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Above 1200 Sq/FT Storage/Office/Garage 36x60 Quonset Hut

Wokspaces above 1200 squarefeet.

buzzboy

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Aug 15, 2015
Messages
77
Location
Buxton NC
A few years ago my family bought half of the lot between us and our neighbor, him buying the other half. He's using the property to store his tow trucks for his towing business. We sat on the property for a while until my mother brought up the idea of putting a garage on it, somewhere to store cars, mowers, etc during hurricanes(almost yearly here). This lot is 5' higher than our home, just next door. The deepest flood we've seen in 44 years here was 9'10" and the new lot is 11' so we should be okay. If you're building storage, always build more than you need right? We're planning a tandem and 3 singles with potential to rent out the singles. There will also be an office with a full bath that can be used as temporary housing for a seasonal employee if necessary. The building will be 24' at the center of the arch so we can have upstairs unfinished storage.

Here's what the lot looked like when we bought it a few years ago. The truck down to the right shows the elevation difference of the land.
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For some reason the county said we needed a drainfield for a 4 bedroom house. That has since been fixed and our new drainfield plan is much smaller
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After hurricane Dorian last year, we lost a lot of trees on the lot so I started cleaning. I found some "gifts" from a previous owner.
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He was a fisherman and just threw his old nets onto the ground. Our neighbor helped me rip them out of the ground with his miniexcavator.
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This was about 1/4 of the nets. The vines really grow up into it nicely. Also found a few sets of tires, car doors, old septic system, batteries etc.
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Now we've got the lot cleaned up and our neighbor moved all his tow trucks onto his side of the line to prep for our build beginning
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Amazing how small a 36x60 building looks when it's all stacked up like this. Admittedly we're doing wood frame front and rear walls.
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And that's where things sit for the moment. We're waiting on a little sitework so we can get concrete then the building shell should go up pretty quickly.

I'm trying different image hosting, so let me know if it works.
 
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txvwnut

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Bedford, Texas
Get ready to tighten a lot of bolts. Myself and my brother spent an entire day tightening bolts after all the arches were up and positioned.
 
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buzzboy

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Joined
Aug 15, 2015
Messages
77
Location
Buxton NC
Glad to hear the photos work. Weird that removing the "s" fixes a photo but good to know.

When I came home for lunch today there was a skidsteer sitting on the lot. That's a good sign.
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I'm not sure how much fill we got today. There will be more after the septic goes in, so we won't know yet. This was the 5th load I believe.
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The back left of the lot is 11.6 feet and we're bringing the pad up to that level. The highest flood water we've ever seen here was 9.75 feet. We hope/think 11.6 isn't possible due to the lay of the land.
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Next will be septic tank/field.
 
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rixtrix1

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Aug 25, 2013
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3,010
Location
Chandler, AZ (from west NE)
Sounds interesting. Lots of bolts. I've read three other quonset threads here and the stories of water leaking in during rain storms are scary. 3 different solutions, too. Best wishes!
 
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buzzboy

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Aug 15, 2015
Messages
77
Location
Buxton NC
11 feet above sea level, wow.
This was my storage shed during Dorian last year. Second highest flood we've seen in 42 years here.
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Sounds interesting. Lots of bolts. I've read three other quonset threads here and the stories of water leaking in during rain storms are scary. 3 different solutions, too. Best wishes!
Our other Quonset hut, 27 years old, only leaked where we had a rust problem. The bolts and stuff don't leak but the baseplate rusted at the bottom. Steelmaster claims the new baseplates don't have the same issues. I hope they're correct. Still we'll seal the bottoms where the bands attach to the baseplates.
 
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buzzboy

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Aug 15, 2015
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77
Location
Buxton NC
We got 9 inches of rain in 5 days. That sets things back a little. Thankfully the rain let up this week and the guys could get everything ready to pour. The pumper is available next on Thursday so we're hoping for good weather
View media item 111969It looks so much smaller than 36x60 for some reason
View media item 111970And I'm just sitting here drooling over my neighbors Deuce. It's for sale!
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buzzboy

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Aug 15, 2015
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Buxton NC
The crew came out and finished up the rebar and then we started waiting for dry skies and pumper availability.
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Heading out for my 7-9am pre-work surf I am greeted by this sight!
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An odd sight to see!
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I was at work while they poured but afterwards we went to check out the new slab! Somehow it looks smaller than it actually is.
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Now we've got 28 days of waiting until we can begin the next steps.
 
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buzzboy

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Aug 15, 2015
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Location
Buxton NC
28 days became a few more than that. Our contractor(and every contractor around here) is swamped with work this summer. In the 2 months since our slab was poured we ordered up windows and doors. They're waiting at the warehouse.

This morning though I came home from my early morning job to see the contractor and sub out on the slab. The crew is stuck waiting for materials on another job so they had time to work on our project. They laid out the baseplates and bolts. Bad news is that they don't have a concrete drill bit long enough for the bolts that Steel Master spec'ed for this application. Contractor ordered the correct length bit and we'll see them again, hopefully soon.
View media item 111976
 
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buzzboy

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Aug 15, 2015
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77
Location
Buxton NC
The crew is back! I came home from job1 this morning and the boys were at work. The new drill bit arrived and they made correct length holes for most of the fancy Hilti concrete anchors. Most? On a few of them they hit rebar about an inch shy of the full depth.

