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Star Island Corporation Project
6/29/93 - 7/16/93
Project Description
Two existing tennis courts were constructed of macadam surface in the 1940's. The courts were patched
with cement and different acrylic compounds. All previous attempts at patching, crack filling, and
coating had proven futile. The customer liked the idea of the NovaGrass synthetic turf systems, as
they would assist in eliminating their recurring cracking situation, however, installation on the
existing base was not recommended as the existing surface was too far deteriorated to successfully
place the NovaGrass turf on top. The solution was to grind up the existing surface into 3" minus
recycled asphalt pavement (RAP), laser grade the RAP and compact same. The RAP then needed to be
penetrated with asphalt emulsion for binding the RAP together. 1-2" of stone dust would need to be
applied, laser graded and compacted. Installation of the NovaGrass sand-filled tennis surface, with
white lines, could then be accomplished.
Difficult Condition Encountered
As this installation was located on an island, 10 miles off the New Hampshire coast, and provided
no landing areas to accommodate a large barge, we had to be creative in order to have appropriate
materials and equipment delivered for the installation. The only accessible venues available to us
included a pier on the island which had a winch that could handle up to 1,200 lbs of material, and a
small landing area between rocks wherein a small barge could land, when the tide was right.
A bobcat was located at Bobcat of Boston (model 853H), with a pulverizing attachment and removable
bracket. This was the answer to grinding up the existing courts to 3" minus RAP. The bobcat was loaded
and transported to the island on a small barge, off loaded in the small landing area when the tide was
right. Also during this time, 55 gallon drums were filled with 1,000 (+-) pounds of stone dust and
ferried to the island via 60' fishing trollers to the accessible pier. These drums were then off loaded
by the winch. The drums were then transported to the site via a small bucket loader, where the stone
dust was then stockpiled. A total of 160 tons of stone dust was maneuvered in this fashion to the courts.
The next problem was getting the necessary sand infill to the jobsite. Thirty six tons of sand was ordered from
Holliston Sand in Rhode Island. The sand had to be palletized and shrink wrapped for the 10 mile voyage
to the island. Only 10 bags could be packed per pallet as the winch on the pier could not safely lift
more than 1200 lbs at a time. Again, the sand, and the rolls of NovaGrass turf, were ferried to the island
via a 60' fishing troller.
After the pulverizing was completed, A laser grader was loaded
onto the barge and was transported to the island. The laser
grader was unloaded (when the tide was right). The RAP was graded, spreading it into a
uniform base. We then penetrated this RAP with asphalt emulsion, pumped out the drums, and sprayed through
a spray wand powered by a pneumatic double diaphragm pump.
Next, the base was compacted with the vibratory plate compactor and rolled with a one ton roller. Stone
dust was then taken from the stockpile and dumped onto the court and laser graded (straight edged into place).
Once the stone dust was dragged smooth, we soaked it with the surrounding salt water pumped from the ocean.
The stone dust was rolled and allowed to firm up overnight.
Once it was determined that the site was level with the appropriate planes, the rolls of NovaGrass could
then be laid. After the rolls were lain in place, the lines were cut in, and all materials were seamed
together, individual bags of sand were placed on the court via hand. The sand was then opened and
manually worked into place, one area at a time.
The hard work resulted in two new NovaGrass Tennis Courts, which amazingly refurbished the area,
providing a more aesthetic appeal and a viable playing area for the client. The owners and players on
this Star Island project were extremely pleased with their new NovaGrass courts.
This project is one of endearment to us as it demonstrates that NovaGrass sand-filled tennis
surfaces can be installed anywhere, regardless of the conditions!
Customer Quote
"... Such a pleasure to see the players out there enjoying the courts - I should have taped all the
compliments for you to hear... many thanks for a great job!"
-- Al Doolittle
Additional Photos
  
 
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