Building-sized bellows-type seals are used to close the space between a new dockside casino and its permanent mooring, while also allowing vertical motion between the two structures as water levels change. The Hollywood Casino-Aurora is actually a barge that is permanently moored, but connected to a pavilion on shore. The floating 53,000 sq ft, single level casino was built in two stages as the cornerstone of a $78.5 million expansion project, replacing two smaller casino boats that were docked at the location.
On the Water But Not On the Move
The new casino, located on the Fox River, in the heart of Aurora, IL, was built in two halves that were floated to the site and anchored close to the pavilion. The first half of the casino began operation on February 15, 2002, with the complete facility finished and opened on June 14, 2002. (In photo, casino is at right, pavilion at left.)
Terry R. Bohr, project superintendent and secretary-treasurer of general contractor R.C. Wegman Construction Co of Aurora, explains the challenges: "We drilled 36-in. diameter caissons into the river bed. Around the caissons, we installed collars that were welded to the barge's hull, which allows the barge to slide up and down as the river level changes."
Because the casino barge actually floats in the river, yet must remain connected to the pavilion, it was necessary to seal the gap between the two structures. One of the challenges was to find a sealing method that would allow substantial vertical motion as well as limited lateral movement due to the clearance between the collars and the caissons. Bohr says the seal had to be able to accommodate a vertical range of motion from 7 ft above to 4 ft below normal level.
Sealing Between Casino and Pavilion
To design a sealing system that would accommodate these needs, Wegman turned to A & A Mfg Co, Inc, New Berlin, WI, a specialist in the design and manufacture of bellows, boots, way covers, and many other protective components for all types of machinery. A & A engineers developed a three-part bellows-type seal made of two-ply hypalon-impregnated polyester material (seal can be seen in center of photo).
The three-part seal consists of a top and bottom section mounted to the pavilion, with a center section mounted to the floating casino. Approximate height of the top bellows is 13 ft 5 in., while the center bellows is 25 ft high, and the bottom bellows is 15 ft high. Overall, the seal measures 35.5 ft high, and the three sections are installed with sufficient overlap to allow for maximum range of motion. Also, when installed, the seal accommodates a lateral change in width between approximately 4 and 16 in., with a 10-in. nominal gap between the two structures.
Each of the three bellows sections is mounted to a vertical track system fabricated from black UHMW material with UV inhibitor. Other hardware is of made of aluminum extrusion or stainless steel. On the barge side, the center bellows is mounted to the track section, which in turn is mounted to the barge. The top and bottom bellows are each mounted to long 3/8 x 2-1/4 in. UHMW strips that ride in two channels of the track section. On the building side of the bellows, the arrangement is reversed. Here, the top and bottom bellows are mounted to the track, while the center bellows is mounted to a UHMW strip that rides in a single channel of that track section. (Photo shows more detail of bellows and mounting hardware during installation.)
Despite the size of the bellows and its complex design, Bohr says it is performing as anticipated. He adds that the success of the seals is the result of close cooperation between A & A engineers and Wegman personnel in addressing the project's complex requirements.
