Main Pumping Station

Orland Park's Main Pumping Station
Posted on 05/06/2009
Project Photos Quick Navigation
Project progress photos and information is displayed in reverse chronological order by the following dates:

Progress as of May 2009
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 6,000 cubic yards of concrete has been placed.
Preparation for pouring concrete
Baffle Wall
Working 30 feet above the base slab, concrete is placed for an interior baffle wall.
Working 30 feet above the base slab
Tight Conditions
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.
Tight conditions in massive excavation
Large Pipes
Two 60-inch pipes (one shown here) connect the existing reservoir on the right with the new addition.
Inch Connection
Center Section
Despite the unusually wet spring, work is progressing at a rapid pace. Of 25 base slabs, 19, have been completed, as well as 10 of 16 wall sections, 40 of 67 columns, and 10 of 15 baffle wall sections.

So far, more than 1.7 million pounds of rebar has been installed or the equivalent weight of more than 492 vehicles.
Center Section
Backfill
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.
Backfill Stock Pile
Progress as of April 2009
A concrete pumper truck accepts concrete from two Ozinga Conrete trucks. Through May, 17 of 25 base slabs have been completed.
Slab Pour
Crane Work
A crane places the form for a column used to support the top deck.
Crane Work Site
Flow Pathing
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; 25 of 67 were also poured.
Flow Pathing
Progress as of March 2009
The East Reservoir Addition is situated immediately outside the Main Pump Station and Reservoir. The neighbors to the east and north are School District 135 and Liberty School.
Panoramic View
Baffle Walls Completed
Inside the existing reservoir, 30-foot tall concrete baffle walls have been completed. The new wall is on left side of photo.
Baffle Walls
Mobile Cranes
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.
Mobile Cranes

Mobile Cranes
Concrete Deliveries
Ozinga Bros. Inc. has delivered almost 4,000 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.
Concrete Delivery
Progress as of February 2009
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 1 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.
Progress of Main Pump Station

Concrete Finishing
Progress as of January 2009
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 30 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.
East Chamber Reservoir

Interior
Exterior Work
A 2-inch thick concrete work mat will cover the entire site and provide a stable work environment to begin construction of the base slab for the new reservoir.
Exterior Work
Installing Pipes
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.
Installing Pipe

Pipe Installation of Main Pumping Station
Progress as of December 2008
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.
Main Wall Expansion
Progress as of November 2008
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.
Installation Progress 2008
Progress as of October 2008
To support the side walls of an excavation that is 35 feet deep, specialized equipment is needed. 

The picture here 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.
Side Walls Excavation
Tieback Machine & Tractor
Shown alongside the tieback machine is one of several excavators being used on site, a John Deere 160C LC Backhoe.
Tie Back Machine
Dirt Removal
C.D. Chidester Excavating, the excavating subcontractor, uses multiple pieces of equipment to remove more than 50,000 cubic yards of dirt.
Dirt Removal
Loading Dirt
The Caterpillar 235 is able to load each truck with only four bucket scoops.
Dirt Loading
Drilling Rig
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.
Drilling Rig
Progress as of 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.
Installing excavation and digging
Progress as of 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 consulting company 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.
Site preparation completed
Groundbreaking Ceremony, June 25, 2008
Attendees from 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
Ground Breaking for Main Pumping Station
Project Planning, April 7, 2008
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.
Water Pump Project Planning
Original Design
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.
Original Orland Park Pumping Station