1/7/2020
Architect: Dan Almond Contractor: Emch Bros Installed: Fall of 2008 First Game Played: Huntington Park April 2009 Columbus, Ohio
Wes Ganobcik
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Sod: Lasted 9 years (through Oct 2017) Tuckahoe Turf (New Jersey) AAA Columbus Clippers Infield Material: Daily camps Kurtz Bros (central Ohio) OHSAA State Championships (annually) Warning Track: Big Ten Tournament Country Stone crushed lava rock (New Concerts Mexico/Colorado) Corporate Events Weddings Rootzone: Movie & Commercial Shoots Kurtz Bros (central Ohio) Irrigation: Hunter
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The best evidence is right in front of you Know your benchmark Drainage Point off which you are basing all elevation measurements Games played & successful events vs cancellations Point can not change Wear tolerance Ours: concrete edge of our shop floor adjacent to the field Annual maintenance and product use Pure conical grade from center of the mound Revenue gained or lost 0.45% grade That equals 5.4” of fall per 100’ of run Put a plan together A 0.5% grade equals 6.0” of fall per 100’ of run Identify what you have Initial desire was for a 0.25% grade Identify what you want That equals 3.0” of fall per 100” of run Proved impossible with existing structural points Research, research, and research some more Elevation changes Stay involved Infield elevation dropped by over 5” Foul territory warning track elevation rose by over 5”
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1 1/7/2020
Running electric to the back of the mound Easy access for pitching machines Running concert power to a valve box buried beneath the turf just behind 2nd base at the top of the arc Easy access for 2nd base stage concerts Running relay lines from the center field wall to a valve box buried beneath the turf just behind 2nd base Easy access for running sound and lighting cords underground for large scale concerts instead of laying them on the surface and using bumblebee strips Glyphosate was applied prior to grass removal 14” blow hole behind the mound Effort to reduce residual poa annua A 14” tube from the warning track to a box behind the mound to attach a turbine blower in order to bubble the tarp Rubber running track warning track Reinforced concrete base and rubber running track in foul territory from bullpen mound to bullpen mound, mimicking our MLB parent club Cleveland Indians
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Anything at the surface must be removed Confirm access to the construction area Irrigation heads Does equipment fit Quick couplers Are any permits required and who is responsible Valve boxes Avoid costly unnecessary damage Drain caps Who is responsible
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Determine how much material to remove Organic layer Change in grade or elevation Soil tests Learn what you have Know what you want Besides the turf, what else will be removed Edges & transition points Infield material Warning track material
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2 1/7/2020
Will it be necessary to remove wall pads Who is responsible
Have a plan for removing the spoils Do you access to a paved area How easy can trucks get to the spoils pile
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Have a plan for where the spoils will be taken to You will likely observe paint buildup Trucking costs Disposal costs Can they be recycled or used by someone else Who is responsible
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You will likely observe paint buildup Have you shifted logos over time for plant health
You will likely observe paint buildup Have you rotated logos
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3 1/7/2020
Removal of surface material can expose surprises Be prepared to adjust your plan Who is responsible for contingency costs
Have a plan to salvage material when possible We removed the rootzone from the infield to be reused
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Pea gravel being removed from infield to expose drain lines
Know the cost of changing elevations & grades We removed and salvaged rootzone from the infield We removed and disposed of pea gravel from the infield
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Note old materials and techniques Clay Renovated Infield Material Original infield material Rootzone Pea Gravel
Document everything
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4 1/7/2020
Infield completely excavated down to subgrade Infield completely excavated down to subgrade
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Have a plan to work in all weather conditions Some tasks are more flexible than others
Have a plan for the new rootzone Take samples once all top material is removed Till as deep as possible
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Removing old surface drains for the tarp Had four 4” drains along the outfield edges of the tarp
Lowering the elevation of the subgrade We removed approximately 3” of subgrade
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5 1/7/2020
Note the different layers
Amended infield
Original infield material
Original subgrade elevation
Have a plan that is conducive for multitasking Efficiency will expedite the project
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Determine the best location for offloading material We had no paved area to use We used the widest portion of our warning track We understood this would include some waste
Lowering the elevation of the subgrade We removed approximately 3” of subgrade
