Thread: Dave's Workshop Build

Build Was complete by a small local business and they were fantanstic throughout the whole process.

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The builders were nice enough to let me borrow the sissor lift to run some initial cabling down the roof/across the far side. Was a couple of late nights to get it done.

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Basic Electrical Fitotu plan, is to have 5 double GPOs per sections along both the 24m long walls. These will be split into 6 circuits creating 2 bays per circuit.
Along the Long wall that have the drive through roller doors, the Plan is to setup the metal working and electironics stations, metal work having a few 15A outlets to cover welder.

The far corner of the shed will have some 3phase installed for Air compressor, cnc dust extractions, cnc vacuum pump which will all eventually be homed in an outside leantoo off the main shed

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Went with a chasis board as the sub board for the shed, more than likely i'l have another board setup for the RCDs for the 3phase units

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Low Bay lights x3 will make up the general lighting, there will be more lighting over the top of work areas setup for what the areas are for. Its only 3 low bays and not 4 as the 4th area will have a Mez built

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And lastly the datacabniet that will go un in the room on the mez and act as the hub for the shed and house.

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So the shed construction was finished Feb 21, so next on the list was to get some insulation and a bucket load of yellow tounge to start lining the walls and insulation.
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Here I made a mistake which makes it more painful to finish this stage than it should be. I worked out that a I could cut a part sheet at the bottom and a full sheet would perfectly. This seemed like a good plan, until you try and solo lift a full sheet 1.3m above the ground vertically. Then you realise who was an idiot while doing this.

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When I started the other side of the shed, i went the other path. I used a full sheet 1st leaving a smaller to lift peice to fill in the top section, this turned out to be a much better idea as the later photos show.

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Progress thus far takes us through to the start of Nov 21 which is where my old man gave me a hand to put up the mez floor framework.

The mez is a 9x5 floor space, that once complete will hold 1 sewing room/office space as well as some storage space for at the end. Ultimately I want to have pallet racking at the far end all the way up to the roof to cover more storage and access from the mez floor.

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After we got the frame up my partner was helping cut and measure the flooring for up there and we floored out most of the mez bar the side with stairs, as the stairs haven't been installed as of yet.

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Once we had the bulk cut and dry fitted, we pulled them all apart again and sikaflexed and screwed them all down

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Not even the next day after putting the floor down the mrs tidied up down stair and moved most of her stuff up there to clear the way to continue walling

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By the look of the gear up on the mezzanine you may need to extend that sooner than later.

And from there the wall lining continued, by this stage I had gotten into a rhythm of solo putting up full sheets

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and this is where the full sheet at the bottom paid off, i was able to easily do the top section straight off a ladder, it may not of been 100% OHS but hey we all push the bounds when its at home.

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Next up I picked up a airless sprayer, for anyone that hasn't used one, BEST THING EVER. I got 1st coat of undercoat done on the 1st for bay sections in 45min.

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Trip to the Paint store for more undercoat and the rest was done that afternoon

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2nd coat on half and I ran out of paint again

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and that about brings us into today,
This swing back home, I got up the 1st ceiling bay with batterns and insulation, and got the window area lined.

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This is what will become the ceiling panels, I have 50mm Insulated sandwich panels.

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Started Preping to put the 1st one up this afternoon, but they are bit too awkward to be able to do solo, and I need to order more insulatation to finish installing batterns and insulating the roof.

A big project but you will enjoy the end result. I did the ground floor of mine (two story) in Besser blocks and it was a mission I never want to repeat. Mrs P has the ground floor for sewing and I have the top floor both of which are 9.5 x 7. It took me about three years to build all up as in those days the small machines did not exist and we had to dig the hole by hand which took a year just for that.

Thank you so much for the build photos and run down. Nice RAM by the way. There are so many questions I'd like to ask.
I also initially wanted besser block lower walls to make a cooler space. But everything is geared for steel sheds and so they are much cheaper. I soon gave up on that idea and like you I'm trying to get the largest steel shed I can afford. Still trying, but I remain hopeful I can get a similar, but slightly smaller one like yours.

Please tell me about your mezzanine steel frame. Where did you get that from and are you happy with it? What is the height of the frame work excluding the yellow tongue? Is it 150mm? How did you get that frame up? Did you pay someone to erect that?
My shed builder estimates a 10 x 4.5 steel frame would end up about $4,000 including erection. He suggested I'd be better off building from timber. Which was plan A anyway.

Originally Posted by DaveVman

Please tell me about your mezzanine steel frame. Where did you get that from and are you happy with it? What is the height of the frame work excluding the yellow tongue? Is it 150mm? How did you get that frame up? Did you pay someone to erect that?
My shed builder estimates a 10 x 4.5 steel frame would end up about $4,000 including erection. He suggested I'd be better off building from timber. Which was plan A anyway.

