Long DriveHigh pressure BSA 120-D trailer pump places concrete incredibly long distances to construct golf cart path with minimal disruption to country club golfers
STURTEVANT, WI (November 1, 2010) – To avoid closing a premier golf course during reconstruction of its half-mile long cart path, a high pressure Putzmeister BSA 120-D trailer-mounted pump placed concrete long distances up to 1,180 feet (360m), quickly and without disrupting golfers at Butte Creek Country Club (BCCC).
Founded in 1962, BCCC in Chico, California is recognized as one of the finest private clubs in northern California. Its pristine 18-hole championship golf course is long, open and well-maintained by mature trees and various displays of nature. Golf memberships are limited to 400 to ensure golfers can play when they want. Therefore, when closing the ninth hole was proposed in order to remove an old asphalt cart path and replace it with a new concrete one, the country club’s board of directors voiced concern.
Concrete contractor, Cedar Valley Concrete (CVC) in Sacramento, California addressed the situation. Dave Carrick, CVC’s regional vice president said, “We needed a strategic plan to complete the job in four days, without major interference with the golf course’s normal operating schedule and keep the area extremely clean throughout the construction process.”
A Challenging Course
BCCC’s course is rated at a high degree of difficulty; and pumping the project would be no different. The 2,500-foot (762m) golf cart path was long with sharp winding curves; plus, no access to the course was available for equipment setup.
Therefore, at a planning meeting, it was decided to remove asphalt one day and pump concrete from two staging areas the next two days. From the first staging area, concrete would travel through a delivery line system at a distance of 1,060 feet (323m), with the remainder of the concrete path poured the following day, from the second staging area.
Bob Bauman, owner of Bob’s Concrete Pumping, Inc. (Bob’s) in Chico, California, was contacted late one afternoon, inquiring if he had the right equipment to pump concrete through a system that stretched almost a quarter mile, and if he could do it the very next day. Bauman said, “It was no problem. I had the perfect pump for the job, but a little more notice would have been nice.”
The machine selected to handle the job’s complexities was the Putzmeister BSA 120-D trailer-mounted concrete pump, which debuted at the World of Concrete 2009. Bauman says, “Since taking delivery in March 2009, the pump has performed well; but it had not been put to any real test prior to this job. Finally, we would see if this pump model matched the manufacturer’s high performance specs on paper.”
These specifications include high pressures up to 1,030 psi (71 bar), high outputs up to 114 cubic yards per hour (87m³/hr), and a powerful 197 hp (147kW) Deutz diesel engine. The machine also features an exclusive Free Flow Hydraulic system for a smooth, controllable concrete flow.
Specifying a mix design was extremely important to effectively pump concrete the far distances required without plug-ups, yet still attain a set time requirement of 3,000 psi (20.7 MPa) in 28 days.
To meet these mix specifications, vice president Craig Zelie of Orland, California-based Western Ready Mix Concrete Co. (Western) was called upon for his recommendation; it resulted in a special mix containing four major ingredients. This included 1,529 pounds (694kg) of one-inch (25mm) rock, 1,484 pounds (673kg) of sand and six sacks of cement.
Plus, 16 ounces (454g) per cubic yard of V-MAR™ 3, a new generation liquid admixture designed to increase the cohesion and stability of extremely high workability concrete, was also added. V-MAR was used in conjunction with a powerful superplasticiser, ADVA® Flow 300, to produce self-compacting concrete, which maintains self-compacting properties while preventing segregation.
To prime the system, Western used one cubic yard (0.76m³) of four-sack sand slurry to additionally help prevent plugging the system.
Ground Under Repair
As the cart path was not a straight line, the delivery line system had to curve with the direction of the meandering pour. Consequently, the crew connected 180 feet (54.86m) of four-inch (102mm) pipe, 680 feet (207.26m) of four-inch (102mm) hose and 200 feet (60.96m) of three-inch (76mm) hose for delivering concrete during the first pour. Ready mix trucks were precisely scheduled 15 minutes apart, as any delays with this length of system out could cause havoc.
“This was a private, upscale golf course; and making a mess was not an option,” says Justin Gray, the trailer pump operator who worked with five other Bob’s employees at the job site. “We knew this was not your typical job, so it was important that we worked as a team to ensure everything went as planned.”
Unfamiliar with the trailer pump’s maximum performance capabilities and with no mulligans in pumping, the crew was in uncharted territory. “Watching concrete come out of the end of 1,060 feet (323m) of system was a sigh of relief to everyone, especially CVC’s foreman Arturo Gonzalec,” notes Gray. “The pump performed without any hesitation and exceeded our expectations, as it had plenty of power to spare.”
Concrete was placed at a maximum five-inch (127mm) slump. The BSA trailer pump, averaging 32 cubic yards per hour (24m³/hr) while operating at a 3,700-psi (255 bar) hydraulic pressure, rapidly placed 130 cubic yards (99m³) of concrete in about four hours for the first pour, which was much faster than planned; and more importantly, it was accomplished without closing the ninth hole.
“A concrete pumping company is only as good as its employees, and employees only look good when a pump performs,” notes Jerry Henderson, Bob’s general manager. “We have been building our reliable reputation with Putzmeister pumps since 1992.”
With the first pour making a long successful drive, it was time to test the trailer pump’s ability to pump concrete an even farther distance the following day. Adding 120 feet (36.58m) of three-inch (76mm) hose to a similar setup as the day before, the trailer pump placed 156 cubic yards (119m³) of concrete at a maximum distance of 1,180 feet (360m).
“It was quite a sight to look back from the second staging area to where the cart path started,” says Greg Jurgenson, Western’s field manager. “You needed binoculars.”
“I’ve been in the concrete pumping business more than 30 years, and this pour went smoother than I could have ever imagined,” notes Bauman. “The BSA’s long-distance pumping capabilities meant we could quickly and cost-effectively place all the concrete in two days instead of three.” The fourth day was reserved for form removal and final cleanup.
As scheduled, the project was completed quickly with minimal disruption to golfers, and the ninth hole was closed only one of the four days. This was due to tee boxes located right next to the second pour, which caused safety concerns. Plus, the course was left in immaculate condition, with only a new, long-lasting concrete golf cart path as a reminder that construction ever occurred.