Detailing, Editing, and Writing

Now that the details for the porch cladding have been resolved, we moved our attention to detailing the door opening. While working through the details we studied the doors in the rest of the hotel, and in our imediate surrounding, particularly the triming and how other doors that have trasom windows, have been adressed. In order to design something that fits with the language of the cladding, but also works with the language of the door.

Zoom call, Pdf detail drawing of bench in background

As is the norm now, the team has had weekly meetings with Andrew and Steve to talk about details and design or book progreess. And from time to time we get to talk with Dr. Dorsey, Director of Project Horseshoe Farm, and our client or consultants such as David Kennedy, about our heavy timber bench.

Sneak Peak of a draft! While working remotely the team has started working on the book, which is an in depth documentation of the design and construction process.

Within a Sixteenth

The moment we have been waiting for years! The screens are finally going up! This week all the metal frames took their last trip around Hale, thanks to Shane Jackson from Stillwater Machine, for transporting all the material and lifting the frames into place with his boom truck. A huge shout out to Mason Hinton, and all the 5th and 3rd-year students that helped lift, carry, and bolt things into place. We couldn’t have done it without all the help! And last, but not least, a big thank you Alabama Power for letting us use their parking until the screen went up.

In order to work as efficiently as possible, we split into groups: a group of four to six including the team bolted the pieces together, with two at the top and four at bottom. Our other volunteers lifted the screens from the ground onto the trailer that drove from the parking lot to site. Then Mason would attach the screens to the boom truck chains and undo the wooden jigs ( jigs held the legs of the frames from bending during transportation). Next Mason or Claudia would guide the screen with a strap into its correct location, and the crew of four would guide Shane ( boom operator) until lifted into place. While the screens were bolted the rest of the volunteers would move on to loading the next screen on the trailer.

footing bolted to screen leg

Leaving the bottom of the footing plate un-grouted while installing the screens allowed us some flexibility to move the footing between an eighth to a quarter of an inch in all directions, depending if it was connected to the walkway or not. This allowed us to level the top of the screens in relation to each other, as well to ensure that all the holes in which the screen connected to each other lined-up within a sixteenth of an inch.

sunset reflecting on screens and wall plates
One of the fun things we observed after the screens were up, was that they reflected the beautiful colors of the sunset or the blue sky in the mornings. In the image above the metal is reflecting the sun, but a few minutes later the it would reflect the oranges and pinks of the sky.

Up next: railings and 9 foot frames!

Bolted Down, Moving Up

While the concrete set, we created templates to help install the threaded rod into the footings. A laminated template ensured the holes drilled into the concrete for the threaded rods were in the correct location. The wooden template held the rods in place while the epoxy dried.

The team used the handy-dandy batter boards and plumb bob to find and mark the exact center of where the footing plates would be installed. They needed to ensure footings were spaced exactly 10 feet apart while also lining-up with the critical connection points of the walkway. Although the footing plate holes were oversized in comparison to the 5/8 inch threaded rods that attach the plates to the concrete, the rest of the screen assembly did not have as much tolerance. The tolerance at the footing plates allowed for minor adjustments as the screens were being connected and leveled to each other.

Before the holes were filled with epoxy, all of the threaded rods were marked (the depth they needed to be embedded) to ensure air bubbles in the epoxy weren’t holding the rods out of place. Nuts were threaded to support the wooden template that holds the rods in place while the epoxy dried. Once the epoxy hardened, the footing plates could be lifted into place and re-leveled in relation to other plates.