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Transferring new pea gravel to the infield Transferring new pea gravel to the infield
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6 1/7/2020
Grading the new pea gravel across the infield Grading the new pea gravel across the infield Use laser guided equipment whenever possible Use laser guided equipment whenever possible
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New infield irrigation install Two zones with heads next to each other
New infield irrigation install New design/layout All new PVC, connections, and heads
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Infield rootzone being reinstalled Infield rootzone being reinstalled Specific amount being brought in Use laser guided equipment whenever possible
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7 1/7/2020
Laser grading the infield rootzone Infield rootzone reinstalled and graded Grading to exactly 4” below new final elevation Laser graded to exactly 4” below new final elevation
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More multitasking Tilling the outfield rootzone Outfield rootzone continues to be tilled Spoils pile continues being removed Edges/transition points being excavated
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Foul territory rootzone Laser grading the outfield rootzone after tilling Tilled Laser graded to exactly 4” below new final elevation Laser graded to exactly 4” below new final elevation
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8 1/7/2020
Installation of warning track irrigation Installation of warning track irrigation Four new zones & valves added Four new zones & valves added
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Foul territory rootzone Paint marks on concrete walls Tilled During the project, everything buried underground Graded to exactly 4” below new final eleveation was noted by a specific paint color on the walls
Red + Number Irrigation valve + the zone it controls Lime Green End points for bullpen mounds and catchers pits Light Blue Capped drain access points
Anything you can do that will make life easier in the future should be done, especially marking underground points.
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Old bullpens removed Old bullpens removed New mounds would be at new elevation and location New mounds would be at new elevation and location
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9 1/7/2020
Outfield rootzone Laser graded to exactly 4” below new final elevation Note the significant change in grade
Foul territory rootzone Laser graded to exactly 4” below new final elevation Note the significant change in grade
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Outfield rootzone Laser graded to exactly 4” below new final elevation Note the significant change in grade
Foul territory rootzone Laser graded to exactly 4” below new final elevation Note the significant change in grade
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Warning track Warning track Laser graded to exactly 4” below new final elevation Laser graded to exactly 4” below new final elevation Used existing material to create the new base Used existing material to create the new base
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10 1/7/2020
Irrigation Game mound rubber Moving two valve boxes from beneath bullpen mound Custom built a tray for the rubber to set in Allows for quick exchange of pitching rubber 4” base to set on same grade as plate 2” lips to maintain side to side and front to back
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Warning track New design added 15” of width in foul territory Allows for easy passage of two vehicles at once In Front of Dugout: Old width: 12’9” New width: 14’ Behind Home Plate: Old width: 14’9” New width: 16’ Added 15” Between Dugout and Bullpen Mound: to the width of the warning track Old width: 17’9” New width: 19’ Remaining Foul Territory: Remained: 15’ Warning track Outfield: New design added 15” of width in foul territory Remained: 20’
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Warning track Rootzone New design added 15” of width in foul territory Approx 1450 tons of new USGA sand was brought in Soil tests were conducted consistently to check Physical makeup Organic levels Drainage A new rootzone composition was determined Based on desired traits Based on what was existing Based on what would need to be added To accomplish that: Created new 3.5” cap of USGA sand
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11 1/7/2020
Rootzone Rootzone Approx 1450 tons of new USGA sand was brought in Approx 1450 tons of new USGA sand was brought in Laser guided bulldozer was used 3.5”cap of new USGA sand was created across the field
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New warning track drainage Irrigation Excavation to approximately 14” below new grade Edge of warning track moved Irrigation along that edge needed to be moved
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New warning track drainage New warning track drainage Excavation to approximately 14” below new grade Excavation to approximately 14” below new grade
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12 1/7/2020
New elevation & grade New USGA rootzone sand An additional step had to be installed at dugout gates Laser graded to exactly 0.5” below new final elevation
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New warning track drainage New USGA rootzone sand New trench drain being laid out Laser graded to exactly 0.5” below new final elevation 4” wide x 7” depth inside the casing
