp objects

Stones, shards of glass, metal parts etc. must be removed immediately.

Oil and fuel

These must be absorbed quickly and completely with sand or sawdust and then removed. It is advisable to replace the granules and sand within a minimum radius of 20 cm to prevent any reactions between the substance and the fibre filament and carpet backing.

Chewing gum/adhesives

Chewing gum can best be removed after it has been frozen. The bonding agent must be peeled off the stalks carefully.

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Contamination by bird droppings, faeces etc.

This type of contamination must be removed immediately; sand and rubber granules in the immediate vicinity must also be replaced if necessary.

Check the lines and seams

Lines must be checked on an ongoing basis to ensure that they are firmly attached.

Check the granulate and sand infill

The entire turf area must be regularly checked to ensure that the sand and granulate infill is at the correct level. Any lost granules or sand must be replaced in accordance with the instructions.

Granules and sand are more liable to be displaced in the areas subject to the greatest wear and tear, such as the six-yard box and the penalty spots. The sand and granules must be refilled to the specified levels. It is also possible to deviate from the specified fill quantities in these areas (e.g. approx. 3 x 3 m in the goalmouth and 1 x 1 m around the penalty spot) and to use more sand and fewer rubber granules.

If touch-ups or repairs are necessary, please contact our experts at Polytan|STI as soon as possible in order to prevent any further damage or potential accidents.

TIP

We recommend that no chemicals be used for general maintenance work (e.g. to remove natural ground cover). The wide range of products and their chemical composition mean that damage to the fibres cannot be ruled out in principle.

In addition, residues may settle in the granulate material and the sand which may be harmful to the health of users and players. Moreover it is not possible to rule out damage to the environment when the chemicals are washed out!

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4 Maintenance of synthetic turf filaments and rubber granules (system)

The smooth synthetic turf filaments (non-textured) always have a specific alignment (= pile direction) and never stand up straight by themselves without sand and rubber granules (= infill). Even after filling with sand and rubber, this directional effect is still visible to some extent.

Football turf before filling Football turf after filling with sand and rubber

This can be used to good effect during maintenance work on the turf filaments, essentially by brushing against the pile direction. This ensures that the blades of grass are more easily caught and made more upright.

The filling in newly installed filled synthetic turf systems is still relatively loose as it has not yet reached its final packing density. In the case of new systems, more thorough and more frequent brushing in the initial stage can help the sand and rubber granules to settle. Fill levels are thus evened out, and sand and rubber granules are neatly brushed into the football pitch and properly distributed.

Synthetic turf filaments

Rubber granules Sand

Synthetic turf filaments

Against pile direction

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4.1 Football turf laid in the same and opposite directions

4.1.1 Synthetic turf strips laid in the same direction

Picture: Football turf laid in the same direction

These pitches show no difference between the strips, as the blades of grass all point in the same direction.

4.1.2 Synthetic turf strips laid in opposite directions

Picture: Football turf laid in opposite directions

The blades of grass on alternating strips of turf point in opposite directions here.

The effect is clearly visible (lawnmower effect). This type of installation can simplify and reduce maintenance substantially.

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4.2 Synthetic turf filament maintenance

The maintenance of synthetic turf filaments has a significant bearing on the playing qualities – especially the ball rolling behaviour – of the football pitch, as well as its tractive and rotational force and its visual appearance.

4.2.1 Football pitch maintenance with the brush on the Polytan ACS unit

The plastic brush on the Polytan ACS unit is an effective piece of equipment for the maintenance and care of Polytan|STI football turf, either on its own or in combination with the needle bars. It is important to ensure that the fixed brush is adjusted to the correct setting (see Section 7) and travels in the right direction during maintenance operations.

Plastic brush on the ACS unit

Tip It is important to ensure that the contact pressure exerted by the maintenance machines is correctly adjusted so that the turf strips do not become corrugated or displaced during maintenance work. Particular care must be taken with the lines.

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4.2.2 Frequency of maintenance of football turf with the brush on the Polytan ACS unit

The synthetic turf filaments should be brushed at least once a week. Additional measures are the responsibility of the operator and depend on the intensity of use (amount of training and number of games played, number of players etc.).

4.2.3 Maintenance and travel direction with Polytan ACS unit

Football turf with strips laid in the same direction

Direction of brushing if the strips of Direction of travel if the strips turf run in one direction depends on of turf run in one direction always the direction of the turf filaments goes against the pile

Football turf with strips laid in opposite directions

Direction of brushing if the strips Direction of travel against the pile if the of turf run in opposite directions strips of turf run in opposite directions

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If the strips have been laid in opposite directions, there are several options for optimum pitch maintenance with no need to travel around the edge of the pitch.

This can be individually determined. Maintenance is easier and less time-consuming if the strips of turf run in opposite directions.

