TECHNICAL MANUAL Limonta Sport S.p.A. | MADE IN ITALY SINCE 1979 www.LimontaSport.com | [email protected]
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy THE CONCEPT VERDEMIX hybrid system is the latest addition to the range of professional services offered by Limonta Sport; a leading company in the artificial turf market for more than 45 years, Limonta Sport has also been active worldwide with top level installations of its carpet based reinforced natural turf MiXto. The stitching of synthetic fiber into natural turf surfaces provides much longer playing hours than traditional natural grass pitches while increasing the safety and the stability of the playing surface – an ideal solution for both stadiums/arena and training facilities of clubs all around the world. ADVANTAGES • Hours of usage up to 4 times higher than traditional natural grass. • Stable and safe playing surface. • Reduced mobility of the grass sod, therefore better traction and safety for the athletes. • Pitch surface uniform and homogenous. • Reinforced grass root zone. • Limited natural turf superficial damage. • Optimal drainage capability. VERDEMIX pitches can perform at top level for at least 10 years if maintained according to correct standards and procedures set in place by Limonta Sport. Full renovation of the organic layer can be easily done as per traditional natural turf surfaces. Standard maintenance operations allow the grounds men to adjust surface hardness/softness, modify level of traction according to the needs of the players/coaches.
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy TECHNOLOGY Coming from the latest technology available in the market, VERDEMIX has self-propelled machinery for tufting artificial turf fibres into the natural grass systems. The synthetic fibres also perform the function of stabilizing the sand layer and ensuring the evenness of the surface.
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy Designed with a waterproof steel frame construction, VERDEMIX has a built-in dashboard for manual and automatic operation.
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy Ninety easily accessible and ready to be loaded fibre bobbin holders allow a quick and efficient workload. The fully electro-hydraulically driven machine is equipped with sensors for directional and elevation control for higher accuracy and precision, with the goal to guarantee a uniformly tufted pitch. The modular pendelum-tufting unit can be adjusted up to 18 cm deep (yarn length up to 40 cm), with a working width of 1760 mm. Fibres are injected into the soil at a distance of 2 cm from each other. The flexibility of the machine allows to tuft and stitch at different depth, adapting to different pitch profiles and according to the needs and specific requirements of the client. Stitching operations are possible on both existing fields and newly built ones (before or after seeding), easily fitting into groundsman and clubs tight schedules.
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy VERDEMIX MACHINE | PERFORMANCE VERDEMIX has a full tufting depth of 18cm; stitching depth can be easily adjusted according to the specifics of the clients. A full size pitch can be fully stitched and handed over in approx. 12-13 days using a single machine and a crew rotating on working shifts of 24 hours; when time is an issue, two machines can be delivered simultaneously on site to speed up operations and handover the pitch in less than a week.
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy VERDEMIX | ARTIFICIAL TURF FIBER The artificial turf fiber used by VERDEMIX has been selected by Limonta Sport for its long lasting resilience and ability to come back into original position year after year; these unique fibre characteristics have been studied and confirmed by hundreds of references worldwide in both Mixto hybrid surfaces and synthetic turf pitches. The additional achievement of this special fibre is to provide optimal visual coverage of the playing surface in periods when the natural grass surface is under intense stress and its density can’t be quickly enhanced/improved (like in winter months – or after a series of back to back events). • 100% Polyethylene • Full monofilament • High Dtex • Thick central core and section • Unique yarn section that guarantees unmatched resilience and top playing conditions • Natural look
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy INSTALLATION | A FLEXIBLE MODEL VERDEMIX stitching operations can be put into place with a certain degree of flexibility according to timeline available: • stitched before seeding into the sandy subbase. • stitched into very young sods to allow harmonious growth of the natural grass into the system. • stitched into a more mature grass sod (grown in a nursery and installed in the facility right before stitching). It is important that the subbase profile is built according to VERDEMIX requirements. VERDEMIX stitched system will not be implemented on surfaces not suitable for the operation.
