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Sod Quality Results with Hydro-Mulching02-01-01 | 16
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Apremium hydro-mulching application will produce sod quality results nearly every time, and will cost substantially less than solid sod. But, premium hydro-mulching applications are almost non-existent in the real world. Therefore, when highly reliable turf or grass establishment is required, it is almost always done with solid sodding. There are a number of reasons why Sod Quality Results hydro-mulching is seldom practiced or recognized. Most of the reasons are within the "hydro-seeding" industry.

Cost Analysis: Utilizing 20.0 Tank

Hydro-Mulching an Acre with 20.0 Tank Loads using a 425 Gallon Hydro-Mulching Machine. (Coverage per Tank Load: Approximately 2,178 Sq. Ft. Bonded Fiber Matrix (BFM) at 4,200 lbs per Acre.)

Approximate Contractor Materials Cost

Materials Used Per Tank Load:

3.5 bags (60 lbs each) Bonded Fiber Matrix at $40.00 per bag, 210 lbs costs $140.00

Seed costs used for this example: $5.00 per 1,000 square feet cost $10.89

1 bags (50 lbs each) 17-17-17 Fertilizer at $7.50 per bag, 50 lbs costs $7.50

0 lbs of tackifier at $0.00 per lb comes to $0.00 (All ingrendients are in the BFM Product.)

Materials Cost Per Tank Load is $158.39

Materials Cost Per Sqaure Foot is $7.27

Materials Cost Per Acre is $3,167.80

Approximate Contractor Applications Costs

The following assumptions were made regarding contractor operations costs:

1. The overall costs for the machine, truck, and crew is assumed to be about $125.00 per hour.

2. Under good operating conditions, a two man crew can apply about 2.5 tank loads per hour using a 425 gallon mahcine and an auxiliary water tank and garden hoses for the water supply.

Application Costs Per Tank Load is $50.00

Application Costs Per Square Foot is $2.30

Application Costs Per Acre is $1,000.00

Summary of Contractor's Total Applications Costs

Total Cost Per Tank Load is $208.39

Total Cost Per Square Foot is $9.57

Total Cost Per Acre is $4,167.80

Analysis of the Effectiveness of the Application

This Bonded Fiber Matrix application provides extraordinary mulch protection. The probability of this application yielding a perfect stand of grass approaches 100%. Note that regular watering during hot and dry periods is absolutely necessary. During cooler times, some watering will still be required. This application will stand up to significant rainfall. It will wash out if placed in the bottom of a ditch with flowing water. Solid sodding, staked to the ground is probably the best treatment for the bottom of a ditch with flowing water.

First, the Paradigm: Today, most "hydro-seeding" contractors just blow and go. It's just the way it is done. The thinner mulch the better. The reason for this is that contractors are constantly being challenged to do jobs cheaper. The easiest way for a contractor to lower costs is to use cheaper mulch and spread it on the ground thinner. Buyers seldom know, or even care what kind of mulch application is needed. When a well meaning contractor tries to explain about better mulch for better results, the buyer frequently turns away because of the higher price. The focus is on price, not on results.

Secondly, the Contractor: The well meaning contractor may even run into resistance from other contractors in a pre-bid conference. Frequently contractors don't want to change the way they normally work. Also, some contractors resist better specifications because their machinery is less capable of handling thicker slurries of higher quality mulches. Some contractors just don't consider that growing grass is more important than painting the ground green.
A good mulch application and frequent watering are absolutely essential for sod quality results. After loading TurfMaker® with mulch and completing hose application, the following case study illustrates the results of the application. The photograph above shows that the color of the mulch has faded 6 days after application. Watering is reduced to twice a day on day 9, and in twelve days, grass is showing color.

Thirdly, the Specifier: For whatever reason, specifiers sometimes do not write good mulch specifications. And sometimes, the best mulch specifications are circumvented by a clever contractor seeking a cost advantage.

Fourth, the Inspector: In some cases there is not an inspector,particularly on a private industrial site or landscape site. On highway jobs, inspectors frequently have other parts of the project to keep up with, so when the inspector is away, the contractor can easily stretch his loads, and use less mulch. And even with the most attentive inspector, the clever contractor may be able to beat the system.

Writing Specifications:
In 15 days, the grass is continuing to develop. Watering is reduced to once a day on day 18.

Specifiers can save their clients substantial amounts of money for the grass planting part of any project. But writing premium hydro-mulching specifications is not easy. In the article, Three Ways to Plant an Acre with a 425 Gallon Hydro-Mulching Machine, it seems that the easiest and safest way to write good specifications is to stick with the Bonded Fiber Matrix approach. There are two wood fiber BFM producers in the U.S., and one in Canada. All three of these companies are well represented in the U.S., and have high performance, highly reliable products.

Getting the Job Done According to the Specifications:
In 21 days, the grass is full and beautiful (below). Hydro-Mulching can provide a premium lawn for less than the cost of sod.