Travel direction for turf laid in opposite directions in detail

4.2.4 Maintenance and direction of travel on older turf

We also recommend sweeping at right angles to the direction in which the strips of turf have been installed, in order to ensure that all the grass filaments on older or heavily used football pitches are reached during the brushing process.

Direction of brushing in Order of travel heavily used areas

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When treating synthetic turf fibres in heavily used areas or at right angles to the direction of installation, the best results are achieved if the final brushing operation goes against the direction of the pile.

4.2.5 Special features of line markings

The formation of a zigzag pattern (sidelines) or bows generally indicates excessive pressure during brushing. The setting on the unit must be checked if this happens.

Passing along the sidelines and goal lines can also help to correct this appearance. This applies in equal measure to turf installed in the same or opposite directions.

Maintenance along the sidelines and goal lines

4.2.6 Textured Polytan|STI football turf systems

In principle the same maintenance methods apply to textured football turf when using the brush on the ACS unit, although the frequency may be reduced depending on the level of usage.

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4.3 Rubber granulate maintenance

The rubber granulate is evenly distributed over the entire pitch after it has been filled for the first time to ensure that the synthetic turf filaments project uniformly above the turf (pile projection).

4.3.1 Pile projection/filling height of rubber granulate

The sand/rubber infill must be packed as evenly as possible below the tips of smooth and textured fibres alike.

Uniform filling with smooth fibres Uniform filling with textured fibres

The appearance of the turf differs as a result of texturing. The textured filaments have a crimped structure so that they are more voluminous and face in different directions.

4.3.2 Measuring pile projection/filling height

The easiest way to measure pile projection is with a gauge. This should be done at several points on the pitch.

Gauge for measuring pile projection

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Cardboard can be laid on textured filaments to assist the measuring process.

The existing filling height can then be read from the gauge. It must be ensured that it is in contact with the surface.

Correct filling height for smooth turf fibres

Filling too high Filling too low

4.3.3 Heavily used areas

Granules are generally displaced during training and games in the main playing areas, around the centre circle and around the goals. Training areas (e.g. small-sided and mini-pitches etc.) are particularly affected by the displacement of granules as well.

Stress distribution on the pitch (orange = high stress green = low stress)

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The goal areas and the penalty spots must be checked particularly carefully to ensure that they are evenly filled, as training and games can result in more granulate and sand displacements here. The penalty spots may therefore be filled with a little more sand and a correspondingly lower amount of rubber granules. The pile projection length in these areas must still be the same as the rest of the pitch, however.

4.3.4 Amount of infill

Heavy usage in general, as well as snow clearing in snowy regions, always results in a slight loss of rubber granulate.

Missing infill material (sand and rubber) must be replaced in the course of routine maintenance measures. This replacement material should ideally be stored near the pitch.

A road brush with slightly harder plastic bristles is all that is required to work in and distribute the new infill material over small areas (e.g. penalty spots).

Experience shows that it may be necessary to keep in reserve about one metric ton of refill material per full-size pitch (approx. 7000 m²) after the second year.

The actual amounts depend on the intensity of use and the extent of displacement.

Note It must be ensured that only infill material of the same type and from the same manufacturer is used, as undesirable reactions may otherwise occur between the synthetic turf filaments and granulate. Such reactions may cause damage to the turf system, synthetic turf filaments or backing.

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4.3.5 Levelling the rubber granulate with fixed ACS brush

The easiest way to evenly distribute the granules is to use the fixed brush on the Polytan ACS unit. It is important to set the correct working depth of the brush.

The reference setting should always be done in such a way that the brush is levelled at a correct pile projection length whilst resting on the surface of the granules.

Correct brush setting

The speed of travel must be adjusted so as to ensure that the brush does not jump.

4.3.6 Frequency of maintenance for levelling granulate

As a general rule, the amount of levelling is in line with the maintenance of the turf filaments.

The turf filaments can be straightened and the granules levelled out in one operation by using the maintenance brush on the ACS unit on the right setting. No further measures are therefore necessary.

Brushing and levelling should only be done when the rubber granules are dry and in dry weather conditions. Only in this way can the granules be evenly distributed in the turf without sticking to machinery or to the blades of grass.

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4.4 Loosening the rubber granulate with ACS needle bars

4.4.1 Polytan|STI turf systems with smooth and textured filaments

The granules are loosened by using the two adjustable needle bars attached to the Polytan ACS unit.

Needle bars on the Polytan ACS 210 unit

It is essential to ensure that the needles only penetrate into the granules and not into the layer of sand. Sand and granules will be mixed if the depth of penetration is set too deep, which adversely affects the functioning of the system. There is also a danger that the turf backing may be damaged.