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New warning track drainage New warning track drainage 14” catch basin installed at low points 14” catch basin installed at low points Concrete base poured Concrete base poured Drains set immediately Drains set immediately
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13 1/7/2020
New warning track drainage New warning track drainage Concrete base poured Concrete base poured Drains set immediately Drains set immediately
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New warning track drainage Concrete base poured Drains set immediately
New warning track drainage Concrete base poured Drains set immediately
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New warning track drainage Finish concrete poured after drains set New warning track drainage Drains set at tolerance of +/‐ 0.25” of new grade Expansion joints cut into concrete
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14 1/7/2020
New warning track drainage New elevation & grade Concrete base poured An additional step had to be installed at dugout gates Drains set immediately
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New warning track drainage New warning track drainage 14” catch basin was installed at each low point 14” catch basin was installed at each low point Drain tile was installed and tied into existing system Drain tile was installed and tied into existing system
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Thanksgiving Party New warning track irrigation Made sure everyone was well fed Trenching for install of new lines 3 roasted turkeys 4 deep fried turkeys 4 smoked turkeys
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15 1/7/2020
New warning track irrigation New warning track irrigation Installation of new lines Installation of new lines Head spacing width: Head spacing width: Same as depth between wall and grass Same as depth between wall and grass
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New warning track irrigation New warning track drainage Installation of new lines Finish concrete poured after drains set Installation of 4 new valves / zones Drains set at tolerance of +/‐ 0.25” of new grade Concrete notched out for each irrigation head location
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Infield Dirt Infield Dirt Old Material Had amended top 3” of existing infield material 8”+ column of a local native mix Contractor carefully removed top 3” Large amount of calcined blended in Donated high quality material (do not blend conditioner into your infield) Old Material Amended No disposal fees / cost Top 3” heavily amended ~ 53% sand ~ 23.5% silt ~ 23.5% clay New Material 4” cap on all dirt surfaces ~ 58% sand ~ 21% silt ~ 21% clay A 3” cap is normally plenty for a new construction build. I wanted to have an inch of buffer should amending ever occur.
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16 1/7/2020
Infield Dirt Infield Dirt Had amended top 3” of existing infield material Removed an additional 5.5” of infield material Contractor carefully removed top 3” Material also donated Donated high quality material No disposal fees / cost No disposal fees / cost Laser graded at exactly 4” below new final elevation
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Infield Dirt Removed an additional 5.5” of infield material Material also donated New Infield Dirt No disposal fees / cost Plywood road built over rootzone Laser graded at exactly 4” below new final elevation Custom designed engineered infield material
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New Infield Dirt Basepaths Plywood road built over rootzone Excavated to exactly 4” below new final elevation Custom designed engineered infield material Old material stockpiled and being removed
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17 1/7/2020
Basepaths & Home Plate Basepaths & Home Plate Excavated to exactly 4” below new final elevation Excavated to exactly 4” below new final elevation Remaining old material being loaded out
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Infield Dirt New Infield Material Laser graded to exactly 4” below new final elevation 4” cap of custom engineered material being installed
Irrigation All irrigation heads and the quick coupler adjacent to the back arc were moved to 4’6” off the edge in order to accommodate a pass with our 4’ wide aerifier
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New Infield Material New Infield Material 4” cap of custom engineered material being installed 4” cap of custom engineered material being installed
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18 1/7/2020
New Warning Track Material 4” cap of engineered dyed lava rock warning track
New Warning Track Material 4” cap of engineered dyed lava rock warning track
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Game Mound Excavated to 4” below new surface grade
Game Mound Removed and disposed of –no materials salvagable
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Rootzone New 3.5” of new USGA sand being tilled and blended Game Mound with the existing rootzone material to achieve the New 4” cap of infield material installed as a base desired blend
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19 1/7/2020
Rootzone New 3.5” of new USGA sand being tilled and blended with the existing rootzone material to achieve the New Warning Track Material desired blend Laser graded with a duel mast attachment
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Home Plate Set firm so absolutely unable to move in any direction
Home Plate Double checking to make sure we’re perfectly square with the foul poles
