Above 1200 Sq/FT Speed Metal Garage - rattle_snake’s 34x40 shop build in AZ

rattle_snake · Feb 1, 2016

rattle_snake’s 34x40 in AZ - Speed Metal Garage

June 30 2017 - Sorry Folks, all photobucket images are broken

Sept 8 2017 - PB Pics can be viewed in Chrome using "photobucket embed fix" extension for Chrome

Finally got my permit (aka county bribe) so it’s time to start my official build thread. This new 34’ x’ 40’ building will be used mainly for automotive / fab and to park what won’t fit in the 3 car (CCLB truck, boat). Before we bought this 1.25 acre property I planned to build a shop on it, so I pulled the relevant records to make sure it was a possibility. For the last year I have been planning and researching the where/what/how/who. Unfortunately, I am an engineer, so I must fully understand and evaluate all options before commiting to anything. This curse is applied to most aspects of my life, beneficial or not.

Original plan was to place building adjacent to existing parking pad, but easements and setback prevented, plus I was told R.O.W. left me only 20’. So I contacted architect to draw a plan for addition to existing garage. After realizing all the problems this approach would present, I deemed it not worth the money.
My architect got a different answer regarding ROW from county, so we drew up site plans for detached building. I then priced all steel, pole barns, stick framing, and sheathing/roofing combinations until I had an idea of what all the pieces cost. I decided to go with stick/stucco to match existing home, as the delta in overall price was not that much more and would pay back on when I sell the place.

So after lots of reading here on GJ I have self-proclaimed myself an expert, complete with industry jargon, overly optimistic schedule and budget. Plan is to sub out dirt/concrete/framing/stucco/roofing and do the rest myself (site prep, electrical, fencing, logistics, funding, ect). Wife is not happy she will lose most of this horse pasture, but is otherwise on board and that is important! So on with the pictures..
Before, looking West

Before, looking North East. What's left of the pasture will still get flood irrigation so it will have to be graded appropriately. Leaves just 20" strip to north.

From above. The horses have added their own survey markers.

My simple site drawing. An Engineer making a drawing with an uncertainty of a foot or so just seems wrong. We’re not allow to frame as everything must be within 1/64” (hey tolerances stack..)

So I'm Finally underway and plan to break ground this week.

Link to my attached garage thread:
http://www.garagejournal.com/forum/showthread.php?t=312068

rattle_snake · Feb 1, 2016

Figuring out how I was going to efficiently use this limited space took awhile. To improve my chance at a decent decision I made a drawing with models that I could move around. This helped me place the doors, and 2 post lift position with different sized vehicles. I plan to have some long term crawler/hotrod projects and this should allow work on the body and chassis separately. The yellow squares are lift posts.

Ideally I would want 2 buildings, one for fabrication and another for clean parking. My existing 3 car isn’t deep enough so the new building will have to do both, but I'm happy to be able to do it.

rattle_snake · Feb 2, 2016

Phase 1: Site prep - Tree & fence removal, Automatic Gate relocation

At least one mature cotton wood has to come completely out for the parking pad. These trees are a messy PITA so I removed 2 more (every other one) from this pasture and plan to eventually do the same to the other pasture.

To accommodate the new building the fence needs to move and also the gate. The change is shown in the site sketch, with the blue lines showing old location. This gate has 2 wired inputs (keypad and underground exit sensor) plus power to be relocated as well. The existing power was in the middle of the drive, so I trenched to the new location. Rental from HD was junk and broke down immediately. Front chain sprocket bolt came out, bearing was total shot with just inner race floating in the void formerly occupied by ball bearing. Instead of wasting time to perhaps get a replacement, I found a suitable bolt and got the POS running.

My portable welding rig. I put in 24’ of this 4’ top rail fence and hung the existing gate on it.

Keypad post was damaged from a vehicular hit and run incident so I rebuilt the whole thing and added protection for the plastic keypad. I also decided to use the wireless capability, and since I just build a partial Faraday cage I tested to make sure it would still work… Which it did for one day.

New post painted and ready for impact.

The power wiring was atrocious. Everything was leftover from another job. Only good part was conduit was down 18”. Wire was stripped romex, and stuffed into ¾ conduit with 4 other #6 and #8 wires near the box. Note the spray painted ‘neutral’ and blk stripped ‘ground’. GND was not connected.

But it gets worse when I decide to attempt to fix this code violation and put remote outlet in its own conduit, as a failed attempt at a sprinkler system was put in over the top (And under the faucet ?!?). Looks like it had been leaking since install and I think the moisture has help the foundation crack. So I removed the sprinkler system as I do not need it. Re-wired the feeder properly so hopefully if electrical inspector looks inside all is well.

