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  1. #1
    Join Date
    Mar 2012
    Location
    Western NSW
    Posts
    518

    Default My New Shed project

    My plan is to start a new thread and document the building of my new workshop. This is a significant job but hopefully will be completed in the next year or so.

    It will be 12m x 24m and custom built to house some of my bigger precision machines. Individual foundations will be built for the jig borer and slideway grinder.
    The main issue will be the 5 tonne travelling overhead gantry that will also be installed. This has required a major upgrade to the plans and most of the local shed builders are hiding if they see me coming. Finally came to an arrangement with one that I will do the foundations/cement floor/posts/gantry running beam/install the gantry and he will do the rest (basically roof and walls). No one wants the responsibility of installing the crane without fully certified plans and structural engineering oversight. Given the cost of that is close to 50% of the shed projected cost and it will be on a farm and I will be the only one working there I have decided to construct it myself. Always liked a challenge!!
    So the last 6-12 months have been about cleaning up the site, collecting information, getting advice, chasing up suitable materials and tools and now it is time to start.

    Will try and post something every couple of weeks and document each aspect of the build.
    Here are some photos of the site and some steel (310 UC 158)that I will use for the shed posts.
    More soon

    Cheers

    Mark

    2016-01-01 17.50.04.jpg2016-02-02 14.56.02.jpg2016-02-02 14.56.35.jpg

  2. #2
    Join Date
    Jul 2010
    Location
    Melbourne
    Posts
    8,685

    Default

    Hi Mark

    Looking forward to watching the build. That's going to be one pretty special shed.

    Stuart

  3. #3
    Join Date
    Oct 2008
    Location
    N.W.Tasmania
    Posts
    1,218

    Default

    That looks really good Mark, I take it that the gantry will hang off those posts, not just the shed itself.
    I once had the experience of the local company who had taken over local council building DAs, site inspections etc from the council, wanted me to have a set of plans re certified by a structural engineer for a shed I put in a tender for. The plans had been drawn up in the 1970s by a long established Hobart engineering firm who probably had the capacity to build Sydney Harbour Bridge, but in the case of the shed in question, had a design using structural steel profiles, channel, angle and UB sections for a skillion shed 18mx11mx4.8 to the high end of the roof. It was a 4 bay shed with a mezzanine on one end in 1 bay. I said "you are looking at the plans, drawn up by P&S", and she replied that they would have certainly complied with all regs when drawn, but that was 30+years ago. I said that the bloody shed is framed in structural steel, not 'c' section, and she grunted and asked if I had a demolition permit to dismantle it, so I concluded that all she was after was as much of my meagre pickings as she could get from my hip pocket. Sadly my tender was not successful, so nothing came of it but as I too live in a rural area with just over 5 Ha, I pretty well decided that when the time comes, I will probably just build my shed, or re-errect a second hand one, without troubling the council or any of their hangers on either. I will document with photos and notes any parts not readily examined later, (like reo in the slab for example) and hope for the best.
    I like the idea that you are installing a gantry crane, with the machines that you have, and the likely size of some of the workpieces you might need to handle, a gantry will be a really useful addition. Best of luck with your build,
    RT

  4. #4
    Join Date
    Sep 2011
    Location
    Emerald Central Qld
    Posts
    348

    Default

    I have been following bcbloc02's barn conversion and he has done all of the work himself , very impressed.
    I doubt that the nanny state here would be as equally impressed .

    I have found that because the council inspectors cant picture how it will look or be done the do everything possible to stop you.

    Michael

  5. #5
    Join Date
    Aug 2008
    Location
    near Rockhampton
    Posts
    6,000

    Default

    Quote Originally Posted by Mike4 View Post

    I have found that because the council inspectors cant picture how it will look or be done the do everything possible to stop you.

    Michael
    Depends where you are I guess. Where I am we are free to build whatever shed I like with no official oversight provided it is more then 200m from a road and for rural use only.