After getting all the baseplates bolted down they assembled the first arch. I wasn't expecting this to be the order of operations but I know nothing about building Quonset Huts. They're going to assemble every arch then bring in a lift/crane to stand them up and bolt them together. I figured it was done arch by arch, but what do I know.

View media item 111977
The scale makes more sense again now, seeing the first arch together.
 
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buzzboy

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Buxton NC
View media item 111978Weather forecast is not favorable. The guys were here until 11 when the skies opened up. 5 arches done. I'm guessing there are 18-20 arches.

I drove 1.5 hours each way to work on my Mercedes today in it's current storage garage. I'm very ready to have a nearby storage solution.
 
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txvwnut

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Jan 1, 2015
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7,620
Location
Bedford, Texas
You can build the arches a piece at a time in place but it will take a lot longer than assembling them on the ground and lifting in place. I would like to see how they are going to use a crane to lift the arches in place. They are rather floppy until they all get linked together. When I did mine my brother went up on the scaffold with ropes and we had four people on each arch and just walked them in place while my brother pulled on the ropes. Took eight hours to set all thirteen arches for my building.
 
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buzzboy

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Aug 15, 2015
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Buxton NC
The weather has been beautiful for the past 2 months. Only raining at night. Not much getting done for a few days
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Yeah, I'm really interested to watch this go up. My work slows down for the next two months so hopefully I'll get to watch more of the process.
 
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buzzboy

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Aug 15, 2015
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Buxton NC
Double bad news today.

For one thing, we've been hit with a lovely north easter. Hurricane Teddy is creating large seas, combined with 30mph NE winds for the last 3 days we've been having some ocean issues. The one road on the island has ocean overwash in multiple places. This means that the crew can't all make it down and that the winds are too high to lift big pieces of metal into place.
View media item 111984And people are morons. Driving through waves... At least my neighbor, the tow truck operator, is making money
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Also, the GC was out on the jobsite on saturday checking things out. He noticed that they had gotten a few pieces of the quonset in the wrong place. Apparently the building should thinner gauge steel higher up. Even though the panels may look the same they are different thicknesses. They'll have to remove a few sections and put them back in the correct place. Yay? At least they're only 8/18ths of the way done.
 
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buzzboy

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Buxton NC
Good week here. Monday was still a bit of North Easter so no work. Something about swinging big pieces of metal around in 30mph sustained winds. Now we've gotten everything put back together that was wrong and 1.5 hoops left. The crew is going to put in a half day tomorrow just to finish up with the crane.
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buzzboy

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Buxton NC
Our neighbor the towtruck driver said he's tired of getting questions about what "he's" building.

The shell is mostly complete. It's all put together but there are still bolts left to complete it. The GC's crew is finishing up another project this week then they'll be on our graj full time until it's complete.

This thing is BIG! Seeing it from the Dollar General parking lot across the street is quite impressive!
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buzzboy

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Buxton NC
The sound of an impact driver must haunt the crew. These are the last few bolt holes to be filled.
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Today the garage doors were delivered. I'm sad I was out of town when it happened because they supposedly unloaded the doors from a box truck, with a backhoe. Must have been a treat. That's four 8x7 doors for the 3 rental bays and the rear of the shop and one 10x7 for the door to the personal garage.
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They also began with what I would call a sill plate, but I'm not sure if that's right in this instance.
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The rental bays look big again to me now that I have some definition of where exactly they are.
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buzzboy

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Buxton NC
Framing always looks so fast! We've had the framing crew and the plumbers come visit.
View media item 111994Seeing my mother standing in the office part really gives a size perspective finally
View media item 111995The rental bays are looking good. Compared to where I rent currently, they feel SOO big
View media item 111996It's also becoming evident how big the upstairs storage area is going to be. I can visualize 36x36 but seeing it makes it look so much bigger! Although I worry how quickly my father will fill it up.
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buzzboy

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Buxton NC
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buzzboy

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Buxton NC
Timing worked out a little late. I move to my winter seasonal on November 15th and the garage space isn't ready yet. But I'm ready to stop paying rent and keeping my stuff 1.5 hours away from home. Thankfully my dad has a few old trailers and I snagged some space in one. Honestly I'm surprised to find empty space with my dad's horrible case of Horizontal Surface Disease.
View media item 112003I need more filing cabinets. I love these things.
 
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buzzboy

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Aug 15, 2015
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Buxton NC
We decided on a little awning over the windows and doors. Hopefully keep some water out with the door open in the rain as well as visually breaking up the big face of the building.
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Also interesting how the wall on the curved side of the office turned out. Gives as much floor space as possible.
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buzzboy

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Aug 15, 2015
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Location
Buxton NC
October was my last month paying rent at my storage unit. I had until tomorrow at 5pm to be out. It's supposed to rain though, so we moved it all today. I leave in 11 days to go to my winter job, 3000 miles from here. I know the building won't be done, but if the doors are hung then I can at least stash my racecar inside and out of the rain all winter. She's not exactly waterproof. Nice to see my fleet all back together again.
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