Gate Finished

Ready for fill and pad prep (almost)

rattle_snake · Feb 5, 2016

Grading

Broke ground yesterday. The 3 stumps were dug out. ~200 tons of fill dirt are going in now to build up pad and driveway. Looks like concrete will start right after dirt is finished, which I am pretty happy about! My shop is finally on it way to being a reality, as indicated by the falling balance in my bank account.
:beer:

Jon In Tucson · Feb 5, 2016

Justin,
Glad to see another Arizonian in the fray! I am in the planning stages for a 20x30 gambrel roof garage/shop here in Tucson. I will watch with great interest your build. :beer:

I hope to get after mine this year. It's neat to see horse property in the city. You are lucky to be on a large lot. God bless.
Jon In Tucson

1/2 Cup · Feb 5, 2016

I am keen to follow your build, all the best with it. :thumbup:

Denwad · Feb 6, 2016

wow within 1/64th!

rattle_snake · Feb 8, 2016

Jon In Tucson said:
Justin,
Glad to see another Arizonian in the fray! I am in the planning stages for a 20x30 gambrel roof garage/shop here in Tucson. I will watch with great interest your build. I hope to get after mine this year. It's neat to see horse property in the city. You are lucky to be on a large lot. God bless.
Jon In Tucson

Thanks. Wish I wasn't in the city but for what I do not many other choices. Although it is nice to have most everything only 5-10 minutes away and still have enough land to have horses and a shop. Good luck with your build

Denwad said:
wow within 1/64th!

Well, attempt to get everything within a /64, that's why (most) engineers are so slow, unnecessary precision!

I put in markers to guide digging for thicker concrete under 2 post lift pad. Had to stop and convince myself an inch or to won't matter. Refrained form using a straight edge to mark the dirt.

TXNinAZ · Feb 8, 2016

Looks like fun, fellow valley resident! I'm on the other side (Laveen), and looking to do the same thing- build a 24x34' on the side of my attached 23x32. Who did you choose for your contractor, or are you managing everything?

j p smith · Feb 8, 2016

Wow, off to a good start, like the land you have. We are on an acre out on the west side of Phoenix, Todd from "Ernie's Place" is a little further than us and has 2 acres.

rattle_snake · Feb 8, 2016

Dirt!

Dirt work is done. 200 tones laser leveled. Since I have driveway drainage issues already, I worked with grading and concrete guys to come up with best plan moving forward. The new built up area will drain north into the irrigation (pasture) basin. I chose to make the finish floor height same as the house. The attached garage floor is sloped and is 4-7" lower than the house, and is not much higher than the irrigation/ storm flood level. Also, the shop will have a flat floor. This puts door height difference about 7". The parking pad will be basically same size, but the end of the shop pad is 6' back.
To help drainage, the existing driveway was dug out and a retention basin dug in the front yard. This should allow water to shed off pad. The retention basin is 'rough' and will need rework...
My 4000 sq ft dirt pile:

Even though it seems I am sub-ing out everything (dirt/concrete/frame/roof/stucco) there are more than enough other issues to solve. Moved a lot of pavers to make way for footings. I plan to install a 2 post lift, so I dug out the area another 2". This will guarantee more than 4" @3000psi. Not planning on any rebar, there is a chance it could be in the way when drilling anchor holes. I made the depression 4'x6' so I have options for placement and width.

The whole 2500 sq ft roof of the house drains into one gutter, that was non-functional when I moved in. I fixed and added a 2nd down pipe on the north side including a drain pipe under the pavers into irrigation basin. I now have a 10' x 34' raised pad on the back of the building that I plan to use for messy jobs, so the drain needed to be extended.

Also, there is no irrigation berm in places and back yard pavers are slowly sinking. So to fix I am adding a berm while the loader is here. But the existing fence is already 4-6" underground and rusting. So I raised the fence, which I knew would be a major pain, and it was. Welding was the easy part, digging the no-climb out of the sod and moving it up the corner posts was a MF. 2 minor grass fires and an escaped puppy slowed progress.

And since dirt equipment is still here, I decided to add yet another project to deter focus. A garden. Wife has mandated no further loss of horse pasture so garden is going in back yard. There was a pair of curved 1/2 wall 'things' in the corner. Purpose unknown. They are foam/concrete, one filled with cement, but under is a 4-6" thick footing. And to make things worse the yard was originally rock, and then 4" of sand was added under pavers. So to grow anything I have to remove everything not dirt and fill with decent soil.