    In reality you can do what you like, build a shed house etc and the council will probably not worry unless they are notified it is happening or receive a complaint.

    Shed building is not rocket science, gantry cranes a bit different though
    Gold, the colour of choice for the discerning person.

  6. #6
    Join Date
    Feb 2003
    Location
    formerly from Sydney (north of The Harbour), NSW, Oz
    Age
    65
    Posts
    299

    Default

    Hi Mark

    I've been following your other thread about designing for the gantry crane and am impressed by your resourcefulness.

    Can I just mention that the loads on a crane running beam (and the support columns) are complex, which is why typical gantry crane posts and running girders are so heavy.
    In essence, design needs to allow for
    1. the load being lifted being off set from directly under the crane winch -- this will tend to pull the gantry (and running beam and posts) inwards on one side and push it outwards on on the other. It will also try to twist the running beam.
    2. starting and stopping the gantry tends to put largish horizontal forces on the running beam that get transferred to the shed posts where the beam attaches -- these forces are trying to bend the posts in line with the long axis of the shed.
    3. moving the crane traveler along the gantry imposes push and pull forces on the running beam that are at 90 degrees to the direction of the beam,
    4. the gantry itself is rarely square to the running beam, more typically it moves along its rails crabwise.

    For these and other reasons, the steel supporting a crane is much heavier than would otherwise be the case, and the normal deflection criteria (deflection to span length) is much more stringent.

    With your second hand steel, please check for defects (eg ripples) in the flanges and be aware any Chinese steel that failed Aust specification testing has likely ended up in the scrap yard looking like more than useable steel.


    good luck with the shed build

    and please don't have your crane drop on you
    regards from Canmore

    ian

  7. #7
    Join Date
    Oct 2006
    Location
    Armidale NSW
    Age
    49
    Posts
    915

    Default

    Quote Originally Posted by .RC. View Post
    In reality you can do what you like, build a shed house etc and the council will probably not worry unless they are notified it is happening or receive a complaint.
    ... or possibly if you want to sell and the buyer determines that it's unapproved.
    Cheers.

    Vernon.
    __________________________________________________
    Bite off more than you can chew and then chew like crazy.

  8. #8
    Join Date
    Jun 2008
    Location
    The Whitsundays
    Posts
    228

    Default

    Hi Mark,

    Interesting project.

    My 2c here is to watch the power lines during construction, you have a service line that appears to go through the construction site (could be wrong on that?) and a set of low voltage mains running parallel with the shed, and also a high voltage Single Wire Earth Return (SWER) line above that. Minimum clearances from those lines is mandated at state level so I cant give you an exact distance for closest approach. That also varies depending on the qualifications of machinery operators and their safety observer, the voltage on the lines and the integrity of the insulation (for low voltage).

    My site was almost exactly the same electrical layout, minus the SWER line. It can make playing with cranes during construction difficult, not supposed to lift over live wires nor encroach clearance limits. Likewise actually playing with metallic roof and wall cladding. I got round the issues by building part of the shed and then relocating the service to the new shed with new underground sub mains to the house. I do have all the authorisations for this, however I am also quite particular about it, having an incident on your own site when you are supposed to be able to police this stuff for the general public goes way beyond merely embarrassing.

    If you have not thought of this already, perhaps speak to an electrician about relocating the service to the shed onto a property pole and running new mains to the existing structure? Getting the service out of the way early will make life much easier and is something that you will have to do anyway (at least from the first photo?)

    I'm looking forward to seeing how the shed progresses.

    Cheers

    The Beryl Bloke
    Equipment er.... Projects I own

    Lathes - Sherline 4410 CNC
    Mills - Deckel FP2LB, Hardinge TM-UM, Sherline 2000 CNC.

  9. #9
    Join Date
    Aug 2008
    Location
    near Rockhampton
    Posts
    6,000

    Default

    Quote Originally Posted by Vernonv View Post
    ... or possibly if you want to sell and the buyer determines that it's unapproved.
    Nah, they are just fancy sheds then. with a few "clean rooms"
    Gold, the colour of choice for the discerning person.

