Shallow Drainage Base for Synthetic Turf Installation
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Solution Overview
Problem
Conventional synthetic grass drainage systems require deep stone bases that are time-consuming and costly to install, necessitating multiple shipments and labor-intensive processes, leading to delays and increased costs.
Innovation Solution
A shallower drainage base system using locally available stone and tiles positioned above the base for leveling, combined with a business method that involves local manufacturing of tiles to minimize storage, shipping, and installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a deep stone base is used for drainage, then drainage effectiveness is improved, but installation time and cost increase substantially
Solution Approach 1:
The base is divided into multiple layers with different functions: a compacted soil base layer for structural support, a shallower stone drainage layer for water management, and a tile leveling layer for surface preparation. This segmentation allows each layer to be optimized independently, reducing the overall depth while maintaining drainage effectiveness.
Solution Approach 2:
The invention changes the depth parameter of the stone base from the conventional 6-8 inches to a shallower configuration. By adjusting the stone layer thickness and using properly sized stones, adequate drainage is achieved without requiring the traditional deep base, thereby reducing excavation time and material costs.
2Reliability
If a deep stone base is used for drainage, then drainage effectiveness is improved, but material cost increases
Solution Approach 1:
The base structure is segmented into functional layers, with the stone drainage layer optimized to the minimum thickness required for effective drainage. This eliminates the need for excessive stone material while maintaining drainage performance.
Solution Approach 2:
The stone layer depth parameter is reduced from conventional depths to a shallower configuration. By changing this critical parameter and using appropriately sized stones, the quantity of stone material required is substantially reduced, lowering material costs while preserving drainage functionality.
3Ease of manufacture
If multiple independent installers are used for base preparation and grass installation, then specialized skills are utilized, but project completion time increases
Solution Approach 1:
The base preparation and grass installation operations are merged into a coordinated process where the shallower base design allows the grass installer to begin work sooner. The tile leveling system enables base finalization to occur concurrently with grass installation preparation, reducing the sequential waiting time between trades.
Solution Approach 2:
The base is prepared to a near-finished state using the shallower stone and tile leveling system, creating a ready-to-install surface that allows the grass installer to begin work immediately. This preliminary preparation reduces the waiting time for grass installation while maintaining the necessary base quality.
4Reliability
If tiles are shipped from distant locations, then material availability is ensured, but shipping cost and time delays increase
Solution Approach 1:
Tiles are manufactured in advance at local facilities near the installation site. This preliminary production action ensures material availability while eliminating long-distance shipping delays, allowing tiles to be ready for installation when needed without requiring distant sourcing.
Data Source
AI summary
A drainage system for use with a synthetic grass surface, the system having a base having a center portion with a first depth and a perimeter channel with a second depth being greater than the first depth, a plurality of tiles above the base, and a synthetic grass above the plurality of tiles. Also, a business method facilitates installation of a synthetic grass system which utilizes drainage tiles positioned between a stone base and the bottom of the synthetic turf, wherein a mold for manufacturing the tile is provided from the turf company to a manufacturing company located in relatively close proximity to where the synthetic turf system is to be installed.