Frequently Asked Questions

What is AirCore?

AirCore is an innovative modular growth system that is an alternative to traditional USGA green construction. AirCore is an engineered geocomposite material designed to create a layer of air to replace the gravel layer currently used as the perch water table that has been the recommended method since the early 1960's. This air layer provides the enhanced element of air and gas exchange at the root tips so critical for healthy turfgrass.

What does AirCore actually do?

The AirCore System replaces the gravel layer in USGA greens and can also be used to enhance drainage in bunkers and any other difficult to drain areas. AirCore not only creates improved growing conditions beneath the greensmix in golf greens through this air and gas exchange, but it also enables greater retention of moisture at the tip of the root zone, providing better root supplement through its use. In addition to providing these enhanced growing conditions, the AirCore System provides superior percolation through the perch water table carrying as much as 12 times more water from under your greens than a typical 4" gravel layer.

The AirCore Modular system consisting of a 20 mil PVC liner, AirCore geocomposite and engineered non-woven geocomposite.

Why is it better than gravel?

AirCore not only moves more water away from under the green, it does not compact over time as gravel is sometimes prone to do. The use of a highly technologically designed non-woven textile membrane over the AirCore geo-composite provides greater than 99% percolation through the membrane while eliminating the chance of sand clogging the gravel layer.

AirCore will not crush the drainage tile in greens that sometimes occurs with traditional gravel construction.

In addition to the agronomic benefits of AirCore, we are also proud to address a critically important area on the construction side which is the continued environmental issues of digging quarries to find more gravel as well as the high cost to transport gravel from these remote quarry locations. With the prices of today’s oil and gas, most haulers are adding surcharges on top of normal delivery charges, driving the cost for gravel skyward. Quality gravel that meets USGA specifications is becoming more difficult to find in many areas and as a result, sometimes non-conforming gravel is substituted, which ultimately leads to sand compaction and intrusion into the gravel layer. This compaction is a sure bet that the greens will be need to be rebuilt, sooner than later.

The AirCore Bunker Modular system consisting of a 20 mil liner, AirCore geocomposite and 6 oz. non woven geocomposite designed for bunker use.

How can this be used in bunkers?

AirCore is an multi-faceted product. Not only does it create an enhanced growth medium under turf, and serve to replace the perch water table in greens, but it is also a fabulous drainage product. The basic science behind AirCore has been used for more than twenty five years in land-fills and other environmental settings. Because of the design, AirCore literally acts as a mat that has thousands of channels all acting as a series of drain channels under the bunker sand. Each of these channels carry water in one of three directions, therefore, we describe the product as being tri-planar in design. You can see this design by examining the photographs of the product in the presentation elsewhere on this site. For bunkers, we AirCore includes a different non-woven geotextile membrane that holds the sand in place while allowing water to percolate through to the geocomposite that will carry water throughout the bunker to the main drains and out of the bunker as quickly as the drains will allow. Positive drainage, whether under a green in a bunker is critical to good agronomic conditions and just as importantly, playing conditions.

What does the USGA say about the product?

As you are probably aware, the USGA basically does not endorse products. The organization tries to maintain a neutral stance on issues such as this; however, the initial AirCore beta product was used in a USGA test in Waco, Texas and has been working successfully since 2002. Since the original installation, we have improved every element of the product. The only element that has remained unchanged is the engineered geotextile membrane. We have not been able to find any product other than this unique membrane that allows 100% percolation of all water and particulates and will still remain intact for more than 25 years. We continue to work with the USGA on our products. The USGA spends hundreds of thousands of dollars each year testing the many elements in greens and bunker construction.

Explain more about the membrane...

AirCore is not just a layer of Polyethylene. It is an integrated modular system designed to provide the best possible growing conditions and drainage available today. We have designed the system to match the specific use. For example, in bunkers, the non-woven geotextile product is designed to act like some of the expensive "filter cloths" on the market today. The AirCore membrane allows total water penetration through to the AirCore geocomposite grid, yet resists allowing any particles of the bunker sand to penetrate through the membrane.

The use of AirCore in greens differs in that we custom match the membrane to the greensmix specified by the architect, or superintendent. We have 10 different fabrications that are engineered to meet specific percolation rates through the greensmix, depending on the amount of organics specified for construction. By matching the membrane to the greensmix, we warrant that the membrane will not clog as long as there are no changes in the greensmix originally matched for use.

How does it work and how is it installed?

First, let's address the installation. Whether a green or bunker (or even a difficult to drain area), the area is prepared just as it would be for a normal USGA green or a regular bunker. Let's address the green first. Once the bunker cavity is carved out and the sub-grade is stabilized, drain lines are cut as in the architectural requirements. The drainage lines should be cut to accommodate flat drain, versus the 4" tile which is normally used. The 4" tile can be used in this process, however, by using the flat tile, we have found that it saves on the amount of labor to dig the extra several of inches of dirt as well as eliminating the need for additional gravel. Once the ditches for the drainage lines are dug, our installation crew takes over. An impervious (PVC) pond liner is laid inside as well as up the walls of the green cavity. Flat drain tiles are placed in the drain ditches. The AirCore geocomposite is then rolled in place. AirCore is shipped to the site in rolls of 2,550 square feet and the product is rolled in place. Sections are tied together using a zip-tie system. When the entire green cavity is covered with the geocomposite grid, the non-woven membrane is laid over the entire surface of the AirCore grid. The green is now ready for the greensmix to be added over the membrane and for final grading and shaping.