Correct setting of the needle bar

4.4.2 Polytan|STI football turf systems with textured filaments

The settings here are the same as for football turf systems with smooth filaments.

The exact settings can be found in the information on maintenance equipment in Section 7.

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5 Special maintenance and servicing work

The following section contains a list of measures that may be necessary in certain regions.

5.1 Winter

5.1.1 Snow clearance

As a general rule, it is possible to clear snow from football turf systems by mechanical means as long as a few precautionary measures are taken.

5.1.2 Clearance height

The full amount of snow is never removed. Around 2 cm of snow must be left on the pitch. This protects the turf filaments from mechanical damage by the shovels. Spacers are used to keep a safe distance to make sure that the blades of grass are not damaged and no tufts are pulled out.

5.1.3 Use of snowploughs

Only small (manually operated) snowploughs may be used to clear snow from synthetic turf.

5.1.4 Use of thawing products (salt, liquid)

The use of thawing products (in liquid or granular form) is generally possible. The use of de-icing salt or other thawing products may lead to temporary discolouration of the infill or the turf fibres, which can simply be rinsed off after the period of frost. This also stops the grains of salt from crystallizing on the synthetic turf filaments.

There must be due compliance with statutory regulations if using salt or thawing products.

5.1.5 Clearance with shovel attachment on the turf tractor

Snow must be cleared with a shovel attachment immediately after it has fallen so as to achieve the best results with the lowest possible impact on the turf. The clearance operation must work outwards from the centre and the goal lines. The snow must be cleared in small quantities due to its weight.

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5.1.6 Topping up granulate after winter

Since it is inevitable that some granules will stick to snow during clearance operations and be removed from the pitch, the missing granules should be spread back on the pitch or it should be filled with new material.

It is best to deposit the snow on the edge of the pitch, preferably on a pre-cleaned paved surface, in order to recover the rubber granules removed during snow clearance. The rubber granules can then be re-used when the frost season is over.

5.1.7 Ice formation

If ice forms on the surface of the pitch (e.g. after sleet), no games should be played for safety reasons. Ice formation or compacted snow that encases the blades of grass can cause the turf filaments to snap off.

5.2 Summer

5.2.1 Watering, irrigation

In certain situations the playing properties of the pitch, its suitability for sport, its protective qualities and its microclimate can be improved by watering or irrigation.

5.3 Temporary coloured markings

Polytan|STI should be consulted on the selection of suitable colours.

Alternatively, quartz sand can be used to apply temporary markings and taken back up after the event.

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6 General instructions for use

Footwear

• Football boots with moulded plastic studs or cleats are the ideal footwear for filled synthetic pitches.

• Football boots with metal (steel or aluminium) studs are not suitable for use on synthetic turf.

• Sports shoes with flat soles are also unsuitable.

• Normal shoes or high-heeled shoes must not be worn on the synthetic turf.

Events

• No naked flames or fireworks must be taken onto the football pitch during events.

• Covers should not be placed on the turf until the last possible moment before an event and only remain there for as long as necessary. As soon as the covers have been removed the turf filaments must be brushed with the ACS brush in order to return them to their correct position.

Before being covered, specific areas of the turf may be temporarily filled with rubber granules to the tips of the fibres in order to stop the filaments from bending or to reduce the effect of being bent.

• The maximum permitted load of the sports field must be duly observed irrespective of the turf. The turf must be covered before heavy equipment is used on it, in order to achieve optimal weight distribution.

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7 Maintenance equipment

7.1. General information

The following section contains a brief description of the maintenance equipment recommended and supplied by Polytan|STI to look after its football turf systems.

It also describes how the equipment should be adjusted for the various types of work.

Polytan|STI maintenance equipment ACS Standard, ball roll ramp, ACS 210

Permitted loads and driving on the turf

Since maintenance work can only be carried out economically and effectively by the use of mechanical means and a motorised mini-tractor, it is particularly important to observe a few basic rules with regard to loads and driving on the surface of the synthetic turf. As a general principle, load-bearing capacity also depends on the type of base layer.

Wheel load

The overall weight of maintenance equipment must not exceed 5 metric tonnes.

The maximum axle load is approx. 2.5 tonnes. This only applies to systems with an elastic layer and bound base course or elastic base course. Vehicles must have pneumatic tyres to ensure that pressure is well distributed.

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Driving on the synthetic turf

Vehicles must be driven at moderate speed. Sudden braking and acceleration must be avoided as these can cause the turf surface to be displaced or turf filaments to be broken off.

The same applies to steering movements. Steering while stationary and full steering locks are to be avoided at all costs, as these can also displace the turf or damage whole sections of it. The radius of turning circles must not be too narrow, in order to ensure that no displacement can occur.