The second, and greater challenge is getting the job done according to the written specifications. Again, a paradigm shift is needed. The basis on which a contractor is paid needs a fresh approach.

When the contractor is paid, based on the square footage covered, the contractor has an incentive to "stretch" the tank load. The more area covered with a each tank load, the thinner the mulch and the lower the costs. Without a good mulch treatment, good seed can be washed away, or not have sufficient moisture for initial germination. Somehow, a good mulch application must be assured. One way to get the mulch applied as specified is to pay the contractor based on the quantity of mulch actually applied, not for the square footage covered.

Cost Analysis: Utilizing 15.0 Tank

Hydro-Mulching an Acre with 15.0 Tank Loads using 425 Gallon Hydro-Mulching Machine.

(Coverage per Tank Load: Approximately 2,904 Sq. Ft. Wood Mulch with Tackifier at 2,700 lbs per acre.)

Approximate Contractor Materials Cost

Materials Used Per Tank Load:

3 bags (60 lbs each) Wood Mulch w/tack at $17.00 per bag, 180 lbs costs $51.00

Seed costs used for this example: $5.00 per 1,000 square feet is $14.52

1 bag (50 lbs each) 17-17-17 Fertilizer at $7.50 per bag, 50 lbs costs $7.50

1.5 lbs of tackifier at $8.00 per lb. (Premium PAM tack and soil conditioner) costs $12.00

Materials Cost Per Tank Load is $85.02

Materials Cost Per Square Foot is $2.93

Materials Cost Per Acre is $1,275.30

Approximate Contractor Applications Costs

The following assumptions were made regarding contractor operations costs:

1. The overall costs for the machine, truck, and crew is assumed to be about $125.00 per hour. These costs include overhead burden and payroll related expenses.

2. Under good operating conditions, a two man crew can apply about 2.5 tank loads per hour using a 425 gallon machine and an auxiliary water tank and garden hoses for the water supply.

Application Costs Per Tank Load are $50.00

Application Costs Per Square Foot are $1.72

Application Costs Per Acre are $750.00

Summary of Contractor's Total Applications Costs

Total Cost Per Tank Load is $135.02

Total Cost Per Square Foot is $4.65

Total Cost Per Acre is $2,025.30

Analysis of the Effectiveness of the Application

This mulching application provides good mulch protection. The probability of this application making a good stand of grass requires attentive watering during hot and dry periods. During cooler times, less watering will be required. This application will resist erosion during moderate rainfall.

A typical specification calls for mulch, seed, fertilizer, and tackifier to be applied on a per acre or per square foot basis. Each tank load will only hold so much mulch and also contains a measured amount of the other ingredients. The quantity of these other ingredients must correspond to the area that is to be covered with the tank load containing a given amount of mulch. Ultimately, each tank load should be applied to a specific sized area.

Since the mulch is the limiting factor, the contractor can be paid, based on the amount of mulch applied. With this payment method, the contractor actually has an incentive to apply the slurried materials at heavier rates.

Cost Analysis: Utilizing 7.0 Tank

Hydro-Mulching an Acre with 7.0 Tank Loads using a 425 Gallon Hydro-Mulching Machine

(Coverage per Tank Load: Approximately 6,223 Sq. Ft. with recycled paper mulch at 1,750 lbs per acre.)

Approximate Contractor Materials Cost

Materials Used Per Tank Load:

5 bags (50 lbs each) recycled paper mulch at $6.50 per bag, 250 lbs costs $32.50

Seed cost used for this example: $5.00 per 1,000 square feet costs $31.11

2 bags (40 lbs each) 17-17-17 fertilizer at $7.50 per bag, 80 lbs costs $15.00

2 lbs of tackifier at $8.00 per lb. (Premium PAM tack and soil conditioner) costs $16.00

Materials Cost Per Tank Load is $94.61

Materials Cost Per Square Foot is $1.52

Materials Cost Per Acre is $662.30

Approximate Contractor Application Costs

The following assumptions were made regarding contractor operations costs:

1. The overall costs for the machine, truck, and crew is assumed to be about $125 per hour. These costs include overhead burden and payroll related expenses.

2. Under good operating conditions, a two man crew can apply about 2.5 tank loads per hour using a 425 gallon machine and an auxiliary water tank and garden hoses for the water supply.

Application Costs Per Tank Load is $50.00

Application Costs Per Square Foot is $0.80

Application Costs Per Acre is $350.00

Summary of Contractor's Total Applications Costs

Total Cost Per Tank Load is $144.61

Total Cost Per Square Foot is $2.32

Total Cost Per Acre is $1,012.30

Analysis of the Effectiveness of the Application

This is a low cost method of distributing seed with some mulch. The probability of this application yielding a nice stand of grass is heavily reliant upon attentive care and watering. While the erosion control additive will reduce erosion during heavy rains, some erosion is highly likely.

