Main Pumping Station - East Reservoir Addition
To maintain efficiency, several sections are formed in preparation for pouring concrete. For today’s pour, columns, a base slab and several upper baffle wall sections are being completed. So far almost 6000 cubic yards of concrete has been placed.
Working thirty feet above the base slab, concrete is placed for an interior baffle wall.
Even in a massive excavation working conditions can become tight. The excavation sidewalls are only a few feet from the new concrete. As work progresses’, storing forms and material still to be used, becomes a challenge.
Two 60 inch pipes (one shown here) connect the existing reservoir on the right with the new addition.
Despite the unusually wet spring work is progressing at a rapid pace. Nineteen of 25 base slabs, ten of sixteen wall sections, forty of 67 columns and ten of fifteen baffle wall sections have been completed. So far more than 1.7 million pounds of rebar has been installed or the equivalent weight of more than 492 vehicles.
Looming high above the fence on the west side of the construction site sits the soil stock pile. Once the concrete work is completed and the new reservoir tested and sterilized this dirt will be used to backfill around it. The black dirt scraped off at the beginning of the project will be spread on top and the grass reseeded.
A concrete pumper truck accepts concrete from two Ozinga Conrete trucks. Seventeen of twenty-five base slabs have been completed through May.
A crane places the form for a column used to support the top deck.
To prevent stagnation of water within the reservoir, baffle walls are used to create a flow path through the interior. Water entering the reservoir must travel through the entire structure before exiting, being pumped out to your homes and businesses. Extending from the base slab to the top deck, the first upper section is seen here being formed. Twenty-five of sixty-seven were also poured.
The East Reservoir addition is situated immediately outside the Main Pump Station and Reservoir. Neighbors are to the east and School District 135, Liberty School, is just a short distance to the north.
Concrete baffle walls, 30 feet tall, inside the existing reservoir have been completed(new wall is on left side of photo).
Two mobile cranes work independently to move wall forms and steel rebar around the site. The placement of each section is choreographed to avoid interference and utilize the material and manpower in the most efficient manner possible.
Ozinga Bros. Inc. has delivered almost 4000 cubic yards of concrete to the job site. Samples for each placement are tested to insure the highest standards are maintained. Concrete pumper trucks pump the concrete into the forms more than 30 feet in the air.
Joseph J. Henderson & Son, Inc. continues to improve efficiency on the project while maintaining high standards of quality and safety. Approximately one million pounds of steel reinforcing bar, the equivalent of more than 300 average vehicles, have been placed to date. Some of the rebar used is one inch thick and more than 40 feet long. Laid end to end the rebar used for construction would stretch more than 150 miles or from Orland Park to Peoria, Illinois.
Even through the cold and snow of the winter, work continues on the reservoir addition and the interior of the existing reservoir.
Inside the east chamber of the existing reservoir, crews work to install baffle walls. Poured between the existing columns, the concrete baffle walls rise from floor to ceiling almost thirty feet. Designed to prevent stagnation, the new walls create a flow path for the stored water to follow. Water will flow from where it enters the chamber through the new East Reservoir Addition to its exit back in the existing chamber.
A two inch thick concrete work mat will cover the entire site and provide a stabile work environment to begin construction of the base slab for the new reservoir.
With the excavation complete, plastic under drain pipes are installed below the new base slab to keep ground water from causing the reservoir to “float” once completed. These pipes connect to pumps inside the Main Pump Station through the existing under drain system. This ground water is discharged to the storm sewer system. Stone is then placed over the pipes and the entire sub-grade.
Portions of the site have been excavated close to the final elevation 36 feet below normal grade. More than 53,000 cubic yards of dirt have been hauled offsite. The remaining dirt will be stockpiled onsite to be used as backfill. The existing reservoir (left side of picture) has been dewatered and interior work for the expansion has begun.
Current overall depth is 26 feet below normal grade with approximately 43,000 cubic yards of dirt having been removed. Of the 177 tiebacks, 110 of them have been installed.
To support the side walls of an excavation that is 35 feet deep, specialized equipment is needed. The picture above shows a custom made Tieback Drilling Rig that Schnabel Foundation Company, the subcontractor for the earth retention system, is using to drill holes diagonally up to 60 feet for inserting steel cables embedded in cement to hold the sides in place.
Shown alongside the tieback machine is one of several excavators being used on site, a John Deere 160C LC Backhoe.
C.D. Chidester Excavating, the excavating subcontractor, uses multiple pieces of equipment to remove more than 50,000 cubic yards of dirt.
The Caterpillar 235 is able to load each truck with only four bucket scoops.
Big holes require big equipment. Schnabel Foundation Company used a Bauer BG-28 Drilling Rig to auger holes up to 40 feet deep. Large steel beams placed in the holes support the dirt through the course of the project.
September 25, 2008
Current overall depth is 13 feet below normal grade with a total of approximately 22,500 cubic yards of dirt having been removed. All 81 H-piles have been installed to support the excavation and allow the continuation of digging. Excavation has begun to the next depth of 20 feet.
August 27, 2008
Construction started with the installation of an 8-foot high wooden fence around the perimeter of the site. The fence provides security and safety.
Site preparation was completed and the excavation of the reservoir area has begun.
Overseeing the project is the Village's consultant Greeley and Hansen. Greeley and Hansen has an engineer on site full time to monitor the construction progress.
The site has been partially excavated approximately 12 feet of the total 33-foot depth.
June 25, 2008
Left to Right – Roger Linde, Greeley & Hansen, Engineer; Dennis Soustek, School District 135, Superintendent; Thomas Cunningham, School District 135, Board Vice President; Patricia A. Gira, Village of Orland Park, Trustee; Kathleen M. Fenton, Village of Orland Park, Trustee; Mayor Daniel J. McLaughlin, Village of Orland Park; Edward G. Schussler, III, Village of Orland Park, Trustee; Paul Grimes, Village of Orland Park, Village Manager; Ken Johnson, Greeley & Hansen, Engineer; Peter J. Casey, Village of Orland Park, Public Works Director; Joe Slattery, J. J. Henderson, Contractor
Main Pumping Station Overview
The Main Pumping Station for water distribution in the Village was originally constructed in 1985. The original station was built with a 4.8 million gallon reservoir to hold the potable water for pumping to the residential and commercial areas.
The original design included long-range plans to expand the reservoirs as the Village grew. The first addition to the reservoir on the west side added 9.3 million gallons. The construction of this addition to the reservoir on the east side will add 7.4 million gallons to the storage area for a total of 21.5 million gallons.
April 7, 2008