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A few projects I have done recently

Discussion in 'Showtime!' started by CM1995, Mar 15, 2012.

  1. dirty4fun

    dirty4fun Senior Member

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    Those boilers were built 30 miles from where I live. Lots of them still being used in large buildings in the area.
     
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  2. CM1995

    CM1995 Administrator

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    As the arena turns...

    So the drilled pier contractor hit an existing storm line 3 times while drilling caissons.

    The first time the foundation contractor hit the 30" line they poured up to the flow line and stopped. The second time they hit the pipe was close to the CMU wall and they stopped.

    After they hit the line the second time we were asked by the GC to uncover the existing 30" storm line from the building to the pump station in order to figure out the extent of damage. We potholed the line in a few places and then had a big on-site white hat meeting with folks wearing shiny shoes - ya'll know that type of meeting. Luckily this time around we weren't the focus of it.:D

    During the meeting I asked the drilled pier super about the last caisson they poured that was in a direct line along the existing 30" from the building to the pump station if they run into anything unusual - He replied no. 5 minutes later he spoke up and said "Well we did dump some extra mud in that hole". I asked how much? He said - "It called for 7 CY's and we dumped 16 CY's". I turned around and told the PM - your storm line is full concrete.:cool:

    The third caisson that filled the line can be seen in the bottom of the pic below - straight inline.


    IMG_1024 (1).jpeg
    So we were awarded a nice CO to replace filled line.

    1970's quality workmanship right here. 30" RCP cut on a 45 and not even grouted. This is where the 30" line that drains the entire arena complex dumps into a pump station with 2 Cat powered 8" pumps that dumps into the box culvert we replaced up thread.

    The gap in that 45 was the way they installed it.

    IMG_1100.jpeg
    The concrete filled pipe looked like a corn dog.

    IMG_1101.jpeg

    Site access was tight to say the least. Yeah we knew the dangers of hammering that close to that deep of a trench but there wasn't another way. There is a fiber optic line underneath the track frame closest to the ditch and a 6" med pressure gas main running under the center of the 325. The hammer purchase has earned it's cost.

    Good talent is priceless ya'll.;)

    IMG_1102 (1).jpeg
     
  3. CM1995

    CM1995 Administrator

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    The repair required 2-60" manhole bases we had cored in the field as the lead time was 2 weeks and the project schedule didn't allow it. Since it was a CO the $5K cost to core holes was covered.

    First two MH's set coming out of the pump station.

    IMG_0923.jpeg
    Setting the second manhole. I thought this was a neat pic.

    IMG_1113 (1).jpeg
    Pulling trench boxes sucks and it sucks even more when you have no room and your closest neighbor is a fiber optic line and a gas line. 14' deep to flow line.

    IMG_0925.jpeg

    Space was tight as the schedule was. Our guys rose to the challenge and got the project back on track.

    This was the tie in point from the new line to the existing. Since this line drains the entire project there was a trailer mounted pump in the trench box for when it rained.

    IMG_1144.jpeg
     
  4. CM1995

    CM1995 Administrator

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    More pics of the tie in.

    IMG_1147.jpeg

    The GC rented a 320 Next Gen excavator for a week and they only used it for 2 days so they let us use the last 3 days to help speed the project along. The Next Gen Cat's are pretty damn nice.

    IMG_1148.jpeg

    Tie into the existing line. The caisson that caused all the problems is behind the road plate next to the trench box.

    IMG_1152.jpeg

    Of course the distance from our last full stick of 30" RCP to the existing line would end up being 9'...

    So we spliced 2 - 4.5 sections of pipe together and poured a concrete collar around them.

    IMG_1162.jpeg

    No we didn't leave the pallet in the ditch..:D
     
  5. Theweldor

    Theweldor Senior Member

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    As always excellent work.
     
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  6. CM1995

    CM1995 Administrator

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    Thanks Weldor. We have a good team that knows what they are doing.
     
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  7. CM1995

    CM1995 Administrator

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    18" DIP discharge line from the pump station to the box culvert we replaced back up thread.

    We received a CO to encase the existing pipe with 4500 PSI concrete 1' minimum around the pipe. Spec's didn't call to dowel into the box culvert or the pump station but it need to be.

    IMG_1196.jpeg

    IMG_1196.jpeg

    This is the first time we have used Stay Form the metal mesh stay in place forming panels. Worked like a charm and we didn't have to wreck forms.

    4" gas line that feeds the natural gas powered Cat's in the pump station is sleeved with some 8" ADS we had on site.

    IMG_0957 (1).jpeg

    Poured out.

    62328289790__D98A6F8B-565E-4CE7-8E1C-66C27A8E9A66.jpeg
     
    Last edited: Oct 17, 2020
  8. AzIron

    AzIron Senior Member

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    That's top notch problem solving right there

    Now I would love to see the pier guys face when he gets the back charge for filling it full of mud
     
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  9. mitch504

    mitch504 Senior Member

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    Impressive
     
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  10. Nige

    Nige Senior Member

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    G..G..G..Granville.........!! Fetch your cloth.
    Don't bet on it. He'll be somebody's BIL no doubt.
     
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  11. CM1995

    CM1995 Administrator

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    Thanks AZ.

    Well as it turns out the caisson company won't owe a dime. According to the GC they have an iron clad contract that indemnifies them from anything they hit underground - I need to hire their lawyer...