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy CONSTRUCTION SPECIFICATION AND SUBBASE MODEL The pitch subbase construction must be implemented according to VERDEMIX specialist requirements, to avoid problems with the artificial fibre injection, base stability, surface infiltration rate, drainage capability and/or correct natural grass growth that could compromise the quality of the finished surface in the medium –long term. It is important to note that a balanced evaluation of the climatic and technical conditions the pitch is built in is fundamental in order to model a playing surface able to guarantee high quality performances year after year. It’s recommended that design and selection of the key elements of the pitch (construction methods and materials, seed mix, additives to be added on, maintenance operations, etc..) is shared within a team of experts – agronomist, turf consultant, VERDEMIX partner – who can evaluate the specific and unique conditions of the pitch itself. 1. PITCH SUBGRADE The subgrade must be a stable/inert material laser leveled rolled and compacted. Formation levels to mirror proposed pitch finished levels with the same slopes. • The sub-surface should have a slope of 5‰ to 6‰running from the centerto the touchline to aid surface water runoff. • Subgrade level to be compacted and leveled 360 mm below pitch finished level. • A geotextile of 250 gr/m2 to cover completely the subgrade. • The geotextile should also line the pipe drain trench. 2. DRAINAGE Typical drainage channels running touchline to touchline – Use perforated plastic pipes The drains within the pitch subgrade should be spaced at about 5 m and be of minimum gradient 1:200 and discharge to a main drain(s)/collecting pipe(s) located at both ends of the pitch. • Drain lines should be dug into the sub-base minimum 200 mm wide and varying in depth with a minimum of 50 mm of stone over pipe when completed. • Drain pipes to be double lined perforated PVC. • Minimum diameter of lateral drains to be 60-90 mm. • Minimum diameter of main drains/collecting pipes to be 160-200 mm. • Drainage gravel to be clean, washed gravel 6-12 mm. • 50 mm of gravel in trench under the pipes and back fill with 6-12 mm gauge stone/gravel. • Drain trench width minimum 200 mm. • Geotextile to line drain trench to prevent infiltration of soil material into drain backfill. • Minimum 50 mm backfill cover over lateral drain pipe.
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy 3. IRRIGATION SYSTEM An automatic pop-up sprinkler system will be required to uniformly irrigate the pitch both during construction and subsequently to establish and maintain the sward. In a stadium situation the facility to irrigate immediately pre-match and at half time is often desirable. The system should therefore include in-situ pitch sprinklers and be radio controlled. The water source and storage system must be capable of providing the peak daily requirement which will range from 5-15 mm per day depending on the local climatic conditions. The quality of the irrigation water must be fully assessed prior to the project by laboratory analysis. This especially important in some parts of the world where salinity and pH issues may be found. The latter can be very high and an acidification system may be required to maintain it within the range 6.5-7.0. A. GRAVEL LAYER Drainage layer comprising of 80 mm of gravel 6-12 mm compacted and leveled with laser guided machines. • Gravel layer of 6-12mm gauge or similar, grading analysis to be confirmed by laboratory testing. • Clean, uncontaminated material with lab tests confirming material stability. • The material should be installed with small low compaction machines and laser level machines driving only on the stone layer not on the natural sub-base
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy B. INTERMEDIATE LAYER • Intermediate layer to contain at least 90% of particles between 1-4 mm diameter and laid to minimum thickness 50 mm. • Materials to be clean and uncontaminated with lab tests confirming theirstability. • The intermediate layer to be compatible with the root-zone sand in terms of bridging factor, permeability and uniformity criteria; to be confirmed by laboratory testing. • The material should be installed with small low compaction machines and laser level machines driving only on the intermediate layer not on the drainage layer. C. SAND LAYER ( LOWER ROOT- ZONE) TOTAL DEPTH OF SAND LOWER ROOT- ZONE= 110 M M. (Sand layer should be compacted to a depth of approx. 110 mm) Maximum of 12% > 0.50mm 50%- 70% between 0.25mm – 0.50mm 20%- 30% between 0.125mm – 0.25mm Maximum of 8% < 0.125mm NOTE: - Use clean, washed medium – fine, silica Sand - High pH sands should be avoided. D. ROOT-ZONE (UPPER ROOT- ZONE) TOTAL DEPTH OF SAND UPPER ROOT - ZONE= 110 M M. (Root-zone laid to a depth of 110 mm.) The upperroot-zone shall comprise of an approved stone-free sand/soil mix orsand/organic (15-20%) mix which is to be imported to site pre-mixed. The type of mix and ingredients will vary from country to country depending on the raw materials available, the climate in the region and the type of grass used. Maximum of 12% > 0.50mm 50%- 70% between 0.25mm – 0.50mm 20%- 30% between 0.125mm – 0.25mm Maximum of 8% < 0.125mm NOTE: Use clean, washed medium – fine, silica Sand
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy Saturated Hydraulic Conductivity @30cm (Drainage) > 150mm/hr Total porosity 35-55% Air-filled porosity 15-30% Water filled porosity 15-25% Ideally pH should be around 6.0 – 7.5 Electrical conductivity (mS/cm) should guarantee low in salt presence (<0,5mS/cm) APPLICATION OF ROOT-ZONE MATERIALS The specified and approved materials should be spread and consolidated to give the uniform minimum depths specified with tolerances as stated below. Each layer must be spread to avoid any disruption of the underlying layer. Allowance must be made for handwork where necessary (e.g. placement and consolidation of materials adjacent to the pitch edge around irrigators and goalposts). The spreading and leveling machine shall be again a laser controlled machine and shall only operate on top of the material being spread. The materialsshall be transported on to the field in dumpers or tractor and trailers fitted with low ground pressure tires which shall travel on the material being spread. The tolerances over a 3 m straight edge for each layer in the pitch profile shall be no more than: plus/minus 3 mm. Allowance should be made for handwork on the root-zone to achieve correct levels with the edge kerb and irrigation equipment (pop-up sprinklers and hydrant boxes) and ensure sufficient consolidation in these areas to avoid future settlement. It will be essential to use the irrigation system constantly during the placement of the lower and upperrootzone to maintain the root-zone in a workable condition and achieve the right degree of consolidation.
