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Rafter J Forgeworks- Texas

mesquiteforge

Well-known member
Joined
Nov 21, 2008
Messages
64
Location
South Texas & Texas Hill Country
After years of carports and small garages-I finally twisted off and started my shop build. In South Texas and the Hill Country of Texas we generally build red iron metal buildings for shops-at least the folks I hang around do anyway-primarily because we all have welders and/or know someone who can build one.
The place I bought is six acres and due to my desire to keep as many trees and stay within my bounds of a power line right-of-way....I kept the footprint down and built up. Settled on 30x40x16, with a 1:12 pitch roof. Light Stone colored walls with dark charcoal trim and galvalum roof. The site drops 2.5' on the 40' run so we had to bag and back fill the foundation. The outside walls on the low end are 3' deep by 1' and at least a 1'x1' beam on the high side. A combination of 3/8, 1/2, and 5/8" rebar was used-no wire mesh, no expansion joints or cuts made- average thickness around 5-6" ending up pouring 47.5 yards including two 10'x20' aprons. I have two 12x12' doors, one 10x10' door with a loading dock and one 3x7 walk door. I am finishing out the interior with a office and full bathroom. I have a loft for storage upstairs and eventually will turn part of the area into a guest room and closet.
I work full time as a oilfield communications sales rep-and have had a passion for metal work and blacksmithing most of my life. The shop will primarily be a modern blacksmith shop-coal forge, gas forge,anvils, hammers and tons of other tools-literally tons-hence the reason for the loading dock.
I also kayak, scuba dive, enjoy some woodwork, and reload some ammo..so I tried to incorporate plans for all of the interests..
I am extremely busy with work-so if you have questions and don't get an answer right away - be patient with me.

As of now- 7/12/14- I still have to get my electrical (3phase already run to pole next to building-lucked out on that one), lighting (T-5 6bulb high bays in shop on two separate circuits to make it dark over the forge when I need to see my heat- led cans in the office and bathroom), plumb my toilet shower and sink, install septic lift station, install rainwater catchment and filtration from gutters- stain and seal the floors-geez- lot left to do...oh and plumb the air compressor too...

Anyway-take a look at the pics if you like and let me know what y'all think!

Thanks for the years of info that I've gleaned from this site- it has helped me to put together a shop that I've been scheming for at least 20 years.







Embed plates.

Starting the pour..





Insulation and siding going up..










 
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atxgsa

Active member
Joined
Jul 21, 2010
Messages
33
Nice work, the land definitely looks like hill country. It is a good place to set up shop. looking forward to see what you do with the place.
 

Countryside

Member
Joined
Jul 13, 2014
Messages
13
Location
New Caney, Texas
Very nice looking shop you got there. :thumbup:

Nothing like the Hill Country, but I'm attached to my East Texas roots and all these pines...if not, I too would be out that way!
 

Lone Star Blaze

Well-known member
Joined
Dec 29, 2009
Messages
1,224
Location
Oklahoma
I really like that layout with the office and upstairs
Can't wait to see more of your shop

I love the Hill Country but I have pretty much given up on ever living there
 
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mesquiteforge

Well-known member
Joined
Nov 21, 2008
Messages
64
Location
South Texas & Texas Hill Country
Despite having built many if these myself-I put this build in the capable hands of John at Hill Country Iron Works in Kerrville, Tx. What took 3 weeks with several rain delays would have taken me months.. Most of the steel came from West Texas Steel in San Angelo.
 
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clcartwr

Well-known member
Joined
Dec 4, 2008
Messages
95
Location
Rogersville, AL
Very nice layout. Looks a lot bigger than just a 30x40! I like the mezzanine. I also like how the steel side columns are not tapered. All the steel buildings I have dealt with locally have the columns tapered so you cannot have a flat interior wall...You planning on putting metal on all the walls like you did under the mezzanine?
 