    This company is local and really the only game in town unless you go with a big national outfit such as Long or Keller. There is not that much to drilling piers except the cost of entry which with money cheap these days as big a barrier as it was.
     
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  12. AzIron

    AzIron Senior Member

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    Cassions are a good business till down hole problems eat your lunch I have seen a few bad days do to soil conditions not being so friendly
     
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  13. Jakebreak

    Jakebreak Senior Member

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    awesome work cm that is a tight area i feel the pain on working in tight areas we have been working like that for 7 months on the coast in rock that has to be jack hammered it sucks
     
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  14. oceanobob

    oceanobob Senior Member

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    That Stay Form product is a worthy method indeed, has "saved" jobs many times for us.
    Sometimes we put a horizontal 2x4 "rail" and hang from the rail in order to establish and control elevation (not directed at your job in photo 'cause we have done that same thing just like that but this is what we have done when we have to say set a column which requires a template and anchor bolts etc).
    Other things we have tried:
    Allthread can be utilized as a tension restraint, sometimes slip a PVC pipe over the allthread or utilize a big washer out of some stiff sheet metal and a companion nut for a line up device to hold it apart "just so" until the concrete arrives (no need to worry about the bridge 2x4 falling into the pour under the concrete pump hose);
    if just tension being desired a length of tie wire say twice as long plus as the forms' width then twine/twist the wire into a two ply strand using a battery powered variable speed drill, then one can just loop the strands around a pin from a pencil rod or 3/8" rebar scrap or sometimes just a 16D nail which the wire can pass through the wood via a small drilled hole.
    Ergo hold the wood like a whaler and the wood will "back up" the stayform. Easy to strip too.


    This Stayform will hold 3 sack sand slurry if the slurry has some small amount of pea gravel. Say for underpinning where there is not a trench wall or pit to hold the underpin material. We have added a lot of air to the concrete for slurry cause it reduces the shrink cause we then dont add as much water. The slurry need to be only stronger than the soil is the premise for the Big Air content (like 20%).

    Needless to Say: Good job in tough conditions (running a breaker in a trench etc etc) going after a mess.
     
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  15. CM1995

    CM1995 Administrator

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    Thanks for the compliments Bob.

    My guys who are not concrete men formed and poured that. I gave some pointers on how to set it up but they took the ball and ran with it.

    Really like the stayform. It's expensive but one makes it up on the labor of not stripping forms. It was the first time we used it after seeing the concrete guys use it for pier caps. They set theirs up like you described with a 2x4 frame around the top to set level and anchor bolt templates.

    We could've just poured the entire trench full of concrete and called it a day but that wasn't the way it needed to be done with the gas line to the pump room, box culvert and wet well being so close in proximity. Also we had to cut a corner out out of one of the culvert sections to get the 45 bend in. I wanted to make sure the encasement concrete also re-poured the section we cut out, hence the dowels.

    Concrete spec was 4500 PSI, 4-6" slump with 3-5% air. No admixtures.

    Side note on the 45 degree bend on the discharge line. If both Cat pumps kick on at the same time the engineers were concerned that the discharge water would deteriorate the opposite wall of the box culvert if ran straight into the culvert. The 45 bend allows several more feet of distance for the water to dissipate it's force.
     
  16. CM1995

    CM1995 Administrator

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    Back at the Arena project. This is the area where we dug up the boiler up thread. Former foundations of some sort of manufacturing facility. It appears they demo'd the buildings into the basement and covered it up.

    IMG_1230 (1).jpeg

    Foundation wall for the former factory. We're running a storm line form the existing box culvert we replaced a section of down thread and down stream. Our hammer has earned it's keep. All excavation to sub-grade is unclassified however anything below sub-grade is not so it's a change order.

    IMG_1234 (1).jpeg

    18" RCP coming out of the box culvert to the back flow vault by the ladder. Storm sewer vault with duck bill one way check valve behind the DI gate valve.

    IMG_1255 (1).jpeg
     
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  17. CM1995

    CM1995 Administrator

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    So the engineer designed 18" RCP transitioning to 18" DIP transitioning to 16" DIP on the inflow side of the back vault then transitioning back to 18" DIP then 18" RCP. Hey I don't get paid to design it - we install which is drawn.:cool:

    IMG_1259 (1).jpeg

    18" RCP coming out of the existing box culvert.

    IMG_1264 (1).jpeg

    The engineer spec'd a MarMac coupling for the connection from 18" DIP to 18" RCP. It's basically an ice and water shield type of material with ratchet straps to bind it tight. There is extra ice and water shield type of material to wrap back over the ratchet straps.

    IMG_1263.jpeg

    Full view of the MarMac coupling and transition fitting from 16" DIP to 18" DIP. This is problably the screwiest thing I have been paid to install in my career.:rolleyes:

    IMG_1298 (1).jpeg
     
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  18. mitch504

    mitch504 Senior Member

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    How did you make the connection from the RCP to the iron?

    Oops, you posted the answer while I posted the question
     
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  19. CM1995

    CM1995 Administrator

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  20. Bumpsteer

    Bumpsteer Senior Member

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    CM1995 to engineer...."turn around"
    Why?
    So I can slap you in the back of the head!

    Wtf?

    Ed
     
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