It's no small feat when a 37 ft. wide pump station is installed close to a pristine golf course.
Manusos General Contracting, based in Fox Lake, Ill., recently completed casting-in-place a new storm-water pump station for the village of Elmwood Park, Ill., which was no small feat.
The structure was 37 ft. (11.3 m) wide, 50 ft. (15 m) long and 30 ft. (9 m) tall. Adding to the excavation project’s already challenging parameters was the fact that the behemoth pump station needed to be installed adjacent to a very exclusive country club, with the golf course’s seventh fairway about 30 ft. (9 m) away from the excavation site.
This was the first time Manusos had ever attempted installing any underground utility of this magnitude. Some may have been concerned that Manusos “had bitten off more than they could chew,” as the saying goes. Instead of being intimidated by the new challenges, Manusos dug right in (no pun intended) and sought the help they needed to get started.
Step by Step Process Leads to Efficiency
Production Slide Rail System
Step one was to determine which shoring system to use on the project; not a simple task considering the size. Really only two shoring system can safely shore a pit so large, driven tight-sheeting or a Slide Rail System.
Don Manusos, consultant of his namesake company, ultimately chose bidding the project with a Slide Rail System for one simple reason: “Compared to sheeting, it was cheaper,” Manusos said, “Maybe $165,000 cheaper. Looking at pictures and video of the [Slide Rail] system, it seemed like it goes in a lot cleaner and easier and takes up less room,” Manusos added.
With the shoring system decided, Manusos needed to find the right Slide Rail System that included factory support and installation assistance. To that end, Manusos contacted manufacturer Efficiency Production’s Special Operations Shoring Division, who could provide both.
Efficiency Production’s Slide Rail is a component shoring system comprised of steel panels (similar to trench shield sidewalls) and vertical steel posts. The highly versatile system can be used in a variety of configurations. In addition to the obstruction-free ClearSpan configuration, Efficiency’s Universal Slide Rail can be configured into small four-sided pits; or in a Multi-Bay configuration to install large tanks and structures; or lengths of pipe over 40 ft. (12 m).
Manusos Crew
Quickly Overcomes Learning Curve on Installing Big Shoring
Manusos rented from Efficiency Shoring & Supply — Efficiency Production’s factory-direct Chicago rental branch — equipment to install a 42 by 53 by 32 ft. ClearSpan Slide Rail System. Efficiency Shoring & Supply’s Chicago Branch Manager, Mark Mitchell, was on site to help Manusos with the critical initial steps of installing the Slide Rail System.
“The Manusos crew were a hardworking group of guys, completely green to something like that,” Mitchell said. “But they caught on very quick despite that fact it was all new.”
Slide Rail is installed simultaneously as the trench or pit is excavated by sliding the panels into integrated rails on the posts — an outside slotted rail first, then an open-face rail on the inside — then pushing the panels and posts incrementally down to grade as the pit is dug; a process commonly referred to as a “dig and push” system.
“We’ve always said that in theory, ClearSpan can have unlimited size, and this excavation proves that a 50 foot wide pit is not just theory,” said Efficiency Production Vice President of Engineering, Mike West. “Other manufacturer’s clear span configurations need to be installed with cumbersome cross-members. Only Efficiency’s ClearSpan system is never encumbered by cross-members at any time,” West added.
In addition to Mitchell, Efficiency Production sent senior Slide Rail Installer Tim Hurst to assist with the installation. About the Efficiency team, Manusos Project Superintendent Kevin Aronson said “They were not afraid to get dirty, not afraid to get on the ugly side of stuff,” he said. “They were very helpful, especially in the initial stages training my guys,” Aronson continued. “[The Efficiency] guys busted their asses, and trust me I would not hesitate to let them know if I was displeased,” he added.
Manusos installed the entire system with a Komatsu PC 400 and PC 490 excavators, plus support equipment. All told, the lift station was entirely installed in a couple of weeks between June and July, 2013.
Incorporated in 1992, Manusos General Contracting Inc. is a Certified Women’s Business Enterprise General Contractor. Manusos also has effectively provided work on individual contracts for concrete, trusses, general trades, etc. They employ union-skilled carpenters and cement masons.
With offices in Chicago, Ill.; Houston, Texas; and Orlando, Tampa, Miami and Jacksonville, Fla.; Efficiency Shoring & Supply is an official Efficiency Production Inc. factory-direct sales and rentals company.
For more information, call 800/220-8707 or visit www.efficiencyshoring.com.
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