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Edges Edges Basepaths Measuring off string lines 4’ wide total Setting edges 8” in fair territory 4” white paint & 4” of dirt 3’4” in foul territory 4” white paint & 4” of dirt Cutouts 15’ radius from 90’ corner 7’4” in from 90’ line Inside edges 28” in from 90’ line Back arc 95’ from center of mound (not front of rubber)
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20 1/7/2020
Edges Edges Measuring off string lines Measuring off string lines Setting edges Setting edges
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New Mound New Mound Setting the rubber Setting the rubber Measuring height, distance, and square Measuring height, distance, and square
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New Mound New Mound Setting the rubber Base was built with infield material Measuring height, distance, and square Top 4” of table and wedge were built with black gumbo
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21 1/7/2020
Rootzone Rootzone New 3.5” of new USGA sand being tilled and blended After tilling the entire outfield and foul territory in two with the existing rootzone material to achieve the directions, the rootzone was then laser graded to 0.5” desired blend below the final grade
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New Mound Rootzone Base was built with infield material New 3.5” of new USGA sand being tilled and blended Top 4” of table and wedge were built with black gumbo with the existing rootzone material to achieve the desired blend
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Rootzone Laser grading the rootzone to 0.5” below the final grade We went from nearly 100 valve boxes throughout the field for drains and quick couplers to a single valve box at the surface of the grass which houses an emergency shutoff for the quick coupler behind the mound
Rootzone After thorough blending and laser grading, additional soil tests were taken to ensure the final rootzone composition matched what was desired
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22 1/7/2020
Sod First of three days of sod trucks Rootzone Kentucky Bluegrass grown on sandy loam Laser graded to 0.5” below the final grade From New Jersey
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Sod Sod 0.5” thick cut 0.5” thick cut Kentucky Bluegrass grown on sandy loam Kentucky Bluegrass grown on sandy loam From New Jersey From New Jersey
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Sod End of the first day of sodding
Sod 0.5” thick cut Kentucky Bluegrass grown on sandy loam From New Jersey
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23 1/7/2020
Sod Delays Snow storm Sod farm put all resources towards resodding an NFL field to be ready for a game that Sunday
Sod Edges cut back to exactly 16’ off the wall
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Warning Track Sod Laser grading to meet the new surface grade Second day of sod trucks
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Sod Edging sod
Sod Second day of sod trucks
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24 1/7/2020
Sod Sod came with a significant amount of river stone All sod was power broomed to work up the river stone and fluff the plants
Sod Third day of sod trucks
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Sod After being cleaned of the rive stone, the sod was mowed to stand up the plants
Irrigation A valve and a portion of the associated zone were crushed by semi trucks during the sand deliveries
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Sod Sod came with a significant amount of river stone Infield Dirt All sod was power broomed to work up the river stone Infield material being prepped for laser grading and fluff the plants
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25 1/7/2020
Warning Track Irrigation The remaining new warning track material was A valve and a portion of the associated zone were delivered and graded out for a final top coat crushed by semi trucks during the sand deliveries
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Infield Dirt Laser graded to new surface grade
Infield Dirt Laser graded to new surface grade
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Infield Dirt New Warning Track Irrigation Laser graded to new surface grade Heads being installed
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26 1/7/2020
Sod A green pigment was applied to the new sod
Warning Track Laser graded to new surface grade
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Warning Track Laser graded to new surface grade
Warning Track Compacted with our 1.5 ton roller
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Final Product Approximately 8 weeks October 30 through December 22
Irrigation Blown out for the winter
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27 1/7/2020
Final Thoughts Entire field was overseeded with 3 varieties of KBG at a rate of approximately 2lbs Hampton, Bewitched, & Noble Ryegrass has been kept off the field except for heavy wear locations within 4’ of dirt edges for easy removal with offseason big roll sod Would absolutely use barrier boards for all edges in the future to create crisp edges and minimize contamination Wish that we had replaced a large percentage of the irrigation lines in the warning track up to the valves with HDPE or High Density Polyethylene Wish that we had installed a separate supply line isolated to quick couplers Wish we had moved valves to several consolidated points
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