RewitAl: System Design of Automated Hybrid-Intelligence Turf Rebuilding System

Synthetic turf surfaces used in sports fields pose growing environmental risks due to the release of microplastics and other synthetic particles as over time. Their end-of-life phase requires systematic removal and replacement, yet current deconstruction methods are labor-intensive, logistically complex, and insufficiently safeguard against environmental emissions. The RewitAl project at Aalen University addresses this challenge through the development of an early-stage conceptual architecture for an automated, hybrid-intelligence turf deconstruction and processing system. The proposed architecture concept integrates four core components: (i) autonomous driving robots for cleaning, (ii) a container-based post-processing unit for on-site separation of infill, fibers, and soil, (iii) a mobile human supervision cockpit for monitoring, control, and adaptive intervention, and (iv) existing specialized machinery for turf layer separation. This hybrid system leverages automation while retaining human oversight, enabling adaptive operation in unstructured outdoor environments. Its modular configuration supports flexible deployment across different sites, reduces transport requirements, and lowers associated emissions. Particular attention is given to minimizing the release of microplastics and particulate matter through mechanical containment and filtration strategies during dismantling. The paper addresses the research question of how automated deconstruction processes can be designed in an early-stage framework to minimize microplastic and particulate emissions compared to current manual and semi-mechanized practices. The main contribution is a system architecture design concept that combines autonomous carriers, legacy turf machinery, containerized on-site postprocessing, and human-in-the-loop supervision into an integrated framework. As this paper presents the first conceptualisation stage, no alternative subsystem architectures were developed yet; instead, the design reflects the functional requirements derived from stakeholder needs and environmental objectives. The study outlines detailed conceptual solution approaches and discusses their potential to improve efficiency, reduce environmental burdens, and support the development of circular-economy business models in sports infrastructure.