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Thursday, April 28, 2016

Lower Patio Project

With a very talented staff and supportive membership we have been able to accomplish great things over the last few years both on the golf course and on the surrounding grounds. Recently, Assistant Superintendent Michael Brown was put in charge of a patio building project on the back club lawn. Michael's background in hardscaping lined up perfectly with the new patio build that was proposed.  After detailing the scope of the project and budget with materials and labor factored in, it was determined that by doing this project with in-house staff vs. contracting it out, the club was able to save over $20,000. Michael did an outstanding job managing the project and the final product is beautiful.  We hope members and their guests enjoy the new patio this year and for many more years to come. Below is an explanation of the process involved with building a patio of this scope, and the detail that goes into it. 

The first step after identifying the shape and size of the patio was to identify the location where it would be built. Using a stake in the center as the proposed fire pit spot, measurements were made and irrigation flags were used to outline the edges of the future patio. Seeing it set up in this fashion allowed everyone to get a feel of the size before any product was ordered.
Four different quotes were collected for our bulk patio supplies order. When the order was placed, all materials were delivered at once to minimize delivery costs.

Once the materials were on site, excavation began using our mini-excavator. To blend the patio and wall into the hill, almost three feet of soil had to be excavated on the back side where the seating wall would be placed.

Mother nature didn't always cooperate and frequent rain during excavation made for a muddy project. 

When all the excavation was complete, the patio shape was re-marked and flagged.  Small tweaks were made at this time to ensure the area was properly graded.

6-8" of stone base was added above the soil grade and compacted to provide a firm base for the patio. Doing this minimizes the risk that the patio blocks will ever move.

Construction first began with the seating wall that wraps around the back of the patio including the steps. This involved custom cutting some blocks to make the shape needed for our build.

Utilizing the wall blocks, steps were built for entering and exiting the patio. It was extremely important at this time to ensure the blocks were set at the proper grade using a laser transit and levels.

Once a level, compacted grade was established, the wall went up fairly quickly. All wall blocks are secured together using construction adhesive.

Wall blocks were placed all around the exterior of the patio to allow for less carrying of the heavy block to set them in place. 

Drainage tile was installed behind the wall to move water away from the patio. Geotextile fabric was also used against the back of the seating wall to prevent the movement of soil through the cracks.

Geotextile fabric installed along the back of the wall
2" of slag sand on top of the compacted stone is used to create a very level surface for the pavers. To get the sand level, pipes are inset and the top of the pipe is set 2 inches below the finish patio grade. A flat board is dragged between the pipes, flattening the sand at the intended grade. When this is complete, pavers can start being set into place. 

Before pavers could be laid across the whole patio, a contractor was hired to run the main gas line and electric service into place.



The patio build didn't come without it's problems! Weather changed and everything froze. This slowed down the build but in the end did not negatively impact it. 

The patio paver process moved quickly when the staff helping was trained to take over the leveling process.


The fire pit was built into the patio over top of the previously placed gas line

Step coping was set in place during the installation of LED lights

Here the patio surface has been completed. After all the patio pavers were laid in place, polymetric sand was broomed into all the joints and a plate compacter was used to work the sand in. This process locks the pavers in place. After the sand broomed in and compacted, water was sprayed on the surface to activate the glue in the sand.


LED lights highlighting the new seating wall and steps

Plumbing of the fire pit was also done by in house staff







Finished patio! Great job by all the staff!