I have 2 helper dogs but combined useful output is negative.

Next step is granite sub-base and a layer of granite on driveway.

rattle_snake · Feb 8, 2016

TXNinAZ said:
Looks like fun, fellow valley resident! I'm on the other side (Laveen), and looking to do the same thing- build a 24x34' on the side of my attached 23x32. Who did you choose for your contractor, or are you managing everything?

I chose myself to be able to afford this project. I knew it would take a lot of time to manage a project like this. I have learned a lot so far. Can't have everything I want right away so have to plan carefully.

PurdueSD · Feb 8, 2016

Wow, crazy to see... You're locale seems like a different world. At least from my midwest perspective. Looking forward to updates!

j p smith · Feb 8, 2016

TXNinAZ said:
Looks like fun, fellow valley resident! I'm on the other side (Laveen), and looking to do the same thing- build a 24x34' on the side of my attached 23x32. Who did you choose for your contractor, or are you managing everything?

Have you started on the new place? I have the guy that did ours, I will get his number for you.

Regifted the slides to my Snap On Buddy, he will clean and use in a couple of used boxes he has.

TXNinAZ · Feb 8, 2016

j p smith said:
Have you started on the new place? I have the guy that did ours, I will get his number for you.

Regifted the slides to my Snap On Buddy, he will clean and use in a couple of used boxes he has.

I'm glad they went to a good cause!! We're at the new place, but haven't started on the garage yet. Lots of small projects to get done first- mostly close on the old house and get the wife's important things done- gas cooktop, new sink and faucet...that kind of stuff. I'll have to post a build thread once it's underway. And thanks for any referrals, that would be helpful, for sure!

j p smith · Feb 9, 2016

TXNinAZ said:
I'm glad they went to a good cause!! We're at the new place, but haven't started on the garage yet. Lots of small projects to get done first- mostly close on the old house and get the wife's important things done- gas cooktop, new sink and faucet...that kind of stuff. I'll have to post a build thread once it's underway. And thanks for any referrals, that would be helpful, for sure!

Will get a couple for you and send in a PM this evening. Did not mean to hijack the Rattle Snakes thread.

papavolume · Feb 9, 2016

Looks like its coming along great. I wish my Phoenix home had that much property but I am too close to down town for that!

rattle_snake · Feb 12, 2016

Some more pics of progress
Existing pad drainage re-work.

75 tons of 3/8- granite for sub base and driveway..

granite spread and compacted

Very happy with grading contractor. High quality work. He also brought in some additional granite to try in one of our horse stalls to mitigate the mud when it rains.

TXNinAZ · Feb 12, 2016

Justin, is he bringing the machine to spread the dirt and gravel, or is it yours?

rattle_snake · Feb 12, 2016

Equipment is his. The tractor has a hydraulic/laser controlled scraper to level material.

He also hauled off a pile of conctrete waste and bricks for cheap, really happy to have that heavy stuff gone.

papavolume · Feb 12, 2016

Nice 03/04 Cobra! I sold my AS 03 Cobra to a teenage kid last year, within a month I got a notice it was impounded only to find out he hadn't even registered or insured it yet and took it out with his gf and let her drive it, and rolled it over and totalled it. Luckily they were safe, but hey....the value of yours went up!

rattle_snake · Feb 12, 2016

Thanks its a fun car. With instant torque, not a good choice for a teenager. It rolls pretty good on a little N20. When I bought this car the PO forgot and left a progressive insurance data logger on it. When I returned it he commented that I hadn't broke 100 mph yet. After title/reg/ins I found out what it would really do.

DBendr · Feb 12, 2016

Cool place. Get rid of the truck and chain link fence and it's like Charles Bronson is going to appear on the roof with a 32/20, flick a crooked cigar and start shooting !
I always like that style of architecture.

1/2 Cup · Feb 12, 2016

Looking great Justin, thanks for the update. :thumbup:

rattle_snake · Feb 16, 2016

Footings dug and rebar in;

150' long trench 20" deep and 2' wide makes a lot of extra dirt.... I used some to build irrigation berms but there is more than I can shovel any time soon. Will have to get a machine to move it later.

TXNinAZ · Feb 16, 2016

Looks great! Did you price compare post tension vs footings/rebar?

TXNinAZ · Feb 16, 2016

Oh and I just got my first quote back- $109k-$117k for a 24x34 lol. No HAVC, no plumbing. Electrical, stucco, a roof, and drywall for over 100 grand. I think I'll keep shopping.

j p smith · Feb 16, 2016

Wow thats around 130.00 per square foot, seems high.

