Backing

Have you ever wondered how synthetic turf is designed to mimic natural grass? The backing plays a crucial role in this process, acting as the final step in manufacturing. It ensures that the fibers are securely anchored, much like the roots of natural grass, helping the finished synthetic turf meet the necessary sports standards. We often receive questions about this stage, so we’ve put together a list of frequently asked questions to clarify.

What is the primary function of synthetic turf backing?

Synthetic turf backing serves two main purposes. First, it provides a medium through which the synthetic grass fibers are tufted, known as the backing cloth. In some cases, multiple layers of backing cloth are used to support the second function, which is to secure the fibers and prevent them from being pulled or falling out. During the tufting process, the needle creates small holes in the backing cloth, and using two layers helps to restrict these holes and provide additional grip on the yarn. Afterward, a secondary coating, typically made of latex or PU, is applied in liquid form to cover the back of the turf and secure the fiber tufts. To enhance the tuft lock, some of the secondary backing is absorbed into the primary backing or through the tufting holes. Once the secondary backing is dried in the oven, the tuft is firmly secured and checked against required measurements before being sent to the roll-up unit.

What is the best secondary backing to use?

In Europe, latex is the most commonly used secondary backing material. It provides a good tuft lock, though it can be sensitive to moisture. If latex absorbs water and is not fully dried during production, it may weaken, leading to reduced tuft lock. However, when applied correctly, these issues are rare, making latex a cost-effective option for synthetic turf backing.

In the US and other regions, PU is more commonly used. Unlike latex, PU is resistant to moisture and does not weaken over time. It also creates a stronger bond with adhesives, which is beneficial for securing roll-edge joints. While PU-backed products are typically stronger than latex-backed ones, they come at a higher cost.

Recently, fully recyclable backings like the PRT system from SCopo have been introduced. These backings provide a stronger seam joint than PU, are up to five times more porous, and are lighter, making installation easier. Additionally, PRT can be fully recycled at local plastic recycling facilities at the end of its life, though it is more expensive upfront.

Why do some products have heavier backing weights than others?

The synthetic turf industry includes specialized producers with backing lines designed specifically for artificial grass, as well as companies using their existing carpet ovens for backing. The latter tend to have longer backing lines, requiring more latex to be applied. This is achieved by adding additives such as water and chalk, resulting in heavier backing weights.

However, a heavier backing does not necessarily mean a stronger tuft lock; the added weight is often a production necessity rather than a product advantage. Typically, more latex is applied to a backing cloth than PU, as PU requires a lighter coating to achieve the desired tuft pull strength.