AU2014218384B2

AU2014218384B2 - A method for producing turf segments

Info

Publication number: AU2014218384B2
Application number: AU2014218384A
Authority: AU
Inventors: Patrick Muscat
Original assignee: GREEN LIFE FARMS Pty Ltd
Current assignee: GREEN LIFE FARMS Pty Ltd
Priority date: 2013-08-26
Filing date: 2014-08-26
Publication date: 2018-05-17
Anticipated expiration: 2034-08-26
Also published as: AU2014218384A1; AU2014218384A2

Abstract

Abstract A method and system for producing turf segments 21 for laying an area of lawn or garden. Lining a growing area 11 to form a weed and erosion barrier with a sheet lining 13. Laying a binding grid 15, 15' to form a base for the segments 21. Disposing a fertile growing medium in for form of an organic soil layer 17 upon the binding grid 15, 15' to a depth sufficient to support and sustain a fully developed root system of the turf segments 21. Planting a turf propagating layer 19 upon the fertile growing medium 13. Cultivating the area 11 over a growing period until the turf propagating layer 19 is grown with a fully developed root system and forms a well-netted surface. Cutting the growing area into segments 21 to a depth sufficient to demarcate and separate the segments incorporating the binding grid 15, 15' into discrete and dispatchable turf segments 21. The turf segments 21 can be stacked and transported to a site for transplanting. The turf system includes a plurality of turf segments 21. Each turf segment 21 comprises a binding grid 15, 15', a fertile growing medium such as the organic soil layer 17 and a turf layer 19. The binding grid 15, 15' forms a binding base for the segment 21. The organic soil layer 17 surmounts the binding grid at a depth sufficient to support and sustain a fully developed root system of the turf segments 21. The turf layer 19 is propagated upon and within the organic soil layer 17 and forms a well-netted surface of the segment 21. The turf segments 21 are of a regular shape, such as square slabs, to facilitate stacking onto a pallet 25 and despatching for subsequent transplantation at a site.

Description

A METHOD FOR PRODUCING TURF SEGMENTS Field of the Invention [01] This invention relates to turf farming and in particular to a method for producing turf segments for transplanting.

[02] The invention has particular, but not exclusive, application in the commercial production of turf for lawns and gardens, road verges and embankments, recreational areas such as ovals and playing areas, environmental applications such as for erosion control along hillsides or excavated areas, and any form of domestic or industrial application where turf may be able to be transplanted.

[03] Throughout the specification, turf is defined to mean any form of grass and the surface layer of earth supporting same that is held together by the roots of the grass.

[04] Throughout the specification, unless the context requires otherwise, the word “comprise” or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

Background Art [05] The following discussion of the background art is intended to facilitate an understanding of the present invention only. It should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was part of the common general knowledge as at the priority date of the application.

[06] Typical turf production involves the cultivating of turf for lawns and gardens in a controlled farm environment to produce high quality turf that can be subsequently transplanted. This transplanting involves cutting and rolling the turf into discrete turf rolls, and then dispatching the rolls to locations where they are transplanted and re-established for ultimate use. At these locations, the turf rolls need to be laid and re-established.

[07] Presently, at the location where the new lawn is to be sited, the cultivated turf rolls are laid on a carefully prepared surface of imported topsoil mix typically obtained from a landscape supplies yard, and then are fertilised and watered daily for a period of from 3 to 6 weeks before the lawn is fully established and trafficable.

[08] The turf rolls are relatively thin, i.e. less than 50 mm in depth, to facilitate rolling into coils and thus easier handling. However, this causes them to break up relatively easily, creating extra time and effort to lay the broken turf in a manner to support ongoing plant growth. Also, as the root system of the turf cannot be fully developed at such depths, a considerable amount of cultivation post-laying is required before the lawn area can be used for playing and support traffic.

Disclosure of the Invention [09] It would be desirable to obviate some or all of the problems associated with establishing new turf as described above, with a view to reducing the time and amount of post-laying cultivation, especially watering, that is required to re-establish the turf before it can be used for its intended purpose.

