DuraEdge, a Pennsylvania-based manufacturer, provides specially-formulated dirt to MLB teams, enhancing moisture control and player safety. Using unique clay from PA mines, their product has become crucial for ball fields across the country, improving game quality and reducing weather-related interruptions.
Photo courtesy of DuraEdge Products Inc.
A Caterpillar excavator works on site to load the clay famously known as the “Pittsburgh Red Bed Claystone.”
In the weeks and months leading up to the World Series, manufacturer DuraEdge Products Inc., headquartered in Grove City, Pa., worked hard to spread its specially-formulated dirt across United States baseball fields in preparation of big games such as this.
Photo courtesy of DuraEdge Products Inc.
From quality assurance and transporting the dirt to spreading soil and collaborating with Major League Baseball (MLB) staff members, DuraEdge ensures engineered materials to more than two dozen MLB teams, including the New York Mets, New York Yankees, Philadelphia Phillies, Pittsburgh Pirates and Boston Red Sox.
Starting out small like every company, DuraEdge opened its doors in 1999 and began by providing sand and soil mixtures for local golf courses. Owner Grant McKnight previously worked at a construction-material company his father owned, which ignited McKnight's interest in sands and soils.
"I'd found that I loved the science of it, so I immersed myself in studying and selling sand," he said.
After a local, yet prominent university, Slippery Rock University, requested infield soil from DuraEdge, McKnight worked tirelessly to formulate the perfect game-day dirt that offered the moisture control and durability baseball fields demand.
It's All in the Details
By studying the unique properties of sand and soil, McKnight sought out a particular red rock clay found in a dirt farm located in Sarver, Pa. The clay, naturally adhesive and particularly absorbent, initially appeared too hard, leading McKnight to nearly "scrap the whole thing." But once he took a gamble and mixed the clay with sand, however, "everything changed," according to McKnight.
Photo courtesy of DuraEdge Products Inc.
This successful find created the perfect soil and fostered a happy client — creating an entirely new niche for DuraEdge. The Slippery Rock job then helped the company secure its first "big-league" client, the Philadelphia Phillies in 2005. After that, McKnight said, "the rest is history" and its soil is now spread across baseball fields across the country.
The clay, which takes nearly two months to excavate from the ground and to process properly, contains illite and chlorite, two unique minerals essential for moisture control and water absorption. The clay, initially very dense and compact, absorbs water without expanding, making it ideal for any ball field and rainy conditions.
Obtaining the clay, however, is no simple task. The clay, also known as the "Pittsburgh Red Bed Claystone," resides in the Glenshaw formation under several layers of overburden, including sandstone, gray shale and limestone — anywhere from 10-60 ft. below the Pennsylvania mine surface. This requires a considerable amount of time and heavy iron, such as the company's Cat D8T R dozer and Cat 323 and 326F excavators. After excavation, the clay is transported to a DuraEdge processing plant, then crushed and screened into a fine powder before being deemed usable.
Once the material arrives on site at the processing facility, DuraEdge uses its D9H dozer, Cat 926M, 962K and 962M wheel loaders and Cat 259D track steer to handle and move the clay through the various stages of the process. A Cat 323 excavator breaks down the clay into just more than an inch in size with the help of a specialty attachment. The primary size reduction is accomplished with an ALLU DH 3-12 screening bucket, compatible with their Cat excavator. It has giant revolving teeth that shred the clay into smaller, more manageable pieces and prepares it for the secondary crushing process.
Conveyors transport the clay, which then runs through a Rock Engineered Machinery Company Inc. (REMco) vertical shaft impact crusher. The REMco crusher contains a rotor that spins at an impressive 1,800 revolutions per minute, which slings the clay mineral outward into a reinforced steel shell that pulverizes the clay into a viable clay powder. The REMco crusher is in a closed circuit with a screening plant, a Terex-Finlay 683 Supertrack double deck screener. The clay remains in this circuit and will go back through the REMco as many times as necessary until it passes through both decks of the screener. This leaves the final clay no larger than 5/32-in. minus particle size.
Photo courtesy of DuraEdge Products Inc.
Next, the clay is combined with sand, dependent on the field and the use of the soil. For example, infield mixtures may receive more sand compared with material used for the pitching mound and batter's box, which requires more hydration. Because this clay is naturally so absorbent and effective as-is, no chemicals, preservatives or additives are necessary. The soil is now ready for send-off.
Altogether, this combination of unique clay and specially graded sand creates impeccable stability, moisture control and traction essential to any baseball player's success, regardless of any rain, sleet or hail. This differentiating mixture also increases player safety by minimizing slips and can even eliminate game downtime. Without concern for harsh weather conditions and with increased player safety, more games can safely continue without the need of rescheduling or postponement, which ultimately helps the league save money and capitalize profitability.
Big-League Dirt With Big-League Results
In addition to this unique infield soil created by DuraEdge, McKnight collaborates closely with MLB staff members, his team of soil experts and the field groundskeepers to address any specific needs of each field. For example, the infield soil for the Boston Red Sox will vary from the San Diego Padres or the Texas Rangers soil because these soils face different climates and, therefore, require a different soil makeup.
In addition, DuraEdge uses local sand to better suit each field's needs.
"This clay is special," McKnight said. "We ship the clay to our plants. They then use sand that's available in those places. That allows for the kind of consistent products that MLB teams want. The MLB guys understand the science," said McKnight, which helps ensure optimal soil and performance.
With minor maintenance required and a substantial lifespan of up to 10 years, DuraEdge's infield mix has become a staple to many baseball fields nationwide, resulting in a substantial demand. One field alone requires approximately 80-100 tons of material including dirt, clay, quick-drying material and topdressing products. Within a year's time, DuraEdge excavates, loads and transports approximately 30,000 tons of clay from the Glenshaw formation to meet the demands of its clients. Because of its hard work, DuraEdge is now an official partner of Minor League Baseball and named the "Official Infield Playing Surface of Minor League Baseball."
While little thought once went into the soil used at baseball fields, its composition now plays a vital role to moisture control, soil stability and the players' abilities to play safely despite inclement weather. Whether it's another practice or to play in the World Series, the perfected soil and infield mix helps players perform their best. CEG
This story also appears on Aggregate Equipment Guide.
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