CLAY COURT CONSTRUCTION

CLAY COURT CONSTRUCTION

A little about the process

Our Company has over 35 years’ experience in the construction of Tennis Courts including Clay Courts and our Clients appreciate that our vast knowledge in building Clay Court goes into each and every project. This experience has allowed Mor Sports to grow to become recognized as the leader in the construction of quality Clay Courts.

Having been involved in the Construction, Refurbishment and Maintenance of Clay Tennis Courts since 1991, we are proud to have been a part of the drive to introduce them in Europe, and we have put those skills to good use in Florida where we build some of the finest Sub irrigated and Overhead irrigated Cay Tennis and Bocce Courts.

“Clay” is part of a group of sports surfaces used for mainly Tennis and Bocce and is just one of the many different types of surface that we provide. Our emphasis on quality has led to Mor Sports working at some of the world’s most prestigious tennis facilities. Indeed we have built clay courts around the World including Clay Tennis Courts at the World Famous Grand Slam Tournament Venue – All England Club (Wimbledon).

What is Clay?

Clay is the term that describes the porous court surface material that consists of natural crushed stone, which has been ground, screened, and graded. All clay courts have an affinity for water and for them to operate correctly they need to be able to retain moisture or be regularly watered.

 

Mor Sports Clay Sports Courts Construction Services

Our construction of Tennis and Bocce Clay Court Facilities begins with excavating, grading and compacting the court’s sub-base. This part of the operation is carried out by machines controlled by laser, ensuring that we have a base that is uniform with the correct slope, which is suitable for us to build the court upon.

Trenches are dug for the floodlight ducting and both net posts and floodlight foundations are set out as part of the base preparation works.

The construction process continues with the with the installation of curbs where accurate string lines are set out each corner and the line of the curbs. Concrete is poured into the formwork and then the curbs are then sat onto the concrete with a clean and tidy haunch formed to the visible side. The fence is then installed to the perimeter curb with openings prepared for each gate.

 

Court Construction – Sub Irrigated Courts

Mor Sports are proud to be builders of the Modified Hydrocourt System. This is a unique underground watering System that is the preferred choice of the majority of our Clay Court Clients and which Mor Sports have been installing since 1991at some of the finest venues in the world.

How the Modified Tennis and Bocce Hydrocourt Watering are Built

Working on the prepared base, firstly, the courts are measured for the 6 cells / court that are to sit hidden below the court surface. The aim of the system is to keep a constant water supply of potable water to the clay surface in all environments. One by one, each liner is laid out ready for the introduction of the water panels. The water panels are laid out onto the prepared liner and set level at three water panels per liner.

Schedule 40 PVC pipe is run along the perimeter of the court and connected into each individual water panel. In turn, each cell is connected to its own water control box. Once each cell has been completed and the pipes connected to the control boxes, they are ready for the introduction of the Screenings.

Water Retaining Screenings are then laid into each cell until the entire court area is covered. Each cell is tested to ensure it is water tight and to allow rough leveling of “low spots” Once completed, the screenings are laser levelled and rolled firm, then the clay material is installed on top of the screenings, a minimum of 1” depth, in a single, firm, unified layer. The clay is locked or “bonded” by the constant presence of moisture. Finally, the screenings are graded to follow the slope of the court and to ensure quality, this operation is carried out by laser-controlled machines.

It is highly recommended that this minimum depth of material is retained throughout the court’s life to ensure the quality of the court is maintained.

Court Construction – overhead Irrigated Courts

For overhead watering systems we install water feed pipes and sprinklers into the court in a set pattern. Once the system has been connected, Screenings are laid onto the court footprint until the entire court area is covered.

For both sub irrigated and overhead irrigated courts the final step is to install the Clay, once the screenings are laser levelled and rolled firm. The clay material is installed on top of the screenings in a single, firm, unified layer “bonded” by the presence of moisture. A minimum of 1” of clay is installed per court and it is recommended that this 1” of material is retained throughout the court’s life. As the clay does remain constantly “wet” a pre mixed binder is added to the clay to ensure that it continues to lock together. Again, to ensure quality, this operation is carried out by laser-controlled machines.

It is highly recommended that this minimum depth of material is retained throughout the court’s life to ensure the quality of the court is maintained.

For all tennis courts, regardless of the watering system, the job is completed with the installation of playing lines, nets and posts.

Clay Tech Courts

Clay Tech is a high tech clay court that is a cost effective way of owning a Clay Tennis Court. The Clay Tech system is ideal for overlaying existing hard courts as the subsurface is a carpet membrane that is laid and glued down over a concrete or asphalt base, then the thin layer of Har Tru material is laid on top. The system is a cost-effective option to convert to clay courts from hard courts. In addition, it is ideal for courts where cracking is an issue as it will bridge many cracks and deficiencies in the substrate. The carpet membrane is a 1/4” needlepunch textile that never requires rolling and the playing lines are painted on as part of the construction process.

ClayTech’s natural clay top layer and synthetic polypropylene membrane create an attractive, uniform, sliding court surface.

Benefits

One of its main benefits is that it requires lower maintenance that true clay courts. An occasional sweep and watering and the court is ready for play. One of its main advantages is that it requires exponentially less water than the true Clay Court. Clay Tech needs water, but far, far less than a true clay court, around 140 gallons a day. It also uses around 85% less clay than a true clay court.

Another maintenance benefit is that the perimeter lines are painted in place when the surface is installed.

Easier to install, easier to maintain, and easier to play on every day—ClayTech provides all-weather play and a consistent, enjoyable playing experience.

In summary, The ClayTech tennis court surface is a cost effective way of owning a clay court that blends the sliding features of Har-Tru clay with the lower more cost-effective maintenance of a hard court.

ALL-WEATHER CLAYTECH TENNIS COURTS

ClayTech is a hybrid surface that combines the benefits of clay with the low maintenance of hard courts. The system blends the sliding features of Har-Tru clay with the easier, more cost-effective maintenance of a hard court. Like hard courts, ClayTech courts require little mmaintenance, just a daily sweep and watering just prior to play and the court is ready go. As the surface need far less clay and water than true clay tennis courts, it is an excellent choice in States and locations where water restrictions apply.

The ClayTech System offers truly all-weather playability: wet, dry, hot, or cold. The ClayTech surface is highly resilient and rapidly returns to playability in all types of weather. It is resistant to UV rays, and freeze-thaw problems are nonexistent. During the hottest days of summer, ClayTech courts remain cooler than hard courts, adding to player comfort.

The beauty of the ClayTech Surfacing System is that surfaces can be installed on top of an existing hard court as the system utilizes a specially designed mat that acts as the base for a thin layer of red or green Har-Tru clay spread on top of the mat. Much like a hard court, ClayTech features permanent lines that only occasionally need to be touched up with new paint. The surface also covers holes and cracks, and the polypropylene membrane mat contributes to a long court life.

The Process

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