[10] In accordance with one aspect of the present invention, there is provided a method for producing turf segments for laying and establishing an area of lawn or garden, the method including: lining a turf growing area with a weed and erosion barrier layer; laying a reinforcing mesh or cellular binding grid on the barrier layer within the growing area to form a base for the turf segments; disposing a soil-based fertile growing medium upon the binding grid to a depth of approximately 50 to 100 mm to support and sustain a fully developed root system of the turf segments; providing a turf propagation layer on the fertile growing medium; cultivating the growing area over a growing period until the turf propagation layer is grown to produce turf with a root system that has grown through the growing medium and reaches and binds with the binding grid; cutting the turf and bound binding grid into discrete planar turf segments for stacking and transporting to a site for transplanting, wherein the combination of the binder grid, the depth of the soil-based growing medium and the bound root system facilitate handling of the turf segments as planar slabs.

[10a] In one embodiment the method further comprises stacking the planar turf segments for transporting to a site for transplanting.

[11] In one embodiment, the binding grid is formed of semi-rigid and flexible mesh material.

[12] In one embodiment, the depth is from approximately 50 to 75 mm.

[13] Preferably, the turf segments are of approximately square formation and sized to be placed on a pallet of dimensions 1.2 m x 1.2 m. In one embodiment, the turf segments have an approximate size of 1 m x 1 m.

[14] In one embodiment, the providing of a turf propagation layer comprises sprigging grass stolons into the fertile growing medium. Alternatively, the providing of a turf propagation layer may comprise laying an initial turf on the fertile growing medium.

[15] In one embodiment, the growing period is 9 months or more.

[16] Preferably, the barrier layer comprises plastic sheet or landscaping fabric.

[17] By the method of the present invention, there is provided a turf system for establishing an area of lawn or garden, the turf system comprising: a plurality of planar turf segments each comprising: (i) a reinforcing mesh or cellular binding grid forming a binding base of the turf segment; (ii) a soil-based fertile growing medium on the binding grid; (iii) a turf layer propagated upon the fertile growing medium, the turf layer having a root system that has grown through the growing medium and has bound with the binding grid; wherein the depth of the soil-based fertile growing medium on which the turf has been propagated is approximately 50 to 100 mm and the combination of the binder grid, the depth of the soil-based growing medium and the bound root system facilitate handling of the turf segments as planar slabs.

[18] In one embodiment, the binding grid is formed of semi-rigid and flexible mesh material.

[19] In one embodiment, the depth of the soil based fertile growing medium on which the turf has been propagated is from approximately 50 to 75 mm.

[20] Preferably, each turf segment is of approximately square formation and sized to be placed on a pallet of dimensions 1.2 m x 1.2 m.

[21] In one embodiment, each turf segment has an approximate size of 1 m x 1 m.

[22] Further by the method of the invention, there is provided a turf segment for laying within and establishing an area of lawn or garden, including: a reinforcing mesh or cellular binding grid forming a binding base of the turf segment; a soil-based fertile growing medium on the binding grid; a turf layer propagated upon the fertile growing medium, the turf layer having a root system that has grown through the growing medium and has bound with the binding grid; wherein the depth of the soil-based fertile growing medium on which the turf has been propagated is approximately 50 to 100 mm and the combination of the binder grid, the depth of the soil-based growing medium and the bound root system facilitate handling of the turf segment as a planar slab.

[23] In one embodiment, the binding grid of the turf segment is formed of a semirigid and flexible mesh material.

[24] In one embodiment, the depth of the soil based fertile growing medium on which the turf has been propagated is from approximately 50 to 75 mm.

[25] Preferably, the turf segment is of approximately square formation and sized to be placed on a pallet of dimensions 1.2 m x 1.2 m. In one embodiment, each turf segment has an approximate size of 1 m x 1 m.

Brief Description of the Drawings [26] An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, wherein:

Fig 1 is a perspective cut-away sketch showing the different layers for producing turf at a turf farm for cultivation;

Fig 2 is a cross-sectional side elevation showing the different layers that make up the turf in Fig 1;

Fig 3A is a plan view of one example of a binding grid used in the embodiment of the invention;

Fig 3B is a schematic side elevation of a portion of one edge of the binding grid shown in Fig 3A;

Fig 4 is a similar view to Fig 2, but showing the cutting blade of the saw for demarcating and separating the turf and bound binding grid into discrete planar turf segments;

Fig 5 is a side view showing a plurality of the planar turf segments stacked on a pallet ready for despatch;

Fig 6 is a perspective view showing a single turf segment stacked on a pallet;

Fig 7 is a series of perspective views showing the transplanting of a turf segment during the fourth stage from a pallet (Fig 7A) across to the plot (Fig 7B) and then into the prepared plot at the site for their use (Fig 7C);

Fig 8A is a plan view of another example of the binding grid;

Fig 8B is a schematic side elevation of a portion of one edge of the binding grid shown in Fig 8A.