TXNinAZ · Feb 16, 2016

j p smith said:
Wow thats around 130.00 per square foot, seems high.

Yeah, pretty comical. I assume they didn't actually want the job.

Bigdaddiy · Feb 16, 2016

TXNinAZ said:
Yeah, pretty comical. I assume they didn't actually want the job.

Dont want to hijack this thread so ill send you a PM....

rattle_snake · Feb 16, 2016

I'm hoping to finish at about $40 /sq ft. So far I'm on track. Eventually I'll be over budget.

TXNinAZ · Feb 16, 2016

rattle_snake said:
I'm hoping to finish at about $40 /sq ft. So far I'm on track. Eventually I'll be over budget.

That seems pretty reasonable.

rattle_snake · Feb 18, 2016

Concrete day, pt1

Building slab was poured this morning. This milestone is important to me because of some issues with the site plan. I chose to stick with my original plan to place the building 6' from the house, although the site plan had 5'. After stucco this distance is even less and I wanted to keep enough room to move hottub if needed or get a quad, riding mower ect though.

I originally used the county's satellite images and measurement tools to dimension property and sent to architect. I didn't inspect close enough to find this issue until permit was issued, and to change would delay about a month. Issue is that house is drawn 2' to the north. After measuring the building location on the pad I found that I had about 2 extra feet to the setback, so my 6' from the house was OK. After gathering all information on my options I went ahead and had forms set to 6' and crossed my fingers that inspector would either not measure or not care about 1'. Not sure what happened but it passed inspection.
:beer:

I knew with my OCD and attention to details that this project would present some problems and stress. Because this is supposed to be 'fun' and I am lucky to be able to afford it, I had to remind myself to keep a positive attitude and not 2nd guess the decision I have already made.

Looks like grading needs to be re-done for proper drainage on parking pad. Won't affect the overall schedule so not a big deal.

west_perf · Feb 18, 2016

Nice build, Justin. I looked at some homes in your area (before deciding the hot summers were just too hot) and love that area with the estate homes, a little land, and the desert landscaping. Will be following along to see this one come up. That's one big truck you have there too!

AZ Garage · Feb 18, 2016

Looks great!

rattle_snake · Feb 18, 2016

west_perf said:
Nice build, Justin. I looked at some homes in your area (before deciding the hot summers were just too hot) and love that area with the estate homes, a little land, and the desert landscaping. Will be following along to see this one come up. That's one big truck you have there too!

Thanks I'm trying to get basic building done before 'summer' but was over 90 yesterday and its February.

Truck got a little bigger this last weekend... Had to replace tires and somehow ended up doing a little more lift to clear 37s.
:dunno:

Most miles are tow/haul so kept it as low as possible to fit the rubber.

rattle_snake · Feb 22, 2016

Slab poured

building slab controlled joints were cut last Friday. Now I can wander around and pretend it's a building.

Trying to get misc items ordered so I'm not hung up waiting for them later. Lots of little details to think through.

TXNinAZ · Feb 22, 2016

Looking like more great progress. How wide/deep are the cuts? One thing I hate about the garages around here are the huge troweled expansion troughs. Need an 8" tire on everything to not get stuck in them!

j p smith · Feb 22, 2016

TXNinAZ said:
Looking like more great progress. How wide/deep are the cuts? One thing I hate about the garages around here are the huge troweled expansion troughs. Need an 8" tire on everything to not get stuck in them!

Generally, saw cut control joint depth is 1/4 the thickness of the slab and done with a 1/8" wide diamond blade. In our shop I used foam backer rod and Sika Flex to fill the joints afterwards.

rattle_snake · Feb 24, 2016

After a quick look at parking pad prep I wasn't happy. The outside of the footing next to the overhead doors was filled with loose dirt. I compacted and filled with granite. The rest of the granite wasn't compacted so I added some water, removed forms from one side and compacted with my truck tires. Much better. I spoke with my concrete guy to understand what happened.... I re-measured pour depth in a bunch of places to make sure we wouldn't run out of mud, added a few more wheel barrows in the low spots. Will never really know if my OCD made any difference in crack prevention. He did a very nice looking finish job and threw in some re-bar on the front edge.

The new driveway is now 3-5" to high, and will have to be re-done as well. My site plan didn't detail the exact height of all corners of the pad, just a verbal agreement. Grading guy said he would fix and I have some other work for him so all will eventually be how I want it.

Above 1200 Sq/FT Speed Metal Garage - rattle_snake’s 34x40 shop build in AZ

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