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mesquiteforge

Well-known member
Joined
Nov 21, 2008
Messages
64
Location
South Texas & Texas Hill Country
Very nice layout. Looks a lot bigger than just a 30x40! I like the mezzanine. I also like how the steel side columns are not tapered. All the steel buildings I have dealt with locally have the columns tapered so you cannot have a flat interior wall...You planning on putting metal on all the walls like you did under the mezzanine?

Thanks for the nice comments! Yes-I don't like the tapered columns either.. I have to start moving in and decide for sure what goes where- once I have an idea-then I'll put some siding on the walls to trim the rest out, I've got to put a hole in the wall somewhere around the 10x10 door to draft my coal forge. Once I confirm where that's going to sit-the rest should fall into place. Should have electrical and doors done by next week. Concrete man strongly suggested that I wait at least 30 days to seal the floor-so that will be on the 17th..forced patience! Gggrrrrhhhh!!!:willy_nil

I mainly want the interior trimmed to keep sparks from burning the joint down.. All of my conduit and air lines will be exposed on top of the wall covering and make future changes much easier.
 

clcartwr

Well-known member
Joined
Dec 4, 2008
Messages
95
Location
Rogersville, AL
Yeah I want to completely cover my walls with metal when I build. I want to be able to pressure wash out the whole inside. I'm also planning on surface mounting all of my electrical etc also. Can't wait to see how yours turns out!

Did you have to have any special engineering for the mezzanine and do you know what psf rating it has?
 
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mesquiteforge

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Joined
Nov 21, 2008
Messages
64
Location
South Texas & Texas Hill Country
Did you have to have any special engineering for the mezzanine and do you know what psf rating it has?

Country boy engineering! Haha! The guys that built this overbuild more than I do- the last one he built with a loft -the owner put 20 alfalfa square bales up on it-which we estimated to be around 30K lbs....so mine should hold the nuts and bolts and stuff I plan to store up there. The structure is made primarily of 8" c-purlins with two boxed together on the outside, strengthened the floor with 2" square tubing and it all ties back into the wall purlin by being welded to 6x6x3/8" plates/tabs.. I live in the country so we have no zoning or permit restrictions and engineered drawings and plans are not required for anything except the septic which is primarily due to the river authority which protects the interests of the river and ground water in our area. I recommend getting an engineer involved if you may sell your property in the foreseeable future or if you are genuinely concerned about the structure-I knew mine would be overbuilt for my purposes-so no "train drivers" were needed to plan it..

 
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mesquiteforge

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Joined
Nov 21, 2008
Messages
64
Location
South Texas & Texas Hill Country

Doors installed, 12x12 on front has Liftmaster opener..

Back Doors 12x12 and 10x10 dock,



Floor prior to sealing..with PW 500# anvil

First coat of Stampcrete SS-07 Clear UltraSheen 3000

One more coat this week..when work allows..

Lighting and most electrical are done, Quincy compressor should be here this week, wire and plumb that..build housing and cover for compressor outside, build a few tables and move in..
 
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mesquiteforge

Well-known member
Joined
Nov 21, 2008
Messages
64
Location
South Texas & Texas Hill Country
Thanks folks. MacTexas-I just found that anvil through the blacksmith rumor mill and picked it up in South Austin last weekend. Not clearly marked-but enough visible to see that it is a Peter Wright-the anvil supposedly weighs around 500 and the base is about the same-sheet metal filled with asphalt.. Lifted with my 2ton engine hoist and on the full extension it's rated at 1000lbs and the tubing was bending.. It's a monster. I'll pick it off the cart when I get the floor sealed completely.
 
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mesquiteforge

Well-known member
Joined
Nov 21, 2008
Messages
64
Location
South Texas & Texas Hill Country
After a huge amount of traveling for work in the past few weeks-I've been able to get a few more things together for the shop..
My Quincy QT-10- 10hp/120gal 3ph/230 compressor came in..and I got a slab of plate- 1"x4'x8' steel for my work/layout table. I've got a ton of welding and plumbing to do now-building the table and some tool racks and plumbing the air lines in.



Also scored a couple of older Craftsman Commercial saws-a table saw and radial arm saw-both 220V and in working order.
 
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