Mode(s) for Carrying Out the Invention [27] The best mode for carrying out the invention essentially involves a method for producing turf segments 21 that form part of a turf system. The method constitutes part of a four stage process, which entails: (i) preparing a plot of ground at a turf farm for cultivating new turf; (ii) cultivating the new turf until it is ready for batching; (iii) batching the turf segments for despatch and transplantation; (iv) transplanting the turf segments at a site for subsequent use.

[28] The first stage entails excavating an area of ground to form a plot 11 for a growing area where new turf is cultivated and farmed. This is undertaken at a turf farm where equipment and facilities are available for controlled growing and care of the new turf to obtain very high quality turf for subsequent despatch to and transplantation at a site where the turf is to be used ultimately for a particular purpose such as a lawn or part of a garden.

[29] The plot 11 is excavated to a depth sufficient to allow for the root system of the turf to be fully developed. For most grasses this depth is approximately from 25 to 100 mm, but to obtain best results in a preferred embodiment it is from 50 to 75 mm.

[30] Once excavated, the plot is lined with a liner 13, which in one embodiment can be nonporous plastic sheet lining with holes introduced in it to allow for draining of water, or in a preferred embodiment, landscaping fabric, both underlying and circumscribing the growing area to form a weed and erosion barrier around the plot 11.

[31] A binding grid 15 is then disposed upon the liner 13 to form a base for the turf segments that are eventually formed as part of the batching stage. The binding grid in one embodiment is formed of a semi-rigid woven plastic mesh having two layers 15A and 15B as shown in Figs 3A and 3B. The binding grid 15 in this embodiment is obtained post-factory, where it is formed by interlacing and heat welding two layers together to form an integrated grid member that can be cut with a saw. The interlacing forms apertures in the grid to allow moisture and roots of the turf to pass through and bind to the grid.

[32] In a preferred embodiment the binding grid 15’ is formed of moulded HDPE (high density polyethylene) turf reinforcement mesh as shown in Figs 8A and 8B, when is pressed to form a single layer sheet as shown in the drawings. This form of binding grid 15’ is more flexible than the semi-rigid plastic woven mesh used as the binding grid 15 of the one embodiment and thus can conform to irregular surfaces where it is ultimately laid, more easily.

[33] In either case, the binding grid 15, 15’ is laid in sections to fully cover the plot and form a binding base for the turf.

[34] A fertile growing medium for the turf such as an organic composted topsoil layer 17 is then spread over the top of the binding grid 15 and levelled to fill the plot 11 to the surface. Thus in the present embodiment, the topsoil layer 17 is of a depth of 50 to 75 mm to allow for full root development of the new turf, but in other embodiments can be extended to be of a depth from approximately 50 to 100 mm.

[35] Finally, new turf stolons 19 of a particular variety of grass desired for the ultimate location, e.g. buffalo, are planted by spreading them over the surface of the organic composted topsoil layer 17 and then sprigging the stolons into the surface to allow for germination. In other embodiments, solid laid turf rolls can be laid on the surface, instead of using sprigged stolons. This completes the first stage, whereupon the second cultivation stage commences.

[36] During the second stage, the new turf 19 is watered daily, fertilised as required and grown in a farm environment to allow for full root development of the new turf 21 through the organic soil layer 17. This typically takes up to 9 months or more.

[37] Once the new turf 19 is fully grown having a well netted surface and a root system that reaches and binds with the binding grid 15, 15’, it is ready for batching at the third stage.

[38] Batching entails cutting the plot 11 into segments 21 to a depth sufficient to demarcate and separate the segments so that each segment has a portion of the binding grid 15 forming its base. This is undertaken using a circular saw mounted on a mobile saw rig (not shown) having a blade 23 of sufficient diameter to penetrate the surface of the plot 11 and cut through the binding grid 15, 15’ as shown in Fig 4.

