#welding

A Little Bit of Everything

The Horseshoe Courtyard Project Team is bringing even more concrete to a blog near you! The team started to dig the footing for the concrete wall at the North end of the site. And, without fail, they ran into more old, buried brick and concrete foundations. Of course they also found dead metal pipes.

These foundations are from the old structures that used to occupy the site. Nevertheless, that did not stop the team from digging the footing to the right depth. They smashed the foundation remnants while carefully avoiding breaking the waterlines.

Snow in Hale?

As much of the country experienced frigid temperatures last week, so did Greensboro, AL. Last Tuesday night, the site was blanketed with a thin layer of snow! Thankfully there was no damage to the project. Just these snowy pictures of the Horseshoe Courtyard.

One Corner Left!

The end of the bricklaying is approaching! The team only has the northwest corner of the brick pad to finish. At the moment, the bricks on the west side reach past the grinder pump, once some plumbing work gets squared away, the remaining bricks can be placed and sanded. After that, all that’s left for the pad is the metal edging, which is already on-site, ready to be installed!

Students laying bricks on sad

A Continuous Railing

For most of the elevated walkway, there are metal frames that serve as railings, with cables spaced out every two inches. However, on the south end of the walkway, the team perforated the back half of the metal screens, to allow the screens to double as railings. The cables span the same length as a railing, meaning one set of cables covers two of the screens.

When installing the cable in the southernmost point, the team used special masonry anchors that attach to the brick wall. In order to make sure the holes for these anchors were drilled in the correct spot and equidistant, the team used a metal jig. To hold the plate jig in the correct spot while drilling, the team screwed some blocking pieces into the masonry wall. Once the perforation holes were cleared of debris, the anchors were tapped into the wall and the hardware piece that holds the cable in place could be attached. And lastly, after cutting the cables to length, they were tensioned with the fastener that attached to the screens.

Out of sight, Out of Mind

If you’ve been keeping up with the blog for a while, this infamous grinder pump cover has come up for months now. And you are probably curious as to what all the fuss is about. Well, here you have it!

In the last post, the metal frame was seen installed in place. Most recently, the “tabs” that are held up by the threaded rods were attached, and the cover lifted into place. In the images above the process of this installation is seen.

First, the metal plate tabs were placed at the correct height and held in place with a nut and washer, while tack welded in place. Second, the washer and nut were removed, and the excess threaded rod ground off, and the plate fully welded to fill the gap. Third, the surface of the plate was ground smooth and clean. Fourth, the remaining debris was cleaned off and the welds covered with spray paint. Last but not least, the team and friends placed the cover once the paint has dried!

The Biggest Puzzle in Hale County

Exciting times at the Horseshoe Courtyard, after cleaning nearly 4,000 bricks, the brick pad is finally coming to life! The team and their helpers began laying bricks to create an intricate, hard surface in the main courtyard space.

Begining corner of brick pad

First, the team made a wooden frame of 2″x 6″ lumber staked into the ground which created a perimeter. This perimeter frame acted as a tray for the sand, which built up underneath the bricks. The sand is tamped and leveled, creating an even surface on which to lay the bricks. Also, the frame acts as a guide, keeping the entire pad square.

A Puzzling Pattern

Diagram of brick pattern

After filling small sections of the frame with leveled, tamped sand the bricklaying begins. The team chose a basket weave pattern for the brick pad. However, it was not until all the bricks were cleaned and sorted that the team understood the variety of shades and sizes of the material. How these different bricks filled the pattern added another layer of complexity. The basketweave pattern is made-up of “squares” which contain eight specific bricks of different colors, sizes, and textures.

So, within the designed pattern, the most important rules were aligning the outer edges of the “squares”, keeping gaps between bricks small, and leveling the bricks to the height of the neighboring concrete. Seen above is the final pattern which contains red, brown, burgundy, orange, and grooved bricks. Some are large, some are small, but together they create a dynamic pattern.

As the brick pad kept growing, Dr.Dorsey would stop by and test out the future dance floor. However, when he didn’t dance away quick enough, the Horseshoe Courtyard team put him to work spreading out sand between the finished bricks!

Once the brick pad is complete, metal edging will keep the bricks in place. As mentioned earlier, the brick pad surface will be level to the concrete for seamless access to the main courtyard space. The brick pad is crucial to the flexibility of the courtyard design, giving a hard surface for outdoor activies such as Dr. Dorsey’s dancing.

More Frames

Time for a throwback! Recently, the team picked up the last of their fabricated metal pieces. This included the railing, grinder pump cover, and bench legs. They took all these pieces to be galvanized, after some on-site welding on the grinder pump cover. Keep checking in to see the Horseshoe Courtyard Project continue to transform.