Special vehicles/special loads

If special vehicles or equipment (cherry pickers, transporters, platforms, poles etc.) heavier than the recommended load have to be driven or operated on the turf, a suitable base must be used or the turf must be covered completely so as to ensure that pressure is equally distributed. Point loads must be avoided or balanced by load distribution plates.

7.2 Polytan ACS unit with brush and two needle bars

The ACS unit guarantees fast optimum care for Polytan|STI football turf systems.

It has been specially designed and tested for use on synthetic turf systems. The ACS units (ACS 210 or Standard) can be affixed to a hydraulic three-point mounting on the mini-tractor. The ACS Standard maintenance unit can also be attached to a tractor by means of a drawbar without a link to the hydraulic system.

ACS 210 hydraulically raised at 3-point ACS Standard with drawbar mounting Brush and needles disengaged

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Connection to the hydraulic system is certainly preferable, as it keeps the surface contact pressure constant, prevents jerks and jolts, and is easier to operate.

The working width of the ACS 210 is around 2.1 metres more, which means that larger surfaces and facilities can be treated more economically.

You will find more technical data on the ACS units in the instruction manual.

7.2.1 ACS maintenance module plastic brush

The fixed plastic brush has two positions: no contact with the ground (raised) to travel to and from the pitch, and lowered for maintenance work on the football turf.

The spindle is used to adjust the brush and the contact pressure. The setting should be done in such a way that the brush is in full contact with the turf system without the bristles actually being immersed in the granules.

Spindles on ACS units for adjusting brush contact pressure

The correct brush setting is essential if the required results are to be achieved.

Not all the turf filaments will be caught if there is too great a distance between the bristles and the reference area, and brushing will be incomplete.

The rubber granules will not be levelled out as a result.

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Setting too high

If the bristles penetrate the rubber granules in the reference area, then too many granules are swept out of the football pitch and too few of them are left in the turf!

Setting too low

The settings for smooth turf fibres and crimped turf filaments are always the same for brushing the turf filaments and levelling out the granules.

7.2.2 ACS maintenance module needle bar

The ACS unit can also be used to loosen the rubber granules at depth. This also helps the turf fibres to recover and improves the grip of synthetic turf.

The steel needles required for this purpose are arranged in rows on two needle bars and spring-mounted. Their height can be adjusted to a suitable setting for the turf conditions.

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The needle bars can be disengaged during routine brushing.

ACS Standard needle bars ACS 210 needle bars with double row of needles with adjusting spindle

Depth adjustment spindle and scale (right and left) on the ACS 210

The result of the loosening work must be checked after a trial run and the depth of penetration readjusted up or down if necessary.

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Diagram for adjusting the needle bars

Working elements set correctly

Working elements set too deep

TIP

Check height settings whilst working to prevent damage to the system or the maintenance unit!

7.3 Adjustment of maintenance equipment

It is best to take measurements and adjust equipment at the edge of the pitch.

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7.4 Ball roll ramp

The ball roll ramp is designed to check the success of the maintenance work which the groundsman or technical personnel has completed. It is particularly suitable for checking whether the turf filaments have been returned to their upright position.

Ball roll ramp

When conducting the test it must be ensured that the ramp is straight and is also not at an angle to the side. The struts must be immersed in the turf in such a way that they rest on the granulate or the synthetic turf filament extend over the struts.

After this the ball is to be rolled from a maximum height of one metre on the angled ramp.

Adjustments on the ball roll ramp

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When it comes to a standstill the distance from approx. 50 mm behind the ends of the struts to the centre of the ball must be measured (see sketch).

The better and more regularly the maintenance work is carried out, the less will be the distance covered by the ball. This applies regardless of the distances achieved but differs in between straight or textured filaments.

FIFA measuring points

The sketch shows the measuring points for the FIFA testing. At the same time these points represent the areas with different usage.

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8 Deep cleaning

Polytan|STI also provides deep cleaning for synthetic turf as a separate service or as part of a fixed maintenance contract. This deep cleaning and a general refill of rubber granules should be carried out regularly in line with the level of usage and the condition of the pitch.

Polytan|STI recommends having a deep clean done at least once a year.

A special brushing vacuum cleaner is used to suck up the rubber granules from the turf system when it is in a dry state. These granules are then separated from small debris (fibre, rubber debris, sand, leaf residues etc.) inside the vacuum cleaner before being redeposited in the football turf system.

Maintenance measures are considerably more effective if the turf is opened up with the Polytan ACS unit and the infill granules loosened immediately before deep cleaning.

Deep cleaning

Filling height ratios in the graphics serve to illustrate working methods and settings and may differ from the actual amounts.

All the maintenance equipment described can be purchased from Polytan|STI.

Subject to change due to new technical developments and practical experience

Polytan Sportstättenbau GmbH – March 2012

File details come from the government source that posted it. Updated .