No BORDER RGE

RGE PROJECT FILE

MECHANICAL WIZARDRY & MOTOR SPORTS

PRODUCT DEVELOPMENT

THE BEAVER DAM PROJECT

29 ACRES. ONE FAILING GATE VALVE.
A LAKE THAT COULDN’T WAIT.

An aging pipe and failing gate valve threatened the future of Beaver Dam’s 29-acre lake. Replacing the problem wasn’t simply a matter of draining the lake and starting over. The challenge was finding a permanent solution without lowering the lake level.

01 / THE PROBLEM

THE CONVENTIONAL SOLUTION WOULD HAVE COST THEM THE LAKE.

The existing pipe incorporated a failing gate valve. Losing the ability to control and seal the system put the lake at risk.

The Lake Association needed a permanent solution—not a temporary repair. Crucially, the work had to be accomplished without lowering the lake level.

Conventional work would have meant lowering or draining the lake to reach the problem. RGE’s challenge was to avoid that disruption and keep the lake in place.

Checking out the problem
BEAVER DAM / EXISTING SITE
Checking out the problem
LAKESIDE / PROJECT ASSESSMENT
BEAVER DAM / THE IDEA

02 / THE IDEA

THE PROBLEM WASN'T GOING TO BE SOLVED
BY DRAINING THE LAKE.

SO THEY BUILT ANOTHER WAY.

BUILD A PERMANENT RISER.

The solution centered on a permanent riser pipe and screen assembly that would replace the dependence on the old pipe and failing gate valve while allowing the work to proceed without lowering the lake.

Making the screen and riser pipe
01 / SCREEN + RISER ASSEMBLY
Making the screen and riser pipe
02 / FRAME + HANDWHEEL DETAIL
Making the screen and riser pipe
03 / COMPONENT INTERFACE
Making the screen and riser pipe
04 / SCREEN + CONNECTION DETAIL

03 / MECHANICAL WIZARDRY

The solution didn’t come out of a catalog. Components had to be worked, fitted and adapted to the problem in front of them.

MEASURE.

01 / FRAME + ASSEMBLY

Making the screen and riser pipe
01 / FRAME + ASSEMBLY — WORKBENCH VIEW

FABRICATE.

Making the screen and riser pipe
02 / HANDS + TOOL — COMPONENT PREPARATION

FIT.

Making the screen and riser pipe
03 / HAND FITTING — COMPONENT DETAIL

ADAPT.

Making the screen and riser pipe
04 / WORKSHOP — ENCLOSED PREPARATION

04 / INTO THE DAM

BUILDING THE SOLUTION WAS ONLY HALF THE JOB.

IT STILL HAD TO GO INTO THE DAM.

The work now moved from fabrication to the lake itself, where access, working conditions and the existing structure became part of the challenge.

P1000907
PREPARING TO DESCEND
P1000886
AT THE ENTRY
P1010028
TENTING FOR PROTECTION
The Master at work
DOWN IN THE HOLE
P1010053
WORK INSIDE

105°F OUTSIDE.
Man, it’s hot.

P1010036
105°F / VEHICLE DASHBOARD
Fitting the debris screen
SCREEN ASSEMBLY / FIELD FITTING

05 / THE SOLUTION

SEALED. PERMANENT.
DONE WITHOUT LOWERING THE LAKE.

The permanent riser provided the new solution, while the old pipe to the failing gate valve was permanently sealed. The work was completed without lowering the lake.

P1010094
INSTALLED SCREEN / THE LAKE AT DUSK
Woah ... is this the same hole?
INTERIOR / WORKED SURFACES

THE LAKE NEVER HAD TO BECOME THE “BEFORE.”

CLIENT VERDICT

“I cannot express how much we appreciate your ‘saving our lake.’ Without the superb efforts of you, Danny, and Terry, we would surely be looking at a mud pit for the next seven years, rather than the beautiful 29 acre lake that we now, thanks to your team, are still able to enjoy.”

Doug Barnum
Co-Project Manager
Beaver Dam Repair Project

A Really Big Thank-You

Monday, June 07, 2010 3:11:16 PM

Robby,

I cannot express how much we appreciate your “saving our lake.” Without the superb efforts of you, Danny, and Terry, we would surely be looking at a mud pit for the next seven years, rather than the beautiful 29 acre lake that we now, thanks to your team, are still able to enjoy.

You in particular “stepped up to bat” when the project started “growing arms and legs” and went well beyond the originally planned efforts.

All of the people in our Lake Association that met you (Linda Bush (Chairman of the Board), Carol Jose (Treasurer), John Finan, Bob Henderson, and of course Robert Cornelia (Co-Project Manager)) have commented to me on how professional and competent you were, and what a great job you did. Others, that did not meet you, know only that the results have exceeded their expectations.

We now have a permanent riser pipe, the old pipe to the failing gate valve has been permanently sealed, and we are now no longer in danger of “losing our lake” – all that is purely due to your efforts; and you accomplished all that without us having to lower the lake level.

Again, words fail me in how deeply I personally appreciate the efforts, and results, that you have delivered to our Lake Association.

If you ever need a great reference, please feel free to have any prospective clients contact me.

All the best,

Doug Barnum

Co-Project Manager

Beaver Dam Repair Project

Robby Galletta Enterprises