Mez is Steel-Deck (Bunnings) Mez/Deck Kit (Home - Steel-Deck – DIY Steel Decks)
100% my old man and me built.
It's a 9x5 size as 5m was the largest single span available wihtout needing a mid post on the width.
It was $6,200 for the Posts/Bolt down bottoms and tops and the all the framing/screws including engineering cert for 400kg/m load rating.
It took the 2 of us 2 days to errect.
We got the 1st half up shown here, by clamping the posts to the shed uprights then using 2 ladders to walk up the main bearer in its 2 halves. We then put in the other posts in their locations leveled and bolted off.
You can see in this pic below one of hte posts on the left is still clamped to the main shed post the head faced backward so the bearer couldn't fall off.
you can see the 2nd half of the bearer just on the floor ready to lift up with all of the joist brackets attached.


Everything is tek screwed together as part of the kit and bolted down to the slab.

When we did the 2nd end was a little harder, we started by lifting up the back joist that runs across the wall and leveled that off and screwed to the 1st bearer, that gave us the location for the corner post on that end, from there you can see in the picture below we used the big ladder on the left to rig up a chain block of the main shed frame and used to lift the fully assembled bearer with joist brackets as a single peice.
We end put a laser level across the frame to line up the closest corner height and bolted down the post and screwed in the top hat and checked for square.

The shed itself is slightly out of sqaure with the end frame on the short wall to the long wall, so when we squaring up the mez floor we deliberately pulled that corner out so that we could hard attach those 2 sides to the existing stucture as well as the posts.

the rest of the joists we just used ladders at each end and we walked up each joist. Using the laser across the top to set the heights we clamped them in place then screwed off. The end product is decent quality within the laser line of level across the platform. The Yellow Tongue just slid across the top when pushing the sheets up.



The Stairs are still to come, I just took a measurement to the top of the yellow tongue and gave that to early bird steels and they fabed me up a set of bolt down stair stringers, so I just need to make a couple of posts to support the stair platform and then bolt all that together. But the ceiling is my current priotity so i can put up the walls on the mez for the sewing/office space.

Sorry, Bearer and Joint Height for mine is 235mm to cover the unsupported span, I think you can get it cheaper with the smaller 185mm on a shorter span.

Here is the 1st ceiling sheet on, only temporarily screwed atm, as i'm still waiting for the surfmist teks to arrive.

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Thank you so much for your reply. I really was wondering how you erected that by yourself!
Will the bolted/screwed brackets require any maintenance? I mean can they eventually come loose?

So in fact, approx $4,000 for 4.5 x 10m steel frame, erected, would be a good deal? SE QLD.
I guess it is a lot cheaper to have built as part of the shed build.
My bearers would be 10m (supported span) and the joists would be 4.5m (unsupported span if placed in-line).

It has to be 10m long if I get the shed company to supply it. If I build it myself from timber it can be whatever width I want x 7m. So less material. Well actually that is not strictly true. The shed company will make it only 7m long if I pay $500 for the custom engineering.
This matters because if it spans the whole 10m then I can't have a rear roller door. I have to replace that roller with an aluminum glass door. The idea of the rear roller door was to allow a cross air flow through the shed. Like you have done. If it is only 7m long then I can keep the roller door.

I was thinking I'd knock up this in timber with guess work, but now I'm thinking I really need an engineer to tell me what size bearers and joists to use. So my current guess is I may only save $1,000 - if that - if I DIY in timber. Plus I would still have to erect 7m long beams by myself! But the steel can be made in-line. This is really important because I don't actually have enough height for a real mezzanine if I go with 3.5m shed walls.

For example, 150mm timber joists on 250mm LVL beams = 400mm. vs 235mm for your inline steel frame. 165mm less, and probably stronger.

I realise I could in theory build a timber floor in-line but I am not confident about that with 4.5m unsupported joists. I think if I go with DIY timber option, I need to have a middle beam so that the joists are supported in the middle.

Did your council give you hassles about the mezzanine and the stairs? Or is this a "large storage shelf" that you built after final council sign-off? Asking for a friend.

Didn't get a huge amount done this swing back,

Insulation is very hard to get a hold of atm, and i need a bucket load for the ceiling. I've had 3 places cancel ordered on me so far, and 1 more email to say they can't supply and have no eta on filling the order.
So not a lot of progress on the ceiling.
So, i've been finishing off the drive through side walls, with the insulation I still have here and more yellow tongue.
I got 3 bays completed and I have 3 bays left to do, unfortunately only enough yellow tongue to complete 1 more so need to order more sheets for that as well as try and source some insulation.

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Next swing back I'll try and get some of the ceiling batterns up and with any luck get a few more bags of insulation to start getting some of the bays ready for the sandwich panel