Steel framework

Much of what we do first starts with welding up a cage or armatire around which we will build our features. As fast as we coat them out in concrete the next frames are underway. One such area is the cave maze we are fabricating onsite. It will be situated under one of the elevated pathways into the park. Building the frames involves welding a web of pencil rod to form the shape of the cave. The grid needs to be about 6" x 6" or 3" x 12" to ensure it is stable when we apply the mesh and concrete. For a cave network that measures 20' x 30' like we are fabricating that's a LOT of pencil rod and welding! Today I finished one long tube of the cave which means I am more than one third of the way done. It looks pretty cool inside. Here's a look from the top side.

Back in the shop Peter was welding up the cage for the giant tree that will be the highest point in the park (except the rides). It's still hard to see the finished shape but it is going to be a spectacular piece.

Stay tuned to see these pieces come together...

-grampa dan

Special delivery day

The morning dawned supper soggy, necessitating a shop day rather than on site. We had plenty to do including a clean and reorganize of the shop. The Bucky sign was carefully loaded into the trailer for delivery when the rain abated just a little. After lunch the rain quit for a bit and four of us made a run up to the lake to make a very special delivery. The first sign for the adventure park was to be installed. The sign post still needs mudding and carving but that will wait until the railing is installed.

I love it when my client has the necessary equipment to handle our heavy installs. Chris has pretty much all of the lifting equipment we need. Today, the zoom boom was the equipment of choice. We unloaded the sign from the trailer and hooked it up to the rugged lift. The skilled operator shifted into four wheel drive and low range and the install began.

The signpost was carefully positioned over a sleeve that had been structurally positioned onto the concrete wall. Then we lowered it into position.

We then adjusted the sign vertically to make sure there was plenty of headroom on the walkway below and once we were happy Bert permanently welded it into position. then it was a simple matter of climbing to the top, unhooking the chain, twisting out the eye bolt and we were done! One sign is complete!

Then it was back to the shop to continue our work there. Jenessa did the bulk of the lighthouse roof and did a great job carving the shingles into the fresh concrete. That makes this piece ready for paint next week after a little curing.

Tomorrow we tackle many projects including the cave up at the lake, the giant mountain topper and the structure of the tree. It's going to be a busy Friday. Stay tuned...

-grampa dan

Shop tour

Our shop isn't large - especially with up to twelve people working hard on some very large pieces. The working area is just over 1200 square feet. The key to efficent production is to keep very organized. The welding and fabrication area is to one end. Flash curtains protect those working in other areas. A big piece is always in the starting stages here. A fabrication table, steel storage and welding tools also take up a good deal of space. 

The area by the big doors is generally where large pieces that are in the paint stage get positioned because they will go outside as soon as they are done. They are so heavy, often just barely fit out the door. They will be moved with sturdy chains and the tractor with the crew doing their best to guide them as we slide them on the smooth concrete floor. Right in front of the doors is kept clear as the doors swing in. This area is used to do odd jobs, Matt used this area today for bending the hundreds of steel rings we will need for our next project onsite.

The paint area is at the east end of the shop. Theoretically the cleanest end of the shop, these days it is pressed into service as the mudding and carving area for smaller pieces that can be moved by hand (sometimes with all the crew needed to do the task)

The center area is where most of the action takes place. Currently five large pieces are in various stages of production with the most finished piece closest to the door. As each piece leaves the shop we do a major shuffle to slide everything down the line. With the colder, damper weather we are trying to do as much as possible inside in a controlled environment.

With careful organization and cheerful teamwork we manage to complete one or two large pieces each week. It is amazing how much work the crew puts out each week.

-grampa dan