This payment method also solves other problems. Job size is seldom what was originally thought or planned. Also, good and experienced contractors know that hydro-mulching applications need to be heavier in some places, and lighter in others. Thirdly, there are frequently additional areas needing to be hydro-mulched which were not originally included in the specifications. This payment agreement solves all those problems.
A good mulch application with dual tackifier costs about $2,000 an acre. This type of application details a better than average mulch application. Since less area is covered with each tank load of slurry, the thickness of mulch application will require 15 tank loads of application with a 425-gallon hydro-mulching machine.

Another way to get the job done as specified, is for the property owner to actually purchase the materials to be used on the site, and pay the contractor for the services of applying the materials, again, based on the amount of mulch applied.

Tips of the Trade:

Three Ways to Plant an Acre with a 425 Gallon Hydro-Mulching Machine (Mulch Quality and Quantity Makes the Difference in Costs and Reliability)

The following section details different ways to apply mulch, seed, fertilizer, and tackifiers to one acre with a 425 gallon hydro-mulching machine. The amount of seed and fertilizer applied to the acre remains the same for each of the three scenarios. The only thing that changes is the quantity and quality of the mulch, and the addition of tackifiers.

These three examples provide insight as to how differently a job can be done, and how the cost of doing the job is dramatically affected by the mulch application. Note the increase in application time and costs when more mulch is applied because it takes more tank loads to apply more mulch! In each case, it is assume that an experienced two-man crew is operating the machinery.

Overview, Scenario 1: A Less Effective Mulch Application, Costing about $1,000 per Acre.

This scenario describes an inexpensive application requiring a total of 7 tank loads of application. This job can be done from start to finish in about 3 hours. This less effective mulch application is common on highway jobs. It is not too likely that this application will yield a perfect stand of grass suitable for a golf course, a home lawn, or some other area demanding turf quality grass.

Overview, Scenario 2: A Good Mulch Application with Dual Tackifier, Costing about $2,000 per Acre.

This application details a better than average mulch application. Since less area is covered with each tank load of slurry, the thickness-of-mulch application will require 15 tank loads of application with the 425 gallon hydro-mulching machine. The thicker wood fiber mulch application will provide significant protection from the hot sun. Along with the extra tackifier, this application will also resist erosion caused by heavy rains.

This is the kind of application that can be used in landscape applications when Sod Quality Results are needed, but where budget constraints preclude the use of Bonded Fiber Matrix products. This application will take about 6 hours.

Overview, Scenario 3: Wood Based Bonded Fiber Matrix, Costing over $4,000 per Acre.

This application details the use of a premium product that demands a premium price. This Bonded Fiber Matrix application will provide significant protection from the hot sun, and resist the threat of erosion caused by heavy rains or other excessive water. The only difference in the results of this grass growing approach and solid sodding is that it will take a few weeks of grow-in time. With appropriate irrigation, this Bonded Fiber Matrix application will yield a perfect stand of grass 99% of the time. This application will require 20 tank loads of slurry, and will take about 8 hours to complete.

In the real world, some contractors will resist this approach. They will feel as though their "secret world of costs" has been invaded. However, if a contractor is paid for "services rendered", instead of how many square feet are covered, each of the contractors are put on the same playing field. The most efficient contractor will be able to provide the services for the least costs. Another contractor will not be rewarded for "stretching the tank loads". This is a simple and effective solution to the problem because mulch is the limiting factor. All the other ingredients are mixed in each tank load at a specified quantity, based on the area to be covered with each tank. The area covered with each tank load is determined by the amount of mulch in each tank.

Note: It would not be appropriate to pay for gallons applied. No two contractors or machines are likely to mix and apply the same mulch/water ratio. And contractors frequently have a quantity of mulch they are accustomed to loading into each tank load. Those quantities are not necessarily the same for two contractors using equivalent machines.

Summary and Conclusions:

Sod Quality Results can occur nearly every time with premium hydro-mulching applications. Specifying a wood fiber Bonded Fiber Matrix is the easiest way to define the mulch product. If the specifier is truly knowledgeable about mulches and tackifiers, then a somewhat lower cost materials specification might be appropriate. With a successful specification and compliance the resulting grass will cost substantially less than solid sod.

 Bonded Fiber Matrix application provides extraordinary mulch protection. The probability of this application yielding a perfect stand of grass approaches 100 percent. Regular watering during hot and dry periods is absolutely necessary. It will wash out if placed in the bottom of a ditch with flowing water. Solid sodding staked to the ground is the best treatment for a ditch with flowing water. Hydro-mulching will also help in erosion control efforts, as seen in this sequence of pictures (top, left, bottom).

No one can loose site of the fact that to enjoy these costs savings, contractors and specifiers must disregard the old "hydro-seeding" thinking, and think in terms of premium hydro-mulching applications. As with changes of any kind, such changes in thinking face resistance. In the new millennium, new ways of doing things do, in fact, come to the world of planting grass. LCM

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