The bunker process is very similar; the cavity is created, (in some instances where heavy soils might cause clogging in the AirCore geocomposite, an impervious PVC liner is laid in place in the bunker and up the walls of the bunker), drain tiles are placed in the drainage ditches to daylight, and the AirCore bunker product is rolled in place. This product differs from the green product as the non-woven 6 oz. geo-textile membrane is already laminated to the geocomposite material. AirCore® is rolled in placed, stapled to the side walls and 4-6" of bunker sand added directly on top.

AirCore replaces all the labor intensive addition of gravel in greens construction. At the heart of AirCore is a 300 mil thick geocomposite grid, engineered to carry vast amounts of water across any surface to a main drain. As long as the main drain stays open, there will never be water standing in the bottoms of bunkers or clogging at the tip of the root zone.

Are there any other applications?

Yes. Recently we have been experimenting with AirCore for use in cart paths. This is ideal where the cost of concrete is prohibitive, or where the architect wants a more environmentally friendly appearance. By using AirCore DiamondPath, which has a crush factor in excess of 25,000 pounds per square feet, you can drive both maintenance and regular vehicles on the path with no worry of crushing. Almost any material that will percolate water can be used with AirCore such as crushed sea shells, decomposed granite, or any other natural material. AirCore is ideal in mountain settings where the cart path may have to cut across fairways. AirCore can even be used with natural grass that can be grown right through the geocomposite with full support of the AirCore geocomposite construction.

If it just rolls in place, can I install it myself?

Certainly installation in bunkers and any other difficult to drain areas can be accomplished by your own crews (however, we recommend our supervision for the initial projects). We will provide one of our construction supervisors to help train your staff on the initial elements for only the cost of the travel expenses on any initial project. Once that is done, your crews should be able to replace the drainage in your bunkers easily and quickly. We even provide a DVD with full instructions, in case any questions arise later. By installing yourself, you save approximately $.25 per square foot on the cost.

For greens installation, we recommend that unless you have extensive experience in greens construction, you have our crew, or a professional construction company such as Landscapes Unlimited or other experienced contractor handle the installation. We have worked with Landscapes Unlimited on several installation projects already including Robert Trent Jones Golf Club, just prior to the last President's Cup.

Since you mentioned cost, what does it cost?

The AirCore System is priced per square foot. In addition to the base square foot requirement, you need to always add approximately 10% for waste (unless you have a square design), because as you are likely aware there is always waste in free form shapes such as greens and bunkers. The price for the AirCore product for greens and bunkers is $1.25-1.35 per square foot including installation. However, as indicated previously, you can save approximately. $25 per square foot on the installation by having your crews do the installation. For a typical golf course with 19 greens averaging 6,000-7000 square feet, the total cost for greens renovation, or new construction would be approximately $160,000 plus freight. For the same 123,500 square feet of greens with typical green construction using gravel (depending on how far the gravel has to be moved and availability), the cost might be $145-160,000 including construction labor, a minimal difference in overall price with the superior performing AirCore modular system.

Then why would I spend the extra money?

There are many reasons, but the primary reasons are 1) AirCore is superior in every way to gravel in greens and bunkers. It provides a better a growing medium and better drainage under your greens and bunkers, and 2) Time savings; in comparing the time to install the 123,500 square feet of gravel versus the installation of AirCore, there is a time labor differential of approximately 1,250 hours (actual bids for the 123,500 square foot project come to 1,303 hours for typical gravel installation and leveling versus 60 hours for installation of AirCore®). Remember, TIME IS MONEY. Whether you are trying to re-open for your members, or in case of public play, your guests, being able to open the course as much as four weeks earlier means money on one hand, or happy members on the other.

Is there anything else that might impact my decision?

Absolutely, there are several things...

• The fact that we warrant against clogging is huge. You will never get that with any gravel construction project. Imagine not having to worry about rebuilding greens every 15 years.
• If this is a renovation project, we eliminate the need for off road gravel trucks driving across the golf course, further damaging the golf course and slowing the potential reopening.
• For new greens, the air and gas exchange created by AirCore creates a healthier environment for grow-in. Research has shown that in test conditions in Waco, Texas, where the air layer created by AirCore was used, turf regeneration is faster.
• Your project will be defined as a more environmentally sensitive project, as you are not contributing to the continuing excavation and strip mining of gravel.
• The system works better than traditional gravel, as the AirCore System creates better growing conditions and superior drainage.
• Finally, in the near future, we will introduce the AirCore Active Drain, which will be a further improvement to the system. This will be a simple addition to any system already installed in greens.

Simply stated, AirCore provides a workable alternative to USGA greens construction that is:

• Environmentally sensitive
• Saves time and money through labor savings in installation
• Provides a superior growing medium for turfgrass
• Creates a better drainage alternative than gravel
• Eliminates the need to renovate greens due to compaction of growth materials over time in the perch water table.

For further information, please phone:

• Bill Ward at 703-402-0042
• CJ McDaniel at 972-618-3178
• John Heap at 303-841-2022.

Or, email us via our Contact Us page.