Cutting Channels in Limestone to Direct Waterfall – 10/23/2005

Over the last 2-3 weeks we’ve been working on a larger commercial project (large for us, anyway). We were excited about taking the project on when I first created the design roughly 12 months ago, but as the DNR and local governement got involved, the project start date got pushed further and further back, to where we were starting the project 6-8 months later than expected. Then came the changes by both the general contractor and their client; our color-rendered design was essentially erased and we were designing and installing on the fly.

Part of our new “design” included a crashing waterfall using weir stones that weighed 5-6,000 pounds each. This change required us to rent much larger equipment just to be able to lift the stones. But once they were in place, I needed a way to help direct the water flow from the two 10,000 gph pumps feeding this waterfall. This is where our Partner concrete saws came into play. Dolomitic limestone is very dense, but not all that bad to cut through. So we simply cut a few channels with out concrete saws to direct the water flow, slicing numerous grooves close together, then using a hammer drill with chisel bit to clean out the material between the grooves to make the channel.

As the client has made and unmade many decisions during this process, he decided that he didn’t like the look of the channels, even though there really would be no way of him seeing them, unless he climbed atop the waterfall without the pumps running (and who would want to do that?). So we’ll be burning up more man-hours chiseling these channels to make them look more “natural”. I’ve often said that if it weren’t for clients and employees, this job would be a breeze.

I’ll post some pictures when the project is done.