[39] The segments are cut in a square grid so that each turf segment is approximately of square formation and of a size of 1 x 1 m2. This size allows the turf segments 21 to be comfortably lifted and handled by two persons and placed on a standard pallet of dimensions 1.2 x 1.2 m2.

[40] Once the cutting of the plot is completed, then each turf segment 21 is manually extracted from the plot and placed on a pallet 23 for despatch. Given the provision of the binding grid 15, 15’ forming a base for each segment, the turf segments 21 can be individually handled reasonably easily as a planar slab. This is particularly advantageous given the relative thickness of the organic soil layer 17 being thicker compared to prior art systems that rely upon a thinner soil layer and rolling of the segments into coils.

[41] The pallet 23 is loaded by stacking a number of turf segments, e.g. 10 in piles thereon until the pallet is fully laden. It can then be despatched by lifting with a fork lift or crane onto the tray of a truck for subsequent transported to the site where the turf segments are to be transplanted.

[42] The fourth stage entails transplanting the turf segments 21 at the site for their intended use. This is simply undertaken by lifting each pallet 25 loaded with the turf segments 21 from the truck using a forklift or crane again, and locating the pallet 25 proximate to where the turf segments are to be laid. Each turf segment 21 can then be lifted from the pallet manually or by mechanical means 27, in sequence, and laid on a prepared plot 29 for the resultant lawn or garden at the site.

[43] Given the slab like nature of the turf segments 21, this can be undertaken relatively quickly and easily without concern of the segment breaking up, as is often the case with the thinner rolled coils of turf used in prior art systems.

[44] The area of the plot 29 is entirely filled with the turf segments 21, with appropriate cutting or breaking up of the turf segments as necessary to fit the transplanted segments exactly to the configuration of the plot.

[45] Once the turf segments 21 are laid, due to their added thickness allowing for a fully developed root system, there is little required in the way of further cultivation before the area can be used. Hence the newly laid plot 29 is ready for use as a trafficable area almost immediately.

[46] In the present mode, the turf system providing the advantages of the present invention includes a plurality of turf segments 21 each effectively comprising the binding grid 15, the organic soil layer 17 and the turf layer 21.

[47] As noted before, the binding grid 15, 15’ forms a binding base for each segment allowing it to form an integrated slab despite being of a greater thickness than turf segments used in the prior art. The organic composted topsoil layer 17, which originally constituted the fertile growing medium for the new turf 19, surmounts the binding grid at a depth sufficient to support and sustain a fully developed root system of the turf segments. The turf layer 19 that is propagated upon and within the fertile growing medium forms a well netted surface that helps to bind the surface of each turf segment and works with the fully developed root system to bind to the binding grid 15, 15’ and retain the organic soil layer as part of an integrated slab.

[48] In other modes, the binding grid 15 instead of being of the woven plastic mesh design shown in Figs 3A and 3B and Figs 8A and 8B, is of a cellular structure having upstanding walls extending at least part way into the fertile growing medium or organic soil layer 17. Whilst being more expensive, such a cellular structure provides for improved binding with the root system of the turf and integration with the organic soil layer 17 to form a stronger integrated slab segment. However, such structures are more difficult to cut when forming the segments, so it is more preferred to use the mesh designs of the binding grids 15 and 15’ described in the specific embodiments.

[49] The aforementioned modes of the invention have several advantages when compared to prior art systems. These include: • The transplanted turf segments are virtually ready for immediate use as a lawn and trafficable area after being laid. • The transplanted turf segments are fully established by having a fully developed root system and do not require further intensive cultivation or caring after they are laid. • The transplanted turf segments function as integrated slabs that do not have a tendency to break up and are visually appealing. • Being fully developed, the transplanted turf segments require far less water than prior art systems. • They similarly require less maintenance. • The turf segments form a firmer and thus safer surface for playing on and trafficking over.

[50] It should be appreciated that due to drier and sandier soil conditions prevailing in most of Australia, prior art cellular grid systems are not suitable, as their thickness is not sufficient to allow for full root development of the turf. This is an important consideration, as it is the ability to farm the turf to the stage where the root system is fully developed that provides the advantages of the present invention.

[51] It should also be appreciated that the scope of the present invention is not limited to the specific modes of the invention described above. Other modes of the invention may be envisaged that are not the same as the described modes, but do not depart from the spirit nor scope of the invention as defined by the claims.

