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Thread: Shed build
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3rd November 2016, 09:42 PM #1Senior Member
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Shed build
Starting on a 7.3 x4.8m RHS portal framed shed. 8 Columns in 75x75x3 mm RHS, girts in RHS. Concrete slab plus footings.
Footplates (150x150x12mm) for the 8 columns and an additional 8 mounting plates (150x150x8mm) were laser cut Monday. All plates have x4 14mm lasercut holes per plate. The mounting plates will be embedded in the slab, levelled and positioned prior to the slab pour. This will avoid having to work around the foundation bolts during the pour. Could be styrene plugged but the mount plates will help the bolt location. All 16 plates were cut for a total $175.
Foundation bolts are fabricated from M12 threaded rod, and are to be caged and initially located in the footings with 100mm of premix. The 4 bolts per footing will be positioned by a mounting plate. The mounting plate heights are adjusted by nuts under the plates. While the slab surface should be levelled to the same height as the top of the mounting plates, any subsequent adjustments can be made by simple shims on top, or if one gets keen and makes up some foam plugs/pads to cover the lower nuts and threads for 50mm or so, adjusting the nuts under the plates. The caged foundation bolts will be aligned laterally, longitudinally and diagonally checked and wired into the reo mesh.
Dug the pad out more than a year ago with the help of a mate (thanks Vince), re-dug the accumulated undergrowth and levelled off earlier this week. Laser level suggests within 5mm, good enough for initial surface. This will be covered by compacted road base and Fortecon.
Bought the M12 gala Threaded Rod yesterday, as 3m lengths (x11) for $5.44 per 3m from building supplies. This compared to c. $9.50 per 1.2m length from the conglomerate barn; so $59.86 (30m) vs 25 x 1.2 for $248 ( for same total length). Cut the allthread into 1m lengths and will bend the ends on the weekend, and weld cut lengths rod of reinforcing rod to the allthread to box cage the foundation bolts.
The Box of x200 M12 galv nuts from the building supplies cost $15 compared to $45 per bx50 from the conglomerate barn; i.e. $15 vs $180. Similar with washers.
Dug the initial footings today with a 2 man auger ( 300mm x 600mm) with the help of my cousin (thanks Tony). Will be manually digging these out to 450x450x600 in the next few days.
House has 3 phase, and this will be supplied to shed, for a 7.5hp 30 CFM Ross upright air compressor, a CIG Transpak 225 MIG welder, and a MEP Cold saw. Doing the trench tomorrow if we can get the trencher down the side of the house; quite limited access.
So far so good with plan A.
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5th November 2016, 11:46 AM #2Senior Member
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Got the trenching (mostly) done yesterday. Hired the smallest trencher I could find, managed to get it down the side of the house (no driveway access). The alternate was through the house, which would definitely fit.
Services trench for power and data dug to 600mm. Due to the chain coming off 4 times, and the starter pull cord disembowelling twice, didn't get to finish the difficult bit down the slope through the garden bed. A manual job digging it will have to be.
Dug a drainage trench under the uphill side of the slab, will go to a sump downhill. Have to widen it today, and pick up river sand.
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5th November 2016, 01:37 PM #3GOLD MEMBER
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Have pulled a chair up to watch this one.
Ross
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6th November 2016, 06:07 PM #4Senior Member
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Saturday spent manually digging out the ag pipe trend under the pad. The trencher slot to 400mm is getting widened to c. 250mm for 80mm Ag pipe. Picked up a half cubic meter of 14mm aggregate (the sand was way too variable in grain size) for the Ag pipe trench. 2/3 the way there. Much easier digging out once one can actually stand in the trench itself, rather than on top of it.
Made a welding jig for caging the allthread this morning out of offcuts, rebated the 2 location boards into the mounting board to locate them square ( handy Festool Kapex trenching cuts).
Cleaned up the ends of the 32 lengths of all thread, and the 64 lengths of reinforcing bar.
Bent the lengths of allthread, setup a initial set, bit short, adjusted the bender and and absolutely fluked the leg length, such that installed in the jig the 4 ends just sat together to make for an easy tack without having to otherwise fix or clamp the ends. Bonus!
Once the ends were welded, the assembly slide easily enough back and forth in the jig.
Welded in the first 4 piece cage 250mm from the bottom end, slide assembly along, second cage at another 250mm.
Result: 8 caged foundation bolts.
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6th November 2016, 06:09 PM #5Senior Member
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more pics. Can you pick the 'prototype' ?
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6th November 2016, 11:35 PM #6
watching this thread, i see that the standard welding clober is in use. just asking did you have thongs on
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7th November 2016, 09:23 AM #7Senior Member
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the chinese safety shoes? no! The absence of a leftie was felt by the end of the session. Not me doing the welding in this instance btw.
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7th November 2016, 11:56 AM #8
Pulling up a chair to watch the progress.
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8th November 2016, 07:29 PM #9Senior Member
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Got the drainage trench finished yesterday. Manually dug out the initial 8m trencher channel, in clay and rock no fun at all. 65mm slotted ag pipe in aggregate, bit of a gradient, aggregate cover and a bit of backfill.