  10. #10
    Join Date
    Mar 2012
    Location
    Western NSW
    Posts
    518

    Default

    So got a spare day this week. Quick compaction of the ground then hurdles erected and slab strung out. Used a laser level to level the top of the hurdle beam with the top of the slab height. So easy compared to using the old theodolite. Rather big fall from one end to the other of 600mm! Will make digging out the foundations for the jig borer and slideway grinder a bit easier though.
    Now waiting for the excavator to dig some foundation holes and some trenching for water pipes. Wondering if 75t of road base and blue metal dust will be enough.

    Might have a line on some 24" x 7" crane runway I-beam not far from home. Just need to talk him into selling it to me at a reasonable price. Fingers are crossed.

    Still need to take the truck to Sydney for reo, 1 inch plate for the base plates, insulation paneling and some other odds and ends.




    2016-02-03 17.52.21.jpg2016-02-04 15.14.06.jpg2016-02-04 15.14.31.jpg

  11. #11
    Join Date
    Nov 2004
    Location
    Port Pirie SA
    Age
    48
    Posts
    882

    Default

    The construction of the "little sheds" I work in is massively oversized to support the two cranes(only 25t SWL), the uprights at a guess are two 36x12" x1.5" at the thin edge IB's with a 1" plate lapping each side joining them... uprights every 12' I reckon the rail support beams would be 36" tall at least.
    And this still wobbles
    All the steel is from Sheffield England!(yeah its been there a while)

    Would it be easier to build a portable motorised gantry? Then it could be wheeled outside too
    ....................................................................

  12. #12
    Join Date
    Mar 2012
    Location
    Western NSW
    Posts
    518

    Default

    So work goes on!


    2016-02-27 17.00.58.jpg2016-02-27 17.01.07.jpg2016-02-27 17.01.20.jpg2016-02-28 16.50.11.jpg2016-02-28 16.50.00.jpg


    Lines strung up and measured/squared for the slab. Also piers and machine foundations marked out for the excavator.

  13. #13
    Join Date
    Mar 2012
    Location
    Western NSW
    Posts
    518

    Default

    Didn't take long with an excavator but a long time with a crow bar

    2016-02-29 17.46.15.jpg A trench for waterline
    2016-03-01 18.16.23.jpg Piers are 900mm x 900mm x 1200mm deep. Will pack the bottom of the holes with cracker dust to gice a nice hard base.
    2016-03-01 18.15.41.jpg Foundation for the slideway grinder. Again the base will be packed with blue metal dust. Aim for slab of around 450mm.


    2016-03-01 18.21.18.jpg
    2016-03-01 18.21.34.jpg
    2016-03-02 17.55.23.jpg2016-03-02 17.56.01.jpg2016-03-02 17.56.05 HDR.jpg Just to remind myself why I need a new shed.


    Away with work again so no work for the next few weeks. Will be building reo cages for the piers and foundations when I get back.

  14. #14
    Join Date
    Aug 2008
    Location
    near Rockhampton
    Posts
    6,000

    Default

    With the picture of the crowbar and shovel here I was thinking you dug all that by hand.
    Gold, the colour of choice for the discerning person.

  15. #15
    Join Date
    Mar 2012
    Location
    Western NSW
    Posts
    518

    Default

    Quote Originally Posted by .RC. View Post
    With the picture of the crowbar and shovel here I was thinking you dug all that by hand.

    I did do some along the wall of the shed which the excavator couldn't really do. Still need to finish the base of the pier holes because the excavator couldn't really finish them flat. If I had to do it all by hand I would never finish. Ended up being about 15m3 soil dug out with foundation holes for the jig borer,slideway grinder and the big stationary engine base. This is turning into a very BIG project.

    Also managed to buy some steel for the crane runways.... 24" x 7" I beam with a heavy duty 12"channel welded on top. Should be big enough!!

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