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The abc’s of AstroTurf

Baylor’s New Bear Grass

Editor’s Note: For now over 75 years, The Baylor Line has been publishing vivid storytelling from across the Baylor Family. I don’t think our archives full of deep, inspirational features should live solely on shelves, so we are bringing them back to life in BL Classics. This September–October 1972 Classic demonstrates the progress of the Bears’ new AstroTurf.

Jack Patterson, Baylor Athletic Director, is looking at the total athletic program when he says, “Baylor has a tremendous potential. In the past we have overlooked some of the school’s strong areas when we have approached outstanding athletes,” he says. “We do not have unlimited state funds or a course of study for every career, so we must sell areas that can provide an exceptional education. Baylor does have a oneness of spirit that can be achieved by only by a school with the personal touch that is provided by a Christian university with a planned limited enrollment, which controls the student-teacher ratio.”

Early this year Baylor alumni began to offer their support to the idea of modernizing the athletic program to make it fully competitive. For at least five years artificial grass has been standard equipment for most other Southwest Conference schools. No one can calculate the exact effect the lack of artificial grass has on many a “blue chip” athlete, but some observers feel that Baylor may have lost several prospects for this reason. One athlete put AstroTurf in the same category as a helmet. He said he would not like to go into a game without either. 

Now that “Thee University” has made a firm commitment to a first-class athletic program, the largest variable is time. The Astroturf is complete. The Letterman’s Lounge will be ready for the first home game. The box seating area of the stadium has been modernized with chair-back seats, and the west side forty to forty-yard line seats will be replaced this year. The remaining sections will be repaired as funds become available.

Head football coach Grant Teaff, says that there is no way to put the upgrading of the athletic program on a timetable. He does not predict a winning season for ’72 or ’73. Teaff avoids promising that Baylor will win a single game this fall, but he does say that the Fighting Baylor Bears will be a team with pride and enthusiasm. Teaff does promise that Bearbackers can be proud of this team — win or lose.

Response has been encouraging from Baylor supporters as pledges for one yard of Astroturf at a cost of $35 and three yards at $100 have come in steadily. The total cost of $400,000 for the artificial grass is expected to be underwritten from these pledges within four years. With facilities improved, emphasis can be shifted to other areas — such as scholarships, summer jobs and recruiting support — that comprise an equal part of the commitment to a first-class program.

The time necessary to produce a winning team is unpredictable, but Patterson and Teaff do feel that within three years we can attract the talent to begin a new era of Baylor football. After a few wins, Teaff expects a new enthusiasm from Baylor exes that will help make the athletic program totally competitive.

After the artificial grass manufacturer was selected, Waco architect John Barnes studied original drawings of Baylor Stadium and then conferred with Monsanto engineers to establish changes that would be necessary. Monsanto required that the subsurface have a grade fall of 1.9 per cent to insure proper field drainage. This means that the center of the field is 16 inches higher than the sidelines.
Initial work on the project began as soon as spring practice was concluded. Young Brothers Construction Co. of Waco brought in heavy equipment and moved out 3,600 cubic yards of soil. After the top 11 inches of dirt had been trucked away, workers compacted 8 inches of sub¬ soil into a preliminary base.
Construction surveyors checked grade cuts made by heavy equipment to determine the correct level at each reference point on the drawings. Lines were stretched to indicate where yard markers and boundary lines were to be located.
The big workhorse during the early earthmoving was the self-loading pan scraper that has the capacity of hauling five cubic yards of dirt in one cut. The 18-ton spiked wheel compactor was used to press dirt and gravel together into a foundation. The ditching machine in the foreground was used to cut into rock so that a new drainage system could be installed.
Construction supervisor John Jadley worked close behind road graders as they spread the 2,700 cubic yards of road gravel that replaced the original sod. Many grade checks with a transit were necessary to assure a less than 1/4-inch variation from the desired slope when the final subsurface paving was complete.
Workers replaced old drainage grates with solid covers over the existing system, which reached 7 feet below the playing field. The new system provides 14 new outlets near the inside rim of the oval to let field and seating area water escape without carrying debris from the stands onto the field. Even though the field is 17 feet below the ground outside, one deep 24-inch drain line has already proven adequate to keep the surface playable after a sudden 4-inch cloudburst.
The AstroTurf area of the field is encircled by a concrete ring with a 2 x 6 board bolted around it which served as an anchor for the artificial grass during installation.
Athletic Director Jack Patterson and Monsanto engineer Dick Walker checked to see that all specifications for the foundation were met. The asphalt foundation on the Baylor field was rated by Walker as the best among the 58 playing surfaces on which Monsanto has installed AstroTurf. Specifications for the Baylor AstroTurf foundation would make the base comparable to an Interstate Highway in strength.
This steel-wheeled roller was used to compact the hot asphalt that was laid down in a 4 1/2-inch layer at 350° F. and then pressed into a solid base 3 1/2 inches thick. Altogether, 2,000 tons of asphalt were paved over the gravel base to form the topping that holds the glue for the AstroTurf pad solidly in place.
A polyurethane glue that dries when exposed to moisture in the air was sprayed over the asphalt base, and the cushion pad was rolled into position. Weighted rollers pressed the pad against the glued surface to assure solid contact.
The closed-cell base pad installed under the Baylor AstroTurf is ¾ -inch thick and offers more resiliency than those pads used for combination fields where football and baseball are played. The foam pad came in 5-foot lengths and was reinforced with a nylon tape over each point that fell under a carpet seam.
The artificial grass is a ⅜ inch thick nylon pile woven into a polyester backing. It took over 2,500 gallons of glue for the installation. The glue was sprayed in place by a unique applicator mounted behind a specially-adapted farm tractor. One edge of the AstroTurf was laid down on a chalk line while the other side overlapped the next line and was later trimmed by a rotary knife.
An actual AstroTurf installation began in July, some 2 months after initial construction, hundreds of interested spectators crowded the sidelines of Baylor Stadium. Shown on the right is first-team quarterback candidate Neal Jeffrey, who was anxious to try his footing on the new surface.
Marking of the yard markers and boundary lines was done by special equipment designed for the purpose. A cable was stretched across the field from points measured from reference marks at the end lines. The line painting machine followed the cable, providing an accurate marking.
With AstroTurf complete, work began on a running track on the inside rim of Baylor Stadium. The base surface was prepared to the same asphalt specifications as the playing field, but some work normally done by machine had to be done by hand tools due to irregular areas.
The World’s first AstroTrack was installed with what engineers called a “Gloop Machine." The machine was completely self-contained down to providing a 110-volt outlet to keep the coffee pot close to the crew. The 3/8-inch ethyl polymer surface was applied as a liquid that dried in less than 15 minutes. The operation was done in one continuous application around the track. High temperatures cause the AstroTrack to dry more quickly, so installation began late in the afternoon and continued until 4 a.m.
The track surface material was spread by a moving nozzle. The gloop quickly formed a mirror-like surface that was sprayed by a sand-blasting machine to coat the top with an abrasive material for added traction.
However, inspection revealed that the sand had been sprayed on the "gloop” after it had already hardened and thus it had not adhered to the surface. A second coat was applied and the sand was added while the track was still soft enough for the sand to stick.
Monsanto engineers declared Baylor Staduim the most attractive installa¬ tion they have done anywhere in the world. Baylor’s 81,767 square feet of AstroTurf ranks as the second largest football area covered anywhere. The 23,561 square feet of AstroTrack will provide a 400-yard running surface that may be used rain or shine.
Cleaning on the seating area of Baylor Stadium continued as Coach Grant Teaff’s 1972 edition of the Fighting Bears began workouts.

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