Brick by Brick
October 01, 2024
The historic El Rancho Hotel in Gallup, New Mexico, is a cherished landmark with a rich history dating back to the 1930s. However, its iconic 70-foot brick chimney had begun to deteriorate, posing a significant risk to the hotel and its surroundings. Several bricks had already fallen onto the hotel’s roof, and deep cracks in the chimney indicated an imminent collapse. Demolition was needed, but the challenges were numerous: The chimney was situated just 12 inches from the historic building, a power transformer needed to remain online during the demolition, and nearby utilities, including ductwork, a gas main, windows and chillers, required protection. To top it off, active overhead power lines limited access to the site.
The Selection Process
NDA member BCS Enterprises was chosen for the project due to the company’s innovative approach and ability to address the owners’ concerns effectively. After a thorough site visit, the team produced a 3D model to develop their methodology. “We find developing these models helps minimize any potential oversights and uncertainties on the job,” says Casey Johansen, BCS Enterprises’ director of operations.
Timeline and Equipment
The project kicked off with initial planning in May 2023 and was awarded that same month. Design and fabrication of the modular protection system began immediately. Demolition commenced on July 31, 2023, and the entire chimney was removed and loaded out in just one week.
The equipment used for the project included a 275-ton mobile crane, a Brokk 160 with a custom frame bracket, a 135-foot boom lift and a Cat 310 excavator.
A Unique Demolition Strategy
The demolition strategy devised by BCS Enterprises was truly unique. The team needed to bring the chimney down within its own footprint, ensuring that materials fell in a controlled manner to avoid damaging the surrounding roof and utilities. To achieve this, a three-section modular protection box was designed and built to fit precisely around the chimney. One corner of the box was designed as a chute for the material to fall at the location farthest from all obstacles.
“The crane suspended our box in the air with the Brokk 160 robotic excavator directly mounted to the side,” Johansen says. “The crane lowered the box as we delicately hammered the chimney down. Sections of the protection box were removed as the work progressed downward.”
Step-by-Step Demolition Process
The demolition process began with the mobilization of all equipment from BCS Enterprises’ yard in Phoenix. Protections were installed over windows and surrounding utilities. After the crane was set up, the protection box was lifted over the power lines and carefully guided around the chimney. The Brokk 160 was then bolted into place, and the crane lifted the system above the top of the chimney to begin the demolition. The Brokk operator and a spotter worked from a boom lift at a safe distance from the chimney, guiding debris to the chute corner of the box. A Cat 310 excavator was used to load out the material, carefully working around power lines and utilities. As demolition proceeded down the chimney, the protection box was lowered by the crane, and sections were removed. Finally, the last box section was removed, and the remaining 10 feet of the chimney base was carefully demolished with the Cat 310 excavator.
The Crew and Recycling Efforts
The demolition team consisted of nine people, including a superintendent, an operator, two spotters, a mechanic, a truck driver, a safety officer, a crane operator and a rigger.
All the bricks from the chimney were recycled and brought to a nearby facility to be repurposed.
Overcoming Challenges
One of the biggest challenges of the project was working around utilities while avoiding any disruption to hotel operations. “Careful planning, protective measures and the use of multiple spotters helped to overcome the challenge,” Johansen says.
Success in Safety and Efficiency
The project was completed safely, on time and on budget, with the chimney removed without causing any damage to the surrounding property. “Success to us means completing the project safely, efficiently and to the client’s satisfaction,” Johansen says.
BCS Enterprises’ unique approach to this challenging project exemplifies the company’s expertise and commitment to delivering innovative and safe demolition solutions. BCS Enterprises’ ability to overcome complex challenges while preserving the historic integrity of the El Rancho Hotel serves as a testament to its skill and dedication in the demolition industry.