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy Granular Fertilizers to be supplied and uniformly spread and incorporated into the root zone layer. • Zeolite or similar at 500 g/m² • Locally available P fertilizer to supply 120 kg/ha P205 (ex. NP 4/30 at 40 gr/ m² = 400 kg/ha) • Sierrablen Plus Active 18-5-18 + MgO at 35 g/m²= 350 kg/ha (controlled release) • Micronutrients plus Mg: STEP Hi-Mag Fertilizer at 10 gr/m²= 100 kg/ha • K+Ca+Mg: CalKMag fertilizer at 70-80 gr/m²= 700-800 kg/ha The upper root-zone should be cultivated to a maximum depth of 110 mm to mix the amendments into the root zone layer. A power harrow or rototiller would be suitable. The root-zone shall then be re-compacted using a steel on steel roller, laser leveled and then fine leveled with a heavy steel bar. Again it will be essential to use the irrigation system during the final leveling to maintain the root-zone in a workable condition and achieve the right degree of consolidation. USE OF PRE-CULTIVATED SODS In occasions when the use of VERDEMIX on pre-cultivated sods is unavoidable due to a limited time frame for the pitch reconstruction prior to the first game. The following are factors to consider in this situation: • A total of minimum 220 mm sand layer (higher root zone + lower root zone) is needed. • In the nursery, grow turf on a compatible root-zone mix similar to what will be used for the construction in the stadium or playing field. • A specific agronomical management is required 2-3 weeks before the harvesting in the nursery. Nutrition with Nitrogen need to be reduced and a strong program to protect and to prevent disease and to allow strengthening the turf need to be followed. • Lay natural grass with the professional process and equipment.
Limonta Sport S.p.A. | Single shareholder Company | www.limontasport.com [email protected] T +39 035 481 2111 Registered Office | Corso XXV Aprile 167/B 22036 Erba (CO) Italy | VAT Code: IT00354970139 Headquarter and Factory | Via Crema 60 24055 Cologno al Serio (BG) Italy UNDER FIELD AIR SYSTEMS Under field air systems comprise of a combined drainage, heating and aeration system passing through a network of large diameter pipes installed below the pitch and linked to a pump/blower in a designated plant room. These systems can be operated to achieve the following: • Blow warm air upwards through the pitch profile for frost/snow protection. • Replace the root-zone atmosphere by drawing out the existing air and pulling in fresh air via the creation of a vacuum below the pitch. This prevents accumulation of toxic gases and maintains optimal oxygen levels within the root-zone surface. • Draw water out of the root-zone into the drainage system effectively accelerating drainage. • This systems will require a deeper drainage layer to distribute homogenously the air through the entire field. HEATING SYSTEMS Stadiums and fields in cold climates can be kept from freezing and stimulate grass growth through underground heating systems These systems use warm water pumped through a system of 35 km, of 25 mm diameter tubes, 30 cm apart placed below 270 mm of sand sub-base (not 200 mm as x unheated systems).
Limonta Sport S.p.A. www.limontasport.com [email protected] Rappo S.r.l. www.mixtosystem.it HYBRID GRASS VERDEMIX: this is the name of the new “stitched” technology to offer to the best stadiums in the world a turf always in perfect conditions. A technology that is having a huge success. Imagine a large loom that weaves blades of artificial turf directly into the natural grass pitch. Like a tailor, the Verdemix technology ‘dresses’ the natural grass pitch, giving it the ‘resistance’ that only an artificial turf can have. INSTALLATION LOCATION SOLUTION AC MILAN, MILANELLO TRAINING CENTER field1 ITALY VERDEMIX AC MILAN, MILANELLO TRAINING CENTER field2 ITALY VERDEMIX AC MILAN, MILANELLO TRAINING CENTER field3 ITALY VERDEMIX FC SOCHAUX, AUGUSTE BONAL STADIUM FRANCE VERDEMIX STADE FRANCOIS BLIN, AVION FRANCE VERDEMIX
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