Claims

The Claims Defining the Invention are as Follows

1. A method for producing turf segments for laying an area of lawn or garden, the method including: laying a binding grid within a growing area to form a base for the turf segments; disposing a fertile growing medium upon the binding liner to a depth sufficient to support and sustain a fully developed root system of the turf segments; planting a turf propagating layer upon the fertile growing medium; cultivating the growing area over a growing period until the turf propagating layer is grown with a fully developed root system and forms a well-netted surface; cutting the growing area into segments to a depth sufficient to demarcate and separate the segment shapes incorporating the binding grid into discrete and despatchable turf segments; wherein the turf segments can be stacked and transported to a site for transplanting.
2. A method as claimed in claim 1, wherein the binding grid is formed of semirigid and flexible mesh material.
3. A method as claimed in claim 1 or 2, wherein the depth is from approximately 25 to 100 mm.
4. A method as claimed in claim 1 or 2, wherein the depth is from approximately 50 to 75 mm.
5. A method as claimed in any one of the preceding claims, wherein the planting of a turf propagating layer comprises sprigging grass stolons into the fertile growing medium.
6. A method as claimed in any one of the preceding claims, including initially lining the growing area to form a weed and erosion barrier for laying the binding grid thereon.
7. A method as claimed in claim 6, wherein the lining comprises lining the growing area with a liner of plastic sheet lining or landscaping fibre underlying and circumscribing the growing area.
8. A turf system for producing turf segments for laying and establishing an area of lawn or garden, including: a plurality of turf segments each comprising: (i) a binding grid to form a binding base for the segment; (ii) a fertile growing medium surmounting the binding grid at a depth sufficient to support and sustain a fully developed root system of the turf segments; (iii) a turf layer propagated upon and within the fertile growing medium and forming a well-netted surface of the segment; wherein the turf segments are of a regular shape to facilitate stacking and despatching for subsequent transplantation at a site.
9. A turf system as claimed in claim 8, wherein the binding grid is formed of semirigid and flexible mesh material.
10. A turf system as claimed in claim 8 or 9, wherein the depth is from approximately 25 to 100 mm.
11. A turf system as claimed in claim 8 or 9, wherein the depth is from approximately 50 to 75 mm.
12. A turf system as claimed in any one of claims 8 to 11, wherein the turf layer comprises turf propagated from grass stolons that have been sprigged into the fertile growing medium.
13. A turf segment for laying within and establishing an area of lawn or garden, including: a binding grid to form a binding base for the segment; a fertile growing medium surmounting the binding grid at a depth sufficient to support and sustain a fully developed root system of the turf segments; a turf layer propagated upon and within the fertile growing medium and forming a well-netted surface of the segment; wherein the turf segment is of a regular shape to facilitate stacking and despatching for subsequent transplantation at a site.
14. A turf segment as claimed in claim 13, wherein the binding grid is formed of semi-rigid and flexible mesh material.
15. A turf segment as claimed in claim 13 or 14, wherein the depth is from approximately 25 to 100 mm.
16. A turf segment as claimed in claim 13 or 14, wherein the depth is from approximately 50 to 75 mm.
17. A turf segment as claimed in any one of claims 13 to 16, wherein the turf layer comprises turf propagated from grass stolons that have been sprigged into the fertile growing medium.
18. A plot for producing turf segments for laying and establishing an area of lawn or garden, including: a binding grid to form a binding base for the segments; a fertile growing medium surmounting the binding grid at a depth sufficient to support and sustain a fully developed root system of the turf segments; a turf layer propagated upon and within the fertile growing medium and forming a well-netted surface for the segments.
19. A plot as claimed in claim 18, wherein the binding grid is formed of semi-rigid and flexible mesh material.
20. A plot as claimed in claim 18 or 19, wherein the depth is from approximately 25 to 100 mm.
21. A plot as claimed in claim 18 or 19, wherein the depth is from approximately 50 to75 mm.
22. A plot as claimed in any one of claims 18 to 21, wherein the turf layer comprises turf propagated from grass stolons that have been sprigged into the fertile growing medium.
23. A plot as claimed in any one of claims 18 to 22, including a liner to line the growing area to form a weed and erosion barrier upon which the binding grid is disposed.
24. A plot as claimed in claim 23, wherein the liner comprises a plastic sheet lining or landscaping fibre underlying and circumscribing the growing area.