Knocked up some forms this morning for the footings ( 450x450mm). Nails on the cross brace centres worked well for roughing the major diagonals (8612) within a few mm, The day spent squaring out the footings and borrowing the spoil to a skip at the front of the house; c.65m), 40 barrow loads, c. 4 ton (tonne?).
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12th November 2016, 12:09 PM #10Senior Member
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Setup was scheduled to be Thursday and pour Friday, rescheduled to setup Friday and pour Monday due to un-availability of the required pump. This was good news as Friday was going to be 33 degC.
Wednesday spent final sizing the foundations. The night before it seemed like it might make it easier to fill the holes with water, to soften up the concrete like clay walls a little, expecting the water to percolate away overnight. After filling three it was obvious the water level was not going down even very slowly, so abandoned that idea, and scooped it all out the following morning. The clay walls of the three were readily scrap-able though, kind of the consistency of firm cheese.
Thursday the concreter arrived and laid up new string lines, barrowed in the base material and made all level. We laid up the caged foundation bolt assemblies, with some concrete mix and positioned, plumbed, squared up, and checked diagonals (to better than 2mm). All good, called it a day.
I got called away to get a cousin's Kombi started (flat battery, RAA membership had expired 3 weeks ago, they wanted $300 plus callout). Then the 33 degree day turned into bucketing rain and hail. When I got back the foundations had 400mm or so of water in each, run-off from the pad. More up/down/knee time bucketing without disturbing the laid up foundation bolts.
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14th November 2016, 05:51 PM #11Senior Member
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slab pour
Concreters arrived at 7 this morning, Forticon laid, formwork brought in, placed and laser levelled, mesh carried in and laid up on chairs and wired.
Foundation bolt plate heights set to the laser, set flat in 2 directions to ≤ c. 0.2 degree using a Stabila electronic level I bought half price on the weekend; 1 degree off horizontal equates to 52mm out of plumb at the top of the 3m columns.
Pump and concrete truck arrived on time, pipe setup and pour finished in about an hour an half.
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14th November 2016, 05:52 PM #12Senior Member
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Manually levelling and initial finishing, plus a slight fall off gradient about 150-200mm wide troweled around the perimeter.
Then the rest of the day spent with multiple Power Trowel (concrete helicopter) circuits across the surface, about 10 in all. Initial 'pizza plate' passes followed by blades. A very smooth surface result. (certainly good enough to polish if one was so inclined).
Great job by the concreters.
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18th November 2016, 09:02 PM #13Senior Member
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trench cabling
Spent a couple of hours yesterday getting the last of the water out of the trench under the lawn stretch, which had been there since last Friday (i.e. 7 days) since the storm. Basically digging out a a gradient along the length of the trench to the top of the drop t the paving, in order to get a flow happening. Clay soil!
Sparkie set up the conduit and we pulled the 4 core 10 sq.mm, 3 phase cable through. There will be a junction box on the wall and a run form the fuse box through the roof space and down the wall cavity.
A bit of electric jack hammering to bible the foundation margins and get under the wall cavity to pull a draw cord for and the cable run from the roof space.
I had half a spool of Cat6 ethernet cable, and the was run through conduit up the cavity.
Supply run from fuse box and terminations and connections a job for next week.
Note the 4 core cable is dated.
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18th November 2016, 11:29 PM #14Senior Member
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23rd November 2016, 09:36 PM #15Senior Member
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Buried the cabling conduit with fine crush and backfill. Sparkie back to run the 3 phase cable through the roof and wall cavities, junction done at back of house and connections made in main fuse box. Just waiting for a plug to terminate the shed end, and give power to the Mig welder. There was already 3 phase supply into the fuse box for the air conditioner.
Cut off the copper pipe going to the irrigation system solenoids, which resided under some plants. Relocating to the side wall. Cut the pipe with a Rigid pipe cutter I use for brake lines and used my trusty Metabo variable speed die grinder and a nylon rotary brush to clean up the pipe crud. Blue stripe 20mm PE pipe and compression fitting, new valve and dug out a few more pavers to run the hose under the retaining sleeper. Low voltage control cable cable is a bit short so will have to splice...
Plan is to add a junction to the blue stripe at the solenoid manifold, and run a line down the side fence and across to the shed. Will have a sink and tap on the side corner (outside, no use occupying valuable floor space).
Dug out a spare Tough morticer (one of 4 Tough drill presses) I had bought a year or so ago for parts, thought it would make a good vice for clamping the RHS columns for drilling. Bit of a frankenstein; the angle iron base came with one of the others, filled with a layer of concrete, bloody heavy, so is the sliding table. Have decided to weld end plates to the front and rear wall girts and centre bay girts and bolt these in, should make squaring up the bays that much easier . Will be more obvious once going up.
Ordered the columns and girt material today, should arrive tomorrow: 4 x 8m 75x75x3, 10 x 8m 65x35x3, and 6m of 50x5 flat bar. 563 kg in all and $1228 (plus freight to be determined). Will leave the mezzanine RHS for another delivery.
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